TM_9-6115-641-10_(5kW_User_Manual).pdf

TECHNICAL MANUAL

OPERATOR'S MANUAL

FOR

GENERATOR SET, SKID MOUNTED, TACTICAL QUIET,

5 kW, 60 Hz, MEP-802A

(NSN: 6115-01-274-7387) (EIC: VG2)

GENERATOR SET, SKID MOUNTED, TACTICAL QUIET,

5 kW, 400 Hz, MEP-812A

(NSN: 6115-01-274-7391) (EIC: VN2)

*ARMY TM 9-6115-641-10

AIR FORCE TO 35C2-3-456-11

*SUPERSEDURE NOTICE. TM 9-6115-641-10 supersedes TM 9-6115-641-10 dated 30 December 1992, including all changes.

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

HEADQUARTERS, DEPARTMENTS OF THE ARMY

AND THE AIR FORCE

15 OCTOBER 2009

FIRST AID

For First Aid information, refer to FM 4-25.11.

5 SAFETY STEPS TO FOLLOW IF SOMEONE IS THE VICTIM OF ELECTRICAL

SHOCK:

DO NOT TRY TO PULL OR GRAB THE INDIVIDUAL.

IF POSSIBLE, TURN OFF THE ELECTRICAL POWER.

IF YOU CANNOT TURN OFF THE ELECTRICAL POWER, PULL, PUSH OR LIFT THE

PERSON TO SAFETY USING A DRY WOODEN POLE OR A DRY ROPE OR SOME

OTHER INSULATING MATERIAL.

SEND FOR HELP AS SOON AS POSSIBLE.

AFTER THE INJURED PERSON IS FREE OF CONTACT WITH THE SOURCE OF

ELECTRICAL SHOCK, MOVE THE PERSON A SHORT DISTANCE AWAY AND IMME-

DIATELY START ARTIFICIAL RESUSCITATION.

This Warning Summary provides a summary of all critical safety information in this manual. The Summary contains all warnings used throughout this manual.

Prior to starting any procedure, the WARNINGS included in the text and at the beginning of each maintenance procedure must be reviewed and understood.

The WARNINGS located in the generator set technical manuals and the trailer technical manuals must also be considered.

This manual describes physical and chemical processes that may require the use of chemicals, solvents, paints, or other commercially available material. Users of the manual should obtain the material safety data sheets (Occupational Safety and Health Act (OSHA) Form 20 or equivalent) from the manufacturers or suppliers of materials to be used. Users must be completely familiar with manufacturer/supplier information and adhere to their procedures, recommendations, warnings, and cautions for safe use, handling, storage, and disposal of these materials.

TM 9-6115-641-10

WARNING SUMMARY

a

WARNING

All metal jewelry can conduct electricity and become entangled in generator set components.

Remove all jewelry when working on generator set. Failure to comply with this warning can cause injury or death to personnel.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to comply with this warning can cause injury or death to personnel.

WARNING

High voltage is produced when this generator set is in operation. SHUT DOWN generator set and make sure it is free of any power source before attempting any repair or maintenance on the set, or when connecting or disconnecting load cables. Failure to comply with this warning can cause injury or death to personnel.

WARNING

Shut down generator set before performing inspection of wiring. Failure to comply with this warning can cause injury or death to personnel.

WARNING

High voltage is produced when the generator set is in operation. Never attempt to start the generator set unless it is properly grounded. Failure to comply with this warning can cause injury or death to personnel.

WARNING

Ensure nuts on ground terminals are properly secured creating a good ground. Failure to comply with this warning can cause injury or death to personnel.

WARNING

High voltage is produced when the generator set is in operation. DO NOT touch live voltage connections. Never attempt to connect or disconnect load cables or paralleling cables while the generator set is running. Failure to comply with this warning can cause injury or death to personnel.

WARNING

High voltage is produced when this generator set is in operation. Ensure engine control and DEAD CRANK switches are set to OFF, negative battery cable is disconnected, and unit is completely shut down and free of any power source before attempting any troubleshooting or maintenance on unit. Failure to comply may cause injury or death to personnel.

WARNING

Dangerous voltage exists on live circuits. Always observe precautions and never work alone.

Failure to comply with this warning can cause injury or death to personnel.

TM 9-6115-641-10

WARNING SUMMARY - Continued b

DC voltages are present at generator set electrical components even with generator set shutdown. Avoid grounding yourself when touching electrical components. Failure to follow this warning can result in personal injury.

WARNING

Power is available when the main contactor is open. Avoid accidental contact. Failure to comply with this warning can cause injury or death to personnel.

WARNING

Slave receptacle (NATO connector) is electrically live at all times and is unfused. The Battery Disconnect Switch does not remove power from the slave receptacle. NATO slave receptacle has 24 VDC even when Battery Disconnect Switch is set to OFF. This circuit is only dead when the batteries are fully disconnected. Disconnect the batteries before performing maintenance on the slave receptacle. Failure to comply with this warning can cause injury or death to personnel.

WARNING

Diesel fuel is flammable and toxic to eyes, skin, and respiratory tract. Skin and eye protection are required when working in contact with diesel fuel. Avoid repeated or prolonged contact. Provide adequate ventilation. Operators are to wash exposed skin and change chemical soaked clothing promptly if exposed to fuel. Failure to comply with this warning can cause injury or death to personnel.

WARNING

Fuels used in the generator set are flammable. Do not smoke or use open flames when performing maintenance. Failure to comply with this warning can cause injury or death to personnel, and damage to the generator set.

