TM_9-6115-641-24_(5kW_Mechanic_Manual).pdf

ARMY *TM 9-6115-641-24

AIR FORCE TO 35C2-3-456-12

HEADQUARTERS, DEPARTMENTS

OF THE ARMY AND AIR FORCE

15 APRIL 2012

TECHNICAL MANUAL

FIELD AND SUSTAINMENT MAINTENANCE 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)

*TM 9-6115-641-24 dated 15 April 2012 superseded TM 9-6115-641-24 dated 1 September 1993, including all changes.

DISTRIBUTION STATEMENT C - Distribution authorized to U.S. Government agencies and their contractors for administrative or operational use 4/15/2012. Other requests for this document shall be referred to Commander, U.S. Army Communications- Electronics Command, 6001 Combat Drive, ATTN: AMSEL-LCL-ECM, Aberdeen Proving Ground, MD 21005-1846.

DESTRUCTION NOTICE - Destroy by any method that will prevent disclosure of contents or reconstruction of the document.

DISTRIBUTION STATEMENT C - Distribution authorized to U.S. Government agencies and their contractors for administrative or operational use 4/15/2012. Other requests for this document shall be referred to Commander, U.S. Army Communications-

DESTRUCTION NOTICE - Destroy by any method that will prevent disclosure of contents or reconstruction of the document.

TM 9-6115-641-24

a

WARNING SUMMARY

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

WARNING AND CAUTION STATEMENTS

Warning and Caution statements have been strategically placed throughout this text prior to operating proce-dures, practices, or conditions considered essential to the protection of personnel (WARNING) or equipment and property (CAUTION).

A WARNING or CAUTION will apply each time the related step is repeated. Prior to starting any task the WARN- INGs or CAUTIONs included in the text for that task must be reviewed and understood. Refer to the materials list at the beginning of the appropriate manual section for materials used during maintenance of this equipment. This warning summary contains the WARNINGs included in the manual.

WARNING SUMMARY – CONTINUED

b

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.

WARNING

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. Make sure generator set is completely shutdown and free of any power source before attempting any repair or mainte-nance on the set, or when connecting or disconnecting load cables. 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. Shutdown 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

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

Shutdown generator set before performing inspection of wiring. 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

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.

WARNING

DC voltages are present at generator set electrical components even with generator set shut down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can cause injury to personnel, and damage to equipment.

c

WARNING

Prior to making any connections for parallel operation, ensure that there is no input to the load and that the generator sets are shutdown. Failure to comply with this warning can cause injury or death to personnel.

WARNING

If it is necessary to move a generator set which has been operating in parallel with another generator set, shutdown remaining generator set connected to the load, prior to removing load and ground cables. Failure to comply with this warning can cause injury or death to per-sonnel.

WARNING

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

WARNING

High voltage power is available when the main contactor is closed. Avoid accidental contact with live components. Ensure load cables are properly connected and the load cable door is shut before closing main contactor. Ensure load is turned off before closing main contac-tor. Ensure that soldiers working with/on loads connected to the generator set are aware that main contactor is about to be closed before closing main contactor. 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 recepta-cle 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 mainte-nance 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 protec-tion are required when working in contact with diesel fuel. Avoid repeated or prolonged con-tact. Provide adequate ventilation. Operators are to wash exposed skin and change chemi-cal 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 per-forming maintenance. Failure to comply with this warning can cause injury or death to person-nel, 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 dis-charge. Failure to comply with this warning can cause injury or death to personnel, and dam-age to the generator set.

d

WARNING

Hot engine surfaces from the engine and generator circuitry are possible sources of igni-tion. When hot refueling with DF-1, DF-2, JP5 or JP8, avoid fuel splash and fuel spill. Do not smoke or use open flame when performing refueling. Remember PMCS is still required. Fail-ure to comply with this warning can cause injury or death to personnel, and damage to the generator set.

WARNING

When running, generator set engine has hot metal surfaces that will burn flesh on contact.

Shutdown generator set and allow engine to cool before performing checks, services, and maintenance. Wear gloves and additional protective clothing as required. Failure to comply with this warning can cause injury or death to personnel.

WARNING

Cooling system operates at high temperature and pressure. Contact with high pressure steam and/or liquids can result in burns and scalding. Shutdown generator set, and allow sys-tem to cool before performing checks, services and maintenance, or wear gloves and addi-tional 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.

WARNING

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 gen-erator 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. Shutdown 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.

e

WARNING

Exercise extreme caution when performing DURING PMCS checks inside engine compart-ment. 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 Kit heater has hot metal surfaces that will burn flesh on con-tact. Shutdown 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

Each battery weighs more than 70 pounds (32 kg) and requires a two-person lift. Lifting bat-teries can cause back strain. Ensure proper lifting techniques are used when lifting batteries.

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

WARNING

Batteries give off a flammable gas. Do not smoke or use open flame when performing mainte-nance. Failure to comply with this warning can cause injury or death to personnel, and dam-age 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.

WARNING

When disconnecting or removing batteries, disconnect the negative lead that connects directly to the grounding stud first; disconnect the negative end of the interconnection cable next. When installing batteries, reverse the connection sequence. Failure to comply with this warning can cause injury to personnel.

