MEP531A 2kW Military Diesel Generator with 90 Day / 100 Hour Parts Warranty

1 review for MEP531A 2kW Military Diesel Generator with 90 Day / 100 Hour Parts Warranty

1. 

   gmg – November 1, 2014

   *ARMY TM 9-6115-673-13&P
   AIR FORCE TO 35C2-3-512-1

   TECHNICAL MANUAL
   OPERATOR AND FIELD MAINTENANCE MANUAL
   (INCLUDING REPAIR PARTS AND SPECIAL TOOLS LIST) FOR
   2 kW MILITARY TACTICAL GENERATOR SETS
   120 VAC, 60 Hz MEP-531A (DEWEY)
   (NSN: 6115-01-435-1565) (EIC: GE2)

   120 VAC, 60 Hz MECHRON
   (NSN: 6115-21-912-0393) (EIC: VIB)

   28 VDC
   MEP-501A (DEWEY)
   (NSN: 6115-01-435-1567) (EIC: LTJ)

   28 VDC MECHRON
   (NSN: 6115-21-912-0392) (EIC: VBD)

   *SUPERSEDURE NOTICE – This manual supersedes TM 9-6115-673-13&P, AND TO 35C2-3-512-1, dated 15 September 2002. Date of issue for the revised manual is: 30 June 2010.

   DISTRIBUTION STATEMENT A – Approved for public release; distribution is unlimited.

   HEADQUARTERS, DEPARTMENTS OF THE ARMY AND AIR FORCE

   30 JUNE 2010

   FIRST AID

   TM 9-6115-673-13&P
   WARNING SUMMARY

   For First Aid information, refer to FM 4-25.11.

   5 SAFETY STEPS TO FOLLOW IF SOMEONE IS THE VICTIM OF ELECTRICAL SHOCK

   DO NOT TRY TO PULL OR GRAB THE INDIVIDUAL IF POSSIBLE, TURN OFF THE ELECTRICAL POWER
   IF YOU CANNOT TURN OFF THE ELECTRICAL POWER, PULL, PUSH OR LIFT THE PERSON TO SAFETY USING A DRY WOODEN POLE OR A DRY ROPE OR SOME OTHER INSULATING MATERIAL

   SEND FOR HELP AS SOON AS POSSIBLE
   AFTER THE INJURED PERSON IS FREE OF CONTACT WITH THE SOURCE OF ELECTRICAL SHOCK, MOVE THE PERSON A SHORT DISTANCE AWAY AND IMME- DIATELY START ARTIFICIAL RESUSCITATION

   a

   TM 9-6115-673-13&P

   WARNING SUMMARY – Continued
   WARNING AND CAUTION STATEMENTS

   Warning and Caution statements have been strategically placed throughout this text prior to operating procedures, practices, or conditions considered essential to the protection of personnel (WARNING) or equipment and property (CAUTION).
   A WARNING or CAUTION will apply each time the related step is repeated. Prior to starting any task the WARNINGs or CAUTIONs included in the text for that task must be reviewed and understood. Refer to the materials list at the beginning of the appropriate manual section for materials used during maintenance of this equipment. This warning summary contains the WARNINGs and CAUTIONs included in the manual. The detailed warnings for hazardous materials only are listed separately in the warning summary as the “Hazardous Materials Warnings” section.
   WARNING
   High voltage is produced when this generator set is in operation. Use care when working around an open control panel with the generator set operating. Improper operation and/or failure to follow this warning could result in personal injury or death by electrocution.

   WARNING
   Never attempt to start the generator set if it is not properly grounded. Failure to observe this warning could result in serious injury or death by electrocution.

   WARNING
   Never attempt to connect or disconnect load cables while the generator set is running. Failure to observe this warning could result in severe personal injury or death by electrocution.

   WARNING
   If 24 VDC battery source is connected to the North Atlantic Treaty Organization (NATO) slave receptacle, DC voltages are present at generator set electrical components even with generator set shut down. Avoid grounding self when touching any electrical components. Failure to observe this warning can result in personal injury.

   WARNING
   The fuels in this generator set are flammable. Do not smoke or use open flames when performing maintenance. Do not service or drain the fuel system while open flames are present. Flames and explosion could result in severe personal injury or death. Use a container or cloth to catch any excess fuel to prevent spilling over engine components. Be sure to properly dispose of diesel fuel and diesel fuel soaked cloths.

   WARNING
   Hot fueling of generator sets while they are operating presents a safety hazard and should not be attempted. Hot engine surfaces and sparks produced from the engine and generator circuitry are possible sources of ignition. Failure to observe this warning could result in severe personal injury or death.

   WARNING
   Exhaust discharge contains deadly gases. Do not operate generator set in enclosed area unless exhaust discharge is properly vented outside. Position as far away from personnel, shelters, and occupied vehicles as possible. Failure to observe this warning could result in severe personal injury or death due to carbon monoxide poisoning.

   WARNING
   High fuel pressure is generated as a result of operation of the generator set. High-pressure leaks could cause severe personal injury or death.

   b

   TM 9-6115-673-13&P

   WARNING SUMMARY – Continued
   WARNING
   Avoid contacting metal items with bare skin in extreme cold weather. Failure to observe this warning can result in personal injury.

   WARNING
   Remove metal jewelry when working on electrical system/components. Failure to observe this warning could cause severe personnel injury from electric shock.

   WARNING
   The noise level of this generator set when operating could cause hearing damage. Hearing protective devices must be worn when operating or working within 13 feet of the generator set when it is running. Failure to observe this warning can result in personal injury.

   WARNING
   Cleaning solvents are flammable and toxic to eyes, skin, and respiratory tract. Skin/eye protection required. Avoid repeated/prolonged contact. Good general ventilation is normally adequate.

   WARNING
   When using compressed air, wear protective glasses and use clean, low-pressure air, 30 psi (206.8 kPa) maximum. Failure to follow these instructions could result in eye injury.

   WARNING
   Chemical Agent Resistant Coating (CARC) paint dust is a health hazard. Wear protective eyewear, mask, and gloves when sanding CARC painted surfaces. Failure to comply can cause personal injury.

   WARNING
   Adhesive is flammable and toxic. Vapors may ignite explosively. Avoid breathing in vapors. Provide adequate ventilation to prevent vapor concentrations in excess of permissible exposure levels. Keep away from heat, sparks, and open flame. Do not smoke. Extinguish all flames and turn off non-explosion-proof electrical equipment during use until vapors are dissipated. Close container tightly after use. Contains Methylethketone. Avoid swallowing.

   WARNING
   Be sure the load terminal retaining clip is closed to prevent contact with the lug cover as electrical shock could occur.

   WARNING
   Note the orientation of the load terminals before removing them. They must be installed in exactly the same way to preclude the possibility of accidental contact with the lug cover and the potential for electrical shock resulting from this contact.

   WARNING
   MEP-531A engine/alternator assembly weighs 100 lbs (45.4 kg). MEP-501A engine/alternator assembly weighs 80 lbs (36.2 kg). Use caution when removing assembly to prevent personal injury.

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   TM 9-6115-673-13&P

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   NOTE: This manual supersedes TM 9-6115-673-13&P, AND TO 35C2-3-512-1, dated 15 September 2002. Zero in the “Change No.” column indicates an original page or work package.