WARNING

Fuels used in the generator set are flammable. When filling the fuel tank, maintain metal-to-metal contact between filler nozzle and fuel tank opening to eliminate static electrical discharge. Failure to comply with this warning can cause injury or death to personnel, and damage to the generator set.

WARNING

Cooling system operates at high temperature and pressure. Contact with high pressure steam and/or liquids can result in burns and scalding. Shut down generator set, and allow system to cool before performing checks, services and maintenance, or wear gloves and additional protective clothing and goggles as required. Failure to comply with this warning can cause injury or death to personnel.

WARNING

In extreme cold weather, skin can stick to metal. Avoid contacting metal items with bare skin in extreme cold weather. Failure to comply with this warning can cause injury to personnel.

TM 9-6115-641-10

c

Operating the generator set exposes personnel to a high noise level. Hearing protection must be worn when operating or working near the generator set when the generator set is running. Failure to comply with this warning can cause hearing damage to personnel.

WARNING

Exhaust discharge contains deadly gases including carbon monoxide. DO NOT operate generator set in enclosed areas unless exhaust discharge is properly vented outside. Failure to comply with this warning can cause injury or death to personnel.

WARNING

Hot exhaust gases can ignite flammable materials. Allow room for safe discharge of hot gases and sparks. Failure to comply with this warning can cause injury or death to personnel.

WARNING

Top housing panels and exhaust system can get very hot. Shut down generator set, and allow system to cool before performing checks, services and maintenance. Failure to comply with this warning can cause severe burns and injury to personnel.

WARNING

Top housing panels and exhaust system can get very hot. When performing DURING PMCS, wear gloves and additional protective clothing as required. Failure to comply with this warning can cause severe burns and injury to personnel.

WARNING

Exercise extreme caution when performing DURING PMCS checks inside engine compartment.

Avoid contact with moving or hot engine parts. Failure to comply with this warning can cause injury or death to personnel.

WARNING

When running, winterization heater has hot metal surfaces that will burn flesh on contact. Shut down generator set and allow heater to cool before performing maintenance. Wear gloves and additional protective clothing as required. Failure to comply with this warning can cause injury or death to personnel.

WARNING

Batteries give off a flammable gas. Do not smoke or use open flame when performing maintenance. Failure to comply with this warning can cause injury or death to personnel, and damage to the generator set.

WARNING

Battery acid can cause burns to unprotected skin. Wear safety goggles and chemical gloves and avoid acid splash while working on batteries. Failure to comply with this warning can cause injury to personnel.

TM 9-6115-641-10

d

Solvent used to clean parts is potentially dangerous to personnel and property. Clean parts in a well-ventilated area. Avoid inhalation of solvent fumes. Wear goggles and rubber gloves to protect eyes and skin. Wash exposed skin thoroughly. Do not smoke or use near open flame or excessive heat. Failure to comply with this warning can cause injury to personnel, and damage to the equipment.

WARNING

Do not remove the Bonding Jumper between GND and N unless the Weapon System requires an ungrounded system. Failure to comply can cause death or serious injury to personnel. Refer to applicable Weapon System TM for specific guidance on power and connection requirements.

TM 9-6115-641-10

e/(f blank)

Front Cover 0 Blank 0 Warning summary (6 pgs) 0 i - iii 0 Chp 1 title page 0 Index 0 WP 0001 (4 pgs) 0 WP 0002 (10 pgs) 0 WP 0003 (8 pgs) 0 Chp 2 title page 0 Index 0 WP 0004 (6 pgs) 0 WP 0005 (16 pgs) 0 WP 0006 (4 pgs) 0 WP 0007 (4 pgs) 0 Chp 3 title page 0 Index 0 WP 0008 (2 pgs) 0 WP 0009 (10 pgs) 0 Chp 4 title page 0 Index 0 WP 0010 (8 pgs) 0 WP 0011 (10 pgs) 0 WP 0012 (10 pgs) 0 Chp 5 title page 0 Index 0 WP 0013 (2 pgs) 0 WP 0014 (6 pgs) 0 WP 0015 (2 pgs) 0 WP 0016 (2 pgs) 0

INDEX-1 - INDEX-6 0

Inside back cover 0 Back cover 0

TM 9-6115-641-10

LIST OF EFFECTIVE PAGES / WORK PACKAGES

NOTE: This manual supersedes TM 9-6115-641-10 dated 30 December 1992, including all changes. Zero in the "Change No." column indicates an original page or work package.

Date of issue for the original manual is:

Original 15 OCTOBER 2009

TOTAL NUMBER OF PAGES FOR FRONT AND REAR MATTER IS 24 AND TOTAL NUMBER OF WORK

PACKAGES IS 16, CONSISTING OF THE FOLLOWING:

Page / WP No. Change No. Page / WP No. Change No.

A/(B blank)

TECHNICAL MANUAL

OPERATOR'S MANUAL

GENERATOR SET, SKID MOUNTED, TACTICAL QUIET,

5 kW, 60 Hz, MEP-802A

(NSN: 6115-01-274-7387) (EIC: VG2)

GENERATOR SET, SKID MOUNTED, TACTICAL QUIET,

5 kW, 400 Hz, MEP-812A

(NSN: 6115-01-274-7391) (EIC: VN2)

REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS

You can help improve this manual. If you find any mistakes or if you know of a way to improve the procedures, please let us know. Reports, as applicable by the requiring Service, should be submitted as follows:

a. (A) Army - Mail your letter or DA Form 2028 (Recommended Changes to Publications and Blank Forms) located in the back of this manual, directly to: Commander, U.S. Army CECOM Life Cycle Management Command (LCMC) Fort Monmouth, ATTN:

AMSEL-LC-LEO-E-CM, Fort Monmouth, NJ 07703-5006. You may also send in your recommended changes via electronic mail or by fax. Our fax number is 732-532-1556, DSN 992-1556. Our e-mail address is MONM-AMSELLEOPUBSCHG@conus.army.mil. Our online web address for entering and submitting DA Form 2028 is http://edm.monmouth.army.mil/pubs/2028.html.

b. (F) Air Force - By Air Force AFTO Form 22 (Technical Manual (TM) Change Recommendation and Reply) in accordance with TO 00-5-1.

