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

TM5-6115-585-34
NAVFAC
P -
8-262-12
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
-

TM
5-6115-585-34
NAVFAC
P
-
8-623-34
TO
-
35C2-3-455-2
TM
-
05684C
/
05685B
- 34
TABLE OF CONTENTS ( CONT )
Page
CHAPTER
7
.
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