MTD 584 Operating instructions

ARMY
TECHNICAL
NAVY
MANUAL
TM
PUBLICATION
NAVFAC
AIR FORCE TECHNICAL ORDER
MARlNE
CORPS
TECHNICAL
OPERATOR
AND
SET,
DIESEL
ENGINE
P-8-622-12
35C2-3-456-1
TM
05682C-12
MANUAL
ORGANIZATIONAL
MAINTENANCE
GENERATOR
TO
MANUAL
TECHINCAL
5-6115-584-12
DRIVEN,
MANUAL
TACTICAL
SKID
MTD
5KW,
1
PHASE
- 2 WIRE, 1 PHASE - 3 WIRE, 3 PHASE - 4 WIRE, 120, 120/240 AND 120/208 VOLTS
DOD
MODEL
MEP-002A
CLASS
HERTZ
NSN
UTILITY
6 0
6115-00-465-1044
This copy is a reprint which includes current
pages from Change 1 through 11.
PUBLISHED UNDER THE AUTHORITY OF THE DEPARTMENTS OF THE ARMY, AIR FORCE, NAVY
AND HEADQUARTERS U.S. MARINE CORPS
JULY 1977
ARMY TM 5-6115-584-12
NAVFAC P-8-622-12
AIR FORCE TO-35C2-3-456-1
MARINE CORPS TM-05682C-12
C 1 1
CHANGE
HEADQUARTERS
DEPARTMENTS OF THE ARMY, NAVY AND AIR FORCE
AND HEADQUARTERS U.S. MARINE CORPS
NO. 1 1
WASHINGTON, D.C., 27 APRIL 1992
Operator and Organizational Maintenance Manual
GENERATOR SET, DIESEL ENGINE DRIVEN, TACTICAL SKID MTD, 5KW
1 PHASE-2 WIRE, 1 PHASE-3 WIRE, 3 PHASE-4 WIRE
120, 120/240 AND 120/208 VOLTS
Approved for public release; Distribution is unlimited
TM 5-6115-584-12, NAVFAC P-8-622-12, TO 35C2-3-456-1, TM 05682C-12, 22 July 1977 is changed as
follows:
1. The banner page for Change 9 to this manual is numbered incorrectly on the left hand side of the page. The
number is changed from 10 to 9.
2. Remove and insert pages as indicated below. New or changed text material is indicated by a vertical bar in
the margin. An illustration change is indicated by a miniature pointing hand.
Remove pages
Insert pages
D-17 and D-18
D-17 and D-18
3. Retain this sheet in front of manual for reference purposes.
ARMY TM 5-6115-584-12
NAVFAC P-8-622-12
AIR FORCE TO-35C2-3-456-1
MARINE CORPS TM-05682C-12
C 1 1
By Order of the Secretaries of the Army, Air Force, and Navy (Including the Marine Corps):
GORDON R. SULLIVAN
General, United States Army
Chief of Staff
Official:
MILTON H. HAMILTON
Administrative Assistant to the
Secretary of the Army
01056
MERRILL A. McPEAK
General, USAF
Chief of Staff
Official:
CHARLES C. McDONALD
General, USAF
Commander Air Force Logistics Command
DAVID E. BOTTORFF
Rear Admiral, CEC, US Navy
Commander
Navy Facilities Engineering Command
H. E. REESE
Deputy for Support
Marine Corps Research, Development and
Acquisition Command
DISTRIBUTION:
To be distributed in accordance with DA Form 12-25E, (qty rqr block no. 0856).
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
C6
ARMY
NAVY
AIR FORCE
MARINE CORPS
HEADQUARTERS
DEPARTMENTS OF THE ARMY, AIR FORCE, NAVY
AND HEADQUARTERS, U.S. MARINE CORPS
WASHINGTON, D.C., 26 March 1990
CHANGE
No. 6
Operator and Organizational
Maintenance Manual
GENERATOR SET, DIESEL ENGINE DRIVEN, TACTICAL SKID
MTD 5 KU, 1 PHASE-2 WIRE, 1 PHASE-3 WIRE
3 PHASE-4 WIRE, 120, 120/240 AND 120/208 VOLTS
CLASS
UTILITY
DOD MODEL
MEP-002A
HERTZ
60
NSN
6115-00-465-1044
Approved for public release; distribution is unlimited.
TM 5-6115-584-12, NAVFAC P-8-622-12, TO 35C2-3-456-1, TM 05682C-12, 22 July
1977, is changed as follows:
1. Remove and insert pages as indicated below. New or changed text material
is indicated by a vertical bar in the margin. An illustration change is indicated
by a miniature pointing hand.
Remove pages
Insert pages
1-1 and 1-2
--1-5 and 1-6
1-11/1-12
2-3 through 2-6
3-1 and 3-2
3-3 and 3-4
3-5 and 3-6
3-9 and 3-10
4-5 and 4-6
4-37 and 4-38
4-41 and 4-42
A-1/A-2
D-9 through D-14
D-17 and D-18
1-1 and 1-2
1-2.1/1-2.2
1-5 and 1-6
1-11/1-12
2-3 through 2-6
3-1
3-4
3-5 and 3-6
3-9 and 3-10
4-5 and 4-6
4-37 and 4-38
4-41 and 4-42
A-1/A-2
D-9 through D-14
D-17 and D-18
2. Retain this sheet in front of manual for reference purposes.
1
DEPARTMENT OF THE ARMY TECHNICAL MANUAL
DEPARTMENT OF THE NAVY PUBLICATION
DEPARTMENT OF THE AIR FORCE TECHNICAL ORDER
MARINE CORPS TECHNICAL MANUAL
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM.05682C-12
HEADQUARTERS
DEPARTMENTS OF THE ARMY, NAVY, AIR FORCE, & USMC
WASHINGTON, D.C.
22 July 1977
OPERATOR AND ORGANIZATIONAL
MAINTENANCE MANUAL
GENERATOR SET, DIESEL ENGINE DRIVEN, TACTICAL SKID MTD 5KW, 1 PHASE
2 WIRE, 1 PHASE–3 WIRE, 3 PHASE–4 WIRE, 120, 120/240 AND 120/208 VOLTS
DOD MODEL
MEP-002A
CLASS
UTILITY
HERTZ
60
NSN
6115-00-465-1044
TABLE OF CONTENTS
LIST OF EFFECTIVE PAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIST OF ILLUSTRATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIST OF TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHAPTER 1.
Section
Section
I.
II.
CHAPTER 2.
Section
I.
Page
v
vi
vii
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1
1-1.
1-2.
1-3.
1-4.
1-5.
1-6.
1-7.
1-8.
Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Limited Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance Forms and Records . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reporting of Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Levels of Maintenance Accomplishment . . . . . . . . . . . . . . . . . . . . .
(A, MC) Destruction of Material to Prevent Enemy Use . . . . . . . .
(A, F, MC) Administrative Storage . . . . . . . . . . . . . . . . . . . . . . . . .
Preparation for Shipment and Storage . . . . . . . . . . . . . . . . . . . . . .
1-1
1-1
1-1
1-1
1-1
1-1
1-1
1-1
DESCRIPTION AND DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-9.
Description of Generator Set. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-10. Tabulated Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2
1-2
1-5
OPERATING INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1
OPERATING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1.
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2.
Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3.
Equipment Reconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-4.
Starting Generator Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5.
Operating in Alternate Modes.. . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-6.
Shutting Down Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1
2-1
2-1
2-1
2-1
2-6
2-6
i
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
TABLE OF CONTENTS (CONT)
Section
II.
OPERATING UNDER UNUSUAL CONDITIONS . . . . . . . . . . . . . . . . .
2-7.
Operation in Extreme Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-8.
Operation in Extreme Cold (-25 °F, -32°C) . . . . . . . . . . . . . . . . . . . .
2-9.
Operation in Dusty or Sandy Areas . . . . . . . . . . . . . . . . . . . . . . . . .
2-10. Operation in Wet or Humid Areas . . . . . . . . . . . . . . . . . . . . . . . . . .
Section
CHAPTER
Section
III.
3.
I.
Section
II.
Section
III.
Section
IV.
OPERATION USING NATO SLAVE CABLE . . . . . . . . . . . . . . . . . . . . . .
OPERATOR MAINTENANCE INSTRUCTIONS . . . . . . . . . . . . . . . . . . .
CONSUMABLE OPERATING AND MAINTENANCE SUPPLIES . . .
3-1.
Consumable Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LUBRICATION INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2.
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3.
PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) .
3-4.
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5.
Correcting and Reporting Deficiencies . . . . . . . . . . . . . . . . . . . . . . .
3-6.
Determining PMCS Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-7.
PMCS for Units in Continuous Operation . . . . . . . . . . . . . . . . . . . .
3-8.
Preventive Maintenance Checks and Services . . . . . . . . . . . . . . . . .
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-9.
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-10. Malfunctions Not Corrected By Use of the
Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATOR MAINTENANCE PROCEDURES . . . . . . . . . . . . . . . . . . . .
3-11. Battery Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-12. Ground Rod and Fuel Drum Adapter Hold-Down Assembly . . . . .
3-13. Fuel Tank Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-14. Shutter Box Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-15. Exhaust Muffler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-16. Engine Starter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-17. AC Output Control Box Assembly . . . . . . . . . . . . . . . . . . . . . . . . . .
3-18. Air Cleaner Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-19. Control Cubicle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-20. Fuel System (Less Tank) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-21. Control Cubicle Support Assembly, Speed Control and Engine
Control Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-22. Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-23. Generator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-24. Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-25. Skid-Base Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ORGANIZATIONAL MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE UPON RECEIPT OF MATERIAL . . . . . . . . . . . . . . . . . . . . . .
4-1.
Inspecting and Servicing Generator Set . . . . . . . . . . . . . . . . . . . . .
4-2.
Installing Generator Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MOVEMENT TO A NEW WORKSITE . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section
V.
CHAPTER
Section
4.
I.
Section
II.
4-3.
4-4.
ii
Change 5
Dismantling Generator Set for Movement . . . . . . . . . . . . . . . . . . .
Reinstalling Generator Set After Movement . . . . . . . . . . . . . . . . . .
Page
2-6
2-6
2-6
2-6
2-6
2-6.1
3-1
3-1
3-1
3-1
3-1
3-1
3-4
3-4
3-4
3-4
3-4
3-4
3-5
3-6
3-6
3-8
3-8
3-9
3-10
3-10
3-13
3-13
3-14
3-14
3-17
3-19
3-20
3-21
3-23
3-23
3-27
4-1
4-1
4-1
4-2
4-4
4-4
4-4
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
TABLE OF CONTENTS (CONT)
Section
III.
REPAIR PARTS; SPECIAL TOOLS; SPECIAL TEST, MEASUREMENT AND DIAGNOSTIC EQUIPMENT AND SPECIAL SUPPORT EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6.
Maintenance Repair Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LUBRICATION INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7.
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS).
4-8.
PMCS, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-12. Troubleshooting, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-13.
Malfunctions Not Corrected By Use of the Troubleshooting
Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RADIO INTERFERENCE SUPPRESSION . . . . . . . . . . . . . . . . . . . . . . .
4-14. General Methods for Proper Suppression . . . . . . . . . . . . . . . . . . . .
4-15. Radio Interference Suppression Components . . . . . . . . . . . . . . . . .
MAINTENANCE OF ENGINE COOLING SYSTEM . . . . . . . . . . . . . . .
4-16. Description and Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-17. Engine Cooling Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE OF FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-18. Description and Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-19. Fuel Tank Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-20. Fuel Filter Assemblies and Strainer Assembly . . . . . . . . . . . . . . . .
4-21. Electric Fuel Pumps, Fuel Hoses and Auxiliary Solenoid Valve . .
4-22. Auxiliary Fuel Solenoid Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-23. Fuel Shut-Off Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE OF ENGINE ELECTRICAL SYSTEM . . . . . . . . . . . .
4-24. Description and Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-25. Battery Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-26. Engine Starter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-27. Battery Charging Alternator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-28. Starter Lockout Switch and Gear . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE OF OIL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-29. Function and Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-30. Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-31. Low Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-32. Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-33. Oil Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE OF CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . .
4-34. Description and Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-35. DC Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5.
Section
IV.
Section
V.
Section
VI.
Section
VII.
Section
VIII.
Section
IX.
Section
X.
Section
XI.
Section
XII.
Page
4-4
4-4
4-4
4-4
4-4
4-5
4-5
4-6
4-6
4-6
4-10
4-10
4-10
4-12
4-12
4-12
4-16
4-16
4-16
4-17
4-21
4-21
4-21
4-24
4-24
4-24
4-26
4-29
4-31
4-33
4-33
4-33
4-34
4-36
4-37
4-38
4-38
4-38
iii
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
TABLE OF CONTENTS (CONT)
Page
Section
Section
Section
XII.
XIII.
XIV.
Section
XV.
CHAPTER 5
Section
Section
I.
II.
MAINTENANCE OF CONTROL SYSTEM (CONT):
4-36. AC Instrumentation System . . . . . . . . . . . . . . . . . . . . . . . . . .
4-37. Load Terminal Board Assembly . . . . . . . . . . . . . . . . . . . . . . .
4-38. Control Cubicle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-38
4-41
4-41
MAINTENANCE OF ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-45
4-39.
4-40.
4-41.
4-42.
4-43.
4-44.
4-46.
4-46.
4-47.
4-48.
4-49.
4-50.
4-51.
4-52.
Description and Function . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Muffler Assemblies . . . . . . . . . . . . . . . . . . . . . . . . .
Air Cleaner Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Intake Manifold Assembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Rocker Arm Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Rocker Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Injector Nozzle Assembly and Fuel Lines . . . . . . . . . . . . . . . . .
Glow Plug Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Drain Hose and Valve . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pan-Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Fill Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Mounting Assembly . . . . . . . . . . . . . . . . . . . . . . . . . .
4-45
4-45
4-47
4-47
4-49
4-50
4-50
4-51
4-52
4-52
4-54
4-54
4-54
4-54
MAINTENANCE OF GENERATOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . .
4-56
4-53. Description and Function . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-54. (Generator/Exciter Assembly . . . . . . . . . . . . . . . . . . . . . . . .
4-55. Screen-Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-56
4-57
4-57
MAINTENANCE OF SKID-BASE . . . . . . . . . . . . . . . . . . . . . .
4-57
4-56. Description and Function . . . . . . . . . . . . . . . . . . . . . . . . .
4-57. Skid-Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-57
4-57
MATERIAL USED IN CONJUNCTION WITH DOD STANDARD
5KW DIESEL ENGINE DRIVEN, MODEL MEP-002A . . . . . . . . . . . . . . . . . . . .
5-1
AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1
5-1.
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1
ACOUSTIC SUPPRESSION KIT.... . . . . . . . . . . . . . . . . . . . . . . . .
5-2
5-2.
Acoustic Suppression Kit . . . . . . . . . . . . . . . . . . . . . . . . .
5-3.
Cover Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4.
Top Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5.
Left Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Right Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6.
5-7.
Rear Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-8.
Exhaust Plenum Assembly . . . . . . . . . . . . . . . . . . . . . . . .
5-9.
Left Support Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-10. Right Support Assembly . . . . . . . . . . . . . . . . . . . . . . . . . .
5-11. Front Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-12. Side Closure Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-13. Rear Closure Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-14. Rear Flap Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .
iv
Change 7
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5-2
5-2
5-8
5-10
5-12
5-14
5-16
5-16
5-18
5-18
5-21
5-21
5-24
TM 5-6115-584-12
NAVFAC P-8-622-12
TO -35C2-3-456-1
TM-05662C-12
TABLE OF CONTENTS (CONT)
Page
Section
III.
ACOUSTIC SUPPRESSION KIT REPAIR . . . . . . . . . . . . . . . . . . . . . .
5-15.
5-16.
5-17.
5-18.
5-19.
5-20.
5-21.
5-21.
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Panel Replacement . . . . . . . . . . . . . . . . . . . . .
Latch Replacement . . . . . . . . . . . . . . . . . . . . .
Catch Replacement . . . . . . . . . . . . . . . . . . . . .
Rubber Flap Replacement . . . . . . . . . . . . . . . . .
Hinges . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Captive Nuts . . . . . . . . . . . . . . . . . . . . . . . . .
Front Panel Silencer . . . . . . . . . . . . . . . . . . . .
APPENDIX A.
REFERENCES
APPENDIX B.
COMPONENTS OF END ITEM LIST
Section
INTRODUCTION
INTEGRAL COMPONENTS OF END ITEM
BASIC ISSUE ITEMS
I.
II.
III.
APPENDIX C.
Section
I.
II.
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5-26
5-26
5-28
5-28
5-28
5-30
5-30
5-30
A-1
B-1
B-2
ADDITIONAL AUTHORIZATION LIST
INTRODUCTION
ADDITIONAL AUTHORIZATION SHEET
C-1
C-1
APPENDIX D.
MAINTENANCE ALLOCATION CHART
Section
INTRODUCTION
MAINTENANCE ALLOCATION CHART
TOOLS, TEST AND SUPPORT EQUIPMENT REQUIREMENTS
EXPLANATION OF REFERENCE CODES
I.
II.
III.
IV.
.
.
.
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.
5-26
INDEX
D-1
D-3
D-18
D-19
INDEX 1
Change 7
iv.1/(iv.2 blank)
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
Reproduction for non-military use of the information or illustrations contained in this publication is not
permitted. The policy for military use reproduction is established for the Army in AR 380-5, for the Navy and
Marine Corps in OPNAVlNST 5510.1B, and for the Air Force in Air Force Regulation 205-1.
LIST OF EFFECTIVE PAGES
Insert latest changed pages; dispose of superseded pages in accordance with applicable regulations.
NOTE: On a changed page, the portion of the text affected by the latest change is indicated by a vertical line, or other
change symbol, in the outer margin of the page. Changes to illustrations are indicated by miniature pointing hands.
Changes to wiring diagrams are indicated by shaded areas.
Total number of pages in this manual is
Page
No.
150 consisting of the following:
#Change
No.
Warning . . . . . . . . . . . .0
Blank . . . . . . . . . . . . .0
i - vii . . . . . . . . . . . . .0
viii Blank . . . . . . . . . . . 0
1-1 - 1-11 . . . . . . . . . . .0
1-12 Blank . . . . . . . . . .0
1-13 - 1-15 . . . . . . . . . .0
1-16 Blank . . . . . . . . . . 0
2-1 - 2-6 . . . . . . . . . . .0
3-1 - 3-27 . . . . . . . . . . .0
3-28 Blank . . . . . . . . . . . 0
4-1 - 4-59 . . . . . . . . . . .0
4-60 Blank . . . . . . . . . . . 0
A-1 . . . . . . . . . . . . . . 0
A-2 Blank . . . . . . . . . . . 0
B-1 . . . . . . . . . . . . . . 0
B-2 Blank . . . . . . . . . . . 0
C-1 - C-19 . . . . . . . . . . 0
C-20 Blank . . . . . . . . . . 0
Index 1 - Index 6 . . . . . . . 0
# Zero in this column indicates an original page.
v
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
vi
LIST OF ILLUSTRATIONS
Figure
Title
Page
1-1.
1-2.
1-2.1
1-3.
1-4.
1-5.
1-6.
1-7.
1-8.
1-9.
1-10.
2-1.
2-2.
2-3.
2-4.
3-1.
3-2.
3-3.
3-4.
3-5.
3-6.
3-7.
3-8.
3-9.
3-10.
3-11.
3-12.
3-13.
3-14.
3-15.
3-16.
3-17.
3-18.
3-19.
3-20.
3-21.
3-22.
3-23.
3-24.
4-1.
4-2.
4-3.
4-4.
4-5.
4-6.
4-7.
4-8.
4-9.
4-10.
4-11.
Engine Generator Set, Right-Rear, Three-Quarter View . . . . . . . . . . . .
Engine Generator Set, Left-Front, Three-Quarter View . . . . . . . . . . . .
Engine Generator Set with Acoustic Suppression Kit... . . . . . . . . . . . . .
Tie Down, Lifting, and Towing Provisions Crated Set . . . . . . . . . . . . . . . .
Installation Plans . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . ..
Fuel System Schematic . . . . . . . . . . . . . . . . . . . . . .
Electrical Cable Schematic.. . . . . . . . . . . . . . . . . . . . .
Generator Set Electrical Schematic . . . . . . . . . . . . . . . . . . . . . .
Generator Set Wiring Harness.. . . . . . . . . . . . . . . . . . . .
AC Output Control Box Wiring Harness . . . . . . . . . . . . . . . . . . . . .
Control Cubicle Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . .
Load Terminals . . . . . . . . . . . . . . . .
Reconnection Switch . . . . . . . . . . . . . . . . . . .
Starting Procedure . . . . . . . . . . . . . . . .
Load Terminal and Reconnection Configuration . . . . . . . . . . . . . . . . .
Lubrication Order . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ground Rod and Fuel Drum Adapter Hold-Down . . . . . . . . . . . . . . . .
Fuel Tank . . . . . . . . . . . . . . . . . . . .
Shutter and Thermo Power Element Assembly . . . . . . . . . . . . . . . . .
Exhaust Muffler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electric Starter . . . . . . . . . . . . . . . . . . . . . . . . . . .
AC Output Control Box Assembly . . . . . . . . . . . . . .. . . . .
Air Cleaner and Shroud Assembly . . . . . . . . . . . . . . . . . . . .
Air Cleaner Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning Air Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Cubicle . . . . . . . . . . . . . . . . . . . . . .
Fuel Filters and Fuel Strainer Assembly . . . . . . . . . . . . . . . . . . . .
Fuel Pump Assembly . . . . . . . . . . . . . . . . . . .
Control Cubicle Support Assembly . . . . . . . . . . . . . . . . . . . . . . . .
Speed Control Assembly . . . . . . . . . . . . . . . . . . . . . . . ..
Engine Cooling Assembly . . . . . . . . . . . . . . . . . . . . . . . ..
Generator Assembly . . . . . . . . . . . . . . . . . . . . . . .
Intake Manifold Assembly . . . . . . . . . . . . . . . . . . . .
Oil Drain Hose . . . . . . . . . . . . .
. . . . . . . . .
Oil Filter and Oil Pressure Switch . . . . . . . . . . . .
. .
Engine Stop Solenoid . . . . . . . . . . . . . . . . . . . . . . .. . ..
Battery and Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ground Stud . . . . . . . . . . . . . . . . . . . . . .
Uncrating Generator Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Grounding Generator Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Primary Radio Interference Suppression Components . . . . . . . . . . . . .
Shutter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting Shutters . . . . . . . . . . . . . . . . . . . .
Adjusting Thermo Unit . . . . . . . . . . . . . ..
Fuel Tank Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing Float Switch . . . . . . . . . . . . . . . . . . . . ..
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Strainer Element, . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Filters and Fuel Strainer Assembly . . . . . . . . . . . . . . . . . . . .
1-3
1-4
1-4.1
1-8
1-9
1-9
1-10
1-11
1-13
1-14
1-15
2-3
2-3
2-4
2-5
3-2
3-9
3-10
3-11
3-12
3-13
3-14
3-14
3-15
3-16
3-17
3-18
3-19
3-20
3-20
3-21
3-22
3-23
3-24
3-25
3-25
3-25
3-26
3-27
4-2
4-3
4-11
4-14
4-15
4-15
4-17
4-18
4-19
4-19
4-20
Change 7
TM 5-6115-584-12
NAVFAC P-6-622-12
TO-35C2-3-456-1
LIST OF ILLUSTRATIONS
Figure
4-12.
4-13.
4-14.
4-15.
4-16.
4-17.
4-18.
4-19.
4-20.
4-21.
4-21A.
4-22.
4-22A.
4-23.
4-24.
4-25.
4-26.
4-27.
4-28,
4-29.
4-30.
4-31.
4-32.
4-32.1
4-33.
4-33.1
4-34.
4-36.
4-36.
4-37.
4-38.
4-39.
4-40.
4-41.
4-42.
4-43.
4-44.
4-45.
4-46.
5-1.
5-2.
5-3.
5-4.
5-5.
5-6.
5-7.
5-8.
5-9.
5-10.
5-11.
5-12.
5-13.
Page
Title
Fuel Pump, Fuel Hoses and Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ......
Adjusting Fuel Shut-Off Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Solenoid Test Set-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing Battery Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Starter installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing Engine Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing Field Coil, Style II Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspecting Engine Starter Brushs, Style l Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspecting Engine Starter Brushes, Style II Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine StarterAssembly, Style l Starler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Starter Assembly, Style ll Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Charging Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing Battery Charging Regulator/Rectifier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lockout Switch and Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting Starter Lockout Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Oil System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ......
Oil Cooler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .......
Replacing Oil Cooler Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Filter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing Oil Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Load Terminal Board Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Terminal Clip Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... ..
Control Cubicle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Relay K1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing Control Cubicle SupportAssembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Cubicle Test Set-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Muffler and Air CleanerAssemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rocker Arm Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning Rocker Arm Cover Oil Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Breather Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking and Adjusting Rocker Arm to Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Fill Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Mounting Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator Screen-Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Skid-Base Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Instruction and Rating Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cover Assembly, Removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Top Panel Assembly and Exhaust Plenum, Removal and installation . . . . . . . . . . . . . . . . . . . .
Left Panel Assembly, Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Right Panel Assembly, Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Panel Assembly, Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Left Support Assembly, Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Right Support Assembly, Removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Panel Assembly, Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Side Closure Assembly, Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Closure Assembly, Removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Flap Assembly, RemovaI and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement of ASK Hardware ltems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Change10
4-22
4-23
4-23
4-24
4-25
4-26
4-27
4-28.1
4-28.2
4-28.2
4-28,3
4-28,4
4-28.4
4-29
4-31
4-32
4-33
4-34
4-34
4-36
4-36.1
4-37
4-39
4-40
4-41
4-43
4-43,1
4-44
4-46
4-48
4-49
4-50
4-51
4-52
4-53
4-54
4-55
4-56
4-58
5-3
5–7
5–9
5-11
5-13
5-15
5-17
5-19
5-20
5–22
5-23
5-25
5-29
vii
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
LIST OF TABLES
Table
2-1
2-2.
3-1.
3-2.
3-3.
4-1.
4-2.
4-3.
4-4.
viii
Title
Generator Set Controls and Instruments
Reconnection Switch Positions . . . . . . . . . . . . . . . . . . . . . . . . . .
Consumable Operating and Maintenance Supplies . . . . . . . . . . . . . .
Preventive Maintenance Checks and Services . . . . . . . . . . . . . . . . . .
Troubleshooting
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preventive Maintenance Check and Services . . . . . . . . . . . . . . . . .
Troubleshooting
Master switch Continuity Check . . . . . . . . . . . . . . . . . . . . .
Voltmeter-Ammeter Range Selector Switch Conttnuity Check . . . . . . . . .
Change 7
2-2
2-4
3-1
3-4
3-6
4-5
4-7
4-41
4-42
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
CHAPTER 1
INTRODUCTION
Section I. GENERAL
1-1. SCOPE.
This manual is for your use in operating and maintaining the DOD Standard Generator Set, 5KW
Diesel Engine Driven, Model MEP-002A. It contains sections for operating procedures for operation under both normal and unusual conditions;
a section for lubrication instructions, including
a Lubrication Order; a section for preventive
maintenance; a section for troubleshooting; and
sections for both operator maintenance procedures
maintenance procedures.
and organizational
Thoroughly familiarize yourself with the unit
before operating or servicing.
1-2. LIMITED APPLICABILITY.
Some portions of this publication are not applicable to all services. These portions are prefixed
to indicate the services to which they pertain:
(A) for Army, (F) for Air Force, (N) for Navy,
and (MC) for Marine Corps. Portions not prefixed
are applicable to all services.
are published to aid in property accountability and
are available through: Commander, US Army
Adjustant General Publication Center, ATTN:
AGDLD, 1655 Woodson Road, St. Louis, MO
63120.
1-4. REPORTING OF ERRORS.
Report of errors, omissions, and recommendations
for improvement of this publication by the individual user is encouraged. Reports should be
submitted as follows:
a. ( A ) A r m y - DA Form 2028 directly to:
Commander, US Army Troop Support Command,
ATTN: AMSTR-MCTS, 4300 Goodfellow Boulevard, St. Louis, MO 63120-1798.
b. (F) Air Force - AFTO Form 22 directly to:
Commander, Sacramento Air Logistics Center,
ATTN: SM-ALC-MMEDTA, McClellan Air Force
Base, CA 95652-5609 in accordance with
TO-00-1-1.
1-3. MAINTENANCE FORMS AND RECORDS.
I
a. (A) Maintenance forms and records used by
Army personnel are prescribed in DA PAM 738750.
b. (F) Maintenance forms and records used by
Air Force personnel are prescribed in AFM-66-1
and the applicable 00-20 Series Technical Orders.
c. (N) Navy - by letter directly to: Commanding Officer, Naval Construction Battalion Center,
ATTN: Code 15741, Bldg. 43, Port Hueneme, CA
93043-5000.
d. (MC) Marine Corps - by NAVMC Form
10772 directly to: Commanding General, Marine
Corps Logistics Base, (Code 850), Albany, GA
31704-5000.
c. (N) Navy users should refer to their service
peculiar directives to determine applicable maintenance forms and records to be used.
1-5. LEVELS OF MAINTENANCE
ACCOMPLISHMENT.
d. (MC) Maintenance forms and records used
by Marine Corps personnel are prescribed in
TM 4700-15/1.
a. (A, MC) Army and Marine Corps users shall
refer to the Maintenance Allocation Chart (MAC)
for tasks and levels of maintenance to be performed.
1-3.1. (A) HAND RECEIPT.
Hand Receipts covering the End Item/Components
of End Item (COEI), Basic Issue (BII) and Additional Authorization List (AAL) items are published
in an Army Hand Receipt Manual. The Hand
Receipt Manual numerical designation is the same
as the related Army Technical Manual with the
letters HR added to the number. These manuals
b. (F) Air Force users shall accomplish maintenance at the user level consistent with their
capability in accordance with policies established
in AFM 66-1.
c. (N) Navy users shall determine their maintenance levels in accordance with their service
directives.
Change 6
1-1
TM 5-6115-584-12
NAVFAC P-8622-12
TO-35C2-3-456-1
TM-05682C-12
1-6. (A, MC) DESTRUCTION OF MATERIAL
TO PREVENT ENEMY USE.
Army and Marine Corps personnel shall refer to
TM 750-244-3 as a source for procedures for the
destruction of material to prevent enemy use.
1-7. (A, F, MC) ADMINISTRATIVE STORAGE.
Air Force personnel shall refer to TO 35-1-4,
Processing and Inspection of Aerospace Ground
Equipment, for storage and shipment of this
equipment. Marine Corps personnel shall refer
to MCO P4450.7. For the Army:
ment serviceable criteria (ESC) evaluations should
be completed, shortcomings and deficiencies
should be corrected, and all modification work
orders (MWO’S) should be applied.
Inside storage is
c. Storage site selection.
preferred for items selected for administrative
storage. If inside storage is not available, trucks,
vans, c o n e x c o n t a i n e r s a n d o t h e r c o n t a i n e r s
may be used.
