ARMY MEP-831A Operator
ARMY TM 9-6115-639-13&P*
AIR FORCE TO 35C2-3-386-51W/IPB
MARINE CORPS TM 10155A-OI/1
OPERATOR, UNIT, AND DIRECT SUPPORT
MAINTENANCE MANUAL
(INCLUDING REPAIR PARTS AND SPECIAL TOOLS LIST)
OPERATING
INSTRUCTIONS 2-1
OPERATOR
TROUBLESHOOTING 3-4
UNIT LEVEL PMCS 4-8
UNIT LEVEL
TROUBLESHOOTING 4-14
UNIT MAINTENANCE
PROCEDURES 4-38
DIRECT SUPPORT
TROUBLESHOOTING 5-4
DIRECT SUPPORT
MAINTENANCE 5-6
MAINTENANCE
ALLOCATION CHART
(MAC) B-1
REPAIR PARTS AND
SPECIAL TOOLS LIST
(RPSTL) C-1
3kW TACTICAL QUIET GENERATOR SET
MEP-831A (60 Hz) (NSN: 6115-01-285-3012) (EIC: VG6)
MEP-832A (400 Hz) (NSN: 6115-01-287-2431) (EIC: VN7)
DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited. DESTRUCTION NOTICE: Destroy
by any method that will prevent disclosure of contents or reconstruction of the document.
*This manual supersedes TM 9-6115-639-13 dated 1 November 2000 thru TM 9-6115-639-13, Change 1 dated 15
September 2002; and TM 9-6115-639-23P dated 15 October 2002.
DEPARTMENTS OF THE ARMY AND THE AIR FORCE
AND HEADQUARTERS, MARINE CORPS
15 AUGUST 2005
PCN 182 101550 00
ARMY TM 9-6115-639-13&P
AIR FORCE TO 35C2-3-386-51W/IPB
MARINE CORPS TM 10155A-OI/1
WARNING SUMMARY
The following safety precautions are for personnel to understand and apply during many phases of operating
and maintaining the 3kW Tactical Quiet Generator (TQG). Disregarding these warnings and precautionary
information can result in serious injury or death.
Warning statements considered essential to the protection of personnel have been strategically placed
throughout this manual prior to operation or maintenance procedures. Before starting any task, be sure to
review and understand all warnings in the text for that task.
This manual describes physical and chemical processes that may require the use of chemicals, solvents,
paints, or other commercially available material. Users of this manual should obtain the material safety data
sheets (Occupational Safety and Health Act (OSHA) Form 20 or equivalent) from the manufacturer or
suppliers of materials to be used. Users must be completely familiar with manufacturer/supplier information
and adhere to their procedures, recommendations, warnings, and cautions for safe use, handling, storage,
and disposal of these materials.
WARNING
Do not replace components or make adjustments with
the voltage supply turned on. Dangerous potentials may
exist under certain conditions when the power control is
off. Avoid casualties by always removing power and by
discharging and grounding a circuit before touching it.
Failure to observe this warning could result in severe
personal injury or death.
WARNING
High voltage is produced when generator set is being
operated. Use care when working around an open control
panel when generator set is on. Improper operation of
generator set or failure to follow this warning could result
in severe personal injury or death by electrocution.
Do not stand or store heavy objects on generator set.
Never attempt to start generator set unless it is properly
grounded. Equipment must be grounded in accordance
with the procedures in para. 2-6.1. Failure to observe
this warning could result in serious personal injury or death by
electrocution.
WARNING
WARNING
a
ARMY TM 9-6115-639-13&P
AIR FORCE TO 35C2-3-386-51W/IPB
MARINE CORPS TM 10155A-13/1
DC voltages are present at generator set electrical
components even with generator set shut down. Avoid
shorting any positive terminal with ground or negative. If no
DC voltage is required, always disconnect DC power source
to generator set before working on it. Failure to observe
this warning could result in severe personal injury or death by
electrocution.
Never attempt to connect or disconnect load cables while
generator set is running. Failure to observe this
warning could result in severe personal injury or death
by electrocution.
Never service or perform maintenance on generator
set while engine is running. Always shut down
generator set before servicing. Allow engine to cool
before handling components. Failure to observe this warning
could result in severe personal injury or death.
Never work alone when reaching into generator set
to service or adjust it. Be sure to work with someone who
could provide aid in case of an emergency. Failure to
observe this warning could result in severe personal
injury or death.
Shut down generator set at first sign of failure.
Continued operation could result in injury to personnel
and will cause damage to equipment. If generator
set is shut down by activation of a safety device,
do not operate again until the cause of the shut down
has been determined and eliminated. Failure to
observe this warning could result in severe personal
injury or death.
WARNING
WARNING
WARNING
WARNING
WARNING
b
ARMY TM 9-6115-639-13&P
AIR FORCE TO 35C2-3-386-51W/IPB
MARINE CORPS TM 10155A-OI/1
WARNING
If damaged or defective components are discovered,
repair must be performed before operations can begin.
Perform required repairs and adjustments before
proceeding. Do not operate generator set with
damaged components. Personal injury could occur if
damaged parts are left unfixed. Failure to observe this
warning could result in severe personal injury or death.
WARNING
Exhaust discharge contains deadly gases including
carbon monoxide. Do not operate generator set in an
enclosed area unless exhaust discharge is properly
vented outside. Position generator set as far away
from personnel, shelters, and occupied vehicles as
possible. Failure to observe this warning could result
in severe personal injury or death due to carbon
monoxide poisoning.
WARNING
Fuel used in this generator set is flammable and toxic to
skin, eyes, and respiratory tract. Avoid repeated or
prolonged contact. Handle only in a well-ventilated area.
Keep away from sparks, open flames, or other sources
of ignition. Do not splash fuel on hot components.
Do not fuel generator set while it is operating. Do not
overfill tank. Ensure generator set is properly grounded
before fueling. Failure to observe this warning could
result in personal injury and equipment damage due to
potential fuel ignition and possible explosion. Ensure
approved gloves and face shield are worn during
handling. Failure to observe this warning could result
in severe personal injury or death.
WARNING
Liquids under pressure are generated as a result of
operating this generator set. High-pressure leaks
could cause severe personal injury or death. Failure
to observe this warning could result in severe
personal injury or death.
c
ARMY TM 9-6115-639-13&P
AIR FORCE TO 35C2-3-386-51W/IPB
MARINE CORPS TM 10155A-13/1
Compressed air is dangerous and could cause serious
bodily harm, if protective means or methods are not
observed to prevent a chip or particle (of whatever size)
from being blown into the eyes or to prevent unbroken skin
of the operator or other personnel. Compressed air shall
not be used for cleaning purposes except where reduced to
less than 30 pounds per square inch gauge (psig). Use it
only with effective chip-guarding and personnel protective
equipment (industrial safety glasses and full face shield).
DO NOT use compressed air to dry parts when solvent
cleaners have been used. Failure to observe this warning
could result in severe personal injury or death.
Do not use TRICHLOROTRIFLUOROETHANE,
TRICHLOROETHANE, and similar chemical solvents
for ordinary cleaning of equipment. These substances
threaten public health and the environment by destroying
ozone in the Earths upper atmosphere. Use suitable
non-hazardous cleaning materials (see Appendix F)
such as a clean cloth, water, and mild detergent or an
approved substitute solvent, such as isopropyl alcohol.
