Onan MEP-003A User manual

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5-6115-585-34
ARMY
TECHNICAL
MANUAL
NAVY
PUBLICATION
AIR
FORCE
TECHNICAL
ORDER
MARINE
CORPS
TECHNICAL
MANUAL
TM5-6115-585-34
NAVFAC
P
-
8-262-12
TO
-
35C2-3-455-2
TM
-
05684C
-
34
TECHNICAL
MANUAL
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
CLASS
HERTZ
NSN
MEP
- 003A
UTILITY 60
6115-00-465-1030
LIBRARY
PIDERMAN
PUBLIC
DOCUMENTS
REFEREXCE
DEPARTMENT
SEP
27
1989
This
copy
is
a
reprint
which
includes
current
pages
from
Changes
1
thru
4
.
VIVERSITY
VIRGINIA
OF
UNIVERSITY
OF
VIRGINIA
LIBRARY
X004816008
PUBLISHED UNDER THE AUTHORITY OF THE DEPARTMENTS OF THE ARMY ,
AIR FORCE , NAVY , AND HEADQUARTERS U.S. MARINE CORPS
JULY
1977
89-571
-P

TM5-6115-585-34
NAVFAC P - 8-262-12
TO - 35C2-3-455-2
TM - 05684C - 34
WARNING
All specific cautions and warnings contained in this manual shall be strictly
adhered to . Otherwise , severe injury , death and / or damage to the equipment may
result .
HIGH VOLTAGE
is produced when this Generator Set is in operation .
DEATH
or severe burns may result if personnel fail to observe safety precautions . Do not
operate this Generator Set until the ground terminal stud has been connected to a
suitable ground . Disconnect the battery ground cable before removing and installing
components on the engine or in the electrical control panel system . Remove all
rings , watches , and other jewelry when performing maintenance on this equipment .
Loose fitting clothing should be secured to prevent it catching in moving parts . Do
not attempt to service or otherwise make any adjustments , connections or recon
nections of wires or cables until Generator Set is shut - down and completely de
energized .
DANGEROUS GASES
Batteries generate explosive gas during charging : therefore , utilize extreme
caution , do not smoke , or use open flame in the vicinity of the Generator Set when
servicing batteries .
Exhaust discharge contains noxious and deadly fumes . Do not operate Generator
Sets in enclosed areas unless exhaust discharge is properly vented to the outside .
To avoid sparking between filler nozzle and fuel tank , always maintain metal to
metal contact between filler nozzle and fuel tank when filling fuel tank .
Do not smoke or use open flame in the vicinity of the Generator Set while fueling .
LIQUIDS
UNDER
HIGH
PRESSURE
are generated as a result of operation of the Generator Set . Do not expose any
part of the body to a high pressure leak in the fuel injection system .
WARNING
Clean parts in a well - ventilated area . Avoid inhalation of solvent fumes and pro
longed exposure of skin to cleaning solvent . Wash exposed skin thoroughly . Dry
cleaning solvent ( Fed . Spec . P - D - 680 ) used to clean parts is potentially dangerous
to personnel and property . Do not use near open flame or excessive heat . Flash
point of solvent is 100 ° F. to 138 ° F. ( 38 ° C . to 59 ° C. ) .
WARNING
If conditions require fuel tank repairs by welding or other methods involving heat
or flame , take care to assure that all fumes are purged from the tank or fill tank
with water before commencing the repair . If possible , tank should be filled with
water prior to welding after being thoroughly purged of fumes . Applying heat or
flame to a fuel tank containing residue , may result in a violent explosion , causing
death or injury to maintenance personnel .
NOISE
Operating level of this generator can cause hearing damage . Ear protectors , as
recommended by the medical or
worn when working near
this set .

