CHAPTER 1 INTRODUCTION
Section II. DESCRIPTION AND DATA
F i g u r e 1 - 1 . E n g i n e G e n e r a t o r S e t , R i g h t - R e a r , T h r e e - Q u a r t e r V i ew
F i g u r e 1 - 2 . E n g i n e G e n e r a t o r S e t , L e f t - F r o n t , T h r e e - Q u a r t e r V i e w ( M E P - 0 0 3 A - O n l y)
Figure 1-2.1. Engine Generator Set, Left-Front, Three-Quarter View (MEP-112A Only)
Figure 1-2.2 Engine Generator Set, Left Front, Three-Quarter View (MEP-003A Only)
TABULATED DATA - TM-5-6115-585-12_44
SERVICE INSTRUCTIONS
Engine.
Batteries - TM-5-6115-585-12_48
Figure 1-3. Tie Down, Lifting, and Towing Provisions Crated Set (MEP-003A)
TM-5-6115-585-12_50
TM-5-6115-585-12_51
TM-5-6115-585-12_54
TM-5-6115-585-12_55
TM-5-6115-585-12_56
TM-5-6115-585-12_58
TM-5-6115-585-12_60
TM-5-6115-585-12_61
TM-5-6115-585-12_62
TM-5-6115-585-12_64
TM-5-6115-585-12_65
TM-5-6115-585-12_66
TM-5-6115-585-12_67
TM-5-6115-585-12_68
TM-5-6115-585-12_70
TM-5-6115-585-12_73
TM-5-6115-585-12_74
TM-5-6115-585-12_75
TM-5-6115-585-12_76
TM-5-6115-585-12_78
TM-5-6115-585-12_79
TM-5-6115-585-12_80
TM-5-6115-585-12_81
TM-5-6115-585-12_82
TM-5-6115-585-12_83
TM-5-6115-585-12_84
TM-5-6115-585-12_85
TM-5-6115-585-12_86
TM-5-6115-585-12_87
TM-5-6115-585-12_88
TM-5-6115-585-12_89
TM-5-6115-585-12_90
TM-5-6115-585-12_91
TM-5-6115-585-12_92
TM-5-6115-585-12_93
TM-5-6115-585-12_94
TM-5-6115-585-12_95
TM-5-6115-585-12_96
TM-5-6115-585-12_97
TM-5-6115-585-12_98
TM-5-6115-585-12_99
SKID-BASE ASSEMBLY
C H A P T E R 4 O R G A N I Z A T I O N A L M A I N T E N A N CE
Figure 4-1. Uncrating Generator Set
Grounding. The Generator Set must be grounded
Figure 4-2. Grounding Generator Set
Section II. MOVEMENT TO A NEW WORKSITE
Section V. PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
TABLE 4-1. ORGANIZATIONAL PREVENTIVE MAINTENANCE CHECKS AND SERVICES--continued - TM-5-6115-585-12_109
TABLE 4-1. ORGANIZATIONAL PREVENTIVE MAINTENANCE CHECKS AND SERVICES--continued - TM-5-6115-585-12_110
S e c t i o n V I . T R O U B L E S H O O T I NG
Table 4-2. Troubleshooting
Table 4-2. Troubleshooting (Cont) - TM-5-6115-585-12_115
Table 4-2. Troubleshooting (Cont) - TM-5-6115-585-12_116
Section VII. RADIO INTERFERENCE SUPPRESSION
Figure 4-3. Primary Radio Interference Suppresion Components
Figure 4-3. Primary Radio Interference Suppresion Components CONT.
