MEP-803A, MEP-813A generator set Technical manual
광고
광고
ARMY
AIR FORCE
MARINE CORPS
*TM 9-6115-642-10
TO 35C2-3-455-11
TM 09247A/09248A-10/1
TECHNICAL MANUAL
OPERATOR'S MANUAL
FOR
GENERATOR SET, SKID MOUNTED,
TACTICAL QUIET, 10 KW, 60 HZ
MEP-803A (NSN 6115-01-275-5061) (EIC VG3)
GENERATOR SET, SKID MOUNTED,
TACTICAL QUIET, 10 KW, 400 HZ
MEP-813A (NSN 6115-01-274-7392) (EIC VN3)
*This manual supersedes TM 9-6115-642-10, TO 35C2-3-455-11 & TM 09247A/09248a-10/1 dated 30 December 1992. Date of issue for the revised manual is: 15 September 2010.
DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.
HEADQUARTERS, DEPARTMENTS OF THE ARMY, AIR
FORCE AND HEADQUARTERS, U.S. MARINE CORPS
15 SEPTEMBER 2010
PCN 184 092471 00
TM 9-6115-642-10
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 IMMEDIATELY START ARTIFICIAL RESUSCITATION.
WARNING AND CAUTION STATEMENTS
Warning and Caution statements have been strategically placed throughout this text prior to operating procedures, 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.
a
TM 9-6115-642-10
WARNING SUMMARY – CONTINUED
WARNING
High voltage is produced when this generator set is in operation. Improper operation could result in personal injury or death by electrocution.
WARNING
Never attempt to start the generator set if it is not properly grounded. Failure to observe this warning could result in serious injury or death by electrocution.
WARNING
Never attempt to connect or disconnect load cables while the generator is running. Failure to observe this warning could result in severe personal injury or death by electrocution.
WARNING
Jumper will not be removed unless the equipment being powered specifically required an isolated ground (floating ground). 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 grounding self when touching any electrical components. Failure to observe this warning can result in personal injury.
Battery acid will cause burns to unprotected skin.
WARNING
WARNING
The fuels in this generator set are highly explosive. Do not smoke or use open flame when performing maintenance. Flames and explosion could result in severe personal injury or death.
WARNING
Hot fueling of generators while they are operating presents a safety hazard and should not be attempted. Hot engine surfaces and sparks produced from the engine and generator circuitry are possible sources of ignition.
Failure to observe this warning could cause severe personal injury or death may result.
WARNING
Batteries give off flammable gas. Do not smoke or use open flame when performing maintenance. Flames and explosion could result in personal injury or death.
WARNING
Exhaust discharge contains deadly gases. Do not operate generator set in enclosed area unless exhaust discharge is properly vented outside. Severe personal injury or death due to carbon monoxide poisoning could result.
WARNING
Liquids under pressure are generated as a result of operation of the generator set. High pressure leaks could cause severe personal injury or death.
b
TM 9-6115-642-10
WARNING SUMMARY – CONTINUED
WARNING
With any access door open, the noise level of this generator set when operating could cause hearing damage.
Hearing protection must be worn when working near the generator set while running.
WARNING
Cooling system operates at high temperatures. Personal injury or death from burns or scalding could result from contact with high pressure steam and/or liquid.
WARNING
Avoid contacting metal items with bare skin in extreme cold weather. Failure to observe this warning can result in personal injury.
c / (d blank)
TM 9-6115-642-10
LIST OF EFFECTIVE PAGES / WORK PACKAGES
NOTE: This manual supersedes TM 9-6115-642-10, TO 35C2-3-455-11 & TM 09247A/09248a-10/1 dated 30
December 1992. Date of issue for the revised manual is: 15 September 2010. Zero in the "Change No." column indicates an original page or work package.
Date of issue for the original manual is:
Original 15 September 2010
THE TOTAL NUMBER OF PAGES FOR FRONT AND REAR MATTER IS 18 AND THE
TOTAL NUMBER OF WORK PACKAGES IS 22, CONSISTING OF THE FOLLOWING:
Page / WP No.
Front cover
Blank
Warning summary (xx pages) i - iii
Chp 1 title page
Chp 1 index
WP 0001 (4 pgs)
WP 0002 (8 pgs)
WP 0003 (8 pgs)
Chp 2 title page
Chp 2 index
WP 0004 (6 pgs)
WP 0005 (14 pgs)
WP 0006 (4 pgs)
WP 0007 (2 pgs)
Chp 3 title page
Chp 3 index
WP 0008 (2 pgs)
WP 0009 (12 pgs)
Chp 4 title page
Chp 4 index
WP 0010 (4 pgs)
WP 0011 (10 pgs)
WP 0012 (2 pgs)
WP 0013 (2 pgs)
WP 0014 (2 pgs)
WP 0015 (2 pgs)
WP 0016 (2 pgs)
WP 0017 (2 pgs)
WP 0018 (2 pgs)
Chp 5 title page
Chp 5 index
WP 0019 (2 pgs)
WP 0020 (2 pgs)
WP 0021 (2 pgs)
WP 0022 (2 pgs)
Index-1 - Index-2
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0
0
0
0
0
0
0
0
0
0
0
0
0
0
Change No.
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Page / WP No.
Inside back cover
Back cover
Change No.
0
0
A/(B blank) USA
ARMY
AIR FORCE
MARINE CORPS
*TM 9-6115-642-10
TO 35C2-3-455-11
TM 09247A/09248A-10/1
HEADQUARTERS, DEPARTMENTS OF THE ARMY, AIR FORCE
AND HEADQUARTERS, U.S. MARINE CORPS
WASHINGTON, D.C.
15 SEPTEMBER 2010
TECHNICAL MANUAL
OPERATOR'S MANUAL
FOR
GENERATOR SET, SKID MOUNTED, TACTICAL QUIET, 10 KW, 60 HZ
MEP-803A (NSN 6115-01-275-5061) (EIC VG3)
GENERATOR SET, SKID MOUNTED, TACTICAL QUIET, 10 KW, 400 HZ
MEP-813A (NSN 6115-01-274-7392) (EIC VN3)
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 (LCMC) and 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 732-532-3421, DSN 992-3421. Our email address is [email protected]. Our online web address for entering and submitting DA Form 2028s is http://edm.monmouth.army.mil/ pubs/2028.html.
(b) (MC) Marine Corps -Submit notice of discrepancies or suggest changes on a
NAVMC 10772 The NAVMC may be submitted via the Internet using website https:// www.ala.usmc.mil, click on Publications, Technical Publications, follow the instructions, and then click on the NAVMC 10772. it may also be submitted by electronic mail to [email protected], or by mailing a paper copy NAVMC 10772 in an envelope addressed to Commander, Marine Corps systems Command, ATTN.
Assistant Commander Acquisition and Logistics (AC LCL/TP), 814 Radford Blvd, suite
20343, Albany, Georgia 31704-0343. In addition, forward an information copy to the
Project Officer at the following address: Commander, Marine Corps Systems Command (GTES-EPS), 2200 Lester Street, Quantico, VA. 22134-6050
(c) (F) Air Force - By Air Force AFTO Form 22 (Technical Manual (TM) change Recommendation and Reply) in accordance with paragraph 6-5, Section VI, TO 00-5-1 directly to prime ALC/MST.
A reply will be furnished to you.
*This manual supersedes TM 9-6115-642-10, TO 35C2-3-455-11 & TM 09247A/09248a-10/1 dated 30 December 1992. Date of issue for the revised manual is: 15 September 2010.
DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.
i
TM 9-6115-642-10
TABLE OF CONTENTS
WP Sequence No.
- Page No.
Chapter 1 - Operator General Information, Equipment Description and Theory of Operation
Figure 1.
Generator Set, 10 kW, Tactical Quiet .................................................. WP 0001-1
Figure 1.
Generator Set Components ................................................................. WP 0002-2
Table 1.
Figure 1.
Figure 2.
Figure 3.
Figure 4.
Figure 5.
Figure 6.
Air Intake and Exhaust System ........................................................... WP 0003-6
Chapter 2 - Operator Instructions
Table 1.
Operator's Controls and Indicators ...................................................... WP 0004-1
Figure 1.
Table 2.
Operator's Controls and Indicators ...................................................... WP 0004-1
Figure 2.
Table 3.
Figure 3.
Figure 1.
Table 1.
Load Terminal, AC Voltage Reconnection Switch and AM-VM Transfer
Switch Selection ...................................................................................
Figure 2.
Figure 3.
Figure 4.
Figure 5.
Operating Instructions (Front and Right Side) ..................................... WP 0005-8
Operating Instructions Plates (Rear and Left Side) ............................. WP 0005-9
Figure 6.
Figure 7.
Figure 8.
Figure 9.
Voltage Connection Caution Plate ....................................................... WP 0005-11
Figure 10.
Figure 11.
NATO Slave Receptacle Plate ............................................................. WP 0005-11
Figure 12.
Figure 13.
Convenience Receptacle Plate ............................................................ WP 0005-12
Figure 14.
Figure 15.
Battery Connection Instruction Plate .................................................... WP 0005-12
ii
TM 9-6115-642-10
Figure 16.
Figure 17.
Figure 18.
Lifting and Tiedown Diagram Plate ...................................................... WP 0005-13
Figure 19.
Chapter 3 - Operator Troubleshooting Procedures
Chapter 4 - Operator Maintenance Instructions
Table 1.
Table 1.
Operator Preventive Maintenance Checks and Services ..................... WP 0011-1
Figure 1.
Air Cleaner Element Replacement ....................................................... WP 0014-1
Table 1.
Table 1.
Figure 1.
Draining Fuel Filter/Water Separator ................................................... WP 0017-1
Chapter 5 - Operator Supporting Information
Table 1.
Component of End Items (COEI) List .................................................. WP 0020-2
Figure 1.
Table 2.
Table 1.
Table 1.
Expendable and Durable Items List ..................................................... WP 0022-1
Reporting Errors and Recommending Improvements DA Form 2028
Back cover
iii
TM 9-6115-642-10
HOW TO USE THIS MANUAL
This manual contains operator maintenance instructions for the MEP-803A/MEP-813A, 10 kW 60 and 400 Hz, skid mounted, tactical quiet generator sets.
NOTE
Throughout the family of manuals, directional orientation in relation to the equipment is described from the point of view of the operator facing the operator's controls looking out over the equipment. From this perspective, the end of the equipment containing the operator's controls will be referred to as the rear.
This manual provides operating procedures, troubleshooting, maintenance, and supporting information required to operate and maintain the generator set. Listed below are some of the features included in this TM to help locate and use the provided information.
WORK PACKAGES
This TM has been organized using the WP format. Each chapter contains a series of WPs rather than sections and paragraphs. Each WP is designed to stand alone as a complete information module; if the user keeps the section(s) of this TM in a loose-leaf binder, the user will be able to remove just the WP needed to complete a specific task. Here are some WP features of which the user should be aware.
Each WP is numbered using a four-digit number beginning with WP 0001. WPs are numbered sequentially
all figures and tables contained within each. Figures and tables are numbered sequentially for each WP.
The WP number is located at the top right of each page. It is also located at the bottom of the page with the WP
Each WP starts on a right-hand page. This is done so the user can remove a single WP from the paper TM if needed for a task. Blank pages are assigned a number, but it appears on the preceding or following page. For
of a WP is blank, page 0001-2 will have the number 0001-1 blank/2.
Each WP containing step-by-step maintenance or troubleshooting procedures will end with the words END OF
TASK, and each WP ends with the statement END OF WORK PACKAGE. Think of each WP as a small, standalone TM.
Typographical conventions are as follows:
[Unload] indicates a soft key or a switch.
[Previous] + [Next] indicates two simultaneous key presses. [ + ] [ - ] indicates two sequential key presses.
References to equipment Data and Description Plates are printed as they appear on the equipment whenever possible.
WARNINGS, CAUTIONS AND NOTES DEFINITIONS
Warnings, cautions, notes. chapter titles, and paragraph headings are printed in bold type.
The following definitions apply to WARNINGS, CAUTIONS and NOTES found throughout this publication. Warning, cautions and notes provide supplemental information. Personnel must understand and apply these Warnings,
Cautions and Notes during many phases of operation and maintenance to ensure personnel safety and health and the protection of property. Portions of this information may be repeated in certain chapters of this publication for emphasis.
TM 9-6115-642-10
WARNINGS, CAUTIONS AND NOTES DEFINITIONS – CONTINUED
WARNING
A warning identifies a clear danger to the person doing that procedure.
CAUTION
A caution identifies a clear danger to the person doing that procedure.
NOTE
A note highlights essential procedures, conditions, or statements or conveys important instructional data to the user.
CHAPTER OVERVIEW
Chapter 1 - General Information, Equipment Description and Theory of Operation
divided into three work packages, as follows:
General Information. This work package 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. Also, a list of abbreviations and acronyms is provided. Also, a nomenclature cross-reference list is provided as well as a list of abbreviations and acronyms.
Equipment Description and Data. This work package describes capabilities, characteristics, and features. It provides basic equipment data and shows the locations of major components. Descriptions of the major components are also provided.
Theory of Operation. This work package provides functional descriptions of the equipment.
Chapter 2 - Operator Instructions
sets. The chapter is divided into three work packages, as follows:
Description and Use of Operator Controls and Indicators. This work package provides references to the applicable generator set technical manuals and trailer technical manuals. Those references contain information on operator's controls and indicators for the equipment.
Operation Under Usual Conditions. This work package contains instructions for preparing the equipment for use and operation under normal conditions. Coverage includes connection instructions and preparation instructions for movement to a new worksite.
Operation Under Unusual Conditions. This work package provides unusual operating procedures or references to the applicable accompanying technical manuals.
Chapter 3 - Operator Troubleshooting Procedures
sets to be performed by the operator. The chapter is divided as follows:
Operator Troubleshooting Index. This work package provides a troubleshooting introduction and malfunction/symptom index to direct you to the appropriate troubleshooting procedure at the operator level.
Operator Troubleshooting Procedures. This work package provides troubleshooting procedures and corrective actions that are to be performed by the operator. It also provides references to the applicable technical manuals.
Chapter 4 - Operator Maintenance Instructions
v
TM 9-6115-642-10
CHAPTER OVERVIEW – CONTINUED
sets to be performed by the operator. Its purpose is to provide you with the information that you need to keep the equipment in good operating condition. The chapter is divided as follows:
Operator Preventive Maintenance Checks and Services (PMCS) Introduction. This work package provides a detailed explanation of each table entry in the PMCS table along with applicable warnings, cautions and notes prior to starting on the PMCS procedures.
Operator Preventive Maintenance Checks and Services (PMCS). This work package contains detailed instructions that the operator must perform before, during, and after preventive maintenance checks and services.
Coverage includes all operator PMCS for the equipment.
Operator Lubrication Instructions. This work package section provides references to the applicable lubrication instructions.
Operator Maintenance Procedures. These work packages refer the operator to the preventive maintenance
checks and services required by WP 0010.
Chapter 5 - Supporting Information
sets to be performed by the operator. Its purpose is to provide you with the information that you need to keep the equipment in good operating condition. The chapter is divided as follows:
Components of End Item (COEI) and Basic Issue Items (BII) Lists. This work package lists the items usually packaged separately but needed for installation and operation of the equipment. The work package has three sections, as follows:
Introduction. This section explains the entries in Tables 1 and 2.
Components of End Item. The equipment is normally shipped fully assembled, so this section is not applicable.
Basic Issue Items. This section contains a list of the accessories needed for installation and operation of the equipment.
Additional Authorization List (AAL). This work package lists additional items you are authorized for support of the equipment. This work package contains two sections, as follows:
Introduction. This section explains the entries in Tables 1.
Additional Authorized Items List. This table lists the Additional Authorized Items.
Expendable and Durable Items List. This work package lists expendable/durable supplies and materials needed to operate and maintain your equipment. The work package contains two sections, as follows:
Introduction. This section explains the entries in Tables 1.