DEPARTMENT OF THE ARMY TECHNICAL MANUAL
TM 5-6115-585-34
DEPARTMENT OF THE NAVY PUBLICATION
DEPARTMENT OF THE AIR FORCE TECHNICAL ORDER
MARINE CORPS TECHNICAL MANUAL
NAVFAC P - 8-623-34
TO - 35C2-3-455-2
TM - 05684C / 05685B - 34
C4
CHANGE HEADQUARTERS
,
DEPARTMENTS
OF
THE ARMY , NAVY , AIR FORCE , AND USMC
WASHINGTON , D.C. , 6 December 1986
No.
4
Intermediate ( Field ) ( Direct and General Support )
and Depot Level Maintenance Manual
GENERATOR SET , DIESEL ENGINE DRIVEN , TACTICAL SKID MTD
10 KW , 1 PHASE - 2 WIRE , 1 PHASE - 3 WIRE , 3 PHASE - 4 WIRE
120
, 120/240
AND 120/208 VOLTS
DOD
MODEL
CLASS
HERTZ
NSN
MEP - 003A
MEP - 112A
UTILITY
UTILITY
60
400
6115-00-465-1030
6115-00-465-1027
TM 5-6115-585-34 , NAVFAC P - 8-623-34 , TO - 35C2-3-455-2 , TM - 05684C / 05685B - 34 ,
25 July 1977 , is changed as follows :
1. Remove and insert pages as indicated below . New or changed text material
is indicated by a vertical bar in the margin . An illustration change is indicated
by a miniature pointing hand .
Remove
pages
Insert
pages
1-3 and 1-4
6-1
and 6-2
6-11
and
6-12
6-19 and 6-20
7-1
and 7-2
7-10.1 and 7-10.2
7-13 and 7-14
7-37 and 7-38
1-3 and 1-4
6-1 and 6-2
6-11 and 6-12
6-19 and 6-20
7-1 and 7-2
7-10.1
and
7-10.2
7-13
and
7-14
7-37
and
7-38
2
.
Retain this sheet
in
front
of
manual
for
reference
purposes
.
:

TM
5-6115-585-34
NAVFAC
P
-
8-623-34
TO 35C2-3-455-2
TM 05684C / 05685B - 34
By Order of the Secretaries of the Army , the Navy , and the Air Force :
E. C. MEYER
General
,
United
States
Army
Chief
of
Staff
Official :
J. C. PENNINGTON
Major General , United States Army
The Adjutant General
D. G. ISELIN
Rear
Admiral
,
CEC
,
US
Navy
Commander
Naval Facilities
Engineering
Command
Official
:
LEW
ALLEN
, JR
. , General
USAF
Chief
of
Staff
VAN
L.
CRAWFORD
,
JR
. ,
Colonel
,
USAF
Director
of
Administration
H. A.
HATCH
Major
General
,
USMC
Deputy Chief of Staff for Installations and Logistics
DISTRIBUTION :
Active
Army
:
To
be
distributed
in
accordance
with
DA
Form
12-25D
,
Direct and
General
Support
Maintenance
Requirements
for
Generator Sets
,
Engine
Driven
10
KW
60
HZ
, 10
KW
400
HZ .
Marine
Corps
:
MARCORPS
CODES
:
AGB

TM
5-6116-686-34
NAVFAC P - 8-623-84
TO
-
85V2-3-456-2
TM
- 06884C
- 34
C1
CHANGE
DEPARTMENT
OF
THE
ARMY
,
AIR FORCE , AND USMC
WASHINGTON
,
DC
.
,
1
August
1979
No. 1
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
CLASS
HERTZ NSN
MEP - 003A
UTILITY
60
6115-00-465-1030
TM
5-6115-586-34 /
NAVFAC
P -
8-623-34
/ TO -
35C2-3-455-2 / TM
- 05684C
- 34 , July 1977
, is
changed
as follows
:
1. Remove and insert pages as indicated below .
Remove
pages
Insert
pages
i thru iv
1.9 / 1-10
6-1 thru 6-8
6-13
and
6-14
INDEX 5 / INDEX 6
i thru iv
1.9 / 1-10
6-1 thru 6-8
6-13
and
6.14
INDEX 5 / INDEX 6
2. New or changed text material is indicated by a vertical bar in the margin . An illustration change is indi .
cated by a miniature pointing hand .
3.
Retain
these
sheets
in
front
of
manual
for
reference
purpose
.
:

TM
6-6116-685-34
NAVFAC P -
8-623-34
TO
-
35V2-3-455-2
TM - 05684C - 34
Ci
By
Order
of
the
Secretaries
of
the
Army
,
the
Air
Force
,
and
the
Marines
:
E. C.
MEYER
General
,
United
States
Army
Chief
of
Staff
Official
:
J. C. PENNINGTON
Major
General
,
United
States
Army
The Adjutant General
DAVID C. JONES
General , USAF
Chief of Staff
Official :
Jack
R.
BENSON
,
Colonel
, USAF
Director of Adminsitration
V.
J.
WALLS
,
Acting
Deputy Chief of Staff for Installations Logistics
DISTRIBUTION :
To be distributed in accordance with DA Form 12-25D Direct and General Support Maintenance
Requirements for Generator Sets , Engine Driven : 10 KW , 60 HZ .
1

DEPARTMENT OF THE ARMY TECHNICAL MANUAL
TM5-6115-585-34
DEPARTMENT OF THE NAVY PUBLICATION
NAVFAC
P
-
8-623-34
DEPARTMENT OF THE AIR FORCE TECHNICAL ORDER
TO
-
35C2-3-455-2
MARINE CORPS TECHNICAL MANUAL
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
CLASS
HERTZ
NSN
MEP - 003A
UTILITY
60
6115-00-465-1030
MEP
-
112A
UTILITY
400
6115-00-465-1027
TABLE OF CONTENTS
Page
.
LIST OF EFFECTIVE PAGES
LIST OF ILLUSTRATIONS
LIST OF TABLES
INTRODUCTION .
iv
V
vi
1-1
CHAPTER
1
.
Section
I.
GENERAL
1-1
1-1 .
1-2
.
1-3
.
1-4
.
1-5
.
Scope .
Limited
Applicability
Maintenance Forms and Records
Reporting
of
Errors
Levels of Maintenance Accomplishment
1-1
1-1
1-1
1-1
1-1
.
.
Section
II
.
DESCRIPTION AND TABULATED DATA
1-1
1-1
.
. . 1-6
.
1-7 .
Description
Tabulated
Data
1-1
.
CHAPTER
2
.
GENERAL MAINTENANCE INSTRUCTIONS
2-1
Section
1
.
REPAIR PARTS , SPECIAL TOOLS , TEST , MEASUREMENT , AND
DIAGNOSIC EQUIPMENT ( TMDE ), AND SUPPORT EQUIPMENT
2-1
2-1
.
2-2
.
2-3
.
Repair
Parts
Tools
and
Equipment
Fabricated Tools and Equipment
2-1
2-1
2-1
Section
II
.
TROUBLESHOOTING
2-5
2-5
0
2-4
.
2-5
.
General
Malfunctions Not Corrected By Use of the Troubleshooting
Table
.
2-5
Change
2
i

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P -
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TO - 35C2-3-455-2
TM
-
05684C
/
05685B
-
34
TABLE OF CONTENTS ( CONT )
Page
Section
II
.
GENERAL MAINTENANCE
2-12
2-6
.
2-7
.
General
Maintenance
General Maintenance Procedures
2-12
2-12 .
Section
IV
.
REMOVAL AND INSTALLATION OF MAJOR COMPONENTS
2-12
2-8
.
Control
Cubicle
2-9
.
Engine
Assembly
.
2-10
.
Generator
Assembly
2-12
2-12
2-16
.
CHAPTER
3 .
MAINTENANCE OF COOLING SYSTEM
3-1 .
Section
I.
DESCRIPTION AND FUNCTION
3-1
. . .
.
3-1 .
General
.
3-1
Section
I.
MAINTENANCE
3-1
3-2
.
3-3
.
Engine Cooling System
High
Temperature
Cut
Out
Switch
3-1
3-1
CHAPTER
4
.
MAINTENANCE OF FUEL SYSTEM
4-1
.
Section 1
.
DESCRIPTION AND FUNCTION
4-1
4-1
.
General
.
4-1
Section
I.
MAINTENANCE OF FUEL TANK
4-1
.
4-2
.
Fuel Tank
4-1
CHAPTER 5
.
MAINTENANCE OF STARTING SYSTEM
5-1
..
Section
I.
DESCRIPTION AND FUNCTION
5-1
. .
5-1
.
General
.
5-1
.
Section
I.
MAINTENANCE 5-1
5-2 .
Starter
Assembly
.
5-1
CHAPTER
6
.
MAINTENANCE OF CONTROL SYSTEM
6-1
Section I.
DESCRIPTION AND FUNCTION
6-1 .
6-1
.
6-2
.
6-3 .
DC
Control
System
AC
Instrumentation
System
Voltage Regulator
6-1
6-1
6-1
.
Section
I.
MAINTENANCE
6-1
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 )
6-1
6-8
6-8
6-9
6-9
6-9
-