Failure to observe this warning could result in severe
personal injury or death.
Handle solvents as combustible liquids. Do not use near
heat, sparks, or flame. Use solvents in well-ventilated
areas only. Avoid prolonged breathing of vapor. Avoid
bodily contact. Use chemical (solvent-resistant) gloves
and chemical splash goggles when using solvent materials.
Solvents may be reactive with acids and oxidizers; do not
mix or cross-apply with other cleaners or chemicals.
An organic vapor respirator with dust and mist filter is
recommended when solvent is applied as a spray.
Keep containers closed between applications.
Provide mechanical ventilation if used in confined spaces.
Store cleaning materials in a well-ventilated area away
from food or drink. To avoid the possibility of spontaneous
combustion, place solvent-saturated waste rags in a sealed
metal container after use. Coordinate the use of this
material with your supporting Industrial Hygiene and
Safety Offices. Ensure you read and understand the
Material Safety Data Sheet (MSDS) for the solvent before
use. Failure to observe this warning could result in severe
personal injury or death.
WARNING
WARNING
WARNING
d
ARMY TM 9-6115-639-13&P
AIR FORCE TO 35C2-3-386-51W/IPB
MARINE CORPS TM 10155A-OI/1
WARNING
Adhesives used in maintaining this generator set
(see Appendix F) are flammable and toxic. Vapors may
ignite explosively. Avoid breathing in vapors. Provide
adequate ventilation to prevent vapor concentrations in
excess of permissible exposure levels. Keep away from
heat, sparks, and open flame. Do not smoke. Extinguish
all flames and turn off non-explosion-proof electrical
equipment during use until vapors are dissipated.
Close containers tightly. Failure to observe this warning
could result in severe personal injury or death.
WARNING
To prevent injury to personnel and damage to equipment,
use caution when lifting or moving generator set. Six
people are required for manual lifting. Use lifting rings for
lifting device and forklift openings for forklift only. Do not lift
generator set over personnel. Failure to observe this warning
could result in severe personal injury or death.
WARNING
Avoid contacting metal items with bare skin in extreme
cold weather. Failure to observe this warning could
result in severe personal injury or death.
WARNING
Metal jewelry could conduct electricity. Loose, dangling
articles and clothing could be caught in moving parts.
Remove jewelry and loose, dangling articles and clothing
before working on generator set. Failure to observe this
warning could result in severe personal injury or death.
WARNING
Chemical Agent Resistive Coating (CARC) paint dust is
a heath hazard. Wear protective eyewear, a mask, and
gloves when sanding CARC-painted surfaces. Failure to
observe this warning could result in severe personal injury
or death.
e
ARMY TM 9-6115-639-13&P
AIR FORCE TO 35C2-3-386-51W/IPB
MARINE CORPS TM 10155A-13/1
If battery is not installed, battery cable ends must be
isolated from each other, and positive end must be
isolated from ground. Failure to isolate battery cable
ends could result in severe electrical discharge. When
not connected to battery, connect battery cable ends to
plastic storage stud. Failure to observe this warning could
result in severe personal injury or death.
With access cover open, noise level of generator set
when operating could cause hearing damage. Hearing
protection must be worn when working near generator set
while it is running. Failure to observe this warning could
result in severe personal injury or death.
To prevent injury to personnel and damage to equipment,
use caution when lifting or moving generator set. Use lifting
rings for lifting device and forklift pockets for forklift only.
Do not lift generator set over personnel. Failure to observe
this warning could result in severe personal injury or death.
Class III oil leaks should be reported IMMEDIATELY to your
supervisor. Fuel leaks of any kind require immediate system
shutdown. Failure to observe this warning could result in severe
personal injury or death.
Make sure personnel are familiar with generator set before
operating. Follow proper procedures. Failure to observe this
warning could result in damage to equipment and could also
result in severe personal injury or death.
Battery acid can cause burns to unprotected skin.
Failure to observe this warning could result in severe
personal injury or death.
WARNING
WARNING
WARNING
WARNING
WARNING
WARNING
f
ARMY TM 9-6115-639-13&P
AIR FORCE TO 35C2-3-386-51W/IPB
MARINE CORPS TM 10155A-OI/1
WARNING
Batteries give off flammable gas. Do not smoke
or use open flame when performing maintenance.
Flames and explosion could result in severe personal
injury or death. Failure to observe this warning could
result in severe injury or personal death.
WARNING
Do not allow battery acid to contact skin or clothing.
Contact of skin with battery acid liquid or inhalation of
battery acid mist can cause severe burns, respiratory
tract infection, and chronic bronchitis. If any battery
acid liquid or mist contacts skin or eyes, immediately
flush affected areas thoroughly with water. If vapors
are inhaled, go to fresh air. Seek medical help
immediately. Failure to observe this warning could
result in severe injury or personal death.
WARNING
When disconnecting battery cables, always remove negative
cable first and positive cable last. Connect cable ends to
enclosure ground lugs to prevent contact. Failure to observe
this warning could result in severe personal injury or death.
WARNING
When connecting battery cables, always connect positive
cable first and negative cable last. Failure to observe this
warning could result in severe personal injury or death.
WARNING
The generator set is heavy. Provide lifting hoist capable of
lifting 100 lbs. Do not lift generator set over personnel.
Enlist the help of an aide to prevent damage to equipment.
Failure to observe this warning could result in severe personal
injury or death.
WARNING
The rotor assembly is held in the stator by magnets. The rotor
will snap into place in stator when installed. Use care to prevent
injury to fingers. Failure to observe this warning could result in
severe personal injury or death.
g/(h Blank)
ARMY TM 9-6115-639-13&P
AIR FPRCE TO 35C2-3-386-51W/IPB
MARINE CORPS TM 10155A-OI/1
LIST OF EFFECTIVE PAGES
Below are the dates of issue For original and changed pages:
Original 0 15 August 2005
Total number of pages in this publication is 516, consisting of the Following:
Page *Change
No. No.
Cover......................................... 0 C-45 Blank ................................ 0 K-1 – K-2 .................................... 0
Blank.......................................... 0 C-46 – C-50 .............................. 0 L-1 – L-2..................................... 0
a-g.............................................. 0 C-51 Blank ................................ 0 Index-1 – Index-5....................... 0
h Blank....................................... 0 C-52 – C-70 .............................. 0 Index-6 Blank ............................. 0
A - B........................................... 0 C-71 Blank ................................ 0 FP-1............................................ 0
i-ix.............................................. 0 C-72 – C-75............................... 0 FP-2 Blank ................................. 0
x Blank....................................... 0 C-76 Blank ................................ 0 FP-3............................................ 0
Page *Change
No. No.
Insert latest change pages. Destroy superseded data.
Page Change
No. No.