   Date of issue for the original manual is:

   Original 30 JUNE 2010

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   *ARMY TM 9-6115-673-13&P
   AIR FORCE TO 35C2-3-512-1
   HEADQUARTERS DEPARTMENTS OF THE ARMY AND AIR FORCE WASHINGTON, D.C., 30 JUNE 2010

   TECHNICAL MANUAL
   OPERATOR AND FIELD MAINTENANCE MANUAL (INCLUDING REPAIR PARTS AND SPECIAL TOOLS LIST) FOR
   2kW MILITARY TACTICAL GENERATOR SETS
   120 VAC, 60 Hz, MEP-531A (DEWEY)
   (NSN: 6115-01-435-1565) (EIC:GE2)
   120 VAC, 60 Hz, MECHRON
   (NSN: 6115-21-912-0393) (EIC:VIB)
   28 VDC,
   MEP-501A(DEWEY)
   (NSN: 6115-01-435-1567) (EIC:LTJ)
   28 VDC, MECHRON
   (NSN: 6115-21-912-0392) (EIC:VBD)

   *SUPERSEDURE NOTICE – This manual supersedes TM 9-6115-673-13&P, AND TO 35C2-3-512-1, dated 15 September 2002. Date of issue for the revised manual is: 30 June 2010.
   DISTRIBUTION STATEMENT A – Approved for public release; distribution is unlimited.

   i

   TM 9-6115-673-13&P

   How to Use This Manual

   TABLE OF CONTENTS

   Page No. WP Sequence No.

   Chapter 1 – General Information, Equipment Description and Theory of Operation
   General Information ……………………………………………………………………………………………………………… WP 0001
   Type of Manual 0001-1
   Table 1. Model Numbers and Equipment Names. 0001-1
   Purpose of Equipment 0001-1
   Figure 1. Military Tactical Generator (MTG) Set – 2 kW 0001-2
   Maintenance Forms, Records, and Reports 0001-3
   Reporting Equipment Improvement Recommendation (EIR) 0001-3
   Corrosion Prevention and Control (CPC) 0001-3
   Destruction of Army Materiel to Prevent Enemy Use 0001-3
   Preparation for Storage or Shipment 0001-3
   Warranty Information 0001-3
   List of Abbreviations/Acronyms 0001-4
   Supporting Information for Repair Parts, Special Tools, TMDE and Support Equipment 0001-4
   Equipment Description and Data ……………………………………………………………………………………………. WP 0002
   Equipment Description 0002-1
   Figure 1. Location of Major Generator Set Components 0002-1
   Equipment Differences 0002-2
   Equipment Data 0002-3
   Table 1. Leading Particulars. 0002-3
   Theory of Operation ……………………………………………………………………………………………………………… WP 0003
   Fuel System 0003-1
   Figure 1. Generator Set Fuel System 0003-2
   Engine Air Intake and Exhaust System 0003-2
   Figure 2. Engine Air Intake and Exhaust System 0003-3
   Speed Control System 0003-3
   Figure 3. Diesel Engine Governor 0003-4
   Diesel Engine Electrical Starting System 0003-5
   Figure 4. Diesel Engine Electrical Starting System 0003-6
   Generator Voltage Regulation and Output Supply (MEP-531A) 0003-6
   Figure 5. Generator Voltage Regulation System (MEP-531A) 0003-7
   Figure 6. Generator Output Supply System (MEP-531A) 0003-8
   Generator Voltage Regulation and Output Supply (MEP-501A) 0003-8
   Figure 7. Generator Voltage Regulation System (MEP-501A) 0003-10
   Figure 8. Generator Output Supply System (MEP-501A) 0003-11
   Generator Control Circuit 0003-11
   Figure 9. Generator Control Circuit 0003-12
   Low Oil Pressure Protection 0003-13
   Figure 10. Low Engine Oil Pressure Protection System 0003-13
   Chapter 2 – Operator Instructions
   Description and Use of Operator Controls and Indicators ………………………………………………………….. WP 0004
   Figure 1. Operator Controls and Indicators (Sheet 1 of 4). 0004-1
   ii

   TM 9-6115-673-13&P

   TABLE OF CONTENTS – Continued

   Page No. WP Sequence No.

   Figure 1. Operator Controls and Indicators (Sheet 2 of 4). 0004-2
   Figure 1. Operator Controls and Indicators (Sheet 3 of 4). 0004-3
   Figure 1. Operator Controls and Indicators (Sheet 4 of 4). 0004-4
   Operator Controls and Indicators 0004-4
   Operation Under Usual Conditions …………………………………………………………………………………………. WP 0005
   General 0005-1
   Installation of Ground Rods 0005-1
   Figure 1. Grounding Connections (Typical Installation) 0005-2
   Installation of Load Cables 0005-2
   Figure 2. Installation of Load Cables 0005-3
   Priming and Bleeding the Fuel System 0005-3
   Figure 3. Fuel Filter Bleed Screws 0005-4
   Operating Procedures 0005-4
   Manual Starting [23oF (-5oC) to 122oF (50o C)] 0005-5
   Figure 4. Air Intake Cover, Normal Operation 0005-6
   Electric Starting [23oF (-5oC) to 122o F (50oC)] 0005-6
   Electric Starting [23oF (-5oC) to -5o F (-21oC)] 0005-7
   Figure 5. Engine RUN and STOP Controls 0005-8
   Electric Starting [Between -5o F (-21o C) to -25o F (-32oC)] 0005-9
   Figure 6. Air Intake Cover, Cold Operation 0005-9
   Figure 7. Adding Oil – Cylinder Head Cover Opening 0005-10
   Stopping Procedure 0005-10
   Identification and Instruction Plates 0005-11
   Figure 8. Decals and Instruction Plates (Sheet 1 of 2). 0005-12
   Figure 8. Decals and Instruction Plates (Sheet 2 of 2). 0005-13
   Preparation for Movement 0005-13
   Operation Under Unusual Conditions ……………………………………………………………………………………… WP 0006
   Operation in Extreme Cold [23oF (-5o C) to -51oF (-46oC)]. 0006-1
   Operation in Extreme Heat [Above 120o F (49o C)]. 0006-2
   Operation in Dusty or Sandy Areas 0006-2
   Operation in Rainy or Humid Conditions 0006-2
   Operation in Salt Water Areas 0006-2
   Operation at High Altitudes 0006-3
   Operating Generator Set Output for High Altitudes and Temperatures. 0006-3
   Table 1. Altitude and Temperature Derating Calculation. 0006-3
   Chapter 3 – Operator Troubleshooting Procedures
   Operator Troubleshooting Index …………………………………………………………………………………………….. WP 0007
   Purpose of Logic Tree Table 0007-1
   Operator Troubleshooting Procedures…………………………………………………………………………………….. WP 0008
   Figure 1. Diesel Engine Will Not Start (Manual Starting) 0008-2
   Figure 2. Diesel Engine Will Not Start (Electric Starting) 0008-3
   Figure 3. Diesel Engine Runs Rough 0008-3
   Figure 4. Voltage Output Drops 0008-4
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   TM 9-6115-673-13&P

   TABLE OF CONTENTS – Continued

   Page No. WP Sequence No.

   Figure 5. Generator Set Vibrating/Bouncing Excessively 0008-4
   Figure 6. No Voltage Indication on VOLTS Meter (M2) 0008-5
   Figure 7. Voltage Indication on VOLTS Meter (M2) is High, Low, or Fluctuating 0008-5
   Figure 8. No Indication on % LOAD Meter (M1) With Load Applied 0008-6
   Figure 9. No Indication on HERTZ Frequency Meter (M4) (MEP-531A) 0008-6
   Figure 10. HOURS Meter (M3) Not Operating 0008-7
   Figure 11. Excessive Voltage Drop When Applying Load 0008-7
   Chapter 4 – Operator Maintenance Instructions
   Operator PMCS Introduction………………………………………………………………………………………………….. WP 0009
   Introduction to Operator PMCS Table 0009-1
   Warnings and Cautions 0009-1
   Operator PMCS 0009-1
   Explanation of Table Entries 0009-1
   Other Table Entries 0009-2
   Reporting and Correcting Deficiencies 0009-2
   PMCS, BEFORE Operations 0009-2
   PMCS, DURING Operations 0009-2
   After You Operate 0009-2
   Order In Which PMCS Will be Done 0009-2
   Fluid Leakage 0009-3
   Table 1. Leakage Definitions. 0009-4
   Operator PMCS, Including Lubrication Instructions …………………………………………………………………… WP 0010
   Operator Lubrication Instructions 0010-1
   Table 1. Operator Preventive Maintenance Checks and Services for MEP-501A/MEP-531A. 0010-1
   Mandatory Replacement Parts List 0010-5
   Instrument Fuse (F1): Removal, Inspection, Installation…………………………………………………………….. WP 0011 Removal 0011-1
   Inspection 0011-1
   Installation 0011-1
   Figure 1. Fuse (F1) Replacement 0011-2
   Chapter 5 – Field Troubleshooting Procedures
   Field Troubleshooting Index…………………………………………………………………………………………………… WP 0012
   Field Troubleshooting 0012-1
   Field Troubleshooting Procedures ………………………………………………………………………………………….. WP 0013 Figure 1. Diesel Engine Will Not Start (Manual Starting) 0013-2
   Figure 2. Diesel Engine Will Not Start (Electric Starting) (Sheet 1 of 2). 0013-3
   Figure 2. Diesel Engine Will Not Start (Electric Starting) (Sheet 2 of 2). 0013-4
   Figure 3. Diesel Engine Hard To Start 0013-5
   Figure 4. Diesel Engine Starts but Fails to Keep Running 0013-6
   Figure 5. Diesel Engine Runs Erratic (Sheet 1 of 2). 0013-7
   Figure 5. Diesel Engine Runs Erratic (Sheet 2 of 2). 0013-8
   Figure 6. Diesel Engine Runs Rough 0013-8
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   TABLE OF CONTENTS – Continued