WARNING

The connection of any electrical equipment and the disconnection of any electrical equip-ment may cause an explosion hazard. Do not connect any electrical equipment or disconnect any electrical equipment in an explosive atmosphere. Failure to comply with this warning can cause injury or death to personnel.

WARNING

Many components require a two-person lift. Lifting heavy components can cause back strain.

Ensure proper lifting techniques are used when lifting heavy components. Failure to comply with this warning can cause injury to personnel.

WARNING

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.

f

WARNING

Do not operate generator set while servicing radiator. Failure to comply with this warning can cause injury to personnel and damage to the equipment.

WARNING

Fan has sharp blades. Use caution and wear gloves when removing or installing belts. Failure to comply with this warning can cause injury to personnel.

WARNING

Oil filter base and housing springs are under tension and can act as projectiles when being removed. Use eye protection when removing springs. Failure to comply with this warning can cause injury to personnel.

WARNING

The high pressure oil system operates at high temperature and pressure. Contact with hot oil can result in burns and scalding. Shutdown generator set, and allow system to cool before performing checks, services, and maintenance. Wear heat resistant gloves and avoid con-tacting hot surfaces. Do not allow hot oil or components to contact skin or hands. Failure to comply with this warning can cause injury or death to personnel.

WARNING

Wear heat resistant gloves and avoid contacting hot metal surfaces with your hands after components have been heated. Wear additional protective clothing as required. Failure to comply with this warning can cause injury to personnel.

WARNING

Ensure that the engine cannot be started while maintenance is being performed (ENGINE CONTROL switch set to OFF/RESET; Battery Disconnect Switch is OFF; DEAD CRANK SWITCH is OFF). Failure to comply with this warning can cause injury or death to personnel.

WARNING

If not shielded, hot exhaust pipe can ignite flammable wall materials. Failure to comply with this warning can cause injury or death to personnel.

WARNING

An unwrapped exhaust pipe can cause injury if touched. Failure to comply with this warning can cause injury to personnel.

WARNING

Always remove radiator cap slowly to permit any pressure to escape. Failure to comply with this warning can cause injury to personnel.

WARNING

Avoid breathing fumes generated by soldering. Eye protection is required. Good general ven-tilation is normally adequate. Failure to comply with this warning can cause injury to person-nel.

g

WARNING

CARC paint is a health hazard, and is irritating to eyes, skin, and respiratory system. Wear protective eyewear, mask, and gloves when applying or removing CARC paint. Failure to comply with this warning can cause injury to personnel.

WARNING

Eye protection is required when working with compressed air. Compressed air can propel particles at high velocity and injure eyes. Do not exceed 15 psi pressure when using com-pressed air. Failure to comply with this warning can cause injury to personnel.

WARNING

High pressure steam can blow particles or chemicals into eyes, can cause severe burns, and creates hazardous noise levels. Wear protective eye, skin, and hearing protection when using high pressure steam. Failure to comply with this warning can cause injury to personnel.

WARNING

The generator set, engine, and generator are extremely heavy and require an assistant and a lifting device (forklift, overhead lifting device) with sufficient capacity. Failure to comply with this warning can cause injury or death to personnel.

WARNING

Rated capacity of overhead hoist should be at least 1,500 pounds (680 kg). Do not use a hoist with less capacity. Failure to comply with this warning can cause injury or death to per-sonnel, and damage to equipment.

WARNING

Keep hands and feet from underside of engine and generator while using lifting device to remove them from the skid base. Failure to comply with this warning can cause injury or death to personnel.

WARNING

Support components when removing attaching hardware or component may fall. Failure to comply with this warning can cause injury to personnel, and damage to equipment.

WARNING

A qualified technician must make the power connections and perform all continuity checks.

The power source may be a generator or commercial power. Failure to comply with this warn-ing can cause injury or death to personnel.

WARNING

Cleaning solvent is flammable and toxic to eyes, skin, and respiratory tract. Skin and eye pro-tection are required when working in contact with cleaning solvent. Avoid repeated or pro-longed contact. Work in ventilated area only. Failure to comply with this warning can cause injury or death to personnel.

WARNING

Cleaning compound is toxic. Avoid prolonged breathing of vapors. Use only in a well-venti-lated area. Failure to comply with this warning can cause injury to personnel.

h

WARNING

Conversion coating material is toxic to eyes, skin, and respiratory tract. Skin and eye protec-tion are required when working in contact with conversion coating material. Avoid repeated or prolonged contact. Work in ventilated area only. Failure to comply with this warning can cause injury or death to personnel.

WARNING

Hot metal surfaces can cause burns to skin. Wear protective gloves and eye protection when applying heat to generator housing. Failure to comply with this warning can cause injury to personnel.

WARNING

Use protective gloves when handling heated rectifier hub. Failure to comply with this warning can cause injury to personnel.

WARNING

Do not use the engine starter to turn the flywheel. Failure to comply with this warning can cause injury to personnel.

WARNING

Catch fuel in suitable container. Keep spilled fuel away from hot engine and all fires. Failure to comply with this warning can cause injury or death to personnel.

WARNING

Do not attempt to perform any maintenance tasks on the Winterization Kit while the generator set is operating. Failure to comply with this warning can cause injury or death to personnel.

WARNING

Disconnect negative battery cable from right battery and the positive battery cable from the left battery before doing the following procedures. Reconnect cables in reverse order. Failure to comply with this warning can cause injury or death to personnel.

