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ARMY TECHNICAL MANUAL NAVY PUBLICATION AIR FORCE TECHNICAL ORDER MARINE CORPS TECHNICAL MANUAL

TM5-6115-585-34 NAVFACP-8-262-12 TO-35C2-3-455-2 TM-05684C-34

TECHNICAL

MANUAL

INTERMEDIATE AND

(FIELD)

(DIRECT

AND

GENERAL

SUPPORT)

DEPOT

LEVEL

MAINTENANCE

MANUAL

GENERATOR SET, DIESEL ENGINE DRIVEN, TACTICAL SKID MTD 10KW, 1 PHASE -2 WIRE, 1 PHASE -3 WIRE,3PHASE -4 WIRE, 120, 120/240 AND 120/208 VOLTS DOD MODEL MEP-003A CLASS UTILITY HERTZ 60 NSN 6115-00-465-1030

T h i s

c o p y

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a

r e p r i n t

w h i c h 1

i n c l u d e s 9 .

c u r r e n t

p a g e s

f r o m

C h a n g e s

t h r o u g h

PUBLISHED UNDER THE AUTHORITY OF THE DEPARTMENTS OF THE ARMY, AIR FORCE, NAVY, AND HEADQUARTERS U.S. MARINE CORPS JULY 1977

DEPARTMENT OF THE ARMY TECHNICAL MANUAL DEPARTMENT OF THE NAVY PUBLICATION DEPARTMENT OF THE AIR FORCE TECHNICAL ORDER MARINE CORPS TECHNICAL MANUAL

TM5-6115-585-34 NAVFAC P-8-623-34 TO-35C2-3-455-2 TM-05684C/05685B-34

HEADQUARTERS DEPARTMENTS OF THE ARMY, NAVY, AIR FORCE, & USMC WASHINGTON, D.C. 25 JULY 1977 INTERMEDIATE (FIELD) (DIRECT AND GENERAL SUPPORT) AND DEPOT LEVEL MAINTENANCE MANUAL

GENERATOR SET, DIESEL ENGINE DRIVEN, TACTICAL SKID MTD 10KW, 1 PHASE -2 WIRE, 1 PHASE - 3 WIRE, 3 PHASE - 4 WIRE, 120, 120/240 AND 120/208 VOLTS

DOD MODEL MEP-003A MEP-112A CLASS UTILITY UTILITY HERTZ 60 400 NSN 6115-00-465-1030 6115-00-465-1027

TABLE OF CONTENTS Page LIST OF EFFECTIVE PAGES. . . . . . . . . . . . . . . . LIST OF ILLUSTRATIONS . . . . . . . . . . . . . . . . . LIST OF TABLES..... . . . . . . . . . . . . . INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv v

vi

CHAPTER 1. Section I.

1-1 1-1 1-1 1-1 1-1 1-1 1-1 1-1 1-1 1-1 2-1 2-1 2-1 2-1 2-1 2-5 2-5 2-5 Change 2 i

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. 1-2. 1-3. 1-4. 1-5. Scope . . . . . . . . . . . . . . . . . . . . . . . . Limited Applicability . . . . . . . . . . . . . . . Maintenance Forms and Records . . . . . . . . . Reporting of Errors . . . . . . . . . . . . . . . . Levels of Maintenance Accomplishment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section II.

DESCRIPTION AND TABULATED DATA . . . . . . . . . . . . . . . 1-6. 1-7. Description. . . . . . . . . . . . . . . . . . . . . . . . . . . Tabulated Data . . . . . . . . . . . . . . . . . . . . . . . . .

CHAPTER 2. Section I.

GENERAL MAINTENANCE INSTRUCTIONS . . . . . . . . . . . . . REPAIR PARTS, SPECIAL TOOLS, TEST, MEASUREMENT, AND D I A G N O S I C E Q U I P M E N T ( T M D E), AND S U P P O R T E Q U I P M E N T . 2-1. 2-2. 2-3. Repair Parts . . . . . . . . . . . . . . . . . . . . . . . . . . Tools and Equipment . . . . . . . . . . . . . . . . . . . . . . Fabricated Tools and Equipment . . . . . . . . . . . . . . .

Section

II.

