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ARMY TM 9-6115-670-14&P DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited. HEADQUARTERS, DEPARTMENT OF THE ARMY 1 October 2002
OPERATOR’S, UNIT, DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE MANUAL
(INCLUDING REPAIR PARTS AND SPECIAL TOOLS LIST) FOR
AUXILIARY POWER UNIT 10 KW, 120/240 VAC, 60 HZ
MODEL NO. MEP-903A (SICPS) NSN 6115-01-431-3062,
MODEL NO. MEP-903B (JTACS) NSN 6115-01-431-3063,
MODEL NO. MEP-903C (WIN-T) NSN 6115-01-458-5329
(EIC: N/A)
OPERATING INSTRUCTIONS PAGE 2-1
OPERATOR MAINTENANCE PAGE 3-1
OPERATOR TROUBLE-SHOOTING PAGE 3-1
UNIT MAINTENANCE PAGE 4-1
UNIT TROUBLESHOOTING PAGE 4-10
DIRECT SUPPORT MAINTENANCE PAGE 5-1
DIRECT SUPPORT TROUBLE SHOOTING PAGE 5-2
GENERAL SUPPORT MAINTENANCE PAGE 6-1
ARMY TM 9-6115-670-14&P
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Technical Manual HEADQUARTERS No. 9-6115-670-14&P DEPARTMENT OF THE ARMY
WASHINGTON, DC, 1 October 2002
Operator's, Unit, Direct Support and General Support Maintenance Manual (Including Repair Parts and Special Tools List)
for AUXILIARY POWER UNIT 10KW, 120/240 VAC, 60 HZ
MODEL NO. MEP-903A (SICPS) NSN 6115-01-431-3062 MODEL NO. MEP-903B (JTACS) NSN 6115-01-431-3063
MODEL NO. MEP-903C (WIN-T) NSN 6115-01-458-5329 (EIC: N/A)
TABLE OF CONTENTS Page HOW TO USE THIS MANUAL................................................................................. viii CHAPTER 1 INTRODUCTION...................................................................................................... 1-1 Section I General Information.................................................................................................. 1-1 II Equipment Description ............................................................................................. 1-4 III Principles of Operation ............................................................................................. 1-15 CHAPTER 2 OPERATING INSTRUCTIONS................................................................................ 2-1 Section I Description and Use of Operator Controls and Indicators ....................................... 2-1 II Operator Preventive Maintenance Checks and Services (PMCS) ........................ 2-4 III Operation Under Usual Conditions........................................................................... 2-12 IV Operation Under Unusual Conditions ...................................................................... 2-14 CHAPTER 3 OPERATOR MAINTENANCE INSTRUCTIONS ..................................................... 3-1 Section I Lubrication Instructions............................................................................................. 3-1 II Operator Troubleshooting ........................................................................................ 3-1 III Operator Maintenance Procedures ...................................................................... 3-13
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 theprocedures, please let us know. Mail your letter, DA Form 2028 (Recommended Changes toPublications and Blank Forms), or DA Form 2028-2 located in the back of this manual directly to:Commander, US Army Communications-Electronics Command, ATTN: AMSEL-LC-LEO-D-CS-CFO,Fort Monmouth, NJ 07703-5006. Or fax it to 732-532-3421 (DSN 992). You may also submit your recommended changes by e-mail to [email protected]. In any case, a reply will be furnished directly to you.