D i s a s s e m b l y o f S h u t t e r A s s e m b l y
F i g u r e 4 - 4 . S h u t t e r A s s e m b l y
Figure 4-5. Adjusting Shutters
Section IX. MAINTENANCE OF FUEL SYSTEM - TM-5-6115-585-12_123
FUEL FILTER ASSEMBLIES AND STRAINER ASSEMBLY
Figure 4-8. Testing Float Switch
Figure 4-9. Fuel Filter
Figure 4-11. Fuel Filters and Fuel Strainer Assembly
ELECTRIC F U E L P U M P , H O S E S A N D AUXILIARY 30 SOLENOID VALVE
Figure 4-12. Fuel Pump, Fuel Hoses and Solenoid - TM-5-6115-585-12_129
Figure 4-13. Fuel Pump
Section X. MAINTENANCE OF ENGINE ELECTRICAL SYSTEM
DESCRIPTION AND FUNCTION
Figure 416. Installing Battery Cables - TM-5-6115-585-12_134
Figure 417. Testing Batteries
Figure 418. Engine Starter installation - TM-5-6115-585-12_136
Connect voltmeter
FIGURE 4-19 TESTING ENGINE STARTER
Figure 421. Inspecting Starter Brushes, Style I Starter
Figure 421 A. Inspecting Starter Brushes, Style II Starter
Figure 422. Engine Starter Assembly, Style I Starter
Figure 423. Battery Charging Alternator
BATTERY CHARGING ALTERNATOR
Figure 4-24. Testing Battery Charging Regulator/Rectifier Assembly
Figure 4-25. Lockout Switch and Gear
Section XI. MAINTENANCE OF OIL SYSTEM
LOW OIL PRESSURE SWITCH - TM-5-6115-585-12_147
Figure 4-29. Replacing Oil Cooler Hoses
Figure 4-29.1. Replacing Oil Cooler Hoses
Figure 4-30. Oil Filter Assembly - TM-5-6115-585-12_150
Figure 4-31. Replacing Oil Pressure Gauge - TM-5-6115-585-12_152
Section XII. MAINTENANCE OF CONTROL SYSTEM
Figure 4-32. Load Terminal Board Assembly - TM-5-6115-585-12_154
LOAD TERMINAL BOARD ASSEMBLY
FIGURE 4-33 CONTROL CUBICLE ASSEMBLY
CONTROL CUBICLE ASSEMBLY - TM-5-6115-585-12_157
Table 4-4. Voltmeter-Ammeter Range Selector Switch Continuity Check - TM-5-6115-585-12_158
Figure 4-33.1. Relay K1. Internal Connection Diagram
Figure 4-34. Removing Control Cubicle Support Assembly
Figure 4-35. Control Cubicle Test Set-Up - TM-5-6115-585-12_161
Section XIII. MAINTENANCE OF ENGINE
FIGURE 4-36 ENGINE ASSEMBLY
FIGURE 4-36 ENGINE ASSEMBLY CONT.
Figure 4-37. Exhaust Muffler and Air Cleaner Assemblies
INTAKE MANIFOLD ASSEMBLY
Figure 4-39. Cleaning Rocker Arm Cover Oil Line
INJECTOR NOZZLE ASSEMBLY AND FUEL LINES
Figure 4-41. Cylinder Head Assembly
Figure 4-42. Oil Fill Tube
Figure 4-43. Engine Mounting Assembly
Section XIV. MAINTENANCE OF GENERATOR ASSEMBLY - TM-5-6115-585-12_172
SECTION XV. MAINTENANCE OF SKID - BASE
Figure 4-45. Skid Base Assembly
Battery Frame Bottom and Tray
CHAPTER 5 MATERIEL USED IN CONJUNCTION WITH DOD STANDARD GENERATOR SET, 10KW DIESEL ENGINE DRIVEN, MODELS MEP-003A AND MEP-112A
Section II. ACOUSTIC SUPPRESSION KIT
Figure 5-1. Instruction and Rating Plates
Figure 5-1. Instruction and Rating Plates CONT. - TM-5-6115-585-12_179
Figure 5-1. Instruction and Rating Plates CONT. - TM-5-6115-585-12_180
Figure 5-1. Instruction and Rating Plates CONT. - TM-5-6115-585-12_181
Figure 5-2. Cover Assembly, Removal and Installation
Installation - TM-5-6115-585-12_183
Figure 5-3. Top Panel Assembly and Exhaust Plenum, Removal and Installation
LEFT PANEL ASSEMBLY WITH SIDE CLOSURE ASSEMBLY
