071030 - radionerds · 2019. 5. 8. · title: 071030 author: atcom subject: tm 9-6115-645-10...

ARMY TM 9-6115-645-10AIR FORCE TO 35C2–3-444–11

MARINE CORPS TM 09244A/09245A–10/1

TECHNICAL MANUAL

OPERATOR’S MANUAL

GENERATOR SET,

SKID MOUNTED, TACTICAL QUIET

60 KW, 50/60 AND 400 HZ

MEP-806A (50/60 HZ) 6115-01-274-7390

MEP-816A (400 HZ) 6115-01-274-7395

*This manual supersededs TM 9-6115-645-10 dated 30 December 1992.

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

HEADQUARTERS, DEPARTMENTS OF THE ARMY, AIR FORCE AND HEADQUARTERS U.S. MARINE CORPS

30 JULY 1993

ARMY TM 9-6115 645 10AIRFORCE TO35C2-3 44 11

MARINE CORPS TM 09244A/09245A-1011C2

CHANGE HEADQUARTERS, DEPARTMENTS OFTHE ARMY AND AIR FORCE, AND

HEADQUARTERS, U.S. MARINE CORPSNO. 2 WASHINGTON, D.C., 30 October 1996

Operator’s ManualGENERATOR SET,

SKID MOUNTED, TACTICAL QUIET

60 KW, 50/60 AND 400 HZMEP-806A (50/60 HZ) 6115-01-274-7390MEP-816A (400 HZ) 6115-01-274-7395


TM 9-6115-645-10/TO 35C2-3-444-1 1/TM 09244A/09245A-10/1, 30 July 1993, is changed as follows:

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

Remove pages Insert pagesi through iv i through iv1-7 and 1-8 1-7 and 1-82-5 through 2-10 2-5 through 2-102-17 and 2-18 2-17 and 2-18------ 2-32.1/(2-32.2 blank)2-33 through 2-36 2-33 through 2-362-39 and 2-40 2-39 and 2-403-9 and 3-10 3-9 and 3-10

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

C1

CHANGE

NO. 1

ARMY TM 9-6115-64510AIR FORCE TO 35C2-3-444-11

MARINE CORPS TM 09244A/0924SA-10/1

HEADQUATERS DEPARTMENTS OFTHE ARMY AND THE AIR FORCE, ANDHEADQUARTERS, U.S. MARINE CORPS

WASHINGTON, D. C., 31 May 1995

Operator’s Manual

GENERATOR SET,SKID MOUNTED, TACTICAL QUIET

60 KW, 50/60 AND 400 HZMEP-806A (50/60 HZ) 6115-01-274-7390MEP-816A (400 HZ) 6115-01-274-7395


TM 9-6115-645-10/TO 35C2-3-444-11/TM 09244A/09245A-10/1, 30 July 1993, is changed 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

i and ii1-11 through 1-142-9 and 2-102-21 and 2-222-29 and 2-302-39 and 2-40

3-3 and 3-43-7 and 3-8

Insert pages

i and ii1-11 through 1-142-9 and 2-102-21 and 2-222-29 and 2-302-39 and 2-40

3-3 and 3-43-7 and 3-8

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

ARMY TM 9-6115-645-10AIR FORCE TO 35C2-3-444-11MARINE CORPS TM 09244A/09246A-10/1

C1

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

Official:

GORDON R. SULLIVANGeneral, United States Army

Chief of Staff

Acting Administrative Assistant to theSecretary of the Army

00164

RONALD R. FOGELMANGeneral, USAFChief of Staff

RONALD W. YATESGeneral, USAFCommander Air Force Materiel Command

JACK E. BUFFINGTONRear Admiral, CEC, US NavyCommanderNavy Facilities EngineeringCommand

D. R. BLOOMERColonel, USMCDirector Program SupportMarine Corps Systems Command

DISTRIBUTION:To be distributed in accordance with DA Form 12-25-E, block no. 5269, requirements for

TM 9-6115-645-10.

ARMY TM 9-6115-645-10AIR FORCE TO 35C2-3-444-11

MARINE CORPS TM 09244A/09245A-10/1

High voltage is produced when this generator set is in operation.Improper operation could result in personal injury or death.

Never attempt to start the generator set if it is not properly

grounded. Failure to observe this warning could result in seriousinjury or death by electrocution.

Never attempt to connect or disconnect load cables while the generatoris running. Failure to observe this warning could result in seriouspersonal injury or death by electrocution.

DC voltages are present at generator set electrical components even

with generator set shut down. Avoid grounding could result in severeany electrical components. Failure to observe this warning can resultin personal injury.

a


WARNING

Battery acid can cause burns to unprotected skin.

WARNING

The fuels in this generator set are highly explosive. DO NOT smoke oruse open flame when performing maintenance. Flames and explosion canoccur resulting in severe personal injury or death.

DO NOT refuel the generator set while it is operating. Hot refuelingof the generator set while in operation presents a safety hazard andshould not be attempted. Hot engine surfaces and sparks produced fromthe engine and generator circuitry are possible sources of ignition.Flames and explosion can occur resulting in severe personal injury ordeath.

WARNING

Batteries give off flammable gas. Do not smoke or use open flame whenperforming maintenance. Flames and explosion could result in personalinjury or death.

b



WARNING

Exhaust discharge containes deadly gases. Do not operate generator set

in enclosed area unless exhaust discharge is properly vented outside.Severe personal injury or death due to carbon monoxide poisoning couldresult.

WARNING

Do not manually discharge or deliberately inhale ether. Breathingether fumes can cause fainting.

WARNING

Liquids under pressure are generated as a result of operation of thegenerator set. High pressure leaks could cause severe personal injuryor death.

WARNING

With any access door open, the noise level of this generator set when

operating could cause hearing damage. Hearing protection must be wornwhen working near the generator set while running.

c


Cooling system operates at high temperatures. Personal injury ordeath from burns or scalding can result from contact with highpressure steam and/or liquid.

WARNING

Avoid contacting metal items with bare skin in extreme cold weather.Failure to observe this warning can result in personal injury.

FOR FIRST AID REFER TO FM 21-11

d

*ARMY TM 9-6115-645-10AIR FORCE TO 35C2-3-444-11

MARINE CORPS TM 09244A/09245A- 10/1C2

TECHNICAL MANUAL HEADQUARTERS, DEPARTMENTS OFTHE ARMY AND AIR FORCE, AND

HEADQUARTERS, U.S. MARINE CORPSNO.9-6115-645-10 WASHINGTON, D.C., 30 July 1993

Operator’s Manual

GENERATOR SET, SEID MOUNTED, TACTICAL QUIET60 KW, 50/60 AND 400 HZ

MEP-806A (50/60 HZ) 6115-01-274-7390MEP-816A (400 HZ) 6115-01-274-7395

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

REPORTING OF ERRORS AND RECOMMENDING IMPROVEMENTSYou can help improve this manual. If you find any mistakes or if you know of a way to improve theprocedures, please let us know.

(A): Army Mail your letter or DA Form 2028 (Recommended Changes to Publications and Blank Forms),or DA Form 2028-2 located in the back of this manual directly to: Commander, US Army Aviation andTroop Command, ATTN: AMSAT-I-MP, 4300 Goodfellow Blvd., St. Louis, MO 63120-1798. You mayalso submit your recommended changes by E-mail directly to . Instructions for sending an electronic 2028 may be found at the back of this publicationimmediately preceding the hard copy 2028.

(F): Air Force AFTO Form 22 directly to: Commander, Sacramento Air Logistics Center, ATTN: TILBA,McClellan AFB, CA 95652-5990.

(M): Marine Corps NVMC Form 10772 directly to: Commander, Marine Corps Logistics Bases (Code850), Albany. GA 31004-5000.

A reply will be furnished directly to you.

* This manual supersedes TM 9-6115-645-10 dated 30 December 1992.

Change 2 i

ARMY TM 9-6115-645-10AIR FORCE TO 35C2-3-444-11MARINE CORPS TM 09244A/09245A-10/l

CHAPTER 1

Section ISection IISection III

CHAPTER 2

Section I

Section II

Section IIISection IV

CHAPTER 3

Section ISection II

Section III

APPENDIX A.APPENDIX B.

APPENDIX C.APPENDIX D.

TABLE OF CONTENTS

HOW TO USE THIS MANUAL

INTRODUCTION

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Equipment Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Technical Principles of Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Description and Use of Operator’sControls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation Under Usual Conditions . .Operation Under Unusual Conditions

MAINTENANCE INSTRUCTIONS . .

Symptom Index . . . . . . . . . . . . .

REFERENCES . . . . . . . . . . . . . . . . . . .

