Chapter 1. INTRODUCTION - TM-9-6115-673-13-P0023
PREPARATION FOR STORAGE OR SHIPMENT.
WARRANTY INFORMATION. - TM-9-6115-673-13-P0025
Figure 1-1. Military Tactical Generator (MTG) Set - 2 kW
SECTION II. EQUIPMENT DESCRIPTION - TM-9-6115-673-13-P0027
DIFFERENCES BETWEEN MODELS.
Figure 1-2. Location of Major Generator Set Components
EQUIPMENT DATA. - TM-9-6115-673-13-P0030
Table 1-1. Leading Particulars - TM-9-6115-673-13-P0031
Table 1-1. Leading Particulars Continued
SECTION III. TECHNICAL PRINCIPLES OF OPERATION
Figure 1-3. Generator Set Fuel System - TM-9-6115-673-13-P0034
Figure 1-4. Engine Air Intake and Exhaust System
SPEED CONTROL SYSTEM.
Figure 1-5. Diesel Engine Governor
DIESEL ENGINE ELECTRICAL STARTING SYSTEM.
Figure 1-6. Diesel Engine Electrical Starting System
GENERATOR VOLTAGE REGULATION AND OUTPUT SUPPLY (MEP-531A).
Figure 1-7. Generator Voltage Regulation System (MEP-531A)
Figure 1-8. Generator Output Supply System (MEP-531A)
GENERATOR VOLTAGE REGULATION AND OUTPUT SUPPLY (MEP-501A).
Figure 1-9. Generator Voltage Regulation System (MEP-501A)
GENERATOR CONTROL CIRCUIT.
Figure 1-10. Generator Output Supply System (MEP-501A)
Figure 1-11. Generator Control Circuit
LOW OIL PRESSURE PROTECTION.
Chapter 2. OPERATING INSTRUCTIONS - TM-9-6115-673-13-P0049
Figure 2-1. Operator's Controls and Indicators (Sheet 1 of 4)
Figure 2-1. Operator's Controls and Indicators (Sheet 2 of 4)
Figure 2-1. Operator's Controls and Indicators (Sheet 3 of 4)
Figure 2-1. Operator's Controls and Indicators (Sheet 4 of 4)
Table 2-1. Operator Controls and Indicators
Table 2-1. Operator Controls and Indicators Continued
Section II. PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) - TM-9-6115-673-13-P0056
PREVENTIVE MAINTENANCE PROCEDURES. - TM-9-6115-673-13-P0057
Table 2-2. Operator Preventive Maintenance Checks and Services
Table 2-2. Operator Preventive Maintenance Checks and Services (Continued) - TM-9-6115-673-13-P0059
Table 2-2. Operator Preventive Maintenance Checks and Services (Continued) - TM-9-6115-673-13-P0060
Table 2-2. Operator Preventive Maintenance Checks and Services (Continued) - TM-9-6115-673-13-P0061
Table 2-2. Operator Preventive Maintenance Checks and Services (Continued) - TM-9-6115-673-13-P0062
Table 2-2. Operator Preventive Maintenance Checks and Services (Continued) - TM-9-6115-673-13-P0063
Section III. OPERATION UNDER USUAL CONDITIONS - TM-9-6115-673-13-P0064
Figure 2-2. Grounding Connections (Typical Installation)
Figure 2-3. Installation of Load Cables
Figure 2-4. Fuel Filter Bleed Screws
INITIAL ADJUSTMENTS AND CHECKS.
Manual Starting [23F (-5C) to 122F (50C)].
Figure 2-5. Air Intake Cover, Normal Operation
Electric Starting [23F (-5C) to 122F (50C)].
Electric Starting [Between 23F (-5C) to -5F (-21C)].
Figure 2-6. Engine RUN and STOP Controls
Electric Starting [Between -5F (-21C) to -25F (-32C)].
Figure 2-7. Air Intake Cover, Cold Operation
Figure 2-8. Adding Oil Cylinder Head Cover Opening
IDENTIFICATION AND INSTRUCTION PLATES.
Figure 2-9. Identification and Instruction Plates (Sheet 1 of 2)
Figure 2-9. Identification and Instruction Plates (Sheet 2 of 2)
Section IV. OPERATION UNDER UNUSUAL CONDITIONS - TM-9-6115-673-13-P0080
Operation in Dusty or Sandy Areas.
NUCLEAR, BIOLOGICAL, AND CHEMICAL DECONTAMINATION PROCEDURES.
Chapter 3. OPERATOR MAINTENANCE INSTRUCTIONS
Section II. TROUBLESHOOTING - TM-9-6115-673-13-P0084
Table 3-1. Diesel Engine Will Not Start (Manual Starting) Troubleshooting
Table 3-2. Diesel Engine Will Not Start (Electric Starting) Troubleshooting
Table 3-3. Diesel Engine Runs Rough Troubleshooting
Table 3-4. Voltage Output Drops Troubleshooting
Table 3-5. Generator Set Vibrating/Bouncing Excessively Troubleshooting
Table 3-6. No Voltage Indication on VOLTS Meter (M2) Troubleshooting
Table 3-7. Voltage Indication on VOLTS Meter (M2) is High, Low, or Fluctuating Troubleshooting
Table 3-8. No Indication on %LOAD Meter (M1) With Load Applied Troubleshooting
Table 3-9. No Indication on HERTZ Frequency Meter (M4) (MEP-531A) Troubleshooting
Table 3-10. HOURS Meter (M3) Not Operating Troubleshooting
Table 3-11. Excessive Voltage Drop When Applying Load Troubleshooting
Section III. OPERATOR MAINTENANCE PROCEDURES - TM-9-6115-673-13-P0096
Figure 3-1. Fuse (F1) Replacement
Chapter 4. UNIT MAINTENANCE INSTRUCTIONS
Section II. REPAIR PARTS; TOOLS; SPECIAL TOOLS; TEST, MEASUREMENT AND DIAGNOSTIC EQUIPMENT (TMDE); AND SUPPORT EQUIPMENT
Section III. SERVICE UPON RECEIPT
Figure 4-1. Oil Level
INSTALLATION. - TM-9-6115-673-13-P0103
Section IV. PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
PREVENTIVE MAINTENANCE PROCEDURES. - TM-9-6115-673-13-P0105
PREVENTIVE MAINTENANCE PROCEDURES. (cont)
Table 4-1. Unit Preventive Maintenance Checks and Services
Table 4-1. Unit Preventive Maintenance Checks and Services (Continued) - TM-9-6115-673-13-P0108
Table 4-1. Unit Preventive Maintenance Checks and Services (Continued) - TM-9-6115-673-13-P0109
Table 4-1. Unit Preventive Maintenance Checks and Services (Continued) - TM-9-6115-673-13-P0110
DETAILED PREVENTIVE MAINTENANCE PROCEDURES.
Figure 4-2. Fuel Filter Element Replacement
Air Filter Element Replacement.
Fuel Injector Replacement.
Figure 4-4. Fuel Injector Replacement
Figure 4-5. AC Alternator Brushes
Alternator Flexible Coupling Inspection. (MEP-501A)
Engine Resilient Mounts Replacement.
Alternator Resilient Mount Replacement. (MEP-531A)
Alternator Resilient Mount Replacement. (MEP-501A)
Cylinder Head Nuts Tightening.
Intake and Exhaust Valve Adjustment.
Figure 4-10. T Position Mark
Section V. TROUBLESHOOTING - TM-9-6115-673-13-P0124
Symptom
Table 4-2. Diesel Engine Will Not Start (Manual Starting) Troubleshooting
Table 4-3. Diesel Engine Will Not Start (Electric Starting) Troubleshooting (Sheet 1 of 2)
Table 4-3. Diesel Engine Will Not Start (Electric Starting) Troubleshooting (Sheet 2 of 2)
Table 4-4. Diesel Engine Hard To Start Troubleshooting
Table 4-5. Diesel Engine Starts But Fails to Keep Running Troubleshooting
Table 4-6. Diesel Engine Runs Erratic Troubleshooting (Sheet 1 of 2)
Table 4-6. Diesel Engine Runs Erratic Troubleshooting (Sheet 2 of 2)
Table 4-7. Unexpected Reverse Rotation at Startup Troubleshooting
Table 4-8. Diesel Engine Stops During Operation Troubleshooting (Sheet 1 of 2)
Table 4-8. Diesel Engine Stops During Operation Troubleshooting (Sheet 2 of 2)
Table 4-9. Diesel Engine Exhausts Black Smoke Troubleshooting
Table 4-10. Diesel Engine Exhausts Blue-White Smoke Troubleshooting
Table 4-11. Recoil Start Rope Hard to Pull Troubleshooting
Table 4-12. Voltage Output Drops (MEP-531A) Troubleshooting
Table 4-13. Voltage Output Drops (MEP-501A) Troubleshooting
Table 4-14. Generator Set Vibrating/Bouncing Excessively Troubleshooting
Table 4-15. No Voltage Indication On VOLTS Meter (M2) Troubleshooting
Table 4-16. No Indication On %LOAD Meter (M1) Troubleshooting (MEP-531A)
Table 4-17. No Indication On %LOAD Meter (M1) Troubleshooting (MEP-501A)
Table 4-18. No Indication On HERTZ Frequency Meter (M4) Troubleshooting (MEP-531A)
Table 4-19. No Indication On HOURS Meter (M3) Troubleshooting
Table 4-20. No Output From Alternator Troubleshooting (MEP-531A)
Table 4-21. No Output From Alternator Troubleshooting (MEP-501A)
Table 4-22. Air Intake Preheaters Do Not Operate Troubleshooting
Table 4-23. Cannot Adjust Alternator Output With VOLTAGE ADJ. Potentiometer Troubleshooting
Section VI. UNIT MAINTENANCE PROCEDURES
FUEL LINES, CLAMPS, FITTINGS, ETC.
FUEL FILTER ASSEMBLY.
Removal. - TM-9-6115-673-13-P0154
FUEL DRAIN COCK.