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TABLE OF CONTENTS
Page CHAPTER 4 UNIT MAINTENANCE INSTRUCTIONS.................................................................. 4-1 Section I Lubrication Instructions............................................................................................. 4-2 II Repair Parts; Special Tools; Test, Measurement, and Diagnostic Equipment (TMDE); and Support Equipment............................... 4-3 III Service Upon Receipt ............................................................................................... 4-3 IV Equipment/User Fitting Instructions.......................................................................... 4-4 V Unit Preventive Maintenance Checks and Services (PMCS)................................... 4-4 VI Unit Troubleshooting Procedures ............................................................................. 4-10 VII Preparation for Storage or Shipment........................................................................ 4-31 VIII Unit Maintenance Instructions .................................................................................. 4-32 CHAPTER 5 DIRECT SUPPORT MAINTENANCE INSTRUCTIONS.......................................... 5-1 Section I Repair Parts; Special Tools; Test, Measurement, and Diagnostic Equipment (TMDE); and Support Equipment.............................. 5-2 II Direct Support Troubleshooting................................................................................ 5-3 III Direct Support Maintenance Procedures.................................................................. 5-24 CHAPTER 6 GENERAL SUPPORT MAINTENANCE INSTRUCTIONS...................................... 6-1 Section I Repair Parts; Special Tools; Test, Measurement and Diagnostic Equipment (TMDE); and Support Equipment............................... 6-2 II General Support Maintenance Procedures .............................................................. 6-3 APPENDIX A REFERENCES .................................................................................................... A-1 APPENDIX B MAINTENANCE ALLOCATION CHART............................................................ B-1 APPENDIX C REPAIR PARTS AND SPECIAL TOOLS LIST (RPSTL) .................................... C-1 Page Illust/ Figure Section I INTRODUCTION...................................................................................C-1 Section II REPAIR PARTS LIST ...........................................................................C-1-1 Group 00 Auxiliary Power Unit 10kW, 120/240V, 60 Hz......................C-1-1 C-1 Group 01 Generator 10kW, APU.........................................................C-2-1 C-2 Group 0101 Frame Assembly, SICPS.....................................................C-3-1 C-3 Group 0102 Frame Assembly, JTACS/WIN-T.........................................C-4-1 C-4 Group 0103 Fuel Tank Assembly, SICPS ...............................................C-5-1 C-5 Group 0104 Fuel Tank Assembly, JTACS/WIN-T ...................................C-6-1 C-6 Group 0105 Engine Assembly.................................................................C-7-1 C-7 Group 010501 Engine, Diesel, Turbo, 3 Cylinder, Liquid Cooled ................C-8-1 C-8 Group 01050101 Lubricating System..............................................................C-9-1 C-9 Group 01050102 Cooling System ...................................................................C-10-1 C-10 Group 01050103 Electrical System.................................................................C-11-1 C-11 Group 01050104 Fuel System ........................................................................C-12-1 C-12 Group 0105010401 Injector Pump ......................................................................C-13-1 C-13 Group 0105010402 Fuel Filter Assembly ............................................................C-14-1 C-14
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Section II REPAIR PARTS LIST (cont’d)
Page/illust/ Figure
Group 01050105 Cylinder Head Assembly ....................................................................... C-15-1 C-15 Group 01050106 Connecting Rod..................................................................................... C-16-1 C-16 Group 0106 Fuel Pump Assembly............................................................................. C-17-1 C-17 Group 0107 Radiator Subassembly .......................................................................... C-18-1 C-18 Group 0108 Speed Sensor Assembly ....................................................................... C-19-1 C-19 Group 0109 Wiring Harness, J3, DC Box, APU......................................................... C-20-1 C-20 Group 0110 Wiring Harness, Engine, P1 .................................................................. C-21-1 C-21 Group 0111 Wiring Harness, J1 ................................................................................ C-22-1 C-22 Group 0112 Governor Control Assembly................................................................... C-23-1 C-23 Group 0113 Generator, 10kW, 60 Hz........................................................................ C-24-1 C-24 Group 011301 Main Rectifier Assembly ........................................................................ C-25-1 C-25 Group 02 Wiring Harness, Control Cable .............................................................. C-26-1 C-26 Group 03 APU Control Box Assembly................................................................... C-27-1 C-27 Group 0301 Wiring Harness J2 ................................................................................. C-28-1 C-28 Group 99 Bulk Material………………………………………………………………………..Bulk-1 Section II SPECIAL TOOLS LIST ........................................................................ C-29-1 C-29 Section IV CROSS-REFERENCE INDEXES ........................................................ C-I-1 National Stock Number (NSN) Index ................................................... C-I-1 Part Number Index............................................................................... C-I-7 Figure and Item Number Index ............................................................ C-I-31 APPENDIX D COMPONENTS OF END ITEM AND BASIC ISSUE ITEMS LIST....................... D-1 APPENDIX E ADDITIONAL AUTHORIZATION LIST.................................................................. E-1 APPENDIX F EXPENDABLE AND DURABLE PARTS ITEMS LIST .......................................... F-1 APPENDIX G OPERATOR’S LUBRICATION INSTRUCTIONS .................................................. G-1 APPENDIX H ILLUSTRATED LIST OF MANUFACTURED ITEMS............................................ H-1 APPENDIX I TORQUE LIMITS………………………………………………………………………..I-1 APPENDIX J MANDATORY REPLACEMENT PARTS…………………………………………..J-1
INDEX…………………………………………………………………………………………………………..INDEX-1