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

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

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

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

COMPONENTS OF END ITEM (COEI) ANDBASIC ISSUE ITEMS (BII) LISTSADDITIONAL AUTHORIZATION LIST (AAL) . . . . . . . . . . . . . . . . . . . . . . . . .EXPENDABLE/DURABLE SUPPLIES ANDMATERIALS LIST (EDSML)

Page

v

1-1

1-11-4

1-12

2-1

2-1

2-82-172-37

3-1

3-13-1

3-2

3-11

A-1

B-1C-1

D-1I-1

ii



LIST OF ILLUSTRATIONS

Number Title Page

1-1 Generator Set, 60kW, Tactical Quiet ....................................................................... 1-21-2 Generator Set Components ..................................................................................... 1-51-3 Engine Starting System............................................................................................ 1-121-4 Fuel System ............................................................................................................. 1-131-5 Engine Cooling System. ........................................................................................... 1-141-6 Engine Lubrication System....................................................................................... 1-151-7 Air Intake and Exhaust System ................................................................................ 1-161-8 Output Supply System.............................................................................................. 1-17

2-1 Control Panel / Controls Bracket Assembly. . ......................................................... 2-22-2 Malfunction Indicator Panel ..................................................................................... 2-62-3 Grounding Connections............................................................................................ 2-182-4 Installation of Load Cables ....................................................................................... 2-212-5 Parallel Operation Setup .......................................................................................... 2-252-6 Operating Instructions Plates

(Front and Right Side)........................................................................................ 2-302-7 Operating Instructions Plates

(Rear and Left Side) .......................................................................................... 2-312-8 Operating Instructions Plate. .................................................................................... 2-322-9 Identification Plates. ................................................................................................. . 2-32.12-10 Set Rating Identification Plate .................................................................................. 2-332-10.1 Fuel System Diagram Plate...................................................................................... 2-332-11 Voltage Connection Caution Plate............................................................................ 2-342-12 Grounding Stud Plate. .............................................................................................. 2-342-13 NATO Slave Receptacle Plate ................................................................................. 2-342-14 Paralleling Receptacle Plate..................................................................................... 2-342-15 Convenience Receptacle Plate ................................................................................ 2-342-16 External Fuel Supply Plate. ...................................................................................... 2-342-17 Battery Connection Instruction Plate. ....................................................................... . 2-352-18 Lifting and Tiedown Diagram Plate. ......................................................................... 2-352-19 Diagnostics Plate...................................................................................................... 2-362-20 Generator Identification Plate................................................................................... 2-36

3-1 Air Cleaner Element Replacement ........................................................................... 3-123-2 Draining Filter / Water Separator ............................................................................. 3-16

Change 2 iii


LIST OF

Title

Leading Particulars . .

Number

1-1

TABLES

2-12-22-3

2-4

3-13-23-3

Control Panel Controls and IndicatorsMalfunction Indicator Panel . .Operator Preventive Maintenance”

Checks and Services (PMCS) . . . .Load Terminal, AC Reconnection Boardand AM-VM Transfer Switch Selection

Troubleshooting . . . . . . . . . .Coolant . . . . . . . . . . . . . .Diesel Fuel . . . . . . . . . . . .

Page

1-7

2-32-7

2-10

2-20

3-43-143-15

iv

HOW TO USE THIS MANUAL

In this manual(TM 9-6115-645-10), paragraphsare underlined and the sectionsand chapters appear in capitalletters. The location ofadditional material that must bereferenced is clearly marked.Drawings in this text arelocated as close as possible totheir references.

Chapter 1 - Introduction.Chapter 1 contains generalinformation, equipmentdescription and technicalprinciples of operation.

Chapter 2 - OperatingInstructions. Chapter 2contains a description ofgenerator set operation controlsand indicators. The controlpanel assembly is illustratedand each control and indicatoris described in a follow-ontable. Operating procedureswhich include PreventiveMaintenance Checks and Services(PMCS) and operation under usualand unusual conditions aredetailed.

Chapter 3 - Maintenance.Chapter 3 lists maintenanceprocedures authorized at theoperator level, andtroubleshooting procedures usedto recognized generator setmalfunction, test or inspection,and corrective action.



Appendices.

Appendix A is a list of theother publications referenced bythis manual. Included are othermanuals which should be usedwith this operator’s manual.

Appendix B is the Components ofEnd Item (COEI) and Basic IssueItems (BII) Lists.

Appendix C is the AdditionalAuthorization List (AAL).

Appendix D is the Expendable/Durable Supplies and MaterialsList (EDSML).

Index. The index contains keytechnical manual subjectsarranged in alphabetical order.If you require information on aspecific subject (i.e.,starting) , but you are not surewhere to look, use index tolocate specific page.

v/(vi blank)



CHAPTER 1

INTRODUCTION

SECTION I. GENERAL INFORMATION

1-1 SCOPE.

1-1.1 Type of Manual. Thismanual contains operation andoperator maintenance instruc-tions for the Tactical Quiet(TQ), 60 kW 50/60 and 400 HzGenerator Sets (FIGURE 1-1),herein referred to as generatorset. Included are descriptionsof major components and theirfunctions in relation to othercomponents.

1-1.2 Model Numbers andEquipment Names.

Model Number

MEP-806A

MEP-816A

1-1.3 Purpose

Equipment Name

Generator Set,Skid Mounted,Tactical Quiet60 kW 50/60 Hz.

Generator Set,Skid Mounted,Tactical Quiet60 kW 400 Hz.

of Equipment.. —The generator set providestactical quiet AC power. Thegenerator set is easilytransported, operated, andmaintained.

1-2 MAINTENANCE FORMS ANDRECORDS.

1-2.1 (A) Department of theArmy forms and procedures usedfor equipment maintenance will

be those prescribed byDA PAM 738-750, The ArmyMaintenance Management System(TAMMS).

1-2.2 (F) Maintenance Forms andRecords maintained by the AirForce are prescribed in AFR 66-1and the applicable TO 00-20Series Technical Orders.

1-2.3 (N) Navy users shouldrefer to their service peculiardirectives to determine theapplicable maintenance forms andrecords to be used.

1-2.4 (MC) Maintenance Formsand Records used by the MarineCorps personnel are prescribedby the current edition ofTM 4700-15/1.

1-3 REPORTING EQUIPMENTIMPROVEMENT RECOMMENDATIONS(EIR).

1-3.1 If your generator setneeds improvement, let us know.Send us an EIR. You, the user,are the only one who can tell uswhat you don’t like about yourequipment. Let us know why youdon’t like the design orperformance. We will send you areply.

1-1


FIGURE 1-1. Generator Set, 60 kW, Tactical Quiet

1-2

1-3.2 (A) Put it on an SF 368(Quality Deficiency Report).EIRs should be mailed directlyto:

CommanderU.S. Army Troop Support CommandAttn: AMSTR-MOF4300 Goodfellow Blvd.St. Louis, MO 63120-1798

1-3.3 (N) Put it on applicableNavy form and mail it directlyto:

Naval Construction BattalionCenterAttn: Code 157 Civil Engineer

Support Office (CESO)Port Hueneme,CA 93043-5000

1-3.4 (MC) Quality DeficiencyReports (QDR) shall be submittedon SF 368 in accordance withMCO 4855.10. Submit to:

CommanderMarine Corps Logistics Bases(Code 856)Albany, GA 31704-5000

1-3.5 (F) Quality DeficiencyReports/Materiel DeficiencyReports shall be sent byelectronic message to:SMALC CA//TILE//.

MTOE

1-4 WARRANTY INFORMATION .

The generator sets (MEP-806A and MEP-816A) are warrantedby Libby Corporation for aperiod of 36 months or 1800operating hours, whichever



occurs first. Refer toWarranty Technical BulletinTB 9-6115-645-24. The warrantystarts on the date found inblock 23, DA Form 2408-9, in thelogbook. Report all defects inmaterial or workmanship to yoursupervisor, who will takeappropriate action through yourUnit Maintenance Shop.

1-5 LIST OF ABBREVIATIONS.

The following list ofabbreviations consists of thosespecial or unique abbreviationsthat are not contained inMIL-STD-12 and do not conflictwith those in MIL-STD-12.

Abbreviation Description

KPA Kilopascal

KVA Kilovolt-ampere

kW

CTA

NATO

JTA

AOAP

Kilowatt

Common Table ofAllowance

Modified Table ofOrganization andEquipment

North AtlanticTreatyOrganization

Joint Table ofAllowances

Army Oil AnalysisProgram

1-3


SECTION II. EQUIPMENT DESCRIPTION

1-6 EQUIPMENT CHARACTERISTICS,CAPABILITIES AND FEATURES.

The generator sets, modelsMEP-806A and MEP-816A (FIGURE1-2), are fully enclosed, self-contained, skid-mounted,portable units. They areequipped with controls,instruments and accessoriesnecessary for operation assingle units or in parallel withanother unit of the same classand mode. The generator setsconsist of a diesel engine,brushless generator, excitationsystem, speed governing system,fuel system, 24 VDC startingsystem, control system and faultsystem.

NOTE

All locations refer-enced in FIGURE 1-2are given facing thecontrol panel assembly(rear) of the genera-tor set.

1-7 LOCATION AND DESCRIPTION OFMAJOR COMPONENTS.

1-7.1 Engine (19) . Thegenerator is powered by a sixcylinder, four cycle, fuelinjected, turbocharged, liquid-cooled diesel engine whichoccupies the front half of thegenerator set. The engine isalso equipped with a fuelfilter/water separator, oilfilter, and an air cleanerassembly. Protection devicesautomatically stop the engineduring conditions of highcoolant temperature, low oilpressure, no fuel, over-speed,or over-voltage.

1-7.2 Radiator (22) . Theradiator is located at the frontof the generator set. It actsas a heat exchanger for theengine coolant.

1-7.3 Muffler (3). The mufflerand exhaust tubing are connectedto the exhaust manifold on theengine. The exhaust exits fromthe top of the generator sethousing. Gases are exhaustedupward.

1-7.4 Starter (9). The starteris located on the right side ofthe engine. The electricstarter mechanically engages theengine flywheel in order tostart the diesel engine.

1-7.5 Battery ChargingAlternator (6) . The batterycharging alternator is locatedon the right side of the engine.It is capable of maintaining thebatteries in a state of fullcharge in addition to providingthe required 24 VDC controlpower.

1-7.6 Batteries (23). Twobatteries are located at frontof the generator set. Thebatteries are electrolyteserviceable, lead acid, 12 volttype, connected in series.After starting, the generatorset is capable of operating withbatteries removed. A diode anda fuse, located behind thecontrol panel assembly, protectthe generator set if thebatteries are incorrectlyconnected.