1-1 – 1-28.................................. 0 C-77 – C-90 .............................. 0 FP-4 Blank ................................. 0
2-1 – 2-32 ................................. 0 C-91 Blank ................................ 0 FP-5............................................ 0
3-1 – 3-14.................................. 0 C-92 - C-100............................. 0 FP-6 Blank ................................. 0
4-1 – 4-176 ................................ 0 C-101 Blank .............................. 0 FP-7............................................ 0
5-1 – 5-18.................................. 0 C-102 – C-133 .......................... 0 FP-8 Blank ................................. 0
A-1 – A-2................................... 0 C-134 Blank............................... 0 FP-9............................................ 0
B-1 – B-9................................... 0 D-1 – D-6................................... 0 FP-10 Blank ............................... 0
B-10 Blank................................. 0 E-1 – E-3................................... 0 FP-11.......................................... 0
C-1 – C-6................................... 0 E-4 Blank .................................. 0 FP-12 Blank ............................... 0
C-7 Blank .................................. 0 F-1 – F-3.................................... 0 FP-13.......................................... 0
C-8 – C-13 ................................ 0 F-4 Blank ................................... 0 FP-14 Blank ............................... 0
C-14 Blank ................................ 0 G-1 ............................................. 0 FP-15.......................................... 0
C-15 – C-18 .............................. 0 G-2 Blank................................... 0 FP-16 Blank ............................... 0
C-19 Blank ................................ 0 H-1 – H-4 ................................... 0 FP-17.......................................... 0
C-20 – C-35 .............................. 0 I-1............................................... 0 FP-18 Blank ............................... 0
C-36 Blank ................................ 0 I-2 Blank .................................... 0 FP-19.......................................... 0
C-37 – C-44 .............................. 0 J-1 – J-4..................................... 0 FP-20 Blank ............................... 0
A
ARMY TM 9-6115-639-13&P
AIR FPRCE TO 35C2-3-386-51W/IPB
MARINE CORPS TM 10155A-OI/1
Page *Change
No. No.
FP-21 ......................................... 0
FP-22 Blank ............................... 0
FP-23 ......................................... 0
FP-24 Blank ............................... 0
FP-25 ......................................... 0
FP-26 Blank ............................... 0
FP-27 ......................................... 0
FP-28 Blank ............................... 0
FP-29 ......................................... 0
FP-30 Blank ............................... 0
FP-31 ......................................... 0
Page *Change
No. No.
Page Change
No. No.
FP-32 Blank ............................... 0
B
ARMY TM 9-6115-639-13&P*
AIR FORCE TO 35C2-3-386-51W/IPB
MARINE CORPS TM 10155A-OI/1
TECHNICAL MANUAL HEADQUARTERS
DEPARTMENT OF THE ARMY
NO. 9-6115-639-13&P Washington, DC, 15 AUGUST 2005
OPERATOR, UNIT, AND DIRECT SUPPORT
MAINTENANCE MANUAL
(INCLUDING REPAIR PARTS AND SPECIAL TOOLS LIST)
3kW TACTICAL QUIET GENERATOR SET
MEP-831A (60 Hz) (NSN: 6115-01-285-3012) (EIC: VG6)
MEP-832A (400 Hz) (NSN: 6115-01-287-2431) (EIC: VN7)
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. We would prefer that you submit your recommended changes electronically, either by e-mail
(AMSEL-LC-LEO-PUBS-CHG@mail1.monmouth.army.mil
Alternatively, you may mail or fax your letter, DA Form 2028, or DA Form 2028-2 located in back of this manual to:
Commander, U.S. Army Communications-Electronics Command and Fort Monmouth, ATTN: AMSEL-LC-LEO-E-ED,
Fort Monmouth, NJ 07703-5006. The fax number is 732-532-3421, DSN 992-3421. For Air Force, use AFTO Form 22 in
accordance with TO 00-5-1 and mail directly to Commander, WR-ALC/LEET, Robins AFB, GA 31098. You may also email your form to http://wralc.tilta.afto@robins.af.mil
changes on a NAVMC 10722. The NAVMC may be submitted via the Internet using website
https://pubs.ala.usmc.mil/front.htm, scrolling down to the NAVMC 10772 Tracking Program, and following instructions
provided. The NAVMC may also be submitted by electronic mail to mbmatcommarlogbases@logcom.usmc.mil
mailing a paper copy NAVMC 10772 in an envelope addressed to Commander, Marine Corps Systems Command,
Attention: Assistant Commander Acquisition and Logistics (LOG/TP), 814 Radford Blvd., Suite 20343, Albany, GA
31704-0343.
*This manual supersedes TM 9-6115-639-13 dated 1 November 2000 thru TM 9-6115-639-13, Change 1 dated 15 September 2002;
and TM 9-6115-639-23P dated 15 October 2002.
TABLE OF CONTENTS
CHAPTER 1 INTRODUCTION………………………………………………………………………. 1-1
Section I General Information…………………………………………………………………… 1-2
Section II Equipment Description………………………………………………………………... 1-8
Section III Theory of Operation…………………………………………………………………… 1-24
CHAPTER 2 OPERATING INSTRUCTIONS……………………………………………………… 2-1
Section I Description and Use of Operator Controls and Indicators………………………... 2-2
Section II Operator Preventive Maintenance Checks and Services (PMCS)………………. 2-9
Section III Operation Under Usual Conditions………………………………………………….. 2-20
Section IV Operation Under Unusual Conditions……………………………………………….. 2-29
CHAPTER 3 OPERATOR MAINTENANCE INSTRUCTIONS…………………………………... 3-1
Section I Operator Lubrication Instructions …………………………………………………… 3-2
Section II Operator Troubleshooting Procedures ……………………………………………... 3-4
Section III Operator Maintenance Instructions………………………………………………….. 3-12
CHAPTER 4 UNIT MAINTENANCE INSTRUCTIONS…………………………………………… 4-1
Section I Unit Lubrication Instructions …………………………………………………………. 4-3
Section II Repair Parts; Tools; Special Tools; Test, Measurement, and Diagnostic
Equipment (TMDE); and Support Equipment………………………………………. 4-6
Section III Service Upon Receipt of Equipment.……………………………………………….. 4-7
) or online (http://edm.monmouth.army.mil/pubs/2028.html).
. For the Marine Corps, submit notice of discrepancies or suggested
or by
Page
i
ARMY TM 9-6115-639-13&P
AIR FORCE TO 35C2-3-386-51W/IPB
MARINE CORPS TM 10155A-OI/1
TABLE OF CONTENTS (Continued)
Page
Section IV Unit Preventive Maintenance Checks and Services (PMCS)…………………….. 4-8
Section V Unit Level Troubleshooting Procedures…………………………………………….. 4-14
Section VI Unit Level Maintenance Instructions………………………………………………… 4-38
Section VII Preparation for Shipment and Storage………………………………………………
CHAPTER 5 DIRECT SUPPORT MAINTENANCE INSTRUCTIONS………………………….. 5-1
Section I Repair Parts; Tools; Special Tools; Test, Measurement, and Diagnostic
Equipment (TMDE); and Support Equipment……………………………………….
