CHAPTER 1 INTRODUCTION - TM-5-6115-545-12_43
Figure 1-1. Engine Generator Set. Right Front, Three Quarter View
Figure 1-2. Engine Generator Set, Left Rear, Three Quarter View
Figure 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 Plate
Figure 1-5. Lifting Instructions Instruction Plate
Figure 1-6. Operating Instruction Plate
Figure 1-7. Service Instructions and System Capacities Instruction Plate
Figure 1-8. Voltage Reconnection Instruction Plate
Figure 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 Plate
Figure 1-12. Set I. D. Plate
Tabulated Data - TM-5-6115-545-12_57
trouble shooting diagram
Figure 1-13.1 Troubleshooting Diagram
Figure 1-14. TSrouble shooting
Figure !-15. DC Troubleshooting diagram
Figure 1-15.1 Troubleshooting Diagram
Figure 1-16. DC Trouble shoting Diagram
Figure 1-17. Schematic Wiring Diagram
Figure 1-17.1 Schematic Wiring Diagram
Figure 1-18. Schematic Wiring Diagram
Figure 1-18.1 Schematic Wiring Diagram
Figure 1-19. Schematic Wiring Diagram
Figure 1-20. Schematic Wiring Diagram
Figure 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 Plate
Figure 1-23. Electric Winterization System Diagram and Electric Heater Control Schematic Diagram Instruction Plate
Figure 1-24. Load Bank Connection and Operation Instruction Plate
oiTable 1-1. Differences in Performance Characteristics
Figure 1-26. 50/60 Hz Precise and Utility Interconnecting Diagram
Figure 1-27. 400 Hz Precise Interconnecting Diagram
Figure 1-28. Hydraulic Flow Diagram (MEP105A)
Figure 1-29. Interconnection Wiring Diagram
Figure 1-30Interconnection Wiring Diagram
CHAPTER 2 INSTALLATION AND OPERATING INSTRUCTIONS
Table 2-1. Freezing Points, Composition, and Specific Gravities of Military Antifreeze Materials
Installation and Setting-up Instructions
Figure 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 Connections
Figure 2-3.1. Parallel Connection
Figure 2-3.2. Parallel Connection
Figure 2-4. Voltage Conversion - TM-5-6115-545-12_93
Section III. CONTROLS AND INSTRUMENTS
Figure 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 Function
Section IV. OPERATION UNDER USUAL CONDITIONS
Stopping - TM-5-6115-545-12_103
Figure 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 Instructions
Figure 2-9. Single Generator Unit, Operating Instructions
Figure 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_121
Figure 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 EQUIPMENT
Figure 2-13. Wheel Mounting Kit Operation
Figure 2-14. Load Bank, Operating Instructions
Section II. LUBRICATION
Figure 3-1. Lubrication Order (Sheet 1 of 2)
Figure 3-1. Lubrication Order (Sheet 2 of 2)
Figure 3-2. Oil Level Gage and Filler
Figure 3-3. Engine Lube Oil Filters
Section III. PREVENTIVE MAINTENANCE CHECKS AND SERVICES
Section IV. OPERATORS MAINTENANCE
Table 3-1. OPERATOR/CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES - TM-5-6115-545-12_137
Table 3-1. OPERATOR/CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES (cont) - TM-5-6115-545-12_138
Table 3-1. OPERATOR/CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES - TM-5-6115-545-12_139
Table 3-1. OPERATOR/CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES (cont) - TM-5-6115-545-12_141
Table 3-1. OPERATOR/CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES (cont)
Figure 3-4. Batteries and Slave Receptacles
Paralleling Receptacles Inspection
Table 3-2. Fault Indicator Test Points
Figure 3-5. Air Cleaner Service
Figure 3-6. Fuel Filter and Strainer
Figure 3-7. Main Fuel Tank
Hydraulic Cooler (MEP105A Only) Inspection.