1-8. PREPARATION FOR SHIPMENT AND
STORAGE.
a. Placement of equipment in administrative
storage should be for short periods of time when
a shortage of maintenance effort exists. Items
should be in mission readiness within 24 hours
or within the time factors as determined by the
directing authority. During the storage period
appropriate maintenance records will be kept.
b. (F) Air Force - Refer to TO 35-1-4 for end
item Generator Sets and to TO 38-1-5 for installed engine.
b. Before placing equipment in administrative
storage, current maintenance services and equip-
c. (N, MC) Navy and Marine Corps refer to
individual service directives for requirements.
1-2
Change 6
a.
(A) Army - Refer to TB 740-97-2.
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
Section II. DESCRIPTION AND DATA
1-9 DESCRIPTION OF GENERATOR SET.
This unit is a 5 kilowatt, 60 Hertz Generator Set. It consists
of a revolving field alternator powered by an air cooled diesel
engine. See figures 1-1 and 1-2 for the location of major
components and figure 1-2.1 for generator with acoustic
suppression kit (ASK) installed.
a. Engine.
(1) The engine powering this Generator Set is a
2 cylinder, 4 cycle air cooled engine, with a 70 cubic
tncb (cu. in) displacement. A mechanical governor
keeps engine speed at 1800 revolutions per minute
(RPM) under rated load conditions.
(2) Fuel is supplied either from this unit's selfcontained fuel tank or, by using an adapter, directly
from a 55 gallon drum or other source. The fuel is
filtered by two cartridge type fuel filters and a single
fuel strainer. Two electric, self-priming fuel pumps
pump fuel to the fuel injection pump which delivers
the fuel at high pressure to fuel injection nozzles in
the cylinder head. When auxiliary source of fuel is
used, three electric fuel pumps are Used.
(3) Two 12 volt “wet cell” battertes in series
supply power for a 24 volt electric starter and for
glow plugs, located in the cylinder head, and two air
heaters located in the intake manifold, used for cold
weather starting. An alternator located beneatb the
blower wheel and completely separate from the main
alternator automatically recharges these batteries
when the engine is operating.
b. Generator.
The generator on this set is a four pole, revolving
field type. Alternating current, supplied by the exciter
assembly, is recitified and used to create the four
pole, revolving field. A “solid-state” voltage regulator assembly automatically adjusts this current to obtain a constant (±3%) voltage in the main stator (output) windings.
c. Controls.
All operator controls and indicator gauges necessary for
running the engine Generator Set are located on the
control panel. On ASK equipped generators, an oil
pressure gauge is located on the engine under air intake
door and a fuel level gauge is located on the fuel tank. The
speed control is located behind a small flap on the rear
panel assembly below the control panel.
Controls for selecting output voltage are located on
the output control box
d. Generator Set Electrical System (see schematic
figure 1-7).
(1) General. The generator set's electrical sys
tem consists of two distinct systems (1) the dc system
used primarily for operating control and excitation
and (2) the ac output system to supply power to the
The dc source consists of a 24 volt battery set (BT1
and BT2) that is kept charged by a battery charging
alternator (G2) and voltage regulator rectifier assembly (A5). Fuse (F1) protects the alternator from
overload Circuit breaker (CB2) protects the battery
charging system from overload. Slave receptacle (J15)
permits an alternate external supply to be connected
to the battery circuit.
(2) Operation. Placing MASTER SWITCH (S1)
into the PREHEAT position, the preheat relay R2 is
activated to energize the heater elements (ER1 and
ER2) and the engine glow plugs (HR3 and HR4).
Placing the MASTER SWITCH in the PRIME-RUNAUXILIARY position activates the fuel pumps E2 and
E3 as well as the auxiliary fuel pump E1. If the fuel
level is down, the fuel level switch S3 will be closed
and the auxiliary fuel solenoid will actuate permitting fuel to be pumped into the tank.
Placing the MASTER SWITCH (S1) into the PRIMERUN position maintains power to the main fuel pumps
but deactivates the auxiliary fuel pump.
(a) Start. Placing the MASTER SWITCH (S1)
into the start position maintains the fuel pump circuits and the preheat circuits to the glow plugs (HR3
and HR4) as well as to energize the governor solenoid K5) and start relay (K1). The crank relay
(K3) is eneregized, in turn energizing the start solenoid (K6) and activating the starter (B1). The governor brings the engine to speed, building up oil
pressure and closing oil pressure switch (S5). The
exciter field is flashed during this starting procedure.
(b) Run. Placing the MASTER SWITCH (S1) in
the PRIME-RUN position keeps the governor solenoid
(K5) energized thru the now closed oil pressure switch
(S5)and fuel will be supplied to the engine as long as
the oil pressure is normal and the align temperature
switch (S4) is not activated by high temperature.
(c) Stop. Placing the MASTER SWITCH (S1) in
the OFF position de-energizes the governor solenoid
(K5) shutttng off fuel to stop the engine. High temperature or low oil pressure will also shut the engine
down.
(3) AC Circuitry. The main alternator (G1) is
wound with six pairs of coils that may be connected
by the AC Reconnect switch (S6) into various combinations, the output of which is available at the load
terminal board (TB1). Circuit breaker (CB1) protects
the alternator from overloads. The volt/ampere se
lect switch (S8) permits switching voltmeter (M5) and
ammeter (M4) to read the load current and voltage
for the various arrangement of outputs.
Voltage regulator (A2) and current voltage transformer CVT1 monitors the alternator output voltage
Change 7
1-2.1/(1-2.2 blank)
TM 5-6115-584-12
P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
NAVFAC
“
Figure 1-1. Engine Generator Set, Right-Rear, Three-Quarter View
1-3
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
Figure 1-2. Engine Generator Set, Left-Front, Three-Quarter View
1-4
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05662C-12
1.
2.
3.
4.
AIR INTAKE
EXHAUST PLENUM
OIL
FUEL FILTERS
5.
6.
7.
8.
9.
AIR CLEANER
BATTERIES
COOLING AIR INTAKE
SPEED CONTROL FLAP
REAR PANEL FLAP
Figure 1-2.1. Engine Generator Set with Acoustic Suppression Kit
Change 7
1-4.1/(1-4.2 blank)
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
and current under load and varies the exciter field either up
or down to keep the generator field at such a value as to
maintain constant alternator output voltage. The regulated
voltage setting can be varied using the voltage adjust
rheostat (R1).
An ac receptacle (J14) is connected through a protective
circuit breaker (CB3) to provide 120 VAC.
Outputs from the voltage regulator (A2) transformed by
transforms (T1 and T2) to a value suitable for input to
frequency transducer (A3) which energizes frequency meter
(M3).
1-10. TABULATED DATA.
Identification and Instruction Plates (see figures 1-1
and l-2).
(1) Identification Plate.
(a) Location. This plate is located on the side
of the control cubicle.
(2) Operating Instruction Plate.
(a) Location. This plate is located on the side
of the control cubicle.
(b) Content.
OPERATING INSTRUCTIONS
Hot refueling of generators while they are operating poses 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. Severe injury or
death to personnel and damage to the equipment may result.
Ground set to avoid shock hazard.
BEFORE STARTING SET
(b) Content.
NOTE: Push in DC CONTROL CIRCUIT
BREAKER. Pull manual governor control
throttle all the way out and then push back
in approximately halfway.
US DEPARTMENT OF DEFENSE
GENERATOR SET DIESEL ENGINE 5KW 60 Hz
MODEL: MEP 002A
1.
SER NO.:
Fill crankcase (do not overfill) and fuel
tank. Ensure that vent cap on underside of
the fuel filler cap is open before starting
generator.
NSN: 6115-00-465-1044
2. Set batteries are negative ground.
REG NO.:
STARTING SET
1. Move “MASTER SWITCH” to “PRIME &
RUN” position to allow fuel to prime set.
TM 5-6115-584-12
TO-35C2-3-456-1
2.
NAVFAC P-8-622-12
NOTE: Preheat is not required when engine
is hot.
TM-05682C-12
VOLTS: 120V 1 PH.
120/240V 1 PH.
120/208V 3PH.
3.
Move “MASTER SWITCH” to “START”
position and hold until engine fires continuously. If engine does not start within 15
seconds repeat steps 1 and 2.
4.
“MASTER SWITCH” will return to
“PRIME & RUN” position when released.
If running from auxiliary fuel source, move
“MASTER SWITCH” to “PRIME & RUN
AUX FUEL” position.
5.
After warm up. Check frequency and
voltage and adjust if necessary.
6.
Move “AC CIRCUIT BREAKER” to “ON”
position.
PF: 0.8
AMPS: 52,26,17.3
LG: 51 IN
W: 32 IN
HGT: 37 IN
DATE MFG:
CONTR NO:
WARRANTY:
DATE INSP:
Move
“MASTER
SWITCH”
“PREHEAT” position and hold for (1)
minute.
STOPPING SET
1. Move “AC CIRCUIT BREAKER” to
“OFF” position.
MFD BY:
2. Move “MASTER SWITCH” to “OFF”
position.
INSP STAMP:
3. For emergency stop pull “DC CONTROL
CIRCUIT BREAKER.”
Change 9
1 - 5
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
SERVICE INSTRUCTIONS
Ambient
Temperature
Lubricating
Oil Capacity
(Less Filter)
3.0QT
Fuels
Capacity-6.75 GAL
Emergency-JP4
Primary-Diesel
-65° to -25°F
-54° to -12°C
VV-F-800Grade DFA
MIL-L-10295
-25° to -10°F
-32° to -23°C
VV-F-800 Grade DF1
MIL-L-10295
-10° to +30°F
-23° to -1°C
VV-F-800 Grade DF1
+30° to +100°F
-l° to +38°C
VV-F-800 Grade DF2
MIL-L-2104 Grade 30
+100° to +125°F
+38° to +52°C
VV-F-800 Grade DF2
MIL-L-2104 Grade 30
For JP4 operation, see
Instruction Manual
MIL-L-2104 Grade 10
b. Tabulated Data for Generator Set.
(1) Generator Set.
Manufacturer: . . . . . . . . . . . . . . . . . . . . . . . . . . . . Onan Division of Onan Corp.
Model: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MEP 002A
Mode: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Hz
Operating temperature range:
without external heat . . . . . . . . . . . . . . . . . . . . . . . -25° to +125°F, -32 to +52°C
with external heat . . . . . . . . . . . . . . . . . . . . . . . . -65° to -25°F, -54° to -32°C
Maximum Rated Output . . . . . . . . . . . . . . . . . . . . . . .
5KW (0.8 power factor)
(0-5000 ft above sea level)
Voltage: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
120V. (single phase, 2 wire)
120/240V. (single phase, 3 wire)
120/208V. (3-phase, 4 wire)
Fuel capacity: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.75 gallons (25.5 liters)
Dimensions and weights:
overall length . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 in. (129.5 cm.)
overall with . . . . . . . . . . . . . . . . . . . . . . . . . . 32in. (81.3 cm)
overall height . . . . . . . . . . . . . . . . . . . . . . . . . . 37in. (94 cm.)
960 1bs. (435.5 kg.)
net weight empty
net weight filled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1040 1bs. (471.7 kg.)
Shipping weight . . . . . . . . . . . . . . . . . . . . . . . . . . 1010 lbs. (458.1 kg.)
cubage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 cu. ft. (.99 cubic meters)
Dimensions and weights with ASK installed:
overall length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 in. (147.4 cm)
overall width. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36 in. (91.4 cm)
overall, height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39 in. (99 cm)
net weight empty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1084 lb (492.2kg)
net weight filled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1164 lb (528.5kg)
shipping weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1084 lb (492.2 kg)
cubage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 cu ft (1.3 cubic meters)
1 - 6 Change 7
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
Ventilation requirements (total): . . . . . . . . . . . . . . . . . . 1350 CFM at 1800 RPM
(2)
Engine.
Manufacturer: . . . . . . . . . . . . . . . . . . . . . . . . . . . . Onan Division of Onan Corp.
Type: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . four cycle, air cooled,
diesel
Number of cylinders: . . . . . . . . . . . . . . . . . . . . . . . . two
Change 7
1-6.1/(1-6.2 blank)
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NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
Displacement: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70cu. in. (1147 cc.)
Compression ratio: . . . . . . . . . . . . . . . . . . . . . . . . . 19:1
Horsepower: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.9 @ 1800 RPM (0-5000 ft above
sea level)
Lubricating oil capacity: . . . . . . . . . . . . . . . . . . . . . . 3 qts, 4 qts if filter is changed
(2.8 liters, 3.7 liters if filter is
changed)
Governor: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . internal flyball, external adjustment
Maximum battery charge rate . . . . . . . . . . . . . . . . . . . . . . . . .
not less than 6.5 ampere
Starting motor voltage: . . . . . . . . . . . . . . . . . . . . . . . 24 VDC
Oil filter element part no.: . . . . . . . . . . . . . . . . . . . .
MS35802-2
(3) Batteries.
Type: . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 2HN (per MS 35000-1)
Voltage: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 VDC
Amp-Hrs: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
(4) Fuel pumps.
Manufacturer: . . . . . . . . . . . . . . . . . . . . . . . . . . . Bendix Corp.
Model: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Part No. 480517
Ground Polarity: . . . . . . . . . . . . . . . . . . . . . . . . . . Negative
(5) Fuel filters.
Manufacturer: . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fram Corp.
Model: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244350
Fuel filter element: . . . . . . . . . . . . . . . . . . . . . . . . . Part No. C-1125PL
(6) Fuel strainer.
Manufacturer: . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fram Corp.
Model: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Part No. 244344
Fuel strainer element: . . . . . . . . . . . . . . . . . . . . . . . Part No. C1824
(7) Air cleaner.
Manufacturer: . . . . . . . . . . . . . . . . . . . . . . . . . . . Donaldson Co., Inc.
Model: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Part No. KAX 00-3851
Air cleaner element: . . . . . . . . . . . . . . . . . . . . . . . . Part No. P101222
(8) Engine oil filter.
Manufacturer: . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fram Corp.
Model: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Part No. 170429
oil filter element: . . . . . . . . . . . . . . . . . . . . . . . . . . Part No. MS35802-2
Change 2
1-7
TM5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
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Figure 1-3. Tie Down, Lifting, and Towing Provisions Crated Set
1-8
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NAVFAC P-8-622-12
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Figure 1-4. Installation Plans
Figure 1-5. Fuel System Schematic
Change 5 1 - 9
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1-10
Figure 1-6.
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Figure 1-7. Generator Set Electrical Schematic.
Change 9
1-11/(1-12 blank)
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Figure 1-8. Generator Set Wiring Harness
1-13
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Figure 1-9. AC Output Control Box Wiring Harness
1-14
Change 5
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Figure 1-10. Control Cubicle Wiring Harness
Change 5
1-15/(1-16 blank)
.
TM 5–6115-584-12
NAVFAC P–8-622-12
TO-35C2-3-456-1
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CHAPTER 2
OPERATING INSTRUCTIONS
Section I. OPERATING PROCEDURE
Stay clear of all exposed electrical terminals
when Generator Set is operating.
2-1. GENERAL.
a. This chapter contains instructions for operation,
power and control connections. Location and function of
controls and indicators, and safety precautions are also provided.
b. Refer to table 3-2 and perform “Before Operation”
Preventive Maintenance Checks and Services before operating the Generator Set.
Remove all rings, watches and other jewelry
when performing maintenance on this equipment. Loose fitting clothing should be secured to
prevent it from catching in moving parts.
2-2. POWER CONNECTIONS.
WARNING
CAUTION
If set will be idle for some time, disconnect the
negative battery lead. Be sure to reconnect when
load is placed on set.
BEFORE ATTEMPTING TO CONNECT
LOAD CABLES, MAKE SURE THE GENERATOR SET IS NOT OPERATING. ALL
SWITCHES ARE IN THE OFF OR OPEN
POSITION.
c. Table 2-1 describes the Generator Set controls and
instruments (see figure 2-3).
WARNING
All personnel involved in the operation or
maintenance of the Generator Set should
become thoroughly familiar with the safety precautions prior to performing operation or
maintenance procedures.
Prior to connection of load cables, make sure all
switches are in OFF or OPEN position, the Generator Set is not operating.
Inspect the Generator Set ground connection
prior to starting the unit. Electrical defects in
load lines or load equipment can cause death by
electrocution when contact is made with an
ungrounded system.
Do not smoke or carry an open flame when servicing the batteries or fuel tank. Exercise
extreme care to prevent electrical arcing in the
area of the batteries.
To connect load cables to Generator Set, attach
load leads to terminals located in output control
box, as required. See figures 2-1 and 2-3.
NOTE
For 120V, 1 PH operation connect safety
ground (generally green) and neutral (white) to
L-1. Connect the hot wire (black) to L-3.
2-3. EOUIPMENT RECONNECTION.
Before operating unit, be certain voltage and frequency rating of the load matches that of the Generator Set. If the
output voltage of the Generator Set must be changed to
match a particular load, rotate reconnection switch located
on Reconnection Panel to desired output connections. See
figure 2-2.
2-4. STARTING GENERATOR SET (SEE FIGURE 2-3).
CAUTION
Do not idle engine.
Battery electrolyte contains sulfuric acid and
can cause severe burns. Handle it with care. If
the electrolyte comes in contact with the body,
eyes, or clothing, rinse immediately with clean
water. Avoid spilling electrolyte on painted surfaces. Do not work alone or smoke when servicing batteries.
Do not operate Generator Set in an enclosed
area unless the exhaust gases are piped to the
outside. Continued breathing of exhaust fumes
is dangerous.
Operate generator set only at rated RPM.
Do not use either to aid starting generator set.
Do not operate in excess of 200 hours continuous with JP-4, MIL-J-5624 bulk fuel.
a. When starting a set with a dry fuel system or after a
filter drain or change:
(1) Push in the DC circuit breaker.
Change 9
2-1
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(2) Ensure vent on underside of fuel filler cap is open.
(3) Open air intake access door on Acoustic Suppression Kit (ASK) (4, figure 1-2.1).
(4) Prime fuel lines by slightly opening plug (1, figure 4-9)
on head (8, figure 4-9). Do this on Filter Assembly
nearest check valve (6, figure 4-11).
(5) Move master switch to PRIME& RUN.
(6) When pump slows down and no further air bubbles
appear around plug, tighten plug (1, fig. 4-9).
2-2
Change 7
NOTE
Preheat is not required when engine is warm.
b. Move master switch to PREHEAT position and hold for
one minute.
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Table 2-1.
Change 9
2-2.1/(2-2.2 blank)
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Table 2-1. Generator Set Controls and Instruments (Cont)
Control
OIL PRESSURE
GAUGE
RECONNECTION
Description
Located on oil fill side of engine.
0-50 pounds per square inch (psi)
Located on output control box.
Used to select 120V, 1 phase; 120/240V, 1 phase; or
SWITCH
Three position rotary switch.
120/208V, 3 phase output for Generator Set.
Function
Indicates engine oil pressure.
c. Place master switch in START position and
hold until engine comes to operating speed. If engine
does not start within 15 seconds repeat steps b and c.
d. Master switch will return to PRIME & RUN
position when released. If running from auxiliary fuel
source, move master switch to PRIME & RUN AUX.
FUEL position.
NOTE
e. Check oil pressure on engine mounted gauge. Oil
pressure should be at least 20 psi minimum. Check
frequency on frequency meter on control panel and
adjust governor if necessary, using speed control.
Frequency meter should read 61.5 with no load. Pulling speed control knob out will increase frequency,
If engine does not come to operating speed
within 15 seconds, a minimum of 30
seconds cooling period must be observed
before attempting another start.
Figure 2-1.. Load Terminals
Figure 2-1.
Figure 2-2.
Change 6
2−3
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Figure 2-3. Starting Procedure
pushing speed control knob in will decrease frequency.Text
For fine-control turn knob CW to increase and CCW
to decrease.
f. Place ammeter-voltmeter transfer switch in
position corresponding to the position of the reconnection switch. Adjust voltage adjust rheostat to desired voltage as read on voltmeter. Turn rheostat
clockwise to increase voltage or counterclockwise to
decrease voltage.
g. Place AC circuit breaker in ON position. Adjust
speed control to obtain 60 Hz.
h. Place ammenter-volmeter transfer switch in
position to check percent rated current for either
1-phase 120 V. output, 1-phase 120/240V. output, or
3-phase 120/208 V. output. See table 2-1 and figure
2-3.
NOTE
For 3-phase output each of the four positions
indicated in table 2-2 must be checked.
Observe percent rated current meter. Do not exceed
5% load difference between phases. A 0.8 power factor
Table 2-2. Reconnection Switch Positions
Load Voltage and Phase
2-4
Switch Position
Amps - Volts - Phase
Measurement Across Terminals
120V 1 phase
L3
L3-L1
1
L3-L1
120/240V 1 phase
L3
L3-L0
1
L3-L0
120/206V 3 phase
L1
L1-L2
3
L1-L2
L2
L2-L3
3
L2-L3
L3
L3-L1
3
L3-L1
L3
L3-L0
3
L3-L0
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load equals a 100% meter reading for maximum rated
load. A 1.0 power factor load equals a 80% meter
reading for maximum rated load.
i. During operating of the Generator Set observe
the following.
(5) Battery indicator should indicate yellow while
battery is charging, green when battery is fully
charged.
(6) AC voltmeter should indicate 120V., 208V. or
240V. depending on load connection.
(1) Check % rated current meter.
(2) Check fuel level gauge periodically.
(7) Frequency meter should indicate 60 Hz (at
full rated load).
(3) Oil pressure gauge located on engine should
indicate 20 psi minimum.
(4) Check running time meter periodically in
order to perform preventive maintenance check and
services at proper intervals.
j. During operation, inspect for leaks, paying particular attention to engine fuel and oil lines and connections.
Figure 2-4. Load Terminal and Reconnection Configuration
2-5
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k. During operation, listen for unusual noises
which may indicate a pending malfunction.
2-5.
OPERATING IN ALTERNATE MODES.
WARNING
When selecting position 120V, 1 PH unit is
in 2 wire conf iguration. A situation
can/may exist in al
lowing a double fault to
occur. To eliminate this possibility the
reconnection switch will be rewired by using an AWG #4 wire jumper between terminals #LO and #6 of section g.
CAUTION
Disconnect load before switching.
This unit can be set for 120 volt–l-phase,
120/240 volt–1-phase, or 120-208
voIt—3-phase output. Rotate reconnection
switch to desired output connection. Refer
to figure 2-2.
Section II.
2-7.
OPERATION IN EXTREME HEAT.
2-8. OPERATION IN EXTREME COLD (-25°F,
-32°C).
To ensure satisfactory operation under conditions of
extreme cold accomplish the following:
a. Use correct lubricating oil in engine crankcase
for temperature conditions. (Refer to figure 3-1).
Change oil only when engine is warm.
b. Use Arctic Grade diesel fuel.
c. Keep batteries in a well charged condition.
d. Be certain air cleaner intake control is in cold
weather position.
e. Shutter blades should be fully closed for cold
engine open only partially under light load, open more
as load increases.
Change 6
a. Place AC circuit breaker in the OFF position.
b. To stop the Generator Set, place the master
switch in the OFF position.
c. After operation of the Generator Set, perform
the inspection and service requirements as outlined in
preventive maintenance checks and services under
Operator Maintenance Instructions, Chapter 3.
d. Emergency Stop. To stop Generator Set in an
emergency, pull out DC control circuit breaker (see
figure 2-3).
e. If Generator Set is not going to be operated for
two weeks or more, disconnect the negative cable from
the battery. The generator set will be ready to go upon
reconnection of the negative cable.
OPERATION UNDER UNUSUAL CONDITIONS
To ensure satisfactory operation under conditions of
extreme heat, accomplish the following:
a. Be sure that nothing obstructs air flow to and
from the unit.
b. Keep cooling fins clean.
c. Inspect battery electrolyte level daily. Add
distilled water if necessary.
d. Keep generator free of dirt and grime. Be sure
ventilating screens are free of obstructions.
2-6
2-6. SHUTTING DOWN UNIT.
f. Hold master switch in START position for 2
minutes after engine comes to operating speed.
2-9. OPERATION IN DUSTY OR SANDY AREAS.
To ensure that the Generator Set will operate satisfactorily in dusty or sandy areas, accomplish the
following
a. Clean Generator Set frequently.
b. Service air cleaner frequently. Check air restriction indicator daily. If red signal is visible, service the
air cleaner. Be certain that all air cleaner and intake
manifold connections do not leak. Be certain oil filler
cap fits snugly.
c. Change crankcase oil and oil filter frequently.
d. Store oil and fuel in dust-free containers.
e. Make sure that Generator Set ground connection is free of dust and sand and connections are tight
before starting the unit.
2-10. OPERATION IN WET OR HUMID AREAS.
To ensure that the Generator Set will operate satisfactorily in wet or humid areas, accomplish the following
a. Keep fuel tank full to protect against moisture
condensation and accumulation.
b. Check wiring connectors for corrosion and wire
insulation for signs of deterioration.
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
CHAPTER 3
OPERATOR MAINTENANCE INSTRUCTIONS
Section I. CONSUMABLE OPERATING AND MAINTENANCE SUPPLIES
3-1. CONSUMABLE SUPPLIES.
Table 3-1 contains all consumable supplies and the required
quantities necessary for operating and maintaining this
Generator Set.
Table 3-1. Consumable Operating and Maintenance Supplies
9130-00-256-8613
9140-00-286-5294
9140-00-286-5286
9140-00-286-5283
9150-00-265-9435
9150-00-265-9435
9150-00-242-7603
6810-00-249-9354
Section II. LUBRICATION INSTRUCTIONS
3-2. GENERAL.
proper lubricant to be used.
To prevent excessive wear and insure continued operation,
lubrication of certain moving parts on this unit is required.
The Lubrication Order reproduced in this section shows
the areas of this unit which require lubrication and also the
3-3. LUBRICATION ORDER.
Refer to Lubrication Order LO 5-6115-584-12 for lubrication instructions.
Pages 3-2 and 3-3 including figure 3-1 deleted.
Change 6
3-1
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Section III. PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
3-8. PREVENTIVE MAINTENANCE CHECKS AND
SERVICES.
3-4. GENERAL.
To ensure that the Generator Set is ready for operation at
all times it must be inspected systematically, so that defects may be discovered and corrected before they result in
serious damage or failure. The necessary preventive maintenance checks and services that are to be performed by the
Operator personnel are listed and described in paragraph 3-8.
Table 3-2 contains a tabulated listing of PMCS which shall
be performed by the Operator personnel. The item numbers
are listed consecutively and indicate the sequence of
minimum requirements.
NOTE
3-5. CORRECTING AND REPORTING DEFICIENCIES.
Defects discovered during operation will be noted for future
correction. Stop operation immediately if a deficiency is
noted which would damage the equipment or is a safety
hazard. All deficiencies and short comings will be recorded
together with the corrective actions taken on the applicable
form. Marine Corps users should refer to current issue of
TM 4700-15/1.
Leakage definitions for operator/crew PMCS
shall be classified as follows:
Class I
Seepage of fluid (as indicated by wetness or discoloration) not great enough to form drops.
Class II
Leakage of fluid great enough to form drops
but not enough to cause drops to drip from item
being checked/inspected.
Class III
Leakage of fluid great enough to form drops that
fall from the item-being checked/inspected.
3-6. DETERMINING PMCS INTERVALS.
Certain Operator PMCS on this unit should be performed
on a - per hours of operation - basis. The running time
meter on the control panel should be used to determine the
Generator Set operating time.
3-7. PMCS FOR UNITS IN CONTINUOUS OPERATION.
For PMCS performed on an operating time basis, perform
PMCS as close as possible to the time intervals indicated.
For units in continuous operation, perform PMCS before
starting operation if continuous operation will extend
service interval past that which is shown.
Equipment operation is allowable with minor
leakages (Class I or II). Of course, you must
consider the fluid capacity in the item/system
being checked/inspected. When in doubt, notify
your supervisor.
When operating with Class I or Class II leaks,
continue to check fluid levels as required.
Table 3-2. Operator/Crew Preventive Maintenance Checks and Services
NOTE
Within designated interval, these checks are to be performed in the order listed.
3-4 Change 5
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TO-35C2-3456-1
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Table 3-2. Operator/Crew Preventive Maintenance Checks and Services (Cont.)
NOTE
Within designated interval, these checks are to be performed in the order listed.
B-Before
D-During
Item To Be
Inspected
Generator set
(cont.)
W-Weekly
A-After
Procedures
Check for and have repaired
or adjusted as necessary
M-Monthly
Equipment is
Not Ready/
Available if:
c. Check that grounding cable is installed and
tight (para 4-2e, fig. 4-2).
Cable is improperly
installed or missing.
d. Check restriction indicator; if RED, clean or
replace air filter element. (para 3-18)
Air cleaner is
missing or
unserviceable.
Indicator indicates
red.
NOTE
During starting and operation, check restriction
indicator. Check for leaks, loose or cracked parts,
unusual noise, rough-running, excessive vibration,
lack of power, incorrect instrument readings, or
any indication of a failing or defective component.
If suspected, notify organizational maintenance.
Controls and
Instruments will indicate within specified limits.
a. Battery
indicator
Normal indication: yellow while charging, green
when fully charged.
Indicating in
the Red.
b. Frequency
meter
Normal indication: 60 Hz (red line) with load
on generator.
Proper frequency
cannot be
maintained.
c. Percent rated
current meter
Normal indication: Percent of load (output) on
each phase. Not to exceed 100% load or 5%
difference between phases.
d. Voltmeter
Normal indication: 120, 208 or 240 volts
depending on AMP Volt transfer switch position.
Desired voltage
cannot be obtained.
e. Oil pressure
gage
Normal indication: 20 to 45 psig at rated RPM.
Oil pressure drops
below 15 psig.
f. Fuel gage
Normal indication: Full
Fuel tank
Fill tank upon completion of operation.
Dangerous gases. Do not smoke or use open flame
while servicing battery, due to possible presence
of hydrogen, a highly explosive gas.
Change 6
3-5
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Table 3-2. Operator/Crew Preventive Maintenance Checks and Services (Cont.)
NOTE
Within designated interval, these checks are to be performed in the order listed.
B-Before
D-During
Interval
Item To Be
Inspected
Item
No.
W-Weekly
A-After
Procedures
Check for and have repaired
or adjusted as necessary
M-Monthly
Equipment is
Not Ready/
Available if:
NOTE
If the Generator Set is not going to be operated for
two weeks or more, disconnect the negative cable
from the battery. The Generator Set will be ready to
go upon reconnection of the negative cable.
Even if the Generator Set is operated every day, the
battery may still run down. A run down battery does
not have time to be recharged. Run the Generator Set
for at least 30 minutes at rated speed. Allow extra
running time if the preheater was used, or if starting
took several tries.
Batteries
Check battery electrolyte levels. Proper level is 3/8
inch above plates. Use clean water (distilled if available).
NOTE
Fuel system temperature must be above freezing
when draining water and sediment.
Fuel strainer
and filters
Drain water and sediment from strainer, primary and
secondary filters. Allow to drain until fuel runs clean
(para 3-20).
Fuel tank
Drain water and sediment. Allow to drain until fuel
runs clean (para 3-13).
Acoustical
Suppression Kit
(ASK)
Make a visual inspection of the ASK for loose or missing hardware, and for any bent, cracked or broken
parts. Tighten all loose hardware.
Front Panel
Assembly
Ensure that front panel assembly is free from obstructions or accumulation of dirt, leaves, debris which
would hinder air flow.
