GENERATOR SET, DIESEL ENGINE DRIVEN,

Transcription

1 AIR FORCE T.O.35C This copy is a reprint which includes current pages from Changes 1 through 7. ARMY TM NAVY NAVFAC P MARINE CORPS TM-07464A-12 TECHNICAL MANUAL OPERATOR AND ORGANIZATIONAL MAINTENANCE MANUAL GENERATOR SET, DIESEL ENGINE DRIVEN, SKID MTD., 100 KW, 3 PHASE, 4 WIRE, 120/208 AND TACTICAL 240/416 VOLTS DOD MODELS MEP007A MEP106A MEP116A CLASS HERTZ UTILITY 50/60 PRECISE 50/60 PRECISE 400 NSN DOD MODELS MEPO07AWF MEPO07AWE MEPO07ALM MEPO07AWM INCLUDING OPTIONAL KITS NOMENCLATURE WINTERIZATION KIT, FUEL BURNING WINTERIZATION KIT, ELECTRIC DUMMY L0AD KIT WHEEL MOUNTING KIT NSN Consolidated Diesel Electric Company Contract Number F D-0192 and F C-0363 Distribution Statement - This publication is required for official use or for administrative or operational purposes only. Distribution is limited to US Government agencies. Other requests for this document must be referred to Sacramento ALC/MMEDPD, McClellan AFB, CA This publication incorporates PCN numbers 1 through 1301 and 1318 Published under authority of the Departments of the Air Force, the Army, and the Navy (Including U.S. Marine Corps) 15 JUNE 1973 CHANGE 7-20 MAY 1982

2 P-9-TM T.O. 35C TABLE OF CONTENTS LIST OF ILLUSTRATIONS iv CHAPTER 1 - INTRODUCTION I GENERAL Scope Forms and Records A. Time Compliance Technical Orders II DESCRIPTION AND DATA CHAPTER 2 - I Description Identification and Tabulated Data Difference in Models INSTALLATION AND OPERATING IN- STRUCTIONS SERVICE UPON RECEIPT OF MATERIAL Unloading Equipment Unpacking the Equipment Inspecting and Servicing the Equipment A. Inspection/Compliance with Paint and Marking Requirements Installation of Separately Packed Components Installation of Setting Up Instructions Equipment Conversion II MOVEMENT TO A NEW WORK SITE Dismantling for Movement Reinstallation After Movement III CONTROLS AND INSTRU- MENTS General Controls and Instruments IV OPERATION UNDER USUAL CONDITIONS General Starting Stopping Operation of Equipment V OPERATION UNDER UN- USUAL CONDITIONS Operation in Extreme Cold (Below -25 F) Operation in Extreme Heat Operation in Dusty or Sandy Areas Operation Under Rainy or Humid Conditions Operation in Salt Water Areas Change 3 i

3 P-9-TM T.O. 35C TABLE OF CONTENTS (Cont) V VI Operation Under Unusual Conditions (Cont) Operation in Snow Operation in High Altitudes OPERATION OF AUXILIARY MATERIEL USED IN CON- JUNCTION WITH THE EQUIPMENT Ether Starting Aid Fire Extinguisher (Army and Marine Corps Only) Fuel Burning Winterization Kit Electric Winterization Kit Wheel Mounting Kit Dummy Load Kit CHAPTER 3 - OPERATOR S AND ORGAN- IZATIONAL MAINTENANCE INSTRUCTIONS I OPERATOR S AND ORGAN- IZATIONAL MAINTENANCE REPAIR PARTS, TOOLS, AND EQUIPMENT Tools and Equipment Organizational Maintenance Repair Parts II LUBRICATION General Lubrication Information Detailed Lubrication Information III IV PREVENTIVE MAIN- TENANCE CHECKS AND SERVICES General Preventive Maintenance Checks and Services (Army, Navy, and Marine Corps Only) OPERATOR S MAIN- TENANCE Battery Servicing Radiator Lamps and Fuse Replacement Control Panel Meters Zero Adjustment Engine Air Cleaner Air Cleaner Panel Filter Fuel Filters and Strainer Day Tank Hydraulic Tank (Precise Generator Sets) Fuel Tank Fuel Filler Cap and Strainer General Cleaning V TROUBLESHOOTING VI General FIELD EXPEDIENT REPAIRS General Loss of Engine Power 3-42 ii

