ARMY TM AIR FORCE TO-35C NAVY NAVFAC P

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AIR FORCE TO-35C TECHNICAL MANUAL Operator And Unit Maintenance Manual GENERATOR SET, DIESEL ENGINE DRIVEN, TACTICAL SKID MTD, 15 KW, 3 PHASE, 4 WIRE, 120/208 AND 240/416 VOLTS DOD MODEL CLASS
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AIR FORCE TO-35C TECHNICAL MANUAL Operator And Unit Maintenance Manual GENERATOR SET, DIESEL ENGINE DRIVEN, TACTICAL SKID MTD, 15 KW, 3 PHASE, 4 WIRE, 120/208 AND 240/416 VOLTS DOD MODEL CLASS HERTZ NSN MEP-004A MEP-103A MEP-113A UTILITY PRECISE PRECISE 50/ / INCLUDING OPTIONAL KITS DOD MODEL NOMENCLATURE NSN MEP-005-AWF WINTERIZATION KIT, FUEL BURNING MEP-005-AWE WINTERIZATION KIT, ELECTRIC MEP-004-ALM LOAD BANK KIT MEP-005-AWM WHEEL MOUNTING KIT APPLICATIONS KIT MEP-015-ASK ACOUSTIC SUPPRESSION KIT DISTRIBUTION STATEMENT A: Approved for public release; distribution Is unlimited This manual supersedes TM , 31 January 1975, including all changes. HEADQUARTERS, DEPARTMENTS OF THE ARMY, AIR FORCE AND NAVY 30 July 1993 NAVY NAVFACP CHANGE NO. 2 HEADQUARTERS, DEPARTMENTS OF THE ARMY, THE AIR FORCE, AND THE NAVY WASHINGTON D.C., 31 MARCH 1997 OPERATOR AND UNIT MAINTENANCE MANUAL GENERATOR SET, DIESEL ENGINE DRIVEN, TACTICAL SKID MTD, 15 KW, 3 PHASE, 4 WIRE, 120/208 AND 240/416 VOLTS DOD MODELS CLASS HERTZ NSN MEP-OO4A MEP-103A MEP-113A UTILITY PRECISE PRECISE 50/ / INCLUDING OPTIONAL KITS DOD MODELS NOMENCLATURE NSN MEP-005AWF MEP-005AWE MEP-004ALM MEP-005AWM MEP-015ASK WINTERIZATION KIT, FUEL BURNING WINTERIZATION KIT, ELECTRIC LOAD BANK KIT WHEEL MOUNTING KIT APPLICATIONS KIT ACOUSTIC SUPPRESSION KIT DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited TM /T.O. 35C /NAVFAC P , dated 30 July 1993, 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 i through viii 1-1 and 1-2 A-1 and A-2 E-1 and E-2 FP-13/(FP-14 BLANK) Insert pages i through ix/(x blank) 1-1 and 1-2 A-1 and A-2 E-1 and E-2 FP-13/(FP-14 BLANK) 2. Retain this sheet in front of manual for reference purposes. C2 By Order of the Secretaries of the Army, Air Force, and Navy: Official: DENNIS J. REIMER General, United States Army Chief of Staff JOEL B. HUDSON Administrative Assistant to the Secretary of the Army RONALD R. FOGELMAN General, USAF Chief of Staff HENRY VICCELLIO, JR. General, USAF Commander, Air Force Materiel Command J. E. BUFFINGTON Rear Admiral, CEC, US Navy Commander Navy Facilities Engineering Command DISTRIBUTION: To be distributed in accordance with DA Form E, block no. 6142, requirements for TM C1 CHANGE HEADQUARTERS DEPARTMENTS OF THE ARMY, THE AIR FORCE AND THE NAVY NO. 1 WASHINGTON, D.C., 28 FEBRUARY 1995 OPERATOR AND UNIT MAINTENANCE MANUAL Generator Set, Diesel Engine Driven, Tactical Skid Mounted, 15 kw, 3 Phase, 4 Wire, 120/208 and 240/416 Volts DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited TM /TO 35C /NAVFAC P , 30 July 1993, 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 FP-19/(FP-20 blank) FP-23/(FP-24 blank) Insert pages FP-19/(FP-20 blank) FP-23/FP-24 blank) 2. Retain this sheet in front of manual for reference purposes. TM TO 35C NAVFAC P C1 By Order of the Secretaries of the Army, Air Force, and Navy: Official: MILTON H. HAMILTON GORDON R. SULLIVAN General, United States Army Chief of Staff MILTON H. HAMILTON Administrative Assistant to the Secretary of the Army MERRILL A. McPEAK General, USAF Chief of Staff RONALD W. YATES General, USAF Commander Air Force Materiel Command DAVID E. BOTTORFF Rear Admiral, CEC, US Navy Commander Navy Facilities Engineering Command DISTRIBUTION: To be distributed in accordance with DA Form E, block no.6142, requirements for TM All specific cautions and warnings contained in this manual shall be strictly adhered to. Otherwise, severe injury, death and/or damage to the equipment may result. HIGH VOLTAGE is produced when this generator set is in operation. DEATH or severe burns may result if personnel fail to