Day Tank
Drain water and sediment.
NOTE
In freezing weather drain shortly after operation.
A11ow to drain until fuel runs clear.
Section IV. TROUBLESHOOTING
3-9. GENERAL
This section contains troubleshooting information for locating and correcting operating troubles which may develop in
the Generator Set. Each malfunction for an individual component, unit, or system is followed by a list of tests or inspections which will help you to determine probable causes and
corrective actions to take. You should perform the test/
inspections and corrective actions in the order listed.
3-6
Change 9
3-10. MALFUNCTIONS NOT CORRECTED BY USE
OF THE TROUBLESHOOTING TABLE.
This manual cannot list all malfunctions that may occur nor
all test or inspections and corrective actions. If a malfunction is not listed or cannot be corrected by listed corrective
actions, notify your supervisor.
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Table 3-3. Troubleshooting (Cont)
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
4, ENGINE STARTS AND RUNS NORMALLY BUT SUDDENLY “STOPS.“
Step 1. Check fuel level indicated by gauge on fuel tank (paragraph 3-13).
Add fuel if necessary.
Step 2. Check to see that shutters on shutter box have fully opened (paragraph 3-14).
Refer to next higher level of maintenance.
Step 3. Check to see that blower housing grille and engine cooling fins are clean (paragraph 3-22).
Refer to next higher level of maintenance.
Step 4.
LOW
oil pressure will cause engine to shut down. Check oil level (paragraph 3-24).
Add correct weight oil, if necessary.
Step 5. Check that vent on under side of fuel filler cap is open (paragraph 3-13).
Clear vent hole.
5. ENGINE RUNS BUT EMITS BLACK SMOKE IN EXHAUST.
Step 1. Check air cleaner assembly to see that inlet shutter assembly is in proper position for either
COLD WEATHER or NORMAL WEATHER operation (paragraph 3-18).
Push knob and slide assembly into proper position.
Step 2. Check for restricted air intake, Red signal on air flow indicator should be visible
(paragraph 3-18).
Remove any restriction from intake port. Check and if neceaaary clean or replace air
cleaner filter
Step 3. Check load on Generator by checking % rated current meter on control panel (paragraph 3-19).
Notify immediate supervisor.
6, ENGINE RUNS WITH EXCESSIVE OIL CONSUMPTION,
Step 1. Inspect for oil leaks especially at front and rear oil seals, at oil pan gasket and dipstick cap
(paragraph 3-24).
Notify higher level of maintenance.
Step 2. Check for red warning signal on air flow indicator indicating a dirty air cleaner filter
(paragraph 3-18).
Clean or replace fiiter. Reset air flow indicator by pushing reset button.
Step 3. Check for air leaks to crankcase (loose oil filler cap, leaks at gaskets, etc) (paragraph 3-24).
Tighten oil filler cap or notify higher level of maintenance.
Change 5
3-7
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Table 3-3. Troubleshooting (Cont)
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
7. GENERATOR SUPPLIES NO VOLTAGE TO LOAD.
Step 1. Check main circuit breaker for ON position on ac output control box.
Place circuit breaker in ON position. If breaker will not stay on, perform the following
actions:
Make certain load leads are attached to the correct load terminals.
Make certain connections are clean and tight.
Verify load is not excessive to generator capability and does not have an internal short.
Notify higher level maintenance.
8. GENERATOR SUPPLIES IMPROPER (UNDER OR OVER) VOLTAGE FREQUENCY TO LOAD.
Step 1. Check reconnection switch on ac output control box.
Make certain switch position matches load.
Disconnect load before switching.
Step 2. Check load terminal board (paragraph 3-17).
Make certain load leads are attached to the correct load terminals. Make certain
connections are clean and tight.
Step 3. Check engine speed.
Adjust engine speed by turning speed control assembly until frequency meter on
control panel indicates 60 Hz with load on Generator Set.
If engine speed cannot be brought up so that Generator operates at 60 Hz, check
external governor linkage for binding and check steps under ENGINE STARTS
BUT DOES NOT RUN SMOOTHLY.
If engine speed cannot be brought down so that Generator operates at 60 Hz, check
external governor linkage for binding or notify higher level maintenance
(paragraph 3-21).
Section V. OPERATOR MAINTENANCE PROCEDURES
3-11. BATTERY ASSEMBLY.
a. Inspect (see figure 3-2). On generators equipped with
acoustic suppression kit (ASK), remove batteries access door for
Inspection.
(1) Inspect battery cable terminal connectors (2), (10) and
(11) for corrosion, deterioration, or physical damage. Inspect
battery terminal covers (16) for proper installation and physical
condition. Replace if cracked, split or torn.
(2) Inspect cables (l), (3), and (4) for breaks, damage and
deteriorated insulation.
3-8
Change 7
(3) Inspect battery top frames (5), bottom frame (12),
and tray (13) for corrosion or physical damage. Check to
see that frame is held securely in place and that all
attaching hardware, nut (7), washer, (8), screw (14), washer
(15), and bolt (9), is securely in place. Check that frame is free
of electrolyte.
(4) Inspect battery (6) for leaks or cracks. Check top
of battery and battery caps for cleanliness. Check battery electrolyte (liquid) level. Level should be
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1. Cable
2. Connecter (2)
3. Cable
4. Jumper
5. Top frame (2)
11. Terminal
12. Bottom frame
13. Tray
14. Screw (4)
15. Washer (4)
16. Battery terminal cover (4)
6, Battery (2)
7. Nut (4)
8. Washer (4)
9. Bolt (4)
10. Terminal
Figure 3-2. Battery Assembly
Electrolyte (NSNs 6810-00-249-9354 and
6810-00-843-1640) have a specific gravity of 1.280
and should be used in these batteries. Do NOT
adjust the electrolyte in wet batteries to a lower
specific gravity.
3/8 inch above top of plates. Check that battery caps are not loose.
b.
Clean.
(1) Clean terminal connectors, (2), (4), (10) and (11),
batteries (6) and frame using a low sodium solution and wipe dry
with a clean cloth. Notify higher level of maintenance if terminals,
cables, batteries or frame is damaged.
c.
Service.
NOTE
The 6TN and 6TL batteries can be mixed or
matched. However, maintenance-free batteries
cannot be mixed or matched with military
batteries. The 6TN and 6TL batteries will perform
properly in bot weather as long as electrolyte levels
are carefully monitored. If the electrolyte expands
and causes the level to rise, some fluid must be
removed. If tbe level becomes too low due to
evaporation, distilled water may be used to obtain
the proper level. A good grade of drinking water
(excluding mineral water) may be used if distilled
water is not available.
(1) Fill batteries (6) with clean distilled water to a level
of 3/8 inch above top of plates. In freezing weather, run engine a
minimum of one hour after adding water.
3-12.
GROUND ROD AND FUEL DRUM ADATPER
HOLD-DOWN ASSEMBLY.
a. Removal (see figure 3-9). On ASK equipped generators,
remove oil acess door and fuel filter acess door and perform the
following procedures.
(1) Ground Rod and Fuel Drum Adapter. Loosen
screws (1) and lockwashers (2). Slide three piece ground rod (3)
out of hold-down assembly (4), then slide out fuel drum adapter
(5).
Hold-down adapter. Grasp hold-down assembly
(2)
(4) and remove screw (1) and lockwasher (2). Remove hold-down
assembly.
Change 8
3-9
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
Do not over-tighten screws as damage to
hold-down assemblies may occur.
(2) Ground Rods and Fuel Drum Adapter. Slide fuel
drum adapter (5) and three piece ground rod assembly (3)
between hold-down assemblies (4) and skid base (6).
Tighten screws (1).
3-13. FUEL TANK ASSEMBLY.
a. Cleaning and Inspection (see figure 3-4).
(1) Fuel Tank Strap Assemblies. Inspect both straps
(1) for damage that would prevent them from securely
holding fuel tank (4) to skid-base (10). Check that both
straps are tight. Tighten straps by tightening nuts (2) and
washers (3) securing each strap to skid-base.
(2) Fuel Tank. Visually check fuel tank (4) for dents
or leaks. Check that filler cap (8) fits securely onto tank and
that filler cap and surrounding area is clean. Clean using
solvent and clean cloth.
(3) Fuel Level Gauge. Check fuel level gauge (6) for
physical damage. Check that gauge shows FULL when tank
is full, and EMPTY when tank is empty. Notify higher level
of maintenance for replacement of fuel level gauge.
1. Screw (2)
2. Lockwasher (2)
3. Ground rod
4. Hold-down assembly (2)
5. Fuel drum adapter
6. Skid-base
Figure 3-3. Ground Rod and Fuel Drum Adapter Hold-Down
b. Cleaning and Inspection.
(1) Ground Rod. Inspect ground rod for damage and
corrosion. Pay particular attention to the threaded portions
of each piece, making certain the three pieces can be
properly assembled.
(2) Fuel Drum Adapter. Inspect adapter (5) for
cleanliness and condition of threaded portions. Clean
adapter with cleaning solvent and dry.
(3) Hold. down. Check hold-down assembly (4) for
physical damage and check condition of hardware (1
and 2).
c. Installation.
(1) Hold-down. Position lockwashers (2) on screws
(1) and insert into holes in skid-base (6). Position holddown assemblies (4) against skid-base (6), then start
screw (1).
3-10
Change 7
(4) Float Switch. Inspect float switch (7) for physical damage. Check that float switch is properly attached to
tank.
(5) Fittings. Inspect three fittings (5) for physical
damage. Check that fittings are secured to fuel tank. Notify
higher level of maintenance of leaky or damaged fittings.
(6) Fuel Drain Valve. Inspect drain valve (9) for
physical damage, Check that valve operates properly. If not,
notify higher level of maintenance.
(7) Filler Cap Assembly. Inspecl filler cap (8) for
physical damage. Check that vent on underside of oap opens
and doses easily. Ensure that vent on underside of filler cap
is open before starting generator.
3-14. SHUTTER
BOX ASSEMBLY.
a. Inspect (see figure.3-5).
Do not operate unit if shutter assembly is
not operating properly.
(1) Shutter Assembly. Check shutter assembly with
unit running under normal operating conditions. When
engine is cold, shutter assembly should be fully closed.
When engine warms up, shutter assembly should be fully
open at 140°F (60°C) or above at full rated load. Make
certain shutter assembly is free of dirt and oil which could
cause shutters to stick.
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
1.
2.
3.
4.
Strap (2)
Nut (4)
Flatwasher (4)
Fuel tank
5. Fitting (3)
6. Fuel level gauge
7. Float switch
8. Filler cap
9. Drain valve
10. Skid-base
TS 6115-584-12/3-4
Figure 3-4. Fuel Tank
(2) Bracket Assembly. Check bracket assembly
(1) for secure mounting to shutter (4) and shutter box
(10). Brackets (11) should turn freely on bearings (12)
without excessive play.
(3) Shutters. Check shutters (4) to see that they
are free of dirt or grease. Check to see shutters are
flat and straight. Check to see that shutters close securely and that they can be easily opened by hand.
(4) Thermo Power Unit. Check thermo power unit
(7) located on inside of shutter assembly to see that
it is free of dirt, grease, or physical damage. Notify
higher level of maintenance for replacement of thermo
power unit.
3-11
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
1.
2.
3.
4.
Bracket Assembly (4)
Screw (8)
Washer (8)
Shutter (2)
5.
6.
7.
8.
Screw (2)
Lockwasher (2)
Thermo power unit
Screw (2)
9.
10.
11.
12.
Washer
Shutter Box
Bracket (4)
Bearing (4)
TS 6115-584-12/3-5
Figure 3-5. Shutter and Thermo Power Element Assembly
3-12
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
1.
2.
3.
4.
5. Adapter (2)
6. Adapter gasket (2)
7. Stud (4)
Lock tab (2)
Nut (4)
Muffler
Muffler gasket (2)
8.
9.
10.
11.
Oil pressure gauge
Oil hose
Oil pressure switch
Engine mount
TS 6115-584-12/3-6
Figure 3-6. Exhaust Muffler Assembly
3-15. EXHAUST MUFFLER ASSEMBLY
Check to see that exhaust is not obstructed and there
is no evidence of leaks.
3-16. ENGINE STARTER ASSEMBLY
Do not touch muffler assembly while unit is
running or immediately after shutdown, as
severe burns may result.
a. Inspect (see figure 3-6). Manually open shutter
assembly and check that muffler assembly (3) is
securely fastened to unit. Check that nuts (2) and lock
tabs (1) attaching muffler to unit are in place.
a. Cleaning and Inspection (see figure 3-7). On ASK equipped
generators, remove BATTERIES access door. Clean engine starter
(1) by removing loose dirt with a stiff nonmetallic brush. Clean off
remaining dirt and oil with dry cleaning solvent (Fed. Spec.
P-D-680). Inspect starter to see that electrical connections (4) are
clean and tight. Check to see that mounting bolts (2) are tight.
Check starter (1) for physical damage.
Change 7
3-13
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
1. Starter
2. Mounting bolts (4)
3. Mounting bracket
4. Electrical terminal (5)
5. Flywheel housing
TS 6115-584-12/3-7
Figure 3-7. Electric Starter
1. 120VAC outlet
3-17. AC OUTPUT CONTROL BOX ASSEMBLY.
a. Inspect (see figure 3-8).
(1) Control Box Assembly. Check box assembly
for cracks, dents, or other physical damage. Inspect
to see that covers (1) for both 120 volt ac outlets
operate properly. Check latches (2) securing load
terminal board cover (3). Check to see that cover (3)
for load terminal board opens and closes properly.
Check to see that electrical connecters (4) are clean
and securely mounted.
cover (2)
2. Latches (2)
3. Load terminal cover
4. Electrical
connectors (4)
5. Load terminal board
6. Load terminal (4)
TS 6115-584-12/3-8
Figure 3-8. AC Output Control Box Assembly
check that clamp (17) attaching dust cap (18) to houseing is secure and arrows on dust cap are pointing up.
check that two clamps (7) holding cold weather
operation intake hose (19) are secure.
(2) Load Terminal Board Assembly. Check condition of load terminal board (5) and load terminals
(6) for cleanliness and tightness. Make certain that
the load leads are secured to terminals.
(2) Bracket Assembly. Inspect bracket assembly
(1) to see that it is securely fastened to generator
housing (2). check that capscrews (3) and lockwashers
(4) which attach bracket to generator housing, and
three spacers (5) are in place.
3-18. AIR CLEANER ASSEMBLY.
a. Inspect on Equipment (see figure
(3) Inlet Shutter (see figure 3-10). Check inlet
shutter (6) to see that it slides easily from COLD
WEATHER to NORMAL WEATHER position and back.
3-9). On ASK
equipped generators, open AIR INTAKE and AIR CLEANER
access doors.
(1) Housing. lnspect housing (8) for dirt, grease,
dents or other physical damage. Check to see that
housing is securely attached to bracket assembly (1).
3-14
Change 7
(4) Air Flow Indicator (see figure 3-10). Check
air flow indicator (7) for dirt, grease, or physical
damage.
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
1.
2.
3.
4.
5.
6.
Bracket assembly
Generator housing
Capscrews (6)
Lockwashers (6)
Spacers (3)
Air flow indicator
7.
8.
9.
10.
11.
12.
13.
Hose clamp
Air cleaner housing
Clamp
Screw (4)
Washer (4)
Engine lifting attachment
Shroud
14.
15.
16.
17.
18.
19.
Panel
Air cleaner assembly
Seal
Clamp
Dust cap
Hose
TS 6115-584-12/3-9
Figure 3-9. Air Cleaner and Shroud Assembly
3-15
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
b. Removal and Service.
(1) Dust Cap (see figure 3-10). Every 100 operating hours (more frequently in dusty areas) service
dust cap (1) by removing cap from air cleaner housing (5), removing rubber seal (9), and cleaning out
any dirt or debris. The clamp (10) is loosened to remove dust cap and seal.
Do not use compressed air of more than 100
psi on the air cleaner element.
(2) Air Cleaner Element (see figure 3-10).Every
1000 operating hours, or more frequently as conditions dictate, or when red warning on air flow indicator becomes visible, clean or replace air cleaner
element (4). To remove the element remove dust cap
(1) and seal (9). Remove wing nut (2), seal (3) and
remove element (4). To clean element, direct dry
clean air up and down pleats on the inside of the element. (See figure 3-11.) If element is very dirty, wash
it by soaking in mild detergent and water. Soak for
fifteen minutes or more. Rinse element thoroughly
with clean water from hose (maximum pressure 40
psi). Air dry completely a minimum of 24 hours before re-using. Do not dry with compressed air or
heat over 150° F (66° C).
1. Dust cap
2. Wing nut
3. Seal
4. Filter element
5. Housing
6. Inlet shutter
7. Indicator
8. Reset button
9. Seal
10. clamp
TS 6115-584-12/3-10
Figure 3-10. Air Cleaner Assembly
3-16
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
ing lamp covers. Check that electrical connections
are clean and tight.
(3) panel Light Switch. Operate lamp switch (2)
to check that lamps are operable.
(4) Meters. Battery Indicator (M1), Hourmeter
(M2), Frequency Meter (M3), Percent Current Meter
(M4) and AC Voltmeter (M5). Inspect meter glass to
see that it is not cracked. Check to see the meter
face is clean and readable. Check to see that pointer
is not bent. Check to see that electrical connection
are clean and tight.
(5) DC Control Circuit Breaker (CB2). Inspect
circuit breaker for physical damage. Inspect electrical connections to see that they are clean and tight.
Check to see that when button on breaker is pushed
in or pulled out, it will remain in that position.
Figure 3-11. Cleaning Air Filter Element
Do not re-use element more than twice. Do
not re-use element if it has even the slightest
rupture.
c. Installation.
(1) Air Cleaner Element. Slide element (4, figure
3-10) over stud in housing (5), install seal (3) on wing
nut (2) and secure element with wing nut (2). Hand
tighten wing nut. Install seal (9) and dust cap (1). Be
certain “Top” on dust cap faces up. Retighten clamp
(10) to secure dust cap.
3-19. CONTROL CUBICLE Assembly.
a. Inspect (see figure 3-12).
(1) Control Cubicle Assembly. Inspect cubicle for
dirt, grease or physical damage which might affect
operation of the unit. Loosen three fasteners holding
control panel to permit access to the inside of the
cubicle. Check to see that all parts mounted to the
cubicle are secure and all hardware is in place.
Check that all instruments and controls operate normally when unit in running. Check for broken or badly
insulated harness wires and, if necessary, refer to
higher level of maintenance.
(2) Panel Light Assemblies (DS1 and DS2). Inspect panel light assemblies (1) for cracked or miss-
(6) Master Rotary Switch (S1). Inspect switch for
physical damage. Inspect electrical connections to
see that they are clean and tight. Check to see that
when placed in the OFF, PRIME & RUN AUX FUEL,
or PRIME & RUN positions the switch will remain in
position. Check to see that when placed in the PREHEAT position and released, switch returns to OFF
position. With DC Control Circuit Breaker (CB2)
pulled out (unit will not crank), check to see that when
released from START position the switch will automatically return to PRIME & RUN position.
(7) Panel Light Switch (S2). Inspect switch for
physical damage. Inspect for clean and tight electrical connections. Check to see that switch will remain in both ON and OFF positions.
(8) Ammeter - Voltmeter Transfer Switch. Inspect
switch for physical damage. Inspect for clean and tight
electrical connection. Check to see that switch will remain in both ON and OFF positions.
(9) Voltage Adjust Rheostat (R1). Inspect rheostat for physical damage. Inspect for clean and tight
electrical connections. Note rheostat position and
check that rheostat moves smoothly thru its range.
Return rheostat to previously noted position.
(10) AC Voltage Regulator (A2). Visually inspect
board and components for signs of overheating,
cleanliness and physical damage. Inspect for clean
and tight connections to the board and that board is
securely mounted.
(11) Transformers (T1 and T2). Inspect transformers for physical damage, cleanliness and that
electrical connections are clean and tight.
(12) Wiring Harness. Inspect wiring harness for
physical damage such as broken or frayed wires or
damaged insulation.
(13) Control Cubicle Box. Inspect box for physical damage.
Change 3
3-17
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
1. Panel light (2)
2. Panel light switch
3. Battery charge indicator
4. Running time meter
5. Frequency meter
6. Percent rated current meter
7. Voltmeter
8. DC control circuit breaker
9. Master switch
10. Ammeter - Voltmeter transfer switch
11. Voltage adjust rheostat
TS 6115-584-12/3-12
Figure 3-12. Control Cubicle
3-18
Change 3
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
b. Service
(1) Panel Light. Panel lamp cover can be removed for cleaning by turning them counterclockwise
when viewed from front.
(2) Panel Lamps. Panel lamps are screw in base
types and are replaceable.
3-20. FUEL SYSTEM (LESS TANK).
a. Inspect (see Figure 1-2.1). On ASK equipped generators,
remove FUEL FILTERS access door.
(1) Fuel Filter Assemblies (see figure 3-13). Inspect iwo fuel filter assemblies (10) for dents or other
1. Drain cock (3)
2. Hose assembly
3. Hose assembly (2)
4. Hose assembly
5. Elbow
6. Check valve
7. Connector
8. Screw (12)
physical damage. Check for leaks especially around
fuel line fittings (12), drains (1), and where bowl joins
the head Check that fuel filter assemblies are securely attached to mounting bracket (16) and that
bracket is securely attached to bracket support on
skid-bass.
(2) Fuel Strainer Assembly (see figure 3-13).
Inspect strainer assembly (11) for dents or other physical damage. Check for leaks especially around fuel
line fittings (12), drain (1), or where the bowl joins the
head. Check that strainer assemblv (11) is securely
attached to mounting bracket (16).
9. Lockwasher (12)
10. Filter (2)
11. Strainer
12. Elbow (6)
13. Nut (2)
14. Lockwasher (2)
15. Screw (2)
16. Bracket
TS 6115-584-12/3-13
Figure 3-13. Fuel Filters and Fuel Strainer Assembly
Change 7
3-19
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
(3) Fuel Pump Assemblies (Three) (see figure
3-14). Inspect fuel pumps (1) for dents or other physical damage. Check for leaks especially around hose
assembly fittings (2). Check that fuel pumps are securely attached to mounting bracket (3) and that
mounting bracket is securely attached to bracket support on skid-base. Inspect electrical leads to fuel
pumps to see that wires and connectors are not
broken, frayed, or damaged. Check that connectors
are tightly connected. Check that cap (4) on auxiliary
fuel pump inlet is securely in place when unit is not
being run from auxiliary fuel supply,
(4) Fuel Hoses. Inspect fuel hoses (2, 3 and 4,
figure 3-13) for leaks or physical damage. Check to
see that fuel hose fittings are securely tightened in
place.
b. Service. On ASK equipped generators, remove fuel
filters access door.
(1) Fuel Filter Assemblies (see figure 3-13). Daily
before operation, open drain valves (1) and drain water
and sediment from filter assemblies.
(2) Fuel Strainer Assembly. Daily, before and after
operation, open drain valves (1) and drain water and sediment from strainer assembly (11).
Figure 3-15. Control Cubicle Support Assembly
3-21. CONTROL CUBICLE SUPPORT ASSEMBLY,
SPEED CONTROL AND ENGINE CONTROL
WIRING HARNESS.
a. Inspect.
(1) Vibration Mounts (Four) (see figure 3-15).
Inspect vibration mounts for deterioration or physical damage. Inspect mounts to see that they are free
of dtrt, fuel, or oil. Check to see that mounts are
securely attached to control cubicle support on skidbase. If mounts are faulty, refer to higher level of
maintenance.
(2) Engine Control Wiring Harness Assembly. On ASK
aquipped generator, open or remove all access doors. Inspect
wiring harness for broken or frayed wires. Check for wires with
damaged or deteriorated insulation. Check that all connectors and
terminals are ciean and tight.
Figure 3-14. Fuel Pump Assembly
3-20
Change 7
(3) Speed Control Assembly (see fiiure 3-16). On ASK
equipped generators lift motor speed control flap. Inspect to see
that speed control is firmly attached to unit. Check that speed
control moves in and out freely. If speed control is loose, refer to
higher level maintenance.
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
T M - 0 5 6 8 2 C - 1 2-
1. Knob
2. Nut
3. support
4.
7. Clevis pin
8. Governor assembly
9. Engine backplate
clamp
5. Nut
6. Cotter pin
TS 6115-584-12/3-16
Figure 3-16. Speed Control Assembly
3-22. ENGINE COOLING SYSTEM.
a. Inspect (see figure 3-17). On ASK equipped generators,
inspection is limited to parts of shroud assembly visible through
access doors.
damage. Check that blower housing assembly is
properly secured to engine. With engine running
check for noise which would indicate blower wheel
is rubbing against blower housing assembly or blower
grille. (For units without ASK.)
(1) Shroud Assembly. Inspect shroud assembly
(11) and door panel (12) for dents or other physical
damage. Inspect hinge attaching air housing panel (12)
to see that it swings freely. Check to see that shroud
assembly and door panel are properly secured to engine.
(2) Blower Housing Assembly. Inspect blower
housing assembly (32) for dents or other physical
(3) Blower Housing Grille Assembly. Inspect
grille (29) for dents or other physical damage and
that grille is properly secured to engine.
(For units without ASK.)
Change 7
3-21
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
Figure 3-17. Engine Cooling Assembly (Sheet 1 of 2)
3-22
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
1. Screw (6)
2. Air duct cover
3. Screw (4)
4. Shutter assembly
5. Connector
6. Clamp
7. Screw (4)
8. Washer (4)
9. Door panel and shroud assembly
10. Rivet (3)
11. Shroud
12. Door panel
13. Screw (4)
14. Latch (2)
15. Screw (2)
16. Lockwasher (2)
17. Screw
18. Screw (4)
19. Tie bar (2)
20. Screw (4)
21. Tie bar
22. shroud
23. Nut
24. Hook bolt
25. Baffle
26. Screw (3)
27. Retainer (3)
28. Cover
29. Grille
30. Screw (5)
31. Screw (3)
32. Blower housing
33. Screw
34. Screw
35. Clip
36. Shroud
37. Lifting eye
38. High temperature cutout switch
39. Lock tab
40. Muffler
41. Oil pressure gauge
TS 6115-584-12/3-14(2)
Figure 3-17. Engine Cooling Assembly (Sheet 2 of 2)
3-23. GENERATOR ASSEMBLY.
On ASK equipped generators, inspection i S limited to
screenguard areas visible through access doors. Inspect
screenguard (3, figure 3-18) to see that is clean and free of
debris and free of dents or cracks. Check that screen-guard
is securely fastaned in place over opening in generator
housing-stator assembly. Inspect end-bell (2) to see that it is
clean and frae of cracks or other physical damage. Check
that openings in end-bell and end-bell covar are free of
debris. Check that end-bell is securely attached to generator
housing.
3-24. ENGINE ASSEMBLY.
a. Lifting attachment (see figure 3-17). On ASK equipped
generators, open air intake door, Inspect for cracks or other
physical damage. Check that lifting eye (37) is securely
mounted.
b. Intake Manifold Assembly (see figure 3-19). On ASK
equipped generators, if intake manifold is suspected of possible
problems, refer to higher level of maintenance. Inspect intake
manifold (1) for cracks or physical damage. Check that manifold
is properly secured to cylinder head and mounting screws (5) and
lock tabs (3) are in place.
c. Oil Drain Hose (see figure 3-20). On ASK equipped generators, remove oil access door and inspect oil drain hose for
physical damage. Check that drain valve operates properly and
does not leak when closed. Check that oil drain hose is properly
stored when not in use.
Figure 3-18. Generator Assembly
d. Engine Mounting Assemblies (see figure 3-19). On ASK
equipped generators, remove oil access door and batteries
access door. Inspect engine mounts (13) for deterioration or
physical damage. Check for accumulations of dirt, fuel, or oil,
Check that mounts are securely attached to engine and to skidbase with all mounting hardware in place.
Change 7
3-23
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
Figure 3-19. Intake Manifold Assembly
3-24
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
Figure 3-21. Oil filter and Oil Pressure Switch
Figure 3-20. Oil Drain Hose
e. Oil Filter Assembly (see figure 1-l). Inspect oil filter
assembly for dents or other physical damage. Check for leaks
especially at gasket (1, figure 3-21) between body (3) and
adapter (5) and between bolt (2) and body (3). Check to see that
drain plug (4) is securely in place and does not leak.
f. Oil Pressure Switch (see figure 3-21). Inspect oil pressure
switch (6) for dents or other physical damage. Check that
switch is securely mounted to oil filter adapter (5). Check for
leaks where switch (6) attaches to adapter(5). Check that both
electrical connections (7) to switch (6) are tight and free of
corrosion.
g. Oil Pressure Gauge Assembly (see 41, figure 3-17). Inspect
glass lens to see that it is not cracked.
Figure 3-22. Engine Stop Solenoid
3-25
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
Inspect to see that there is no dirt or oil underneath lens indicating that gauge is no longer properly sealed. Check to see
that pointer is not bent or damaged. Check that markings on
gauge are readable. Check to see that meter is fastened securely to engine.
i. Engine Stop Solenoid (see figure 3-22). Inspect stop
solenoid (1) for dents or other physical damage. Check that
solenoid is securely attached to cylinder shroud bottom pan
with two screws (2) and lockwashers (3). Check that electrical
connections (4) to solenoid are clean and tight.
h. Flexible Oil Lines (see figure 1-1). Inspect flexible oil lines
to the oil pressure gauge and the oil cooler for physical damage.
Check for leaks especially around fittings.
j. Oil Dip-Stick and Housing (see figure 1-1). Inspect oil dip-stick and housing (9) for physical damage. Check for leaks especially at gasket between
Figure 3-23. Battery and Frame
3-26
Change 4
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
housing and engine block. Check that dip-stick fits
securely into housing with no leaks.
3-25. SKID- BASE ASSEMBLY.
Battery electrolyte can cause severe burns to
skin. Always flush exposed parts of the
skin with water as quickly as possible.
the
a. Inspect (see figure 3-23).
(1) Battery Frame Bottom. On ASK equipped generators, remove BATTERIES access door. Inspect battery
frame bottom (6) for dents, cracks, corrosion, or other
physical damage. Check to see that battery frame bottom
is free of corrosion.
(2) Battery Frame Top. Inspect battery frame top
(2) for dents, cranks, corrosion, or other physical
damage. Check to see that battery tray (8) is free of
corrosion. Check that battery tray is securely attached to skid-base (9) with screw (7). Check that
battery frame top (2) is securely attached to battery
frame bottom (6) with hook bolts (3), nuts (4) washer
(5).
(3) Inspecting Ground Stud (see figure 3-24). On ASK
equipped generators, lift rear panel flap and inspect
ground stud for deformed threads, corrosion, or other
physical damage. Check that ground stud is securely
attached to skid-base. Check that connections to stud are
clean and tight.
(4) Inspect ground wire and ground rod for physical
damage and check that connections are tight.
Figure 3-24. Ground Stud
b. Cleaning. Remove corrosion with a suitable
neutralizing agent. Wipe dry with a clean cloth.
Change 7
3-27/(3-28 blank)
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TO-35C2-3-456-1
CHAPTER 4
ORGANIZATIONAL MAINTENANCE
Section I. SERVICE UPON RECEIPT OF MATERIAL
4-1. INSPECTING AND SERVICING GENERATOR
SET.
a.