4 TABLE OF CONTENTS (Cont) P-9-TM T.O. 35C VI VII Field Experiment Repairs (Cont) Loss of Fuel Engine Overheats Engine Oil Pressure Low A. Loss of Frequency Control Class 1 Sets RADIO INTERFERENCE SUPPRESSION General Methods Used to Attain a Proper Suppression lnterference Suppression Components Replacement of Suppression Components Testing of Radio Interference Suppression Components X MUFFLER AND PIPES General Muffler and Exhaust Pipe Crankcase Breather Tube and Hose XI HOUSING ASSEMBLY XII General Doors, Covers, Seals, and Associated Hardware RADIATOR AND SHUTTER ASSEMBLY General Grill and Fan Guards Shutter Control Assembly Radiator Hoses Radiator and Shutter VIII I X ORGANIZATIONAL MAIN- TENANCE PROCEDURES General General Maintenance Data BATTERIES AND RELATED COMPONENTS General Batteries and Rollout Tray Battery Cables and Slave Receptacles XIII ENGINE ELECTRICAL CONTROL ELEMENTS AND WIRING HARNESSES Oil Pressure Transmitter Low Oil Pressure Switch Coolant Temperature Transmitter High Coolant Temperature Switch Air Cleaner Restriction Indicator and Indicator Switch Change 2 iii

5 P-9-TM TM-07464A-12 T.O. 35C TM TABLE OF CONTENTS (Cont) XIII XIV Engine Electrical Control Elements and Wiring Harnesses (Cont) Engine Shutdown Solenoid Valve Wiring Harnesses CONTROL CUBICLE WIRING HARNESS Control Cubicle Wiring Harness AC Voltmeter Kilowatt Meter (Percent of Power Meter)..... AC Ammeter (Percent of Rated Current Meter).... Adjust Rheostats.... Frequency Meter and Transducer.... Thermal Watt Converter Toggle Switches..... Ammeter - Voltmeter Selector Switch Oil Pressure Gauge.. Fuel Level Gauge... Coolant Temperature Gauge Battery Charging Ammeter Indicator Lights... Panel and Synchronizing Lights.. Running Time Meter. DC Control Circuit Breaker XV ENGINE ASSEMBLY AND COMPONENTS Alternator Belt and Fan Belts Speed Switch Battery Charging Alternator and Mounting Group Starter and Solenoid Starter Brushes Lubricating Oil Filter Group Fuel Transfer Valve, Auxiliary Fuel Inlet Fitting, and Fuel Supply Outlet Fitting Fuel Transfer Pumps. Fuel Filter and Strainer Assembly and Fuel Solenoid Valve Day Tank Secondary Fuel Filter and Relief Valve Group Fuel Lines Fuel System Bleeding Coolant Temperature Regulator Water Pump Turbo Charger..... Breather Assembly.. Valve Lash Adjustment Manual Speed Control. Governor Linkage Utility Generator Sets iv

