TM-5-6115-634-14P Power Plant AN/MJQ-16 (NSN 6115-00-033-1395) (2) MEP-002A 5 Kw 60 Hz Generator Sets M103A3 2-Wheel 2-Tire Modified Trailer Manual

CHAPTER 1 INTRODUCTION - TM-5-6115-634-14P_23
Destruction to Prevent Enemy Use
Glossary - TM-5-6115-634-14P_25
Figure 1-1. Curbside View PU 794/G
Figure 1-2. Roadside View PU 794/G
Tabulated Data - TM-5-6115-634-14P_28
Section III. PRINCIPLES OF OPERATION
Figure 1-3. Identification Plates
Inspecting and Servicing PU 794/G
External Fuel Line Connections
Figure 1-4. External Line Connections
CHAPTER 2 OPERATION/INSTRUCTIONS
Figure 2-1. Junction Box Connections
Figure 2-2. Remote Control Unit Controls and Indicators
TABLE 2-1. OPERATOR/CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES
TABLE 2-1. OPERATOR/CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES (CONTD) - TM-5-6115-634-14P_39
TABLE 2-1. OPERATOR/CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES (CONTD) - TM-5-6115-634-14P_40
TABLE 2-1. OPERATOR/CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES (CONTD) - TM-5-6115-634-14P_41
TABLE 2-1. OPERATOR/CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES (CONTD) - TM-5-6115-634-14P_42
TABLE 2-1. OPERATOR/CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES (CONTD) - TM-5-6115-634-14P_43
TABLE 2-1. OPERATOR/CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES (CONTD) - TM-5-6115-634-14P_44
Section III. OPERATION UNDER USUAL CONDITION
Preparation for Use
Cable Connections for a single PU 794/G
Figure 2-3. Cable Connections Locations - PU 794/G
Figure 2-4. Cable   Connections Locations - Shelter
Figure 2-5. Cable Connection for Two PU 794/Gs
Single Unit Operating Procedures
Preparation for Movement
Section IV. OPERATION UNDER UNUSUAL CONDITIONS
Mobile Operations
Figure 2-6. Cable Routing For Mobile Operation
CHAPTER 3 OPERATOR MAINTENANCE
Table 3-1. TROUBLESHOOTING
Section III. MAINTENANCE PROCEDURES
Weighing
CHAPTER 4 UNIT MAINTENANCE INSTRUCTIONS
Table 4-1. UNIT PREVENTIVE MAINTENANCE CHECKS AND SERVICES - TM-5-6115-634-14P_62
Table 4-1. UNIT PREVENTIVE MAINTENANCE CHECKS AND SERVICES - TM-5-6115-634-14P_63
Table 4-1. UNIT PREVENTIVE MAINTENANCE CHECKS AND SERVICES - TM-5-6115-634-14P_64
Table 4-1. UNIT PREVENTIVE MAINTENANCE CHECKS AND SERVICES - TM-5-6115-634-14P_65
Table 4-2. PU 794/G, TROUBLESHOOTING PROCEDURES - TM-5-6115-634-14P_66