WARNING

Muffler and flex hoses can get very hot. Allow them to cool before touching them. Failure to comply with this warning can cause severe burns and injury to personnel.

WARNING

Oil fumes or oil can ignite above 380 °F (193 °C). Use a thermometer and do not exceed 360 °F (182 °C). Do not allow a flame or heating element to be in direct contact with oil. Heat oil in a well ventilated area. Plan a safe handling procedure to avoid burns. Failure to comply with this warning can cause severe burns and injury to personnel.

WARNING

Engine exhaust fumes contain deadly poisonous gases.

Severe exposure can cause death or permanent brain damage.

Exhaust gases are most dangerous in places with poor airflow. Best defense against exhaust gas poisoning is very good airflow.

i/j blank

To protect yourself and your partners, always obey the following rules:

• DO NOT run engine indoors unless you have VERY GOOD AIRFLOW.

• DO NOT idle engine for a long time unless there is VERY GOOD AIRFLOW.

• Be alert at all times. Check for smell of exhaust fumes.

• REMEMBER: Best defense against exhaust gas poisoning is VERY GOOD AIRFLOW.

• Exhaust gas poisoning causes dizziness, headache, loss of muscle control, sleepiness, coma, and death. If anyone shows signs of exhaust gas poisoning, get ALL PERSONNEL clear of exhaust area. Make sure they have lots of fresh air. KEEP THEM WARM, CALM, AND INACTIVE. GET MEDICAL HELP. If anyone stops breathing, give artificial respira-tion. See FM 4-25.11 for first aid.

A USA

LIST OF EFFECTIVE PAGES / WORK PACKAGES

NOTE: TM 9-6115-641-24 dated 15 April 2012 superseded TM 9-6115-641-24 dated 1 September 1993, includ-ing 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 April 2012

TOTAL NUMBER OF PAGES FOR FRONT AND REAR MATTER IS 32 AND TOTAL

NUMBER OF WORK PACKAGES IS 150, CONSISTING OF THE FOLLOWING:

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

Front cover 0 Blank 0 Warning summary ( 10 pages) 0 i - xv 0

Chp 1 title page 0 Blank 0 WP 0001 (6 pgs) 0 WP 0002 (10 pgs) 0 WP 0003 (16 pgs) 0 Chp 2 title page 0 Blank 0 WP 0004 (2 pgs) 0 WP 0005 (30 pgs) 0 Chp 3 title page 0 Blank 0 WP 0006 (8 pgs) 0 WP 0007 (4 pgs) 0 WP 0008 (2 pgs) 0 WP 0009 (4 pgs) 0 WP 0010 (4 pgs) 0 WP 0011 (4 pgs) 0 WP 0012 (4 pgs) 0 WP 0013 (4 pgs) 0 WP 0014 (4 pgs) 0 WP 0015 (4 pgs) 0 WP 0016 (2 pgs) 0 WP 0017 (6 pgs) 0 WP 0018 (6 pgs) 0 WP 0019 (4 pgs) 0 WP 0020 (4 pgs) 0 WP 0021 (4 pgs) 0 WP 0022 (4 pgs) 0 WP 0023 (4 pgs) 0 WP 0024 (4 pgs) 0 WP 0025 (4 pgs) 0 WP 0026 (4 pgs) 0 WP 0027 (4 pgs) 0 WP 0028 (4 pgs) 0 WP 0029 (4 pgs) 0

WP 0030 (4 pgs) 0 WP 0031 (4 pgs) 0 WP 0032 (4 pgs) 0 WP 0033 (2 pgs) 0 WP 0034 (6 pgs) 0 WP 0035 (6 pgs) 0 WP 0036 (4 pgs) 0 WP 0037 (4 pgs) 0 WP 0038 (4 pgs) 0 WP 0039 (4 pgs) 0 WP 0040 (4 pgs) 0 WP 0041 (4 pgs) 0 WP 0042 (4 pgs) 0 WP 0043 (4 pgs) 0 WP 0044 (4 pgs) 0 WP 0045 (4 pgs) 0 WP 0046 (4 pgs) 0 WP 0047 (4 pgs) 0 WP 0048 (4 pgs) 0 WP 0049 (4 pgs) 0 WP 0050 (4 pgs) 0 WP 0051 (4 pgs) 0 WP 0052 (4 pgs) 0 WP 0053 (4 pgs) 0 WP 0054 (4 pgs) 0 WP 0055 (4 pgs) 0 WP 0056 (4 pgs) 0 WP 0057 (2 pgs) 0 WP 0058 (6 pgs) 0 WP 0059 (4 pgs) 0 WP 0060 (6 pgs) 0 WP 0061 (2 pgs) 0 WP 0062 (4 pgs) 0 WP 0063 (4 pgs) 0 WP 0064 (4 pgs) 0 WP 0065 (4 pgs) 0 WP 0066 (4 pgs) 0 WP 0067 (4 pgs) 0 WP 0068 (4 pgs) 0 xvi Blank 0

