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    ARMY TECHNICAL MANUAL TM5-6115-465-12NAVY PUBLICATION NAVFAC P-8-625-12

    AIR FORCE TECHNICAL ORDER TO-35C2-3-446-1

    MARINE CORPS TECHNICAL MANUAL TM-06858B/ 06859D-12

    TECHNICAL MANUAL

    OPERATOR AND ORGANIZATIONAL MAINTENANCE MANUAL

    GENERATOR SET, DIESEL ENGINE DRIVEN, TACTICAL SKID MTD. 30 KW,

    3 PHASE, 4 WIRE, 120/ 208 AND 240/ 416 VOLTS

    DOD MODEL CLASS HERTZ FSN

    MEP-005A UTILITY 50/ 60 6115-118-1240

    MEP-104A PRECISE 50/ 60 6115-118-1247

    MEP-114A PRECISE 400 6115-118-1248

    INCLUDING AUXILIARY EQUIPMENT

    DOD MODEL NOMENCLATURE FSN

    MEP-005AWE WINTERIZATION KIT, FUEL BURNING 6115-463-9083

    MEP-005AWE WINTERIZATION KIT, ELECTRIC 6115-463-9085

    MEP-005ALM LOA D BANK KIT 6115-463-9088

    MEP-005AWM WHEEL MOUNTING KIT 6115-463-9094

    PUBLISHED UNDER THE AUTHORITY OF THE DEPARTMENTS OF THE ARMY, A IR FORCE, AND NAVY(INCLUDING U.S. MARINE CORPS)

    JANUARY 1975

    This copy is a reprint which includes current

    pages from Changes 1 though 9

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    TM5-6115-465-12

    NAVFAC P-8-625-12TM 06858B/06859D-12

    TO 35C2-3-446-1

    C 19

    CHANGE

    NO. 19

    HEADQUARTERS, DEPARTMENTS OFTHE ARMY, NAVY, AND AIR FORCE

    AND HEADQUARTERS U.S. MARINE CORPSWASHINGTON, D.C., 30JUNE1995

    Operator and Organizational Maintenance Manual

    GENERATOR SET, DIESEL ENGINE DRIVEN,

    TACTICAL SKID MOUNTED, 30 KW, 3 PHASE 4 WIRE,

    120/208 AND 240/416 VOLTS

    DOD MODEL CLASS HERTZ NS N

    MEP-005A Utility 50/60 6115-00-118-1240

    MEP-104A Precise 50/60 6115-00-118-1247

    MEP-114A Precise 6115-00-118-1248

    INCLUDING AUXILIARY EQUIPMENT

    DOD MODEL NOMENCLATURE NSN

    MEP-005-AWF Winterization Kit, Fuel Burning 6115-00-463-9083

    MEP-005-AWE Winterization Kit, Electric 6115-00-463-9085

    MEP-005-ALM Load Bank Kit 6115-00-463-9088

    MEP-005-AWM Wheel Mounting Kit 6115-00-463-9094

    MEP-005-AAS Accoustic Suppression Kit (Army Only) 6115-01-234-6545

    DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited

    TM5-6115-465-12/TO35C2-3-446-1/NAVFAC-P-8-625-12/TM-06858B/06859D-12,31 January1975,ischanged as follows:

    1.

    2.

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

    Remove pages Insert pages

    C-11 and C-12 C-11 and C-12

    Retain this sheet in front of manual for reference purposes.

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    C 19

    TM5-6115-465-12TO 35C2-3-446-1NAVFAC P-8-625-12TM 06858B/06859D-12

    By Order of the Secretaries of the Army, Air Force, and Navy (Including the Marine Corps):

    DENNIS J. REIMER

    General, United States ArmyChief of Staff

    RONALD R. FOGELMAN

    General, USAF

    Chief ofStaff

    Official:

    RONALD W. YATES

    General, USAF

    Commander, Air Force Materiel Command

    JACK E. BUFFINGTON

    Rear Admiral, CEC, US Navy

    Commander NAVFAC

    D. R. BLOOMER

    Colonel, USMCDirector Program Support

    Marine Corps Systems Command

    DISTRIBUTION:

    To be distributed in accordance with DA Form 12-25-E, block no. 0850, requirements for

    TM 5-6115-465-12.

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    TM5-6115-465-12TO 35C2-3-446-1

    NAVFAC P-8-625-12TM 06858B/06859D-12

    C 1 8

    CHANGE HEADQUARTERS DEPARTMENTS OFTHE ARMY, NAVY AND THE AIR FORCE AND

    HEADQUARTERS U.S. MARINE CORPNO. 18 WASHINGTON, D. C., 30 JUNE 1995

    OPERATOR AND ORGANIZATIONAL MAINTENANCE MANUAL

    GENERATOR SET, DIESEL ENGINE DRIVEN,TACTICAL SKID MTD., 30 KW, 3-PHASE,

    4 WIRE, 120/208 AND 240/416 VOLTS

    DOD MODEL

    MEP-O05A

    MEP-104A

    MEP-114A

    CLASS HERTZ

    UTILITY 50/60

    PRECISE 50/60

    PRECISE 400

    6115-00-118-1240

    6115-00-118-1247

    6115-00-118-1248

    INCLUDING OPTIONAL KITS

    DOD MODEL NOMENCLATURE NSNMEP-005-AWF WINTERIZATION KIT, FUEL BURNING 6115-00-463-9083

    MEP-005-AWE WINTERIZATION KIT, ELECTRIC 6115-00-463-9085MEP-002-ALM LOAD BANK KIT 6115-00-463-9088

    MEP-005-AWM WHEEL MOUNTING KIT 6115-00-463-9094

    DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited

    TM 5-6115-465-12/TO 35C2-3-446-1/NAVFAC P-8-625-12/TM 0658D/0659D,31 January 1975 ischanged as follows:

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

    Remove pages Insert pages

    FO-7/BLANK FO-7/BLANK

    FO-9/BLANK FO-9/BLANK

    2. Retain this sheet in front of manual for reference purposes.

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    TM 5-6115-465-12TO 35C2-3-446 1NAVFAC P-8-625-12TM 0658B/06859D-12

    C18

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    TM5-6115-465-12

    TO 35C2-3-446-1

    NAVFAC P-8-625-12

    TM 06858B/06859D-12

    WARNINGAll specific cautions and warnings contained in this manual shall be strictly adhered to. Othewise, severe injury,death and/or damage to the equipment may result.

    WARNINGHot refueling of generators while they are operating, poses a safety hazard and should not be attempted. Hot enginesurfaces and sparks produced from the engine and generator circuitry are possible sources of ignition. Severeinjury, death and/or damage to the equipment may result.

    HIGH VOLTAGEis produced when this generator set is in operation.

    DEATHor severe burns may result if personnel fail to observe safety precautions. Do not operate this generator set until theground terminal stud has been connected to a suitable ground. Disconnect the battery ground cable beforeremoving and installing components on the engine or in the electrical control panel system. Do not attempt toservice or otherwise make any adjustments, connections or reconnection of wires or cables until generator set isshut-down and completely deenergized.

    DANGEROUS GASESBatteries generate explosive gas during charging therefore, utilize extreme caution, do not smoke, or use openflame in vicinity when servicing batteries. Use only Slave Receptacle (SR1) when extra cranking power is required;Incorrect method of slaving could cause arcing at battery terminals. Exhaust discharge contains noxious anddeadly fumes. Do not operate generator sets in enclosed areas unless exhaust discharge is properly vented to theoutside. When filling fuel tank, maintain metal-to-metal contact between filler nozzle and fuel tank. Do not smokeor use an open flame between filler nozzle and fuel tank. Do not smoke or use an open flame in the vicinity. Useextreme care, should a selenium rectifier malfunction, to avoid inhalation of poisonous fumes.

    LIQUIDS UNDER PRESSUREare generated as a result of operation of the generator set. Do not expose any part of the body to a high pressure leakin the fuel or hydraulic system of the generator set. Relieve pressure from radiator before removing radiator cap.

    NOISE

    operating level of this generator can cause hearing damage. Ear protectors, as recommended by the medical orsafety officer, must be worn when working near this set.

    BATTERY ACIDBattery electrolyte contains sulfuric acid which can cause severe burns. Always dilute electrolyte with water. Neverpour water into electrolyte: spattering of the electrolyte may result. If electrolyte comes in contact with skin orclothing, rinse immediately with clean water.

    If acoustic suppression kit is installed, do not allow personnel to open or close exhaust discharge door when unit ishot. Serious burns or personal injury may result.