Figure 5-4. Left Panel Assembly and Side Closure Assembly, Removal and Installation
RIGHT PANEL ASSEMBLY
Figure 5-5. Right Panel Assembly, Removal and Installation
REAR PANEL ASSEMBLY
Figure 5-6. Rear Panel Assembly, Removal and Installation
EXHAUST PLENUM ASSEMBLY
Figure 5-7. Left Support Assembly, Removal and Installation
FRONT PANEL ASSEMBLY - TM-5-6115-585-12_193
Figure 5-8. Right Support Assembly, Removal and Installation
Figure 5-9. Front Panel Assembly, Removal and Installation
REAR CLOSURE ASSEMBLY
Figure 5-10. Rear Closure Assembly, Removal and Installation
REAR FLAP ASSEMBLY
Figure 5-11. Rear Flap Assembly, Removal and Installation
SECTION III. ACOUSTIC SUPPRESSION KIT REPAIR
REPLACEMENT OF ASK COMPONENTS - TM-5-6115-585-12_201
LATCH REPLACEMENT
Figure 5-12. Replacement of ASK Hardware Items
FRONT PANEL SILENCER
APPENDIX A REFERENCES - TM-5-6115-585-12_206
APPENDIX B ITEMS TROOP INSTALLED OR AUTHORIZED LIST
APPENDIX C MAINTENANCE ALLOCATION CHART
EXPLANATION OF COLUMNS IN SECTION IV
SECTION II MAINTENANCE ALLOCATION CHART
SECTION II MAINTENANCE ALLOCATION CHART CONT. - TM-5-6115-585-12_213
SECTION II MAINTENANCE ALLOCATION CHART CONT. - TM-5-6115-585-12_214
SECTION II MAINTENANCE ALLOCATION CHART CONT. - TM-5-6115-585-12_215
SECTION II MAINTENANCE ALLOCATION CHART CONT. - TM-5-6115-585-12_216
SECTION II MAINTENANCE ALLOCATION CHART CONT. - TM-5-6115-585-12_217
SECTION II MAINTENANCE ALLOCATION CHART CONT. - TM-5-6115-585-12_218
SECTION II MAINTENANCE ALLOCATION CHART CONT. - TM-5-6115-585-12_219
SECTION II MAINTENANCE ALLOCATION CHART CONT. - TM-5-6115-585-12_220
SECTION II MAINTENANCE ALLOCATION CHART CONT. - TM-5-6115-585-12_221
SECTION II MAINTENANCE ALLOCATION CHART CONT. - TM-5-6115-585-12_222
SECTION II MAINTENANCE ALLOCATION CHART CONT. - TM-5-6115-585-12_223
SECTION II MAINTENANCE ALLOCATION CHART CONT. - TM-5-6115-585-12_224
SECTION II MAINTENANCE ALLOCATION CHART CONT. - TM-5-6115-585-12_225
SECTION II MAINTENANCE ALLOCATION CHART CONT. - TM-5-6115-585-12_226
SECTION II MAINTENANCE ALLOCATION CHART CONT. - TM-5-6115-585-12_228
Section III. TOOLS, TEST AND SUPPORT EQUIPMENT REQUIREMENTS - TM-5-6115-585-12_229
Section IV. EXPLANATION OF REFERENCE CODES
APPENDIX D ADDITIONAL AUTHORIZATION LIST
ALPHABETICAL INDEX - TM-5-6115-585-12_234
ALPHABETICAL INDEX (CONT) - TM-5-6115-585-12_235
ALPHABETICAL INDEX (CONT) - TM-5-6115-585-12_236
ALPHABETICAL INDEX (CONT) - TM-5-6115-585-12_237
ALPHABETICAL INDEX (CONT) - TM-5-6115-585-12_238
ALPHABETICAL INDEX (CONT) - TM-5-6115-585-12_239
Section II. DESCRIPTION AND DATA
F i g u r e 1 - 1 . E n g i n e G e n e r a t o r S e t , R i g h t - R e a r , T h r e e - Q u a r t e r V i ew
F i g u r e 1 - 2 . E n g i n e G e n e r a t o r S e t , L e f t - F r o n t , T h r e e - Q u a r t e r V i e w ( M E P - 0 0 3 A - O n l y)
Figure 1-2.1. Engine Generator Set, Left-Front, Three-Quarter View (MEP-112A Only)
Figure 1-2.2 Engine Generator Set, Left Front, Three-Quarter View (MEP-003A Only)
TABULATED DATA - TM-5-6115-585-12_44
SERVICE INSTRUCTIONS
Engine.