Section II Service Upon Receipt of Equipment…………………………………………………. 5-3
Section III Direct Support Troubleshooting Procedures………………………………………… 5-4
Section IV Direct Support Maintenance Instructions……………………………………………. 5-6
APPENDIX A REFERENCES…………………………………………………………………………. A-1
APPENDIX B MAINTENANCE ALLOCATION CHART (MAC)……………………………………. B-1
APPENDIX C REPAIR PARTS AND SPECIAL TOOLS LIST (RPSTL)………………………….. C-1
Section I Introduction……………………………………………………………………………… C-1
Section II Repair Parts List……………………………………………………………………….. C-8
Group 00 – Generator Set…………………………………………………….………. C-9
Group 01 – Engine Assembly, Diesel………………………………………………... C-10
Group 0101 – Governor Control Module…………………………………………….. C-11
Group 010101 – Governor Actuator Assembly……………….…………………….. C-13
Group 02 – Permanent Magnet Alternator (PMA)…………….. C-17
Group 03 – Electrical System Assembly……………………………………………. C-18
Group 0301 – Electrical System Assembly/Battery Charging Regulator…..…….. C-21
Group 0302 – Electrical System Assembly/Battery………………………………… C-23
Group 030201 – Electrical System Assembly/Battery Cables…………………….. C-25
Group 0303 – Electrical System Assembly/Contactor Assembly…………….…… C-27
Group 0304 – Electrical System Assembly/Frequency Converter (A8)………….. C-29
Group 0305 – Electrical System Assembly/Relays, Electromagnetic………….…. C-31
Group 04 – Control Box Assembly……………………… C-33
Group 0401 – Control Box Assembly/Control Panel Assembly…………………… C-35
Group 040101 – Control Panel Assembly/Panel Meters, Gauges, & Switches…. C-41
Group 0402 – Control Box Assembly/Receptacle, Filters, Terminals, and
Voltage Resistor………………………………………………………………………… C-43
Group 05 – Cooling System…………………………………………………………… C-44
Group 0501 – Cooling System/Cooling Fan Assembly…………………………….. C-47
Group 0502 – Cooling System/HI/LO Temperature Switches…………………….. C-49
Group 06 – Fuel System Assembly…………………………………………………... C-50
Group 0601 – Fuel System Assembly/Fuel Tank Strainer Assembly……………. C-53
Group 0602 – Fuel System Assembly/Fuel Tank…………………………………… C-55
Group 060201 – Fuel System Assembly/Fuel-Level Assembly…………………… C-57
Group 060202 – Fuel System Assembly/Fuel-Level Switch………….…………… C-59
Group 060203 – Fuel System Assembly/Fuel Tank Pickup Tube……. C-61
Group 0603 – Fuel System Assembly/Primary Fuel Pump………………………... C-63
Group 0604 – Fuel System Assembly/Auxiliary Fuel Pump……………………….. C-65
Group 0605 – Fuel System Assembly/Fuel Filter/Water Separator………………. C-67
Group 0606 – Fuel System Assembly/Air Cleaner Assembly……………………... C-69
Group 07 – Frame and Housing Assembly………………………………………….. C-70
Group 0701 – Frame and Housing Assembly/Main Access Cover……………….. C-77
Group 0702 – Frame and Housing Assembly/Frame and Housing Panels……... C-83
4-175
5-2
ii
ARMY TM 9-6115-639-13&P*
AIR FORCE TO 35C2-3-386-51W/IPB
MARINE CORPS TM 10155A-OI/1
TABLE OF CONTENTS (Continued)
Page
APPENDIX C REPAIR PARTS AND SPECIAL TOOLS LIST (RPSTL) (Continued)
Group 706 – Frame and Housing Assembly/ID Plates…………………………….. C-91
Group 08 – Lubrication System……………………………………………………….. C-92
Group 0801 – Lubrication System/Oil Drain Assembly…………………………….. C-95
Group 0802 – Lubrication System/Oil Pressure Switch……………………………. C-97
Group 0803 – Lubrication System/Engine Oil Temperature Switch………………. C-99
Group 0804 – Lubrication System/Oil Filter…………………………………………. C-101
Group 09 – Exhaust System Assembly……………………………………….……... C-102
Group 0901 – Exhaust System Assembly/Muffler Assembly…..………………….. C-105
Group 0902 – Exhaust System Assembly/Bellows Assembly.……………………. C-107
Group 0903 – Exhaust System/Duct Assembly...…………………………………. C-109
Section III Cross-Reference Indexes……………………………………………………………… C-111
Part Number Index……………………………………………………………………... C-111
Figure and Item Number Index……………………………………………………….. C-124
APPENDIX D COMPONENTS OF END ITEM (COEI) AND BASIC ISSUE ITEMS (BII) LIST… D-1
APPENDIX E ADDITIONAL AUTHORIZATION LIST (AAL)………………………………………. E-1
APPENDIX F EXPENDABLE AND DURABLE ITEMS LIST………………………………………. F-1
APPENDIX G ILLUSTRATED LIST OF MANUFACTURED ITEMS………………………………. G-1
APPENDIX H TORQUE LIMITS………………………………………………………………………. H-1
APPENDIX I MANDATORY REPLACMENT PARTS……………………………………………… I-1
APPENDIX J WARRANTY INFORMATION………………………………………………………… J-1
APPENDIX K ON-BOARD SPARES…………………………………………………………………. K-1
APPENDIX L SPECIAL PACKAGING INSTRUCTIONS…………………………………………... L-1
ALPHABETICAL INDEX………………………………………………………………. Index-1
Group 0703 – Frame and Housing Assembly/Frame and Lifting Handles, Lifting
Rings……………….……………………………………………………………………. C-85
Group 0704 – Frame and Housing Assembly/NATO Slave Receptacle…………. C-87
Group 0705 – Frame and Housing Assembly/Skid Base ……………………….… C-89
iii
ARMY TM 9-6115-639-13&P
AIR FORCE TO 35C2-3-386-51W/IPB
MARINE CORPS TM 10155A-OI/1
TABLE OF CONTENTS (Continued)
LIST OF ILLUSTRATIONS
Figure Title Page
1-1 3kW Tactical Quiet Generator Set…………………………………………………… 1-2
1-2 Location of Generator Set Components…………………………………………….. 1-10
1-3 Diesel Engine/Generator Assembly…………………………………………………. 1-12
1-4 Generator Set Fuel System…………………………………………………………... 1-14
1-5 Generator Set Data, Instruction, and Warning Plates (Sheet 1 of 7)…………….. 1-17
1-5 Generator Set Data, Instruction, and Warning Plates (Sheet 2 of 7)…………….. 1-18
1-5 Generator Set Data, Instruction, and Warning Plates (Sheet 3 of 7)…………….. 1-19
1-5 Generator Set Data, Instruction, and Warning Plates (Sheet 4 of 7)…………….. 1-20
1-5 Generator Set Data, Instruction, and Warning Plates (Sheet 5 of 7)…………….. 1-21
1-5 Generator Set Data, Instruction, and Warning Plates (Sheet 6 of 7)…………….. 1-22
1-5 Generator Set Data, Instruction, and Warning Plates (Sheet 7 of 7)…………….. 1-23
1-6 Fuel System Schematic……………………………………………………………….. 1-28
2-1 Generator Set Controls and Indicators (Sheet 1 of 4)……………………………... 2-5
2-1 Generator Set Controls and Indicators (Sheet 2 of 4)……………………………... 2-6
2-1 Generator Set Controls and Indicators (Sheet 3 of 4 )…………………………….. 2-7
2-1 Generator Set Controls and Indicators (Sheet 4 of 4 )…………………………….. 2-8
2-2 Ground Rod and Cable Installation………………………………………………….. 2-22
2-3 Operating Procedures…………………………………………………………………. 2-24
2-4 Manual Engine Starting……………………………………………………………….. 2-32