LIST OF EFFECTIVE PAGES - CONTINUED

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

USA B

WP 0069 (4 pgs) 0 WP 0070 (2 pgs) 0 WP 0071 (2 pgs) 0 WP 0072 (6 pgs) 0 WP 0073 (2 pgs) 0 WP 0074 (2 pgs) 0 WP 0075 (4 pgs) 0 WP 0076 (2 pgs) 0 WP 0077 (4 pgs) 0 WP 0078 (4 pgs) 0 WP 0079 (4 pgs) 0 WP 0080 (4 pgs) 0 WP 0081 (2 pgs) 0 WP 0082 (2 pgs) 0 WP 0083 (2 pgs) 0 WP 0084 (2 pgs) 0 WP 0085 (4 pgs) 0 WP 0086 (4 pgs) 0 WP 0087 (4 pgs) 0 WP 0088 (4 pgs) 0 WP 0089 (2 pgs) 0 WP 0090 (4 pgs) 0 WP 0091 (4 pgs) 0 WP 0092 (4 pgs) 0 WP 0093 (4 pgs) 0 WP 0094 (4 pgs) 0 WP 0095 (4 pgs) 0 WP 0096 (4 pgs) 0 WP 0097 (4 pgs) 0 WP 0098 (2 pgs) 0 WP 0099 (4 pgs) 0 WP 0100 (4 pgs) 0 WP 0101 (4 pgs) 0 WP 0102 (2 pgs) 0 WP 0103 (2 pgs) 0 WP 0104 (10 pgs) 0 WP 0105 (4 pgs) 0 WP 0106 (8 pgs) 0 WP 0107 (8 pgs) 0 WP 0108 (8 pgs) 0 WP 0109 (2 pgs) 0 WP 0110 (4 pgs) 0 WP 0111 (2 pgs) 0 WP 0112 (2 pgs) 0 WP 0113 (4 pgs) 0 WP 0114 (10 pgs) 0 WP 0115 (2 pgs) 0 WP 0116 (4 pgs) 0 WP 0117 (4 pgs) 0 WP 0118 (14 pgs) 0 WP 0119 (2 pgs) 0 WP 0120 (4 pgs) 0

WP 0121 (4 pgs) 0 WP 0122 (4 pgs) 0 WP 0123 (2 pgs) 0 WP 0124 (4 pgs) 0 WP 0125 (2 pgs) 0 WP 0126 (4 pgs) 0 WP 0127 (4 pgs) 0 WP 0128 (2 pgs) 0 WP 0129 (4 pgs) 0 WP 0130 (8 pgs) 0 WP 0131 (2 pgs) 0 WP 0132 (2 pgs) 0 WP 0133 (2 pgs) 0 WP 0134 (2 pgs) 0 WP 0135 (2 pgs) 0 WP 0136 (2 pgs) 0 WP 0137 (2 pgs) 0 WP 0138 (2 pgs) 0 WP 0139 (2 pgs) 0 WP 0140 (2 pgs) 0 WP 0141 (2 pgs) 0 WP 0142 (2 pgs) 0 WP 0143 (2 pgs) 0 WP 0144 (2 pgs) 0 Chp 4 title page 0 Blank 0 WP 0145 (8 pgs) 0 WP 0146 (2 pgs) 0 Chp 5 title page 0 Blank 0 WP 0147 (2 pgs) 0 WP 0148 (4 pgs) 0 WP 0149 (14 pgs) 0 WP 0150 (2 pgs) 0

FP-1 0

Inside back cover 0 Back cover 0

FP-2 Blank

FP-3

FP-4 Blank

ARMY *TM 9-6115-641-24

AIR FORCE TO 35C2-3-456-12

i

HEADQUARTERS, DEPARTMENTS OF THE ARMY AND AIR FORCE

Washington, D.C., 15 APRIL 2012

TECHNICAL MANUAL

FIELD AND SUSTAINMENT MAINTENANCE 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)

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 Pub-lications and Blank Forms) located in the back of this manual, directly to: Com-mander, U.S. Army Communications-Electronics Command, 6001 Combat Drive, ATTN: AMSEL-LCL-ECM, Aberdeen Proving Ground, MD 21005-1846. You may also send in your recommended changes via electronic mail or by fax. Our fax number is 443-861-5521, DSN 848-5521. Our e-mail address is MONM- AMSELLEOPUBSCHG@conus.army.mil. Our online web address for entering and submitting DA Form 2028s is http://edm.apg.army.mil/pubs/2028.html.

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

A reply will be furnished to you.

*TM 9-6115-641-24 dated 15 April 2012 superseded TM 9-6115-641-24 dated 1 September 1993, including all changes.

DISTRIBUTION STATEMENT C - Distribution authorized to U.S. Government agencies and their contractors for administrative or operational use 4/15/2012. Other requests for this document shall be referred to Commander, U.S. Army Communications-

DESTRUCTION NOTICE - Destroy by any method that will prevent disclosure of contents or reconstruction of the document.

DISTRIBUTION STATEMENT C - Distribution authorized to U.S. Government agencies and their contractors for administrative or operational use 4/15/2012. Other requests for this document shall be referred to Commander, U.S. Army Communications-

DESTRUCTION NOTICE - Destroy by any method that will prevent disclosure of contents or reconstruction of the document.

ii

TABLE OF CONTENTS

Page No.

WP Sequence No.