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 2-4. 2-5. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Malfunctions Not Corrected By Use of the Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TM5-6115-585-34 NAVFAC P-8-262-12 TO-35C2-3-455-2 TM-05684C/05685B-34 TABLE OF CONTENTS (CONT) Page Section III. GENERAL MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . 2-6. 2-7. Section IV. General Maintenance . . . . . . . . . . . . . . . . . . . . . . General Maintenance Procedures . . . . . . . . . . . . . . . 2-12 2-12 2-12 2-12 2-12 2-12 2-16 3-1 3-1 3-1 3-1 3-1 3-1 4-1 4-1 4-1 4-1 4-1 5-1 5-1 5-1 5-1 5-1 6-1 6-1 6-1 6-1 6-1 6-1 6-1 6-8 6-8 6-9 6-9 6-9

REMOVAL AND INSTALLATION OF MAJOR COMPONENTS . . . . 2-8. Control Cubicle . . . . . . . . . . . . . . . . . . . . . . . . 2-9. Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . 2-10. Generator Assembly . . . . . . . . . . . . . . . . . . . . . .

CHAPTER 3. Section I.

MAINTENANCE OF COOLING SYSTEM . . . . . . . . . . . . . . . DESCRIPTION AND FUNCTION. . . . . . . . . . . . . . . . . . . . 3-1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section II.

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2. 3-3. Engine Cooling System . . . . . . . . . . . . . . . . . . . . High Temperature Cut Out Switch . . . . . . . . . . . . . .

CHAPTER 4. Section I.

MAINTENANCE OF FUEL SYSTEM . . . . . . . . . . . . . . . . . DESCRIPTION AND FUNCTION. . . . . . . . . . . . . . . . . . . . 4-1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section II.

MAINTENANCE OF FUEL TANK. . . . . . . . . . . . . . . . . . . 4-2. Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHAPTER 5. Section I.

MAINTENANCE OF STARTING SYSTEM . . . . . . . . . . . . . . . DESCRIPTION AND FUNCTION.. . . . . . . . . . . . . . . . . . . 5-1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section II.

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2. Starter Assembly . . . . . . . . . . . . . . . . . . . . . . . .

CHAPTER 6. Section I.

MAINTENANCE OF CONTROL SYSTEM . . . . . . . . . . . . . . . DESCRIPTION AND FUNCTION. . . . . . . . . . . . . . . . . . . . 6-1. 6-2. 6-3. DC Control System . . . . . . . . . . . . . . . . . . . . . . . AC Instrumentation System . . . . . . . . . . . . . . . . . . Voltage Regulator . . . . . . . . . . . . . . . . . . . . . . .

Section

II.

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4. 6-5. 6-6. 6-7. 6-8. 6-9. Control Cubicle . . . . . . . . . . . . . . . . . . . . . . . Generator Set Wiring Harness . . . . . . . . . . . . . . . Voltage Regulator . . . . . . . . . . . . . . . . . . . . . . AC Output Control Box Wiring Harness . . . . . . . . . . . AC Output Control Box Assembly . . . . . . . . . . . . . . AC Output Control Box (Internal Components) . . . . . . . . . . . . .

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TM 5-6115-585-34 NAVFAC P-8-623-34 TO-35C2-3-455-2 TM-05684C/05685B-34 TABLE OF CONTENTS (CONT)

Page

CHAPTER 7. Section I.

MAINTENANCE OF ENGINE. . . . . . . . . . . . . . . . . . . . . DESCRIPTION AND FUNCTION. . . . . . . . . . . . . . . . . . . . 7-1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1 7-1 7-1 7-1 7-1 7-1 7-5 7-6 7-6 7-6 7-8 7-9 7-9 7-10.1 7-13 7-19 7-19 7-19 7-21 7-25 7-25 7-27 7-30 7-41 7-41 8-1 8-1 8-1 8-1 8-1 9-1 9-1 9-1 9-1 9-1 9-1 9-1 9-1 9-1 9-1

Section II.

ENGINE EXTERNAL ASSEMBLY.. . . . . . . . . . . . . . . . . . 7-2. 7-3. 7-4. 7-5. 7-6. 7-7. 7-8. Fuel-Lines . . . . . . . . . . . . . . . . . . . . . . . . . . External Governor Parts and Speed Control Assembly . . . Flywheel and Ring Gear Assembly . . . . . . . . . . . . . Flywheel Housing . . . . . . . . . . . . . . . . . . . . . . Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . Blower Wheel Assembly . . . . . . . . . . . . . . . . . . . Battery Charge Alternator . . . . . . . . . . . . . . . . . . . . . . . . . .