3-1 Oil Fill Cap……………………………………………………………………………… 3-3
3-2 Air Filter Replacement………………………………………………………………… 3-14
4-1 Engine Oil Servicing…………………………………………………………………… 4-5
4-2 Diagnostic Test Points………………………………………………………………… 4-16
4-3 Generator Set………………………………………………………………………….. 4-37
4-4 Engine Assembly………………………………………………………………………. 4-39
4-5 Control Panel…………………………………………………………………………… 4-40
4-6 Governor Control Module……………………………………………………………... 4-41
4-7 Governor Actuator Assembly…………………………………………………………. 4-45
4-8 Governor Adjustment………………………………………………………………….. 4-45
4-9 Governor Control Module……………………………………………………………... 4-46
4-10 Governor Actuator……………………………………………………………………... 4-46
4-11 Engine Wiring Harness………………………………………………………………... 4-48
4-12 Permanent Magnet Alternator (PMA)………………………………………………... 4-50
4-13 Battery Charging Regulator…………………………………………………………... 4-53
4-14 Battery System…………………………………………………………………………. 4-59
4-15 Battery Cable Assembly………………………………………………………………. 4-62
4-16 Contactor Assembly…………………………………………………………………… 4-64
4-17 Frequency Converter (A8) Assembly……………………………………………….. 4-67
4-18 Relays, Electromagnetic………………………………………………………………. 4-69
4-19 Control Box Assembly…………………………………………………………………. 4-72
4-20 Control Panel Assembly………………………………………………………………. 4-74
4-21 HOURS Meter………………………………………………………………………….. 4-77
4-22 FUEL LEVEL Gauge…………………………………………………………………... 4-78
4-23 VOLTAGE Meter………………………………………………………………………. 4-79
4-24 LOAD Meter…………………………………………………………………………….. 4-80
4-25 Fault Indicator Module………………………………………………………………… 4-82
4-26 Operator Switches…………………………………………………………………….. 4-84
4-27 EMERGENCY STOP Button…………………………………………………………. 4-86
4-28 DC CIRCUIT BREAKER………………………………………………………………. 4-87
4-29 CIRCUIT INTERRUPTER Indicator Light.………………………………………….. 4-89
iv
ARMY TM 9-6115-639-13&P*
AIR FORCE TO 35C2-3-386-51W/IPB
MARINE CORPS TM 10155A-OI/1
TABLE OF CONTENTS (Continued)
LIST OF ILLUSTRATIONS (Continued)
Figure Title Page
4-30 VOLTAGE ADJUST Rheostat………………………………………………………... 4-91
4-31 Control Box Relays…………………………………………………………………….. 4-93
4-32 Fuses, Diodes, and Terminal Block………………………………………………….. 4-96
4-33 Convenience Receptacle……………………………………………………………... 4-98
4-34 Ground Fault Circuit Interrupter (GFCI)……………………………………………... 4-100
4-35 Load Terminals and EMI Filter (Sheet 1 of 2)………………………………………. 4-102
4-35 Load Terminals and EMI Filter (Sheet 2 of 2)………………………………………. 4-103
4-36 Voltage Resistors………………………………………………………………………. 4-105
4-37 Control Box Wiring Harness………………………………………………………….. 4-106
4-38 Cooling System………………………………………………………………………… 4-108
4-39 Temperature Switch and Cooling Fan………………………………………………. 4-111
4-40 HI/LO Temperature Switches………………………………………………………… 4-113
4-41 Fuel System Assembly………………………………………………………………... 4-115
4-42 Fuel Tank Strainer Assembly………………………………………………………… 4-118
4-43 Fuel-Level Sender Assembly………………………………………………………… 4-120
4-44 Fuel-Level Switch……………………………………………………………………… 4-123
4-45 Fuel Tank Pickup Tube……………………………………………………………….. 4-125
4-46 Primary Fuel Pump……………………………………………………………………. 4-127
4-47 Auxiliary Fuel Pump…………………………………………………………………… 4-129
4-48 Fuel Filter/Water Separator…………………………………………………………… 4-131
4-49 Air Cleaner Assembly…………………………………………………………………. 4-133
4-50 Frame and Housing Assembly……………………………………………………….. 4-135
4-51 Main Access Cover (Sheet 1 of 3)…………………………………………………… 4-139
4-51 Main Access Cover (Sheet 2 of 3)…………………………………………………… 4-140
4-51 Main Access Cover (Sheet 3 of 3)…………………………………………………… 4-141
4-52 Frame and Housing Panels…………………………………………………………... 4-144
4-53 Frame and Lifting Handles……………………………………………………………. 4-146
4-54 NATO Slave Receptacle……………………………………………………………… 4-148
4-55 Skid Base………………………………………………………………………………. 4-150
4-56 ID Plates………………………………………………………………………………… 4-152
4-57 Lubrication System…………………………………………………………………….. 4-154
4-58 Oil Drain Assembly…………………………………………………………………….. 4-156
4-59 Oil Pressure Switch……………………………………………………………………. 4-158
4-60 Engine Oil Temperature Switch……………………………………………………… 4-160
4-61 Oil Filter…………………………………………………………………………………. 4-161
4-62 Exhaust System Assembly…………………………………………………………… 4-163
4-63 Muffler Assembly………………………………………………………………………. 4-166
4-64 Bellows Assembly……………………………………………………………………… 4-169
4-65 Duct Assembly…………………………………………………………………………. 4-172
5-1 Generator Set Engine/Alternator Assembly………………………………………… 5-8
5-2 Permanent Magnet Alternator………………………………………………………... 5-13
5-3 Control Box Wiring Harness………………………………………………………….. 5-16
5-4 Fuel Tank……………………………………………………………………………….. 5-18
v
ARMY TM 9-6115-639-13&P
AIR FORCE TO 35C2-3-386-51W/IPB
MARINE CORPS TM 10155A-OI/1
TABLE OF CONTENTS (Concluded)
LIST OF TABLES
Table Title Page
1-1 Nomenclature Cross-Reference 1-4
1-2 Equipment Data 1-15
2-1 Operator PMCS for MEP-831A/MEP-832A 2-14
3-1 Operator Symptom Index 3-4
3-2 Operator-Level Troubleshooting 3-7
4-1 Lubricant Table for Generator Set MEP-831A/MEP-832A 4-3
4-2 Unit PMCS for MEP-831A/MEP-832A 4-12
4-3 Unit Symptom Index 4-15
4-4 Unit-Level Troubleshooting 4-17
5-1 Direct Support Symptom Index 5-4
5-2 Direct Support Level Troubleshooting 5-5
vi
ARMY TM 9-6115-639-13&P*
AIR FORCE TO 35C2-3-386-51W/IPB
MARINE CORPS TM 10155A-OI/1
HOW TO USE THIS MANUAL
1. DESCRIPTION OF THE MANUAL
Chapter Organization. This manual has five chapters, covering introductory information, principles
a.
of operation, Operator maintenance instructions, Unit maintenance instructions, and Direct
Support maintenance instructions. Each chapter is divided into sections. These sections
contain the cleaning, inspection, troubleshooting, and repair tasks appropriate for the specific
maintenance level. Each chapter contains a table of contents containing the tasks within that
chapter. See the Table of Contents (page i) for the chapters and sections of this manual.
b. Paragraph and Task Numbering. All paragraphs and maintenance tasks are numbered.
This helps you find what you need when you need it. Use the Table of Contents (page i) or
alphabetical index (at the back of the manual) to find the paragraph or task you need.
Appendices. The appendices in this manual contain both general maintenance information and
c.
specific data for this generator set. Appendix A is a list of reference manuals and materials.