    Change 17 a/(b blank)

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    TM 5-6115-465-12TO 35C2-3-446-1NAVFAC P-8-625-12TM 06858B/06859D-12

    C H A P T E R

    S e c t i o n

    1 - 11 - 1

    S e c t i o n

    C H A P T E R

    S e c t i o n

    S e c t i o n

    S e c t i o n

    S e c t i o n

    S e c t i o n

    D E P A R T ME N T S O F T H E A R MY , T H E N A V YA N D T H E A I R F O RC E

    ( I N CL U DI N G U S MA RI N E COR PS )Wa s h i n g t o n , DC. , 3 1 J a n u a r y 1 9 7 5

    P a g eL I S T OF I L L U ST RA T I ONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    L I S T OF T A BL E S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    1 . I N T ROD UC T I ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1

    I . GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1

    1 - 1 . S c o p e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 11 - 2 . F o r ms a n d Re c o r d s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 2 . 1 . Ha n d R e c e i p t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 3 . D e m o l i t i o n t o P r e v e n t E n e m y U s e . . . . . . . . . . . . . . . . . . . . 1 - 11 - 4 . S h i p me n t a n d St o r a g e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1

    I I . D ES CR I P T I ON A ND DA TA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 3

    1 - 5 . D e s cr i p t i o n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 31 - 6 . I d e n t i f i c a t i o n a n d Ta b u l a t e d Da t a . . . . . . . . . . . . . . . . . . 1 - 51 - 7 . Di f f e r e n c e s Be t we e n Mo de l s . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 8

    2 . I N S T A L L A T I ON A N D OP E R AT I ON I N S T RU CT I ON S . . . . . . . . . . . . . . . . . . . . 2 - 1

    I . S E RV I C E UP ON RE C E I P T O F MA T E R I A L . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1

    2 - 1 . I n s p e c t i n g a n d Se r v i c i n g t h e Ge n e r a t o r S e t . . . . . . . . . 2 - 12 - 2 . I n s t a l l a t i o n o f S e p a r a t e l y Pa c k e d Co mp o n e n t s . . . . . . . 2 - 32 - 3 . I n s t a l l a t i o n I n s t r u c t i o n s . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 32 - 4 . Ge n e r a t o r S e t Co n v e r s i o n I n s t r u c t i o n s . . . . . . . . . . . . . . 2 - 6

    I I . M OVEM EN T T OA N EW WOR K S I T E . . . , . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 9

    2 - 5 . Di s ma n t l i n g t h e Ge n e r a t o r S e t f o r Mo v e me n t . . . . . . . . . 2 - 92 - 6 . R e i n s t a l l a t i o n Af t e r Mo v e n en t . . . . . . . . . . . . . . . . . . . . . . 2 - 9

    I I I . C O NT R O L S AN D I N ST R U MEN T S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1 1

    2 - 7 . Ge n er a l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1 12 - 8 . Co n t r o l s a n d I n s t r u me n t s . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1 1

    I V . O P E RA T I O N U ND E R U S U A L C ON DI T I ON S . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1 3

    2 - 9 . Ge n e r a l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1 32 - 1 0 . S t a r t i n g t h e Ge ne r a t o r S e t . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1 32 - 1 1 . S t o p p i n g t h e Ge ne r a t o r S e t . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1 42 - 1 2 . Op e r a t i o n o f T a c t i c a l P r e c i s e Ge n e r a t o r S e t s . . . . . . . 2 - 1 42 - 1 3 . Op e r a t i o n o f T a c t i c a l Ut i l i t y Ge n e r a t o r S e t s . . . . . . . 2 - 2 02 - 1 4 . E x e r c i s e o f E n g i n e o n S t a n d b y S e r v i c e . . . . . . . . . . . . . . 2 - 2 0

    v . O P E RA T I O N U ND E R UN U S UA L C O N DI T I O NS . . . . . . . . . . . . . . . . . . . . . . . . 2 - 2 0

    2 - 1 5 . Op e r a t i o n i n E x t r e me Co l d ( B e l o w - 2 5oF ) . . . . . . . . . . . . 2 - 2 0

    2 - 1 6 . Op e r a t i o n i n E x t r e me H e a t ( U p t o 1 2 5 o F ) . . . . . . . . . . . . 2 - 2 12 - 1 7 . Op er a t i o n i n Du s t y o r S a nd y A r e a s . . . . . . . . . . . . . . . . . . 2 - 2 1

    i

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    TO 35C2-3-446-1

    NAVFAC P-8-625-12TM 06858B/06859D-12

    TABLE OF CONTENTS (CONT)

    CHAPTER 2.

    Section VI.

    CHAPTER 3.

    Section I.

    Section II.

    Section III.

    Section IV.

    INSTALLATION AND OPERATION INSTRUCTIONS Page

    (CONTINUED)

    2-18. Operation Under Rainy or Humid Conditions . . 2-21

    2-19. Operation in Salt Water Areas . . . . . . . . . . . . . . 2-21

    2-20. Operation at High Altitudes . . . . . . . . . . . . . . . . 2-23

    OPERATION OF EQUIPMENT USED IN CONJUNCTION WITH

    THE GENERATOR SET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23

    2-21. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23

    2-22. Fuel Burning Winterization Kit . . . . . . . . . . . . . 2-232-23. Electric Winterization Kit . . . . . . . . . . . . . . . . . 2-23

    2-24. Wheel Mounting Kit . . . . . . . . . . . . ... . .2-23

    2-25. Load Bank Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23

    2-26. Acoustic Suppression Kit (Army only) . . . . . . . 2-27

    OPERATOR AND ORGANIZATIONAL MAINTENANCE

    INSTRUCTIONS . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . 3-1

    OPERATOR AND ORGANIZATIONAL MAINTENANCE

    REPAIR PARTS , TOOLS AND EQUIPMENT . . . . . . . . . . . . . . . . . 3-1

    3-1. Tools and Equipment (Not Applicable toAir Force) . . . . . . . . . .. . .. . . . . . . . . . . . . . . . . 3-1

    3-2. Organizational Maintenance Repair Parts . . . . . 3-1

    LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

    3-3. General Lubrication Information . . . . . . . . . . . . . 3-1

    3-4. Detailed Lubrication Information . . . . . . . . . . . . 3-1

    PREVENTIVE MAINTENANCE CHECKS AND SERVICES . . . . . . . . 3-5

    3-5. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . , . . . . . . . . 3-5

    3-6. Preventive Maintenance Checks and Services(Army and Navy) . . . . . . . . . . . . . . . . . . . . . . . . 3-5

    OPERATORS MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

    3-7.

    3-8.3-9.

    3-10.

    3-11.

    General . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . 3-9

    Batteries . . . . . . . . . . . . . . . . . . . . . . . 3-9Slave Receptacle . . . . . . . . . . . . . . . . . . . . . . . 3-9Breather Tube, Exhaust Pipe and Muffler . . . . 3-9

    Convenience Receptacles and CircuitBreaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

    ii

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    NAVFAC P-8-625-12

    TO 06858B/06859D-12

    TABLE OF CONTENTS (CONT)

    CHAPTER 3. OPERATOR AND ORGANIZATIONAL MAINTENANCEINSTRUCTIONS (CONT)

    3-12. Plate and Sleeve Assembly . . . . . . . . . . . . . . . . . . 3-93-13. Paralleling Receptacles . . . . . . . . . . . . . . . . . . . . 3-93-14. AC Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

    3-15. Kilowatt (Percent Power) Meter . . . . . . . . . . . . . 3-9

    3-16. AC (Percent Rated Current) Ammeter . . . . . . . . . . 3-93-17. Frequency Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

    3-18. Control Panel Switches . . . . . . . . . . . . . . . . . . . . . 3-9

    3-19. Control Panel Gauges . . . . . . . . . . . . . . . . . . . . . . . 3-10

    3-20. Running Time Meter . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

    3-21. Battery Charging Ammeter . . . . . . . . . . . . . . . . . . . 3-10

    ii.1/(ii.2 blank)

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    C H A P T E R 3 .

    T A B L E O F C ON T E N T S ( C ON T )

    O PE R A T OR A N D OR GA N I Z A T I ON A L M A I N T E N A NC EI N S T RU CT I ON S ( C ON T I N UE D )

    S e c t i o n

    S e c t i o n

    S e c t i o n

    3 - 2 2 .3 - 2 3 .3 - 2 4 .3 - 2 5 .3 - 2 6 .3 - 2 7 .3 - 2 8 .3 - 2 9 .3 - 3 0 .3 - 3 1 .3 - 3 2 .3 - 3 3 .3 - 3 4 .3 - 3 5 .3 - 3 6 .

    3 - 3 7 .3 - 3 8 .3 - 3 9 .3 - 4 0 .3 - 4 1 .3 - 4 2 .3 - 4 3 .3 - 4 4 .3 - 4 5 .3 - 4 6 .3 - 4 7 .3 - 4 8 .3 - 4 9 .3 - 5 0 .3 - 5 1 .

    Ge n e r a t o r S e t Ho u s i n g . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Wi r i n g H a r n e s s e s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A i r C l e a ne r A s s e mb l y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Da y T a n k A s s e mb l y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    F u e l F i l t e r a n d St r a i n e r A s s e mb l yS t a r t A i d As s e mb l y . . . . . . . . . . . . .F u e l T r a n s f e r P u mp s . . . . . . . . . . .R a d i a t o r Gr i l l e . . . . . . . . . . . . . . .S h u t t e r A s s e mb l y a n d T h e r mo s t a tRa di a t o r . . . . . . . . . . . . . . . . . .Hy d r a u l i c A c t u a t o r ( ME P 1 0 4 A On l y )Hy d r a u l i c S u mp a n d F i l t e r ( ME PE ng i n e A s s e mb l y . . . . . . . . . . . . . . .V - B e l t . . . . . . . . . . . .B a t t e r y Ch a r g i n g A l t e r n a t o r . . .

