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CHAPTER 1 INTRODUCTION - TM-9-4910-458-120009
SECTION II DESCRIPTION AND DATA
Difference Between Models
Data 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-9-4910-458-120015
CHAPTER 2 OPERATING INSTRUCTIONS - TM-9-4910-458-120016
Depot Installation.
Figure 7. Installation of generator, alternator, and starter mounting bracket assembly.
FIGURE 8. BATTERY WIRING DIAGRAM
Figure 9. 6-, 12-, 24-volt series battery hook-up using four 6-volt batteries and hook-up for battery charger.
Inspection. - TM-9-4910-458-120021
Figure 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 diagram
Section Il. CONTROLS, INSTRUMENTS, AND RELATED ITEMS
Load Dc Ammeter Calibrating Binding Posts
Ac Ammeter Calibrating Jack
Dc Voltmeter Circuit Selector Switch
Ac 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 Panel
Battery Charge Timer
40-Ohm Field Current Rheostat (Designated as FIELD `CURRENT INCREASE)
250-Ohm Field Current Rheostat Fuse Holder (Designated as FUSE)
Interlock Switch
Auxiliary 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-9-4910-458-120043
Operation - TM-9-4910-458-120044
Mounting Direct-Driven Generator or Alternator
Mounting Pulley-Driven Generator or Alternator
table 1. generator test data
Figure 19. Direct-driven generator-installed view.
Operating the Tachometer Indicator Circuitry
Figure 21. Pulley-driven generator installed view
Pulley-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 Operation
6-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-9-4910-458-120061
Operation in Extreme Cold-Weather Conditions
chapter 3 OPERATOR TESTING INSTRUCTIONS
Section II TESTING DELCO PRODUCTS AND AUTO-LITE
Table 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 REGULATOR
Preparation. - TM-9-4910-458-120071
Table 4. Position of Switches and Controls Before and After 25-Ampere Generator Regulator Control Units Test
Table 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 REGULATOR
Circuit Breaker Relay Unit (Cut-out Relay).
Voltage regulator unit.
Figure 35. 25-Ampere 4-unit vibrating contack type (Delco-Remy 1118606) generator regulator cover removed
Table 5. Genarator Regulator and Generator Control Box Test Data
Table 5. Genarator Regulator and Generator Control Box Test Data (Cont)
Section V. TESTING BENDIX ECLIPSE PIONEER 150-AMPER GENERATOR
Table 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 BOX
Tabulated Data. - TM-9-4910-458-120086
Test Procedures. - TM-9-4910-458-120087
Figure 38. Testing the performance of Bendix Pioneer type 40E27, model 1, style B.
Test Procedures. - TM-9-4910-458-120089
Figure 39. Wiring diagram for Bendix exclipse pioneer type 40E27, model 1, style B.
Section VII. TESTING GENERAL ELECTRIC COMPANY 150-AMPERE GENERATOR CONTROL BOX
Figure 40. Wiring diagram for General Electric, ordnance no. 7355925, 150-amper generator control box complete hook-up to vehicle electrical system
Preparation. - TM-9-4910-458-120093
Section Vlll. TESTING DELCO PRODUCTS (DELCO-REMY) 150-AMPERE GENERATOR CONTROL BOX
FIGURE 41. WIRING DIAGRAM FOR DELCO PRODUCTS (DELCO REMY) MODEL 1118413
Section IX. TESTING JACK AND HEINTZ 300-AMPERE GENERATOR
Figure 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-9-4910-458-120099
Section X. TESTING RETT PRODUCTS COMPANY, THE ELECTROMECHANICAL PRODUCTS COMPANY, AND TENN-TRONICS, INC. 400-AMPERE GENERATOR CONTROL BOXES
FIGURE 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 BOX
SECTION XI. TESTING LEECE NEVILLE COMPANY 100-AMPERE GENERATOR (ALTERNATOR) (PULLEY OR DIRECT-DRIVEN)
Tabulated Data. - TM-9-4910-458-120107
FIGURE 47. SWITCHES, CONTROL, AND METERS USED TO PERFORM 100-AMPER GENERATOR
Table 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) REGULATOR
FIGURE 51. TESTING THE PERFORMANCE OF THE LEECE-NEVILLE COMPANY NO. R0013392RP ORDNANCE NO. 8699744 100-AMPER GENERATOR (ALTERNATOT) REGULATOR
Preparation. - TM-9-4910-458-120115
Test Procedures for Control Units as an Assembly
Test Procedures for Individual Control Units
Figure 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 view
Checking performance.