Figure 3-8. Hydraulic Sump and Filter (MEP105A)
Figure 3-9. Secondary Fuel Filter
Fuel System Bleeding Procedure
Section V. TROUBLESHOOTINGi
Table 3-3 Troubleshooting
Table 3-3. Troubleshooting (Cont) - TM-5-6115-545-12_155
Table 3-3. Troubleshooting (Cont) - TM-5-6115-545-12_156
Table 3-3. Troubleshooting (Cont) - TM-5-6115-545-12_157
Table 3-3. Troubleshooting (Cont) - TM-5-6115-545-12_158
Section VI.FIELD EXPEDIENT REPAIRS
Section VII. RADIO INTERFERENCE SUPPRESSION
Section VIII. ORGANIZATIONAL MAINTENANCE
Figure 3-11. Interference Suppression Components Removal and Installation
Section X. MUFFLER AND EXHAUST PIPES AND BREATHER SYSTEM
Figure 3-12. Exhaust Pipe
Figure 3-12.1. Crankcase Breather System
Figure 3-13. Convenience Receptacle
Figure 3-15. Plate and Sleeve Assembly
Section XIV. PARALLELING RECEPTACLES
SECTION XV. GENERATOR SET CONTROLS
Figure 3-17. Generator Set Controls
AC Voltmeter Replacement
Frequency Adjust Rheostat
REPLACEMENT - TM-5-6115-545-12_173
Single/Parallel Operation Switch
Engine Primer Switch
Coolant Temperature Gage
Fuel Level Gage
Panel Light Assembly
Door Holder
KEY to fig. 3-18
Figure 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 2
Figure 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 Schematic
Section XVI. ENGINE GENERATOR SET HOUSING GROUP
KEY to fig. 3-22
KEY 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.3-23
Figure 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 Group
Testing - TM-5-6115-545-12_197
Figure 3-24.1 Terminal Clip Replacement
Electric Governor Control Box Frequency Adjust Rheostat (MEP115A)
Figure 3-24.2 Governor Control Unit
Figure 3-25. Reconnection Board
Figure 3-26.Air Cleaner and Related Parts
Section XXII. GENERATOR ASSEMBLY
Figure 3-27.Day Tank and Fuel Filter Assembly
Day Tank and Float Switch
Start Aid Assembly
Fuel Transfer Pumps
Figure 3-28. Center Support and Related Parts
Figure 3-29. Cooling Group and Related Parts
Section XXV. COOLING GROUP
Figure 3-30. Shutter Thermostat Replacement
Figure 3-31. Cooling Group
Removal. - TM-5-6115-545-12_214
Figure 3-32. Hydraulic Actuator Servicing (MEP105A)
Figure8-33. Hydraulic Sump and filter
Section XXVII. ENGINE ASSEMBLY
Figure 3-34. Drain Hose Removal
Figure 3-35. Belt Adjustment and Replacement
Figure 3-36. Alternator and Related Parts
Figure 3-37. Speed Switch
Figure 3-38. Oil Level Gage and Adapter and Filler Elbow and Cap
Section XXXI. ELECTRICSTARTER AND ADAPTER
Figure 3-38.1 Electronic Starter Removal
Section XXXIII. SECONDARY FUEL FILTER
Figure 3-39. Secondary Fuel Filter Assembly
Section XXXIV. LUBE OIL COOLER
Figure 3-40. Lube Oil Cooler
Testing - TM-5-6115-545-12_230
Figure 3-41. Nozzle Holder and Line Assemblies
Installation - TM-5-6115-545-12_232
Figure 3-42. Diffuser and Turbocharger
Installation - TM-5-6115-545-12_234
Section XXXVII. WATER PUMP AND FAN
Figure 3-43. Water Pump and Fan
Figure 3-44. Thermostat and Housing
Thermostat Testing
Figure 3-45. Idler Pulley and Mounting Bracket
Section XLI. INTAKE MANIFOLD
Figure 3-47. Exhaust Manifold
Section XLII. EXHAUST MANIFOLD
Figure 3-49. Valve Locations
Section XLIV. BASE GROUP AND RELATED COMPONENTS
Figure 3-50. Base Group and Related Components
Figure 3-51. Base Group
Related Components Replacement
Figure 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 Services
Figure 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 Troubleshooting
Figure 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 KIT
Figure 4-6. Electric Winterization Kit. Schematic Wiring Diagram
Figure 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 Services
Figure 4-8. Coolant Pump Motor - Brush and Connector Replacement
Table 4-4. Electric Winterization Kit Troubleshooting
Figure 4-9. Electric Winterization Kit Control Box Fuse and Lamp Replacement
Section IV. WHEEL MOUNTING KIT