    S p e e d Swi t c h a n d Ad a p t e r. . . . . .

    Hy d r a u l i c Oi l P ump ( ME P 1 0 4 A On l y )Oi l L e v e l Ga u g e a n d F i l l e r T u b e

    . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . .

    . . . . . . . . . . . . . . . . . . .

    . . . . . . . . . . . . . . . . . . .

    . . . . . . . . . . . . . . . . . . .

    . . . . . . . . . . . . . . . . . . .

    . . .1 0 4 A O n l y ). . . . . .

    . . . . . .

    . . . . . .

    . . . . . .

    . . . .. . . . . .

    . . . . . . . . . . . .

    . . . . . . . . .. . . . . . . . . . . .

    . . . . . . . . . . . .

    . . . . . . . . . . . .

    . . . . . . . . . . . .

    . . . . . . . . . . . .

    . . . . . . . . . . . .

    S t a r t e r A s s e mb l y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Oi l P r e s s u r e T r a n s mi t t e r . . . . . . . . . . . . . . . . . . . . . . . . . .L u b e Oi l F i l t e r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .S e c o n d a r y F u e l F i l t e r . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F u e l I n j e c t i o n Pu mp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F a n As s e mb l y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Wa t e r P u mp A s s e mb l y . . . . . .

    C o o l a n t T e mp e r a t u r e T r a n s mi t t e rOi l P a n A s s e mb l y . . . . . . . . .Ma i n F u e l T an k . . . . . . . . . . .P a r a l l e l i n g Ca b l e . . . . . . . .A u x i l i a r y Fu e l L i n e . . . . . .

    . . . . . . . . . . . . . . . . . . . . . . . .

    . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .

    . . . . . . . . . . . . . . . . . . . . . . .

    . . . . . . . . . . . . . . . . . . . . . . . .

    . . . . . . . . . . . . . . . . . . . . . . . .

    V . T R OU B L E S H OO T I N G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    3 - 5 2 . Ge n e r a l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    V I . F I E L D EX P ED I E NT R EP A I R S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    3 - 5 3 . Ge n e r a l . . . . . . . . . . . . . . .3 - 5 4 . F u el i s n o t S t r a i n e d . . . . . . . .3 - 5 5 . Ho u s i n g F i l l e d Wi t h Smo k e . . .3 - 5 6 . E n g i n e Ov e r h e a t i n g . . . . . . . . . .3 - 5 7 . L os s o f Co ol a n t . . . . . . . . . . . . .3 - 5 8 . B a t t e r y Ch a r g i n g Amme t e r S h o ws3 - 5 9 . L o s s o f F r e q u e n c y Co n t r o l

    ( T a c t i c a l P r e c i s e S e t s On l y

    . . . . . . . . . . . . . . . . . . . . .

    . . . . . . . . . . . . . . . . . . . . .

    . . . . . . . . . . . . . . . . . . . . .

    . . . . . . . . . . . . . . . . . . . . .

    . . . . . . . . . . . . . . . . . . . . .

    N O C h a r g e . . . . . . . . . .

    . . . . . . . . . . . . . . . . . . . .

    V I I . E L E C T R O MA GN E T I C I N T E R F E R E NC E S UP P R E S S I O N . . . . . . . . . . . . . . . . .

    3 - 6 0 . Ge n e r a l Me t h o d s Us e d t o Ob t a i n Pr o p e r S u p p r e s s i o n .

    P a g e

    3 - 1 03 - 1 03 - 1 03 - 1 03 - 1 03 - 1 23 - 1 23 - 1 23 - 1 23 - 1 23 - 1 43 - 1 43 - 1 43 - 1 43 - 1 4

    3 - 1 43 - 1 43 - 1 43 - 1 43 - 1 43 - 1 43 - 1 43 - 1 53 - 1 53 - 1 53 - 1 53 - 1 53 - 1 53 - 1 83 - 1 8

    3 - 1 8

    3 - 1 8

    3 - 2 4

    3 - 2 43 - 2 43 - 2 43 - 2 43 - 2 43 - 2 4

    3 - 2 4

    3 - 2 5

    3 - 2 5

    C h an g e 9 i i i

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    TO 35C2-3-446-1NAVFAC P-8-625-12TM06858B/06859D-12

    C H A P T E R 3 .

    S e c t i o n V I I I .

    S e c t i o n I X .

    S e c t i o n X .

    T A B L E O F CO NT E N T S ( C ON T )

    O P ER A T OR A N D O RGA N I Z A T I O NA L M A I N T E N A NC EI N ST R UC T I ON S ( C ON T I N UE D)

    3 - 6 1 . I n t e r f e r e n c e S u p p r e s s i o n Co mp o n e n t s . . . . . . . . . . . . . . .3 - 6 2 . Re p l a c e me n t o f E l e c t r o ma g n e t i c I n t e r f e r e n c e

    Co mp o n e n t s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 6 3 . T e s t i n g o f I n t e r f e r e n c e S u p p r e s s i o n

    Co mp o n e n t s . . . . . . , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    OR GA N I Z A T I ON A L M AI N T E NA N CE O F T H E E N GI N EE L E C T R I C A L S Y S T E M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    3 - 6 4 .3 - 6 5 .3 - 6 6 .3 - 6 7 .3 - 6 7 A.

    3 - 6 8 .3 - 6 9 .3 - 7 0 .3 - 7 1 .3 - 7 2 .3 - 7 3 .3 - 7 4 .3 - 7 5 .3 - 7 6 .

    Ge n e r a l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B a t t e r i e s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .S l a v e Re c e p t a c l e . . . . . , . . . . . . . . . . . . . . . . . . . . . . . . . . . .S t a r t e r A s s e mb l y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .S t a r t e r A s s e mb l y ( E f f e c t i v e wi t h Se r i a l No . R Z7 0 0 0 1a n d K Z OOOO1 t h r u K Z 0 2 7 5 2 ) . . . . . . . . . . . . . . . . . . . . . . . . .B a t t e r y Ch a r g i n g Al t e r n at o r . . . . . . . . . . . . . . . . . . . . . . .S p e e d Swi t c h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Co o l a n t T e mp er a t u r e T r a n s mi t t e r . . . . . . . . . . . . . . . . . . .Ov e r - t e mp e r a t u r e Swi t c h . . . . . . . . . . . . . . . . . . . . . . . . . . .Oi l P r e s s u r e Tr a n s mi t t e r . . . . . . . . . . . . . . . . . . . . . . . . . .L o w Oi l P r e s s u r e Sw i t c h . . . . . . . . . . . . . . . . . . . . . . . . . . .Da y T a n k F u e l L e v e l a n d L o w F u e l Cu t o f f S w i t c h . . . .F u e l S o l e n o i d V a l v e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E n g i n e Wi r i n g Ha r n e s s As s e mb l y . . . . . . . . . . . . . . . . . . . .

    OR GA N I Z A T I ON A L M AI N T E NA N CE O F T H E E N GI N EF U E L S Y S T E M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    3 - 7 7 . Ge n e r a l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 7 8 . F u e l T r a n s f e r P u mp s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 7 9 . F u e l S t r a i n e r a n d F i l t e r A s s e mb l y . . . . . . . . . . . . . . . . .

    3 - 8 0 . Da y T a n k A s s e mb l y. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    3 - 8 1 . S e c o n d a r y F u e l F i l t e r . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 8 2 . F u e l I n j e c t i o n No z z l e H o l d e r s a n d L i n e s . . . . . . . . . . .3 - 8 3 . F u e l L i n e s a n d F i t t i n g s . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 8 4 . S t a r t A i d As s e mb l y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    OR GA N I Z A T I ON A L M AI N T E NA N CE O F T H E E N GI N EC OO L I N G S Y S T E M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    3 - 8 5 . Ge n e r a l . . . . . . . . . . . . . . . . . . . . . . . , . . . . . . . . . . . . . . . . . . .3 - 8 6 . Gr i l l e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 8 7 . S h ut t e r Co nt r o l T h e r mo s t a t . . . . . . . . . . . . . . . . . . . . . . . .3 - 8 8 . Ra di a t o r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 8 9 . S h u t t e r A s s e mb l y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 9 0 . V - B e l t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 9 1 . Co o l i n g F a n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    3 - 9 2 . Wa t e r P u mp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 9 3 . Co o l a n t T h e r m o s t a t a n d Ho u s i n g . . . . . . . . . . . . . . . . . . . .

    P a g e

    3 - 2 5

    3 - 2 5

    3 - 2 5

    3 - 2 5

    3 - 2 53 - 2 53 - 2 73 - 2 9

    3 - 3 33 - 3 4 C3 - 3 63 - 3 63 - 3 73 - 3 73 - 3 93 - 3 93 - 4 03 - 4 0

    3 - 4 1

    3 - 4 13 - 4 13 - 4 1

    3 - 4 33 - 4 43 - 4 73 - 4 73 - 4 7

    3 - 5 1

    3 - 5 13 - 5 13 - 5 13 - 5 33 - 5 33 - 5 33 - 5 4

    3 - 5 53 - 5 5

    i v Ch an g e 9

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    C H A P T E R 3 .