Table 4-2. PU 794/G, TROUBLESHOOTING PROCEDURES - TM-5-6115-634-14P_67
REPLACE BATTERY
INSPECTION - TM-5-6115-634-14P_69
REPLACE BATTERY CABLES
FABRICATION
REPLACE BATTERY BOX
INSTALL BATTERY CABLES
REPLACE BATTERY BOX COVER
REPLACE INTAKE BAFFLE ASSEMBLY
INSTALLATION - TM-5-6115-634-14P_76
REPLACE GRID
INSTALLATION - TM-5-6115-634-14P_78
REPLACE FLANGE, BOTTOM, LOWER AND UPPER SIDE
INSTALLATION - TM-5-6115-634-14P_80
REPLACE CONNECTOR PLATE
REMOVAL - TM-5-6115-634-14P_82
INSTALLATION - TM-5-6115-634-14P_83
REPLACE FRONT ACCESS DOORS
REPLACE SIDE ACCESS DOORS, LEFT AND RIGHT
REPLACE TOP REAR COVER
INSTALLATION - TM-5-6115-634-14P_87
REPLACE REAR HOUSING FRAME
INSTALLATION - TM-5-6115-634-14P_89
REPLACE BAFFLE ASSEMBLY
REPLACE EXHAUST BAFFLE MOUNTING BRACKETS
INSTALLATION - TM-5-6115-634-14P_92
REMOVE TOP FRONT COVER
INSTALLATION - TM-5-6115-634-14P_94
REPLACE FRONT FRAME
REPLACE SILENCER
INSTALLATION - TM-5-6115-634-14P_97
REPLACE FLEXIBLE TUBE ASSEMBLY AND GASKET
INSTALLATION - TM-5-6115-634-14P_99
MAINTENANCE AIR CLEANER SYSTEM - TM-5-6115-634-14P_100
INSTALLATION - TM-5-6115-634-14P_101
INSTALL AIR INLET HOSE
REPLACE AIR INLET HOSE
INSTALLATION - TM-5-6115-634-14P_104
REPLACE AIR BREATHER HOSE
INSTALLATION - TM-5-6115-634-14P_106
REPLACE AIR INLET ADAPTER AND GASKET
INSTALLATION - TM-5-6115-634-14P_108
MAINTENANCE AIR CLEANER SYSTEM - TM-5-6115-634-14P_109
SERVICE - TM-5-6115-634-14P_110
INSPECT REMOTE FUNCTIONS BOX ASSEMBLY
REPLACE FAN
REPLACE V-BELT
REPLACE FAN GUARD, LEFT AND RIGHT
REPLACE DOCUMENT BOX
INSTALLATION - TM-5-6115-634-14P_116
INSPECT SKID BASE ASSEMBLY
INSPECT, TEST AND REPLACE JUNCTION BOX ASSEMBLY
REMOVAL - TM-5-6115-634-14P_119
REPLACE CABLE REEL ASSEMBLY
INSTALLATION - TM-5-6115-634-14P_121
REPLACE PULLER BRACKET
REPLACE FRONT STEP, CURBSIDE AND ROADSIDE
INSTALLATION - TM-5-6115-634-14P_124
INSTALLATION (cont) - TM-5-6115-634-14P_125
REPLACE FENDER, ROADSIDE AND CURBSIDE
INSTALLATION - TM-5-6115-634-14P_127
REPLACE REAR STEP, ROADSIDE AND CURBSIDE
INSTALLATION - TM-5-6115-634-14P_129
REPLACE PLATFORM TAILGATE
REPLACE CABLE STORAGE PAN
INSTALLATION - TM-5-6115-634-14P_132
TEST AND REPLACE REMOTE CONTROL UNIT
TEST AND REPLACE CONTROL CABLE
INSTALLATION - TM-5-6115-634-14P_135
TEST AND REPLACE POWER CABLE, 25 FT
INSTALLATION - TM-5-6115-634-14P_137
TEST POWER CABLE, 5 FT.
TEST CONTROL CABLE, 5 FT. AND 25 FT.
