OPERATOR, UNIT, DIRECT SUPPORT AND GENERAL SUPPORT

1 ARMY TM 9-6115-672-14 air force TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 TECHNICAL manual OPERATOR, UNIT, DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE manual GENERATOR SET, SKID MOUNTED, TACTICAL QUIET 60 KW, 50/60 AND 400 HZ MEP-806B (50/60 HZ) (NSN 6115-01-462-0291) EIC: GGW MEP-816B (400 HZ) (NSN 6115-01-462-0292) EIC: GGX DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited. DEPARTMENTS OF THE ARMY, AND THE air force AND HEADQUARTERS, MARINE CORPS 1 July 2000 PCN 182 092443 00 HOW TO USE THIS manual PAGE ix EQUIPMENT DESCRIPTION AND DATA PAGE 1-4 PRINCIPLES OF OPERATION PAGE 1-16 CONTROLS AND INDICATORS PAGE 2-1 OPERATOR PMCS PAGE 2-14 OPERATOR TROUBLESHOOTING PAGE 3-1 OPERATOR MAINTENANCE PAGE 3-18 UNIT TROUBLESHOOTING PAGE 4-10 UNIT MAINTENANCE PAGE 4-49 DIRECT SUPPORT TROUBLESHOOTING PAGE 5-2 DIRECT SUPPORT MAINTENANCE

2 PAGE 5-14 GENERAL SUPPORT MAINTENANCE PAGE 6-1 TM 9-6115-672-14 A (B blank) Change 0 USA INSERT LATEST CHANGED PAGES, DESTROY SUPERSEDED PAGES NOTE: The portion of the text affected by the changes is indicated by a vertical line in the outer margins of the page. Changes to illustrations are indicated by miniature pointing hands. Changes to wiring diagrams are indicated by shaded areas. Dates of issue for original and changed pages is: July 2000 TOTAL NUMBER OF PAGES IS 500, CONSISTING OF THE FOLLOWING: Page * Change Page * Change Page * Change No. No. No. No. No. 0 Title 0 A .. 0 B 0 0 i x .. 0 1-1 0 1-40 blank .. 0 2-1 0 3-1 0 4-1 0 5-1 0 6-1 .. 0 6-2 blank .. 0 A-1 .. 0 A-2 blank .. 0 B-1 B-13.

3 0 B-14 blank .. 0 C-1 C-5 .. 0 C-6 blank .. 0 0 D-2 0 E-1 E-2 .. 0 F-1 .. 0 F-2 blank .. 0 G-1 G-37 .. 0 G-38 0 H-1 H-3 .. 0 H-4 0 I-1 I-2 .. 0 Ind-1 0 FO-1 .. 0 FO-2 0 FO-3 .. 0 FO-4 blank .. 0 FO-5 .. 0 FO-6 blank .. 0 FO-7 .. 0 FO-8 blank .. 0 LIST OF EFFECTIVE PAGES * Zero in this column indicates an original page. ARMY TM 9-6115-672-14 air force TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 a WARNING PAGES _____ WARNING High voltage is produced when this generator set is in operation. Make sure unit is completely shut down and free of any power source before attempting any repair or maintenance on the unit. Failure to comply can cause injury or death to personnel. _____ WARNING High voltage is produced when the generator set is in operation. Never attempt to start the generator set unless it is properly grounded.

4 Failure to comply can cause injury or death to personnel. _____ WARNING High voltage is produced when the generator set is in operation. Never attempt to connect or disconnect load cables while the generator set is running. Failure to comply can cause injury or death to personnel. _____ WARNING DC voltages are present at generator set electrical components even with generator set shut down. Avoid shorting any positive with ground/negative. Failure to comply can cause injury to personnel and damage to equipment. _____ WARNING Metal jewelry can conduct electricity. Remove metal jewelry when working on electrical system or components. Failure to comply can cause injury or death to personnel by electrocution. _____ WARNING Diesel fuel is flammable and toxic to eyes, skin, and respiratory tract. Skin and eye protection are required when working in contact with diesel fuel, and avoid repeated or prolonged contact.

