CHAPTER 1 INTRODUCTION - TM-5-6115-545-12_43Figure 1-1. Engine Generator Set. Right Front, Three Quarter ViewFigure 1-2. Engine Generator Set, Left Rear, Three Quarter ViewFigure 1-3. Data Instruction Plate Locations (Sheet 1 of 2)Figure 1-3. Data Instruction Plate Locations (Sheet 2 of 2)Figure 1-4. Fuel System Diagram Instruction PlateFigure 1-5. Lifting Instructions Instruction PlateFigure 1-6. Operating Instruction PlateFigure 1-7. Service Instructions and System Capacities Instruction PlateFigure 1-8. Voltage Reconnection Instruction PlateFigure 1-9. Operational Data Information Plate (Mode I)Figure 1-10. Operational Data Information Plate (Mode II)Figure 1-11. Battery Arrangement and Connections Instruction PlateFigure 1-12. Set I. D. PlateTabulated Data - TM-5-6115-545-12_57trouble shooting diagram Figure 1-13.1 Troubleshooting Diagram Figure 1-14. TSrouble shooting Figure !-15. DC Troubleshooting diagram Figure 1-15.1 Troubleshooting DiagramFigure 1-16. DC Trouble shoting Diagram Figure 1-17. Schematic Wiring DiagramFigure 1-17.1 Schematic Wiring DiagramFigure 1-18. Schematic Wiring DiagramFigure 1-18.1 Schematic Wiring DiagramFigure 1-19. Schematic Wiring DiagramFigure 1-20. Schematic Wiring DiagramFigure 1-21. Kit Data and Instruction Plate Location (Sheet 1 of 2)Figure 1-21. Kit Data and Instruction Plate Location (Sheet 2 of 2)Figure 1-22. Fuel Burning Winterization System Diagram and Heater Control Schematic Diagram Instruction PlateFigure 1-23. Electric Winterization System Diagram and Electric Heater Control Schematic Diagram Instruction PlateFigure 1-24. Load Bank Connection and Operation Instruction PlateoiTable 1-1. Differences in Performance CharacteristicsFigure 1-26. 50/60 Hz Precise and Utility Interconnecting DiagramFigure 1-27. 400 Hz Precise Interconnecting DiagramFigure 1-28. Hydraulic Flow Diagram (MEP105A)Figure 1-29. Interconnection Wiring Diagram Figure 1-30Interconnection Wiring Diagram CHAPTER 2 INSTALLATION AND OPERATING INSTRUCTIONSTable 2-1. Freezing Points, Composition, and Specific Gravities of Military Antifreeze MaterialsInstallation and Setting-up InstructionsFigure 2-1. Installation Plan Figure 2-2. Grounding Procedures (Sheet 1 of 3)Figure 2-2. Grounding Procedures (Sheet 2 of 3)Figure 2-2. Grounding Procedures (Sheet 3 of 3)Figure 2-3. Generator Load Terminal Board ConnectionsFigure 2-3.1. Parallel ConnectionFigure 2-3.2. Parallel ConnectionFigure 2-4. Voltage Conversion - TM-5-6115-545-12_93Section III. CONTROLS AND INSTRUMENTSFigure 2-5. Generator Set Controls and Instruments (Sheet l of 6)Figure 2-5. Generator Set Controls and Instruments (Sheet 2 of 6)Figure 2-5. Generator Set Controls and Instruments (Sheet 3 of 6)Figure 2-5. Generator Set Controls and Instruments (sheet 4 of 6)Figure 2-5. Generator Set Controls and Instruments (Sheet 5 of 6)Figure 2-5. Generator Set Controls and Instruments (Sheet 6 of 6)Table 2-2. Fault Indicators FunctionSection IV. OPERATION UNDER USUAL CONDITIONSStopping - TM-5-6115-545-12_103Figure 2-6. Preparation for Starting (sheet 1 of 2)Figure 2-6. Preparation for Starting (Sheet 2 of 2)Figure 2-7. Starting Instructions (Sheet 1 of 2)Figure 2-7. Starting Instructions (Sheet 2 of 2)Figure 2-8. Stopping InstructionsFigure 2-9. Single