Unloading Equipment.
(1) The dry weight of the engine Generator Set is
960 pounds. A crane, fork lift, or similar lifting device or
fabricated skids must be used to unload the equipment. The
equipment must be kept in the UP position while unloading.
Do not use a lifting device with a capacity of less
than 1500 pounds. Do not allow the crated Generator Set to swing while it is suspended. Failure to
observe this warning may result in serious injury or
death to personnel.
b. Unpacking.
(1) Before unpacking, move the engine Generator
Set as near as possible to the location where it will be operated.
Exercise care in the use of bars, hammers, and similar tools while uncrating the unit to avoid damaging
the equipment.
(2) Remove the top and then the sides of the crate
(figure 4-1).
(3) Remove barrier bag, dessicant bags, and shipping material from engine Generator Set.
(4) Disconnect engine Generator Set from crate
skid by removing carriage bolts, nuts, washers, and lift
engine Generator Set off skid.
c.
Service and Inspection.
(1) Prepare the engine Generator Set for inspection
and servicing as outlined in the following paragraphs. For
Army users, refer to D Form 2258.
(2) Make a thorough visual inspection of the entire
Generator Set for loose or missing hardware or damaged or
missing parts. Report all damaged or missing parts on DD
Form 6.
(3) Inspect all air cleaner connections for tightness
and damage.
(3.1)
On ASK equipped generators, inspect ASK
for damage. Check that exhaust plenum is clear of debris.
(4) Check engine intake and exhaust systems (figure
1-2) to make certain they are unobstructed by foreign material.
(5) Check that main fuel tank drain cock (figure 1-2)
is closed.
(6) Remove all preservative material except for
preservatives crankcase oil.
Do not smoke or use an open flame in the vicinity
when filling fuel tank.
Hot refueling of generators while they are operating
poses 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. Severe injury or death to personnel and
damage to the equipment may result.
NOTE
On generators equipped with acoustic suppression
kit (ASK), route auxiliary fuel line under rear flap
on skid to auxiliary fuel pump.
(7) Fill fuel tank with appropriate fuel and set MASTER SWITCH (figure 2-3) to RUN position to connect main
fuel tank to electrical fuel pumps. If an auxiliry source of fuel
is to be used in operating the engine Generator Set, connect
fuel hose to AUXILIARY FUEL, CONNECTION and set
MASTER SWITCH to RUN AUX FUEL position.
(8) Batteries are shipped in a dry state. If batteries
are hermetically sealed, destroy sealing device inside each
cell by tapping with a blunt instrument. Remove all sealing
particles. Battery electrolyte must be requisitioned separately. To activate the battery, remove all caps and fill battery cells with electrolyte. Electrolyte level should be 3/.8
inch above top of plates for each cell. Make sure vent holes in
caps are open, and replace caps. Connect batteries as shown
in figure 4-16.
NOTE
The electrolyte level must be rechecked approximately 30 minutes after initial filling as the plates
and separators will absorb the solution, thus resulting in a low level. If the battery is not to be used
within 12 hours after initial filling, it should be put
on a charger and brought up, to the correct specific
gravity. Test batteries as described in paragraph
4-25c, for the ambient temperature in effect.
Do not smoke or use an open flame in the vicinity
when servicing batteries. Batteries generate hydrogen, a highly explosive gas. Electrolyte contains sulphuric acid and can cause severe burns. Handle it
with care. If the solution comes in contact with the
body, eyes or clothing, rinse immediately with
clean water. Avoid spilling electrolyte on ainted
surfaces.
Change 9
4-1
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NAVPAC P-8-622-12
TO-35C2-3-456-1
Figure 4-1. Uncrating Generator Set
(9) Check crankcase oil level (paragraph 3-2)
and add oil as necessary (paragraph 3-3) in accordance with the lubrication order (figure 3-1).
4-2. INSTALLING GENERATOR SET
a. General. The engine Generator Set should be installed on a site clear of obstacles, with ample ventilation and level within ±15 degrees maximum.
b. Outdoor Installation. When preparing for a permanent installation, be sure the base is solid enough
to support the weight of the unit. See figure 1-4 for
dimensions of the base. Select a location where there
will be sufficient space on all sides for servicing and
operation of the engine Generator Set. When preparing a temporary installation, move the engine Generator Set as close to the worksite as practical. Use
suitable planks, logs, or other material for a base in
an area where the ground is soft.
c. Indoor Installation, Keep the area well ventilated
.t all times, so that the engtne Generator Set will receive a maxtmum supply of air. If a free supply of
fresh air is not available, provide duct work which
will assure at least 1350 cubic feet of air per minute.
4-2
Change 10
If louvers are used at the air entrance, increase the
duct work size by 25 to 50 percent. Install a gas-tight
metal pipe exhaust from the exhaust outlets to the
outside of the installation. The termination of the
exhaust pipe shall be such that hot gases or sparks
will be discharged harmlessly and will not be directed
against combustible material or into an area containing flammable gases or vapors. Use as few bends
in the pipe and as short a pipe as possible. The exhaust pipe should include a low point with suitable
means for draining of condensate. Provide metal
shields, 12 inches larger in diameter than the exhaust pipe where the line passes through flammable
walls. Line the exhaust pipe with fiberglass if there is any
danger of anyone touching it.
Do not operate the engine Generator Set in an
enclosed area unless the exhaust gases are
piped to the outside. Inhalation of exhaust
fumes will result in serious illness or death.
d. Leveling. The Generator Set is a portable unit
and is designed to operate satisfactorily up to 15°
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TM-05682C-12
out-of-level. Set up the unit as level as possible and
keep it as level as possible during operation.
e. Grounding. The Generator Set must be grounded
prior to operation. The ground can be, in order of
preference: (1) an underground metallic water piping
system, (2) a driven metal rod, or (3) a buried metal
plate (figure 4-2). If the effectively grounded portion
of the buried metallic water pipe is less than 10 feet
due to insulated sections or joints, this preferred
grounding method must be supplemented by an additional driven metal rod ground or a buried metal
plate ground. A driven metal ground rod must have a
minimum diameter of 5/8 inch if solid or 3/4 if pipe,
and driven to a minimum depth of 8 feet. A buried
metal ground plate must have a minimum area of 9
square feet, minimum thickness of 1/4 inch, and be
buried at a minimum depth of 4 feet. The ground lead
must be at least No. 6 AWG (American Wire Gauge)
copper wire. Ground rods are available as optional
equipment.
Figure 4-2. Grounding Generator Set
4-3
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Section II. MOVEMENT TO A NEW WORKSITE
4.3 DISMANTLING GENERATOR SET FOR MOVE-
MENT.
(6) On ASK equipped generators, remove batteries
access door. Disconnect negative battery cable from
battery.
a. Preparation for Movement.
(7) Disconnect any other hoses, lines or cables, if
used.
(1) Disconnect the load cables.
(2) Remove exhaust pipe extension if used.
(3) Make certain vent on underside of fuel filler cap
is closed.
(4) Refer to the Items Troop Installed or Authorized
List (Appendix B and make sure all items are on the
equipment.
(5)Disconnect the ground lead from the ground stud.
(8) Close and secure all doors and panels.
b. Movement. Preferred means of movement is to
transport. Towing for short distance is permissible if terrain
is suitable.
4-4. REINSTALLING GENERATOR SET AFTER MOVEMENT.
Refer to paragraph 4-2 for reinstallation after movement
to a new worksite.
Section III. REPAIR PARTS; SPECIAL TOOLS; SPECIAL TEST, MEASUREMENT
AND DIAGNOSTIC EQUIPMENT AND SPECIAL SUPPORT EQUIPMENT
4-5. SPECIAL TOOLS AND EQUIPMENT.
4-6. MAINTENANCE REPAIR PARTS.
Special tools are listed in Appendix D, Section Ill.
Repair parts and equipment are listed and illustrated
in the repair parts and special tools list manual
covering organizational maintainenace for this Generator Set.
Section IV. LUBRICATION INSTRUCTIONS
4-7. LUBRICATION.
a. Lubrication Order. Lubrication instructions for the Generator
Set are contained in L05-6115-564-12.
(F) Air Force lubrication instructions appear in the
applicable work card set in the TO 35C2-3-1-428 series.
(5) Open drain plug (1, figure 4-30) and drain
oil filter oil into a container having at least a 1
quart capacity.
(6) Remove through bolt (2) and Pull oil filter
body (3) loose from oil filter adapter (5).
NOTE
Insure that crankcase is hot before draining
oil.
(6).
(b) Oil Change (see figure 3-20). On ASK equipped
generators, remove oil access door.
rag.
(1) With drain valve closed, disconnect oil drain
hose from the plug on the skid-base.
(2) Open drain valve and drain oil into a container having at least a 7 quart capacity.
(3) Close drain vaive.
(4) Connect oil drain hose to plug on skid-base.
4-4
Change 7
(7) Discard gasket (4) and oil filter element
(8) Wipe inside of oil filter body (3) clean with a
(9) Wipe inside of adapter (6) clean with a
rag. Insure the gasket groove is free of foreign
m a t e r i a l . I n s p e c t g a s k e t s ( 7 ) a n d ( 1 0 ) tO b e s u r e
they are not torn or frayed. Check that retainer (8),
and spring (9) are not deformed. Replace damaged
components.
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(10) Apply a thin coat of clean engine oil,
MIL-L-2104 to a new gasket (4). Install new gasket
(4) in groove of adapter (5).
(11) Assemble components on through belt (2) in
the order shown in figure 4-30. Position body (3) with
drain plug (1) down on adapter (5). Tighten through bolt
(2) to 13±2 ft-lb.
(12) Pour 4 quarts of engine oil (see lubrication order for proper grade of oil) into oll fill tube
(9, figure 1-1).
(13) Check oil level with dip-stick.
(14) After 5 minutes of engine operation, check
crankcase oil level and bring oil level to full mark.
Section V. PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
4-8. PMCS, GENERAL.
To ensure that the Generator Set is ready for operation at all
times, it must be inspected systematically so defects may be
discovered and corrected before they result in serious damage,
failure or safety hazard. The necessary preventive maintenance
checks and services that are to be performed by Organizational
personnel are listed and described in the following paragraphs.
Defects discovered during operation will be noted for future correction. Stop operation immediately if a deficiency is noted which
would damage the equipment or present a safety hazard. All
faults will be recorded together with the corrective actions taken
on the applicable form. Air Force users shall refer to the
applicable inspection manuals and work card sets in the TO
35C2-3-1-426 series for periodic requirements. Marine Corps
users should refer to current issue of TM 4700-15/1. On ASK
equipped generators, full or partial removal of ASK may be
necessary to perform PMCS.
Table 4-1.
INTERVAL
4-9. Determining PMCS Intervals. Organizational
PMCS on this unit should be performed on a - per
hours of operation - basis. The running time meter
on the control panel should be used to determine the
Generator Set operating time.
4-10. PMCS for Units in Continuous Operation. For
PMCS performed on an operating time basis, perform PMCS as close as possible to the time intervals
indicated. For units in continuous operation, perform
PMCS before starting operation if continuous operation will extend service interval past that which is
shown.
4-11. (A. N, MC) Preventive Maintenance Checks and
Services. Table 4-1 contains a tabulated listing of
PMCS which shall be performed by Organizational
personnel. The item numbers are listed consecutively
and indicate the sequence of minimum requirements.
ORGANIZATIONAL PREVENTIVE MAINTENANCE CHECKS AND SERVICES
W-Weekly (40 Hours)
M-Monthly (100 Hours)
H-HOURS (AS INDICATED)
EQUIPMENT IS
PROCEDURES
Not Ready/
Check for and have repaired
Available if:
or adjusted as necessary
Inspect the generator set for
loose or missing components and
hardware, and unusual wear or
deterioration. Clean generator
set.
Note
Fuel system must be
above freezing temperatures when draining
water and sediment
from the strainer,
filters, and tank.
Change 7
4-5
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TABLE 4-1. ORGANIZATIONAL PREVENTIVE MAINTENANCE CHECKS AND SERVICES--continued
para 3-20
para 3-13
fig, 3-1
para 4-20
para 4-20
para 4-20
para 4-25c
para 4-45
4-6
Change 5
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TABLE 4-1. ORGANIZATIONAL PREVENTIVE MAINTENANCE CHECKS AND SERVICES--continued
W-WEEKLY (40 HOURS)
M-MONTHLY (100 HOURS)
INTERVAL
ITEM
NO.
W M
H
ITEM TO BE
INSPECTED
H-HOURS (AS INDICATED)
PROCEDURES
Check for and have repaired
or adjusted as necessary
12
500
Bonding Strap
(Engine to
skid base)
Remove bolts from both ends
of bonding strap (see item 1,
Fig 4-3) and inspect for
corrosion on the bonding strap
or mating surfaces of the
engine and skid base. Clean
surfaces and replace strap.
13
500
Rocker Arm
Covers
Service rocker arm covers
every 500 operating hours
(para 4-44).
14
500
Valve Rocker
Arms
Adjust the rocker arm to proper
valve clearance every 500
operating hours (para 4-46).
Change 9
EQUIPMENT IS
Not Ready/
Available if:
4-6.1/(4-6.2 blank)
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NA\/FAC P-8-622-12
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TM-05682C-12
Section VI. TROUBLESHOOTING
4-12. TROUBLESHOOTING, GENERAL.
This section contains troubleshooting information for locating and correcting operating troubles which may develop in
the Generator Set. Each malfunction for an individual component, unit or system is followed by a list of tests or inspections which will help you to determine probable causes and
corrective actions to take. You should perform the tests/
inspections and corrective actions in the order listed.
4-13. MALFUNCTIONS NOT CORRECTED BY USE OF
THE TROUBLESHOOTING TABLE.
This manual cannot list all malfunctions that may occur, nor
all tests or inspections and corrective actions. If a malfunction is not listed or cannot be corrected by listed corrective
actions, notify your supervisor.
Change 9
4-6.3/(4-6.4 blank)
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NAVFAC P-8-622-12
TO-35C2-3-456-1
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Table 4.2. Troubleshooting
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
1. ENGINE FAILS TO CRANK WHEN MASTER SWITCH IS HELD IN THE START POSITION.
Step 1. Test batteries (paragraph 4-25).
Replace defective batteries. Check battery alternator fuse and replace if necessary.
Step 2. Inspect battery and starter cables for corrosion and loose connections.
Clean or tighten cables.
Step 3. Test “START” position of master switch (paragraph 4-38).
Replace defective master switch.
Step 4. Inspect and test for open starter solenoid switch or for short to ground (paragraph 4-26).
Replace defective solenoid.
Step 5. Inspect and test starter lockout switch (paragraph 4-28).
Adjust switch points if they are not closing or replace defective switch.
2. STARTER TURNS BUT WILL NOT ENGAGE ENGINE.
Step 1. Inspect starter drive assembly (paragraph 4-26).
Clean drive assembly if it is sticking.
Step 2. Inspect starter drive gear assembly for worn or broken teeth (paragraph 4-26).
Replace starter.
9. ENGINE CRANKS NORMALLY BUT FAILS TO START.
Step 1. Test stop solenoid for correct operation (Paragraph 4-23).
Replace bad solenoid.
Step 2. Inspect fuel pumps for clogged strainers (paragraph 4-21).
Replace strainer element.
Step 3. Inspect for clogged fuel strainer element or fuel filter elements (paragraph 4-20).
Clean strainer element; replace fuel filter elements.
Step 4. Check for clogged fuel lines to injector pump.
Clean or replace clogged fuel lines.
Step 5. Test for worn or damaged fuel pumps (paragraph 4-21).
Replace bad pumps.
Step 6. Inspect and test intake manifold heaters (paragraph 4-43).
Replace bad heaters.
4-7
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NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
Table 4-2. Troubleshooting (Cont)
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
3. ENGINE CRANKS NORMALLY BUT FAILS TO START (Cont).
Step7. Inspect and test glow plug assemblies (paragraph 4-48).
Replace bad glow plugs.
4. ENGINE STARTS BUT DOES NOT RUN SMOOTHLY (MISFIRES, KNOCKS, OR MAKES UNUSUAL
NOISES).
Step 1. Check steps 1, 2, 3, 4 and 5 under ENGINE CRANKS NORMALLY BUT FAILS TO
START above.
Perform corrective action as necessary.
Step 2. Check valve to rocker arm clearance (paragraph 4-46).
Adjust clearance if necessary.
5. LOW ENGINE POWER ESPECIALLY UNDER HEAVY LOAD.
Step 1. Check steps 1, 2, 3, 4 and 5 under ENGINE CRANKS NORMALLY BUT FAILS TO
START above.
Perform corrective actions as necessary.
Step 2. Check air cleaner assembly for obstructions (paragraph 4-41).
Remove obstructions.
6. ENGINE HAS EXCESSIVE OIL CONSUMPTION.
Step 1. Check air cleaner element.
Clean or replace element if necessary.
Step 2. Check breather pipe (paragraph 4-45).
Clean or replace breather pipe.
7. LOW OIL PRESSURE.
Step 1. Check oil level (paragraph 4-51).
Add oil if required,
Step 2. Check oil pressure gauge (paragraph 4-33).
Replace a bad gauge.
8. HIGH OIL PRESSURE.
Step 1. Check oil.
Add proper grade of oil.
Step 2. Check oil pressure gauge (paragraph 4-33).
Replace gauge if necessary.
4-8
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NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
Table 4-2. Troubleshooting (Cont)
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
9. ENGINE SHUTS DOWN.
Step 1. Check oil level (paragraph 4-51).
Add proper grade of oil.
Step 2. Check for restricted air cooling system (paragraph 4-41).
Clean restrictions from system.
Step 3. Check for overload on generator.
Keep generator load within set capability.
Step 4. Check low oil pressure switch (paragraph 4-31).
Replace a bad switch.
Step 5. Check thermo over heat switch (paragraph 4-17c).
Replace a bad switch.
10. ENGINE VIBRATES.
Step 1. Engine mounts loose or bad (paragraph 4-52).
Tighten mounting or replace as necessary.
Step 2. Check for loose blower wheel.
Tighten blower wheel.
Step 3. Check valve clearance (paragraph 4-46).
Reset valve clearance.
11. LOW GENERATOR OUTPUT VOLTAGE (NO LOAD).
Step 1. Low engine speed.
Set engine speed to achieve 60 Hz at frequency meter (paragraph 2-4).
Step 2. Check voltage adjust rheostat (R1) setting (paragraph 4-38).
Set rheostat (R1) for proper output voltage.
12. HIGH GENERATOR OUTPUT VOLTAGE (NO LOAD).
Step 1. Check voltage adjust rheostat (R1) setting (paragraph 4-38).
Set rheostat (R1) for proper output voltage.
13. AC CIRCUIT BREAKER (CB1) WILL NOT CLOSE.
Step 1. Check for short circuit load.
Remove short circuit.
4-9
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NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
Table 4-2. Troubleshooting (Cont)
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
14. BATTERIES DO NOT RETAIN CHARGE.
Step 1. Check for blown alternator protection fuse (F1) (paragraph 4-27).
Replace fuse.
Step2. Check for bad battery or batteries (paragraph 4-25).
Replace defective battery.
Section VII. RADIO INTERFERENCE SUPPRESSION
4-14. GENERAL METHODS FOR PROPER SUPPRESSION.
function it is to supress radio interference. The primary suppression components are shown in figure
4-3.
Essentially, suppression is attained by providing a low
resistance path to ground for stray currents. The
methods used include shielding the ignition and highfrequency wires, grounding the frame with bonding
straps, and using filtering systems.
4-15. RADIO INTERFERENCE SUPPRESSION COMPONENTS.
a. Primary Suppression Components. The primary
suppression components are those whose primary
4-10
b. Secondary Suppression Components. These components have radio interference suppression functions
which are incidental or secondary to their primary
function. They are the internal-external tooth lockwashers on the fuel pumps and battery charging regulator-rectifier.
TM 5-6115-584-12
NAVFAC P-8-622-12
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Figure 4-3. Primary Radio Interference Suppression Components (Sheet 1 of 2)
4-11
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
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Figure 4-3. Primary Radio Suppression Components (Sheet 2 of 2)
Section VIII. MAINTENANCE OF ENGINE COOLING SYSTEM
4-17. ENGINE COOLING ASSEMBLY.
4 - 1 6 . DESCRIPTION AND FUNCTION.
The engine has a pressure air cooling system. Fins
on the engine blower draw air into the front of tbe engine housing and force it past the cylinders and out
the right side of the engine. The engine air outlet
uses a shutter assembly to control engine temperature. Part of the air is directed thru the air cleaner
at cold temperatures. A thermo power unit controls
shutter opening which limits air flow when the engine
is cold When the engine air temperature reaches
approximately 120° F (49° C), the shutters begin to
open. The shutters are completely open at 140° F
(60° C). The cooling system contains a high temperature cut-out switch that shuts down the engine
in
can the engine temperature reaches 394°F (201 0C).
4-12
Change 7
lnspection (see figure 3-14). On ASK equipped generators,
refer to para. 5-3 and 5-8 and remove ASK cover and exhaust
plenum assemblies. Check that ASK front panei assembly is clear
of debris.
(1) Check shutters on shutter assembly (4) for
cleanliness and obstructions. Check blower housing
(32) externally and internally at engine blower for
cleanliness and obstructions.
(2) Open panel (12) by opening latches (14) and
check that panel hinge works properly. With panel
open, check engine fins for cleanliness and obstructions to airflow.
b. Removal.
(1) Disconnect negative lead from batteries.
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TM-05682C-12
(2) Air Housing Duct Cover. Loosen hose clamp
(6) and remove air housing duct cover (2) by removing screws (1).
(3) Shutter Assembly. Disconnect wiring to thermal switch at connector plug (5) on outside of shutter
assembly. Remove capscrews (3) attaching shutter
assembly to engine and blower housing (33). Carefully pull shutter assembly (4) away from muffler
(40) until lead from connector (5) to high temperature cutout switch (38) becomes accessible. Disconnect leads from high temperature cutout switch (38)
and remove shutter assembly (4).
(1) and nuts (2). Remove screws (4) and special washer
(5) attaching thermo unit assembly (6) to shutter assembly and remove thermo power unit assembly. Be
careful plunger does not fall out of thermo unit assembly.
(2) Shutters. Remove eight screws (7) and washers
(8) attaching shutters (9 and 10) to bracket assemblies (11, 12 and 13). Remove shutters. Remove nuts
(14) washer (15) and shutter torsion springs (6).
Brackets (12) can now be removed. Remove bracket
bearings (17). Remove screws (19) and remove bearing (17) and washer (18), brackets (11 and 13).
(3) Brackets.
(4) Remove screws (33 and 34) and remove front
shroud (36).
(5) Shroud Assembly. Open latches (14), remove
screws (7), and washers (8), lift panel (9) and shroud
(11) as an assembly from the engine and blower housing (33).
(6) Baffles and Shrouds. Remove rear shroud
(22) by removing screw (17), screw (15), washer (16),
screws (20 and 18) and tie bars (19 and 21). Remove
baffle (25) by removing nuts (23) and J bolt (24).
(7) Blower Grille Assembly. Remove screws (26)
and retainers (27) and remove grille (29).
(8) Blower Housing. Remove screws (30) attaching housing (32) to engine and remove screw (31) attaching housing to oil cooler support bracket. Remove
housing (32).
(9) Refer to paragraph 4-30 and remove oil oooler
and base. Remove screw (33), clip (35), and remove
shroud (36).
c. Cleaning and Testing.
(a) Remove clips (20) that retain lower rod
(21) in bracket (11) and pivot arm (22). Remove lower
rod and bracket (9). Remove bracket bearing, screw
(19) and remove bearing (17) and washer (18).
(b) Remove nut (23), clip (24) and ball arm assembly (25). Remove bracket (12) and associated
bearing (17), washer (18) and screw (19) using procedure as in paragraph (a) above.
(c) Remove pivot arm (22) by removing nut
(26), lockwasher (27), flatwasher (28), washer (29),
bearings (30) and bolt (31).
e. Test.
(1) Thermo Power Unit Assembly. Immerse the
thermo unit into a container of oil while monitoring
the oil temperature. Plunger of thermo unit should
start to extend when temperature reaches 120° F (49°
C). Total extension at 140° F (60° C) should be at least
13/64 inch. Replace thermo unit if it does not operate
properly.
f. Reassembly of Shutter Assembly.
(1) Brackets.
(1) Inspect the engine fins and the housing assemblies for debris and remove as necessary. Clean
using detergent, clean cloth and brush.
(a) Reassemble pivot arm (22) using bolt (31),
bearings (30), washer (29), flatwasher (28), lockwasher
(27) and nut (26).
(2) Disconnect leads and remove high temperature cutout switch from cylinder head. Check continuity
between two terminals while heating switch with its
mounting stud submerged in oil. When the temperature
of the oil reaches 394 ±10° F (201 ±5° C) the switch
should open. Switch should close when temperature
drops below 394 ±1O° F (201 ±5° C). If switch does not
perform as indicated, replace.
(b) Mount bracket (13) to box (32) using bearings (17), lockwasher (18), and screw (19). Be careful
not to confuse bracket (13) with bracket (12). Connect
ball arm assembly (25) to bracket (13) and pivot arm
(22) using clip (24) and nut (23).
d. Disassembly of Shutter Assembly (see figure
4-4).
(1) Shutter Thermo Power Unit Assembly. Remove electrical comector (3) by removing screws
(c) Mount bracket (11) along with bearing (17),
lockwasher (18) and screw (19). Ensure that bracket
is mounted so that shutter divider acts as inside stop.
Mount lower rod (21) to bracket (11) and pivot arm
(22) using clips (21).
(d) Install brackets (12), bearings (17) and lockwasher (18). Ensure that lower bracket is mounted so
that shutter divider acts as inside stop.
4-13
TM5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
Figure 4-4. Shutter Assembly
4-14
Change 2
TM5-6115-584-12
NAVFAC P-8-622-12
TO-33C2-S-4S6-1
TM-05682C-12
(2) Install power unit assembly (6) into shutter
assembly box (32) using screws (4) and special washer
(5). Mount connector (3) using screws (1) and nuts (2).
(3) Shutters. Mount torsion spring (16) using nut (14)
and washer (15). Mount shutters using screws (7) and
washers (8). Ensure that adequate clearance between
shutter and shutter box sides is maintained and that
brackets (12) are seated againat shoulder of bearing (17)
prior to tightening Screws (7). Check shutter to ensure
they will fully open and close without binding.
g. Adjustments.
(1) Shutters (see figure 4-5). Disconnect ball
joint from upper shutter. Adjust ball joint until upper
shutter closes tightly on lower shutter when lower
shutter is held closed. Re-attach ball joint to upper
shutter.
(2) Thermo Unit be figure 4-6). With Generator
Set at 70° F, (21°C) loosen thermo unit guide mounting
screws, the mounting holes in the shutter box are
slotted. Slide the assembly to a position where the
thermo unit plunger rests on roll pins with shutters
closed. Tighten mounting screws.
h. Installation (see.figure 3-17).
(2) Blower Housing. Install blower housing (32)
on engine using screws (30 and 31).
(3) Blower Grille Assembly. Install grille (29)
on blower housing (32) using screws (26) and retainers (27). (For units without ASK.)
(4) Baffles and Shrouds. Install shroud (22) using
screws (15 and 17) and washer (16). Install rear shroud
(36) using screw (33), clip (35) and screw (34). Install
baffle (25) with hook bolt (24) and nut (23).
(5) Shroud Assembly. Install door panel (12) and
shroud (11] as an assembly to the engine and blower
housing (32) using screws (7) and washers (8). Close
latches (14).
(6) Shutter Assembly. Install shutter assembly (4)
on engine and blower housing (32) using capscrews (3).
Connect connector plug to thermo unit connector
receptacle (5).
(7) Air Housing Duct Cover. Mount air housing
duct cover (2) to shutter assembly (4) using screws
(1). Connect air intake hose to duct cover using hose
clamp (6).
(1) Install oil cooler and base as described in
paragraph 4-28. Install shroud (36), clip (35) and screw
(33).
(8) On ASK equipped generators, refer to para 5-3
and 5-8 and replace ASK cover assembly and exhaust
plenum.
Figure 4-5. Adjusting Shutters
Figure 4-6. Adjusting Thermo Unit
Change 7
4-15
TM5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
Section IX. MAINTENANCE OF FUEL SYSTEM
4-18. DESCRIPTION AND FUNCTION.
a. Low Pressure System (see Schematic figure
1-5).
(1) Fuel pump may draw fuel from an external
source to fill set tank or set tank may be filled manually. If an external fuel source is selected, a float
valve assembly in the set tank maintains the fuel
level in the tank. Two other fuel pumps (in series)
draw fuel from the set tank and force the fuel through
a primary strainer, two filters, and a check valve
assembly, to the injection pump.
b. High Pressure System.
(1) Fuel tnjection pump forces the fuel, under
high pressure, to the fuel injection nozzles. The injection nozzles provide fuel to each combustion
chamber of the engine. Unused fuel is returned from
the injectors to the fuel tank. A cam and gear on the
camshaft drives the fuel injection pump. The gear
drives the pump face gear, providing fuel distribution
to each cylinder in the proper order. The cam operates the pump plunger, pressurizing fuel to the nozzles. A control sleeve meters fuel by controlling the
length of time the plunger spill port is closed, maintaining pressure, and therefore, the amount of fuel
delivered in each stroke. The pintle type injection
nozzles are conventional inward opening with adjustable opening pressure. They are factory adjusted
t o open at 1900 to 1950 psi.
4-19. FUEL TANK ASSEMBLY,
a. Inspection on Equipment. Refer to paragraph
3-13a.
b. Removal (see figure 4-7). Drain fuel into suitable container
by opening drain valve. Tag and disconnect fuel hoses from fuel
tank fittings. Disconnect electrical lead from electrical connector
(10). Remove nut (1) and flatwasher (2) from straps (3) on outside
of fuel tank. Remove tank from skid-base. On ASK equipped
generators, remove top panel, left side panel and side closure
(Refer to paragraphs 5-4, 5-5, and 5-12).
c. Disassembly.
(1) Fuel Level Gauge. Unscrew and remove fuel
level gauge (5) using tools only on the hex portion of
the gauge.
(2) Float Switch. Unscrew collar and disconnect
electrical connector (10) if not previously disconnected. Unscrew and remove float switch (6) using
tools only on the square portions of the switch.
(3) Unscrew and remove fittings (7).
(4) Holding pipe adapter (11) with a wrench, unscrew and remove drain valve (8).
4-16
Change 7
(5) Loosen filler cap and remove filler cap (4) and
strainer (5).
d. Cleaning and Inspection.
(1) Tank. Clean tank exterior using suitable solvent and clean cloth and brush. Inspect tank for
signs of physical damage. If damaged refer to higher
level of maintenance.
(2) Fuel Level Gauge. Check that fuel level gauge
face is clean and readable. Check that as cork float
is moved up and down, the meter movement rotates.
(3) Float Switch. Inspect terminal connector for
damage to threads. Check to see that float slides on
shaft without binding. Clean with suitable solvent if
required.