FUEL TANK ASSEMBLY.
Disassembly. - TM-9-6115-673-13-P0157
Figure 4-15. Fuel Tank Assembly
Assembly. - TM-9-6115-673-13-P0159
AIR INTAKE SYSTEM COMPONENTS.
EXHAUST SYSTEM COMPONENTS.
Figure 4-17. Exhaust System Components
CONTROL PANEL ASSEMBLY. - TM-9-6115-673-13-P0163
Figure 4-19. Control Panel Assembly
INSTRUCTION PLATE (S).
INSTRUMENT COVER.
INSTRUMENT PANEL. - TM-9-6115-673-13-P0167
Figure 4-22. Instrument Panel
Repair. - TM-9-6115-673-13-P0169
HERTZ FREQUENCY METER. (MEP-531A)
VOLTS METER.
Testing. (VOLTS DC Meter)
%LOAD METER.
Testing. (MEP-531A)
Removal. - TM-9-6115-673-13-P0175
HOURS METER.
Testing. - TM-9-6115-673-13-P0177
VOLTAGE ADJ. POTENTIOMETER.
Removal. - TM-9-6115-673-13-P0179
INSTRUMENT SHUNT. (MEP-501A)
Figure 4-28. Instrument Shunt (MEP-501A)
CAPACITOR. (MEP-501A)
TRANSIENT SUPPRESSOR ASSEMBLY. (MEP-501A)
Figure 4-30. Transient Suppressor Assembly (MEP-501A)
FUSEHOLDER (S).
GROUND STRAP (S).
GFCI RECEPTACLE AND RECEPTACLE COVER. (MEP-531A)
Figure 4-33. GFCI Receptacle and Receptacle Cover (MEP-531A)
START-PREHEAT/PREHEAT/OFF/START ROTARY SWITCH.
Figure 4-34. START-PREHEAT/PREHEAT/OFF/START Rotary Switch
DISCHARGE VARISTOR.
NATO SLAVE RECEPTACLE.
LOAD TERMINAL (S). (MEP-501A AND MECHRON SETS)
Figure 4-37. Load Terminal(s) (MEP-501A and Mechron Sets)
TERMINAL BOARD.
Figure 4-38. Terminal Board
LOAD TERMINAL BOARD. (MEP-501A AND MECHRON SETS).
ON-OFF LOAD CIRCUIT BREAKER ASSEMBLY AND BOOT.
Testing. (MEP-501A)
Figure 4-40. ON-OFF Load Circuit Breaker Assembly and Boot
FLYWHEEL DIODE ASSEMBLY.
DIESEL ENGINE WIRING HARNESS AND GASKET, CONTROL PANEL.
Testing. - TM-9-6115-673-13-P0203
ALTERNATOR WIRING HARNESS AND GASKET, CONTROL PANEL.
Testing. - TM-9-6115-673-13-P0205
Figure 4-43. Alternator Wiring Harness and Gasket, Control Panel
ELECTRICAL LEAD WIRE (S) (TYPICAL).
LOAD TERMINAL BOARD COVER (LUG COVER).
Figure 4-45. Load Terminal Board Cover (Lug Cover)
EMI FILTER (MEP-531A).
Figure 4-46. EMI Filter (MEP-531A)
LOW OIL PRESSURE (LOP) SWITCH.
Figure 4-47. Low Oil Pressure (LOP) Switch
LOW OIL PRESSURE (LOP) SOLENOID ASSEMBLY.
Figure 4-48. Low Oil Pressure (LOP) Solenoid Assembly
LOW OIL PRESSURE (LOP) ENGINE SHUTDOWN CABLE.
Figure 4-49. Low Oil Pressure (LOP) Engine Shutdown Cable
AIR INTAKE HEATING ELEMENTS AND PIPE.
Figure 4-51. Air Intake Heating Elements and Pipe
GOVERNOR REGULATOR BRACKET.
Figure 4-52. Governor Regulator Bracket
Figure 4-53. Governor Spring Positioning
COOLING FAN COVER.
RECOIL STARTER ASSEMBLY.
ENGINE OIL STRAINER.
Cleaning and Inspection.
VALVE COVER.
STARTER ASSEMBLY. (MEP-501A)
Figure 4-59. Starter Assembly
Figure 4-60. Engine Wiring Harness
ALTERNATOR WIRING HARNESS. (MEP-501A)
Figure 4-61. Alternator Wiring Harness
PREHEATER LEAD.
GROUND STUD TERMINAL.
FRAME. - TM-9-6115-673-13-P0235
Figure 4-64. Frame
Section VII. PREPARATION FOR SHIPMENT AND STORAGE
PACKING.
Chapter 5. DIRECT SUPPORT MAINTENANCE INSTRUCTIONS - TM-9-6115-673-13-P0239
Section II. TROUBLESHOOTING - TM-9-6115-673-13-P0240
Symptom Index.
Table 5-1. Diesel Engine Will Not Start (Manual Starting) Troubleshooting
Table 5-2. Diesel Engine Hard To Start Troubleshooting
Table 5-3. Diesel Engine Starts But Fails to Keep Running Troubleshooting
Table 5-4. Diesel Engine Runs Rough Troubleshooting
Table 5-5. Unexpected Reverse Rotation at Startup Troubleshooting
Table 5-6. Diesel Engine Races Exceeding Governed Speed Troubleshooting
Table 5-7. Diesel Engine Runs Unevenly (Surges) Troubleshooting
Table 5-8. Diesel Engine Seizes During Operation Troubleshooting
Table 5-9. Diesel Engine Exhausts Black Smoke Troubleshooting
Table 5-10. Diesel Engine Exhausts Blue-White Smoke Troubleshooting
Table 5-11. Recoil Start Rope Hard To Pull Troubleshooting
Table 5-12. Voltage Output Drops Troubleshooting
Table 5-14. No Indication On HOURS Meter (M3) Troubleshooting
Table 5-15. No Output Voltage (MEP-531A) Troubleshooting
Table 5-16. No Output Voltage (MEP-501A) Troubleshooting
Table 5-17. Cannot Adjust Alternator Output With VOLTAGE ADJ. Potentiometer Troubleshooting
Table 5-18. Generator Set Vibrating/Bouncing Excessively (MEP-531A) Troubleshooting
Section III. DIRECT SUPPORT MAINTENANCE PROCEDURES - TM-9-6115-673-13-P0260
GENERATOR CONTROL UNIT.
Testing (MEP-501A). - TM-9-6115-673-13-P0262
Testing (MEP-501A). (cont)
Figure 5-1. Generator Control Unit (MEP-531A)
VOLTAGE REGULATOR ASSEMBLY.
Testing (MEP-501A). - TM-9-6115-673-13-P0266
Figure 5-2. Voltage Regulator Assembly (MEP-531A)
DIESEL ENGINE WIRING HARNESS, CONTROL PANEL.
ENGINE/ALTERNATOR ASSEMBLY.
Figure 5-3 Engine/Alternator Assembly
DIESEL ENGINE.
STARTER. (MEP-531A)
ROCKER ARMS AND PUSH RODS.
Inspection. - TM-9-6115-673-13-P0274
CYLINDER HEAD ASSEMBLY.
Figure 5-6. Cylinder Head Assembly
INTAKE AND EXHAUST VALVES.
Figure 5-7. Intake and Exhaust Valves
Figure 5-9. Measuring Valve Sinkage
FUEL INJECTION PUMP.
Figure 5-11. Fuel Injection Pump Removal
Figure 5-12. Governor Linkage Setting
Figure 5-13. Fuel Injection Limitation Setting
Figure 5-14. T Position Mark
CRANKCASE COVER.
Figure 5-15. Crankcase Cover
OIL PUMP ASSEMBLY.
Figure 5-16. Oil Pump Assembly
CAMSHAFT.
Figure 5-17. Camshaft
Figure 5-18. Positioning Camshaft Bearing in Cylinder Block
BALANCER SHAFT.
PISTON AND CONNECTING ROD ASSEMBLY.
Figure 5-22. Piston and Connecting Rod Assembly
Figure 5-23. Measuring Piston Ring Width
Figure 5-24. Measuring Side Clearance Between Ring and Piston Groove
Figure 5-26. Measuring Large End Hole Diameter
Figure 5-27. Measuring Crank Pin Clearance
FLYWHEEL.
Figure 5-29. Flywheel Locking Handle
Figure 5-31. Flywheel Extractor
Figure 5-32. Crankshaft Assembly
Figure 5-33. Positioning Crankshaft Bearing in Crankcase Cover.
DYNAMO.
Removal. - TM-9-6115-673-13-P0305
GOVERNOR GEAR.
Figure 5-36. Governor Gear
CYLINDER BLOCK.
