ARMY TECHNICAL MANUAL AIR FORCE TECHNICAL ORDER NAVY PUBLICATION MARINE CORPS STOCK LIST TM 9-6115-545-24P TO 35C2-3-444-4 TECHNICAL MANUAL UNIT, DIRECT AND GENERAL SUPPORT, AND DEPOT MAINTENANCE REPAIR PARTS AND SPECIAL TOOLS LIST GENERATOR SET, DIESEL ENGINE DRIVEN, TACTICAL, SKID RTD., 60 KW, 3 PHASE, 4 WIRE, 120/208 AND 240/416 VOLTS DOD MODEL CLASS HERTZ NSN MEP-006A UTILITY 50/60 6115-00-118-1243 MEP-105A PRECISE 50/60 6115-00-118-1252 MEP-115A PRECISE 400 6115-00-118-1253 INCLUDING OPTIONAL KITS DOD MODEL NOMENCLATURE NSN MEP-006AWF WINTERIZATION KIT, FUEL BURNING 6115-00-407-8314 MEP-006AWE WINTERIZATION KIT, ELECTRIC 6115-00-455-7693 MEP-006ALM LOAD BANK KIT 6115-00-407-8322 MEP-O06AWM WHEEL MOUNTING KIT 6115-00-463-9092 DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited. This manual supersedes TM 5-6115-545-24P/TO 35C2-3-444-4/NAVFAC P-8-626- 24P/SL-400038G/7499A, dated 27 December 1983, including all changes. DEPARTMENTS OF THE ARMY, AIR FORCE, NAVY AND HEADQUARTERS, MARINE CORPS 28 JUNE 1995
ARMY TECHNICAL MANUAL AIR FORCE TECHNICAL ORDER NAVY PUBLICATION MARINE CORPS STOCK LIST TM 9-6115-545-24P TO 35C2-3-444-4 TECHNICAL MANUAL HEADQUARTERS, DEPARTMENTS OF THE ARMY, AIR FORCE, AND NAVY, AND HEADQUARTERS, U.S. MARINE CORPS NO. 9-6115-545-24P WASHINGTON, D.C., 28 JUNE 1995 UNIT, DIRECT AND GENERAL SUPPORT, AND DEPOT MAINTENANCE REPAIR PARTS AND SPECIAL TOOLS LIST GENERATOR SET, DIESEL ENGINE DRIVEN, TACTICAL, SKID MTD., 60 KW, 3 PHASE, 4 WIRE, 120/208 AND 240/416 VOLTS DOD MODEL CLASS HERTZ NSN MEP-006A UTILITY 50/60 6115-00-118-1243 MEP-105A PRECISE 50/60 6115-00-118-1252 MEP-115A PRECISE 400 6115-00-118-1253 INCLUDING OPTIONAL KITS DOD MODEL NOMENCLATURE NSN MEP-006AWF WINTERIZATION KIT, FUEL BURNING 6115-00-407-8314 MEP-006AWE WINTERIZATION KIT, ELECTRIC 6115-00-455-7693 MEP-006ALM LOAD BANK KIT 6115-00-407-8322 MEP-O06AWM WHEEL MOUNTING KIT 6115-00-463-9092 The effective date of this publication is 28 June 1995. Instructions herein shall not be used prior to that date. REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS You can help improve this manual. If you find any mistakes or if you know of a way to improve the procedures, please let us know. Mail your letter or DA Form 2028 (Recommended Changes to Publications and Blank Forms), or DA Form 2028-2 located in the back of this manual directly to: Commander, US Army Aviation and Troop Command, ATTN: AMSAT-I-MP, 4300 Goodfellow Blvd., St. Louis, MO 63120-1798. A reply will be furnished directly to you. DISTRIBUTION STATEMENT: A: Approved for public release; distribution Is unlimited. This manual supersedes TM5-6115-545-24P/T035C2-3-444-4// dated 27 DECEMBER 1983 including all changes. i
TO 35C2-3-441-4 TABLE OF CONTENTS SECTION I INTRODUCTION SECTION II INTRODUCTION Group 01 Batteries and Slave Receptacles... 8 1 Group 02 Muffler, Exhaust and Breather Pipes... 11 2 Group 03 Convenience Receptacles... 16 3 Group 05 Plate and Sleeve Assembly... 18 4 Group 06 Paralleling Receptacles... 20 5 Wiring Harness, Convenience and Paralleling... 22 6 Group 07 Generator Set Controls... 24 7 Wiring Harness, Control Cubicle... 26 8 Wiring Harness, Fault Indicator... 26 9 Fault Locating Indicator... 28 10 Wiring Harness... 30 11 Components Board Assembly... 32 12 Control Box, Generator... 35 13 Wiring Harness, Branched, Control Box.... 40 14 Circuit Card Assembly... 42 15 Group 08 Housing Group... 45 16 Plates, Diagram, AC and DC... 52 17 Group 09 Engine Generator and Chassis Wiring Harness... 55 18 Wiring Harness, Precise Relay Box... 60 19 Wiring Harness, Tactical Relay Box....60 20 Wiring Harness, Excitation System... 60 21 Wiring Harness, LMU Assembly... 62 22 Wiring Harness, Governor Control to Precise Relay... 62 23 Wiring Harness Assembly, Governor Control to Actuator.... 62 24 Wiring Harness Assembly, Governor Control to Actuator.... 64 25 Wiring Harness, Branched, Engine Accessories... 64 26 Wiring Harness, AC Power Control... 66 27 Wiring Harness, RFI Capacitors... 