(4) Fittings. Inspect fittings for good leak-free
seating on tank and check threads for physical damage.
(5) Fuel Drain Valve Assembly. Check that drain
valve does not leak and threads for physical damage.
e. Test.
(1) Float Switch. Remove float switch (6) from
tank (9). Using an ohmmeter, check for continuity
between terminals A and B of Switch (see figure
4-8). Switch should show no continuity when float is
up. Switch should close when float drops to 2-7/8
±3/16 inch from threaded collar of float switch. Replace switch if it does not operate properly.
(2) Tank. If tank shows signs of physical damage or leaks refer to higher level of maintenance.
f. Reassembly (see figure 4-7).
(1) Fuel Drain Valve. Engage threads of fuel
drain valve assembly (8) 1/2 turn into fuel tank
adapter (11). Coat threads with sealing compound
MIL-S-22473. Tighten valve assembly into adapter
(11).
(2) Fittings. Engage threads of fitting (7) l/2 turn
into fuel tank (9). Coat threads with sealing compound MIL-S-22473. Tighten fittings into tank. Fittings should face Generator Set for proper connection
of fuel lines. Attach fuel lines to fittings.
(3) Float Switch. Engage threads of float switch
(6) 1/2 turn into tank (9). Coat threads with sealing
compound MIL-S-22473. Tighten float switch (6) into
tank using tools only on square portion of switch. Attach electrical lead to connector (10) on top of float
switch and tighten.
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
Figure 4-7. Fuel Tank Assembly
(4) Fuel . Level
. . . Gauge. Engage threads of fuel
level gauge (5) 1/2 turn into tank (9). Coat threads
with sealing compound MIL-S-22473. Tighten float
level gauge into tank using tools only on hex portion
of gauge. Install filler cap (4) and strainer (5) into tank
(9).
g. Installation.
(1) Install straps (3) onto the skip-base and secure with
nut (1) and flatwasher (2) on inside of skid-base only.
(2) Position fuel tank assembly onto skid-base, position
straps over tank assembly and secure with nut (1) and flatwasher
(2). “On ASK equipped generators, install side closure, left side
panel, and top panel (refer to paragraphs 5-12, 5-5 and 5-4).
(3). Check that drain valve is closed before filling
tank with proper grade of fuel.
NOTE
After each time fuel filters or strainer is
drained or elements replaced, purge air from
fuel system by moving master switch on control panel to PRIME & RUN position. This
should activate the f u e l t r a n s f e r p u m p a n d
force trapped air back to the vented fuel tank.
4-20. FUEL FILTER ASSEMBLIES AND STRAINER
ASSEMBLY.
There are two identical fuel filter assemblies (see
figure 3- 13), one which acts as the primary and the
Change 7
4-17
TM 5 - 6 1 1 5 - 5 8 4 - 1 2
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
Figure • 4-8. Testing Float Switch
other as secondary, plus there is one fuel strainer. If these filters
or leaking fittings and hoses, leaking valves and leakor strainer are plugged, fuel flow will be restricted and the engine
ing at bowl and head interface.
may not run properly, Periodic maintenance is required for this
assembly.
b. Service.
a. Inspection (on Equipment), On ASK equipped generators,
remove FUEL FILTERS access door,
(1) Fuel Filters (see figure 4-9). On ASK equipped generators, remove tight panel assembly (para 6-6). Remove plug (1),
(1) Fuel Filter Assemblies and Strainer Assembly. Inspect
open drain cock (2) and drain fuel Into suitable container. Remove
the assembly for secure mounting, loose or leaking fittings and
bolt assembly (3), gasket (4) and filter body (5). Remove filter elehoses, leaking valves and leaking at bowl and head interface.
ment (6) and gasket (7), Inspect element for ruptures, clogs or other
4-18
Change 7
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
1. Nut (4)
2. Flatwasher (4)
3. Srap (2)
4. Filler cap
5. Strainer
6. Fuel gauge
7. Float switch
8. Fitting (3)
9. Drain valve
10. Fuel tank
11. Connector
18. Adapter
TS 6115-584-12/4.7
Figure 4-7. Fuel Tank Assembly
(4) Fuel Level Gauge. Engage threads of fuel
level gauge (5) 1/2 turn into tank (9). Coat threads
with sealing compound MIL-S-22473. Tighten float
level gauge into tank using tools only on hex portion
of gauge. Install filler cap (4) and strainer (5) into tank
(9).
g. Installation.
(1) Install straps (3) onto the skid-base and secure with nut (1) and flatwasher (2) on inside of skidbase only.
(2) Position fuel tank assembly onto skid-base.
position straps over tank assembly and secure with
nut (1) and flatwasher (2).
(3) Check. that drain valve is closed before filling
tank with proper grade of fuel.
NOTE
After each time fuel filters or strainer is
drained or elements replaced, purge air from
fuel system by moving master switch on control panel to PRIME & RUN position. This
should activate the fuel transfer pump and
force trapped air back to the vented fuel tank.
4-20. FUEL FILTER ASSEMBLIES AND STRAINER
ASSEMBLY <
There are two identical fuel filter assemblies (see
figure 3-13), one which acts as the primary and the
4-17
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
Figure • 4-8. Testing Float Switch
other plus there is one fuel strainer.
If
these filters or strainer are plugged, fuel flow will be
restricted and the engine may not run properly.
Periodic maintenance is required for this assembly.
a. Inspection (on Equipment).
(1) Fuel Filter Assemblies and Strainer Assembly. Inspect the assembly for secure mounting, loose
4-18
or leaking valves and
ing at bowl and head interface.
leak-
b. Service.
(1) Fuel Filters (see figure 4-9). Remove plug
(1), open drain cock (2) and drain fuel into suitable
container. Remove bolt assembly (3), gasket (4) and
filter body (5). Remove filter element (6) and gasket
(7). Inspect element for ruptures, clogs or other
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
Figure 4-9. Fuel Filter
Figure 4-10. Fuel Strainer Element
physical damage. Replace element if necessary.
Change primary element every 500 operating hours,
and secondary filter elements every 1000 operating
hours. Replace filter element (6), gasket (7), filter
body (5), gasket (4), and bolt assembly (3). Close drain
cock (2) and install plug (l).
(2) Fuel Strainer Element (see figure 4-10).
Open drain valve (4) and drain fuel into suitable container. Remove nut (1) and washer (2) attaching body
(5) to head (10) and remove body and gasket (9). Remove retainer (6) and remove strainer element (7).
Inspect element for physical damage or clogging.
4-19
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
heat. Flash point of solvent is 100° F to 138°F
(38°C to 59°C).
Clean parts in a well-ventilated area. Avoid
inhalation of solvent fumes and prolonged exposure of skin to cleaning solvent. Wash exposed skin thoroughly. Dry cleaning solvent
(Fed. Spec P-D-680) used to clean parts is
potentially dangerous to personnel and property. Do not use near open flame or excessive
Every 300 operating hours, clean strainer element
(7) by soaking in dry cleaning solvent (Fed. Spec
P-D-680) and dry thoroughly using a clean dry cloth.
Replace strainer element (7) on stud (3) and secure
with retainer (6). Position gasket (9) and body (5) on
head (10) and secure with washer (2) and nut(1).
Close drain cock (4).
Figure 4-11. Fuel Filters and Fuel Strainer Assembly
4-20
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
c. Removal.
(1) Fuel Filter Assembly (see figure 4-11). Drain
fuel into a suitable container by opening drain valve
(1). Disconnect feul lines (2, 3 and 4) and drain fuel
lines. Remove elbow (5), check valve (6) and coupling (7). Plug fuel lines to prevent accumulation of
foreign material.
(2) Remove screws (8) and lockwasher (9) attaching each filter assembly (10) and strainer assembly (11) to mounting bracket and remove filter or
strainer assembly. Remove inlet and outlet fittings
(12). Be careful when removing fittings not to damage housing.
(3) Remove nuts (13), lockwashers (14), screws
(15) and remove bracket (16).
(4) Inspect check valve (6) for cleanliness. Using a clean punch depress check valve from seat (opposite end of arrow) and check for free movement
and reseating upon release. Replace check valve if
it does not move freely.
d. Installation.
(1) Position bracket (16) on frame and secure
with screws (15), lockwashers (14) and nuts (13).
(2) Position fuel filter assembly (10) or fuel
strainer (11) on bracket (16) and secure with lockwashers (9) and screws (8).
hoses clean and plug to prevent contamination. Disconnect electrical connector (22) at solenoid valve (6).
(2) Fuel Pumps. Tag and disconnect electrical
lead from each fuel pump at connector on wiring
harness. Remove nuts (7), lockwashers (8 and 11) and
screws (9) attaching each pump (12 and 13) and pump
lead (10) to bracket (21) and remove pumps.
(3) Remove solenoid valve (6) from fittings (16
and 17) and remove fitting (5) from solenoid valve.
(4) Remove fittings (14, 15, 16 and 17) from fuel
pumps. Remove nuts (18), Iockwasher (19), screw (20)
and remove bracket (21).
d. Installation.
(1) Position bracket (21) on frame and secure
with screws (20), Iockwashers (19) and nuts (18).
(2) Install fuel fittings (17, 16, 15, 14 and 5) in
fuel pumps (12 and 13).
(3) Turn solenoid valve (6) onto fuel pump outlet
fittings (16 and 17) and position on fuel pump as shown
in figure 4-12.
(4) Install fuel pumps (12 and 13) on bracket (21)
and secure with screws (9), washers (8 and 11) and
nuts (7). Reconnect electrical leads to wiring harness
and fuel solenoid valve.
(5) Install and tighten fuel hoses (4, 3, 2 and 1).
(3) Install coupling (7), check valve (6) and elbow
(5) on fuel line (4). Make sure arrow on check valve
points toward coupling (7).
(4) Connect fuel lines (4, 3 and 2). Tighten drain
valve (1) in each filter assembly and strainer assembly.
(5) On ASK equipped generators, install right panel assembly
(para. 5-6).
4-21. ELECTRIC FUEL P U M P S . F U E L A N D
AUXILIARY SOLENOID VALVE.
a. Testing on Equipment. Perform operational test
for each pump individually. Each pump should pump
at 6 to 7 psi as registered on an accurate fuel pressure gauge. Connect fuel pressure gauge to output
port of pump. Turn master switch to PRIME A N D
RUN position. pressure gauge should register 6 to 7
psi. Replace defective pumps.
b. Service (see figure 4-13). On ASK equipped generators,
remove fuel access door. Remove cover (1), gasket (2) and
strainer (3). Be careful not to lose magnet (4). Every 500 operating hours replace gasket (2) and strainer (3) in both main
pumps and auxiliary pump. Ensure that chamfered surface of
magnet (4) is up prior to installation of new strainer and gasket.
c. Removal (see figure 4-12).
(1) Fuel Roses. Tag and remove fuel hoses (1, 2,
3 and 4) by unscrewing at fittings (5, 15 and 16). Keep
4-22. AUXILIARY FUEL SOLENOID VALVE.
a. Test on Equipment. On ASK equipped generators, remove
fuel access door and perform the following procedures:
(1) Ensure output pressure of auxiliary fuel pump
is 6 to 7 psi and fuel level in set tank is below 1/2
full. Disconnect harness at solenoid valve connector.
Place master switch in PRIME RUN and AUX position.
Ensure voltage between points A and B on harness
connector is 24 VDC. Reconnect harness to solenoid
valve. Test output pressure at output side of solenoid
valve. Pressure should be same as output pressure
of auxiliary fuel pump, if not replace solenoid valve.
(2) With 24 volts dc applied across solenoid terminals A and B, the solenoid should draw approximately 1/2 ampere, if not replace solenoid valve.
4-23. FUEL SHUT-OFF SOLENOID
a. Inspect (on Equipment) (see figure 4-14). On ASK equipped
generators, remove right panel assembly (para 5-6). Check that
electrical connections (1) are secure and clean. Check that rubber boot (11 ) is clean and not broken. Check that governor and
pump linkage moves freely and is clean.
b.
Test (on Equipment) (see figure 4-15).
(1) Tag and remove the solenoid harness leads
(1). Figure 4-14.
Change 7
4-21
TM 5-6115-584-12
NAVPAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
Figure 4-12. Fuel Pump, Fuel Hoses and Solenoid
4-22
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
e. Adjust. The solenoid plunger (3) should be adjusted so it
fully stops Injection when In the de-energized position. With
engine running at full rated bad, clearance between plunger (3)
and control arm (4) should be at least 1/8 inch. To adjust the
plunger length, turn the knurled head screw (5) and jam nut (6)
on bottom of plunger. On ASK equipped Generator Sets, install
right panel assembly (para. 5-6).
1.
2.
3.
4.
5.
Cover
Gasket
Strainer
Magnet
Fuel pump
TS
6115-58412/4-13
Figure 4-13. Fuel Pump
(2) Check for continuity between terminals of the
fuel shut-off solenoid. If continuity is not obtained, the
unit is unserviceable.
(3) Check for ground between fuel shut-off solenoid
terminals and ground. If terminals are grounded, the
unit is unserviceable.
(4) Connect the solenoid into test set-up (fig 4-15).
(5) With switch (S1) closed, the plunger should actuate and the currant draw should be 0.25 ampere dc.
(6) If plunger does not actuate or, if meter reads
above 0.35 ampere, replace solenoid.
c. Remove (see figure 4-14). Tag and disconnect
harness leads (1). Remove the shut-off solenoid by
removing screws (9) and lockwashers (10).
d. Installation. Mount shut-off solenoid using screws
(9) and lockwashers (10). Reconnect previously tagged
and removed harness wires (1).
Figure 4-14. Adjusting Fuel Shut-Off Solenoid
Change 7
4-23
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
Figure 4-15
Section X. MAINTENANCE OF ENGINE ELECTRICAL SYSTEM
4–24. DESCRIPTION AND FUNCTION
a. The engine is cranked by a 24 volt electric
starting motor (see figure 1–7). When starting motor
solenoid is energized, the solenoid core pulls in, shifting the pinion gear into engagement with the engine
flywheel ring gear. At the same time, contacts in the
solenoid close to provide a circuit for the starter. The
starting motor is protected from overspeeding by an
overrunning clutch. Two 12 volt batteries in series are
used. The starting switch for this starting circuit is located in the control cubicle, A blower wheel alternator
is utilized to maintain the battery charge. The stator is
mounted on the engine block and the permanent magnet rotor is mounted into the air cooling system blower.
Solid state diode rectifiers convert the alternating current generated in the stator to direct current for battery
charging.
b. Anew (Style II) gear–reduction electric starter
will be installed on engines manufactured during 1990;
and will be available as a replacement when the original starter, (Style 1) is no longer available. The Style II
starters are interchangeable with the Style I starter.
4-25. BATTERY ASSEMBLY.
Metal objects making contact between the positive and negative
4-24
Change 10
battery terminals, or between the
positive battery terminal and the generator frame can cause FIRE or
EXPLOSION . Always keep the battery terminal covers on the battery
terminals. See Figure 3-23.
a. Battery Cables (Including Jumper Cable) (see
figure 4–1 6). On ASK equipped generators, remove
BATTERIES access door.
(1) Test. Test battery cable for continuity. Replace any cable that does not show continuity.
(2) Remove. Remove negative battery cable
from negative (–) battery terminal. Remove positive
(+) battery cable from positive battery terminal.
Tag and disconnect cables from starter case and
starter solenoid. Remove jumper between batteries.
Clean battery, starter, and starter solenoid terminals
thoroughly and install new cables as given below.
(3) Replace. Attach jumper cable between
negative (–) terminal of one battery and positive (+) terminal of the other battery. Attach positive battery cable
to the “B” Terminal stud on starter solenoid. Attach
negative battery cable (-) to the ground terminal “G” of
the starter. See figure 4-16. Attach positive cable (+)
to positive terminal on one battery and negative cable
(-) to negative terminal on the other battery. Tighten all
terminal connectors securely.
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
Figure 4–16. Installing Battery Cables.
Change 10
4-25
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
NOTE
Always detach negative (–) cable first
and reattach it last.
b. Battery Top (Hold–down) Frame (see figure
3-23).
(1) Remove. Tag and disconnect battery cables (10) and jumper cable (11 ) from batteries (1).
Remove six nuts (4) and flatwashers (5) holding top
frame (2) in place, and remove top frame. If hook bolts
(3) do not need replacing, they need not be removed
from frame (6).
(2) Replace. Hook six bolts (3) onto bottom
frame (6). Place top frame (2) over batteries (1) making certain hook bolts slide through the top frame.
Secure top frame in place with six flatwashers (5) and
nuts (4). Reattach battery cables (10) and jumper cable (11).
(3) Repair. Straighten battery top frames
making certain they fit securely over batteries and hold
batteries in place.
c. Storage Batteries.
Figure 4–17. Testing Batteries
4-26. ENGINE STARTER ASSEMBLY,
a. Test. On equipment (see figure 4–1 9). On
ASK equipped generators, remove BATTERIES access door.
Battery electrolyte can cause severe
burns to the skin. Always flush exposed parts of the skin with water as
quickly as possible.
(1) Make sure batteries are fully charged and
that all battery and starter cables are serviceable and
properly installed. Disconnect all starter to solenoid
connection.
(1) Test. Charge battery for a sufficient time
for battery to be fully charged (1 to 2 hours). Test each
cell of battery separately using a hydrometer. Remove
cap from one cell and draw fluid from that cell into hydrometer. Hydrometer must register a specific gravity
of 1.260 to 1.280. If specific gravity is below 1.260,
charge battery. See figure 4–17. Replace fIuid into cell
and replace cap. Check each battery cell using this
procedure. If one or more cells in a battery will not take
a charge, replace battery.
(2) Connect voltmeter as shown in figure
4–19, Test a. If voltage is indicated, solenoid is defective. Proceed to step (4).
(3) Reconnect all starter to solenoid connections. Connect voltmeter as shown in figure 4–19, Test
a. If battery voltage (24 volts) is not indicated, the
starter (B1 ) may be defective. Proceed to step (4).
(2) Remove. Remove battery cables and top
frames, a and b above. Remove batteries from battery
frame.
(4) Momentarily connect a jumper as shown
in figure 4–19, Test b. Voltmeter reading should drop
to zero and starter should crank engine. If voltmeter
reading does not drop to zero, solenoid is defective. If
voltmeter readings drop to zero but starter fails to crank
engine, starter is defective.
(3) Replace. Place batteries in battery frame
with negative (-) terminals toward control panel end of
generator and positive (+) terminals toward blower
housing end of generator. Install battery top frame and
battery cables as outlined above.
b. Removal (see figure 4-18). On ASK generaTag and
tors remove batteries access door.
disconnect leads (1) thru (6). On Style I Starters, remove nut (7), Iockwasher (8), screw (9). Loosen but do
not remove screw (1 0), Iockwasher (11) and swing
4-26
Change 10
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
Figure 4–18. Engine Starter Installation
Change 10
4–27
TM S-6115-584-12
NAVFAC P-6-622-12
TO-35C2-3-456-1
support bracket (12) down and away from starter. On
Style II Starter, support bracket is not fastened to the
starter, loosen screw (10), Iockwasher (11) and swing
support bracket down and away.
NOTE
Support bracket and associated hardware must remain with engine at all
times! It provides support for Style I
Starters that may be used to replace
Style II Starters during Operator and
Organizational maintenance. The
support bracket and associated hardware is supplied on all engines
manufactured with either the Style I or
Style II Starters.
Support starter (15) and remove screws (13), lock
washers (14) attaching starter to flywheel housing
(17). Slide starter out of housing.
c. Cleaning and Inspection of Starter Brushes
Solenoid and Drive.
(1) Cleaning Starter. Refer to paragraph
3-16a.
(2) Inspecting Solenoid Switch.
(a) Style I Starter. Refer to figure 4-22.
Inspect solenoid switch (1) for cracks, dents, or other
physical damage. Check to see that the electrical terminals are clean and free of corrosion. Check that the
rubber boot (2) on plunger (3), cotter pin (4), clevis pin
(5), and yoke (6) are in good condition. Check that
plunger (3) and yoke (6) operate freely. Check that solenoid switch (1) is securely fastened to the starter
motor (8), with screws (14).
(b) Style II Starter. Refer to figure 4-22A.
Inspect solenoid switch (3) for cracks, dents, or other
physical damage. Check to see that the electrical terminals are clean and free of corrosion. Check that
solenoid switch (3) is securely fastened to the starter
motor (4), with screws (1).
(3) Inspecting Drive Assembly. Refer to figure 4-22 for Style I Starter and figure 4-22A for Style II
Starter. Inspect drive gear for cracks or chipped teeth.
Check that gear and spring of drive moves freely, and
returns to rear position when released.
(4) Inspecting Brushes.
4-28
Change 10
(a) Style I Starter. Refer to figure 4-21.
Remove two through bolts (1) and lift end plate (2)
away from frame. Lift brush tension springs (3) and lift
each brush (4) from holder for inspection. Check brush
face for deep surface pits, cracks, or excessive chipping. Measure brush length. See figure 4-21. When
brush is worn to length less than 1/4 inch, notify higher
level maintenance for replacement of brushes (4).
Clean area around brushes and commutator and dry
with low pressure compressed air. Lift brush springs
(3) and insert brushes (4) in brush holder. Reposition
end plate (2) on frame and insert and tighten through
bolts (1) securely.
d. Bench Test.
(1) Starter Assembly. Refer to paragraph
4-26a.
(2) Field Coil. Connect continuity tester as
shown In figure 4-19, Test c. An open circuit indicates
a defective field coil.
Test for continuity between field coil lead and field
frame as shown in figure 4-19, Test d. Continuity indicates that the field coil is shorted to the field frame.
(3) Field Coil. Style II Starter.
(a) Connect tester for continuity between
the field coil brushes as shown in figure 4-20, Test C.
An open circuit indicates a defective field coil.
(b) Connect tester for continuity between
afield brush and stator frame as shown in figure 4-20,
Test D. Continuity indicates that the field coil is shorted
to the frame.
e. Repair. Style I Starter.
(1) Remove Solenoid. If solenoid is defective,
remove as follows: Refer to figure 4–22. Remove nut
and Iockwasher holding lead (12) on small solenoid
switch terminal. Remove nut and Iockwasher from
negative terminal (9) freeing lead (12). Remove nut
and Iockwasher from solenoid field terminal (11). Remove cotter pin (4) and clevis pin (5) from plunger (3)
and yoke (6). Remove screws (14) and lift solenoid
switch (1) from frame (8). Retain hardware from terminals for solenoid installation.
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
Figure 4-19. Testing Engine Starter
Change 10
4-28.1
TM 5-6115-584-12
NAVFAC P-8-622-12
TO 35C2-3-456-1
Figure 4-21.
4-28.2
Change 10
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
Figure 4–21 A. Inspecting Starter Brushes, Style II Starter
(2) Install Solenoid. Refer to figure 4-22.
Place solenoid (1) on frame (8) and move to rear until
field terminal (11) enters field coil lead strap. Install nut
and Iockwasher, do not tighten. Install screws (14), do
not tighten. Align the plunger (3) on yoke (6) and insert
clevis pin (5) and secure with cotter pin (4). Install lead
(12) on small solenoid terminal and on negative terminal (9) Secure with nuts and Iockwashers. Tighten nut
and Iockwasher on field terminal (11), and screws (14)
f. Repair. Style II Starter.
(1) Remove Solenoid. If solenoid is defective, remove as follows: Refer to figure 4–22A.
Remove nut and Iockwasher on terminal (M) freeing
lead (L). Remove screws (1), solenoid switch (3) and
Spacers (2). Retain hardware from terminal (M).
g. Install Starter. Refer to figure 4–18. Slide
starter into opening in flywheel housing (17). Make
certain starter lies flat against housing, Attach starter
to housing with screws (13) and Iockwashers (14). For
Style I Starter, swing support bracket (12) into position
at back of the starter, and attach with screw (9), nut (7)
and Iockwasher (8). Tighten screw (1 0) and lock
washer (11) securing support bracket (12) to engine
block. Replace tagged leads per diagram, figure 4-18.
Remove tags.
4–27. BATTERY CHARGING ALTERNATOR.
a. Battery Alternator Stator (see figure 4-23).
On ASK equipped generators; remove ASK cover assembly (para 5-3).
(1) Remove blower housing (see paragraph
NOTE
Solenoid mounting screw removal
may require the use of an impact type
driver.
(2) Install Solenoid. Refer to figure 4-22A.
Support new solenoid (3) and original spacer(s), engage solenoid plunger on Iever(yoke), secure using
new screws (1).
4-17).
(2) Inspect. The presence of the blower
wheel limits inspection of the battery alternator to inspecting that two leads (1) from stator (2) are free of
damage and are not rubbing against blower wheel and
are securely connected to terminal block (3) located on
engine back plate (4).
Change 10
4-28.3
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
Figure 4-22.
Figure 4-22A.
4-28.4
Change 10
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
Figure 4–23. Battery Charging Alternator
Avoid contact with blower wheel while
testing battery alternator voltage.
(3) Test.
Do not operate unit more than 3 minutes with blower housing removed.
(a) Tag and disconnect stator lead (1) from
stator at terminal block (3) Check between two stator
leads for approximately 0.6 ohms continuity. If open or
shorted, notify higher level of maintenance. Check for
continuity between each lead and ground. If continuity
is found, notify higher level of maintenance.
(b) With the stator leads (1) disconnected,
check voltage across two leads (1) from stator. Voltage
should be in a range of 30-35 volts AC with the engine
operating normally at 1800 RPM, If voltage is less than
30 volts AC, stator on magnets in rotor maybe defective. Refer to higher level of maintenance for
replacement of stator or rotor. Reconnect stator leads
(1).
Change 10
4-29
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35iC2-3-456-1
(2) Test.
(a) Test stator as given In paragraph
4-27a above to see that it is operating correctly.
Avoid operation of Generator Set for
more than 3 minutes with engine
blower housing removed, as engine
will overheat.
b. Battery Charging Regulator/Rectifier Assembly (see figure 4-23).
(1) Inspect. Inspect regulator/rectifier assembly (5) for physical damage. Check that leads from
assembly to terminal block (3) are not damaged or
frayed. Check that assembly is securely mounted to
engine back plate (4).
4-30
Change 10
(b) Remove fuse (9, figure 4-23) and connect a 10 amp ammeter across the fuse holder
terminals as shown in figure 4–24. With engine operating normally at 1800 RPM, charge rate should be no
less than 6.5 amps when loaded by a discharged battery. Charge rate should taper-off as battery becomes
charged.
NOTE
Observe proper polarity when making
current test.
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
Figure 4-24. Testing Battery Charging Regulator/Rectifier Assembly
(3) Remove (see figure 4-23). Disconnect and tag
leads on regulator/rectifier assembly. Remove screws
(7), washers (8) and nuts (6) attaching assembly to
engine back plate and remove assembly.
(1) Inspect. Inspect terminal block (3) for physical damage. Check that electrical connections to block
are clean and tight. Check that block is securely
fastened to engine back plate (4).
(4) Replace. Attach assembly to engine back plate
with three screws (7), six lockwashers (8), and three
nuts (6). Attach tagged leads from assembly.
(2) Test. Tag and disconnect leads to terminal
block. Check to see that there is no continuity between terminals on terminal block and ground.
c. Battery Charger Circuit Fuse (see figure 4-23).
(1) Inspect. Inspect fuse (9) for physical damage.
Check that end caps on fuse are free of corrosion.
Check that fuse is properly mounted in fuse holder.
(2) Test. Test fuse (9) for continuity using an
ohmmeter. Replace fuse that does not show continuity.
(3) Replace. Remove fuse holder cap and remove
fuse. Install new fuse in fuse holder body and attach
fuse holder cap.
d. Terminal Block (see figure 4-23).
(3) Replace. Tag and disconnect leads at terminal block.
Remove two screws and nuts attaching block to engine plate and
remove block. Attach new terminal block to engine back plate with
two screws and nuts. Connect previously tagged leads to terminal
block. Remove tags. On ASK equipped generators, install ASK
cover assembly (para 5-3).
4-28. STARTER LOCKOUT SWITCH AND GEAR
ASSEMBLY.
On ASK equipped generators, remove oil access door.
a. Inspect (see figure 4-25). Disconnect negative
battery cable. Remove wing nut (1) and cover (3) and
inspect switch contact points between contact spring (15)
and adjusting screw (14) for physical damage.
b. Test. With engine off, disconnect switch at
connector (8). Using an ohmmeter, test that there is
Change 7 4-31
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
Figure 4-25.
Starter Lockout Switch and Gear Assembly
continuity between connector (8) pins A and Bon lead
from switch. Reconnect switch, operate engine at
operating speed disconnect connector (8) and
between pins A and B On switch, check that switch is
open (no continuity).
4-32
Change 3
c. Remove. Disconnect switch lead from connector
(8). Remove two screw (9) and lockwashers (10)
attaching switch to engine back plate. Carefully remove switch taking care not to lose thrust plunger
TM 5-6115-584-12
NAVPAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
(20) and spring (12). Slide gear (5) out through
opening in engine back plate. Clean any gasket (13)
material from switch and back plate.
d. Repair. Repair starter lockout switch by replacing parts found to be defective under inspection
e. Replace. Make certain spacer (16) is on shaft
and slip timing gear (5) through opening in engine
back plate. Make certain that shaft seats properly in
gear cover and that gear teeth are properly meshed.
Place thrust plunger (20) and spring (12) in gear
shaft. Slide switch and gasket (13) over shaft and
attach to engine back plate with two screws (9) and
Iockwashers (10). Use a new gasket (13) between
switch and engine back plate. Reconnect electrical
connector (8).
f. Adjust. With engine stopped, remove cover retaining wing nut (1) and remove cover (3). Turn
adjusting screw (14) clockwise until points open.
Turn adjusting screw counterclockwise until points
just C lOSe (see figure 4-26). Start engine and disconnect switch from wiring harness at connector (8,
figure 4-25). Adjust adjusting screw for a 0.040 point
gap. Replace cover (3) and wing nut (1). Reconnect
connector (8).
Be sure two wires are recessed in slot of
housing before tightening cover down.
Figure 4-26. Adjusting Starter Lockout Switch
Section XI. MAINTENANCE OF OIL SYSTEM
4-29. FUNCTION AND DESCRIPTION
The diesel engine has pressure Iubrication to all
working parts (see figure 4-27). The oil system
includes oil intake cup, gear type oil pump, bypass
valve, oil pressure gauge, low oil pressure shutoff,
full-flow oil filter, oil coder, and passages to deliver oil throughout the engine. Oil is held in the oil
base, and forced through the oil filter and oil cooler
by the pump. Lines leading to the rocker housing,
passages through the block to crankshaft and front
camshaft bearing, crankshaft passages to connecting
rod bearings and connecting rod passages to piston
pin bushings complete the oil system network The
bypass valve controls oil pressure by allowtng excess
oil to flow directly back to the crankcase.