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5-6115-585-34
NAVFAC
P
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8-623-34
TO
-
35C2-3-455-2
TM
-
05684C
/
05685B
- 34
TABLE OF CONTENTS ( CONT )
Page
CHAPTER
7
.
MAINTENANCE OF ENGINE
7-1
Section
I.
DESCRIPTION AND FUNCTION
7-1
..
.
7-1
.
General
.
7-1
Section
I.
ENGINE EXTERNAL ASSEMBLY
7-1
.
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
7-1
7-1
7-5
7-6
7-6
7-6
7-8
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
O
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
.
.
.
CHAPTER
8
.
MAINTENANCE OF GENERATOR ASSEMBLY
8-1
Section
I.
DESCRIPTION AND FUNCTION
8-1
.
8-1
.
General
.
8-1
Section
0
.
MAINTENANCE
8-1
8-2
.
Generator Maintenance
8-1
CHAPTER
9
.
GENERATOR SET TEST AND INSPECTION AFTER REPAIR OR
OVERHAUL
9-1
Section
1
.
GENERAL REQUIREMENTS
9-1 .
.
9-1
.
General Information
9-1
.
Section
I.
INSPECTION .
9-1
9-2
.
9-3
.
General
.
Engine
Cooling
System
Wiring
Harnesses
9-1
9-1
9-1
.
9-4
.
Section
III .
OPERATIONAL TESTS
9-1
O
.
Generator and
Generator
Control
Circuitry
Engine Control Circuitry .
REFERENCE
9-5
.
9-6
.
9-1
9-1
O
APPENDLX
A.
A - 1
INDEX
. INDEX 1
Change
3
iii

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5-6115-585-34
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P
-
8-623-34
TO
-
35C2-3-455-2
TM
-
05684C
/
05685B
-
34
LIST OF ILLUSTRATIONS
.
Figure
1-1
.
1.1.1
2-1
.
2-2
.
2-3
.
2-4
.
3-1
.
5-1
.
5-2
.
.
5-3
.
.
.
O
.
.
.
.
Title
Generator
Set
Electrical
Schematic
(
MEP
-
003A
)
Generator
Set
Electrical
Schematic
(
MEP
-
112A
)
Speed
Control
Assembly
...
Disconnecting
Engine
from
Generator
Lifting
Engine
Lifting
Engine
and
Generator
Assembly
Engine
Cooling System
.
Electric
Starter
Assembly
Testing
Solenoid
Switch
Testing
Armature
for
Grounds
Testing
Armature
for
Shorted
Coils
Checking
Commutator
Runout
Testing
Armature
Shaft
Runout
Testing
Brush
Spring
Tension
Undercutting
Mica
.
Brush
Replacement
Checking
Pinion
Clearance
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
Assembly
A
-
4
Injector
Fuel
Lines
Speed
Control
Assembly
and
Governor
Control
Assembly
Engine
Flywheel
and
Ring
Gear
Assembly
Governor
Linkage
Adjustsment
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
Gear
Cover
Components
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
5-4
.
5-5
.
5-6
.
5-7
.
5-8
.
5-9
.
5-10
.
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
.
7-8
.
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
.
7-22
.
7-23
.
7-24
.
7-25
.
7-26
.
7-27
.
7-28
.
7-29
.
7-30
.
Page
1-9
1.10.1
2-13
2-14
2-15
2-17
3-2
5-2
5-3
5-4
5-4
5-5
5-5
5-6
5-6
5-7
5-8
6-2
6-6
6-10
6-12
6-13
6-14
6-14.1
6-14.2
6-15
6-16
6-18
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
7-23
7-24
7-25
7-26
7-27
7-27
7-28
7-28
7-29
.
. .
.
..
.
.
iv
Change
3