    S e c t i o n

    S e c t i o n

    S e c t i o n

    S e c t i o n

    S e c t i o n

    S e c t i o n

    X I .

    X I I .

    X I I I .

    X I V .

    X V .

    X VI .

    T A B L E O F C ON T E N T S ( C ON T )

    OP E R A T OR A N D O RG AN I Z A T I ON A L M A I N T E N A NC E P a g eI N ST R UC T I ON S ( C ON T I N UE D)

    OR GA N I Z A T I O NA L MA I N T E N A NC E O FL U B R I C A T I O N S Y S T E M . . . . . . . . . .

    3 - 9 4 . Ge n er a l . . . . . . . . . . .3 - 9 5 . L u b r i c a t i o n o f Oi l F i l

    T H E E N GI N E. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 5 6

    . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 5 6t e r A s s e mb l y . . . . . . . . . . . 3 - 5 6

    OR GA N I Z A T I O NA L MA I N T E N A NC E O F T H EH Y DR A UL I C S Y S T E M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 5 9

    3 - 9 6 . Ge n e r a l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 5 93 - 9 7 . Hy d r a u l i c Su mp an d F i l t e r . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 5 93 - 9 8 . Hy d r a u l i c A c t u a t o r Un i t F i l3 - 9 9 . H y d r a u l i c L i n e s . . . . . . . . . .

    O RGA N I Z A T I O NA L MA I N T E N A NC E O F T H EE X H A U S T S Y S T E M S A N D B R E A T H E R T U B E

    3 - 1 0 0 . Ge n e r a l . . . . . . . . . . . . . . .

    t e r . . . . . . . . . . . . 3 - 5 9. . . . . . . . . . . . . . . . . . . . . . . . 3 - 5 9

    I N T AK E. . . . . . . . . . . . . . . . . . . . . . . . 3 - 6 3

    . . . . . . . . . . . . . . . . . . . . . . . . 3 - 6 33 - 1 0 1 . A i r C l e a n e r A s s e mb l y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 6 33 - 1 0 2 . Mu f f l e r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 6 33 - 1 0 3 . B r e a t h e r a n d Br e a t h e r T ub e . . . . . . . . . . . . . . . . . . . . . . . . 3 - 6 4

    O RG AN I Z A T I ON A L MA I N T E N A N CE OF T H EE N GI N E A S S E MB L Y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 6 5

    3 - 1 0 4 . Ge n e r a l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 6 5

    3 - 1 0 5 . Cr a n k s h a f t P u l l e y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 6 53 - 1 0 6 . I n t a k e Ma n i f o l d . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 6 53 - 1 0 7 . E x h a u s t Ma n i f o l d . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 6 53 - 1 0 8 . Ro c k e r A r m A s s e mb l y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 6 5

    3 - 1 0 9 . V a l v e Ta p p e t C l e a r a nc e A d j u s t me n t . . . . . . . . . . . . . . . . . 3 - 6 7

    3 - 1 1 0 . E n g i n e T e s t i n g. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    3 - 6 7

    O RG A NI Z A T I O NA L MA I N T E N A N CE OF T H EG E N E R A T O R S E T C O N T R O LS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 6 8

    3 - 1 1 1 . Ge n e r a l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 6 83 - 1 1 2 . Co n t r o l Cu b i c l e As s e mb l y . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 6 83 - 1 1 3 . F a u l t L o c a t i n g I n d i c a t o r . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 8 03 - 1 1 4 . Ma n u a l S p e e d Co n t r o l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 8 03 - 1 1 5 . DC Co n t r o l Ci r c u i t B r e a k e r . . . . . . . . . . . . . . . . . . . . . 3 - 8 23 - 1 1 6 . L o a d Me a s u r i n g Un i t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 8 2

    3 - 1 1 7 . Go v e r n o r C o n t r o l Un i t( P r e c i s e S e t s On l y ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 8 4

    3 - 1 1 8 . I n t e r c o n n e c t i n g Wi r i n g Ha r n e s s . . . . . . . . . . . . . . . . . . . . 3 - 8 4

    O RGA N I Z A T I ON A L MA I N T E N A N CE OF T H E

    G E NE R A T OR E L E C T R I C A L S Y S T E M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 8 5

    3 - 1 1 9 . Ge n e r a l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 8 5

    Ch an g e 9 v

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    3 - 1 2 0 .3 - 1 2 1 .3 - 1 2 2 .3 - 1 2 3 .3 - 1 2 4 .3 - 1 2 5 .3 - 1 2 6 .3 - 1 2 7 .

    V o l t a g e Re c o n n e c t i o n Bo a r d . . . . . . . . . . . . . . . . . . . . . . . .Ma i n l o a d Co n t a c t o r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cu r r e n t T r a n s f o r me r As s emb l i e s . . . . . . . . . . . . . . . . . . . .L o a d Te r mi n a l B o a r d A s s e mb l y . . . . . . . . . . . . . . . . . . . . . .Co n v e n i e n c e Re c e p t a c l e a n d Ci r c u i t B r e a k e r . . . . . . . .P a r a l l e l i n g Re c e p t a c l e s . . . . . . . . . . . . . . . . . . . . . . . . . . .T a c t i c a l Re l a y As s e mb l y . . . . . . . . . . . . . . . . . . . . . . . . . . .P r e c i s e Re l a y As s e mb l y

    ( 5 0 / 6 0 Hz Pr e c i s e Se t s ) . . . . . . . . . . . . . . . . . . . . . .

    3 - 8 53 - 8 63 - 8 6 B3 - 8 6 B3 - 8 6 B3 - 8 6 B3 - 8 7

    3 - 8 7

    S e c t i o n X V I I .

    3 - 1 2 8 .

    3 - 1 2 9 .

    3 - 1 3 0 .

    ORGAN

    S e c t i o n XV I I I .

    X I X .

    x x .

    X X I .

    C H A P T E R 4 .

    S e c t i o n I .

    S p e c i a l Re l a y A s s e mb l y( 5 0 / 6 0 Hz P r e c i s e a n d

    S p e c i a l Re l a y A s s e mb l y( 4 0 0 H z P r e c i s e S e t s )

    P r e c i s e Re l a y As s e mb l y

    ( 4 0 0 H z P r e c i s e S e t s )

    Z A T I ON A L M A I N T E NA N CE O F

    U t i l i

    . . . .

    . . . .

    t y Se t s ) . . . . . . . . . . . . . 3 - 8 7

    . . . . . . . . . . . . . . . . . . . . . . 3 - 8 7

    . . . . . . . . . . . . . . . . . . . . . . 3 - 8 7

    T H E G E N E R A T O R A S S E M B LY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 8 9

    3 - 1 3 1 . Ge n e r a l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 8 9

    3 - 1 3 2 . Or g a n i z a t i o n a l Ma i n t e n a n c e I n s p e c t i o no f Ge n e r a t o r A s s e mb l y . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 8 9

    OR GA N I Z A T I ON A L M A I N T E NA N CE O F T H E H O US I N GA N D S K I D B A SE A S S E MB L I E S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 8 9

    3 - 1 3 3 . Ge n e r a l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 8 93 - 1 3 4 . Do o r s , C o v e r s , a n d Pa n e l s . . . . . . . . . . . . . . . . . . . . . . . 3 - 8 93 - 1 3 5 . P l a t e a n d S l e e v e As s e mb l y . . . . . . . . . . . . . . . . . , . . . . . . . 3 - 8 93 - 1 3 6 . L i f t i n g F r a me . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 9 43 - 1 3 7 . S k i d Ba s e As s e mb l y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 9 4

    TOOL STOWAGE BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 9 5

    3 - 1 3 8 . Ge n e r a l . . . . . . . . . , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 9 5

    A UX I L I A RY FU EL L I N E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 9 6

    3 - 1 3 9 . Ge n e r a l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 9 63 - 1 4 0 . Re p a i r o f A u x i l i a r y F u e l L i n e . . . . . . . . . . . . . . . . . . . . . 3 - 9 6

    P A R AL L E L I N G C A BL E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 9 7

    3 - 1 4 1 . Ge n e r a l . . . . . . . . . . . . . . . . . .3 - 1 4 2 . Ma i n t e n a n c e o f Pa r a l l e l i n g

    MA T E R I A L U S E D I N CON J U N CT I ON WI T HG E N E R A T O R S E T . . . . . . . . . . . . . . . . . . . .

    G E N E R A L . . . . . . . . . . . . . . . . . . . . . . . . . .

    . . .

    C a b l e

    T HE. . .

    . . .

    . . . . . . . . . . . . . . . . . . . 3 - 9 7. . . . . . . . . . . . . . . . . . 3 - 9 7

    . . . . . . . . . . . . . . . . . . . . 4 - 1

    . . . . . . . . . . . . . . . . . . . . 4 - 1

    4 - 1 . S c o p e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 14 - 2 . S e r v i c e Up o n Re c e i p t o f Ma t e r i a l . . . . . . . . . . . . . . . . . . 4 - 1

    v i Ch an g e 9

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    CHAPTER 4.

    II.

    III .

    IV.

    V.