Appendix B is the Maintenance Allocation Chart (MAC). Appendix C is the Repair Parts and Special
Tools List (RPSTL). Appendix D lists Components of End Item (COEI) and Basic Issue Items (BII).
Appendix E is an Additional Authorization List (AAL). Appendix F is an Expendable and Durable
Items List. Appendix G is an Illustrated List of Manufactured Items. Appendix H contains Torque
Limits. Appendix I contains Mandatory Replacement Parts information. Appendix J contains
Warranty Information. Appendix K is a List of On-Board Spares. Appendix L contains Special
Packaging Instructions. See the Table of Contents (page i) for a complete list of the appendices
used in this manual.
2. HOW TO FIX A GENERATOR SET MALFUNCTION
a.
Determining the Cause. Figuring out the cause of the malfunction, or troubleshooting, is the first
step in fixing the generator set and returning it to operation. Follow the steps below to determine the
root of your problem:
(1) Turn to the Table of Contents section in this manual (page i).
(2) Locate Troubleshooting for your maintenance level, and turn to the page indicated.
(3) In the Troubleshooting section, find the troubleshooting symptom for the component affected by
the malfunction. See the Symptom Index for help.
NOTE
If the specific symptom is not addressed,
the maintenance required is most likely
more detailed than authorized for your level.
Notify personnel at a higher maintenance level.
(4) Begin troubleshooting. Carefully work your way down through the troubleshooting table.
Try to determine what the problem is.
(5) Once the trouble has been determined, go to the maintenance task called out. Remedy the
malfunction, test the generator set, and return it to service.
vii
ARMY TM 9-6115-639-13&P
AIR FORCE TO 35C2-3-386-51W/IPB
MARINE CORPS TM 10155A-OI/1
Preparing for a Task
b.
NOTE
You must familiarize yourself with the entire
maintenance procedure before starting any
maintenance task. Ensure all parts, materials,
and tools are handy. Read through all steps
before beginning.
(1) PAY ATTENTION TO WARNINGS, CAUTIONS, AND NOTES.
(2) Maintenance tasks are arranged in a logical disassembly/assembly sequence and address only
the component or assembly to be replaced. Locator illustrations are included for removal and
replacement. These illustrations show you the area of the generator set on which to work.
(3) All mandatory replacement parts are listed, including gaskets, packings, cotter pins, and
lockwashers. They are listed by Repair Parts and Special Tools List (RPSTL) name. The
Expendable and Durable Items List (see Appendix F) and support materials are listed, including
solvents, rags, grease, and safety wire.
(4) Each maintenance task lists tools, tool kits, or shop sets needed to do the task. If tools from a
repairmans kit are needed, the kit is listed. Tools not in a kit or set are listed by name, type,
and size. Special tools and test equipment, if necessary, are listed by part number.
(5) Related technical manuals (TMs) needed to accomplish the task are listed. The steps tell when
these TMs are needed.
(6) Read the entire task carefully before starting. DO NOT START A TASK UNTIL:
You know which replacement parts, tools, and supplies are needed.
You have the things you need.
You understand what to do.
c. How to Do the Task. Before starting, read the entire task and familiarize yourself with the entire
procedure. Below are standard maintenance practices. Instructions about these practices will not
normally be included in the task steps. Task steps will tell you when standard maintenance practices
do not apply.
(1) Electrical wiring must be tagged before it is disconnected.
(2) Used packings, retainers, gaskets, cotter pins, lockwashers, and safety wire shall be discarded.
Do not reuse. New parts shall be installed.
(3) Packings shall be coated with lubricant before installation, in accordance with task instructions.
(4) Disassembly procedures list all steps required to support total authorized repair of a component.
You may not need to disassemble a part as far as described in the task. Follow the steps to
disassemble as far as required to replace worn or damaged parts.
(5) Before components or the disassembled parts of a component are inspected, they must be
cleaned as required.
(6) Components must be inspected for serviceable condition before installation.
viii
ARMY TM 9-6115-639-13&P*
AIR FORCE TO 35C2-3-386-51W/IPB
MARINE CORPS TM 10155A-OI/1
(7) When a nut is tightened or loosened on a bolt, the bolt head must be held with a wrench.
(8) A special torque will be cited when the words TORQUE TO are used in the task. Standard
torques are used at all other times. See Torque Limits, Appendix H, for information.
(9) When tightening hardware, observe compliance with the drag torque as required. Drag torque
is defined as the torque required to begin turning the nut. To determine drag torque, thread nut
onto bolt until at least two threads protrude. The nut must not contact the mating part.
(10) After maintenance, inspect for foreign objects.
NOTE
This manual contains the new two-level Maintenance Allocation Chart (MAC) broken into
Field and Sustainment Maintenance. The procedures within the manual are still divided
by maintenance level (Operator, Unit and Direct Support for Field). If you cannot find a
generator set malfunction in the troubleshooting section for your maintenance level, or
cannot find the appropriate corrective actions in the maintenance section, notify
personnel at a higher maintenance level.
3. REPAIR PARTS AND SPECIAL TOOLS LIST
See Appendix C for the Repair Parts and Special Tools List (RPSTL). The RPSTL contains exploded-view
illustrations and parts lists keyed to the illustrations. It lists part number, part name, and quantity used in
each application. Use the RPSTL to identify and order replacement parts.
ix/(x Blank)
ARMY TM 9-6115-639-13&P
AIR FORCE TO 35C2-3-386-51W/IPB
MARINE CORPS TM 10155A-OI/1
CHAPTER 1
INTRODUCTION
Section I GENERAL INFORMATION................................................................................................... 1-2
1-1 Scope ....................................................................................................................... 1-2
1-2 Consolidated Index of Army Publications and Blank Forms.................................... 1-2
1-3 Maintenance Forms, Records, and Reports ............................................................ 1-3
1-4 Reporting Equipment Improvement Recommendations (EIRs) .............................. 1-3
1-5 Corrosion Prevention and Control ..........................................................................1-4
1-6 Destruction of Army Materiel to Prevent Enemy Use .............................................. 1-4
1-7 Preparation for Storage and Shipment .................................................................... 1-4
1-8 Warranty Information ............................................................................................... 1-4
1-9 Nomenclature Cross-Reference List ....................................................................... 1-4
1-10 List of Abbreviations and Acronyms ........................................................................ 1-4
1-11 Quality of Material .................................................................................................... 1-7
1-12 Safety, Care, and Handling...................................................................................... 1-7
1-13 Administrative Storage............................................................................................. 1-7
Section II EQUIPMENT DESCRIPTION .................................................................................. 1-8
1-14 Equipment Characteristics, Capabilities, and Features........................................... 1-8
1-15 Location and Description of Major Components...................................................... 1-9
1-16 Differences Between Models .................................................................................1-13
1-17 Equipment Data ..................................................................................................... 1-13
1-18 Identification and Instruction Plates ....................................................................... 1-13
Section III THEORY OF OPERATION................................................................................................. 1-24
1-19 Theory of Operation ............................................................................................... 1-24
1-20 Electrical System ................................................................................................... 1-24
1-21 Direct Current System............................................................................................ 1-24
1-22 Alternating Current System.................................................................................... 1-25
1-23 Generator ............................................................................................................... 1-26
1-24 Fuel System ...........................................................................................................1
-26
1-1
ARMY TM 9-6115-639-13&P
AIR FORCE TO 35C2-3-386-51W/IPB
MARINE CORPS TM 10155A-OI/1
Section I. GENERAL INFORMATION
1-1 SCOPE
a. This manual provides instructions on operating, troubleshooting, and maintaining the 3kW Tactical
Quiet Generator Set, MEP-831A (60Hz), NSN: 6115-01-285-3012, and MEP-832A (400Hz), NSN:
6115-01-287-2431. Information is provided on principles of operation, controls and indicators,
Preventive Maintenance Checks and Services (PMCS), lubrication, operation, troubleshooting, and
maintenance. See Figure 1-1 for a full-view illustration of the generator set, showing features
pertinent to set operation and maintenance.
b. See TM 9-2815-257-24 for detailed information regarding operation and maintenance of the Diesel
Engine Assembly, Model Number L70AE-DEGFR, NSN: 2815-01-465-5993, manufactured by
Yanmar Diesel Engine Company, Ltd.