Batteries - TM-5-6115-585-12_48
Figure 1-3. Tie Down, Lifting, and Towing Provisions Crated Set (MEP-003A)
TM-5-6115-585-12_50
TM-5-6115-585-12_51
TM-5-6115-585-12_54
TM-5-6115-585-12_55
TM-5-6115-585-12_56
TM-5-6115-585-12_58
TM-5-6115-585-12_60
TM-5-6115-585-12_61
TM-5-6115-585-12_62
TM-5-6115-585-12_64
TM-5-6115-585-12_65
TM-5-6115-585-12_66
TM-5-6115-585-12_67
TM-5-6115-585-12_68
TM-5-6115-585-12_70
TM-5-6115-585-12_73
TM-5-6115-585-12_74
TM-5-6115-585-12_75
TM-5-6115-585-12_76
TM-5-6115-585-12_78
TM-5-6115-585-12_79
TM-5-6115-585-12_80
TM-5-6115-585-12_81
TM-5-6115-585-12_82
TM-5-6115-585-12_83
TM-5-6115-585-12_84
TM-5-6115-585-12_85
TM-5-6115-585-12_86
TM-5-6115-585-12_87
TM-5-6115-585-12_88
TM-5-6115-585-12_89
TM-5-6115-585-12_90
TM-5-6115-585-12_91
TM-5-6115-585-12_92
TM-5-6115-585-12_93
TM-5-6115-585-12_94
TM-5-6115-585-12_95
TM-5-6115-585-12_96
TM-5-6115-585-12_97
TM-5-6115-585-12_98
TM-5-6115-585-12_99
SKID-BASE ASSEMBLY
C H A P T E R 4 O R G A N I Z A T I O N A L M A I N T E N A N CE
Figure 4-1. Uncrating Generator Set
Grounding. The Generator Set must be grounded
Figure 4-2. Grounding Generator Set
Section II. MOVEMENT TO A NEW WORKSITE
Section V. PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
TABLE 4-1. ORGANIZATIONAL PREVENTIVE MAINTENANCE CHECKS AND SERVICES--continued - TM-5-6115-585-12_109
TABLE 4-1. ORGANIZATIONAL PREVENTIVE MAINTENANCE CHECKS AND SERVICES--continued - TM-5-6115-585-12_110
S e c t i o n V I . T R O U B L E S H O O T I NG
Table 4-2. Troubleshooting
Table 4-2. Troubleshooting (Cont) - TM-5-6115-585-12_115
Table 4-2. Troubleshooting (Cont) - TM-5-6115-585-12_116
Section VII. RADIO INTERFERENCE SUPPRESSION
Figure 4-3. Primary Radio Interference Suppresion Components
Figure 4-3. Primary Radio Interference Suppresion Components CONT.