   Page No. WP Sequence No.

   Figure 7. Unexpected Reverse Rotation at Startup 0013-9
   Figure 8. Diesel Engine Races Exceeding Governed Speed 0013-10
   Figure 9. Diesel Engine Runs Unevenly (Surges) 0013-10
   Figure 10. Diesel Engine Seizes During Operation 0013-11
   Figure 11. Diesel Engine Stops During Operation (Sheet 1 of 2). 0013-12
   Figure 11. Diesel Engine Stops During Operation (Sheet 2 of 2). 0013-13
   Figure 12. Diesel Engine Exhausts Black Smoke 0013-14
   Figure 13. Diesel Engine Exhausts Blue-White Smoke 0013-15
   Figure 14. Recoil Start Rope Hard to Pull 0013-16
   Figure 15. Voltage Output Drops (MEP-531A) 0013-17
   Figure 16. Voltage Output Drops (MEP-501A) 0013-18
   Figure 17. No Output Voltage (MEP-531A) 0013-19
   Figure 18. No Output Voltage (MEP-501A) 0013-19
   Figure 19. Generator Set Vibrating/Bouncing Excessively 0013-20
   Figure 20. No Voltage Indication on VOLTS Meter (M2) 0013-21
   Figure 21. No Indication on % LOAD Meter (M1) (MEP-531A) 0013-22
   Figure 22. No Indication on % LOAD Meter (M1) (MEP-501A) 0013-23
   Figure 23. No Indication on HERTZ Frequency Meter (M4) (MEP-531A) 0013-24
   Figure 24. No Indication on HOURS Meter (M3) 0013-25
   Figure 25. No Output from Alternator (MEP-531A) 0013-26
   Figure 26. No Output from Alternator (MEP-501A) 0013-27
   Figure 27. Air Intake Preheaters Do Not Operate 0013-28
   Figure 28. Cannot Adjust Alternator Output With VOLTAGE ADJ. Potentiometer 0013-29
   Chapter 6 – Field Maintenance Instructions
   Service Upon Receipt …………………………………………………………………………………………………………… WP 0014
   Figure 1. Oil Level 0014-3
   Field PMCS Introduction ……………………………………………………………………………………………………….. WP 0015
   Introduction to Field PMCS Table 0015-1
   Warnings and Cautions 0015-1
   Field PMCS 0015-1
   Explanation of Table Entries 0015-1
   Other Table Entries 0015-2
   Reporting and Correcting Deficiencies 0015-2
   Monthly 0015-2
   Quarterly 0015-2
   Semi-annually 0015-2
   Bi-annually 0015-2
   Hourly 0015-3
   Order In Which PMCS Will be Done 0015-3
   Fluid Leakage 0015-4
   Table 1. Leakage Definitions. 0015-4
   Field PMCS, Including Lubrication Instructions ………………………………………………………………………… WP 0016
   Field Lubrication Instructions 0016-1
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   TABLE OF CONTENTS – Continued

   Page No. WP Sequence No.