1-4



1234567891011

Malfunction Indicator PanelControl Panel AssemblyMufflerNATO Slave ReceptacleFan BeltsBattery Charging AlternatorOil FilterDipstickStarterFuel Filter/Water SeparatorVoltage ReconnectionTerminal Board

121314151617181920212223

Load Output Terminal BoardSkid BaseConvenience ReceptacleParalleling ReceptacleAir Cleaner AssemblyAC GeneratorFuel TankEngineDead CrankWater PumpRadiatorBatteries

Switch

FIGURE 1-2. Generator Set Components

1-5


1-7.7 Air Cleaner Assembly(16). The air cleaner assemblyis located on the left sidebehind the air cleaner accessdoor. It consists of a dry-type, disposable paper elementand canister. The air cleanerassembly features a dustcollector which traps large dustparticles. The air cleanerassembly has a restrictionindicator which will indicatewhen the air cleaner elementrequires servicing.

1-7.8 Fuel Tank (18). The fueltank is located below the engineand between the skid base sidemembers. The fuel tank has acapacity of 43 gallons (162.7liters) which will allow thegenerator set to operate for atleast 8 hours without refueling.

1-7.9 AC Generator (17). TheAC generator is a singlebearing, drip-proof,synchronous, brushless, threephase, fan-cooled generator.The generator is coupleddirectly to the rear of thediesel engine.

1-7.10 Load Output TerminalBoard (12) . The load outputterminal board is located on theright side (rear) of thegenerator set. There are fouroutput terminals located on theboard. They are marked L1, L2,L3 and LO. A fifth terminal,marked GND, is located next tothe output terminals and servesas equipment ground for thegenerator set. A removable,solid copper bar is connectedbetween the LO and GNDterminals.

1-7.11 Control Panel Assembly(2). The generator set controlpanel assembly is located at therear of the generator set and

1-6

contains controls andinstruments for operating theengine and the generator.

1-7.12 Malfunction IndicatorPanel (1). The malfunctionindicator panel is located tothe left of the control panelassembly. It indicatesmalfunctions of the generatorset components.

1-7.13 NATO Slave Receptacle(4). The NATO slave receptacleis located on the right side(front) of the generator set.It is used for slave starting.

1-7.14 Skid Base (13). Theskid base supports the generatorset. It has fork lift accessopenings and cross members forshort distance movement. Theskid base has provisions in thebottom for installation of thegenerator set on a trailer.

1-7.15 Voltage ReconnectionTerminal Board (11). Thevoltage reconnection terminalboard is located on the rightside (rear) of the generatorset. The board allowsreconfiguration from 120/208 to240/416 VAC output.

1-7.16 Fuel Filter/WaterSeparator (10) The fuelfilter/water separator islocated in the enginecompartment on the right side.The element removes impuritiesand water from the diesel fuel.

1-7.17 Dipstick (8). Thedipstick is located in theengine compartment on the rightside. The dipstick shows thelubricating oil level in theengine crankcase.



1-7.18 Oil Filter (7). The oil filter is located in the enginecompartment on the left side. The filter removesimpurities from the engine lubricating oil.

1-7.19 Fan Belts (5). The fan belt is located in theengine compartment on the front of the engine. The beltdrives the fan, water pump and battery chargingalternator.

1-7.20 Water Pump(21). The water pump is located inthe engine compartment on the front of the engine. Thepump circulates the engine coolant through the engineblock and the radiator.

1-7.21 Dead Crank Switch (20). The Dead Crank switchis located in the engine compartment on the left side.The switch allows the engine to be cranked withoutstarting for maintenance.

1-7.22 Paralleling Receptacle. The paralleling receptacleis used to connect the paralleling cable between twogenerator sets of the same size and mode to operatein parallel.

1-7.23 Convenience Receptacle (22). The conveniencereceptacle is a 10 Amp, 120 VAC receptacle used tooperate small plug in type equipment. It is protectedby a Ground Fault Circuit Interrupter located below themalfunction indicator (1-7.12), an over load circuitbreaker located inside the control box, and an in-linefuse on generator sets, contract number DAAK01-88D-D082. The convenience receptacle power is available atall times during operation of the generator set.

1-8 DIFFERENCES BETWEEN MODELS. Thedifferences between models of the generator setscovered in this manual are as follows:

Model MEP-806A is equipped with a 50/60 Hz generator.

Model MEP-816A is equipped with a 400 Hz generator.

1-9 EOUIPMENT DATA. For a list of LeadingParticulars refer to TABLE 1-1.

Table 1-1. Leading Particulars

1. Generator Set:

Model Numbers60 kW 50/60 Hz Tactical Quiet MEP-806A60 kW 400 Hz Tactical Quiet MEP-816A

National Stock Numbers60 kW 50/60 Hz Tactical Quiet NSN 6115-01-274-739060 kW 400 Hz Tactical Quiet NSN 6115-01-274-7395

Overall LengthMEP-806A 87 in. (221 cm)MEP-816A 87 in. (221 cm)

Change 2 1-7


Table 1-1. Leading Particulars - Continued

1. Generator Set - Continued:

Overall WidthMEP-806AMEP-816A

Overall HeightMEP-806AMEP-816A

35.7 in. (90.8 cm)35.7 in. (90.8 cm)

59 in. (149.9 cm)59 in. (149.9 cm)

Dry Weights (less Basic Issue Items)MEP-806AMEP-816A 3556 lb. (1613 kg.)

3606 lb. (1635.7 kg.)Wet Weights

MEP-806AMEP-816A

2. Engine:

ManufacturerModelType

DisplacementAltitude Degradation,4000 ft (1220 m)to 8000 ft (2440m)Firing OrderCold Weather Starting Aid System Use

3992 lb. (1810.8 kg.)4042 lb. (1833.5 kg.)

John Deere6059T

six cylinder, four cycle,turbocharged diesel

359 cu. in. (5.9 liters)

3.5% per 1000 ft (305 m)1, 5, 3, 6, 2, 4When temperatureis 40°F (4°C) orbelowValve Tappet Clearance Adjustment

Hot or Cold (Intake)Hot or Cold (Exhaust) 0.014 in. (0.35 cm)

0.018 in. (0.45 cm)

3. Cooling System:

Type Pressurized radiator and pumpCapacityNormal Operating Temperature

20.5 qts. (19.4 liters)170-200°F (77-93°C)Temperature Indicating System

Voltage Rating24 VDC

4. Lubricating System:

TypeOil Pump Type

Full flow, circulating pressurePositive displacement gear

1-8



TABLE 1-1. Leading Particular - Continued

4. Lubricating System - Continued:

Normal Operating Pressure 25-60 psi (172-414 kPa)

Oil Filter Type Full flow, spin-on, replaceable element

Lubricating System Capacity18 qts. (17 liters)

Pressure Indicating System 24 VDC

DF-1, DF-2, DF-A, JP4, JP5, JP843 gal. (162.7 liters)50/60 HZ

5.06 gal. (19.2 liters) per hour400 HZ

5.37 gal. (20.3 liters) per hour

Voltage Rating

5. Fuel System:

Type of FuelFuel Tank CapacityFuel Consumption Rate:

Auxiliary Fuel Pump:Voltage RatingDelivery Pressure

Fuel Level Switch:TypeCurrent

6. Engine Starting System:

BatteriesStarter:ManufacturerModelVoltage RatingDrive Type

Battery Charging Alternator:ManufacturerModelRatingProtective Fuse

7. AC Generator:

Manufacturer

24 VDC

5.0-6.5 psi (34.5-65.5 kPa) (max)

Float3.0 amp at 6 to 32 VDC

Two 12 volt, connected in series

Nipponde.03nso Co. LtdRE39930A

24 VDCGear Reduction

MEP-806A

MarathonElectric

Prestolite8EM3002GC

42 amps at 24 VDC30 amps

MEP-816A

MarathonElectric

1-9


TABLE 1-1. Leading Particulars - Continued

7. AC Generator - Continued:

Type

8.

9.

Load Capacity

Current Ratings:120/208 volt connection240/416 volt connection

120/208 volt connection240/416 volt connection

Power Factor

Cooling

Drive Type

Duty Classification

Governing System:

Load Measuring Unit:ManufacturerModel

Governor Control Unit:ManufacturerModel

Protection Devices:

Low Oil Pressure Switch:Trip PressureVoltage RatingCurrent Rating

MEP-806A

Rotatingfieldsynchronous

60 kW

60 Hz:208 amps104 amps


0.8

fan cooled

directcoupling

continuous

MEP-816A

Rotatingfieldsynchronous

60 kW


0.8

fan cooled

directcoupling

continuous

Technology Research19310

Barber-ColmanDYNA 10502-003-0-2

15 ± 3 psi (103.4 ± 20.7 kPa)

Coolant High Tefiperature Switch:Trip Temperature

225 ± 50Voltage RatingCurrent Rating

24 VDC5 amps

F (107 ± 3° C)12-120 VDC

2 amps

1-10

ARMY TM 9-6115-645-10AIR FORCE TO 35C2-3444-11

MARINE CORPS TM 09244A/09245-10/1

Table 1-1. Leading Particulars - Continued

9. Protection Devices:

Speed Switch:Element Trip and ResetVoltage RatingCurrent Rating

Overvoltage:Trip Point Conditions

Trip Point

153 ± 3 VAC forno less than

200 milliseconds(120 VAC coil winding)

No more than 1.25seconds after trip

conditions exist

1-11

ARMY TM 9-6115-645-10AIR FORCE TO 35C2-3-444-11MARINE CORPS TM 09244A/09M5A-10/l

1-10

SECTION III. TECHNICAL

INTRODUCTION. This section contains func-tional descriptions of the generator set and explainshow the controls and indicators interact with the sys-tem.

PRINCIPLES OF OPERATION

1-11 ENGINE STARTING SYSTEM.

