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TM-9-6115-730-10 - Liberated Manuals

1. 0016 00 1 Em 0016 00 2 Fuel Filt r Water Separator cc iii e e ER teases eas 0016 00 2 Fuel DE PER 0016 00 2 Index 3 9 6115 730 10 INDEX Continued Subject WP Sequence No Page No E Continued Engine Fuel System Maintenance Continued ES 0016 00 3 Fuel Filter Water Separator Service 2 20 4 4 0016 00 4 Fuel Tank Service oie UE PO ketenes is 0016 00 3 Table L Diesel B el nece D rapit OE oen UR 0016 00 3 Engine Lubrication System 0017 00 1 Inspection aa 0017 00 1 c 0017 00 1 PESOS 0017 00 2 Equipment Characteristics Capabilities and 0002 00 1 Equipment Dita ia a a iii 0002 00 9 Table 1 200 kW Equipment 0002 00 9 Equipment Deficiency 0001 00 1 Equipment Desctiptiori and Dt aaa 0002 00 1 Expendable and Durable Items 15 0022 00 1 Expendable and Durable Items List Column Descriptions Table 0022 00 1 Tab
2. 0005 00 15 Table 9 Reconnection Board TB esses enne 0005 00 15 Resistor Assembly VERE 0005 00 11 Table 5 Resistor Assembly A7 Controls 0005 00 11 E Electronic Modular Control Panel Characteristics E 0002 00 1 beant 02 0002 00 4 Emergency Stopping nasi RI E RR ER Ee EY ERE EE AER Eee P Fee E EET e RE E Pee erae RISE dean 0006 00 16 Engine Characteristics a tias 0002 00 1 Description DEM 0002 00 1 Engine Ait Cleaner RESE 0014 00 1 Inspechion UU tees 0014 00 1 SEVICE 0014 00 3 Engine Compartment PMCS IC 0012 00 5 EM LI ME 0012 00 14 Berore a 0012 00 5 During 0012 00 11 Engine Control Module Characteristics eene Iunii bete 0002 00 1 Ivan TIERE 0002 00 7 Engine Cooling System Maintenance nbsp 0015 00 1 Inspection ii M 0015 00 1 Pc LEER 0015 00 2 Table Te Coolant ib ete irte a 0015 00 2 Engine Fuel System
3. TC 9 237 PAMPHLETS Consolidated Index of Publications and Blank DA PAM 25 30 Functional Users Manual for The Army Maintenance Management System TAMMS DA PAM 738 750 0019 00 1 Change 1 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0019 00 REFERENCES Continued TECHNICAL BULLETINS Color Marking and Camouflage Painting of Military Vehicles Construction Equipment and Materials Handling Equipment TB 43 0209 Corrosion Prevention and Control esses eene eene nennen TB 43 0213 Description Use Bonding Techniques and Properties of TB ORD 1032 MILITARY STANDARDS AND SPECIFICATIONS Lubricating Oil Internal Combustion Engine Combat Tactical Service MIL PRF 2104 Lubricating Oil Internal Combustion Engine Preservative and Break In MIL L 21260 Lubricating Oil Internal Combustion Engine Arctic eese MIL L 46167 Turbine Fuels Aviation Kerosene Types NATO F 34 JP 8 NATO F 35 and IOU MIL DTL 83133E Er 52557 Requirements for the Certification of Sling Loaded Military Equipment for External Transportation by Department of Defense MIL STD 913 DEPARTMENT OF DEFENSE DOD STANDARDS Department of Defense Materiel Management
4. FUEL PUMP CONTROL EMCP FUEL LEVEL FUEL LEVEL rut DRAIN 4 LOW LEVEL SHUTDOWN SIGNAL SWITCH SENDER VALVE FUEL LEVEL GAUGE SIGNAL ee 200KW 10 1048 0003 00 2 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0003 00 THEORY OF OPERATION Continued FUEL SYSTEM Continued The fuel system consists of hoses steel injector piping fuel tank fuel filter water separator transfer pump and injectors The transfer pump draws fuel from the fuel tank through a fuel filter water separator that removes water and small impurities The fuel is then pushed through the secondary fuel filter that removes even smaller particles from the fuel The fuel then enters a fuel manifold servicing unit injectors Through the cam actuated injectors fuel enters the diesel engine combustion chamber where it is mixed with air and ignited The fuel that is not used is cooled and returned to the fuel tank via an excess fuel return line When the fuel level is low the fuel level switch will either supply power to the external auxiliary fuel pump for external fuel supply or shut down the TQG to prevent it from completely running out of fuel If a diesel engine runs out of fuel it is necessary to fill the fuel filters purge all air from lines and pumps and bleed all injectors one at a time AUXILIARY FUEL PUMP The auxiliary fuel system consists of an external fuel supply fuel filter piping a 24 Vdc
5. 0016 00 ENGINE LUBRICATION SYSTEM MAINTENANCE uussusssssssssssnssonssusssnssonsnonsnnssonsnansnnnsnnssnnsnnnsnnssnnesnnesnnsnnnnnn 0017 00 PREPARATION FOR STORAGE OR SHIPMENT 0018 00 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0011 00 SERVICE UPON RECEIPT THIS WORK PACKAGE COVERS Preliminary Checks and Adjustment of Equipment INITIAL SETUP Maintenance Level References Operator AFTO Form 22 DA 2028 2 DA Form 2404 Tools and Special Tools DA Form 5988 E None DA PAM 738 750 DD Form 314 SF Form 368 Personnel Required TM 9 6115 730 24 One Materials Parts None PRELIMINARY CHECKS AND ADJUSTMENT OF EQUIPMENT 1 2 Inspect equipment for possible damage incurred during shipment If equipment has been damaged report damage on SF Form 368 Product Quality Deficiency Report US Army Check equipment against packing slip to see if shipment is complete Report all differences using procedure given in DA PAM 738 750 Operator perform unit Preventive Maintenance Checks and Services PMCS WP 0012 00 US Army and Air Force notify maintenance to perform unit PMCS per TM 9 6115 730 24 Schedule next PMCS on DD Form 314 Preventive Maintenance Schedule and Record US Army report all deficiencies including deficiencies that appear to involve unsatisfactory design on DA Form 5988 E automated form in the Unit Lev
6. Sars Equipment Description and 4 2 9 11 20 1 0 eese ta seta sense ta seta seta sense ta seta sess sens sens enne ena n Theory of 00442 Supporting Data for Repair Parts Special Tools TMDE and Support Equipment CHAPTER 2 OPERATOR INSTRUCTIONS FOR 200 kW TACTICAL QUIET GENERATOR SET Description and Use of Operator Controls and Indicators Operation Under Usual Conditions is AVVENE SEESE SESEO K EENES ESTs Operation Under Unusual 1 CHAPTER 3 OPERATOR TROUBLESHOOTING PROCEDURES FOR 200 kW TACTICAL QUIET GENERATOR SET Introduction 0008 00 Malfunction Symptom Index 4 eese eee eese eese esses enne tn tnn tn setas tasa setas tasa tasto 0009 00 Troubleshooting 2 0 0 0 0010 00 OPERATOR MAINTENANCE INSTRUCTIONS FOR 200 kW TACTICAL QUIET GENERATOR SET Service Upon Receipt Preventive Maintenance Checks and Services PMCS Including Lubrication Instructions Control Box Assembly M
7. 0002 00 1 a dal E 0002 00 1 Index 9 9 6115 730 10 INDEX Continued Subject WP Sequence No Page No W Warranty Information Also see WP 0001 00 2 0023 00 1 Manufacturer Warranty 0023 00 1 Table 1 Manufacturer s Warranties for 100 kW Generator 5 0023 00 2 Water Pump Characteristics RR 0002 00 1 Description 0002 00 1 Winterization Kit PMCS MEE 0012 00 10 Beltore scuro E 0012 00 10 Winterization Kit Operation ERN 0007 00 2 Winterization Kit eb credis 2 e 0002 00 1 IDESCHIDIOR ae eiit dopo door 0002 00 4 Index 10 RECOMMENDED CHANGES TO PUBLICATIONS AND Use Part Il reverse for Repair Parts and DATE BLANK FORMS Special Tool Lists RPSTL and Supply For use of this form see AR 25 30 the proponent agency is OAASA Catalogs Supply Manuals SC SM 30 August 2002 TO Forward to proponent of publication or form Include ZIP Code FROM Activity and location Include ZIP Code Commander US Army CECOM LCMC Jane Q Doe SFC ATTN AMSEL LC LEO E ED 1234 Any Street Fort Monmouth NJ 07703 5006 Anytown AL 34565 PART ALL PUBLICATIONS EXCEPT RPSTL AND SC SM AND BLANK FORMS PUBLICATION
8. 200KW 10 218A LOAD L1 L1 L2 12 NO 1 L3 L3 N GND GND L1 L2 NO 2 L3 N GND 0006 00 19 Change 2 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0006 00 OPERATION UNDER USUAL CONDITIONS Continued PARALLEL UNIT OPERATION LOAD SHARING Continued Operation in AUTO Mode Qv Uv de OO ches a 10 11 12 CAUTION When paralleling a 200 kW TOG to a 100 kW TOG that is supplying a load an unstable condition can occur This condition does not occur when paralleling at no load or when paralleling a 100 kW to a 200 kW that is supplying a load When you connect a 200 kW to the load bus with a 100 kW already under load and the load sharing becomes unstable you should immediately disconnect the 100 kW TOG from the load bus to prevent damage to equipment by setting the 100 kW AC CIRCUIT INTERRUPTER switch to OPEN The 100 kW TOG should then be synchronized to the load bus and the AC CIRCUIT INTERRUPTER switch set to CLOSED Perform INITIAL ADJUSTMENTS BEFORE USE AND SELF TEST procedures WP 0006 00 10 On each generator EMCP set ENGINE CONTROL switch to MANUAL START and start each set Rotate VOLTAGE adjust potentiometers to obtain same voltage indication on each set Rotate FREQUENCY adjust potentiometers to obtain same frequency indication on each set Ensure that all external load contactors between the
9. 14 H bii DANGER 5 H 3 i COOLANT DRAIN i O FORK UFT HERE FORK UFT HERE RIGHT SIDE WARNINGS CAUTIONS LABELS 200KW 10 242 0006 00 31 Change 2 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0006 00 OPERATION UNDER USUAL CONDITIONS Continued DECALS AND INSTRUCTION PLATES Continued BATTERY ARRANGEMENT AND CONNECTIONS DISCONNECT STARTER SWITCH GND CAUTION 1 ALWAYS POSITION AND CONNECT BATTERIES AS SHOWN 2 WHEN REMOVING BATTERIES DISCONNECT NEGATIVE LEAD FIRST 3 WHEN INSTALLING BATTERIES CONNECT NEGATIVE LEAD LAST DANGER HOT EXHAUST CAUTION HIGH INTENSITY NOISE HEARING PROTECTION REQUIRED WITHIN 11 FEET DANGER EXTREME NOISE HAZARD DOUBLE HEARING PROTECTION REQUIRED WHEN THE SET 15 OPERATING WITH THE DOOR OPEN BATTERIES FRONT WARNINGS CAUTIONS LABELS 200KW 10 225A Change 2 0006 00 32 200 kW TACTICAL QUIET GENERATOR SET OPERATION UNDER USUAL CONDITIONS Continued DECALS AND INSTRUCTION PLATES Continued TM 9 6115 730 10 0006 00 US DEPARTMENT OF D ENS NO GENERATOR ALTERNATING CURRENT SYNCHRONOUS BRUSHLESS MAKE MILITARY DESIGN MODEL 0116 2000 SER NO KW 1200 VOLTS 120 208 240 416 AMPS
10. DA Form 2408 Equipment Control Record alode RR ee edes DA Form 2408 9 Analysis E0g neu REIR SEEN EA ERR HN ee Tees DA Form 2408 20 Equipment Inspection and Maintenance Worksheet DA Form 5988 E Preventive Maintenance Schedule and Record seen DD Form 314 Accident Identification Card beate edere peo t lee nes DD Form 518 Processing and Deprocessing Record for Shipment Storage and Issue of Vehicles and Spare Engines sess DD Form 1397 Motor Vehicle Accident Report enne ener SF Form 91 Transportation Discrepancy SF Form 361 Product Quality Deficiency Report essere enne SF Form 368 MISCELLANEOUS PUBLICATIONS Army Logistics Readiness and AR 1700 138 Reporting of Supply AR 735 11 2 Army Materiel Maintenance Policy and Retail Maintenance AR 750 1 Procedures for Destruction of Electronics Materiel to Prevent Enemy 5 AR 750 244 2 Army Medical Department Expendable Durable CTA 8 100 Expendable Items Except Medical Class V Repair Parts and Heraldic Items CTA 50 970 Operator sCircular Welding Theory and
11. 9 6115 730 10 35 2 3 520 1 MARINE CORPS 11598A OR NAVAIR 19 50 28 TECHNICAL MANUAL OPERATOR S MANUAL FOR GENERATOR SET SKID MOUNTED TACTICAL QUIET 200 kW 50 60 Hz MEP 809A NSN 6115 01 296 1462 GENERATOR SET TRAILER MOUNTED TACTICAL QUIET 200 kW 50 60 Hz PU 809A NSN 6115 01 471 7085 COS ST 55525552525 52 lt 5 200KW 10 101A DISTRIBUTION STATEMENTA Approved for public release distribution is unlimited HEADQUARTERS DEPARTMENTS OF THE ARMY AIR FORCE NAVY AND HEADQUARTERS U S MARINE CORPS NAVAIR STATEMENT Published by Direction of Commander Naval Air Systems Command 15 January 2006 PCN 184 115980 03 5 9 6115 730 10 WARNING SUMMARY The following icons are sometimes used in conjunction with WARNINGs so that you do not miss important information They are not meant to be a substitute for reading the WARNINGs but they give graphic descriptions of dangers E ELECTRICAL electrical wire to hand with electricity symbol running through hand shows that shock hazard exists RADIATOR steam in face and body shows that escaping steam and hot water exist EAR PROTECTION headphones over ears shows that noise level will harm ears EXPLOSION flame and burst shows that material may explode if subjected to high temperatures sources of ignition or high pressure COLD hand in touching cold surface shows t
12. DOD 4100 1 R FLIS Program Manual n Dette EPRS DOD 4100 39 TECHNICAL MANUALS Chemical Biological and Radiological CBR Decontamination TM 3 220 Inspection Care and Maintenance of Antifriction 0 422021 9 214 Deepwater Fording of Ordnance Material TM 9 238 Materials Used for Cleaning Preserving Abrading and Cementing Ordnance Material and Related Material Including 5 44211 442000000 000000000000 TM 9 247 Painting Instructions for Army TM 43 0139 Installation Practices for Aircraft Electrical and Electronic TM 55 1500 323 24 Administrative Storage of Equipment TM 740 90 1 TO 35 1 4 Procedures for Destruction of Electronics Materiel to Prevent Enemy Use TM 750 244 2 Field and Sustainment Maintenance for Generator Set Skid Mounted Tactical Quiet 200 kW 50 60 Hz 809 and Generator Set Trailer Mounted Tactical Quiet 200 kW 50 60 Hz PU 809A sisi ses Pee TM 9 6115 730 24 Repair Parts and Special Tools Lists for Tactical Quiet Generator Set Skid Mounted 200 kW 50 60 Hz 809 and Tactical Quiet Generator Set Trailer Mounted 200 kW 50 60 Hz 809 2 22 0 22 2 0 1 1010100000000000000000
13. 0008 00 1 Malfunction S ymptom Index u a anne re ee EE Hee Fede be nie e 0009 00 1 Muffler Bie Tesi ME EN 0002 00 1 Description scient nausea 0002 00 1 N NATO Slave Receptacle Characteristics D eH UR ee 0002 00 1 Description essen nn sen Tee TEE he nern 0002 00 4 Nomenclature Cross Reference List cccscssssssescescsseeeceseeeessecseesecnecaeesecaeveecsaeeeceaesaeeeeeaecaeesecaeeatenasensaeeateaes 0001 00 2 Operator Controls and Indicators See Description and Use of Operator Controls and Indicators Operating Procedures eet aia 0006 00 11 0006 00 12 Stopping A 0006 00 16 Operation Under Usual Conditions vna HEC HE EE 0006 00 1 Assembly and Preparation for 0006 00 1 Decals and instruction Plates sess nnne 0006 00 26 Em Stopping RM 0006 00 16 Initial Adjustments Before Use 20 4 1 000 0 00 enne 0006 00 10 NATO Slave Receptacle Start 0006 00 11 Index 6 9 6115 730 10 INDEX Continued Subject WP Sequence No Page No O Continued Operation Under Usual Conditions Continued Opera
14. N 2 A Figure 1 200 kW Tactical Quiet Generator Location of Components Sheet 4 0002 00 6 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0002 00 EQUIPMENT DESCRIPTION AND DATA Continued LOCATION AND DESCRIPTION OF MAJOR COMPONENTS Continued STARTER The engine starter motor figure 1 sheet 5 26 is located on the left rear side of the engine The electric starter engages the flywheel mechanically to start the diesel engine SKID BASE The skid base 27 provides the main structural support for the engine and generator The skid base consists primarily of two formed side rails cross members mounting pads forklift openings and a bottom plate Main cross members complete the primary skid base structure to support the engine and generator mounting pads and vibration isolators and reinforce the fork lift openings 28 Four 25 000 Ib 11 400 kg capacity LIFT TIEDOWN rings 28 are attached to the skid base frame In addition to supporting the engine generator assembly housing battery and other components the skid base has provisions for engine oil drain 30 coolant drain opposite side a water separator drain 31 and fuel tank drain 32 The skid base also serves as a support and protective enclosure for the fuel tank FUEL TANK The fuel tank 33 is a 128 gallon 485L molded tank located below the diesel engine between the sk
15. 30 31 32 33 34 35 36 AL8 Generator Under Voltage ALO Generator Over Frequency AL10 Generator Under Frequency AL11 Generator Reverse Power AL12 Phase Over Current AL13 Generator Total Over Current AL14 Phase No Voltage Input AL15 GSC Configuration Error AL16 Incorrect Phase Sequence AL17 Improper Generator or Bus Voltage AL18 Synchronizer Time out GSC SP Fault Codes SP1 Low Fuel Level SP2 DVR fault SP3 When relay is energized and one or both of the following 15 true for more than 2 seconds an SP3 fault is announced The difference in frequency between the generator and the bus is greater than 0 2 Hz The difference in phase between the generator and the bus is greater than 10 degrees The GSC will then stop the synchronization process until the fault is cleared and corrected SP4 Input is active when 208 or 416 VAGs detected on the load bus by relay DBLO or DBHI This input 1s compared to the reading of the bus voltage P7 17 and P7 18 If the voltage of phase A 15 less than 20 of the rated voltage it is considered to be dead If the condition of these measurements is different with regards to presence or absence of bus voltage a fault is announced DVR Alarm Fault Codes 601 Internal Memory Failure Alarm 602 Internal Watchdog Failure Alarm 603 Rotating Diode Failure Alarm 604 Reverse VAR Alarm 0009 00 2 Notify maintenance Notify maintenance No
16. Check for loose or damaged wiring or connectors 0012 00 8 Loose or damaged wiring or cables Damaged loose or missing hardware Reconnection Board is set for incorrect voltage output Indicators or controls damaged or missing Loose or damaged wiring or connectors 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0012 00 PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS INCLUDING LUBRICATION INSTRUCTIONS Continued Table 1 Preventive Maintenance Checks and Services Continued LOCATION NOT FULLY ITEM ITEM TO MISSION NO INTERVAL CHECK SERVICE PROCEDURE CAPABLE IF 24 Before Generator Set Touch LAMP TEST on keypad and check GSC indicator lights Control that all eight indicator lights on GSC and and display upper and lower display segments light segments do not light 25 Before Alarm Module Press LAMP TEST and check that alarm Alarm Module lights indicators light and alarm sounds do not light and alarm does not sound 26 Before Parallel Cable If required for generator set operation Paralleling cable inspect parallel cable for damage missing or cable and connectors are damaged 27 Before Ground Rod Cable _____ and Connection WARNING High voltage is produced when the generator set is in operation Never attempt to start the generator set unless it is properly grounded Failure to comply can cause injury or death to personnel Inspect ground rod and cable for loose Any missing or co
17. 10 221 2 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0006 00 OPERATION UNDER USUAL CONDITIONS Continued DECALS AND INSTRUCTION PLATES Continued PARALLELING RECEPTACLES GROUND FAULT OCIRCUT INTERRUPTER CAUTION Y HIGH INTENSITY NOISE LR HEARING PROTECTION REQUIRED WITHIN 11 FEET O 120 VOLTS 15 AMPS 60 HZ OO Sooo COOLANT HEATER OPERATING INSTRUCTIONS GROUND THE GENERATING SET SWITCH THE HEATER CONTROL SWITCH TO THE ON POSITION ALLOW THE HEATER OPERATE UNTIL THE TEMPERATURE SENSOR SWITCHES TO LOW HEAT OR FOR 55 MINUTES THEN FOLLOW THE GENERATOR STARTING INSTRUCTIONS lt AFTER STARTING THE GENERATOR SWITCH THE HEATER CONTROL SWITCH THE OFF POSITION THE COMBUSTION AIR BLOWER AND WATER PUMP WILL CONTINUE TO RUN FOR APPROXIMATELY 3 MIN NOTE SWITCH THE HEATER ON FOR APPROXIMATELY 1 MIN ABOUT ONCE A MONTH DURING THE WARM SEASON TOO THIS PREVENTS THE WATER PUMP AND BURNER MOTOR SEIZING UP 200KW 10 222C Change 2 0006 00 28 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0006 00 OPERATION UNDER USUAL CONDITIONS Continued DECALS AND INSTRUCTION PLATES Continued GENERATOR SET DIESEL FUELED MODE 50 60 HERTZ SIZE 200 200 KW KW CAPACITY OUTPUT
18. 200 kW TACTICAL QUIET GENERATOR SET 0016 00 ENGINE FUEL SYSTEM MAINTENANCE THIS WORK PACKAGE COVERS Inspection Service INITIAL SETUP Maintenance Level References Ope rator None Tools and Special Tools Materials Parts None Diesel fuel A A 52557 1 D item 3 WP 0022 00 Diesel fuel A A 52557 2 D item 4 Personnel Required JP5 per MIL PRF 5624 item 16 One JP8 per MIL T 83133 item 17 WP 0022 00 D 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 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 amp 3 E 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 Avoid repeated or prolonged contact Provide adequate ventilation Operators are to wash exposed skin and change chemical soaked clothing promptly if exposed to fuel Failure to comply can cause injury or death to personnel 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 an
19. Change 2 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0006 00 OPERATION UNDER USUAL CONDITIONS Continued OPERATING AUXILIARY EQUIPMENT Use of the Convenience Receptacle WARNING D Power is available when the main contactor is closed Avoid accidental contact Failure to observe this warning can result in severe personal injury or death by electrocution CAUTION The maximum power rating for the convenience receptacle is 15A To prevent circuit breaker from opening the total current drawn should be limited to 15A only Failure to limit the load to less than 15A may trip the circuit breaker and damage the generator set or load On EMCP set ENGINE CONTROL switch to MANUAL START 2 Ensure load does not exceed maximum rating 3 Reset Ground Fault Circuit Interrupter overcurrent protection WP 0013 00 4 Plug appropriate connector into convenience receptacle END OF TASK Change 2 0006 00 36 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0006 00 OPERATION UNDER USUAL CONDITIONS Continued PREPARATION FOR MOVEMENT DAA WARNING D Metal jewelry can conduct electricity Remove all metal jewelry when working on electrical system or components Failure to comply can cause injury or death to personnel by electrocution 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
20. Power Output osc EE 0003 00 7 Air Intake and Exhaust System With 0003 00 6 Auxiliary Fuel P tnp recie rere e Hr HH PE He ER EAE etae ree Fiere Phe ere 0003 00 3 Engine Cooling eto ettet n Dae e ERR Ee e MR Pues 0003 00 4 Engine Starting System RR 0003 00 1 Fuel Cnm PTT 0003 00 2 Fuel Fired Heater System Winterization Kit Issued to Selected Units sess 0003 00 8 Lubrication EE 0003 00 5 Trailer Installation PU 809A PMCS Operator sats naaa pisa 0012 00 9 c 0012 00 9 5c doen 0012 00 16 Trailer Mounted Configuration PU 809A Characteristics metadata 0002 00 1 Description 0002 00 8 Troubleshooting ei i E I e RE Er E E e eie RE 0010 00 1 Introduction ee 0008 00 2 Malfunc on Sym ptom Index i Ree HE 0009 00 1 Troubleshooting Procedures eta tesis tun ttv bed Fo cede et eie vta 0010 00 3 Table 1 Operator Troubleshootitig pica 0010 00 3 Turbocharger Characteristics md OBI
21. 0012 00 PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS INCLUDING LUBRICATION INSTRUCTIONS Continued Table 1 Preventive Maintenance Checks and Services Continued ITEM NO INTERVAL LOCATION ITEM TO CHECK SERVICE PROCEDURE NOT FULLY MISSION CAPABLE IF 20 Before 21 Before 22 Before 23 Before Control Output Load Terminal Board Reconnection Board CONTROL PANEL ASSEMBLY Indicators and Controls Panel Wiring Harness Check for loose or damaged wiring or load cables inside generator set Check output terminals for damaged or missing hardware Verify position of Reconnection Board and check to see if it is in the correct position for voltage outputs required by load Notify maintenance if repositioning is required WARNING Metal jewelry can conduct electricity and become entangled in generator set components Remove all metal jewelry when working on generator set Failure to comply can cause injury or death to personnel 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 Set DEAD CRANK SWITCH to NORMAL WP 0005 00 Set Battery Disconnect Switch to ON WP 0005 00 Set ENGINE CONTROL switch to COOL DOWN STOH WP 0005 00 Check all indicators and controls for damaged or missing parts
22. Continued The DC battery system provides 24 Vdc for engine starting and control circuits The four sealed 12 Vdc batteries are charged by the engine alternator The DC AMMETER on EMCP indicates alternator charging rate Battery condition is also shown on the EMCP lower display ENGINE METER function Charge rate is shown from 25 amperes to 50 amperes in 5 ampere increments Normal operating indication depends on the state of charge in the batteries A low charge such as exists immediately after engine starting will cause a high reading The battery system includes a manually operated Battery Disconnect Switch to isolate the batteries from the engine The Battery Disconnect Switch can be used to remove DC power from the TQG Battery condition is also shown on the EMCP lower display ENGINE METER function The batteries connect directly to 24 Vdc NATO slave receptacle FUEL SYSTEM ENGINE GENERATOR ASSEMBLY FUEL SECONDARY ma r EL FILTER a INJECTORS m COOLER FUEL FILTER WATER CYLINDERS SEPARATOR 2 i x FUEL RETURN WATER FUEL E FROM ENGINE DRAIN T EXTERNAL ic MANUAL FUEL SUPPLY FUEL FILL AUXILIARY FUEL FUEL AUXILIARY FUEL FUEL FILLER c FUEL HOSE STRAINER FUEL TANK STRAINER FUEL PUMP CONTROL FUEL LEVEL SIGNAL FOR AUXILIARY
23. GSC HIGH WATER TEMP ted indicator flashes GSC LOW COOLANT LEVEL red indicator flashes Alarm module OVERCURRENT amber indicator flashes TQG disconnects from load Alarm module GENERATOR OVERLOAD amber indicator flashes TQG disconnects from load Alarm module LOW FUEL LEVEL red indicator glows steady TQG engine shuts down Convenience receptacle on PARALLELING RECEPTACLES panel has no power Winterization kit Issued to selected units only is not operating DIAGNOSTIC light is red GSC Alarm Fault Codes ALI High Water Temperature AL2 Low Water Temperature AL3 Low Engine Oil Pressure ALA Fault Detected by Engine ECM ALS Low Engine Coolant Level AL6 High Engine Oil Temperature AL7 Generator Over Voltage 0009 00 1 0010 00 0010 00 0010 00 0010 00 0010 00 0010 00 0010 00 0010 00 0010 00 0010 00 Troubleshoot as Malfunction 4 0010 00 4 AL2 can be a transient code that will go away after the TQG is running If not notify maintenance Troubleshoot as Malfunction 0010 00 3 Notify maintenance Troubleshoot as Malfunction 3 0010 00 5 Troubleshoot as Malfunction 3 0010 00 3 Notify maintenance Notify maintenance 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR MALFUNCTION SYMPTON INDEX Continued 0009 00 Malfunction Symptom Work Package and Page No 18 19 20 21 22 23 24 25 26 27 28 29
24. ahi Sa 0020 00 5 Batteries Characteristics Dem 0002 00 1 Description HR 0002 00 4 Components of End Item 0020 00 1 List Descriptions Table 1 0020 00 1 Table 1 Components of End Item List nennen eren enne 0020 00 2 Common Tools and Test Equipment sese nennt enne teen nennen enne enne nennen 0004 00 1 Connecting Auxiliary Fuel nee cite 0006 00 8 Consolidated Index of Army Publications and Blank 8 0001 00 1 Control Box Assembly Maintenance eere enne enne entente intent nnne nnne ener nennen 0013 00 1 e ILE EE 0013 00 1 Replace Control Panel Lights on Electronic Modular Control Panel een 0013 00 1 Reset GROUND FAULT CIRCUIT INTERRUPTER Circuit Breaker eee 0013 00 3 Index 1 9 6115 730 10 INDEX Continued Subject WP Sequence No Page No C Continued Controls and Indicators See Description and Use of Operator Controls and Indicators Control Panel Assembly PMCS ecc M 0012 00 8 w MTM ES 0012 00 16 ee ee E 0012 00 8 D ring O OO 0012 00 13 Us oi 00
25. wear gloves and additional protective clothing and goggles as required Contact with high pressure steam and or liquids can result in burns and scalding 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 or death to personnel WARNING Operating the generator set exposes personnel to a high noise level Hearing protection must be worn when operating or working near the generator set when the generator set is running Failure to comply can cause hearing damage to personnel WARNING DO NOT wear loose clothing when performing checks services and maintenance Failure to comply can cause injury or death to personnel 9 6115 730 10 WARNING SUMMARY Continued WARNING When running generator set engine has hot metal surfaces that will burn flesh on contact Shut down generator set and allow engine to cool before checks services and maintenance Wear gloves and additional protective clothing as required Failure to comply can cause injury or death to personnel WARNING When running generator set engine has hot metal surfaces that will burn flesh on contact When performing DURING PMCS wear gloves and additional protective clothing as required Failure to comply can cause injury or death to personnel WARNING Exhaust discharge contains deadly gases including carbon monoxide Do not operate gene
26. 13 POWER METER Displays power data to lower display When pressed following functions scroll automatically Total real power kW Total reactive power Percentage of rated power kW Power factor average PF Display scrolling stops when operator presses key for less than 5 seconds Display will show a particular parameter continuously 0005 00 7 Change 3 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0005 00 DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS Continued GENERATOR SET CONTROL Continued Table 2 Generator Set Control Controls and Indicators Continued CONTROL OR INDICATOR FUNCTION AC METER ENGINE METER LAMP TEST ALARM CODES EXIT SERVICE MODE Change 3 Additional functions will scroll if key held for more than 5 seconds Total real power kW Real power phase A kW Real power phase B kW Real power phase C kW Total apparent power kVA Total reactive power kVA Percentage of rated power kW Power factor average PF Power factor phase A Power factor phase B Power factor phase C Total energy output kWh Total reactive energy output kVARHr Selects phase of generator output that is shown on upper display Pressing this key allows operator to check voltage current and frequency of each phase one at a time Options are as follows Voltage average frequency current total Voltage line to line frequency current line for a
27. 4 Ifyou find a fault or shortcoming when performing the PMCS record it on your DA Form 2404 or automated DA From 5988 E ARMY if ULLS is available Repair it if you can or notify maintenance 5 Ifsomething appears to be a fault and you cannot repair it record it on your DA Form 2404 or automated DA Form 5988 E Army If you find something seriously wrong report it to maintenance as soon as possible 6 Item numbers in column 1 of PMCS Table 1 indicate the PMCS sequence Use these item numbers for the item number column on your DA Form 2404 or automated DA Form 5988 E Army 7 Information in column 5 of PMCS Table 1 lists conditions that make the 200 kW TQG not fully mission capable Write up items not repaired on DA Form 2404 or automated DA Form 5988 E for maintenance For further information on how to use these forms see DA PAM 738 750 FLUID LEAKAGE Wetness around seals gaskets fittings or connections indicates leakage A stain also denotes leakage Ifa fitting or connector is loose tighten it if you can hand tighten If not notify maintenance fitting or connector is broken or defective report it to maintenance Leak Definitions for PMCS CAUTION Operation is allowable with class I and II leakage However any wetness or leakage of fuel is classified as a class III leak and the TQG must be shut down immediately and the problem corrected WHEN IN DOUBT NOTIFY YOUR SUPERVISOR When operating with class I or leaks c
28. COMPLETE LOOPS 4X 50 OR LESS Li L LI PLACE UNIT WITH CG EQUIDISTANT FROM SIDES OF FLATCAR 3 4 IN CABLE COMPLETE LOOPS 4X 30 OR LESS 0116 2900 04 RIGHT SIDE 200KW 10 224 Change 2 0006 00 30 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0006 00 OPERATION UNDER USUAL CONDITIONS Continued DECALS AND INSTRUCTION PLATES Continued EXTREME NOISE HAZARD DOUBLE HEARING PROTECTION REQUIRED fo WHEN THE SET IS OPERATING WITH THE COVER MUST BE INSTALLED PRIOR TO OPERATING WARNING HIGH VOLTAGE 4 INSIDE DOORS CAUTION DO NOT STAND OR STORE HEAVY OBJECTS H ON TOP OF UNIT gt DOCUMENTS EY g H a H q H d CAUTION H ION fl HIGH INTENSITY NOISE H HIGH INTENSITY NOISE H HI HEARING PROTECTION H H DANGER HEARING PROTECTION M REQUIRED WITHIN 11 FEET E H XTREME NOISE HAZA REQUIRED WITHIN 11 FEET DANGER p H DOUBLE HEARING PROTECTION Ne mu EXTREME NOISE HAZARD REQUIRED WHEN THE WARNING H DOUBLE HEARING PROTECTION IH H IS OPERATING WITH THE D a REQUIRED WHEN THE SET Ht DOOR OPEN IS OPERATING WITH THE IH H THE DOOR OPEN H He H H N H H H d H H H a a H i E H OIL FILTER H H H
29. Column 5 QTYRECM Indicates the quantity recommended AAL Table 1 Additional Authorized List 1 2 3 NATIONAL STOCK USABLE NUMBER DESCRIPTION CAGEC AND PART NUMBER ON CODE 5975 00 878 3791 RODS GROUND WITH ATTACHMENTS SECTIONAL 9 58536 55804 5975 00 794 2523 COUPLINGS THREE IN SET 5975 00 924 9927 DRIVE HEAD STUD 6145 00 395 8799 WIRE ELECTRICAL NO 6 AWG 7 STRANDS CLASS B TEMPER 6 FT LONG ASTM B8 5999 00 186 3912 CLAMP 5940 00 271 9504 GROUND TERMINAL LUG 5310 01 477 1264 WASHER 30554 88 20564 15 5310 01 365 5788 NUT SELF LOCKING HEXAGON PREVAILING TORQUE 30554 88 21930 2 0021 00 1 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0021 00 ADDITIONAL AUTHORIZED LIST AAL Continued AAL Continued Table 1 Additional Authorized List Continued 1 2 3 4 5 NATIONAL STOCK DESCRIPTION CAGEC AND PART NUMBER USABLE QTY NUMBER ON CODE RECM 2540 01 520 3497 WINTERIZATION KIT VEHICLE 49N 78C 93742 0116 2810 5120 01 013 1676 HAMMER SLIDE 45225 P74 144 4210 00 361 6921 EXTINGUISHER FIRE CARBON DIOXIDE 5 LB 54905 322 5342 00 066 1235 ADAPTER CONTAINER 97403 13211 7541 4710 00 185 6948 PIPE 97403 13211 7543 4710 00 597 8731 PIPE EXTENSION 97403 1311E7542 7240 00 222 3088 FUEL CAN 7240 00 177 6154 FLEXIBLE SPOUT 0021 00 2 9 6115 730 10 200 KW TACTICAL QUIET G