   Table 1. Field Preventive Maintenance Checks and Services for MEP-501A/MEP-531A. 0016-1
   Mandatory Replacement Parts List 0016-4
   Fuel Filter Element Replacement: Removal, Installation ……………………………………………………………. WP 0017 Removal 0017-1
   Installation 0017-1
   Figure 1. Fuel Filter Element Replacement 0017-2
   Air Filter Element Replacement: Removal, Cleaning, Installation………………………………………………… WP 0018 Removal 0018-1
   Cleaning 0018-1
   Figure 1. Air Filter Elements 0018-2
   Installation 0018-2
   Fuel Injector Replacement: Removal, Inspection, Installation …………………………………………………….. WP 0019 Removal 0019-1
   Inspection 0019-1
   Figure 1. Fuel Injector Replacement 0019-2
   Installation 0019-2
   Alternator Brushes Inspection (MEP-531A): Removal, Inspection, Installation ……………………………… WP 0020 Removal 0020-1
   Figure 1. AC Alternator Brushes 0020-1
   Inspection 0020-2
   Installation 0020-2
   Alternator Flexible Coupling Inspection (MEP-501A): Removal, Inspection, Installation …………………. WP 0021 Removal 0021-1
   Inspection 0021-1
   Installation 0021-1
   Figure 1. Alternator Flexible Coupling (MEP-501A) 0021-2
   Engine Resilient Mounts Replacement: Removal, Installation…………………………………………………….. WP 0022 Removal 0022-1
   Installation 0022-1
   Alternator Resilient Mount Replacement (MEP-531A): Removal, Installation ……………………………….. WP 0023 Removal 0023-1
   Installation 0023-1
   Figure 1. Resilient Mounts 0023-2
   Alternator Resilient Mount Replacement (MEP-501A): Removal, Installation ……………………………….. WP 0024 Removal 0024-1
   Installation 0024-1
   Figure 1. Alternator Resilient Mount (MEP-501A) 0024-2
   Cylinder Head Nuts Tightening: Adjustment …………………………………………………………………………….. WP 0025 Adjustment 0025-1
   Figure 1. Torquing Cylinder Head Nuts 0025-2
   Fuel Lines, Clamps, Fittings, Etc.: Removal, Installation ……………………………………………………………. WP 0026
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   Removal 0026-1
   Figure 1. Fuel Lines, Clamps, Fittings (Typical) 0026-1
   Installation 0026-2
   Fuel Filter Assembly: Removal, Inspection, Installation……………………………………………………………… WP 0027 Removal 0027-1
   Figure 1. Fuel Filter Assembly 0027-2
   Inspection 0027-2
   Installation 0027-2
   Fuel Drain Cock: Removal, Installation ……………………………………………………………………………………. WP 0028 Removal 0028-1
   Figure 1. Fuel Drain Cock 0028-1
   Installation 0028-2
   Fuel Tank Assembly: Removal, Disassembly, Inspection, Assembly, Installation………………………….. WP 0029 Removal 0029-1
   Disassembly 0029-2
   Inspection 0029-2
   Figure 1. Fuel Tank Assembly 0029-3
   Assembly 0029-4
   Installation 0029-4
   Air Intake System Components: Removal, Inspection, Installation………………………………………………. WP 0030 Removal 0030-1
   Figure 1. Air Intake System Components 0030-1
   Inspection 0030-1
   Installation 0030-2
   Exhaust System Components: Removal, Cleaning, Installation ………………………………………………….. WP 0031 Removal 0031-1
   Cleaning 0031-1
   Figure 1. Exhaust System Components 0031-2
   Installation 0031-2
   Figure 2. Spark Arrester Clamp Positioning 0031-3
   Control Panel Assembly: Inspection, Removal, Repair, Installation …………………………………………….. WP 0032 Inspection 0032-1
   Removal 0032-1
   Repair 0032-2
   Installation 0032-2
   Figure 1. Control Panel Assembly 0032-2
   Instruction Plate(s): Removal, Installation………………………………………………………………………………… WP 0033 Removal 0033-1
   Installation 0033-1
   Figure 1. Instruction Plate(s) 0033-2
   Instrument Cover: Inspection, Removal, Repair, Installation ………………………………………………………. WP 0034
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   Inspection 0034-1
   Removal 0034-1
   Repair 0034-1
   Installation 0034-2
   Figure 1. Instrument Cover 0034-2
   Instrument Panel: Inspection, Removal, Repair, Installation ………………………………………………………. WP 0035 Inspection 0035-1
   Removal 0035-1
   Figure 1. Instrument Panel 0035-2
   Repair 0035-2
   Installation 0035-2
   Hertz Frequency Meter (MEP-531A): Inspection, Testing, Removal, Installation …………………………… WP 0036 Inspection 0036-1
   Testing 0036-1
   Removal 0036-1
   Figure 1. HERTZ Frequency Meter (MEP-531A) 0036-2
   Installation 0036-2
   Volts Meter: Inspection, Testing, Removal, Installation ……………………………………………………………… WP 0037 Inspection 0037-1
   Testing 0037-1
   Removal 0037-2
   Figure 1. VOLTS Meter 0037-3
   Installation 0037-3
   % Load Meter: Inspection, Testing, Removal, Installation ………………………………………………………….. WP 0038 Inspection 0038-1
   Testing 0038-1
   Removal 0038-3
   Figure 1. % LOAD Meter 0038-3
   Installation 0038-3
   HOURS Meter: Inspection, Testing, Removal, Installation …………………………………………………………. WP 0039 Inspection 0039-1
   Testing 0039-1
   Removal 0039-2
   Installation 0039-2
   Figure 1. HOURS Meter 0039-2
   VOLTAGE ADJ. Potentiometer: Inspection, Testing, Removal …………………………………………………… WP 0040 Inspection 0040-1
   Testing 0040-1
   Removal 0040-1
   Repair 0040-2
   Installation 0040-2
   Figure 1. VOLTAGE ADJ. Potentiometer 0040-2
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   Instrument Shunt (MEP-501A): Inspection, Removal, Testing, Installation …………………………………… WP 0041 Inspection 0041-1
   Removal 0041-1
   Figure 1. Instrument Shunt (MEP-501A) 0041-2
   Testing 0041-2
   Installation 0041-2
   Capacitor (MEP-501A): Inspection, Removal, Testing, Repair, Installation…………………………………… WP 0042 Inspection 0042-1
   Removal 0042-1
   Testing 0042-1
   Figure 1. Capacitor (MEP-501A) 0042-2
   Repair 0042-2
   Installation 0042-2
   Transient Suppressor Assembly (MEP-501A): Inspection, Removal, Testing, Repair, Installation …… WP 0043 Inspection 0043-1
   Removal 0043-1
   Testing 0043-1
   Figure 1. Transient Suppressor Assembly (MEP-501A) 0043-2
   Repair 0043-2
   Installation 0043-2
   Fuseholder(s): Inspection, Removal, Installation ………………………………………………………………………. WP 0044 Inspection 0044-1
   Removal 0044-1
   Installation 0044-1
   Figure 1. Fuseholder(s) 0044-2
   Ground Strap(s): Inspection, Removal, Installation …………………………………………………………………… WP 0045 Inspection 0045-1
   Removal 0045-1
   Installation 0045-1
   Figure 1. Ground Strap(s) 0045-2
   GFCI Receptacle and Receptacle Cover (MEP-531A): Inspection, Testing, Removal, Installation ….. WP 0046 Inspection 0046-1
   Testing 0046-1
   Removal 0046-1
   Figure 1. GFCI Receptacle and Receptacle Cover (MEP-531A) 0046-2
   Installation 0046-2
   START-PREHEAT/PREHEAT/OFF/START Rotary Switch: Inspection, Testing, Removal,
   Installation …………………………………………………………………………………………………………………………… WP 0047
   Inspection 0047-1
   Testing 0047-1
   Removal 0047-1
   Installation 0047-2
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   Figure 1. START-PREHEAT/PREHEAT/OFF/START Rotary Switch 0047-2
   Discharge Varistor: Inspection, Testing, Removal, Installation ……………………………………………………. WP 0048 Inspection 0048-1
   Testing 0048-1
   Removal 0048-1
   Installation 0048-1
   Figure 1. Discharge Varistor 0048-2
   NATO Slave Receptacle: Inspection, Removal, Installation ……………………………………………………….. WP 0049 Inspection 0049-1
   Removal 0049-1
   Figure 1. NATO Slave Receptacle 0049-2
   Installation 0049-2
   Load Terminal(s) (MEP-501A and Mechron Sets): Inspection, Removal, Installation …………………….. WP 0050 Inspection 0050-1
   Removal 0050-1
   Figure 1. Load Terminal(s) (MEP-501A and Mechron Sets) 0050-2
   Installation 0050-2
   Terminal Board: Inspection, Removal, Testing, Installation ………………………………………………………… WP 0051 Inspection 0051-1
   Removal 0051-1
   Testing 0051-1
   Figure 1. Terminal Board 0051-2
   Installation 0051-2
   Load Terminal Board (MEP-501A and Mechron Sets): Inspection, Removal, Installation……………….. WP 0052 Inspection 0052-1
   Removal 0052-1
   Installation 0052-1
   Figure 1. Load Terminal Board (MEP-501A and Mechron Sets) 0052-2
   ON-OFF Load Circuit Breaker Assembly and Boot: Inspection, Testing, Removal, Installation ……….. WP 0053 Inspection 0053-1
   Testing MEP-531A 0053-1
   Testing MEP-501A 0053-2
   Removal 0053-2
   Installation 0053-2
   Figure 1. ON-OFF Load Circuit Breaker Assembly and Boot 0053-3
   Flywheel Diode Assembly: Inspection, Testing, Removal, Repair, Installation………………………………. WP 0054 Inspection 0054-1
   Testing 0054-1
   Removal 0054-1
   Repair 0054-2
   Figure 1. Flywheel Diode Assembly 0054-2
   Installation 0054-2
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   Diesel Engine Wiring Harness and Gasket, Control Panel: Inspection, Testing, Removal, Repair,
   Installation …………………………………………………………………………………………………………………………… WP 0055
   Inspection 0055-1
   Testing 0055-1
   Removal 0055-2
   Repair 0055-2
   Figure 1. Diesel Engine Wiring Harness and Gasket, Control Panel 0055-2
   Installation 0055-2
   Alternator Wiring Harness and Gasket, Control Panel: Inspection, Testing, Removal, Repair,
   Installation …………………………………………………………………………………………………………………………… WP 0056
   Inspection 0056-1
   Testing 0056-1
   Removal 0056-1
   Figure 1. Alternator Wiring Harness and Gasket, Control Panel 0056-2
   Repair 0056-2
   Installation 0056-2
   Electrical Lead Wire(s) (Typical): Inspection, Testing, Removal, Installation ………………………………… WP 0057 Inspection 0057-1
   Testing 0057-1
   Removal 0057-1
   Installation 0057-2
   Figure 1. Electrical Lead Wire(s) (Typical) 0057-2
   Load Terminal Board Cover (Lug Cover): Inspection, Removal, Repair, Installation ……………………… WP 0058 Figure 1. Load Terminal Board Cover (Lug Cover) 0058-1
   Inspection 0058-1
   Removal 0058-2
   Repair 0058-2
   Installation 0058-2
   Electromagnetic Interference (EMI) Filter (MEP-531A): Inspection, Removal, Testing, Installation ….. WP 0059 Inspection 0059-1
   Removal 0059-1
   Figure 1. EMI Filter (MEP-531A) 0059-2
   Testing 0059-2
   Installation 0059-3
   Low Oil Pressure (LOP) Switch: Testing, Removal, Installation ………………………………………………….. WP 0060 Testing 0060-1
   Figure 1. Low Oil Pressure (LOP) Switch 0060-1
   Removal 0060-2
   Installation 0060-2
   Low Oil Pressure (LOP) Solenoid Assembly: Testing, Removal, Cleaning and Inspection, Repair,