Expendable and Durable Items List. The list indicates the maintenance level that needs each item and identifies the items by National Stock Number (NSN), description, and unit of measure.
Definition of Unusual Terms. This section lists and defines the terms used in this technical manual that are not listed in the Army Regulation (AR 310-25).
Rear Matter
Alphabetical Index. An alphabetical index at the back of this technical manual provides a listing of subjects covered, cross-referenced to the applicable work packages.
HOW TO FIX AN EQUIPMENT MALFUNCTION
Determining the Cause
Finding the cause of a malfunction, troubleshooting, is the first step in fixing your equipment 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.
vi
TM 9-6115-642-10
HOW TO FIX AN EQUIPMENT MALFUNCTION – CONTINUED
2. Locate "Troubleshooting" under the chapter that covers your level of maintenance. Turn to the page indicated.
3. For operator troubleshooting, follow the instructions in the references listed in Chapter 3.
vided as indicated by the symptom index.
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 can get the needed parts. National stock numbers (NSNs) and part numbers for Electric Power Plant III parts are listed in the Repair Parts and Special Tools List (RPSTL).
for 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/Acronyms if you do not understand the special abbreviations or unusual terms 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 items.
c. Coat packing before installation, in accordance with the task instructions.
d. Disassembly procedures describe the disassembly needed for total authorized repair. You may not need to disassemble an item as far as described in the task. Follow the disassembly steps only as far as needed to repair/replace worn or damaged parts.
e. Clean the assembly, subassembly, or part before inspecting it.
f. Before installing components having mating surfaces, inspect the mating surfaces to make sure they are in serviceable condition.
g. Hold the bolt (or screw) head with a wrench (or screwdriver) while tightening or loosening a nut on the bolt (or screw).
h. Torque to the special torque cited when the task instructions include the words "torque to." Use standard torques at all other times.
i. When a cotter pin is required, align the cotter pin holes within the allowable torque range.
j. Inspect for foreign objects after performing maintenance.
vii / ( viii blank)
TM 9-6115-642-10
CHAPTER 1
OPERATOR GENERAL INFORMATION, EQUIPMENT
DESCRIPTION AND THEORY OF OPERATION
FOR
GENERATOR SET, SKID MOUNTED, TACTICAL QUIET
10 kW, 60 Hz
MEP-803A
GENERATOR SET, SKID MOUNTED, TACTICAL QUIET
10 kW, 400 Hz
MEP-813A
TM 9-6115-642-10
CHAPTER 1
OPERATOR GENERAL INFORMATION, EQUIPMENT DESCRIPTION AND THEORY OF OPERATION
WORK PACKAGE INDEX
Title WP Sequence No.
TM 9-6115-642-10
OPERATOR MAINTENANCE
GENERAL INFORMATION
SCOPE
This manual is designed to help you operate and mainte the MEP-803A and MEP-813A Tactical Quiet Generator
(TQG) Sets. Warning pages are located at the front of this manual. Read the warnings before operating or doing maintenance on the equipment.
Type of Manual. This manual contains operation and operator maintenance instructions for the Tactical Quiet
(TQ), 10 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.
Purpose of Equipment.The generator set provides tactical quiet AC power. The generator set is easily transported, operated, and maintained.
Figure 1. Generator Set, 10 kW, Tactical Quiet.
TM 9-6115-642-10 0001
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.
(MC) Maintenance forms and records used by Marine Corps personnel are prescribed by TM 4700-15/1.
(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)
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.
CORROSION PREVENTION AND CONTROL (CPC)
Corrosion Prevention and Control (CPC) of Army materiel is a continuing concern. It is important that any corrosion problems with this item be reported so that the problem can be corrected and improvements can be made to prevent the problem in future items.
Corrosion specifically occurs with metals. It is an electrochemical process that causes the degradation of metals.
It is commonly caused by exposure to moisture, acids, bases, or salts. An example is the rusting of iron. Corrosion damage in metals can be seen, depending on the metal, as tarnishing, pitting, fogging, surface residue, and/ or cracking.
Plastics, composites, and rubbers can also degrade. Degradation is caused by thermal (heat), oxidation (oxygen), solvation (solvents), or photolytic (light, typically UV) processes. The most common exposures are excessive heat or light. Damage from these processes will appear as cracking, softening, swelling, and/or breaking.
SF Form 368, Product Quality Deficiency Report 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 electronics materiel to prevent enemy use shall be in accordance with Procedures for
Destruction of Electronics Materiel to Prevent Enemy Use (Electronics Command) TM 750-244-3.
PREPARATION FOR STORAGE OR SHIPMENT
For information on Preparation for Storage or Shipment, refer to WP 0005, Preparation for Movement.
TM 9-6115-642-10 0001
WARRANTY INFORMATION
The generator sets, models MEP-803A and MEP-813A, are warranted by Libby Corporation for a period of 36 months or 1,800 operating hours, whichever occurs first. Refer to Warranty Technical Bulletin TB 9-6115-642-24.
The warranty starts on the date found in block 23, DA Form 2408-9 Equipment Control Record. Report all defects in material or workmanship to your supervisor, who will take appropriate action through your Unit Maintenance
Shop.
NOMENCLATURE CROSS-REFERENCE LIST
Model Number
MEP-803A
MEP-813A
Equipment Name
Generator Set, Skid Mounted, Diesel Powered, Tactical Quiet 10 kW 60 Hz.
Generator Set, Skid Mounted, Diesel Powered, Tactical Quiet 10 kW 400 Hz.
LIST OF ABBREVIATIONS/ACRONYMS
CAGEC cm
COEI
CPC
CTA
DMWR
DOD
EIR
Abbreviation
°C
°F
AAL
AMP
BII
BOI
CAGE
FGC
Hz
JTA
Definition
Degrees Celsius
Degrees Fahrenheit
Additional Authorization List
Ampere
Basic Issue Item
Basis Of Issue
Commercial And Government Entity
Commercial And Government Entity Code
Centimeter
Components Of End Item
Corrosion Prevention And Control
Common Table of Allowance
Depot Maintenance Work Requirement
Department Of Defense
Equipment Improvement Recommendation
Functional Group Code
Hertz
Joint Table of Allowances
0001-3
TM 9-6115-642-10
LIST OF ABBREVIATIONS/ACRONYMS – CONTINUED
NHA
NIIN
NSN
N•m mS
MTOE
NATO
NBC kW
L lbf•ft m kg kPa kVa kW
P/N pa
PMCS
PSI
SMR
TAMMS
UOC
V
VAC
VDC
END OF WORK PACKAGE
Kilogram
Kilopascals
Kilovolt-ampere
Kilowatt
Kilowatt
Liter
Foot Pound•Force
Meter (Metric Measure)
Millisecond
Modified Table of Organization and Equipment
North Atlantic Treaty Organization
Nuclear Biological Chemical
Next Higher Assembly
National Item Identification Number
National Stock Number
Newton•Meter
Part Number
Pascal
Preventive Maintenance Checks And Services
Pounds per Square Inch
Source, Maintenance, And Recoverability
The Army Maintenance Management System
Usable On Code
Volts
Volts Alternating Current
Volts Direct Current
0001-4
0001
TM 9-6115-642-10
OPERATOR MAINTENANCE
EQUIPMENT DESCRIPTION AND DATA
EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES
The generator sets, models MEP-803A and MEP-813A (Figure 1), are fully enclosed, self-contained. skidmounted, 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 referenced in Figure 1 are given facing the control box side (rear) of the generator set.
0002-1
TM 9-6115-642-10
LOCATION AND DESCRIPTION OF MAJOR COMPONENTS
0002
Legend
1 Oil Filter
2 Dipstick
3 Fuel Filter/Water Separator
4 AC Generator
5 Dead Crank Switch
6 Engine
7 Batteries
8 Water Pump
9 Radiator
10 Fuel Tank
11 Air Cleaner Assembly
12 Muffler
13 Fan Belt
14 Battery Charging Alternator
15 Stater
16 NATO Slave Receptacle
17 Skid Base
18 Load Output Terminal Board
19 Control Panel Assembly
20 Frequency Adjust Control
21 Malfunction Indicator Panel
22 Convenience Receptacle
Figure 1. Generator Set 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.
TM 9-6115-642-10
LOCATION AND DESCRIPTION OF MAJOR COMPONENTS – CONTINUED
0002
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.
Engine (6)
The generator is powered by a four 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, over-voltage.
Batteries (7)
Two batteries are required, one on each side of the generator set. The batteries are maintenance free, lead acid,
12 volt type, connected in series. After starting, the generator set is capable of operating with batteries removed.
A fuse and a diode, located behind the control panel assembly, protects 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 9 gallon (34 L) 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 air filter element made of paper 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.
0002-3
TM 9-6115-642-10
LOCATION AND DESCRIPTION OF MAJOR COMPONENTS – CONTINUED
0002
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.
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 on the right side (rear) of the generator set. Four output terminals are located on the board. They are marked L1, L2, L3 and LO. 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 LO 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.
0002-4
TM 9-6115-642-10 0002
LOCATION AND DESCRIPTION OF MAJOR COMPONENTS – CONTINUED
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 panel (21), an overload circuit breaker located inside the control box, and an in-line fuse on generator sets, contract number DAAK01-88- D-
D080. The convenience receptacle power is available at all times during operation of the generator set.
DIFFERENCES BETWEEN MODELS
The differences between models of the generator sets covered in this manual are as follows:
Model MEP-803A is equipped with a 60 Hz generator.
Model MEP-813A is equipped with a 400 Hz generator.
EQUIPMENT DATA
For a list of Leading Particulars refer to Table 1
Table 1. Leading Particulars.
1. Generator Set:
Model Numbers:
10 kW 60 Hz Tactical Quiet MEP-803A
10 kW 400 Hz Tactical Quiet MEP-813A
National Stock Numbers:
10 kW 60 Hz Tactical Quiet NSN 6115-01-275-5061
10 kW 400 Hz Tactical Quiet NSN 6115-01-274-7392
Overall Length:
MEP-803A
MEP-813A
Overall Width:
MEP-803A
62 in. (157.5 cm)
62 in. (157.5 cm)
32 in. (81.28 cm)
32 in. (81.28 cm) MEP-813A
Overall Height:
MEP-803A
MEP-813A
37 in. (93.98 cm)
37 in. (93.98 cm)
Dry Weights (less Basic Issue Items):
MEP-803A
MEP-813A
Wet Weights:
MEP-803A
MEP-813A
1,140 lb. (516.4 kg)
1,170 lb. (530 kg)
1,242 lb. (562.6 kg)
1,272 lb. (576.2 kg)
TM 9-6115-642-10
EQUIPMENT DATA – CONTINUED
Table 1. Leading Particulars. – Continued
2. Engine:
Manufacturer
Model
Type
Displacement
Altitude Degradation, 4,000 to 8,000 ft.
(1,220 to 2,240 m)
Onan
DN4M
Naturally-aspirated, four cylinder, four cycle diesel
114 cu. in. (1.9 L)
Valve Tappet Clearance Adjustment
3. Cooling System:
3.5% per 1,000 feet (305 m)
Firing Order 1, 3, 4, 2
Cold Weather Starting Aid System Use When temperature is +40 °F (4 °C)
None Required
Type
Capacity
Normal Operating Temperature
Temperature Indicating System
Voltage Rating
4. Lubricating System:
Type
Oil Pump Type
Normal Operating Pressure
Oil Filter Type
Lubricating System Capacity
Pressure Indicating System
Voltage Rating
5. Fuel System:
Type of Fuel
Fuel Tank Capacity
Fuel Consumption Rate
Pressurized radiator and pump
8.2 qts. (7.8 L)
170-200 °F (77-93 °C)
24 VDC
Full flow, circulating pressure
Positive displacement gear
25-60 psi (172-414 kPa)
Full flow, spin-on, replaceable element
5.9 qts. (5 6 L)
24 VDC
DF-1, DF-2, DF-A, JP4, JP5, JP8
9 gal. (34 L)
60 Hz: .99 gal. (3.75 L) per hour
400 Hz: 1.07 gal. (4.05 L) per hour
Auxiliary Fuel Pump:
Voltage Rating
Delivery Pressure
Fuel Level Switch:
Type
Current
6. Engine Starting System:
Batteries
24 VDC
5.0-6.5 psi (34.5-65.5 kPa) range
Float
3.0 amp at 6 to 32 VDC
Two 12 VDC, connected in series
0002
0002-6
TM 9-6115-642-10
EQUIPMENT DATA – CONTINUED
Table 1. Leading Particulars. – Continued
Starter:
Manufacturer
Model
Voltage Rating
Drive Type
Battery Charging Alternator:
Manufacturer
Models
Rating
Protective Fuse
7. AC Generator:
Manufacturer
Onan
191-1550
24 VDC
Gear Reduction
Prestolite
8EM3005CA and 8MR3005CA
18 amps at 24 VDC
30 amps
Type
Load Capacity
Current Rating:
Cooling
Drive Type
120/240 volt connection
120/208 volt connection
120 volt connection
Power Factor
Duty Classification
8. Protective Devices:
Low Oil Pressure Switch:
Trip Temperature
Voltage Rating
Current Rating
Coolant High Pressure Switch:
Trip Temperature
Voltage Rating
Current Rating
Overvoltage:
Trip Point Conditions
Trip Point
Onan
MEP-803A
Rotating field synchronous
10 kW
60 Hz:
52 amps
34 amps
104 amps
0.8
Fan cooled
Direct coupling continuos
15 ±3 psi (103.4 ±20.7 kPa)
24 VDC
5 amps
225 °F ±5 °F (107 °C ±3 °C)
12-24 VDC
5 amps
MEP-813A
Rotating field synchronous
10 kW
400 Hz:
52 amps
34 amps
104 amps
0.8
Fan cooled
Direct coupling continuos
153 ±3 VAC for no less than 200 mS (120 VAC coil winding)
No more than 1.25 seconds after trip conditions exist.
0002
0002-7
EQUIPMENT DATA – CONTINUED
END OF WORK PACKAGE
TM 9-6115-642-10 0002
0002-8
TM 9-6115-642-10
OPERATOR MAINTENANCE
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
Figure 1. 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
ENGINE STARTING SYSTEM – CONTINUED
TM 9-6115-642-10 0003
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. The starting sequence may also be stopped by moving the MAS-
TER SWITCH to OFF. The engine may be cranked without starting by use of the DEAD CRANK switch. With the
DEAD CRANK switch in the CRANK position, the cranking day, starter solenoid and starter motor are energized without activating any other starting or control function.
The batteries are charged by the battery charging alternator that is belt driven by the engine. Generator set control system power is also supplied by the battery charging alternator. The BATTERY CHARGE ammeter indicates the charge/discharge rate of the batteries, from -10 AMPS to +20 AMPS, in 5 AMPS increments. Normal operating indication depends on the state of charge in the batteries. A low charge, such as exists immediately after engine starting. will cause a high reading (needle moves toward CHARGE area). When the charge in the batteries has been restored, the indicator moves near zero, 0.
FUEL SYSTEM
Figure 2. Fuel System.
TM 9-6115-642-10 0003
FUEL SYSTEM – CONTINUED
The Fuel System (Figure 2), consists of piping, fuel tank. fuel filter, electrically driven transfer pump, fuel filter/water separator, four injection pumps and four injectors, one for each cylinder. Fuel is drawn from the fuel tank by the transfer pump when the MASTER SWITCH is in the PRIME & RUN position. After reaching the transfer pump, fuel passes through a fuel filter/water separator where water and small impurities are removed. The fuel then goes to the injection pumps where it is pressurized and pushed into the injectors. Through the injectors fuel enters the diesel engine combustion chamber, where it is mixed with air and ignited. The fuel that is not used is returned to the fuel tank via an excess fuel return line.