A reply will be furnished to you.

*ARMY TM 9-6115-641-10

AIR FORCE TO 35C2-3-456-11

HEADQUARTERS,

DEPARTMENTS OF THE ARMY AND THE AIR FORCE

WASHINGTON, D.C., 15 OCTOBER 2009

*SUPERSEDURE NOTICE. TM 9-6115-641-10 supersedes TM 9-6115-641-10 dated 30 December 1992, including all changes.

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

i

TABLE OF CONTENTS

Page No.

WP Sequence No.

HOW TO USE THIS MANUAL

Chapter 1 - Operator General Information, Equipment Description and Theory of Operation

General Information .............................................................................................................................. WP 0001 Table 1. Model Numbers and Equipment Names...............................................................................0001-1 Figure 1. Generator Set, Skid Mounted, 5 kW, Tactical Quiet............................................................0001-2

Equipment Description and Data .......................................................................................................... WP 0002 Figure 1. Generator Set Components. ...............................................................................................0002-4 Figure 2. Location of Major Winterization Kit Components. ...............................................................0002-6 Table 1. Leading Particulars, Generator Set. .....................................................................................0002-7 Table 2. Winterization Kit Heater Operating Data. .............................................................................0002-9

Theory of Operation .............................................................................................................................. WP 0003 Figure 1. Engine Starting System.......................................................................................................0003-2 Figure 2. Fuel System. .......................................................................................................................0003-3 Figure 3. Engine Cooling System. ......................................................................................................0003-4 Figure 4. Engine Lubrication System..................................................................................................0003-5 Figure 5. Air Intake and Exhaust System. ..........................................................................................0003-6 Figure 6. Output Supply System.........................................................................................................0003-7

Chapter 2 - Operator Instructions

Description and Use of Operator Controls and Indicators .................................................................... WP 0004 Figure 1. Operator's Controls and Indicators......................................................................................0004-2 Table 1. Control Panel Controls and Indicators..................................................................................0004-2 Table 2. Load Terminal, AC Voltage Reconnection Switch and VM-AM Transfer Switch Selec-tion......................................................................................................................................................0004-4 Figure 2. Malfunction Indicator Panel. ................................................................................................0004-4 Table 3. Malfunction Indicator Panel. .................................................................................................0004-5 Figure 3. Frequency Adjust Control....................................................................................................0004-5 Table 4. Frequency Adjust Control. ....................................................................................................0004-5

Operation Under Usual Conditions ....................................................................................................... WP 0005 Figure 1. Grounding Connections.......................................................................................................0005-3 Table 1. Load Terminal, AC Voltage Reconnection Switch and VM-AM Transfer Switch Selec-tion......................................................................................................................................................0005-3 Figure 2. Installation of Load Cables. .................................................................................................0005-4 Figure 3. Operating Instructions Plates (Front and Right Side)..........................................................0005-9 Figure 4. Operating Instructions Plates (Rear and Left Side).............................................................0005-10 Figure 5. Operating Instructions Plate - Sample.................................................................................0005-11 Figure 6. Generator Set Identification Plates (DAAK01-88-D-0080). .................................................0005-11 Figure 7. Generator Set Identification Plates (DAAK01-94-D-0036). .................................................0005-11 Figure 8. Generator Set Identification Plates (DAAK01-97-D-0034). .................................................0005-12 Figure 9. Set Rating Identification Plates - Sample. ...........................................................................0005-12 Figure 10. Item Unique Identification (IUID) Plates - Sample.............................................................0005-12 Figure 11. Voltage Connection Caution Plate. ...................................................................................0005-13 Figure 12. Grounding Stud Plate. .......................................................................................................0005-13 Figure 13. NATO Slave Receptacle Plate. .........................................................................................0005-13

TM 9-6115-641-10

ii

TABLE OF CONTENTS - Continued Page No.

WP Sequence No.

Figure 14. Diagnostics Plate...............................................................................................................0005-13 Figure 15. Convenience Receptacle Plate. ........................................................................................0005-14 Figure 16. External Fuel Plate Supply. ...............................................................................................0005-14 Figure 17. Battery Connection Instruction Plate. ................................................................................0005-14 Figure 18. Generator Identification Plate............................................................................................0005-14 Figure 19. Frequency Adjust Plate. ....................................................................................................0005-15 Figure 20. Lifting and Tiedown Diagram Plate. ..................................................................................0005-15 Figure 21. Fuel System Diagram Plate...............................................................................................0005-16

Operation Under Unusual Conditions ................................................................................................... WP 0006

Emergency............................................................................................................................................ WP 0007 Chapter 3 - Operator Troubleshooting Procedures

Troubleshooting Index .......................................................................................................................... WP 0008

Troubleshooting Procedures................................................................................................................. WP 0009 Figure 1. Heater Function Codes Plate. .............................................................................................0009-10

Chapter 4 - Operator Maintenance Instructions

PMCS Introduction................................................................................................................................ WP 0010 Figure 1. Generator Set Components. ...............................................................................................0010-6 Figure 2. Location of Major Winterization Kit Components. ...............................................................0010-7 Figure 3. Operator PMCS Routing Diagram for Winterization Kit.......................................................0010-8