66 28 Wiring Harness, AC, Power Control.... 68 29 Group 10 Load Connection Group... 71 30 Main Load Contactor... 82 31 Load Terminal Board Assembly... 88 32 Current Transformer Assembly... 90 33 Wiring Harness, Current Transformer... 94 34 Reconnection Board... 96 35 Group 11 Governor Control Unit and Related Parts... 98 36 Governor Control Unit... 100 37 Wiring Harness, Governor Control Unit 50/60 HZ... 102 38 Electric Governor Printed Circuit Board Assembly... 105 39 Hydraulic Pump Cover Plate... 110 40 Control Unit and Magnetic Pickup... 112 41 Actuator, Electric Governor... 114 42 Actuator Linkage... 116 43 Wiring Harness, Electric Governor... 118 44 ii
TO 35C2-3 4M4-4 TABLE OF CONTENTS - Continued Group 12 Air Cleaner and Related Parts... 120 45 Group 13 Relay Table and Related Parts... 122 46 Relay Box Assembly... 126 47 Tactical Relay... 130 48 Wiring Harness Assembly, Branched... 134 49 Tactical Relay... 136 50 Resistor, Electrical... 138 51 Tactical Relay... 140 52 Precise Relay Assembly, 50/60 HZ... 142 53 Wiring Harness Assembly... 146 54 Excitation System Assembly... 148 55 Wire Harness Assembly... 152 56 Voltage Regulator... 154 57 Wiring Harness, Voltage Regulator... 156 58 Voltage Regulator Circuit Card Assembly... 158 59 Circuit Card Assembly... 162 60 Special Relay Assembly... 165 61 Wiring Harness, Special Relay Box 50/60 HZ and 400 HZ... 171 62 Resistor Assembly... 174 63 Circuit Card Assembly... 176 64 Load Measuring Unit... 178 65 Wiring Harness Assembly... 180 66 Group 14 AC Generator and Related Parts... 182 67 AC Generator Assembly... 184 68 Rectifier Assembly... 190 69 Group 15 Day Tank and Primary Fuel Filter... 192 70 Filter, Fluid... 196 71 Group 16 Center Support and Related Parts... 199 72 Lifting Frame Assembly... 206 73 Group 17 Hydraulic Cooler and Related Parts... 208 74 Cooling Group and Related Parts... 210 75 Control Assembly and Related Parts... 212 76 Control Assembly... 214 77 Cooling Group... 218 78 Shutter Assembly... 220 79 Group 18 Hydraulic Actuator and Related Parts... 222 80 Actuator Assembly, Electric... 226 81 Group 19 Hydraulic Sump and Filter... 230 82 Group 20 Engine Assembly and Related Parts... 234 83 Alternator and Related Parts... 236 84 Generator, Engine... 238 85 Alternator, Battery Charging... 242 86 Alternator, Battery Charging... 246 87 Hydraulic Pump and Related Parts... 248 88 Speed Switch and Tachometer Drive... 250 89 Switch Overspeed... 252 90 Oil Level Gage and Filter... 254 91 Electric Starter and Related Parts... 256 92 Electrical Starter Assembly... 258 93 iii
TO 35C2-3-444-4 TABLE OF CONTENTS - Continued Group 20 Engine Assembly and Related Parts - (Continued) Relay, Engine... 262 94 Frame and Field Assembly... 266 95 Engine Lube Oil Filters... 268 96 Secondary Fuel Filter... 270 97 Lube Oil Cooler... 272 98 Nozzle Holder and Line Assemblies... 274 99 Fuel Injection System... 278 100 Nozzle Holder Assembly... 280 101 Injection Pump and Related Parts... 282 102 Pump, Fuel, Metering... 284 103 Diffuser and Turbocharger... 298 104 Turbocharger Assembly.... 302 105 Water Pump and Fan... 304 106 Thermostat and Housing... 308 107 Crankshaft Pulley and Related Parts... 310 108 Idler Pulley and Related Parts... 312 109 Intake Manifold... 314 110 Exhaust Manifold... 314 111 Engine Front Support... 316 112 Oil Pan Assembly... 318 113 Oil Pump and Related Parts... 320 114 Oil Pump Assembly... 324 115 Flywheel and Housing... 326 116 Timing Gear and Cover... 328 117 Cylinder Head and Valve Operating Mechanism... 332 118 Rocker Arm Shaft Assembly... 336 119 Cylinder Head Assembly... 336 120 Piston, Crankshaft and Block... 339 121 Cylinder Block Assembly... 344 122 Group 21 Base Group... 347 123 Group 22 Accessory Items... 354 124 Group 25 Fuel Burning Winterization Kit... 357 125 Wiring Harness Assembly... 362 126 Wiring Harness Assembly... 362 127 Engine Coolant Heater... 364 128 Heater Control Box Assembly... 368 129 Group 26 Electric Winterization Kit... 371 130 Wiring Harness, Winterization Kit, Electric....376 131 Electric Heater Control Box... 378 132 Wire Harness Assembly....382 133 Electric Winterization Pump Motor Assembly....384 134 Group 27 Wheel Mounting Kit... 386 135 Running Gear Assembly... 388 136 Handbrake Lever and Shaft Assembly... 390 137 Hand Lever and Bracket Assembly... 392 138 Rear Unit Axle Assembly... 394 139 Brake Assembly... 396 140 Front Unit Axle Assembly... 398 141 iv