6 TABLE OF CONTENTS (Cont) P-9-TM TM-07464A-12 T.O. 35C TM XV ENGINE ASSEMBLY AND COMPONENTS (Cont) CHAPTER 4 - Governor Linkage Precise Generator Sets Hydraulic Filter (Precise Generator Sets) Precise Governor Actuator Filter (Precise Generator Sets) Hydraulic System Bleeding (Precise Generator Sets).. MATERIAL USED IN CONJUNCTION WITH MAJOR ITEM I GENERAL Scope Service Upon Receipt of Materiel IV V 4-8. Fire Extinguisher (Army and Marine Corps only) PARALLEL CABLE (PRE- CISE GENERATOR SETS) General Test Repair FUEL BURNING WINTER- IZATION KIT General Initial Installation Preventive Maintenance Troubleshooting Kit Control Box Heater Igniter Heater Coolant Pump Test Thermostat Switch Test II ETHER STARTING AID General Troubleshooting Ether Starting Aid. III FIRE EXTINGUISHER..... General (Army and Marine Corps only) Preventive Maintenance (Army and Marine Corps only) VI ELECTRIC WINTERIZA- TION KIT General Initial Installation... Preventive Maintenance Troubleshooting.... Electric Winterization Kit Control Box Coolant Pump Test.. Thermostat Test Heater Test V

7 P-9-TM TM-07464A-12 T.O. 35C TM TABLE OF CONTENTS (Cont) VII WHEEL MOUNTING KIT General Preventive Maintenance... Troubleshooting.... Lubrication Jacking Instructions Wheels and Tires... Wheel Bearings.... Wheel Brakes Front Axle Assembly Rear Axle Assembly... Brake Linkages and Cables VIII DUMMY LOAD KIT General Installation and Setting Up Instructions Troubleshooting... Dummy Load Kit... Control Panel Heater Elements... Radio Suppression Capacitors... CHAPTER 5 - SHIPMENT AND LIMITED STORAGE AND DEMOLITION TO PREVENT ENEMY USE... I SHIPMENT AND LIMITED STORAGE Preparation For Shipment II APPENDICES 5-2. Loading Equipment For Shipment Preparation For Limited Storage Inspection and Maintenance of Equipment in Limited Storage.. DEMOLITION OF MATE- RIEL TO PREVENT ENEMY USE General (Army Only). A REFERENCES A-1. Fire Protection..... A-2. Lubrication A-3. Painting A-4. Radio Suppression.... A-5. Maintenance A-6. Shipment and Storage. A-7. Destruction of Materiel B BASIC ISSUE ITEMS LIST.. I - INTRODUCTION B-1. B-2. B-3. B-4. B-5. B-6. B-7. Scope General Explanation of Columns Explanation of Columns in the Tabular List of Maintenance and Operating Supplies - III Special Information... Abbreviations... Federal Supply Code for Manufacturers A-1 A-1 A-1 A-1 A-1 A-1 A-2 A-3 B-1 B-1 B-1 B-1 B-1 B-3 B-3 B-4 B-4 vi

8 P9-TM T.O. 35C TM-07464A-12 TM APPENDIX APPENDIX B BASIC ISSUE ITEMS LIST (Cont) II - BASIC ISSUE ITEMS... B-5 III - MAINTENANCE AND OPERATING SUPPLIES B-7 C MAINTENANCE ALLO- CATION CHART C-1 I - INTRODUCTION C-1 C-1. General C-1 C-3. C-4. Explanation of Columns in III C-2 Explanation of Columns in IV C-3 II - MAINTENANCE ALLOCATION CHART. C-4 III - TOOLS, TEST AND SUPPORT EQUIP- MENT REQUIRE- MENTS C-26 C-2. Explanation of Columns in II C-1 IV - REMARKS C-27 ALPHABETICAL INDEX I-1 vii