How To Use This Manual............................................................................................................. xi

Chapter 1 - Field and Sustainment General Information, Equipment Description and Theory of Operation General Information.............................................................................................................. WP 0001

Figure 1. 5 kW 60 Hz and 400 Hz Tactical Quiet Generator Sets.............................. WP 0001-2 Equipment Description and Data......................................................................................... WP 0002

Figure 1. Generator Set Components........................................................................ WP 0002-2 Table 1. Tabulated Data.............................................................................................. WP 0002-5 Table 2. Performance Characteristics......................................................................... WP 0002-8

Theory of Operation............................................................................................................. WP 0003 Figure 1. Generator Schematic................................................................................... WP 0003-1 Figure 2. Excitation Block Diagram............................................................................ WP 0003-2 Figure 3. Fault System............................................................................................... WP 0003-3 Figure 4. Generator Set Fuel System........................................................................ WP 0003-5 Figure 5. Generator Set Cooling System................................................................... WP 0003-6 Figure 6. Engine Cooling System............................................................................... WP 0003-7 Figure 7. Engine Lubrication System......................................................................... WP 0003-8 Figure 8. Engine Air Intake and Exhaust System...................................................... WP 0003-9 Figure 9. Output Supply System................................................................................ WP 0003-10 Figure 10. Engine Starting System............................................................................. WP 0003-12 Figure 11. Governor Control System.......................................................................... WP 0003-14 Figure 12. Voltage Regulation System....................................................................... WP 0003-15

Chapter 2 - Field Troubleshooting Procedures Troubleshooting Index.......................................................................................................... WP 0004 Troubleshooting Procedures................................................................................................. WP 0005

Chapter 3 - Field Maintenance Instructions Service Upon Receipt .......................................................................................................... WP 0006

Table 1. Coolant.......................................................................................................... WP 0006-3 Table 2. Fuel ............................................................................................................... WP 0006-4 Table 3. Lubricating Oil ............................................................................................... WP 0006-5 Figure 1. Base Mounting Measurements.................................................................... WP 0006-6 Figure 2. Minimum Enclosure Clearance Measurements........................................... WP 0006-8

PMCS Introduction............................................................................................................... WP 0007 PMCS, Including Lubrication Instructions............................................................................ WP 0008

Table 1. Field Preventive Maintenance Checks and Services.................................... WP 0008-1 Maintenance of DC Electrical System, Battery and Slave Receptacle Cables: Inspection, Removal, Cleaning, Repair, Installation

WP 0009

Figure 1. Batteries and Cables................................................................................... WP 0009-3 Maintenance of DC Electrical System, Batteries: Testing, Removal, Inspection, Servicing, Installation

WP 0010

TABLE OF CONTENTS – CONTINUED

Page No.

WP Sequence No.

iii

Table 1. State of Charge with Specific Gravity Correct to 80 °F (27 °C).................... WP 0010-1 Table 2. Specific Gravity Temperature Corrections.................................................... WP 0010-2

Maintenance of DC Electrical System, Nato Slave Receptacle: Inspection, Removal, Installation

WP 0011

Figure 1. NATO Slave Receptacle and Cables.......................................................... WP 0011-2 Maintenance of DC Electrical System, Battery Charging Alternator: Inspection, Testing, Removal, Installation

WP 0012

Figure 1. Battery Charging Alternator......................................................................... WP 0012-3 Maintenance of Housing, Access Doors: Inspection, Removal, Repair, Installation............ WP 0013

Figure 1. Generator Set Access Doors...................................................................... WP 0013-2 Maintenance of Housing, Control Box Top Panel: Removal, Inspection, Repair, Installa-tion

WP 0014

Figure 1. Control Box Top Panel ................................................................................ WP 0014-2 Maintenance of Housing, Top Housing Panel: Removal, Inspection, Repair, Installation.... WP 0015

Figure 1. Generator Set Front Housing Section......................................................... WP 0015-3 Maintenance of Housing, Front Housing Panel: Removal, Inspection, Repair, Installation.. WP 0016 Maintenance of Housing, Front Housing Section: Removal, Inspection, Repair, Installa-tion

WP 0017

Maintenance of Housing, Rear Housing Section: Removal, Inspection, Repair, Installation WP 0018 Figure 1. Generator Set Rear Housing Section......................................................... WP 0018-3

Maintenance of Control Box Assembly, Control Box Assembly: Inspection, Removal, Repair, Installation

WP 0019

Figure 1. Control Box Assembly................................................................................. WP 0019-3 Maintenance of Control Box Assembly, Convenience Receptacle: Inspection, Testing, Removal, Installation

WP 0020

Figure 1. Control Box Components............................................................................ WP 0020-2 Maintenance of Control Box Assembly, Ground Fault Circuit Interrupter: Inspection, Test-ing, Removal, Installation

WP 0021

Figure 1. In-Line Fuse Installation.............................................................................. WP 0021-3 Maintenance of Control Box Assembly, Malfunction Indicator Panel: Inspection, Testing, Removal, Installation

WP 0022

Maintenance of Control Box Assembly, Battery Charger Fuse Assembly: Inspection, Test-ing, Removal, Installation

WP 0023

Maintenance of Control Box Assembly, DC Control Power Circuit Breaker: Inspection, Testing, Removal, Installation

WP 0024

Maintenance of Control Box Assembly, AC Voltage Regulator: Inspection, Testing, Removal, Installation

WP 0025

Table 1. Voltage Adjustment Range........................................................................... WP 0025-1 Maintenance of Control Box Assembly, Frequency Transducer: Inspection, Testing, Removal, Installation

WP 0026

Maintenance of Control Box Assembly, Shunt: Inspection, Testing, Removal, Installation.. WP 0027 Maintenance of Control Box Assembly, Overvoltage Relay: Inspection, Testing, Removal, Installation

WP 0028

Page No.