   Installation …………………………………………………………………………………………………………………………… WP 0061
   Testing 0061-1
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   Removal 0061-1
   Cleaning 0061-2
   Figure 1. Low Oil Pressure (LOP) Solenoid Assembly 0061-2
   Repair 0061-3
   Installation 0061-3
   Low Oil Pressure (LOP) Engine Shutdown Cable: Inspection, Removal, Installation, Adjustment……. WP 0062 Figure 1. Low Oil Pressure (LOP) Engine Shutdown Cable 0062-1
   Inspection 0062-1
   Removal 0062-2
   Installation 0062-2
   Adjustment 0062-2
   Figure 2. LOP Engine Shutdown Cable Adjustment 0062-3
   Air Intake Heating Elements and Pipe: Removal, Inspection, Testing, Installation…………………………. WP 0063 Removal 0063-1
   Inspection 0063-1
   Figure 1. Air Intake Heating Elements and Pipe 0063-2
   Testing 0063-2
   Installation 0063-2
   Governor Regulator Bracket: Removal, Inspection, Repair, Installation ……………………………………….. WP 0064 Removal 0064-1
   Inspection 0064-1
   Repair 0064-1
   Installation 0064-1
   Figure 1. Governor Regulator Bracket 0064-2
   Figure 2. Governor Spring Positioning 0064-3
   Cooling Fan Cover: Inspection, Removal, Repair, Installation…………………………………………………….. WP 0065 Inspection 0065-1
   Removal 0065-1
   Repair 0065-1
   Figure 1. Cooling Fan Cover 0065-2
   Installation 0065-2
   Recoil Starter Assembly: Inspection, Removal, Installation ………………………………………………………… WP 0066 Inspection 0066-1
   Removal 0066-1
   Figure 1. Recoil Starter Assembly 0066-2
   Installation 0066-2
   Engine Oil Strainer: Removal, Cleaning, Installation …………………………………………………………………. WP 0067 Removal 0067-1
   Figure 1. Engine Oil Strainer 0067-2
   Cleaning 0067-2
   Installation 0067-2
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   Valve Cover: Removal, Inspection, Installation…………………………………………………………………………. WP 0068 Removal 0068-1
   Inspection 0068-1
   Installation 0068-1
   Figure 1. Valve Cover 0068-2
   Starter Assembly (MEP-501A): Removal, Installation ……………………………………………………………….. WP 0069 Removal 0069-1
   Installation 0069-1
   Figure 1. Starter Assembly 0069-2
   Engine Wiring Harness: Inspection, Removal, Disassembly, Repair, Installation ………………………….. WP 0070 Inspection 0070-1
   Removal 0070-1
   Disassembly 0070-1
   Figure 1. Engine Wiring Harness 0070-2
   Repair 0070-2
   Installation 0070-3
   Alternator Wiring Harness (MEP-501A): Inspection, Testing, Removal, Repair, Installation ……………. WP 0071 Inspection 0071-1
   Testing 0071-1
   Figure 1. Alternator Wiring Harness 0071-2
   Removal 0071-2
   Repair 0071-2
   Installation 0071-3
   Preheater Lead: Inspection, Testing, Removal, Repair, Installation …………………………………………….. WP 0072 Inspection 0072-1
   Testing 0072-1
   Removal 0072-1
   Repair 0072-1
   Figure 1. Preheater Lead 0072-2
   Installation 0072-2
   Ground Stud Terminal: Inspection, Removal, Installation …………………………………………………………… WP 0073 Inspection 0073-1
   Removal 0073-1
   Installation 0073-1
   Figure 1. Ground Stud Terminal 0073-2
   Generator Control Unit: Inspection, Testing, Removal, Installation ……………………………………………… WP 0074 Inspection 0074-1
   Testing MEP-531A 0074-1
   Testing MEP-501A 0074-2
   Removal 0074-3
   Installation 0074-3
   Figure 1. Generator Control Unit (MEP-531A) 0074-4
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   Voltage Regulator Assembly: Inspection, Testing, Removal, Installation ……………………………………… WP 0075 Inspection 0075-1
   Testing MEP-531A 0075-1
   Testing MEP-501A 0075-2
   Removal 0075-2
   Figure 1. Voltage Regulator Assembly (MEP-531A) 0075-3
   Installation 0075-3
   Diesel Engine Wiring Harness, Control Panel: Testing, Repair …………………………………………………… WP 0076 Testing 0076-1
   Repair 0076-1
   Alternator Wiring Harness, Control Panel: Testing, Repair…………………………………………………………. WP 0077 Testing 0077-1
   Repair 0077-1
   Engine/Alternator Assembly: Removal, Installation …………………………………………………………………… WP 0078 Removal 0078-1
   Figure 1. Engine/Alternator Assembly 0078-2
   Installation 0078-3
   Diesel Engine: Installation, Removal ………………………………………………………………………………………. WP 0079
   Removal 0079-1
   Installation 0079-1
   Starter (MEP-531A): Removal, Installation ………………………………………………………………………………. WP 0080 Removal 0080-1
   Figure 1. Starter (MEP-531A) 0080-1
   Installation 0080-2
   Rocker Arms and Push Rods: Removal, Inspection, Installation …………………………………………………. WP 0081 Removal 0081-1
   Inspection 0081-1
   Installation 0081-1
   Figure 1. Rocker Arms and Push Rods Assembly 0081-2
   Cylinder Head Assembly: Removal, Inspection, Installation ……………………………………………………….. WP 0082 Removal 0082-1
   Figure 1. Cylinder Head Assembly 0082-2
   Inspection 0082-2
   Installation 0082-2
   Intake and Exhaust Valves: Removal, Inspection, Installation, Adjustment…………………………………… WP 0083 Removal 0083-1
   Figure 1. Intake and Exhaust Valves 0083-1
   Inspection 0083-2
   Figure 2. Valve Seat Measurements 0083-2
   Figure 3. Measuring Valve Sinkage 0083-2
   Installation 0083-3
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   Adjustment 0083-3
   Figure 4. T Position Mark 0083-3
   Figure 5. Valve Adjustment 0083-4
   Fuel Injection Pump: Removal, Inspection, Installation, Adjustment ……………………………………………. WP 0084 Removal 0084-1
   Figure 1. Fuel Injection Pump Removal 0084-2
   Inspection 0084-2
   Installation 0084-2
   Figure 2. Governor Linkage Setting 0084-3
   Figure 3. Fuel Injection Limitation Setting 0084-3
   Adjustment 0084-3
   Figure 4. T Position Mark 0084-4
   Crankcase Cover: Removal, Inspection, Installation …………………………………………………………………. WP 0085 Removal 0085-1
   Inspection 0085-1
   Installation 0085-2
   Figure 1. Crankcase Cover………………………………………………………………………………………………. …. 0085-
   Oil Pump Assembly: Removal, Inspection, Installation ………………………………………………………………. WP 0086 Removal 0086-1
   Figure 1. Oil Pump Assembly 0086-1
   Inspection 0086-2
   Installation 0086-2
   Flywheel: Removal, Inspection, Installation ……………………………………………………………………………… WP 0087 Removal 0087-1
   Figure 1. Flywheel Locking Handle 0087-1
   Figure 2. Flywheel 0087-2
   Inspection 0087-2
   Installation 0087-2
   Dynamo: Testing, Removal, Inspection, Installation ………………………………………………………………….. WP 0088 Testing 0088-1
   Removal 0088-1
   Figure 1. Aligning Timing Marks 0088-2
   Inspection 0088-2
   Installation 0088-2
   Figure 2. Dynamo 0088-3
   AC Alternator Assembly (MEP-531A): Removal, Disassembly, Assembly, Inspection, Testing,
   Installation …………………………………………………………………………………………………………………………… WP 0089
   Removal 0089-1
   Figure 1. AC Alternator Assembly (MEP-531A) (Sheet 1 of 2). 0089-2
   Figure 1. AC Alternator Assembly (MEP-531A) (Sheet 2 of 2). 0089-3
   Disassembly 0089-3
   Assembly 0089-4
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   Table 1. Power Harness Connector Plug Connections. 0089-4
   Inspection 0089-4
   Testing (alternator Installed) 0089-5
   Installation 0089-5
   AC Alternator Bearing (MEP-531A): Removal, Installation …………………………………………………………. WP 0090 Removal 0090-1
   Figure 1. AC Alternator Bearing 0090-1
   Installation 0090-2
   DC Alternator Assembly (MEP-501A): Removal, Disassembly, Inspection, Testing, Assembly,
   Installation …………………………………………………………………………………………………………………………… WP 0091
   Removal 0091-1
   Figure 1. DC Alternator Installation (MEP-501A) 0091-2
   Disassembly 0091-2
   Figure 2. DC Alternator Assembly 0091-3
   Figure 3. Heatsink Tie Point Locations 0091-4
   Inspection 0091-4
   Testing 0091-4
   Figure 4. Brush Assembly Test 0091-5
   Figure 5. Stator Test 0091-6
   Figure 6. Rotor Test 0091-6
   Assembly 0091-7
   Installation 0091-7
   DC Alternator Bearings (MEP-501A): Inspection, Removal, Installation ………………………………………. WP 0092 Inspection 0092-1
   Removal 0092-1
   Figure 1. Alternator Bearing Replacement 0092-2
   Installation 0092-2
   DC Alternator Diodes and Capacitors (MEP-501A): Removal, Testing, Installation ……………………….. WP 0093 Removal 0093-1
   Figure 1. Diodes and Capacitor Replacement 0093-2
   Testing 0093-2
   Installation 0093-3
   Frame: Inspection, Removal, Repair, Installation ……………………………………………………………………… WP 0094 Inspection 0094-1
   Figure 1. Frame 0094-2
   Removal 0094-2
   Repair 0094-2
   Installation 0094-3
   2 kW Deprocessing Checklist ………………………………………………………………………………………………… WP 0095
   Dewey/Mechron Cross-Reference List ……………………………………………………………………………………. WP 0096
   Table 1. MEP-531A Cross-Reference List for Component Identifiers. 0096-1
   Table 2. MEP-531A Cross-Reference List for Wiring Identifiers. 0096-2
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   Table 3. MEP-501A Cross-Reference List for Component Identifiers. 0096-4
   Table 4. MEP-501A Cross-Reference List for Wiring Identifiers. 0096-5
   Electrical Lead Fabrication for Control Panel……………………………………………………………………………. WP 0097
   Table 1. Electrical Lead Fabrication for Control Panel (MEP-531A). 0097-1
   Table 2. Electrical Lead Fabrication for Control Panel (MEP-501A). 0097-2
   Illustrated List of Manufactured Items Introduction ……………………………………………………………………. WP 0098
   Potentiometer, VOLTAGE ADJ. (P/N: 95-8077) ……………………………………………………………………….. WP 0099 Figure 1. Potentiometer, VOLTAGE ADJ. (P/N: 95-8077) (Sheet 1 of 2). 0099-1
   Figure 1. Potentiometer, VOLTAGE ADJ. (P/N: 95-8077) (Sheet 2 of 2). 0099-2
   Potentiometer, VOLTAGE ADJ. (P/N: 95-8014) ……………………………………………………………………….. WP 0100 Figure 1. Potentiometer, VOLTAGE ADJ. (P/N: 95-8014) (Sheet 1 of 2). 0100-1
   Figure 1. Potentiometer, VOLTAGE ADJ. (P/N: 95-8014) (Sheet 2 of 2). 0100-2
   Flywheel Diode Assembly (P/N: 95-8050) ……………………………………………………………………………….. WP 0101
   Figure 1. Flywheel Diode Assembly (P/N: 95-8050) 0101-1
   Capacitor Assembly (P/N: 95-8017) ……………………………………………………………………………………….. WP 0102
   Figure 1. Capacitor Assembly (P/N: 95-8017) 0102-1
   LOP Solenoid Valve Assembly (P/N: 95-8019)…………………………………………………………………………. WP 0103
   Figure 1. LOP Solenoid Valve Assembly (P/N: 95-8019) 0103-1