PMCS, Including Lubrication Instructions ............................................................................................. WP 0011 Table 1. Preventive Maintenance Checks and Service. .....................................................................0011-1

Generator Set Servicing and Inspection ............................................................................................... WP 0012 Figure 1. Air Cleaner Element Replacement. .....................................................................................0012-4 Table 1. Coolant. ................................................................................................................................0012-6 Table 2. Diesel Fuel............................................................................................................................0012-7 Figure 2. Draining Fuel Filter/Water Separator...................................................................................0012-9

Chapter 5 - Supporting Information

References............................................................................................................................................ WP 0013

Components of End Item (COEI) and Basic Issue Items (BII) Lists...................................................... WP 0014 Table 1. Components of End Item List. ..............................................................................................0014-1 Figure 1. Technical Manual TM 9-6115-641-10. ................................................................................0014-3 Figure 2. Lubrication Order LO 9-6115-641-12. .................................................................................0014-4 Table 2. Basic Issue Items List...........................................................................................................0014-4

Additional Authorization List (AAL) ....................................................................................................... WP 0015 Table 1. Additional Authorization List. ................................................................................................0015-1

Expendable and Durable Items List ...................................................................................................... WP 0016 Table 1. Expendable and Durable Items List......................................................................................0016-1

Index INDEX-1 iii

HOW TO USE THIS MANUAL

Manual Overview

This manual is designed to help you operate and maintain the MEP-802A and MEP-812A Tactical Quiet Generator (TQG) Sets. Warning pages are located in the front of this manual. Read all warnings before operating or doing any maintenance on the equipment.

The major elements of this manual are chapters and work packages. Each chapter has one or more work packages. The Table of Contents, beginning on page ii, is provided for quick reference to the subjects covered by each chapter and work package. Each chapter also has a chapter index. The chapter index lists the work packages in the chapter.

An alphabetical index is at the end of the manual. That index is for use in locating specific items of information.

Chapters This manual has chapters and each chapter is divided into work packages. Each work package is divided into descriptive paragraphs. The paragraphs have specific information about the generator sets and their major components.

Work Package Numbering This manual is prepared in functionally divided individual task packages (work packages (WP)) in the logical order of work sequence. Work packages may contain a scope of tasks, initial setups, descriptive information, operating tasks and maintenance tasks. These data types are further divided into paragraphs, procedural steps, tables, listings, warnings, cautions and notes, and supporting illustrations.

The WPs are standalone general information, operating, maintenance, and supporting information units containing all information required for directing task performance.

Work Packages are numbered using four (4) digits starting with 0001 (that is, work package 1). Inserted work packages are indicated by a decimal point and a number. For example, 0001.1 indicates the first work package inserted between work package 0001 and work package 0002. This permits adding one or more WPs between any two existing WPs during any revision cycle. Page numbers within each work package are indicated by -1, -2, -3 (that is, 0001-1 indicates work package 1, page 1).

WARNING

Warning highlights an essential operating or maintenance procedure, practice, condition, statement, etc, which, if not strictly observed, could result in injury to, or death of, personnel or long term health hazards.

CAUTION

Highlights an essential operating or maintenance procedure, practice, condition, statement, etc., which, if not strictly observed, could result in damage to, or destruction of, equipment or loss of mission effectiveness.

NOTE

Highlights an essential operating or maintenance procedure, condition, or statement.

Chapter 1 - Operator General Information, Equipment Description, and Theory of Operation

Chapter 1 provides an introduction to the generator sets. It is divided into three WPs, as follows:

iv

WP 0001 - General Information This WP provides general information about this manual and the related forms and records. Instructions are provided for making equipment improvement recommendations. Coverage includes a reference to the TM that contains instructions on destruction of materiel to prevent enemy use.

WP 0002 - Equipment Description and Data This WP describes generator set capabilities, characteristics, and features. It provides basic equipment data and shows the locations of major generator set components. Descriptions of the major components are also provided.

WP 0003 - Theory of Operation This WP provides functional descriptions of the generator sets.

Chapter 2 - Operator Instructions Chapter 2 provides instructions for operating the generator sets. The chapter is divided into four WPs, as follows:

WP 0004 - Description and Use of Operator's Controls and Indicators This WP describes and illustrates the controls and indicators to ensure proper operation of the generator sets.

WP 0005 - Operation Under Usual Conditions This WP contains instructions for preparing the generator sets for use and operating them under normal conditions. Coverage includes instructions for connecting load cables to the generator sets. This section also covers preparation of the generator sets for movement to a new worksite.

WP 0006 - Operation Under Unusual Conditions This WP provides detailed instructions for operation of the generator sets under unusual conditions.

WP 0007 - Emergency This WP provides emergency information.

Chapter 3 - Operator Troubleshooting Procedures Chapter 3 includes a troubleshooting index, troubleshooting procedures, and corrective actions that are to be performed by the operator.

WP 0008 - Troubleshooting Index This WP provides an index of malfunctions and symptoms for troubleshooting procedures.

WP 0009 - Troubleshooting Procedures This WP provides troubleshooting procedures and corrective actions that are to be performed by the operator.

Chapter 4 - Operator Maintenance Instructions

Chapter 4 covers maintenance of the generator sets to be performed by the operator. Its purpose is to provide you with the information that you need to keep the generator sets in good operating condition.