observe safety precautions. Do not operate this generator set until the ground terminal stud has been connected to a suitable ground. Disconnect the battery ground cable before removing and installing components on the engine or in the electrical control panel system. Do not attempt to service or otherwise make any adjustments, connections or reconnections of wires or cables until generator set is shut-down and completely de-energized. DANGEROUS GASES Batteries generate explosive gas during charging; therefore, utilize extreme caution, do not smoke, or use open flame in vicinity when servicing batteries. Use only Slave Receptacle (SR1) when extra cranking power is required, as incorrect method of slaving could cause arcing at battery terminals. Exhaust discharge contains noxious and deadly fumes. Do not operate generator sets in endosed areas unless exhaust discharge is properly vented to the outside. When filling fuel tank, maintain metal-to-metal contact between filler nozzle and fuel tank. Do not smoke or use an open flame in the vicinity. Use extreme care, should a selenium rectifier malfunction, to avoid inhalation of poisonous fumes. LIQUIDS UNDER PRESSURE are generated as a result of the generator set. Do not expose any part of the body to a high pressure leak in the fuel or hydraulic system of the generator set. Relieve pressure from radiator before removing radiator cap. NOISE operating level of this generator can cause hearing damage. Ear protectors, as recommended by the medical or safety officer, must be worn when working near this set. DAMAGE to the equipment may result if personnel fail to observe the cautions contained in this manual. If generator set is shut down by the operation of a safety device, do not attempt to operate the unit until the cause has been determined and eliminated. HEAT If acoustic suppression kit is installed, do not allow personnel to open or close exhaust discharge door when unit is hot. Serious burns or personnel injury may result. a Hot refueling of generators while they are operating poses 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. Severe Injury, death to personnel and/or damage to the equipment may result. ROTATING PARTS Severe injury may result from contact with moving or rotating components such as fan blades, pulleys, and belts. Do not attempt to service or make any adjustments in the vicinity of such components while generator set is in operation. Do not operate without all guards in place. b TECHNICAL MANUAL OPERATOR AND UNIT MAINTENANCE MANUAL GENERATOR SET, DIESEL ENGINE DRIVEN, TACTICAL SKID MTD, 15 KW, 3 PHASE, 4 WIRE, 120/208 AND 240/416 VOLTS DOD MODELS CLASS HERTZ NSN MEP-OO4A MEP-103A MEP-113A UTILITY PRECISE PRECISE 50/ / INCLUDING OPTIONAL KITS DOD MODELS NOMENCLATURE NSN MEP-005AWF MEP-005AWE MEP-004ALM MEP-005AWM MEP-015ASK WINTERIZATION KIT, FUEL BURNING WINTERIZATION KIT, ELECTRIC LOAD BANK KIT WHEEL MOUNTING KIT APPLICATIONS KIT ACOUSTIC SUPPRESSION KIT 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. Mail your letter or DA Form 2028 (Recommended Changes to Publications and Blank Forms), or DA Form located in the back of this manual directly to: Commander, US Army Aviation and Troop Command, ATTN: AMSAT-I-MP, 4300 Goodfellow Blvd., St. Louis, MO A reply will be furnished directly to you. For AIR FORCE, Submit AFTO Form 22 directly to: COMMANDER, SACRAMENTO AIR LOGISTICS CENTER, Al-TN: TILBA MCCLELLAN AFB, CA For Navy, mail comments to the Commander, Naval Construction Battalion Center, ATTN: Code , Bldg. 1443, Port Hueneme, CA DISTRIBUTION STATEMENT A. Approved for public release, distribution is unlimited. Change 2 i TABLE OF CONTENTS HOW TO USE THIS MANUAL... CHAPTER 1 Section I. Section ii. Section iii. CHAPTER 2 Section I. Section ii. Section iii. Section IV. Section V. Section VI. CHAPTER 3 Section I. Section Ii. Section III. CHAPTER 4 Section I. Section ii. Section iii. Section IV. Section V. Section