4-30. OIL COOLER
a. Inspect (see figure 4-28). On ASK equipped generators,
remove ASK cover assembly (para 5-3). Inspect oil cooler (1)
for physical damage. Visually check for leaks where oil cooler
is connected to oil hoses (figure 4-29). Check that cooler Is
securely fastened to mounting plate (2, figure 4-28) and that
plate is securely fastened to engine. Inspect all hoses for
leaks and physical damage. Inspect seal (1A, figure 4-28)
and replace if damaged. Blower housing must be removed
to inspect cooler and hoses.
b. Service. Every 500 operating hours clean oil
cooler fins with air gun (50 psi) held 12 inches away
from the fins. Every 2500 operating hours remove
oil cooler and flush in both directions using solvent
at 25 psi.
c. Remove. Remove blower housing. Disconnect oil
cooler hoses at valve of oil filter adapter (see figure
4-29), Drain cooler into suitable container. Remove
four machine screws (3, figure 4-26) and special Ushaped washers (4) attaching oil cooler (1) and oil
cooler seal (1A) to mounting plate (2) and remove
cooler (1). Remove and check hoses. Plug hose
if not used immediately.
d. Replace. Install oil cooler (1) and oil cooler seal (1A) on
mounting plate (2) and secure with screws (3) and special
U-shaped washers (4), Attach oil hoses to cooler as shown in
figure 4-29. Replace blower housing shown in figure 4-29.
Replace blower housing, Replace any oil lost. On ASK equipped
generators, replace ASK cover assembly (para 5-3).
Change 7
4-33
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
Figure 4-27. Pressure Oil System
4-31. LOW OIL PRESSURE SWITCH.
On ASK equppied generators, remove oil access door.
a. Test on Equipment (see figure 4-30). Disconnect
leads from terminals 1 and 2. With master switch in off
position, use ohmmeter to check for continuity between
terminals 1 and 2 of switch. If continuity is indicated,
replace switch. Connect leads to switch terminals 1 and
2.
b. Removal. Disconnect leads from terminals 1 and 2.
Use wrench on square portion at base of switch (11) and
remove from adapter (5).
c. Bench Test. Connect switch to a controllable supply of dry compressed air. Connect ohmmeter across terminals 1 and 2 and slowly apply compressed air. Switch
should close (continuity) when 14 ± 2 psi of compressed
air is applied.
4-34
Change 7
Figure 4-28. Oil Cooler Assembly
TM 5-6115-584-12
NAVEAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
Figure 4-29.
Replacing Oil Cooler Hoses
Change 2
4-35
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
Figure 4-30. Oil Filter Assembly
d. Install. Install switch (11) in adapter (5) and
tighten. Use wrench on square portion of switch base.
Connect leads at terminals 1 and 2.
b. Remove. Drain oil filter into suitable container
by removing drain plug (1). Loosen through bolt (2)
and remove body (3). Remove and discard filter (6)
and gasket (4).
4-32. OIL FILTER.
On ASK equipped generators, remove oil access door.
a. Service (see figure 4-30). Every 100 operating hours
replace oil filter element. Clean inside of bowl while filter is
removed. Replace defective hoses.
4-36
Change 7
c. Replace. Clean filter mounting area in adapter (5) and
inside of body (3). Install new element (6) in body (3). Install new
gasket (4) In groove of adapter (5). Position body (3) (drain down)
with element Installed on adapter (6) and secure with through bolt
(2). Tighten through bolt 10 to 15 ft-lb.
TM 5-6115-584.12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
Figure 4-31. Replacing Oil Pressure Gauge
On ASK equipped generators, remove oil access door.
Iockwasher (9), clamp (4) and remove oil Pressure gauge
and bracket. Remove fitting (5) and nuts (6) attaching
gauge (7) to mounting bracket (8) and remove gauge (7).
a. Test. Attach a pressure gauge of known accuracy between
flexible oil line and unit pressure gauge. Operate unit for 1/2 hour
and check that both gauges read the same. At rated RPM the
normal oil pressure is 20 to 45 PSI which is dependent on air
and engine temperature, grads of oil, and wear tolerance of
engine. If the unit pressure gauge is in error by more than 5
Ibs, replace.
c. Replace. Install oil pressure gauge (7) on mounting
bracket (8) with nuts (6) two on each side of bracket (8).
Maintain gap between gauge and bracket as indicated on
figure 4-31. Position oil pressure gauge and bracket on
engine and install clamp (4), lockwasher (3) and screw (2).
Connect and tighten oil line (1).
4-33. OIL PRESSURE GAUGE.
b. Remove (see figure 4-31). Disconnect and drain
oil Iine (1) top oil pressure gauge (7), Remove screw (2),
Change 7
4-37
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
Section XII. MAINTENANCE OF CONTROL SYSTEM
4-34. DESCRIPTION AND FUNCTION.
NOTE
All symbols (CB2, S1, etc.) are the same as
used on the wiring diagram, figure 1-7, and
elsewhere throughout the manual.
4-35. DC CONTROL SYSTEM.
Operation of the dc control system is as follows.
Operator controlled dc functions are all contained in
three items mounted on the control panel. These are
the dc circuit breaker (CB2), the master switch (S1),
and the panel light switch (S2) (see figure 4-33).
a. The dc circuit breaker (CB2) controls all dc
power to the unit. When it is de-energized (pulled
out), all dc control circuits are de-energized, except
the battery charging system which is self protected
by fuse (F1). This breaker can be used for emergency stopping of the unit.
b. The master switch (S1) controls all starting and
operating of the set under normal conditions. It is a
five position rotary switch with the extreme position
in either direction being a momentary position. The
five positions control set operates as follows. When
the master switch is placed in position 1, marked
PREHEAT on control panel, a circuit is completed
between terminals 11 and 15 of the master switch,
this applies power to the coil of the preheat relay
(K2). When the preheat relay contacts close, power is
then applied to the glow plugs and preheater on the
engine. This position of the switch should be used for
starting any time the engine is cold, or has not been
run for sometime. The normal period for preheating
is 1 minute, but can be as long as 1 minute 30 seconds
as conditions dictate. This switch position is momentary so that the preheat circuit remains activated
only as long as the operator holds the switch in
PREHEAT or START position. When the master switch
is placed in position 2, marked OFF on control panel,
all dc circuits are de-energized except the panel
lights, battery indicator, and the battery charging
system. This position is used to stop the set under
normal operation. When the master switch is placed
in position 3, marked PRIME & RUN AUX. FUEL on
control panel, circuits are completed between terminals 11-13, 11-14, 11-17 of the master switch.
This applies power to the engine fuel pumps, and the
auxiliary fuel system and also to one side of an
open contact of relay (K1). This position is used when
the set is running and the auxiliary fuel system is
being used, and also to prime the entire fuel system
before starting. Position 4 of the master switch,
marked PRIME & RUN on the control panel, is the
same as position 3 except that the circuit between
terminals 11-17, of the master switch is not made.
This position is used when the set is running and the
auxiliary fuel system is not being used, and also to
prime the engine fuel system only before starting.
4-38
When the master switch is placed in position 5,
marked START on the control panel, circuits are completed between terminals 11-13, 11-14, 11-15, 25-27,
25-28. The circuits between 11-13, 11-14, 11-15
activate the engine fuel pumps, apply power to one side
of an open contact of relay K1 and activate the preheat circuit as described in previous positions of the
switch. The circuit between 25-28 of the master
switch bypasses the safety devices which are capable
of stopping the engine. Bypassing the low oil pressure
safety device (S5) is essential until the engine has
sufficient oil pressure to close its contacts. Bypassing the safety device completes a circuit to the
engine fuel solenoid and relay coil (K1). Energizing
the start relay (K1) completes a circuit through the
contacts of (K1) to the running time meter, and to
one side of the low oil pressure switch. The circuit
between 25-27 of the master switch applies battery
voltage to the field flash resistor through diode (CR2).
This action applies field flashing current to the
exciter field. It sled applies power through diode
(CR1), which prevents starting set when the battery
polarity is reversed, and the closed contacts of the
start disconnect switch (S7) to the crank relay coil
(K3). When the crank, relay contacts close, a circuit
is completed to the starter solenoid (K6), which
closes and starts the cranking motor. With the
engine fuel solenoid energized and the starting motor
cranking the engine, the engine should start and accelerate toward the speed setting of the governor.
When engine speed passes approximately 1000 RPM
the start disconnect switch contact opens de-energizing the crank relay (K3) and in turn the start
solenoid and starting motor. With the engine accelerating and ac voltage building up, the governor
will take control of the engine and the voltage regulator will bring voltage to the value set by voltage
adjust rheostat. By the time the Generator Set is
under control of the regulator and governor, the
engine oil pressure will be sufficient to permit returning master switch (S1) to the PRIME & RUN or
PRIME & RUN AUX. FUEL position depending on
desired set operation. The set will now be operating
under control of the voltage regulator and governor
but without any load. As stated above, the set is now
ready to accept a load. Placing the ac circuit breaker
in the ON position connects the selected generator
output to the set load terminals. The breaker can be
opened manually or by automatic action of the internal
relay trip device in the case of an overload or a
short circuit. The panel light switch activates the
panel lights when placed in the ON position.
4-36. AC lNSTRUMENTATION SYSTEM.
Operation of the ac instrumentation system which
consists primarily of ammeter voltmeter and ammeter-voltmeter transfer switch is as follows. The
function of the ammeter-voltmeter transfer switch
(S8) and the meter switching section of the reconnection switch (S6) is to provide the connections
TM 5-6115-584-12
NAVFAC P-8-622.12
TO-35C2-3-456-1
TM-05682C-12
for correct readings of voltmeter and ammeter in all
voltage connections and to ensure that the secondaries
of the current transformers are never open circuited.
This combination also ensures that when the Generator Set is connected for 3 phase operation that no
meter indications will be obtained with the ammeter.
voltmeter transfer switch (S8) in positions 5 or 6,
which are single phase positions. It also ensures the
reverse of this condition for positions 1, 2, 3, and 4
of switch (S8).
Figure 4-32. Load Terminal Board Assembly
Change 5
4-39
TM 5.6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
4-37. LOAD TERMINAL BOARD ASSEMBLY.
a. Load Terminal Removal (see figure 4-32).
(1) Unlatch door (3).
(2) Remove screws (1), lockwasher (2), and cover
and door assembly (3).
(3) Remove screws (4) and lockwashers (5).
(4) Carefully lift terminal board (6) and tag and
disconnect leads from load terminals (7) by removing
nut (11 ), lockwasher (10) and flatwasher (9).
(5) Remove load terminal (7) from terminal board (6)
by removing nut (8), flatwasher (12) and lockwasher (13).
b. Load Terminal Installation (see figure 4-32).
(1) Install load terminal (7) to terminal board (6)
by installing lockwasher (13), flatwasher (12) and nut (8).
(2) Connect leads to terminals (7) by installing
flatwashers (9), lockwashers (10) and nut ( 11).
(3) Install lockwashers (5) and screws (4).
(4) Install door assembly (3), lockwashers (2) and
screws (1).
(5) Latch door.
c. Replacement of Lost or Broken Terminal Clip
(Retainer Safety Clip), The terminal clip is a component of
both the load terminal and the ground terminal. If the terminal clip is lost or broken, fabricate as follows:
(1) Requisition bulk wire NSN 9505-00-804-3814
(0.042 inch diameter) for the ground terminal (ground
stud). Requisition bulk wire NSN 9505-01-049-0144 (0.050
inch diameter) for the load terminal.
(2) Cut off about 3 inches of the wire, short enough
to keep the clips from touching another terminal or the
generator frame in the open or closed position,
(3) Slip the wire through the hole in the terminal.
(4) Hold the terminal as shown (Detail A, figure
4-32.1) and bend both ends of the wire straight up keeping
the wire in as straight a line as you can with terminal body.
(5) Bend the wire into back-to-back 90° angles
(Detail B, figure 4-32.1) so that the legs of both angles are
about one-half inch long.
(6) Bend the ends of each 90° angle down and
around into a U-shape (Detail C, figure 4-32.1) so that if
done properly, the clip will hold the nut when it is unscrewed to install the cable (Detail D, figure 4-32.1).
Figure 4-32.1. Terminal Clip Replacement
4-40
Change 5
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
Figure 4-33. Control Cubicle Assembly
Change 5
4-41
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
4-38. CONTROL CUBICLE ASSEMBLY.
a. Test, On Equipment (see figure 4-33).
NOTE
When disconnecting leads from terminals, tape
leads to prevent electrical shorts.
(1) Control Cubical. Perform operational test on control cubicle, checking for proper operation in each of the
Generator Set’s three modes using a voltmeter of known
accuracy. Check that ac output voltage indicated on control
panel matches output voltage at terminal board. Check that
Generator Set does come to an EMERGENCY STOP when
dc control circuit breaker (figure 2-3) is pulled. Test individual components of the control cubicle as given below. See
figure 4-33 for location of components.
(2) With the generator operating at rated speed or 60
Hz, flash the generator field by placing the master switch on
the control cubicle in the start position. If the generator
voltage fails to build up after flashing, the control cubicle
may be defective.
(3) Voltage Adjust Reheostat (R1). Turn the Ammeter Voltmeter transfer switch to its various positions. For
each position of the switch, turn voltage adjust reheostat to
its extreme positions, Voltage readings should be as follows.
Voltage adjust range shall be between 205 and 220V for the
120/208V, 3 phase, 4 wire connection. Between 114 and
126V for the 120V, 1 phase, 2 wire connection. Between 228
and 252V for the 120/240V, 1 phase, 3 wire connection.
(4) Panel Light Assemblies (DS1) and (DS2). With a
good incandescent lamp in place and 24 vdc present at terminals of panel light (panel light switch ON) check that
lamps do not light.
NOTE
Be certain panel light switch is OFF before
installing or replacing panel light assembly.
(5) Hour Meter (M2). Operate Generator Set. Check
hour meter against a known accurate time source. Replace
meter if necessary.
4-42
Change 9
(6) Battery Charging Indicator (MI), Connect meter
capable of reading at least 35 volts DC from terminal on
battery charging indicator to ground. Operate Generator
Set. With the needle in the yellow area, the meter should read
between 18 and 27.5 volts. With the needle in the green area,
the meter should read between 24.5 and 31.5 volts. NOTE:
The apparent overlap in voltage between the yellow high and
green low is the result of a plus or minus 1.5 voltmeter
tolerance.
(7) DC Control Circuit Breaker (CB2). Operate Generator Set. Pull circuit breaker (CB2). If generator does not
come to an emergency stop, stop the unit using master switch
and replace breaker.
CAUTION
Disconnect battery cable before making checks,
unless otherwise noted.
(8) Master Switch (S1). Disconnect battery. Tag and
disconnect seven leads to master switch. Using an ohmmeter, check for continuity between terminals for each of the
five switch positions as given in table 4-3. If continuity is not
found for each set of terminals listed, replace master switch.
(9) Panel Light Switch (S2). Tag and disconnect two
leads to panel light switch. Using an ohmmeter, test for
continuity between terminals on switch. With the switch in
the OFF position, there should be no
Table 4-3 Master Switch Continuity Check
Check for Continuity
Between Terminals
Switch Position
I
PREHEAT
OFF
RUN AUX FUEL
RUN
START
I
11-15
NONE
11-13-17
11-13
11-13-15 25-27-38
I
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
Table 4-4. Voltmeter-Ammeter Range Selector Switch Continuity Check
Switch Position
volts
Phase
Amps
L1-L2
L2-L3
L3-L1
L3-L0
L3-L1
L3-L0
3
3
3
3
1
1
L2
L3
L3
L3
L3
L1
Check for Continuity Between Terminals
11-15
11-17
11-17-18*
11-18
11-12
11-12
21-23
21-24
21-25
21-26
21-27
21-28
31-33
31-33
31-33
31-33
31-37
31-37
41-46-47
41-42-47
41-42-43
41-42-43
41-42-43-45
41-43-45-46
51-52
51-53
51-54
51-55
51-56
51-57
* Terminal 17 is jumped to terminal 18.
continuity. With the switch in the ON position, there
should be continuity. Replace switch if necessary.
(10) Ammeter . Voltmeter Transfer Switch (S8).
Tag and disconnect sixteen leads to range selector
switch. Check for continuity between terminals for each
of the six switch positions as given in table 4-4. If continuity is not found for each set of terminals listed,
replace switch.
(11) Relays (K1), (K2), (K3), Assembly A-1, CR-1, and
CR-2. Open circuit breaker (CB2). On ASK equipped generators,
remove batteries access door. Disconnect battery cable. Tag, disconnect and tape terminals lugs of the following: A1 and A2 on
crank relay (K3), A1 and A2 on preheat relay (K2), and A1-4 and
A1-3 on relay assembly A1, Tag and disconnect terminals A1-5,
A1-6, A1-7, and A1-8 on relay assembly A1Test for shorted or
open diodes CR-1 and CR-2 by using an ohmmeter. Connect positive lead of the ohmmeter to A1-5 and negative lead to A1-6,
ohmmeter should indicate high resistance, then reverse the leads
and ohmmeter should indicate low resistance. Connect positive
lead of the ohmmeter to A1-7 and negative lead to A1-8, ohmmeter should read high resistance, then reverse leads and ohmmeter should read low resistance. Replace defective diodes that
fail the above test. Reconnect wire to A1-5, A1-6, A1-7, and
A1-8 to A1 relay assembly. Reconnect battery cable, close circuit
breaker (CB2). Hold master switch in START position and using an
ohmmeter check for continuity between terminals A1 and A2 on
crank relay K3 and A1-3 and A1-4 on A1 relay assembly. Continuity should end when master switch is released. Repeat test for
preheat relay K2 holding master switch in PREHEAT position. Replace defective relays. Reconnect wires to relay K2, K3, and A1
relay assembly.
(12) Terminal Board Assemblies (TB4) and (TB5). Tag and
disconnect leads to terminal boards. Test from each terminal to
ground for shorts. Replace board if any terminal shows continuity
to ground.
NOTE
On ASK equipped generators, access to J1 and J2 is through
air intake door.
(13) Wiring Harness. Test wiring harness by
using an ohmmeter checking continuity of each wire.
Perform point to point checks between points indicated on figure 1-10. Wiring harness need not be
totally disconnected for checking continuity.
(14) Transformer (T1) (see figure 4-33). Tag
and disconnect five leads to transformer T1. Using
an ohmmeter check primary winding by measuring
resistance from terminal H1 to H2. Resistance
should be 18.6 ohms ± 1.86 ohms. Check secondary
winding bv measuring resistance from terminal X1 to
X3. Resistance should be 1.6 ohms ± .16 ohms. If
either of the windings do not show the proper resistance, replace transformer.
(15) Transformer (T2) (see figure 4-33). Tag
and disconnect four leads to transformer T2. Check
primary winding by measuring resistance from terminal H1 to H2. Resistance should be 155 ohms
± 15.5 ohms. Check secondary winding by measuring
resistance from terminal X1 to X2. Resistance should
be 18.8 ohms ± 1.88 ohms. If either of the windings
do not show the proper resistance, replace transformer.
b. Remove.
(1) Control Cubicle. On ASK equipped generators, remove
rear panel assembly (para. 5-7). Open air intake door. Tag and
detach two connectors for wiring harness from control cubicle (see
figure 1-2). Remove screw (6, figure 4-34) and nut (8) attaching
ground strap to cubicle support frame. Remove four screws (2),
Iockwashers (3) and flatwashers (4) attaching control cubicle to
vibration mounts (5) and remove cubicle (1).
c. Inspect.
(1) Inspect the control cubicle assembly per
paragraph 3-19.
(2) Frequency Transducer (A3) (see figure 4-33).
for physical damage. Check to see
that the electrical connections to transducer are clean
and tight. Check to see that transducer is securely
attached to the control cubicle.
Inspect transducer
Change 7 4 - 4 2 . 1
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
(3) Relay Assembly (A1). Inspect relay assembly
(5) for physical damage. Check that electrical connections to assembly are clean and tight. Check that
assembly is securely attached to control cubicle.
(4) Relay (K1). Inspect relay (6) for physical
damage and continuity (see figure 4-33.1). Remove relay
from socket and inspect for bent or missing pins. Check
that relay is secured to socket with two screws.
Figure 4-33.1.
4-42.2 Change 5
d. Disassembly.
(1) Panel Light Assemblies (DS1) and (DS2) (see
figure 4-33). Tag and detach two leads to each panel
light assembly (DS1) and (DS2). Remove nut and lockwasher securing light assembly to control panel and
remove light assembly.
(2) Hour Meter (M2). Tag and disconnect two
leads to hour meter. Remove three screws, lockwashers, and nuts attaching hour meter to control
panel and remove meter.
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
Figure 4-34. Removing Control Cubicle Support Assembly
(3) Battery Charging Indicator (M1). Tag and
disconnect lead to indicator. Remove two lockwashers
and nuts and retainer holding meter in place and
remove indicator.
Remove switch knob by loosening two setscrews.
Remove nut attaching switch to control panel and
remove switch. Install new switch as given above.
(4) DC Control Circuit Breaker (CB2). Disconnect two leads to breaker. Remove two screws
attaching breaker to control panel and remove breaker.
(8) Voltage Adjust Rheostat (R1). Tag and disconnect two leads to rheostat. Remove rheostat knob
by loosening two allen setscrews. Remove nut and
washer attaching rheostat to panel and remove rheostat
(9).
(5) Master Switch (S1). Disconnect battery. Tag
and disconnect seven leads to master switch. Remove switch knob by loosening two setscrews. Remove
nut attaching switch to control panel and remove
switch.
(6) Panel Light Switch (S2). Tag and disconnect
two leads to switch. Remove nut attaching switch
to control panel and remove switch.
(7) Ammeter - Voltmeter Transfer Switch (S8). Tag
and disconnect sixteen leads to range selector switch.
(9) Transformer (T1). Tag and disconnect five
leads to transformer. Remove four screws and
lockwashers attaching transformer to control cubicle
and remove transformer.
(10) Transformer (T2). Tag and disconnect four
leads to transformer. Remove two screws and lockwashers attaching transformer to cubicle and remove
transformer.
Change 3
4-43
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
(11) Relay (K2-K3). Disconnect battery. Tag and
disconnect four leads to relay. Remove two screws
and nuts attaching relay to control cubicle.
(12) Terminal Board Assemblies (TB4 and TB5).
Tag and disconnect leads to terminal boards. Remove
two screws and nuts attaching board to control cubicle
and remove board.
NOTE
(10) Terminal Board Assemblies (TB4) and (TB5).
Attach board to control cubicle with two screws and
nuts. Attach tagged leads to board (if necessary, refer
to schematic, figure 1-10).
(11) Voltage Adjust Rheostat (R1). Attach rheostat
(9) to control panel with nut and lockwasher provided with rheostat. Make certain that rheostat aligns
with slot on panel. Push rheostat knob onto shaft and
attach using two allen screws. Attach two tagged
leads to rheostat per wiring diagram, figure 1-7.
.
TB4 has 27 leads and TB5 has 36 leads.
e. Assembly.
(1) Panel Light Assemblies (DS1 and DS2). Attach
new light assembly to control panel with the nut and
lockwasher supplied with each assembly. Attach two
tagged leads to each panel light (if necessary refer
to wiring diagram, figure 1-7).
(2) Hour Meter (M2). Attach hour meter to control
panel with three screws, lockwashers, and nuts provided with meter. Attach two tagged leads to meter
(if necessary, refer to wiring diagram, figure 1-7).
(12) Transformer (T1). Attach transformer to
control cubicle with four screws and nuts. Connect
five tagged leads to (T1) per wiring diagram, figure .
1-7.
(13) Transformer (T2). Attach transformer to
control cubicle with four screws and nuts. Connect
four tagged leads to (T2) per wiring diagram, figure
1-7.
f. Bench Test. Connect the control cubicle as shown
in figure 4-35 and proceed as follows.
(3) Battery Charging Indicator (M1). Slide battery
charging indicator into opening in control panel. Place
retainer over back of indicator and secure with two
lockwashers and nuts. Attach lead to indicator (if
necessary, refer to wiring diagram, figure 1-7).
(4) DC Control Circuit Breaker (CB2). Attach
circuit breaker to control panel with the two screws.
Reconnect tagged leads to breaker (if necessary, refer
to wiring diagram, figure 1-7).
(5) Master Switch (S1). Attach master switch to
control panel with nut and key ring provided with
switch. Make certain key on key ring aligns with slot
in control panel. Push switch knob onto shaft and
attach with two allen screws. Attach seven tagged
leads to switch (if necessary, refer to wiring diagram, figure 1-7).
(6) Panel Light Switch (S2). Attach panel light
switch to control panel with nut and key ring. Make
certain key on key ring aligns with slot in control
panel. Attach two tagged leads to switch (if necessary,
refer to wiring diagram, figure 1-7).
(7) Ammeter . Voltmeter Transfer Switch (S8). Attach range selector switch to control panel with nut and
key ring. Make certain key on key ring aligns with slot in
control panel. Push switch knob onto shaft and attach
with two allen screws. Attach sixteen tagged leads to
switch (if necessary, refer to wiring diagram, figure 1-7).
(8) Relay (K1). Plug new relay into socket on
relay assembly A1 and secure with two screws.
(9) Relay (K2 and K3). Attach relay to control
cubicle with two screws and nuts. Reconnect four
tagged leads per wiring diagram, figure 1-7.
4-44
Change 3
Figure 4-35. Control Cubicle Test Set-Up
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
(2) Place master switch in preheat position.
Lamps L2 and L3 shall light indicating that the preheat circuitry is correct.
(9) Place master switch in the stop position.
All lamps shall be out indicating that all stop circuits
are correct.
(3) Place master switch in start position. Lamps
L1, L2, L3, L-4, L5 and L6 shall light indicating that
all circuits for starting are correct.
(10) Place panel light switch in the on position
Panel lights shall be on indicating that the panel light
circuit is correct.
(4) With the master switch in the start position,
open switch S1. Lamp L1 shall extinguish indicating
that the start disconnect circuitry is correct.
(11) Reposition all switches as in step 1 and disconnect test setup.
(12) Test CR1 and CR2 as follows:
(5) With the master switch in the start position.
Close switch S2 and then, place the master switch in
the prime and run position. Lamps L2 and L3 shall
extinguish. Lamps L4, L5 and L6 shall remain lit
indicating that the prime and run circuitry are correct.
(6) With the master switch in the prime and run
position and lamps L4, L5 and L6 lit open switch S2.
Lamp L4 shall extinguish indicating that the engine
protective devices circuit and the prime circuit is
correct.
(7) Repeat the procedure of step 5, except that
the master switch shall be placed in the prime and
run aux fuel position after closing switch S2. Lamps
L4, L5, L6 and L7 shall remain lit indicating that
the prime and run aux fuel circuitry is correct.
(8) With the master switch in the prime and run
aux fuel position and lamps L4, L5, L6 and L7 lit
open switch S2. Lamp L4 shall extinguish indicating
that the engine protective devices circuit and the
prime circuit is correct.
(a) Remove wires from terminals 6 and 7 of
A1.
(b) Measure forward and backward resistance
of CR1 between terminals 5 and 6 of A1. Resistance
should read high in one direction and low in the other.
If not, CR1 is bad.
(c) Measure forward and backward resistance
of CR2 between terminals 7 and 8 of A1. Resistance
should read high in one direction and low in the other
If not, CR2 is bad.
g. Install.
(1) Control Cubicle. Attach control cubicle (1, figure 4-34) to
four vibration mounts (5) with four screws (2), Iockwashers (3), and
flatwashers (4). Attach ground strap (7) to cubicle support frame
with screw (6) and nut (8). Attach two connectors from wiring harness to connectors on back of control cubicle. On ASK equipped
generators, install rear panel assembly (para. 5-7).
Section XIII. MAINTENANCE OF ENGINE
4-39. DESCRIPTION AND FUNCTION.
(See figure 4-36. ) The engine assembly is a two
cylinder, air cooled, overhead valve, fuel injected
diesel equipped with; a blower housing (1) and a
shutter assembly (2) used to direct and control
cooling air, an oil cooler (3) and gear type oil pump
used to cool and circulate lubricating oil in the
engine, a replaceable cartridge type oil filter (4) to
remove contaminants from the lubricating oil, fuel
injection pump (5) to supply metered fuel to the
engine combustion cylinders through fuel injectors
located in the cylinder heads, air intake manifold (16)
and heaters (18) that receive combustion air from the
external air cleaner (9) and heat the combustion air
if required, starter motor (6) coupled to the engine
drive gear for cranking the engine for starting, a corrosion resistant exhaust muffler (7) to reduce engine
exhaust noise, and a mechanical governor used to
maintain engine speed at 1800 RPM under varying
load.
4-40. EXHAUST MUFFLER ASSEMBLY
a. Inspect (see figure 4-37). If engine exhaust is
noisy or if exhaust gases are detected from shutter
assembly, indications are that muffler (3) or gaskets
(4) and (6) may be defective.
b. Remove. Remove shutter assembly as outlined
in paragraph 4-17. Bend lock tabs (2) down and
remove four nuts (1) holding muffler (3) in place.
Remove lock tabs (2), mufflers (3). muffler gaskets (4),
adapters (5) and adapter gaskets (6) from each
cylinder head.
c. Replace. Place gaskets (6), adapters (5) in place
on each cylinder head. Slide new muffler gaskets (4),
muffler (3), and lock tabs (2) over studs (7) in cylinder head and secure to cylinder head with nuts (1).
Change
7
4-45
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
Figure 4-36. Engine Assembly (Sheet 1 of 2)
4-46
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
1. Blower housing
2. Shutter assembly
3. Oil cooler
4. Oil filter
5. Injection pump
6. Starter
7. Muffler
8. Governor
9. Air cleaner
10. Oil filter tube and
dipstick
11. Shroud and panel
12. Engine lifting eye
13. Screw (2)
14. Lock tab (2)
15. Casket
16. Intake manifold
17. Lead
18. Heater (2)
19. Lead
20. Screw (2)
21. Washer (2)
22. Washer (4)
23. Spacer (2)
24. Adapter
25. Gasket
Figure 4-36. Engines Assembly (Sheet 2 of 2)
NOTE
Upper and lower nut must be tightened evenly
in small increments so that muffler will lay
flat against adapters.
Bend lock tabs (2) up to secure nuts (1).
4-41. AIR CLEANER ASSEMBLY.
a. Inspect (see figure 4-37). On ASK equipped generators, open
air intake door and air cleaner door.
(1) Air Cleaner Assembly. Check air cleaner assembly for
corrosion, broken or dented components or split hoses.
b. Remove.
(1) Air Cleaner Assembly. Loosen hose clamps
(9 and 11) attaching two air intake hoses (10 and 12)
to housing and detach hoses. Remove screws (13),
lockwashers (14) and remove air cleaner and bracket
and spacers (15). Remove air flow indicator (16) by
turning Counterclockwise.
(2) Remove nut (17), lockwashers (18), screw
(19) and separate air cleaner (20) and bracket (21).
c. Repair.
(1) Air Cleaner Assembly. Weld and straighten
air cleaner housing as necessary.
(2) Mounting Bracket (see figure 4-37). If bracket
(21) is split or bent, weld and straighten bracket as
necessary. After completing repairs, check that
bracket securely attaches air cleaner to set.
d. Install.
(1) Air Cleaner Assembly (see figure 4-37).
Install air cleaner (20) on bracket (21) and secure
with screws (19), lockwashers (18) and nuts (17).
Install airflow indicator (16) on air cleaner.
(2) Install air cleaner, bracket and spacers (15)
on generator housing and secure with lockwashers (14)
and screws (13). Install hoses (10 and 12) and secure
with clamps (9) and (11).