Section XIII. TESTING STARTERS (CRANKING MOTORS)
Testing Procedures - TM-9-4910-458-120131
Table 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 Data
Table 9. Starter (cranking motor) Test Data - Continued
chapter 4 OPERATOR OR CREW MAINTENANCE INSTRUCTIONS
Figure 62. Lubrication chart
Figure 62. Lubrication chart - cont
Section Ill. PREVENTIVE-MAINTENANCE SERVICES - TM-9-4910-458-120143
Cleaning - TM-9-4910-458-120144
Preventive Maintenance by Operator and Crew
Table 10. Preventive-Maintenance Checks and Services
Section IV. TROUBLESHOOTING - TM-9-4910-458-120147
Table 11. Troubleshooting - Continued
Maintenance - TM-9-4910-458-120149
chapter 5 ORGANIZATIONAL MAINTENANCE INSTRUCTIONS
General Procedures
Section IV. TROUBLESHOOTING - TM-9-4910-458-120152
Table 13. Troubleshooting
Section V. INPUT POWER SUPPLY FUSE GROUP
SECTION VII. MERCURY SWITCH GROUP
SECTION III. MAGNETIC MOTOR STARTER GROUP
SECTION IX. VARIDRIVE ASSEMBLY AND TACHOMETER GENERATOR GROUP
Inspection. - TM-9-4910-458-120158
Figure 64. Removal of varidrive assembly V belt and tachometer generator.
CHAPTER 6 SHIPMENT AND ADMINISTRATIVE STORAGE AND DEMOLITION TO PREVENT ENEMY USE
Section Il. SHIPMENT OF MATERIEL TO PREVENT ENEMY USE
Destruction of the Automotive Generator, Alternator, and Starter Test Stand
APPENDIX I REFERENCES - TM-9-4910-458-120163
Other Publications - TM-9-4910-458-120164
Other Publications (CONT) - TM-9-4910-458-120165
Other Publications (CONT) - TM-9-4910-458-120166
APPENDIX II BASIC ISSUE ITEMS LIST - TM-9-4910-458-120167
Abbreviations - TM-9-4910-458-120168
SECTION II. BASIC ISSUE ITEMS - TM-9-4910-458-120169
SECTION II. BASIC ISSUE ITEMS (CONT) - TM-9-4910-458-120170
SECTION II. BASIC ISSUE ITEMS (CONT) - TM-9-4910-458-120171
SECTION II. BASIC ISSUE ITEMS (CONT) - TM-9-4910-458-120172
SECTION II. BASIC ISSUE ITEMS (CONT) - TM-9-4910-458-120173
FIGURE 65. Rpair prts and equipment
Figure 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-9-4910-458-120184
Maintenance Allocation Chart - TM-9-4910-458-120185
Maintenance Allocation Chart - CONT - TM-9-4910-458-120186
Maintenance Allocation Chart - CONT - TM-9-4910-458-120187
APPENDIX IV REPAIR PARTS AND SPECIAL TOOL LISTS - TM-9-4910-458-120188
Abbreviations and Symbols - TM-9-4910-458-120189
Section Il. REPAIR PARTS AND SPECIAL TOOLS
Section Il. REPAIR PARTS AND SPECIAL TOOLS (CONT) - TM-9-4910-458-120191
Section Il. REPAIR PARTS AND SPECIAL TOOLS (CONT) - TM-9-4910-458-120192
Section Il. REPAIR PARTS AND SPECIAL TOOLS (CONT) - TM-9-4910-458-120193
TM-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
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