    TM 5-6115-465-12

    TO 35C2-3-446-1

    NAVFAC P-8-625-12

    TO 06858B/06859D-12

    TABLE OF CONTENTS (CONT)

    MATERIAL USED IN CONJUNCTION WITH GENERATOR

    SET (CONT)

    FUEL BURNING WINTERIZATION KIT . . . . . . . . . . . . . . . . . . . . .

    4-3. General

    4-4. Fuel Burning Winterization Kit Installation

    and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    4-5. Preventive Maintenance Checks and Services . . .

    4-6. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    4-7. Operator Inspection and Service of Fuel

    Burning Winterization Kit . . . . . . . . . . . . . . . . . .

    4-8. Organizational Maintenance of Fuel Burning

    Winterization Kit . . . . . . . . . . . . . . . . . . . . . . . . . .

    ELECTRIC WINTERIZATION KIT . . . . . . . . . . . . . . . . . . . . . . . . .

    4-9. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    4-10. Electric Winterization Kit Installation

    and Replacement

    4-11. Reventive Maintenance Checks and Services . .

    4-12. Troubleshooting

    4-13. Operators Maintenance of Electric

    Winterization Kit . . . . . . . . . . . . . . . . . . . . . . . . .

    4-14. Organizational Maintenance of ElectricWinterization Kit . . . . . . . . . . . . . . . . . . . . . . . . .

    WHEEL MOUNTING KIT

    4-15. General

    4-16. Preventive Maintenance Checks and Services . .

    4-17. Troubleshooting

    4-18. Operator Maintenance of Wheel Mounting Kit . .

    4-19. Organizational Maintenance of Wheel MountingKit

    LOAD BANK KIT

    4-20.

    4-21.

    4-22.

    4-23.

    4-24.

    4-25.

    GeneralInstallation, Testing, and Replacement of

    Load Bank

    Preventive Maintenance Checks and Services . .

    TroubleshootingOperator Maintenance Inspection of Load

    Bank

    Organizational Maintenance of Load Bank . . . . .

    4-1

    4-1

    4-1

    4-3

    4-4

    4-4

    4-4

    4-11

    4-11

    4-11

    4-14

    4-14

    4-14

    4-16

    4-22

    4-22

    4-22

    4-22

    4-22

    4-26

    4-29

    4-29

    4-29

    4-31

    4-31

    4-31

    4-31

    Change 13 vii

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    TM 5-6115-465-12

    TO 35C2-3-446-1

    NAVFAC P-8-625-12

    TM 06858B/06859D-12

    TABLE OF CONTENTS (CONT)

    VI. ACOUSTICSUPPRESSIONKIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40

    4-26. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40

    4-27. Acoustic suppression kit installation and removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41

    A P P E N D I X A . REFERENCESA P P E N D I X B . COMPONENTS OF ENDITEMLIST

    A P P E N D I X C . MAINTENANCE ALLOCATION CHART(ARMY ONLY)

    A P P E N D I X D . MAINTENANCE AND OPERATING SUPPLIES (ARMY ONLY)

    A P P E N D I X E . ADDITIONAL AUTHORIZATION LIST

    Figure

    1-1.1-1.1.1-2.1-2.1

    1-3.1-4.2-1.

    1-92-4

    2-2.2-3.2-4. 2-7

    2-82-5.2-6.2-7.2-8.2-9.2-10.2-11.2-12.2-13.2-14.

    3-1.3-2.

    3-4.3-5.3-6.

    3-3.

    3-7.3-7A.3-7B.

    3-8.3-9.3-10.3-11.3-12.3-12A.

    3-12B

    3-13.3-14.3-15.3-16.

    3-17.3-18.

    3-19.3-20.

    LIST OF ILLUSTRATIONS

    Title

    Engine Generator Set, Right Front, Three-Quarter View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine Generator Set, Right Front, Electric Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine Generator Set,Left Rear, Three-Quarter View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Acoustic Suppression Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Fuel System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hydraulic System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Installation Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ground Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Load Terminal Board Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Paralleling for Load Sharing.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Paralleling for Load Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Voltage Reconnection Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Generator Set Controls and Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Starting the Generator Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Stopping the Generator Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Operating the Fuel Burning Winterization Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Operating the Electric Winterization Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Using the Wheel Mounting Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Operating the Load Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Acoustic Suppression Kit...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    DeletedServicing the Engine Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Servicing the Engine Air Cleaner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Servicing Fuel Strainer and Filter Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Radiator Hose Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Servicing Secondary Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Main Fuel Tank Inspection and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Emergency Conversion Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Emergency Conversion Connections (effective with Serial

    No. RZ70001 and XZ00001 thru KZ02752 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Battery Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Slave Receptacle, Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Starter Assembly, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Starter Brushes Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Starter Solenoid Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Starter Solenoid Replacement (effective with Serial

    No. RZ70001) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Starter Brushes Replacement (effective with SerialNo. RZ70001) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Battery Charging Alternator Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Alternator Test Leads Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Alternator Test Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Day Tank Fuel Level and Low Fuel Cutoff Switch and

    Fuel Solenoid Valve Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel Transfer Pumps, Service and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel Strainer and Filter Assembly, Removal and

    Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Day Tank Assembly, Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SecondaryFuel Filter Assembly, Removal and

    Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    viii Change 17

    Page

    1-21-2A1-4.11-4.2

    1-9

    2-52-7

    2-82-102-152-182-222-242-252-262-29

    3-43-113-113-133-163-173-24A

    3-24B3-263-283-293-303-32

    3-34

    3-34B3-34D3-353-35

    3-383-42

    3-433-44

    3-45

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    Figure

    3-21.3-22.

    3-23.3-24.3-25.3-26.3-27.3-28.3-29.3-30.3-31.3-32.3-33.3-34.3-35.3-36.

    3-37.

    3-38.3-39.3-91.13-40.3-41.3-42.3-43.3-43A.3-43B.3-44.

    3-45.3-46.3-47.3-48.3-49.3-50.4-1.4-2.

    4-3.4-4.4-5.4-6.

    4-7.4-8.4-9.

    4-10.4-11.4-12.4-13.

    4-14.4-15.

    4-16.FO-1.

    FO-2.

    FO-3.

    TM5-6115-465-12

    TO 35C2-3-446-1

    NAVFAC P-8-625-12

    TM 06858B/06859D-12

    LIST OF ILLUSTRATIONS (CONT)

    Title

    Fuel Injection Nozzle Holders and Lines, Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel Lines and Fittings, Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Start Aid Assembly, Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Grille, Radiator, and Shutter Assembly, Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Water Pump, Cooling Fan and V-Belt, Removal and Installation . . . . . . . . . . . . . . . . . . . . . . .Coolant Thermostat, Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Lubrication Oil Filter Assembly, Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hydraulic Sump and Filter Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Servicing the Hydraulic Actuator Unit Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hydraulic Lines and Fittings, Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Air Cleaner Assembly, Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Muffler, Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Breather and Breather Tube, Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Intake Manifold, Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Exhaust Manifold, Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rocker Arm Assembly Inspection and Valve Tappet Clearance

    Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Control Cubicle Assembly, Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Volts-Amps Transfer Switch Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fault Locating Indicator Lamp and Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fault Locating Indicator, Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Manual Speed Control, Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DC Circuit Breaker, Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Load MeasuringUnit, Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Voltage Reconnection Board, Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Main Load Contactor, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Terminal Clip Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Convenience Receptacle and Circuit Breaker, Removal and

    Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Paralleling Receptacles, Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Housing Assembly, Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Plate and Sleeve Assembly, Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tool Stowage Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Repair of Auxiliary Fuel Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Repair of Paralleling Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel Burning Winterization Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel Burning Winterization Kit Heater Assembly, Inspection and

    ServiceFuel Burning Winterization Kit Heater Control Assembly Maintenance . . . . . . . . . . . . .Fuel Burning Winterization Kit Heater Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . .Electric Winterization Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Electric Winterization Kit Control Assembly Indicator Lamp

    Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Electric Winterization Kit Control Assembly, Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . .Electric Winterization Kit Wiring Harness, Dwg. No. 72-2855 . . . . . . . . . . . . . . . . . . . . . . . . .Wheel Mounting Kit, Front Axle and Tow Bar Assembly, Exploded

    View

    Wheel Mounting Kit, Wheels and Brakes, Exploded View. . . . . . . . . . . . . . .Load Bank Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Load Bank Assembly Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Load Bank Wiring Diagram, Dwg. No. 72-2826 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Load Bank Schematic Diagram, Dwg. No. 72-2827 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Roof Stiffeners, Sealing Angle, Oil Drain, Isolators, Bottom Panel

    Tray Assembly, and Trailer BracketsAcoustic Suppression Kit Major Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .AC and DC, 15 and 30 KW, 50/60 and 400 Hz, Precise and

    Utility, Wiring Diagram, Dwg. No. 72-2205 (4 sheets) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .AC Schematic Diagram, 15 and 30 KW, Precise Generator

    Sets, Dwg. No. 72-2200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DC Schematic Diagram, 15 and 30 KW, Precise Generator

    Sets, Dwg. No. 72-2269 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Page

    3-463-48

    3-503-523-543-553-573-583-603-613-623-623-643-663-66

    3-673-69

    3-753-80A3-80B3-823-833-833-863-86A3-86B

    3-873-883-913-933-953-963-974-2

    4-74-84-104-12

    4-174-184-21

    4-254-284-304-344-36

    4-38

    4-424-43

    FO-1

    FO-2

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    LIST OF ILLUSTRATIONS (CONT)

    Figure Title

    1-1.2-1.