FOLDOUTS …………………………………………………………………………………………………FO1 – FO7
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List of Illustrations Figure Title Page 1-0. Auxiliary Power Unit ......................................................................................................................... 1-0 1-1. Auxiliary Power Unit Major Components (2 Sheets) ........................................................................ 1-7 1-2. Instructions and Warning Plates (3 Sheets)..................................................................................... 1-12 1-3. Combustion System ......................................................................................................................... 1-15 1-4. Lubrication System........................................................................................................................... 1-16 1-5. Cooling System ................................................................................................................................ 1-17 1-6. Fuel System...................................................................................................................................... 1-18 1-7. Intake/Exhaust System..................................................................................................................... 1-19 1-8. Electrical System.............................................................................................................................. 1-20 1-9. Main Stator and AVR Interface......................................................................................................... 1-21 1-10. Engine Speed Control System ....................................................................................................... 1-22 1-11. Current Control ............................................................................................................................... 1-23 2-1. APU Control Unit Front Panel .......................................................................................................... 2-2 2-2. Operator PMCS Routing Diagram (3 Sheets) .................................................................................. 2-9 3-1. Oil Dipstick........................................................................................................................................ 3-15 3-2. Engine Oil ......................................................................................................................................... 3-17 3-3. Radiator Cap .................................................................................................................................... 3-19 3-4. Radiator ............................................................................................................................................ 3-21 4-1. Engine Oil ......................................................................................................................................... 4-33 4-2. Oil Filter ............................................................................................................................................ 4-35 4-3. Oil Cooler.......................................................................................................................................... 4-37 4-4. Low Oil Pressure Switch (2 Sheets)................................................................................................. 4-39 4-5. Fan Guard, Fan Shroud, and Shroud Housing (2 Sheets)............................................................... 4-43 4-6. Radiator (3 Sheets) .......................................................................................................................... 4-46 4-7. Radiator Coolant Drain Valve........................................................................................................... 4-51 4-8. Engine Coolant Drain Valve ............................................................................................................. 4-53 4-9. Thermostat ....................................................................................................................................... 4-55 4-10. Fan Belt .......................................................................................................................................... 4-57 4-11. Radiator Hoses............................................................................................................................... 4-59 4-12. Temperature Sender ..................................................................................................................... 4-62 4-13. Temperature Switch ....................................................................................................................... 4-64 4-14. Breather (2 Sheets) ........................................................................................................................ 4-66 4-15. Radiator Overflow Tank.................................................................................................................. 4-69 4-16. Fuel System.................................................................................................................................... 4-71 4-17. Fuel Filter Assembly....................................................................................................................... 4-74 4-18. Fuel Pump Assembly ..................................................................................................................... 4-77 4-19. Fuel Day Tank Assembly (JTACS and WIN-T).............................................................................. 4-83 4-20. Fuel Day Tank Assembly (SICPS) ................................................................................................. 4-87 4-21. Fuel Feeder Pump.......................................................................................................................... 4-90 4-22. Fuel Lines and Fittings (SICPS) ..................................................................................................... 4-93 4-23. Fuel Lines and Fittings (JTACS and WIN-T).................................................................................. 4-94 4-24. Battery Charging Alternator............................................................................................................ 4-97 4-25. Starter ............................................................................................................................................. 4-99 4-26. Glow Plug (2 Sheets)...................................................................................................................... 4-100 4-27. Muffler Wrap ................................................................................................................................... 4-104 4-28. Muffler (JTACS and WIN-T) ........................................................................................................... 4-106 4-29. Muffler (SICPS) .............................................................................................................................. 4-108 4-30. Exhaust Pipe (JTACS and WIN-T)................................................................................................. 4-110 4-31. Exhaust Pipe (SICPS) .................................................................................................................... 4-112