5 Provide adequate ventilation. Failure to comply can cause injury or death to personnel. ARMY TM 9-6115-672-14 air force TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 b _____ WARNING Fuels used in the generator set are flammable. When filling the fuel tank, maintain metal-to-metal contact between filler nozzle and fuel tank opening to eliminate static electrical discharge. Failure to comply can result in flames and possible explosion and can cause injury or death to personnel and damage to the generator set. _____ WARNING Fuels used in the generator set are flammable. Do not smoke or use open flames when performing maintenance. Failure to comply can result in flames and possible explosion and can cause injury or death to personnel and damage to the generator set. _____ WARNING CARC paint is a health hazard. Wear protective eyewear, mask and gloves when sanding CARC painted surfaces.

6 Failure to comply can cause personal injury. _____ WARNING Dry cleaning solvent is flammable and toxic to eyes, skin, and respiratory tract. Skin and eye protection are required when working in contact with dry cleaning solvent. Avoid repeated or prolonged contact. Work in ventilated area only. Failure to comply can cause injury or death to personnel. _____ 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. Failure to comply can cause injury or death to personnel. _____ WARNING Batteries give off a flammable gas. Do not smoke or use open flame when performing maintenance. Failure to comply can cause injury or death to personnel and equipment damage due to flames and explosion. ARMY TM 9-6115-672-14 air force TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 c _____ WARNING Hot engine surfaces and sparks from the engine and generator circuitry are possible sources of ignition.

7 When hot refueling with DF-1, DF-2, DF-A, JP5 or JP8, avoid fuel splash and fuel spill. Do not smoke or use open flame when performing refueling. Failure to comply can result in flames and possible explosion and can cause injury or death to personnel and damage to the generator set. _____ WARNING Hot exhaust gases can ignite flammable materials. Allow room for safe discharge of hot gases and sparks. Failure to comply can cause injury or death to personnel. _____ WARNING If necessary to move a generator set which has been operating in parallel with another generator set, shut down both generator sets prior to removing load cables or ground. Failure to comply can cause injury or death to personnel by electrocution. _____ WARNING Engine exhaust is hot. When it is required to extend exhaust pipe through flammable material ( , wall), shield the extension pipe to protect personnel from burns and prevent fire hazard.

8 Failure to comply can cause injury to personnel, damage to equipment, and fire. _____ WARNING Prior to making any connections for parallel operation or moving a generator set which has been operating in parallel, ensure there is no input to the load output terminal board and the generator sets are shut down. Failure to comply can cause injury or death to personnel by electrocution. ARMY TM 9-6115-672-14 air force TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 d _____ WARNING Cooling system operates at high temperature and pressure. Contact with high pressure steam and/or liquids can result in burns and scalding. Shut down generator set, and allow system to cool before performing checks, services, and maintenance. Failure to comply can cause injury to personnel. _____ WARNING Cooling system operates at high temperatures.

9 Hot coolant is under high pressure and can spray when cooling system is opened. Shut down generator set and allow to cool before servicing radiator. Failure to comply can cause damage to equipment and injury to personnel. _____ WARNING In extreme cold weather, skin can stick to metal. Avoid contacting metal items with bare skin in extreme cold weather. Failure to comply can cause injury to personnel. _____ WARNING Battery acid can cause burns to unprotected skin. Wear protective gloves and safety goggles. Failure to comply can cause injury to personnel. _____ WARNING Cleaning with compressed air can cause flying particles. When using compressed air, wear protective glasses and use clean, low pressure air, less than 30 psi ( kPa). Failure to comply can cause eye injury. _____ WARNING Exhaust system can get very hot. Allow system to cool before performing maintenance.

10 Failure to comply can cause severe burns and injury to personnel. _____ WARNING If not wrapped, hot exhaust pipe can cause burns. Wrap exhaust pipe with protective material. Failure to comply can cause severe injury to personnel. ARMY TM 9-6115-672-14 air force TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 e _____ WARNING Lifting batteries from the battery tray can cause back strain. Ensure proper lifting techniques are used when lifting batteries. Failure to comply can cause personal injury. _____ WARNING Top housing panels can get very hot. Allow panels to cool down before performing maintenance. Failure to comply can result in severe burns to personnel. _____ WARNING Operating the generator set with any access door open exposes personnel to a high noise level. Hearing protection must be worn when operating or working near the generator set with any access door open.