.

Section

III.

ENGINE INTERNAL ASSEMBLIES . . . . . . . . . . . . . . . . 7-8.1. Engine Compression Test . . . . . . . . . . . . . . . . . . 7-9. Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . 7-10. Piston and Connecting Rod . . . . . . . . . . . . . . . . . 7-11. Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . 7-12. Oil Filter Adapter Assembly . . . . . . . . . . . . . . . . 7-13. Oil By-Pass Valve . . . . . . . . . . . . . . . . . . . . . . 7-14. Gear Cover Assembly. . . . . . . . . . . . . . . . . . . . 7-15. Governor Cup. . . . . . . . . . . . . . . . . . . . . . . . 7-16. Camshaft Assembly and Tappets . . . . . . . . . . . . . . 7-17. Crankshaft and Main Block Bearings . . . . . . . . . . . . 7-18. Fuel Injection Pump. . . . . . . . . . . . . . . . . . . . . 7-19. Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . 7-20. Fuel Injector . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . .

CHAPTER 8. Section I.

MAINTENANCE OF GENERATOR ASSEMBLY . . . . . . . . . . . . DESCRIPTION AND FUNCTION . . . . . . . . . . . . . . . . . . . . 8-1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section II

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2. Generator Maintenance . . . . . . . . . . . . . . . . . . . .

CHAPTER 9. Section I.

GENERATOR SET TEST AND INSPECTION AFTER REPAIR OR OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . 9-1. General Information . . . . . . . . . . . . . . . . . . . . . .

Section II.

INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2. 9-3. 9-4. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Cooling System . . . . . . . . . . . . . . . . . . . . . Wiring Harnesses . . . . . . . . . . . . . . . . . . . . . . .

Section III.

OPERATIONAL TEST . . . . . . . . . . . . . . . . . . . . . . . . 9-5. Generator and Generator Control Circuitry . . . . . . . . . . 9-6. Engine Control Circuitry . . . . . . . . . . . . . . . . . . . .

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TM 5-6115-585-34 NAVFAC P-8-623-34 TO-35C2-3-455-2 TM-05684C/05685B-34

TABLE OF CONTENTS (CONT) Page CHAPTER 1 0 . MATERIAL USED IN CONJUNCTION WITH DOD STANDARD GENERATOR SET, 10KW DIESEL ENGINE, MODEL MEP-003A AND MEP-112A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section I I . ACOUSTIC SUPPRESSION KIT INSTALLATION . . . . . . . . . . . . . . . . . 10-2. 10-3. 10-4. 10-5. APPENDIX A . INDEX . . . . . Acoustic Suppression Kit. . . . . . . . . . . . . . . . . Preliminary Procedures. . . . . . . . . . . . . . . . . . Acoustic Suppression Kit Installation . . . . . . . . . Post Installation Procedures . . . . . . . . . . . . . . . ...... . . . . . . . . . . . . . . . . . . . ...... . . . . . . . . . . . . . . . . . . .

10-1 10-1 10-1 10-2 10-2 10-5 10-5 10-16 A-1 INDEX 1

Section I .

REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

...................................................

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TM 5-6115-585-34 NAVFAC P-8-623-34 TO-35C2-3-455-2 TM-05684C/05685B-34

LIST OF ILLUSTRATIONS

Figure Title Page

l­l. 1­1.1 2­1. 2-2. 2-3. 2-4. 3-1. 5-1. 5-2. 5-3. 5-4. 5-5. 5-6. 5-7. 5-8. 5-9. 5-10. 5-11. 5­12. 5-13. 5-14. 6-1. 6-2. 6-3. 6-4. 6-5. 6-5.1. 6-6. 6-6.1. 6-7. 6-8. 6-9. 6-10. 6-11. 7-1. 7-2. 7-3. 7-3.1. 7-4. 7-5. 7-6. 7-7. 7­8. 7-8.1. 7-9. 7-10. 7-11. 7-12. 7-13. 7-14. 7-15. 7-16. 7-17. 7-18. 7-19. 7-20. 7-21.