TM5-6115-585-34
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P
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TO
-
35C2-3-455-2
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-
05684C
/
05685B
-
34
LIST OF ILLUSTRATIONS ( CONT )
Figure
Title
Page
O
.
.
.
.
.
7-31
.
7-32
.
7-33
.
7-34
.
7-35
.
7-36
.
7-37
.
7-38
.
7-39
.
7-40
.
7-41
.
7-42
.
7-43
.
7-44
.
7-45
.
7-46
.
7-47
.
8-1
.
8-2
.
8-3
.
8-3.1
.
8-4
.
8-5
.
8-5.1
,
9-1
.
9-2
.
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 ( MEP - 003A )
Generator Frame Assembly Winding Data ( MEP - 112A )
Exciter Rotor Assembly Winding Data .
Generator Rotor Winding Data ( MEP - 003A ) .
Generator Rotor Winding Data ( MEP - 112A )
Adjusting R3 Resistor
Testing Engine Control Circuitry
7-29
7-30
7-31
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
8-8.1
8-9
8-11
8-12.1
9-2
9-2
.
.
.
.
.
LIST OF TABLES
Table
Title
Page
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
.
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 - 112A only )
Terminal Voltages
.
Reconnection
Switch Continuity
Testing Bridge Assembly ( 60 HZ only )
Button Code Letter and Size
Test Schedule
1-3
1-4
2-1
2-2
2-6
6-3
6-5
6-7
6-8.1
6-9
6-15
6-17
7-40
9-2
0
:
Change
2
v
/
(
vi
blank
)

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 . 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
:
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
sec
tions for general maintenance , including trouble
shooting , 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 .
a
.
( A )
Army
DA
Form 2028
directly
to
:
Com
mander
,
US
Army
Troop
Support
and
Aviation
Materiel
Readiness
Command
,
ATTN
:
DRSTS
.
MTT
,
4300
Goodfellow
Boulevard
,
St.
Louis
,
MO
63120
.
1-2
.
LIMITED
APPLICABILITY
.
b . ( F ) Air Force
AFTO
Form 22
directly
to :
Commander , Sacramento Air Logistics Center , ATTN :
MMEDT , McClellan Air Force Base , CA 95652 , in
accordance with TO - 00-5-1 .
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
.
c . ( N ) Navy - by letter directly to : Commanding
Officer , US Navy , Ships Parts Control Center , ATTN :
Code 783 , Mechanicsvurg , PA 17055 .
1-3 . MAINTENANCE FORMS AND RECORDS .
d
.
(
MC
)
Marine
Corps
by
NAVMC
form
10772
directly
to
:
Commandant
,
US
Marine
Corps
,
ATTN
:
Code
LMA
- 1
,
WASH
DC
20380
.
I
a . ( A ) Maintenance forms and records used by
Army personnel are prescribed in TM 38-750 .
1-5 . LEVELS OF MAINTENANCE ACCOMPLISH
MENT
.
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 .
a . ( A , MC ) Army and Marine Corps users shall
refer to the Maintenance Allocation Chart ( MAC ) for
tasks and levels of maintenance to be performed .
c . ( N ) Navy users should refer to their service
peculiar directives to determine applicable mainten
ance forms and records to be used .
b . ( F ) Air Force users shall accomplish mainte
nance at the user level consistent with their capability
in accordance with policies established in AFM 66-1 .
d . ( MC ) Maintenance forms and records used by
Marine Corps personnel are prescribed in TM 4700
15/1
.
c . ( N ) Navy users shall determine their maintenance
levels in accordance with their service directives .
Section II . DESCRIPTION AND TABULATED DATA
1-6 . DESCRIPTION .
1-7
. TABULATED
DATA
.
a
.
General
.
This
paragraph
contains
all
maintenance
data
pertinent
to
intermediate
(
field
)(
direct
,
general
support
)
and
depot
maintenance
personnel
.
are
A
general
description
of
the
Diesel
Engine
Generator
Sets
and
information
pertaining
to
the
identification
plates
contained
in
the
Cperator
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
.
b
.
Engine
Generator
Sets
.
Refer
to
Operator
and
Organizational
Maintenance
Manual
.
Change
2
1-1