Generator Unit, Operating InstructionsFigure 2-10. Parallel Operation (Load Sharing and Load Transfer) (Sheet 1 of 5 )Figure 2-10. Parallel Operation (Load Sharing and Load Transfer) (Sheet 2 of 5)Figure 2-10. Parallel Operation (Load Sharing and Load Transfer) (Sheet 3 of 5)Figure 2-10. Parallel Operation (Load Sharing and Load Transfer) (Sheet 4 of 5)Figure 2-10. Parallel Operation (Load Sharing and Load Transfer) (Sheet 5 of 5)Figure 2-10A. Parallel Operation of Tactical Utility Generator Sets (Load Sharing and Load Transfer) (Sheet 1 of 4)Figure 2-10A. Parallel Operation of Tactical Utility Generator Sets (Load Sharing and Load Transfer) (Sheet 2 of 4)Figure 2-l0.l. Parallel Operation of Tactical Utility Generator Sets (Load Sharing and Load Transfer) (Sheet 3 of 4)Figure 2-10.1. Parallel Operation of Tactical Utility Generator Sets (Load Sharing and Load Transfer) (Sheet 4 of 4)Section V. OPERATION UNDER UNUSUAL CONDITIONS - TM-5-6115-545-12_121Figure 2-11. Fuel Burning Winterization Kit Operating Instructions (Sheet 1 of 2)Figure 2-11. Fuel Burning Winterization Kit Operating Instructions (Sheet 2 of 2)Figure 2-12. Electric Winterization Kit, Operating Instructions (Sheet 1 of 2)Figure 2-12. Electric Winterization Kit. Operating Instructions (Sheet 2 of 2)Section VI. OPERATION OF AUXILIARY MATERIAL USED IN CONJUNCTION WITH THE EQUIPMENTFigure 2-13. Wheel Mounting Kit OperationFigure 2-14. Load Bank, Operating Instructions Section II. LUBRICATIONFigure 3-1. Lubrication Order (Sheet 1 of 2)Figure 3-1. Lubrication Order (Sheet 2 of 2)Figure 3-2. Oil Level Gage and FillerFigure 3-3. Engine Lube Oil FiltersSection III. PREVENTIVE MAINTENANCE CHECKS AND SERVICESSection IV. OPERATORS MAINTENANCETable 3-1. OPERATOR/CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES - TM-5-6115-545-12_137Table 3-1. OPERATOR/CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES (cont) - TM-5-6115-545-12_138Table 3-1. OPERATOR/CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES - TM-5-6115-545-12_139Table 3-1. OPERATOR/CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES (cont) - TM-5-6115-545-12_141Table 3-1. OPERATOR/CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES (cont)Figure 3-4. Batteries and Slave ReceptaclesParalleling Receptacles InspectionTable 3-2. Fault Indicator Test PointsFigure 3-5. Air Cleaner ServiceFigure 3-6. Fuel Filter and StrainerFigure 3-7. Main Fuel TankHydraulic Cooler (MEP105A Only) Inspection.Figure 3-8. Hydraulic Sump and Filter (MEP105A)Figure 3-9. Secondary Fuel FilterFuel System Bleeding ProcedureSection V. TROUBLESHOOTINGiTable 3-3 TroubleshootingTable 3-3. Troubleshooting (Cont) - TM-5-6115-545-12_155Table 3-3. Troubleshooting (Cont) - TM-5-6115-545-12_156Table 3-3. Troubleshooting (Cont) - TM-5-6115-545-12_157Table 3-3. Troubleshooting (Cont) - TM-5-6115-545-12_158Section VI.FIELD EXPEDIENT REPAIRSSection VII. RADIO INTERFERENCE SUPPRESSIONSection VIII. ORGANIZATIONAL MAINTENANCEFigure 3-11. Interference Suppression Components Removal and InstallationSection X. MUFFLER AND EXHAUST PIPES AND BREATHER SYSTEMFigure 3-12. Exhaust PipeFigure 3-12.1. Crankcase Breather SystemFigure 3-13. Convenience ReceptacleFigure 3-15. Plate and Sleeve AssemblySection XIV. PARALLELING RECEPTACLESSECTION