   Wiring Harness, Control Panel (P/N: 95-8084) …………………………………………………………………………. WP 0104
   Figure 1. Wiring Harness, Control Panel (P/N: 95-8084) (Sheet 1 of 2). 0104-1
   Figure 1. Wiring Harness, Control Panel (P/N: 95-8084) (Sheet 2 of 2). 0104-2
   Wiring Harness, Control Panel (P/N: 95-8023) …………………………………………………………………………. WP 0105
   Figure 1. Wiring Harness, Control Panel (P/N: 95-8023) (Sheet 1 of 2). 0105-1
   Figure 1. Wiring Harness, Control Panel (P/N: 95-8023) (Sheet 2 of 2). 0105-2
   Wiring Harness, Control Panel (P/N: 95-8075) …………………………………………………………………………. WP 0106
   Figure 1. Wiring Harness, Control Panel (P/N: 95-8075) (Sheet 1 of 2). 0106-1
   Figure 1. Wiring Harness, Control Panel (P/N: 95-8075) (Sheet 2 of 2). 0106-2
   Wiring Harness, Control Panel (P/N: 95-8022) …………………………………………………………………………. WP 0107
   Figure 1. Wiring Harness, Control Panel (P/N: 95-8022) (Sheet 1 of 2). 0107-1
   Figure 1. Wiring Harness, Control Panel (P/N: 95-8022) (Sheet 2 of 2). 0107-2
   Wiring Harness, Engine (P/N: 95-8029)…………………………………………………………………………………… WP 0108 Figure 1. Wiring Harness, Engine (P/N: 95-8029) (Sheet 1 of 3). 0108-2
   Figure 1. Wiring Harness, Engine (P/N: 95-8029) (Sheet 2 of 3). 0108-3
   Figure 1. Wiring Harness, Engine (P/N: 95-8029) (Sheet 3 of 3). 0108-4
   LOP Shutdown Cable (P/N: 95-8082) ……………………………………………………………………………………… WP 0109
   Figure 1. LOP Shutdown Cable (P/N: 95-8082) 0109-1
   Preheater Lead, Electrical (P/N: 95-8141) ……………………………………………………………………………….. WP 0110 Figure 1. Preheater Lead, Electrical (P/N: 95-8141) (Sheet 1 of 2). 0110-1
   Figure 1. Preheater Lead, Electrical (P/N: 95-8141) (Sheet 2 of 2). 0110-2
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   Wiring Harness, Alternator (P/N: 95-8028) ………………………………………………………………………………. WP 0111 Figure 1. Wiring Harness, Alternator (P/N: 95-8028) (Sheet 1 of 2). 0111-1
   Figure 1. Wiring Harness, Alternator (P/N: 95-8028) (Sheet 2 of 2). 0111-2
   Transient Suppressor (P/N: 95-8025) ……………………………………………………………………………………… WP 0112
   Figure 1. Transient Suppressor (P/N: 95-8025) 0112-1
   Flywheel Locking Handle (P/N: 114250-92101) ……………………………………………………………………….. WP 0113
   Figure 1. Flywheel Locking Handle (P/N: 114250-92101) 0113-1
   Flywheel Extractor (P/N: 114250-92130) …………………………………………………………………………………. WP 0114
   Figure 1. Flywheel Extractor (P/N: 114250-92130) 0114-1
   Torque Limits ………………………………………………………………………………………………………………………. WP 0115
   How to Use the Torque Tables 0115-1
   Table 1. Torque Limits for Steel Fasteners. 0115-2
   Table 2. Torque Limits for Brass Fasteners. 0115-2
   Table 3. Torque Limits for Metric Fasteners into Steel. 0115-2
   Chapter 7 – Parts Information
   Introduction …………………………………………………………………………………………………………………………. WP 0116
   Table 1. SMR Code Explanation. 0116-1
   GROUP 00 Generator Set Assembly, 2 kW (MEP-531A/501A) ………………………………………………….. WP 0117
   Figure 1. Generator Set Assembly, 2 kW (MEP-531A/501A) (Sheet 1 of 2). 0117-1
   Figure 1. Generator Set Assembly, 2 kW (MEP-531A/501A) (Sheet 2 of 2). 0117-2
   GROUP 01 Frame Assembly (MEP-531A/501A)………………………………………………………………………. WP 0118
   Figure 2. Frame Assembly (MEP-531A/501A) 0118-2
   GROUP 02 Fuel System Assembly (MEP-531A/501A) ……………………………………………………………… WP 0119
   Figure 3. Fuel System Assembly (MEP-531A/501A) 0119-2
   GROUP 0201 Fuel Tank Assembly ………………………………………………………………………………………… WP 0120
   Figure 4. Fuel Tank Assembly 0120-2
   GROUP 0202 Fuel Filter Assembly ………………………………………………………………………………………… WP 0121
   Figure 5. Fuel Filter Assembly 0121-2
   GROUP 03 Engine Alternator Assembly (MEP-531A)……………………………………………………………….. WP 0122
   Figure 6. Engine Alternator Assembly (MEP-531A) (Sheet 1 of 2). 0122-1
   Figure 6. Engine Alternator Assembly (MEP-531A) (Sheet 2 of 2). 0122-2
   GROUP 03 Engine Alternator Assembly (MEP-501A)……………………………………………………………….. WP 0123
   Figure 7. Engine Alternator Assembly (MEP-501A) 0123-2
   GROUP 0301 Diesel Engine Modified …………………………………………………………………………………….. WP 0124
   Figure 8. Diesel Engine Modified 0124-2
   GROUP 030101 Diesel Engine Assembly ……………………………………………………………………………….. WP 0125
   Figure 9. Diesel Engine Assembly 0125-2
   GROUP 03010101 Cylinder Block Installation………………………………………………………………………….. WP 0126
   Figure 10. Cylinder Block Installation 0126-2
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   GROUP 03010102 Cylinder Head Installation ………………………………………………………………………….. WP 0127
   Figure 11. Cylinder Head Installation 0127-2
   GROUP 03010103 Air Intake Pipe and Muffler ………………………………………………………………………… WP 0128
   Figure 12. Air Intake Pipe and Muffler 0128-2
   GROUP 03010104 Cam/Crankshaft/Balancer Installation …………………………………………………………. WP 0129
   Figure 13. Cam/Crankshaft/Balancer Installation 0129-2
   GROUP 03010105 Piston and Rod Assembly………………………………………………………………………….. WP 0130
   Figure 14. Piston and Rod Assembly 0130-2
   GROUP 03010106 Lube Oil Pump and Governor …………………………………………………………………….. WP 0131
   Figure 15. Lube Oil Pump and Governor 0131-2
   GROUP 03010107 Cooling/Starting Installation ……………………………………………………………………….. WP 0132
   Figure 16. Cooling/Starting Installation 0132-2
   GROUP 03010108 Fuel Injection Pump/Injector Installation ………………………………………………………. WP 0133
   Figure 17. Fuel Injection Pump/Injector Installation 0133-2
   GROUP 03010109 Starting Motor and Dynamo Installation……………………………………………………….. WP 0134
   Figure 18. Starting Motor and Dynamo Installation 0134-2
   GROUP 0302 AC Alternator Assembly (MEP-531A) …………………………………………………………………. WP 0135
   Figure 19. AC Alternator Assembly (MEP-531A) 0135-2
   GROUP 0303 DC Alternator Assembly (MEP-501A)…………………………………………………………………. WP 0136
   Figure 20. DC Alternator Assembly (MEP-501A) (Sheet 1 of 2). 0136-1
   Figure 20. DC Alternator Assembly (MEP-501A) (Sheet 2 of 2). 0136-2
   GROUP 04 Control Panel Assembly (MEP-531A)…………………………………………………………………….. WP 0137
   Figure 21. Control Panel Assembly (MEP-531A) (Sheet 1 of 3). 0137-2
   Figure 21. Control Panel Assembly (MEP-531A) (Sheet 2 of 3). 0137-3
   Figure 21. Control Panel Assembly (MEP-531A) (Sheet 3 of 3). 0137-4
   GROUP 04 Control Panel Assembly (MEP-501A)…………………………………………………………………….. WP 0138
   Figure 22. Control Panel Assembly (MEP-501A) (Sheet 1 of 3). 0138-2
   Figure 22. Control Panel Assembly (MEP-501A) (Sheet 2 of 3). 0138-3
   Figure 22. Control Panel Assembly (MEP-501A) (Sheet 3 of 3). 0138-4
   GROUP 0401 Control Panel Constructions (MEP-531A/501A) …………………………………………………… WP 0139
   Figure 23. Control Panel Constructions (MEP-531A/501A) 0139-2
   GROUP 0402 Voltage Adjust Potentiometer ……………………………………………………………………………. WP 0140
   Figure 24. Voltage Adjust Potentiometer 0140-2
   GROUP 0407 LOP Shutdown Solenoid Assembly ……………………………………………………………………. WP 0141
   Figure 25. LOP Shutdown Solenoid Assembly 0141-2
   GROUP 0408 Control Panel Engine Wiring Harnesses (MEP-531A/501A) ………………………………….. WP 0142
   Figure 26. Control Panel Engine Wiring Harnesses (MEP-531A/501A) 0142-2
   GROUP 0409 Control Panel Alternator Wiring Harnesses (MEP-531A/501A) ………………………………. WP 0143
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   Figure 27. Control Panel Alternator Wiring Harnesses (MEP-531A/501A) 0143-2
   GROUP 0411 Flywheel Diode Assembly…………………………………………………………………………………. WP 0144
   Figure 28. Flywheel Diode Assembly 0144-2
   GROUP 0412 Control Panel Electrical Leads (MEP-531A) ………………………………………………………… WP 0145
   Figure 29. Control Panel Electrical Leads (MEP-531A) (Sheet 1 of 5). 0145-2
   Figure 29. Control Panel Electrical Leads (MEP-531A) (Sheet 2 of 5). 0145-3
   Figure 29. Control Panel Electrical Leads (MEP-531A) (Sheet 3 of 5). 0145-4
   Figure 29. Control Panel Electrical Leads (MEP-531A) (Sheet 4 of 5). 0145-5
   Figure 29. Control Panel Electrical Leads (MEP-531A) (Sheet 5 of 5). 0145-6
   GROUP 0412 Control Panel Electrical Leads (MEP-501A) ………………………………………………………… WP 0146
   Figure 30. Control Panel Electrical Leads (MEP-501A) (Sheet 1 of 6). 0146-1
   Figure 30. Control Panel Electrical Leads (MEP-501A) (Sheet 2 of 6). 0146-2
   Figure 30. Control Panel Electrical Leads (MEP-501A) (Sheet 3 of 6). 0146-3
   Figure 30. Control Panel Electrical Leads (MEP-501A) (Sheet 4 of 6). 0146-4
   Figure 30. Control Panel Electrical Leads (MEP-501A) (Sheet 5 of 6). 0146-5
   Figure 30. Control Panel Electrical Leads (MEP-501A) (Sheet 6 of 6). 0146-6
   GROUP 0413 Capacitor Assembly (MEP-501A) ………………………………………………………………………. WP 0147
   Figure 31. Capacitor Assembly (MEP-501A) 0147-2
   GROUP 0414 Transient Suppressor Assembly (MEP-501A) ……………………………………………………… WP 0148
   Figure 32. Transient Suppressor Assembly (MEP-501A) 0148-2
   GROUP 05 Engine Wiring Harness (MEP-531A/501A) ……………………………………………………………… WP 0149
   Figure 33. Engine Wiring Harness (MEP-531A/501A) 0149-2
   GROUP 06 LOP Engine Shutdown Cable Assembly (MEP-531A/501A) ……………………………………… WP 0150
   Figure 34. LOP Engine Shutdown Cable Assembly (MEP-531A/501A) 0150-2
   GROUP 07 Preheater Lead Assembly (MEP-531A/501A) …………………………………………………………. WP 0151
   Figure 35. Preheater Lead Assembly (MEP-531A/501A) 0151-2
   GROUP 08 Alternator Wiring Harness (MEP-501A) ………………………………………………………………….. WP 0152
   Figure 36. Alternator Wiring Harness (MEP-501A) 0152-2
   Bulk Items …………………………………………………………………………………………………………………………… WP 0153
   Special Tools List …………………………………………………………………………………………………………………. WP 0154
   Figure 1. Special Tools for Field Maintenance (Diesel Engine) 0154-2
   NSN Index…………………………………………………………………………………………………………………………… WP 0155
   Table 1. NSN Index. 0155-1
   P/N Index ……………………………………………………………………………………………………………………………. WP 0156
   Table 1. Part Number Index. 0156-1
   Chapter 8 – Supporting Information References………………………………………………………………………………………………………………………….. WP 0157
   Introduction for Standard Two-Level Maintenance MAC ……………………………………………………………. WP 0158
   The Army Maintenance System MAC 0158-1
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   TABLE OF CONTENTS – Continued