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List of Illustrations (cont’d)
Figure Title Page 4-32. Engine Turbocharger ..................................................................................................................... 4-114 4-33. Air Filter (SICPS, JTACS and WIN-T) (2 Sheets).......................................................................... 4-116 4-34. Deleted........................................................................................................................................... 4-118 4-35. Air Intake Pipe................................................................................................................................ 4-120 4-36. Governor Control Assembly........................................................................................................... 4-123 4-37. Actuator/Solenoid (2 Sheets) ......................................................................................................... 4-125 4-38. Actuator Linkage (2 Sheets) .......................................................................................................... 4-128 4-39. Electrical Output Terminal Board ................................................................................................... 4-132 4-40. Contactor Mounting Plate .............................................................................................................. 4-135 4-41. Main AC Contactor (2 Sheets) ....................................................................................................... 4-137 4-42. Ground Strap.................................................................................................................................. 4-140 4-43. Current Shunt................................................................................................................................. 4-143 4-44. Speed Sensor ................................................................................................................................ 4-144.2 4-45. Electrical Meters............................................................................................................................. 4-148 4-46. Hour Meter ..................................................................................................................................... 4-150 4-47. AC Voltage Adjust Potentiometer .................................................................................................. 4-153 4-48. Emergency Shut-Down Switch ...................................................................................................... 4-155 4-49. Toggle Switches............................................................................................................................. 4-157 4-50. Momentary Toggle Switch ............................................................................................................. 4-159 4-51. Indicator Lamps.............................................................................................................................. 4-161 4-52. Cylinder Head Cover (Valve Cover)............................................................................................... 4-163 5-1. Oil Pan Cover................................................................................................................................... 5-26 5-2. Oil Pan.............................................................................................................................................. 5-28 5-3. Oil Pan Strainer................................................................................................................................ 5-30 5-4. Relief Valve ...................................................................................................................................... 5-31 5-5. Radiator Cap .................................................................................................................................... 5-32 5-6. Water Pump ..................................................................................................................................... 5-34 5-7. Injection Nozzles (2 Sheets) ............................................................................................................ 5-36 5-8. Injection Pump (3 Sheets)................................................................................................................ 5-41 5-9. Current Transformer......................................................................................................................... 5-45 5-10. Overload Relay .............................................................................................................................. 5-47 5-11. Contactor Plate .............................................................................................................................. 5-49 5-12. Relay Board ................................................................................................................................... 5-52 5-13. DC Box Subassembly .................................................................................................................... 5-54 5-14. Electromagnetic Safety Relays ...................................................................................................... 5-57 5-15. Relay Sockets ................................................................................................................................ 5-59 5-16. Automatic Voltage Regulator (2 Sheets) ....................................................................................... 5-61 5-17. Regulator Box ................................................................................................................................ 5-66 5-18. Generator, 10 kW, 60 Hz (5 Sheets).............................................................................................. 5-71 5-19. APU DC Box Wiring Harness J3.................................................................................................... 5-81 5-20. Engine Wiring Harness P1............................................................................................................. 5-85 5-21. Wiring Harness J1.......................................................................................................................... 