4-42. ENGINE ASSEMBLY.
a. Inspect (see figure 1-1). Inspect engine for loose
connections, leaks in oil and fuel systems, and free action of all
moving parts. Check that engine is securely mounted to skidbase. On ASK equipped generators, inspections of the engine
assembly are limited to components accessible through the
access doors.
b. Test. Operate engine with no load on Generator
Set, until it warms up to normal operating temperature indicated by shutters being in an intermediate position between open and closed. Check oil
pressure. Oil pressure should be 20-45 psi. Check
frequency on frequency meter. Frequency should be
approximately 60 Hz indicating that engine speed is
about 1800 RPM. Apply full rated load to engine.
Check that governor adjusts engine quickly, smoothly,
and without excessive hunting. Check that exhaust is
normal under load. Check that engine runs without
excessive fuel or oil consumption. Check that no
unusual noise is heard. Inability of engine to meet
these tests may indicate engine malfunctioning. See
Troubleshooting, Section VI.
c. Service. Service engine according to the schedule
given in table 4-1, Preventive Maintenance Checks
and Services.
d. Adjust. The only engine adjustments applicable
to this level of maintenance are to the valve rocker
arms, stop solenoid, and starter lockout switch.
NOTE
Engine lifting attachment is for lifting engine
alone. Do not use this attachment for lifting
engine if generator is still attached. Use the
set lifting eye for this purpose (see figure 1-1).
Change 7
4-47
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
Figure 4-37. Exhaust Muffler and Air Cleaner Assemblies
4-48
TM 5-6115-584-12
NAVIFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
4-43. INTAKE MANIFOLD
A S SEMBLY.
a. Test On Equipment (see figure 4-36). On ASK equipped
generators, remove right panel assembly (para. 5-6). Remove hose
between intake manifold and air cleaner to permit visual inspection
of heater coils (18). Place master switch (see figure 2-3) in the
PREHEAT position. Good coils should start to heat within one
minute. Release switch as soon as coil begins to heat. Replace a
bed heater.
b. Inspect. Inspect heater for physical damage.
Check that electrical connections to heater are clean
1. Screw (4)
2. Lockwasher (4)
and tight. While engine is operating, check for leaks
especially at the gasket (15; figure 4-36) between
manifold and cylinder head and the gasket (25) between
the manifold heater adapter (24) and the manifold.
Drop oil from an oil can or hold piece of thin paper
on point suspected of leaking. If leak exists, oil will
be sucked in or paper will be sucked against leaking
area.
c. Remove. Tag and disconnect leads (17 and 19)
from heaters (18) and remove heaters (18). Remove
lead (19) by removing screw (20), washers (21 and
22) and spacer (23). Remove adapter (24) and gasket
3. Rocker arm cover
4. Gasket
5. Cylinder head
TS
6115-584-12/4-38
Figure 4-38. Rocker Arm Covers
Change 7
4-49
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
c. Bend lock tabs (14) down and remove four screws (13)
attaching manifold to cylinder heads and remove manifold
(16). Clean away any gasket material (15) stuck to cylinder
heads or manifold.
d. Repair. Remove manifold as given above and replace
gasket if leaks occur.
e. Install. Install intake manifold (16) and new gasket
(15) to cylinder head and secure with two screws (13) and
lock tabs (14). Torque screws 13 to 15 ft-lbs. Bend lock tabs
(14) up to prevent screws (13) from loosening. Install good
heater elements (18) into heater adapter (24). If heater
adapter threads are damaged, replace adapters. Install
heater adapter (24), gasket (25) and lead (19) on intake
manifold and secure with spacer (33), washers (21 and 22)
and screw (20). Reconnect lead (17) to heater.
NOTE
If heater adapter is removed, make certain new
gaskets and spacer are used for reassembly.
4.44. ROCKER ARM COVERS.
a. Inspect (see figure 4-38). Inspect rocker arm cover (3)
for dents or other physical damage. Check for leaks especially at the gasket (4) between cover and cylinder head (5).
Check that cover (3) is securely attached to cylinder head
with screws (1), and lockwashers (2).
b. Remove. Remove shroud (13, figure 3-9) per paragraph 4-17b. Remove four screws (1, figure 4-38) and lockwashers (2) attaching each rocker arm cover (3) to cylinder
head (5) and remove cover carefully. Clean gasket (4) from
both cover and cylinder head.
Figure 4-39. Cleaning Rocker Arm Cover Oil Line
b. Service.
(1) Remove tube (2) from breather valve (6).
(2) Loosen screw (3) and remove clamp (4).
c. Service. Every 500 operating hours, remove rocker
arm covers and clean oil lines. Flush oil lines with clean
diesel fuel and clean small holes with a fine wire. See figure
4-39.
NOTE
Adjust valve rocker arms and clean breather
while cover is off.
(3) Remove insulators (5) and pull off vlave (6),
screen (8) and filter (10).
(4) Wipe parts with clean cloth. Wash filter mesh (10)
and valve (6) in dry cleaning solvent Fed, Spec. PD 680.
c. Remove,
d. Replace. Place gasket (4, figure 4-38) in position on
each cylinder head. Install each rocker arm cover (3) to
cylinder head and secure with four screws (1) and lockwashers (2). Tighten screws 7 to 8 ft-lb.
(1) Loosen clamp (1) and remove tube (2) from
valve (6).
NOTE
(3) Remove valve (6), screen (7), retainer (8) and
packing (9),
(2) Remove clamp (4) by loosening screw (3).
Always use a new gasket when installing rocker
arm covers.
(4) Remove filter (10) and cup (11 ) from tube ( 12).
4-45. BREATHER.
a. Inspect (see figure 4-40). Inspect exterior of breather
for damage. Inspect that tube (2) is securely attached to
breather valve (6). Inspect that tube (12) is securely seated in
engine (13),
4-50
Change 9
(5) Remove tube ( 12) from engine ( 13).
d. Install.
(1) Assemble filter ( 10) and cup (11) in breather tub
(12).
.
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
Figure 4-40. Breather Assembly
(2) Place screen (7) in valve (6) and install retainer (8).
(3) Assemble valve (6) on breather tube (12) with
packing (9) between them.
(4) Install insulators (5) on breather assembly
and install clamp (4) over insulators (5).
(5) Tighten screw (3).
(6) Install breather and insulator assembly on
engine (13).
(7) Connect tube (2) and clamp (1) to breather
valve (6).
4-46. VALVE ROCKER ARMS.
a. Inspect (see figure 4-41). Inspect rocker arms
for physical damage or excessive wear.
b. Adjust.
proper valve
Correct valve
and .007 inch
Check and adjust the rocker arm to
clearance every 500 operating hours.
clearance is .010 inch for intake valve
for exhaust valve.
NOTE
Readjust rocker arm to valve clearance after
the first 50 hours of operation on a new or
rebuilt engine.
4-51
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
Figure 4-41. Checking and Adjusting Rocker Arm to Valve Clearance
Always check and adjust the valve tappet clearance
when the engine is at an ambient of approximately
70°F (18°C). Remove rocker cover and proceed as
follows :
head. Correct valve clearance is 0.010 for intake
valve, 0.007 for exhaust valve.
Turn blower wheel clockwise only.
(5) Install rocker cover and tighten screws 7 to
8 ft-lb.
(1) Using 5/8" socket wrench and extension, turn
the blower wheel clockwise until No. 1 cylinder is on
its compression stroke, which follows the closing of
its intake valve. See figure 4-41 for identification of
intake valve assembly.
(2) Continue clockwise rotation until the letter
“A” appears in the timing port on the side of the
generator adapter. This puts No. 1 cylinder in the
power stroke with both valves closed.
(3) By using a feeler gauge, check the clearance
between the rocker arm and the valve stem cap. See
figure 4-41. Increase or reduce the clearance until
the proper gap is established, adjusting with the locknut which secures the rocker arm to the cylinder
4-52
(4) To adjust the valve clearance for No. 2 cylinder, turn the blower wheel clockwise 180° until the
letter “B“ appears in the timing port and adjust valves
as given in step 3.
4-47. INJECTOR NOZZLE ASSEMBLY AND FUEL
LINES.
a. Inspect.
(1) Injector Nozzle Assembly (see figure 4-42).
Inspect for leaking fuel. Inspect fuel fittings for tightness.
(2) Fuel Lines. Inspect fuel lines for leaks and
damage to fittings.
4-48. GLOW PLUG ASSEMBLIES.
a. Inspect (see figure 4-42). Inspect glow plugs for
physical damage. Check that electrical lead to glow
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
Figure 4-42. Cylinder Head Assembly
4-53
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NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
plug is clean and tight. Check for leakage where the
glow plug enters cylinder head.
b. Test. Remove electrical lead to glow plug. Use
ohmmeter to test for continuity. from terminal of
glow plug and ground, Open circuit indicates bad glow
plug.
With master switch in the PREHEAT position,
24 volts dc is applied to the glow plug body. Do
not handle plug with the master switch in the
PREHEAT position.
c. Remove. Disconnect lead to glow plug. Unscrew
glow plug and remove it from cylinder head. If glow
plug was leaking where it entered cylinder head, remove gasket with a hooked wire and replace.
d. Install, If gasket (2, figure 4-42) has been removed, place
new gasket over glow plug. Coat plug threads with anti-seize
compound and screw glow plug into cylinder head. Tighten glow
plug 10 to 15 ft-lb dry. Attach electrical lead to plug. On ASK
equipped generators, install top panel assembly (para. 5-4).
4-49. OIL DRAIN HOSE VALVE.
a. Replace (see figure 3-20). On ASK equipped generators, remove oil access door, Drain engine 011 Into a suitable
container. Disconnect oil drain hose from valve. Remove
valve. Attach serviceable hose to valve. Use pipe thread
sealant on allpipe threads, Always store hose against frame
when not in use.
1. Oil level indicator
Screw (2)
2.
Ž3. Lockwasher (2)
4. Oil f
5. Gasket
ill
6. Cylinder block
TS 6115-584-12/4-43
4-50. OIL BASE.
a. Inspect. Inspect oil base for dents, cracks, or
other physical damage. Check for leaks, especially at
the gasket between oil base and cylinder block.
4-51. OIL PILL TUBE.
a. Remove (see figure 4-43). On ASK equipped generators, remove oil access door. Remove oil level indicator (1).
Remove screw (2), and Iockwasher (3). Remove oil fill tube
(4) and scrape gasket (5) from mating surface on cylinder
block (6) and oil fill tube (4).
b. Installation. Install gasket (5) between oil fill
tube (4) and cylinder block (6). Attach oil fill tube (4)
with screw (2) and lockwasher (3). Install oil level
indicator (1) in oil fill tube (4).
4-52.
ENGINE MOUNTING ASSEMBLY.
a. Inspect (see figure 4-44). On ASK equipped generators, remove cover assembly. (para 5-3). Check to see that
mounting nuts and bolts are tight. Cheek rubber mounts (14)
for cracks and breaks.
b. Remove. Use engine lifting assembly to remove
weight off of mounting assembly and remove screws
4-54
Change 7
Figure 4-43. Oil Fill Tube
(1), lockwasher(3), flatwasher (2) and nuts (4) that
secure each mounting assembly to skid-base (5). Remove screws (6), lockwashers (7) and flatwashers (8)
and remove mounts.
c. Disassembly. Remove screw (9), nut (10), lockwasher (11) and flatwasher (12). Remove brackets
(13). Remove resilient mounts (14) and spacer (16)
from bracket (17). Do not remove alignment pin (15),
unless it is damaged.
d. Reassembly. Install mounts (14) and spacer (16)
into bracket (17). Using screw (9), flatwasher (12),
lockwasher (11) and nut (10), assemble brackets (13)
to the mount.
e. Installation. Install mounts on engine and secure with screw
(6), Iockwasher (7) and flatwasher (8). Lower engine and mounts
to skid-base and secure mounts to base with screws (1), washers
(2), Iockwashers (3) and nuts (4). On ASK equipped generators,
install ASK cover assembly (para 5-3).
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
Figure 4-44. Engine Mounting Assembly
4-55
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NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
Section XIV. MAINTENANCE OF GENERATOR ASSEMBLY
4-53. DESCRIPTION AND FUNCTION.
The generator (main alternator) (see figure l-l) is
a single bearing, splashproof, self -ventilated unit, with
a flange to attach to the engine flywheel housing.
Major generator components are stator, rotor, and
brushless exciter. The stator is composed of a compressed stack of one piece laminations held in position by stator bars welded axially on the outside
diameter of the laminations. A steel wrapper welded
to these bars provides the generator frame. The
generator windings each occupy two groups of slots
180 mechanical degrees apart. The generator rotor is
composed of one piece rotor laminations, stacked,
compressed, and held in position by copper damper
bars welded to the copper end laminations. Rotor
windings are made of Type L2 Class 155 copper wire
insulated from ground with MIL-I-22834A synthetic
bonded paper. The rotor is press fitted and keyed to
the rotor shaft, and balanced. The brushless rotating exciter with rotating rectifier unit is used for
providing excitation current to the rotating field of the
generator. The complete excitation unit consists of
four basic component assemblies: a three-phase rotating armature, alternating current generator; a
three-phase full-wave bridge rectifier composed of six
semi-conductor “diodes mounted on two heat sinks, a
voltage regulator and current-voltage transformers.
The exciter armature and the bridge rectifier assembly are mounted on the rotor shaft of the synchronous
generator and are connected to the generator field
windings. The stator of the brushless exciter consists of field coils wound on the poles and attached
to the generator endbell. During operation of the
generator, the three-phase power generated in the
rotating exciter armature is applied directly to the
rotating rectifier assembly. The six diodes, mounted
on rotating heat sinks, are connected to forma threephase, full-wave bridge. The direct current output of
the bridge rectifier is applied to the rotating field
of the generator. Thus, the two assemblies; exciter
armature and synchronous field form a single rotating
assembly, enabling electrical connections to be made
without the use of brushes, collector rings or commutator. Excitation current for the stationary field
coils of the excitation unit is supplied by the synchronous generator, and controlled through the static type
automatic voltage regulator. The voltage regulator
continuously compares the output voltage of the
synchronous generator with a stable reference voltage. The difference between the two voltages constitutes an error signal which indicates an output
Figure 4-45. Generator Screen-Guard
4-56
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TM-05682C-12
voltage, that is higher or lower than the Generator Set
point. This error signal is amplified and used to control
the direct current output of the voltage regulator which
is applied to the control windings of the current-voltage
transformers.
4-54. GENERATOR/EXCITER ASSEMBLY.
a. Inspect (see figure 1-1). On ASK equipped generatom, remove ASK cover assembly (para 5-3). Inspect the
generator/excitor assembly for physical damage. Check that
assembly is clean and free of dirt, or oil. Check that
electrical Ieads from generator/exciter are free of damage.
Check that assembly is securely mounted to engine and to
the skid-base.
4-55. SCREEN-GUARD.
a. Inspect. Inspect screen-guard for cleanliness and
physical damage.
b. Remove (see figure 4-45), Remove two screws (1),
lockwashers (3), and nuts (2) holding screen-guard (4)
in place and remove screen-guard.
c, Repair. Weld and straighten screen-guard as necessary. After repairs are completed, check that screen-guard
attaches properly to generator and does not touch any
moving part.
d. Install. Place serviceable screen-guard in position over
openings in generator stator-housing assembly (5). Tighten
screen-guard (4) in position with two screws (1), lockwashers (3) and nuts (2). On ASK equipped generators,
install ASK cover assembly (para 5-3).
Section XV. MAINTENANCE OF SKID-BASE
4-56. DESCRIPTION AND FUNCTION,
(See figure l-l.) The skid-base serve. os a base for mounting all major components of the Generator Set. Revisions
for towing or lifting with a forklift are built into the skidbase. Tie down rings are also provided.
4-57. SKID-BASE.
a. Inspect (see figure 4-46). On ASK equipped generators,
refer to Chapter 5 for removal procedures for the entire ASK.
(1) Vibration Mounts, Inspect vibration mounts (3)
for cracked rubber and loose or missing hardware.
(2) Battery Frame Bottom. Inspect battery frame
(11) for corrosion, bends, dents or broken welds.
(3) Battery Tray, Inspect battery tray (12) for
corrosion, or physical damage.
(b) Remove four screws (1, figure 4-46) and nuts
(2) attaching each mount in place and remove mounts (3).
(2) Battery Frame and Tray Removal.
(a) See paragraph 4-25 and remove battery holddowns and batteries,
(b) Remove screws (4 and 8, figure 4-46), bevel
washers (7), lockwashers (6 and 10), and nuts (5 and 9).
Remove frame (11) and tray (12).
(3) Ground Stud. Remove nut (13) and lockwasher
(14) attaching wound leads (15) from starter to ground
stud (16). Remove nut (13) and lockwasher (14) attaching
ground stud to skid-base (24). Remove stud.
(4) Slave Receptacle. Tag and remove leads (17)
from slave receptacle (21 ). Remove receptacle (21) by
removing screws (18), nuts (19) and lockwashers (20).
Remove mounting bracket (23) by removing screws (22).
c. Repair.
(4) Ground Stud. Inspect ground stud (16) for
physical damage to threads, nuts and washers.
(6) Tie Down Ring. Inspect tie down rings (25)
for physical damage. Check that they are securely mounted
to skid-base.
(6) Skid-Base. Inspect skid-base (24) for physical
damage. Check that skid-base is not bent or bowed,
b. Remove (see figure 4-46).
(1) Vibration Mounts.
(a) Refer to paragraph 4-38 and remove control
cubicle.
(1) Battery Frame Bottom. Clean, weld and
straighten battery frame as required.
(2) Battery Tray, Clean and straighten battery tray
as necessary.
(3) Broken or Loot Terminal Clip (Retainer, Safety
Clip). For fabrication procedure, see Chapter 4, Section XII
Maintenance of Control System, paragraph 4-37.
d. Install (see figure 4-46).
(1) Vibration Mounts.
(a) Position mounts (3) and install screws (1)
and nuts (2).
Change 7
4-57
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NAVFAC P-8-622-12
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Figure 4-46. Skid-Base Assembly
4-58
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NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
(b) Refer to paragraph 4-38 and install control cubicle.
(2) Battery Frame Bottom and Tray.
(a) Position battery tray (12) and bottomframe
(11) on skid-base (24). Attach by installing nuts (5 and
9), lockwashers (6 and 10), bevel washers (7) and
screws (4 and 8).
NOTE
Bevel. washers are only on the four bolts at
the outside of the skid-base.
(b) See paragraph 4-25 and install batteries
and battery hold-downs.
(3) Slave Receptacle. Install bracket (23) with
screws (22). Install slave receptacle (21) on bracket
with screws (18), lockwashers (20) and nuts (19).
Install leads (17) on slave receptacle as tagged. Remove tags.
(4) Ground Stud. Install ground stud (16) on skid-base
(24) with Iockwasher (14) and nut (13). Install leads (15 and
17) on ground stud (16) with Iockwasher (14) and nut (13).
On ASK equipped generators, install entire ASK (refer to
chapter 5).
Change 7
4-59/ (4-60 blank)
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NAVFAC P-8-622-12
TO 35C2-3-456-1
TM-05682C-12
CHAPTER 5
MATERIEL USED IN CONJUNCTION WITH DOD STANDARD GENERATOR
SET, 5KW DIESEL ENGINE DRIVEN, MODEL MEP-002A
Section I.
5-1.
AUXILIARY EQUIPMENT
GENERAL .
This chapter describes all Organizational Level Maintenance procedures for auxiliary equipment (kits) which are used in conjunction with the generator set. Any effects of the auxiliary
equipment on the operation or maintenance procedures for the
generator set are identified in the procedures where they occur.
Change 7
5-1
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TM-05682C-12
Section II.
5-2.
ACOUSTIC SUPPRESSION KIT
ACOUSTIC SUPPRESSION KIT.
The acoustic suppression kit (ASK) is an add-on enclosure that
reduces the noise level from the DOD Standard Generator Set, 5KW
Diesel Engine Driven, Model MEP-002A. The control cubicle and ac
output control box assembly are not covered and the fuel tank is
only partially covered. Other controls or areas requiring frequent service can be reached through top, right and left panel
access doors. All ASK information plates are shown in figure
5-1.
5-3.
COVER ASSEMBLY.
See figure 5-2. Remove cover assembly
a. Removal.
consisting of top panel, left and right panels, and front panel
assemblies as follows:
(1) Remove three screws (1) and washers (2) securing
left panel assembly (3) to left support assembly (4).
(2) Remove three screws (5) and locknuts (6), and six
washers (7 and 8) securing left panel assembly (3) to side
closure assembly (9).
(3) Remove five screws (10) and washers (11) securing
right panel assembly (12) to right support assembly (13).
(4) Remove two screws (14) and washers (15) securing
right panel assembly (12) to rear panel assembly (16) and remove
two screws (17) and locknuts (18), and four washers (19 and 20)
securing right panel assembly (12) to rear closure assembly (21).
(5)
Remove seven screws (22) and locknuts (23), and 14
washers (24 and 25) securing top panel assembly (26) to rear
closure (21) and side closure assembly (9).
WARNING
The ASK Cover assembly is heavy. Four (4) people are
required to lift cover. Failure to follow safety
rules could result in personal injury.
(6) Lift and remove cover assembly from generator set.
5-2
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TM-05682C-12
OPERATING INSTRUCTIONS
BEFORE STARTING SET
1. INSURE MAIN CIRCUIT BREAKER IS OFF.
2. REMOVE ASK DOOR LABELED “OIL-FILL, DRAIN, FILTER”. FILL CRANKCASE (DO NOT
ENSURE THAT VENT ON UNDERSIDE OF FUEL FILLER
FILL FUEL TANK.
OVERFILL).
CAP IS OPEN BEFORE STARTING GENERATOR SET.
3. ‘WARNING” - GROUND SET TO AVOID SHOCK HAZARD. LIFT FLAP ON ASK REAR PANEL
ASSEMBLY TO CHECK THAT GENERATOR SET IS PROPERLY GROUNDED.
4. SET BATTERIES ARE NEGATIVE GROUND.
INSURE ALL DOORS ARE IN PLACE, CLOSED AND LATCHED FOR OPERATION.
5.
STARTING SET
1. MOVE “MASTER SWITCH” TO “PRIME & RUN” POSITION TO ALLOW FUEL TO PRIME SET.
2. MOVE “MASTER SWITCH” TO “PREHEAT” POSITION AND HOLD FOR (1) MINUTE.
NOTE: PREHEAT IS NOT REQUIRED WHEN ENGINE IS HOT.
3. MOVE “MASTER SWITCH” TO “START” POSITION AND HOLD UNTIL ENGINE FIRES
IF ENGINE DOES NOT START WITHIN 15 SECONDS, REPEAT STEPS 1
CONTINUOUSLY.
AND 2.
4.
“MASTER SWITCH” WILL RETURN TO “PRIME & RUN” POSITION WHEN RELEASED. IF
RUNNING FROM AUXILIARY FUEL SOURCE, MOVE ‘MASTER SWITCH” TO “PRIME & RUN AUX
FUEL” POSITION.
LIFT
5. AFTER WARM UP, CHECK FREQUENCY AND VOLTAGE AND ADJUST IF NECESSARY.
FLAP LABELED ‘SPEED CONTROL” FOR SET FREQUENCY ADJUSTMENT.
6. MOVE “AC CIRCUIT BREAKER” TO “ON” POSITION.
STOPPING SET
1. MOVE “AC CIRCUIT BREAKER” TO “OFF” POSITION.
2. MOVE “MASTER SWITCH” TO ‘OFF” POSITION.
3. FOR EMERGENCY STOP, PULL “DC CONTROL CIRCUIT BREAKER”.
SERVICE
LUBRICATING OIL
FUELS
CAPACITY: 5KW-7 GAL 1OKW-12.5 GAL CAPACITY (LESS FILTER)
5KW-3 QT 1OKW-5.5 QT
EMERGENCY-JP4
PRIMARY-DIESEL
AMBIENT
TEMPERATURE
-65°
-54°
TO
TO
-25°
-32°
F
C
-25”
-32°
TO
TO
-10”
-23”
F
C
-10°
-23°
TO +30° F
TO -1° C
+30°
-1°
TO +100° F
TO +38° C
+100° TO +107° F
+38° TO +42° C
Figure 5-1.
INSTRUCTIONS
VV-F-800
GRADE DFA
FOR JP4 OPERATION
SEE INSTRUCTION
. MANUAL
MIL-L-10295
VV-F-800
GRADE DF1
MIL-L-2104
GRADE 10
VV-F-800
GRADE DF2
MIL-L-2104
GRADE 30
Instruction and Rating Plates (Sheet 1 of 4)
Change 7
5-3
TM 5-6115-584-12
NAVFAC P-8-622-12
TO 35C2-3-456-1
TM-05682C-12
Figure 5-1.
5-4
Change 7
Instruction and Rating Plates (Sheet 2)
TM 5-6115-584-12
NAVFAC P-8-622-12
TO 35C2-3-456-1
TM-05682C-12
Figure 5-1.
Instruction and Rating Plates (Sheet 3)
Change 7
5-5
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NAVFAC P-8-622-12
TO 35C2-3-456-1
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Figure 5-1.
5-6
Change 7
Instruction and Rating Plates (Sheet 4)
TM 5-6115-584-12
NAVFAC P-8-622-12
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TM-05682C-12
14
Figure 5-2.
Cover Assembly, Removal and Installation
Change 7
5 - 7
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NAVFAC P-8-622-12
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TM-05682C-12
b.
Installation.
See figure 5-2. Replace cover assembly
consisting of top panel assembly, left and right panel assemblies
and front panel assembly on generator as follows:
WARNING
The ASK Cover assembly is heavy. Four (4) people are
required to lift cover. Failure to follow safety
rules could result in personal injury.
(1)
Position cover assembly on generator set.
(2)
Install seven screws (22) and locknuts (23), and
14 washers (24 and 25) securing top panel assembly (26) to rear
closure assembly (21) and side closure assembly (9).
(3)
Torque screws (22) to 16 ±2 ft-lbs dry.
(4)
Install two screws (17) and locknuts (18), and
four washers (19 and 20) securing right panel assembly (12) to
rear closure assembly (21) and install two screws (14) and
washers (15) securing right panel assembly (12) to rear panel
assembly (16).
(5)
(6)
Torque screws (17) to 16 ±2 ft-lbs dry.
Torque screws (14) to 18 ±2 in.-lbs dry.
(7)
Install five screws (10) and washers (11) securing
right panel assembly (12) to right support assembly (13).
(8)
Torque screws (10) to 18 ±2 in.-lbs dry.
(9)
Install three screws (5) and locknuts (6), and six
washers (7 and 8) securing left panel assembly (3) to side
closure assembly (9)
(10) Torque screws (5) to 16 ±2 ft-lbs dry.
(11) Install three screws (1) and washers (2) securing
left panel assembly (3) to left support assembly (4).
(12) Torque screws (1) to 18 ±2 in.-lbs dry.
5-4.
TOP PANEL ASSEMBLY.
a . Removal.
See figure 5-3. Remove top panel assembly
from left, right and front panel assemblies and side and rear
closure assemblies as follows:
(1) Remove 11 screws (1) and washers (2) securing top
panel assembly (3) to left panel assembly (4), right panel
assembly (5) and front panel assembly (6).
5-8
Change 7
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NAVFAC P-8-622-12
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Fiqure 5-3.
Top Panel Assembly and Exhaust Plenum,
Removal and Installation
Change 7
5-9
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NAVFAC P-8-622-12
TO 35C2-3-456-1
TM-05682C-12
(2) Remove seven screws (7) and locknuts (8), and 14
washers (9 and 10) securing top panel assembly (3) to side
closure assembly (11) and rear closure assembly (12).
(3) Lift off top panel assembly (3).
Installation. See figure 5-3. Install top panel
b.
assembly to left, right and front panel assemblies and to side
and rear closure assemblies as follows:
Position top panel assembly (3) on left panel
(1)
right panel assembly (5), front panel assembly (6),
assembly (4)
side closure assembly (11), and rear closure assembly (12).
(2)
Install seven screws (7) and locknuts (8), and 14
washers (9 and 10) securing top panel assembly (3) to side
closure assembly (11) and rear closure assembly (12).
Install 11 screws (1) and washers (2) securing top
(3)
panel assembly (3) to left panel assembly (4), right panel
assembly (5) and front panel assembly (6).
(4) Torque screws (7) to 16 ±2 ft-lbs dry.
(5)
5-5.
Torque screws (1) to 18 ±2 in.-lbs dry.
LEFT PANEL ASSEMBLY.
a. Removal.
See figure 5-4. Remove left panel assembly
from left support assembly, side closure assembly, and front and
top panel assemblies as follows:
(1) Remove three screws (1) and washers (2) securing
left panel assembly (3) to left support assembly (4).
(2) Remove three screws (5) and washers (6) securing
left panel assembly (3) to front panel assembly (7).
(3) Remove three screws (8) and washers (9) securing
left panel assembly (3) to top panel assembly (10).
(4) Remove three screws (11) and locknuts (12), and
six washers (13 and 14) securing left panel assembly (3), to
side closure assembly (15) and lift off left panel assembly (3).
5-10
Change
7
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NAVFAC P-8-622-12
TO 35C2-3-456-1
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Figure 5-4.
Left Panel Assembly, Removal and Installation
Change 7
5-11
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NAVFAC P-8-622-12
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TM-05682C-12
b. Installation. See figure 5-4. Install left panel
assembly to left support assembly, side closure assembly and
front and top panel assemblies as follows:
(1) Position left panel assembly (3) on left support
assembly (4) and install three screws (11) and locknuts (12), and
six washers (13 and 14) securing left panel assembly (3) to side
closure assembly (15) .
(2) Torque screws (11) to 16 ±2 ft-lbs dry.
(3) Install three screws (8) and washers (9) securing
left side panel assembly (3) to top panel assembly (10).
(4)
Torque screws (8) to 18 ±2 in.-lbs dry,
(5) Install three screws (5) and washers (6) securing
left panel assembly (3) to front panel assembly (7).
(6) Torque screws (5) to 18 ±2 in.-lbs dry.
(7)
Install three screws (1) and washers (2) securing
left panel assembly (3) to left support assembly (4).
(8) Torque screws (1) to 18 ±2 in.-lbs dry.
5-6.
RIGHT PANEL ASSEMBLY.
a. Removal.
See figure 5-5. Remove right panel assembly
from right support assembly, rear closure assembly and rear, top
and front panel assemblies as follows:
(1) Remove five screws (1) and washers (2) securing
right panel assembly (3) to right support assembly (4).
(2) Remove three screws (5) and washers (6) securing
right panel assembly (3) to front panel assembly (7).
Remove four screws (8) and washers (9) securing
(3)
right panel assembly (3) to top panel assembly (10).
(4) Remove two screws (11) and locknuts (12), and four
washers (13 and 14) securing right panel assembly (3) to rear
closure assembly (15) and remove two screws (16) and washers (17)
securing right panel assembly (3) to rear panel assembly (18) and
lift off right panel assembly (3).
5-12
Change 7
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NAVFAC P-8-622-12
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Figure 5-5.