Figure 5-38. Cylinder Block
AC ALTERNATOR ASSEMBLY. (MEP-531A)
Figure 5-39. AC Alternator Assembly (MEP-531A) (Sheet 1 of 2)
Figure 5-39. AC Alternator Assembly (MEP-531A) (Sheet 2 of 2)
Inspection. - TM-9-6115-673-13-P0313
Assembly. - TM-9-6115-673-13-P0314
Table 5-19. Power Harness Connector Plug Connections
Installation. - TM-9-6115-673-13-P0316
AC ALTERNATOR BEARING. (MEP-531A)
DC ALTERNATOR ASSEMBLY. (MEP-501A)
Figure 5-41. DC Alternator Installation (MEP-501A)
Inspection. - TM-9-6115-673-13-P0320
Figure 5-42. DC Alternator Assembly
Figure 5-43. Heatsink Tie Point Locations
Figure 5-44. Brush Assembly Test
Figure 5-46. Rotor Test
Installation. - TM-9-6115-673-13-P0325
DC ALTERNATOR BEARINGS. (MEP-501A)
DC ALTERNATOR DIODES AND CAPACITORS. (MEP-501A)
Testing. - TM-9-6115-673-13-P0328
Figure 5-48. Diodes and Capacitor Replacement
FRAME. - TM-9-6115-673-13-P0330
Installation. - TM-9-6115-673-13-P0331
Appendix A. REFERENCES - TM-9-6115-673-13-P0333
TECHNICAL BULLETINS - TM-9-6115-673-13-P0334
Appendix B. MAINTENANCE ALLOCATION CHART - TM-9-6115-673-13-P0335
MAINTENANCE FUNCTIONS - TM-9-6115-673-13-P0336
EXPLANATION OF COLUMNS IN THE MAC, SECTION II - TM-9-6115-673-13-P0337
EXPLANATION OF COLUMNS IN REMARKS, SECTION IV - TM-9-6115-673-13-P0338
Section II. MAINTENANCE ALLOCATION CHART FOR MEP-501A AND MEP-531A
Section II. MAINTENANCE ALLOCATION CHART FOR MEP-501A AND MEP-531A (cont) - TM-9-6115-673-13-P0340
Section II. MAINTENANCE ALLOCATION CHART FOR MEP-501A AND MEP-531A (cont) - TM-9-6115-673-13-P0341
Section II. MAINTENANCE ALLOCATION CHART FOR MEP-501A AND MEP-531A (cont) - TM-9-6115-673-13-P0342
Section II. MAINTENANCE ALLOCATION CHART FOR MEP-501A AND MEP-531A (cont) - TM-9-6115-673-13-P0343
Section II. MAINTENANCE ALLOCATION CHART FOR MEP-501A AND MEP-531A (cont) - TM-9-6115-673-13-P0344
Section III. TOOLS AND TEST EQUIPMENT REQUIREMENTS FOR MEP-501A AND MEP-531A
Section IV. REMARKS - TM-9-6115-673-13-P0346
Appendix C. COMPONENTS OF END ITEM (COEI) AND BASIC ISSUE ITEMS LISTS (BIIL)
EXPLANATION OF COLUMNS - TM-9-6115-673-13-P0348
Section III. BASIC ISSUE ITEMS - TM-9-6115-673-13-P0349
Appendix D. ADDITIONAL AUTHORIZATION LIST
Section II. ADDITIONAL AUTHORIZATION LIST - 2 kW Military Tactical Generator Sets
Appendix E. EXPENDABLE AND DURABLE ITEMS LIST
Section II. EXPENDABLE AND DURABLE ITEMS LIST
Appendix F. UNIT AND DIRECT SUPPORT MAINTENANCE REPAIR PARTS AND SPECIAL TOOLS LIST
Section I. INTRODUCTION - TM-9-6115-673-13-P0357
Source Code - TM-9-6115-673-13-P0358
Source Code (cont)
Maintenance Code - TM-9-6115-673-13-P0360
Recoverability Code - TM-9-6115-673-13-P0361
Part Number [Column (4)]
EXPLANATION OF COLUMNS (Section IV) - TM-9-6115-673-13-P0363
SPECIAL INFORMATION - TM-9-6115-673-13-P0364
HOW TO LOCATE REPAIR PARTS - TM-9-6115-673-13-P0365
Figure F-1. Generator Set Assembly, 2kW (MEP531A/501A) (Sheet 1 of 2)
Figure F-1. Generator Set Assembly, 2kW (MEP-531A/501A) (Sheet 2 of 2)
Repair Parts List - TM-9-6115-673-13-P0369
Repair Parts List (cont) - TM-9-6115-673-13-P0370
Figure F-2. Frame Assembly (MEP-531A/501A)
Repair Parts List (cont) - TM-9-6115-673-13-P0373
Figure F-3. Fuel System Assembly (MEP-531A/501A)
Repair Parts List (cont) - TM-9-6115-673-13-P0375
Figure F-4. Fuel Tank Assembly
Repair Parts List (cont) - TM-9-6115-673-13-P0377
Figure F-5. Fuel Filter Assembly
Repair Parts List (cont) - TM-9-6115-673-13-P0379
Figure F-6. Engine Alternator Assembly (MEP-531A) (Sheet 1 of 2)
Figure F-6. Engine Alternator Assembly (MEP-531A) (Sheet 2 of 2)
Repair Parts List (cont) - TM-9-6115-673-13-P0383
Figure F-7. Engine Alternator Assembly (MEP-501A)
Repair Parts List (cont) - TM-9-6115-673-13-P0385
Figure F-8. Diesel Engine Modified
Repair Parts List (cont) - TM-9-6115-673-13-P0387
Figure F-9. Diesel Engine Assembly
Repair Parts List (cont) - TM-9-6115-673-13-P0389
Figure F-10. Cylinder Block Installation
Repair Parts List (cont) - TM-9-6115-673-13-P0391
Figure F-11. Cylinder Head Installation
Repair Parts List (cont) - TM-9-6115-673-13-P0393
Figure F-12. Air Intake Pipe and Muffler
Repair Parts List (cont) - TM-9-6115-673-13-P0395
Figure F-13. Cam/Crankshaft/Balancer Installation
Repair Parts List (cont) - TM-9-6115-673-13-P0397
Figure F-14. Piston and Rod Assembly
Repair Parts List (cont) - TM-9-6115-673-13-P0399
Figure F-15. Lube Oil Pump and Governor
Repair Parts List (cont) - TM-9-6115-673-13-P0401
Figure F-16. Cooling/Starting Installation
Repair Parts List (cont) - TM-9-6115-673-13-P0403
Figure F-17. Fuel Injection Pump/Injector Installation
Repair Parts List (cont) - TM-9-6115-673-13-P0405
Figure F-18. Starting Motor and Dynamo Installation
Repair Parts List (cont) - TM-9-6115-673-13-P0407
Figure F-19. AC Alternator Assembly (MEP-531A)
Repair Parts List (cont) - TM-9-6115-673-13-P0409
Figure F-20. DC Alternator Assembly (MEP-501A) (Sheet 1 of 2)
Figure F-20. DC Alternator Assembly (MEP-501A) (Sheet 2 of 2)
Repair Parts List (cont) - TM-9-6115-673-13-P0413
Repair Parts List (cont) - TM-9-6115-673-13-P0414
Figure F-21. Control Panel Assembly (MEP-531A) (Sheet 1 of 3)
Figure F-21. Control Panel Assembly (MEP-531A) (Sheet 2 of 3)
Figure F-21. Control Panel Assembly (MEP-531A) (Sheet 3 of 3)
Repair Parts List (cont) - TM-9-6115-673-13-P0419
Repair Parts List (cont) - TM-9-6115-673-13-P0420
Repair Parts List (cont) - TM-9-6115-673-13-P0421
Figure F-22. Control Panel Assembly (MEP-501A) (Sheet 1 of 3)
Figure F-22. Control Panel Assembly (MEP-501A) (Sheet 2 of 3)
Figure F-22. Control Panel Assembly (MEP-501A) (Sheet 3 of 3)
Repair Parts List (cont) - TM-9-6115-673-13-P0425
Repair Parts List (cont) - TM-9-6115-673-13-P0426
Figure F-23. Control Panel Construction (MEP-531A/501A)
Repair Parts List (cont) - TM-9-6115-673-13-P0429
Figure F-24. Voltage Adjust Potentiometer
Repair Parts List (cont) - TM-9-6115-673-13-P0431
Figure F-25. LOP Shutdown Solenoid Assembly
Repair Parts List (cont) - TM-9-6115-673-13-P0433
Figure F-26. Control Panel Engine Wiring Harnesses (MEP-531A/501A)
Repair Parts List (cont) - TM-9-6115-673-13-P0435
Figure F-27. Control Panel Alternator Wiring Harnesses (MEP-531A/501A)
Repair Parts List (cont) - TM-9-6115-673-13-P0437
Figure F-28. Flywheel Diode Assembly
Repair Parts List (cont) - TM-9-6115-673-13-P0439
Figure F-29. Control Panel Electrical Leads (MEP-531A) (Sheet 1 of 5)
Figure F-29. Control Panel Electrical Leads (MEP-531A) (Sheet 2 of 5)
Figure F-29. Control Panel Electrical Leads (MEP-531A) (Sheet 3 of 5)
Figure F-29. Control Panel Electrical Leads (MEP-531A) (Sheet 4 of 5)
Figure F-29. Control Panel Electrical Leads (MEP-531A) (Sheet 5 of 5)
Repair Parts List (cont) - TM-9-6115-673-13-P0445
Repair Parts List (cont) - TM-9-6115-673-13-P0446
Repair Parts List (cont) - TM-9-6115-673-13-P0447
Repair Parts List (cont) - TM-9-6115-673-13-P0448
Figure F-30. Control Panel Electrical Leads (MEP-501A) (Sheet 1 of 6)
Figure F-30. Control Panel Electrical Leads (MEP-501A) (Sheet 2 of 6)
Figure F-30. Control Panel Electrical Leads (MEP-501A) (Sheet 3 of 6)
Figure F-30. Control Panel Electrical Leads (MEP-501A) (Sheet 4 of 6)
Figure F-30. Control Panel Electrical Leads (MEP-501A) (Sheet 5 of 6)
Figure F-30. Control Panel Electrical Leads (MEP-501A) (Sheet 6 of 6)
Repair Parts List (cont) - TM-9-6115-673-13-P0455
Repair Parts List (cont) - TM-9-6115-673-13-P0456