The Engine Starting System (Figure 1-3), consists of two12-volt batteries connected in series, a starter, a 24 voltbattery charging alternator, a magnetic pickup (for sensingengine speed) and the related switches and relays requiredfor control of the starting system. For engine cranking,battery power is supplied to tie starter motor through thestarter solenoid which in turn is controlled by the crankingrelay. The starter then engages the engine flywheel caus-ing the engine to turnover. For engine starting, the DEADCRANK switch must be in the NORMAL position, theDC Control power circuit breaker must be pushed in, theEMERGENCY STOP switch must be in the OUT posi-tion, and the MASTER SWITCH is moved to the STARTposition. The cranking relay is then controlled by a circuitconsisting of the start relay and crank disconnect switch.As the engine accelerates to the preset speed (sensed bythe magnetic pickup), the crank disconnect switch opensand deenergizes the cranking relay to stop and disengagethe starter. The starting sequence may also be stopped bymoving the MASTER SWITCH to OFF. The engine maybe cranked without starting by use of the DEAD CRANKswitch. With the DEAD CRANK switch in the CRANKposition, the cranking relay, starter solenoid and startermotor are energized without activating any other startingor control function.

Figure 1-3. Engine Starting System

1-12 Change 1



The batteries are charged by the battery charging alternat-or that is belt driven by the engine. Generator set controlsystem power is also supplied by the battery chargingalternator. The BATTERY CHARGE ammeter indicatesthe charge/discharge rate of the batteries, from -10 AMPSto +20 AMPS, in 5 AMPS increments. Normal operatingindication depends on the state of charge in the batteries.A low charge, such as exists immediately after enginestarting, will cause a high reading (needle moves towardCHARGE area). When the charge in the batteries has beenrestored, the indicator moves near zero.

1-12 FUEL SYSTEM.

1-12.1 The Fuel System (Figure 1-4), consists of piping,fuel tank transfer pump, fuel falter/water separator, injec-tion pump and injectors. Fuel is drawn from the fuel tankby the transfer pump. After reaching the transfer pump,fuel passes through a fuel filter/water separator wherewater and small impurities are removed. The fuel thengoes to an injection pump where it is pressurized andpushed into the injectors. Through the injectors fuel entersthe diesel engine combustion chamber, where it is mixedwith air and ignited. The fuel that is not used is returnedto the fuel tank via an excess fuel return line.

1-12.2 The Auxiliary Fuel System consists of an externalfuel supply, fuel filter, piping, a 24 VDC auxiliary fuelpump and a fuel level float switch. When the MASTERSWITCH is set on PRIME & RUN AUX FUEL it actu-ates the auxiliary fuel pump and transfers fuel from theexternal fuel supply to the generator fuel tank. The fuellevel float Figure 1-4. Fuel System

Change 1 1-13


switch shuts off the auxiliary fuel pump when the genera-tor fuel tank is full and reactivates the pump as the leveldrops. The FUEL LEVEL indicator indicates fuel level ofgenerator fuel tank from (E) empty to (F) full in quartertank increments.

1-13 ENGINE COOLING SYSTEM..1-13.1 The Engine Cooling System (Figure 1-5) consistsof a radiator, hoses, thermostat, water pump, a belt drivenfan, cooling jackets and oil cooler. The water pump forcescoolant through passages (cooling jackets) in the engineblock and cylinder head where the coolant absorbs heatfrom the engine. When the engine reaches normal operat-ing temperature, the thermostat opens and the heated cool-ant flows through the upper radiator hose assembly intothe radiator. The cooling fan circulates air through theradiator where the coolant temperature is reduced.

1-13.2 A coolant high temperature switch provides auto-matic shut down in the event that coolant temperatureexceeds 225 ± 5°F (107 + 3°C) . The COOLANT TEMPindicator indicates the engine coolant temperature, from120°F to 240°F (48°C to 115°C).

Figure 1-5. Engine Cooling System

1-14 Change 1

1-14 LUBRICATION SYSTEM.

The Lubrication System(FIGURE 1-6) consists of an oilpan, dipstick, pump, oilpressure sender, AOAP samplevalve, and filter. The oil panis a reservoir for enginelubricating oil. The dipstickindicates oil level in the oilpan. A pump draws oil from theoil pan and through a screenremoving large impurities. Theoil then passes through a spin-on type filter where smallimpurities are removed. Fromthe filter, oil enters theengine and is distributed to theengine’s internal moving parts.After passing through theengine, the oil returns to theoil pan. The OIL PRESSUREindicator indicates oil pressuresensed by the oil pressuresender in the engine. Theengine will shut offautomatically if the oilpressure drops to a dangerouslylow level. The oil level can bechecked with engine running.

1-15 AIR INTAKE AND EXHAUSTSYSTEM .

1-15.1 The Air Intake andExhaust System (FIGURE 1-7),consists of an air cleanerassembly, intake manifold,turbocharger, exhaust manifoldand muffler. Ambient air isdrawn into the air cleanerassembly where it passes throughthe air cleaner element.Airborne dirt is removed andtrapped in the element. Arestriction indicator, locatedon the air cleaner assemblyhousing, displays red when theair cleaner element should beserviced. Dirt can be removedfrom the air cleaner housing bypinching an evacuator valve.



FIGURE 1-6. EngineSystem

Lubrication

Filtered air is drawn out of theair cleaner assembly through airintake tubes to the turbochargerwhere it is forced into theintake manifold to the combusionchambers and mixed with fuelfrom the injectors.

1-15


FIGURE 1-7. Air Intake andExhaust System

1-15.2 The engine exhaust gasesare released into theturbocharger. The exhaust gasesdrive the turbocharger forcinglarge amounts of air into theintake manifold. After passingthrough the turbocharger, the

exhaust gases are channeled intothe muffler that deadens thesound of the exhaust gases. Thegases pass from the mufflerthrough the muffler outlet andare vented upward from thegenerator set housing.

1-15.3 Cold outsidetemperatures make starting theengine difficult. To improveengine starting, a cold weatherstarting aid has been providedthat features an ether injectionsystem. Ether is injected intothe combustion chamber when theETHER switch is ON and theMASTER SWITCH is in the STARTposition.

1-16 OUTPUT SUPPLY SYSTEM.

1-16.1 The Output Supply System(FIGURE 1-8) consists primarilyof the AC generator, the outputload terminal board, the voltagereconnection terminal board, theAM-VM transfer switch and the ACcircuit interrupter relay.Power created by the ACgenerator is supplied throughthe voltage reconnectionterminal board and the ACcircuit interrupter relay to theoutput load terminals on theoutput load terminal board. Thevoltage reconnection terminalboard allows configuration ofthe generator set for 120/208volt connections or 240/416 voltconnections.

1-16.2 The AC CIRCUITINTERRUPTER switch closes andopens the AC circuit interrupterrelay. This enables orinterrupts the power flowbetween the voltage reconnectionterminal board and the outputload terminals. The AC circuitinterrupter relay is also opened

1-16

automatically during any of thespecified set faults. Thevoltage regulator senses ACgenerator output voltage andprovides control voltage to theAC generator exciter to maintainthe desired AC generator outputvoltage. The position of theAM-VM transfer switch selectsthe output load terminals fromwhich current and voltage aremeasured and are indicated onthe AC voltmeter (VOLTS AC) andthe ammeter (PERCENT RATEDCURRENT).



FIGURE 1-8. Output SupplySystem

1-17/(1-18 blank)



CHAPTER 2

OPERATING INSTRUCTIONS

SECTION I. DESCRIPTIONCONTROLS AND

2-1 GENERAL .

This section describes andillustrates the controls andindicators to ensure properoperation of the generator set.

AND USE OFINDICATORS

OPERATOR’S

2-2 CONTROL PANEL ASSEMBLY.

The control panel assemblycontains most of the operatingcontrols and indicators for thegenerator set. FIGURE 2-1 showsthe control panel assemblylayout and TABLE 2-1 describeseach control and indicator.

2-1


FIGURE 2-1. Control Panel/Controls Bracket Assembly

2-2



TABLE 2-1. Control Panel Controls and Indicators

FunctionControl or IndicatorKey

FUEL LEVEL indicator Indicates fuel level.1

Illuminates control panel.

Indicates engine coolanttemperature.

Activates or deactivates coldstarting aid system.

Activates or deactivates panellights.

Panel lights

COOLANT TEMP. indicator

2

3

ETHER switch4

PANEL LIGHTS switch5

Indicates generator set outputfrequency.

Indicates generator set loadcurrent as a percent of ratedcurrent.

FREQUENCY meter (HERTZ)6

Ammeter (PERCENT RATEDCURRENT)

7

AM-VM transfer switch Allows selection of current andvoltage readings between outputload terminals as follows:

8

SwitchPosition Voltage CurrentL1-LO 120* 240** L1L2-LO 120* 240** L2L3-LO 120* 240** L3L1-L2 208* 416** NoneL2-L3 208* 416** NoneL1-L3 208* 416** None

AC Reconnection Terminal BoardSetting* 120/208** 240/416

Indicates generator set outputpower as a percent of rated power.

Indicates output voltage ofgenerator set.

Amber light indicates switch on.

Kilowattmeter(PERCENT POWER)

9

10 AC Voltmeter (VOLTS AC)

BATTLE SHORT light

VOLTAGE adjustPotentiometer

11

Adjusts generator set voltage.12

BATTLE SHORT switch Bypasses protective devices.13

2-3


TABLE 2-1. Control Panel Controls and Indicators - Continued

Key Control or Indicator Function

Indicates synchronization of unitsto be paralleled.

14 SYNCHRONIZING LIGHTS

15 AC CIRCUIT INTERRUPTERswitch

Opens or closes AC circuitinterrupter relay.

16 AC CIRCUIT INTERRUPTERlight

Green light indicates AC circuitinterrupter is closed.

Adjusts frequency of generatorset.

17 FREQUENCY adjustpotentiometer

EMERGENCY STOPpushbutton

18 Shuts down generator set.

Energizes or deenergizesparalleling circuits.

OFF - Deenergizes all circuits,except panel lights.