30. RESET Pushbutton resets GFCI circuit breaker TEST Convenience receptacles Two convenience receptacles provide 120 Vac 15A power for external use Output frequency will be same as generator output frequency 0005 00 13 Change 3 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0005 00 DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS Continued BATTERY DISCONNECT SWITCH Table 8 describes the positions and functions of the Battery Disconnect Switch located inside the battery storage compartment at front of generator set 200 10 210 Table 8 Battery Disconnect Switch Controls CONTROL OR INDICATOR FUNCTION 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 NATO slave receptacle has 24 Vdc even when disconnect switch is set to OFF Connects batteries to generator set Disconnects batteries from generator set Change 3 0005 00 14 9 6115 730 10 100 kW TACTICAL QUIET GENERATOR SET 0005 00 DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS Continued ORECONNECTION BOARD TB1 OPERATORS ARE NOT AUTHORIZED TO REPOSITION THIS BOARD Table 9 describes the Reconnection Board TBI located at right rear upper left of generator set WP 0002 00 Figure 1 sheet 2 100 10 211 Table 9
31. TQG units Make very small adjustments to the VOLTAGE and FREQUENCY potentiometers to maintain balanced readings of TOTAL Amperes kW and kVAR across all units in parallel Pressing POWER METER on GSC keypad periodically compare kW and kVAR readings on lower display of all generator sets If readings are not within plus or minus 10 of one another notify maintenance Operation in SEMI AUTO Mode obe CAUTION When paralleling a 200 kW to a 100 kW that is supplying a load an unstable condition can occur This condition does not occur when paralleling at no load or when paralleling a 100 kW TQG to a 200 KW TQG that is supplying a load When you connect 200 kW to the load bus with a 100 kW already under load and the load sharing becomes unstable you should immediately disconnect the 100 KW TQG from the load bus to prevent damage to equipment by setting the 100 kW TQG AC CIRCUIT INTERRUPTER switch to OPEN The 100 kW should then be synchronized to the load bus and the AC CIRCUIT INTERRUPTER switch set to CLOSED Perform INITIAL ADJUSTMENTS BEFORE USE AND SELF TEST procedures WP 0006 00 10 On each generator EMCP set ENGINE CONTROL switch to MANUAL START Rotate VOLTAGE adjust potentiometers to obtain same voltage indication on each set Rotate FREQUENCY adjust potentiometers to obtain same frequency indication on each set 0006 00 21 Change 2 9 6115 730 10 200 kW TACTICAL
32. VOLTAGE CURRENT 120 DEG 95 DEG F 95 DEG F PF FREQ FUEL VOLTAGE ADJUST CAPACITY S L 3PH 4 RANGE AMPS 200 60 1 0 2 D 120 208 197 240 200 1 60 1 D 2 D 240 416 395 480 i i D 2 D B 50 50 1 0 2 0 JP5 JP amp 1207208 197 240 60 JP5 JP8 240 416 395 480 50 5 8 120 208 190 213 50 JPS JP8 240 416 380 426 0116 2900 03 17v 30554 Y P PU 309A E 205 2220250 RIGHT SIDE WARNING DO NOT OPERATE THE GENERATOR SET UNTIL IT HAS BEEN CONNECTED TO A SUITABLE GROUND SEE OPERATOR S MANUAL 4 WIRE CONNECTION CONNECT THE LOAD LINES TO L1 L2 amp L3 TERMINALS CONNECT THE NEUTRAL LINE TO LO TERMINAL 5 WIRE CONNECTION CONNECT THE LOAD LINES TO L1 L2 amp L 3 TERMINALS CONNECT THE NEUTRAL LINE TO LO TERMINAL CONNECT THE 5TH WIRE GROUND TO THE GND TERMINAL CAUTION AVOID DAMAGE TO THE LOAD FIRST CHECK VOLTAGE FREQUENCY AND PHASE REQUIREMENTS OF THE USING EQUIPMENT 30554 88 20110 30554 88 20126 200 10 223 0006 00 29 2 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0006 00 OPERATION UNDER USUAL CONDITIONS Continued DECALS AND INSTRUCTION PLATES Continued LIFTING DIAGRAM 12 FT MIN SUNG LENGTH 4 LIFTING AND TIEDOWN POINTS 10 4 WEE FLATCAR TIEDOWN 3 4 IN CABLE
33. number PN and vendor part number VPN where available Column 3 WARRANTY PERIOD This column lists the length of the warranty period 0023 00 1 9 6115 730 10 200 KW TACTICAL QUIET GENERATOR SET 0023 00 WARRANTY INFORMATION Continued MANUFACTURER WARRANTY INFORMATION Continued Table 1 Manufacturer s Warranties for 200 kW Generator Set 1 2 3 WARRANTY MANUFACTURER COMPONENT UNDER WARRANTY PERIOD Caterpillar Inc Diesel Engine 12 Months Defense Products Engine Service Engineer PO Box 470 Mossville IL 61552 0470 Phone 309 578 4562 Fax 309 578 3739 CAGE 11083 PN 0116 2110 VPN 212 3802 Digital Control System Components GSC P Controller PN 0116 1201 41 VPN 198 9253 Alarm Module PN 0116 1201 34 VPN 130 3324 Warranty repairs can also be obtained through any Caterpillar dealer Nearest dealer can be located at www cat com Digital Voltage Regulator PN 0116 1201 37 VPN 155 3832 Load Sharing Module PN 0116 1201 39 VPN 161 0797 Transformer PN 0116 1201 32 VPN 118 0175 Transformer PN 0116 1201 40 VPN 169 4701 Harness Assembly PN 0116 1201 43 VPN 212 8737 Marathon Electric P O Box 8003 Wausau WI 54402 8003 Phone 715 675 8237 Generator PN 0116 2120 VPN 571PSL4800 12 months from date of startup or 18 months from date of shipment whichever period shall expire first Signal Transfor
34. uesusssssssssssessonssonsnonsnnnsnnssnnsnnnsnnssnnssnnesnnesnnennnsnnnsssnsnnsnnnsnusssnsnonsnansnansnnnsnnssnnssnnesnnesnnsnnnene EQUIPMENT DESCRIPTION AND DATA THEORY OF OPERATION P SUPPORTING DATA FOR REPAIR PARTS SPECIAL TOOLS TMDE AND SUPPORT EQUIPMENT 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0001 00 GENERAL INFORMATION SCOPE This technical manual TM contains instructions for operation operator maintenance checks and adjustments theory of operation troubleshooting and corrective maintenance for the 200 kW Tactical Quiet Generator Set MEP 809A and PU 809A Type of Manual Operator crew maintenance Model Number and Equipment Name Generator Set Skid Mounted Tactical Quiet 200 kW 50 60 Hz MEP 809A and Generator Set Trailer Mounted Tactical Quiet 200 kW 50 60 Hz PU 809A Purpose of Equipment The 200 kW TQG provides 120 208 Vac or 240 416 Vac 50 60 Hz 3 phase power for a wide variety of military applications offering the mobility and operational characteristics demanded by modern armed forces Operational characteristics include the ability to operate at all possible humidity levels at ambient temperature levels from 25 F to 120 F 32 C to 49 C down to 50 F 46 C with winterization kit and at altitudes up to 10 000 feet CONSOLIDATED INDEX OF ARMY PUBLICATIONS AND BLANK FORMS Refer to the latest issue of DA Pam 25 30 to determine whether
35. 03 Fuel Pressure Sensor Voltage above normal Logged CID 94 E FMI 04 Fuel Pressure Sensor Voltage data is valid but below normal operating mode Logged CID 96 E FMI01 High Fuel Pressure Warning Active and Logged CID 97 E FMI01 Derate Overridden Logged Only CID 100 E FMI02 Engine Oil Pressure Sensor Erratic intermittent or incorrect signal Logged CID 100 E FMI 03 Engine Oil Pressure Sensor Voltage above normal Logged CID 100 E FMI 04 Engine Oil Pressure Sensor Voltage below normal Logged CID 110 FMI 02 Engine Coolant Temperature Sensor Erratic intermittent or incorrect signal Logged CID 110 03 Engine Coolant Temperature Sensor Voltage above normal Logged CID 110 FMI 04 Engine Coolant Temperature Sensor Voltage below normal Logged CID 111 FMI 03 Engine Low Coolant Sensor Voltage above normal CID 168 E FMI 02 Electrical System Voltage Erratic intermittent CID 168 E FMI 03 Electrical System Voltage Above Normal CID 168 E FMI 04 Electrical System Voltage Below Normal CID 169 E FMI 01 Engine Oil Maintenance Required CID 170 E FMI 01 Fuel Filter Change Required CID 172 E FMI 03 Inlet Air Temperature Sensor Data is Valid but Above Normal Operating Range Logged CID 172 E FMI 04 Inlet Air Temperature Sensor Failure Data is Valid but Below Normal Operating Range Logged CID 174 E 03 Fuel Temperature Sensor Data is Valid but Above Normal Operating Range Logged CID 174 E FMI 04 Fuel Te
36. 1 iEn snp Ea M 0018 00 1 SES 0018 00 1 Pr seryatlon AAA ERU DIRE nn ER RE 0018 00 1 Special Instructions for Administrative Storage sess eere eene enne 0018 00 1 Use of Corrosion Preventive Compounds Moisture Barriers and Desiccant Materials 0018 00 1 R Radiator Characteristics ami a IL M MI LAT LU EE Ete 0002 00 1 Ib vapor dada das 0002 00 1 Reconnection Board Characteristics preteen tepore unti e e EH CREE E eps 0002 00 1 Description ea m YR He IRE HE TCU A EET EFE 0002 00 3 lire E 0019 00 1 Com mercial Manuals 0019 00 2 Department of Defense DOD 0019 00 2 Field Manuals seien ea aes 0019 00 1 eee EL E 0019 00 1 Military Standards and Specifications esses eene 0019 00 2 Miscellaneous Publications atico 0019 00 1 Pam IL 0019 00 1 Technical Bulletins cies ss tpe mE Ree 0019 00 2 Technical Manuals A iiie t WERE EUR Re 0019 00 2 Removal from Parallel Operation essere nenne enn
37. 10 200 kW TACTICAL QUIET GENERATOR SET 0020 00 COMPONENT OF END ITEMS AND BASIC ISSUE ITEMS LISTS Continued PA DELETED DELETED 22 0020 00 9 10 blank Change 1 083008 001 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0021 00 ADDITIONAL AUTHORIZED LIST AAL INTRODUCTION Scope This work package lists additional items you are authorized for the support of the 200 kW Tactical Quiet Generator Set General The AAL Table 1 identifies items that do not have to accompany the 200 kW Tactical Quiet Generator Set and that do not have to be turned in with it These items are all authorized to you by Common Table of Allowances CTA MTOE Table of Distribution and Allowances TDA or Joint Table of Allowances JTA AAL COLUMN DESCRIPTIONS TABLE 1 Column 1 NATIONAL STOCKNUMBER Identifies the stock number of the item to be used for requisitioning purposes Column 2 DESCRIPTION CAGEC AND PART NUMBER This column identifies the Federal item name in all capital letters followed by a minimum description when needed The last line below the description is the CAGE in parentheses and the part number Column 3 USABLE ON CODE When applicable a code if the item you need is not the same for different models of equipment Column 4 UNIT OF MEASURE U M Indicates the physical measurement or count of the item as issued per the National Stock Number shown in column 1
38. 4 and remove cables from generator set and from all paralleled generator sets if paralleled WP 0006 00 Secure wrench 1 inside load terminal door and close door 0006 00 37 Change 2 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET OPERATION UNDER USUAL CONDITIONS Continued PREPARATION FOR MOVEMENT Continued H W 0006 00 200KW 10 234A 9 Disconnect paralleling cable if used and store in storage box located inside battery compartment access door 10 Disconnect ground cable 5 from ground terminal 6 and clamp 7 11 Remove ground rods 8 and couplers 9 Store ground rods in holding clips located inside generator set housing on left side Store cable and couplers in storage box 775 27 M E E O C 3 SN E 12 Secure all generator set access doors and panels END OF TASK Change 2 0006 00 38 8 REF E JREF BREF 200KW 10 235A 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0007 00 OPERATION UNDER UNUSUAL CONDITIONS THIS WORK PACKAGE COVERS Operation in Extreme Cold Weather Below 25 F 32 C Operation of Winterization Kit Operation in Extreme Heat Above 120 F 49 C Operation in Dusty or Sandy Conditions Operation Under Rainy or Humid Conditions Operation in Salt Water Areas Operation at High Altitudes Operation Using Battle Short Switch Operation While Contamin
39. 694 347 578 289 OF WIRESL 19 HERTZ 150 60 KVA 250 0 8 PH 5 RPM 1500 1800 MFD BY MARATHON ELECTRIC 0116 2900 02 GROUND ROO Fr Qu HIGH INTENSITY NOISE HEARING PROTE REQUIRED WITHIN 11 FEET NOISE HAZARD DOUBLE HEARING PROTECTION REQUIRED WHEN THE SET 5 OPERATING WITH THE THE DOOR OPEN STORAGE CAUTION HIGH INTENSITY NOISE HEARING PROTECTION REQUIRED WITHIN t1 FEET DANGER EXTREME NOISE HAZARD DOUBLE HEARING PROTECTION H REQUIRED WHEN THE SET H 2 15 OPERATING WITH THE 2 DOOR OPEN 0006 00 33 200KW 10 226A Change 2 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET OPERATION UNDER USUAL CONDITIONS Continued DECALS AND INSTRUCTION PLATES Continued L SYSTEM DIAGRAM INJECTORS INJECTION PUMP PUMP WITH FUEL STRAINER FILTER ENGINE FUEL PUMP WATER SEPARATOR W FILTER FUEL FUEL TANK FUEL LEVEL FUEL PICKUP FUEL LEVEL swirCH SEND UNIT NOTE FOR AUX FUEL SUPPLY OPERATIO CONNECT AUX FUEL pip tose TO AUX FUEL SUPPLY INLET VEL SWITCH TO ON BOSON SEE OPERATOR S MANUAL FOR ADDITIONAL INFORMATION 0116 1901 01 EXTERNAL FUEL SUPPLY 30554 88 20102 INTENSITY NOISE CO WITHIN 11 FEET AR PUR STORAGE ea CAUTION 22 Un vi De SET HIGH INTENSITY N
40. 730 10 200 kW TACTICAL QUIET GENERATOR SET 0020 00 COMPONENT OF END ITEMS AND BASIC ISSUE ITEMS LISTS Continued LIST 1 ILLUS NUMBER Change 1 2 NATIONAL STOCK NUMBER 115 01 296 1462 330 01 207 3533 Table 1 Components of End Item List 3 4 DESCRIPTION CAGEC USABLE AND PART NUMBER ON CODE GENERATOR SET 30554 MEP 809A DELETED 5 TON TRAILER MODEL XM1061E FLAT BED MODIFIED DELETED DELETED DELETED DELETED 0020 00 2 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0020 00 COMPONENT OF END ITEMS AND BASIC ISSUE ITEMS LISTS Continued COEI LIST Continued DELETED QoS 200KW 10 501 1A 0020 00 3 Change 1 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0020 00 COMPONENT OF END ITEMS AND BASIC ISSUE ITEMS BII LISTS Continued COEI LIST Continued 4 b i DELETED DELETED 6 N d DELETED 2 DELETED Change 1 0020 00 4 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0020 00 COMPONENT OF END ITEMS AND BASIC ISSUE ITEMS LISTS Continued BII LIST Table 2 Basic Issue Items List 1 2 3 4 NATIONAL ILLUS STOCK DESCRIPTION CAGEC USABLE NUMBER NUMBER AND PART NUMBER ON CODE 14 730 01 340 7594 ADAPTER STRAIGHT PIPE TO HOSE 78C EA 1 IKPD5 125 HBL 10 12 24 730 00 908 3194 CLAMP HOSE 78C EA 2 96906 MS35842 11 DELETED 45 120 01 013 1676
41. CONTROL switch to OFF RESET and let cool 2 Open both engine access doors 3 Inspect engine assembly for oil leaks 4 Check for damage proper mounting or missing parts CAUTION The dipstick is marked so that the crankcase oil can be checked while engine is stopped or running Always make sure dipstick is checked Remove oil filler cap when checking oil with engine running 5 Remove oil dipstick 1 to check engine crankcase oil level Dipstick is marked on both sides for stopped or running engine If crankcase oil level is below ADD mark on dipstick for either stopped or running engine perform SERVICE task 6 Close both engine access doors END OF TASK SERVICE 1 On EMCP set ENGINE CONTROL switch to OFF RESET and let engine cool 2 Openright engine access door 3 Remove oil filler cap 2 4 Add oil to engine crankcase for operations temperature range per Table 1 0017 00 1 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0017 00 ENGINE LUBRICATION SYSTEM MAINTENANCE Continued SERVICE Continued 5 Install oil filler cap 2 6 Close right side engine access door 0 3 SDE 342 f MO SL v NIE u iy k M ADD FULL ENGINE STOPPED ADD FULL ENGINE RUNNING 200KW 10 406A Table 1 Engine Oil AMBIENT F 50 25 150 5 15 30 40 70 90 100 120 TEMPERATURE C 46 32 26 18 15 9 1 4 21 32 38 49 MI
42. DESCRIPTION OF MAJOR COMPONENTS Continued AAA my V a MIE D RIGHT SIDE 200KW 10 102 1A Figure 1 200 kW Tactical Ouiet Generator Location of Components Sheet 1 of 6 0002 00 2 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0002 00 EQUIPMENT DESCRIPTION AND DATA Continued LOCATION AND DESCRIPTION OF MAJOR COMPONENTS Continued LOAD BOARD The load board figure 1 sheet 2 item 8 connects load cables to the TQG with heavy duty connector lugs and nuts RECONNECTION BOARD The reconnection board 9 is used to change the TQG generator output voltage for different load applications The TQG can be configured for 120 208 Vac or 240 416 Vac operation for 50 Hz or 60 Hz MAIN CONTACTOR The main contactor 10 controls generator load output to the load AC GENERATOR The generator 11 used in the 200 kW TQG is Marathon Electric model DOD 751 FR designed to meet military applications for the TQG The generator is a brushless single bearing rotating rectifier generator It is close coupled to the engine via flexible drive disks Each generator is made up to five major components main stator armature main rotor field exciter stator field exciter rotor armature and rotating rectifier assembly 8 9 10 11 USA iE um 2 MA Q HH rans a Se NUN T ES N e L
43. DRIVER PULLER GROUND ROD 78C EA 1 97403 13226 7741 54 730 00 809 9703 ELBOW PIPE TO HOSE 78C EA 1 97403 13230 6380 4 6 DELETED 7 DELETED 84 210 01 361 6921 EXTINGUISHER FIRE CARBON 78C EA 2 DIOXIDE 5LB 54905 322 0020 00 5 Change 1 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0020 00 COMPONENT OF END ITEMS AND BASIC ISSUE ITEMS LISTS Continued BII LIST Continued Table 2 Basic Issue Items List Continued 1 2 3 4 5 6 NATIONAL ILLUS STOCK DESCRIPTION CAGEC USABLE QTY NUMBER NUMBER AND PART NUMBER ON CODE U M REQ 95 120 00 251 4489 HAMMER HAND ENGINEERS 78C EA 1 DOUBLE FACE 8 LB 58536 A A 1293 10 HOSE ASSEMBLY NONMETALLIC 78 1 FUEL AND OIL 97403 13230E6381 11 HOSE NONMETALLIC 78C AR 1 30554 88 20580 5 12 LAMINATE PLASTIC REFERENCE 49N 78C EA 1 93742 0116 1912 134 720 00 021 3320 LINE FUEL AUXILIARY 49N 78C EA 1 30554 69 668 144 710 00 185 6948 78 1 97403 13211 7543 154 710 00 597 8731 PIPE EXTENSION 78C EA 1 97403 13211 7542 165 975 00 878 3791 RODS GROUND WITH 49N 78C EA 1 ATTACHMENTS SECTIONAL 9 58536 55804 17 TECHNICAL MANUAL 78C EA 1 TM 9 2330 376 14 amp P PIN 064498 18 TECHNICAL MANUAL 49N 78C EA 1 TM 9 6115 730 10 19 DELETED 20 DELETED 216 150 01 406 9533 PARALLELING CABLES 49N 78C EA 1 30554 88 22209 225 120 01 3
44. Durable Items CTA 8 100 as applicable to your unit SPECIAL TOOLS TMDE AND SUPPORT EQUIPMENT Special Tools Test Measure and Diagnostic Equipment and support equipment are not authorized to operators These are needed for unit and direct support maintenance They are listed in the Repair Parts and Special Tools List RPSTL and in the Maintenance Allocation Chart MAC in TM 9 6115 730 24 REPAIR PARTS Repair parts are listed in TM 9 6115 730 24P RPSTL 0004 00 1 2 blank 9 6115 730 10 2 OPERATOR INSTRUCTIONS FOR 200 kW TACTICAL QUIET GENERATOR SET 9 6115 730 10 CHAPTER 2 OPERATOR INSTRUCTIONS FOR 200 kW TACTICAL QUIET GENERATOR SET WORK PACKAGE INDEX Title WP Sequence No DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS 0005 00 OPERATION UNDER USUAL 8 1 sanas ee titan a ss e sesta asses e sesta s e sesta sss s 0006 00 OPERATION UNDER UNUSUAL CONDITIONS enean setas tasse tasa ta sens senses 0007 00 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS 0005 00 GENERAL The following paragraphs contain references and illustrations that show the location and function of each control and indicator for operation of the TQG Each control and indicator is clearly labeled as i
45. EMEN i S B 9 9 D REAR FRONT RIGHT SIDE HOUSING REMOVED FOR CLARITY 200 10 102 2 Figure 1 200 kW Tactical Quiet Generator Location of Components Sheet 2 0002 00 3 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0002 00 EQUIPMENT DESCRIPTION AND DATA Continued LOCATION AND DESCRIPTION OF MAJOR COMPONENTS Continued ELECTRONIC MODULAR CONTROL PANEL The EMCP figure 1 sheet 3 item 12 contains controls and indicators for monitoring operation Located at the rear end of the generator set the EMCP contains the Generator Set Control GSC 13 an alarm module 14 and a Digital Voltage Regulator DVR 15 EMCP displays and indicators allow the operator to monitor all engine and generator functions with alarm and identification of malfunctions The Malfunction Symptom Index in WP 0009 00 lists all of the alarm codes and fault codes for TQG malfunctions The GSC monitors the output frequency of the generator and controls the engine speed to maintain a constant output frequency regardless of load The PUSH TO STOP EMERGENCY STOP pushbutton 16 shuts down the TQG immediately when it is pushed PARALLELING RECEPTACLES The PARALLELING RECEPTACLES panel is located to the left of the EMCP The paralleling receptacles 17 are used to connect the paralleling cable for multiple 100kW or 200 kW sets of same mode A 200kW set MEP 809A and PU 809A may be paralleled
46. HOFFMAN General United States Air Force Commander AFMC By Order of the Secretary of the Navy By Order of the Marine Corps Army Distribution GEORGE W CASEY JR General United States Army Chief of Staff NORTON A SCHWARTZ General United States Air Force Chief of Staff WALTER H CANTRELL Rear Admiral United States Navy Commander Space and Naval Warfare Systems Command G W TAYLOR Product Group Director PG 15 Ground Transportation Engineer Systems Marine Corps Systems Command To be distributed in accordance with the initial distribution number IDN 256886 requirements for TM 9 6115 730 10 Marine Corps Distribution To be distributed in accordance with PCN 184 115980 03 9 6115 730 10 HEADQUARTERS NO 2 DEPARTMENTS OF THE ARMY AIR FORCE NAVY AND HEADQUARTERS U S MARINE CORPS WASHINGTON DC 15 February 2009 TECHNICAL MANUAL OPERATOR S MANUAL FOR GENERATOR SET SKID MOUNTED TACTICAL QUIET 200kW 50 60 HZ MEP 809A NSN 6115 01 296 1462 GENERATOR SET TRAILER MOUNTED TACTICAL QUIET 200KW 50 60 HZ PU 809A NSN 6115 01 471 7085 DISTRIBUTION STATEMENT A Approved for public release distribution is unlimited TM 9 6115 730 10 dated 15 January 2006 is updated as follows 1 File this sheet in front of the manual for reference 2 This change is a result of adding a Unique Identification Plate to the housing of the Generator set 3 New or updated text is indicated
47. Hearing protection must be worn when operating or working near the generator set when the generator set is running Failure to comply can cause hearing damage to personnel CAUTION The dipstick is marked so that the crankcase oil can be checked while engine is stopped or running Always make sure dipstick is checked Remove oil filler cap when checking oil with engine running 3 GSC LOW OIL PRESSURE red indicator flashes 1 Set ENGINE CONTROL switch to COOL DOWN STOP 2 Set DEAD CRANK SWITCH to OFF 3 Set Battery Disconnect Switch to OFF 4 After engine stops check oil level pel WP 0017 00 0010 00 3 If oil is below ADD mark fill as required pei WP 0017 00 If oil level is correct or problem continues notify maintenance 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR 0010 00 TROUBLESHOOTING Continued Table 1 Operator Troubleshooting Continued MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION 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 or death to personnel WARNING Operating the generator set exposes personnel to a high noise level Hearing protection must be worn when operating or working near the generator set w
48. Index contains a table listing only the Alarm Codes and Fault Codes for the TQG engine and control systems including the Digital Voltage Regulator DVR This WP includes the codes that the operator can troubleshoot and take corrective action The table also includes the transient codes necessary for the Operator to know in order to notify maintenance to take corrective action Chapter 4 work packages contain Operator Maintenance Instructions Preventive Maintenance Checks and Services PMCS including Lubrication Instructions that the operator is authorized to perform It also includes Service Upon Receipt WP which contains instructions for reporting preliminary checks and adjustment of the equipment It also contains information in a WP for preparation for storage or shipment ork packages provide information on all related reference material Components of End Item and Basic Issue Items BII List Additional Authorized List AAL and Expendable and Durable Items List This Chapter also contains detailed Warranty Information including manufacturers warranted list of components While performing the procedures in this manual you may find errors and or make recommended changes that will improve the manual At the back of this manual you will find copies of DA Form 2028 which invite you to submit your suggestions digitized or on paper iii Change 1 HOW USE THIS MANUAL Continued MAINTENANCE WORK PACKAGES Read the INIT
49. PERMISSIVE Mode Continued 11 12 13 14 15 16 17 18 19 CAUTION If square symbol l on synchroscope lower display does not stop at center and synchronizing lights V HZ and Du amp on left side of GSC panels on paralleling generator sets do not glow steady yellow the voltage frequency and phasing are wrong and must be corrected Failure to observe this caution can result in damage to generator sets NOTE When generator sets are operated in parallel a switch or external load contactor should be placed between the generator set and load to connect and disconnect power If square symbol lon synchroscope lower display does not stop at center and synchronizing lights V HZ and Du on left side of GSC panels on paralleling generator sets do not glow steady yellow shut down the generator sets Check that load cables are connected properly Repeat steps thru 10 above On incoming TQG No 2 EMCP adjust VOLTAGE potentiometer until yellow V indicator on GSC stops flashing AC CIRCUIT INTERRUPTER switch cannot be set to CLOSE unless voltage is stable On incoming TQG No 2 adjust FREQUENCY potentiometer as necessary to match generator set frequencies On GSC lower display observe that the square symbol on synchroscope of TQG No 2 stops rotating Clockwise rotation indicates that frequency of TQG No 2 power is higher than load bus Counterclockwise rotation indicates that frequency of TQG
50. PN 0116 2600 VPN FVG16 0587 0023 00 3 4 blank 9 6115 730 10 GLOSSARY TERM DEFINITION Bus Dead Bus De energize Droop EMI Energize Excitation voltage Generator overload condition Ground fault circuit interrupter Incoming generator Isochronous kV KVAR KVARhr kW Load bus Overcurrent condition Paralleling Reverse power The common power conducting wires or bars to which all power sources within the power system are connected through their individual circuit breakers A bus from which all the available power sources are disconnected To remove voltage from a circuit or device in order to deactivate it Paralleling mode that allows slight fluctuations in frequency so that lagging generator set can match frequency of companion generator Electromagnetic interference is any electromagnetic disturbance that interrupts obstructs or other wise degrades or limits the effective performance of electronics and electrical equipment as a result of spurious emissions and responses To apply voltage to a circuit or device in order to activate it DC voltage applied from the voltage regulator to the generator exciter field windings Load greater than the load for which the system or mechanism was intended For TQGs overload is defined as the condition when current in all three phases exceeds 100 of rated current or when current in a single phase exceeds 130 of
51. QUIET GENERATOR SET 0006 00 OPERATION UNDER USUAL CONDITIONS Continued PARALLEL UNIT OPERATION LOAD SHARING Continued Operation in SEMI AUTO Mode Continued 5 6 10 11 12 13 14 15 16 17 Ensure that all external load contactors between the generator sets and the load are open On TQG No 1 EMCP position AC CIRCUIT INTERRUPTER switch to CLOSED until press to test green indicator lights On TQG No 1 EMCP set SYNC MODE switch to OFF and on GSC panel keypad press and hold POWER METER to display kW continuously Set UNIT PARALLEL switch on both units to PARALLEL On TQG No 2 EMCP set SYNC MODE switch to SEMI AUTO Perform steps 8 and 9 for each additional set to be paralleled CAUTION If square symbol lon synchroscope lower display does not stop at center and synchronizing lights V HZ and Du amp on left side of GSC panels on paralleling generator sets do not glow steady yellow the voltage frequency and phasing are wrong and must be corrected Failure to observe this caution can result in damage to generator sets NOTE When generator sets are operated in parallel a switch or external load contactor should be placed between the generator set and load to connect and disconnect power If square symbol lon synchroscope lower display does not stop at center and synchronizing lights V HZ and D amp on left side of GSC panels on paralleling generator sets do not glo
52. Reconnection Board TB1 CONTROL OR KEY INDICATOR FUNCTION onnection board base 120 208 240 416 Reconnection board top plate can be positioned to provide 120 208 Vac 3 phase or 240 416 Vac 3 phase power output from TQG set Aligned arrows determine output Contains 12 connector lugs for DA B C and neutral legs L1 L2 L3 N or GND for 3 phase power output Voltage output is for three phase power Setting for 120 208 Vac 3 phase power output Each phase is nominal 120 Vac to ground and 208 Vac between any two phases Setting for 240 416 Vac 3 phase power output Each phase is nominal 240 Vac to ground and 416 Vac between any two phases 0005 00 15 Change 3 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0005 00 DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS Continued OUTPUT LOAD TERMINAL BOARD TB2 Table 10 describes Output Load Terminal Board TB2 connections located at lower right rear of generator set 2 200KW 10 212B Table 10 Output Load Terminal Board TB2 Connections CONTROL OR KEY INDICATOR FUNCTION GND Jumper Jumper will only be removed ifthe equipment being powered requires an isolated Floating ground N Neutral line for generator output loads Ll Connection for L1 A leg of three phase output power L2 Connection for L2 B leg of three phase output power L3 Connection for L3 C leg of three phase output power WA
53. Symptom Index WP 0009 00 MALFUNCTIONS are numbered in sequence and are to be performed in the order in which they appear TESTs INSPECTIONS are steps you take to isolate the malfunction Each test or inspection has a corrective action These are the if statements that tell you what to do when the malfunction is not fixed CORRECTIVE ACTIONS are actions intended to correct the problem If the problem cannot be identified or corrected report the problem as follows US Army report all deficiencies including deficiencies that appear to involve unsatisfactory design on DA Form 5988 E automated form in the Unit Level Logistics System ULLS generated Equipment Maintenance and Inspection Worksheet When no automation is available use DA Form 2404 Equipment Inspection and Maintenance Worksheet Both forms serve the same purpose Air Force report all deficiencies on SF Form 368 0008 00 2 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR MALFUNCTION SYMPTOM INDEX 0009 00 The Malfunction Symptom Index provides a quick reference by work package number and page number for error messages and troubleshooting procedure malfunctions Malfunction Symptom Work Package and Page No 10 11 12 13 14 15 16 17 Dedicated Fault Indicators EMCP AC CIRCUIT INTERRUPTER lamp does not light when TQG is connected to load EMCP panel lamp is not lit GSC LOW OIL PRESSURE red indicator flashes
54. brings TQG on line by closing AC CIRCUIT INTERRUPTER switch 7 VOLTAGE adjust knob Potentiometer control permits fine adjustment of generator set voltage 8 PARALLEL UNIT switch Two position toggle switch Controls dead bus monitoring and paralleling of load sharing modules PARALLEL Activates paralleling circuits up Used when placing TQG in parallel mode Bus is monitored by relays that will not allow generator output to be connected to load if there is power on load bus Load sharing module is connected to paralleling cable connector for paralleling in ISOCHRONOUS mode UNIT Deactivates paralleling circuits down Generator is operating independently of other generators GSC monitors bus and load can be connected automatically or enabled for operator connection Load sharing module is disconnected from paralleling cable connector output 9 Alarm module Alarm will sound if an overcurrent an overload or a low fuel condition exists Refer to Table 3 10 DVR DVR provides excitation to control and regulate generator voltage Refer to Table 4 for controls and indicators Change 3 0005 00 2 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0005 00 DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS Continued ELECTRONIC MODULAR CONTROL PANEL Continued Table 1 Tactical Quiet Generator Electronic Modular Control Panel Controls and Indicators Continued CONTROL OR KEY INDICATOR FUNCTION CIRCUIT Three position toggle sw
55. 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 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 Slave receptacle NATO connector is electrically live at all times and is unfused The Battery Disconnect Switch does not remove power from the slave receptacle NATO slave receptacle has 24 VDC even when disconnect switch is set to OFF This circuit is only dead when the batteries are fully disconnected Disconnect the batteries before performing maintenance on the slave receptacle Failure to comply can cause injury or death to personnel 9 6115 730 10 WARNING SUMMARY Continued WARNING High voltage power is available when the main contactor is closed Avoid accidental contact with live components Ensure load cables are properly connected and the load cable door is shut before closing main contactor Ensure load is turned off
