MEP-002A_generator_diesel_user_TM5-6115-584-12_1977.pdf

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MEP-002A_generator_diesel_user_TM5-6115-584-12_1977.pdf

ARMY TECHNICAL MANUAL T M 5 - 6 1 1 5 - 5 8 4 - 1 2 NAVY PUBLICATION N A V F A C P - 8 - 6 2 2 - 1 2 AIR FORCE TECHNICAL ORDER T O 3 5 C 2 - 3 - 4 5 6 - 1 MARlNE CORPS TECHNICAL MANUAL T M 0 5 6 8 2 C - 1 2 T E C H I N C A L M A N U A L OPERATOR AND ORGANIZATIONAL MAINTENANCE MANUAL G E N E R A T O R S E T , D I E S E L E N G I N E D R I V E N , T A C T I C A L S K I D M T D 5 K W , 1 P H A S E - 2 WIRE, 1 PHASE - 3 WIRE, 3 PHASE - 4 WIRE, 120, 120/240 AND 120/208 VOLTS D O D M O D E LC L A S SH E R T ZN S N M E P - 0 0 2 AU T I L I T Y6 0 6 1 1 5 - 0 0 - 4 6 5 - 1 0 4 4 This copy is a reprint which includes current pages from Change 1 through 11. PUBLISHED UNDER THE AUTHORITY OF THE DEPARTMENTS OF THE ARMY, AIR FORCE, NAVY AND HEADQUARTERS U.S. MARINE CORPS JULY 1977 ARMY TM 5-6115-584-12 NAVFAC P-8-622-12 AIR FORCE TO-35C2-3-456-1 MARINE CORPS TM-05682C-12 C 1 1 CHANGEHEADQUARTERS DEPARTMENTS OF THE ARMY, NAVY AND AIR FORCE AND HEADQUARTERS U.S. MARINE CORPS NO. 11 WASHINGTON, D.C., 27 APRIL 1992 Operator and Organizational Maintenance Manual GENERATOR SET, DIESEL ENGINE DRIVEN, TACTICAL SKID MTD, 5KW 1 PHASE-2 WIRE, 1 PHASE-3 WIRE, 3 PHASE-4 WIRE 120, 120/240 AND 120/208 VOLTS Approved for public release; Distribution is unlimited TM 5-6115-584-12, NAVFAC P-8-622-12, TO 35C2-3-456-1, TM 05682C-12, 22 July 1977 is changed as follows: 1. The banner page for Change 9 to this manual is numbered incorrectly on the left hand side of the page. The number is changed from 10 to 9. 2. Remove and insert pages as indicated below. New or changed text material is indicated by a vertical bar in the margin. An illustration change is indicated by a miniature pointing hand. Remove pagesInsert pages D-17 and D-18D-17 and D-18 3. Retain this sheet in front of manual for reference purposes. ARMY TM 5-6115-584-12 NAVFAC P-8-622-12 AIR FORCE TO-35C2-3-456-1 MARINE CORPS TM-05682C-12 C 1 1 By Order of the Secretaries of the Army, Air Force, and Navy (Including the Marine Corps): Official: GORDON R. SULLIVAN General, United States Army Chief of Staff MILTON H. HAMILTON Administrative Assistant to the Secretary of the Army 01056 MERRILL A. McPEAK General, USAF Chief of Staff Official: CHARLES C. McDONALD General, USAF Commander Air Force Logistics Command DAVID E. BOTTORFF Rear Admiral, CEC, US Navy Commander Navy Facilities Engineering Command H. E. REESE Deputy for Support Marine Corps Research, Development and Acquisition Command DISTRIBUTION: To be distributed in accordance with DA Form 12-25E, (qty rqr block no. 0856). ARMY NAVY AIR FORCE MARINE CORPS CHANGE No. 6 TM 5-6115-584-12 NAVFAC P-8-622-12 TO-35C2-3-456-1 TM-05682C-12 C 6 HEADQUARTERS DEPARTMENTS OF THE ARMY, AIR FORCE, NAVY AND HEADQUARTERS, U.S. MARINE CORPS WASHINGTON, D.C., 26 March 1990 Operator and Organizational Maintenance Manual GENERATOR SET, DIESEL ENGINE DRIVEN, TACTICAL SKID MTD 5 KU, 1 PHASE-2 WIRE, 1 PHASE-3 WIRE 3 PHASE-4 WIRE, 120, 120/240 AND 120/208 VOLTS DOD MODEL CLASS HERTZNSN MEP-002A UTILITY 606115-00-465-1044 Approved for public release; distribution is unlimited. TM 5-6115-584-12, NAVFAC P-8-622-12, TO 35C2-3-456-1, TM 05682C-12, 22 July 1977, is changed as follows: 1.Remove and insert pages as indicated below. New or changed text material is indicated by a vertical bar in the margin. An illustration change is indicated by a miniature pointing hand. Remove pages 1-1 and 1-2 - 1-5 and 1-6 1-11/1-12 2-3 through 2-6 3-1 and 3-2 3-3 and 3-4 3-5 and 3-6 3-9 and 3-10 4-5 and 4-6 4-37 and 4-38 4-41 and 4-42 A-1/A-2 D-9 through D-14 D-17 and D-18 Insert pages 1-2.1/1-2.2 1-5 and 1-6 1-1 and 1-2 1-11/1-12 2-3 through 2-6 3-1 3-4 3-5 and 3-6 3-9 and 3-10 4-5 and 4-6 4-37 and 4-38 4-41 and 4-42 A-1/A-2 D-9 through D-14 D-17 and D-18 2. Retain this sheet in front of manual for reference purposes. 1 DEPARTMENT OF THE ARMY TECHNICAL MANUAL TM 5-6115-584-12 DEPARTMENT OF THE NAVY PUBLICATION NAVFAC P-8-622-12 DEPARTMENT OF THE AIR FORCE TECHNICAL ORDER TO-35C2-3-456-1 MARINE CORPS TECHNICAL MANUAL TM.05682C-12 HEADQUARTERS DEPARTMENTS OF THE ARMY, NAVY, AIR FORCE, SPECIAL TOOLS; SPECIAL TEST, MEASURE- MENT AND DIAGNOSTIC EQUIPMENT AND SPECIAL SUP- PORT EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5.Special Tools and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6.Maintenance Repair Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LUBRICATION INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7.Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS). 4-8.PMCS, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12.Troubleshooting, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13.Malfunctions Not Corrected By Use of the Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RADIO INTERFERENCE SUPPRESSION . . . . . . . . . . . . . . . . . . . . . . . 4-14.General Methods for Proper Suppression . . . . . . . . . . . . . . . . . . . . 4-15.Radio Interference Suppression Components . . . . . . . . . . . . . . . . . MAINTENANCE OF ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . 4-16.Description and Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17.Engine Cooling Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE OF FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18.Description and Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19.Fuel Tank Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20.Fuel Filter Assemblies and Strainer Assembly . . . . . . . . . . . . . . . . 4-21.Electric Fuel Pumps, Fuel Hoses and Auxiliary Solenoid Valve . . 4-22.Auxiliary Fuel Solenoid Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23.Fuel Shut-Off Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE OF ENGINE ELECTRICAL SYSTEM . . . . . . . . . . . . 4-24.Description and Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25.Battery Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26.Engine Starter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27.Battery Charging Alternator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28.Starter Lockout Switch and Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE OF OIL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29.Function and Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30.Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31.Low Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32.Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33.Oil Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE OF CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . Page 4-4 4-4 4-4 4-4 4-4 4-5 4-5 4-6 4-6 4-6 4-10 4-10 4-10 4-12 4-12 4-12 4-16 4-16 4-16 4-17 4-21 4-21 4-21 4-24 4-24 4-24 4-26 4-29 4-31 4-33 4-33 4-33 4-34 4-36 4-37 4-38 4-34.Description and Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35.DC Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38 4-38 iii TM 5-6115-584-12 NAVFAC P-8-622-12 TO-35C2-3-456-1 TM-05682C-12 Section XII. SectionXIII. Section XIV. Section XV. CHAPTER 5 SectionI. SectionII. TABLE OF CONTENTS (CONT) Page MAINTENANCE OF CONTROL SYSTEM (CONT): 4-36. AC Instrumentation System . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37.Load Terminal Board Assembly . . . . . . . . . . . . . . . . . . . . . . . 4-38. Control Cubicle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE OF ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39. Description and Function . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40. Exhaust Muffler Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . 4-41. Air Cleaner Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42. Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43. Intake Manifold Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44. Rocker Arm Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46. Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46. Valve Rocker Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47.Injector Nozzle Assembly and Fuel Lines . . . . . . . . . . . . . . . . . 4-48.Glow Plug Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-49. Oil Drain Hose and Valve . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50. Oil Pan-Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-51. Oil Fill Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-52. Engine Mounting Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE OF GENERATOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 4-53. Description and Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54. (Generator/Exciter Assembly . . . . . . . . . . . . . . . . . . . . . . . . 4-55. Screen-Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE OF SKID-BASE . . . . . . . . . . . . . . . . . . . . . . 