Figure 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 s
Figure 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 g
Figure 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_277
Figure 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 s
Figure 4-15. Fan and Motor Assembly
Table 4-8. Load Bank Troubleshooting
Table 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 k
Figure 4-18. Load Selector Switch Contact Positions
Installation - TM-5-6115-545-12_287
Inspection
APPENDIX A REFERENCE - TM-5-6115-545-12_290
APPENDIX A REFERENCE - TM-5-6115-545-12_291
APPENDIX B. BASIC ISSUE ITEM LIST AND ITEMS
Section III. ITEMS TROOP INSTALLED OR AUTHORIZED LIST
Section III. ITEMS TROOP INSTALLED OR AUTHORIZED LIST (CONT)
APPENDIX C MAINTENANCE ALLOCATION CHART
Section II. MAINTENANCE ALLOCATION CHART - TM-5-6115-545-12_297
Section II. MAINTENANCE ALLOCATION CHART - TM-5-6115-545-12_298
Section II. MAINTENANCE ALLOCATION CHART - TM-5-6115-545-12_299
Section II. MAINTENANCE ALLOCATION CHART - TM-5-6115-545-12_300
Section II. MAINTENANCE ALLOCATION CHART - TM-5-6115-545-12_301
Section II. MAINTENANCE ALLOCATION CHART - TM-5-6115-545-12_302
Section II. MAINTENANCE ALLOCATION CHART - TM-5-6115-545-12_303
Section II. MAINTENANCE ALLOCATION CHART - TM-5-6115-545-12_304
Section II. MAINTENANCE ALLOCATION CHART - TM-5-6115-545-12_305
Section II. MAINTENANCE ALLOCATION CHART - TM-5-6115-545-12_306
Section II. MAINTENANCE ALLOCATION CHART - TM-5-6115-545-12_307
TOOL AND TEST EQUIPMENT REQUIREMENTS
TOOL AND TEST EQUIPMENT REQUIREMENTS
Section IV MAITENANCE ALLOCATION CHART - TM-5-6115-545-12_310
Section IV MAITENANCE ALLOCATION CHART - TM-5-6115-545-12_311
ALPHBETICAL INDEX
ALPHBETICAL INDEX (Cont)
ALPHBETICAL INDEX (Cont) - TM-5-6115-545-12_314
G 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_316
ALPHBETICAL INDEX (Cont) - TM-5-6115-545-12_317
ALPHBETICAL INDEX (Cont) - TM-5-6115-545-12_318
ALPHBETICAL INDEX (Cont) - TM-5-6115-545-12_319
ALPHBETICAL INDEX (Cont) - TM-5-6115-545-12_320
ALPHBETICAL INDEX (Cont) - TM-5-6115-545-12_321
Figure 1-1. Engine Generator Set. Right Front, Three Quarter View
Figure 1-2. Engine Generator Set, Left Rear, Three Quarter View
Figure 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 Plate
Figure 1-5. Lifting Instructions Instruction Plate
Figure 1-6. Operating Instruction Plate
Figure 1-7. Service Instructions and System Capacities Instruction Plate
Figure 1-8. Voltage Reconnection Instruction Plate
Figure 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 Plate
Figure 1-12. Set I. D. Plate
Tabulated Data - TM-5-6115-545-12_57
trouble shooting diagram
Figure 1-13.1 Troubleshooting Diagram
Figure 1-14. TSrouble shooting
Figure !-15. DC Troubleshooting diagram
Figure 1-15.1 Troubleshooting Diagram
Figure 1-16. DC Trouble shoting Diagram
Figure 1-17. Schematic Wiring Diagram
Figure 1-17.1 Schematic Wiring Diagram
Figure 1-18. Schematic Wiring Diagram
Figure 1-18.1 Schematic Wiring Diagram
Figure 1-19. Schematic Wiring Diagram
Figure 1-20. Schematic Wiring Diagram
Figure 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 Plate
Figure 1-23. Electric Winterization System Diagram and Electric Heater Control Schematic Diagram Instruction Plate
Figure 1-24. Load Bank Connection and Operation Instruction Plate
oiTable 1-1. Differences in Performance Characteristics
Figure 1-26. 50/60 Hz Precise and Utility Interconnecting Diagram
Figure 1-27. 400 Hz Precise Interconnecting Diagram
Figure 1-28. Hydraulic Flow Diagram (MEP105A)
Figure 1-29. Interconnection Wiring Diagram
Figure 1-30Interconnection Wiring Diagram
CHAPTER 2 INSTALLATION AND OPERATING INSTRUCTIONS
Table 2-1. Freezing Points, Composition, and Specific Gravities of Military Antifreeze Materials
Installation and Setting-up Instructions
Figure 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 Connections