WP Sequence No.

iv

Maintenance of Control Box Assembly, Short Circuit/Overload Relay: Inspection, Testing, Removal, Installation

WP 0029

Maintenance of Control Box Assembly, Crank Disconnect Switch: Inspection, Testing, Removal, Installation

WP 0030

Maintenance of Control Box Assembly, Relays: Inspection, Testing, Removal, Installation. WP 0031 Maintenance of Control Box Assembly, Resistor-Diode Assembly: Inspection, Testing, Removal, Repair, Installation

WP 0032

Figure 1. Diode Identification...................................................................................... WP 0032-2 Maintenance of Control Box Assembly, Control Box Wiring Harness: Inspection, Testing, Repair

WP 0033

Maintenance of Control Box Assembly, Control Box Wiring Harness: Removal, Inspec-tion, Testing, Repair, Installation

WP 0034

Figure 1. Control Box Wiring Harness........................................................................ WP 0034-4 Maintenance of Control Box Assembly, Diagnostic Connector: Inspection, Removal, Installation

WP 0035

Figure 1. Diagnostic Connector Pin Positions............................................................ WP 0035-3 Table 1. Diagnostic Connector Connection Points..................................................... WP 0035-4

Maintenance of Control Box Assembly, Control Panel Lights: Inspection, Removal, Disas-sembly, Assembly, Installation

WP 0036

Figure 1. Control Panel Indicators and Switches Lights............................................. WP 0036-2 Maintenance of Control Box Assembly, Press-to-Test Indicator Lights: Inspection, Testing, Removal, Installation

WP 0037

Maintenance of Control Box Assembly, Fuel Level Indicator: Inspection, Testing, Removal, Installation

WP 0038

Maintenance of Control Box Assembly, Coolant Temperature Indicator: Inspection, Test-ing, Removal, Installation

WP 0039

Maintenance of Control Box Assembly, Oil Pressure Indicator: Inspection, Testing, Removal, Installation

WP 0040

Maintenance of Control Box Assembly, Time Meter (Total Hours): Inspection, Testing, Removal, Installation

WP 0041

Maintenance of Control Box Assembly, Battery Charge Ammeter: Inspection, Testing, Removal, Installation

WP 0042

Maintenance of Control Box Assembly, Frequency Meter (Hertz): Inspection, Testing, Removal, Installation

WP 0043

Maintenance of Control Box Assembly, Ammeter (Percent Rated Current): Inspection, Testing, Removal, Installation

WP 0044

Maintenance of Control Box Assembly, AC Voltmeter (VOLTS AC): Inspection, Testing, Removal, Installation

WP 0045

Maintenance of Control Box Assembly, Master Switch: Inspection, Testing, Removal, Installation

WP 0046

Maintenance of Control Box Assembly, Voltage Adjust Potentiometer: Inspection, Testing, Removal, Installation

WP 0047

Maintenance of Control Box Assembly, Emergency Stop Switch Assembly: Inspection, Testing, Removal, Installation

WP 0048

Page No.

WP Sequence No.

v

Maintenance of Control Box Assembly, Battle Short Switch: Inspection, Testing, Removal, Installation

WP 0049

Maintenance of Control Box Assembly, AC Circuit Interrupter Switch: Inspection, Testing, Removal, Installation

WP 0050

Maintenance of Control Box Assembly, VM-AM Transfer Switch: Inspection, Testing, Removal, Installation

WP 0051

Maintenance of Control Box Assembly, Panel Lights Switch: Inspection, Testing, Removal, Installation

WP 0052

Maintenance of Control Box Assembly, Control Panel: Inspection, Removal, Repair, Installation

WP 0053

Figure 1. Control Box Housing and Control Panel ..................................................... WP 0053-3 Maintenance of Control Box Assembly, Control Panel Frame: Removal, Inspection, Repair, Installation

WP 0054

Maintenance of Control Box Assembly, Control Box Side Panels: Inspection, Removal, Repair, Installation

WP 0055

Maintenance of Control Box Assembly, Control Box Tray (Bottom): Removal, Inspection, Repair, Installation

WP 0056

Maintenance of Output Box Assembly, Output Box Assembly: Inspection, Repair .............. WP 0057 Maintenance of Output Box Assembly, Output Box Assembly: Removal, Installation.......... WP 0058

Figure 1. Output Box Assembly.................................................................................. WP 0058-3 Maintenance of Output Box Assembly, Output Box/Engine Wiring Harness: Inspection, Repair

WP 0059

Figure 1. Output Box Assembly.................................................................................. WP 0059-2 Maintenance of Output Box Assembly, Output Box/Engine Harness: Testing, Removal, Inspection, Repair, Installation

WP 0060

Maintenance of Output Box Assembly, Current Transformer: Inspection, Testing............... WP 0061 Maintenance of Output Box Assembly, Current Transformer: Removal, Testing, Installa-tion