PRIME & RUN AUX FUEL - Energizesgenerator set run circuits withauxiliary fuel pump operating.

PRIME & RUN - Energizes generatorset run circuits with auxiliaryfuel system deenergized.

START - Energizes starter.

Indicates oil pressure.

Indicates total engine operatinghours.

19 PARALLEL UNIT switch

20 MASTER SWITCH

21 OIL PRESSURE indicator

22 Time meter(TOTAL HOURS)

BATTERY CHARGE ammeter23 Indicates charge/discharge rate ofbatteries.

Protects battery chargingalternator from overload.

24 BATTERY CHARGER FUSE(Located on controlsbracket assembly)

REACTIVE CURRENTADJUST rheostat(Located on controlsbracket assembly)

25 Adjusts current for load sharingrequirements (maintenancepersonnel only).

2-4



TABLE 2-1. Control Panel Controls and Indicators - Continued

Key Control or Indicator Function

26 LOAD SHARING ADJUST Adjusts power for load sharingrheostat (Located requirements (maintenancebehind control panel) personnel only).

27 OVERSPEED RESET switch Resets generator set after an(Located on controls overspeed condition (maintenancebracket assembly) personnel only).

28 FREQUENCY SELECT switch Allows selection of 50 Hz or 60(MEP-806A only)(Located on controls

Hz.

bracket assembly)

29 DC CONTROL POWER Energizes or deenergizes DCcircuit breaker circuits.(Located on controlsbracket assembly)

2-5


2-3 MALFUNCTION INDICATOR PANEL.

The malfunction indicator panel (FIGURE 2-2) islocated to the left of the control panel.

It contains a series of lights which indicate a generatorset failure or abnormal operating condition. TABLE 2-2describes each indicator light.

FIGURE 2-2. Malfunction Indicator Panel

2-6 Change 2



TABLE 2-2. Malfunction Indicator Panel

KEY CONNECTOR FUNCTION

1 NO FUEL indicator Lights when fuel level in fuel tank is below preset level.

2 COOLANT HIGH TEMP Lights when engine coolant indicator temperature exceeds 2250 + 5° F (107 +±30 F).

3 OVERVOLTAGE indicator Lights when voltage in 120 volt generator coil exceeds 153 + 3 volts.

4 OVERSPEED indicator Lights when engine speed exceeds 22d0 ± 40 RPM.

5 REVERSE POWER indicator Lights when power flow into generator set exceeds 20 + 3 percent of ratedcurrent.

6 OVER LOAD indicator Lights when current in any phase exceeds 110 percent of rated current.7 GROUND FAULT CIRCUIT Tests GROUND FAULT CIRCUIT

INTERRUPTER TEST INTERRUPTER.Pushbutton

8 GROUND FAULT CIRCUIT Indicates a ground fault condition.INTERRUPTER indicator

9 GROUND FAULT CIRCUIT Rests GROUND FAULT CIRCUITINTERRUPTER RESET INTERRUPTER.Pushbutton

10 SHORT CIRCUIT indicator Lights when generator set output inany phase exceeds 425 + 25 percentof rated current.

11 UNDER VOLTAGE indicator Lights when voltage in 120 voltgenerator coil winding drops below99 ± 4 VAC.

12 PUSH TEST RESET LAMPS Tests and resets fault indicatorswitch lamps.

13 LOW OIL PRESSURE Lights when engine lubricationindicator systems pressure is less than 15 + 3

psi (103.4 + 20.7 kPa) during engineoperation.

14 Convenience Receptacle Circuit breaker trips on when loadOverload Circuit on convenience receptacle exceeds 10Breaker (10-amp in-line amps (fuse blows on generator sets,fuse on generator sets, contract number DAAK01-88-D-D082).

contract number DAAK01-88-D-D082)

Change 2 2-7


SECTION II. PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)

2-4 GENERAL.

To ensure that thegenerator set is ready foroperation at all times, it mustbe inspected so that defects canbe discovered and correctedbefore they result in seriousdamage or failure.

2-4.1 Before You Operate.Always keep in mind the CAUTIONSand WARNINGS. Perform yourbefore (B) PMCS.

2-4.2 While You Operate.Always keep in mind the CAUTIONSand WARNINGS. Perform yourduring (D) PMCS.

2-4.3 After You Operate. Besure to perform your after (A)PMCS.

2-4.4 If Your Equipment Failsto Operate If your equipmentdoes not perform as required,refer to Chapter 3 underTroubleshooting for possibleproblems. Report anymalfunctions or failures onDA Form 2404, refer toDA PAM 738-750.

2-5 PMCS PROCEDURES.

NOTE

For general locationof items to be in-spected in TABLE 2-3,refer to FIGURE 1-2and FIGURE 2-1.

2-5.1 Purpose of PMCS Table.Your Preventive MaintenanceChecks and Services (TABLE 2-3)list the inspections and care ofyour equipment required to keepit in good operating condition.

2-5.2 Purpose of ServiceIntervals. The internal columnof your PMCS table tells youwhen to do a certain check orservice.

2-5.3 Special Instructions.The following guidelines havebeen provided to help you inclassifying leaks observed whileperforming PMCS.

Class I. Seepage of fluid(as indicated by wetness ordiscoloration) not great enoughto form drops.

Class II. Leakage of fluidgreat enough to form drops butnot enough to cause drops todrip from item beingchecked/inspected.

Class III. Leakage offluid great enough to form drops that fall from the item beingchecked/inspected.

2-8

ARMY TM 9-6115-645-10AIR FORCE TO 35 C2-3-444-11


2-5.5 The “Equipment is not ready/availtable if". Thiscolumn tells you when and why the generator set cannotbe used.

Equipment operation is allowable with minoroil and coolant leakage (Class I or II).

Of course, you must consider the fluid capacityin the item/system being checked/inspected.When in doubt, notify the next higher level ofmaintenance.

When operating with Class I or Class II leaks,continue to check fluid levels as required inyour PMCS. All leaks should be reported to thenext higher level of maintenance.

2-5.4 Procedures Column The procedures column ofyour PMCS table tells you how to do the required checksand services. Carefully follow these instructions. If youdo not have the tools, or if the procedures indicate, com-plete a DA Form 2404 and submit it to the next higherlevel of maintenance.

NOTE

The terms ready/ available and mission capa-ble refer to the same status: Generator set is onhand and is able to perform its combat mis-sions, refer to DA PAM 738-750.

2-5.6 Reporting and Correcting Deficiencies. If yourgenerator set does not perform as required, refer to Chap-ter 3 under Troubleshooting for possible problems. Reportany malfunctions of failures on DA Form 2404, refer toDA PAM 738-750.

2-5.7 Removal of Assemblies/Equipment to PerformPMCS. There is no requirement to remove assemblies/equipment prior to performing the PMCS.

2-9

ARMY TM 9-6115-645 10AIR FORCE TO 35C2-3-444- 11MARINE CORPS TM 09244A/09245A-10/1

Table 2-3. Operator Preventive Maintenance Checks and ServicesNOTE

If the equipment must be kept in continuous operation, check and service only those items that can be checked andserviced without disturbing operation. Make the complete checks and services when the equipment can be shut down

NOTE

The generator set can be operated continuously at any load from no load up to and including rated load: However. at lightloads (less than 25% of set rating) an oily residue (unburned fuel oil) may occasionally be noticed in the exhaust systemoutlet and around connection joints in the exhaust system. This residue is caused by the inability of the fuel injectionsystem to consistently meter the small amount of fuel required to operate at these low load levels and is not a defect in thefuel system. The oily residue could affect engine performance and create a cosmetic problem on and around thegenerator set. Operation at rated load will bum off this oily residue. The length of time required at rated load depends onthe amount of residue. The muffler may also need to be removed and cleaned if excessive build up occurs. This oilyresidue can be prevented by increasing the electrical load on the set.

B-BERORE D-DURING A-AFTER

Interval Procedures: Equipment IsItem Item to be Check for and have repaired Not Ready/No. B D A Inspected or adjusted as necessary Available If:

GENERATOR SET1. • • • .Housing Check doors, panels, hinges, and latches Cannot secure

for damaged, loose or corroded items. doors.Inspect air intake and exhaust grills fordebris.

2. • • Identification plates Check to ensure identification plates aresecure.

3. • • Skid Base Inspect skid base for cracks or Skid base is crackedcorrosion. or shows signs of

structural damage.4. • Acoustical Materials Ensure that acoustical materials are free

of damage or not missing.

2-10 Change 2

TABLE 2-3.

ItemNo.

5

Operator Preventive Maintenance Checks and Services -Continued

B - BEFORE

Internal

B D A



Item tobe inspected

ENGINECOMPARTMENT

EngineAssembly

D - DURING

ProceduresCheck for and haverepaired or adjusted

as necessary

WARNING

With any accessdoor open, the noiselevel of this genera-tor set when opera-ting could cause hear-ing damage. Hearingprotection must beworn when workingnear the generatorwhile running.

WARNING

The fuels in thisgenerator set arehighly explosive.DO NOT smoke or useopen flame whenperforming mainte-nance. Flames andexplosion can occurresulting in severepersonal-injurydeath.

or

Check for loosedamaged or missinghardware.

set

A - AFTER

Equipment isnot ready/available if:

2-11


Continued

B - BEFORE

TABLE 2-3. Operator Preventive Maintenance Checks and Services -

D - DURING A - AFTER

ItemNo.

6

7

8

9

Interval

B D A

Item tobe inspected

Fuel System

Fuel Filter/WaterSeparator

Ether StartSystem

LubricationSystem


as necessary

Inspect fuel systemfor leaks, damaged,loose or missingparts.

Inspect fuel filter/water separator forleaks, propermounting, cracks,damage, or missingparts.

Drain waterfrom fuel filter/water separator.

Check fordeteriorated, looseor missing parts.