Figure 2-3.1. Parallel Connection
Figure 2-3.2. Parallel Connection
Figure 2-4. Voltage Conversion - TM-5-6115-545-12_93
Section III. CONTROLS AND INSTRUMENTS
Figure 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 Function
Section IV. OPERATION UNDER USUAL CONDITIONS
Stopping - TM-5-6115-545-12_103
Figure 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 Instructions
Figure 2-9. Single Generator Unit, Operating Instructions
Figure 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_121
Figure 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 EQUIPMENT
Figure 2-13. Wheel Mounting Kit Operation
Figure 2-14. Load Bank, Operating Instructions
Section II. LUBRICATION
Figure 3-1. Lubrication Order (Sheet 1 of 2)
Figure 3-1. Lubrication Order (Sheet 2 of 2)
Figure 3-2. Oil Level Gage and Filler
Figure 3-3. Engine Lube Oil Filters
Section III. PREVENTIVE MAINTENANCE CHECKS AND SERVICES
Section IV. OPERATORS MAINTENANCE
Table 3-1. OPERATOR/CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES - TM-5-6115-545-12_137
Table 3-1. OPERATOR/CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES (cont) - TM-5-6115-545-12_138
Table 3-1. OPERATOR/CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES - TM-5-6115-545-12_139
Table 3-1. OPERATOR/CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES (cont) - TM-5-6115-545-12_141
Table 3-1. OPERATOR/CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES (cont)
Figure 3-4. Batteries and Slave Receptacles
Paralleling Receptacles Inspection
Table 3-2. Fault Indicator Test Points
Figure 3-5. Air Cleaner Service
Figure 3-6. Fuel Filter and Strainer
Figure 3-7. Main Fuel Tank
Hydraulic Cooler (MEP105A Only) Inspection.
Figure 3-8. Hydraulic Sump and Filter (MEP105A)
Figure 3-9. Secondary Fuel Filter
Fuel System Bleeding Procedure
Section V. TROUBLESHOOTINGi
Table 3-3 Troubleshooting
Table 3-3. Troubleshooting (Cont) - TM-5-6115-545-12_155
Table 3-3. Troubleshooting (Cont) - TM-5-6115-545-12_156
Table 3-3. Troubleshooting (Cont) - TM-5-6115-545-12_157
Table 3-3. Troubleshooting (Cont) - TM-5-6115-545-12_158
Section VI.FIELD EXPEDIENT REPAIRS
Section VII. RADIO INTERFERENCE SUPPRESSION
Section VIII. ORGANIZATIONAL MAINTENANCE
Figure 3-11. Interference Suppression Components Removal and Installation
Section X. MUFFLER AND EXHAUST PIPES AND BREATHER SYSTEM
Figure 3-12. Exhaust Pipe
Figure 3-12.1. Crankcase Breather System
Figure 3-13. Convenience Receptacle
Figure 3-15. Plate and Sleeve Assembly
Section XIV. PARALLELING RECEPTACLES
SECTION XV. GENERATOR SET CONTROLS
Figure 3-17. Generator Set Controls
AC Voltmeter Replacement
Frequency Adjust Rheostat
REPLACEMENT - TM-5-6115-545-12_173
Single/Parallel Operation Switch
Engine Primer Switch
Coolant Temperature Gage
Fuel Level Gage
Panel Light Assembly
Door Holder
KEY to fig. 3-18
Figure 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 2
Figure 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 Schematic
Section XVI. ENGINE GENERATOR SET HOUSING GROUP
KEY to fig. 3-22
KEY 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.3-23
Figure 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 Group
Testing - TM-5-6115-545-12_197
Figure 3-24.1 Terminal Clip Replacement
Electric Governor Control Box Frequency Adjust Rheostat (MEP115A)
Figure 3-24.2 Governor Control Unit
Figure 3-25. Reconnection Board
Figure 3-26.Air Cleaner and Related Parts
Section XXII. GENERATOR ASSEMBLY
Figure 3-27.Day Tank and Fuel Filter Assembly
Day Tank and Float Switch
Start Aid Assembly
Fuel Transfer Pumps
Figure 3-28. Center Support and Related Parts
Figure 3-29. Cooling Group and Related Parts
Section XXV. COOLING GROUP
Figure 3-30. Shutter Thermostat Replacement
Figure 3-31. Cooling Group
Removal. - TM-5-6115-545-12_214
Figure 3-32. Hydraulic Actuator Servicing (MEP105A)