TM 9-6115545-24P TO 35C2-3 444-4 TABLE OF CONTENTS - Continued Group 28 Load Bank Kit... 402 142 Cable Assembly, Electrical, Special Purpose... 406 143 Wiring Harness Tactical Relay Box... 406 144 Wiring Harness Assembly, Load Bank Control PNL... 408 145 Wiring Harness Load Bank Capacitors....408 146 Wiring Harness Branched, Load Bank....410 147 Fan and Motor Assembly... 412 148 SECTION III SPECIAL TOOLS, TEST AND SUPPORT EQUIPMENT (Not Applicable) IV NATIONAL STOCK NUMBER AND PART NUMBER... 415 INDEX... 440 V REFERENCE DESIGNATOR INDEX... 485 v
TO 35C2-3 444 4 NAVFAC P-8626-24P SECTION I. INTRODUCTION 1. Scope. This joint Army, Navy, Air Force and Marine Corps manual lists repair parts and special tools required for the performance of unit, direct and general support and depot maintenance of the generator set. The following paragraphs are keyed to applicable users. All users should read paragraph 4, Special Information, prior to using this manual. 2. General. This Repair Parts and Special Tools List is divided into the following section: a. (ALL) Repair Parts - Section II. A list of repair parts authorized for the performance of maintenance at the unit, direct support, general support and depot level in figure and item number sequence. b. (ALL) Special Tools, Test and Support Equipment - Section III. A list of special tools, test and support equipment authorized for the performance of maintenance at the unit, direct support, general support and depot level (Not Applicable). c. National Stock Number and Reference Number Index - Section IV. A list of National Stock Numbers in ascending numerical sequence followed by a list of reference numbers appearing in all the listings, in ascending alphanumeric sequence, cross-referenced to the illustration figure number and item number. d. Reference Designator Index - Section V. The Reference Designator Column includes all assigned reference designators arranged first in alphabetical order, second in numeric order. Opposite each symbol is listed the figure and item number of the part in Section II and the reference number. 3. Explanation of Columns. The following provides an explanation of columns in the tabular lists in Sections II and III. a. (ALL) s. (Column 1) This column is divided as follows: (1) Figure number. (Column 1a) Indicates the figure number of the illustration on which the item is shown. (2) Item number. (Column lb) Indicates the number used to identify the item on the illustration. b. (ALL) Source, Maintenance, and Recoverability Codes (SMR). (Column 2). (1) Uniform Source Codes applicable to all Military Services. GENERAL: Source Codes are assigned to support items to indicate the manner of acquiring support items for maintenance, repair, or overhaul of end items. Source codes are entered in the first and second positions of the Uniform SMR Code format as follows: Code Definition PA Item procured and stocked for anticipated or known usage. PB Item procured and stocked for insurance purposes because essentiality dictates that a minimum quantity be available in the supply system. PC Item procured and stocked and which otherwise would be coded PA except that it is deteriorative in nature. PD Support item, excluding support equipment, procured for initial issue or outfitting and stocked only for subsequent or additional initial issues or outfittings. Not subject to automatic replenishments. PE Support equipment procured and stocked for initial issue or outfittings to specified maintenance repair activities. PF Support equipment which will not be stocked but which will be centrally procured on demand. 1