56. driving stud 4 into coupler 5 Make sure that driving stud is screwed completely into coupler and contacts top of ground rod Drive ground rod into ground until coupler is just above surface 9 Remove driving stud and install another section of ground rod into coupler 10 Repeat steps 7 8 and 9 until ground rod has been driven 8 feet or deeper Drive ground rod down until last coupler is just above ground surface 11 Remove coupler 5 and driving stud 4 and return to storage inside left rear housing door 0006 00 3 Change 2 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0006 00 OPERATION UNDER USUAL CONDITIONS Continued ASSEMBLY AND PREPARATION FOR USE Continued Installation of Ground Rod Continued 12 Insert ground cable 2 through clamp 3 and slide clamp on last ground rod section 1 Tighten clamp and ground cable eT OUTPUT ore 8 CABLES 4 LOO j 1 4 E p 6 N 9 SKID MOUNTED 200KW 10 241A Change 2 0006 00 4 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0006 00 OPERATION UNDER USUAL CONDITIONS Continued ASSEMBLY AND PREPARATION FOR USE Continued Installation of Ground Rod Continued 13 If TQG is trailer mounted configuration PU 809A insert ground cable 2 through terminal 10 on end of XM1061E1 trailer 11 14 Insert trailer ground cable 12 through terminal 10 on end of XM1061E1 trailer 11
57. generator sets and the load are open No 1 EMCP set SYNC MODE switch to AUTO The AC CIRCUIT INTERRUPTER will close and indicator will light No 1 GSC panel keypad press and hold POWER METER to display kW continuously on the lower display Set UNIT PARALLEL switch on both units to PARALLEL CAUTION If square symbol lon synchroscope lower display does not stop at center and synchronizing lights V HZ and D on left side of GSC panels on paralleling generator sets do not glow steady yellow the voltage frequency and phasing are wrong and must be corrected Failure to observe this caution can result in damage to generator sets NOTE When generator sets are operated in parallel a switch or external load contactor should be placed between the generator set and load to connect and disconnect power If square symbol lon synchroscope lower display does not stop at center and synchronizing lights V HZ and D amp on left side of GSC panels on paralleling generator sets do not glow steady yellow shut down the generator sets Check that load cables are connected properly Repeat steps 1 thru 8 above On TQG No 2 EMCP set SYNC MODE switch to AUTO Set will automatically synchronize and close AC CIRCUIT INTERRUPTER Change 2 0006 00 20 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0006 00 OPERATION UNDER USUAL CONDITIONS Continued PARALLEL UNIT OPERATION LOAD SHA
58. or cannot clear debris PU 809A TRAILER INSTALLATION 55 After Accessory Box Inspect accessory box clamping hasp for operation Check accessory box contents to ensure that Ground rod and all required items are present and components are serviceable missing or unserviceable END OF TASK 0012 00 16 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0013 00 CONTROL BOX ASSEMBLY MAINTENANCE THIS WORK PACKAGE COVERS Repair INITIAL SETUP Maintenance Level References Ope rator None Tools and Special Tools Materials Parts None Incandescent lamp Personnel Required One WARNING D Metal jewelry can conduct electricity and become entangled in generator set components Remove all metal jewelry when working on generator set Failure to comply can cause injury or death to personnel 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 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 REPAIR Replace Control Panel Lights On Electronic Modular Control Panel EMCP l 2 3 4 5 6 7 EMCP set ENGINE CONTROL switch to OFF RESET Set DEAD CRA
59. or maintenance on the unit Failure to comply can cause injury or death to personnel 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 If necessary to move a generator set that has been operating in parallel with another generator set shut down all generator sets prior to removing load cables or ground Failure to comply can cause injury or death to personnel by electrocution Before making any connections for parallel operation or moving a generator set that has been operating in parallel ensure there is no input to the load board and the generator sets are shut down Failure to comply can cause injury or death to personnel by electrocution 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 Set ENGINE CONTROL switch to OFF RESET Perform all After PMCS requirements pet WP 0012 00 Open rear left housing door and set DEAD CRANK SWITCH to OFF WP 0005 00 12 Open battery compartment and set Battery Disconnect switch to OFF WP 0005 00 14 Open output load terminal door at right rear of TQG Using terminal nut wrench 1 loosen load terminal nuts 2 Disconnect all load cables 3 from output load terminals
60. performance and possible overheating and automatic shutdown 1 Keep generator set doors closed to optimize engine cooling keep the engine clean and reduce noise Check vents and radiator air passages frequently for obstructions Check coolant temperature indicator frequently for any indication of overheating Allow sufficient space for fuel expansion when filling fuel tank WP 0016 00 Keep generator clean and free of dirt Clean obstructions from generator intake and outlet screens Clean external surface of engine when generator set is not operating A Ue de Ue Using Table 1 determine the allowable load capacities for the 100 kW for local operating temperatures Notify maintenance to evaluate and adjust TQG loads as necessary It may be necessary to add another TQG or to reduce the load demand Table 1 High Temperature Load Capacities AMBIENT TEMPERATURE PERCENTAGE OF RATED LOAD 125 52 100 130 54 C 80 2 135 57 C 75 140 60 70 END OF TASK 0007 00 3 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0007 00 OPERATION UNDER UNUSUAL CONDITIONS Continued OPERATION IN DUSTY OR SANDY CONDITIONS 1 ge qu 8 9 If possible provide a shelter for generator set Use available natural barriers to shield generator set from blowing dust or sand Keep generator set doors closed to optimize engine cooling keep the engine cl
61. s fraying and looseness 51 After Overflow Bottle Check overflow bottle for cracks leaks or Class ITI leaks Overflow Bottle Continued missing parts Check coolant level WP 0015 00 0012 00 15 Coolant level is below COLD line 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0012 00 PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS INCLUDING LUBRICATION INSTRUCTIONS Continued Table 1 Preventive Maintenance Checks and Services Continued LOCATION NOT FULLY ITEM ITEM TO MISSION NO INTERVAL CHECK SERVICE PROCEDURE CAPABLE IF Electronic Modular Control Panel EMCP 52 After Indicators and Check all indicators and controls for Indicators or controls Controls damaged or missing parts damaged or missing 53 After Indicators and Check all indicators and controls for Indicators or controls Controls damaged or missing parts damaged or missing 54 After Overall Exterior Check external doors panels hinges and Cannot shut doors latches for damaged loose or corroded items CAUTION Operating the generator set with restricted airflow for cooling can cause the generator set to overheat Keep all access door inlet panels clear to ensure maximum airflow for engine and generator cooling Failure to comply can result in poor engine performance and possible overheating and automatic shutdown Inspect air intake and exhaust grills for Any restrictions of air debris flow
62. should be corrected and all Modification Work Orders MWO Modification Instructions MI or Time Compliance Technical Orders TCTO should be applied Inside storage is preferred for items selected for administrative storage If inside storage is not available trucks vans CONEX containers and other containers may be used For general storage information refer to TM 740 90 1 TO 35 1 4 END OF TASK 0018 00 1 2 blank 9 6115 730 10 5 SUPPORTING INFORMATION FOR 200 kW TACTICAL QUIET GENERATOR SET 9 6115 730 10 CHAPTER 5 SUPPORTING INFORMATION FOR 200 kW TACTICAL QUIET GENERATOR SET WORK PACKAGE INDEX Title WP Sequence No REFERENCES COMPONENTS END ITEM COED AND BASIC ISSUE ITEMS BID LISTS ADDITIONAL AUTHORIZED LIST AAL usussnssnssusssnsssnesnessnnsnusnsnssnnssunssnssnnsnansnonsnnssonsnnnsnnssnnssnnsnnnssnnssnnssnnne EXPENDABLE AND DURABLE ITEMS LIST 2 20022000000000200n000n000n0nnsonnssnnnsnnssnensnensnrnnnsnonsnnnsansnansnansnunsnnnsnnnnne WARRANTY INFORMATION P 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0019 00 REFERENCES SCOPE This work package lists all field manuals forms technical manuals technical bulletins commercial manuals and miscellaneous publications for use with the Ta
63. that is supplying a load When you connect 200 kW to the load bus with a 100 kW already under load and the load sharing becomes unstable you should immediately disconnect the 100 kW TQG from the load bus to prevent damage to equipment by setting 100 kW TQG AC CIRCUIT INTERRUPTER switch to OPEN The 100 kW TQG should then be synchronized to the load bus and the AC CIRCUIT INTERRUPTER switch set to CLOSED Perform INITIAL ADJUSTMENTS BEFORE USE AND SELF TEST procedure On each generator set EMCP set ENGINE CONTROL switch to MANUAL START Rotate VOLTAGE adjust potentiometers to obtain same voltage indication on each set Rotate FREQUENCY adjust potentiometers to obtain same frequency indication on each set Ensure that all external load contactors between the generator sets and the load are open On No EMCP position and hold AC CIRCUIT INTERRUPTER switch to CLOSED until press to test green indicator lights No EMCP set SYNC MODE switch to OFF and on GSC panel keypad press and hold POWER METER to display kW continuously Set UNIT PARALLEL switch on both units to PARALLEL On TQG No 2 EMCP set SYNC MODE switch to PERMISSIVE Perform steps 8 and 9 for each additional set to be paralleled 0006 00 23 Change 2 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0006 00 OPERATION UNDER USUAL CONDITIONS Continued PARALLEL UNIT OPERATION LOAD SHARING Continued Operation in
64. the generator set is running Failure to comply can cause hearing damage to personnel CAUTION The ideal load for the generator set is 80 of rated capacity When operated at less than 80 of rated load the diesel engine operates at lower temperatures and burns fuel incompletely resulting in carbon and moisture in the exhaust and carbon buildup or wetstacking in the engine To avoid damage to the engine if possible mission loads should be distributed among available generator sets to achieve an average 80 load on each generator set The minimum load that the generator set should be operated at is 25 to 30 of its rated capacity Operating at lower loads for long periods of time may damage the engine and cause wetstacking and damage to the engine Engines operated at low loads for long periods of time should be operated at full load for a few hours until the wetstacking residues are burned out This should be performed every 300 hours of generator set operation NOTE At temperatures below 30 F 1 C the cold weather starting aid will be activated In normal operating temperatures the EMCP will temporarily display low temperature alarm code AL2 upon startup This is a normal part of the operation and the fault code will go away when starting is complete Perform INITIAL ADJUSTMENTS BEFORE USE AND SELF TEST procedures WP 0006 00 10 Change 2 0006 00 12 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0006 00 OPERATION UNDE
65. to monitor for current and voltage measurements The values and terminals are indicated on the upper and lower displays 0003 00 7 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0003 00 THEORY OF OPERATION Continued FUEL FIRED HEATER SYSTEM ISSUED TO SELECTED UNITS ONLY RESISTORS FUEL TANK al ENGINE FUEL FIRED HEATER CONTROL COOLANT FUEL FIRED HEATER EXHAUST 200KW 10 110 The winterization kit consists of a fuel fired heater assembly with an internal water pump The fuel fired heater assembly preheats coolant and internal water pump circulates heated engine coolant through the engine The fuel fired heater system uses a 24 Vdc electric system that powers the heater fuel pump and circulating pump and a resistor circuit that warms EMCP components The EMCP resistors are also automatically energized when EMCP has power applied to it and the thermostat closes temperature below 20 F 29 C 0003 00 8 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0004 00 SUPPORTING DATA FOR REPAIR PARTS SPECIAL TOOLS TMDE AND SUPPORT EQUIPMENT COMMON TOOLS AND TEST EQUIPMENT For authorized common tools and equipment refer to the Modified Table of Organization and Equipment MTOE Common Table of Allowances CTA 50 970 Expendable Durable Items Except Medical Class V Repair Parts and Heraldic Items or Army Medical Department Expendable
66. turning knob to right or pulling out 3 HIGH WATER TEMP Red indicator flashes when engine coolant temperature rises above programmed shutdown indicator setpoint for high coolant temperature shutdown Engine shuts down and does not start until fault is corrected Change 3 0005 00 4 200 kW TACTICAL QUIET GENERATOR SET TM 9 6115 730 10 0005 00 DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS Continued GENERATOR SET CONTROL Continued Table 2 Generator Set Control Controls and Indicators Continued CONTROL OR KEY INDICATOR FUNCTION 4 10 ENGINE OVERSPEED Red indicator flashes when engine speed rises above programmed setpoint for engine shutdown indicator OVERCRANK shutdown indicator FUNCTION I LOW COOLANT LEVEL indicator BATTLE SHORT indicator IN 50 Hz MODE FUNCTION II V left side of light HZ left side of light D left side of light FAULT SHUTDOWN indicator FAULT ALARM indicator overspeed Engine shuts down and does not start until fault is corrected Red indicator flashes when engine does not start within programmed setpoint for total cycle crank time Engine not allowed to start until fault is corrected NOTE Indicator lights key 6 thru 8 perform dual functions depending on the position of the UNIT PARALLEL switch When UNIT PARALLEL switch is set to UNIT FUNCTION I the indicators display the following Yellow light flashes when coolant le
67. with ground cable 2 and tighten nut 15 Insert trailer ground cable 12 through clamp 3 and slide clamp on last ground rod section 1 Tighten clamp and ground cable 3 WD TRAILER MOUNTED 2 gt EX PRI UO 200 10 240 0006 00 5 2 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0006 00 OPERATION UNDER USUAL CONDITIONS Continued ASSEMBLY AND PREPARATION FOR USE Continued Installation of Load Cables dO CUN 9 D 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 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 A qualified technician must make the power connections and perform all continuity checks The power source may be a generator or commercial power Failure to comply with this warning can result in injury or death to personnel CAUTION When using single phase connections balance loads between terminals Do not connect all loads between one terminal and N Failure to observe this caution can result in damage to equipment On Electronic Modular Control Pane
68. with a 100kW set MEP 807A or PU 807A CONVENIENCE RECEPTACLES Two convenience receptacles 18 are located to the left of the EMCP on the PARALLELING RECEPTACLES panel The receptacles rated 120 Vac 15 are available at all times during generator operation The receptacles are protected by a GROUND FAULT CIRCUIT INTERRUPTER with TEST and RESET 19 functions The frequency at the convenience receptacle outlets is set by generator frequency and will be 50 Hz or 60 Hz DEAD CRANK SWITCH The DEAD CRANK SWITCH figure 1 sheet 4 item 21 is located inside the generator housing at the left rear During maintenance the dead crank switch allows the engine to be cranked without starting the engine NATO SLAVE RECEPTACLE The NATO slave receptacle 22 is located on the left side front of the TQG It is used for 24 Vdc slave starting BATTERIES Four sealed 12 Vdc batteries 23 located at the front of the generator are connected in series and parallel The batteries provide power for EMCP controls engine starting and to the NATO slave receptacle These batteries can be disconnected with the Battery Disconnect Switch 24 WINTERIZATION KIT ISSUED TO SELECTED UNITS ONLY The winterization kit consists of a fuel fired heater 25 to heat engine coolant and connecting control wiring and tubes The kit also includes resistor heaters located in EMCP The fuel fired heater is controlled with the winterization kit control panel figure 1
69. 0 200KW 10 402A END OF TASK 0014 00 2 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0014 00 ENGINE AIR CLEANER MAINTENANCE Continued SERVICE 1 On EMCP set ENGINE CONTROL switch to OFF RESET 2 Set DEAD CRANK SWITCH to OFF 3 Set Battery Disconnect Switch to OFF 4 Open access door at left rear of generator set housing 5 Loosen wing nut 3 and remove outer filter element 4 from air cleaner housing 1 6 Remove cotter key 5 indicator nut 6 and inner filter element 7 7 Squeeze rubber dust cup 8 on extension on air cleaner housing 1 several times to expel dust and debris 8 Inspect inside of air cleaner housing 1 for debris 9 Wipe housing interior with clean lint free cloth WARNING Eye protection is required when working with compressed air Compressed air can propel particles at high velocity and injure eyes Do not exceed 15 psi pressure when using compressed air Failure to comply could cause serious injury to personnel 10 Clean inner filter element 4 and outer filter 3 with compressed air or by tapping elements to remove loose dirt 11 Inspect indicator nut 6 12 Reset indicator nut 6 by applying suction to window 13 Install inner filter element 7 with indicator nut 6 and cotter key 5 14 Install outer filter element 4 and hand tighten wing nut 3 15 Close left rear access door 16 After operating TQG inspect restriction indicator 2 when performing DURING PMCS If
70. 0 1 Fuel Level Fuel Tank Inspection 0016 00 2 Fuel Falt t Water patada 0016 00 2 Oil 0017 00 1 Le List of Abbreviations Acronyms 0001 00 2 Load Board Output Load Terminal Board Characteristics EUR cee ae ES 0002 00 1 Pl 0002 00 3 Toad Cables Installation cscs 0006 00 6 Table 1 Load Terminal and AC Reconnection Board 0006 00 7 Location and Description of Major Components 0002 00 1 AC GIC T 0002 00 3 Air Cleaner Assembly 2 11 00042 0 600000000000 enne nennen 0002 00 1 EX MM 0002 00 1 Batteries s vecina A 0002 00 4 Convenience Receptacles eimi en PR a HERE I ERREUR E 0002 00 4 Dead Crank Switch re E reinen ernten 0002 00 4 Electronic Modular Control Panel esee ener enne tene enne 0002 00 4 Engine e 0002 00 1 Engine Control M
71. 0 3 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0016 00 ENGINE FUEL SYSTEM MAINTENANCE Continued SERVICE Continued Fuel Filter Water Separator Service ISR erw D L 1 659 AZ ASA Y OH TAL J D la KL 104 b PL JA 5 4 200KW 10 405A 1 On set ENGINE CONTROL switch to OFF RESET 2 Open front left side engine access door 3 Place a suitable container under drain hose 5 at WATER SEPARATOR DRAIN on the left side of the skid base 4 Open fuel drain cock 4 on fuel filter water separator assembly and drain any sediment and water through coolant drain line 5 into a suitable container and dispose of using current procedures and local Standard Operating Procedure 5 Close drain cock 4 6 Close front left side engine access door END OF TASK 0016 00 4 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0017 00 ENGINE LUBRICATION SYSTEM MAINTENANCE THIS WORK PACKAGE COVERS Inspection Service INITIAL SETUP Maintenance Level References Ope rator None Tools and Special Tools Materials Parts None MIL L 46167 OEA item d WP 0022 00 MIL PRF 2104 OE HDO 10 items 7 8 or 9 WP 0022 00 Personnel Required MIL PRF 2104 OE HDO 30 items 10 or 11 WP 0022 00 One MIL PRF 2104 OE HDO 40 item 15 WP 0022 00 MIL PRF 2104 OE HDO 15 40 items 12 13 or 14 WP 0022 00 INSPECTION On EMCP set ENGINE
72. 0 6 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0005 00 DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS Continued GENERATOR SET CONTROL Continued Table 2 Generator Set Control Controls and Indicators Continued CONTROL OR KEY INDICATOR FUNCTION NOTE Active during paralleling only 200KW 10 230 Lower display During paralleling operations lower display operates as synchroscope in SEMI Synchroscope for AUTO and PERMISSIVE settings of SYNC MODE switch 6 A square symbol Parallel Operation revolves around perimeter of display to indicate phase angle and frequency relationships between bus and incoming generator Yellow indicator lights for three fault alarms also show status of paralleling Synchronizing lights indicate that voltages match V 6 that frequencies are matched HZ 7 and that phases are matched I v 8 Indicator lights flash speed is relative to speed of synchroscope symbol Frequency of incoming generator is greater than load bus 1 Rotating clockwise L1 Rotating Frequency of incoming generator is less than load bus counterclockwise L Stopped in any Frequency of incoming generator and load bus are the same Phases are different position other than top center IN SYNC Frequency of incoming generator and load bus are the same In phase phase angle is 0 _ Stopped at top center 13 19 Keypad Used to control information shown on upper display and lower display
73. 000 TM 9 6115 730 24P Operator s Organizational DS and GS Maintenance Manual Including Repair Parts and Special Tools Lists for Trailer 5 Ton 4 Wheel GEMSS XM979 Trailer Flatbed 5 Ton 4 Wheel XM1061 M1061A1 and Trailer General Purpose Flatbed 7 1 2 Ton 1073 9 2330 376 14 amp P Change 1 0019 00 2 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0020 00 COMPONENT OF END ITEMS AND BASIC ISSUE ITEMS LISTS INTRODUCTION Scope This work package contains COEI and BII information for the 200 kW Tactical Quiet Generators MEP 809A and PU 809A to help you inventory items for safe and efficient operation of the equipment General The COEI and BII information is divided into the following COEI This list Table 1 is for information purposes only and is not authority to requisition replacements These items are part of the 200 kW Tactical Quiet Generators MEP 809A and PU 809A As part of the end item these items must be with the end item whenever it is issued or transferred between property accounts Items of COEI are removed and separately packaged for transportation or shipment only when necessary Illustrations are furnished to help you find and identify the 1tems BII This list Table 2 provides essential items required to place the 200 kW Tactical Quiet Generators MEP 809A and PU 809A in operation to operate them and to do emergency repairs Although shipped separate
74. 06 00 36 Convenience Receptacles Characteristics M 0002 00 1 Description iria diia 0002 00 4 Cooling System PMCS lt 0012 00 6 ee 0012 00 15 0012 00 6 2 EE 0012 00 12 Corrosion Prevention and Control 2 020204244 020000000000 eee eene nennen nennen nenne nennen 0001 00 2 D Dead Crank Switch Characteristics 0002 00 1 Description esse isn tens en E EE EE A ET ES 0002 00 4 Decals and Instruction Plates Front E 0006 00 32 os 0006 00 33 a IM I 0006 00 26 Right Sides oae IUE es 0006 00 29 Destruction of Army Materiel to Prevent Enemy 0001 00 2 Description and Use of Operator Controls and Indicators Alarm Module id epe REPE PERO P aoe EE eles 0005 00 9 Table 3 Alarm Module Controls and Indicators sss 0005 00 9 Battery Disconnect Switch PR 0005 00 14 Table 8 Battery Disconnect Switch 0005 00 14 Dead Crank Swit er USUS UE T 0005 00 12 Table 6 Dead Crank Switch ceesesessesecseseceesencesececeneeneeec
75. 17 0 Tools and Special Tools DA Form 5988 E None DA PAM 738 750 Personnel Required Materials Parts One Cleaning compound item 2 WP 0022 00 Wiping rags item 18 WP 0022 00 INTRODUCTION PMCS are performed to keep the 200 kW TQG in operating condition Inspect the within specified intervals so defects are found and corrected or problems are reported before any serious damage or failure occurs Do the PMCS per Table 1 Pay attention to WARNINGs and CAUTIONs A WARNING means someone could be hurt A CAUTION means equipment could be damaged NOTE Designated intervals are performed under usual operating conditions PMCS intervals must be performed more frequently when operating under unusual conditions BEFORE PMCS is done before you start and operate the 200 kW TQG DURING PMCS is done while the equipment and or its component systems are in operation AFTER PMCS is done immediately after operating and shutting down the 200 kW 0012 00 1 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0012 00 PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS INCLUDING LUBRICATION INSTRUCTIONS Continued INTRODUCTION Continued 1 Ifyou are operating the 200 kW TQG for the first time you must do your BEFORE PMCS 2 Always perform preventive maintenance in the same order so it gets to be a habit Once you have had some practice you will spot anything wrong in a hurry 3 Wiping rags are needed to remove dirt or grease
76. 5 hp 1800 rpm 60 Hz 329 hp 1500 rpm 50 Hz 732 in 12 0L Four two inlet two exhaust Inlet 0 015 in 0 38 mm Exhaust 0 025 in 0 64 mm Pressurized radiator and coolant pump 42 qt 39 7L 170 F to 200 F 77 C to 93 C 24 Vdc range programmable Full flow circulating pressure Positive displacement gear 36 qt 34 1L 35 to 70 psi 241 to 483 kPa DF 1 DF 2 JP5 JP8 128 gal 485L 8 hour tank capacity at full load Walbro Corp 24 Vdc 16 to 30 Vdc 34 gph at 30 Vdc 17 gph at 18 Vdc 0002 00 9 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0002 00 EQUIPMENT DESCRIPTION AND DATA Continued EQUIPMENT DATA Continued Table 1 200 kW Equipment Data Continued Fuel level switch Manufacturer Madison Type Float Voltage 24 Vdc Engine starting system Batteries Manufacterer Optima 12 Vdc qty 4 sealed units Starter Manufacturer Caterpillar Model 6V0890 Voltage rating 24 Vdc Drive type Direct Alternator Manufacturer Caterpillar Model 4N3986 Voltage rating 24 Vdc Drive type Belt Generator Manufacturer Marathon Model DOD 751 FR Type Alternating current synchronous brushless Load capacity 200 kW at 60 Hz 167 kW at 50 Hz 1 800 rpm 1 500 rpm Current ratings 60 Hz 50 Hz 120 208 Vac connection 694A 578A 240 416 Vac connection 347A 289A Power factor 0 8 Cooling Fan cooled Drive type Direct coupling Duty classification Continuous Governing system Load measuring u
77. 61 E FMI 01 High Engine Coolant Temperature Active and Logged CID 361 E FMI 02 High Engine Coolant Derate Active and Logged 0009 00 5 Notify maintenance Notify maintenance Notify maintenance Notify maintenance Notify maintenance Notify maintenance Notify maintenance Notify maintenance Notify maintenance Notify maintenance Notify maintenance Notify maintenance Notify maintenance Notify maintenance Notify maintenance Notify maintenance Notify maintenance Notify maintenance Notify maintenance Notify maintenance Notify maintenance Notify maintenance Notify maintenance Notify maintenance Notify maintenance Notify maintenance 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR MALFUNCTION SYMPTON INDEX Continued 0009 00 Malfunction Symptom Work Package and Page No 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 361 CID 362 CID 362 CID 368 CID 391 CID 441 CID 442 CID 443 E FMI03 High Engine Coolant Shutdown Active and Logged E FMI01 Overspeed Warning Active and Logged 03 Overspeed Shutdown Active and Logged E FMI01 High Inlet Air Temperature Warning Active and Logged FMI 01 Inlet Air Restriction Warning Active and Logged FMI 12 GSC Electronic
78. 69 1646 WRENCH LOAD TERMINAL 49N 78C EA 1 30544 88 21148 Change 1 0020 00 6 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0020 00 COMPONENT OF END ITEMS AND BASIC ISSUE ITEMS BII LISTS Continued BII LIST Continued 1 DELETED 2 3 SR DELETED DELETED 4 5 6 7 8 m 0020 00 7 Change 1 200KW 10 505 1A 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0020 00 COMPONENT OF END ITEMS AND BASIC ISSUE ITEMS LISTS Continued BII LIST Continued 13 14 15 ARMY TM 9 6115 730 10 AIR FORCE TO 35 2 2 620 1 NAVAIR 19 50 28 TECHNICAL MANUAL OPERATOR S MANUAL FOR GENERATOR SET SKID MOUNTED TACTICAL QUIET 290 Ma 9 2330 376 14 amp P TECHNICAL MANUAL 7 50 66 MEP 8094 0MCLUDINO REPAR PARTE AND SPECIAL TOOLS USTE von CHASES TRAILER STON 4 WHEEL GEMES 1 7 KARTE MEN 13 0 01 170 4747 NSN 6115 01 296 1462 XXX GENERATOR SET TRAILER MOUNTED TACTICAL QUIET 200 kW 50 00 409 FLATBEO TOM XM1001 NBM 2330 01 207 3532 MIO61A1 NBN 222001 TRARER GENERAL PURPOSE FLATBED 7 1 2 10N NSN TIO DITA NSN 6115 01 473 7085 ee te me WEADQUARTERS DEPARTMENTS OF THE ARMY _ WEADQUARTEAS DEPARTMENT OF THE ARMY MARCH 1992 200KW 10 505 2B BII LIST Continued Change 1 0020 00 8 9 6115 730
79. 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0005 00 DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS Continued ELECTRONIC MODULAR CONTROL PANEL Continued Table 1 Tactical Quiet Generator Electronic Modular Control Panel Controls and Indicators Continued CONTROL OR KEY INDICATOR FUNCTION 4 DC AMMETER Indicates DC current from engine alternator 5 FREQUENCY adjust knob Potentiometer permits adjustment of generator set frequency 6 SYNC MODE switch label Cautions user to ensure sync mode switch is in off postion prior to starting SYNC MODE switch Four position switch used to control TQG paralleling operations and modes If not in paralleling mode switch should be OFF OFF Disables synchronizing and synchroscope functions SEMI AUTO With PARALLEL switch closed up GSC brings TQG in synchronization with load bus and holds it there indefinitely AC CIRCUIT INTERRUPTER switch is enabled and operator can connect TQG to others Automatic voltage matching is not enabled AUTO Provides complete automatic paralleling with another unit Bus Live GSC brings TQG into sync with load bus and sends a signal to connect TQG to load bus Bus Dead GSC adjusts voltage to programmed value and connects output to load automatically PERMISSIVE With PARALLEL switch closed up manual paralleling mode allows operator to adjust voltage frequency and phase of TQG to match load bus When is synchronized with bus operator
80. A B blank Change 3 ARMY 9 6115 730 10 35 2 3 520 1 MARINE CORPS 11598A OR NAVAIR 19 50 28 HEADQUARTERS DEPARTMENTS OF THE ARMY AIR FORCE NAVY AND HEADQUARTERS U S MARINE CORPS WASHINGTON DC 15 JANUARY 2006 TECHNICAL MANUAL OPERATOR S MANUAL FOR GENERATOR SET SKID MOUNTED TACTICAL QUIET 200 kW 50 60 Hz MEP 809A NSN 6115 01 296 1462 EIC XXX GENERATOR SET TRAILER MOUNTED TACTICAL QUIET 200 kW 50 60 Hz PU 809A NSN 6115 01 471 7085 EIC XXX DISTRIBUTION STATEMENT A Approved for public release distribution is unlimited 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 Reports as applicable by the requiring Service should be submitted as follows a A Army Mail your letter or DA Form 2028 Recommended Changes to Publications and Blank Forms located in the back of this manual directly to Commander U S Army CECOM Life Cycle Management Command LCMC Fort Monmouth ATTN AMSEL LC LEO E amp AS CM Fort Monmouth NJ 07703 5006 You may also send in your recommended changes via electronic mail or by fax Our fax number is 732 532 1556 DSN 992 1556 Our e mail address is MONM AMSELLEOPUBSCHG conus army mil Our online web address for entering and submitting DA Form 2028s is http edm monmouth army mil pubs 2028 html MC Marine Corps Subm
81. ANCE CHECKS AND SERVICES PMCS INCLUDING LUBRICATION INSTRUCTIONS Continued Table 1 Preventive Maintenance Checks and Services Continued LOCATION NOT FULLY ITEM ITEM TO MISSION NO INTERVAL CHECK SERVICE PROCEDURE CAPABLE IF 43 After 44 After 45 After Overall Exterior Continued ENGINE COMPARTMENT Engine Assembly Fuel System Fuel Filter Water Separator CAUTION Operating the generator set with restricted airflow for cooling can cause the generator set to overheat Keep all access door inlet panels clear to ensure maximum airflow for engine and generator cooling Failure to comply can result in poor engine performance and possible overheating and automatic shutdown Inspect air intake and exhaust grills for debris Check for loose damaged or missing hardware 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 Inspect fuel system for leaks damaged loose or missing parts Inspect fuel filter water separator for leaks proper mounting cracks damage or missing parts Drain water from fuel filter water separator WP 0016 00 0012 00 14 Any restrictions of air flow or cannot clear debris Hardware loose damaged or missing Any fuel leaks damaged loos
82. ATOR 0010 00 TROUBLESHOOTING THIS WORK PACKAGE COVERS Troubleshooting INITIAL SETUP Maintenance Level References Operator WP 0006 0 WP 0013 0 Tools and Special Tools WP 0015 0 None WP 0016 0 Personnel Required One Materials Parts None Equipment Condition Operating D Metal jewelry can conduct electricity and become entangled in generator set components Remove all metal jewelry when working on generator set Failure to comply can cause injury or death to personnel 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 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 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 or death to personnel 0010 00 1 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR 0010 00 TROUBLESHOOTING Continued WARNING Rs When running generator set engine has hot metal s