Figure8-33. Hydraulic Sump and filter
Section XXVII. ENGINE ASSEMBLY
Figure 3-34. Drain Hose Removal
Figure 3-35. Belt Adjustment and Replacement
Figure 3-36. Alternator and Related Parts
Figure 3-37. Speed Switch
Figure 3-38. Oil Level Gage and Adapter and Filler Elbow and Cap
Section XXXI. ELECTRICSTARTER AND ADAPTER
Figure 3-38.1 Electronic Starter Removal
Section XXXIII. SECONDARY FUEL FILTER
Figure 3-39. Secondary Fuel Filter Assembly
Section XXXIV. LUBE OIL COOLER
Figure 3-40. Lube Oil Cooler
Testing - TM-5-6115-545-12_230
Figure 3-41. Nozzle Holder and Line Assemblies
Installation - TM-5-6115-545-12_232
Figure 3-42. Diffuser and Turbocharger
Installation - TM-5-6115-545-12_234
Section XXXVII. WATER PUMP AND FAN
Figure 3-43. Water Pump and Fan
Figure 3-44. Thermostat and Housing
Thermostat Testing
Figure 3-45. Idler Pulley and Mounting Bracket
Section XLI. INTAKE MANIFOLD
Figure 3-47. Exhaust Manifold
Section XLII. EXHAUST MANIFOLD
Figure 3-49. Valve Locations
Section XLIV. BASE GROUP AND RELATED COMPONENTS
Figure 3-50. Base Group and Related Components
Figure 3-51. Base Group
Related Components Replacement
Figure 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 Services
Figure 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 Troubleshooting
Figure 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 KIT
Figure 4-6. Electric Winterization Kit. Schematic Wiring Diagram
Figure 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 Services
Figure 4-8. Coolant Pump Motor - Brush and Connector Replacement
Table 4-4. Electric Winterization Kit Troubleshooting
Figure 4-9. Electric Winterization Kit Control Box Fuse and Lamp Replacement
Section IV. WHEEL MOUNTING KIT
Figure 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 s
Figure 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 g
Figure 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_277
Figure 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 s
Figure 4-15. Fan and Motor Assembly
Table 4-8. Load Bank Troubleshooting
Table 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 k
Figure 4-18. Load Selector Switch Contact Positions
Installation - TM-5-6115-545-12_287
Inspection
APPENDIX A REFERENCE - TM-5-6115-545-12_290
APPENDIX A REFERENCE - TM-5-6115-545-12_291
APPENDIX B. BASIC ISSUE ITEM LIST AND ITEMS
Section III. ITEMS TROOP INSTALLED OR AUTHORIZED LIST
Section III. ITEMS TROOP INSTALLED OR AUTHORIZED LIST (CONT)
APPENDIX C MAINTENANCE ALLOCATION CHART
Section II. MAINTENANCE ALLOCATION CHART - TM-5-6115-545-12_297
Section II. MAINTENANCE ALLOCATION CHART - TM-5-6115-545-12_298
Section II. MAINTENANCE ALLOCATION CHART - TM-5-6115-545-12_299
Section II. MAINTENANCE ALLOCATION CHART - TM-5-6115-545-12_300
Section II. MAINTENANCE ALLOCATION CHART - TM-5-6115-545-12_301
Section II. MAINTENANCE ALLOCATION CHART - TM-5-6115-545-12_302
Section II. MAINTENANCE ALLOCATION CHART - TM-5-6115-545-12_303
Section II. MAINTENANCE ALLOCATION CHART - TM-5-6115-545-12_304
Section II. MAINTENANCE ALLOCATION CHART - TM-5-6115-545-12_305
Section II. MAINTENANCE ALLOCATION CHART - TM-5-6115-545-12_306
Section II. MAINTENANCE ALLOCATION CHART - TM-5-6115-545-12_307
TOOL AND TEST EQUIPMENT REQUIREMENTS
TOOL AND TEST EQUIPMENT REQUIREMENTS
Section IV MAITENANCE ALLOCATION CHART - TM-5-6115-545-12_310
Section IV MAITENANCE ALLOCATION CHART - TM-5-6115-545-12_311
ALPHBETICAL INDEX
ALPHBETICAL INDEX (Cont)
ALPHBETICAL INDEX (Cont) - TM-5-6115-545-12_314
G 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_316
ALPHBETICAL INDEX (Cont) - TM-5-6115-545-12_317
ALPHBETICAL INDEX (Cont) - TM-5-6115-545-12_318
ALPHBETICAL INDEX (Cont) - TM-5-6115-545-12_319
ALPHBETICAL INDEX (Cont) - TM-5-6115-545-12_320
ALPHBETICAL INDEX (Cont) - TM-5-6115-545-12_321
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