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   Explanation of Columns in the MAC 0158-3
   Explanation of Columns In the Tools and Test Equipment Requirements 0158-3
   Explanation of Columns In the Remarks 0158-4
   MAC …………………………………………………………………………………………………………………………………… WP 0159 Table 1. MAC for 2 kW Military Tactical Generator Sets. 0159-1
   Table 2. Tools and Test Equipment Requirements for 2 kW Military Tactical Generator Sets. 0159-4
   Table 3. Remarks for 2 kW Military Tactical Generator Sets. 0159-5
   Components of End Item (COEI) and Basic Issue Items (BII) Lists……………………………………………… WP 0160 Table 1. Components of End Item List. 0160-1
   Figure 1. Technical Manual TM 9-6115-673-13&P and Ground Rod Electrical Equipment 0160-2
   Table 2. Basic Issue Items List. 0160-2
   Additional Authorization List (AAL) …………………………………………………………………………………………. WP 0161
   Table 1. Additional Authorization List. 0161-1
   Expendable and Durable Items List ………………………………………………………………………………………… WP 0162
   Table 1. Expendable and Durable Items List. 0162-1
   Mandatory Replacement Parts List …………………………………………………………………………………………. WP 0163
   Table 1. Mandatory Replacement Parts List. 0163-1
   Special Packaging Instructions ………………………………………………………………………………………………. WP 0164
   Figure 1. Special Packaging Instructions, MEP-531A (Sheet 1 of 2). 0164-1
   Figure 1. Special Packaging Instructions, MEP-531A (Sheet 2 of 2). 0164-2
   Figure 2. Special Packaging Instructions, MEP-501A (Sheet 1 of 2). 0164-3
   Figure 2. Special Packaging Instructions, MEP-501A (Sheet 2 of 2). 0164-4
   Components and Instructions for Auxiliary Fuel System ……………………………………………………………. WP 0165 Scope 0165-1
   General 0165-1
   Item Description 0165-1
   Explanation of Columns – Figure 1 0165-1
   Auxiliary Fuel System Instructions 0165-2
   Fabrication Instructions 0165-2
   Tools Required for Pre-assembly, Assembly, and Disassembly 0165-2
   Pre-assembly Instructions 0165-2
   Disassembly Instructions 0165-4
   Figure 1. Auxiliary Fuel System (Sheet 1 of 2). 0165-5
   Figure 1. Auxiliary Fuel System (Sheet 2 of 2). 0165-6
   Table 1. Auxiliary Fuel System Components. 0165-7
   Figure 2. Three Way Valve Bracket 0165-8
   Figure 3. Auxiliary Fuel Tank Bracket 0165-9
   Figure 4. 2 kW Set with Auxiliary Fuel System Installed 0165-10
   Figure 5. Fuel Can Bracket Shown in the Stowed Position 0165-11
   Index
   Foldout Figures
   FO 1. ……………………………………………………………………………………………………………………………………….. FP-1
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   FO 2. ……………………………………………………………………………………………………………………………………….. FP-3
   FO 3. ……………………………………………………………………………………………………………………………………….. FP-5
   FO 4. ……………………………………………………………………………………………………………………………………….. FP-7
   FO 5. ……………………………………………………………………………………………………………………………………….. FP-9
   FO 6. ……………………………………………………………………………………………………………………………………… FP-11