83. Clean as you work and as needed Use Simple Green cleaning compound to clean metal surfaces and rubber or plastic material 2 Bolts clamps nuts and screws Continuously check for looseness Look for chipped paint bare metal rust or corrosion around bolts and screw heads and nuts Tighten them when you find them loose If tools are not available notify maintenance 3 Welds Many items on the TQG skid mount are welded To check these welds look for chipped paint rust corrosion or gaps If broken welds exist notify maintenance on DA Form 2404 or automated DA Form 5988 E Army 4 Electrical wires connectors and harnesses Tighten loose cannon plugs Look for cracked or broken insulation bare wires loose cannon plugs and broken connectors When these conditions exist notify maintenance 5 Hoses and fluid lines Check hoses and fluid lines for wear damage and leaks Ensure clamps and fittings are tight 6 Hinges Check hinges for security and operation 7 Data plates Check data caution and warning plates for security and legibility PMCS COLUMN DESCRIPTIONS TABLE 1 ARMY ITEM NO This colum lists order in which PMCS should be performed also used as a source of item numbers for the TM number column on DA Form 2404 or automated DA Form 5988 E Army when recording results of PMCS INTERVAL This column indicates when each check is to be performed LOCATION ITEM TO CHECK SERVICE This column lists location and item
84. Connections are loose or corroded 31 Before Accessory Box Inspect accessory box clamping hatch hasp and rivets for rust corrosion and wear Check accessory box contents to ensure that Ground rod and all required items are present and components are serviceable missing pr unserviceable WINTERIZATION KIT 32 Before Fuel lines _ _ 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 Open battery access doors and inspect fuel Any fuel leaks lines to fuel fired heater for leaks damaged loose or damaged loose or missing parts missing parts 33 Before Coolant hoses Check hoses for leaks or cracks Class III leaks 34 Betol Coolant shutoff Verify that coolant shutoff valves on engine Shutoff valves are not valves 0012 00 10 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0012 00 PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS INCLUDING LUBRICATION INSTRUCTIONS Continued Table 1 Preventive Maintenance Checks and Services Continued LOCATION NOT FULLY ITEM ITEM TO MISSION NO INTERVAL CHECK SERVICE PROCEDURE CAPABLE IF ENGINE COMPARTMENT 35 During Fuel System WARNING Operating the generator set exposes personnel to a high noise level Hearing protect
85. E IF 14 Before Cooling Fan Check fan for damage or looseness Cooling fan is damaged or loose 15 Before Fan Belts Inspect belts to ensure that they are not Broken missing or missing Inspect for cracks fraying and loose belt s looseness 16 Before Overflow Bottle Check over flow bottle for leaks or missing Class leaks parts overflow bottle missing Check coolant level above COLD line in Coolant level is below overflow bottle WP 0015 00 COLD line 17 Before Exhaust System Check muffler and exhaust system for Muffler or exhaust corrosion damaged or missing parts system have missing parts Check exhaust system for restrictions and Restricted exhaust proper venting to atmosphere 18 Before Air Cleaner Inspect air cleaner assembly and piping for Clogged element is Assembly loose or damaged connections indicated red Check restriction indicator for clogged an as element WP 0014 00 loose indicator broken or missing 19 Before Battery Cables 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 Inspect cables and connectors for corrosion loose damaged or missing parts 0012 00 7 Cables are loose damaged or missing Batteries fail to start generator 200 kW TACTICAL QUIET GENERATOR SET TM 9 6115 730 10
86. EIR 1 Arm y If your equipment needs improvement let us know Send us an EIR You the user are the only one who can tell us what you don t like about your equipment Let us know why you don t like the design or performance If you have Internet access the easiest and fastest way to report problems or suggestions is to go to https aeps ria army mil aepspublic cfm scroll down and choose the Submit Quality Deficiency Report bar The Internet form lets you choose to submit an Equipment Improvement Recommendation EIR a Product Quality Deficiency Report PQDR or a Warranty Claim Action WCA You may also submit your information using an SF 368 Product Quality Deficiency Report You can send your SF 368 via e mail regular mail or facsimile using the addresses facsimile numbers specified in DA PAM 750 8 The Army Maintenance Management System TAMMS Users Manual We will send you a reply 0001 00 1 Change 2 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0001 00 GENERAL INFORMATION Continued 2 Air Force Air Force personnel are encouraged to submit EIR s in accordance with AFR 900 4 3 Navy Navy personnel are encouraged to submit EIR s through their local Beneficial Suggestion Program 4 Marine Corps QDR shall be reported on SF 368 in accordance with MCO P4855 10 Product Quality Deficiency Report Manual Submit to Commanding General Marine Corps Logistics Base Code 850 Albany Georgia 31704 5000 A re
87. ENERATOR SET 0022 00 EXPENDABLE AND DURABLE ITEMS LIST INTRODUCTION This work package lists expendable and durable items that you will need to operate and maintain the 200 kW Tactical Quiet Generator Set This list is for information only and is not authority to requisition the listed items These items are authorized to you by CTA 50 970 Expendable Durable Items Except Medical Class V Repair Parts and Heraldic Items or CTA 8 100 Army Medical Department Expendable Durable Items EXPENDABLE AND DURABLE ITEMS LIST COLUMN DESCRIPTIONS TABLE 1 Column 1 ITEM NUMBER This column gives you a number assigned to the entry in the list and the number is referenced the narrative instructions to identify the item e g Use antifreeze item 1 WP 0024 00 Column 2 LEVEL This column includes the lowest level of maintenance that requires the listed item C Operator Crew Column 3 NATIONAL STOCK NUMBER This column identifies the stock number of the item to be used for requisitioning purposes Column 4 ITEM NAME DESCRIPTION PART NUMBER AND CAGE This column provides the other information you need to identify the item Column 5 U M This column provides unit of measure or count of an item such as gallon dozen gross etc 0022 00 1 200 KW TACTICAL QUIET GENERATOR SET TM 9 6115 730 10 0022 00 EXPENDABLE AND DURABLE ITEMS LIST Continued EXPENDABLE AND DURABLE ITEMS LIST NUMBER LEVEL Tab
88. FMI 11 Cylinder 5 Failure mode is not identifiable Mechanical Failure Logged CID 6 E FMI 11 Cylinder 6 Failure mode is not identifiable Mechanical Failure Logged CID 9 E FMI 02 High Altitude Derate Active Only CID 41 E FMI 03 Above normal 8 Volt Power Supply Failure mode is not identifiable Mechanical Failure Logged 8 volt supply not used CID 41 E 04 Below normal 8 Volt Power Supply Failure mode is not identifiable Mechanical Failure Logged 8 volt supply not used CID 85 E FMI01 Shutdown Overridden Logged Only CID 91 E FMI 08 PWM Throttle Position Sensor Abnormal frequency pulse width or period Not Logged 0009 00 3 Notify maintenance Notify maintenance Notify maintenance Notify maintenance Notify maintenance Notify maintenance Notify maintenance Notify maintenance Notify maintenance Notify maintenance Notify maintenance Notify maintenance Notify maintenance Notify maintenance Notify maintenance Notify maintenance Notify maintenance Notify maintenance Notify maintenance Notify maintenance 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR MALFUNCTION SYMPTON INDEX Continued 0009 00 Malfunction Symptom Work Package and Page No 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 13 74 75 76 77 78 79 CID 94 E
89. FORM NUMBER PARA FIGURE ITEM P GRAPH LINE TABLE RECOMMENDED CHANGES AND REASON TYPED NAME GRADE OR TITLE TELEPHONE EXCHANGE AUTOVON SIGNATURE PLUS EXTENSION DA FORM 2028 FEB 74 REPLACES DA FORM 2028 1 DEC 68 WHICH WILL BE USED APD V4 00 Forward to proponent of publication or form Include ZIP Code FROM Activity and location Include ZIP Code PART Il REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS SUPPLY MANUALS PUBLICATION FORM NUMBER DATE TITLE TOTAL NO OF MAJOR PAGE COLM LINE NATIONAL STOCK REFERENCE FIGURE ITEM ITEMS RECOMMENDED ACTION NO NO NO NUMBER NO NO NO SUPPORTED PART III REMARKS Any general remarks or recommendations or suggestions for improvement of publications and blank forms Additional blank sheets may be used if more space is needed TYPED NAME GRADE OR TITLE TELEPHONE EXCHANGE AUTOVON SIGNATURE PLUS EXTENSION APD V4 00 RECOMMENDED CHANGES PUBLICATIONS AND Use Part Il reverse for Repair Parts and BLANK FORMS Special Tool Lists RPSTL and Supply For use of this form see AR 25 30 the proponent agency is OAASA Catalogs Supply Manuals SC SM TO Forward to proponent of publication or form Include ZIP Code FROM Activity and location Include ZIP Code PART I ALL PUBLICATIONS EXCEPT RPSTL AND SC SM AND BLANK FORMS PUBLICATION FORM NUMBER PARA FIGURE ITEM P GRAPH LINE TABLE RECOMMENDED CHANGES AND REASON TYPED NAME GRADE OR TITLE TELEPHO
90. FORM NUMBER DATE TITLE TM 11 1234 567 14 16 2001 Operator Field and Sustainment Support Maintenance Manual for Radio AN ABC 123 PARA FIGURE ITEM P GRAPH LINE TABLE RECOMMENDED CHANGES AND REASON 1W P0005 2 Test or Action column should identify a different WP number PG3 TYPED NAME GRADE OR TITLE TELEPHONE EXCHANGE AUTOVON SIGNATURE PLUS EXTENSION Jane Q Doe SFC 123 4567 DA FORM 2028 FEB 74 REPLACES DA FORM 2028 1 DEC 68 WHICH WILL BE USED APD V4 00 Forward to proponent of publication or form Include ZIP Code FROM Activity and location Include ZIP Code PART Il REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS SUPPLY MANUALS PUBLICATION FORM NUMBER DATE TOTAL NO OF MAJOR PAGE COLM LINE NATIONAL STOCK REFERENCE FIGURE ITEM ITEMS RECOMMENDED ACTION NO NO NO NUMBER NO NO NO SUPPORTED K PART REMARKS 0 remar kod RK S or suggestions for improvement of publications and dditiona FR bla or be used if more space is needed TYPED NAME GRADE OR TITLE TELEPHONE EXCHANGE AUTOVON SIGNATURE PLUS EXTENSION APD V4 00 RECOMMENDED CHANGES PUBLICATIONS AND Use Part Il reverse for Repair Parts and BLANK FORMS Special Tool Lists RPSTL and Supply For use of this form see AR 25 30 the proponent agency is OAASA Catalogs Supply Manuals SC SM TO Forward to proponent of publication or form Include ZIP Code FROM Acti
91. Governor Relay A1K1 Failed Component 12 GSC Generator Fault Relay A1K2 Failed Component FMI 12 GSC Crank Termination Relay A1K3 Output External contacts not used Failed Component CID 444 CID 445 CID 446 used CID 447 FMI 12 GSC Starting Motor Relay A1K4 Failed Component 12 GSC Run Relay A1K5 Failed Component FMI 12 GSC Air Shutoff Relay Failed Component Note Relay not FMI 12 GSC Fuel Control Relay A1K7 Output External contacts not used Failed Component CID 448 CID 500 CID 545 CID 545 CID 566 CID 590 CID 770 Update CID 858 CID 858 FMI 12 GSC Programmable Spare Relay A1K8 Failed Component FMI 12 GSC Failed Component 05 Ether Control Relay Current Low Open Circuit FMI 06 Ether Control Relay Current High Grounded FMI 07 Unexpected Shutdown Improper Mechanical Response 09 Engine Electronic Control Abnormal Update FMI 09 Customer Communication Module Not used Abnormal 03 Close Breaker Output Voltage Above Normal FMI 04 Close Breaker Output Voltage Below Normal CID 1038 FMI 03 Speed Adjust 1 Output Voltage Above Normal CID 1038 FMI 04 Speed Adjust 1 Output Voltage Below Normal CID 1167 04 Sense Input P7 25 Voltage Below Normal CID 1168 FMI 03 Dead Bus Sensor Voltage Above Normal CID 1168 FMI 04 Dead Bus Sensor Voltage Below Normal 0009 00 6 Notify maintenance Notify maintenance Notify maintenance Notify maintenance No
92. H to NORMAL WP 0005 00 12 4 On Electronic Modular Control Panel EMCP momentarily set AC CIRCUIT INTERRUPTER to OPEN down NOTE FREQUENCY and VOLTAGE potentiometers should be adjusted in the center position The position is not marked on the control panel To center each potentiometer the operator must turn the potentiometer as far as it will go in one direction and then rotate it five full turns in the opposite direction 5 Adjust FREQUENCY potentiometer to center position Rotate potentiometer clockwise until it stops Then rotate it five full turns counterclockwise 6 Adjust VOLTAGE potentiometer to center position Rotate potentiometer clockwise until it stops Then rotate it five full turns counterclockwise 7 Set PARALLEL UNIT switch to UNIT 8 Pull out PUSH TO STOP EMERGENCY STOP switch 9 Set Battery Disconnect Switch to ON WP 0005 00 14 Self Test 1 On EMCP set ENGINE CONTROL switch to COOL DOWN STOP WP 0005 00 3 2 Verify that there is fuel in the TQG fuel tank A full fuel tank will provide at a minimum eight hours of operation Service as required per WP 0016 00 3 On Generator Set Control GSC touch LAMP TEST on keypad Ensure that all indicator lights on GSC light WP 0005 00 4 4 On Alarm Module press LAMP TEST on panel Ensure that alarm indicators light WP 0005 00 9 Indicator lights turn on and alarm module horn sounds 5 Press AC CIRCUIT INTERRUPTER press to test green indicator on the EMCP Ens
93. IAL SETUP section carefully before you start any maintenance procedure Get the tools and supplies listed and the personnel needed TITLE N kW TACTICAL QUIET GENERATOR 0013 00 CONTROL BOX ASSEMBLY MAINTENANCE THIS WORK PACKAGE COVERS SUMMARY ee emoval Installation INITIAL SETUP MAINTENANCE M LEVEL aintenance Level References REFERENCES Operator TM 9 6115 730 10 WP 0013 00 Tools and Special Tools Tool kit and supplement general en mechanic s NSN 5180 00 177 7033 Personnel Required Materials Parts MATERIALS PARTS Corrosion preventive compound item 9 WP 0023 00 ne PERSONNEL REQUIRED LEGEND TITLE SUMMARY MAINTENANCE LEVEL TOOLS AND SPECIAL TOOLS PERSONNEL REQUIRED REFERENCES MATERIALS PARTS Change 1 The name of the procedure A listing of the general actions to be performed The level of maintenance authorized to do the procedures The tools and equipment needed to do the procedures The personnel needed to do the procedures Other work packages manuals and publications needed to do the procedure The supplies and parts needed to do the procedures 9 6115 730 10 CHAPTER 1 INTRODUCTORY INFORMATION WITH THEORY OPERATION FOR 200 kW TACTICAL QUIET GENERATOR SET 9 6115 730 10 CHAPTER 1 INTRODUCTORY INFORMATION WITH THEORY OF OPERATION FOR 200 kW TACTICAL QUIET GENERATOR SET WORK PACKAGE INDEX Title WP Sequence No GENERAL INFORMATION
94. KID MOUNTED TACTICAL QUIET 200kW 50 60 HZ MEP 809A NSN 6115 01 296 1462 GENERATOR SET TRAILER MOUNTED TACTICAL QUIET 200KW 50 60 HZ PU 809A NSN 6115 01 471 7085 DISTRIBUTION STATEMENT A Approved for public release distribution is unlimited TM 9 6115 730 10 dated 15 January 2006 is updated as follows 1 File this sheet in front of the manual for reference 2 This change 15 a result of changes to and AAL list and change to How to Use incorporating changing title of TM 9 6115 730 24 to Field Maintenance Manual 3 New or updated text is indicated by a vertical bar in the outer margin of the page 4 Remove old pages and insert new pages as indicated below REMOVE PAGES INSERT PAGES i iv i iv 5 Replace the following work packages with their revised version Work Packaqe Number Work Package 19 Work Package 20 By Order of the Secretary of the Army Official MORROW Administrative Assistant to the Secretary of the Army 0635205 By Order of the Secretary of the Air Force Official GEORGE T BABBITT General United States Air Force Commander AFMC By Order of the Secretary of the Navy DISTRIBUTION PETER J SCHOOMAKER General United States Army Chief of Staff JOHN P JUMPER General United States Air Force Chief of Staff WALTER H CANTRELL Rear Admiral United States Navy Commander Space and Naval Warfare Systems Command To be distributed in accordance with
95. L L 46167 MIL PRF 2104 OE HDO 10 MIL PRF 2104 OE HDO 30 EA ss 2 MIL PRF 2104 OE HDO 40 CA MIL PRF 2104 OE HDO 15 40 END OF TASK 0017 00 2 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0018 00 PREPARATION FOR STORAGE OR SHIPMENT PRESERVATION There are no special preservation requirements The generator set should be started and run until operating temperature is reached a minimum of every 60 days and ideally every 30 days If the generator set is not going to be started for over 60 days recommend you contact the Army Material Command Major Subordinate Command responsible for Generators to obtain special maintenance storage and preservation requirements and procedures PACKING There are no special packaging requirements MARKING Mark for shipment or storage in accordance with MIL STD 129 USE OF CORROSION PREVENTIVE COMPOUNDS MOISTURE BARRIERS AND DESICCANT MATERIALS Refer to Corrosion Prevention and Control TB 43 0213 SPECIAL INSTRUCTIONS FOR ADMINISTRATIVE STORAGE Placement of equipment in administrative storage should be for short periods of time when a shortage of maintenance effort exists Items should be in mission readiness within 24 hours or within the time factors as determined by the directing authority Before placing the equipment in administrative storage current preventive maintenance checks and services should be completed shortcomings and deficiencies
96. L UNIT OPERATION LOAD SHARING Continued Operation in SEMI AUTO Mode Continued 18 19 20 21 22 Read TOTAL Amperes on the upper display right side and make slight adjustments of the VOLTAGE adjust potentiometers to balance this reading between all sets at the lowest possible reading This must be performed as quickly as possible and repeated back and forth between VOLTAGE and FREQUENCY adjust potentiometers to prevent reverse power and overcurrent faults Repeat steps 14 thru 18 for each additional generator set to be paralleled Close all external load contactors between the generator sets and load Generator sets are now operating with load applied Observe upper display for voltage and total current readings and the lower display for kW and kVAR readings on all TQG units Make very small adjustments to the VOLTAGE and FREQUENCY potentiometers to maintain balanced reading of total amperes kW KVAR across all units in parallel Pressing POWER METER on GSC keypad periodically compare kW and kVAR readings on lower display of all generator sets If readings are not within plus or minus 10 of one another notify maintenance Operation in PERMISSIVE Mode CD 8 9 10 CAUTION When paralleling a 200 kW to 100 kW that is supplying a load an unstable condition can occur This condition does not occur when paralleling at no load or when paralleling a 100 kW to a 200 kW
97. LACE UNIT PARALLEL SW ON ALL UNITS TO BE PARALLELED IN THE PARALLEL POSITION C PLACE ISOCHRONOUS DROOP SW ON ALL UNITS TO BE PARALLELED IN THE DROOP POSITION D PLACE SYNC MODE SELECTOR SW ON FIRST SET TO BE PARALLELED IN THE AUTO PARALLEL POSITION THE AC LOAD CONTACTOR WILL AUTOMATICALLY CLOSE ONTO THE DEAD BUS E REPEAT STEP D ABOVE FOR EACH OF THE SETS TO BE PARALLELED THESE SETS WILL BE AUTOMATICALLY SYNCHRONIZED TO THE BUS AND THE AC LOAD CONTACTOR AUTOMATICALLY CLOSED F IF REQUIRED THE LOAD SHARING BETWEEN UNITS CAN BE EQUALIZED BY ADJUSTING THE VOLTAGE OR FREQUENCY POTENTIOMETERS AS REQUIRED FLUIDS f FUEL COOLANT AMBIENT AMBIENT FUE AMBIENT RADIATOR TEMPERATURE TEMPERATURE L TEMPERATURE COOLANT ES MIL L 46167 Dem gt 52624 SOF TO 120 Antrages 3 MIL PRF 2104 WATER WITH CONF TO 40 25F 120 52524 2104 ANTIFREEZE 15 F TO 90 F E MD A WATER WITH an 40 F TO 1207 MIL A 53009 PRF ADDITIVE 1207 RU re AND MIL PRF 2104 MIL T 83133 Sf To 120 DT CAPACITIES FUEL TANK LUBRICATING OIL COOLING SYSTEM REFILL WITH FILTER CHANGE REAR 0006 00 27 FUEL 36 015 COOLANT 128 GALS FULL TO LOW 42 015 4 015 ERES 0115 2900 05 200
98. LESHOOTING Continued Table 1 Operator Troubleshooting Continued MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION 5 GSC LOW COOLANT LEVEL red 1 Set ENGINE CONTROL switch to indicator flashes COOL DOWN STOP 2 Set DEAD CRANK SWITCH to OFF 3 Set Battery Disconnect Switch to OFF 4 Allow engine to cool 5 Check coolant level in coolant overflow bottle WP 0015 00 6 Visually inspect radiator and coolant system for damage leaks loose clamps fan guards fan and shrouds or obstructions per WP 0015 00 0010 00 5 1 If coolant level is low refill coolant overflow bottle with correct mixture of water and coolant per WP 0015 00 2 Monitor coolant level and refill as required Remove obstructions and debris from fan guards and shroud area tighten clamps If radiator is obstructed and coolant system damaged or you cannot tighten clamps notify maintenance 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR 0010 00 TROUBLESHOOTING Continued Table 1 Operator Troubleshooting Continued MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION WARNING Metal jewelry can conduct electricity and become entangled in generator set components Remove all metal jewelry when working on generator set Failure to comply can cause injury or death to personnel High voltage is produced when this generator set is in operation Make sure unit is completely shut down and f
99. N If the ENGINE OVERSPEED light on the malfunction indicator panel is illuminated set AC CIRCUIT INTERRUPTER to OPEN down until indicator goes out on each set END OF TASK OPERATION WHILE CONTAMINATED NBC Generator set will operate in a normal manner when exposed to nuclear biological or chemical NBC contamination It is capable of being operated by personnel wearing NBC clothing without special tools or support equipment Refer to FM 3 3 FM 3 4 and FM 3 5 END OF TASK 0007 00 6 9 6115 730 10 CHAPTER 3 OPERATOR TROUBLESHOOTING PROCEDURES FOR 200 kW TACTICAL QUIET GENERATOR SET 9 6115 730 10 CHAPTER 3 OPERATOR TROUBLESHOOTING PROCEDURES FOR 200 kW TACTICAL QUIET GENERATOR SET WORK PACKAGE INDEX Title WP Sequence No INTRODUCTION e o NR MALFUNCTION SYMPTOM INDEX ccsssssscssssssssrscccsssssceeccesscscsssenccescsssssscececcecesssccecsccesessssssenecsecessssceesscsseees TROUBLESHOOTING PROCEDURES 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR 0008 00 INTRODUCTION MALFUNCTION SYMPTOM INDEX The troubleshooting Malfunction Symptom Index WP 0009 00 lists common malfunctions found during operation or crew servicing of the 200 kW TQG In addition it lists all of the fault codes that will be displayed on the Generator Set Control GSC Use the Malfunction Symptom index to identify the malfunction symptom that best describes your problem and then follow the instruct
100. NE EXCHANGE AUTOVON SIGNATURE PLUS EXTENSION DA FORM 2028 FEB 74 REPLACES DA FORM 2028 1 DEC 68 WHICH WILL BE USED APD V4 00 Forward to proponent of publication or form Include ZIP Code FROM Activity and location Include ZIP Code PART Il REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS SUPPLY MANUALS PUBLICATION FORM NUMBER DATE TITLE TOTAL NO OF MAJOR PAGE COLM LINE NATIONAL STOCK REFERENCE FIGURE ITEM ITEMS RECOMMENDED ACTION NO NO NO NUMBER NO NO NO SUPPORTED PART III REMARKS Any general remarks or recommendations or suggestions for improvement of publications and blank forms Additional blank sheets may be used if more space is needed TYPED NAME GRADE OR TITLE TELEPHONE EXCHANGE AUTOVON SIGNATURE PLUS EXTENSION APD V4 00 By Order of the Secretary of the Army Official andan K flocs SANDRA R RILEY Adminis rative Assistant to the Secretar of the Army 0602502 By Order of the Secretary of the Air Force Official GEORGE T BABBITT General United States Air Force Commander AFMC By Order of the Secretary of the Navy DISTRIBUTION PETER J SCHOOMAKER eneral United States Army Chief of Staff JOHN P JUMPER General United States Air Force Chief of Staff WALTER H CANTRELL Rear Admiral United States Navy Commander Space and Naval Warfare Systems Command To be distributed in accordance with the initial distribution number IDN 256884 requi
101. NK SWITCH to OFF Set Battery Disconnect Switch to OFF Open control panel access cover and turn three captive retainers 1 and lower EMCP front panel 2 Inspect wiring to lamps If wiring is broken notify maintenance Close EMCP front panel 2 and secure with three captive retainers 1 0013 00 1 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0013 00 CONTROL BOX ASSEMBLY MAINTENANCE Continued REPAIR Continued Replace Control Panel Lights On Electronic Modular Control Panel EMCP Continued 8 If wiring is not broken remove lamp lens 3 and light bulb 4 of defective panel light 5 or indicator light 6 9 Replace burned out light bulb with new light bulb 4 and install lamp lens 3 3 200KW 10 408A 0013 00 2 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0013 00 CONTROL BOX ASSEMBLY MAINTENANCE Continued REPAIR Continued Reset GROUND FAULT CIRCUIT INTERRUPTER Circuit Breaker If the GROUND FAULT CIRCUIT INTERRUPTER circuit breaker is not operating correctly perform the following steps to reset it 1 On EMCP set ENGINE CONTROL switch to OFF RESET 2 Set DEAD CRANK SWITCH to OFF 3 Set Battery Disconnect switch to OFF 4 Open control panel access panel and turn three captive retainers 1 and lower EMCP front panel 2 5 Visually inspect wiring to body of GFCI 7 6 If wiring is
102. NOUS DROOP switch to DROOP for all generators to be paralleled WP 0005 00 11 5 Identify one generator set as No 1 and the other as incoming No 2 If a 200 kW is being paralleled with a 100 kW designate the 200 kW as No 1 6 Oneach generator set set ENGINE CONTROL switch to OFF RESET Battery Disconnect Switch to OFF and DEAD CRANK SWITCH to OFF 7 Verify that generator sets are grounded Ground each generator set WP 0006 00 2 NOTE Common ground should be used TQG 1 TQG 2 5 200 10 216 2 0006 00 18 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET OPERATION UNDER USUAL CONDITIONS Continued PARALLEL UNIT OPERATION LOAD SHARING Continued Pre Operation Continued 8 9 10 Connect generator sets to load observing proper phase polarity CAUTION Remove paralleling cable from storage box located inside battery compartment access door 0006 00 Connect paralleling cable between connectors on PARALLELING RECEPTACLES panels WP 0005 Table 7 Do not close the AC CIRCUIT INTERRUPTER switch on either of the generator sets nor close the load contactor at load until specifically directed to do so Closing any of these devices at any other time may severely damage one or both of the generator sets
103. No 2 power is less than load bus NOTE When the square synchroscope symbol lis centered at top of display and stable and V HZ and 7 yellow indicator lights all glow steady the paralleling generator sets in phase When synchroscope lower display indicates that TQG frequencies and phases match and synchronizing lights V HZ and 7 on GSC panels stop flashing set AC CIRCUIT INTERRUPTER switch on incoming TQG No 2 to CLOSED until press to test green indicator lights Generator sets are now operating in parallel with no load Immediately set SYNC MODE switch to OFF and press POWER METER key on GSC keypad to indicate kW Read TOTAL Amperes on the upper display right side and make slight adjustments of the VOLTAGE adjust potentiometers to balance this reading between all sets at the lowest possible reading This must be performed as quickly as possible and repeated back and forth between VOLTAGE and FREQUENCY adjust potentiometers to prevent reverse power and overcurrent faults Repeat steps 14 thru 18 for each additional generator set to be paralleled Change 2 0006 00 24 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0006 00 OPERATION UNDER USUAL CONDITIONS Continued PARALLEL UNIT OPERATION LOAD SHARING Continued Operation in PERMISSIVE Mode Continued 20 21 22 Close all external load contactors between the generator sets and load Generator sets now operating with l
104. OISE HEARING PROTECTION REQUIRED WITHIN 11 FEET EXTREME Nose 4 HEARING PROTECTION WITH THE DOOR OPEN LEFT SIDE Change 2 0006 00 34 DO 25000 185 lt 2 AN 200KW 10 227A 0006 00 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET OPERATION UNDER USUAL CONDITIONS Continued DECALS AND INSTRUCTION PLATES Continued EXTREME NOISE HAZARD DOUBLE HEARING PROTECTION REQUIRED WHEN THE SET IS OPERATING WITH THE DOORS OPEN INSIDE DOORS CAUTION 09 NOT STAND R STORE HEAVY OBJECTS ON UNIT 0006 00 H CAUTION HIGH INTENSITY NOISE HEARING PROTECTION REQUIRED WITHIN 11 FEET DANGER EXTREME NOISE HAZARD IS OPERATING WITH THE THE DOOR OPEN EHE DIESEL FUEL me GROUND ROD 4 SZ AR FILTER STORAGE UTON MENS NOISE EARING PROTECTION REQUIRED WITHIN 11 FEET DANGER EXTREME NOISE HAZAR DOUBLE HEARING PROTECTION REQUIRED WHEN THE 5 mE bou lt FORK LIFT HERE 2 24 VOC SLAVE l RECEPTACLE vr VAN JFT TIEDOW m rs umm UN ET ANED FUEL DRAIN FORK LIFT HERE 25 000 LBS lt 2 END TASK LEFT SIDE WARNINGS CAUTIONS LABELS 0006 00 35 200KW 10 243A
105. Operation Load 0006 00 17 Operation in Auto 0006 00 20 Operation in Permissive Mode sess enne enne nennen 0006 00 23 Operation i Semi Auto Mode etie Sec ette DA redde aides 0006 00 21 Tr 0006 00 17 Removal from Parallel Operation err ten e re e ere ri RE Ee teda 0006 00 25 Paralleling Receptacles Characteristics ME EI 0002 00 1 DESCHPUON a 0002 00 4 PMCS Including Lubrication 8 11 6 002 00 000 nennen eene ennt nennen 0012 00 1 EET CO 0012 00 2 Introduchon NN 0012 00 1 Inspection A A at 0012 00 2 PMCS Column Descriptions Table 1 rnit rmi namens 0012 00 3 Table 1 Preventive Maintenance Checks and Services 0012 00 4 Before E o Mete edt E 0012 00 4 During 0012 00 11 After Siesta aa 0012 00 14 Preliminary Checks and Adjustment of Equipment nnne 0011 00 1 Preparation for Moment perpetrata tete 0006 00 37 Index 7 9 6115 730 10 INDEX Continued Subject WP Sequence No Page No P Q Continued Preparation for Storage or Shipment sse enne enne enne 0018 00
106. R USUAL CONDITIONS Continued OPERATING PROCEDURES Continued Starting Continued CAUTION Do not crank engine in excess of fifteen seconds Allow starter to cool at least fifteen seconds between attempted starts Failure to observe this caution could result in damage to the starter 2 Ensure that all generator set access doors except control panel access door are closed 3 1 set ENGINE CONTROL switch 2 to MANUAL START Engine should crank and ramp up to operating speed 4 Operate engine at no load for approximately 5 minutes or until coolant temperature reaches 100 F 38 C If required load can be applied immediately 5 When TQG is running smoothly fine tune VOLTAGE 3 and FREQUENCY 4 adjust potentiometers to required values for voltage and frequency if necessary WARNING High voltage power is available when the main contactor is closed Avoid accidental contact with live components Ensure load cables are properly connected and the load cable door is shut before closing main contactor Ensure load is turned off before closing main contactor Ensure that soldiers working with on loads connected to the generator set are aware that main contactor is about to be closed before closing main contactor Failure to observe this warning can result in severe personal injury or death by electrocution 6 Set AC CIRCUIT INTERRUPTER 5 switch to CLOSED up and release to connect load to TQG 7 If operating wit
107. RING Continued Operation in AUTO Mode Continued 13 14 19 NOTE With no load the kW readings on all sets in parallel should be less than plus or minus 5 With no load the TOTAL Amperes on all sets in parallel should be less than plus or minus 5 of generator set rated current Ideally there should be zero kW and zero TOTAL Amperes Once load is applied to paralleled sets slight adjustments may be needed to keep the values balanced to within plus or minus 5 of one another On TQG No 2 GSC panel keypad press POWER METER to display kW continuously on the lower display Make slight adjustment of the FREQUENCY adjust potentiometers to balance the kW between all sets at the lowest possible reading Read TOTAL Amperes on the upper display right side and make slight adjustments of the VOLTAGE adjust potentiometers to balance this reading between all sets at the lowest possible reading This must be performed as quickly as possible and repeated back and forth between VOLTAGE and FREQUENCY adjust potentiometers to prevent reverse power and overcurrent faults Perform steps 8 thru 14 for each additional set to be paralleled Generator sets are now operating in parallel with no load Close all external load contactors between the generator sets and load Generator sets are now operating with load applied Observe upper display for voltage and TOTAL Amperes readings and the lower display for kW and kVAR readings on all
108. RM SILENCE Alarm horn Amber light flashes to indicate overcurrent condition Generator is immediately disconnected from load Amber light flashes to indicate generator overload condition Generator is immediately disconnected from load Red light glows steady to indicate low fuel level Engine will immediately shut down Press to test button lights indicator lamps LAMP TEST also resets overload short circuit module Pushbutton silences alarm horn When LOW FUEL LEVEL red light glows steady alarm horn will sound until ALARM SILENCE pushbutton switch is pushed 0005 00 9 Change 3 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0005 00 DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS Continued DIGITAL VOLTAGE REGULATOR Table 4 describes the EMCP DVR module controls and indicators DVR is a module that displays 3 digit DVR fault codes WP 0009 00 Operator can only record the alarm codes and notify maintenance when DVR Fault Codes are displayed Operators are not authorized to use this control to change TQG settings 200 10 206 Table 4 Digital Voltage Regulator Controls and Indicators Display area Displays three digit DVR fault codes WP 0009 00 Also displays numbers representing different parameters of DVR system Display and keypad are used to select and manipulate parameter values that control operation of DVR Colon indicates that number is a parameter code If colon is not present