WP 0062

Figure 1. Testing Current Transformer....................................................................... WP 0062-3 Maintenance of Output Box Assembly, AC Circuit Interrupter Relay: Inspection, Removal, Testing, Installation

WP 0063

Maintenance of Output Box Assembly, Cranking Relay: Inspection, Removal, Testing, Installation

WP 0064

Maintenance of Output Box Assembly, Pre-Heat Relay: Inspection, Removal, Testing, Installation

WP 0065

Figure 1. Pre-Heat Relay Terminals........................................................................... WP 0065-3 Maintenance of Output Box Assembly, Voltage Reconnection Switch: Inspection, Removal, Testing, Installation

WP 0066

Maintenance of Air Intake and Exhaust System, Muffler: Removal, Cleaning and Inspec-tion, Installation

WP 0067

Figure 1. Muffler .......................................................................................................... WP 0067-2 Maintenance of Air Intake and Exhaust System, Air Restriction Indicator: Inspection, Removal, Installation

WP 0068

Page No.

WP Sequence No.

vi

Figure 1. Air Cleaner Assembly.................................................................................. WP 0068-2 Maintenance of Air Intake and Exhaust System, Air Cleaner Assembly: Removal, Inspec-tion and Service, Repair, Installation

WP 0069

Maintenance of Air Intake and Exhaust System, Air Cleaner Element: Removal, Cleaning, Installation

WP 0070

Maintenance of Coolant System, Coolant System: Testing, Servicing................................ WP 0071 Maintenance of Coolant System, Radiator: Removal, Inspection, Cleaning, Repair, Instal-lation

WP 0072

Figure 1. Radiator Assembly and Cooling System..................................................... WP 0072-3 Maintenance of Coolant System, Upper Coolant Hose: Removal, Inspection, Installation.. WP 0073 Maintenance of Coolant System, Lower Coolant Hose: Removal, Inspection, Installation.. WP 0074 Maintenance of Coolant System, Coolant Recovery System: Inspection, Removal, Instal-lation

WP 0075

Maintenance of Coolant System, Cooling Fan: Inspection, Removal, Installation............... WP 0076 Maintenance of Coolant System, Fan Belt: Inspection, Removal, Installation, Adjustment.. WP 0077 Maintenance of Fuel System, Fuel Level Sender: Inspection, Removal, Testing, Installa-tion

WP 0078

Figure 1. Fuel Tank, Switches, and Auxiliary Fuel Pump........................................... WP 0078-3 Maintenance of Fuel System, Low Fuel Level/Auxiliary Fuel Pump Float Switch: Inspec-tion, Removal, Testing, Installation

WP 0079

Maintenance of Fuel System, Fuel Pickup: Removal, Inspection, Installation..................... WP 0080 Maintenance of Fuel System, Fuel Float Module: Testing, Removal, Installation................ WP 0081 Maintenance of Fuel System, Low Pressure Fuel Lines: Inspection, Removal, Installation. WP 0082 Maintenance of Fuel System, Fuel Tank Filler Neck: Removal, Inspection, Installation....... WP 0083 Maintenance of Fuel System, Fuel Drain Valve: Removal, Installation................................ WP 0084 Maintenance of Fuel System, Fuel Tank: Removal, Inspection, Installation........................ WP 0085 Maintenance of Fuel System, Auxiliary Fuel Pump: Inspection, Testing, Removal, Installa-tion

WP 0086

Maintenance of Fuel System, Fuel Transfer Pump: Inspection, Testing, Removal, Installa-tion

WP 0087

Figure 1. Fuel Filter/Water Separator and Transfer Pump......................................... WP 0087-3 Maintenance of Fuel System, Fuel Filter/Water Separator: Inspection, Removal, Repair, Installation

WP 0088

Maintenance of Fuel System, Fuel Filter/Water Separator Element: Removal, Inspection, Installation

WP 0089

Maintenance of Lubrication System, Oil Drain Line: Inspection, Removal, Repair, Installa-tion

WP 0090

Figure 1. Oil Drain Line.............................................................................................. WP 0090-3 Maintenance of Engine Accessories, Frequency Adjust Control Cable: Removal, Inspec-tion, Installation, Adjustment

WP 0091

Figure 1. Frequency Adjust Control Cable Assembly................................................. WP 0091-2

Page No.

WP Sequence No.

vii

Maintenance of Engine Accessories, Low Oil Pressure Switch: Testing, Removal, Clean-ing and Inspection, Installation

WP 0092

Figure 1. Engine Related Switches and Senders....................................................... WP 0092-3 Maintenance of Engine Accessories, Oil Pressure Sender: Testing, Removal, Cleaning and Inspection, Installation

WP 0093

Maintenance of Engine Accessories, Coolant Temperature Sender: Testing, Removal, Cleaning and Inspection, Installation

WP 0094

Maintenance of Engine Accessories, Coolant High Temperature Switch: Removal, Clean-ing and Inspection, Testing, Installation

WP 0095

Maintenance of Engine Accessories, Magnetic Pickup: Removal, Cleaning and Inspec-tion, Installation, Adjustment

WP 0096

Maintenance of Engine Accessories, Fuel Solenoid: Testing, Inspection, Removal, Repair, Installation

WP 0097

Maintenance of Engine Accessories, Dead Crank Switch: Inspection, Removal, Testing, Installation