WP 0010 and WP 0011 - Preventive Maintenance Checks and Services (PMCS), including Lubrication Instructions This section contains detailed instructions that the operator must perform BEFORE, DURING, and AFTER preventive maintenance checks and services. Coverage includes all operator PMCS for the generator sets.

v

WP 0012 - Generator Set Servicing and Inspection This WP refers the operator to the preventive maintenance checks and services required by WP 0011.

Chapter 5 - Supporting Information

Chapter 5 provides supporting information.

WP 0013 - References This WP lists all publications referenced in the various chapters of the technical manual. The listing includes the title and document number of each publication.

WP 0014 - Components of End Item (COEI) and Basic Issue Items (BII) Lists Work Packages This WP lists the items usually packaged separately but needed for installation and operation of the generator sets.

WP 0015 - Additional Authorization List (AAL) This WP lists additional items you are authorized for support of the generator sets.

WP 0016 - Expendable and Durable Items List This WP lists expendable/durable supplies and materials needed to operate and maintain the generator sets.

Alphabetical Index An alphabetical index at the back of this technical manual provides a listing of subjects covered, cross-referenced to the applicable page number.

HOW TO FIX A GENERATOR SET MALFUNCTION

Determining the Cause Finding the cause of a malfunction, troubleshooting, is the first step in fixing the generator set and returning it to operation. Follow these simple steps to determine the root of the problem:

1. Turn to the Table of Contents in this manual.

2. Locate "Troubleshooting Procedures" under Chapter 3. Turn to the page indicated.

3. Follow the instructions in the references listed in Chapter 3.

Preparing for a Task Be sure that you understand the entire maintenance procedure before beginning any maintenance task. Make sure that all parts, materials, and tools are handy. Read all steps before beginning. Prepare to do the task as follows:

1. Carefully read the entire task before starting. It tells you what you will need and what you have to know to start the task. DO NOT START THE TASK UNTIL:

a. You know what is needed

b. You have everything you need

c. You understand what to do

2. If parts are listed, they can be drawn from technical supply. Before you start the task, check to make sure you vi can get the needed parts.

3. If expendable/durable supplies or materials are needed, get them before starting the task. Refer toWP 0016for the correct nomenclature and NSN.

How to Do the Task Before starting, read the entire task. Be sure that you understand the entire procedure before you begin the task.

As you read, remember the following:

1. PAY ATTENTION TO WARNINGS, CAUTIONS, AND NOTES.

2. Use the List of Abbreviations and Acronyms in WP 0001 if you do not understand the special abbreviations and acronyms used in this manual.

3. The following are standard maintenance practices. Instructions about these practices are usually not included in task steps. When standard maintenance practices do not apply, the task steps will tell you.

a. Tag electrical wiring before disconnecting it.

b. Discard used preformed packing, retainers, gaskets, cotter pins, lockwashers, and similar items. Install new parts to replace the discarded.

vii/(viii blank)

CHAPTER 1

OPERATOR GENERAL INFORMATION, EQUIPMENT

DESCRIPTION AND THEORY OF OPERATION

FOR

5 kW GENERATOR SET (60 Hz AND 400 Hz), SKID MOUNTED, TACTICAL QUIET

CHAPTER 1

OPERATOR GENERAL INFORMATION, EQUIPMENT DESCRIPTION AND THEORY OF OPERATION

WORK PACKAGE INDEX

Title WP Sequence No.

GENERAL INFORMATION

EQUIPMENT DESCRIPTION AND DATA

THEORY OF OPERATION

OPERATOR MAINTENANCE

5 KW GENERATOR SET (60 HZ AND 400 HZ), SKID MOUNTED, TACTICAL QUIET

GENERAL INFORMATION

SCOPE

Type of Manual This manual contains operation and operator maintenance instructions for the Tactical Quiet (TQ), 5 kW 60 and 400 Hz Generator Sets (Figure 1), herein referred to as generator set. Included are descriptions of major components and their functions in relation to other components. SeeTable 1below for a list of model numbers and equipment names for the generator sets.

Table 1. Model Numbers and Equipment Names.

Model Number Equipment Name

MEP-802A Generator Set, Skid Mounted, Diesel Powered, Tactical Quiet, 5 kW 60 Hz

MEP-812A Generator Set, Skid Mounted, Diesel Powered, Tactical Quiet, 5 kW 400 Hz

Purpose of Equipment The generator set provides tactical quiet AC power. The generator set is easily transported, operated, and maintained.

TM 9-6115-641-10 0001

0001-1

Figure 1. Generator Set, Skid Mounted, 5 kW, Tactical Quiet.

0001-2

MAINTENANCE FORMS, RECORDS, AND REPORTS

(A) Department of the Army forms and procedures used for equipment maintenance will be those prescribed by (as applicable) DA PAM 750-8, The Army Maintenance Management System (TAMMS) Users Manual; DA PAM 738-751, Functional Users Manual for the Army Maintenance Management Systems - Aviation (TAMMS-A); or AR 700-138, Army Logistics Readiness and Sustainability.

(F) Maintenance forms and records used by Air Force personnel are prescribed in AFI 21-101 and the applicable TO 00-20 Series Technical Orders.

REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR)

(A) If your generator set needs improvement, let us know. Send us an EIR. You, the user, are the only one who can tell us what you don't like about your equipment. Let us know why you don't like the design or performance. If you have Internet access, the easiest and fastest way to report problems or suggestions is to go to https://aeps.ria.army.mil/aepspublic.cfm (scroll down and choose the "Submit Quality Deficiency Report" bar). The Internet form lets you choose to submit an Equipment Improvement Recommendation (EIR), a Product Quality Deficiency Report (PQDR) or a Warranty Claim Action (WCA). You may also submit your information using an SF 368 (Product Quality Deficiency Report). You can send your SF 368 via e-mail, regular mail, or facsimile using the addresses/facsimile numbers specified in DA PAM 750-8, The Army Maintenance Management System (TAMMS) Users Manual. We will send you a reply.