Repair Parts List (cont) - TM-9-6115-673-13-P0457
Repair Parts List (cont) - TM-9-6115-673-13-P0458
Repair Parts List (cont) - TM-9-6115-673-13-P0459
Figure F-31. Capacitor Assembly (MEP-501A)
Repair Parts List (cont) - TM-9-6115-673-13-P0461
Figure F-32. Transient Suppressor Assembly (MEP-501A)
Repair Parts List (cont) - TM-9-6115-673-13-P0463
Figure F-33. Engine Wiring Harness (MEP-531A/501A)
Repair Parts List (cont) - TM-9-6115-673-13-P0465
Figure F-34. LOP Engine Shutdown Cable Assembly (MEP-531A/501A)
Repair Parts List (cont) - TM-9-6115-673-13-P0467
Figure F-35. Preheater Lead Assembly (MEP-531A/501A)
Repair Parts List (cont) - TM-9-6115-673-13-P0469
Figure F-36. Alternator Wiring Harness (MEP-501A)
Repair Parts List (cont) - TM-9-6115-673-13-P0471
Repair Parts List (cont) - TM-9-6115-673-13-P0473
Figure F-37. Special Tools for Direct Support Maintenance (Diesel Engine)
NATIONAL STOCK NUMBER INDEX - TM-9-6115-673-13-P0477
NATIONAL STOCK NUMBER INDEX (cont) - TM-9-6115-673-13-P0478
NATIONAL STOCK NUMBER INDEX (cont) - TM-9-6115-673-13-P0479
NATIONAL STOCK NUMBER INDEX (cont) - TM-9-6115-673-13-P0480
PART NUMBER INDEX - TM-9-6115-673-13-P0481
PART NUMBER INDEX (cont) - TM-9-6115-673-13-P0482
PART NUMBER INDEX (cont) - TM-9-6115-673-13-P0483
PART NUMBER INDEX (cont) - TM-9-6115-673-13-P0484
PART NUMBER INDEX (cont) - TM-9-6115-673-13-P0485
PART NUMBER INDEX (cont) - TM-9-6115-673-13-P0486
PART NUMBER INDEX (cont) - TM-9-6115-673-13-P0487
PART NUMBER INDEX (cont) - TM-9-6115-673-13-P0488
PART NUMBER INDEX (cont) - TM-9-6115-673-13-P0489
PART NUMBER INDEX (cont) - TM-9-6115-673-13-P0490
PART NUMBER INDEX (cont) - TM-9-6115-673-13-P0491
PART NUMBER INDEX (cont) - TM-9-6115-673-13-P0492
PART NUMBER INDEX (cont) - TM-9-6115-673-13-P0493
PART NUMBER INDEX (cont) - TM-9-6115-673-13-P0494
PART NUMBER INDEX (cont) - TM-9-6115-673-13-P0495
PART NUMBER INDEX (cont) - TM-9-6115-673-13-P0496
PART NUMBER INDEX (cont) - TM-9-6115-673-13-P0497
PART NUMBER INDEX (cont) - TM-9-6115-673-13-P0498
PART NUMBER INDEX (cont) - TM-9-6115-673-13-P0499
PART NUMBER INDEX (cont) - TM-9-6115-673-13-P0500
PART NUMBER INDEX (cont) - TM-9-6115-673-13-P0501
FIGURE AND ITEM NUMBER INDEX - TM-9-6115-673-13-P0502
FIGURE AND ITEM NUMBER INDEX (cont) - TM-9-6115-673-13-P0503
FIGURE AND ITEM NUMBER INDEX (cont) - TM-9-6115-673-13-P0504
FIGURE AND ITEM NUMBER INDEX (cont) - TM-9-6115-673-13-P0505
FIGURE AND ITEM NUMBER INDEX (cont) - TM-9-6115-673-13-P0506
FIGURE AND ITEM NUMBER INDEX (cont) - TM-9-6115-673-13-P0507
FIGURE AND ITEM NUMBER INDEX (cont) - TM-9-6115-673-13-P0508
FIGURE AND ITEM NUMBER INDEX (cont) - TM-9-6115-673-13-P0509
FIGURE AND ITEM NUMBER INDEX (cont) - TM-9-6115-673-13-P0510
FIGURE AND ITEM NUMBER INDEX (cont) - TM-9-6115-673-13-P0511
FIGURE AND ITEM NUMBER INDEX (cont) - TM-9-6115-673-13-P0512
FIGURE AND ITEM NUMBER INDEX (cont) - TM-9-6115-673-13-P0513
FIGURE AND ITEM NUMBER INDEX (cont) - TM-9-6115-673-13-P0514
FIGURE AND ITEM NUMBER INDEX (cont) - TM-9-6115-673-13-P0515
FIGURE AND ITEM NUMBER INDEX (cont) - TM-9-6115-673-13-P0516
FIGURE AND ITEM NUMBER INDEX (cont) - TM-9-6115-673-13-P0517
FIGURE AND ITEM NUMBER INDEX (cont) - TM-9-6115-673-13-P0518
FIGURE AND ITEM NUMBER INDEX (cont) - TM-9-6115-673-13-P0519
FIGURE AND ITEM NUMBER INDEX (cont) - TM-9-6115-673-13-P0520
FIGURE AND ITEM NUMBER INDEX (cont) - TM-9-6115-673-13-P0521
FIGURE AND ITEM NUMBER INDEX (cont) - TM-9-6115-673-13-P0522
Appendix G. ILLUSTRATED LIST OF MANUFACTURED ITEMS - TM-9-6115-673-13-P0523
Figure G-1. Potentiometer, VOLTAGE ADJ. (P/N: 95-8077)
Figure G-2. Potentiometer, VOLTAGE ADJ. (P/N: 95-8014)
Figure G-3. Flywheel Diode Assembly (P/N: 95-8050)
Figure G-4. Capacitor Assembly (P/N: 95-8017)
Figure G-5. LOP Solenoid Valve Assembly (P/N: 95-8019)
Figure G-6. Wiring Harness, Control Panel (P/N: 95-8084)(Sheet 1 of 2)
Figure G-6. Wiring Harness, Control Panel (P/N: 95-8084)(Sheet 2 of 2)
Figure G-7. Wiring Harness, Control Panel (P/N: 95-8023)(Sheet 1 of 2)
Figure G-7. Wiring Harness, Control Panel (P/N: 95-8023)(Sheet 2 of 2)
Figure G-8. Wiring Harness, Control Panel (P/N: 95-8075)(Sheet 1 of 2)
Figure G-8. Wiring Harness, Control Panel (P/N: 95-8075)(Sheet 2 of 2)
Figure G-9. Wiring Harness, Control Panel (P/N: 95-8022)(Sheet 1 of 2)
Figure G-9. Wiring Harness, Control Panel (P/N: 95-8022) (Sheet 2 of 2)
Figure G-10. Wiring Harness, Engine (P/N: 95-8029) (Sheet 1 of 3)
Figure G-10. Wiring Harness, Engine (P/N: 95-8029) (Sheet 2 of 3)
Figure G-10. Wiring Harness, Engine (P/N: 95-8029) (Sheet 3 of 3)
Figure G-11. LOP Shutdown Cable (P/N: 95-8082)
Figure G-12. Preheater Lead, Electrical (P/N: 95-8141)
Figure G-13. Wiring Harness, Alternator (P/N: 95-8028) (Sheet 1 of 2)
Figure G-13. Wiring Harness, Alternator (P/N: 95-8028) (Sheet 2 of 2)
Figure G-14. Transient Suppressor (P/N: 95-8025)
Figure G-15. Flywheel Locking Handle (P/N: 114250-92101)
Figure G-16. Flywheel Extractor (P/N: 114250-92130)
Table G-1. Electrical Lead Fabrication for Control Panel (MEP-531A)
Table G-2. Electrical Lead Fabrication for Control Panel (MEP-501A)
Appendix H. TORQUE LIMITS
Table H-1. Torque Limits for Steel Fasteners
Appendix I. MANDATORY REPLACEMENT PARTS
Appendix J. DEWEY/MECHRON CROSS-REFERENCE LIST
Table J-1. MEP-531A Cross-Reference List for Component Identifiers
Table J-2. MEP-531A Cross-Reference List for Wiring Identifiers
Table J-2. MEP-531A Cross-Reference List for Wiring Identifiers - Continued - TM-9-6115-673-13-P0558
Table J-2. MEP-531A Cross-Reference List for Wiring Identifiers - Continued - TM-9-6115-673-13-P0559
Table J-3. MEP-501A Cross-Reference List for Component Identifiers
Table J-3. MEP-501A Cross-Reference List for Component Identifiers - Continued
Table J-4. MEP-501A Cross-Reference List for Wiring Identifiers
Table J-4. MEP-501A Cross-Reference List for Wiring Identifiers - Continued - TM-9-6115-673-13-P0563
Table J-4. MEP-501A Cross-Reference List for Wiring Identifiers - Continued - TM-9-6115-673-13-P0564
Appendix K. SPECIAL PACKAGING INSTRUCTIONS
Special Packaging Instructions, MEP-531A (Sheet 2 of 2)
Special Packaging Instructions, MEP-501A (Sheet 1 of 2)
Special Packaging Instructions, MEP-501A (Sheet 2 of 2)
Appendix L. COMPONENTS AND INSTRUCTIONS FOR AUXILIARY FUEL SYSTEM
EXPLANATION OF COLUMNS - TM-9-6115-673-13-P0570
Auxiliary Fuel System Instructions
Pre-assembly Instructions
Assembly Instructions
Disassembly Instructions
Figure L-1. Auxiliary Fuel System (Sheet 1 of 2)
Figure L-1. Auxiliary Fuel System (Sheet 2 of 2)
Table L-1. Auxiliary Fuel System Components
Figure L-2. Three Way Valve Bracket
NOTES TO FIGURE L-2
Figure L-3. Auxiliary Fuel tank Bracket
NOTES TO FIGURE L-3
Figure L-4. 2 KW Set with Auxiliary Fuel System Installed
Figure L-5. Fuel Can Bracket Shown in the Stowed Position
Appendix M. 2 KW DEPROCESSING CHECKLIST
DEPROCESSING CHECKSHEET
Deprocessing Servicing.
Quality Deficiency Report (QDR)
Figure FO-1. Electrical Schematic, MEP-531A
Figure FO-2. Electrical Schematic, MEP-501A
Figure FO-3. Wiring Diagram, MEP-531A
Figure FO-4. Wiring Diagram, MEP-501A
Figure FO-5. Generator Set Schematic, Mechron 120 VAC
Figure FO-6. Generator Set Schematic, Mechron 28 VDC
TM-9-6115-673-13-P 2 Kw Military Tactical Generators Sets 120 VAC 60 Hz: MEP-531A (Dewey) Mechron 28 VDC: MEP-501A (Dewey) Manual
PREPARATION FOR STORAGE OR SHIPMENT.