XV. GENERATOR SET CONTROLSFigure 3-17. Generator Set ControlsAC Voltmeter ReplacementFrequency Adjust RheostatREPLACEMENT - TM-5-6115-545-12_173Single/Parallel Operation SwitchEngine Primer SwitchCoolant Temperature Gage Fuel Level GagePanel Light AssemblyDoor HolderKEY to fig. 3-18Figure 3-18. Control Cubicle Assemlby (Sheet 1 of 2)Figure 3-18. Control Cubicle Assembly (Sheet 2 of 2)Figure 3-19. Control Cubicle Schematic Diagram (Sheet 1 of 2)Figure 3-19. Control Cubicle Schematic Diagram (Sheet 2 of 2Figure 3-20. Control Cubicle Wiring Diagram (Sheet 1 of 2)Figure 3-20. Control Cubicle Wiring Diagram (Sheet 2 of 2)Figure 3-21. Ammeter-Voltmeter Selector Switch SchematicSection XVI. ENGINE GENERATOR SET HOUSING GROUPKEY to fig. 3-22KEY to fig. 3-22 (cont)Figure 3-22. Housing Group, Top and Side (Sheet 1 of 2)Figure 3-22. Housing Group, Front and Rear (Sheet 2 of 2)KEY to fig.3-23Figure 3-23. Engine Generator and Chassis Wiring Harness (Sheet 1 of 2)Figure 3-23. Engine Generator and Chassis Wiring Harness (Sheet 2 of 2)Figure 3-24. Load Connection GroupTesting - TM-5-6115-545-12_197Figure 3-24.1 Terminal Clip ReplacementElectric Governor Control Box Frequency Adjust Rheostat (MEP115A)Figure 3-24.2 Governor Control Unit Figure 3-25. Reconnection BoardFigure 3-26.Air Cleaner and Related PartsSection XXII. GENERATOR ASSEMBLYFigure 3-27.Day Tank and Fuel Filter AssemblyDay Tank and Float SwitchStart Aid AssemblyFuel Transfer PumpsFigure 3-28. Center Support and Related PartsFigure 3-29. Cooling Group and Related Parts Section XXV. COOLING GROUPFigure 3-30. Shutter Thermostat ReplacementFigure 3-31. Cooling GroupRemoval. - TM-5-6115-545-12_214Figure 3-32. Hydraulic Actuator Servicing (MEP105A)Figure8-33. Hydraulic Sump and filter Section XXVII. ENGINE ASSEMBLYFigure 3-34. Drain Hose Removal Figure 3-35. Belt Adjustment and Replacement Figure 3-36. Alternator and Related PartsFigure 3-37. Speed SwitchFigure 3-38. Oil Level Gage and Adapter and Filler Elbow and Cap Section XXXI. ELECTRICSTARTER AND ADAPTERFigure 3-38.1 Electronic Starter Removal Section XXXIII. SECONDARY FUEL FILTERFigure 3-39. Secondary Fuel Filter Assembly Section XXXIV. LUBE OIL COOLERFigure 3-40. Lube Oil CoolerTesting - TM-5-6115-545-12_230Figure 3-41. Nozzle Holder and Line Assemblies Installation - TM-5-6115-545-12_232Figure 3-42. Diffuser and Turbocharger Installation - TM-5-6115-545-12_234Section XXXVII. WATER PUMP AND FANFigure 3-43. Water Pump and Fan Figure 3-44. Thermostat and HousingThermostat TestingFigure 3-45. Idler Pulley and Mounting BracketSection XLI. INTAKE MANIFOLDFigure 3-47. Exhaust ManifoldSection XLII. EXHAUST MANIFOLDFigure 3-49. Valve LocationsSection XLIV. BASE GROUP AND RELATED COMPONENTSFigure 3-50. Base Group and Related ComponentsFigure 3-51. Base Group Related Components ReplacementFigure 3-51A. Base Group (with Plastic Fuel Tank)Figure 3-52. Fuel Quantity Transmitter Test Figure 3-53. Accessory Items With Attaching Hardware Section I. GENERAL Table 4-1. Preventive Maintenance Checks and ServicesFigure 4-1. Fuel Burning Winterization Kit (Sheet 1 of 2) Figure 4-1. Fuel Burning Winterization Kit (Sheet 2 of 2) T a b l e 4 - 2 . Fuel Burning Winterization Kit TroubleshootingFigure 4-2. Fuel Burning Winterization