TEST PARALLELING CABLE
REPLACE FIRE EXTINGUISHER
INSTALLATION - TM-5-6115-634-14P_142
CHAPTER 5 INTERMEDIATE DIRECT SUPPORT MAINTENANCE INSTRUCTIONS
Table 5-1. TROUBLESHOOTING
Figure 5-1. Special Relay Assembly Wiring Harness (Sheet 1 of 3)
Figure 5-1. Special Relay Assembly Wiring Harness (Sheet 2 of 3)
Figure 5-1. Special Relay Assembly Wiring Harness (Sheet 3 of 3)
Section IV. MAINTENANCE PROCEDURES
TEST GENERATOR SET 20 KW
REPAIR INTAKE BAFFLE
REPAIR - TM-5-6115-634-14P_151
REPAIR OF THE ACCESS DOORS
REPAIR OF GENERATOR SET TOP REAR COVER
INSTALLATION - TM-5-6115-634-14P_154
REPAIR OF REAR HOUSING FRAME
REPAIR OF EXHAUST BAFFLE ASSEMBLY
REPAIR - TM-5-6115-634-14P_157
MAINTENANCE OF GENERATOR SET, TOP FRONT ASSEMBLY
REPAIR - TM-5-6115-634-14P_159
REPAIR GENERATOR SET FRONT HOUSING
REPAIR - TM-5-6115-634-14P_161
REPAIR OF CONTROL WIRING HARNESS
TEST - TM-5-6115-634-14P_163
REPAIR - TM-5-6115-634-14P_164
REPAIR OF POWER WIRING HARNESS
TEST - TM-5-6115-634-14P_166
REMOVAL - TM-5-6115-634-14P_167
TEST AND REPLACE SPECIAL RELAY ASSEMBLY TO REMOTE FUNCTIONS BOX ASSEMBLY WIRING HARNESS
TEST
REPAIR - TM-5-6115-634-14P_170
TEST AND REPLACE REMOTE FUNCTIONS BOX ASSEMBLY TO CONNECTOR PANEL WIRING HARNESS
wiring unit list
REPAIR - TM-5-6115-634-14P_173
TEST AND REPLACE SS2P TO CONVENIENCE RECEPTACLE WIRING HARNESS
TEST - TM-5-6115-634-14P_175
REPAIR THE REMOTE FUNCTIONS BOX ASSEMBLY
REPAIR - TM-5-6115-634-14P_177
INSTALLATION - TM-5-6115-634-14P_178
MAINTENANCE OF CURRENT TRANSFORMER ASSEMBLIES
REMOVAL - TM-5-6115-634-14P_180
TESTING - TM-5-6115-634-14P_181
INSTALLATION - TM-5-6115-634-14P_182
INSTALLATION (cont) - TM-5-6115-634-14P_183
REPLACE CRANKSHAFT PULLEY
TEST SPECIAL RELAY ASSEMBLY
TEST - TM-5-6115-634-14P_186
TEST (cont) - TM-5-6115-634-14P_187
TEST (cont) - TM-5-6115-634-14P_188
INSTALLATION - TM-5-6115-634-14P_189
INSPECT ISOLATORS
REPLACE LIFTING FRAME
INSTALLATION - TM-5-6115-634-14P_192
INSTALLATION (cont) - TM-5-6115-634-14P_193
JUNCTION BOX MAINTENANCE
TEST AND REPAIR REMOTE CONTROL UNIT
TEST - TM-5-6115-634-14P_196
REPAIR - TM-5-6115-634-14P_197
REPAIR (cont) - TM-5-6115-634-14P_198
REPAIR (cont) - TM-5-6115-634-14P_199
REPAIR (cont) - TM-5-6115-634-14P_200
FIRE EXTINGUISHER MAINTENANCE
REPLACE - TM-5-6115-634-14P_202
Section V. PREPARATION FOR STORAGE AND SHIPMENT
CHAPTER 6 INTERMEDIATE GENERAL SUPPORT MAINTENANCE INSTRUCTIONS
REPLACE THE GENERATOR SET
INSTALLATION - TM-5-6115-634-14P_207
REPLACE FAULTY COMPONENT OF SPECIAL RELAY ASSEMBLY
REPLACEMENT - TM-5-6115-634-14P_209
REPLACEMENT (cont)
INSTALLATION - TM-5-6115-634-14P_211
REPLACE ISOLATORS
INSTALLATION - TM-5-6115-634-14P_213
REPLACE THE SKID BASE ASSEMBLY
JUNCTION BOX REPAIR
INSTALLATION - TM-5-6115-634-14P_216
INSTALLATION (cont) - TM-5-6115-634-14P_217
REPLACE THE M200A1 TRAILER
INSTALLATION - TM-5-6115-634-14P_219
APPENDIX A REFERENCES - TM-5-6115-634-14P_221
TECHNICAL MANUALS
APPENDIX B MAINTENANCE ALLOCATION CHART
