TM-9-6115-642-24 Generator Set Tactical Quiet 6 Kw 60/400 Hz (MEP-802A) (MEP-812A) Manual

CHAPTER 1 INTRODUCTION - TM-9-6115-642-24_19
FIGURE   1-1. 1-2 Generator Set, 10 kW, Tactical Quiet
EQUIPMENT IMPROVEMFNT RECCOMMENDATIONS (FIRs).
SECTION Il. EQUIPMENT DESCRIPTION AND DATA
Table 1-1. Tabulated Data - Continued - TM-9-6115-642-24_23
TABLE   1-1.   Tabulated   Data   -   Continued - TM-9-6115-642-24_24
TABLE    1-2.    Performance    Characteristics
SECTION   Ill.   PRINCIPLES   OF   OPERATION - TM-9-6115-642-24_26
FIGURE 1-2. Fault System
Fuel   System - TM-9-6115-642-24_28
FIGURE 1-3. Generator Set Fuel System - TM-9-6115-642-24_29
Engine Lubrication System - TM-9-6115-642-24_30
FIIGURE   1-4.   Generator   Set   Cooling   System
FIGURE 1-5. Engine Cooling System - TM-9-6115-642-24_32
FIGURE   1-6.   Engine   Lubrication   System - TM-9-6115-642-24_33
FIGURE 1-7. Engine Air Intake and Exhaust System - TM-9-6115-642-24_34
FIGURE 1-8. Output Supply System
Generator   Set   Controls
FIGURE   1-9.   Engine   Starting   System - TM-9-6115-642-24_37
Shutdown
FIGURE   1-10.   Governor   Control   System - TM-9-6115-642-24_39
FIGURE   1-11.   Voltage   Regulation   System - TM-9-6115-642-24_40
NATO SlAVE RECEPTACLE - TM-9-6115-642-24_41
FIGURE 1-12. Generator Set Components
CHAPTER   2 UNIT    MAINTENANCE    INSTRUCTIONS
TABLE   2-1.   COOLANT - TM-9-6115-642-24_44
TABLE   2-2.   DIESEL   FUEL
Outdoor   Installation - TM-9-6115-642-24_46
FIGURE 2-1. Minimum Enclosure Clearance Measurements
FIGURE 2-2. BASE MOUNTING MEASUREMENTS - TM-9-6115-642-24_48
FABRICATION/ASSEMBLY OF PARTS
SECTION   Il.   REPAIR   PARTS;   SPECIAL   TOOLS;   TEST,   MEASUREMENT,   AND   DIAGNOSTIC EQUIPMENT   (TMDE);   AND   SPECIAL   SUPPORT   EQUIPMENT
TABLE   2-5.   Unit   Preventive   Maintenance   Checks   and   Services   (PMCS)
TABLE   2-5.   Unit   Preventive   Maintenance   Checks   and   Services   (PMCS)   -   Continued
SECTION   V. TROUBLESHOOTING
SYMPTOM INDEX GENERATOR SET
TABLE   2-6.   UNIT   TROUBLESHOOTING - TM-9-6115-642-24_55
TABLE 2-6. UNIT TROUBLESHOOTING - Continued - TM-9-6115-642-24_56
TABLE   2-6.   UNIT   TROUBLESHOOTING   -   Continued - TM-9-6115-642-24_57
TABLE   2-6.   UNIT   TROUBLESHOOTING   -   Continued - TM-9-6115-642-24_58
TABLE   2-6.   UNIT   TROUBLESHOOTING   -   Continued - TM-9-6115-642-24_59
TABLE   2-6.   UNIT   TROUBLESHOOTING   -   Continued - TM-9-6115-642-24_60
TABLE   2-6.   UNIT   TROUBLESHOOTING   -   Continued - TM-9-6115-642-24_61
TABLE   2-6.   UNIT   TROUBLESHOOTING   -   Continued - TM-9-6115-642-24_62
TABLE   2-6.   UNIT   TROUBLESHOOTING   -   Continued - TM-9-6115-642-24_63
TABLE   2-6.   UNIT   TROUBLESHOOTING   -   Continued - TM-9-6115-642-24_64
TABLE   2-6.   UNIT   TROUBLESHOOTING   -   Continued - TM-9-6115-642-24_65
TABLE   2-6.   UNIT   TROUBLESHOOTING   -   Continued - TM-9-6115-642-24_66
TABLE   2-6.   UNIT   TROUBLESHOOTING   -   Continued - TM-9-6115-642-24_67
SECTION   VI.   RADIO   INTERFERENCE   SUPPRESSION - TM-9-6115-642-24_68
SECTION   VIII.   MAINTENANCE   OF   DC   ELECTRICAL   SYSTEM - TM-9-6115-642-24_69