WP 0098

Maintenance of Engine Accessories, Adjusting Frequency Droop at Engine Governor:

Adjustment

WP 0099

Figure 1. Frequency Droop Adjustment...................................................................... WP 0099-3 Maintenance of Skid Base, Skid Base: Removal, Inspection, Repair, Installation............... WP 0100

Figure 1. Skid Base.................................................................................................... WP 0100-3 Maintenance of Load Output Terminal Board Assembly, Load Output Terminal Board Assembly: Removal, Inspection, Repair, Installation

WP 0101

Figure 1. Load Output Terminal Board Assembly...................................................... WP 0101-4 Maintenance of Load Output Terminal Board Assembly, Load Output Terminals: Removal, Inspection, Installation

WP 0102

Maintenance of Load Output Terminal Board Assembly, Varistors: Removal, Inspection, Installation

WP 0103

Removal and Installation of Major Components, Engine and Generator Assembly:

Removal, Installation

WP 0104

Figure 1. Engine and Generator Assembly Removal................................................. WP 0104-7 Removal and Installation of Major Components, Engine Replacement: Replacement........ WP 0105 Maintenance of Generator Assembly, Adjustments and Tests............................................. WP 0106

Table 1. Generator Resistance Values at 25 °C (77 °F)............................................. WP 0106-1 Figure 1. Testing Rotating Rectifiers.......................................................................... WP 0106-2 Figure 2. Testing Exciter Field.................................................................................... WP 0106-3 Figure 3. Testing Exciter Armature............................................................................. WP 0106-4 Figure 4. Testing Rotor for Open or Shorted Windings.............................................. WP 0106-5 Figure 5. Testing Rotor for Grounds........................................................................... WP 0106-5 Figure 6. Testing Stator Windings.............................................................................. WP 0106-6

Maintenance of Generator Assembly, Generator Assembly (MEP-802A): Removal and Disassembly, Inspection, Repair, Assembly and Installation

WP 0107

Figure 1. Support of Rotor Assembly......................................................................... WP 0107-3 Figure 2. Generator Assembly (MEP-802A)............................................................... WP 0107-4

Page No.

WP Sequence No.

viii

Maintenance of Generator Assembly, Generator Assembly (MEP-812A): Removal, Disas-sembly, Inspection, Repair, Assembly, Installation

WP 0108

Figure 1. Generator Assembly (MEP-812A)............................................................... WP 0108-4 Winterization Kit, General Information................................................................................. WP 0109 Winterization Kit, Equipment Description and Data............................................................. WP 0110

Figure 1. Location of Major Components................................................................... WP 0110-2 Table 1. Description of Major Components................................................................ WP 0110-2 Table 2. Tabulated Data for the Heater...................................................................... WP 0110-3

Winterization Kit, Theory of Operation................................................................................. WP 0111 Winterization Kit, Description and Use of Controls and Indicators...................................... WP 0112

Table 1. Data Plates................................................................................................... WP 0112-1 Winterization Kit, Troubleshooting Index.............................................................................. WP 0113

Figure 1. Heater Function Codes Plate...................................................................... WP 0113-2 Figure 2. Example Troubleshooting Table.................................................................. WP 0113-2 Table 1. Symptom Troubleshooting Procedures Index............................................... WP 0113-3

Winterization Kit, Troubleshooting Procedures.................................................................... WP 0114 Winterization Kit, Service Upon Receipt .............................................................................. WP 0115 Winterization Kit, PMCS Introduction................................................................................... WP 0116

Figure 1. PMCS Routing Diagram.............................................................................. WP 0116-4 Winterization Kit, PMCS, Including Lubrication Instructions................................................ WP 0117

Table 1. Preventive Maintenance Checks and Services............................................ WP 0117-1 Winterization Kit, Installation Procedures............................................................................. WP 0118

Figure 1. Winterization Kit Control Unit Assembly..................................................... WP 0118-2 Figure 2. Winterization Kit Fuel System Assembly..................................................... WP 0118-3 Figure 3. Winterization Kit Bulkhead Housing............................................................ WP 0118-4 Figure 4. Winterization Kit Heater Assembly.............................................................. WP 0118-5 Figure 5. Winterization Kit Fuel Pump Assembly....................................................... WP 0118-6 Figure 6. Winterization Kit Expansion Plug................................................................ WP 0118-7 Figure 7. Winterization Kit Coolant Hoses.................................................................. WP 0118-8 Figure 8. Winterization Kit Exhaust Hose and Heater Brace..................................... WP 0118-9 Figure 9. Butt Joint ..................................................................................................... WP 0118-10 Figure 10. Winterization Kit Fuse and Wiring Harness.............................................. WP 0118-11 Figure 11. Winterization Kit Cover and Instrument Panel ........................................... WP 0118-12

Winterization Kit, Control Unit Maintenance: Testing, Inspection, Removal, Replacement, Installation

WP 0119

Figure 1. Winterization Kit Control Unit ...................................................................... WP 0119-2 Winterization Kit, Heater Assembly Maintenance: Inspection, Removal, Repair, Replace-ment, Installation

WP 0120

Figure 1. Winterization Kit Heater Assembly.............................................................. WP 0120-3 Winterization Kit, Fuel Pump Maintenance: Testing, Removal, Replacement, Installation... WP 0121

Figure 1. Winterization Kit Fuel Pump....