Kit Control Box Lamp Replacement Figure 4-3. Fuel Rgulator Valve Adjustment Figure 4-4. Ajusting Flame Switch Section III. ELECTRIC WINTERIZATION KITFigure 4-6. Electric Winterization Kit. Schematic Wiring DiagramFigure 4-7. Electric Winterization Kit (Sheet 1 of 3)Figure 4-7. Electric Winterization Kit (sheet 2 of 3)Figure 4-7. Electric Winterization Kit (sheet 3 of 3)Table 4-3. Electric Winterization Kit Preventive Maintenance Checks and ServicesFigure 4-8. Coolant Pump Motor - Brush and Connector ReplacementTable 4-4. Electric Winterization Kit TroubleshootingFigure 4-9. Electric Winterization Kit Control Box Fuse and Lamp ReplacementSection IV. WHEEL MOUNTING KITFigure 4-10. Running Gear Assembly T a b l e 4 - 5 . W h e e l M o u n t i n g K i t P r e v e n t i v e M a i n t e n a n c e C h e c k s a n d S e r v i c e sFigure 4-11. Hand Lever and bracket Assembly T a b l e 4 - 6 . W h e e l M o u n t i n g K i t T r o u b l e s h o o t i n gFigure 4-12. Hub and Brake and Front Unit Axle Assemblies (Sheet 1 of 2)Figure 4-12. Hub and Brake and Front Unit Axle Assemblies (Sheet 2 of 2)Cleaning and Inspection GENERAL Troubleshooting - TM-5-6115-545-12_277Figure 4-13. Load Bank Szchematic Diagram Figure 4-14. Load Bank (Sheet 1 of 2)Figure 4-14. Load Bank (Sheet 2 of 2)T a b l e 4 - 7 . L o a d B a n k P r e v e n t i v e M a i n t e n a n c e C h e c k s a n d S e r v i c e sFigure 4-15. Fan and Motor Assembly Table 4-8. Load Bank TroubleshootingTable 4-8. Load Bank Troubleshooting (Cont)F i g u r e 4 - 1 6 . W i r i n g D i a g r a m , L o a d B a n kFigure 4-18. Load Selector Switch Contact PositionsInstallation - TM-5-6115-545-12_287Inspection APPENDIX A REFERENCE - TM-5-6115-545-12_290APPENDIX A REFERENCE - TM-5-6115-545-12_291APPENDIX B. BASIC ISSUE ITEM LIST AND ITEMS Section III. ITEMS TROOP INSTALLED OR AUTHORIZED LISTSection III. ITEMS TROOP INSTALLED OR AUTHORIZED LIST (CONT)APPENDIX C MAINTENANCE ALLOCATION CHARTSection II. MAINTENANCE ALLOCATION CHART - TM-5-6115-545-12_297Section II. MAINTENANCE ALLOCATION CHART - TM-5-6115-545-12_298Section II. MAINTENANCE ALLOCATION CHART - TM-5-6115-545-12_299Section II. MAINTENANCE ALLOCATION CHART - TM-5-6115-545-12_300Section II. MAINTENANCE ALLOCATION CHART - TM-5-6115-545-12_301Section II. MAINTENANCE ALLOCATION CHART - TM-5-6115-545-12_302Section II. MAINTENANCE ALLOCATION CHART - TM-5-6115-545-12_303Section II. MAINTENANCE ALLOCATION CHART - TM-5-6115-545-12_304Section II. MAINTENANCE ALLOCATION CHART - TM-5-6115-545-12_305Section II. MAINTENANCE ALLOCATION CHART - TM-5-6115-545-12_306Section II. MAINTENANCE ALLOCATION CHART - TM-5-6115-545-12_307TOOL AND TEST EQUIPMENT REQUIREMENTS TOOL AND TEST EQUIPMENT REQUIREMENTS Section IV MAITENANCE ALLOCATION CHART - TM-5-6115-545-12_310Section IV MAITENANCE ALLOCATION CHART - TM-5-6115-545-12_311ALPHBETICAL INDEX ALPHBETICAL INDEX (Cont)ALPHBETICAL INDEX (Cont) - TM-5-6115-545-12_314G e n e r a t o r S e t C o n t r o l s ( C o n t ALPHBETICAL INDEX (Cont) - TM-5-6115-545-12_316ALPHBETICAL INDEX (Cont) - TM-5-6115-545-12_317ALPHBETICAL INDEX (Cont) - TM-5-6115-545-12_318ALPHBETICAL INDEX (Cont) - TM-5-6115-545-12_319ALPHBETICAL INDEX (Cont) - TM-5-6115-545-12_320ALPHBETICAL INDEX (Cont) - TM-5-6115-545-12_321