109. RNING GND Jumper will only be removed if the equipment being powered requires an isolated Floating ground Failure to comply can cause death or serious injury to personnel Change 3 0005 00 16 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0005 00 DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS Continued FUEL FIRED HEATER CONTROL PANEL ISSUED TO SELECTED UNITS ONLY Table 11 describes the fuel fired heater winterization kit controls and indicators located on left rear of generator set FUEL FIRED HEATER CONTROL 200 10 213 Table 11 Winterization Kit Controls and Indicators 1 DIAGNOSTIC indicator Red lamp lights upon fuel fired heater failure or winterization kit malfunction 2 HEATER indicator Amber press to test lamp lights when fuel fired heater is operating 3 CIRCUIT BREAKER Fused 15A circuit breaker for fuel fired heater control circuit Applies 24 Vdc to fuel fired heater 4 Circuit switch Two position switch activates or deactivates winterization kit circuits ON Energizes fuel fired heater for coolant heating and applies 24 Vdc to EMCP resistors OFF Deenergizes fuel fired heater and EMCP resistors 0005 00 17 18 blank Change 3 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0006 00 OPERATION UNDER USUAL CONDITIONS THIS WORK PACKAGE COVERS Siting Requirements Shelter Requirements Assembly and Preparation for Use Initial Adjustments Before Use and Self
110. RRUPTER m a 5 5 9 VOLTAGE ADJUST gt gt DVR 2 Ad GROUND TERMINAL FREQUENCY GROUND PROTECTED MANUAL 120VAC CIRCUIT BREAKER 120 WITH GROUND CONVENIENCE CONNECTION TO LOAD FAULT PROTECTION RECEPTACLE 200KW 10 108B The AC output system consists primarily of the AC generator the output load terminal board the voltage reconnection terminal board the main load contactor and the AC CIRCUIT INTERRUPTER switch on the EMCP Power created by the AC generator is supplied through the voltage reconnection terminal board and the main load contactor to the output load terminals on the output load terminal board The voltage reconnection terminal board allows configuration of the generator set for 120 208 volt connections or 240 416 volt connections The AC CIRCUIT INTERRUPTER switch located on the EMCP closes and opens the main load contactor This enables or interrupts the power flow between the voltage reconnection terminal board and the output load terminals The main load contactor is also opened automatically during any of the specified set faults The DVR module in the EMCP senses AC generator output voltage and provides excitation voltage to the AC generator to maintain the desired output voltage The VOLTAGE adjust potentiometer is connected to the DVR to allow the operator to adjust the voltage The operator can use the GSC keypad AC METER key to select which output load terminals
111. TERY DISCONNECT SWITCH IS CLOSED 1 PRESTART CHECKS A CHECK RADIATOR COOLANT ENGINE LUBE OIL FUEL B DRAIN WATER FROM FUEL WATER SEPARATOR FILTER IF PRESENT PLACE CONTROL SWITCHES TO OFF OR EQUIVALENT POSITION TURN BATTERY DISCONNECT SW TO ON 2 NORMAL START A PLACE THE MASTER SW IN THE MANUAL START POSITION ENGINE WILL START AND COME UP TO THE PRESET VOLTAGE AND FREQUENCY ADJUST FREQUENCY AND VOLTAGE 5 REQUIRED THE ETHER INJECTION SYSTEM WILL BE ENERGIZED AUTOMATICALLY BELOW APPROXIMATELY 30 F DURING CRANKING B UNDER NORMAL CONDITIONS OPERATE ENGINE AT NO LOAD FOR APPROXIMATELY 5 MINUTES OR UNTIL COOLANT OPERATING INSTRUCTIONS 0006 00 TEMPERATURE REACHES 100 F IF REQUIRED LOAD CAN BE APPLIED IMMEDIATELY CLOSE THE AC CIRCUIT INTERRUPTER BY MOMENTARILY PLACING THE AC CIRCUIT INTERRUPTER SW IN THE CLOSED POSITION 3 STOPPING THE SET REMOVE THE LOAD BY MOMENTARILY PLACING THE AC CIRCUIT INTERRUPTER SW IN THE OPEN POSITION B ALLOW THE SET TO COOL DOWN FOR APPROXIMATELY 5 MINUTES BY PLACING THE CONTROL SW IN THE COOL DOWN STOP POSITION THE SET WILL AUTOMATICALLY SHUT DOWN AFTER 5 MINUTES OF OPERATION IF REQUIRED THE SET CAN BE SHUT DOWN IMMEDIATELY BY PLACING THE CONTROL SW IN THE SHUT DOWN POSITION 4 PARALLEL OPERATION A MAKE LOAD CABLE INTERCONNECTIONS BETWEEN SETS TO BE PARALLELED AND THE LOAD CONNECT PARALLELING CABLE BETWEEN ALL SETS TO BE OPERATED IN PARALLEL B P
112. TIONS Continued OPERATION OF WINTERIZATION KIT The winterization kit can be used at temperatures below 30 F 1 1 C 200KW 10 231A NOTE If temperatures are below 30 F 1 1 C winterization kit may require 30 to 60 minutes to warm the engine up to starting temperature 1 Perform INITIAL ADJUSTMENTS BEFORE USE AND SELF TEST procedure WP 0006 00 10 Open right front access doors and verify that winterization kit coolant valves 1 are open Verify the TQG is properly grounded WP 0006 00 On winterization kit control panel press in CIRCUIT BREAKER On FUEL FIRED HEATER CONTROL set switch to ON to energize fuel fired heater On EMCP set ENGINE CONTROL switch to COOL DOWN STOP SD Moe Ye On GSC keypad press ENGINE METER key and observe coolant temperature Generator set can be started when coolant temperature reaches 120 F 49 C 8 After starting the TQG set switch to OFF The combustion air blower and water pump will continue to run for approximately 3 minutes END OF TASK 0007 00 2 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0007 00 OPERATION UNDER UNUSUAL CONDITIONS Continued OPERATION IN EXTREME HEAT ABOVE 120 F 49 C CAUTION Operating the generator set with restricted air flow for cooling can cause the generator set to overheat Keep all access door inlet panels clear to ensure maximum air flow for engine and generator cooling Failure to comply can result in poor engine
113. TQG can be located by using the index at the end of the manual NOTE The generator end of the TQG is referred to as the REAR of the TQG The control panel is also located on the generator end REAR of the Figure 1 Sheets 1 6 ir WP 0002 00 shows where components are located Chapter 1 contains Introductory Information with Theory of Operation The general information work packages includes the required maintenance forms records and reports safety care and handling warranty information about the TQG list of abbreviations and acronyms equipment description and data and theory of operation The chapter also contains WPs that describe the equipment and data including location of major components Chapter 2 work packages contain Operating Instructions which include Description and Use of Operator Controls and Indicators It also contains operation under usual conditions to include assembly and preparation for use installation of ground rod and load cables connecting auxiliary fuel hose initial adjustments before use and self test operating procedures parallel unit operation load sharing and operation under unusual conditions including operation of winterization kit issued to selected units only Chapter 3 work packages contain Operator Troubleshooting Procedures It includes an Introduction WP a Malfunction Symptom Index WP and operator troubleshooting procedures Chapter 3 WP 0009 00 Malfunction Symptom
114. Test NATO Slave Receptacle Start Operation Operating Procedures Em ergency Stopping Parallel Unit Operation Load Sharing Decals and Instruction Plates Operating Auxiliary Equipment Preparation for Movement INITIAL SETUP Maintenance Level References Operator Tools and Special Tools None DA Form 5988 E DA PAM 738 750 Personnel Required DD Form 314 One SF Form 361 SF Form 368 TM 9 2330 376 14 amp P TM 9 6115 730 24 Materials Parts None SITING REQUIREMENTS Select a site that provides or has the following features Ample space for maneuvering vehicles that may be used to move trailer mounted generator set Firm reasonably level well drained terrain Not adjacent to low areas where exhaust fumes might collect SHELTER REQUIREMENTS Under normal operating conditions the generator set does not require a shelter ASSEMBLY AND PREPARATION FOR USE 1 Notify maintenance to uncrate unpack the equipment if applicable 2 Notify maintenance to inspect equipment for possible damage incurred during shipment If equipment has been damaged report damage on SF Form 361 Transportation Deficiency Report 3 Notify maintenance to check equipment against packing slip to see if shipment is complete Report all differences using procedure given in DA PAM 738 750 4 Notify maintenance to perform Preventive Maintenance Checks and Services PMCS see TM 9 61 15 730 24 If required notify maintenance to repositi
115. aintenancce cscsscssscssscssssssssssssccssssssssssssssscsssesssssssssssssssscsssessssscsssnsessssssssesssesees Engine Air Cleaner 2 21 0 1 1 esee seta con seta sess sesta Engine Cooling System 2 2 1 esten tns tn netus tasas tasa ta setae se tastes tasses Engine Fuel System Maintenance 1 1 1 1 stet tn sess sesta Engine Lubrication System Maintenance 2 1 2 1 1 stas tosta Preparation for Storage or Shipment e eee eee eese eee ense testen setae nor SUPPORTING INFORMATION FOR 200 kW TACTICAL QUIET GENERATOR SET References P pSS Components of End Item COET and Basic Issue Items Lists Additional Authorized List 0 4 4 Expendable and Durable Items List ssssssssssscsscssscsscessessssessssssssessssnessesssssenesssesesssesss
116. ated NBC INITIAL SETUP Maintenance Level References Operator FM 3 3 FM 3 4 Tools and Special Tools FM 3 5 None Personnel Required Materials Parts One None OPERATION IN EXTREME COLD WEATHER BELOW 25 F 32 C 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 NOTE If temperatures are below 25 F 32 C activate winterization kit approximately 30 minutes to one hour before attempting to start generator set or your generator set may not start The generator set can operate in ambient temperatures as low as 25 F 32 C If temperatures are below 10 F 12 C activate winterization kit following the procedure below To ensure satisfactory operation under extreme cold weather the following additional steps must be taken prior to starting Keep generator set and surrounding area as free of ice and snow as practical Keep fuel tank full to protect against moisture condensation and accumulation of water Ensure proper grade diesel fuel is used WP 0016 00 Table 1 Keep batteries free from corrosion and in a well charged condition WP 0013 00 Check for presence of ether start aid bottle BEFORE PMCS and if winterization kit is installed activate and operate END OF TASK m 2 ip 0007 00 1 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0007 00 OPERATION UNDER UNUSUAL CONDI
117. ator WP 0016 00 0007 00 4 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0007 00 OPERATION UNDER UNUSUAL CONDITIONS Continued OPERATION UNDER RAINY OR HUMID CONDITIONS Continued WARNING D 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 High voltage is produced when the generator set is in operation Never attempt to start the generator set unless it is properly grounded Failure to comply can cause injury or death to personnel 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 5 Remove moisture from generator set components before and after each operating period 6 Keep fuel tank full to protect against moisture condensation and accumulation of water END OF TASK OPERATION IN SALT WATER AREAS CAUTION Failure to remove waterproof material before operating generator set could result in equipment damage 1 Ifpossible provide a shelter for the generator set Locate generator set so that radiator faces into prevailing winds Use natural barriers or if possible construct a barrier to protect generator set from salt water Cover generator se
118. ator set starting stopping monitory and fault annunciation Wet stacking Buildup of unburned diesel fuel and carbon residues in the engine and exhaust system of diesel engines Wet stacking can cause an oily tar like residue to exit from the exhaust pipe Glossary 2 9 6115 730 10 INDEX Subject WP Sequence No Page No A Abbreviations Acronyms List 0001 00 2 AC Generator Characteristics PE YII ev tee ERO eee ES 0002 00 1 ER 0002 00 3 Additional Authorization List 0021 00 1 AAL Column Descriptions Table IY ini seen 0021 00 1 Table 1 Additional Authorization List essere nnne nnns 0021 00 1 Air Cleaner Assembly Characteristics 0002 00 1 Ip uet M 0002 00 1 Alternator Characteristics RR EE Y cm eH e eee 0002 00 1 Iren Ret 0002 00 1 Auxiliary Equipment Operd titig 5 2 inire rc D epi Derek denis Pe ho eve UP dp 0006 00 36 B Basic Issue lems 0020 00 1 List Descriptions Table 2 0020 00 1 Table2 Basie Issue Item Dist
119. ause the generator set to overheat Keep all access door inlet panels clear to ensure maximum airflow for engine and generator cooling Failure to comply can result in poor engine performance and possible overheating and automatic shutdown Inspect air intake and exhaust grills for Any restrictions of air debris flow or cannot clear debris 3 Before Identification Plates Check to ensure identification plates on generator set are secure 4 Before Skid Base Inspect skid base for cracks or corrosion Skid base is cracked missing or damaged lift rings or other or shows signs of damage structural damage or lifting rings are missing or damaged 0012 00 4 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0012 00 PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS INCLUDING LUBRICATION INSTRUCTIONS Continued Table 1 Preventive Maintenance Checks and Services Continued LOCATION NOT FULLY ITEM ITEM TO MISSION NO INTERVAL CHECK SERVICE PROCEDURE CAPABLE IF 5 Before 6 Before 7 Before 8 Before Acoustical Materials ENGINE COMPARTMENT Engine Assembly Fuel System Fuel Filter Water Separator Ensure that acoustical materials are securely in place free of damage or not missing 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 injur
120. auxiliary fuel pump and a fuel level float switch When the EMCP AUX FUEL switch is ON the auxiliary fuel pump is enabled to transfer fuel from the external fuel supply to the generator fuel tank The fuel level float switch shuts off the auxiliary fuel pump when the generator fuel tank is full and reactivates the pump as the level drops The fuel level indicator indicates fuel level of generator fuel tank from empty E full to F 0003 00 3 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET THEORY OF OPERATION Continued ENGINE COOLING SYSTEM TOP HOSE BOTTOM HOSE COOLING AIR TO COOLANT EXTENSION DRAIN SURGE TANK COOLANT RETURN THERMOSTAT _ COOLANT ENESE WATER PUMP 1 l 4 Ej ox i ENGINE DRIVEN z o o z 2 Y EMCP COOLANT xX DRAIN VALVE RADIATOR 0003 00 HEATED AIR 200KW 10 105B The engine cooling system consists of a radiator hoses thermostat surge tank expansion tank water pump a belt driven fan and cooling jackets The water pump forces coolant through passages cooling jackets in the engine block and cylinder head where the coolant absorbs heat from the engine When the engine reaches normal operating temperature the thermostat opens and the heated coolant flows through the upper radiator hose asse
121. before closing main contactor Ensure that soldiers working with on loads connected to the generator set are aware that main contactor is about to be closed before closing main contactor Failure to observe this warning can result in severe personal injury or death by electrocution WARNING A qualified technician must make the power connections and perform all continuity checks The power source may be a generator or commercial power Failure to comply with this warning can result in injury or death to personnel 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 Avoid repeated or prolonged contact Provide adequate ventilation Operators are to wash exposed skin and change chemical soaked clothing promptly if exposed to fuel Failure to comply can cause injury or death to personnel WARNING Fuels used the generator set are flammable When filling 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 dea
122. by a vertical bar in the outer margin of the page 4 Remove old pages and insert new pages as indicated below Remove Pages Insert Pages Cover blank Cover blank A B blank A B blank i and ii i and ii 5 Replace the following work packages with their revised version Work Package Number Work Package 1 Work Package 6 By Order of the Secretary of the Army Rape Marin JOYCE E MORROW Administrative Assistant to the Secretary of the Army 0904302 By Order of the Secretary of the Air Force Official DONALD J HOFFMAN General United States Air Force Commander AFMC By Order of the Secretary of the Navy By Order of the Marine Corps Army Distribution GEORGE W CASEY JR General United States Army Chief of Staff NORTON A SWARTZ General United States Air Force Chief of Staff WALTER H CANTRELL Rear Admiral United States Navy Commander Space and Naval Warfare Systems Command G W TAYLOR Product Group Director PG 15 Ground Transportation Engineer Systems Marine Corps Systems Command To be distributed in accordance with the initial distribution number IDN 256886 requirements for TM 9 6115 730 10 Marine Corps Distribution To be distributed in accordance with PCN 184 115980 02 9 6115 730 10 NO 1 HEADQUARTERS DEPARTMENTS OF THE ARMY AIR FORCE and NAVY Washington DC 1 February 2007 TECHNICAL MANUAL OPERATOR S MANUAL FOR GENERATOR SET S
123. ch in turn is controlled by the EMCP The starter engages the engine flywheel causing the engine to turn over As the engine accelerates above crank speed sensed by a magnetic pickup the EMCP disengages the starter The starting sequence may also be stopped by moving the ENGINE CONTROL switch on the EMCP to COOL DOWN STOP The engine may be cranked without starting using the DEAD CRANK switch The DEAD CRANK SWITCH is a three position switch Up position is CRANK the center position is OFF and the lower position is NORMAL operation With the DEAD CRANK SWITCH in CRANK position the starter motor is energized without activating any other starting or control function With the switch in the OFF center position the system is off With the switch in the NORMAL operation position the TQG will crank and start The batteries are charged by the belt driven engine alternator The belt driven battery charging alternator also supplies GSC power Normal operating indication depends on the state of charge in the batteries A low charge such as exists immediately after engine starting will cause a high reading Cold outside temperatures make starting the engine difficult To improve engine starting in cold weather the engine contains an ether start The ether start 15 described in the Air Intake and Exhaust System paragraph 0003 00 1 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0003 00 THEORY OF OPERATION Continued ENGINE STARTING SYSTEM
124. component part number CAGE must be included in the documentation b OTHER SERVICES For reporting warranty claims fill out and forward SF 368 or DA Form 2407 to US Army Communications Electronics Life Cycle Management Command ATTN AMSEL LC CCS G GN 1200 Nealis Avenue Fort Monmouth NJ 07703 5043 2 Warranty service be obtained by contacting the actual warranted component manufacturer listed in column 1 Each manufacturer will provide instructions on filing the claim Troubleshooting should be performed to the level of warranted component but no further unless directed by the warranted component manufacturer Troubleshooting to the failed part inside warranted components may invalidate the warranty There are some components with short warranty periods that may not be listed in Table 1 Warranty coverage may be available for these components Submit warranty claims in accordance with DA PAM 738 750 to determine if the components are covered If you have difficulty with or questions about the warranty process contact your local CECOM LAR or the CECOM Generator Branch DSN 992 1313 732 532 1313 MANUFACTURER WARRANTY INFORMATION Column 1 MANUFACTURER This column gives you the name and address of the manufacturer of a component under warranty Telephone numbers fax numbers and internet addresses are listed where available Column 2 COMPONENT UNDER WARRANTY This column describes the component under warranty with part
125. ctical Quiet Generator FIELD MANUALS Chemical and Biological Contamination FM 3 3 INBG Protections ee e eal ee die a es 3 4 NBG cereo Fe rere cro M3 5 First Aids eite e T waste esse E b et ere pet FM 4 25 11 G mouflage ana et ee RSEN ORT ER ELI NOR RRR FM 5 20 Operation and Maintenance of Ordnance Materiel in Cold Weather 0 to 65 FM 9 207 Techniques of Military Instruction esee eene FM 21 6 Military Symbols vd 21 30 Chemical Biological Radiological and Nuclear 22 FM 21 40 Manual for Wheeled Vehicle 40004 0100 00 21 305 Basic Cold Weather Manual esee dae e rete te diner t FM 31 70 NOMAS M31 71 Mountain Operations 90 6 FORMS Technical Order Publication Improvement Report esses AFTO Form 22 Recommended Changes to Publications and Blank Forms DA Form 2028 Recommended Changes to Equipment Technical Publications esses DA Form 2028 2 Hand s uet o dte eene des DA Form 2062 Equipment Inspection and Maintenance DA Form 2404 Maintenance Request 2 5 oe eR DEN E RINT UNIES DA Form 2407 Equipment Log Assembly
126. d Control Common Table of Allowances Current Digital Voltage Regulator Engine Control Module agnetic Interference Electronic Modular Control Panel Discharge Government Furnished Equipment Ground Fault Circuit Interrupter Generator Set Control Hertz cycles per second pere reactive pere reactive hour pere hour Joint Table of Allowances Liquid Crystal Display Light Emitting Diode Maintenance Allocation Chart Modified Table of Organization and Equipment North Atlantic Treaty Organization Nuclear Biological and Chemical Factor Preventive Maintenance Checks and Services Number Product Quality Deficiency Report Repair Parts and Special Tools Lists Supply Discrepancy Report Source of Supply The Army Maintenance Management System Table of Distribution and Allowances Discrepancy Report Manual 0001 00 3 Change 2 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0001 00 GENERAL INFORMATION Continued LIST OF ABBREVIATIONS ACRONYMS Continued Abbreviation Acronym Definition TMDE Test Measurement and Diagnostic Equipment TQG Tactical Quiet Generator U M Unit of Measure ULLS Unit Level Logistics System USEPA U S Environmental Protection Agency Vac Volts Alternating Current Vde Volts Direct Current SAFETY CARE AND HANDLING The TQG contains no radioactive components or parts or radioactive material requiring special handling or consideration The TQG contains no electronic modules or components req
127. d can cause injury or death to personnel and damage to the generator set 0016 00 1 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0016 00 ENGINE FUEL SYSTEM MAINTENANCE Continued INSPECTION Fuel Tank Inspection 1 2 3 4 5 Verify that DEAD CRANK SWITCH is set to NORMAL and Battery Disconnect switch is ON On GSC set ENGINE CONTROL to COOL DOWN STOP Check fuel level by observing fuel level indicator Remove fuel cap 1 and ensure strainer in filler tube 2 is free of dirt and other foreign material If dirt or debris are present clean strainer On EMCP set ENGINE CONTROL switch to OFF RESET Fuel Filter Water Separator Inspection On EMCP set ENGINE CONTROL switch to OFF RESET 2 Open front left engine access door 3 Inspect fuel filter water separator assembly for proper mounting cracks dents leaks loose fuel lines and other damage 4 Inspect fuel filter water separator for sediment or water and perform Fuel Filter Water Separator Service procedures WP 0016 00 4 if any present 5 Close front left engine access door 200KW 10 404 END OF TASK 0016 00 2 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0016 00 ENGINE FUEL SYSTEM MAINTENANCE Continued SERVICE Fuel Tank Service WARNING E Fuels used in the generator set are flammable When filling the fuel tank maintain metal to metal contact between filler nozzle and fuel tank openin
128. e 6 describes DEAD CRANK SWITCH functions The dead crank switch is located inside the housing Access is through the rear left side housing door DEAD CRANK SWITCH CRANK 30554 88 21776 200KW 10 208 Table 6 Dead Crank Switch Controls CONTROL OR INDICATOR FUNCTION CRANK Energizes starter motor to crank engine for service and maintenance purposes Engine will not start OFF Center position removes power from GSC DVR and Engine Control Module ECM Engine will not crank or start NORMAL Supplies power to GSC DVR and ECM allowing normal operation of generator starting controls and circuits Change 3 0005 00 12 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0005 00 DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS Continued PARALLELING RECEPTACLES PANEL Table 7 describes the controls and indicators of the paralleling receptacles panel PARALLELING RECEPTACLES GROUND FAULT CIRCUIT INTERRUPTER 120 VOLTS 15 AMPS 60HZ O REAR 200 10 209 Table 7 Paralleling Receptacles Panel Controls and Indicators CONTROL OR INDICATOR FUNCTION PARALLELING RECEPTACLES Two five pin receptacles for connecting TQG sets for parallel operation GROUND FAULT CIRCUIT Provides ground fault protection and circuit breaker protection for two 120 INTERRUPTER circuit breaker Vac utility outlets TEST Pushbutton allows testing of GFCI circuit breaker
129. e erret nennen nennen nnne 0006 00 25 0004 00 1 Reporting Equipment Improvement Recommendations 0001 00 1 S Safety Care and Handling inicia ner i e ERE RE RU E ER REL dead 0001 00 4 Scope General 2 2 1 10 0 ener enne nnne enne enne 0001 00 1 SEE 0006 00 10 Air perum 0014 00 3 Cooling Algae EC 0015 00 2 cocoa 0016 00 3 Fuel Filter W ater S patator un ass alas lin an 0016 00 4 Lubrication 0017 00 1 Index 8 9 6115 730 10 INDEX Continued Subject WP Sequence No Page No S Continued Service Upon Receipt RM 0011 00 1 Preliminary Checks and Adjustment of Equipment 1 24 1 0 2001212 20 200 24 0400 00 0011 00 1 Skid Base Characteristics 22 5 0002 00 1 beo mE 0002 00 7 Special Tools TMDE and Support Equipment 0004 00 1 Starter Characteristics ad cda db t taut 0002 00 1 Description 220000 0002 00 7 Supporting Data for Repair Parts Special Tools TMDE and Support 0004 00 1 T U V Theory of Operation RM 0003 00 1
130. e or missing parts Any fuel leaks cracks or missing parts Fuel filter water separator contains sediment and or water or cannot be drained 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0012 00 PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS INCLUDING LUBRICATION INSTRUCTIONS Continued Table 1 Preventive Maintenance Checks and Services Continued LOCATION NOT FULLY ITEM ITEM TO MISSION NO INTERVAL CHECK SERVICE PROCEDURE CAPABLE IF 46 After Lubrication System Inspect lubrication system for leaks Class III leaks damaged loose or missing parts Damaged loose or missing parts Check engine oil level WP 0017 00 Oil level is below low oil level mark on dipstick COOLING SYSTEM 47 After Radiator 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 or death to personnel Check radiator for leaks damage or missing Class III leaks parts Coolant refill cap missing 48 After Hoses Check hoses for leaks or cracks or loose Class ITI leaks clamps 49 After Cooling Fan Check fan for damage or looseness Cooling fan is damaged or loose 50 After Fan Belts Inspect belts to ensure that they are not Broken missing or broken or missing Inspect for cracks loose belt
131. ean and reduce noise Wet down dusty and sandy surface areas around generator set frequently if water is available Keep all access doors closed as much as possible to prevent entry of dust and sand into housing assembly Wipe dust and sand frequently from the generator set external surface and components Wash exterior surfaces frequently with clean water when generator set is not operating Service engine air cleaner assembly frequently to compensate for intake of additional dust sand WP 0014 00 Drain sediment frequently from fuel filter water separator WP 0016 00 When servicing fuel tank be careful to prevent dust or sand from entering fuel tank Notify maintenance to change engine oil and oil filter frequently Store oil and fuel in dust free containers 10 Ensure generator set ground connections are free of dust and sand and connections are tight before starting unit END OF TASK OPERATION UNDER RAINY OR HUMID CONDITIONS CAUTION Failure to remove waterproof material before operating generator set could result in equipment damage If possible provide a shelter for generator set Cover generator set with canvas or other waterproof material when it is not being operated Provide adequate drainage to prevent water from accumulating on operation site Keep all generator set access doors closed as much as possible to prevent entry of water into housing assembly Drain water frequently from fuel filter water separ
132. el Logistics System ULLS generated Equipment Maintenance and Inspection Worksheet When no automation is available use DA Form 2404 Equipment Inspection and Maintenance Worksheet Both forms serve the same purpose Air Force report all deficiencies on SF Form 368 If there is a recommended change to equipment technical publications complete form DA 2028 2 and forward it by email AMSEL LC LEO PUBS CHG maill monmouth army mil or online http edm Monmouth army mil pubs 2028 html Alternately you ay mail or fax your letter DA Form 2028 Recommended Changes to Publications and Blank Forms or DA Form 2028 2 located in back of this manual direct to Commander U S Army Communications Electronics Life Cycle Management Command ATTN AMSEL LC LEO E ED Fort Monmouth New Jersey 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 31098 You may also e mail your form to lt http wralc tilta afto robins af mil gt END OF TASK 0011 00 1 2 blank 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0012 00 PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS INCLUDING LUBRICATION INSTRUCTIONS THIS WORK PACKAGE COVERS Introduction Fluid Leakage Inspection PMCS Column Descriptions PMCS Table 1 INITIAL SETUP Maintenance Level References Operator WP 0005 0 WP 0014 0 WP 0015 0 WP 0016 0 WP 00
133. enesnessnenaseceeaesasesessesacenaseneeaeseses 0005 00 12 Digital Voltage A enne ranei ne ikikaa e uak ieni kasiat ERa 0005 00 10 Table 4 Digital Voltage Regulator Controls and 0005 00 10 Electronic Modular Control enne trennen nennen nenne 0005 00 1 Table 1 Tactical Quiet Generator Electronic Modular Control Panel Controls and Indicators 0005 00 1 Index 2 9 6115 730 10 INDEX Continued Subject WP Sequence No Page No D Continued Description and Use of Operator Controls and Indicators Continued Fuel Fired Heater Control Panel Issued to Selected Units 0005 00 17 Table 11 Fuel Fired Heater Control Panel Winterization Kit Controls and Indicators 0005 00 17 Generator Set Control me erm ote e CU He e TREE 0005 00 4 Table 2 Generator Set Control Controls and 0005 00 4 Output Load Terminal Board 2 22 1 1 10 000 000000000 EAA E AROSE EARE 0005 00 16 Table 10 Output Load Terminal Board TB2 Connections 0005 00 16 Parallehng Receptacles Panel iore an 0005 00 13 Table 7 Paralleling Receptacles Panel Controls and Indicators 0005 00 13 Recon ection Board EB
134. ersonnel Check for deteriorated loose or missing Ether bottle missing parts with temperatures below 10 9029 10 Before Lubrication System Inspect lubrication system for leaks Class leaks damaged loose or missing parts Damaged loose or missing parts Check engine oil level WP 0017 00 Oil level is below cold low oil level mark on dipstick Check engine oil for contamination Engine oil is milky discolored or shows signs of contamination COOLING SYSTEM 11 Before Radiator AAA 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 or death to personnel Check radiator for leaks damage or missing Class leaks parts Coolant fill cap missing or damaged 12 Before Fan Guards Check fan guards and shroud for dirt and Dirt or debris block debris blocking air flow air flow 13 Before Hoses Check hoses for leaks or cracks Class III leaks 0012 00 6 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0012 00 PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS INCLUDING LUBRICATION INSTRUCTIONS Continued Table 1 Preventive Maintenance Checks and Services Continued LOCATION NOT FULLY ITEM ITEM TO MISSION NO INTERVAL CHECK SERVICE PROCEDURE CAPABL
135. fore attempting any repair or maintenance on the unit Failure to comply can cause injury or death to personnel High voltage is produced when the generator set is in operation Never attempt to start the generator set unless it is properly grounded Failure to comply can cause injury or death to personnel 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 The Troubleshooting Procedured WP 0010 00 contain a table that lists the malfunctions tests or inspections and corrective actions required to return the TQG to normal operation The operator troubleshooting procedures cannot list all possible malfunctions or tests and inspections required for corrective action If a malfunction is not listed or is not corrected by the listed corrective actions notify maintenance Thd WP 0010 OO INITIAL SETUP outlines what is needed for the task as well as certain conditions that must be met before starting the task Don t start a task until the following conditions exist 1 You understand the task 2 You understand what you are to do 3 You understand what is needed to do the work 4 You have the things you need WP 0010 00 Troubleshooting Table 1 has three columns MALFUNCTION TEST OR INSPECTION and CORRECTIVE ACTION Note that the malfunctions are also listed in the Malfunction