Figure 2-3. Batteries and Cables
BATTERIES - TM-9-6115-642-24_71
Removal - TM-9-6115-642-24_73
NATO   SLAVE   RECEPTACLE
FIGURE 2-4. NATO Slave Receptacle and Cables - TM-9-6115-642-24_75
Removal - TM-9-6115-642-24_76
FIGURE 2-5. Battery Charging Alternator
SECTION   IX.   MAINTENANCE   OF   HOUSING - TM-9-6115-642-24_78
FIGURE 2-6. Generator Set Access Doors
CONTROL BOX TOP PANEL - TM-9-6115-642-24_80
FIGURE 2-7. Control Box Top Panel - TM-9-6115-642-24_81
FIGURE 2-7. Control Box Top Panel - TM-9-6115-642-24_82
TOP HOUSING PANEL
FRONT HOUSING SECTION - TM-9-6115-642-24_84
FIGURE 2-8. Generator Set Front Housing Section - TM-9-6115-642-24_85
Inspection - TM-9-6115-642-24_86
REAR HOUSING SECTION
FIGURE 2-9. Generator Set Rear Housing Section - TM-9-6115-642-24_88
Removal - TM-9-6115-642-24_89
Installation - TM-9-6115-642-24_90
CONTROL BOX ASSEMBLY
FIGURE 2-10. Control Box Assembly
Removal - TM-9-6115-642-24_93
In-Line   Fuse   Installation
MALFUNCTION INDICATOR PANEL
DC CONTROL POWER CIRCUIT BREAKE
AC VOLTAGE REGULATOR
FREQUENCY TRANSDUCER.
FREQUENCY TRANSDUCER. (cont)
SHUNT. - TM-9-6115-642-24_100
OVERVOLTAGE    RELAY
FIGURE 2-11. Control Box Components
SHORT CIRCUIT/OVERLOAD RELAY - TM-9-6115-642-24_103
Testing - TM-9-6115-642-24_104
RELAYS - TM-9-6115-642-24_105
RESISTOR - DIODE ASSEMBLY
CONTROL   BOX   HARNESS.
FIGURE 2-13. Diagnostic Connector Pin Positions
TABLE 2-10. Diagnostic Connector Connection Points
PRESS TO TEST INDICATOR LIGHTS
FIGURE 2-14. Control Panel Indicators and Switches
FUEL LEVEL INDICATOR - TM-9-6115-642-24_112
COOLANT   TEMP   INDICATOR
OIL PRESSURE INDICATOR - TM-9-6115-642-24_114
TIME METER (TOTAL HOURS).
BATTERY   CHARGE   AMMETER
FREQUENCY METER (HERTZ). - TM-9-6115-642-24_117
AMMETER (PERCENT RATED CURRENT). - TM-9-6115-642-24_118
AC VOLTMETER (VOLTS AC)
MASTER   SWITCH - TM-9-6115-642-24_120
VOLTAGE ADJUST POTENTIOMETER - TM-9-6115-642-24_121
EMERGENCY STOP SWITCH - TM-9-6115-642-24_122
BATTLE   SHORT   SWITCH
AC CIRCUIT INTERRUPTER SWITCH - TM-9-6115-642-24_124
AM-VM TRANSFER SWITCH - TM-9-6115-642-24_125
CONTROL   PANEL.
CONTROL PANEL FRAME - TM-9-6115-642-24_127
CONTROL BOX SIDE PANELS
FIGURE 2-15. Control Box Housing and Control Panel
CONTROL BOX TRAY
SECTION   XI.   MAINTENANCE   OF   OUTPUT   BOX   ASSEMBLY
CURRENT   TRANSFORMER - TM-9-6115-642-24_132
CRANKING   RELAY - TM-9-6115-642-24_133
FIGURE   2-16. Output   Box   Assembly
PREHEAT RELAY
FIGURE   2-17.   Pre-Heat   Relay   Terminals
SECTION   XII.   MAINTENANCE   OF   AIR   INTAKE   AND   EXHAUST   SYSTEM - TM-9-6115-642-24_137
AIR RESTRICTION INDICATOR - TM-9-6115-642-24_138
FIGURE   2-18.   Muffler - TM-9-6115-642-24_139
AIR CLEANER ELEMENT
FIGURE   2-19.   Air   Cleaner   Assembly - TM-9-6115-642-24_141
SECTION   XIII.   MAINTENANCE   OF   COOLANT   SYSTEM
RADIATOR - TM-9-6115-642-24_143
UPPER COOLANT HOSE
FIGURE 2-20. Radiator Assembly and Cooling System
COOLANT RECOVERY SYSTEM - TM-9-6115-642-24_146
COOLING   FAN
FAN BELT - TM-9-6115-642-24_148
SECTION XIV. MAINTENANCE OF FUEL SYSTEM
LOW FUEL LEVEL/AUXILIARY FUEL PUMP FLOAT SWITCH
FUEL FLOAT MODULE.