VI. Section VII. Section VIII. Section IX. Section X. Section Xl. Section XII. Section XIII. Section XIV. Section XV. Section XVI. Section XVII. INTRODUCTION GENERAL INFORMATION EQUIPMENT DESCRIPTION AND DATA Page PRINCIPLES OF OPERATION OPERATING INSTRUCTIONS OPERATING PROCEDURES OPERATION UNDER UNUSUAL CONDlTlONS OPERATION UNDER BATTLE CONDITIONS OPERATION OF ANCILLARY EQUIPMENT PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) MOVEMENT TO A NEW WORK SITE OPERATOR MAINTENANCE INSTRUCTIONS LUBRICATION INSTRUCTIONS OPERATOR S MAINTENANCE INSTRUCTIONS OPERATOR TROUBLESHOOTING UNIT MAINTENANCE INSTRUCTIONS SERVICE UPON RECEIPT OF EQUIPMENT REPAIR PARTS; SPECIAL TOOLS, TEST, MEASUREMENT, AND DIAGNOSTIC EQUIPMENT (TMDE); AND SPECIAL SUPPORT EQUIPMENT SPECIAL LUBRICATION INSTRUCTIONS PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) UNIT TROUBLESHOOTING RADIO INTERFERENCE SUPPRESSION UNIT MAINTENANCE OF THE ENGINE ELECTRICAL SYSTEM UNIT MAINTENANCE OF THE ENGINE FUEL SYSTEM UNIT MAINTENANCE OF THE ENGINE COOLING SYSTEM UNIT MAINTENANCE OF THE ENGINE LUBRICATION SYSTEM UNIT MAINTENANCE OF THE HYDRAULIC SYSTEM UNIT MAINTENANCE OF THE INTAKE AND EXHAUST SYSTEMS AND BREATHER TUBE UNIT MAINTENANCE OF THE ENGINE ASSEMBLY UNIT MAINTENANCE OF THE GENERATOR SET CONTROLS UNIT MAINTENANCE OF THE GENERATOR ELECTRICAL SYSTEM UNIT MAINTENANCE OF THE GENERATOR ASSEMBLY UNIT MAINTENANCE OF THE HOUSING AND SKID BASE ASSEMBLIES i ii Change 2 ARMY TM TABLE OF CONTENTS - Continued Page Section XVIII. TOOL STOWAGE BOX Section XIX. Section XX. AUXILIARY FUEL LINE... PARALLELING CABLE CHAPTER 5 MATERIAL USED IN CONJUNCTION WITH THE GENERATOR SET Section I. GENERAL Section II. Section Ill. Section IV. Section V. Section VI. Section VII. Appendix A FUEL BURNING WINTERIZATION KlT... ELECTRIC WINTERIZATION KIT... WHEEL MOUNTING KIT... LOAD BANK KIT... APPLICATIONS KIT... ACOUSTIC SUPPRESSION KIT... REFERENCES) A-1 Appendix B MAINTENANCE ALLOCATION CHART (MAC)... B-1 Appendix C REPAIR PARTS AND SPECIAL TOOLS LIST... C-1 Appendix D EXPENDABLE AND DURABLE ITEMS LIST... D-1 Appendix E ADDITIONAL AUTHORIZATION LIST... E-1 LIST OF ILLUSTRATIONS Page Engine Generator Set, Right-Front, Three-Quarter View Engine Generator Set, Left-Rear, Three-Quarter View Acoustic Suppression Kit Engine Generator Set, Right-Front, Three-Quarter Internal View Engine Generator Set, Left-Rear, Three-Quarter Internal View Engine Starting System Fuel System Diagram Engine Cooling System Engine Lubrication System Air Intake and Exhaust System Output Supply System Hydraulic System Diagram Electra- Hydraulic Governor Equipped Precise Sets Only) Generator Set Controls and Instruments Installation Plan Ground Connections Load Terminal Board Assembly Parallel Connection Change 2 iii LIST OF ILLUSTRATIONS - Continued Page Paralleling for Load Transfer... Voltage Reconnection Board... Starting the Generator Set (Sheet 1 of 3)... Stopping the Generator Set... Operating the Fuel Burning Winterization Kit... Operating the Electric Winterization Kit... Using the Wheel Mounting Kit... Operating the Load Bank... Applications Kit Components... Acoustic Suppression Kit... Inspecting the Breather and Breather Tube... Inspecting the Muffler... Inspecting the Engine Air Cleaner... Inspecting and Servicing Fuel Strainer and Filter Housing... Main Fuel Tank Inspection and Service... Servicing the Engine Oil Filter... Battery Installation... Slave Receptacle, Removal and Installation... Starter Assembly, Removal... Starter Brushes Replacement... Starter Solenoid Replacement... Starter Assembly Removal... Starter Brushes Replacement (effective with serial no. KZ00001 through KZ01226 and RZ00001 and up) Starter Solenoid Replacement (effective with serial no. KZ00001 through KZ01226 and RZ60001 and up) Battery Charging Alternator Removal and Installation... Day Tank Fuel Level, Low Fuel Cutoff Switch, Fuel Solenoid Valve and Rectifier Assembly, Removal and