136. fy maintenance Reduce load below output capacity of generator set Reduce load as necessary 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR 0010 00 TROUBLESHOOTING Continued Table 1 Operator Troubleshooting Continued MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION 7 Alarm module GENERATOR OVERLOAD amber indicator flashes TQG disconnects from load Continued 8 Alarm module LOW FUEL LEVEL red indicator glows steady TQG engine shuts down 7 Set Battery Disconnect Switch to ON 8 Set DEAD CRANK SWITCH to NORMAL 9 Set ENGINE CONTROL switch to STOP COOL DOWN 10 Press LAMP TEST on alarm module to reset overload fault detection circuit 11 Start and operate TQG WP 0006 00 11 1 On EMCP verify low fuel level on fuel gauge 2 Check that auxiliary fuel source is in use verify that auxiliary fuel line is connected pet WP 0006 00 3 On EMCP verify AUX FUEL pump switch is set to ON 4 Verify that external auxiliary fuel source is present and fuel is in the container CAUTION 1 Monitor TQG for further problems 2 If there is no identifiable problem with the load and alarm recurs notify maintenance Service and fill fuel tank per WP 0016 00 If needed connect auxiliary fuel hose to TQG per WP 0006 00 Set AUX FUEL pump switch to ON If external fuel is present at source notify maintenance to troubleshoot auxiliary fuel pump The maxi
137. g 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 Hot engine surfaces from the engine and generator circuitry are possible sources of ignition When hot refueling with DF 1 DF 2 JP5 or JP8 avoid fuel splash and fuel spill Do not smoke or use open flame when performing refueling Remember PMCS is still required Failure to comply can result in flames and possible explosion and can cause injury or death to personnel and damage to the generator set NOTE Fuel tank holds 128 gallons 485 L The TQG can be refueled while it is operating without stopping the engine and allowing the TQG to cool down If you are hot refueling Step 1 1s not required 1 On EMCP set ENGINE CONTROL switch to OFF RESET Remove fuel cap 1 3 Remove filler tube with strainer 3 clean as necessary and reinstall in filler neck 2 CAUTION To prevent damage to the diesel engine use only specified diesel fuel to service the fuel tank To prevent condensation of water in fuel tank always keep level at full Refer to Table 1 for appropriate fuel Add diesel fuel to fuel tank 5 Install fuel cap 1 Table 1 Diesel Fuel AMBIENT F 50 25 150 5 20 30 40 70 90 100 TEMPERATURE C 46 32 26 18 15 7 1 4 21 32 38 Diesel A A 52557 1 D Diesel A A 52557 2 D JP5 MIL PRF 5624 JP8 MIL T 83 133 0016 0
138. h auxiliary fuel source set AUX PUMP 6 switch to ON 8 GSC panel keypad 7 press ENGINE METER 8 and check coolant temperature to be 170 to 200 F 77 to 93 C and oil pressure to be 35 to 70 psi 241 to 483 kPa 0006 00 13 Change 2 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0006 00 OPERATION UNDER USUAL CONDITIONS Continued OPERATING PROCEDURES Continued Starting Continued OPEN AC CIRCUIT ENGINE CONTROL INTERRUPTER PUSH TO STOP RESET EMERGENCY STOP SERVICE MODE CODES 10 9 8 200KW 10 232A 9 On GSP keypad 7 press AC METER 9 to ensure voltage and frequency are still at rated values Adjust if necessary 10 Press POWER METER 10 on keypad and cycle through each phase position while observing current readings If more than rated load is indicated in any phase reduce load Change 2 0006 00 14 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0006 00 OPERATION UNDER USUAL CONDITIONS Continued OPERATING PROCEDURES Continued Starting Continued 11 On PARALLELING RECEPTACLES panel 11 press TEST 12 pushbutton on GROUND FAULT CIRCUIT INTERRUPTER Ensure that indicator window is red Press RESET 13 pushbutton and ensure indicator is clear of 200 10 235 WARNING Operating the generator set exposes personnel to a high noise level Hearing protection must be worn when operating
139. hat the material is extremely cold and can injure human skin or tissue VAPOR human figure in a cloud shows that vapors fumes or exhaust present a danger to life or cause death HOT hand touching hot surface shows that the surface is extremely hot and can burn human skin or tissue 9 6115 730 10 WARNING SUMMARY Continued This section provides a summary of all critical safety information in this manual It includes a list of all WARNINGs in work package procedures In some cases WARNINGs on the same subject that are shown separately below are separate paragraphs under same WARNING heading in work packages Prior to starting any work package procedure the WARNINGs included in the initial setup and text for that work package must be reviewed and understood Also review the MATERIALS PARTS in the INITIAL SETUP of the work package for hazardous materials used during maintenance of the equipment Then refer to the detailed WARNINGs for hazardous materials listed separately in this WARNING SUMMARY WARNING Metal jewelry can conduct electricity and become entangled in generator set components Remove all metal jewelry when working on generator set Failure to comply can cause injury or death to personnel 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
140. heck fluid levels more frequently Class III leaks must be reported immediately to your supervisor or to maintenance Failure to do this could result in damage to the 200 kW and or components ClassI Leakage indicated by wetness or discoloration but not great enough to form drops 2 ClassII Leakage great enough to form drops but not enough to cause drops to drip from item being checked inspected 3 Class III Leakage great enough to form drops that fall from the item being checked inspected INSPECTION Look for signs of a problem or trouble You can feel smell hear or see many problems Be alert when in or around the 200 kW TQG Inspect the 200 kW TQG to see if items are in proper condition Are they correctly assembled stowed and secured excessively worn leaking corroded or properly lubricated Correct any problems found or notify maintenance 0012 00 2 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0012 00 PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS INCLUDING LUBRICATION INSTRUCTIONS Continued INSPECTION Continued There are some common items to check all over the TQG These include the following WARNING Cleaning compound is toxic Avoid prolonged breathing of vapors Use only in a well ventilated area Failure to comply can cause serious injury to personnel 1 Dirt grease oil and debris They only get in the way and may cover up a serious problem Keep the equipment clean
141. hen the generator set is in operation Never attempt to start the generator set unless it is properly grounded Failure to comply can cause injury or death to personnel 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 NOTE The following installation is for skid mounted TQG and trailer mounted TQG For the trailer mounted TQG the ground cable is connected between the TQG and a terminal on the trailer and then connected to the ground rod 1 Remove three ground rods 1 from storage inside left front housing door 2 Remove ground cable 2 clamp 3 driving stud 4 and three couplers 5 from storage inside left rear housing door 3 Open door to output load terminal board TB2 6 on right rear side of generator housing and remove terminal nut wrench 7 Change 2 0006 00 2 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0006 00 OPERATION UNDER USUAL CONDITIONS Continued ASSEMBLY AND PREPARATION FOR USE Continued Installation of Ground Rod Continued 200KW 10 214A Route ground cable 2 from outside to inside of housing through OUTPUT CABLES boot 8 Insert ground cable 2 through slot on ground terminal located on TQG skid frame 9 Tighten nut on terminal 9 with wrench 7 toy Connect coupler 5 to ground rod 1 and screw
142. hen the generator set is running Failure to comply can cause hearing damage to personnel CAUTION Operating the generator set with restricted airflow for cooling can cause the generator set to overheat Keep all access door inlet panels clear to ensure maximum airflow for engine and generator cooling Failure to comply can result in poor engine performance and possible overheating and automatic shutdown 4 GSC HIGH WATER TEMP red indicator flashes 1 Set ENGINE CONTROL switch to COOL DOWN STOP 2 Set DEAD CRANK SWITCH to OFF 3 Set Battery Disconnect Switch to OFF 4 Allow engine to cool 5 Inspect water level in coolant overflow bottle pet WP 0015 00 6 Visually inspect radiator and coolant system for damage leaks loose clamps fan guards fan and shrouds or obstructions per WP 0015 00 7 Visually inspect engine for missing or loose fan belt 0010 00 4 1 If coolant level is low refill coolant overflow bottle with correct mixture of water and coolant per WP 0015 00 2 Monitor coolant level and refill as required pei WP 0015 00 Remove obstructions and debris from fan guards and shroud area tighten clamps If radiator is obstructed and coolant system damaged or you cannot tighten clamps notify maintenance If fan belt is missing or loose notify maintenance to tighten or replace belt 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR 0010 00 TROUB
143. ial to meeting U S Environmental Protection Agency USEPA and fuel consumption requirements All the electrical components and assemblies including the voltage regulator that provide the required instrumentation and control functions are contained in the Electronic Modular Control Panel EMCP located on the generator end REAR of the TQG as shown in figure 1 sheet 3 Opening the EMCP and side access panels gives access to all the electrical components and essential engine components Paralleling receptacles are used to connect the paralleling cable between generator sets of the same family The generator set family includes a 100 kW TQG The 100 kW TQG is skid mounted and is designated MEP 807A When the 100 kW TQG is mounted on a trailer it is designated PU 807A The 100kW generator sets MEP 807A and PU 807A use the same control system as the 200kW generator sets MEP 809A PU 809A and can operate in parallel to share an electrical load LOCATION AND DESCRIPTION OF MAJOR COMPONENTS ENGINE The engine for the 200 kW TQG is the Caterpillar Model C 12 engine figure 1 sheet 1 item 1 The engine is electronically controlled The Engine Control Module ECM controls the amount of fuel that is injected by the unit injectors The EMCP provides frequency speed control controls long and short term stability and accommodates load conditions High injection pressures help to reduce fuel consumption and emissions Precise injection timing optim
144. id assembly side members ENGINE CONTROL MODULE The ECM 34 monitors most of the engine sensors and controls the fuel injectors and engine timing functions Tita 2 GS ai EN lo fa il Je 27 le el 59 520 REAR 29 30 31 28 53 32 26 34 28 29 LEFT SIDE HOUSING REMOVED FOR CLARITY 200 10 102 80 Figure 1 200 kW Tactical Quiet Generator Location of Components Sheet 5 0002 00 7 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0002 00 EQUIPMENT DESCRIPTION AND DATA Continued LOCATION AND DESCRIPTION OF MAJOR COMPONENTS Continued GENERATOR HOUSING INSTALLATION The housing figure 1 sheet 6 item 34 is fabricated from sheet steel and attaches directly to mating flanges on the skid base The housing is thus removable for unscheduled maintenance and engine or generator removal Access openings and doors 36 allow engine generator and external component servicing Each side of the rear housing has a set of double doors and the large doors at the front of the housing provide accessibility The housing structure incorporates acoustic damping foam and internal baffle structures to reduce engine noise The rugged design of the housing includes stiffened corners and access openings to meet transportability operational and handling requirements of a mobile military generator se
145. ion must be worn when operating or working near the generator set when the generator set is running Failure to comply can cause hearing damage to personnel WARNING Top housing panels can get very hot When performing DURING PMCS wear gloves and additional protective clothing as required Failure to comply can result in severe burns to personnel WARNING DO NOT wear loose clothing when performing checks services and maintenance Failure to comply can cause injury or death to personnel WARNING When running generator set engine has hot metal surfaces that will burn flesh on contact When performing DURING PMCS wear gloves and additional protective clothing as required Failure to comply can cause injury or death to personnel 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 0012 00 11 9 6115 730 10 36 During 37 During 38 During Lubrication System COOLING SYSTEM Cooling fan Overflow Bottle loose or missing parts Inspect lubrication system for leaks damaged loose or missing parts Check engine oil level WP 0017 00 WARNING Cooling system operates at high temperature and pressure When performing DURING PMCS wear gloves and additional protective cl
146. ions in the Work Package and Page No column for the troubleshooting that you can do These will refer you to the Troubleshooting Procedures WP 0010 00 Ih WP 0010 00 follow each step in sequence through the tests or inspections listed in the Troubleshooting Procedures Table until a fault is identified Most of the listings in the Malfunction Symptom index are keyed to Fault Codes that are described ih WP 0009 00 in the brief descriptions below Dedicated Fault Indicators The Malfunction Symptom index begins with procedures to use for troubleshooting the dedicated fault indicators on the GSC These are the lights and alarms that will tell you what problems are occurring that you can usually troubleshoot GSC Alarm Fault Codes The GSC Alarm Fault Codes are a set of fault codes displayed in the upper display on the EMCP These are engine fault codes protective relay function codes and paralleling fault codes They rely on programmed setpoints but you can do some troubleshooting that will correct the problems Generator Set Control GSC SP Fault Codes These special codes are monitored by the GSC The operator can troubleshoot the low fuel level fault SP1 but maintenance must be notified for the codes associated with paralleling the TQG Digital Voltage Regulator DVR Alarm Fault Codes When errors in the operation of the TQG output and voltage regulation are detected these codes are displayed Record DVR alarm codes and notif
147. it notice of discrepancies or suggest changes on a NAVMC 10772 NAVMC be submitted via the Internet using website https www ala usmc mil click on Publications Technical Publications follow the instructions and then click on NAVMC 10772 It may also be submitted by electronic mail to smb log tech pubs fct usme mil or by mailing a paper copy NAVMC 10772 in an envelope addressed to Commander Marine Corps Systems Command ATTN Assistant Commander Acquisition and Logistics AC LCL TP 814 Radford Blvd Suite 20343 Albany Georgia 31704 0343 In addition forward an information copy to the Project Officer at the following address Commander Marine Corps Systems Command GTES EPS 2200 Lester Street Quantico VA 22134 6050 N Navy By letter directly to Commander Space and Naval Warfare Systems Command ATTN SPAWAR 8122 Washington DC 20363 5100 F Air Force By Air Force AFTO Form 22 Technical Manual TM Change Recommendation and Reply in accordance with paragraph 6 5 Section VI TO 00 5 1 directly to prime ALC MST A reply will be furnished to you i Change 2 9 6115 730 10 TABLE OF CONTENTS WP Sequence No and or Page No MV WINLOERIDUIN EVIS a O HOW TO USE THIS MANUAL hu M iii E CHAPTER 1 INTRODUCTORY INFORMATION WITH THEORY OF OPERATION FOR 200 kW TACTICAL QUIET GENERATOR SET General Information P
148. itch INTERRUPTER switch CLOSED Up momentary toggle activates circuits to close load contactor Connects TQG to load Press to test green indicator is lit when load contactor is closed Normal Toggle switch spring loaded to return to this position OPEN Down momentary toggle activates circuits to open load contactor Disconnects TQG from load Press to test green indicator is off when load contactor is open Press to test green indicator Indicator lights when AC CIRCUIT INTERRUPTER switch is set to CLOSED Indicator off when AC CIRCUIT INTERRUPTER switch is set to OPEN PUSH TO STOP Press for emergency stop of TQG Switch pulled out for normal operations EMERGENCY STOP Switch can be reset by turning knob to right and pulling out pushbutton switch BATTLE SHORT switch Two position toggle switch Hinged red safety cover must be raised to set to ON ON Disables all safety or protective devices except short circuit and overspeed Disables starting of engine Yellow LED on GSC is lit OFF Normal operation of generator set Lowering red cover returns switch to OFF ENGINE CONTROL switch Four position rotary switch OFF RESET Engine shuts down and fault indicators and overload short circuit module are reset except in emergency stop while EMERGENCY STOP pushbutton is in AUTO Allows remote start stop control MANUAL START Starts and runs generator set diesel engine COOL DOWN STOP Shuts engine down after 5 minute cool down period has
149. ity Module Erratic Intermittent or Incorrect Signal CID 254 E FMI 12 Engine Control Module Self Test Failed Component CID 261 E FMI 13 Engine Timing cal Device is not calibrated CID 262 E FMI 03 5 Volt Sensor Power Supply Voltage Above Normal CID 262 E FMI 04 5 Volt Sensor Power Supply Voltage Below Normal CID 264 E FMI 03 E Stop Shutdown Active Only CID 268 FMI 02 GSC Electronic Control Erratic Intermittent or Incorrect Signal CID 269 FMI 03 GSC 8V Sensor Power Supply Voltage Above Normal CID 269 FMI 04 GSC 8V Sensor Power Supply Voltage Below Normal CID 273 FMI 03 Turbo Outlet Pressure Sensor Voltage Above Normal CID 273 FMI 04 Turbo Outlet Pressure Sensor Voltage Below Normal CID 274 FMI 03 Atmospheric Pressure Sensor Voltage Above Normal CID 274 FMI 04 Atmospheric Pressure Sensor Voltage Below Normal CID 334 FMI 03 Spare Output P7 36 Voltage Above Normal CID 334 FMI 04 Spare Output P7 36 Voltage Below Normal CID 336 E FMI 02 Engine Control Switch Erratic Intermittent or Incorrect Signal CID 342 E 02 Secondary Engine Speed Timing Sensor Erratic Intermittent or Incorrect Signal Logged CID 342 E FMI 11 Secondary Engine Speed Timing Sensor Failure mode is not identifiable Mechanical Failure Logged CID 360 E FMI 01 Low Engine Oil Pressure Warning Active and Logged CID 360 E FMI 02 Low Engine Oil Pressure Derate Active and Logged CID 360 E FMI 03 Low Engine Oil Pressure Shutdown Active and Logged CID 3
150. izes engine performance for starting emissions noise and fuel consumption MUFFLER The muffler 2 and exhaust tubing are connected to the engine and turbocharger This system reduces engine exhaust noise Exhaust gases are exhausted upward from the top of the generator set TURBOCHARGER The turbocharger 3 is located on the right side of the engine Powered by engine exhaust gases the turbocharger compresses air from the air filter to provide pressurized air to the engine for combustion AIR CLEANER ASSEMBLY The air cleaner assembly 4 is located on the left side of the engine 4 inside the rear access doors The air cleaner filters intake air used for engine combustion ALTERNATOR The alternator 5 is located on the right side of the engine The alternator maintains the batteries in a state of full charge The alternator also provides 24 Vdc voltage for TQG control circuits and to the NATO slave receptacle RADIATOR The radiator 6 located at the front of the TQG eliminates engine heat via circulated coolant and air The radiator and engine fan are the primary heat exchanger for cooling engine coolant and for turbocharged engine intake air WATER PUMP The water pump 7 located on the right side of the engine circulates coolant through the engine block and radiator to cool the engine 0002 00 1 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0002 00 EQUIPMENT DESCRIPTION AND DATA Continued LOCATION AND
151. l EMCP set ENGINE CONTROL switch to OFF RESET WP 0005 00 1 Perform all BEFORE PMCS requirements pdr WP 0012 00 Open rear left housing door and set DEAD CRANK SWITCH to OFF WP 0005 00 12 Open battery compartment and set Battery Disconnect Switch to OFF WP 0005 00 14 Select required output terminals from Table 1 Open output load terminal door on rear side right of housing Using terminal nut wrench 7 loosen terminal nuts 13 on output load terminals 14 selected in step 5 Insert ends of load cables 15 through OUTPUT CABLES boots 8 Insert ends of cables into slots of output load terminals 14 Tighten load terminal nuts 13 using terminal nut wrench 7 10 Secure wrench 7 inside load terminal board door and close door Change 2 0006 00 6 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET OPERATION UNDER USUAL CONDITIONS Continued ASSEMBLY AND PREPARATION FOR USE Continued Installation of Load Cables Continued 0006 00 Table 1 Load Terminal AC Reconnection Board LOAD VOLTAGE RECONNECTION BOARD POSITION LOAD BOARD TERMINALS 120 Vac single phase 120 Vac single phase 120 Vac single phase 208 Vac 3 phase 208 Vac 3 phase 208 Vac 3 phase 240 Vac single phase 240 Vac single phase 240 Vac single phase 416 Vac 3 phase 416 Vac 3 phase 416 Vac 3 phase 120 208 120 208 240 416 240 416 L1 to N L2 to N or L3 to N Single phase loads can be c
152. le 1 Expendable and Durable Items 0022 00 2 F Fuel Fired Heater Characteristics 0003 00 8 22 0002 00 4 IS CUM 0007 00 2 Fuel Tank Characteristics eee 0002 00 1 Ip uut ita 0002 00 7 G H General Information EEN REEERE 0001 00 1 Generator See AC Generator Generator Housing Installation Characteristics 5 obs depa a 0002 00 1 bem ERES 0002 00 8 Index 4 9 6115 730 10 INDEX Continued Subject WP Sequence No Page No G H Continued Generator Set PMCS OperatoE toute etie dete 0012 00 4 tas 0012 00 4 MOSS O Glossary 1 Ground Rod Installation 0006 00 2 l J K Initial Adjustments Before Use and Self Test 0006 00 10 Initial Adjustments REM 0006 00 10 t ec tcI DE 0006 00 10 Inspections Coolant E p 0015 00 1 Engine A Cleaner MES 0014 0
153. le 1 Expendable and Durable Items List 3 NATIONAL STOCK NUMBER 6850 00 664 1403 7930 01 306 8369 9140 00 286 5288 9140 00 286 5296 6850 01 287 8067 9150 01 402 4478 9150 00 189 6727 9150 00 183 7807 9150 00 186 6668 9150 00 186 6681 9150 00 188 9858 9150 01 152 4117 9150 01 213 3118 9150 01 152 4119 9150 00 405 2987 9130 00 273 2379 9130 01 031 5816 7920 00 205 3571 4 ITEM NAME DESCRIPTION CAGEC AND PART NUMBER Antifreeze 1 gallon 58536 A A 52624 Cleaning Compound Simple Green gallon 1Z575 Fuel Oil Diesel 1 D 55 gallon 58536 A A 52557 Fuel Oil Diesel 2 D 55 gallon 58536 A A 52557 Inhibitor Corrosion Liquid Cooling System 1 gallon 81349 MIL A 53009 Lubricating Oil Internal Combustion Engine Arctic 81349 MIL L 46167 Lubricating Oil Internal Combustion Engine OE HDO 10 1 quart 81349 MIL PRF 2104 Lubricating Oil Internal Combustion Engine OE HDO 10 1 gallon 81349 MIL PRF 2104 Lubricating Oil Internal Combustion Engine OE HDO 10 5 gallon 81349 MIL PRF 2104 Lubricating Oil Internal Combustion Engine OE HDO 30 1 quart 81349 MIL PRF 2104 Lubricating Oil Internal Combustion Engine OE HDO 30 5 gallon 81349 MIL PRF 2104 Lubricating Oil Internal Combustion Engine OE HDO 15 40 1 quart 81349 MIL PRF 2104 Lubricating Oil Internal Combustion Engine OE HDO 15 40 1 gallon 81349 MIL PRF 2104 Lubrica
154. ly packaged must be with the 200 kW Tactical Quiet Generator Set during operation and when it is transferred between property accounts Listing these items is your authority to request requisition them for replacement based on authorization of the end item by the Table of Organization and Equipment Modified Table of Organization and Equipment TOE MTOE Illustrations are furnished to help you find and identify the items COEI LIST AND BII LISTS COLUMN DESCRIPTIONS TABLES 1 AND 2 Column 1 ILLUS NUMBER Identifies the number of the item illustrated Column 2 NATIONAL STOCK NUMBER Identifies the stock number of the item to be used for requisitioning purposes Column 3 DESCRIPTION CAGEC AND PART NUMBER Identifies the Federal item name in all capital letters followed by a minimum description when needed The stowage location of COEI and BII is also included in this column The last line below the description is the CAGEC commercial and Government entity code in parentheses and the part number Column 4 USABLE ON CODE When applicable gives a code if the item you need is not the same for different models of equipment These codes are identified below Code Used On 49N 809 78 PU 809A Column 5 U M Indicateslte unit of measure or count of the item as issued per the National Stock Number shown in column 2 Column 6 QTY REQ Indicates the quantity required 0020 00 1 Change 1 9 6115
155. mbly into the radiator The cooling fan circulates air through the radiator where the coolant temperature is reduced In addition the fan cools engine and generator set components within the TQG housing by drawing in air from outside the housing through the baffles circulating the air through the housing and forcing the air through the radiator and out through the housing exhaust vents on the roof The housing is designed to operate with the doors closed which ensures that the main alternator and other components have access to a good flow of cooling air from outside the generator set A coolant temperature sensor provides automatic engine shut down in the event that coolant temperature exceeds 230 F 110 C The lower Generator Set Control GSC display indicates the engine coolant temperature 0003 00 4 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0003 00 THEORY OF OPERATION Continued LUBRICATION SYSTEM ENGINE OIL PUMP OIL COOLER FILTER NES ENGINE MECHANICAL OIL PRESSURE SENDER TURBOCHARGER 200 10 106 The lubrication system consists of an oil pan dipstick pump oil pressure sender and filter The oil pan is reservoir for engine lubricating oil Engine oil lubricates cleans cools seals and preserves engine parts The dipstick indicates oil level in the oil pan A pump draws oil from the
156. mer 500 Bayview Avenue Inwood NY 11096 1792 Phone 516 239 5777 Transformer 1250 VA PN 0116 1257 VPN HP1 12 0023 00 2 12 Months 9 6115 730 10 200 KW TACTICAL QUIET GENERATOR SET 0023 00 WARRANTY INFORMATION Continued MANUFACTURER WARRANTY INFORMATION Continued Table 1 Manufacturer s Warranties for 200 kW Generator Set Continued 1 2 3 WARRANTY MANUFACTURER COMPONENT UNDER WARRANTY PERIOD Derema Group Switch Battery Disconnect 12 Months 46 Acorn Drive PN 0116 1298 VPN 2304 Westbrook CT 06498 Phone 860 399 5669 Madison Company Fuel Level Switch 12 Months 27 Business Park Drive PN 0116 2304 VPN M3863 Branford CT 06405 Phone 203 488 4477 Technology Research Co Relay Overload Short Circuit 12 Months 140 Avenue North Clearwater FL 33760 Phone 727 535 0572 PN 0116 1219 VPN 19970 Rwood TRClL net G amp O Manufacturing Co Radiator Assembly 18 months from 100 Gando Drive PN 0116 2400 VPN X6635 00 50 shipment or 12 months New Haven CT 60513 Phone 601 366 1423 in service Parker Hannifin Corporation Filter Crankcase Ventilation 12 Months Racor Division PN 0116 1607 02 VPN CCV6000 08L Phone 209 575 765 1 hbrizuela parker com Donaldson Company Inc Muffler Exhaust 36 Months Minneapolis MN 55440 1299 PN 0116 2500 VPN WOM12 0744 Phone 800 374 1374 Air Cleaner Assembly 12 Months www donaldson filters com
157. mperature Sensor Data is Valid but Below Normal Operating Range Logged CID 190 02 Magnetic Pickup Unit Erratic Intermittent or Incorrect Signal Logged CID 190 FMI 03 Magnetic Pickup Unit Voltage Above Normal Logged CID 190 E 02 Primary Engine Speed Timing Sensor Erratic Intermittent or Incorrect Signal Logged 0009 00 4 Notify maintenance Notify maintenance Notify maintenance Notify maintenance Notify maintenance Notify maintenance Notify maintenance Notify maintenance Notify maintenance Notify maintenance Notify maintenance Notify maintenance Notify maintenance Notify maintenance Notify maintenance Notify maintenance Notify maintenance Notify maintenance Notify maintenance Notify maintenance Notify maintenance Notify maintenance Notify maintenance 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR MALFUNCTION SYMPTOM INDEX Continued Malfunction Symptom Work Package and Page No 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 CID 190 EFMI 11 Primary Engine Speed Timing Sensor Failure mode not identifiable Mechanical Failure Logged CID 198 E FMI 01 Low Fuel Pressure Warning Logged CID 248 09 Data Link Abnormal Update CID 253 E FMI 02 Personal
158. mum power rating for the convenience receptacle is 15A To prevent circuit breaker from opening the total current drawn should be limited to 15A only Failure to limit the load to less than 15A may trip the circuit breaker and damage the generator set or load 9 Convenience receptacle on PARALLELING RECEPTACLES panel has no power 1 Check that load is no more than 15A 2 Turn off equipment powered by convenience receptacles and remove all plugs from outlets 3 Check GROUND FAULT CIRCUIT INTERRUPTER circuit breaker WP 0013 00 0010 00 8 If load is greater than 15A reduce load 2 If tripped reset thermal overload on GROUND FAULT CIRCUIT INTERRUPTER circuit breaker WP 0013 00 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR 0010 00 TROUBLESHOOTING Continued Table 1 Operator Troubleshooting Continued MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION 9 Convenience receptacle on 4 Under GROUND FAULT If TEST window is not red when TEST PARALLELING RECEPTACLES CIRCUIT INTERRUPTER is pressed notify maintenance panel has no power Continued 10 Winterization kit issued to selected units only is not operating Red DIAGNOSTIC light is on nameplate press TEST pushbutton circuit breaker 5 Press RESET pushbutton on GFCI circuit breaker 6 Check load is no more than 15A and for possible ground fault 1 On FUEL FIRED HEATER CONTROL
159. nance Checks and Services Continued LOCATION NOT FULLY ITEM ITEM TO MISSION NO INTERVAL CHECK SERVICE PROCEDURE CAPABLE IF 39 During Exhaust System 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 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 Exhaust system can get very hot When performing DURING PMCS wear gloves and additional protective clothing as required Failure to comply can cause severe burns and injury to personnel Visually check muffler and exhaust system Muffler or exhaust for leaks or missing parts system missing parts 40 During Electronic Modular Ensure all indicators are operating properly Fuel gage DC Control Panel ammeter GSC EMCP display module or Digital Voltage Regulator DVR inoperative 41 During Ground Rod Cable Visually inspect ground rod and cable for Cable is missing or and Connection breaks and damage damaged 42 During Overall Exterior Check external doors panels hinges and Cannot shut doors latches for damaged loose or corroded items 0012 00 13 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0012 00 PREVENTIVE MAINTEN
160. ner element requires servicing The inner air filter element retaining nut contains a second restriction indicator that changes from green to red as air flow is restricted Filtered air is drawn out of the air cleaner assembly through air intake tubes to the turbocharger where it is forced through the radiator aftercooler coil This pressurized air enters the intake manifold to the combustion chambers where it is mixed with fuel from the injectors When cold weather starting is required ether is injected into the air intake manifold to initiate combustion When the engine is running exhaust gases are released into the exhaust manifold and then to the turbocharger The exhaust gases drive the turbocharger forcing large amounts of air into the intake manifold After passing through the turbocharger the exhaust gases are channeled into a muffler to deaden the sound 0003 00 6 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0003 00 THEORY OF OPERATION Continued AC POWER OUTPUT MANUAL MANUAL CONNECTION CHANGE TO LOAD 120 208 ri POWER 240 416VAC BUS 13 ENGINE 60 50HZ RECONNECTION POWER MAIN LOAD VOLTAGE AND L GENERATOR BOARD CONTACTOR TERMINALS x EN 2 Eu 5 a 5 YM lt E O gt a EMCP a 2 2 OPEN CLOSE 00000 z AC CIRCUIT CONTROL 5 INTE
161. nit Manufacturer Woodward Model 9907 175 0002 00 10 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0002 00 EQUIPMENT DESCRIPTION AND DATA Continued EQUIPMENT DATA Continued Table 1 200 kW Equipment Data Continued Electronic control module Manufacturer Caterpillar Model 137 7392 GSC Protective Relay Setpoint Values Low oil pressure shutdown 30 psi 207 kPa High water coolant temperature shutdown 230 F 110 C Engine overspeed 2120 rpm Overcrank total cycle crank time 90 seconds High oil temperature shutdown 253 F 123 C Overvoltage alarm threshold 125 overvoltage for programmed voltage Generator overvoltage shutdown threshold 125 of nameplate voltage Generator undervoltage alarm threshold 82 of programmed voltage Generator undervoltage shutdown threshold 75 of nameplate voltage Generator overfrequency alarm threshold 63 Hz for 60 Hz operation 53 Hz for 50 Hz operation Generator overfrequency shutdown threshold 66 Hz for 60 Hz operation 55 Hz for 50 Hz operation Generator underfrequency alarm threshold 57 Hz for 60 Hz operation 48 Hz for 50 Hz operation Generator underfrequency shutdown 54 Hz for 60 Hz operation 45 Hz for 50 Hz operation Generator phase overcurrent alarm threshold 160 of nameplate current Generator total overcurrent alarm threshold 160 of nameplate current Generator phase overcurrent shutdown threshold 160 of nameplate current Generator total overcurrent shutdown th