LOW PRESSURE FUEL LINES
FUEL TANK FILLER NECK
FIGURE 2-21. Fuel Tank, Switches, and Auxiliary Fuel Pump
FUEL TANK
AUXILIARY FUEL PUMP - TM-9-6115-642-24_156
FUEL TRANSFER PUMP.
FUEL FILTER/WATER SEPARATOR ASSEMBLY. - TM-9-6115-642-24_158
FIGURE 2-22 Fuel Filter/Water Separator and Transfer Pump
FUEL FILTER/WATER SEPARATOR ELEMENT - TM-9-6115-642-24_160
ENGINE OIL DRAIN LINE
FIGURE   2-23.   Engine   Oil   Drain   Line - TM-9-6115-642-24_162
FREQUENCY ADJUST CONTROL CABLE ASSEMBLY
LOW OIL PRESSURE SWITCH
FIGURE 2-25. Engine Related Switches and Senders
OIL PRESSURE SENDER - TM-9-6115-642-24_166
COOLANT TEMPERATURE SENDER - TM-9-6115-642-24_167
COOLANT HIGH TEMPERATURE SWITCH.
MAGNETIC PICKUP
FUEL   SOLENOID
DEAD CRANK SWITCH - TM-9-6115-642-24_171
SECTION   XVII.   MAINTENANCE   OF   LOAD   OUTPUT   TERMINAL   BOARD   ASSEMBLY - TM-9-6115-642-24_172
FIGURE   2-26. Load Output Terminal Board Assembly
Inspection - TM-9-6115-642-24_174
LOAD OUTPUT TERMINALS - TM-9-6115-642-24_175
VARISTORS - TM-9-6115-642-24_176
SECTION XVIII. PREPARATION FOR SHIPMENT AND STORAGE
CHAPTER   3 GENERAL    MAINTENANCE    INSTRUCTIONS - TM-9-6115-642-24_178
SYMPTOM INDEX GENERATOR   SET
TABLE   3-1.   DIRECT   SUPPORT   TROUBLESHOOTING - TM-9-6115-642-24_180
TABLE 3-1. DIRECT SUPPORT TROUBLESHOOTING - Continued - TM-9-6115-642-24_181
TABLE 3-1. DIRECT SUPPORT TROUBLESHOOTING - Continued - TM-9-6115-642-24_182
TABLE 3-1. DIRECT SUPPORT TROUBLESHOOTING - Continued - TM-9-6115-642-24_183
TABLE 3-1. DIRECT SUPPORT TROUBLESHOOTING - Continued - TM-9-6115-642-24_184
SECTION   Ill.   REMOVAL   AND   INSTALLATION   OF   MAJOR   COMPONENTS - TM-9-6115-642-24_185
ENGINE AND GENERATOR ASSEMBLY
Installation - TM-9-6115-642-24_187
FIGURE   3-1.   Engine   and   Generator   Assembly   Removal - TM-9-6115-642-24_188
Installation (cont) - TM-9-6115-642-24_189
Installation (cont) - TM-9-6115-642-24_190
ENGINE REPLACEMENT - TM-9-6115-642-24_191
CHAPTER 4 DIRECT SUPPORT MAINTENANCE INSTRUCTIONS - TM-9-6115-642-24_192
Disassembly
Figure 4-2. Brush Test
Figure 4-4. Rectifier Bridge Test
Figure 4-6. Rotor Test (Both Models)
Figure 4-7. Alternator Assembly (8EM3005CA) (Sheet 1 of 2)
Figure 4-7. Alternator Assembly (8MR3005CA) (Sheet 2 of 2)
Assembly - TM-9-6115-642-24_199
Assembly - TM-9-6115-642-24_200
Figure 4-9. Performance Test Circuit
SECTION   II.   MAINTENANCE   OF   CONTROL   BOX   ASSEMBLY
FIGURE   4-10.   Control   Box   Harness - TM-9-6115-642-24_203
SECTION   Ill.   MAINTENANCE   OF   OUTPUT   BOX   ASSEMBLY - TM-9-6115-642-24_204
OUTPUT   BOX/ENGINE   HARNESS - TM-9-6115-642-24_205
Inspection - TM-9-6115-642-24_206
FIGURE   4-11.   Output   Box   Assembly - TM-9-6115-642-24_207
CURRENT   TRANSFORMER - TM-9-6115-642-24_208
FIGURE   4-12.   Testing   Current   Transformer - TM-9-6115-642-24_209
FIGURE   4-13.   Frequency   Droop   Adjustment
SECTION   VI.   MAINTENANCE   OF   SKID   BASE
FIGURE   4-14.   Skid   Base
FIGURE   4-15.   Generator   Schematic
ADJUSTMENTS AND TESTS - TM-9-6115-642-24_214
FIGURE 4-17. Testing Rotating Rectifiers
FIGURE 4-18. Testing Exciter Field
FIGURE 4-20. Testing Rotor for an Open or Shorted Windings.