    3-1.3-2.3-3.

    FO-4.

    FO-5.

    Table

    4-2.4-3.

    4-4.4-5.4-6.

    AC Schematic Diagram, 15 and 30 KW, Utility Generator

    Sets, Dwg. No. 72-2295 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DC Schematic Diagram, 15 and 30 KW, Utility Generator

    Sets, Dwg. No. 72-2277 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    LIST OF TABLES

    Title

    3-63-18

    3-4.

    3-5.4-1.

    Differences in Performance Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Freezing Points, Composition and Specific Gravities of Military

    Anti-Freeze Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Preventive Maintenance Checks and Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Specific Gravity Temperature Corrections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .State of Charge With Specific Gravity Corrected to 80F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Alternator Voltages at Ambient Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel Burning Winterization Kit Preventive Maintenance Checks

    and Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel Burning Winterization Kit Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Electric Winterization Kit Preventive Maintenance Checks and

    Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Electric Winterization Kit Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Wheel Mounting Kit Preventive Maintenance Checks and Services . . . . . . . . . . . . . . . . . . . . . . .Wheel Mounting Kit Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Load Bank Preventive Maintenance Checks and Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Load Bank Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Page

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    Page

    1-10

    2-2

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    1 - 1 . S c o p e

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    CHAPTER 1

    I N T R O D U C T I O N

    Section I. GENERAL

    a . T h i s ma n u a l i s p ub l i s h ed f o r t h e i n f o r ma t i o na n d g u i d a n c e o f p e r s o n n e l t o wh o m t h e 3 0 KW Di e -s e l E n g i n e Dr i v e n Ge n e r a t o r S e t i s i s s u e d . I tc o n t a i n s i n s t r u c t i o n s f o r o p e r a t i o n a n d o r g a n i z a -t i o n a l ma i n t e n a n c e o f 5 0 / 6 0 Hz ( Mo d e I ) T a c t i c a lP r e c i s e ( C l a s s 1 ) a n d 40 0 Hz ( Mo d e I I ) T a c t i c a lP r e c i s e ( C l a s s 1 ) mo d e l s o f t h e g e ne r a t o r s e t .A l s o i n c l u d e d a r e d e s c r i p t i o n s o f ma j o r c o mp o n e n t sa n d t h e i r f u n c t i o n s i n r e l a t i o n t o o t h e r c o mp o -n e n t s .

    b . A p p e n d i x A c o n t a i n s a l i s t o f r e f e r e n c e pu b -l i c a t i o n s ap p l i c a b l e t o t h i s ma n u a l .

    N O T E

    Ma r i n e Co r p s u s e r s s h o u l d r e f e r t o t h eS L - 1 - 2 u n d e r t h e e q u i p me n t I D n u mb e r sf o r a l i s t i n g o f r e l a t e d p u b l i c a t i o n s .T h e y s h o u l d r e f e r t o t h e a pp l i c a b l es t o c k l i s t f o r i s s u e o f ma i n t e n a n c e an do p e r a t i n g s up p l i e s .

    c . A p p e n d i x B ( A r my On l y ) l i s t s i n t e g r a l c o m-p o n e n t s o f a n d b a s i c i s s u e i t e ms . A p p e n d i x Cc o n t a i n s t h e Ma i n t e n a n c e Al l o c a t i o n Ch a r t wh i c hd e t e r mi n e s l e v e l o f ma i n t e n a n c e f o r A r my u s e r s .A p p e n d i x D l i s t s ma i n t e n a n c e a n d o p e r a t i n g s u p -p l i e s . A p p e n d i x E l i s t s a d d i t i o n a l i t e ms t h a ta r e au t h o r i z e d .

    1 - 2 .

    a .

    N O T E

    A i r F o r c e u s e r s s h a l l a c c omp l i s h ma i n -t e n a n c e a t u s e r l e v e l c o n s i s t e n t w i t ht h e i r c a p a b i l i t y i n a c c o r d a n c e wi t h p o l -i c i e s e s t a b l i s h e d b y AF M 6 6 - 1 .

    F o r ms a n d Re c o r d s

    N O T E

    T h i s ma n u a l i s u s e d b y Ar my , A i r F o r c e ,Na v y , a n d Ma r i n e Co r p s p e r s o n n e l . Us eo f f o r ms a s d i r e c t e d i n t h i s ma n u a l wi l lb e a c c o mp l i s h e d o n l y b y p e r s o n n e l o f t h a ts e r v i c e t o w h i c h s u c h f o r ms a p p l y .

    Ma i n t e n a n c e F o r ms a n d r e c o r d s u s e d b y A r myp e r s o n n e l w i l l b e o n l y t h o s e p r e s c r i b e d b y

    DA PA M 7 3 8 - 7 5 0 . T h o s e t o b e u s e d b y Ma r i n aCo r p s p e r s o n n e l a r e p r e s c r i b e d i n t h a c u r r e n te d i t i o n o f T M 4 7 0 0 - 1 5 / 1 . A i r F o r c e f o r ms a n dr e c o r d s u s e d wi l l b e t h o s e p r e s c r i b e d b yA F M 6 6 - 1 a n d t h e a p p l i c a b l e 0 0 - 2 0 S e r i e sT e c h n i c a l Or d e r s . Na v y u s e r s s h o u l d r e f e rt o t h e i r a p p r o p r i a t e s p e c i f i c a t i o n s o r p u b l i -c a t i o n t o d e t e r mi n e t h e a p p l i c a b l e ma i n t e n a n c eF o r ms a n d r e c o r d s t o b e u s e d .

    b . Re p o r t o f e r r o r s , o mi s s i o n s , a n d r e c o mme n -d a t i o n s f o r i mp r o v e me n t o f t h i s ma n u a l b y i t su s e r i s e n c o u r a g e d . S uc h r e p o r t s s h o u l d b e s u b -mi t t e d by v a r i o u s s e r v i c e p e r s o n n e l a s f o l l o ws :

    ( 1 ) A i r F o r c e . A F TO F o r m 2 2 d i r e c t l y t o Co m-ma n d e r , S a c r a me n t o Ai r L o g i s t i c s Ce n t e r , S M- A LC-MME DT A, Mc Cl e l l a n A i r F o r c e B a s e , CA 9 56 5 2 - 5 6 0 9i n a c c o r d a n c e wi t h T O- 0 0 - 5 - 1 .

    ( 2 ) A r my . DA F o r m 20 2 8 d i r e c t l y t o C o mma n d er ,U S A r my T r o o p S u p p o r t C o mma n d , A T T N: A MS T R- MC TS ,4 3 0 0 Go o d f e l l o w B l v d . , S t . L o u i s , MO 6 3 1 2 0 - 1 7 9 8 .

    ( 3 ) Ma r i n e Co r p s . NA V MC 1 0 7 7 2 d i r e c t l y t oCo mma n d i n g Ge n e r a l , U S Ma r i n e Co r p s , Ma r i n e Co r p s

    L o g i s t i c s Ba s e , ( Co d e 8 5 0 ) , A l b a n y , GA 3 1 7 0 4 - 5 0 0 0 .

    ( 4 ) Na v y . B y l e t t e r d i r e c t l y t o Co mma n de r ,Na v a l Co n s t r u c t i o n Ba t t a l i o n Ce n t e r , A T TN: Co d e1 5 7 4 1 , P o r t Hu e n e me , CA 9 3 0 43 - 5 0 0 0 .

    1 - 2 . 1 . Ha n d Re c e i p t . A r my . Ha n d r e c e i p t s CO V -e r i n g t h e Co mp o n en t s o f E n d I t e m ( COE I ) , B a s i cI s s u e I t e ms ( B I I ) a n d A d d i t i o n a l A u t h o r i z a t i o nL i s t ( A AL ) i t e ms a r e p u b l i s h e d i n a Ha n d Re c e i p tMa n u a l . T h e Ha n d Re c e i p t Ma n u a l n u me r i c a l d e s i g -n a t i o n i s t h e s a me a s t h e r e l a t e d T e c h n i c a l Ma n -u a l wi t h t h e l e t t e r s H R a d d e d t o t h e nu mb e r .T he s e ma n u a l s a r e p u b l i s h e d t o a i d i n p r o p e r t ya c c o u n t a b i l i t y a n d a r e a v a i l a b l e t h r o u g h :Co mma n d e r , US Ar my A d j u t a n t Ge n e r a l P u b l i c a t i o nCe n t e r , 2 8 0 0 Ea s t e r n B l v d . , B a l t i mo r e , MD 21 2 2 0 -2 8 9 6 .

    1 - 3 . De mo l i t i o n t o P r e v e n t E n e my Us e

    De mo l i t i o n o f t h e ge n e r a t o r s e t t o p r e v e n t e n e myu s e wi l l b e i n a c c o r d a nc e wi t h t h e r e q u i r e me n t so f T M 7 5 0 - 2 4 4 - 3 ( P r o c e d u r e s f o r D e s t r u c t i o n o fE q u i p me n t t o P r e v e n t E ne my U s e f o r US Ar my a n dUS Ma r i n e Co r p s ) .