162. nnections breaks damage and damaged parts corrosion PU 809A TRAILER INSTALLATION 28 Before Identification plates If generator set is trailer mounted PU 809A check to ensure identification plates on trailer are secure 29 Before Fire Extinguisher Verify that two fire extinguishers mounted Fire extinguishers are to trailer brackets and fully charged not present or not Check that fire extinguisher needle if eS MM not 1n green zone applicable is in green zone Check fire extinguisher seal If seal is broken or missing replace fire extinguisher Visually inspect bracket for obvious damage 0012 00 9 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0012 00 PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS INCLUDING LUBRICATION INSTRUCTIONS Continued Table 1 Preventive Maintenance Checks and Services Continued LOCATION NOT FULLY ITEM ITEM TO MISSION NO INTERVAL CHECK SERVICE PROCEDURE CAPABLE IF 30 Before Ground Rod Cable A and Connection 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 Inspect ground rod grounding cable to Any missing or trailer terminal and grounding cable to damaged parts generator set for loose connections breaks damage and corrosion
163. not broken reset GFCI 7 by pressing PUSH TO RESET THERMAL BREAKER 8 located behind the control panel on side of GFCI and then pushing RESET button 7 on front of panel 7 If wiring to GFCI appears to be broken notify maintenance 8 Close EMCP front panel 2 and secure with three captive retainers 1 SHORT CIRCUIT OVERCURRENT CIRCUIT BREAKER PUSH TO RESET e 4 200KW 10 409A END OF TASK 0013 00 3 4 blank 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0014 00 ENGINE AIR CLEANER MAINTENANCE THIS WORK PACKAGE COVERS Inspection Service INITIAL SETUP Maintenance Level References Ope rator None Tools and Special Tools Materials Parts None Wiping rag item 18 WP 0022 00 Personnel Required One INSPECTION 1 On EMCP set ENGINE CONTROL switch to OFF RESET Open air cleaner access door at left rear of generator set Open right engine compartment access door Inspect air cleaner housing 1 for dents corrosion damaged seal missing hardware and other damage On right side of air cleaner inspect restriction indicator 2 for indication of a clogged air cleaner element If restriction indicator red cylinder is in the clear body of the indicator 2 SERVICE air cleaner Close air cleaner access door 0014 00 1 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0014 00 ENGINE AIR CLEANER MAINTENANCE Continued INSPECTION Continued ROTATED 18
164. ntinued CAUTION The ideal load for the generator set is 80 of rated capacity When operated at less than 80 of rated load the diesel engine operates at lower temperatures and burns fuel incompletely resulting in carbon and moisture in the exhaust and carbon buildup or wetstacking in the engine To avoid damage to the engine if possible mission loads should be distributed among available generator sets to achieve an average 80 load on each generator set The minimum load that the generator set should be operated at is 25 to 30 of its rated capacity Operating at lower loads for long periods of time may damage the engine and cause wetstacking and damage to the engine Engines operated at low loads for long periods of time should be operated at full load for a few hours until the wetstacking residues are burned out This should be performed every 300 hours of generator set operation 1 Ensure load requirement is equal or below combined rated capacity of generator sets If load is greater than combined capacity of the generator sets that are being paralleled the generators will overload and the TQG could be damaged 2 Determine voltage requirements of load Ensure voltage Reconnection Boards WP 0005 Table 9 of generator sets match voltage requirements of load WP 0006 Table 1 3 Notify maintenance to change Reconnection Board and to reprogram the GSC and DVR to obtain required output 4 Inside EMCP control box assembly set ISOCHRO
165. ny one phase Voltage line to line for all three phases at once Current line for all three phases at once Voltage line to neutral for all three phases at once Stops scrolling of engine condition data shown on lower display Pointer flashes to indicate that scrolling is stopped Pressing key again resumes scrolling Sequence of reported data is as follows Fuel filter run hours Oil filter run hours Battery voltage Engine run hours Engine rpm Engine oil pressure Engine coolant temperature Performs lamp test on GSC Eight fault indicators are on continuously and all segments of upper display and lower display are on If FAULT ALARM light is flashing pressing this key displays diagnostic code WP 0009 00 in upper display Pressing key again resumes display of generator output information If FAULT ALARM light is off this key has no function Service Mode FOR MAINTENANCE PERSONNEL USE ONLY Service Mode FOR MAINTENANCE PERSONNEL USE ONLY 0005 00 8 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0005 00 DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS Continued ALARM MODULE Table 3 describes the EMCP alarm module controls and indicators HSS Dm O O Ba i CATERPILLAR 4 LAMP TEST 200KW 10 205A Table 3 Alarm Module Controls and Indicators 2 GHNERATOR OVERLOAD indicator LOW FUEL LEVEL indicator LAMP TEST ALA
166. oad applied Observe upper display for voltage and total current readings and the lower display for kW and kVAR readings on all TQG units Make very small adjustments to the VOLTAGE and FREQUENCY potentiometers to maintain balanced reading of total amperes kW KVAR across all units in parallel Pressing POWER METER on GSC keypad periodically compare kW and kVAR readings on lower display of all generator sets If readings are not within plus or minus 10 of one another notify next higher level of maintenance Removal from Parallel Operation WARNING If necessary to move a generator set that has been operating in parallel with another generator set shut down all generator sets prior to removing load cables or ground Failure to comply can cause injury or death to personnel by electrocution CAUTION Before removing generator set from parallel operation make sure that load does not exceed full load rating of generator set s remaining on the line Failure to observe this caution can result in damage to generator set On EMCP set AC CIRCUIT INTERRUPTER switch to OPEN down until press to test green indicator goes out 2 Return UNIT PARALLEL switch to UNIT 3 Set ENGINE CONTROL switch to COOL DOWN STOP Wait 5 minutes with no load 4 Set ENGINE CONTROL switch to OFF RESET 5 Perform all After PMCS requirements WP 0012 00 6 Open rear left housing door and set DEAD CRANK SWITCH to OFF 7 Open battery compartmen
167. od of parallel operation will be used to share the load between two or more generator sets Additional generator sets can be added as necessary by following the same procedures The generator to be brought on line also called the incoming generator is designated TQG No 2 MEP 809A PU 809A 200 kW TQG and MEP 807A PU 807A 100 kW TQG generator sets have the same controls and operating systems These generator sets may be safely paralleled The paralleling procedures describe three different modes of operation AUTO mode SEMI AUTO mode and PERMISSIVE mode AUTO mode is the preferred mode of operation and requires the least operator action SEMI AUTO mode allows the operator to check anything or make manual adjustments prior to connecting generator sets in parallel SEMI AUTO mode may be used if the operator has trouble paralleling the generator sets automatically PERMISSIVE mode requires the operator to manually synchronize the generator sets prior to paralleling using the displays on the GSC and control knobs on the EMCP PERMISSIVE mode is useful for troubleshooting WP 0005 00 2 Pre Operation WARNING D Metal jewelry can conduct electricity and become entangled in generator set components Remove all metal jewelry when working on generator set Failure to comply can cause injury or death to personnel High voltage is produced when this generator set is in operation Make sure unit is completely shut down and free of any power s
168. odule ii PEE RR HERR 0002 00 7 Fuel Tank A HEP 0002 00 7 Generator Housing 0002 00 8 Load a a ere IT Iu 0002 00 3 Main Contactor Eau mide ee nice fueris 0002 00 3 M tller a oia 0002 00 1 NATO Slave Receptacle cunas daicii 0002 00 4 Parallelins Receptacles qui as 0002 00 4 Index 5 9 6115 730 10 INDEX Continued Subject WP Sequence No Page No L Continued Location and Description of Major Components Continued Radiator de eee 0002 00 1 Reconnection np 0002 00 3 Skid Bastidas 0002 00 7 TOTEM 0002 00 7 Trailer Mounted Configuration 809 0002 00 8 Turbochatger dada a CP etg Ue 0002 00 1 W ater PUMP 0002 00 1 Winterization Kit Issued to Selected Units 0002 00 4 M Main Contactor Characteristics A a 0002 00 1 Description ir id Fer 0002 00 3 Maintenance Forms Records and Reports sss ener enne nennen 0001 00 1 Malfunction Symptom Index Introduction eese eene
169. oil pan and through a screen that blocks large objects from entering the oil pump and oil cooler The oil then passes through a spin on type filter where small impurities are removed From the filter oil enters the engine and is distributed to the engine s internal moving parts through internal passageways Oil is also supplied to the turbocharger After passing through the engine the oil returns to the oil pan The lower GSC display indicates oil pressure sensed by the oil pressure sender in the engine The engine will shut off automatically if the oil pressure drops below 30 psi 207 kPa and the red LOW OIL PRESSURE indicator on the GSC will flash The oil level can be checked with the engine running 0003 00 5 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0003 00 THEORY OF OPERATION Continued AIR INTAKE AND EXHAUST SYSTEM WITH TURBOCHARGER AIR FILTER TURBOCHARGER AFTERCOOLER COIL INTAKE MANIFOLD ENGINE COMBUSTION CHAMBER INLET AIR EXHAUST EXHAUST GASES MANIFOLD MUFFLER EXHAUST GASES 200KW 10 107A The air intake and exhaust system consists of an air filter assembly intake manifold turbocharger exhaust manifold and muffler Ambient air is drawn into the air filter assembly where it passes through the air cleaner element Airborne dirt is removed and trapped in the element A restriction indicator located on the air cleaner assembly housing displays red when the air clea
170. on Reconnection Board and reprogram DVR for specified voltage and frequency and reprogram the GSC set points as determined by the mission 0006 00 1 Change 2 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0006 00 OPERATION UNDER USUAL CONDITIONS Continued ASSEMBLY AND PREPARATION FOR USE Continued 6 Army and Air Force Schedule next PMCS on DD Form 314 Preventive Maintenance Schedule and Record 7 Army Report all deficiencies DA Form 5988 E Automated form in the Unit Level Logistics System ULLS Equipment Inspection and Maintenance Worksheet including deficiencies that appear to involve unsatisfactory design When no automation is available use DA Form 2404 Equipment Maintenance and Inspection Worksheet Both forms serve the same purpose Air Force report all deficiencies on SF Form 368 8 Army and Air Force Operator perform PMCS WP 0012 00 Setting Up Trailer Mounted Tactical Quiet Generator Set 1 If TQG set is trailer mounted level trailer per procedures in TM 9 2330 376 14 amp P 2 If TQG is to be installed or it must be removed from XM1061E1 trailer inform maintenance 3 Perform trailer PMCS per TM 9 2330 376 14 amp P Installation of Ground Rod WARNING D Metal jewelry can conduct electricity and become entangled in generator set components Remove all metal jewelry when working on generator set Failure to comply can cause injury or death to personnel High voltage is produced w
171. on alarm module to reset overload fault detection circuit 10 Start and operate WP 0006 00 11 WARNING 1 Monitor TQG for further problems 2 If there is no identifiable problem with the load and alarm recurs notify maintenance Metal jewelry can conduct electricity and become entangled in generator set components Remove all metal jewelry when working on generator set Failure to comply can cause injury or death to personnel 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 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 7 Alarm module GENERATOR OVERLOAD amber indicator flashes TQG disconnects from load 1 Set ENGINE CONTROL switch to OFF RESET Set DEAD CRANK SWITCH to OFF Set Battery Disconnect Switch to OFF Check load connected to TQG to see if there was a problem there that could cause TQG to overload Determine if load is too large for generator set Power requirement cannot be larger than TQG rating Determine if load has been increased 0010 00 7 Repair cause of overload or noti
172. onnected between any terminal and N L1 L2 L3 and L1 to N L2 to N or L3 toN Single phase loads can be connected between any terminal and N L1 L2 L3 and N 15 0006 00 7 200KW 10 215B Change 2 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0006 00 OPERATION UNDER USUAL CONDITIONS Continued ASSEMBLY AND PREPARATION FOR USE Continued Connecting Auxiliary Fuel Hose WARNING Metal jewelry can conduct electricity and become entangled in generator set components Remove all metal jewelry when working on generator set Failure to comply can cause injury or death to personnel WARNING A 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 Avoid repeated or prolonged contact Provide adequate ventilation Operators are to wash exposed skin and change chemical soaked clothing promptly if exposed to fuel Failure to comply can cause injury or death to personnel 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 Fuels used in the generator set are flammable Do not smoke or use open flame
173. oose mountings corrosion chafing and missing parts If coolant level in coolant recovery overflow bottle is above HOT line check for GSC fault HIGH WATER TEMP red 6 Check coolant level at coolant recovery overflow bottle Perform SERVICE if coolant level in recovery overflow bottle is below HOT line if coolant is hot or below COLD line if coolant is cold 7 Close all engine access doors END OF TASK 0015 00 1 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET ENGINE COOLING SYSTEM MAINTENANCE Continued SERVICE 1 On set ENGINE CONTROL switch to OFF RESET 2 Open right side engine access door 3 Remove cap 2 on coolant recovery overflow bottle 1 4 coolant antifreeze in accordance with Table 1 5 Install coolant recovery overflow bottle cap 2 6 Close right side engine access door Table 1 Coolant 0015 00 200KW 10 403 Fill coolant recovery overflow bottle 1 to HOT line if coolant is hot or to COLD line if coolant is cold with proper AMBIE NT TEMPERATURE RADIATOR COOLANT RATIO NOTES 50 to 120 F 45 6 to 49 C 40 to 120 F 4 to 49 C A A 52624 antifreeze water Water with MIL A 53009 corrosion inhibitor Antifreeze 60 Water 40 35 1 This offers the best freeze protection 60 F and the best boil protection 232 F No freeze or boil protection END OF TASK 0015 00 2 9 6115 730 10
174. or working near the generator set when the generator set is running Failure to comply can cause hearing damage to personnel NOTE Perform all DURING PMCS checks every four hours if TQG is operating continuously 12 Perform all DURING PMCS requirements pet WP 0012 00 0006 00 15 Change 2 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0006 00 OPERATION UNDER USUAL CONDITIONS Continued OPERATING PROCEDURES Continued Stopping Procedure 1 To remove load on EMCP set AC CIRCUIT INTERRUPTER 5 switch to OPEN down NOTE ENGINE CONTROL switch may be set to MANUAL START to continue operation by turning counterclockwise 2 SetENGINE CONTROL 2 switch to COOL DOWN STOP This will allow generator set to operate with no load applied for 5 minutes The generator set will shut down automatically 3 Set ENGINE CONTROL 2 switch to OFF RESET 4 Perform all AFTER PMCS requirements pdr WP 0012 00 5 Openleft rear housing door and set DEAD CRANK SWITCH to 0005 00 12 6 Open battery compartment and set Battery Disconnect Switch to OFF WP 0005 00 14 END OF TASK EMERGENCY STOPPING 1 Press PUSH TO STOP EMERGENCY STOP 14 pushbutton to stop generator set 2 Set ENGINE CONTROL switch to OFF RESET END OF TASK Change 2 0006 00 16 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0006 00 OPERATION UNDER USUAL CONDITIONS Continued PARALLEL UNIT OPERATION LOAD SHARING The following meth
175. othing and goggles as required Contact with high pressure steam and or liquids can result in burns and scalding Check for unusual noise being emitted from fan area Check coolant level between COLD and HOT lines in overflow bottle WP 0015 00 0012 00 12 200 kW TACTICAL QUIET GENERATOR SET 0012 00 PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS INCLUDING LUBRICATION INSTRUCTIONS Continued Table 1 Preventive Maintenance Checks and Services Continued LOCATION NOT FULLY ITEM ITEM TO MISSION NO INTERVAL CHECK SERVICE PROCEDURE CAPABLE IF Fuel System WARNING Continued When running winterization heater has hot metal surfaces that will burn flesh on contact Shut down generator set and allow heater to cool before performing maintenance Wear gloves and additional protective clothing as required Failure to comply can cause injury or death to personnel NOTE If the TQG is operating continuously do the DURING PMCS checks every four hours Inspect fuel system for leaks damaged Any fuel leaks damaged loose or missing parts Class III leaks Damaged loose or missing parts Oil level is below hot add oil mark on dipstick Cooling fan is damaged or loose Coolant level is below COLD line 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0012 00 PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS INCLUDING LUBRICATION INSTRUCTIONS Continued Table 1 Preventive Mainte
176. ource before attempting any repair or maintenance on the unit Failure to comply can cause injury or death to personnel High voltage is produced when the generator set is in operation Never attempt to start the generator set unless it is properly grounded Failure to comply can cause injury or death to personnel Before making any connections for parallel operation or moving a generator set that has been operating in parallel ensure there is no input to the load board and the generator sets are shut down Failure to comply can cause injury or death to personnel by electrocution 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 CAUTION Ensure generator sets are the correct size and model before attempting parallel operation MEP 809A PU 809A 200 kW and MEP 807A PU 807A 100 kW generator sets may be paralleled When two or more generator sets are combined their total capacities must be greater than the demand of the electric load If generator set capacities are not rated to support the load drawing power from them damage to equipment may result 0006 00 17 Change 2 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0006 00 OPERATION UNDER USUAL CONDITIONS Continued PARALLEL UNIT OPERATION LOAD SHARING Continued Pre Operation Co
177. panel press CIRCUIT BREAKER and verify that switch is set to ON and indicator is lit 2 Push press to test HEATER indicator light 3 Verify red DIAGNOSTIC light is on If TEST window is not clear when RESET is pressed notify maintenance If load is greater than 15A reduce size of load If no ground fault or overload exists plug equipment back into convenience receptacle If switch is OFF set to ON If indicator does not light notify maintenance Set CIRCUIT BREAKER switch to OFF and notify maintenance END OF TASK 0010 00 9 10 blank 9 6115 730 10 4 OPERATOR MAINTENANCE INSTRUCTIONS FOR 200 kW TACTICAL QUIET GENERATOR SET 9 6115 730 10 4 OPERATOR MAINTENANCE INSTRUCTIONS FOR 200 kW TACTICAL QUIET GENERATOR SET WORK PACKAGE INDEX Title WP Sequence No SERVICE UPON RECEIPT einen nee PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS INCLUDING LUBRICATION INSTRUCTIONS lata CONTROL BOX ASSEMBLY 013 00 ENGINE AIR CLEANER MAINTENANCE 0014 00 ENGINE COOLING SYSTEM MAINTENANCE ccscsssssssssssssssssssscssessssssnssncssnsssesssssesesnsssessnsssesssssnsesnsescensesseeseesses 0015 00 ENGINE FUEL SYSTEM 2 tosta tantes testes
178. passed AUX FUEL switch Two position switch controls auxiliary fuel pump ON Turns on auxiliary fuel pump to supply fuel from external fuel supply Only allows fuel to be consumed from generator set fuel tank 0005 00 3 Change 3 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0005 00 DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS Continued GENERATOR SET CONTROL Table 2 describes the EMCP GSC indicator lights and light emitting diode LED displays 1 2 11 O 2 CATERPILLAR EMERGENCY 4 lane HIGH WATER 2 ol 5 N ENGINE 20 6 OVERSPEED 12 OVERCRANK O LOW COOLANT V LEVEL 8 BATTLE SHORT 9 T gt IN 50 Hz MODE FAULT sumom 16 O Aw fe o 7 G f f GO jJ 13 14 15 16 17 18 19 200KW 10 202A Table 2 Generator Set Control Controls and Indicators 1 LOW OIL PRESSURE Red indicator flashes when oil pressure drops below the programmed low oil pressure shutdown indicator setpoints Engine shuts down and does not run until fault is corrected 2 EMERGENCY STOP Red indicator flashes when PUSH TO STOP EMERGENCY STOP pushbutton is shutdown indicator pressed on control panel Engine shuts down and does not start until pushbutton is pulled out and ENGINE CONTROL switch is set to OFF RESET and back to AUTO or MANUAL START PUSH TO STOP EMERGENCY STOP pushbutton switch can be reset by
179. pletely familiar with manufacturer supplier information and adhere to their procedures recommendations warnings and cautions for safe use handling storage and disposal of these materials FOR FIRST AID REFER TO FM 4 25 11 9 6115 730 10 HEADQUARTERS NO 3 DEPARTMENTS OF THE ARMY AIR FORCE NAVY AND HEADQUARTERS U S MARINE CORPS WASHINGTON DC 15 August 2009 TECHNICAL MANUAL OPERATOR S MANUAL FOR GENERATOR SET SKID MOUNTED TACTICAL QUIET 200kW 50 60 HZ MEP 809A NSN 6115 01 296 1462 GENERATOR SET TRAILER MOUNTED TACTICAL QUIET 200KW 50 60 HZ PU 809A NSN 6115 01 471 7085 DISTRIBUTION STATEMENT A Approved for public release distribution is unlimited TM 9 6115 730 10 dated 15 January 2006 is updated as follows 1 File this sheet in front of the manual for reference 2 This change is a result of correcting a grounding procedure in the Generator set manual 3 New or updated text is indicated by a vertical bar in the outer margin of the page 4 Remove old pages and insert new pages as indicated below Remove Pages Insert Pages Cover blank Cover blank A B blank AJ B blank 5 Replace the following work packages with their revised version Work Package Number Work Package By Order of the Secretary of the Army Official e JOYCE E MORROW Administrative Assistant to the Secretary of the Army 0923208 By Order of the Secretary of the Air Force Official DONALD J
180. ply will be furnished to you CORROSION PREVENTION AND CONTROL CPC Corrosion Prevention and Control CPC of Army materiel is a continuing concern It is important that any corrosion problems with this item be reported so that the problem can be corrected and improvements can be made to prevent the problem in future items Corrosion specifically occurs with metals It is an electrochemical process that causes the degradation of metals It is commonly caused by exposure to moisture acids bases or salts An example is the rusting of iron Corrosion damage in metals can be seen depending on the metal as tarnishing pitting fogging surface residue and or cracking Plastics composites and rubbers can also degrade Degradation is caused by thermal heat oxidation oxygen solvation solvents or photolytic light typically UV processes The most common exposures are excessive heat or light Damage from these processes will appear as cracking softening swelling and or breaking SF Form 368 Product Quality Deficiency Report should be submitted to the address specified in DA PAM 750 8 The Army Maintenance Management System TAMMS User s Manual DESTRUCTION OF ARMY ELECTRONICS MATERIEL Destruction of Army electronics materiel to prevent enemy use shall be in accordance with TM 750 244 2 WARRANTY INFORMATION See WP 0023 for detailed information concerning the Warranty period and list of warranted components Report all defects to your
181. rated current A device intended for the protection of personnel that functions to de energize a circuit or portion thereof within an established period of time when a current to ground exceeds some predetermined value that is less than that required to operate the overcurrent protection device of the supply circuit The TQG convenience receptacle is protected by a GFCI The generator that is being connected to the bus Paralleling mode that requires precise matching of frequency for companion generators Kilovolt One kilovolt equals 1000 volts Kilovolt amperes reactive Measure of reactive power Kilovolt amperes reactive hours Measure of reactive power over time Kilowatt One kilowatt equals 1000 watts Measure of real power Common power conducting wires or bars to which all generator set loads are connected through their individual circuit breakers Any current in excess of the rated current of equipment The condition may result from overload short circuit or ground fault The procedure for synchronizing and connecting two or more generator sets to a common load bus Power flows from one generator set into another generator set when operating in parallel For the TQGs reverse shutdown power occurs when reverse power exceeds 17 of rated value Glossary 1 9 6115 730 10 GLOSSARY Continued TERM DEFINITION TQG control circuit Primarily consists of 24 VDC circuitry meters and controls for gener
182. rator set in an enclosed area unless exhaust discharge is properly vented outside Failure to comply can cause injury or death to personnel 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 Exhaust system can get very hot Shut down generator set and allow system to cool before performing checks services and maintenance Failure to comply can cause severe burns and injury to personnel WARNING Exhaust system can get very hot When performing DURING PMCS wear gloves and additional protective clothing as required Failure to comply can cause severe burns and injury to personnel WARNING When running winterization heater has hot metal surfaces that will burn flesh on contact Shut down generator set and allow heater to cool before performing maintenance Wear gloves and additional protective clothing as required Failure to comply can cause injury or death to personnel 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 9 6115 730 10 WARNING SUMMARY Continued WARNING Top housing panels can get very hot When performing DURING PMCS wear gloves and additional protective clothing as required Failure to comply can result in severe burns to personnel WARNING Eye pro
183. red plunger returns to clear body of indicator remove outer filter element repeat steps 1 thru 8 17 If green has disappeared from window in indicator nut 6 notify maintenance to replace filter elements 0014 00 3 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET ENGINE AIR CLEANER MAINTENANCE Continued SERVICE Continued lt gt 5 NR UKR ES N END OF TASK 0014 00 4 200KW 10 410 0014 00 200 kW TACTICAL QUIET GENERATOR SET ENGINE COOLING SYSTEM MAINTENANCE THIS WORK PACKAGE COVERS Inspection Service INITIAL SETUP Maintenance Level Ope rator Tools and Special Tools None Personnel Required One TM 9 6115 730 10 WARNING 0015 00 References None Materials Parts Antifreeze A A 52624 item 1 WP 0022 00 Corrosion inhibitor MIL A 53009 item 5 WP 0022 00 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 or death to personnel INSPECTION 1 EMCP set ENGINE CONTROL switch to OFF RESET Open all engine access doors A 2 Po indicator flashing WP 0010 00 Check fan guards and shroud for dirt and debris blocking air flow Check radiator and hoses for leaks loose connections l
184. ree of any power source before attempting any repair or maintenance on the unit Failure to comply can cause injury or death to personnel 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 6 Alarm module OVERCURRENT amber indicator flashes TQG disconnects from load 1 Set ENGINE CONTROL switch to OFF RESET Set DEAD CRANK SWITCH to OFF Set Battery Disconnect Switch to OFF Check load connected to TQG to see if there was a problem there that could cause TQG to go overcurrent Inspect cables to load for shorts broken insulation exposed wires signs of overheating or failed components Determine if load is too large for generator set Power requirement cannot be larger than TQG rating Set Battery Disconnect witch to ON Set DEAD CRANK SWITCH to NORMAL Set ENGINE CONTROL switch to STOP COOL DOWN 0010 00 6 Repair cause of overcurrent or notify maintenance Reduce load as necessary 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR 0010 00 TROUBLESHOOTING Continued Table 1 Operator Troubleshooting Continued MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION 6 Alarm module OVERCURRENT amber indicator flashes TQG disconnects from load Continued 9 Press LAMP TEST
185. rements for TM 9 6115 730 10 083008 000 This fine document Was brought to you by me Liberated Manuals free army and government manuals Why do I do it I am tired of sleazy CD ROM sellers who take publicly available information slap watermarks and other junk on it and sell it Those masters of search engine manipulation make sure that their sites that sell free information come up first in search engines They did not create it They did not even scan it Why should they get your money Why are not letting you give those free manuals to your friends I am setting this document FREE This document was made by the US Government and is NOT protected by Copyright Feel free to share republish sell and so on I am not asking you for donations fees or handouts If you can please provide a link to liberatedmanuals com so that free manuals come up first in search engines lt A HREF http www liberatedmanuals com gt Free Military and Government Manuals lt A gt Sincerely Igor Chudov http igor chudov com
186. reshold 160 of nameplate current Reverse power shutdown 15 to 17 0002 00 11 12 blank 200 kW TACTICAL QUIET GENERATOR SET THEORY OF OPERATION GENERAL TM 9 6115 730 10 0003 00 This work package contains functional descriptions of the generator set and explains how TQG functional systems interact with one another ENGINE STARTING SYSTEM DC AMMETER NATO SLAVE CHARGING RECEPTACLE CURRENT DEAD amp amp ALTERNATOR CRANK SWITCH gt gt e BT4 BT2 BT3 BT1 ENGINE STARTER 4 BATTERY STARTER DISCONNECT CONTROL SWITCH c GROUND ENGINE ENGINE CONTROL DATA EMCP PUSH TO STOP EMERGENCY STOP POWER 200KW 10 103A The engine starting system consists of four 12 volt batteries connected in series and parallel a 24 Vdc starter a 24 volt battery charging alternator a magnetic pickup for sensing engine speed and the related switches and relays described below required for control of the starting system The PUSH TO STOP EMERGENCY STOP pushbutton on the EMCP will automatically disable the starting system and shut down the TQG if it is pushed in For engine cranking battery power is supplied to the starter motor through the starter solenoid whi
187. s 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 NOTE Fuel tank holds 128 gallons 485L The following procedure is for using an external fuel source 1 On EMCP set ENGINE CONTROL switch to OFF RESET 2 At DIESEL FUEL fill port 16 remove protective cap and attach auxiliary fuel hose 17 to fuel connection marked EXTERNAL FUEL SUPPLY and to external fuel source Change 2 0006 00 8 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0006 00 OPERATION UNDER USUAL CONDITIONS Continued ASSEMBLY AND PREPARATION FOR USE Continued Connecting Auxiliary Fuel Hose Continued END OF TASK 0006 00 9 EXTERNAL FUEL SUPPLY 30554 88 20102 100 10 217 2 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0006 00 OPERATION UNDER USUAL CONDITIONS Continued INITIAL ADJUSTMENTS BEFORE USE AND SELF TEST Initial Adjustments 1 Open right rear side access door and ensure voltage Reconnection Board WP 0005 Table 9 is set to match voltage requirements of load WP 0006 Table 1 If voltage Reconnection Board must be changed and GSC and DVR must be programmed to give required output notify maintenance 2 Ifusing external fuel supply connect auxiliary fuel supply hose per WP 0006 00 6 3 Open left rear generator housing door and set DEAD CRANK SWITC
188. sheet 3 item 20 0002 00 4 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET EQUIPMENT DESCRIPTION AND DATA Continued LOCATION AND DESCRIPTION OF MAJOR COMPONENTS Continued O E EE EE FUEL FIRED HEATER CONTROL 2 2 9 CIRCUIT BREAKER 8 20 CATERPILLAR Of O T4 Ja vum pe 20000 ome 0000 ooo Mee LONE Um Em Um E 2 O Bee OFF 6 f AUTO FREQUENCY VOLTAGE BATTLE SHORT AUX FUEL 9 9 Orr OFF OPEN AC CIRCUIT ENGINE CONTROL INTERRUPTER or PUSH TO STOP NEUE EMERGENCY STOP e e EN DOWN AUTO STOP Y e e MANUAL START 0002 00 O PARALLELING O RECEPTACLES GROUND FAULT O CIRCUIT INTERRUPTER 19 120 VOLTS 15 AMPS 60HZ 00000000 200KW 10 102 3B Figure 1 200 kW Tactical Quiet Generator Location of Components Sheet 3 0002 00 5 9 6115 730 10 0002 00 200 kW TACTICAL QUIET GENERATOR SET EQUIPMENT DESCRIPTION AND DATA Continued LOCATION AND DESCRIPTION OF MAJOR COMPONENTS Continued i 30554 88 2177 DEAD CRANK SWITCH 3QREF 102 4 ig 200KW