(F) USAF Deficiency Reporting and Investigating System, TO 00-35D-54, Appendix A procedures will be used for electronic submission. Submit mailed SF 368 forms to:

Robins AFB WRALC/LGMTC 375 Perry Street Robins AFB, GA 31098-1865

CORROSION PREVENTION AND CONTROL (CPC)

CPC of Army material is of continuing concern. It is important that any corrosion problems with the equipment be reported so that the problem can be corrected and improvements can be made to prevent the problem in future items. Although corrosion is typically associated with rusting of metals, it can also include deterioration of other materials, such as rubber and plastic. Unusual cracking, softening, swelling, or breaking of these materials may be a corrosion problem. If a corrosion problem is identified, it shall be reported using Standard Form 368, Product Quality Deficiency Report. Use of key words such as corrosion, rust, deterioration, or cracking will ensure that the information is identified as a CPC problem. The form should be submitted to the address specified in DA PAM 750-8, The Army Maintenance Management System (TAMMS) Users Manual.

DESTRUCTION OF ARMY MATERIEL TO PREVENT ENEMY USE

Destruction of Army materiel to prevent enemy use shall be in accordance with TM 750-244-3.

PREPARATION FOR STORAGE OR SHIPMENT

For information on Preparation for Storage or Shipment, refer toWP 0005, Preparation for Movement.

WARRANTY INFORMATION

Generator sets MEP-802A/MEP-812A manufactured under contract number DAAK01-97-D-0034 and W1SP7T-08-DA005 are warranted by Engineered Electric Company (Fermont), for a period of 36 months or 1800 operating hours, whichever occurs first. Refer to Warranty Technical Bulletin TB 9-6115-641-24. The warranty starts on the date found in block 23, DA Form 2408-9, in the logbook. Report all defects in material or workmanship to your supervisor, who will take appropriate action through your Maintenance Shop.

0001-3

LIST OF ABBREVIATIONS / ACRONYMS

Term Definition AAL Additional Authorization List

BII Basic Issue Item

BOI Basis Of Issue

CAGE Commercial And Government Entity

CAGEC Commercial And Government Entity Code

COEI Components Of End Item

CPC Corrosion Prevention And Control

CTA Common Table Of Allowance

DMWR Depot Maintenance Work Requirement

DOD Department Of Defense

EIR Equipment Improvement Recommendation

FGC Functional Group Code

Hz Hertz

JTA Joint Table Of Allowances kg Kilogram kPa Kilopascals kVA Kilovolt-ampere kW Kilowatt lbf·ft Foot Pound-Force

M Meter (Metric Measure)

MTOE Modified Table Of Organization And Equipment

N·m Newton-Meter

NATO North Atlantic Treaty Organization

NHA Next Higher Assembly

NIIN National Item Identification Number

NSN National Stock Number

P/N Part Number

PMCS Preventive Maintenance Checks And Services

SMR Source, Maintenance, And Recoverability

TAMMS The Army Maintenance Management System

UOC Usable On Code

ºC Degrees Celsius

ºF Degrees Fahrenheit

END OF WORK PACKAGE

0001-4

EQUIPMENT DESCRIPTION AND DATA

EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES

Generator sets MEP-802A/MEP-812A (Figure 1) are fully enclosed, self-contained, skid-mounted, portable units.

They are equipped with controls, instruments and accessories necessary for operation. The generator sets consist of a diesel engine, brushless generator, excitation system, speed governing system, fuel system, 24 VDC starting system, control system and fault system.

NOTE

All locations (index numbers) referenced in Figure 1 are given facing the control box side (rear) of the generator set.

The Winterization Kit (NSN 6115-01-476-8973) is designed to be mounted in 5 kW Tactical Quiet Generator (TQG) Sets where extreme cold temperatures are anticipated. The kit contains a coolant heater that allows the generator set to operate to -50 °F (-45.6 °C). The kit heater pump circulates the generator set coolant through the heater pump, heats the coolant and then returns the coolant back through the radiator of the generator set. This cycle continues in high heat mode until the temperature reaches 176 °F (80 °C). The heater then switches into a low heat mode. If the coolant temperature drops to 158 °F (70 °C) the heater will automatically switch to the high heat mode.

The Winterization Kit contains a coolant heater that heats the coolant and allows the generator set to operate to -50 °F (-45.6 °C).

The heater burns fuel from the generator set fuel tank to heat the coolant that is pumped back through the engine block. The kit consists of a heater and coolant pump, a control unit, an ON-OFF switch, a fuel pump and line, coolant circulating lines, bypass valve, a wiring harness and mounting hardware to ensure operation to -50 °F (-45.6 °C).

LOCATION AND DESCRIPTION OF MAJOR COMPONENTS

Oil Filter (1)

The oil filter is located in the engine compartment on the left side. The filter removes impurities from the engine lubricating oil.

Dipstick (2)

The dipstick is located in the engine compartment on the left side. The dipstick shows the lubricating oil level in the engine crankcase.

Fuel Filter/Water Separator (3)

The fuel filter/water separator is located to the rear of the engine compartment on the left side. The element removes impurities and water from the diesel fuel.

AC Generator (4)

The AC generator is a single bearing, drip-proof, synchronous, brushless, three phase, fan-cooled generator. The generator is coupled directly to the rear of the diesel engine.