TM5-6115-585-34
NAVFAC
P
-
8-623-34
TO
-
35C2-3-455-2
TM
-
05684C
/
05685B
-
34
f
.
Engine
.
Refer
to
Operator
and
Organizational
Maintenance
Manual
.
g
.
Exciter
Assembly
.
MEP
- 003A
MEP
-
112A
+
1.8
c . Main
Generator
. Exciter
field
voltage
and
current
versus
load
, see
the
following
:
Exciter
Percent of Rated Load
10 - .8PF , 120 V
Volts Amps
0
17.8
0.96
25
21.7
0.56
50
25.5
0.66
75
29.8
0.77
100
34.0
0.87
125
38.7
1.0
$
6.0
1.2
#4.0
Frequency
Regula
tion
,
Hz
Short
Term
.
Steady
State
,
Hz
Stability
(
30
sec
)
Long
Term
Steady
State
,
Hz
Stability
(
4
hrs
)
Frequency
Drift
...
(
8
Hr
period
)
,
Hz
1.8
6.0
$
1.2
#
4.0
1
.
.
h
.
Exciter
Stator
.
DOD Drawing No.
Number of Poles
Turns per coil
Conductor
.
0
.
.
d . Generator Frame Assembly .
Model ....
MEP
-
003A
DOD
Drawing
No.
72-5270
Number
of
Slots
60
Pitch
of
Coil
.
1-11
Coil
Groups
12
Coils
per
Group
5
Turns
per
Coil
Group
5-5-5-5-5
Conductor
8
strands
of
#
18
AWG
magnet
wire
Resistance
between
lead
.
..0.115
+
0.012
ohms
pairs
T1
-
T4
,
T2
-
T5
,
T3
-
T6
T7
-
T10
,
Tg
-
T11
and
Tg
-
T12
at
25
°
C
(
87
° F )
.
72-5240
8
400
1
stand
of
#
23
AWG
magnet
wire
series
36.0 + 3.6 ohms
.
Connection
Resistance
at
25
°
C
(
87
°
F
)
.
.
i
.
Exciter
Rotor
.
DOD
Drawing
No.
Air
Gap
...
Number
of
Slots
Pitch
of
Coil
Coil
Groups
Coils
per
Group
Turns per
Coil
Conductor
.
72-5220
.052
to .064
36
1-4
24
2-1
11
1 strand of # 17
AWG magnet wire
0.677 + 0.068 ohms
Model
MEP
-
112A
DOD
Drawing
No.
72-5272
Number of Slots .
108
Pitch
of
Coil
.
1-4
Turns
per
Coil
2
Conductor
.
5
strands
of
#
18
AWG
magnet
wire
Resistance
between
lead
0.071
+
0.007
ohms
pairs
T1
-
T4
,
T2
-
T5
,
T3
-
T6
,
17
-
T10
,
T8
-
T11
and
Tg
-
T12
at
25
°
C
.
.
Resistance
between
T1
-
T2
,
T2
-
T3
and
T1
-
T3
at
25
°
C
(
87
°F)
...
O
.
.
.
e
.
Generator
Rotor
.
Model
...
DOD
Drawing
No.
Air
Gap
Number
of
Poles
Turns
per
Pole
Conductor
..
.
. .
MEP
-
003A
72-5265
0.090 to 0.106 in .
4
207
1
strand
of
#
14
AWG
magnet
wire
series
3.31 + 0.33 ohms
.
.
.
Connection
Resistance of Connected
Poles at 25 ° C ( 77 ° F )
j
.
Circuit
Breaker
.
DOD
Drawing
No.
(
MEP
-
003A
)
72-5173
(
MEP
-
112A
)
72-5174
Construction
Handle
Spacers
aluminum
Handle Tie Bars
aluminum
Mounting Insert
.
steel
Washer
external
tooth
Studs
brass
with
silver
or
tin
plated
Handle
Tie
Pin
corrosion
resistant
steel
Type
relay trip
Voltage
250
vac
Frequency
(
MEP
-
003A
)
60
Hz
(
MEP
-
112A
)
400
Hz
Interrupting
Capacity
5000A
Relay Coil ..
calibrated
to
carry 0.82A
Trip
1.13A
6
+
3
min
Trip
3.00A
instantaneously
Maximum
Contact
Capacity
104A
Temperature
Range
.
54
°
C
thru
85
°
C
129
°
F
thru
185
°
F
.
.
.
.
.
.
Model
...
DOD
Drawing
No.
Air
Gap
Number
of
Poles
Turns per
Pole
Conductor
.
MEP
-
112A
72-5267
0.030 to 0.048 in .
24
55
4 strands of #18
AWG
magnet
wire
...
3.05
+
0.305
ohms
O.
.
.
Resistance
of
Connected
Poles
at
25
°
C
1-2
Change
2

