CHAPTER 1 INTRODUCTION - TM-9-4910-458-120009SECTION II DESCRIPTION AND DATADifference Between ModelsData Plates (fig. 5)Figure 4. Test stand (type II, part number 7336) (4910-316-5252) - right front view.Figure 5. Data plates.Tabulated Data - TM-9-4910-458-120015CHAPTER 2 OPERATING INSTRUCTIONS - TM-9-4910-458-120016Depot Installation.Figure 7. Installation of generator, alternator, and starter mounting bracket assembly.FIGURE 8. BATTERY WIRING DIAGRAMFigure 9. 6-, 12-, 24-volt series battery hook-up using four 6-volt batteries and hook-up for battery charger.Inspection. - TM-9-4910-458-120021Figure 11. Location of power supply connection points, circuit breaker, intake power toggle switch, and motor starter.Figure 12. Location of lifting eyes, interlock switch, drive reversing switch, terminal boards, and fuses.Figure 13. Power supply wiring diagramSection Il. CONTROLS, INSTRUMENTS, AND RELATED ITEMSLoad Dc Ammeter Calibrating Binding PostsAc Ammeter Calibrating JackDc Voltmeter Circuit Selector SwitchAc Ammeter Phase Selector Switch (Designated as AC AMMETER PHASE SELECTOR)Variable Volts Circuit Instrument Panel (Designated as VARIABLE VOLTS, ON OFF FUSE, DC VARIABLE VOLTS)Pile Flutter Circuit Instrument Panel (Designated as PILE FLUTTER JACK)REGULATOR CHECK FIXED RESISTANCE METHOD (OHMS), REGULATOR CHECK INPUT)Battery Circuit Selector Instrument PanelBattery Charge Timer40-Ohm Field Current Rheostat (Designated as FIELD `CURRENT INCREASE)250-Ohm Field Current Rheostat Fuse Holder (Designated as FUSE)Interlock SwitchAuxiliary Start Momentary-On Switch (Designated as AUX START)Field Shorting Switch (Designated as FIELD SHORTING)Figure 15. Receptacle panel, binding post side panel, and auxiliary panel.Alternator Input Binding Posts (Designated as ALTERNATOR)Figure 16. Controls, instruments, and related items.SECTION III OPERATION UNDER USUAL CONDITIONS - TM-9-4910-458-120043Operation - TM-9-4910-458-120044Mounting Direct-Driven Generator or AlternatorMounting Pulley-Driven Generator or Alternatortable 1. generator test data Figure 19. Direct-driven generator-installed view.Operating the Tachometer Indicator CircuitryFigure 21. Pulley-driven generator installed viewPulley-Driven Generator or Alternator.Pulley-Driven Generator or Alternator (cont)Figure 24. Starter torque test-starter mounting bracket mounted for clockwise rotation starter (hook type torque arm drive.) Example II.Battery Charger Operation6-Volt battery charging procedures.6-Volt battery charging procedures (cont)Testing and Polarizing Internal-Ground Field and External-Ground Field Generators (fig. 28)Polarizing generator using the test stand (heavy-duty system).Checking the Setting of Voltage Regulator Unit Section IV. OPERATION UNDER UNUSUAL CONDITIONS - TM-9-4910-458-120061Operation in Extreme Cold-Weather Conditionschapter 3 OPERATOR TESTING INSTRUCTIONSSection II TESTING DELCO PRODUCTS AND AUTO-LITETable 2. Position of Switches and Controls Before and After Generator Performance Test (Delco-Remy or Auto-Lite 25-Ampere Generator)Figure 30. Testing output of Delco-Remy or Auto-Lite 25-ampere generator.Table 3. Position of Switches and Controls Before and After Generator Draw Test (Delco-Remy or Auto-Lite 25-ampere Generator)FIGURE 31. DRAW TESTING DELCO-REMY OR AUTO-LIFE 25-AMPERE GENERATOR AND TESTING THE PERFORMANCE OF DELCO-REMY OR AUTO-LITE 25-AMPER GENERATOR REGULATOR.Figure 32. Switches, controls, and meters used to perform generator performance and draw tests, and generator regulator serviceability test.Section III. TESTING DELCO PRODUCTS AND AUTO-LITE 25-AMPERE 3-UNIT VIBRATING CONTACT TYPE GENERATOR REGULATORPreparation. - TM-9-4910-458-120071Table 4. Position of Switches and Controls Before and After 25-Ampere Generator Regulator Control Units TestTable 4 - Continued.Current regulator unit.Figure 34. 