5-89 5-22. Water Temperature Gauge............................................................................................................ 5-94 5-23. Wiring Harness J2.......................................................................................................................... 5-98 5-24. Frame and APU Vibration Isolator Mount Assembly (6 Sheets) ................................................... 5-104 5-25. Diesel Engine (11 Sheets) ............................................................................................................. 5-111 5-26. Exhaust Manifold............................................................................................................................ 5-126 5-27. Intake Manifold............................................................................................................................... 5-128 5-28. Rocker Arm Assembly ................................................................................................................... 5-130 5-29. Valve Clearance............................................................................................................................. 5-133 5-30. Flywheel ......................................................................................................................................... 5-135
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List of Illustrations (cont’d)
Figure Title Page 6-1. Push Rods........................................................................................................................................ 6-4 6-2. Cylinder Head (4 Sheets)................................................................................................................. 6-6 6-3. Tappets ............................................................................................................................................ 6-11 6-4. Valves (3 Sheets)............................................................................................................................. 6-13 6-5. Valve Guide...................................................................................................................................... 6-18 6-6. Valve Spring..................................................................................................................................... 6-20 6-7. Valve Seat (2 Sheets) ...................................................................................................................... 6-21 6-8. Speed Control Plate ......................................................................................................................... 6-25 6-9. Gear Case (2 Sheets) ...................................................................................................................... 6-28 6-10. Idle Gear (2 Sheets)....................................................................................................................... 6-31 6-11. Idle Gear Bushings......................................................................................................................... 6-34 6-12. Idle Gear Shaft ............................................................................................................................... 6-35 6-13. Camshaft (4 Sheets) ...................................................................................................................... 6-37 6-14. Camshaft Gear............................................................................................................................... 6-42 6-15. Fuel Camshaft................................................................................................................................ 6-44 6-16. Injection Pump Gear ...................................................................................................................... 6-46 6-17. Crankshaft Gear............................................................................................................................. 6-48 6-18. Oil Pump Gear ............................................................................................................................... 6-49 6-19. Piston (2 Sheets)............................................................................................................................ 6-51 6-20. Connecting Rod (4 Sheets)............................................................................................................ 6-55 6-21. Piston Rings (4 Sheets) ................................................................................................................. 6-60 6-22. Bearing Case Cover....................................................................................................................... 6-65 6-23. Crankshaft ...................................................................................................................................... 6-68 6-24. Connecting Rod Bearing................................................................................................................ 6-70 6-25. Crankshaft Bearing 1 (2 Sheets).................................................................................................... 6-72 6-26. Crankshaft Bearings 2 and 3 ......................................................................................................... 6-75 6-27. Cylinder .......................................................................................................................................... 6-77 6-28. Oil Pump Assembly (2 Sheets) ...................................................................................................... 6-79 6-29. Radiator Seal Faring ...................................................................................................................... 6-81 6-30. Water Flange.................................................................................................................................. 6-83 6-31. Exciter Stator (4 Sheets) ................................................................................................................ 6-85 6-32. Main Rectifier Assembly................................................................................................................. 6-89 6-33. Generator Bearing.......................................................................................................................... 6-90 6-34. Rotor............................................................................................................................................... 6-92 D-1. Auxiliary Power Unit, 10 kW, 120/240 VAC, 60 Hz......................................................................... D-3 D-2. Operator's, Unit, Direct Support, and General Support Maintenance Manual ................................ D-4 FO-1. APU Wiring Diagram (SICPS and WIN-T).................................................................................... FO-1 FO-2. Wiring Harness, Engine P1 Wiring Diagram................................................................................. FO-2 FO-3. Wiring Harness, APU DC Box J3 Wiring Diagram........................................................................ FO-3 FO-4 Wiring Harness, J1 Wiring Diagram.............................................................................................. FO-4 FO-5. Wiring Harness, J2, APU Control Box, Wiring Diagram ............................................................... FO-5 FO-6. Wiring Harness, Control Cable Wiring Diagram ........................................................................... FO-6 FO-7. APU Wiring Diagram (JTACS)...................................................................................................... FO-7