D i s a s s e m b l y o f S h u t t e r A s s e m b l y
F i g u r e 4 - 4 . S h u t t e r A s s e m b l y
Figure 4-5. Adjusting Shutters
Section IX. MAINTENANCE OF FUEL SYSTEM - TM-5-6115-585-12_123
FUEL FILTER ASSEMBLIES AND STRAINER ASSEMBLY
Figure 4-8. Testing Float Switch
Figure 4-9. Fuel Filter
Figure 4-11. Fuel Filters and Fuel Strainer Assembly
ELECTRIC F U E L P U M P , H O S E S A N D AUXILIARY 30 SOLENOID VALVE
Figure 4-12. Fuel Pump, Fuel Hoses and Solenoid - TM-5-6115-585-12_129
Figure 4-13. Fuel Pump
Section X. MAINTENANCE OF ENGINE ELECTRICAL SYSTEM
DESCRIPTION AND FUNCTION
Figure 416. Installing Battery Cables - TM-5-6115-585-12_134
Figure 417. Testing Batteries
Figure 418. Engine Starter installation - TM-5-6115-585-12_136
Connect voltmeter
FIGURE 4-19 TESTING ENGINE STARTER
Figure 421. Inspecting Starter Brushes, Style I Starter
Figure 421 A. Inspecting Starter Brushes, Style II Starter
Figure 422. Engine Starter Assembly, Style I Starter
Figure 423. Battery Charging Alternator
BATTERY CHARGING ALTERNATOR
Figure 4-24. Testing Battery Charging Regulator/Rectifier Assembly
Figure 4-25. Lockout Switch and Gear
Section XI. MAINTENANCE OF OIL SYSTEM
LOW OIL PRESSURE SWITCH - TM-5-6115-585-12_147
Figure 4-29. Replacing Oil Cooler Hoses
Figure 4-29.1. Replacing Oil Cooler Hoses
Figure 4-30. Oil Filter Assembly - TM-5-6115-585-12_150
Figure 4-31. Replacing Oil Pressure Gauge - TM-5-6115-585-12_152
Section XII. MAINTENANCE OF CONTROL SYSTEM
Figure 4-32. Load Terminal Board Assembly - TM-5-6115-585-12_154
LOAD TERMINAL BOARD ASSEMBLY
FIGURE 4-33 CONTROL CUBICLE ASSEMBLY
CONTROL CUBICLE ASSEMBLY - TM-5-6115-585-12_157
Table 4-4. Voltmeter-Ammeter Range Selector Switch Continuity Check - TM-5-6115-585-12_158
Figure 4-33.1. Relay K1. Internal Connection Diagram
Figure 4-34. Removing Control Cubicle Support Assembly
Figure 4-35. Control Cubicle Test Set-Up - TM-5-6115-585-12_161
Section XIII. MAINTENANCE OF ENGINE
FIGURE 4-36 ENGINE ASSEMBLY
FIGURE 4-36 ENGINE ASSEMBLY CONT.
Figure 4-37. Exhaust Muffler and Air Cleaner Assemblies
INTAKE MANIFOLD ASSEMBLY
Figure 4-39. Cleaning Rocker Arm Cover Oil Line
INJECTOR NOZZLE ASSEMBLY AND FUEL LINES
Figure 4-41. Cylinder Head Assembly
Figure 4-42. Oil Fill Tube
Figure 4-43. Engine Mounting Assembly
Section XIV. MAINTENANCE OF GENERATOR ASSEMBLY - TM-5-6115-585-12_172
SECTION XV. MAINTENANCE OF SKID - BASE
Figure 4-45. Skid Base Assembly
Battery Frame Bottom and Tray
CHAPTER 5 MATERIEL USED IN CONJUNCTION WITH DOD STANDARD GENERATOR SET, 10KW DIESEL ENGINE DRIVEN, MODELS MEP-003A AND MEP-112A
Section II. ACOUSTIC SUPPRESSION KIT
Figure 5-1. Instruction and Rating Plates
Figure 5-1. Instruction and Rating Plates CONT. - TM-5-6115-585-12_179
Figure 5-1. Instruction and Rating Plates CONT. - TM-5-6115-585-12_180