    1 - 4 . S h i p me n t a n d St o r a g e

    P r e p a r a t i o n f o r s h i p me n t a n d s t o r a g e f o r U S A i rF o r c e w i l l b e i n a c c o r d a n c e wi t h . T O 3 5 - 1 - 4 . S h i p -me n t a n d S t o r a g e f o r US Ar my a n d U S Ma r i n e Co r p swi l l b e i n a c c o r d a nc e wi t h T B 7 4 0 - 9 7 - 2 .

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    a.

    (5)

    (6)

    TM 5-6115-465-12

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    Section II. DESCRIPTION AND DATA

    1-5. DESCRIPTION.

    General. The generator

    sets, models MEP-005A, MEP-104A andMEP-114A (figures 1-1, 1-1.1 and

    1-2) are fully enclosed, self-

    contained, skid mounted, portable

    units. They are equipped with

    controls, instruments and acces-

    sories necessary for operation as

    single unit or in parallel with one

    or more units of the same class and

    mode. Each set is equipped with

    engine oil pan heating elements and

    necessary connections for field

    installation of winterization kits.

    Lifting clevises for hoisting the

    enerator set are located at the top

    of the lifting frame and center

    support assembly. Tubular cross

    members, that will accept a chain,

    have been provided at the front and

    rear of the skid base assembly to

    permit towing or short distances.

    Mobility of the units may be

    obtained by mounting on trailers or

    equipping with a wheel mounting

    kit. To extend the capability of

    the generator sets, they have also

    been designed to accept and operate

    with the following optional kits:

    (1) Fuel Burning Winteriza-

    tion Kit (paragraph 4-3).

    (2) Electric Winterization

    Kit (paragraph 4-9).

    (3) Wheel Mounting Kit

    (paragraph 4-15).

    (4) Load Bank Kit (paragraph

    4-20).

    Automatic Transfer Panel

    primary power and automatically

    starts and transfers the load to astandby generator set in the event

    of abnormal primary power fluctu-

    ation or failure. Continues

    sensing primary power and upon

    satisfactory resumption, will

    return the load to the primary

    power source, shut-off and recycle

    the generator set to a standby

    condition. (See Appendix A for

    manual.)

    Automatic Transfer Panel

    : Monitors 400 Hz power and

    automatically starts and transfers

    the load from an operating 400 Hz

    generator set to a like standby set

    in the event the operating set load

    contactor opens due to a faulty

    condition. (See Appendix A formanual.)

    (7) Remote Control Box:

    Permits starting and stopping of

    the generator set from a remote

    location. (See Appendix A formanual.)

    (8) Auxiliary Fuel Burning

    Winterization: Provides a

    dependable external source of

    battery power for starting of the

    generator set in ambient

    temperatures from -25F to -65oF.

    (See Appendix A for manual.)

    (9) Auxiliary Electric

    Winterization: Provides a

    dependable external source of

    battery power for starting a

    generator set in ambient

    temperatures from -25F to -65oF.

    (See Appendix A for manual.)

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    (10) Acoustic Suppression

    Kit: Provides noise suppression to

    lower sound to 70 dB(A) at 7 meters

    (paragraph 1-6.e).

    b. Engine. Power source of thegenerator set is a six cylinder,

    four cycle, fuel injected, liquid

    cooled diesel engine. The engine

    electrical system contains a

    cranking motor, two 12 volt

    batteries in series, and a battery

    charging alternator with integral

    rectifier and voltage regulator.

    The engine is also equipped with a

    fuel filter and strainer assembly,

    a secondary fuel filter, a

    lubricating oil filter, and an air

    cleaner. Cooling water iscirculated through the engine by a

    water pump. Safety devices

    automatically stop the engine

    during conditions of high coolant

    temperature, low oil pressure, no

    fuel, over-speed, or over-voltage.

    c. Generators. The alternating

    current generators are single

    bearing, drip-proof, synchronous,

    brushless, three phase, fan cooled

    generators. Rated voltages are

    maintained by excitation of the

    generator-exciter field by a static

    exciter mounted on the relay table.

    The cooling fan, located at the

    front of the generator, impels

    cooling air which enters the

    generator and passes over the

    windings. Safety devices are

    provided to protect the generator

    in the event of short circuit,

    overload, under-voltage,

    under-frequency, reverse power, and

    over-voltage.

    d. Control Cubicle. The

    generator set control cubicle is

    located at the rear top of the

    generator set and contains controls

    and instruments for operating the

    engine and the generator. The

    control panel is grounded to

    protect the operator from

    electrical shock in the event of a

    short in the equipment. Thegenerator section of the control

    panel contains meters for

    monitoring generator output,

    adjusting knobs for increasing and

    decreasing frequency (Class 1 only)

    and voltage, and a circuit breaker

    switch for interrupting all output

    from the generator set. Also

    included on the generator control

    panel are an operations switch and

    synchronizing lights for operating

    the set as a single unit or in

    parallel with other units. Theengine section of the control panel

    contains switches for priming,

    starting, and stopping the engine

    and meters for monitoring set fuel

    level, oil pressure, and coolant

    temperature. Also included is an

    ammeter for the battery charging

    alternator.

    e. Electric/Electro-Hydraulic

    Governing System (Precise Sets

    only). The governing system senses

    the speed and load electrically andprovides the controls and load

    responses necessary for effective

    single unit or parallel operation.

    The system consists of a rheostat

    for frequency adjustment, a load

    measuring unit for sensing load

    changes, and governor control unit

    which signals the actuator for

    rapid governor response. The

    MEP-104A Electro-Hydraulic System

    has a hydraulic actuator, a

    hydraulic pump and a hydraulic

    sump.The MEP-114A sets use an

    Electric-Magnetic Actuator.

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    f . Me c ha n i c a l G o v e r n i n g Sy s t e m ( U t i l i t y S e t sOn l y ) . T h e me c h an i c a l g o v e r n i n g s y s t e m p r o v i d est h e c on t r o l s a n d l o a d r e s p o n s e s n e c e s s a r y f o r e f -f i c i e n t s i n g l e u n i t , o r p ar a l l e l , o pe r a t i o n o fu t i l i t y g en er a t o r s e t s . E n g i n e r p m a n d s e t f r e -q u en c y a r e c o n t r o l l e d b y t h e me c h an i c a l g o v e r n o r ,a n i n t e g r a l p a r t o f t h e f u e l i n j e c t i o n p u mp ,wh i c h a c t u a t e s t h e f u e l me t e r i n g v a l v e . A d j u s t -me n t o f e n g i n e r p m a n d s e t f r e q ue n c y i s a c c o m-

    p l i s h e d b y u s e o f a ma n ua l s p e ed c o nt r o l l o c a t e da d j a c e n t t o t h e c o n t r o l c u b i c l e . T hi s c o nt r o li s a k n o b t y p e de v i c e wh i c h p e r mi t s r a p i d f r e -q u e n c y a d j u s t me n t , l o c k i n g i n a n y p o s i t i o n , a n dv e r n i e r a d j u s t me n t f o r f i n e r c o n t r o l .

    1 - 6 . I D EN T I F I C AT I ON A ND T AB UL A T E D D AT A .

    a . I d en t i f i c a t i o n . T h er e a r e e l e v e n ma j o ri d e n t i f i c a t i o n an d i n s t r u c t i o n p l a t e s o n t h e g e n-e r a t o r s e t .

    ( 1 ) Ge n e r a t o r S e t I d e n t i f i c a t i o n P l a t e .L oc a t e d a t t h e t o p l e f t s i d e o f t h e f r o n t h o u s i n ga s s e mb l y . S p e c i f i e s n o me n c l a t u r e , mo d e l n u mb e r ,s e r i a l n u mb e r , s t o c k nu mb e r , c o n t r a c t n u mb e r , e n -g i n e s e r i a l n u mb e r , ma n u f a c t u r e r , a n d s h i p p i n gwe i g h t a n d d i me n s i o n s .

    ( 2 ) Ge n e r a t o r S e t Ra t i n g Pl a t e . L o c a t e d a tt o p l e f t s i d e o f f r o n t h o u s i n g a d j a c en t t o g e n e r -a t o r s e t i d en t i f i c a t i o n p l a t e . Sp e c i f i e s k i l o wa t tc a pa c i t y r e l a t i v e t o a l t i t u d e a n d t e mp e r a t u r e ,h e r t z r a t i n g , r a t e d v o l t a g e s a n d ph a s e s , v o l t a g ea d j u s t me n t r a n g es , p o we r f a c t o r , t y p e , c l a s s , mo d ea n d s i z e .

    ( 3 ) F u e l S y s t e m D i a g r a m P l a t e . L o c a t e d oni n s i d e f a c e o f l e f t s i d e ge n e r a t o r c o mp a r t me n ta c c e s s d o o r . Co n t a i n s d i a g r a m o f f u e l s y s t e m.

    ( 4 ) O p e r a t i n g I n s t r u c t i o n P l a t e . L o c a t e do n i n s i d e f a c e o f r i g h t h a n d c o n t r o l p a n e l a c c es sd o o r . S p e c i f i e s p r e s t a r t c h e c k s , s t a r t i n g s e -q u e n c e , s t o p p i n g s e q u e n c e , a n d i n s t r u c t i o n s f o rp ar a l l e l o p er a t i o n .