Generator Set Electrical Schematic (MEP-003A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator Set Electrical Schematic (MEP-l12A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Speed Control Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disconnecting Engine from Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lifting Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lifting Engine and Generator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electric Starter Assembly (STYLE I). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electric Starter Assembly (STYLEII) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pinion Gear Stopper Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Testing Armature for Grounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Testing Armature for Shorted Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Testing Armature for Open Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking Commutator Runout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking Armature Shaft Runout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Testing Brush Spring Tension STYLE I Starter Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Testing Solenoid Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Undercutting Mica . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brush Replacement STYLE I Starter Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking Pinion Clearance STYLE I Starter Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking Pinion Clearance STYLE II Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Cubicle Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator Set Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Cubicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Testing Voltage Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AC Voltage Regulator Schematic (MEP-003A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AC Voltage Regulator Schematic (MEP-112A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AC Output Control Box Wiring Harness (MEP-003A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . AC Output Control Box Wiring Harness (MEP-112A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AC Output Control Box Test Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AC Control Box Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AC Output Control Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AC Output Control Assembly (Switch, Receptacle and Circuit Breaker) . . . . . . . . . . . . . . . Bridge Rectifier AssemblyA-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Injector FueI Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Speed Control Assembly and Governor Control Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Flywheel and Ring Gear Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Governor Linkage Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Timing Port and Port Closing Mark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Measuring Top Dead Center.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Testing Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery Charge Alternator and Blower Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Resistively Loading the Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Testing Engine Compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Head Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Spring Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Seat Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Head Bolt Tightening Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston and Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft Pistons and Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston Ring Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connecting Rod and Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connecting Rod Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Bypass Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Internal Engine Assembly..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-9 1-10.1 2-13 2-14 2-15 2-17 3-2 5-2 5-3 5-4 5-5 5-5 5-5 5-6 5-6 5-7 5-8 5-10 5-10 5-11 5-12 6-2 6-6 6-10 6-12 6-13 6-14 6-14.1 6-14.2 6-15 6-16.2 6-19 6-20 6-21 7-2 7-3 7-4 7-5 7-5 7-6 7-6 7-7 7-8 7-10 7-10.2 7-11 7-12 7-13 7-14 7-15 7-16 7-17 7-18 7-19 7-20 7-21 7-22

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Change 8

TM 5-6115-585-34 NAVFAC P-8-623-34 TO-35C2-3-455-2 TM-05684C/05685B-34 Figure 7­22. 7­23. 7-24. 7-25. 7-26. 7-27. 7-28. 7-29. 7-30. 7-31. 7-32. 7­33. 7-34. 7-35. 7-36. 7­37. 7-38. 7­39. 7-40. 7-41. 7-42. 7-43. 7-44. 7-45. 7-46. 7-47. 8-1. 8-2. 8-3. 8-4. 8-5. 9-1. 9-2. 10-1. 10-2. 10-3. 10-4. 10-5. 10-6. Table 1-1. 1-2. 2-1. 2-2. 2-3. 6-1. 6-2. 6-3. 6-3.1. 6-4. 6-5. 6-6. 7-1. 9-1. 10-1. vi LIST OF ILLUSTRATIONS (CONT) Title Gear CoverComponents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear Cover Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Governor Cup Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Camshaft Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft and Camshaft Gear Timing Marks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Timing Gear Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft Gear Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft Peening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft End Play Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Injection Pump Adjustment and Button Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly of Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing Lower Spring Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Delivery Valve Test Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspecting Tappet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembling Hydraulic Head. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Unit Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking Plunger Sleeve Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Testing Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Injection Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Delivery Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Timing Port and Port Closing Mark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Injector Nozzle Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Centering Sleeve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Testing Exciter Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator Frame Assembly Winding Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exciter Rotor Assembly Winding Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator Rotor Winding Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting R3 Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Testing Engine Control Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Relocation of Trailer Items to Accomodate ASK Modification . . . . . . . . . . . . . . . . . . . . . . . Installation of Right Support, Rear Panel, and Rear Flap Assemblies . . . . . . . . . . . . . . . . . . Installation of Left Support Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation of Rear Closure Assembly and Exhaust Plenum Asscmblies . . . . . . . . . . . . . . . Installation of Right Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation of Left Panel, Side Closure, Front Panel and Top Panel Assemblies . . . . . . . . . LIST OF TABLES Title Torque Values (Ft-Lb) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repair and Replacement Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Special Tools, Test and Support Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fabricated Tools and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Cubicle Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10KW Generator Set Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AC Output Control Box Wiring Harness (MEP-003A only) . . . . . . . . . . . . . . . . . . . . . . . . . AC Output Control Box Wiring Harness (MEP-112Aonly) . . . . . . . . . . . . . . . . . . . . . . . . . Terminal Voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reconnection Switch Continuity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Testing Bridge Assembly (60 Hz only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Button Code Letter and Size. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Acoustic Suppression Kit Parts and Required Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . Change 8 Page 7-23 7-24 7-25 7-26 7-27 7-27 7-28 7-28 7-29 7-29 7-30 7­31 7-32 7-33 7-34 7-35 7-35 7-36 7-37 7-37 7-38 7-39 7-40 7-42 7-43 7-44 8-2 8-5 8-7 8-9 8-11 9-2 9-2 10-4 10-4 10-8 10-11 10-13 10-14 Page 1-3 1-4 2-1 2-2 2-4 6-3 6-5 6-7 6-8.1 6-9 6-15 6-17 7-40 9-2 10-2