Figure 1-1. 3kW Tactical Quiet Generator Set
1-2 CONSOLIDATED INDEX OF ARMY PUBLICATIONS AND BLANK FORMS
See the latest issue of DA Pam 25-30 to determine whether there are new additions, changes, or
additional publications pertaining to the equipment.
1-3 MAINTENANCE FORMS, RECORDS, AND REPORTS
Reports of Maintenance and Unsatisfactory Equipment. Department of the Army forms and
a.
procedures used for equipment maintenance will be those prescribed by DA Pam 738-750, as
contained in the current maintenance management update (The Army Maintenance Management
System (TAMMS)). Fill out and forward to the TAMMS clerk DD Form 5988-E, an automated form in
1-2
ARMY TM 9-6115-639-13&P
AIR FORCE TO 35C2-3-386-51W/IPB
MARINE CORPS TM 10155A-OI/1
the Unit Level Logistics System (ULLS), Equipment Maintenance and Inspection Worksheet. If you
cannot access ULLS, fill out and forward to the TAMMS clerk DA Form 2404. Air Force personnel
will use AFR 66-1 for maintenance reporting and TO 00-35D-54 for unsatisfactory equipment
reporting. Marine Corps units using the Asset Tracking Logistics and Supply System (ATLASS) will
maintain forms and records information in accordance with applicable ATLASS requirements. All
other Marine Corps units will maintain forms and records associated with operating and maintaining
ground equipment, as prescribed by TM 4700-15.
Reporting of Item and Packaging Discrepancies. Army, Air Force, and Marine Corps users will
b.
fill out and forward SF 364 (Report of Discrepancy (ROD)) as prescribed in AR 735-11-2,
DLAR 4140.55, SECNAVINST 4355.18A, AFJ 23-215. For shipping discrepancies, Marine Corps
users will fill out and forward to the Source of Supply (SOS) SF 364,
as prescribed in UM 4400-123, UM 4400-124, and SECNAVINST 4355.18 As prescribed in
UM 4400-123, UM 4400-124, and SCENAVINST 4355.18, for packing discrepancies Marine Corps
users will fill out and forward to the applicable control point identified in the SECNAVINST SF 364.
c. Transportation Discrepancy Report (TDR) (SF 361)
. Army users will fill out and forward SF 361,
Transportation Discrepancy Report (TDR), as prescribed in AR 55-38, NAVSUPINST 4610.33C,
AFR 75-18, MCO P4610.19D, and DLAR 4500.15. Marine Corps users will fill out and forward
SF 361, as prescribed in DoD 4500.9-R, Defense Transportation Regulation, Part II, Cargo
Movement.
1-4 REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIRs)
a. Army
. If your engine assembly needs improvement, let us know. Send us an EIR. You are the only
one who can tell us what you do not like about your equipment. Put it on an SF 368 (Product Quality
Deficiency Report (QDR)) and mail it to the address below:
Commander
U.S. Army Communications and
Electronics Command (CECOM)
ATTN: AMSEL-LC-LEO-E-ED
Fort Monmouth, NJ 07703-5006
We will send you a reply.
b. Air Force
. Air Force personnel should submit TO 00-35D-54 to the address below:
Commander
WRALC/LGMTC
375 Perry Street
Robins AFB, GA 31098-1865
c. Marine Corps
. Marine Corps units will submit all fit, form, or function deficiencies in accordance with
standard Product Quality Deficiency Report (PQDR) procedures contained in TM 4700-15/1 and
MCO 4855.10. Submit your PQDR to Navy PDREP automated systems by going to
http://www.nslcptsmh.navsea.navy.mil/pdrep/pdrep.htm, requesting access, and then filling out the
PQDR. For additional assistance, use this e:mail address:
mbmatcompqdrs@logcom.usmc.mil.
Only deployed units may mail PQDRs to the address below:
Marine Corps LogCom Command Element
Attn: Quality Assurance Office (L15)
814 Radford Boulevard, Suite 20330
Albany, GA 31704-0330
A reply will be furnished to you.
1-3
ARMY TM 9-6115-639-13&P
AIR FORCE TO 35C2-3-386-51W/IPB
MARINE CORPS TM 10155A-OI/1
1-5 CORROSION PREVENTION AND CONTROL
a. Corrosion Prevention and Control (CPC) of Army materiel is a continuing concern. Be sure you
report any corrosion problems with the engine assembly so that the problem can be corrected and
improvements can be made.
b. Although corrosion is typically associated with rusting of metals, it may also include deterioration of
other materials, such as rubber or plastic. Unusual cracking, softening, swelling, or breaking of
these materials may be a corrosion problem.
c. If a corrosion problem is identified, report it using SF-368, Product Quality Deficiency Report. Use of
keywords such as corrosion, rust, deterioration, or cracking will ensure that the information is
identified as a CPC problem.
d. Submit SF-368 to the address specified in DA Pam 738-750. Air Force personnel will use
TO 35-1-3.
1-6 DESTRUCTION OF ARMY MATERIEL TO PREVENT ENEMY USE
For destruction of Army materiel to prevent enemy use, see TM 750-244-3.
1-7 PREPARATION FOR STORAGE AND SHIPMENT
Requirements for packaging, preservation, and administrative storage are in Chapter 4, section VII. See
also Appendix L for special packaging instructions and TB 740-97-2, Preservation of USAMECOM
Mechanical Equipment for Shipment and Storage.
1-8 WARRANTY INFORMATION
Components for the 3kW TQG are warranted in accordance with the component manufacturers latent
defect commercial warranty. The warranty starts on the date found in block 23, DA Form 2408-9, in the
log book. Report all defects in material and workmanship to your supervisor, who will take appropriate
action. See Appendix J for information on manufacturers component warranties and conditions.
1-9 NOMENCLATURE CROSS-REFERENCE LIST
Shortened nomenclature is used in this manual to make procedures easier for you to read.
Table 1-1 is a cross-reference between the shortened nomenclature and the official nomenclature.