Installation... Fuel Transfer Pumps, Service and Replacement... Fuel Strainer and Filter Assembly, Removal and Installation... Secondary Fuel Filter, Disassembly and Reassembly... Fuel Injection Nozzle Holders and Lines, Exploded View Alternator Test Leads Attachment... Alternator Test Circuit Fuel Strainer and Filter Housing, Disassembly and Reassembly Day Tank Assembly, Removal and Installation Secondary Fuel Filter Assembly, Removal and Installation iv Change 2 LIST OF ILLUSTRATIONS - Continued Page l Fuel Lines and Fittings, Exploded View (Sheet 1 of 2) Start Aid Assembly, Removal and Installation Grille, Radiator, and Shutter Assembly, Exploded View Radiator Hose Replacement Water Pump, Cooling Fan and V-Belt, Removal and Installation Coolant Thermostat, Removal and Installation Lubrication Oil Filter Assembly, Removal and Installation Hydraulic Sump and Filter Service Servicing the Hydraulic Actuator Unit Filter Hydraulic Lines and Fittings, Exploded View Servicing the Engine Air Cleaner Air Cleaner Assembly, Exploded View Muffler, Exploded View Breather and Breather Tube, Exploded View Intake Manifold, Removal and Installation Exhaust Manifold, Removal and Installation Rocker arm assembly inspection and valve tappet clearance adjustment Control Cubicle Assembly, Exploded View (Sheet 1 of 3) Volts-Amps Transfer Switch Schematic Diagram Fault Locating Indicator Lamp and Fuse Replacement Fault Locating Indicator, Exploded View (Sheet 1 of 2) Manual Speed Control, Exploded View DC Circuit Breaker, Removal and Installation Load Measuring Unit, Removal and Installation Voltage Reconnection Board, Removal and Installation Main Load Contactor, Removal Terminal Clip Replacement Convenience Receptacle and Circuit Breaker, Removal and Installation Paralleling Receptacles, Removal and Installation Housing Assembly, Exploded View (Sheet 1 of 2) Plate and Sleeve Assembly, Exploded View Tool Stowage Box Repair of Auxiliary Fuel Line Repair of Paralleling Cable Fuel Burning Winterization Kit Installation (Sheet 1 of 2) Fuel Burning Winterization Kit Heater Assembly, Inspection and Service Fuel Burning Winterization Kit Heater Control Assembly Maintenance Change 2 v LIST OF ILLUSTRATIONS - Continued Page FO-1 FO-1 FO-1 FO-1 FO-2 FO-3 FO-4 FO-5 FO-6 FO-7 FO-8 FO-9 FO-10 Fuel Burning Winterization Kit Heater Assembly Maintenance Electric Winterization Kit Installation (Sheet 1 of 2) Electric Winterization Kit Control Assembly Indicator Lamp Fuse Replacement Electric Wintetization Kit Control Assembly, Exploded View Electric Winterization Kit Wiring Harness, Dwg. No Wheel Mounting Kit, Front Axle and Tow Bar Assembly, Exploded View Wheel Mounting Kit, Wheels and Brakes, Exploded View Load Bank Installation Load Bank Assembly, Exploded View Load Bank Wiring Diagram, Dwg, No (Sheet 1 of 2) Load Bank Schematic Diagram, Dwg. No Remote Functions Assembly Applications Kit Cable Harness Assembly Installation (Right Side) Applications Kit Cable Harness Assembly Installation (Left Side) Roof Stiffeners, Sealing Angle, Gil Drain, Isolators, Bottom Panel Tray Assembly, and Trailer Brackets Acoustic Suppression Kit Major Components AC and DC, 15 and 30 KW, 50/60 and 400 Hz, Precise and Utility, Wiring Diagram, Dwg. No (Sheet 1 of 4)... FP-1/FP-2 AC and DC, 15 and 30 KW, 50/60 and 400 Hz, Precise and Utility, Wiring Diagram, Dwg. No (Sheet 2 of 4)... FP-3/FP-4 AC and DC, 15 and 30 KW, 50/60 and 400 Hz, Precise and Utility Wiring Diagram, Dwg. No (Sheet 3 of 4)... FP-5/FP-6 AC and DC, 15 and 30 KW, 50/60 and 400 Hz, Precise and Utility, Wiring Diagram, Dwg. No (Sheet 4 of 4)... FP-7/FP-8 AC Schematic Diagram, 15 and 30 KW, Precise Generator Sets, Dwg. No DC Schematic Diagram, 15 and 30 KW, Precise Generator Sets, Dwg.No AC Schematic Diagram, 15 and 30 KW, Utility Generator Sets, Dwg. No FP-13/FP-14 DC Schematic Diagram, 15 and 30 KW, Utility Generator Sets, Dwg. No FP-15/FP-16 DC Schematic Diagram FP-17/FP-18 