FIGURE   4-21.   Testing   Rotor   for   Grounds - TM-9-6115-642-24_218
FIGURE   4-22.   Testing   Stator   Windings - TM-9-6115-642-24_219
Inspection. - TM-9-6115-642-24_220
Assembly/Installation
FIGURE 4-24. Generator Assembly (MEP-803A)
Disassembly - TM-9-6115-642-24_223
Assembly - TM-9-6115-642-24_224
Installation - TM-9-6115-642-24_225
FIGURE   4-25.   Generator   Assembly   (MEP-813A)
APPENDIX A. REFERENCES
APPENDIX   B. MAINTENANCE    ALLOCATION    CHART
EXPLANATION OF COLUMNS IN THE MAC, SECTION II - TM-9-6115-642-24_231
SECTION II. MAINTENANCE ALLOCATION CHART - TM-9-6115-642-24_232
SECTION   Il.   MAINTENANCE   ALLOCATION   CHART   -   Continued - TM-9-6115-642-24_233
SECTION   Il.   MAINTENANCE   ALLOCATION   CHART   -   Continued - TM-9-6115-642-24_234
SECTION   Il.   MAINTENANCE   ALLOCATION   CHART   -   Continued - TM-9-6115-642-24_235
SECTION   Il.   MAINTENANCE   ALLOCATION   CHART   -   Continued - TM-9-6115-642-24_236
SECTION   Il.   MAINTENANCE   ALLOCATION   CHART   -   Continued - TM-9-6115-642-24_237
SECTION   Ill.   SPECIAL   TOOLS   AND   SPECIAL   TEST   EQUIPMENT
APPENDIX   C EXPENDABLE/DURABLE   SUPPLIES   AND   MATERIALS   LIST - TM-9-6115-642-24_240
SECTION   II.   TABULAR   LIST - TM-9-6115-642-24_241
APPENDIX   D FABRICATION/ASSEMBLY   OF   PARTS
FIGURE   D-1.   Cable   Assembly,   Battery   (P/N:   88-20312)
FIGURE   D-2.   Cable   Assembly,   Battery   (P/N:   88-20313) - TM-9-6115-642-24_244
FIGURE   D-3.   Cable   Assembly,   Battery   (P/N:   88-20314)
FIGURE   D-4.   Cable   Assembly,   Battery   (PIN:   88-20315)
FIGURE D-5. Cable Assembly, Battery (P/N: 88-20316)
FIGURE D-6. Cord, Load Wrench (P/N: 88-22460)
FIGURE D-7. Diode Assembly (P/N: 88-22418-1)
FIGURE D-8. Holder, Control Panel (P/N: 88-20134)
FIGURE D-9. Insulation, Air Discharge (P/N: 88-20294)
FIGURE D-10. Insulation, Air Intake (P/N: 88-20295)
FIGURE  D-11. Insulation, Skid (P/N: 88-20523)
FIGURE D-12. Pump Assembly, Fuel (P/N: 88-20479)
FIGURE D-13. Pump Assembly, Fuel (P/N: 88-22546)
FIGURE D-14. Solenoid Assembly, Fuel (P/N: 88-20482)
FIGURE D-15. Transducer Assembly (P/N: 88-20480)
FIGURE D-16. Wire, Varistor (P/Ns: 88-20305-1 through 88-20305-4)
TABLE D-1. INCHES TO METRIC CONVERSION

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