3KW TQG MEP-831A and Info

[LuckeyD]

Good Day: All the manuals you need to keep your 3KW TQG operational. There is an updated manual but it is not open for the public. It had something to do with the vendor of the gen set the government obtained it from. Issues, Governor being messed with, exhaust breaking, flames from the exhaust muffler, A8 issues, loose electrical connections, incorrect pull starting. Recommend reading the manual and set it up correctly for the desired output. Fill the oil lever at the dip stick, just stick the dip stick in and pull out for oil check, and the oil filter is a screen and should be changed if it gets a hole in it. Clean every other oil change. Keep air filter clean. Runs at 2 speeds, low load, and high load.

For those who do not know about how the Army TM's are laid out:
1. LO is the Lubrication order. It tells you when, how and with what, about how to service the Equipment.
2. TM is for Technical Manuals
3. TM's ending in -12 are the Operators Manual. A must read before trying to operate the Equipment
4. TM's ending in -24 are the Unit, Direct Support and General Support Maintenance Manuals.
5. TM's ending in -24P are the Repair Parts Listing for the Unit, Direct Support and General Support Maintenance Manuals.
6. TB is a Technical Bulletin.
7. MWO is a Modification Work Order.

Thanks to members @Ray70 , @kloppk , @DieselAddict , @Chief_919 ,@Dwnorton1 and anyone else who I might have forgotten for some of this information.

Basic TM's
TM 9-6115-639-13&P dated 2010

Engine TM's
TM 9-2815-257-24 dated 2000
TM 9-2815-257-24P dated 2001

 

[Guyfang]

Electrical "Stuff"
Extracted Schematics & Wire Diagrams
MEP-831A Color Coded Schematics
MEP-831A Schematic Training Guide, Corrected

 

[Guyfang]

MEP-831A Parts Listing

 

[Guyfang]

Some MEP-831A users have experienced flames coming out of the exhaust and possibly cracking of the exhaust pipe.

If you find this occurring with an 831A it’s caused by incomplete combustion of the diesel fuel that is then being forced into the muffler. The incomplete combustion can be caused by a clogged air-filter. A clogged air filter will restrict the amount of combustion air entering the cylinder causing the unburned fuel to enter the exhaust system. The fuel then catches fire as the temperature in the muffler increases. Under light loading conditions the generator can cause the generator to run cool and hasten the buildup of fuel and carbon residue in the engine and exhaust system of the generator. I.E. wet stacking.

The issue can also be due to the engine valve clearance being incorrect.

Important News, Exhaust System problems

The exhaust pipe cracks and failures are caused by loosening of the muffler mounting hardware on the rear of the engine. Due to the single-cylinder engine design, the muffler mounting hardware on the rear of the engine will be subjected to high vibrations. The muffler will become loose and eventually destroy the mounting bolts leading to the exhaust pipe cracking and failing.

Suggested precautions and corrective actions to take are:

1) Inspect and replace air filter more frequently when operating in an extremely dusty environment.
2) Increase the load to the generator to the rated capacity as close as possible to prevent wet stacking.
3) Inspect, tighten and replace, if necessary, muffler mounting hardware.
4) Adjust engine valve clearance in accordance with TM 9-2815-257-24.
5) For additional Information see the below attached P.S. Article.

 

[Guyfang]

Power Plants for the MEP-831A

TM 9-6115-658-13&P dated 2002
TECHNICAL MANUAL, OPERATOR, UNIT AND DIRECT SUPPORT MAINTENANCE MANUAL (INCLUDING REPAIR PARTS AND SPECIAL TOOLS LIST)

POWER PLANT, DIESEL ENGINE DRIVEN, 1-TON TRAILER MOUNTED (WITH RACKS) 3kW, 60 Hz, AN/MJQ-42 (NSN 6115-01-322-8583)

POWER PLANT, DIESEL ENGINE DRIVEN, 1-TON TRAILER MOUNTED (WITHOUT RACKS) 3kW, 60 Hz, AN/MJQ-43 (NSN 6115-01-322-8582)

TM 9-2330-202-14&P dated 1997 wc#2

TECHNICAL MANUAL, OPERATOR’S, UNIT, DIRECT SUPPORT, AND GENERAL SUPPORT MAINTENANCE MANUAL (INCLUDING REPAIR PARTS AND SPECIAL TOOLS LIST) FOR:
TRAILER, CARGO, 3/4-TON, 2-WHEEL M101A1 (2330-00-898-6779)
TRAILER, CARGO, 3/4-TON, 2-WHEEL M101A2 (2330-01-102-4697)
TRAILER, CARGO, 3/4-TON, 2-WHEEL M101A3 (2330-01-372-5641)

TRAILER, CHASSIS, 3/4-TON, 2-WHEEL, M116A1 (2330-00-898-6780)
TRAILER, CHASSIS, 3/4-TON, 2-WHEEL, M116A2 (2330-01-101-8434)
TRAILER, CHASSIS, 3/4-TON, 2-WHEEL, M116A2E1 (2330-01-333-9773)

TRAILER, CHASSIS, 1-TON, 2-WHEEL, M116A3 (2330-01-359-0080)

 

[Guyfang]

P.S. Magazine Articles

 

[Guyfang]

These documents pertain to the Governor Adjustment procedures.