Troubleshooting Diagram, DC, 15 and 30 KW, 50/60 and 400 Hz, DOD Generator Sets, Tactical Precise and Tactical Utility FP-19/FP-20 Troubleshooting Diagram, AC, 15 and 30 KW, 50/60 and 400 Hz, DOD Generator Sets, Precise and Utility FP-21/FP-22 Troubleshooting Diagram, DC, 15Kw, 400 Hz, DOD Generator Sets, Precise, Electric Governed Troubleshooting Diagram, AC, 15w, 400 Hz, DOD Generator Sets, Precise, Electric Governed FP-9/FP-10 FP-11/FP-12 FP-23/FP-24 FP-25/FP-26 vi Change 2 LIST OF TABLES Page Differences in Performance Characteristics Freezing Points, Composition and Specific Gravities of Military Anti-freeze Materials Operator Preventive Maintenance Checks and Services Operator Troubleshooting Unit Preventive Maintenance Checks and Services Unit Troubleshooting Specific Gravity Temperature Corrections State of Charge With Specific Gravity Corrected to 805F Alternator Voltages at Ambient Temperature Operator Preventive Maintenance Checks and Services Unit Preventive Maintenance Checks and Services for Fuel Burning Winterization Kit Operator Troubleshooting For Fuel Burning Winterization Kit Unit Troubleshooting For Fuel Burning Winterization Kit Operator Preventive Maintenance Checks and Services For Electric Winterization Kit Unit Preventive Maintenance Checks and Services For Electric Winterization Kit Operator Troubleshooting for Electric Winterization Kit Unit Troubleshooting for Electric Winterization Kit Operator Preventive Maintenance Checks and Services for Wheel Mounting Kit Unit Preventive Maintenance Checks and Services for Wheel Mounting Kit Operator Troubleshooting For Wheel Mounting Kit Unit Troubleshooting For Wheel Mounting Kit Operator Preventive Maintenance Checks and Services for Load Bank Unit Preventive Maintenance Checks and Services for Load Bank Unit Troubleshooting For Load Bank Unit Troubleshooting For Applications Kit Change 2 vii NAVY NAVFAC P HOW TO USE THIS MANUAL This manual provides information for use in operating and maintaining the generator set Maintaining the generator set includes preventive maintenance checks and services, observation of symptoms d trouble, troubleshooting procedures, and maintenance procedures to coned a malfunction. You must familiarize yourself with the maintenance procedures before beginning the maintenance tasks. Any maintenance task that is not described within this manual is considered a task that must be performed by a higher level of maintenance. To help you become familiar with this new manual as quickly as possible, spend some time looking through the pages. The manual has a new look that is very different from the look of the manuals you ve been using. You ll find that it s a lot easier to use and you ll be able to find what you re looking for a lot faster. We eliminated many words and put in illustrations to show you how to repair, replace, inspect, test, or service those item(s) and component(s) that are the responsibility of the Operator or Unit level technician. The following instructions provide a general description of the entire manual, special features and characteristics, and detailed information on how to use this manual. MANUAL CONTENT 1. This manual consists of the following: a. Cover page index b. Warning pages c. Table of contents d. How to use this manual e. Chapters 1 through 5 f. Appendixes A through E g. Index h. Wiring diagrams and schematics 2. Further explanation of the manual contents follows. a. Chapter 1. Introduction. Contains general information, equipment description and data, along with principles of operation regarding the complete generator set. b. Chapter 2. Operating Instructions. Contains operating instructions, both under normal and unusual conditions, and preventive maintenance checks and services (PMCS). c. Chapter 3. Operator Maintenance Instructions. Contains detailed maintenance procedures for the operator. This chapter also cont
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