Dead Crank Switch (5)

The Dead Crank switch is located in the engine compartment on the left side. For maintenance purposes, the switch allows the engine to be cranked without starting.

TM 9-6115-641-10 0002

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Engine (6)

The generator is powered by a two cylinder, four cycle, fuel injected, naturally-aspirated, liquid-cooled diesel engine which occupies the front half of the generator set. The engine is also equipped with a fuel filter/water separator, oil filter, and an air cleaner assembly. Protection devices automatically stop the engine during conditions of high coolant temperature, low oil pressure, no fuel, or over-voltage.

Batteries (7)

Two batteries are required, one on each side of the generator set. The batteries are electrolyte serviceable, lead acid, 12 volt type, connected in series. After starting, the generator set is capable of operating with batteries removed. A diode and a fuse, located behind the control panel assembly, protect the generator set if the batteries are incorrectly connected.

Water Pump (8)

The water pump is located in the engine compartment on the front of the engine. The pump circulates the engine coolant through the engine block and the radiator.

Radiator (9)

The radiator is located at the front of the generator set. It acts as a heat exchanger for the engine coolant.

Fuel Tank (10)

The 5 gallon (18.9 liters) fuel tank is located in the front of the generator set below the engine and between the skid base side members. The fuel tank is a fuel reservoir and has sufficient capacity to enable the generator set to operate for at least 8 hours without refueling.

Air Cleaner Assembly (11)

The air cleaner assembly is located on the right side behind the engine. It consists of a dry-type, disposable paper element and canister. The air cleaner assembly features a dust collector which traps large dust particles. The air cleaner assembly has a restriction indicator which will indicate red when the air filter element requires servicing.

Muffler (12)

The muffler and exhaust tubing are connected to the exhaust manifold on the engine. The exhaust exits from the top of the generator set housing. Gases are exhausted upward.

Fan Belt (13)

The fan belt is located in the engine compartment on the front of the engine. The belt drives the fan, water pump, and battery charging alternator.

Battery Charging Alternator (14)

The battery charging alternator is located on the right side of the engine. It is capable of maintaining the batteries in a state of full charge in addition to providing the required 24 VDC control power.

Starter (15)

The starter is located on the right side of the engine. The electric starter mechanically engages the engine flywheel in order to start the diesel engine.

NATO Slave Receptacle (16)

The NATO slave receptacle is located on the right side (rear) of the generator set. It is used for slave starting.

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Skid Base (17)

The skid base supports the generator set. It has fork lift access openings and cross members for short distance movement. The skid base has provisions in the bottom for installation of the generator set on a trailer.

Load Output Terminal Board (18)

The load output terminal board is located at the rear of the generator set. Four output terminals are located on the board. They are marked L1, L2, L3 and L0. A fifth terminal, marked GND, is located next to the output terminals and serves as equipment ground for the generator set. A removable, solid copper bar is connected between the L0 and GND terminals.

Control Panel Assembly (19)

The generator set control panel assembly is located at the rear of the generator set and contains controls and instruments for operating the engine and the generator.

Frequency Adjust Control (20)

The Frequency adjust control is located at the rear left side of generator set. It is used to adjust the generator frequency output.

Malfunction Indicator Panel (21)

The malfunction indicator panel is located to the left of the control panel assembly. It indicates malfunctions of the generator set components.

Convenience Receptacle (22)

The convenience receptacle is a 10 Amp, 120 VAC receptacle used to operate small plug in type equipment. It is protected by a Ground Fault Circuit Interrupter located below the malfunction indicator, an overload circuit breaker located inside the control box, and an in-line fuse on generator sets. The convenience receptacle power is available at all times during operation of the generator set.

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Figure 1. Generator Set Components.

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Winterization Kit

A fuel-burning heater pre-heats engine coolant permitting generator set Operation to -50 °F (-45.6 °C).Figure 2illustrates the major components of the Winterization kit and shows their locations on the 5 kW TQG Set.

Location and Description of Winterization Kit Major Components

A fuel-burning heater pre-heats engine coolant permitting generator set Operation to -50 °F (-45.6 °C).

Control Unit (1)

Controls heater operations.

Heater (2)

Heats coolant for operation in extreme cold temperatures.

Fuel Pump (3)

Pumps fuel from the generator set fuel tank to the heater.

Fuel Lines (4)

Provides a means of transporting fuel to heater.

Coolant Pump (5)

Circulates coolant from generator set through the heater.

Coolant Lines (6)

Provides a means of transporting coolant for circulation.

Switch/Lamp (7)

Switches heater on or off / lamp indicates heater function codes.

Wiring Harness (8)

Electrically connects Winterization Kit components.

Exhaust Hose (9)

Provides a means of exhausting combustion gases from heater.

Air Inlet Hose (10)

Provides intake air to Winterization Kit heater.

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Figure 2. Location of Major Winterization Kit Components.

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DIFFERENCES BETWEEN MODELS

The differences between models of the generator sets covered in this manual are as follows: Model MEP-802A is equipped with a 60 Hz generator. Model MEP-812A is equipped with a 400 Hz generator.

EQUIPMENT DATA

For a list of Leading Particulars refer toTable 1.

Table 1. Leading Particulars, Generator Set.

1. Generator Set:

Model Numbers

5 kW, 60 Hz Tactical Quiet MEP-802A

5 kW, 400 Hz Tactical Quiet MEP-812A

National Stock Numbers

5 kW, 60 Hz Tactical Quiet NSN 6115-01-274-7387

5 kW, 400 Hz Tactical Quiet NSN 6115-01-274-7391

Overall Length

MEP-802A 50.6 in. (128.6 cm)

MEP-812A 50.6 in. (128.6 cm)

Overall Width

MEP-802A 32 in. (81.28 cm)

MEP-812A 32 in. (81.28 cm)

Overall Height

MEP-802A 37 in. (93.98 cm)

MEP-812A 37 in. (93.98 cm)

Dry Weights (less Basic Issue Items)

MEP-802A 800 lb. (362.8 kg.)