189. sssesssessseesecssessecees Warranty Information srsosssorssonsnnsnonsnonsnnsnnnsnnssnnssnnsnnnsnnssnnsnnssnnssnnesnnsnnssnnssnnsnnssnnssnnesnsnssnsnanssnnssnsansnansnansnnne LEONE WIS er 9 6115 730 10 HOW USE THIS MANUAL This manual contains operator instructions for the 200 kW Tactical Quiet Generator Set TQG Skid Mounted MEP 809A and for the Tactical Quiet Generator Set Trailer Mounted PU 809A The TQG can be mounted on a 5 ton trailer Model XM1061E1 Detailed operation and maintenance information for the trailer is in TM 9 2330 376 14 amp P Refer to References work package WP 0019 00 located ih Chapter 4 for a listing of other related manuals This Operator s Manual is part of a family of manuals which includes a Unit Direct Support and General Support Maintenance Manual TM 9 6115 730 24 and a Repair Parts and Special Tools Lists RPSTL Manual TM 9 61 15 730 24P These manuals implement the Army Maintenance Transformation and change the Maintenance Allocation Chart MAC to support Field and Sustainment Maintenance under the new Two Level Maintenance Concept This manual is written in Work Package WP format The Table of Contents will help you understand the organization of the manual and will direct you to the major sections It lists the specific work packages contained in each chapter Details such as operational instructions or information about parts of the
190. supervisor who will take appropriate action NOMENCLATURE CROSS REFERENCE LIST Nomenclature for common names is listed alphabetically with a cross reference to the official nomenclature i e Maintenance Allocation Chart MAC Repair Parts and Special Tools Lists RPSTL Common Name Official Nomenclature 200 kW TQG Generator Set Skid Mounted Tactical Quiet 200 kW 50 60 Hz MEP 809A Generator Set Trailer Mounted Tactical Quiet 200 kW 50 60 Hz PU 809A LIST OF ABBREVIATIONS ACRONYMS Abbreviation Acronym Definition AAL Additional Authorization List AC Alternating Current AMP Ampere ATLASS Asset Tracking Logistics and Supply System AUX Auxiliary BAT Battery BII Basic Issue Items BIT Built in Test CAGE Commercial and Government Entity CBR Chemical Biological and Radiological Change 2 0001 00 2 200 kW TACTICAL QUIET GENERATOR SET GENERAL INFORMATION Continued TM 9 6115 730 10 0001 00 LIST OF ABBREVIATIONS ACRONYMS Continued Abbreviation Acronym CCW Counterclockwise COEI CPC CTA CW Clockwise DC Direct DVR ECM EMI Electrom EMCP ESD Electrostatic GFE GFCI GND Ground GSC Hz kPa KiloPascal KVAR Kilovolt am KVARHr Kilovolt am kVA Kilovolt am kWh Kilowatt kW Kilowatt JTA LCD LED MAC MTOE NATO NBC PF Power PMCS PN Part PQDR RPSTL SDR SOS TAMMS TDA TDR Transportation Technical Definition Components of End Item Corrosion Prevention an
191. t TRAILER MOUNTED CONFIGURATION PU 809A The skid mounted can be mounted a model 1061 1 5 ton trailer 37 In this configuration the can towed and positioned as required In the power unit configuration the trailer mounted TQG has an accessory box 38 and two fire extinguishers 39 The TQG skid is bolted directly to the trailer bed and frame C2 200KW 10 102 6D Figure 1 200 kW Tactical Quiet Generator Location of Components Sheet 6 0002 00 8 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0002 00 EQUIPMENT DESCRIPTION AND DATA Continued EQUIPMENT DATA Table 1 lists equipment data for the 200 kW Table 1 200 kW Equipment Data 200 kW Tactical Quiet Generator Set Overall length Width Height Weight Wet includes fuel Dry Engine Manufacturer Model Type Horsepower Displacement Valves per cylinder Valve lash setting cold engine Cooling system Type Capacity Normal operating temperature Temperature indicating system voltage Lubricating system Type Pump type Capacity Normal operating pressure Fuel system Fuel type Fuel tank capacity Consumption rate Auxiliary fuel pump Manufacturer Voltage rating Delivery rate 809 114 in 290 cm 50 in 127 cm 75 in 191 9300 Ib 4218 kg 8200 Ib 3719 kg Caterpillar 0116 2110 Six cylinder in line four cycle turbocharged diesel 39
192. t Failure to comply can cause injury or death to personnel 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 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 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 0006 00 11 Change 2 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0006 00 OPERATION UNDER USUAL CONDITIONS Continued OPERATING PROCEDURES Continued NOTE If generator set is to be operated in parallel with another unit refer to PARALLEL UNIT OPERATION WP 0006 00 17 Starting 1 D High voltage is produced when the generator set is in operation Never attempt to start the generator set unless it is properly grounded Failure to comply can cause injury or death to personnel WARNING Operating the generator set exposes personnel to a high noise level Hearing protection must be worn when operating or working near the generator set when
193. t and set Battery Disconnect Switch to OFF 8 Push in PUSH TO STOP EMERGENCY STOP pushbutton END OF TASK 0006 00 25 Change 2 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0006 00 OPERATION UNDER USUAL CONDITIONS Continued DECALS AND INSTRUCTION PLATES U S DEPARTMENT OF DEFENSE NATO STANDARD OTAN CAUTION u GENERATOR SET DIESEL ENGINE 200KW 50 60HZ HEARING PROTECTION MODEL 0116 2000 NSN 5115 01 290 1462 REQUIRED WHEN SERNO 1 O NAVFAC 19 50 OPERATING THE SET T a VOLTS 120 208V 3PH 240 416V 3PH 50 60 HZ AMPS 694 347 60HZ 578 289 50HZ PF 08 DRY WT 8200 LB LG 114 IN W 50 IN HGT 75 iN DATE MFD CONTR NO DAABO7 00 D B207 WARRANTY DATE INSP FERMONT INSP STAMP CAUTION HIGH INTENSITY NOISE HEARING PROTECTION REQUIRED WITHIN 11 FEET REAR WARNINGS CAUTIONS LABELS m Change 2 0006 00 26 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET OPERATION UNDER USUAL CONDITIONS Continued DECALS AND INSTRUCTION PLATES Continued CAUTION TO AVOID SHOCK HAZARD SET FRAME MUST BE GROUNDED CONNECT AWG NO 6 OR LARGER FROM SET GROUND GND TERMINAL TO EARTH GROUND BATTERY NEGATIVE TERMINAL IS CONNECTED TO CHASSIS GROUND WHEN BDS BAT
194. t appears on the equipment Call out numbers on the illustrations are keyed to the tabular listing which contains the name based on the panel markings and the functional description of each control and indicator ELECTRONIC MODULAR CONTROL PANEL Table 1 describes the controls and indicators located on the Electronic Modular Control Panel EMCP The EMCP includes the Generator Set Control GSC 1 Digital Voltage Regulator DVR 10 and alarm module 9 These three components are illustrated and described separately in this work package 10 6 7 0 __ CATERPILLAR pea 88 88 om S v OF O oom cars O 2 Oc O o ol bad CATERPILLAR AO weg O atten 10 ZA um EMERGENC SIOP o M 16 15 14 15 12 11 1 GSC display module GSC monitors generator operation and controls engine speed to maintain a constant 50 or 60 Hz output regardless of load Refer to Table 2 for controls and indicators 2 PANEL LIGHTS Two position toggle switch ON Control panel lights are lit OFF Control panel lights are out 3 Fuel level gauge Indicates fuel level 0005 00 1 Change 3
195. t with canvas or other waterproof material when it is not being operated 2 Keep all generator access doors closed as much as possible to prevent entry of salt water into housing assembly 3 Wash exterior surfaces frequently with clean water when generator set is not operating 4 Check wiring connections for corrosion and wire insulation for signs of deterioration END OF TASK OPERATION AT HIGH ALTITUDES Generator set will operate at elevations up to 4 000 feet 1219 1m above sea level without special adjustment or reduction in load At elevations greater than 4 000 feet 1219 1m above sea level kilowatt rating is reduced approximately 3 5 percent for each additional 1 000 feet 304 8m END OF TASK 0007 00 5 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0007 00 OPERATION UNDER UNUSUAL CONDITIONS Continued OPERATION USING BATTLE SHORT SWITCH CAUTION Continued operation using the BATTLE SHORT switch can result in damage to the generator set NOTE If any emergency situation requires continued operation of the generator set the BATTLE SHORT switch is used to override all protection devices except the overspeed short circuit devices and EMERGENCY STOP function BATTLE SHORT switch must be OFF to start generator set 1 On set BATTLE SHORT switch to OFF 2 set ENGINE CONTROL switch to MANUAL START 3 Once generator set starts lift cover on BATTLE SHORT switch and set to ON CAUTIO
196. tection is required when working with compressed air Compressed air can propel particles at high velocity and injure eyes Do not exceed 15 psi pressure when using compressed air Failure to comply could cause serious injury to personnel WARNING Cleaning compound is toxic Avoid prolonged breathing of vapors Use only in a well ventilated area Failure to comply can cause serious injury to personnel WARNING Breathing ether fumes can cause fainting Do not manually discharge or deliberately inhale ether Failure to comply can cause injury to personnel WARNING When disconnecting or removing batteries disconnect the negative lead that connects directly to the grounding stud first Disconnect the negative end of the interconnection cable next When installing batteries reverse the connection sequence Failure to comply can cause serious personal injury 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 WARNING This manual describes physical and chemical processes that may require the use of chemicals solvents paints or other commercially available material Users of the manual should obtain the material safety data sheets Occupational Safety and Health Act OSHA Form 20 or equivalent from the manufacturers or suppliers of materials to be used Users must be com
197. th to personnel and damage to the generator set WARNING Hot engine surfaces from the engine and generator circuitry are possible sources of ignition When hot refueling with DF 1 DF 2 JP5 or JP8 avoid fuel splash and fuel spill Do not smoke or use open flame when performing refueling Remember PMCS is still required Failure to comply can result in flames and possible explosion and can cause injury or death to personnel and damage to the generator set 9 6115 730 10 WARNING SUMMARY Continued WARNING If necessary to move a generator set that has been operating in parallel with another generator set shut down all generator sets prior to removing load cables or ground Failure to comply can cause injury or death to personnel by electrocution WARNING Before making any connections for parallel operation or moving a generator set that has been operating in parallel ensure there is no input to the load board and the generator sets are shut down Failure to comply can cause injury or death to personnel by electrocution 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 or death to personnel WARNING Cooling system operates at high temperature and pressure When performing DURING PMCS
198. the number is a parameter value Used to change information shown on display FOR MAINTENANCE PERSONNEL USE ONLY Function key used to toggle between parameter code and parameter value for the code and to enter new code or value into DVR memory Scroll down key is used to move down to previous parameter code or decrease value Scroll up key is used to move up to next parameter code or increase value Change 3 0005 00 10 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0005 00 DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS Continued RESISTOR ASSEMBLY A7 Table 5 describes controls located on resistor assembly A7 Resistor assembly A7 is located inside the control box assembly behind the EMCP UN 9 ISOCHRONOUS DROOP CRFF DC CONTROL oT 200KW 10 207A Table 5 Resistor Assembly A7 Controls KEY CONTROL OR INDICATOR FUNCTION ISOCHRONOUS DROOP switch Two position toggle switch Used for frequency stabilization circuits and TQG paralleling functions ISOCHRONOUS Up position used for generator constant 50 60 Hz operation DROOP Down position will accommodate fluctuations for under load conditions DC CONTROL POWER When pushed in circuit breaker supplies 24 Vdc power to GSC 0005 00 11 Change 3 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0005 00 DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS Continued DEAD CRANK SWITCH Tabl
199. the initial distribution number IDN 256884 requirements for TM 9 6115 730 10 9 6115 730 10 INSERT LATEST UPDATED PAGES WORK PACKAGES DESTROY SUPERSEDED DATA LIST OF EFFECTIVE PAGES WORK PACKAGES NOTE The portion of text affected by the updates is indicated by a vertical line in the outer margins of the page Updates to illustrations are indicated by miniature pointing hands and or vertical lines Updates to wiring diagrams are indicated by shaded boxes Dates of issue for original and updated pages work packages are 0 15 January 2006 Change 3 15 August 2009 1 1 February 2007 2 15 2009 TOTAL NUMBER OF PAGES FOR FRONT AND REAR MATTER IS 36 AND TOTAL NUMBER OF WORK PACKAGES IS 23 CONSISTING OF THE FOLLOWING Page WP Change Page WP Change No WP 0008 00 2 pgs WP 0009 00 8 pgs WP 0010 00 10 pgs Chp 4 Title Page Chp 4 Index WP 0011 00 2 pgs WP 0012 00 16 pgs WP 0013 00 4 pgs Chp 1 Title Page WP 0014 00 4 pgs Chp 1 Index WP 0015 00 2 pgs WP 0001 00 4 pgs WP 0016 00 4 pgs WP 0002 00 12 pgs WP 0017 00 2 pgs WP 0003 00 8 pgs WP 0018 00 2 pgs WP 0004 00 2 pgs Chp 5 Title Page Chp 2 Title Page Chp 5 Index Chp 2 Index WP 0019 00 WP 0005 00 18 pgs WP 0020 00 WP 0006 00 38 pgs WP 0021 00 WP 0007 00 6 pgs Chp 3 Title Page Chp 3 Index WP 0008 00 WP 0009 00 Zero in this column indicates an original page or work package
200. there are new editions changes or additional publications pertaining to the equipment MAINTENANCE FORMS RECORDS AND REPORTS 1 Army Department of the Army forms and procedures used for equipment maintenance will be those prescribed by as applicable DA PAM 750 8 The Army Maintenance Management System TAMMS Users Manual DA PAM 738 751 Functional Users Manual for the Army Maintenance Management Systems Aviation 5 or AR 700 138 Army Logistics Readiness and Sustainability 2 Marine Corps Maintenance forms and records used by Marine Corps personnel are prescribed by TM 4700 15 1 3 Air Force Maintenance forms and records used by Air Force personnel are prescribed in 21 101 and the applicable TO 00 20 Series Technical Orders 4 Navy Navy users should refer to their service peculiar directives to determine applicable maintenance forms and records to be used REPORTING OF ITEM AND PACKAGING DISCREPANCIES Army and Air Force users fill out and forward SF 364 Supply Discrepancy Report SDR as prescribed in AR 735 11 2 DLAR 4140 55 SECNAVINST 4355 18A AFJ 23 215 4430 3J TRANSPORTATION DISCREPANCY REPORT TDR DD 361 Fill out and forward Transportation Discrepancy Report TDR DD 361 as prescribed by Federal Property Management Regulation FPMR Code of Federal Regulations Title 41 Chapter 101 Public Contracts and Property Management REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS
201. tify maintenance Notify maintenance Notify maintenance Notify maintenance Notify maintenance Notify maintenance Notify maintenance Notify maintenance Notify maintenance Notify maintenance Notify maintenance Notify maintenance Notify maintenance Notify maintenance Notify maintenance Notify maintenance Notify maintenance Notify maintenance Notify maintenance Notify maintenance Notify maintenance Notify maintenance 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR MALFUNCTION SYMPTOM INDEX Continued 0009 00 Malfunction Symptom Work Package and Page No 132 133 134 135 136 137 CID 1169 FMI 02 AC Transformer Box Sensor Erratic Intermittent or Incorrect Signal CID 1170 02 Bus Transformer Box Sensor Erratic Intermittent or Incorrect Signal CID 1170 04 Bus Transformer Box BTB Sensor Voltage Below Normal CID 1170 08 Bus Transformer Box Sensor Abnormal frequency pulse width or period CID 1589 E FMI03 Turbocharger Air Inlet Pressure Sensor Voltage Above Normal CID 1589 04 Turbocharger Air Inlet Pressure Sensor Voltage Below Normal Notify maintenance Notify maintenance Notify maintenance Notify maintenance Notify maintenance Notify maintenance 0009 00 7 8 blank 9 6115 730 10 200 kW TACTICAL QUIET GENER
202. tify maintenance Notify maintenance Notify maintenance Notify maintenance Notify maintenance Notify maintenance Notify maintenance Troubleshoot as Malfunction 8 0010 00 8 Notify maintenance Notify maintenance Notify maintenance Notify maintenance Notify maintenance Notify maintenance Notify maintenance 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR MALFUNCTION SYMPTOM INDEX Continued Malfunction Symptom Work Package and Page No 31 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 701 Undervoltage Shutdown 702 Overvoltage Shutdown 703 Overexcitation Shutdown 704 Reverse VAR Shutdown 705 Reverse Power Shutdown 801 Instantaneous Trip Shutdown 802 Loss of Sensing Shutdown 803 Loss of Frequency Shutdown 9xx Severe Fault There are several possible failures in the 900 s All require replacement of the DVR GSC Fault Codes including Engine Control Module ECM Codes and Event Codes Sorted in CID Number Sequence CID 1 E FMI 11 Cylinder 1 Failure mode is not identifiable Mechanical Failure Logged CID 2 E FMI 11 Cylinder 2 Failure mode is not identifiable Mechanical Failure Logged CID 3 E FMI 11 Cylinder 3 Failure mode is not identifiable Mechanical Failure Logged CID 4 E FMI 11 Cylinder 4 Failure mode is not identifiable Mechanical Failure Logged CID 5 E
203. ting 0005 00 5 Change 3 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0005 00 DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS Continued GENERATOR SET CONTROL Continued Table 2 Generator Set Control Controls and Indicators Continued CONTROL OR KEY INDICATOR FUNCTION PROG PH B C SERV TOTAL KVAHZ i COUNT MID 200KW 10 203 11 Upper display Shows AC voltage current and frequency of one phase of generator output Each Normal Operation phase be viewed at a time by pushing AC METER key 14 at bottom of GSC Upper display also displays diagnostic codes for system faults Refer to Keypad descriptions 13 thru 19 for more information Upper display NOTE Synchroscope for Parallel Operation Active during paralleling only In paralleling modes upper display toggles between bus and incoming generator phase C A voltage and frequency Right side display shows bUS or GEn Pressing AC METER key 14 stops cycle 200KW 10 204A 12 Lower display When POWER METER key 13 is pressed displays values for power metering When ENGINE METER key 15 is pressed displays system battery voltage engine hours engine speed engine oil pressure and engine coolant temperature Each value is shown for two seconds A small pointer that lines up with the icon for the condition indicates the value shown Refer to Keypad description for more information Change 3 0005 0
204. ting Auxiliary Equipment 0006 00 36 Operating Proced res MD P 0006 00 11 Parallel Unit Operation Load Sharing nase nn 0006 00 17 Preparation for MovYetuent oco ee oar 0006 00 37 Shelter Requirements adornos uM La Mea 0006 00 1 Siting Requirements esee eite ree 0006 00 1 Operation Under Unusual Conditions sess enne enne enn ennt 0007 00 1 Operation at High Altitudes ic cis cei terret ne re e HATH E Ee ee Ee oe desear 0007 00 5 Operation in Extreme Cold Weather Below 25 F 390 0007 00 1 Operation in Extreme Heat Above 120 F 49 0007 00 3 Operation in Dusty or Sandy 0007 00 4 Operation in Salt Water Areas 0007 00 5 Operation of Winterization Kit Fuel Fired 0007 00 2 Operation Under Rainy or Humid 8 0007 00 4 Operation Using Battle Short Switch 0007 00 6 Operation While Contaminated nennen 0007 00 6 P Q Parallel Unit
205. ting Oil Internal Combustion Engine OE HDO 15 40 55 gallon 81349 MIL PRF 2104 Lubricating Oil Internal Combustion Engine OE HDO 40 1 gallon 81349 MIL PRF 2104 Turbine Fuel Aviation 55 gallon 58536 MIL PRF 5624 JP5 Turbine Fuel Aviation 81349 MIL T 83133 JP8 Wiping Rag Cotton and Cotton Synthetic 81348 DDD R 0030 Grade B 0022 00 2 9 6115 730 10 200 KW TACTICAL QUIET GENERATOR SET 0023 00 WARRANTY INFORMATION INTRODUCTION This appendix provides information of the Warranty for generator set components See Table One for list of warranted components NOTE Check the Inspection Date on the end item data place on the generator set If the Inspection Date is prior to 09 06 the 12 month Warranty period shall begin on 08 3 1 06 If the Inspection Date on the data plate is 09 06 or after the standard 12 month Warranty begins on the date stamped Warranty service may be obtained through the following methods 1 a ARMY ONLY Fill out the preferred warranty claim SF 368 Product Quality Deficiency Report or fill out a warranty claim per DA PAM 738 750 The DA Form 2407 Maintenance Request is also acceptable Mail completed form to Commander US Army Communications Electronics Life Cycle Management Command ATTN AMSEL LC CCS G GN 1200 Nealis Avenue Fort Monmouth New Jersey 07703 5043 At a minimum the end item NSN Serial number and date of shipment to the government and the defective
206. to be checked or serviced PROCEDURE This column provides brief description of procedure as well as any information required to accomplish each check or service NOT FULLY MISSION CAPABLE IF This column lists condition that would cause 200 kW TQG to be less than fully ready to perform its assigned mission 0012 00 3 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0012 00 PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS INCLUDING LUBRICATION INSTRUCTIONS Continued Table 1 Preventive Maintenance Checks and Services LOCATION NOT FULLY ITEM ITEM TO MISSION NO INTERVAL CHECK SERVICE PROCEDURE CAPABLE IF GENERATOR SET 1 Before NATO Slave Connector WARNING Slave receptacle NATO connector is electrically live at all times and is unfused The Battery Disconnect Switch does not remove power from the slave receptacle NATO slave receptacle has 24 VDC even when disconnect switch is set to OFF This circuit is only dead when the batteries are fully disconnected Disconnect the batteries before performing maintenance on the slave receptacle Failure to comply can cause injury or death to personnel Check for cracked or broken NATO slave NATO slave connector or other damage connector is cracked or broken 2 Before Overall Exterior Check external doors panels hinges and Cannot shut doors latches for damaged loose or corroded items CAUTION Operating the generator set with restricted airflow for cooling can c
207. uiring special handling to protect them from electrostatic discharge ESD This manual describes physical and chemical processes that may require the use of chemicals solvents paints or other commercially available material Users of the manual should obtain the material safety data sheets Occupational Safety and Health Act OSHA Form 20 or equivalent from the manufacturers 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 Change 2 0001 00 4 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0002 00 EQUIPMENT DESCRIPTION AND DATA EQUIPMENT CHARACTERISTICS CAPABILITIES AND FEATURES The 200 kW Tactical Quiet Generator TQG is skid mounted and is designated MEP 809A When the 200 kW TQG is mounted on a trailer it is designated PU 809A The TQG consists of a diesel engine that can operate using diesel fuel or aviation fuel a brushless AC generator a digital voltage regulator DVR an electronic governing system a fuel system a 24 cranking system a control system a protection system and other devices as described below to achieve a complete engine driven generator set The system uses the Caterpillar C 12 engine and a Marathon generator model DOD 751 FR The engine is electronically controlled The electronic control is essent
208. ure indicator lights up When press to test indicator is released light should go out WP 0005 00 3 6 Ifequipped with winterization kit press HEATER press to test lamp on FUEL FIRED HEATER CONTROL panel Indicator should light WP 0005 00 17 END OF TASK Change 2 0006 00 10 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0006 00 OPERATION UNDER USUAL CONDITIONS Continued NATO SLAVE RECEPTACLE START OPERATION WARNING Slave receptacle NATO connector is electrically live at all times and is unfused The Battery Disconnect Switch does not remove power from the slave receptacle NATO slave receptacle has 24 VDC even when disconnect switch is set to OFF This circuit is only dead when the batteries are fully disconnected Disconnect the batteries before performing maintenance on the slave receptacle Failure to comply can cause injury or death to personnel NOTE The NATO slave receptacle can be used to start the generator set when batteries are discharged Connect one end of NATO slave cable to fully charged 24 Vdc system and other end to discharged generator set NATO SLAVE RECEPTACLE 2 On EMCP of discharged TQG set ENGINE CONTROL switch to MANUAL START to start generator 3 Remove NATO slave cable after generator set starts END OF TASK OPERATING PROCEDURES D Metal jewelry can conduct electricity and become entangled in generator set components Remove all metal jewelry when working on generator se
209. urfaces that will burn flesh on contact Shut down generator set and allow engine to cool before checks services and maintenance Wear gloves and additional protective clothing as required Failure to comply can cause injury or death to personnel WARNING Operating the generator set exposes personnel to a high noise level Hearing protection must be worn when operating or working near the generator set when the generator set is running Failure to comply can cause hearing damage to personnel 0010 00 2 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR 0010 00 TROUBLESHOOTING Continued TROUBLESHOOTING Table 1 Operator Troubleshooting MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION 1 EMCP AC CIRCUIT Press AC CIRCUIT INTERRUPTER If AC CIRCUIT INTERRUPTER INTERRUPTER lamp does not press to test lamp press to test lamp does not light light when is connected to load 2 EMCP panel lamp is not lit 1 Open EMCP door and inspect wiring to lamps for loose connections or damaged wires 2 If wiring is not broken perform CORRECTIVE ACTION WARNING replace light bulb WP 0013 00 If AC CIRCUIT INTERRUPTER press to test lamp lights notify maintenance If wiring is loose or broken notify maintenance 1 Replace lamp WP 0013 00 2 Ifreplacing lamp does not correct problem notify maintenance Operating the generator set exposes personnel to a high noise level
210. vel drops below probe of coolant loss sensor Engine shuts down and does not start until fault is corrected Yellow indicator lights when BATTLE SHORT switch is set to ON Indicates TQG is operating in battle short condition Yellow indicator lights when TQG is in 50 Hz mode NOTE When UNIT PARALLEL switch is set to PARALLEL FUNCTION the indicators display the following Yellow indicator flashes in paralleling mode until TQG and paralleling bus voltages are within acceptable limits Yellow indicator lights when voltages match Yellow indicator flashes in paralleling mode until TQG and paralleling bus frequencies are within acceptable limits Yellow indicator lights when frequencies match Yellow indicator flashes in paralleling mode until TQG and paralleling bus phases are within acceptable limits Yellow indicator lights when phases match Red indicator flashes when GSC detects a fault that is a shutdown fault If engine is running it is shut down The engine will not start A diagnostic code is displayed on upper GSC display 11 Diagnostic codes are described i Troubleshooting Yellow light flashes when GSC detects an alarm fault Alarm fault does not cause engine status to change and engine will continue to run If engine was not started it may be started A diagnostic code is displayed on upper GSC display 11 when ALARM CODES 17 key at bottom of GSC is pressed Diagnostic codes are described Chapter 3 Troubleshoo
211. vity and location Include ZIP Code PART I ALL PUBLICATIONS EXCEPT RPSTL AND SC SM AND BLANK FORMS PUBLICATION FORM NUMBER PARA FIGURE ITEM P GRAPH LINE TABLE RECOMMENDED CHANGES AND REASON TYPED NAME GRADE OR TITLE TELEPHONE EXCHANGE AUTOVON SIGNATURE PLUS EXTENSION DA FORM 2028 FEB 74 REPLACES DA FORM 2028 1 DEC 68 WHICH WILL BE USED APD V4 00 Forward to proponent of publication or form Include ZIP Code FROM Activity and location Include ZIP Code PART Il REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS SUPPLY MANUALS PUBLICATION FORM NUMBER DATE TITLE TOTAL NO OF MAJOR PAGE COLM LINE NATIONAL STOCK REFERENCE FIGURE ITEM ITEMS RECOMMENDED ACTION NO NO NO NUMBER NO NO NO SUPPORTED PART III REMARKS Any general remarks or recommendations or suggestions for improvement of publications and blank forms Additional blank sheets may be used if more space is needed TYPED NAME GRADE OR TITLE TELEPHONE EXCHANGE AUTOVON SIGNATURE PLUS EXTENSION APD V4 00 RECOMMENDED CHANGES PUBLICATIONS AND Use Part Il reverse for Repair Parts and BLANK FORMS Special Tool Lists RPSTL and Supply For use of this form see AR 25 30 the proponent agency is OAASA Catalogs Supply Manuals SC SM TO Forward to proponent of publication or form Include ZIP Code FROM Activity and location Include ZIP Code PART I ALL PUBLICATIONS EXCEPT RPSTL AND SC SM AND BLANK FORMS PUBLICATION
212. w steady yellow shut down the generator sets Check that load cables are connected properly Repeat steps 1 thru 10 above On incoming No 2 EMCP adjust VOLTAGE potentiometer until yellow V indicator on GSC stops flashing AC CIRCUIT INTERRUPTER switch cannot be set to CLOSE unless voltage is stable On incoming TQG No 2 adjust FREQUENCY potentiometers as necessary to match generator set frequencies On GSC lower display observe that the square symbol on synchroscope of TQG No 2 stops rotating Clockwise rotation indicates that frequency of TQG No 2 power is higher than load bus Counterclockwise rotation indicates that frequency of TQG No 2 power is less than load bus NOTE When the square synchroscope symbol _ is centered at top of display and stable and V HZ and D yellow indicator lights all glow steady the paralleling generator sets are in phase When synchroscope lower display indicates that TQG frequencies and phases match and synchronizing lights V HZ and 8 GSC panels stop flashing set AC CIRCUIT INTERRUPTER switch on incoming TQG No 2 to CLOSED until press to test green indicator lights Generator sets are now operating in parallel with no load Immediately set SYNC MODE switch to OFF and press POWER METER key on GSC keypad to indicate kW Change 2 0006 00 22 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0006 00 OPERATION UNDER USUAL CONDITIONS Continued PARALLE
213. y maintenance when DVR Fault Codes are displayed Generator Set Control GSC Fault Codes including Engine Control Module ECM Codes and Event Codes The GSC Fault codes are displayed on the upper display when faults are detected in the operation of the engine or of the TQG Sometimes they are displayed along with the Dedicated Shutdown Indicators and your troubleshooting will correct the faults and they will not return Some of the codes are Event Codes that simply announce a condition of the engine or the TQG that needs attention You can notify maintenance when these fault codes appear on the GSC The GSC Fault Codes consist of a component identification CID number followed by a Fault Mode Identification FMI If the code originates with the Engine Control Module ECM the CID will be followed by an E before the FMI code The meaning of the CID FMI codes are given in the Malfunction Symptom Index When you see these codes record them and notify maintenance 0008 00 1 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR 0008 00 INTRODUCTION Continued TROUBLESHOOTING PROCEDURES WARNING D Metal jewelry can conduct electricity and become entangled in generator set components Remove all metal jewelry when working on generator set Failure to comply can cause injury or death to personnel High voltage is produced when this generator set is in operation Make sure unit is completely shut down and free of any power source be
214. y to personnel and damage to equipment Check for loose damaged or missing hardware 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 Inspect fuel system for leaks damaged loose or missing parts If using auxiliary fuel source check for leaks damaged loose or missing parts Inspect fuel filter water separator for leaks proper mounting cracks damage or missing parts Drain water from fuel filter water separator WP 0016 00 0012 00 5 Hardware loose damaged or missing Any fuel leaks damaged loose or missing parts Any fuel leaks damaged loose or missing parts Any fuel leaks cracks or missing parts Fuel filter water separator contains sediment and or water or cannot be drained 9 6115 730 10 200 kW TACTICAL QUIET GENERATOR SET 0012 00 PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS INCLUDING LUBRICATION INSTRUCTIONS Continued Table 1 Preventive Maintenance Checks and Services Continued LOCATION NOT FULLY ITEM ITEM TO MISSION NO INTERVAL CHECK SERVICE PROCEDURE CAPABLE IF 9 Before Ether Start System WARNING Breathing ether fumes can cause fainting Do not manually discharge or deliberately inhale ether Failure to comply can cause injury to p

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