9 P-9-TM T.O. 35C LIST OF ILLUSTRATIONS Number Number A Generator Set, Front Three-Quarters View... Generator Set, Rear Three-Quarters View... AC System Troubleshooting Diagram 50/60 Hertz Generator Sets DC System Troubleshooting Diagram 50/60 Hertz Generator Sets AC System Troubleshooting Diagram 400 Hertz Generator Sets... DC System Troubleshooting Diagram 400 Hertz Generator Sets Interconnecting Wiring Diagram 50/60 Hertz Generator Sets (3 Sheets). Interconnecting Wiring Diagram 400 Hertz Generator Sets (3 Sheets). Generator Set Fuel System Diagram..... Kit Wiring Diagram.... Electric Winterization Kit Wiring Diagram (2 Sheets) Dummy Load Kit Wiring Diagram (2 Sheets)..... Shipping Crate Noise Level Warning Sign. Installation Plan Grounding Procedures Fuel Connections Load Cable Connections... Control Cubicle Connection for Remote Operation Voltage Conversion Location of Controls, Instruments, and Receptacles (2 Sheets) Starting Instructions..... Stopping Instructions.... Single Unit Operation.... Parallel Unit Connection Diagram Parallel Unit Operation.. Removal from Parallel Operation... Ether Starting Aid, Operating Instructions.. Kit, Operating Instructions Electric Winterization Kit, Operating Instructions Wheel Mounting Kit, Operating Instructions.. Dummy Load Kit, Operating Instructions.. Lubrication Order (2 Sheets) Lubricating Oil Filter Servicing Battery, Servicing Location of Fill and Drain Points and Drain Valves. Lamp and Fuse Replacement Control Panel Meters, Zero Adjustment Air Cleaner, Removal and Installation Air Cleaner Panel Filters, Removal and Installation. Fuel Filler Cap and Strainer Removal and Installation Radio Interference Suppression Components, Removal and Installation... Batteries and Rollout Tray, Exploded View viii Change 2

10 List of Illustrations (Cont) P-9-TM T.O. 35C Number Number Battery Cables and Slave Receptacles, Removal and Installation Muffler, Exhaust Pipe, and Crankcase Breather Tube and Hose, Removal and Installation Housing, Partially Exploded View (2 Sheets) Radiator and Shutter Assembly, Exploded View Shutter Control Assembly, Adjustment Engine Electrical Control Elements, Removal and Installation (2 Sheets) Wiring Harnesses 50/60 Hertz Generator Sets, Removal and Installation (5 Sheets) Wiring Harnesses 400 Hertz Generator Sets, Removal and Installation (5 Sheets) Control Cubicle Components, Removal and Installation (2 Sheets) Ammeter - Voltmeter Selector Switch, Simplified Schematic Gauge, Test Setup DC Control Circuit Breaker, Removal and Installlation Alternator Belt and Fan Belts, Removal and Installation Speed Switch, Removal and Installation Speed Switch, Test Setup Battery Charging Alternator and Mounting Group, Removal and Installation Battery Charging Alternator, Test and Adjustment Starter and Solenoid, Test Starter and Solenoid, Removal and Installation Starter Drive Assembly Pinion Clearance Adjustment Starter Brushes, Removal and Installation Lubricating Oil Filter Group, Exploded View Fuel Transfer Valve, Auxiliary Fuel Inlet Fitting, and Fuel Supply Outlet Fitting, Removal and Installation Electric Fuel Transfer Pumps, Exploded View Fuel Filter and Strainer Assembly and Fuel Solenoid Valve, Exploding View Day Tank, Exploded View Secondary Fuel Filter and Relief Valve Group, Exploded View Coolant Temperature Regulator, Removal and Installation Water Pump, Removal and Installation Turbo Charger, Removal and Installation Breather Assembly, Removal and Installation Valve Lash, Adjustment Manual Speed Control, Removal and Installation Governor Linkage Utility Generator Sets Removal, Installation, and Adjustment ix