The Auxiliary Fuel System consists of an external fuel supply, piping, fuel filter, a 24 VDC auxiliary fuel pump and a fuel level float switch. When the MASTER SWITCH is set on PRIME & RUN AUX FUEL it actuates the auxiliary fuel pump and transfers fuel from the external fuel supply to the generator fuel tank. The fuel level float switch shuts off the auxiliary fuel pump when the generator fuel tank is full and reactivates the pump as the level drops.
The FUEL LEVEL indicator indicates fuel level of generator fuel tank from (E) empty to (F) full in quarter tank increments.
0003-3
ENGINE COOLING SYSTEM
TM 9-6115-642-10 0003
Figure 3. Engine Cooling System.
The Engine Cooling System (Figure 3) consists of a radiator, hoses, thermostat, water pump, a belt driven fan, and cooling jackets. The water pump forces coolant through passages (cooling jackets) in the engine block and cylinder head where the coolant absorbs heat from the engine. When the engine reaches normal operating temperature, the thermostat opens and the heated coolant flows through the upper radiator hose assembly into the radiator. The cooling fan circulates air through the radiator where the coolant temperature is reduced.
A coolant high temperature switch provides automatic shut down in the event that coolant temperature exceeds
225 ±5 °F (107 ±3 °C) . The COOLANT TEMP indicator indicates the engine coolant temperature, from 120 °F to
240 °F (48 °C to 115 ° C).
LUBRICATION SYSTEM
TM 9-6115-642-10 0003
Figure 4. Engine Lubrication System.
The Lubrication System (Figure 4) consists of an oil sump, dipstick, pump, oil pressure sender, and filter. The oil sump is a reservoir for engine lubricating oil. The dipstick indicates oil level in the sump. A pump draws oil from the sump and through a screen removing large impurities. The oil then passes through a spin-on type filter where d impurities are removed. From the filter, oil enters the engine and is distributed to the engine's internal moving parts.
After passing through the engine, the oil returns to the oil sump. The OIL PRESSURE indicator indicates oil pressure sensed by the oil pressure sender in the engine. The engine will shut off automatically if the oil pressure drops to a dangerously low level. The oil level can be checked when the engine is not operating.
AIR INTAKE AND EXHAUST SYSTEM
TM 9-6115-642-10 0003
Figure 5. Air Intake and Exhaust System.
The Air Intake and Exhaust System (Figure 5). consists of an air cleaner assembly, intake manifold, exhaust manifold and muffler. Ambient air is drawn into the air cleaner assembly where it passes through the air cleaner element.
Airborne dirt is removed and trapped in the element. A restriction indicator, located on the air cleaner assembly housing, displays red when the air cleaner element should be serviced. Filtered air is drawn out of the air cleaner assembly through air intake tubes to the air intake manifold where it passes into the engine and is mixed with fuel from the injectors.
The engine exhaust gases are expelled into the exhaust manifold. The exhaust manifold channels the gases into the muffler that deadens the sound of the exhaust gases. The gases pass from the muffler through the muffler outlet and are vented upward from the generator set housing.
TM 9-6115-642-10
AIR INTAKE AND EXHAUST SYSTEM – CONTINUED
0003
Cold outside temperatures make starting the engine difficult. To improve engine starting, a cold weather starting aid has been provided that features four preheaters.The preheaters warm up the air intake manifold when the
MASTER SWITCH is in the PREHEAT position
OUTPUT SUPPLY SYSTEM
Figure 6. Output Supply System.
The Output Supply System (Figure 6) consists primarily of the generator, the output load terminal board, the AC voltage reconnection switch, AM-VM transfer switch and the AC circuit interrupter relay.
Power created by the generator is supplied through the voltage reconnection switch and the AC output load terminals on the output load terminal board.
The voltage reconnection switch allows configuration of the generator set for the following voltage ranges:
OUTPUT SUPPLY SYSTEM – CONTINUED
TM 9-6115-642-10 0003
120-Volt, single phase, 2 wire.
120/240-Volt, single phase, 3 wire,
120/208-Volt, 3-phase, 4 wire.
The AC INTERRUPTER switch closes and opens the AC circuit interrupt relay. This enables or interrupts the power flow between the voltage reconnection switch and the output load terminals. The AC circuit interrupter relay is also opened automatically during any of the specified set faults. The voltage regulator senses AC generator output voltage and provides control voltage to the AC generator exciter to maintain the desired AC generator output voltage. The position of the AM-VM transfer switch selects the output load terminals from which current and voltage are measured and are indicated on the ammeter (PERCENT RATED CURRENT) and AC volt meter
(VOLTS AC).
END OF WORK PACKAGE
0003-8
TM 9-6115-642-10
CHAPTER 2
OPERATOR INSTRUCTIONS
FOR
GENERATOR SET, SKID MOUNTED, TACTICAL QUIET
10 kW, 60 Hz
MEP-803A
GENERATOR SET, SKID MOUNTED, TACTICAL QUIET
10 kW, 400 Hz
MEP-813A
TM 9-6115-642-10
CHAPTER 2
OPERATOR INSTRUCTIONS
WORK PACKAGE INDEX
Title WP Sequence No.
TM 9-6115-642-10
OPERATOR MAINTENANCE
DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS
SCOPE
This WP describes and illustrates the controls and indicators to ensure proper operation of the generator set.
CONTROL PANEL ASSEMBLY
The control panel assembly contains most of the operating controls and indicator for the generator set. Figure 1 shows the control panel assembly layout and Table 1 describes each control and indicator.
Table 1. Operator's Controls and Indicators.
Figure 1. Operator's Controls and Indicators.
9
10
11
12
13
14
15
16
TM 9-6115-642-10 0004
CONTROL PANEL ASSEMBLY – CONTINUED
Table 1. Operator's Controls and Indicators – Continued
6
7
4
5
2
3
KEY
1
8
CONTROL/INDICATOR
FUEL LEVEL indicator
Panel lights
COOLANT TEMP indicator
OIL PRESSURE indicator
EMERGENCY STOP pushbutton
FREQUENCY meter (Hz)
Ammeter (PERCENT RATED CUR-
RENT METER)
AM-VM transfer switch
FUNCTION
Indicates fuel level.
Illuminates control panel.
Indicates engine coolant temperature.
Indicates oil pressure.
Shuts down generator set.
Indicates generator set output frequency.
Indicates generator set load current as a percent of rated current.
Allows selection of current and voltage readings between output load terminals as follows:
SWITCH POSITION
L1 - L2 (3 Phase)
L2 - L3 (3 Phase)
L3 - L1 (3 Phase)
L3 - L0 (3 Phase)
L3 - L1 (1 Phase)
L3 - L0 (1 Phase)
VOLTAGE
L1 - L2
L2 - L3
L3 - L1
L3 - L0
L3 - L0
L3 - L0
CURRENT
L1
L2
L3
L3
L3
L3
17
AC Voltmeter (VOLTS AC)
VOLTAGE adjust Potentiometer
BATTLE SHORT light
BATTLE SHORT switch
PANEL LIGHTS switch
AC CIRCUIT INTERRUPTER switch
Indicates output voltage of generator set.
Adjusts generator set voltage.
Amber light indicates battle short switch on.
Bypasses protective devices.
ON - Activates or deactivates panel lights.
Opens and closes AC circuit interrupter relay.
AC CIRCUIT INTERRUPTER light Green light indicates AC circuit interrupter relay is closed.
MASTER SWITCH PREHEAT - Energizes heater plugs.
OFF - Deenergizes all circuits, except panel lights.
PRIME 8 RUN AUX FUEL -Energizes generator set run circuits with fuel pump operating and with auxiliary fuel pump system activated.
PRIME 8 RUN - Energizes generator set run circuits with fuel pump operating and auxiliary fuel system deenergized.
START - Energizes starter.
Time meter (TOTAL HOURS) Indicates total engine operating hours.
0004-2
TM 9-6115-642-10
CONTROL PANEL ASSEMBLY – CONTINUED
Table 1. Operator's Controls and Indicators – Continued
KEY
18
19
20
21
CONTROL/INDICATOR
BATTERY CHARGE ammeter
DC CONTROL POWER circuit breaker (CB1) (Located Behind
Control Panel)
AC Voltage Reconnection Switch
(Located Behind Control Panel)
BATTERY CHARGER FUSE (FU1)
(Located Behind Control Panel)
FUNCTION
Indicates charge/discharge rate of batteries.
Energizes or deenergizes DC circuits.
Selects 120/208 VAC, three-phase; 120 VAC, single phase; or
120/240 VAC, single phase output at load terminal board.
Protects battery charging alternator.
0004
MALFUNCTION INDICATOR PANEL
The malfunction indicator panel (Figure 2) is located to the left of the control panel. It contains a series of lights which indicate a generator set failure or abnormal operating condition. Table 2 describes each indicator light.
0004-3
TM 9-6115-642-10
MALFUNCTION INDICATOR PANEL – CONTINUED
Table 2. Malfunction Indicator Panel.
0004
Figure 2. Malfunction Indicator Panel.
KEY
1
2
3
4
CONTROL/INDICATOR FUNCTION
NO FUEL indicator
OVERVOLTAGE indicator
Lights when fuel level in fuel tank is below preset level.
COOLANT HIGH TEMP indicator Lights when engine coolant temperature exceeds 225±5 °F
(107±30 °F).
Lights when voltage in 120 Volt generator coil exceeds 153±3
Volts.
PUSH TEST RESET LAMPS Tests and resets fault indicator lamps.
TM 9-6115-642-10 0004
MALFUNCTION INDICATOR PANEL – CONTINUED
Table 2. Malfunction Indicator Panel – Continued
KEY
5
6
7
8
9
10
11
CONTROL/INDICATOR
OVER LOAD indicator
GROUND FAULT CIRCUIT INTER-
RUPTER TEST pushbutton
Ground Fault Circuit Interrupter indicator
Ground Fault Circuit Interrupter
PUSH TO TEST Pushbutton
SHORT CIRCUIT indicator
LOW OIL PRESSURE indicator
Convenience Receptacle Overload
Circuit Breaker (10-amp in-line fuse on generator sets, contract number
DAAK01-88-D-D080)
FUNCTION
Lights when current in any phase exceeds 110 percent of rated current.
Tests Ground Fault Circuit Interrupter.
Mechanically trips red indicator, at ground fault condition in circuit of convenience receptacle.
Depress to reset Ground Fault Circuit Interrupter after test or ground fault has occurred.
Lights when generator set output in any phase exceeds 425±25 percent of rated current.
Lights when engine lubrication systems pressure is less than 15 +
3 psi (103.4±20.7 kPa) during engine operation.
Circuit breaker trips on when load on convenience receptacle exceeds 10 amps (fuse blows on generator sets, contract number
DAAK01-88-D-D080).
FREQUENCY ADJUST CONTROL
The frequency adjust control (Figure 3), is to the left and below the control panel. Table 3 describes each part and its function.
Table 3. Frequency Adjust Control.
KEY
1
CONTROL/INDICATOR
Locking Ring
Figure 3. Frequency Adjust Control.
FUNCTION
Turn locking ring counterclockwise to unlock frequency adjust control. Turn locking ring clockwise to lock frequency adjust control at desired setting.
TM 9-6115-642-10 0004
FREQUENCY ADJUST CONTROL – CONTINUED
Table 3. Frequency Adjust Control – Continued
KEY
2
3
CONTROL/INDICATOR
Frequency adjust button
Frequency adjust knob
FUNCTION
Press frequency adjust button and pull frequency adjust knob to increase frequency. Press frequency adjust button and push frequency adjust knob to decrease frequency. This enables a rapid adjustment of frequency.
Turn knob clockwise to increase frequency and counterclockwise to decrease frequency. This provides a fine adjustment in frequency.
END OF WORK PACKAGE
0004-6
TM 9-6115-642-10
OPERATOR MAINTENANCE
OPERATION UNDER USUAL CONDITIONS
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit P/
N (S25885) (NSN 4910-01-490-6453)
Materials/Parts
Ground Rod Assembly P/N
Ground Conductor Cable P/N
Personnel Required
One (1): Power Generation Mechanic (91D)
References
WP 0004 (Table 1 & Figure 1, Item 10 & Figure 1,
Item 10)
Equipment Condition
Grounded, Off & Operational (Stopping Procedure,
SCOPE
This WP provides information and guidance for generator set operation under normal conditions, refer to FM
20-31.
0005-1
TM 9-6115-642-10
ASSEMBLY AND PREPARATION FOR USE
Installation of Ground Rod
WARNING
Do not operate the generator set until it has been connected to a suitable ground. Serious injury or death can result from operating an ungrounded generator set.
0005
Figure 1. Grounding Connections.
1.
Insert ground cable (Figure 1, Item 2) through slot on load output terminal board terminal marked GND (1).
Tighten terminal nut.
2.
Connect coupling (5) to ground rod (4) and screw driving stud (3) into coupling (5). Make sure that driving stud (3) seats on ground rod (4).
TM 9-6115-642-10 0005
ASSEMBLY AND PREPARATION FOR USE – CONTINUED
3.
Drive ground rod into ground until coupling is just above surface.
4.
Remove driving stud and install another section of ground rod.
5.
Install another coupling (5) and driving stud (3). Drive ground rod down until new coupling is just above ground surface.
6.
Repeat Steps 4 and 5 until ground rod has been driven eight feet or deeper, providing an effective ground.
7.
Connect clamp (6) and ground cable (2) to ground rod (4) and tighten clamp screw.
Installation of Load Cables
WARNING
Never attempt to connect or disconnect load cables while the generator set is running. Failure to observe this warning could result in severe personal injury or death by electrocution.
CAUTION
Do not connect the load cables to the convenience receptacle. Failure to observe this caution can result in damage to the generator set.
1.
Shutdown generator set.
CAUTION
When using single phase connections, always attempt to balance loads between terminals (do not connect all loads between one terminal and LO). Failure to observe this caution can result in damage to generator set.
2.
Select required output terminals from Table 1.
3.
Open output load terminal door.
WARNING
Jumper will not be removed unless the equipment being powered specifically required an isolated ground (floating ground). Failure to comply with this warning can cause injury or death to personnel.
4.
Ensure jumper is securely fastened between LO and ground.
5.
Using terminal nut wrench (Figure 2, Item 3) loosen terminal nuts (1) on terminals (2) selected in Step 2.
6.
Insert ends of load cables through load cable exit. then insert ends of cables into slots of load terminal studs
(2).
7.
Tighten load terminal nuts (1).
8.
Secure wrench (3) in bracket inside load terminal door, and close door.
RECONNEC-
TION SWITCH
POSITION
120/208V 3PH
Table 1. Load Terminal, AC Voltage Reconnection
Switch and AM-VM Transfer Switch Selection.
TERMINALS
L1, L2,
AM-VM TRANS-
FER SWITCH
POSITION
L1-L2 3 PHASE
VOLTAGE
READING
208 VOLTS
CURRENT
READING (TER-
MINAL)
L1
TM 9-6115-642-10
ASSEMBLY AND PREPARATION FOR USE – CONTINUED
RECONNEC-
TION SWITCH
POSITION
120V 1PH
120/240V 1PH
Table 1. Load Terminal, AC Voltage Reconnection Switch and AM-VM Transfer Switch Selection. – Continued
TERMINALS AM-VM TRANS-
FER SWITCH
POSITION
VOLTAGE
READING
L3, LO L2-L3 3 PHASE 208 VOLTS
L3-LO
L3-L1
L3-LO
OR
L1-LO
L3-L1 3 PHASE 208 VOLTS
L3-LO 3 PHASE 120 VOLTS
L3-LO 1 PHASE 120 VOLTS
L3-L1 1 PHASE 240 VOLTS
L3-LO 1 PHASE 120 VOLTS
L1-LO 1 PHASE 120 VOLTS
L3
L3
L3
L3
L3
CURRENT
READING (TER-
MINAL)
L2
L1
0005
Figure 2. Installation of Load Cables.
INITIAL ADJUSTMENTS, BEFORE USE, AND SELF-TEST
Perform all before (B) PMCS, refer to WP 0011.