TM5-6115-585-34
NAVFAC P - 8-623-34
TO
-
35
C2-3-455-2
TM
-
05684C
/
05685B
-
34
k . Engine
Accessories
.
( 4 ) Battery charging alternator . Refer to Operator
and Organizational Maintenance Manual .
(
1
)
Fuel
injection
pump
.
( 5 ) Fuel solenoid valve .
..
.
Manufacturer
Model
Type
..
Onan
147-0333
PSU , single plunger
multi outlet
gear and cam
block mounted
.
Drive
Type
Mounting
DOD
Drawing
No.
Volts
Watts
Input
Pressure
Orifice
Size
72-5069
24 vdc
12
w
.
20
psi
0.187
inch
.
(
2
)
Fuel
transfer
pumps
.
Refer
to
Operator
and
Organizational
Maintenance
Manual
.
(
6)
Oil
pump
.
( 3 ) Electric starter . Refer to Operator and
Organizational Maintenance Manual .
Type .
gear
driven
:
Change
2
1-2.1
/ (
1-2.2
blank
)

1
1
1
1
1
1
1
1
1
1
1

TM5-6115-585-34
NAVFAC
P - 8-623-34
TO
-
35C2-3-455-2
TM
-
05684C
/
05685B
-
34
Table 1-1 . Torque Values ( Ft - Lb )
Torque
Range
(
Cadmium
Plated
) (
Ft
-
Lb
)
Item
Min
.
Max
.
Connecting
rod
bolt
27
29
Cover - rocker box
7
8
Exhaust
manifold
nuts
11
*
13
*
.
Flywheel mounting screw
54 58
Gearcase
cover
15
17
Rear
bearing
plate
40
**
45
**
Rocker
arm
nut
(
prevailing
torque
locknut
)
10***
Rocker
arm
stud
35
40
Oil pump mounting screws
13
17
Oil
base
mounting
screws
42 47 ****
Oil
filter
base
mounting
screws
18
20
Cylinder
head
bolt
44
*
46
*
Oil
cooler
mounting
screws
20
22
Blower
wheel
mounting
screw
65
70
Intake
manifold
mounting
screws
13
15
Injector
nozzle
mounting
screws
.
17
18
Glow
plug
10
*
15 *
Governor
arm
locking
screw
.
32
(
in
.
lb.
)
36 ( in . lb. )
Damper blower wheel assembly nut
28
30
Backplate screw ( hex - socket flathead )
75 ( in . Ib . )
85
(
in
.
lb.
)
Center main bolt
97
102
High
temperature
cutout
switch
50
(
in
:
lb.
)
60
(
in
.
Ib
. )
Fuel
supply
line
nut
Fuel
return
line
fitting*****
16
18
*
Anti
Seize
Compound
.
**
Apply
MIL
-S-
22473C
,
Grade
CV
,
to
threads
.
***
Torque
specifications
to
be
used
only
to
determine
if
used
locknuts
meet new
part tolerances
.
****
Torque
these
screws
twice
.
****
Tighten
to 1/6
turn
beyond
a
hand
tightened
snug
fit
.
Change
4
1-3