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   How to Use This Manual
   This manual contains operator and field maintenance instructions for the 2 kW Military Tactical Generator Sets.

   NOTE
   Throughout the family of manuals, directional orientation in relation to the equipment is described from the point of view of the operator facing the operator’ scontrols looking out over the equipment. From this perspective, the end of the equipment containing the operator’ scontrols will be referred to as the rear.

   This manual provides operating procedures, troubleshooting, maintenance, and supporting information required to operate and maintain the generator sets. Listed below are some of the features included in this TM to help locate and use the provided information.
   WORK PACKAGES
   This TM has been organized using the WP format. Each chapter contains a series of WPs rather than sections and paragraphs. Each WP is designed to stand alone as a complete information module; if the user keeps the section(s) of this TM in a loose-leaf binder, the user will be able to remove just the WP needed to complete a specific task. Here are some WP features of which the user should be aware.
   Each WP is numbered using a four-digit number beginning with WP 0001. WPs are numbered sequentially throughout the TM (ex. WP 0016. WP 0020. etc.). The Table of Contents lists each chapter and WP title as well as all figures and tables contained within each. Figures and tables are numbered sequentially for each WP.
   The WP number is located at the top right of each page. It is also located at the bottom of the page with the WP page number included (0001-1 would be page 1 of the General Information WP (WP 0001, General Information)).
   Each WP starts on a right-hand page. This is done so the user can remove a single WP from the paper TM if needed for a task. Blank pages are assigned a number, but it appears on the preceding or following page. For example. if page 0001-10 of a WP is blank. page 0001-9 will have the number 0001-9/10 blank; or if page 0001-1 of a WP is blank, page 0001-2 will have the number 0001-1 blank/2.
   Each WP containing step-by-step maintenance or troubleshooting procedures will end with the words END OF TASK, and each WP ends with the statement END OF WORK PACKAGE. Think of each WP as a small, standalone TM.
   Typographical conventions are as follows: [Unload] indicates a soft key or a switch.
   [Previous] + [Next] indicates two simultaneous key presses. [ + ] [ – ] indicates two sequential key presses.
   References to equipment Data and Description Plates are printed as they appear on the equipment whenever possible.
   Warnings, Cautions and Notes Definitions
   Warnings, cautions, notes. chapter titles, and paragraph headings are printed in bold type. Icons related to warnings are shown directly above the warning text.
   The following definitions apply to WARNINGS, CAUTIONS and NOTES found throughout this publication. Warning, cautions and notes provide supplemental information. Personnel must understand and apply these Warnings, Cautions and Notes during many phases of operation and maintenance to ensure personnel safety and health and the protection of property. Portions of this information may be repeated in certain chapters of this publication for emphasis.
   WARNING
   A warning identifies a clear danger to the person doing that procedure.

   CAUTION
   A caution identifies risk of damage to the equipment.

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   TM 9-6115-673-13&P

   NOTE
   A note highlights essential procedures, conditions, or statements or conveys important instructional data to the user.

   CHAPTER OVERVIEW

   Chapter 1 – General Information, Equipment Description and Theory of Operation
   Chapter 1 provides an introduction to the generator sets. It is divided into three work packages, as follows:
   General Information. This work package provides general information about this manual and the related forms and records. Instructions are provided for making equipment impr