4-56. Description and Function . . . . . . . . . . . . . . . . . . . . . . . . . 4-57. Skid-Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MATERIAL USED IN CONJUNCTION WITH DOD STANDARD 5KW DIESEL ENGINE DRIVEN, MODEL MEP-002A . . . . . . . . . . . . . . . . . . . . AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1.General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ACOUSTIC SUPPRESSION KIT. . . . . . . . . . . . . . . . . . . . . . . . . 5-2.Acoustic Suppression Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3.Cover Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4.Top Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5.Left Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6.Right Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7.Rear Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8.Exhaust Plenum Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9.Left Support Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10.Right Support Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11. Front Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12. Side Closure Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13.Rear Closure Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14. Rear Flap Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38 4-41 4-41 4-45 4-45 4-45 4-47 4-47 4-49 4-50 4-50 4-51 4-52 4-52 4-54 4-54 4-54 4-54 4-56 4-56 4-57 4-57 4-57 4-57 4-57 5-1 5-1 5-1 5-2 5-2 5-2 5-8 5-10 5-12 5-14 5-16 5-16 5-18 5-18 5-21 5-21 5-24 ivChange 7 TM 5-6115-584-12 NAVFAC P-8-622-12 TO -35C2-3-456-1 TM-05662C-12 SectionIII. APPENDIX A. APPENDIX B. SectionI. II. III. APPENDIX C. Section I. II. APPENDIX D. SectionI. II. III. IV. INDEX TABLE OF CONTENTS (CONT) Page ACOUSTIC SUPPRESSION KIT REPAIR . . . . . . . . . . . . . . . . . . . . . . 5-26 5-15. 5-16. 5-17. 5-18. 5-19. 5-20. 5-21. 5-21. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26 Panel Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26 Latch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28 Catch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28 Rubber Flap Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28 Hinges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30 Captive Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30 Front Panel Silencer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30 REFERENCESA-1 COMPONENTS OF END ITEM LIST INTRODUCTION INTEGRAL COMPONENTS OF END ITEM B-1 BASIC ISSUE ITEMSB-2 ADDITIONAL AUTHORIZATION LIST INTRODUCTIONC-1 ADDITIONAL AUTHORIZATION SHEETC-1 MAINTENANCE ALLOCATION CHART INTRODUCTIOND-1 MAINTENANCE ALLOCATION CHARTD - 3 TOOLS, TEST AND SUPPORT EQUIPMENT REQUIREMENTSD-18 EXPLANATION OF REFERENCE CODESD-19 INDEX 1 Change 7 iv.1/(iv.2 blank) TM 5-6115-584-12 NAVFAC P-8-622-12 TO-35C2-3-456-1 TM-05682C-12 Reproduction for non-military use of the information or illustrations contained in this publication is not permitted. The policy for military use reproduction is established for the Army in AR 380-5, for the Navy and Marine Corps in OPNAVlNST 5510.1B, and for the Air Force in Air Force Regulation 205-1. LIST OF EFFECTIVE PAGES Insert latest changed pages; dispose of superseded pages in accordance with applicable regulations. NOTE: On a changed page, the portion of the text affected by the latest change is indicated by a vertical line, or other change symbol, in the outer margin of the page. Changes to illustrations are indicated by miniature pointing hands. Changes to wiring diagrams are indicated by shaded areas. Total number of pages in this manual is150 consisting of the following: Page#Change No.No. Warning . . . . . . . . . . . .0 Blank . . . . . . . . . . . . .0 i - vii . . . . . . . . . . . . .0 viii Blank . . . . . . . . . . .0 1-1 - 1-11 . . . . . . . . . . .0 1-12 Blank . . . . . . . . . .0 1-13 - 1-15 . . . . . . . . . .0 1-16 Blank . . . . . . . . . . 0 2-1 - 2-6 . . . . . . . . . . .0 3-1 - 3-27 . . . . . . . . . . .0 3-28 Blank . . . . . . . . . . . 0 4-1 - 4-59 . . . . . . . . . . .0 4-60 Blank . . . . . . . . . . . 0 A-1 . . . . . . . . . . . . . . 0 A-2 Blank . . . . . . . . . . . 0 B-1 . . . . . . . . . . . . . . 0 B-2 Blank . . . . . . . . . . . 0 C-1 - C-19 . . . . . . . . . . 0 C-20 Blank . . . . . . . . . . 0 Index 1 - Index 6 . . . . . . . 0 # Zero in this column indicates an original page. v T M 5 - 6 1

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