TM5-6115-585-34 NAVFAC P-8-262-12 TO-35C2-3-455-2 TM-05684C/05685B-34

CHAPTER 1 INTRODUCTION Section I. GENERAL 1-1. SCOPE. This manual is for your use in maintaining the DOD Standard Generator Set, 10KW Diesel Engine Driven, Models MEP-003A and MEP-112A. It contains sections for general maintenance, including troubleshooting, and removal and installation of major components, and maintenance of individual components of the unit. Thoroughly familiarize yourself with the unit before servicing or repairing unit.

1-2. LIMITED APPLICABILITY.

1-4. REPORTING OF ERRORS.

Report of errors, omissions, and recommendations for improvement of this publication by the individual user is encouraged. Reports should be submitted as follows: a. (A) Army - DA Form 2028 directly to: Commander, US Army Troop Support and Aviation Materiel Readiness Command, ATTN: DRSTSMTT, 4300 Goodfellow Boulevard, St. Louis, MO 63120. b, (F) Air Force - AFTO Form 22 directly to: Commander, Sacramento Air Logistics Center, ATTN:

Some portions of this publication are not applicable to all services. These portions are prefixed to indicate the services to which they pertain: (A) for Army, (F) for Air Force, (N) for Navy, and (MC) for Marine Corps. Portions not prefixed are applicable to all services. 1-3. MAINTENANCE FORMS AND RECORDS. a. (A) Maintenance forms and records used by Army personnel are prescribed in TM 38-750. b. (F) Maintenance forms and records used by Air Force personnel are prescribed in AFM-66-1 and the applicable 00-20 Series Technical Orders. c. (N) Navy users should refer to their service peculiar directives to determine applicable maintenance forms and records to be used.

d. (MC) Maintenance forms and records used by Marine Corps personnel are prescribed in TM 470015/ 1.

MMEDT, McClellan Air Force Base, CA 95652, in accordance with TO-00-5-1. c. (N) Navy - by letter directly to: Commanding officer, US Navy, Ships Parts Control Center, ATTN: Code 783, Mechanicsburg, PA 17055. d. (MC) Marine Corps - by NAVMC form 10772 directlv to: Commandant. US Marine Corps, ATTN:

Code L-MA-l, WASH DC 20380.

1-5. LEVELS OF MAINTENANCE ACCOMPLISHMENT. a. (A, MC) Army and Marine Corps users shaIl refer to the Maintenance Allocation Chart (MAC) for tasks and levels of maintenance to be performed. b. (F) Air Force users shall accomplish maintenance at the user level consistent with their capability in accordance with policies established in AFM 66-1. c. (N) Navy users shall determine their maintenance levels in accordance with their service directives.

Section II. DESCRIPTION AND TABULATED DATA 1-6. DESCRIPTION.

A general description of the Diesel Engine Generator Sets and information pertaining to the identification plates are contained in the Operator and Organizational Maintenance Manual. Detailed descriptions of the components of the Diesel Engine Generator Sets are provided in the applicable maintenance paragraphs of this manual. 1-7. TABULATED DATA. a. General. This paragraph contains all maintenance data pertinent to intermediate (field) (direct, general support) and depot maintenance personnel.

b. Engine Generator Sets. Refer to Operator and Organizational Maintenance Manual. Change 2 1-1

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