TM 9-6115-642-10
INITIAL ADJUSTMENTS, BEFORE USE, AND SELF-TEST – CONTINUED
0005
Initial Adjustments
1.
Place DEAD CRANK SWITCH in NORMAL position.
2.
Push DC CONTROL POWER circuit breaker in.
3.
Ensure AC voltage reconnection switch is positioned to match voltage requirements.
4.
5.
Pull our EMERGENCY STOP switch.
Self Test
1.
Place MASTER SWITCH to PRIME 8 RUN position.
2.
Push PRESS TO TEST pushbutton on malfunction indicator panel. Ensure all indicator lights are lit. When
PRESS TO TEST pushbutton is released, all lights should go out.
3.
Press BATTLE SHORT press to test light on the control panel assembly. Ensure indication light is lit. When press to test light is released, light should go out.
4.
Press AC CIRCUIT INTERRUPTER press to test light on the control panel assembly. Ensure indicator light is lit. When press to test light is released, light should go out.
OPERATING PROCEDURES
WARNING
High voltage is produced when generator set is in operation. Improper operation could result in personal injury or a death by electrocution.
WARNING
Exhaust discharge contains deadly gases. Do not operate the generator set in enclosed areas unless exhaust discharge is properly vented outside. Severe personal injury or death due to carbon monoxide poisoning could result.
Starting Procedures
WARNING
Never attempt to start the generator set if it is not properly grounded. Failure to observe this warning could result in serious injury or death by electrocution.
CAUTION
Do not crank engine in excess of 15 seconds. Allow starter to cool at least 15 seconds between attempted starts. Failure to observe this caution could result in damage to the starter.
NOTE
At temperatures below 40 °F (4 °C) it may be necessary to use the Cold Weather Starting
Aid.
0005-5
OPERATING PROCEDURES – CONTINUED
TM 9-6115-642-10 0005
NOTE
Ensure all generator set access doors, except control are closed.
1.
In cold weather conditions, place MASTER SWITCH to PREHEAT position for approximately 30 seconds.
2.
Rotate MASTER SWITCH to START position.
3.
Hold MASTER SWITCH in START position until oil pressure reaches at least 25 psi (172 kPa), voltage has increased to its approximate rated value, and engine has reached stable operating speed.
4.
Release MASTER SWITCH to PRIME 8 RUN position.
5.
If operating with an auxiliary fuel source, rotate MASTER SWITCH to PRIME 8 RUN AUX FUEL position.
NOTE
Under normal conditions warm up engine without load for five minutes. (If required, load can be applied immediately.)
6.
Check COOLANT TEMP 170-200 °F (77-93 °C) and OIL PRESSURE 25-60 psi (172-414 kPa) indicators for normal readings.
7.
Using VOLTAGE adjust potentiometer (WP 0004, Figure 1, Item 10) and Frequency Adjust Control (WP
0004, Figure 3), adjust voltage and frequency to rated values.
8.
Press GROUND FAULT CIRCUIT INTERRUPTER TEST pushbutton. Ensure indicator window is clear.
Press RESET pushbutton and ensure indicator is red.
9.
Place AC CIRCUIT INTERRUPTER switch to CLOSED position.
10. Ensure frequency and voltage are still at required values. Adjust if necessary.
11. Rotate AM-VM transfer switch to each phase position while observing ammeter (PERCENT RATED CUR-
RENT meter). If more than rated load is indicated in any phase, reduce load.
WARNING
High Voltage is produced when this generator set is in operation. Improper operation could result in personal injury or death by electrocution.
WARNING
With any access door open, the noise level of this generator set when operating could cause hearing damage. Hearing protection must be worn when working near the generator set while running.
12. Perform all DURING (D) OPERATION PMCS requirements in accordance with WP 0011, Table 1.
Stopping Procedure
1.
Place AC CIRCUIT INTERRUPTER switch in OPEN position.
2.
Allow generator set to operate 5 minutes with no load applied.
3.
Place MASTER SWITCH in OFF position.
4.
Perform all AFTER OPERATION (A) PMCS requirements in accordance with WP 0011, Table 1.
5.
Place DEAD CRANK switch to OFF position
0005-6
TM 9-6115-642-10
USE OF THE CONVENIENCE RECEPTACLE
WARNING
Power is available when the main contactor is open. Avoid accidental contact. Failure to observe this warning can result in severe personal injury or death by electrocution.
CAUTION
The maximum power rating for the convenience receptacle is 10 Amps. Continuous operation above 10 Amps can result in damage to the generator set
1.
Start the generator set if it is not operating. Refer to Operating Procedures.
2.
Ensure the load does not exceed the maximum rating.
3.
Reset the Ground Fault Circuit Interrupter.
4.
Plug appropriate connector into convenience receptacle.
DECALS AND INSTRUCTION PLATES
There are identification and instruction plates on the generator set. Figure 3 through 19 show the location and contents of each plate on the generator set.
0005
0005-7
TM 9-6115-642-10
DECALS AND INSTRUCTION PLATES – CONTINUED
0005
Figure 3. Operating Instructions (Front and Right Side).
TM 9-6115-642-10
DECALS AND INSTRUCTION PLATES – CONTINUED
0005
Figure 4. Operating Instructions Plates (Rear and Left Side).
Figure 5. Operating Instructions Plate.
TM 9-6115-642-10
DECALS AND INSTRUCTION PLATES – CONTINUED
Figure 6. Generator Set Identification Plate.
Figure 7. Generator Set Identification Plate.
Figure 8. Set Rating Identification Plate.
0005
TM 9-6115-642-10
DECALS AND INSTRUCTION PLATES – CONTINUED
0005
Figure 9. Voltage Connection Caution Plate.
Figure 10. Grounding Stud Plate.
Figure 11. NATO Slave Receptacle Plate.
Figure 12. Diagnostics Plate.
TM 9-6115-642-10
DECALS AND INSTRUCTION PLATES – CONTINUED
Figure 13. Convenience Receptacle Plate.
Figure 14. External Fuel Supply Plate.
0005
Figure 15. Battery Connection Instruction Plate.
TM 9-6115-642-10
DECALS AND INSTRUCTION PLATES – CONTINUED
Figure 16. Generator Identification Plate.
Figure 17. Frequency Adjust Plate.
0005
Figure 18. Lifting and Tiedown Diagram Plate.
TM 9-6115-642-10
DECALS AND INSTRUCTION PLATES – CONTINUED
0005
Figure 19. Fuel System Diagram Plate.
PREPARATION FOR MOVEMENT
1.
Shut down generator set, refer to Stopping Procedure.
2.
Disconnect load cables.
3.
When using auxiliary fuel line, disconnect line, drain excess fuel from line and store line in storage box.
4.
Disconnect ground cable and remove ground rods. Store ground rod in holding clip on right side of skid base. Store cable and couplings in storage box.
5.
Secure all generator set access doors and panels.
6.
For initial set up after movement, refer to Assembly and Preparation for Use.
END OF TASK
END OF WORK PACKAGE
TM 9-6115-642-10
OPERATOR MAINTENANCE
OPERATION UNDER UNUSUAL CONDITIONS
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit P/
N (S25885) (NSN 4910-01-490-6453)
Materials/Parts
Antifreeze Coolant P/N (81349) A-A-52624
Personnel Required
One (1): Power Generation Mechanic (91D)
References
WP 0014 (Air Cleaner Assembly)
Equipment Condition
Grounded, Off & Operational
UNUSUAL ENVIRONMENT/WEATHER
Operation in Extreme Cold Weather Below -25 °F (-31 °C)
The generator set operates in ambient temperatures as low as -25 °F (-31 °C) without special winterization equipment. To ensure satisfactory operation under extreme cold weather the following steps must be taken.
WARNING
Avoid contacting metal items with bare skin in extreme cold weather. Failure to observe this warning can cause personal injury.
1.
Keep generator set and surrounding area as free of ice and snow as practical.
2.
Keep fuel tank full to protect against moisture, condensation and accumulation of water.
3.
Ensure that proper grade diesel fuel is used.
4.
Keep batteries free from corrosion and in a well charged condition.
OPERATION IN EXTREME HEAT ABOVE 120 °F (49 °C)
1.
Check vents and radiator air passages frequently for obstructions.
2.
Check coolant temperature indicator frequently for any indication of overheating.
3.
Allow sufficient space for fuel expansion when filling fuel tank.
4.
Keep generator clean and free of dirt. Clean obstructions from generator intake and outlet screens.
5.
Clean external surface of engine when generator set is not operating.
OPERATION IN DUSTY OR SANDY AREAS
1.
If possible, provide a shelter for generator set. Use available natural barriers to shield generator set from blowing dust or sand.
0006-1
TM 9-6115-642-10
OPERATION IN DUSTY OR SANDY AREAS – CONTINUED
0006
2.
Wet down dusty and sandy surface areas around generator set frequently if water is available.
3.
Keep all access doors closed, as much as possible, to prevent entry of dust and sand into housing assembly.
4.
Wipe dust and sand frequently from the generator set external surface and components. Wash exterior surfaces frequently with clean water when generator set is not operating.
5.
Service engine air cleaner assembly frequently to compensate for intake of additional dust or sand. Refer to
6.
Drain sediment frequently from fuel filter/water separator. When servicing fuel tank be careful to prevent dust or sand from entering fuel tank.
7.
Change engine oil and oil filter frequently.
8.
Store oil and fuel in dust-free containers.
9.
Ensure that generator set ground connections are free of dust and sand and connections are tight before starting the unit.
OPERATION UNDER RAINY OR HUMID CONDITIONS
CAUTION
Failure to remove waterproof material before operating generator set could result in equipment damage.
1.
If possible, provide a shelter for generator set. Cover generator set with canvas or other waterproof material when it is not being operated.
2.
Provide adequate drainage to prevent water from accumulating on operation site.
3.
Keep all generator set access doors closed, as much as possible, to prevent entry of water into housing assembly.
4.
Drain water frequently from fuel filter/water separator
WARNING
DC voltages are present at generator set electrical components even with generator set shutdown. Avoid grounding yourself when touching any electrical components. Failure to follow this warning can result in personal injury.
5.
Remove moisture from generator set components before and after each operating period.
6.
Keep fuel tank full to protect against moisture, condensation and accumulation of water.
OPERATION IN SALT WATER AREAS
CAUTION
Failure to remove waterproof material before operating generator set could result in equipment damage.
1.
If possible. provide a shelter for the generator set. Locate generator set so that radiator faces into prevailing winds. Use natural barriers or, if possible, construct a barrier to protect generator set from salt water. Cover generator set with canvas or other waterproof material when it is not being operated.
0006-2
TM 9-6115-642-10
OPERATION IN SALT WATER AREAS – CONTINUED
0006
2.
Keep all generator access doors closed, as much as possible, to prevent entry of salt water into housing assembly.
3.
Wash exterior surfaces frequently with clean water when generator set is not operating.
4.
Check wiring connections for corrosion insulation for signs of deterioration.
OPERATION IN SALT WATER AREAS
The generator set will operate at elevations up to 4,000 feet (1,219.1 meters) above sea level without special adjustment or reduction in load. At elevations greater than 4,000 feet (1219.1 meters) above sea level, the kilowatt rating is reduced approximately 3.5 percent for each additional 1,000 feet (304.8 meters).
OPERATION WHILE IN CONTAMINATED AREAS
The generator set is capable of being operated by personnel wearing nuclear, biological, or chemical (NBC) protective clothing without special tools or supporting equipment. Refer to FM 3-5, NBC Decontamination for information on decontamination procedures. Specific procedures for the generator set are the following:
1.
Control panel indicators sealing gasket, rubber sleeves, and rope draw cords at output terminal access ports, control panel door gaskets, access door gaskets, rubber tubing, and belts within the engine compartment, coverings for electrical conduits, external water drain tubing, and retaining cords for slave receptacle covers will absorb and retain chemical agents. Replacement of these items is the recommended method of decontamination.
2.
Lubricants, fuel, coolant, or battery fluids may be present on the external surfaces of the generator set or components due to leaks or normal operation. These fluids will absorb NBC agents. The preferred method of decontamination is removal of these fluids using conventional decontamination methods in accordance with FM 3-5.
3.
Continued decontamination of external generator set surfaces with supertropical bleach (STB)/decontamination solution number 2 (DS2) will degrade clear plastic indicator coverings to a point where reading indicators will become impossible. This problem will become more evident for soldiers wearing protective masks.
Therefore, the use of STB or DS2 decontamination in these areas should be minimized. Indicators should be decontaminated with warm soapy water.
4.
External surfaces of the control panel assembly that are marked with painted or stamped lettering will not withstand repeated decontamination with STB or DS2 without degradation of this lettering. Therefore, the recommended method of decontamination for these areas is with warm soapy water.
5.
Areas that will entrap contaminants, making efficient decontamination extremely difficult, include the following: a.
Exposed heads of screws.
b.
Areas adjacent to and behind exposed wiring conduits.
c.
Hinged areas or access doors.
d.
Retaining chains for external receptacle covers.
e.
Areas around the tie-down/lifting rings, crevices around access doors, external screens covering ventilation areas, the external oil drain valve, and areas adjacent to the external fuel drain valve.
f.
Areas behind knobs and switches on the control panel, externally mounted equipment specification data plates, external receptacle covers, access doors, access door locking mechanisms, recessed wells for access door handles, fuel cap, load terminal board, slave receptacles, and frequency adjustment controls.
0006-3
TM 9-6115-642-10
OPERATION WHILE IN CONTAMINATED AREAS – CONTINUED
0006
Replacements of these items, if available, is the preferred method of decontamination. Conventional methods of decontamination should be used on these areas, while stressing the importance of thoroughness and the probability of some degree of continuing contact and vapor hazard.
6.
In an NBC contaminated environment, the generator set should be operated with all access doors closed to reduce the effects of contamination.
7.
The use of overhead shelters or chemical protective covers is recommended as an additional means of protection against contamination in accordance with FM 3-5. However, if using covers, care should be taken to provide adequate space for air flow and exhaust.
8.
For additional NBC information, refer to FM 3-3 and FM 3-4. Other services use applicable publications for
NBC.
END OF TASK
END OF WORK PACKAGE
0006-4
TM 9-6115-642-10
OPERATOR MAINTENANCE
EMERGENCY INFORMATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit P/
N (S25885) (NSN 4910-01-490-6453)
Personnel Required
One (1): Power Generation Mechanic (91D)
References
Equipment Condition
Grounded, Off & Operational
NATO SLAVE RECEPTACLE START OPERATION
General. The NATO slave receptacle can be used to start the generator set when batteries are discharged.
NATO Slave Emergency Starting Procedure
1.
Connect one end of NATO slave cable to fully charged 24 VDC system and other end to discharged generator set's NATO slave receptacle. Start discharged generator set.
2.
Refer to WP 0005, Operating Procedures.
3.
Remove NATO slave cable after generator set starts.
EMERGENCY STOPPING
General. Depressing the EMERGENCY STOP pushbutton will stop the generator set.
NOTE
The generator set cannot be restarted without resetting the EMERGENCY STOP pushbutton and turning MASTER SWITCH to OFF position.
OPERATION USING BATTLE SHORT SWITCH
CAUTION
Continued operation using the BATTLE SHORT switch can result in damage to the generator set.
NOTE
If any emergency situation requires continued operation of the generator set, the BATTLE
SHORT switch is used to override all the safety devices except the short circuit devices, and
EMERGENCY STOP function.
NOTE
BATTLE SHORT switch must be OFF to start generator set.
0007-1
❋❋❋❋❋❋❋❋❋❋❋❋❋❋❋❋❋❋❋❋❋❋❋❋❋❋❋❋❋❋
❋❋❋❋❋❋❋❋❋❋❋❋❋❋❋❋❋❋❋❋❋❋❋❋❋❋❋❋❋❋
❋❋❋❋❋❋❋❋❋❋❋❋❋❋❋❋❋❋❋❋❋❋❋❋❋❋❋❋❋❋
TM 9-6115-642-10 0007
OPERATION USING BATTLE SHORT SWITCH – CONTINUED
1.