WARRANTY INFORMATION. - TM-9-6115-673-13-P0025
Figure 1-1. Military Tactical Generator (MTG) Set - 2 kW
SECTION II. EQUIPMENT DESCRIPTION - TM-9-6115-673-13-P0027
DIFFERENCES BETWEEN MODELS.
Figure 1-2. Location of Major Generator Set Components
EQUIPMENT DATA. - TM-9-6115-673-13-P0030
Table 1-1. Leading Particulars - TM-9-6115-673-13-P0031
Table 1-1. Leading Particulars Continued
SECTION III. TECHNICAL PRINCIPLES OF OPERATION
Figure 1-3. Generator Set Fuel System - TM-9-6115-673-13-P0034
Figure 1-4. Engine Air Intake and Exhaust System
SPEED CONTROL SYSTEM.
Figure 1-5. Diesel Engine Governor
DIESEL ENGINE ELECTRICAL STARTING SYSTEM.
Figure 1-6. Diesel Engine Electrical Starting System
GENERATOR VOLTAGE REGULATION AND OUTPUT SUPPLY (MEP-531A).
Figure 1-7. Generator Voltage Regulation System (MEP-531A)
Figure 1-8. Generator Output Supply System (MEP-531A)
GENERATOR VOLTAGE REGULATION AND OUTPUT SUPPLY (MEP-501A).
Figure 1-9. Generator Voltage Regulation System (MEP-501A)
GENERATOR CONTROL CIRCUIT.
Figure 1-10. Generator Output Supply System (MEP-501A)
Figure 1-11. Generator Control Circuit
LOW OIL PRESSURE PROTECTION.
Chapter 2. OPERATING INSTRUCTIONS - TM-9-6115-673-13-P0049
Figure 2-1. Operator's Controls and Indicators (Sheet 1 of 4)
Figure 2-1. Operator's Controls and Indicators (Sheet 2 of 4)
Figure 2-1. Operator's Controls and Indicators (Sheet 3 of 4)
Figure 2-1. Operator's Controls and Indicators (Sheet 4 of 4)
Table 2-1. Operator Controls and Indicators
Table 2-1. Operator Controls and Indicators Continued
Section II. PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) - TM-9-6115-673-13-P0056
PREVENTIVE MAINTENANCE PROCEDURES. - TM-9-6115-673-13-P0057
Table 2-2. Operator Preventive Maintenance Checks and Services
Table 2-2. Operator Preventive Maintenance Checks and Services (Continued) - TM-9-6115-673-13-P0059
Table 2-2. Operator Preventive Maintenance Checks and Services (Continued) - TM-9-6115-673-13-P0060
Table 2-2. Operator Preventive Maintenance Checks and Services (Continued) - TM-9-6115-673-13-P0061
Table 2-2. Operator Preventive Maintenance Checks and Services (Continued) - TM-9-6115-673-13-P0062
Table 2-2. Operator Preventive Maintenance Checks and Services (Continued) - TM-9-6115-673-13-P0063
Section III. OPERATION UNDER USUAL CONDITIONS - TM-9-6115-673-13-P0064
Figure 2-2. Grounding Connections (Typical Installation)
Figure 2-3. Installation of Load Cables
Figure 2-4. Fuel Filter Bleed Screws
INITIAL ADJUSTMENTS AND CHECKS.
Manual Starting [23F (-5C) to 122F (50C)].
Figure 2-5. Air Intake Cover, Normal Operation
Electric Starting [23F (-5C) to 122F (50C)].
Electric Starting [Between 23F (-5C) to -5F (-21C)].
Figure 2-6. Engine RUN and STOP Controls
Electric Starting [Between -5F (-21C) to -25F (-32C)].
Figure 2-7. Air Intake Cover, Cold Operation
Figure 2-8. Adding Oil Cylinder Head Cover Opening
IDENTIFICATION AND INSTRUCTION PLATES.
Figure 2-9. Identification and Instruction Plates (Sheet 1 of 2)
Figure 2-9. Identification and Instruction Plates (Sheet 2 of 2)
Section IV. OPERATION UNDER UNUSUAL CONDITIONS - TM-9-6115-673-13-P0080
Operation in Dusty or Sandy Areas.
NUCLEAR, BIOLOGICAL, AND CHEMICAL DECONTAMINATION PROCEDURES.
Chapter 3. OPERATOR MAINTENANCE INSTRUCTIONS
Section II. TROUBLESHOOTING - TM-9-6115-673-13-P0084
Table 3-1. Diesel Engine Will Not Start (Manual Starting) Troubleshooting
Table 3-2. Diesel Engine Will Not Start (Electric Starting) Troubleshooting
Table 3-3. Diesel Engine Runs Rough Troubleshooting
Table 3-4. Voltage Output Drops Troubleshooting
Table 3-5. Generator Set Vibrating/Bouncing Excessively Troubleshooting
Table 3-6. No Voltage Indication on VOLTS Meter (M2) Troubleshooting
Table 3-7. Voltage Indication on VOLTS Meter (M2) is High, Low, or Fluctuating Troubleshooting
Table 3-8. No Indication on %LOAD Meter (M1) With Load Applied Troubleshooting
Table 3-9. No Indication on HERTZ Frequency Meter (M4) (MEP-531A) Troubleshooting
Table 3-10. HOURS Meter (M3) Not Operating Troubleshooting
Table 3-11. Excessive Voltage Drop When Applying Load Troubleshooting
Section III. OPERATOR MAINTENANCE PROCEDURES - TM-9-6115-673-13-P0096
Figure 3-1. Fuse (F1) Replacement
Chapter 4. UNIT MAINTENANCE INSTRUCTIONS
Section II. REPAIR PARTS; TOOLS; SPECIAL TOOLS; TEST, MEASUREMENT AND DIAGNOSTIC EQUIPMENT (TMDE); AND SUPPORT EQUIPMENT
Section III. SERVICE UPON RECEIPT
Figure 4-1. Oil Level
INSTALLATION. - TM-9-6115-673-13-P0103
Section IV. PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
PREVENTIVE MAINTENANCE PROCEDURES. - TM-9-6115-673-13-P0105
PREVENTIVE MAINTENANCE PROCEDURES. (cont)
Table 4-1. Unit Preventive Maintenance Checks and Services
Table 4-1. Unit Preventive Maintenance Checks and Services (Continued) - TM-9-6115-673-13-P0108
Table 4-1. Unit Preventive Maintenance Checks and Services (Continued) - TM-9-6115-673-13-P0109
Table 4-1. Unit Preventive Maintenance Checks and Services (Continued) - TM-9-6115-673-13-P0110
DETAILED PREVENTIVE MAINTENANCE PROCEDURES.
Figure 4-2. Fuel Filter Element Replacement
Air Filter Element Replacement.
Fuel Injector Replacement.
Figure 4-4. Fuel Injector Replacement
Figure 4-5. AC Alternator Brushes
Alternator Flexible Coupling Inspection. (MEP-501A)
Engine Resilient Mounts Replacement.
Alternator Resilient Mount Replacement. (MEP-531A)
Alternator Resilient Mount Replacement. (MEP-501A)
Cylinder Head Nuts Tightening.
Intake and Exhaust Valve Adjustment.
Figure 4-10. T Position Mark
Section V. TROUBLESHOOTING - TM-9-6115-673-13-P0124
Symptom
Table 4-2. Diesel Engine Will Not Start (Manual Starting) Troubleshooting
Table 4-3. Diesel Engine Will Not Start (Electric Starting) Troubleshooting (Sheet 1 of 2)
Table 4-3. Diesel Engine Will Not Start (Electric Starting) Troubleshooting (Sheet 2 of 2)
Table 4-4. Diesel Engine Hard To Start Troubleshooting
Table 4-5. Diesel Engine Starts But Fails to Keep Running Troubleshooting
Table 4-6. Diesel Engine Runs Erratic Troubleshooting (Sheet 1 of 2)
Table 4-6. Diesel Engine Runs Erratic Troubleshooting (Sheet 2 of 2)
Table 4-7. Unexpected Reverse Rotation at Startup Troubleshooting
Table 4-8. Diesel Engine Stops During Operation Troubleshooting (Sheet 1 of 2)
Table 4-8. Diesel Engine Stops During Operation Troubleshooting (Sheet 2 of 2)
Table 4-9. Diesel Engine Exhausts Black Smoke Troubleshooting
Table 4-10. Diesel Engine Exhausts Blue-White Smoke Troubleshooting
Table 4-11. Recoil Start Rope Hard to Pull Troubleshooting
Table 4-12. Voltage Output Drops (MEP-531A) Troubleshooting
Table 4-13. Voltage Output Drops (MEP-501A) Troubleshooting
Table 4-14. Generator Set Vibrating/Bouncing Excessively Troubleshooting
Table 4-15. No Voltage Indication On VOLTS Meter (M2) Troubleshooting
Table 4-16. No Indication On %LOAD Meter (M1) Troubleshooting (MEP-531A)
Table 4-17. No Indication On %LOAD Meter (M1) Troubleshooting (MEP-501A)
Table 4-18. No Indication On HERTZ Frequency Meter (M4) Troubleshooting (MEP-531A)
Table 4-19. No Indication On HOURS Meter (M3) Troubleshooting
Table 4-20. No Output From Alternator Troubleshooting (MEP-531A)
Table 4-21. No Output From Alternator Troubleshooting (MEP-501A)
Table 4-22. Air Intake Preheaters Do Not Operate Troubleshooting
Table 4-23. Cannot Adjust Alternator Output With VOLTAGE ADJ. Potentiometer Troubleshooting
Section VI. UNIT MAINTENANCE PROCEDURES
FUEL LINES, CLAMPS, FITTINGS, ETC.
FUEL FILTER ASSEMBLY.
Removal. - TM-9-6115-673-13-P0154
FUEL DRAIN COCK.
FUEL TANK ASSEMBLY.