11 P-9-TM T.O. 35C List of Illustrations (Cont.) Number Number 3-45A Governor Spring Installation, Proper Alignment... Governor Linkage Precise Generator Sets, Removal, Installation and Adjustment... Hydraulic Filter (Precise Generator Sets), Exploded View Precise Governor Actuator Filter Servicing and Test Points (Precise Generator Sets) Ether Starting Aid, Exploded View Kit, Removal and Installation (2 Sheets) Kit Control Box Lamp Replacement... Kit Control Box Schematic. Kit Heater Igniter, Removal and Installation A Electric Winterization Kit Removal and Installation (2 Sheets) Electric Winterization Kit Control Box, Partially Exploded View Wheel Mounting Kit, Lubrication Data Wheel Mounting Kit, Wheels and Tires, Removal and Installation Wheel Bearings and Brakes, Exploded View Front Axle Assembly, Exploded View Rear Axle Assembly, Exploded View Brake Linkages and Cables, Exploded View Dummy Load Kit Drilling Diagram Dummy Load Kit Dummy Load Kit Control Panel and Components, Removal and Installation. Dummy Load Kit, Partially Exploded View X Change 2

12 P-9-TM T.O. 35C LIST OF TABLES Number Number Special Torque Data Model Differences Freezing Points, Composition, and Specific Gravities of Military Antifreeze Material Function of Controls, Instruments, and Receptacles Recommended Tools Preventive Maintenance Checks and Services Troubleshooting Ether Starting Aid Troubleshooting Fire Extinguisher Preventive Maintenance Checks and Services Kit Preventive Maintenance Checks and Services Kit Troubleshooting Electric Winterization Kit Preventive Maintenance Checks and Services Electric Winterization Kit Troubleshooting Wheel Mounting Kit Preventive Maintenance Checks and Services Wheel Mounting Kit Troubleshooting Dummy Load Kit Troubleshooting Change 3 xi

13 P-9-TM T.O. 35C CHAPTER 1 INTRODUCTION I. GENERAL 1-1. SCOPE. a. This technical manual contains instructions for use by operation and organizational maintenance personnel maintaining the 100 KW, Diesel Engine Generator Sets, Military Models MEP007A, MEP106A, and MEP116A as allocated by the Maintenance Allocation Chart. The instructions provided cover operation, lubrication, preventive maintenance checks and services, and maintenance procedures within the scope of the operator and organizational maintenance personnel for the generator sets, their accessories, and auxiliaries. b. THIS TECHNICAL MANUAL IS USED BY THE ARMY, AIR FORCE, NAVY, AND MARINE CORPS. THE USE OF FORMS AND COMPLIANCE WITH DIRECTIVES AS STATED HEREIN WILL BE ACCOMPLISHED ONLY BY PERSONNEL OF THE SERVICE TO WHICH THEY APPLY FORMS AND RECORDS. a. Forms and records used by the Army will be only those prescribed by TM Those used by the Marine Corps will be those prescribed by TM /1. Other Service users should refer to appropriate specifications/publications for equipment maintenance forms and records. b. Report of errors, omissions and recommendations for improvements of this publication by the individual users is encouraged. Reports should be submitted as follows: 1. Air Force - AFTO Form 22 in accordance with T.O and direct to: Commander, Sacramento Air Logistics Center, ATTN: MMEDT, McClellan AFB, California Army - DA Form 2028 direct to: Commanding General, U.S. Army Troop Support and Aviation Material Readiness Command, ATTN: DRSTS-MTP, 4300 Goodfellow Blvd., St. Louis, Missouri Marine Corps - by letter direct to: Commandant, U.S. Marine Corps, ATTN: Code LME, Washington, D. C Navy - by letter direct to: Commanding Officer, U.S. Navy Ships Parts Control Center, ATTN: Code 783, Mechanicsburg, Pennsylvania A. TIME COMPLIANCE TECHNICAL ORDERS. This technical manual incorporates the Time Compliance Technical Order (TCTO) 35C ; dated 15 July 1977; Modification of Generator Set DED 100 KW, 400 Hz, DOD Model ME P116A for compatability with E3A- AWACS program (EC P76CE2122). II. DESCRIPTION AND DATA 1-3. DESCRIPTION. (figures 1-1 and 1-2) are multi-purpose, portable skid-mounted, self-contained a. Generator sets, military models: units. Each set is equipped with engine MEP007A, MEP006A and MEP116A pan heating elements and connections oil Change 4 1-1