Start generator set if set is not running. Refer to WP 0005, Starting Procedures.
2.
Lift cover on BATTLE SHORT switch and position switch to ON.
END OF WORK PACKAGE
0007-2
❋❋❋❋❋❋❋❋❋❋❋❋❋❋❋❋❋❋❋❋❋❋❋❋❋❋❋❋❋❋
TM 9-6115-642-10
CHAPTER 3
OPERATOR TROUBLESHOOTING PROCEDURES
FOR
GENERATOR SET, SKID MOUNTED, TACTICAL QUIET
10 kW, 60 Hz
MEP-803A
GENERATOR SET, SKID MOUNTED, TACTICAL QUIET
10 kW, 400 Hz
MEP-813A
TM 9-6115-642-10
CHAPTER 3
OPERATOR TROUBLESHOOTING PROCEDURES
WORK PACKAGE INDEX
Title WP Sequence No.
TM 9-6115-642-10
OPERATOR MAINTENANCE
TROUBLESHOOTING INDEX
GENERAL
This section lists common malfunctions you may find during operation of the generator set.You should perform the tests/inspections and corrective actions in the order listed.
This manual cannot list all malfunctions that may occur, nor all tests or inspections and corrective actions. If a malfunction is not listed or is not corrected by listed corrective actions, notify your supervisor.
NOTE
Air Force and Marine Corps users may perform maintenance only as authorized.
SYMPTOM TROUBLESHOOTING PROCEDURES INDEX
MALFUNCTION/SYMPTOM
COOLING SYSTEM
COOLANT TEMPERATURE indicator indicates engine overheating.
ELECTRICAL SYSTEM
BATTERY CHARGE ammeter shows low or no charge.
BATTERY CHARGE ammeter shows excessive charge.
TROUBLESHOOTING PROCEDURE
Symptom 11
Symptom 12
Symptom 13
AC VOLTMETER (VOLTS AC) Indicates low voltage.
Symptom 14
AC VOLTMETER (VOLTS AC) Indicates correct voltage but frequency meter (HERTZ) is off scale.
Symptom 15
AC VOLTMETER (VOLTS AC) Voltage fluctuates.
Symptom 16
FREQUENCY meter (HERTZ) Frequency fluctuates.
AC CIRCUIT INTERRUPTER Light fails to light when
AC CIRCUIT INTERRUPTER switch is closed.
No voltage at the Convenience Receptacle.
ENGINE
Fails to crank.
Cranks but fails to start.
Symptom 17
Symptom 18
Symptom 19
Symptom 1
Symptom 2
Symptom 3 Stops when MASTER SWITCH is released from
START position.
Stops suddenly.
Symptom 4
0008-1
TM 9-6115-642-10
SYMPTOM TROUBLESHOOTING PROCEDURES INDEX – CONTINUED
MALFUNCTION/SYMPTOM
Runs erratically or misfires.
Does not develop full power.
Knocks.
EXHAUST SYSTEM
Blue or white exhaust smoke.
Black exhaust smoke.
LUBRICATING SYSTEM
Low oil pressure.
TROUBLESHOOTING PROCEDURE
Symptom 5
Symptom 6
Symptom 7
Symptom 8
Symptom 9
Symptom 10
0008
END OF WORK PACKAGE
0008-2
TM 9-6115-642-10
OPERATOR MAINTENANCE
TROUBLESHOOTING PROCEDURES
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit P/
N (S25885) (NSN 4910-01-490-6453)
Personnel Required
One (1): Power Generation Mechanic (91D)
References
LO 9-6115-642-12
WP 0004 (Figure 1 & Table 1, Items: 3, 18 & 21)
References - cont'd
WP 0005 (Installation of Load Cables)
WP 0014 (Air Cleaner Assembly) (Figure 1 & Table
1, Items: 3, 18 & 21)
WP 0016 (No Fuel Light & Table 1)
WP 0017 (Fuel Filter/Water Separator)
Equipment Condition
Grounded, Off & Operational
TROUBLESHOOTING PROCEDURE(S)
SYMPTOM
1. Engine fails to crank.
TEST OR INSPECTION
Step 1. Check that DEAD CRANK switch is in the NORMAL position.
CORRECTIVE ACTION
Place switch in NORMAL position.
TEST OR INSPECTION
Step 2. Check that DC CONTROL POWER circuit breaker is energized (in).
CORRECTIVE ACTION
If DC CONTROL POWER circuit breaker is deenergized (out), go to Step 3.
TEST OR INSPECTION
Step 3. Check that Emergency Stop Switch is out.
CORRECTIVE ACTION
Pull Emergency Stop Switch out.
0009-1
TM 9-6115-642-10 0009
TROUBLESHOOTING – CONTINUED
TEST OR INSPECTION
Step 4. Defect is Engine Starting/Electrical System. Check battery connections.
CORRECTIVE ACTION
If loose or corroded, notify next higher maintenance level.
SYMPTOM
2. Engine cranks but fails to start.
TEST OR INSPECTION
Step 1. Cold ambient temperature.
CORRECTIVE ACTION
If ambient temperature is below 40 °F (4 °C) turn MASTER SWITCH to PREHEAT position for
a maximum of 30 seconds prior to cranking engine, refer to WP 0005, Starting Procedures.
TEST OR INSPECTION
Step 2. Check for dirty air cleaner element.
CORRECTIVE ACTION
Service air cleaner assembly, refer to WP 0014, Servicing.
TEST OR INSPECTION
Step 3. Check for dirty fuel filter/water separator.
CORRECTIVE ACTION
Service fuel filter/water separator, refer to WP 0017, Servicing. If engine still fails to start,
notify next higher maintenance level.
SYMPTOM
3. Engine starts but stops when MASTER SWITCH is released from START position.
TEST OR INSPECTION
Step 1. Check for proper starting procedure.
CORRECTIVE ACTION
Hold MASTER SWITCH in START position until 25 PSI (172 kPa) is reached, refer to WP
0009-2
TM 9-6115-642-10 0009
TROUBLESHOOTING – CONTINUED
TEST OR INSPECTION
Step 2. Check to see if any FAULT INDICATOR lights are lit.
CORRECTIVE ACTION
NO FUEL light is lit. refer to WP 0016. If any other lights are lit, notify next higher mainte-
nance level.
SYMPTOM
4. Engine stops suddenly.
TEST OR INSPECTION
Step 1. Check to see if any FAULT INDICATOR lights are lit.
CORRECTIVE ACTION
NO FUEL light is lit, refer to WP 0016. If any other lights are lit, go to step 2.
TEST OR INSPECTION
Step 2. Check that DC CONTROL POWER circuit broker is energized (in).
CORRECTIVE ACTION
If DC CONTROL POWER circuit breaker is deenergized (out), notify next higher maintenance level.
SYMPTOM
5. Engine runs erratically or misfires.
TEST OR INSPECTION
Step 1. Check for dirty air cleaner element.
CORRECTIVE ACTION
Service air cleaner assembly. refer to WP 0014, Servicing.
TEST OR INSPECTION
Step 2. Check for contaminated fuel.
CORRECTIVE ACTION
Service fuel filter/water separator, refer to WP 0017, Servicing.
TEST OR INSPECTION
Step 3. Check for improper type of fuel.
0009-3
TM 9-6115-642-10 0009
TROUBLESHOOTING – CONTINUED
CORRECTIVE ACTION
If improper fuel is suspected, refer to WP 0016, Table 1, notify next higher maintenance level.
SYMPTOM
6. Engine does not develop full power.
TEST OR INSPECTION
Step 1. Check for dirty air clearer element.
CORRECTIVE ACTION
Service air cleaner assembly, refer to WP 0014, Servicing.
TEST OR INSPECTION
Step 2. Check for contaminated fuel.
CORRECTIVE ACTION
Service fuel filter/water separator, refer to WP 0017, Servicing.
TEST OR INSPECTION
Step 3. Check for restricted exhaust system.
TEST OR INSPECTION
Step 4. Check for improper type of fuel.
CORRECTIVE ACTION
If improper type of fuel is suspected, refer to WP 0016, Table 1, notify next higher mainte-
nance level.
SYMPTOM
CORRECTIVE ACTION
Make sure exhaust opening is free from obstructions. If no obstructions are found, notify next higher maintenance level.
7. Engine knocks.
TEST OR INSPECTION
Step 1. Check for low lubrication oil level.
CORRECTIVE ACTION
If necessary add oil, refer to LO 9-6115-642-12.
0009-4
TM 9-6115-642-10
TROUBLESHOOTING – CONTINUED
TEST OR INSPECTION
Step 2. Check for loose parts or foreign objects in engine compartment.
CORRECTIVE ACTION
If no loose parts or foreign objects are found, go to Step 3.
TEST OR INSPECTION
Step 3. Check for improper type of fuel.
CORRECTIVE ACTION
If improper type of fuel is suspected, refer to WP 0016, Table 1, notify next higher mainte-
nance level.
SYMPTOM
8. Blue or white exhaust smoke.
TEST OR INSPECTION
Check for improper type of fuel.
CORRECTIVE ACTION
If improper type of fuel is suspected, refer to WP 0016, Table 1, notify next higher mainte-
nance level.
SYMPTOM
9. Black exhaust smoke.
TEST OR INSPECTION
Step 1. Check for improper type of fuel.
CORRECTIVE ACTION
If improper type of fuel is suspected, refer to WP 0016, Table 1, notify next higher mainte-
nance level.
TEST OR INSPECTION
Step 2. Check for dirty air cleaner element.
CORRECTIVE ACTION
Service air cleaner assembly, refer to WP 0014, Servicing.
0009-5
0009
TM 9-6115-642-10 0009
TROUBLESHOOTING – CONTINUED
TEST OR INSPECTION
Step 3. Check for generator set overload
CORRECTIVE ACTION
Check for generator set overload by checking the ammeter (PERCENT RATED CURRENT)
on the control panel assembly, refer to WP 0004, Figure 1. If unable to adjust, notify next
higher maintenance level.
SYMPTOM
10. Low oil pressure.
TEST OR INSPECTION
Step 1. Check for low lubrication oil level.
CORRECTIVE ACTION
If necessary add oil, refer to LO 9-6115-642-12.
TEST OR INSPECTION
Step 2. Check for high coolant temperature, above 200 °F (93 °C), refer to WP 0004, Table 1, Item
3.
CORRECTIVE ACTION
If coolant temperature is high, go to Step 3.
TEST OR INSPECTION
Step 3. Check coolant level. If low, add coolant, refer to WP 0015, Servicing.
CORRECTIVE ACTION
If full, go to Step 4.
TEST OR INSPECTION
Step 4. Check for obstruction in air intake system.
CORRECTIVE ACTION
If obstructions are found, remove debris. If no obstructions are found, go to Step 5.
TEST OR INSPECTION
Step 5. Check for loose fan belt.
CORRECTIVE ACTION
If loose, notify next higher maintenance level.
0009-6
TM 9-6115-642-10 0009
TROUBLESHOOTING – CONTINUED
SYMPTOM
11. COOLANT TEMPERATURE indicator indicates engine overheating.
TEST OR INSPECTION
Step 1. Check for generator set overload by checking the ammeter (PERCENT RATED CURRENT)
on the control panel assembly, refer to WP 0004, Table 1.
CORRECTIVE ACTION
If unable to adjust, notify next higher maintenance level.
TEST OR INSPECTION
Step 2. Check coolant level.
CORRECTIVE ACTION
If low, add coolant, refer to WP 0015, Servicing. If full, go to Step 3.
TEST OR INSPECTION
Step 3. Check for low lubrication oil level.
CORRECTIVE ACTION
If necessary add oil, refer to LO 9-6115-642-12. If full, go to Step 4.
TEST OR INSPECTION
Step 4. Check for obstruction in air intake system.
CORRECTIVE ACTION
If obstructions are found, remove debris. If no obstructions are found, go to Step 5.
TEST OR INSPECTION
Step 5. Check for loose fan belt.
CORRECTIVE ACTION
If loose, notify next higher maintenance level.
SYMPTOM
12. BATTERY CHARGE ammeter shows low or no charge.
TEST OR INSPECTION
Step 1. Check BATTERY CHARGER FUSE.
0009-7
TM 9-6115-642-10 0009
TROUBLESHOOTING – CONTINUED
CORRECTIVE ACTION
If BATTERY CHARGER FUSE (WP 0004, Table 1, Item 21) is blown, notify next higher main-
tenance level.
TEST OR INSPECTION
Step 2. Check fan belt.
CORRECTIVE ACTION
If fan belt is loose, notify next higher maintenance level.
TEST OR INSPECTION
Step 3. Check for loose or broken wires.
CORRECTIVE ACTION
broken, notify next higher maintenance level.
SYMPTOM
13. BATTERY CHARGE ammeter shows excessive charging after prolonged operation.
TEST OR INSPECTION
Step 1. Check batteries for low electrolyte level.
CORRECTIVE ACTION
If low refer to WP 0013. If level is correct, go to step 2.
TEST OR INSPECTION
Step 2. Check battery connection.
CORRECTIVE ACTION
If loose or corroded, notify next higher maintenance level.
SYMPTOM
14. AC voltmeter (VOLTS AC) indicates low voltage.
TEST OR INSPECTION
Step 1. Check that AM-VM transfer switch position corresponds to readings on the AC voltmeter
(VOLTS AC), refer to WP 0011, Table 1.
0009-8
TM 9-6115-642-10 0009
TROUBLESHOOTING – CONTINUED
CORRECTIVE ACTION
Set VOLTAGE adjust potentiometer.
TEST OR INSPECTION
Step 2. Check for loose or broken wires at back of AM-VM transfer switch VOLTAGE adjust potentiometer. and AC voltmeter (VOLTS AC).
CORRECTIVE ACTION
If wires are loose or broken, notify next higher maintenance level.
SYMPTOM
15. AC voltmeter (VOLTS AC) indicates correct voltage, but frequency meter (HERTZ) is off scale.
TEST OR INSPECTION
Step 1. Check FREQUENCY adjust control.
CORRECTIVE ACTION
Set FREQUENCY adjust control.
TEST OR INSPECTION
Step 2. Check for loose or broken wires at back of FREQUENCY adjust control.
CORRECTIVE ACTION
If wires are loose or broken, notify next higher maintenance level.
SYMPTOM
16. AC voltmeter (VOLTS AC) fluctuates.
TEST OR INSPECTION
Check back of AC voltmeter (VOLTS AC) for loose or broken wires.
CORRECTIVE ACTION
If wires are loose or broken, notify next higher maintenance level.
SYMPTOM
17. Frequency meter (HERTZ) fluctuates.
TEST OR INSPECTION
Check back of frequency meter (HERTZ) for loose or broken wires.
0009-9
TM 9-6115-642-10 0009
TROUBLESHOOTING – CONTINUED
CORRECTIVE ACTION
If wires are loose or broken, notify next higher maintenance level.
SYMPTOM
18. AC CIRCUIT INTERRUPTER light fails to light when AC CIRCUIT INTERRUPTER switch is closed.
TEST OR INSPECTION
Step 1. TEST AC CIRCUIT INTERRUPTER light by depressing.
CORRECTIVE ACTION
If light fails to light, refer to next higher maintenance level.
TEST OR INSPECTION
Step 2. Check load cables for proper connection. For proper connection of the load cables, refer to
WP 0005, Installation of Load Cables.
TEST OR INSPECTION
Step 3. Ensure load does not exceed generator rating.
CORRECTIVE ACTION
Decrease load, if load is correct, refer to next higher maintenance level.
SYMPTOM
CORRECTIVE ACTION
If correct go to Step 3.
19. No voltage at the Convenience Receptacle.
TEST OR INSPECTION
Step 1. Open control panel and inspect circuit breaker on side of Ground Fault Circuit Interrupter device.
CORRECTIVE ACTION
If tripped, reset device. Check fuse on black wire of Ground Fault Circuit Interrupter for generator sets, contract number DAAK01-88-D-D080.