Disassembly. - TM-9-6115-673-13-P0157
Figure 4-15. Fuel Tank Assembly
Assembly. - TM-9-6115-673-13-P0159
AIR INTAKE SYSTEM COMPONENTS.
EXHAUST SYSTEM COMPONENTS.
Figure 4-17. Exhaust System Components
CONTROL PANEL ASSEMBLY. - TM-9-6115-673-13-P0163
Figure 4-19. Control Panel Assembly
INSTRUCTION PLATE (S).
INSTRUMENT COVER.
INSTRUMENT PANEL. - TM-9-6115-673-13-P0167
Figure 4-22. Instrument Panel
Repair. - TM-9-6115-673-13-P0169
HERTZ FREQUENCY METER. (MEP-531A)
VOLTS METER.
Testing. (VOLTS DC Meter)
%LOAD METER.
Testing. (MEP-531A)
Removal. - TM-9-6115-673-13-P0175
HOURS METER.
Testing. - TM-9-6115-673-13-P0177
VOLTAGE ADJ. POTENTIOMETER.
Removal. - TM-9-6115-673-13-P0179
INSTRUMENT SHUNT. (MEP-501A)
Figure 4-28. Instrument Shunt (MEP-501A)
CAPACITOR. (MEP-501A)
TRANSIENT SUPPRESSOR ASSEMBLY. (MEP-501A)
Figure 4-30. Transient Suppressor Assembly (MEP-501A)
FUSEHOLDER (S).
GROUND STRAP (S).
GFCI RECEPTACLE AND RECEPTACLE COVER. (MEP-531A)
Figure 4-33. GFCI Receptacle and Receptacle Cover (MEP-531A)
START-PREHEAT/PREHEAT/OFF/START ROTARY SWITCH.
Figure 4-34. START-PREHEAT/PREHEAT/OFF/START Rotary Switch
DISCHARGE VARISTOR.
NATO SLAVE RECEPTACLE.
LOAD TERMINAL (S). (MEP-501A AND MECHRON SETS)
Figure 4-37. Load Terminal(s) (MEP-501A and Mechron Sets)
TERMINAL BOARD.
Figure 4-38. Terminal Board
LOAD TERMINAL BOARD. (MEP-501A AND MECHRON SETS).
ON-OFF LOAD CIRCUIT BREAKER ASSEMBLY AND BOOT.
Testing. (MEP-501A)
Figure 4-40. ON-OFF Load Circuit Breaker Assembly and Boot
FLYWHEEL DIODE ASSEMBLY.
DIESEL ENGINE WIRING HARNESS AND GASKET, CONTROL PANEL.
Testing. - TM-9-6115-673-13-P0203
ALTERNATOR WIRING HARNESS AND GASKET, CONTROL PANEL.
Testing. - TM-9-6115-673-13-P0205
Figure 4-43. Alternator Wiring Harness and Gasket, Control Panel
ELECTRICAL LEAD WIRE (S) (TYPICAL).
LOAD TERMINAL BOARD COVER (LUG COVER).
Figure 4-45. Load Terminal Board Cover (Lug Cover)
EMI FILTER (MEP-531A).
Figure 4-46. EMI Filter (MEP-531A)
LOW OIL PRESSURE (LOP) SWITCH.
Figure 4-47. Low Oil Pressure (LOP) Switch
LOW OIL PRESSURE (LOP) SOLENOID ASSEMBLY.
Figure 4-48. Low Oil Pressure (LOP) Solenoid Assembly
LOW OIL PRESSURE (LOP) ENGINE SHUTDOWN CABLE.
Figure 4-49. Low Oil Pressure (LOP) Engine Shutdown Cable
AIR INTAKE HEATING ELEMENTS AND PIPE.
Figure 4-51. Air Intake Heating Elements and Pipe
GOVERNOR REGULATOR BRACKET.
Figure 4-52. Governor Regulator Bracket
Figure 4-53. Governor Spring Positioning
COOLING FAN COVER.
RECOIL STARTER ASSEMBLY.
ENGINE OIL STRAINER.
Cleaning and Inspection.
VALVE COVER.
STARTER ASSEMBLY. (MEP-501A)
Figure 4-59. Starter Assembly
Figure 4-60. Engine Wiring Harness
ALTERNATOR WIRING HARNESS. (MEP-501A)
Figure 4-61. Alternator Wiring Harness
PREHEATER LEAD.
GROUND STUD TERMINAL.
FRAME. - TM-9-6115-673-13-P0235
Figure 4-64. Frame
Section VII. PREPARATION FOR SHIPMENT AND STORAGE
PACKING.
Chapter 5. DIRECT SUPPORT MAINTENANCE INSTRUCTIONS - TM-9-6115-673-13-P0239
Section II. TROUBLESHOOTING - TM-9-6115-673-13-P0240
Symptom Index.
Table 5-1. Diesel Engine Will Not Start (Manual Starting) Troubleshooting
Table 5-2. Diesel Engine Hard To Start Troubleshooting
Table 5-3. Diesel Engine Starts But Fails to Keep Running Troubleshooting
Table 5-4. Diesel Engine Runs Rough Troubleshooting
Table 5-5. Unexpected Reverse Rotation at Startup Troubleshooting
Table 5-6. Diesel Engine Races Exceeding Governed Speed Troubleshooting
Table 5-7. Diesel Engine Runs Unevenly (Surges) Troubleshooting
Table 5-8. Diesel Engine Seizes During Operation Troubleshooting
Table 5-9. Diesel Engine Exhausts Black Smoke Troubleshooting
Table 5-10. Diesel Engine Exhausts Blue-White Smoke Troubleshooting
Table 5-11. Recoil Start Rope Hard To Pull Troubleshooting
Table 5-12. Voltage Output Drops Troubleshooting
Table 5-14. No Indication On HOURS Meter (M3) Troubleshooting
Table 5-15. No Output Voltage (MEP-531A) Troubleshooting
Table 5-16. No Output Voltage (MEP-501A) Troubleshooting
Table 5-17. Cannot Adjust Alternator Output With VOLTAGE ADJ. Potentiometer Troubleshooting
Table 5-18. Generator Set Vibrating/Bouncing Excessively (MEP-531A) Troubleshooting
Section III. DIRECT SUPPORT MAINTENANCE PROCEDURES - TM-9-6115-673-13-P0260
GENERATOR CONTROL UNIT.
Testing (MEP-501A). - TM-9-6115-673-13-P0262
Testing (MEP-501A). (cont)
Figure 5-1. Generator Control Unit (MEP-531A)
VOLTAGE REGULATOR ASSEMBLY.
Testing (MEP-501A). - TM-9-6115-673-13-P0266
Figure 5-2. Voltage Regulator Assembly (MEP-531A)
DIESEL ENGINE WIRING HARNESS, CONTROL PANEL.
ENGINE/ALTERNATOR ASSEMBLY.
Figure 5-3 Engine/Alternator Assembly
DIESEL ENGINE.
STARTER. (MEP-531A)
ROCKER ARMS AND PUSH RODS.
Inspection. - TM-9-6115-673-13-P0274
CYLINDER HEAD ASSEMBLY.
Figure 5-6. Cylinder Head Assembly
INTAKE AND EXHAUST VALVES.
Figure 5-7. Intake and Exhaust Valves
Figure 5-9. Measuring Valve Sinkage
FUEL INJECTION PUMP.
Figure 5-11. Fuel Injection Pump Removal
Figure 5-12. Governor Linkage Setting
Figure 5-13. Fuel Injection Limitation Setting
Figure 5-14. T Position Mark
CRANKCASE COVER.
Figure 5-15. Crankcase Cover
OIL PUMP ASSEMBLY.
Figure 5-16. Oil Pump Assembly
CAMSHAFT.
Figure 5-17. Camshaft
Figure 5-18. Positioning Camshaft Bearing in Cylinder Block
BALANCER SHAFT.
PISTON AND CONNECTING ROD ASSEMBLY.
Figure 5-22. Piston and Connecting Rod Assembly
Figure 5-23. Measuring Piston Ring Width
Figure 5-24. Measuring Side Clearance Between Ring and Piston Groove
Figure 5-26. Measuring Large End Hole Diameter
Figure 5-27. Measuring Crank Pin Clearance
FLYWHEEL.
Figure 5-29. Flywheel Locking Handle
Figure 5-31. Flywheel Extractor
Figure 5-32. Crankshaft Assembly
Figure 5-33. Positioning Crankshaft Bearing in Crankcase Cover.
DYNAMO.
Removal. - TM-9-6115-673-13-P0305
GOVERNOR GEAR.
Figure 5-36. Governor Gear
CYLINDER BLOCK.