TM
5-6115-585-34
NAVFAC
P
-
8-623-34
TO
-
35C2-3-455-2
TM
-
05684C
/
05685B
-
34
Table 1-2 . Repair and Replacement Standards
( All values in inches unless otherwise specified . )
Manufacturer Dimensions
and Tolerances
Maximum Allowable
Wear Limit
Component
Minimum
Maximum
CYLINDER BLOCK :
Cylinder
bore
diameter
3.
4993
3.
5005
0.005
Cylinder
bore
out
of
round
0.001
0.001
Cylinder bore taper
0.001 0.002
Main bearing bore - less bearings
2. 4365
2. 4375
2. 4375
Camshaft bearing bore - less
bearings
Front
Center
Rear
2. 3745
1. 7500
1. 3120
2.3755
1. 7510
1. 3130
2. 3755
1. 7510
1.3130
Valve tappet bore
0.
8755
0.8765
0.8775
CRANKSHAFT
:
Main bearing journal diameter
2. 2427
2.
2435
0.001
Main bearing journal clearance
0.0012 0.0037
0.0047
Main bearing journal out of round
0.0005 0.001
Main
bearing
journal
taper
0.0004
0.0015
Connecting
rod
journal
diameter
2. 0597
2. 0605 0.002
Connecting
rod
journal
out
of
round
0.0005
0.001
Connecting
rod
journal
taper
0.0004
0.0015
Fillet
radii
0. 1100
0. 1200
0. 1200
*
Crankshaft
main
bearing
clearance
0.0024
0.0049
0.0054
Crankshaft thrust clearance
0.010 0.015
0.015
**
Seal surface diameter
rear
1.
8740
1. 8750
0.0050
Seal surface diameter - front
1.6870 1. 6875
0.0050
CONNECTING
ROD
:
Length
c
toc
5.
9980
6.
002
6.002
Bearing bore - less bearings
2. 1871 2.
1876
2.
1886
Bearing
to
crankshaft
clearance
0.0010
0.0030
0.0040
Connecting
rod
side
clearance
0.0020 0.0160 0.0160
* Replacement Bearing Only
**
Shim
Controlled
1-4
Change
4

TM5-6115-585-34
NAVFAC P - 8-262-12
TO - 35C2-3-455-2
TM
-
05684C
-
34
Table 1-2 . Repair and Replacement Standards ( Cont )
Manufacturer Dimensions
and Tolerances
Maximum Allowable
Wear Limit
Component
Minimum
Maximum
CONNECTING
ROD
(
Cont
):
Connecting
rod
side
clearance
0.0020 0.0160
0.0160
1.
043
1.045
1.0455
Piston pin bushing bore - less
bushing
Piston pin bushing bore
0.9903
0.
9906
0.001
CAMSHAFT :
Bearing
journal
diameter
Front
Rear
2. 2500
1. 1875
2.
2505
1.1880
0.002
0.002
Lobe
diameter - base
to
tip
1.
185
1.
189
0.005
Journal runout in vee blocks
0.004
Bearing clearance
0.0012
0.0037
0.0057
End Thrust 0.0070
0.0390
0.0450
Backlash
camshaft
to
crank
gear
0.005 0.0100 0.0120
PISTON :
0.0062
0.0082 0.010
Clearance in
cylinder
bore
( pull
on
1/2
x
0.0050
ribbon
)
Piston pin bore
0.99005
0.
99025
0.9903
Width
of
ring
groove
-
top
0.097 0.098 0.005
0.0965 0.0975 0.005
Width of ring groove - 2nd & 3rd
compression
Width of ring groove - oil control
0. 1880
0.1895 0.005
PISTON PIN :
Length
2. 988
3.
003
N
/
A
Diameter
0.9899 0.9901
Clearance
in
piston
0.0005
0.0025
Clearance in
connecting rod
0.0002 0.0007
PISTON RING :
Clearance
in
groove
-
top
0.0035 0.0075
2nd & 3rd
0.0030
0.0050
0.001
0.0003
0.0008
0.0100
0.0080 Clearance
in
groove
compression
1-5