Inspect lubricationsystem for leaks,damaged, loose ormissing parts.

Check engine oillevel.

Check engine oilfor contamination.

Equipment isnot ready/

available if:

Any fuelleaks,damaged,loose ormissing parts

Any fuelleaks.

Fuel filter/water separa-tor notdrained.

Oil leaksat Class III.Damaged, looseor missingparts.

Oil levelis belowoil level.

Engine oilshows signsof contami-nation.

2-12

ItemNo.



TABLE 2-3. Operator Preventive Maintenance Checks and Services -Continued

B - BEFORE D - DURING A - AFTER

10

11

12

13

Interval

B

Item tobe inspected

COOLINGSYSTEM

Radiator

Hoses

Cooling Fan

Fan Belts


as necessary

WARNING

Cooling systemoperates at hightemperatures.Personal injury ordeath from burnsor scalding canresult from contactwith high pressuresteam and/or liquid.

Check radiator forleaks, damage ormissing parts.

Check hoses forleaks or cracks.

Check fan for damageor looseness.

Check for unusualnoise being emittedfrom fan area.

Inspect belts forcracks, frayingand looseness.


available if:

Class IIIleaks.Radiator capmissing.

Class IIIleaks.

Cooling fan isdamaged orloose.

Brokenbelt(s).

2-13



ItemNo.

14

15

16

Continued

B - BEFORE

Interval

E D A

Item tobe inspected

Over-flowBottle

ExhaustSystem

Air CleanerAssembly

D - DURING


as necessary

Check over-flowbottle for leaks ormissing parts.

Check

Checkleaks

coolant level.

muffler forand exhaust

system for corrosion,damaged, or missingparts.

Inspect air cleanerassembly and pipingfor loose or damagedconnections.Check restrictionindicator forclogged element.

WARNING

Battery acid cancause burns to un-protected skin.

WARNING

Batteries give offflammable gas. Donot smoke or useopen flame whenperforming mainte-nance. Flames andexplosion couldresult in personalinjury or death.

A - AFTER


available if:

Class IIIleaks.

Coolant levelis at coldline.

Muffler orexhaust systemdamaged orleaking.

Cloggedelement isindicated orpiping andconnectionsare loose.

2-14




ItemNo.

17

18

19

20

Continued

B - BEFORE

Interval

B

Item tobe inspected

Batteries

BatteryCables

OutputBoxAssembly

CONTROL BOXASSEMBLY

Indicatorsand Controls


ProceduresCheck for and have Equipment isrepaired or adjusted not ready/

as necessary available if:

Check electrolytelevel.

Inspect cables andconnectors forcorrosion, loose,damaged or missingparts.

WARNING

High voltage isproduced when thisgenerator set is inoperation. Improperoperation couldresult in personalinjury or death.

Check for loose ordamaged wiring orcables.

Check output termi-nals for damagedor missing hardware.

Check all indicatorsand controls fordamaged or missingparts.

Ensure all indicatorsare operatingproperly.

Cables areloose, damagedor missing.

Loose ordamagedwiring orcables.

Damaged ormissinghardware.

Indicatorsor controlsdamaged ormissing.

Frequency orAC Voltmeterinoperative.

2-15


Continued

B - BEFORE



ItemNo

21

22

23

Interval

B D A

Item tobe inspected

Control BoxHarness

ParallelCable

Ground RodCable andConnection


as necessary

Check for loose ordamaged wiring.

If required forgenerator setoperation, inspectparallel cable fordamage.

ENSURE generator setis properly groundedprior to starting.Otherwise seriousinjury or death couldresult by electrocu-tion.

Inspect ground rodand cable for loose-connections, breaks,damage and corrosion.


available if:

Loose ordamagedwires.

Cable isis missing ordamaged.

2-16



SECTION III. OPERATION UNDER USUAL CONDITIONS

2-6 GENERAL. This section provides information andguidance for generator set operation under normalconditions, refer to FM 20-31.

2-7 ASSEMBLY AND PREPARATION FOR USE.

2-7.1 Installation of Ground Rod.

WARNING

Do not operate the generator set until it has beenconnected to a suitable ground. Serious injury ordeath can result from operating an ungroundedgenerator set.

a. Insert ground cable (2, FIGURE 2-3) throughslot on load output terminal board terminal marked GND(1). Tighten terminal nut.

b. Connect coupling (5) to ground rod (4) andscrew driving stud (3) into coupling (5). Make sure thatdriving stud (3) seats on ground rod (4).

c. Drive ground rod into ground until coupling is justabove surface.

d. Remove driving stud and install another sectionof ground rod.

e. Install another coupling (5) and driving stud (3).Drive ground rod down until new coupling is just aboveground surface.

f. Repeat steps d and e until ground rod has beendriven eight feet or deeper, providing an effective ground.

g. Connect clamp (6) and ground cable (2) toground rod (4) and tighten clamp screw.

2-7.2 Installation of Load Cables.

WARNING

Never attempt to connect or disconnect loadcables while the generator set is running.Failure to observe this warning could result insevere personal injury or death by electrocution.

CAUTIONDo not connect the load cables to theconvenience receptacle. Failure to observe thiscaution can result in damage to the generatorset.

a. Shutdown generator set.

b. Select required output terminals from TABLE 2-4.

c. Open output load terminal door.

Change 2 2-17


FIGURE 2-3. Grounding Connections

2-18

d. Using terminal nutwrench (3, FIGURE 2-4) loosen terminalnuts (1) on terminals(2) selected in Stepb.

e. Insert ends of loadcables through loadcable entrance box.Insert ends of cablesinto slots of loadterminal studs (2).

f. Tighten load terminalnuts (1).



g. Secure wrench (3) inbracket inside loadterminal board door,and close door.

CAUTION

When using singlephase connections,always attempt tobalance loadsbetween terminals(do not connectall loads betweenone terminal andLO). Failure toobserve thiscaution can resultin damage togenerator set.

TABLE 2-4. Load Terminal, AC Reconnection Boardand AM-VM Transfer Switch Selection

RECONNEC- AM-VMTION BOARD TERMINALS TRANSFER VOLTAGE CURRENT

POSITION SWITCH READING READINGPOSITION (TERMINAL)

120/208 L1, L2, L3, LO L1 -LO 120 VOLTS L13 PHASE. L2 -LO 120 VOLTS L2(SINGLE PHASE L3-LO 120 VOLTS L3LOADS CAN BE L1-L2 208 VOLTS NONESERVED USING L2-L3 208 VOLTS NONEANY TERMINAL L3-L1 208 VOLTS NONETO LO)

240/416 L1, L2, L3, LO L1-LO 240 VOLTS L13 PHASE. L2-LO 240 VOLTS L2(SINGLE PHASE L3-LO 240 VOLTS L3LOADS CAN BE L1-L2 416 VOLTS NONESERVED USING L2-L3 416 VOLTS NONEANY TERMINAL L3-L1 416 VOLTS NONETO LO)

2-19


FIGURE 2-4. Installation of Load Cables

2-20

2-8 INITIAL ADJUSTMENTS, DAILY CHECKSAND SELF TEST.

2-8.1 Perform all before (B) PMCS, refer to Table 2-3.

2-8.2 Initial Adjustments.

a.

b.c.

d.

e.

f.

g.

Place DEAD CRANK switch in NORMAL posi-tion.Push DC CONTROL POWER circuit breaker in.Place FREQUENCY SELECT switch to requiredposition (MEP-806A).Ensure voltage reconnection terminal board is posi-tioned to match voltage requirements. If voltagereconnection terminal board must be changed,notify next higher maintenance level.Place AM-VIM transfer switch in a position corre-sponding to output terminal load connections, referto Table 2-4.Place PARALLEL UNIT switch in UNIT position.

Pull out EMERGENCY STOP switch.

ARMY TM 9-6115-645-10AIR FORCE TO 35C2-3444-11


2-8.3 Self Test.

a

b.

c.

d.

Place MASTER SWITCH to PRIME AND RUNposition.

Push PRESS TO TEST pushbutton on malfunctionindicator panel. Ensure all indicator lights are lit.When PRESS TO TEST pushbutton is released, alllights should go out.

Press BATTLE SHORT press to test light on thecontrol panel assembly. Ensure indicator light is lit.When press to test light is released, light should goout.

Press AC CIRCUIT INTERRUPTER press to testlight on the control panel assembly. Ensure indica-tor light is lit. When press to test light is releasedlight should go out.

Change 1 2-21


2-9 OPERATING PROCEDURE.

High voltage is produced when generator set isin operation. Improper operation could resultin personal injury or death.

Exhaust discharge contains deadly gases. Donot operate the generator set in enclosed areasunless exhaust discharge is properly ventedoutside. Severe personal injury or death due tocarbon monoxide poisoning could result.

NOTE

If generator set is to be operated in parallel withanother unit, refer to PARALLEL UNIT OP-ERATION, paragraph 2-10.

2-9.1 Starting Procedure

Never attempt to start the generator set if it hasnot been properly grounded. Failure to observethis warning could result in serious injury ordeath by electrocution.

Do not crank engine in excess of fifteen se-conds. Allow starter to cool at least fifteen se-conds between attempted starts. Failure toobserve this caution could result in damage tothe starter.

NOTEAt temperatures below 40°F (4°C) it may benecessary to use the cold weather starting aid.

NOTE

Ensure all generator set access doors,control panel access door, are closed.

except

2-22

a. Rotate MASTER SWITCHto START position.

b. In cold weatherconditions, pushETHER switch to ONposition as required,until engineaccelerates togoverned speed.

c. Hold MASTER SWITCH inSTART position untiloil pressure reachesat least 25 psi (172kPa), voltage hasincreased to itsapproximate ratedvalue, and engine hasreached stableoperating speed.

d. Release MASTER SWITCHto PRIME AND RUNposition.

e. If operating with anauxiliary fuelsource, rotate MASTERSWITCH to PRIME ANDRUN AUX FUELposition.