Figure 5-38. Cylinder Block
AC ALTERNATOR ASSEMBLY. (MEP-531A)
Figure 5-39. AC Alternator Assembly (MEP-531A) (Sheet 1 of 2)
Figure 5-39. AC Alternator Assembly (MEP-531A) (Sheet 2 of 2)
Inspection. - TM-9-6115-673-13-P0313
Assembly. - TM-9-6115-673-13-P0314
Table 5-19. Power Harness Connector Plug Connections
Installation. - TM-9-6115-673-13-P0316
AC ALTERNATOR BEARING. (MEP-531A)
DC ALTERNATOR ASSEMBLY. (MEP-501A)
Figure 5-41. DC Alternator Installation (MEP-501A)
Inspection. - TM-9-6115-673-13-P0320
Figure 5-42. DC Alternator Assembly
Figure 5-43. Heatsink Tie Point Locations
Figure 5-44. Brush Assembly Test
Figure 5-46. Rotor Test
Installation. - TM-9-6115-673-13-P0325
DC ALTERNATOR BEARINGS. (MEP-501A)
DC ALTERNATOR DIODES AND CAPACITORS. (MEP-501A)
Testing. - TM-9-6115-673-13-P0328
Figure 5-48. Diodes and Capacitor Replacement
FRAME. - TM-9-6115-673-13-P0330
Installation. - TM-9-6115-673-13-P0331
Appendix A. REFERENCES - TM-9-6115-673-13-P0333
TECHNICAL BULLETINS - TM-9-6115-673-13-P0334
Appendix B. MAINTENANCE ALLOCATION CHART - TM-9-6115-673-13-P0335
MAINTENANCE FUNCTIONS - TM-9-6115-673-13-P0336
EXPLANATION OF COLUMNS IN THE MAC, SECTION II - TM-9-6115-673-13-P0337
EXPLANATION OF COLUMNS IN REMARKS, SECTION IV - TM-9-6115-673-13-P0338
Section II. MAINTENANCE ALLOCATION CHART FOR MEP-501A AND MEP-531A
Section II. MAINTENANCE ALLOCATION CHART FOR MEP-501A AND MEP-531A (cont) - TM-9-6115-673-13-P0340
Section II. MAINTENANCE ALLOCATION CHART FOR MEP-501A AND MEP-531A (cont) - TM-9-6115-673-13-P0341
Section II. MAINTENANCE ALLOCATION CHART FOR MEP-501A AND MEP-531A (cont) - TM-9-6115-673-13-P0342
Section II. MAINTENANCE ALLOCATION CHART FOR MEP-501A AND MEP-531A (cont) - TM-9-6115-673-13-P0343
Section II. MAINTENANCE ALLOCATION CHART FOR MEP-501A AND MEP-531A (cont) - TM-9-6115-673-13-P0344
Section III. TOOLS AND TEST EQUIPMENT REQUIREMENTS FOR MEP-501A AND MEP-531A
Section IV. REMARKS - TM-9-6115-673-13-P0346
Appendix C. COMPONENTS OF END ITEM (COEI) AND BASIC ISSUE ITEMS LISTS (BIIL)
EXPLANATION OF COLUMNS - TM-9-6115-673-13-P0348
Section III. BASIC ISSUE ITEMS - TM-9-6115-673-13-P0349
Appendix D. ADDITIONAL AUTHORIZATION LIST
Section II. ADDITIONAL AUTHORIZATION LIST - 2 kW Military Tactical Generator Sets
Appendix E. EXPENDABLE AND DURABLE ITEMS LIST
Section II. EXPENDABLE AND DURABLE ITEMS LIST
Appendix F. UNIT AND DIRECT SUPPORT MAINTENANCE REPAIR PARTS AND SPECIAL TOOLS LIST
Section I. INTRODUCTION - TM-9-6115-673-13-P0357
Source Code - TM-9-6115-673-13-P0358
Source Code (cont)
Maintenance Code - TM-9-6115-673-13-P0360
Recoverability Code - TM-9-6115-673-13-P0361
Part Number [Column (4)]
EXPLANATION OF COLUMNS (Section IV) - TM-9-6115-673-13-P0363
SPECIAL INFORMATION - TM-9-6115-673-13-P0364
HOW TO LOCATE REPAIR PARTS - TM-9-6115-673-13-P0365
Figure F-1. Generator Set Assembly, 2kW (MEP531A/501A) (Sheet 1 of 2)
Figure F-1. Generator Set Assembly, 2kW (MEP-531A/501A) (Sheet 2 of 2)
Repair Parts List - TM-9-6115-673-13-P0369
Repair Parts List (cont) - TM-9-6115-673-13-P0370
Figure F-2. Frame Assembly (MEP-531A/501A)
Repair Parts List (cont) - TM-9-6115-673-13-P0373
Figure F-3. Fuel System Assembly (MEP-531A/501A)
Repair Parts List (cont) - TM-9-6115-673-13-P0375
Figure F-4. Fuel Tank Assembly
Repair Parts List (cont) - TM-9-6115-673-13-P0377
Figure F-5. Fuel Filter Assembly
Repair Parts List (cont) - TM-9-6115-673-13-P0379
Figure F-6. Engine Alternator Assembly (MEP-531A) (Sheet 1 of 2)
Figure F-6. Engine Alternator Assembly (MEP-531A) (Sheet 2 of 2)
Repair Parts List (cont) - TM-9-6115-673-13-P0383
Figure F-7. Engine Alternator Assembly (MEP-501A)
Repair Parts List (cont) - TM-9-6115-673-13-P0385
Figure F-8. Diesel Engine Modified
Repair Parts List (cont) - TM-9-6115-673-13-P0387
Figure F-9. Diesel Engine Assembly
Repair Parts List (cont) - TM-9-6115-673-13-P0389
Figure F-10. Cylinder Block Installation
Repair Parts List (cont) - TM-9-6115-673-13-P0391
Figure F-11. Cylinder Head Installation
Repair Parts List (cont) - TM-9-6115-673-13-P0393
Figure F-12. Air Intake Pipe and Muffler
Repair Parts List (cont) - TM-9-6115-673-13-P0395
Figure F-13. Cam/Crankshaft/Balancer Installation
Repair Parts List (cont) - TM-9-6115-673-13-P0397
Figure F-14. Piston and Rod Assembly
Repair Parts List (cont) - TM-9-6115-673-13-P0399
Figure F-15. Lube Oil Pump and Governor
Repair Parts List (cont) - TM-9-6115-673-13-P0401
Figure F-16. Cooling/Starting Installation
Repair Parts List (cont) - TM-9-6115-673-13-P0403
Figure F-17. Fuel Injection Pump/Injector Installation
Repair Parts List (cont) - TM-9-6115-673-13-P0405
Figure F-18. Starting Motor and Dynamo Installation
Repair Parts List (cont) - TM-9-6115-673-13-P0407
Figure F-19. AC Alternator Assembly (MEP-531A)
Repair Parts List (cont) - TM-9-6115-673-13-P0409
Figure F-20. DC Alternator Assembly (MEP-501A) (Sheet 1 of 2)
Figure F-20. DC Alternator Assembly (MEP-501A) (Sheet 2 of 2)
Repair Parts List (cont) - TM-9-6115-673-13-P0413
Repair Parts List (cont) - TM-9-6115-673-13-P0414
Figure F-21. Control Panel Assembly (MEP-531A) (Sheet 1 of 3)
Figure F-21. Control Panel Assembly (MEP-531A) (Sheet 2 of 3)
Figure F-21. Control Panel Assembly (MEP-531A) (Sheet 3 of 3)
Repair Parts List (cont) - TM-9-6115-673-13-P0419
Repair Parts List (cont) - TM-9-6115-673-13-P0420
Repair Parts List (cont) - TM-9-6115-673-13-P0421
Figure F-22. Control Panel Assembly (MEP-501A) (Sheet 1 of 3)
Figure F-22. Control Panel Assembly (MEP-501A) (Sheet 2 of 3)
Figure F-22. Control Panel Assembly (MEP-501A) (Sheet 3 of 3)
Repair Parts List (cont) - TM-9-6115-673-13-P0425
Repair Parts List (cont) - TM-9-6115-673-13-P0426
Figure F-23. Control Panel Construction (MEP-531A/501A)
Repair Parts List (cont) - TM-9-6115-673-13-P0429
Figure F-24. Voltage Adjust Potentiometer
Repair Parts List (cont) - TM-9-6115-673-13-P0431
Figure F-25. LOP Shutdown Solenoid Assembly
Repair Parts List (cont) - TM-9-6115-673-13-P0433
Figure F-26. Control Panel Engine Wiring Harnesses (MEP-531A/501A)
Repair Parts List (cont) - TM-9-6115-673-13-P0435
Figure F-27. Control Panel Alternator Wiring Harnesses (MEP-531A/501A)
Repair Parts List (cont) - TM-9-6115-673-13-P0437
Figure F-28. Flywheel Diode Assembly
Repair Parts List (cont) - TM-9-6115-673-13-P0439
Figure F-29. Control Panel Electrical Leads (MEP-531A) (Sheet 1 of 5)
Figure F-29. Control Panel Electrical Leads (MEP-531A) (Sheet 2 of 5)
Figure F-29. Control Panel Electrical Leads (MEP-531A) (Sheet 3 of 5)
Figure F-29. Control Panel Electrical Leads (MEP-531A) (Sheet 4 of 5)
Figure F-29. Control Panel Electrical Leads (MEP-531A) (Sheet 5 of 5)
Repair Parts List (cont) - TM-9-6115-673-13-P0445
Repair Parts List (cont) - TM-9-6115-673-13-P0446
Repair Parts List (cont) - TM-9-6115-673-13-P0447
Repair Parts List (cont) - TM-9-6115-673-13-P0448
Figure F-30. Control Panel Electrical Leads (MEP-501A) (Sheet 1 of 6)
Figure F-30. Control Panel Electrical Leads (MEP-501A) (Sheet 2 of 6)
Figure F-30. Control Panel Electrical Leads (MEP-501A) (Sheet 3 of 6)
Figure F-30. Control Panel Electrical Leads (MEP-501A) (Sheet 4 of 6)
Figure F-30. Control Panel Electrical Leads (MEP-501A) (Sheet 5 of 6)
Figure F-30. Control Panel Electrical Leads (MEP-501A) (Sheet 6 of 6)
Repair Parts List (cont) - TM-9-6115-673-13-P0455
Repair Parts List (cont) - TM-9-6115-673-13-P0456