TEST OR INSPECTION
Step 2. Check reset button for red band.
0009-10
TM 9-6115-642-10 0009
TROUBLESHOOTING – CONTINUED
CORRECTIVE ACTION
If red band is visible, push reset button. If Ground Fault Circuit Interrupter can not be reset, refer to next higher maintenance level.
END OF WORK PACKAGE
0009-11 / (12 blank)
TM 9-6115-642-10
CHAPTER 4
OPERATOR MAINTENANCE INSTRUCTIONS
FOR
GENERATOR SET, SKID MOUNTED, TACTICAL QUIET
10 kW, 60 Hz
MEP-803A
GENERATOR SET, SKID MOUNTED, TACTICAL QUIET
10 kW, 400 Hz
MEP-813A
TM 9-6115-642-10
CHAPTER 4
OPERATOR MAINTENANCE INSTRUCTIONS
WORK PACKAGE INDEX
Title WP Sequence No.
TM 9-6115-642-10
OPERATOR MAINTENANCE
PMCS INTRODUCTION
INITIAL SETUP:
References
References - cont'd
WP 0019, Equipment Inspection and Maintenance
Worksheet
GENERAL
To ensure that the generator set is ready for operation at all times, it must be inspected so that defects can be discovered and corrected before they result in serious damage or failure.
Before You Operate
Always keep in mind the CAUTIONS and WARNINGS. Perform your Before PMCS.
While You Operate
Always keep in mind the CAUTIONS and WARNINGS. Perform your During PMCS.
After You Operate
Be sure to perform your After PMCS.
If Your Equipment Fails to Operate
Report any malfunctions or failures on the proper DA Form 2404, or refer to DA PAM 750-8.
PMCS PROCEDURES
NOTE
For general location of the items to be inspected in WP 0011, Table 1, refer to WP 0002, Fig-
ure 1, and WP 0004, Figure 1 through Figure 3.
Purpose of PMCS Table
required to keep it in good operating condition.
Warnings, Cautions, and Notes
Always observe the WARNINGS, CAUTIONS, and NOTES appearing in your PMCS table. Warnings and cautions appear before applicable procedures. You must observe WARNINGS to prevent serious injury to yourself and others. You must observe CAUTIONS to prevent your equipment from being damaged. You must observe
NOTES to ensure procedures are performed properly.
0010-1
TM 9-6115-642-10 0010
GENERAL – CONTINUED
Explanation of Table Entries
The PMCS table is divided into five columns. Each column is explained in the following paragraphs.
Item No. Column. Numbers in this column are for reference. When completing DA Form 2404 (Equipment
Inspection and Maintenance Worksheet), include the item number for the check/service indicating a fault. Item numbers also appear in the order that you must do checks and services for the intervals listed.
Interval Column. This column tells you when you must do the procedure described in the procedure column.
"BEFORE" procedures must be done before you operate the equipment for its intended mission. "DURING" procedures must be done during the time you are operating the equipment for its intended mission. "AFTER" procedures must be done immediately after you have operated the equipment. Perform "WEEKLY" procedures at the listed interval.
Item to be Checked or Service Column. This column lists the location and the item to be checked or serviced.
The item location is underlined.
Procedure Column. This column gives the procedure for checking or servicing the item listed in the location, item to check/service column. You must perform the procedure to know if the power unit or power plant is ready or available for its intended mission or operation. You must do the procedure at the time stated in the interval column.
Equipment Not Ready/Available if: Column. Information in this column tells you what faults will keep your equipment from being capable of performing its primary mission. If you perform checks or services that show faults listed in this column, do not operate the equipment.
Other Table Entries
Be sure to observe all special information and notes that appear in your table.
Special Instructions
Preventive maintenance is not limited to performing the checks and services listed in the PMCS Table. Covering unused receptacles, stowing unused accessories and performing other routine procedures such as equipment inventory, cleaning components, and touch-up painting are not listed in the table. These are things you should do any time you see that they need to be done. If a routine check is listed in the PMCS Table, it is because experience has shown that problems may occur with this item. Take along tools and cleaning cloths needed to perform the required checks and services. Use the information in the following paragraphs to help you identify problems at any time and to help identify potential problems before and during checks and services.
1. Keep the generator set clean. Dirt, grease, and oil get in the way and may cover up a serious problem. Use cleaning solvent to clean metal surfaces.
2. Use soap and water to clean rubber or plastic parts and material.
3. Check all bolts, nuts, and screws to make sure they are not loose, missing, bent, or broken. Do not try to check them with a tool, but look for chipped paint, bare metal, or rust around bolt heads. If you find one loose, report it to the next-higher level of maintenance.
4. Inspect welds for loose or chipped paint, rust, or gaps where parts are welded together. If a broken weld is found, report it to the next-higher level of maintenance.
5. Inspect electrical wires, connectors, terminals, and receptacles for cracked or broken insulation, bare wires, and loose or broken connectors. Tighten loose connectors. Examine terminals and receptacles for serviceability. If deficiencies are found, report them to the next-higher level of maintenance.
6. Inspect hoses and fluid lines. Look for wear, damage, and leaks. Make sure that clamps and fittings are tight. Wet spots and stains around a fitting or connector can mean a leak. If a leak comes from a loose connector, or if something is broken or worn out, report it to the next-higher level of maintenance.
0010-2
TM 9-6115-642-10 0010
GENERAL – CONTINUED
Leakage Definitions
You must know how fluid leakage affects the status of your equipment. The following are definitions of the types/ classes of leakage you need to know to be able to determine the status of your equipment. Learn and be familiar with them. When in doubt, notify your supervisor.
LEAKAGE
CLASS
Class I
Class II
Class III
Table 1. Leakage Definitions.
LEAKAGE DEFINITION
Seepage of fluid (as indicated by wetness or discoloration) not great enough to form drops
Leakage of fluid great enough to form drops, but not enough to cause drops to drip from the item being checked/inspected.
Leakage of fluid (other than fuel) greater than three drops per minute that fall from the item being inspected.
Operation of Generator Set with Minor Leaks
a. Consider the equipment's capacity for the fluid that is leaking. If the capacity is small, the fluid level may soon become too low for continued operation. If in doubt, notify your supervisor.
b. Check the fluid level more often than required in the PMCS Table. Add fluid as needed.
c. All leaks should be reported to the next higher level of maintenance.
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 can 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.
Removal of Assemblies/Equipment to Perform PMCS
There is no requirement to remove assemblies/equipment prior to performing the PMCS.
END OF WORK PACKAGE
TM 9-6115-642-10
OPERATOR MAINTENANCE
PMCS, INCLUDING LUBRICATION INSTRUCTIONS
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit P/
N (S25885) (NSN 4910-01-490-6453)
Personnel Required
One (1): Power Generation Mechanic (91D)
References
LO 9-6115-642-12
WP 0019, Equipment Inspection and Maintenance
Worksheet
Equipment Condition
Grounded, Off & Operational (Stopping Procedure,
Table 1. Operator Preventive Maintenance Checks and Services.
ITEM
NO. INTERVAL
ITEM TO BE
CHECKED OR
SERVICED PROCEDURE
EQUIPMENT
NOT READY/
AVAILABLE IF:
NOTE
The generator set can be operated continuously at any load from no load up to and including rated load; However, at light loads (less than 25% of set rating) and oily residue
(unburned fuel oil) may occasionally be noticed in the exhaust system outlet and around connection joints in the exhaust system. This residue is caused by the inability of the fuel injection system to consistently meter the small amount of fuel required to operate at these low load levels. It is not a defect in the fuel system. The oily residue could affect engine performance and create a cosmetic problem on and around the generator set. Operation at rated load will bum off this oily residue. The length of time required at rated load depends on the amount of residue. The muffler may also need to be removed and cleaned if excessive build up occurs. This oily residue can be prevented by increasing the electrical load on the set.
1
2
NOTE
If the equipment must be kept in continuous operation, check and service only those Items that can be checked and serviced without disrupting operations. Complete all checks and services when equipment is shut down.
Before Generator Set
Exterior: Housing
Cannot secure door.
Before Generator Set
Exterior: Identification Plates
Operator
1. Check door panels, hinges, and latches for damage, loose, or corroded items.
2. Inspect air intake and exhaust grills for debris.
Operator
Check to ensure identification plates are secure.
TM 9-6115-642-10 0011
ITEM
3
4
5
Table 1. Operator Preventive Maintenance Checks and Services – Continued
NO. INTERVAL
Before
Before
Before Engine Assembly
ITEM TO BE
CHECKED OR
SERVICED
Generator Set
Exterior: Skid
Base
Generator Set
Exterior: Acoustical Materials
Operator
Operator
Inspect to ensure acoustical materials, located in the grill areas and under the engine are secure, not damaged, or missing.
Operator
PROCEDURE
Inspect skid base for cracks and/or corrosion.
EQUIPMENT
NOT READY/
AVAILABLE IF:
Skid base is cracked or shows signs of structural damage.
WARNING
With any access door open, the noise level of this generator set when operating could cause hearing damage. Hearing protection must be worn when working near the generator set while running.
6 Before
WARNING
The fuels in this generator set are highly explosive. Do not smoke or use open flame when performing maintenance. Flames and explosion could result in severe personal injury or death.
Inspect for loose, damaged, or missing hardware.
Any loose, damaged, or missing hardware.
Any fuel leaks, damaged, or missing parts.
7
8
Before
Before
Engine Assembly: Fuel System
Engine Assembly: Fuel Filter/Water Separator
Engine Assembly: Lubrication
System
Operator
Inspect for leaks, damage, loose, or missing hardware.
Operator
1. Inspect for leaks, cracks, damage, proper mounting, loose, or missing hardware.
2. Drain water from fuel filter/water separator
Operator
1. Inspect for leaks, damage, loose, or missing parts.
Any fuel leaks.
Water not drained.
Class III leaks, damage, loose, or missing parts.
0011-2
TM 9-6115-642-10 0011
ITEM
Table 1. Operator Preventive Maintenance Checks and Services – Continued
NO. INTERVAL
ITEM TO BE
CHECKED OR
SERVICED PROCEDURE
2. Inspect oil level.
3. Inspect for contamination.
EQUIPMENT
NOT READY/
AVAILABLE IF:
Oil level is low.
Oil shows signs of contamination.
9 Before Cooling System:
Radiator
Operator
WARNING
Cooling system operates at high temperatures. Personal injury or death from burns or scalding could result from contact with high pressure steam and/or liquid.
Inspect for leaks, damage, loose, or missing parts.
10 Before
11 Before
Cooling System:
Hoses
Cooling System:
Cooling Fan
Operator
Inspect for leaks, cracks, or missing parts.
Operator
1. Inspect for obstruction, damage, or looseness.
2. Inspect for unusual noise in fan area.
Class III leaks or missing radiator cap.
Class III leaks or missing clamps or hoses.
Damaged or loose.
12 Before Cooling System:
Fan Belt
Unusual noise from area.
Broken or missing belt.
13 Before Cooling System:
Overflow Bottle
Operator
Inspect for cracks, fraying or looseness.
Operator
Inspect for proper mounting, leaks, or missing hardware.
Class III leaks or missing hardware.
0011-3
TM 9-6115-642-10 0011
ITEM
14 Before
Table 1. Operator Preventive Maintenance Checks and Services – Continued
NO. INTERVAL
ITEM TO BE
CHECKED OR
SERVICED
Exhaust/Intake
System: Exhaust
System
Operator
PROCEDURE
EQUIPMENT
NOT READY/
AVAILABLE IF:
WARNING
Exhaust discharge contains deadly gases. Do not operate generator set in enclosed area unless exhaust discharge is properly vented outside. Severe personal injury or death due to carbon monoxide poisoning could result.
Inspect for leaks, corrosion, and missing parts.
15 Before Exhaust/Intake
System: Air
Cleaner Assembly
Operator
1. Inspect for loose, damaged, or missing parts.
Leaks, damaged, or missing parts.
Loose or missing parts
16 Before
2. Inspect restriction indicator for clogged air cleaner element.
Operator
Clogged air cleaner element.
Grounding
Rod Assembly: Ground Rod
Cable and Connections
WARNING
Never attempt to start the generator set if it is not properly grounded. Failure to observe this warning could result in serious injury or death by electrocution.
Inspect for damage, corrosion, and loose connections.
Damaged, corroded, or loose connections.
17 Before Electrical System: Batteries
Operator
WARNING
Battery acid will cause burns to unprotected skin.
0011-4
TM 9-6115-642-10 0011
ITEM
Table 1. Operator Preventive Maintenance Checks and Services – Continued
NO. INTERVAL
ITEM TO BE
CHECKED OR
SERVICED
EQUIPMENT
NOT READY/
AVAILABLE IF: PROCEDURE
WARNING
Batteries give off flammable gas. Do not smoke or use open flame when performing maintenance. Flames and explosion could result in personal injury or death.
WARNING
DC voltages are present at generator set electrical components even with generator set shut down. Avoid grounding self when touching any electrical components. Failure to observe this warning can result in personal injury.
Inspect for secure mounting.
18 Before
Broken or missing mounting hardware.
Damaged, loose, or missing parts.
19 Before
20 Before
21 Before
Electrical System: Battery
Cables
Electrical System: Output Box
Assembly
Control Box
Assembly: Controls and Indicators
Control Box
Assembly: Control Box Harness
Operator
Inspect for corrosion, damage, loose connections, or missing parts.
Operator
1. Inspect cables for damage or loose connections.
2. Inspect output terminals for damage or missing hardware.
Operator
Inspect for damage or missing parts.
Operator
WARNING
High Voltage is produced when this generator set is in operation. Improper operation could result in personal injury or death by electrocution.
Inspect for damage and looseness.
Damaged, loose, or missing parts.
Damaged or missing hardware.
Damaged or missing parts.
Damaged or loose.
0011-5
TM 9-6115-642-10 0011
ITEM
22 During
Table 1. Operator Preventive Maintenance Checks and Services – Continued
NO. INTERVAL
ITEM TO BE
CHECKED OR
SERVICED
Generator Set
Exterior: Housing
Operator
PROCEDURE
EQUIPMENT
NOT READY/
AVAILABLE IF:
23 During Engine Assembly
NOTE
If the equipment must be kept in continuos operation, check and service only those items that can be checked and serviced without disrupting operations.
Complete all checks and services when equipment is shut down.
Check door panels, hinges, and latches for damage, loose, or corroded items.
Operator
Cannot secure door.
WARNING
With any access door open, the noise level of this generator set when operating could cause hearing damage. Hearing protection must be worn when working near the generator set while running.
24 During Engine Assembly: Fuel System
WARNING
The fuels in this generator set are highly explosive. Do not smoke or use open flame when performing maintenance. Flames and explosion could result in severe personal injury or death.
Inspect for loose, damaged or missing hardware. Any loose, damaged or missing hardware.
Operator
Inspect for leaks, damage, loose, or missing hardware.
Any fuel leaks, damage, loose, or missing parts.
0011-6
TM 9-6115-642-10 0011
ITEM
Table 1. Operator Preventive Maintenance Checks and Services – Continued
NO. INTERVAL
25 During
ITEM TO BE
CHECKED OR
SERVICED
Engine Assembly: Lubrication
System
Operator
PROCEDURE
1. Inspect for leaks, damage or missing parts.
26 During Cooling
System:Cooling
Fan
2. Inspect for contamination.
Operator
1. Inspect for obstruction, damage, or looseness.
2. Inspect for unusual noise in fan area.
EQUIPMENT
NOT READY/
AVAILABLE IF:
Class III leaks, damage, loose, or missing parts.
Oil shows signs of contamination.
Damaged or loose.
27 During Cooling System:
Overflow Bottle
Unusual noise from area.
Class III leaks or missing hardware.
28
29
During
During
Grounding
Rod Assembly: Ground Rod
Cable and Connections
Control Box
Assembly: Controls and Indicators
Operator
Inspect for proper mounting, leaks, or missing hardware.