Warm up enginewithout load forfive minutes. (Ifrequired, load canbe appliedimmediately) .



g.

h.

i.

j.

k.

l

Turn VOLTAGE andFREQUENCY adjustpotentiometers torequired values forvoltage andfrequency.

Press GROUND FAULTCIRCUIT INTERRUPTERTEST pushbutton.Ensure indicatorwindow is clear.Press RESETpushbutton and ensureindicator is red.

Place AC CIRCUITINTERRUPTER switch toCLOSED position.

Ensure voltage andfrequency are stillat rated values.Adjust if necessary.

Rotate AM-VM transferswitch to each phaseposition whileobserving ammeter(PERCENT RATEDCURRENT) . If morethan rated load isindicated in anyphase, reduce load.

Check kilowattmeter(PERCENT POWER). Ifindication is morethan 100 percentrated load, reduceload.

f. Check COOLANT TEMP[170-200°F (77-93°C)]and OIL PRESSURE [25-60 psi (172-414 kPa)]indicators for normalreadings.

2-23


With any accessdoor open, thenoise level ofthis generator setwhen operatingcould causehearing damage.Hearing protectionmust be worn whenworking near thegenerator setwhile running.

m. Perform all DURING(D) OPERATION PMCSrequirements inaccordance with TABLE2-3.

2-9.2 Stopping Procedure.

a. Place AC CIRCUITINTERRUPTER switch inOPEN position.

b. Allow generator setto operate fiveminutes with no loadapplied.

c. Place MASTER SWITCHin OFF position.

d. Perform all AFTER (A)OPERATION PMCSrequirements inaccordance with TABLE2-3.

e. Place DEAD CRANKswitch in OFFposition.

2-10

2-10.1method

PARALLEL UNIT OPERATION(LOAD SHARING).

CAUTION

Ensure generatorsets are the samesize and modebefore attemptingparalleloperation.

General. The followingof parallel operation

will be used to share the loadbetween two generator sets.Refer to FIGURE 2-1 for locationof operator controls andindicators mentioned below andFIGURE 2-5 for properparalleling configuration.

2-10.2 Pre-Operation.

Prior to makingany connectionsfor paralleloperation, ensurethat there is noinput to the loadand that thegenerator sets areshut down.Failure to observethis warning canresult in injuryor death byelectrocution.

a. Ensure that loadrequirement is equalor below thecombined ratedcapacity of the twogenerator sets.

2-24



FIGURE 2-5. Parallel Operation Setup

2-25


Never attempt tostart thegenerator set ifit is notproperlygrounded.Failure toobserve thiswarning couldresult inserious injuryor death byelectrocution.

b. Determine voltagerequirements of loadand position voltagereconnectionterminal boards ofthe two generatorsets to the requiredvoltage connection.Ensure FREQUENCYSELECT switch (MEP-806A) for bothgenerators arepositioned for thesame loadrequirements.

c. Identify onegenerator set as No.1 and the other asNo. 2.

d. Remove parallelingcable from storagebox located insidebattery compartmentaccess door.

e. Connect theparalleling cablebetween the twogenerator sets.Connect thegenerator sets tothe load observingthe proper phasepolarity.

CAUTION

Do not close theAC CIRCUITINTERRUPTERswitch on eitherof the generatorsets, nor closethe loadcontactor atload untilspecificallydirected to doSO. Closing anyof these devicesat any othertime mayseverely damageone or both ofthe generatorsets.

2-10.3 Operation.

a. Start each generatorset, refer toparagraph 2-9.1.

b. Rotate both VOLTAGEadjust potentio-meters to obtain thesame voltageindication on eachset.

2-26

c. Rotate bothFREQUENCY adjustpotentiometers toobtain the samefrequency indicationon both sets.Ensure loadcontactor at load isopen.

d. Position and hold ACCIRCUIT INTERRUPTERswitch, on generatorset No. 1, to CLOSEDuntil indicatorlights.

e. Place the UNIT-PARALLEL switch onboth units inPARALLEL position.

CAUTION

If synchronizinglights ongenerator setNo. 2 do notglow bright anddark in unison,the phasing iswrong. Shutdown generatorsets and checkthat load cablesare connectedproperly.Failure toobserve thiscaution canresult in damageto generatorsets.

f. Observe synchroni-zing lights ongenerator set No. 2.The lights should beglowing bright anddark in unison.



g. Adjust frequency ofgenerator set No. 2until synchronizinglights glow brightand dark in unisonat 2 to 3 secondinternals.

CAUTION

Check that loadcontactor atload is openbefore attempt-ing to placegenerators onthe line.Failure toobserve thiscaution canresult in damageto generatorsets.

h. When bothsynchronizing lightsare dark, positionand hold AC CIRCUITINTERRUPTER switchof generator set No.2 to the CLOSEDposition untilindicator lights.

NOTE

The generatorsets are nowoperating inparallel with noload.

i. Rotate FREQUENCYadjust potentio-meter of generatorset No. 1 untilkilowattmeter(PERCENT POWER)indicatesapproximately “O”.

2-27


j. Rotate the VOLTAGEadjust potentio-meter of generatorset No. 1 untilammeter (PERCENTRATED CURRENT) readsapproximately “O".

k. Close the loadcontactor at theload.

NOTE

If the REVERSEPOWER indicatorof eithergenerator setlights, and theAC CircuitInterrupterrelay opens,open the loadcontactor atload and de-synchronize thegenerator sets.(Repeat thenecessary stepsd through kabove.)

l. Compare ammeter(PERCENT RATEDCURRENT) readings ofboth generator sets.If readings are notwithin 10 percent,notify next higherlevel ofmaintenance.

m. Compare kilowatt-meter (PERCENTPOWER) readings ofboth generator sets.If readings are notwithin 10 percent,notify next higherlevel ofmaintenance.

2-10.4 Removal from ParallelOperation.

If necessary tomove a generatorset which hasbeen operatingin parallel withanother genera-tor set, shutdown remaininggenerator setconnected to theload, prior toremoving loadcables orground. Failureto observe thiswarning canresult in injuryor death byelectrocution.

Prior to removalof generator setfrom paralleloperation, makesure load doesnot exceed fullload rating ofgenerator setremaining on theline. Failureto observe thiscaution canresult in damageto generatorset.

a. Position AC CIRCUITINTERRUPTER switchto OPEN untilindicator goes out.

b. Return UNIT-PARALLELswitch to UNITposition.

2-28


MARINE CORPS TM 09244A/09245A-10/l

c.

2-11 PREPARATION FOR MOVEMENT .

a.

b.

c.

d.

Refer to paragraph 2-9.2 to stop generator set. e.

Shut down generator set. Refer to paragraph 2-9.2.If generator set is operating in parallel refer to para- f.graph 2-10.4

Disconnect load cables. g.

Disconnect paralleling cable, if used, and store instorage box. 2-12

Disconnect ground cable and remove ground rods.Store ground rods in holding clips located insidehousing left side generator set. Store cable and cou-plings in storage box.

Secure all generator set access doors and panels.

For assembly and preparation for use, refer to para-graph 2-7.

OPERATING INSTRUCTIONS ON PLATES .

When using auxiliary fuel line, disconnect line, There are identification and instruction plates on the gen-drain excess fuel from line and store line in storage erator set. Figure 2-6 through Figure 2-20 show the loca-box. tion and contents of each plate on the generator set.

Change 1 2-29


Figure 2-6. Operating Instructions Plates (Front and Right Side)

2-30


MARINE CORPS TM 09244A/09245A-10/ l

FIGURE 2-7. O p e r a t i n g I n s t r u c t i o n s P l a t e s ( R e a r a n d L e f t S i d e )

2 - 3 1


FIGURE 2-8. Operating Instruction Plate

2-32



Figure 2-9. Identification Plates

Change 2 2-32.1/(2-32.2 blank)



Figure 2-10. Set Rating Identification Plate

Figure 2-10.1. Fuel System Diagram Plate

Change 2 2-33



FIGURE 2-11. Voltage ConnectionCaution Plate

FIGURE 2-13. NATO Slave ReceptaclePlate

FIGURE 2-15. ConvenienceReceptacle Plate

FIGURE 2-12. Grounding StudPlate

FIGURE 2-14. ParallelingReceptacle Plate

FIGURE 2-16. External FuelSupply Plate

2-34 Change 2



Figure 2-17. Battery Connection Instruction Plate

Figure 2-18. Lifting and Tiedown Diagram PlateChange 2 2-35


FIGURE 2-19. Diagnostics Plate

FIGURE 2-20. Generator Identification Plate

2-36



SECTION IV. OPERATION UNDER UNUSUAL CONDITIONS

2-13 OPERATION IN EXTREME COLDWEATHER BELOW -25°F(-31°C) .

The generator set operatesin ambient temperatures as lowas -25°F (-31°C) without specialwinterization equipment. TOensure satisfactory operationunder extreme cold weather thefollowing steps must be taken:

WARNING

Avoid contactingmetal items withbare skin in extremecold weather.Failure to observethis warning cancause personalinjury.

a.

b.

c.

d.

Keep generator set andsurrounding area asfree of ice and snowas practical.

Keep fuel tank full toprotect againstmoisture, condensationand accumulation ofwater.

Ensure that propergrade diesel fuel isused.

Keep batteriesfrom corrosiona well chargedcondition.

freeand in

2-14 OPERATION IN EXTREME HEATABOVE 120°F (48.8°C) .

2-15

a.

b.

c.

d.

e.

Check vents andradiator air passagesfrequently forobstructions.

Check coolanttemperature indicatorfrequently for anyindication ofoverheating.

Allow sufficient spacefor fuel expansionwhen filling fueltank.

Keep generator cleanand free of dirt.Clean obstructionsfrom generator intakeand outlet screens.