Repair Parts List (cont) - TM-9-6115-673-13-P0457
Repair Parts List (cont) - TM-9-6115-673-13-P0458
Repair Parts List (cont) - TM-9-6115-673-13-P0459
Figure F-31. Capacitor Assembly (MEP-501A)
Repair Parts List (cont) - TM-9-6115-673-13-P0461
Figure F-32. Transient Suppressor Assembly (MEP-501A)
Repair Parts List (cont) - TM-9-6115-673-13-P0463
Figure F-33. Engine Wiring Harness (MEP-531A/501A)
Repair Parts List (cont) - TM-9-6115-673-13-P0465
Figure F-34. LOP Engine Shutdown Cable Assembly (MEP-531A/501A)
Repair Parts List (cont) - TM-9-6115-673-13-P0467
Figure F-35. Preheater Lead Assembly (MEP-531A/501A)
Repair Parts List (cont) - TM-9-6115-673-13-P0469
Figure F-36. Alternator Wiring Harness (MEP-501A)
Repair Parts List (cont) - TM-9-6115-673-13-P0471
Repair Parts List (cont) - TM-9-6115-673-13-P0473
Figure F-37. Special Tools for Direct Support Maintenance (Diesel Engine)
NATIONAL STOCK NUMBER INDEX - TM-9-6115-673-13-P0477
NATIONAL STOCK NUMBER INDEX (cont) - TM-9-6115-673-13-P0478
NATIONAL STOCK NUMBER INDEX (cont) - TM-9-6115-673-13-P0479
NATIONAL STOCK NUMBER INDEX (cont) - TM-9-6115-673-13-P0480
PART NUMBER INDEX - TM-9-6115-673-13-P0481
PART NUMBER INDEX (cont) - TM-9-6115-673-13-P0482
PART NUMBER INDEX (cont) - TM-9-6115-673-13-P0483
PART NUMBER INDEX (cont) - TM-9-6115-673-13-P0484
PART NUMBER INDEX (cont) - TM-9-6115-673-13-P0485
PART NUMBER INDEX (cont) - TM-9-6115-673-13-P0486
PART NUMBER INDEX (cont) - TM-9-6115-673-13-P0487
PART NUMBER INDEX (cont) - TM-9-6115-673-13-P0488
PART NUMBER INDEX (cont) - TM-9-6115-673-13-P0489
PART NUMBER INDEX (cont) - TM-9-6115-673-13-P0490
PART NUMBER INDEX (cont) - TM-9-6115-673-13-P0491
PART NUMBER INDEX (cont) - TM-9-6115-673-13-P0492
PART NUMBER INDEX (cont) - TM-9-6115-673-13-P0493
PART NUMBER INDEX (cont) - TM-9-6115-673-13-P0494
PART NUMBER INDEX (cont) - TM-9-6115-673-13-P0495
PART NUMBER INDEX (cont) - TM-9-6115-673-13-P0496
PART NUMBER INDEX (cont) - TM-9-6115-673-13-P0497
PART NUMBER INDEX (cont) - TM-9-6115-673-13-P0498
PART NUMBER INDEX (cont) - TM-9-6115-673-13-P0499
PART NUMBER INDEX (cont) - TM-9-6115-673-13-P0500
PART NUMBER INDEX (cont) - TM-9-6115-673-13-P0501
FIGURE AND ITEM NUMBER INDEX - TM-9-6115-673-13-P0502
FIGURE AND ITEM NUMBER INDEX (cont) - TM-9-6115-673-13-P0503
FIGURE AND ITEM NUMBER INDEX (cont) - TM-9-6115-673-13-P0504
FIGURE AND ITEM NUMBER INDEX (cont) - TM-9-6115-673-13-P0505
FIGURE AND ITEM NUMBER INDEX (cont) - TM-9-6115-673-13-P0506
FIGURE AND ITEM NUMBER INDEX (cont) - TM-9-6115-673-13-P0507
FIGURE AND ITEM NUMBER INDEX (cont) - TM-9-6115-673-13-P0508
FIGURE AND ITEM NUMBER INDEX (cont) - TM-9-6115-673-13-P0509
FIGURE AND ITEM NUMBER INDEX (cont) - TM-9-6115-673-13-P0510
FIGURE AND ITEM NUMBER INDEX (cont) - TM-9-6115-673-13-P0511
FIGURE AND ITEM NUMBER INDEX (cont) - TM-9-6115-673-13-P0512
FIGURE AND ITEM NUMBER INDEX (cont) - TM-9-6115-673-13-P0513
FIGURE AND ITEM NUMBER INDEX (cont) - TM-9-6115-673-13-P0514
FIGURE AND ITEM NUMBER INDEX (cont) - TM-9-6115-673-13-P0515
FIGURE AND ITEM NUMBER INDEX (cont) - TM-9-6115-673-13-P0516
FIGURE AND ITEM NUMBER INDEX (cont) - TM-9-6115-673-13-P0517
FIGURE AND ITEM NUMBER INDEX (cont) - TM-9-6115-673-13-P0518
FIGURE AND ITEM NUMBER INDEX (cont) - TM-9-6115-673-13-P0519
FIGURE AND ITEM NUMBER INDEX (cont) - TM-9-6115-673-13-P0520
FIGURE AND ITEM NUMBER INDEX (cont) - TM-9-6115-673-13-P0521
FIGURE AND ITEM NUMBER INDEX (cont) - TM-9-6115-673-13-P0522
Appendix G. ILLUSTRATED LIST OF MANUFACTURED ITEMS - TM-9-6115-673-13-P0523
Figure G-1. Potentiometer, VOLTAGE ADJ. (P/N: 95-8077)
Figure G-2. Potentiometer, VOLTAGE ADJ. (P/N: 95-8014)
Figure G-3. Flywheel Diode Assembly (P/N: 95-8050)
Figure G-4. Capacitor Assembly (P/N: 95-8017)
Figure G-5. LOP Solenoid Valve Assembly (P/N: 95-8019)
Figure G-6. Wiring Harness, Control Panel (P/N: 95-8084)(Sheet 1 of 2)
Figure G-6. Wiring Harness, Control Panel (P/N: 95-8084)(Sheet 2 of 2)
Figure G-7. Wiring Harness, Control Panel (P/N: 95-8023)(Sheet 1 of 2)
Figure G-7. Wiring Harness, Control Panel (P/N: 95-8023)(Sheet 2 of 2)
Figure G-8. Wiring Harness, Control Panel (P/N: 95-8075)(Sheet 1 of 2)
Figure G-8. Wiring Harness, Control Panel (P/N: 95-8075)(Sheet 2 of 2)
Figure G-9. Wiring Harness, Control Panel (P/N: 95-8022)(Sheet 1 of 2)
Figure G-9. Wiring Harness, Control Panel (P/N: 95-8022) (Sheet 2 of 2)
Figure G-10. Wiring Harness, Engine (P/N: 95-8029) (Sheet 1 of 3)
Figure G-10. Wiring Harness, Engine (P/N: 95-8029) (Sheet 2 of 3)
Figure G-10. Wiring Harness, Engine (P/N: 95-8029) (Sheet 3 of 3)
Figure G-11. LOP Shutdown Cable (P/N: 95-8082)
Figure G-12. Preheater Lead, Electrical (P/N: 95-8141)
Figure G-13. Wiring Harness, Alternator (P/N: 95-8028) (Sheet 1 of 2)
Figure G-13. Wiring Harness, Alternator (P/N: 95-8028) (Sheet 2 of 2)
Figure G-14. Transient Suppressor (P/N: 95-8025)
Figure G-15. Flywheel Locking Handle (P/N: 114250-92101)
Figure G-16. Flywheel Extractor (P/N: 114250-92130)
Table G-1. Electrical Lead Fabrication for Control Panel (MEP-531A)
Table G-2. Electrical Lead Fabrication for Control Panel (MEP-501A)
Appendix H. TORQUE LIMITS
Table H-1. Torque Limits for Steel Fasteners
Appendix I. MANDATORY REPLACEMENT PARTS
Appendix J. DEWEY/MECHRON CROSS-REFERENCE LIST
Table J-1. MEP-531A Cross-Reference List for Component Identifiers
Table J-2. MEP-531A Cross-Reference List for Wiring Identifiers
Table J-2. MEP-531A Cross-Reference List for Wiring Identifiers - Continued - TM-9-6115-673-13-P0558
Table J-2. MEP-531A Cross-Reference List for Wiring Identifiers - Continued - TM-9-6115-673-13-P0559
Table J-3. MEP-501A Cross-Reference List for Component Identifiers
Table J-3. MEP-501A Cross-Reference List for Component Identifiers - Continued
Table J-4. MEP-501A Cross-Reference List for Wiring Identifiers
Table J-4. MEP-501A Cross-Reference List for Wiring Identifiers - Continued - TM-9-6115-673-13-P0563
Table J-4. MEP-501A Cross-Reference List for Wiring Identifiers - Continued - TM-9-6115-673-13-P0564
Appendix K. SPECIAL PACKAGING INSTRUCTIONS
Special Packaging Instructions, MEP-531A (Sheet 2 of 2)
Special Packaging Instructions, MEP-501A (Sheet 1 of 2)
Special Packaging Instructions, MEP-501A (Sheet 2 of 2)
Appendix L. COMPONENTS AND INSTRUCTIONS FOR AUXILIARY FUEL SYSTEM
EXPLANATION OF COLUMNS - TM-9-6115-673-13-P0570
Auxiliary Fuel System Instructions
Pre-assembly Instructions
Assembly Instructions
Disassembly Instructions
Figure L-1. Auxiliary Fuel System (Sheet 1 of 2)
Figure L-1. Auxiliary Fuel System (Sheet 2 of 2)
Table L-1. Auxiliary Fuel System Components
Figure L-2. Three Way Valve Bracket
NOTES TO FIGURE L-2
Figure L-3. Auxiliary Fuel tank Bracket
NOTES TO FIGURE L-3
Figure L-4. 2 KW Set with Auxiliary Fuel System Installed
Figure L-5. Fuel Can Bracket Shown in the Stowed Position
Appendix M. 2 KW DEPROCESSING CHECKLIST
DEPROCESSING CHECKSHEET
Deprocessing Servicing.
Quality Deficiency Report (QDR)
Figure FO-1. Electrical Schematic, MEP-531A
Figure FO-2. Electrical Schematic, MEP-501A
Figure FO-3. Wiring Diagram, MEP-531A
Figure FO-4. Wiring Diagram, MEP-501A
Figure FO-5. Generator Set Schematic, Mechron 120 VAC
Figure FO-6. Generator Set Schematic, Mechron 28 VDC
TM-9-6115-673-13-P 2 Kw Military Tactical Generators Sets 120 VAC 60 Hz: MEP-531A (Dewey) Mechron 28 VDC: MEP-501A (Dewey) Manual