Operator
Inspect for damage, corrosion, and loose connections.
Operator
Damaged, corroded, or loose connections.
WARNING
High Voltage is produced when this generator set is in operation. Improper operation could result in personal injury or death by electrocution.
Inspect indicators are operating properly.
Indicators are not operating properly.
30 After Generator Set
Exterior: Housing
Operator
NOTE
If the equipment must be kept in continuos operation, check and service only those items that can be checked and serviced without disrupting operations.
Complete all checks and services when equipment is shut down.
Check door panels, hinges, and latches for damage, loose, or corroded items.
Cannot secure door.
0011-7
TM 9-6115-642-10 0011
ITEM
31 After
32
33
After
After
Table 1. Operator Preventive Maintenance Checks and Services – Continued
NO. INTERVAL
ITEM TO BE
CHECKED OR
SERVICED
Generator Set
Exterior: Identification Plates
Generator Set
Exterior: Skid
Base
Engine Assembly
Operator
Check to ensure identification plates are secure.
Operator
Inspect skid base for cracks and/or corrosion.
Operator
PROCEDURE
EQUIPMENT
NOT READY/
AVAILABLE IF:
Skid base is cracked or shows signs of structural damage.
34 After
35 After
Engine Assembly: Fuel System
Engine Assembly: Fuel Filter/Water Separator
WARNING
The fuels in this generator set are highly explosive. Do not smoke or use open flame when performing maintenance. Flames and explosion could result in severe personal injury or death.
Inspect for loose, damaged or missing hardware. Any loose, damaged or missing hardware.
Operator
Inspect for leaks, damage, loose, or missing hardware.
Any fuel leaks, damage, loose, or missing parts.
Operator
1. Inspect for leaks, cracks, damage, proper mounting, loose, or missing parts.
Any fuel leaks.
36 After Engine Assembly: Lubrication
System
2. Drain water from fuel filter/water separator
Operator
1. Inspect for leaks, damage or missing parts.
2. Inspect oil level.
3. Inspect for contamination.
Water not drained.
Class III leaks, damage, loose, or missing parts.
Oil level is low.
Oil shows signs of contamination.
0011-8
TM 9-6115-642-10 0011
ITEM
37 After
Table 1. Operator Preventive Maintenance Checks and Services – Continued
NO. INTERVAL
ITEM TO BE
CHECKED OR
SERVICED
Cooling System:
Radiator
Operator
PROCEDURE
EQUIPMENT
NOT READY/
AVAILABLE IF:
WARNING
Cooling system operates at high temperatures. Personal injury or death from burns or scalding could result from contact with high pressure steam and/or liquid.
Inspect for leaks, damage, loose, or missing parts.
38 After
39 After
40 After
Cooling System:
Hoses
Cooling System:
Fan Belt
Control Box
Assembly: Controls and Indicators
Operator
Inspect for leaks, cracks, or missing parts.
Operator
Inspect for cracks, fraying or looseness.
Operator
Inspect for damage or missing parts.
Class III leaks or missing radiator cap.
Class III leaks or missing clamps or hoses.
Broken or missing belt.
Damaged or missing parts.
MANDATORY REPLACEMENT PARTS
There are no replacement parts required for these PMCS procedures.
LUBRICATION INSTRUCTIONS
Refer to LO 9-6115-642-12 for lubrication information.
END OF WORK PACKAGE
0011-9 / (10 blank)
TM 9-6115-642-10
OPERATOR MAINTENANCE
GENERATOR SET: INSPECTION AND SERVICE
INITIAL SETUP:
Not Applicable
GENERATOR SET INSPECTION AND SERVICE
INTRODUCTION
This section contains operator maintenance procedures. Deficiencies noted during inspection which are beyond the maintenance scope of the operator shall be reported to next higher maintenance level.
END OF WORK PACKAGE
0012-1 / (2 blank)
TM 9-6115-642-10
OPERATOR MAINTENANCE
BATTERIES: INSPECTION, SERVICING
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit P/
N (S25885) (NSN 4910-01-490-6453)
Materials/Parts
Protective Clothing P/N foo mtrlpart partno
Personnel Required
One (1): Power Generation Mechanic (91D)
References
Equipment Condition
Grounded, Off & Operational
WARNING
Battery acid will cause burns to unprotected skin.
WARNING
Batteries give off flammable gas. Do not smoke or use open flame when performing maintenance. Flames and explosion could result in personal injury or death.
INSPECTION
1.
Shut down generator set, refer to WP 0005, Stopping Procedure.
2.
Open engine access door.
3.
Inspect for damaged battery case, corrosion, and loose connections on terminal cable, and damaged or missing battery caps.
WARNING
Batteries give off flammable gas. Do not smoke or use open flame when performing maintenance. Flames and explosion could result in personal injury or death.
4.
Remove battery caps.
CAUTION
Electrolyte level must cover battery plates in all cells. Failure to observe this caution can cause damage to the battery.
5.
Inspect electrolyte level.
NOTE
Electrolyte level should be at bottom of each cap cylinder.
0013-1
TM 9-6115-642-10
INSPECTION – CONTINUED
6.
Perform service procedures if required.
7.
Install battery caps.
8.
Close engine access door.
END OF TASK
SERVICING
1.
Shut down generator set, refer to WP 0005, Stopping Procedure.
2.
Open engine access door.
WARNING
Batteries give off flammable gas. Do not smoke or use open flame when performing maintenance. Flames and explosion could result in personal injury or death.
3.
Remove battery caps.
NOTE
Electrolyte level should be at bottom of each cap cylinder.
4.
Add distilled water to each battery cell as required.
5.
Replace battery caps.
6.
Close engine access door.
7.
If necessary contact next higher maintenance level to clean or replace batteries or battery terminals.
END OF TASK
END OF WORK PACKAGE
0013
0013-2
TM 9-6115-642-10
OPERATOR MAINTENANCE
AIR CLEANER ASSEMBLY: INSPECTION, SERVICING
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit P/
N (S25885) (NSN 4910-01-490-6453)
Personnel Required
One (1): Power Generation Mechanic (91D)
References
Equipment Condition
Grounded, Off & Operational
Figure 1. Air Cleaner Element Replacement.
INSPECTION
1.
Shut down generator set, refer to WP 0005, Stopping Procedure.
TM 9-6115-642-10 0014
INSPECTION – CONTINUED
2.
Open left side engine access door.
3.
Inspect air cleaner housing (Figure 1, Item 5) for dents, corrosion, missing hardware and other damage.
4.
Open right side engine access door and inspect air cleaner restriction indicator for indication of a clogged air cleaner element.
5.
Close engine access door.
END OF TASK
SERVICING
1.
Shut down generator set, refer to WP 0005, Stopping Procedure.
2.
Open left side engine access door.
3.
Loosen wing nut clamp (1) and remove end cap (2) on air cleaner housing (5).
4.
Remove wing nut (3) and air cleaner element (4). If fouled, discard air cleaner element.
5.
Inspect inside of air cleaner housing (5) for debris. Wipe air cleaner housing interior with clean lint-free cloth.
6.
Install air cleaner element (4), wing nut (3), end cap (2) and tighten wing nut (1).
7.
Close engine compartment access door.
END OF TASK
END OF WORK PACKAGE
0014-2
TM 9-6115-642-10
OPERATOR MAINTENANCE
COOLING SYSTEM: INSPECTION, SERVICING
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit P/
N (S25885) (NSN 4910-01-490-6453)
Materials/Parts
Inhibitor P/N MIL-A-53009
Antifreeze P/N MIL-A-46153
Antifreeze P/N MIL-A-11755
Personnel Required
One (1): Power Generation Mechanic (91D)
References
Equipment Condition
Grounded, Off & Operational
INSPECTION
1.
Shut down generator set, refer to WP 0005, Stopping Procedure.
2.
Open both engine access doors.
WARNING
Cooling system operates at high temperatures. Personal injury or death from burns or scalding could result from contact with high pressure steam and/or liquid.
3.
Check radiator for dirt, leaves, insects, etc. blocking air flow.
4.
Check radiator and hoses for leaks, loose connections, loose mounting, corrosion, chafing and missing parts.
5.
Check coolant level in coolant recovery (overflow) bottle.
6.
Close engine compartment access doors.
END OF TASK
SERVICING
WARNING
Cooling system operates at high temperatures. Personal injury or death from burns or scalding could result from contact with high pressure steam and/or liquid.
1.
Shut down generator set, refer to WP 0005, Stopping Procedure.
2.
Open right side engine access door.
3.
Remove coolant recovery (overflow) bottle cap.
4.
Fill coolant recovery (overflow) bottle to HOT line if coolant is hot or to COLD line if coolant is cold, with proper coolant/antifreeze in accordance with Table 1.
5.
Install coolant recovery (overflow) bottle cap. Close right side engine access door.
0015-1
TM 9-6115-642-10
SERVICING – CONTINUED
AMBIENT TEMPERATURE
+40 to +120 °F (+4 to +49 °C)
-25 to +120 °F (-32 to +49 °C)
-25 to +120 °F (-32 to +49 °C)
Table 1. Coolant.
RADIATOR COOLANT
Water: MIL-A-53009 Inhibitor,
Corrosion
Water: MIL-A-46153
Antifreeze
MIL-A-11755 Antifreeze
RATIO
35:1
1:1
NA
END OF TASK
END OF WORK PACKAGE
0015
TM 9-6115-642-10
OPERATOR MAINTENANCE
FUEL TANK: SERVICING
INITIAL SETUP:
Tools and Special Tools Personnel Required
Generator Mechanical Tool Kit P/
N (S25885) (NSN 4910-01-490-6453)
Materials/Parts
One (1): Power Generation Mechanic (91D)
References
Disel Fuel P/N W-F 800 Grade DF-2 JP4, JP5, JP8
Disel Fuel P/N W-F 800 Grade DF-1 JP4, JP5, JP8
Disel Fuel P/N W-F 800 Grade DF-1
Disel Fuel P/N W-F 800 Grade DF-A
Equipment Condition
Grounded, Off & Operational
SERVICING
WARNING
The fuels in this generator set are highly explosive. Do not smoke or use open flame when performing maintenance. Flames and explosion could result in severe personal injury or death.
CAUTION
Use only specified diesel fuel to service the fuel tank, refer to Table 1. Otherwise, equipment damage could result, if improper fuel is used.
1.
Shut down generator set, refer to WP 0005, Stopping Procedure.
2.
Remove fuel cap.
3.
Remove strainer, clean as necessary and reinstall.
NOTE
Fuel tank holds 9 gallons (34 liters).
4.
Add diesel fuel to fuel tank.
5.
Install fuel cap.
Diesel Fuel
AMBIENT TEMPERATURE
+20 to +120 °F (-7 to +49 °C)
0 to +20 °F (-17 to +7 °C)
Table 1. Fuel.
DIESEL FUEL
W-F-800 GRADE DF-2 JP4, JP5, JP8
W-F-800 GRADE DF-1 JP4, JP5, JP8
SERVICING – CONTINUED
AMBIENT TEMPERATURE
-25 to 0 °F (-32 to -17 °C)
-25 to 0 °F (-32 to -17 °C)
END OF TASK
END OF WORK PACKAGE
TM 9-6115-642-10
Table 1. Fuel. – Continued
DIESEL FUEL
W-F-800 GRADE DF-1
W-F-800 GRADE DF-A
0016
0016-2
TM 9-6115-642-10
OPERATOR MAINTENANCE
FUEL FILTER/WATER SEPARATOR: INSPECTION, SERVICING
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit P/
N (S25885) (NSN 4910-01-490-6453)
Materials/Parts
Suitable Container to Drain Contaminants P/N
Personnel Required
One (1): Power Generation Mechanic (91D)
References
Equipment Condition
Grounded, Off & Operational
Figure 1. Draining Fuel Filter/Water Separator.
TM 9-6115-642-10 0017
INSPECTION
1.
Shut down generator set, refer to WP 0005, Stopping Procedure.
2.
Open left side engine access door.
3.
Inspect fuel filter/water separator assembly (Figure 1) for proper mounting, cracks, dents, leaks, loose fuel lines and other damage.
4.
Close left engine access door.
END OF TASK
SERVICING
1.
Shut down generator set, refer to WP 0005, Stopping Procedure.
2.
Rotate MASTER SWITCH to PRIME & RUN.
3.
Open left side engine access door.
4.
Open fuel drain cock (1) on fuel filter/water separator housing (2) and drain contaminants into a suitable container.
5.
Close drain cock (1).
6.
Close left side engine access door.
7.
Rotate MASTER SWITCH to OFF.
END OF TASK
END OF WORK PACKAGE
0017-2
TM 9-6115-642-10
OPERATOR MAINTENANCE
LUBRICATION SYSTEM: INSPECTION, SERVICING
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit P/
N (S25885) (NSN 4910-01-490-6453)
Personnel Required
One (1): Power Generation Mechanic (91D)
References
LO 9-6115-642-12
Equipment Condition
Grounded, Off & Operational
INSPECTION
1.
Shut down generator set, refer to WP 0005, Stopping Procedure.
2.
Open both engine access doors.
3.
Inspect engine assembly for oil leaks.
4.
Check for damage, proper mounting, or missing parts.
5.
Check engine crankcase oil level. Refer to LO 9-6115-642-12.
6.
Close both engine access doors.
END OF TASK
SERVICING
1.
Shut down generator set, refer to WP 0005, Stopping Procedure.
2.
Open left engine access door.
3.
Remove oil filler cap.
4.
Add oil to engine crankcase. Refer to LO 9-6115-642-12.
5.
Install oil filler cap.
6.
Close left engine access door.
END OF TASK
END OF WORK PACKAGE
0018-1 / (2 blank)
TM 9-6115-642-10
CHAPTER 5
OPERATOR SUPPORTING INFORMATION
FOR
GENERATOR SET, SKID MOUNTED, TACTICAL QUIET
10 kW, 60 Hz
MEP-803A
GENERATOR SET, SKID MOUNTED, TACTICAL QUIET
10 kW, 400 Hz
MEP-813A
TM 9-6115-642-10
CHAPTER 5
OPERATOR SUPPORTING INFORMATION
WORK PACKAGE INDEX
Title WP Sequence No.
TM 9-6115-642-10
OPERATOR MAINTENANCE
REFERENCES
SCOPE
This work package lists all forms, field manuals, technical manuals and miscellaneous publications referenced in this manual.
FORMS
AFTO Form 22
DA Form 2028
DA Form 2028-2
DA Form 2404
DA Form 2408-9
NAVMC 10772
SF 368
Recommending Improvements to Technical Publications
Recommended Changes to Publications and Blank Forms
Recommended Changes to Equipment Technical Publications
Equipment Inspection and Maintenance Worksheet
Equipment Control Log
Reporting Errors and Recommending Improvements to Technical Publications
Quality Deficiency Report
FIELD MANUALS
FM 3-3
FM 3-4
FM 3-5
FM 4-25.11
FM 20-31
TECHNICAL MANUALS
TM 4700-15/1
NBC Contamination Avoidance
NBC Protection
NBC Decontamination
First Aid
Electric Power Generation in the Field
Marine Corps Forms
MISCELLANEOUS PUBLICATIONS
AFR 66-1
DA PAM 738-750
LO 9-6115-642-12
MCO 4855.10
MIL-STD-12
TB 9-6115-642-24
Air Force Maintenance Forms and Records
The Army Maintenance Management System (TAMMS)
Lubrication Order
Quality and Deficiency Reporting
Military Standard Abbreviations
Warranty Technical Bulletin
END OF WORK PACKAGE
0019-1 / (2 blank)
TM 9-6115-642-10
OPERATOR MAINTENANCE
COMPONENTS OF END ITEM (COEI) AND BASIC ISSUE ITEMS (BII) LISTS
INTRODUCTION
Scope
This work package lists COEI and BII for the generator set to help you inventory items for safe and efficient operation of the equipment.