Clean external surfaceof engine whengenerator set is notoperating.

OPERATION IN DUSTY ORSANDY AREAS .

a. If possible, provide ashelter for generatorset. Use availablenatural barriers toshield generator setfrom blowing dust orsand.

b. Wet down dusty andsandy surface areasaround generator setfrequently if water isavailable.

2-37


c.

d.

e.

f.

g.

h.

i.

Keep all access doorsclosed, as much aspossible, to prevententry of dust and sandinto housing assembly.

Wipe dust and sandfrequently from thegenerator set externalsurface andcomponents. Washexterior surfacesfrequently with cleanwater when generatorset is not operating.

Semite engine aircleaner assemblyfrequently tocompensate for intakeof additional dust orsand.

Drain sedimentfrequently from fuelfilter/waterseparator. Whenservicing fuel tank becareful to preventdust or sand fromentering fuel tank.

Change engine oil andoil filter frequently.

Store oil and fuel indust-free containers.

Ensure that generatorset ground connectionsare free of dust andsand and connectionsare tight beforestarting the unit.

2-16 OPERATION UNDER RAINY ORHUMID CONDITIONS .

CAUTION

Failure to removewaterproof materialbefore operatinggenerator set couldresult in equipmentdamage.

a.

b.

c.

d.

If possible, provide ashelter for generatorset. Cover generatorset with canvas orother waterproofmaterial when it isnot being operated.

Provide adequatedrainage to preventwater fromaccumulating onoperation site.

Keep all generator setaccess doors closed,as much as possible,to prevent entry ofwater into housingassembly.

Drain water frequentlyfrom fuel filter/waterseparator.

DC voltages arepresent at generatorset electricalcomponents even withgenerator set shut-down . Avoidgrounding yourselfwhen touching elec-trical components.Failure to followthis warning canresult in personalinjury.

2-38

e.

f.

2-17

a.

b.

c.

Remove moisture from generator set componentsbefore and after each operating period.Keep fuel tank full to protect against moisture, con-densation and accumulation of water.

OPERATION IN SALT WATER AREAS .

Failure to remove waterproof material beforeoperating generator set could result in equip-ment damage.

If possible, provide a shelter for the generator set.Locate generator set so that radiator faces into pre-vailing winds. Use natural barriers or, if possible,construct a barrier to protect generator set from saltwater. Cover generator set with canvas or other wa-terproof material when it is not being operated.Keep all generator access doors closed, as much aspossible, to prevent entry of salt water into housingassembly.Wash exterior surfaces frequently with clean waterwhen generator set is not operating.



d. Check wiring connections for corrosion and wireinsulation for signs of deterioration

2-18 OPERATION AT HIGH ALTITUDES .

The generator set will operate at elevations up to 4000 feet(1219.1 meters) above sea level without special adjust-ment or reduction in load. At elevations greater than 4000feet (1219.1 meters) above sea level, the kilowatt rating isreduced approximately 3.5 percent for each additional1000 feet (304.8 meters)

2-19 NATO SLAVE RECEPTACLE START OP-ERATION.

2-19.1 General . The NATO slave receptacle can be usedto start the generator set when batteries are discharged.

2-19.2 NATO Slave Emergency Starting Procedure .

a.

b.

c.

Connect one end of NATO slave cable to fullycharged 24 VDC system and other end to dischargedgenerator set’s NATO SLAVE RECEPTACLE.

Start discharged generator set, refer to paragraph2-9.1.

Remove NATO slave cable after generator set starts.

2-39

ARMY TM 9-6115-645-10AIR FORCE TO 35C2-3444-11MARINE CORPS TM 09244A/09245A-10/1

2-20 EMERGENCY STOPPING.

Depressing the EMERGENCY STOP pushbutton willstop the generator set.

NOTEThe generator set cannot be restarted withoutresetting the EMERGENCY STOP pushbuttonand turning MASTER SWITCH to OFF position.

2-21 OPERATION USING BATTLE, SHORT SWITCH.

CAUTIONContinued operation using the BATTLE SHORTswitch can result in damage to the generator set.

NOTEIf any emergency situation requires continuedoperation of the generator set, the BATTLESHORT switch is used to override all protectiondevices except the overspeed, short circuitdevices, and EMERGENCY STOP function.

NOTEBATTLE SHORT switch must be OFF to startgenerator set.

a. Start generator set, if set is not running.

Refer to paragraph 2-9. .

b. Lift cover on BATTLE SHORT switch andposition switch to ON.

CAUTION

If the OVERSPEED light on the malfunctionindicator panel is illuminated. position the ACcircuit interrupter to the OPEN position untilindicator goes out on each set.

2-22 OPERATION WHILE CONTAMINATED.

The generator set will operate in a normal manner whenexposed to nuclear, biological or chemical (NBC)contamination. It is capable of being operated bypersonnel wearing NBC clothing without special tools orsupport equipment. Refer to FM 3-3, FM 3-4, and FM 3-5.

2-23 USE OF THE CONVENIENCE RECEPTACLE.

Power is available when the main contractor isopen. Avoid accidental contact. Failure toobserve this warning can result in severepersonal injury or death by electrocution.

CAUTIONThe maximum power rating for the conveniencereceptacle is 10 Amps. Continuous operationabove 10 Amps can result in damage to thegenerator set.

a. Start the generator set if it is not operating.Refer to paragraph 2-9.

b. Ensure the load does not exceed the maximumrating.

c. Reset the Ground Fault Circuit Interrupter.

d. Plug appropriate connector into conveniencereceptacle.

2-40 Change 2



CHAPTER 3

MAINTENANCE INSTRUCTIONS

SECTION I. LUBRICATION INSTRUCTIONS

3-1 LUBRICATION ORDER .

Refer to LO 9-6115-645-12for lubrication information.

SECTION II. TROUBLESHOOTING

3-2 GENERAL .

This section lists commonmalfunctions you may find duringoperation of the generator set.You should perform thetests/inspections and correctiveactions in the order listed.

This manual cannot list allmalfunctions that may occur, norall tests or inspections andcorrective actions. If amalfunction is not listed or isnot corrected by listedcorrective actions, notify yoursupervisor.

NOTE

Air Force and MarineCorps users mayperform maintenanceonly as authorized.

3-1


SYMPTOM INDEX

COOLING SYSTEM

COOLANT TEMPERATURE indicatorindicates engine overheating

ELECTRICAL SYSTEM

BATTERY CHARGE ammeterShows low or no charge . . .Shows excessive charge . . .

AC VOLTMETER (VOLTS AC)Indicates low voltage . . .

ENGINE

Indicates correct voltage but Frequencymeter (HERTZ) is off scale . . . . . .

Voltage fluctuates .

Frequency meter (HERTZ)Frequency fluctuates

AC CIRCUIT INTERRUPTERLight fails to light

INTERRUPTER switchwhen AC CIRCUITis closed . . . . .

Light fails to come on generatorSet No. 2 in parallel operation . . .

SYNCHRONIZING LIGHTSFail to light . . . . . . . . . . . . .Do not glow bright and dark in unison

on generator Set No. 2 duringparallel operation . . . . . . . . . .

Fails to crank . . . . . . . . . . . . ..Cranks but fails to start . . . . . . . . .Stops when MASTER SWITCH is released

from START position . . . . . . . . . . .Stops suddenly . . . . . . . . . . . . . .Runs erratically or misfires . . . . . . .Does not develop full power . . . . . . . .Knocks . . . . . . . . . . . . . . . . . .

TroubleshootingProcedure

Page

3-7

3-83-8

3-8

3-93-9

3-9

3-9

3-10

3-10

3-10

3-43-4

3-43-53-53-53-6

3-2



SYMPTOM INDEX - Continued

EXHAUST SYSTEMBlue or white exhaust smoke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6Black exhaust smoke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6

LUBRICATING SYSTEMLow oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6

3-3


Table 3-1. Troubleshooting

MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

1. Engine fails to crank.

Step 1. Check that DEAD CRANK switch is in the NORMAL position.Place switch in NORMAL position.

Step 2. Check that DC CONTROL POWER circuit breaker is energized (in).If DC CONTROL POWER circuit breaker is deenergized (out), go to Step 4.

Step 3. Check that EMERGENCY STOP switch is out.

Step 4. Defect in Engine Starting/Electrical System. Check battery connections.If loose or corroded, notify next higher maintenance level.

2. Engine cranks but fails to start.

Step 1. Cold ambient temperature.If ambient temperature is below 40°F (4°C) turn MASTER SWITCH to START and positionETHER switch to ON, refer to paragraph 2-9.1.

Step 2. Check for dirty air cleaner element.Service air cleaner assembly, refer to paragraph 3-3.3.2.

Step 3. Check for dirty fuel filter/water separator.Service fuel filter/water separator, refer to paragraph 3-3.6.2. If engine still fails to start, notifynext higher maintenance level.

3. Engine starts but stops when MASTER SWITCH is released from START position.

Step 1. Check for proper starting procedure.Hold MASTER SWITCH in START position until 25 psi (172 kpa) is reached, refer to paragraph2-9.1.

Step 2. Check to see if any FAULT INDICATOR lights are lit.NO FUEL light is lit, refer to paragraph 3-3.4.2. If any other lights are lit, notify next highermaintenance level.

3-4 Change 1

TABLE 3-1. Troubleshooting - Continued



MALFUNCTIONTEST OR INSPECTION

CORRECTIVE ACTION

4. Engine stops suddenly.

Step 1. Check to see if any FAULT INDICATOR lights are lit.NO FUEL light is lit, refer to paragraph 3-3.4.2.If any other lights are lit, go to step 2.

Step 2. Check that DC CONTROL POWER

071030 - radionerds · 2019. 5. 8. · title: 071030 author: atcom subject: tm 9-6115-645-10...

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