    ( 5 ) S c h e ma t i c a n d T r o u b l e s h o o t i n g Di a g r a m

    P l a t e s . T r o u b l e s h oo t i n g p l a t e i s l o c a t e d on i n -s i d e f a c e o f r i g h t a n d l e f t e n g i n e c o mp a r t me n td o o r s . A s c h e ma t i c d i a g r a m p l a t e i s l o c a t e d o nt h e i n s i d e o f t h e ba t t e r y d o o r s o f t h e po we r g e n -e r a t i o n a n d c o n t r o l c i r c u i t s .

    ( 6 ) Wi n t e r i z a t i o n Sy s t e m Di a g r a m a n d C a u -t i o n P l a t e s ( f u r n i s h e d wi t h Wi n t e r i z a t i o n K i t ) .I n s t a l l e d o n i n s i d e f a c e o f l e f t r e a r u p p e r c o n -t r o l a n d l o we r l e f t v e n t d o o r . S p e c i f i e s i n s t a l -l a t i o n a n d op e r a t i o n o f w i n t e r i z a t i o n s y s t e ms .A l s o i n c l u d e s c a u t i o n s p er t i n e n t t o o p e r a t i o n o fwi n t e r i z a t i o n k i t s .

    ( 7 ) L i f t i n g a n d T i e - Do wn A t t a c h me n t I n f o r ma -t i o n P l a t e . L o c a t e d i n t h e l o we r r i g h t r e a rg e ne r a t o r c o mp a r t me n t d o o r . S p e c i f i e s c e n t e r o fg r a v i t y , t i e - d o wn l o c a t i o n , l i f t i n g s h a c k l e l o -c a t i o n a n d c a p a c i t y a n d d i r e c t i o n o f t r a v e l .

    ( 8 ) B a t t e r y Re c o n n e c t i o n I n s t r u c t i o n P l a t e .L o c at e d i n s i d e f a c e o f b a t t e r y c o mp a r t me n t a c c e s sd o o r . Co n t a i n s d i a g r a m o f b a t t e r y i n s t a l l a t i o na n d s p e c i f i e s c a u t i o n s t o b e ob s e r v e d wh e n r e -p l a c i n g b a t t e r i e s .

    ( 9 ) G e n e r a t o r I d e n t i f i c a t i o n P l a t e . L o c a t e do n u p pe r r i g h t s i d e o f g e n e r a t o r h o u s i n g . S p e c i -f i e s n o me n c l a t u r e , p a r t n u mb e r , s t y l e , r a t e d r p m,f r e q u en c y s er i a l n u mb e r , k v a r a t i n g , P / F , a mp e r er a t i n g , v o l t a g e , a n d ma n u f a c t u r e r .

    TM 5-6115-465-12

    TO 35C2-3-446-1

    NAVFAC P-8-625-12

    TM-06858B/06859D-12

    ( 1 0 ) E n g i n e I d e n t i f i c a t i o n P l a t e . L o c a t e do n l e f t s i d e o f e n g i n e b l o c k . S p e c i f i e s ma n u f a c -t u r e r , ma n u f a c t u r e r s s p e c i f i c a t i o n , mo d e l n u mb e r ,s e r i a l n u mb e r , d a t e o f ma n u f a c t u r e , b o r e , s t r o k e ,d i s p l a c e me n t , ma x i mu m c o n t i n u o u s s p ee d , m ax i mu ms e t c o n t i n u o u s b r a k e h or s e p o we r , l u b e o i l p r e s -s u r e , f i r i n g o r d e r , i n t a k e a n d e x h a u s t v a l v e t a p -p e t c l e a r a n c e s , a n d mi l i t a r y s p e c i f i c a t i o n .

    ( 1 1 ) V o l t a g e R e c o n n e c t i o n Pl a t e . L o c a t e d o nt e r mi n a l g u a r d o v e r v o l t a g e r e c on n e c t i o n b oa r d .Co n t a i n s i n s t r u c t i o n s f o r r e c o n n e c t i n g t h e g e n e r -a t o r f r o m 1 2 0 / 2 0 8 t o 2 4 0 / 4 1 6 v o l t s a n d r e c on f i g -u r a t i o n b a c k t o 1 2 0 / 2 0 8 v o l t s .

    b . T ab u l a t e d Da t a .

    ( 1 ) E n g i n e G e n e r a t o r S e t ( E n d I t e m) :

    Mo d e l Nu mb e r s :

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    D OD Dr a w i n g N u mb e r s :

    ME P - 0 0 5 A . . . . . . . . . . . . . . . . . . . 7 0 - 0 0 5

    ME P - 1 0 4 A . . . . . . . . . . . . . . . . . . . . 7 0- 1 0 4ME P - 1 1 4 A . . . . . . . . . . . . . . . . . . . . 7 0 - 1 1 4

    Ov e r a l l Di me n s i o n s an d We i g h t s :

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    Ov e r a l l h e i g h t ( MEP - 0 0 5 A,ME P- 1 0 4 A , a n d M EP - 1 1 4 A ) . . . . .

    Dr y We i g h t s ( l e s s k i t s a n d o p t

    ME P - 0 0 5 A . . . . . . . . . . . . . .ME P - 1 0 4 A . . . . . . . . . . . . . .ME P - 1 1 4 A . . . . . . . . . . . . . .

    ( 2 ) E n g i n e :

    Ma nu f a c t u r e r . . . . . . . . .

    Mo de l . . . . . . . . . . . .D OD d r a w i n g n u mb e r . . . . . .T y p e . . . . . . . . . . . . . . . . . .

    . . . . 5 5 i n c h es

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    . . . . 2 8 5 0 p o u n d s

    . . . . 2 8 5 0 p o u n d s

    . . . 3 0 0 0 p o u n d s

    Wh i t e En g i n e s , I n c .He r c u l e s E ng i n e Di v .

    D - 2 9 8 - E RX 3 77 2 - 2 2 0 66 c y l i n d e r , f o u r

    c y c l e , l i q u i d c o o l e dd i e s e l

    Ra t e d h o r s e p o we r a t 1 5 0 0 RP M . . . . . . 5 0 c o n t i n u o u sRa t e d h o r s e p o we r a t 1 8 0 0 RP M . . . . . . 5 7 c o n t i n u o u sRa t e d h o r s e p o we r a t 2 0 0 0 RPM . . . . . . 6 4 c o n t i n u ou sA l t i t u d e de g r a d a t i o n ,

    5 00 0 t o 8 00 0 f t . . . . . . . . 3 % p e r 1 0 0 0 f e e tF i r i n g o r d e r . . . . . . . . . . . 1 , 5 , 3 , 6 , 2 , 4Wi n t e r i z a t i o n k i t u s e . . . . Wh e n t e mp e r a t u r e

    i s - 2 5 F o r b e l o w

    V a l v e t a p pe t c l e a r a n c e a d j u s t me n t :

    Ho t . . . . . . . . . . . . .

    ( 3 ) C o o l i n g Sy s t e m:

    T y p e . . . . . . . . . . . . . . . . . . . . .

    Ca p a c i t y . . . . . . . . . . . . . . . . .

    0 . 0 1 5 I n c h

    P r e s s u r i z e d r a d i a -t o r a n d c e n t r i f u g a lp u m p

    2 3 . 5 q t s .

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  • 8/2/2019 013545

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    ( 9 ) G e n e r a t o r ( 4 0 0 Hz T a c t i c a l P r e c i s e )

    T y p e . . . . . . . . . . . . . . . . . . . . . . Ro t a t i n g f i e l d s y n -

    c h r o n o u s , b r u s h l e s s

    L o ad c a p a c i t y ( 2 0 0 0 r p m) . . 3 0 k w a t 4 0 0 H Z

    Cu r r e n t r a t i n g ( 2 0 0 0 r p m) . 1 0 4 a mp s a t 1 2 0 / 2 0 8

    V a c o r 5 2 a mp s a t2 4 0 / 4 1 6 Va c

    P o we r f a c t o r . . . . . . . . . . . . . . 0 . 8

    C o o l i n g . . . . . . . . . . . . . . . . . . . I mp e l l e r f a n

    L u b r i c a t i o nr e q u i r e me nt s . . . . . . . . . . . . N on e

    Dr i v e t y p e . . . . . . . . . . . . . . . D i r e c t c o u pl i n g

    Du t y c l a s s i f i c a t i o n . . . . . . . Co nt i n uo us

    ( 1 0 ) E l e c t r o - h y d r a u l i c G o v e r n i n g Sy s t e m:

    T yp e s y s t e m . . . . . . . . . . . . . . . Cl o s e d l o op f e e d ba c k

    L o a d me a s u r i n g u n i t :

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    I n d u s t r i e s , I n c .

    Mo d e l N o . . . . . . . . . . . . . . . . 6 9 - 5 0 0

    DOD d r a wi n g n u mb e r . . . . . . . 6 9 - 7 8 5

    Go v e r n o r c o n t r o l u n i t :

    Ma nu f a c t u r e r . . . . . . . . . . . . . E l e c t r o ma gn e t i cI n d u s t r i e s , l n C.

    Mo d e l N o .

    5 0 / 6 0 H Z . . . . . . . . . . . . . . . . 6 9 -


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