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List of Tables
Number Title Page 1-1. Differences Between Models ........................................................................................................... 1-5 2-1. APU Control Unit Controls and Indicators........................................................................................ 2-3 2-2. Operator Preventative Maintenance Checks and Services (PMCS) for Auxiliary Power Unit, 10 kW, 120/240 VAC, 60 Hz ............................................................................................................ 2-4 2-3. Control Unit Start-Up Switch Positions ............................................................................................ 2-12 3-1. Ambient Temperature and Engine Oil Type .................................................................................... 3-16 3-2. Freezing Points, Composition, and Specific Gravities ..................................................................... 3-20 4-1. Freezing Points, Composition, and Specific Gravities of Military Antifreeze Materials ................... 4-4 4-2. Unit Preventive Maintenance Checks and Services (PMCS).......................................................... 4-7 5-1. APU DC Box Wiring Harness J3 Continuity Test............................................................................. 5-77 5-2. Engine Wiring Harness P1 Continuity Test...................................................................................... 5-81 5-3. Wiring Harness J1 Continuity Test................................................................................................... 5-85 5-4. Wiring Harness Control Cable Continuity Test ................................................................................ 5-88 5-5. Wiring Harness J2 Continuity Test................................................................................................... 5-94 6-1. Undersize Connecting Rod Bearing................................................................................................. 6-69 6-2. Undersize Crankshaft Bearing I ....................................................................................................... 6-71 6-3. Undersize Crankshaft Bearings 2 and 3 .......................................................................................... 6-74 E-1. Additional Authorization List ............................................................................................................ E-2 G-1. Lubricant Table for the APU……………………………………………………………………………. G-2 H-1. Materials and Specifications. .......................................................................................................... H-3 H-2. Chamfer and Fine Finish Requirements. ........................................................................................ H-3 H-3. Materials and Specifications. .......................................................................................................... H-5 H-4. Chamfer and Fine Finish Requirements. ........................................................................................ H-5 H-5. Materials and Specifications. .......................................................................................................... H-7 H-6. Chamfer and Fine Finish Requirements. ........................................................................................ H-7 H-7. Materials and Specifications. .......................................................................................................... H-9 H-8. Chamfer and Fine Finish Requirements. ........................................................................................ H-9 H-9. Parts, Materials, and Specifications. .............................................................................................. H-11 H-10.Chamfer and Fine Finish Requirements. ........................................................................................ H-11 I-1 Torque Values for Special Use Screws, Belts and Nuts................................................................. I-1 I-2 Torque Values for Special Use Screws, Belts and Nuts................................................................. I-2 I-3 Torque Values for Special Use Screws, Belts and Nuts…………………………………………….. I-2
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HOW TO USE THIS MANUAL
This manual tells you how to operate and maintain Auxiliary Power Unit, 10 KW, 120/240 VAC, 60 HZ. Step-by-step procedures with illustrations give you all the necessary information to install, operate, and maintain this equipment at operator, unit, direct support and general support levels. However, do not attempt any procedure before you first familiarize yourself with the entire procedure. The front cover index identifies frequently used information. Each item is boxed and identified by topic and page number. The first page containing the information you are looking for has a black box on the edge of the paper. Bend the manual in half and follow the margin index to the page with the black edge marker. Topics in the table of contents which are the same as topics on the front cover are also boxed. If you are looking for general information, use the table of contents in the front of this manual to locate chapters and sections containing this information. If you are looking for specific information, use the chapter index in the front of each chapter or the alphabetical index located in the back of the manual to locate the paragraph and page where the topic is discussed. The glossary contains an explanation of technical terms and acronyms. Foldout illustrations are located in the back of this manual. NOTE: Contains information of special interest or of importance. CAUTION: Contains conditions, practices, or procedures that must be observed to avoid damage to the equipment. WARNING : Contains conditions, practices, or procedures that must be observed to avoid personal injury, loss of life, or long term health hazard.
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Figure 1-0. Auxiliary Power Unit