Explanation of Columns in the MAC, Section II
Explanation of Columns in Tool and Test Equipment Requirements, Section III
Section II. MAINTENANCE ALLOCATION CHART - TM-5-6115-634-14P_226
MAINTENANCE   ALLOCATION   CHART   -   CONTINUED - TM-5-6115-634-14P_227
MAINTENANCE   ALLOCATION   CHART   -   CONTINUED - TM-5-6115-634-14P_228
MAINTENANCE   ALLOCATION   CHART   -   CONTINUED - TM-5-6115-634-14P_229
SECTION Ill. TOOL AND TEST EQUIPMENT REQUIREMENTS
APPENDIX C COMPONENTS OF END ITEM AND BASIC ISSUE ITEMS LIST
Figure C-1. Basic Issue Items
Section III. BASIC ISSUE ITEMS
APPENDIX D ADDITIONAL AUTHORIZATION LIST ITEMS
APPENDIX E EXPENDABLE/DIRABLE SUPPLIES AND MATERIALS LIST
Section I. INTRODUCTION
Source Code - TM-5-6115-634-14P_240
Source Code (cont)
Maintenance Code
PART NUMBER (Column (4))
Explanation of Columns
When National Stock Number or Part Number is known
Figure F-1. Battery Box Assembly, Batteries and Cables
SECTION II. REPAIR PARTS LIST - TM-5-6115-634-14P_247
DECRIPTION - TM-5-6115-634-14P_248
Figure F-2. Generator Set
DECRIPTION - TM-5-6115-634-14P_250
Figure f-3. intake baffle assembly
DECRIPTION - TM-5-6115-634-14P_252
DECRIPTION - TM-5-6115-634-14P_253
Figure F-4. Connector Plate
DECRIPTION - TM-5-6115-634-14P_255
Figure F-5. Access Doors
DECRIPTION - TM-5-6115-634-14P_257
Figure F-6. Generator Set Top Rear Cover
DECRIPTION - TM-5-6115-634-14P_259
Figure F-7. Generator Set Rear Housing
DECRIPTION - TM-5-6115-634-14P_261
Figure F-8. Exhaust Baffle Assembly
DECRIPTION - TM-5-6115-634-14P_263
DECRIPTION - TM-5-6115-634-14P_264
Figure F-9. Generator Set Top Front Cover
DECRIPTION - TM-5-6115-634-14P_266
Figure F-10. Generator Set Front Housing
DECRIPTION - TM-5-6115-634-14P_268
Figure F-11. Power Wiring Harness and Control Wiring Harness
DECRIPTION - TM-5-6115-634-14P_270
DECRIPTION - TM-5-6115-634-14P_271
Figure F-12. Wiring Harnesses
DECRIPTION - TM-5-6115-634-14P_273
DECRIPTION - TM-5-6115-634-14P_274
Figure F-13. Silencer and Exhaust System
DECRIPTION - TM-5-6115-634-14P_276
Figure F-14. Air Cleaner System
DECRIPTION - TM-5-6115-634-14P_278
Figure F-15. Remote Functions Box Assembly
DECRIPTION - TM-5-6115-634-14P_280
Figure F-16. Engine Belt, Fan and Pulley
DECRIPTION - TM-5-6115-634-14P_282
Figure F-17. Fan Guard, Left and Right
DECRIPTION - TM-5-6115-634-14P_284
Figure F-18. Special Relay Assembly (Sheet 1 of 3)
Figure F-18. Special Relay Assembly (Sheet 2 of 3)
Figure F-18. Speical Relay Assembly (Sheet 3 of 3)
DECRIPTION - TM-5-6115-634-14P_288
DECRIPTION - TM-5-6115-634-14P_289
DECRIPTION - TM-5-6115-634-14P_290
DECRIPTION - TM-5-6115-634-14P_291
Figure   F-19. Isolators,   Front   and   Rear
DECRIPTION - TM-5-6115-634-14P_293
Figure F-20. Document Box, Lifting Frame and Skid Base
DECRIPTION - TM-5-6115-634-14P_295
DECRIPTION - TM-5-6115-634-14P_296
Figure F-21. Junction Box Assembly
DECRIPTION - TM-5-6115-634-14P_298
DECRIPTION - TM-5-6115-634-14P_299