Figure 5-1. Instruction and Rating Plates CONT. - TM-5-6115-585-12_181
Figure 5-2. Cover Assembly, Removal and Installation
Installation - TM-5-6115-585-12_183
Figure 5-3. Top Panel Assembly and Exhaust Plenum, Removal and Installation
LEFT PANEL ASSEMBLY WITH SIDE CLOSURE ASSEMBLY
Figure 5-4. Left Panel Assembly and Side Closure Assembly, Removal and Installation
RIGHT PANEL ASSEMBLY
Figure 5-5. Right Panel Assembly, Removal and Installation
REAR PANEL ASSEMBLY
Figure 5-6. Rear Panel Assembly, Removal and Installation
EXHAUST PLENUM ASSEMBLY
Figure 5-7. Left Support Assembly, Removal and Installation
FRONT PANEL ASSEMBLY - TM-5-6115-585-12_193
Figure 5-8. Right Support Assembly, Removal and Installation
Figure 5-9. Front Panel Assembly, Removal and Installation
REAR CLOSURE ASSEMBLY
Figure 5-10. Rear Closure Assembly, Removal and Installation
REAR FLAP ASSEMBLY
Figure 5-11. Rear Flap Assembly, Removal and Installation
SECTION III. ACOUSTIC SUPPRESSION KIT REPAIR
REPLACEMENT OF ASK COMPONENTS - TM-5-6115-585-12_201
LATCH REPLACEMENT
Figure 5-12. Replacement of ASK Hardware Items
FRONT PANEL SILENCER
APPENDIX A REFERENCES - TM-5-6115-585-12_206
APPENDIX B ITEMS TROOP INSTALLED OR AUTHORIZED LIST
APPENDIX C MAINTENANCE ALLOCATION CHART
EXPLANATION OF COLUMNS IN SECTION IV
SECTION II MAINTENANCE ALLOCATION CHART
SECTION II MAINTENANCE ALLOCATION CHART CONT. - TM-5-6115-585-12_213
SECTION II MAINTENANCE ALLOCATION CHART CONT. - TM-5-6115-585-12_214
SECTION II MAINTENANCE ALLOCATION CHART CONT. - TM-5-6115-585-12_215
SECTION II MAINTENANCE ALLOCATION CHART CONT. - TM-5-6115-585-12_216
SECTION II MAINTENANCE ALLOCATION CHART CONT. - TM-5-6115-585-12_217
SECTION II MAINTENANCE ALLOCATION CHART CONT. - TM-5-6115-585-12_218
SECTION II MAINTENANCE ALLOCATION CHART CONT. - TM-5-6115-585-12_219
SECTION II MAINTENANCE ALLOCATION CHART CONT. - TM-5-6115-585-12_220
SECTION II MAINTENANCE ALLOCATION CHART CONT. - TM-5-6115-585-12_221
SECTION II MAINTENANCE ALLOCATION CHART CONT. - TM-5-6115-585-12_222
SECTION II MAINTENANCE ALLOCATION CHART CONT. - TM-5-6115-585-12_223
SECTION II MAINTENANCE ALLOCATION CHART CONT. - TM-5-6115-585-12_224
SECTION II MAINTENANCE ALLOCATION CHART CONT. - TM-5-6115-585-12_225
SECTION II MAINTENANCE ALLOCATION CHART CONT. - TM-5-6115-585-12_226
SECTION II MAINTENANCE ALLOCATION CHART CONT. - TM-5-6115-585-12_228
Section III. TOOLS, TEST AND SUPPORT EQUIPMENT REQUIREMENTS - TM-5-6115-585-12_229
Section IV. EXPLANATION OF REFERENCE CODES
APPENDIX D ADDITIONAL AUTHORIZATION LIST
ALPHABETICAL INDEX - TM-5-6115-585-12_234
ALPHABETICAL INDEX (CONT) - TM-5-6115-585-12_235
ALPHABETICAL INDEX (CONT) - TM-5-6115-585-12_236
ALPHABETICAL INDEX (CONT) - TM-5-6115-585-12_237
ALPHABETICAL INDEX (CONT) - TM-5-6115-585-12_238
ALPHABETICAL INDEX (CONT) - TM-5-6115-585-12_239
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