General
The COEI and BII information is divided into the following lists:
Components of End Item (COEI)
This list is for information purposes only and is not authority to requisition replacements. These items are part of the generator set. As part of the end item, these items must be with the end item whenever it is issued or transferred between property accounts. Items of COEI are removed and separately packaged for transportation or shipment only when necessary. Illustrations are furnished to help you find and identify the items.
Basic Issue Items (BII)
These essential items are required to place the generator set in operation, operate it, and to do emergency repairs. Although shipped separately packaged, BII must be with the generator set during operation and when it is transferred between property accounts. Listing these items is your authority to request/requisition them for replacement based on authorization of the end item by the TOE/MTOE. Illustrations are furnished to help you find and identify the items.
Explanation of Columns in the COEI List and BII List
Column (1), Illus Number, gives you the number of the item illustrated.
Column (2), National Stock Number, identifies the stock number of the item to be used for requisitioning purposes.
Column (3), Description, Part Number, and CAGEC, identifies the Federal item name (in all capital letters) followed by a minimum description when needed. The stowage location of COEI and BII is also included in this column. The last line below the description is the CAGEC (Commercial and Government Entity Code) (in parentheses) and the part number.
Column (4), Usable on Code, gives you a code if the item you need is not the same for different models of equipment.
Column (5), U/I (unit of issue), indicates how the item is issued for the National Stock Number shown in column
(2).
Column (6), Qty Rqr, indicates the quantity required.
0020-1
TM 9-6115-642-10
Table 1. Component of End Items (COEI) List.
(1) (2) (3)
ILLUS
NUMBER
NATIONAL STOCK
NUMBER (NSN)
0000-00-000-0000
DESCRIPTION, PART NUMBER/(CAGEC)
NOT APPLICABLE
(4)
USABLE
ON
CODE
(5)
U/I
0020
(6)
QTY
RQR
-
Figure 1. Basic Issue Items.
Table 2. Basic Issue Items (BII).
(1) (2) (3)
ILLUS
NUMBER
1
2
3
NATIONAL STOCK
NUMBER (NSN) DESCRIPTION, PART NUMBER/(CAGEC)
TECHNICAL MANUAL, TM 9-6115-642-10
LUBRICATION ORDER, LO 9-6115-642-12
WARRANTY TECHNICAL BULLETIN, TB
9-6115-642-24
(4)
USABLE
ON
CODE
(5)
U/I
EA
EA
EA
END OF WORK PACKAGE
(6)
QTY
RQR
1
1
1
TM 9-6115-642-10
OPERATOR MAINTENANCE
ADDITIONAL AUTHORIZATION LIST (AAL)
INTRODUCTION
Scope
This work package lists additional items you are authorized for the support of the generator set.
General
This list identifies items that do not have to accompany the generator set and that do not have to be turned in with it. These items are all authorized to you by CTA, MTOE, TDA, or JTA.
Explanation of Entries in the AAL
Column (1) National Stock Number (NSN). Identifies the stock number of the item to be used for requisitioning purposes.
Column (2) Description, Part Number/(CAGEC). Identifies the Federal item name (in all capital letters) followed by a minimum description when needed. The last line below the description is the part number and the Commercial and Government Entity Code (CAGEC) (in parentheses).
Column (3) Usable On Code. When applicable, gives you a code if the item you need is not the same for different models of equipment.
Column (4) U/I. Unit of Issue (U/I) indicates the physical measurement or count of the item as issued per the
National Stock Number shown in column (1).
Column (5) Qty Recm. Indicates the quantity recommended.
(1)
NATIONAL STOCK
NUMBER (NSN)
2910-00-066-1235
7240-00-222-3088
4210-00-270-4512
5120-01-013-1676
7240-00-177-6154
Table 1. Additional Authorization List.
(2)
DESCRIPTION, PART NUMBER/(CAGEC)
ADAPTER, CONTAINER
13211E7541 (97403)
CAN, GASOLINE, MILITARY
42-D-1280 (80372)
EXTINGUISHER, FIRE, CARBON DIOXIDE
O-E-91O (81348)
SLIDE HAMMER, GROUND
13226E7741 (97403)
SPOUT, CAN, FLEXIBLE
MIL-S-1285 (81349)
END OF WORK PACKAGE
(3)
USABLE
ON
CODE
(4)
U/I
EA
EA
EA
EA
EA
(5)
QTY
RECM
1
1
1
1
1
TM 9-6115-642-10
OPERATOR MAINTENANCE
EXPENDABLE AND DURABLE ITEMS LIST
INTRODUCTION
Scope
This work package lists expendable and durable items that you will need to operate and maintain the generator set. This list is for information only and is not authority to requisition the listed items. These items are authorized to you by CTA 50-970, Expendable/Durable Items (Except Medical, Class V Repair Parts, and Heraldic Items),
CTA 50-909, Field and Garrison Furnishings and Equipment or CTA 8-100, Army Medical Department Expendable/Durable Items.
Explanation of Columns in the Expendable/Durable Items List
Column (1) Item No. This number is assigned to the entry in the list and is referenced in the narrative instructions to identify the item (e.g., Use brake fluid (WP 0098, item 5)).
Column (2) Level. This column identifies the lowest level of maintenance that requires the listed item (include as applicable: C = Crew, O = AMC, F = Maintainer or ASB, H = Below Depot or TASMG, D = Depot).
Column (3) National Stock Number (NSN). This is the NSN assigned to the item which you can use to requisition it.
Column (4) Item Name, Description, Part Number/(CAGEC). This column provides the other information you need to identify the item. The last line below the description is the part number and the Commercial and Government Entity Code (CAGEC) (in parentheses).
Column (5) U/I. Unit of Issue (U/I) code shows the physical measurement or count of an item, such as gallon, dozen, gross, etc.
Table 1. Expendable and Durable Items List.
(2) (5) (1)
ITEM
NO.
2
1
4
5
3
LEVEL
O
O
O
O
O
(3)
NATIONAL STOCK
NUMBER (NSN)
6850-00-181-7929
7920-01-338-3329
9150-00-189-6727
9150-01-152-4117
6810-00-107-1510
(4)
ITEM NAME, DESCRIPTION,
PART NUMBER/(CAGEC)
ANTIFREEZE, MIL-A-46153
(81349)
CLOTH, CLEANING,
LUBRICATING OIL, ENG, MIL-L-2104, OEA HDO 10
(81349)
LUBRICATING OIL, ENG, MIL-L-2104, OEA HDO
15/40
(81349)
WATER, DISTILLED,
U/I
GL
EA
QT
QT
GL
END OF WORK PACKAGE
TM 9-6115-642-10
INDEX
Subject WP Sequence No.-Page No.
A
Additional Authorization List (AAL) ..........................................................................................
WP 0021-1
Air Cleaner Assembly: Inspection, Servicing ...........................................................................
WP 0014-1
B
Batteries: Inspection, Servicing ...............................................................................................
WP 0013-1
C
Components of End Item (COEI) and Basic Issue Items (BII) Lists ........................................
WP 0020-1
Cooling System: Inspection, Servicing ....................................................................................
WP 0015-1
D
Description and Use of Operator Controls and Indicators ......................................................
WP 0004-1
E
Emergency Information ............................................................................................................
WP 0007-1
Equipment Description and Data .............................................................................................
WP 0002-1
Expendable and Durable Items List ........................................................................................
WP 0022-1
F
Fuel Filter/Water Separator: Inspection, Servicing ..................................................................
WP 0017-1
Fuel Tank: Servicing ................................................................................................................
WP 0016-1
G
General Information .................................................................................................................
WP 0001-1
Generator Set: Inspection and Service ...................................................................................
WP 0012-1
L
Lubrication System: Inspection, Servicing ...............................................................................
WP 0018-1
O
Operation Under Unusual Conditions ......................................................................................
WP 0006-1
Operation Under Usual Conditions ..........................................................................................
WP 0005-1
P
PMCS, Including Lubrication Instructions ................................................................................
WP 0011-1
Index-1
TM 9-6115-642-10
PMCS Introduction ...................................................................................................................
WP 0010-1
R
References ...............................................................................................................................
WP 0019-1
T
Theory of Operation .................................................................................................................
WP 0003-1
Troubleshooting Index ..............................................................................................................
WP 0008-1
Troubleshooting Procedures ....................................................................................................
WP 0009-1
Index-2
RECOMMENDED CHANGES TO PUBLICATIONS AND
BLANK FORMS
For use of this form, see AR 25-30; the proponent agency is OAASA
TO: (Forward to proponent of publication or form) (Include ZIP Code)
Commander, US Army CECOM LCMC
ATTN: AMSEL-LC-LEO-E-CM
Fort Monmouth, NJ 07703-5006
Use Part II (reverse) for Repair Parts and
Special Tool Lists (RPSTL) and Supply
Catalogs/Supply Manuals (SC/SM).
DATE
30 August 2002
FROM: (Activity and location) (Include ZIP Code)
Jane Q. Doe, SFC
1234 Any Street
Anytown, AL 34565
PART I - ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS
PUBLICATION/FORM NUMBER
TM 11-1234-567-14
DATE
16 Sep 2001
TITLE
Operator, Field and Sustainment Support Maintenance Manual for
Radio, AN/ABC-123
ITEM PAGE
PARA-
GRAPH
1 WP0005
PG 3
TYPED NAME, GRADE OR TITLE
Jane Q. Doe, SFC
DA FORM 2028, FEB 74
LINE
2
TABLE
FIGURE
NO.
RECOMMENDED CHANGES AND REASON
Test or Correctiive Action column should identify a different WP number.
SIGNATURE TELEPHONE EXCHANGE/AUTOVON,
PLUS EXTENSION
123-4567
REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED.
TO:
(Forward to proponent of publication or form) (Include ZIP Code)
FROM:
(Activity and location) (Include ZIP
Code)
DATE
PART II- REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS
PUBLICATION/FORM NUMBER DATE TITLE
PAGE
NO.
COLM
NO.
LINE
NO.
NATIONAL STOCK
NUMBER
REFERENCE
NO.
FIGURE
NO.
ITEM
NO.
TOTAL NO.
OF MAJOR
ITEMS
SUPPORTED
RECOMMENDED
ACTION
PART III - REMARKS
(Any general remarks or recommendations, or suggestions for improvement of publications and
blank forms. Additional blank sheets may be used if more space is needed.)
TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON,
PLUS EXTENSION
SIGNATURE
APD V4.00
RECOMMENDED CHANGES TO PUBLICATIONS AND
BLANK FORMS
For use of this form, see AR 25-30; the proponent agency is OAASA
TO:
(Forward to proponent of publication or form) (Include ZIP Code)
Use Part II (reverse) for Repair Parts and
Special Tool Lists (RPSTL) and Supply
Catalogs/Supply Manuals (SC/SM).
DATE
FROM:
(Activity and location) (Include ZIP Code)
PART I - ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS
PUBLICATION/FORM NUMBER DATE TITLE
ITEM PAGE
PARA-
GRAPH
LINE
FIGURE
NO.
TABLE RECOMMENDED CHANGES AND REASON
TYPED NAME, GRADE OR TITLE
DA FORM 2028, FEB 74
TELEPHONE EXCHANGE/AUTOVON,
PLUS EXTENSION
SIGNATURE
REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED.
TO:
(Forward to proponent of publication or form) (Include ZIP Code)
FROM:
(Activity and location) (Include ZIP
Code)
DATE
PART II- REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS
PUBLICATION/FORM NUMBER DATE TITLE
PAGE
NO.
COLM
NO.
LINE
NO.
NATIONAL STOCK
NUMBER
REFERENCE
NO.
FIGURE
NO.
ITEM
NO.
TOTAL NO.
OF MAJOR
ITEMS
SUPPORTED
RECOMMENDED
ACTION
PART III - REMARKS
(Any general remarks or recommendations, or suggestions for improvement of publications and
blank forms. Additional blank sheets may be used if more space is needed.)
TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON,
PLUS EXTENSION
SIGNATURE
APD V4.00
RECOMMENDED CHANGES TO PUBLICATIONS AND
BLANK FORMS
For use of this form, see AR 25-30; the proponent agency is OAASA
TO:
(Forward to proponent of publication or form) (Include ZIP Code)
Use Part II (reverse) for Repair Parts and
Special Tool Lists (RPSTL) and Supply
Catalogs/Supply Manuals (SC/SM).
DATE
FROM:
(Activity and location) (Include ZIP Code)
PART I - ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS
PUBLICATION/FORM NUMBER DATE TITLE
ITEM PAGE
PARA-
GRAPH
LINE
FIGURE
NO.
TABLE RECOMMENDED CHANGES AND REASON
TYPED NAME, GRADE OR TITLE
DA FORM 2028, FEB 74
TELEPHONE EXCHANGE/AUTOVON,
PLUS EXTENSION
SIGNATURE
REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED.
TO:
(Forward to proponent of publication or form) (Include ZIP Code)
FROM:
(Activity and location) (Include ZIP
Code)
DATE
PART II- REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS
PUBLICATION/FORM NUMBER DATE TITLE
PAGE
NO.
COLM
NO.
LINE
NO.
NATIONAL STOCK
NUMBER
REFERENCE
NO.
FIGURE
NO.
ITEM
NO.
TOTAL NO.
OF MAJOR
ITEMS
SUPPORTED
RECOMMENDED
ACTION
PART III - REMARKS
(Any general remarks or recommendations, or suggestions for improvement of publications and
blank forms. Additional blank sheets may be used if more space is needed.)
TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON,
PLUS EXTENSION
SIGNATURE
APD V4.00
RECOMMENDED CHANGES TO PUBLICATIONS AND
BLANK FORMS
For use of this form, see AR 25-30; the proponent agency is OAASA
TO:
(Forward to proponent of publication or form) (Include ZIP Code)
Use Part II (reverse) for Repair Parts and
Special Tool Lists (RPSTL) and Supply
Catalogs/Supply Manuals (SC/SM).
DATE
FROM:
(Activity and location) (Include ZIP Code)
PART I - ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS
PUBLICATION/FORM NUMBER DATE TITLE
ITEM PAGE
PARA-
GRAPH
LINE
FIGURE
NO.
TABLE RECOMMENDED CHANGES AND REASON
TYPED NAME, GRADE OR TITLE
DA FORM 2028, FEB 74
TELEPHONE EXCHANGE/AUTOVON,
PLUS EXTENSION
SIGNATURE
REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED.
TO:
(Forward to proponent of publication or form) (Include ZIP Code)
FROM:
(Activity and location) (Include ZIP
Code)
DATE
PART II- REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS
PUBLICATION/FORM NUMBER DATE TITLE
PAGE
NO.
COLM
NO.
LINE
NO.
NATIONAL STOCK
NUMBER
REFERENCE
NO.
FIGURE
NO.
ITEM
NO.
TOTAL NO.
OF MAJOR
ITEMS
SUPPORTED
RECOMMENDED
ACTION
PART III - REMARKS
(Any general remarks or recommendations, or suggestions for improvement of publications and
blank forms. Additional blank sheets may be used if more space is needed.)
TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON,
PLUS EXTENSION
SIGNATURE
APD V4.00
TM 9-6115-642-10
By Order of the Secretary of the Army:
Official:
JOYCE E. MORROW
Administrative Assistant to the
Secretary of the Army
1024303
GEORGE W. CASEY, JR
General, United States Army
Chief of Staff
By Order of the Secretary of the Air Force:
NORTON A. SCHWARTZ
Official:
DONDALD J. HOFFMAN
General, United States Air Force
Commander, AFMC
By Order of the Marine Corps:
General, United States Air Force
Chief of Staff
M.A. MICUCCI
Product Group Director, PG-15
Ground Transportation Engineer Systems
Marine Corps System Command
Army Distribution:
To be distributed in accordance with the initial distribution number (IDN) 255243 requirements for TM 9-6115-642-10.
Marine Corps Distribution:
To be distributed in accordance with PCN 184 092471 00.
PIN: 071026-000
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