2 5 - a m p e r e 3 control unit vibrating contact type (Delco-Remy 1118656) generator regulator - cover removed.Section IV. TESTING DELCO PRODUCTS 25-AMPERE 4-UNIT VIBRATING CONTACT TYPE GENERATOR REGULATORCircuit Breaker Relay Unit (Cut-out Relay).Voltage regulator unit.Figure 35. 25-Ampere 4-unit vibrating contack type (Delco-Remy 1118606) generator regulator cover removedTable 5. Genarator Regulator and Generator Control Box Test DataTable 5. Genarator Regulator and Generator Control Box Test Data (Cont)Section V. TESTING BENDIX ECLIPSE PIONEER 150-AMPER GENERATORTable 6. Position of Switches and Controls Before and After Generator Performance Test (Bendix Eclipse Pioneer 150-ampere Generator and Jack and Heintz 300-ampere Generator)Figure 36. Testing the output of Bendix Eclipse Pioneer model EC30E003-A 150-ampere generator.Section VI. TESTING BENDIX ECLIPSE PIONEER 150-AMPERE GENERATOR CONTROL BOXTabulated Data. - TM-9-4910-458-120086 Test Procedures. - TM-9-4910-458-120087Figure 38. Testing the performance of Bendix Pioneer type 40E27, model 1, style B. Test Procedures. - TM-9-4910-458-120089Figure 39. Wiring diagram for Bendix exclipse pioneer type 40E27, model 1, style B.Section VII. TESTING GENERAL ELECTRIC COMPANY 150-AMPERE GENERATOR CONTROL BOXFigure 40. Wiring diagram for General Electric, ordnance no. 7355925, 150-amper generator control box complete hook-up to vehicle electrical systemPreparation. - TM-9-4910-458-120093Section Vlll. TESTING DELCO PRODUCTS (DELCO-REMY) 150-AMPERE GENERATOR CONTROL BOXFIGURE 41. WIRING DIAGRAM FOR DELCO PRODUCTS (DELCO REMY) MODEL 1118413Section IX. TESTING JACK AND HEINTZ 300-AMPERE GENERATORFigure 42. Testing output of Jack and Heintz, model G22-7F, 300-ampere generator.Figure 43. Schematic internal wiring diagram for Jack and Heintz models G22, G22-2, and G22-7F, 300-ampere generators.Test Procedures. - TM-9-4910-458-120099Section X. TESTING RETT PRODUCTS COMPANY, THE ELECTROMECHANICAL PRODUCTS COMPANY, AND TENN-TRONICS, INC. 400-AMPERE GENERATOR CONTROL BOXESFIGURE 44. WIRING DIAGRAM FOR ORDINANCE NUMBER 8723894 GENERATOR CONTROL BOX COMPLETE HOOK-UP TO VEHICLE ELECTRICAL SYSTEM Miscellaneous resistors.Figure 45. Wiring diagram for Tenn-Tronics, Inc. ordnance no. 8723894, part no. 30074, model II, 400-ampere generator control box--w/o hook-up to vehicle.Test Procedure.FIGURE 46. TESTING PERFORMANCE OF 400-AMPER GENERATOR CONTROL BOXSECTION XI. TESTING LEECE NEVILLE COMPANY 100-AMPERE GENERATOR (ALTERNATOR) (PULLEY OR DIRECT-DRIVEN)Tabulated Data. - TM-9-4910-458-120107FIGURE 47. SWITCHES, CONTROL, AND METERS USED TO PERFORM 100-AMPER GENERATORTable 7. Position of Switches and Controls Before and After Generator (alternator) Performance Test and Generator (alternator) Regulator Test (Leece Neville Company)FIGURE 48. TESTING THE OUTPUT OF LEECE-NEVILLE COMPANY no. A0015320GP or no. 5320-G12P, ORDINANCE no. 8376691 100-AMPER PULLEY-DRIVEN GENERATOR (ALTERNATOR)Figure 49. Leece-Neville Company no. C0011029CP ordnance no. 7954343 100-ampere rectifier - installed view and hook-up to test stand.Figure 50. Leece-Neville Company no. A0015504AA ordnance no. 10922191 100-ampere direct-driven generator (alternator - installed view and hook-up to test stand.SECTION XII. TESTING LEECE NEVILLE COMPANY 100-AMPERE (ALTERNATOR) REGULATORFIGURE 51. TESTING THE PERFORMANCE OF THE LEECE-NEVILLE COMPANY NO. R0013392RP ORDNANCE NO. 8699744 100-AMPER GENERATOR (ALTERNATOT) REGULATORPreparation. - TM-9-4910-458-120115Test Procedures for Control Units as an AssemblyTest Procedures for Individual Control UnitsFigure 53. Testing the voltage regulator of Leece-Neville Company generator (alternator) regulator for grounds.Line switch (load relay) - closing and opening test.Figure 54. Testing the line switch (load relay) of the Leece-Neville Company generator (alternator) regulator for closing and opening voltage.Figure 55. Setting the carbon pile of the Leece-Neville Company generator (alternator) regulator.F i g u r e 56. Generator (alternator) regulator (top cover removed) voltage adjustment control and line switch (load relay) adjustment control.Figure 57. Generator (alternator) generator regulator - external voltage adjustments. Preliminary voltage adjustment.Figure 58. Voltage regulator element assembly - partially exploded view.Testing voltage adjustment at 4,000 rmp. Testing and adjustment at 6,000 rpm.FIGURE 59. Voltage regulator element assembly-exploded viewChecking performance.Section XIII. TESTING STARTERS (CRANKING MOTORS)Testing Procedures - TM-9-4910-458-120131Table 8. Position of Switches and Controls Before and After No Load (free running) and Stall Torque (measuring stall curent and torque) Tests.Using Generator for Power Source for no Load (free running) Test.Figure 60. Testing Starter (cranking motor ) for no load (free running)Using the Test Stand for Power Source for S t a l l Torque (measuring stall current and torque) test.P r e p a r a t i o n .Tigure 61. Testing starter (cranking motor) for stall torque (measuring stall current and torque)Table 9. Starter (cranking motor) Test DataTable 9. Starter (cranking motor) Test Data - Continuedchapter 4 OPERATOR OR CREW MAINTENANCE INSTRUCTIONSFigure 62. Lubrication chartFigure 62. Lubrication chart - contSection Ill. PREVENTIVE-MAINTENANCE SERVICES - TM-9-4910-458-120143Cleaning - TM-9-4910-458-120144Preventive Maintenance by Operator and CrewTable 10. Preventive-Maintenance Checks and ServicesSection IV. TROUBLESHOOTING - TM-9-4910-458-120147Table 11. Troubleshooting - ContinuedMaintenance - TM-9-4910-458-120149chapter 5 ORGANIZATIONAL MAINTENANCE INSTRUCTIONSGeneral ProceduresSection IV. TROUBLESHOOTING - TM-9-4910-458-120152Table 13. TroubleshootingSection V. INPUT POWER SUPPLY FUSE GROUPSECTION VII. MERCURY SWITCH GROUPSECTION III. MAGNETIC MOTOR STARTER GROUPSECTION IX. VARIDRIVE ASSEMBLY AND TACHOMETER GENERATOR GROUPInspection. - TM-9-4910-458-120158Figure 64. Removal of varidrive assembly V belt and tachometer generator.CHAPTER 6 SHIPMENT AND ADMINISTRATIVE STORAGE AND DEMOLITION TO PREVENT ENEMY USESection Il. SHIPMENT OF MATERIEL TO PREVENT ENEMY USE Destruction of the Automotive Generator, Alternator, and Starter Test StandAPPENDIX I REFERENCES - TM-9-4910-458-120163Other Publications - TM-9-4910-458-120164Other Publications (CONT) - TM-9-4910-458-120165Other Publications (CONT) - TM-9-4910-458-120166APPENDIX II BASIC ISSUE ITEMS LIST - TM-9-4910-458-120167Abbreviations - TM-9-4910-458-120168SECTION II. BASIC ISSUE ITEMS - TM-9-4910-458-120169SECTION II. BASIC ISSUE ITEMS (CONT) - TM-9-4910-458-120170SECTION II. BASIC ISSUE ITEMS (CONT) - TM-9-4910-458-120171SECTION II. BASIC ISSUE ITEMS (CONT) - TM-9-4910-458-120172SECTION II. BASIC ISSUE ITEMS (CONT) - TM-9-4910-458-120173FIGURE 65. Rpair prts and equipmentFigure 66. Equipment - mounting and testing.Figure 67. Equipment - mounting.Figure 69. Equipment - mounting.Figure 70. Equipment - testing, cable harnesses.Figure 72. Equipment - testing, cable harnesses.Figure 72. Equipment - testing, cable harnesses. (cont)Figure 74. Equipment - test leads and cable harnesses.Figure 75. Equipment - battery cable harnesses.Figure 76. Equipment - mounting.APPENDIX II MAINTENANCE ALLOCATION CHART - TM-9-4910-458-120184Maintenance Allocation Chart - TM-9-4910-458-120185Maintenance Allocation Chart - CONT - TM-9-4910-458-120186Maintenance Allocation Chart - CONT - TM-9-4910-458-120187APPENDIX IV REPAIR PARTS AND SPECIAL TOOL LISTS - TM-9-4910-458-120188Abbreviations and Symbols - TM-9-4910-458-120189Section Il. REPAIR PARTS AND SPECIAL TOOLSSection Il. REPAIR PARTS AND SPECIAL TOOLS (CONT) - TM-9-4910-458-120191Section Il. REPAIR PARTS AND SPECIAL TOOLS (CONT) - TM-9-4910-458-120192Section Il. REPAIR PARTS AND SPECIAL TOOLS (CONT) - TM-9-4910-458-120193TM-9-4910-458-12 Test Stand Automotive Generator Alternator and Starter Floor Mounted 10 TO 50-V 500-AMP DC and 25 to 50-V 100 to 400 AMP Manual