MEP-812A 825 lb. (374.2 kg.)

Wet Weights

MEP-802A 868 lb. (393.7 kg.)

MEP-812A 878 lb. (398.2 kg.)

2. Engine:

Manufacturer Onan

Model DN2M-1

Type Two cylinder, four cycle, naturally-aspirated diesel

Displacement 57 cu. in. (0.9 liters)

Altitude Degradation

4000 ft (1220 m) to 8000 (2440 m) 3.5% per 1000 ft (305 m)

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Table 1. Leading Particulars, Generator Set. - Continued

Firing Order 1,2

Cold Weather Starting Aid System Use When temperature is +40 °F (4 °C) or below

Valve Tappet Clearance Adjustment None Required

3. Cooling System:

Type Pressurized radiator and pump

Capacity 6.2 qts. (5.9 liters)

Normal Operating Temperature 170-200 °F (77-93 °C)

Temperature Indicating System Voltage Rating 24 VDC

4. Lubricating System:

Type Full flow, circulating pressure

Oil Pump Type Positive displacement gear

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

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

Lubricating System Capacity 3.2 qts. (3.0 liters)

Pressure Indicating System Voltage Rating 24 VDC

5. Fuel System:

Type of Fuel DF-1, DF-2, DF-A, JP4, JP5, JP8

Fuel Tank Capacity 5 gal. (18.9 liters)

Fuel Consumption Rate: 60 Hz: .55 gal. (2.1 liters) per hour 400 Hz: .61 gal. (2.3 liters) per hour

Auxiliary Fuel Pump:

Voltage Rating 24 VDC

Delivery Pressure 5.0-6.5 psi (34.5-65.5 kPa) range

Fuel Level Switch:

Type Float

Current 3.0 amp at 6 to 32 VDC

6. Engine Starting System:

Batteries Two 12 volt, connected in series

Starter:

Manufacturer Onan

Model 191-1550

Voltage Rating 24 VDC

Drive Type Gear Reduction

Battery Charging Alternator:

Manufacturer Prestolite

Model 8EM3005CA and 8MR3005CA

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Table 1. Leading Particulars, Generator Set. - Continued

Rating 18 amps at 24 VDC

Protective Fuse 30 amps

7. AC Generator:

Manufacturer Onan

Type (MEP-802A/MEP-812A) Rotating field synchronous

Load Capacity 5kW

Current Ratings: 60Hz: 400Hz:

120/240 volt connection 26 amps 26 amps

120/208 volt connection 17 amps 17 amps

120 volt connection 52 amps 52 amps

Power Factor 0.8

Cooling Fan cooled

Drive Type Direct coupling

Duty Classification Continuous

8. Protection Devices:

Low Oil Pressure Switch:

Trip Pressure 15 ± 3 psi (103.4 ± 20.7 kPa)

Voltage Rating 24 VDC

Current Rating 5 amps

Coolant High Temperature Switch:

Trip Temperature 225 ± 5 °F (107 + 3 °C)

Voltage Rating 12-120 VDC

Current Rating 2 amps

Overvoltage:

Trip Point Conditions 153 ± 3 VAC for not less than 200 milliseconds (120 VAC coil winding)

Trip Point No more than 1.25 seconds after trip conditions exist

Tabulated data for the heater is located inTable 2.

Table 2. Winterization Kit Heater Operating Data.

National Stock Number 6115-01-476-8973

Overall Length 10.787 inches

Overall Width 5.984 inches

Overall Height 7.815 inches

Weight 15 lbs.

Heater

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Table 2. Winterization Kit Heater Operating Data. - Continued

Manufacturer Active Gear

Model D5W

Heating Water Coolant

Capacity High: 17,000 BTU/Hr.

Low: 4250 BTU/Hr.

Rated Voltage 24 VDC

Operating Voltage Range 20-28 VDC

Current at 24 VDC Start: 20 Amps/Hr.

Running High: 1.8 Amps/Hr.

Running Low: 1.2 Amps/Hr.

Fuel Diesel

Fuel Consumption High: 0.06 Gal/Hr.

Low: 0.04 Gal/Hr.

Coolant Pump Flow 250 Gal/Hr.

END OF WORK PACKAGE

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THEORY OF OPERATION

INTRODUCTION

This WP contains functional descriptions of the generator set and explains how the controls and indicators interact with the system.

ENGINE STARTING SYSTEM

The Engine Starting System (Figure 1), consists of two 12-volt batteries connected in series, a starter, a 24 volt battery charging alternator, a magnetic pickup (for sensing engine speed) and the related switches and relays required for control of the starting system. For engine cranking, battery power is supplied to the starter motor through the starter solenoid which in turn is controlled by the cranking relay. The starter then engages the engine flywheel causing the engine to turn over. For engine starting, the DEAD CRANK switch must be in the NORMAL position, the DC Control power circuit breaker must be pushed in, the EMERGENCY STOP SWITCH must be in the OUT position, and the MASTER SWITCH is moved to the START position. The cranking relay is then controlled by a circuit consisting of the crank disconnect relay and crank disconnect switch. As the engine accelerates to the preset speed (sensed by the magnetic pickup), the crank disconnect switch opens and de-energizes the cranking relay to stop and disengage the starter.