Figure F-22. Cable Reel Assembly
DECRIPTION - TM-5-6115-634-14P_301
Figure F-23. Modified Trailer M200A1, Puller Bracket and Storage Pan
DECRIPTION - TM-5-6115-634-14P_303
DECRIPTION - TM-5-6115-634-14P_304
DECRIPTION - TM-5-6115-634-14P_305
Figure F-24. Fender and Step Assemblies
DECRIPTION - TM-5-6115-634-14P_307
DECRIPTION - TM-5-6115-634-14P_308
Figure F-25. Remote Control Unit
DECRIPTION - TM-5-6115-634-14P_311
DECRIPTION - TM-5-6115-634-14P_312
iFigure    F-26. Interconnection    Cables
DECRIPTION - TM-5-6115-634-14P_315
DECRIPTION - TM-5-6115-634-14P_316
DECRIPTION - TM-5-6115-634-14P_317
Figure F-27. Accessories and Schematics
DECRIPTION - TM-5-6115-634-14P_319
DECRIPTION - TM-5-6115-634-14P_320
DECRIPTION - TM-5-6115-634-14P_321
DECRIPTION - TM-5-6115-634-14P_322
SECTION IV. NATIONALSTOCK    ANDPARTNUMBER    INDEX - TM-5-6115-634-14P_323
SECTION IV. NATIONALSTOCK    ANDPARTNUMBER    INDEX - TM-5-6115-634-14P_324
SECTION IV. NATIONALSTOCK    ANDPARTNUMBER    INDEX - TM-5-6115-634-14P_325
SECTION IV. NATIONALSTOCK    ANDPARTNUMBER    INDEX - TM-5-6115-634-14P_326
SECTION IV. NATIONALSTOCK    ANDPARTNUMBER    INDEX - TM-5-6115-634-14P_327
SECTION IV. NATIONALSTOCK    ANDPARTNUMBER    INDEX - TM-5-6115-634-14P_328
SECTION IV. NATIONALSTOCK    ANDPARTNUMBER    INDEX - TM-5-6115-634-14P_329
SECTION IV. NATIONALSTOCK ANDPARTNUMBER INDEX
APPENDIX G ILLUSTRATED LIST OF MANUFACTURED ITEMS
Figure G-1. Fabrication of Battery Cables (Sheet 1 of 2)
PARTS LIST - TM-5-6115-634-14P_333
Figure G-2. Fabrication of Special Relay Assembly to Remote Functions Box Assembly Wiring Harness (Sheet 1 of 2)
PARTS LIST - TM-5-6115-634-14P_335
Figure G-3. Fabrication of Remote Functions Box Assembly to Connector Panel Wiring Harness (Sheet 1 of 2)
PARTS LIST - TM-5-6115-634-14P_337
Figure G-4. Fabrication of SS2P to Convenience Receptacle Wiring Harness (Sheet 1 of 2)
PARTS LIST - TM-5-6115-634-14P_339
Figure G-5. Fabrication of Ground Wire (Sheet 1 of 2)
PARTS LIST - TM-5-6115-634-14P_341
APPENDIX H TORQUE LIMITS (IF APPLICABLE)
ALPHABETICAL INDEX - TM-5-6115-634-14P_345
ALPHABETICAL INDEX (Continued) - TM-5-6115-634-14P_346
ALPHABETICAL INDEX (Continued) - TM-5-6115-634-14P_347
ALPHABETICAL INDEX (Continued) - TM-5-6115-634-14P_348
ALPHABETICAL INDEX (Continued) - TM-5-6115-634-14P_349
ALPHABETICAL INDEX (Continued) - TM-5-6115-634-14P_350
ALPHABETICAL INDEX (Continued) - TM-5-6115-634-14P_351
FO-1. FUEL SYSTEM DIAGRAM
fo-2. power unit schematic and troubleshooting diagrams
FO-3. GENERATOR SET AC CIRCUITS TROUBLESHOOTING DIAGRAM (SHEET 1 OF 2)
FO-3. GENERATOR SET AC CIRCUITS TROUBLESHOOTING DIAGRAM (SHEET 2 0F 2)
FO-4. generator set dc circuits schematic diagram
FO-5. GENERATOR SET AC CIRCUITS SCHEMATIC DIAGRAM
FO-6. GENERATOR SET DC CIRCUITS TROUBLESHOOTING DIAGRAM (SHEET 2 OF 2)
FO-6. GENERATOR SET DC CIRCUITS TROUBLESHOOTING DIAGRAM (SHEET 1 OF 2)

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