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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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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.
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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
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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
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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
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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
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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 . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .
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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
. . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . .
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N O C h a r g e . . . . . . . . . .
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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
-
8/2/2019 013545
51/333
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
-
8/2/2019 013545
52/333
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
-
8/2/2019 013545
53/333
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
FO-3
Change 17 ix
-
8/2/2019 013545
54/333
TM 5-6115-465-12
TO 35C2-3-446-1
NAVFAC P-8-625-12
TM 06858B/06859D-12
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
FO-4
FO-5
Page
1-10
2-2
3-273-27
3-36
4-54-6
4-154-164-234-244-324-33
4-7.4-8.
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1 - 1 . S c o p e
TM 5-6115-465-12TO 35C2-3-446-1NAVFAC P-8-625-12TM 06858B/06859D-12
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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F i g u r e 1 - 1 . E n g i n e Ge n e r a t o r S e t Ri g h t F r o n t
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a.
(5)
(6)
TM 5-6115-465-12
TO 35C2-3-446-1
NAVFAC P-8-625-12
TM 06858B/06859D-12
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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TM 5-6115-465-12
TO 35C2-3-446-1
NAVFAC P-8-625-12
TM 06858B/06859D-12
(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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TO 35C2-3-446-1
NAVFAC P-8-625-12
TM 06858B/ 06859D-12
F i g u r e 1- 2 .1 . A co u st ic Su p p r e ss io n Ki t
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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 :
5 0 / 6 0 Hz T a c t i c a l Ut i l i t y . . . . . . . . . . . . ME P- 0 0 5 A5 0 / 6 0 Hz T ac t i c a l P r e c i s e . . . . . . . . . . . . ME P- 1 0 4 A4 0 0 Hz T ac t i c a l P r e c i s e . . . . . . . . . . . . . . ME P - 1 1 4A
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 :
Ov e r a l l l e n g t h ( MEP - 0 0 5 A,ME P- 1 0 4 A , a n d ME P- 1 1 4 A ) . . . . . . . . . . 8 0 i n c h es
Ov e r a l l w i d t h ( ME P- 0 0 5 A,ME P- 1 0 4 A , a n d M EP - 1 1 4 A ) . . . . . . . . . . 3 6 i n c h es
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
i o n a l e q u i p me n t ) :
. . . . 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 .
Change 9 1-5
-
8/2/2019 013545
64/333
-
8/2/2019 013545
65/333
( 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 :
Ma nu f a c t u r e r . . . . . . . . . . . . . E l e c t r o ma gn e t i c
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 -