Table 1-1. Nomenclature Cross-Reference
Common Name Official Nomenclature
Generator Set 3kW Tactical Quiet Generator Set,
1-10 LIST OF ABBREVIATIONS AND ACRONYMS
Below are the abbreviations and acronyms used in this manual:
A2 Fault Indicator Module
A5 Governor Control
AAL Additional Authorization List
AC Alternating Current
AFB Air Force Base
1-4
MEP-831A/MEP-832A
AIR FORCE TO 35C2-3-386-51W/IPB
AFR Air Force Regulation
AFTO Air Force Task Order
ALC Air Logistics Center
AOAP Army Oil Analysis Program
App Appendix
AR Army Regulation
ATLASS Asset Tracking Logistics and Supply System
BII Basic Issue Items
BT Battery/Battery Terminal
C Centigrade
CAGEC Commercial and Government Entity Code
CARC Chemical Agent Resistive Coating
CB1 DC CIRCUIT BREAKER
CB3 GFCI (60Hz only)
CECOM Communications and Electronics Command
cm Centimeter
CN Change Notice
COEI Components of End Item
CPC Corrosion Prevention and Control
CTA Consolidated Table of Allowance
DA Department of the Army
dBA Decibels referred to 1 kilowatt
DC Direct Current
DLAR Defense Logistics Agency Regulation
DS Direct Support
DS2 Decontaminating Solution 2
DS6 AC CIRCUIT INTERRUPTER Indicator
DSN Defense Switched Network
ECP Engineering Change Proposal
EIC End Item Code/Equipment Item Code
EIR Equipment Improvement Recommendation
EMI Electromagnetic Interference
ESD Electrostatic Discharge
F Fahrenheit
FL FUEL LEVEL Switch
FM Field Manual
FO Foldout
ft Foot
GFCI Ground Fault Circuit Interrupter
GND Ground
Hg Mercury
HP Horsepower
HT Engine Temperature Switch
Hz Hertz
J1 Convenience Receptacle
IPB Illustrated Parts Breakdown
JTA Joint Table(s) of Allowance
kg Kilogram
kW Kilowatt
L1 AC output terminal 1 (load)
L2 AC output terminal 2 (load)
LOEP List of Effective Pages
LOG/TP Logistics/Technical Publication
M1 VOLTAGE Meter
M2 LOAD Meter
M3 HOURS Meter
M5 FUEL LEVEL Meter
ARMY TM 9-6115-639-13&P
MARINE CORPS TM 10155A-OI/1
1-5
ARMY TM 9-6115-639-13&P
AIR FORCE TO 35C2-3-386-51W/IPB
MARINE CORPS TM 10155A-OI/1
MAC Maintenance Allocation Chart
MCO Marine Corps Order
MCPDS Marine Corps Publication Data System
MEP Mobile Electric Power
MIL Military
MIL-HDBK Military Handbook
ml Milliliter
MST Maintenance Support Team
MT5 Fuel Level Sender
MTOE Modified Table of Organization and Equipment
N Neutral
NATO North Atlantic Treaty Organization
NAVMC Navy Marine Corps
NAVSUPINST Naval Supplementary Instruction
NBC Nuclear, Biological, and Chemical
NSN National Stock Number
OEA Office of Energy Assurance
OP Oil Pressure/Low Oil Pressure Switch
OSHA Occupational Safety and Health Act
P/N Part Number
Pam Pamphlet
PMCS Preventive Maintenance Checks and Services
P/O Part of
PQDR Product Quality Deficiency Report
psi Pounds per Square Inch
QC Quality Control
QDR Quality Deficiency Report
QTY Quantity
R1 VOLTAGE ADJUST Potentiometer
ROD Report of Discrepancy
RPM Revolutions per Minute
RPSTL Repair Parts and Special Tools List
RTV Room Temperature Vulcanizing
S1 START/RUN/STOP Switch
S17 AUX FUEL Switch
S18 PREHEAT Switch
S19 EMERGENCY STOP button
S20 Temperature Switch
S21 Temperature Switch
S5 CIRCUIT INTERRUPTER Switch
S7 BATTLE SHORT Switch
SAE Society of Automotive Engineers
SDR Supply Discrepancy Report
SE Support Equipment
SF Standard Form
SECNAVINST Secretary of the Navy Instruction
SMR Source, Maintenance, and Reliability
SOS Source of Supply
SPAWAR Space and Naval Warfare Center
SR1 NATO Slave Receptacle
SRA Specialized Repair Activity
STB Supertropical Bleach
TAMMS The Army Maintenance Management System
TB Technical Bulletin/Terminal Board
TDA Table of Distribution and Allowances
TDR Transportation Discrepancy Report
TM Technical Manual
1-6
TMDE Test, Measurement, and Diagnostic Equipment
TO Task Order (Air Force)
TOE Table of Organization and Equipment
TQG Tactical Quiet Generator
UM Unit of Measure, Unit Manual
U.S./US United States
USAMECOM U.S. Army
UUT Unit Under Test
V Volt
VAC Volts Alternating Current
VDC Volts Direct Current
1-11 QUALITY OF MATERIAL
Material used for replacement, repair, or modification must meet the requirements of this technical
manual. If quality or material requirements are not stated in this technical manual, the material must
meet the requirements of the drawings, standards, specifications, or approved Engineering Change
Proposals (ECPs) applicable to the subject equipment.
1-12 SAFETY, CARE, AND HANDLING
The following general precautions and safety regulations will be prepared: Electrostatic Discharge
(ESD) control standards for the protection of electrical and electronic parts, assemblies, and
equipment will be prepared. ESD classes will be identified. (See MIL-STD-1686 and
MIL-HDBK-263, which contains ESD control procedures and material necessary to protect these
items.
1-13 ADMINISTRATIVE STORAGE
Administrative storage of equipment issued to and used by Army activities will have Preventive
Maintenance Checks and Services (PMCS) performed before storing. When removing the
equipment from administrative storage, perform PMCS to ensure operational readiness.
ARMY TM 9-6115-639-13&P
AIR FORCE TO 35C2-3-386-51W/IPB
MARINE CORPS TM 10155A-OI/1
1-7
ARMY TM 9-6115-639-13&P
AIR FORCE TO 35C2-3-386-51W/IPB
MARINE CORPS TM 10155A-OI/1
Section II. EQUIPMENT DESCRIPTION
1-14 EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES
a. Characteristics
• 3kW, 60Hz (MEP-831A)/400Hz (MEP-832A), Tactical Quiet Generator (TQG)
• Skid-mounted with forklift provisions
• Six lifting handles, four tie-down rings
• Hinged enclosure, allowing quick access for preventive and scheduled maintenance
• Thermostatically controlled, two-fan enclosure cooling system
• 24VDC cranking system
• Single-cylinder, air-cooled, direct-injection, four-stroke-cycle diesel engine
. The 3kW generator set has the following characteristics:
• Permanent Magnet Alternator (PMA) with frequency converter (A8)
• Four-gallon fuel tank (allowing 8 hours of continuous operation at full load)
b. Capabilities and Features
• 3000 to 3600 RPM operating speed
• 3.0kW, 1 phase, 2 wire, 120VAC or 1 phase, 3 wire, 120/240VAC
• Rated engine power of 6.7 HP at 3600 RPM
• Equipped with a 24VDC NATO slave receptacle
• Equipped with a 2-plug 120VAC convenience receptacle with Ground Fault Circuit Interrupter
(GFCI) for the 120VAC convenience receptacle (MEP-831A, 60Hz only)
• Audio noise rating less than 72 dBA at 23 feet from enclosure; less than 85 dBA at operators
position
• Weight: dry = 304.0 pounds (maximum) (MEP-831A), 302.0 pounds (maximum) (MEP-832A);
wet (fuel tank full) = 334.0 pounds (maximum)
• Dimensions: 34.8 x 27.8 x 26.5 inches
. The 3kW generator set has the following capabilities and features:
1-8
Loading...