Right Panel Assembly, Removal and Installation
Change 7
5-13
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NAVFAC P-8-622-12
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b. Installation. See figure 5-5. Install right panel
assembly to right support assembly, rear closure assembly and
front, top and rear panel assemblies as follows:
(1) Position right panel assembly (3) on right support
assembly (4) and install two screws (16) and washers (17)
securing right panel assembly (3) to rear panel assembly (18),
and install two screws (11) and locknuts (12), and four washers
(13 and 14) securing right panel assembly (3) to rear closure
assembly (15).
(2) Torque screws (16) to 18 ±2 ft-lbs dry.
(3) Torque screws (11) to 16 ±2 in.-lbs dry.
(4) Install four screws (8) and washers (9) securing
right panel assembly (3) to top panel assembly (10).
(5) Torque screws (8) to 18 ±2 in.-lbs dry.
(6) Install three screws (5) and washers (6) securing
right panel assembly (3) to front panel assembly (7).
(7)
Torque screws (5) to 18 ±2 in.-lbs dry.
(8)
Install five screws (1) and washers (2) securing
right panel assembly (3) to right support assembly (4).
(9) Torque screws (1) to 18 ±2 in.-lbs dry.
5-7.
REAR PANEL ASSEMBLY.
a. Removal.
See figure 5-6. Remove rear panel assembly
from control cubicle support frame and right panel assembly as
follows:
(1) Remove two screws (1) and washers (2) securing
right panel assembly (3) to rear panel assembly (4).
(2) Remove four screws (5) and locknuts (6) and eight
washers (7 and 8) securing rear panel assembly (4) to control
cubicle support frame (9), and remove rear panel assembly (4).
b. Installation.
See figure 5-6. Install rear panel
assembly to control cubicle support frame and right panel
assembly as follows:
(1) Position rear panel assembly (4) on control
cubicle support frame (9) and install four screws (5) and
locknuts (6), and eight washers (7 and 8) securing rear panel
assembly (4) to control cubicle support frame (9).
(2) Torque screws (5) to 16 ±2 ft-lbs dry.
5-14
Change 7
TM 5-6115-584-12
NAVFAC P-8-622-12
TO 35C2-3-456-1
TM-05682C-12
Figure 5-6.
Rear Panel Assembly, Removal and Installation
Change 7
5-15
TM 5-6115-584-12
NAVFAC P-8-622-12
TO 35C2–3-456–1
TM-05682C-12
Install two screws (1) and washers (2) securing
(3)
right panel assembly (3) to rear panel assembly (4).
(4)
5-8.
Torque screws (1) to 18 ±2 in.-lbs dry.
EXHAUST PLENUM ASSEMBLY.
See figure 5-3. Remove exhaust plenum
a. Removal.
assembly from shutter assembly as follows:
(1)
Remove top panel assembly (3) as described in
paragraph 5-4.
(2)
Remove four screws (13) and locknuts (14), and
eight washers (15 and 16) securing exhaust plenum assembly (17)
to shutter assembly (18) and lift off exhaust plenum assembly
(17) .
See figure 5-3.
Installation.
b.
assembly on shutter assembly as follows:
Install exhaust plenum
(1) Position exhaust plenum assembly (17) on shutter
assembly (18) and install four screws (13) and locknuts (14), and
eight washers (15 and 16) securing exhaust plenum assembly (17)
to shutter assembly (18).
(2)
Torque screws (13) to 16 ±2 ft-lbs dry.
(3)
Install top panel assembly (3) as described in
paragraph 5-4.
5-9.
LEFT SUPPORT ASSEMBLY.
See figure 5-7. Remove left support assembly
a. Removal.
from skid and left panel assembly as follows:
(1) Remove four screws (1) and washers (2) securing
access plate (3) to AC output control box (4).
(2)
Remove left panel assembly (5), as described in
paragraph 5-5.
(3)
Loosen six screws (6) and slide out left support
assembly (7) from under skid (8).
Install left support
Installation.
See figure 5-7.
b.
assembly to skid and left panel assembly as follows:
(1) With six screws (6) loosened, slide left support
assembly (7) between skid (8) and bevel washers (9).
(2) Torque screws (6) to 26 ±2 ft-lbs dry.
5-16
Change 7
TM 5-6115-584-12
NAVFAC P-8-622-12
TO 35C2-3-456-1
TM-05682C-12
Figu re 5 - 7 .
Left Support Assembly, Removal and Installation
Change 7
5-17
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NAVFAC P-8-622-12
TO 35C2-3-456-1
TM-05682C-12
(3) Install left panel assembly (5) as described in
paragraph 5-5.
(4) Install access plate (3) to AC output control box
(4) with four screws (1) and washers (2).
5-10. RIGHT SUPPORT ASSEMBLY.
a. Removal.
See Figure 5-8. Remove right support
assembly from skid and right panel assembly as follows:
(1) Remove right panel assembly (1) as described in
paragraph 5-6.
(2) Loosen six screws (2) securing right support
assembly (3) to skid (4) and slide out right support assembly (3)
from under skid (4).
Installation.
See figure 5-8. Install right support
b.
assembly to skid and right panel assembly as follows:
(1) With six screws (2) loosened, slide right support
assembly (3) between skid (4) and bevel washers (5).
(2) Torque screws (2) to 26 ±2 ft-lbs dry.
(3) Replace right side panel (1) as described in
paragraph 5-6.
5-11. FRONT PANEL ASSEMBLY.
a. Removal.
See figure 5-9. Remove front panel assembly
from top, right and left panel assemblies as follows:
(1) Remove four screws (1) and washers (2) securing
the front panel assembly (3) to top panel assembly (4).
(2)
Remove six screws (5) and washers (6) securing
front panel assembly (3) to left panel assembly (7) and right
panel assembly (8).
(3) Remove front panel assembly (3).
b.
Installation.
See figure 5-9. Install front panel
assembly to top, right and left panel assemblies as follows:
(1) Position front panel assembly (3) against left
panel assembly (7) and right panel assembly (8) and secure with
six screws (5) and washers (6).
(2)
Install four screws (1) and washers (2) securing
front panel assembly (3) to top panel assembly (4).
(3) Torque screws (5 and 1) to 18 ±2 in.-lbs dry.
5-18
Change 7
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NAVFAC P-8-622-12
TO 35C2-3-456-1
TM-05682C-12
Figure 5-8.
Right Support Assembly, Removal and Installation
Change 7
5-19
TM 5-6115-584-12
NAVFAC P-8-622-12
TO 35C2-3-456-1
TM-05682C-12
Figure 5-9.
5-20
Front Panel Assembly, Removal and Installation
Change 7
TM 5-6115-584-12
NAVFAC P-8-622-12
TO 35C2-3-456-1
TM-05682C-12
5-12. SIDE CLOSURE ASSEMBLY.
See figure 5-10. Remove side closure
a. Removal.
assembly from rear closure assembly, top and left panel
assemblies as follows:
(1) Remove top panel assembly (1) as described in
paragraph 5-4.
(2)
Remove three screws (2) and locknuts (3) and six
washers (4 and 5) securing side closure assembly (6) to left
panel assembly (7).
Remove two screws (8) and locknuts (9), and four
(3)
washers (10 and 11) securing side closure assembly (6) to rear
closure assembly (12) and remove side closure assembly (6).
Install side closure
b. Installation.
See figure 5-10.
assembly to rear closure assembly, top & left panel assemblies as
follows:
(1)
Position side closure assembly (6) against rear
closure assembly (12).
(2)
Install side closure assembly (6) to rear closure
assembly (12) using two screws (8) and locknuts (9), and four
washers (10 and 11).
(3) Torque screws (8) to 16 ±2 ft-lbs dry.
(4)
Install three screws (2) and locknuts (3) and six
washers (4 and 5).
(5) Torque screws (2) to 16 ±2 ft-lbs dry.
Install top panel assembly (1) as described in
(6)
paragraph 5-4.
5-13. REAR CLOSURE ASSEMBLY.
a. Removal.
See figure 5-11. Remove rear closure
assembly from control box support, side closure assembly and
right and top panel assemblies as follows:
(1) Remove top panel assembly (1) as described in
paragraph 5-4.
(2)
Remove two screws (2) and locknuts (3), and four
washers (4 and 5) securing rear closure assembly (6) to right
panel assembly (7).
(3) Remove two screws (8) and locknuts (9), and four
washers (10 and 11) securing side closure assembly (12) to rear
closure assembly (6).
Change 7
5-21
TM 5-6115-584-12
NAVFAC P-8-622-12
TO 35C2-3-456-1
TM-05682C-12
Figure 5-10.
5-22
Side Closure Assembly, Removal and Installation
Change 7
TM 5-6115-584-12
NAVFAC P-8-622-12
TO 35C2-3-456-1
TM-05682C-12
Figure 5-11.
Rear Closure Assembly, Removal and Installation
Change 7
5-23
TM 5-6115-584-12
NAVFAC P-8-622-12
TO 35C2-3-456-1
TM-05682C-12
Remove four screws (13) and locknuts (14), and
(4)
eight washers (15 and 16) securing rear closure assembly (6) to
mounting brackets (17) and remove rear closure assembly (6).
b.
Installation. See figure 5-11. Install rear closure
assembly to control box support, side closure assembly, right and
top panel assemblies as follows:
(1) Install four screws (13) and locknuts (14), and
eight washers (15 and 16) securing rear closure assembly (6) to
mounting brackets (17).
(2.)
Tighten screws (13) to 16 ±2 ft-lbs dry.
Install two screws (8) and locknuts (9), and four
(3)
washers (10 and 11) securing side closure assembly (12) to rear
closure assembly (6).
(4)
Torque screws (8) to 16 ±2 ft-lbs dry.
(5)
Install two screws (2) and locknuts (3) and four
washers (4 and 5) securing rear closure assembly (6) to right
panel assembly (7).
(6)
Torque screws (2) to 16 ±2 ft–lbs dry.
(7)
Install top panel assembly (1) as described in
paragraph 5-4.
5-14.
REAR FLAP ASSEMBLY.
a. Removal.
See figure 5-12.
from skid as follows:
Remove rear flap assembly
(1)
Remove three screws (1) and locknuts (2), and six
washers (3 and 4) securing rear flap assembly (5) to skid (6).
(2)
Remove rear flap assembly (5).
Installation.
b.
See figure 5-12.
assembly to skid as follows:
Install rear flap
(1) Position rear flap assembly (5) on skid (6) and
install three screws (1) and locknuts (2), and six washers (3
and 4).
(2)
5-24
Torque screws (1) to 16 ±2 ft-lbs dry.
Change 7
TM 5-6115-584-12
NAVFAC P-8-622-12
TO 35C2-3-456-1
TM-05682C-12
Figure 5-12.
Rear Flap Assembly, Removal and Installation
Change 7
5-25
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NAVFAC P-8-622-12
TO 35C2-3-456-1
TM-05682C-12
SECTION III.
5-15.
ACOUSTIC SUPPRESSION KIT REPAIR
GENERAL .
WARNING
The local safety office and Preventative Medicine
Suppport Activity must be consulted prior to initial
CARC painting.
This section provides repair procedures for the acoustic suppression kit (ASK) . Repair of the ASK at all levels of Maintenance
is limited to replacement of panel assemblies and replacement of
hinges, latches, catches, captive nuts, rubber flaps and the
front panel silencer assembly. After repair is accomplished,
paint needed areas in accordance with MIL-T-704 using paint
colors green 383, brown 383, and black as required by
FED-STD-595 .
5-16.
REPLACEMENT OF ASK COMPONENTS.
a. Refer to Table 3-2 for inspection of ASK components for
damage and to determine if replacement is necessary.
b. Remove the ASK component to be replaced by following
the applicable removal procedures outlined in Section II.
c. Prior to replacement of the rear panel, left support,
right support, side closure and rear closure assemblies; adhesive
backed teflon tape must be applied to the new assemblies as
follows:
(1) Rear Panel Assembly (refer to figure 5-6, item 4).
(a)
Wipe surface clean.
(b) Cut a 11 3/4 in. length of adhesive backed
teflon tape from supplied bulk material.
(c) Apply adhesive backed teflon tape to the
right edge of rear panel assembly (edge with captive nuts) . Use
hand pressure to remove air bubbles.
(d)
(2)
Clear tape from captive nut openings.
Left Support Assembly (refer to figure 5-7,
item 7) .
(a)
Wipe surface clean.
Cut a 50 in. length of adhesive backed teflon
(b)
tape from supplied bulk material.
5-26
Change 7
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NAVFAC P-8-622-12
TO 35C2-3-456-1
TM-05682C-12
(c) Apply adhesive backed teflon tape to left
support assembly top surface (slotted surface which mounts
against underside of skid) . Use hand pressure to remove air
bubbles.
(d) Clear tape from slotted openings.
(3)
Right Support Assembly (refer to figure 5-8,
item 3).
(a)
Wipe surface clean.
(b) Cut a 50 in. length of adhesive backed teflon
tape from supplied bulk material.
(c) Apply adhesive backed teflon tape to right
support assembly top surface (slotted surface which mounts
against underside of skid). Use hand pressure to remove air
bubbles.
(d)
(4)
Clear tape from slotted openings.
Side Closure Assembly (refer to figure 5-10,
item 6).
(a)
Wipe surface clean.
(b) Cut a 20 1/2 in. length and a 29 1/4 in.
length of adhesive backed teflon tape from supplied bulk
material.
(c) Apply adhesive backed teflon tape to top
edges (edges with four holes) and left edge (edge with three
holes). Use hand pressure to remove air bubbles.
(d) Clear tape from holes.
(5) Rear Closure Assembly (refer to figure 5-11,
item 6).
(a)
Wipe surface clean.
Cut a 23 in. length and a 14 in. length of
(b)
adhesive backed teflon tape from supplied bulk material.
(c) Apply adhesive backed teflon tape to top edge
(edge with three holes) and right edge (edge with two holes which
will contact right panel assembly). Use hand pressure to remove
air bubbles.
(d)
Clear tape from holes.
Change 7
5-27
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NAVFAC P-8-622-12
TO 35C2-3-456-1
TM-05682C-12
Install ASK replacement components by following the
d.
applicable installation procedures outlined in Section II.
5-17. LATCH REPLACEMENT.
The following procedures are for replacement of side closure door
latch assemblies. Figure 5-13 (Illustration A) shows a typical
latch assembly replacement.
a. Remove damaged latch assembly (1) by drilling out rivet
(2) using a No. 11 drill bit (0.191 dia.).
Install new latch assembly (1) with a 3/16 inch dia.
b.
rivet (2) using hand riveter.
5-18.
CATCH REPLACEMENT.
The following procedures are typical for replacement of all
access door catch assemblies. Figure 5-13 (Illustration B) shows
a typical catch assembly replacement using the left panel as an
example.
a. Remove damaged catch assembly (1) by drilling out
rivets (2) using a No. 11 drill bit (0.191 dia.).
b.
Install new catch assembly (1) with four 3/16 inch dia.
rivets (2) using hand riveter.
5-19.
RUBBER FLAP REPLACEMENT.
The following procedures are typical for replacement of all
rubber flaps. Figure 5-13 (Illustration C) shows a rubber flap
replacement using the rear flap assembly as an example.
a. Remove rubber
from panel, support, or
(4) and nuts (5) (or by
bit) . Save retainer(s)
flap (1) (and retainer(s) if provided)
angle (2) by removing screws (3), washers
drilling out rivets using a No. 11 drill
(if provided) for reuse.
b. Use old rubber flap as a pattern to cut a new flap from
bulk material and to mark new holes in flap for rivets or screws.
flap.
c. Drill out holes for rivets or screws in new rubber
Use No. 11 (0.191 dia.) drill bit for rivet holes.
d.
Install new rubber flap (1) (with old retainer(s) if
provided) on panel, support, or angle (2) with same number of
screws (3), washers (4) and nuts (5) (or 3/16 inch dia. rivets
using hand riveter).
5-28
Change 7
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NAVFAC P-8-622-12
TO 35C2-3-456-1
TM-05682C-12
Figure 5-13.
Replacement of ASK Hardware Items
Change 7
5-29
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NAVFAC P-8-622-12
TO 35C2-3-456-1
TM-05682C-12
5-20.
HINGES .
The following procedures are for hinge replacement on the top
panel assembly access door. See figure 5-13.
(Illustration D).
a. Remove hinge (1) from panel assembly (2) and access
door (3) by drilling out rivets (4 and 5) using a No. 11 drill
bit (0.191 dia.).
b. Install hinge (1) to access door (3) and panel assembly
(2) with same number of 3/16 inch dia. rivets (4 and 5) using
hand riveter.
5-21.
CAPTIVE NUTS.
The following procedures are typical for replacement of captive
nuts installed in the left and right panel assemblies, rear panel
assembly, and front panel assembly. See figure 5-13 (Illustration E) showing an example for replacement of captive nuts.
a. Remove captive nut (1) from panel (2) by squeezing
sides of cage with pliers. Pull out until nut is freed.
b. Install new captive nut (1) by squeezing sides of cage
with pliers until nut can be inserted into square opening in
panel .
5-22.
FRONT PANEL SILENCER.
The following procedures are to be followed for replacement of
the silencer attached to the front panel. See figure 5-13
(Illustration F).
a. Remove nine rivets (1) securing silencer (2) to front
panel (3) by drilling out rivets using a No. 11 drill bit (0.191
dia.).
b. Apply adhesive backed teflon tape to all four inside
edges of new silencer. Clear tape from rivet hoses. Locate
silencer on front panel by aligning rivet holes.
c.
Install new silencer (2) to front panel (3) with nine
3/16 inch dia. rivets (1) using hand riveter.
5-30
Change 7
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NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
APPENDIX A
REFERENCES
1. PAINTING:
Painting and marking of USAF aerospace Ground Equipment.
T.O. 35-1-3
Painting and marking of USAF aerospace Ground Equipment.
TM 43-0139
Painting Instructions for Field Use.
2. RADIO SUPPRESSION:
MIL-STD-461
Radio Interference Suppression.
3. MAINTENANCE
T.O. 1-1-1
T.O. 1-1-2
T.O. 35-1-11
T.O. 35-1-12
T.O. 35-1-26
T.O. 35-1-524
Cleaning of Aerospace Equipment.
Corrosion Control and Treatment for Aerospace Equipment.
Organization, Intermediate and Depot Level Maintenance for FSC 6115
Equipment.
Components and Procedures for Cleaning Aerospace Ground Equipment.
Repair/Replacement Criteria for FSC 6115 Aerospace Ground Equipment.
USAF Equipment Registration Number System Applicable to FSC 6115
Equipment.
TM5-764
TM5-766
DA PAM 738-750
Electric Motor and Generator Repair.
Electric Power Generation in the Field.
The Army Maintenance Management System.
TM 5-6115-584-24P
NAVFAC P-8-622-24P
TO 35C2-3-456-4
SL-4-05682C
Organizational, Intermediate (field) Direct Support and General Support and
Depot Maintenance Repair Parts List.
4. SHIPMENT AND STORAGE:
T.O. 35-1-4
T.O. 38-1-5
Processing and Inspection of Aerospace Ground Equipment for Storage and
Shipment.
Processing and Inspection of Non-Mounted, Non-Aircraft Gasoline and
Diesel Engines for Storage and Shipment.
5. DESTRUCTION OF MATERIAL:
TM 750-244-3
Procedures for Destruction of Equipment to Prevent Enemy Use.
Change 6
A-1/(A-2 blank)
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NAVFAC P-8-622-12
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TM-05682C-12
APPENDIX B
COMPONENTS OF END ITEMS LIST
Section I. INTRODUCTION
B-1. SCOPE.
This appendix lists Integral Components of and Basic
Issue Items (BII) for the 5KW Generator Set to help you
inventory items required for safe and efficient operation.
B-2. GENERAL.
The components of end item list are divided into the
following sections:
a. Section II. Integral Components of the End Item.
These Items, when assembled, comprise the 5KW Generator Set and must accompany it whenever it is transferred
or turned in.
b. Section III. Basic Issue Items.
These are minimum essential items required to place the
5KW Generator Set in operation, to operate it and to perform emergency repairs. Although shipped separately
packed, they must accompany the Generator Set during
operation and whenever it is transferred between accountable officers. The illustrations will assist you with hard-toidentify items. This manual is your authority to requisition
replacement BII based on Table(s) of Organization and
Equipment (TOE) /Modification Table of Organization and
Equipment (MTOE) authorization of the end item.
B-3. EXPLANATION OF COLUMNS.
a. Illustration: This column is divided as follows:
(1) Figure Number. Indicates the figure number of
the illustration on which the item is shown (if applicable).
(2) Item Number. The number used to identify item
called out in the illustration.
b. National Stock Number (NSN); Indicates the national
stock number assigned to the end item which will be
used for requisitioning.
c. Part Number (P/N): Indicates the primary number
used by the manufacturer which controls the design and
characteristics of the item by means of its engineering
drawings, specifications, standards and inspection requirements to identify an item or range of items.
d. Description: Indicates the federal item name and
if required, a minimum description to identify the item.
e. Location. The physical location of each item Iisted
is given in this column. The lists are designed to inventory all items in one area of the major item before moving
on to an adjacent area.
f. Quantity Required (Qty Reqd): This column lists
the quantity of each item required for a complete major
item.
g. Quantity: This column is left blank for use during
inventory. Under the received column, list the quantity
you actually receive on your major item. The date columns
are for use when you inventory the major item at a later
date, such as for shipment to another site.
Change 2 B-1
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NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
Section II. INTEGRAL COMPONENTS OF END ITEM
(1)
Illustration
(a)
(b)
Figure Item
No.
No.
(2)
(3)
(4)
(5)
(6)
(7)
National
Stock
Number
Part No.
&
FSCM
Description
Location
Usable
On
Code
Qty
Reqd
NONE
Section III. ITEMS TROOP INSTALLED OR AUTHORIZED LIST
(3)
(4)
(5)
Description
Unit
of
Mess
Qty Auth
Case, Maintenance and Operational Manual
EA
1
5975-00-878-3791
Rod, Ground w/attachments and wire
EA
1
PAC
6145-00-960-6278
6 AWG Copper Wire
FT
5
PAC
5935-00-322-8959
Adapter Connector
EA
1
PAC
5120-01-013-1676
Slide Hammer, Ground Rod
EA
1
PAC
4210-00-566-8837
Extinguisher, Fire, Monobromotrifluoromethane w/mounting
bracket (charged replacement cylinder only NSN 4210-00708-0031). Operating temperature range -50° F (-10°C) to
+120° F (+49° C).
EA
1
EA
4
(1)
(2)
SMR
Code
Federal Stock
Number
PAC
7520-00-559-9618
PAC
Note: When inspection, maintenance or replacement of
cylinder on Walter Kidde Co. extinguisher is necessary, the
proper torque for swivel nut is not to exceed 160 inch pounds
maximum,
PAC
B-2
6140-00-179-8418
Change 5
Boot, Battery Terminal
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NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
APPENDIX C
ADDITIONAL AUTHORIZATION LIST
Section I. INTRODUCTION
C-1. SCOPE.
in with it. These items are authorized to you by CTA,
MTOE, TDA or JTA.
This appendix lists additional items you are authorized for
the support of the 5KW Generator Set
C-3. EXPLANATION OF LISTING,
C-2. GENERAL.
This list identifies items that do not have to accompany
the 5KW Generator Set and that do not have to be turned
National stock number, descriptions and quantities are
provided to help you identify and request the additional
items you require to support this equipment.
Section II. ADDITIONAL AUTHORIZATION LIST
(1)
NATIONAL
STOCK
NUMBER
6115-01-273-7377
(2)
(3)
(4)
DESCRIPTION
U/M
QTY
AUTH
Acoustic Suppression Kit
KT
1
Change 7
C-1/(C.2 blank)
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NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
APPENDIX D
MAINTENANCE ALLOCATION CHART
Section I. INTRODUCTION
D-1. GENERAL.
The maintenance functions are defined as follows:
a. This section provides a general explanation of all
maintenance and repair functions authorized at various
maintenance levels.
A - INSPECT. To determine serviceability of an
item by comparing its physical, mechanical and
electrical characteristics with established standards.
b. Section II designates overall responsibility for
the performance of maintenance functions on the
identified end item or component. The implementation
of the maintenance functions upon the identified end
item or component will be consistent with the assigned
maintenance functions.
B - TEST. To verify serviceability and to detect
electrical or mechanical failure by use of test equipment.
c. Section III lists the tools and test equipment
required for each maintenance function as referenced from Section II.
d. Section IV contains supplemental instructions or
explanatory notes required for a particular maintenance function.
D-2. EXPLANATIONS OF COLUMS IN SECTION II.
a. Group Number. Column 1. The assembly group
number is a numerical group assigned to each assembly. The assembly groups are listed on the MAC in
disassembly sequence beginning with the first assembly removed in a top down disassembly sequence.
C - SERVICE. To clean, to preserve, to charge and
to add fuel, lubricants, cooling agents and air. (If it is
desired that elements, such as painting and lubricating, be defined separately, they may be so listed.)
D - ADJUST. To rectify to the extent necessary to
bring into proper operating range.
E - ALIGN. To adjust specified variable elements
of an item to bring to optimum performance.
F - CALIBRATE. To determine the corrections to
be made in the readings of instruments or test equipment used in precise measurement. Consists of the
comparison of two instruments, one of which is a
certified standard of known accuracy, to detect and
adjust any discrepancy in the accuracy of the instrument being compared with the certified standard.
G - INSTALL. To set-up for use in an operational
environment such as an emplacement, site or vehicle.
b. Assembly Group. Column 2. This column contains a brief description of the components of each
assembly group.
c. Maintenance Functions. Column 3. This column
lists the various maintenance functions (A through K).
The upper case letter placed in the appropriate
column indicates the lowest maintenance level authorized to perform these functions. The active repair
time required to perform the maintenance function is
included directly below the symbol identifying the
category of maintenance. The symbol designations for
the various maintenance levels are as follows:
C - Operator or Crew
O - Organizational Maintenance
F - Direct Support Maintenance
H - General Support Maintenance
D-
Depot Maintenance
H - REPLACE. To replace unserviceable items with
serviceable like items.
I - REPAIR. Those maintenance operations necessary to restrore an item to serviceable condition
through correction of material damage or a specific
failure. Repair may be accomplished at each level of
maintenance.
J - OVERHAUL. Normally, the highest degree of
maintenance performed by the Army in order to
minimize time work is in process consistent with
quality and economy of operation. It consists of that
maintenance necessary to restore an item to completely serviceable condition as prescribed by maintenance standards in technical publications for each
item of equipment. Overhaul normally does not return
an item to like new, zero mileage or zero hour condition.
K - REBUILD. The highest degree of material
maintenance. It consists of restoring equipment as
nearly as possible to new condition in accordance with
Change 2
D-1
TM5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
original manufacturing standards. Rebuild is performed only when required by operational considerations or other paramount factors and then only at
the depot maintenance level. Rebuild reduces to zero
the hours of miles the equipment, or component
thereof, has been in use.
b. Maintenance Level. This column shows the lowest
level of maintenance authorized to use the tool or
test equipment.
c. Nomenclature. This column lists the name or
identification of the tool or test equipment.
d. Tools and Equipment. Column 4. This column is
provided for referencing by code the tools and test
equipment (Section III), required to perform the maintenance functions (Section II).
d. Tool Number. This column lists the manufacturer’s code and part number or federal stock number of tool or test equipment.
e. Remarks. Column 5. This column is provided
for referencing by code the remarks (Section IV)
pertinent to the maintenance functions.
D-4. EXPLANATION OF COLUMNS IN SECTION IV.
D-3. EXPLANATION OF
COLUMNS IN SECTION III.
a. Reference Code. This column consists of a
number and a letter separated by a dash. The number
references the T&TE requirements listed in Section
II. The letter represents the specific maintenance
function the item is to be used with in Columns (A
through K) of Section II.
D-2
Change 2
a. Reference Code. This column consists of two
letters separated by a dash (entered from Column 5
of Section II). The first letter references Alpha
sequence in Column 5 and the second letter references a maintenance function, Column 3 (A through K).
b. Remarks. This column lists information pertinent to the maintenance function to be performed
(as indicated in Section II).
Section II.
01
02
03
TM5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
D-3
NAVFAC P-8-622-12
TM5-6115-584-12
TM-05682C-12
Section II.
D-4
03
04
Section II.
[
04
TM 5-6115-584-12
NAVFAC P-8-622.12
TO-35C2-3-456-1
TM-05682C-12
D-5
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
Section II.
D-6
04
05
06
Section II.
06
TM5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
07
D-7
TM5-6115-584-12
NAVFAC P-8-622-12
Change 2
TM-05682C-12
TO-35C2-3-456-1
Section II.
D-8
07
08
Section II.
08
09
TM 5-6115-584-12
NAVFAC P-8-622-12
TO35C2-3-456-1
TM-05682C-12
D-9
Change 2
TM5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
Section II.
D-10
09
10
11
12
Section II.
12
13
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
14
D-11
Gi
● ON dflO?K)
L33dSNl
LLS3’11
3XAI13S
F
ILsrmlv
N!X’IV
‘1’-IVLSNI
ZIIVd3M
WWIW3A0
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
Section II.
D-12
14
k
o
0:
Section II.
14
15
TM 5-6115-584-13
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
D-13
Change 9
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-l
TM-05682C-l2
Section II.
D-14
15
Section II.
15
TM5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
D-15
Change 9
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
Section II.
D-16
15
16
Section II.
16
17
TM 5-6115-584-12
NAVFAC P-8-622-12
TM-05682C-12
TO-35C2-3-456-1
D-16.1/(D-16.2 blank)
Section II.
17
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
D-17
TM5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-l
TM-05682C-12
Section III. TOOLS, TEST AND SUPPORT EQUIPMENT REQUIREMENTS
Reference
Code
Nomenclature
Tool
Number
1-B
0
Tester, Battery Electrolyte Solution
6630-171-5126 or Equal
2-1
F
Torch Outfit, Cutting and Welding Tool
Set L/t W67706
3433-357-6311 or Equal
3-B
Multimeter
6625-581-2036 or Equal
4-B
o
o
Thermometer, Self Indicating 50-400
Degrees F Range
6685-527-7867 or Equal
5-B
F
Test Set Armature
6625-233-1459 or Equal
6-1
F
Tool Kit, Electrical Connector Repair
5180-876-9366 or Equal
7-H
F
Hoist, Chain, 3 Ton
3950-292-9879 or Equal
8-H
F
Trestle, Hoist, Portable 5 Ton
3950-449-7005 or Equal
9-H
F
Multimeter, Split Core
6625-892-1497 or Equal
10-I-J
F
Ohmmeter
6625-581-2466 or Equal
II-H
F
Puller Attachment Component of Puller
Kit 5180-701-8046
5180-711-6753 or Equal
12-1
F
Soldering Outfit, Electric
3439-853-8760 or Equal
13-H
F
Wrench, Torque 1/2” Drive
5120-640-6364 or Equal
14-H
F
Lifter, Valve Spring
5120-239-8686 or Equal
15-B
F
Tester, Spring Resiliency
5120-449-8028 or Equal
1 6-H
F
Grinding Machine, Valve Face
4910-540-4679 or Equal
17-H
H
Remover & Replacer, Valve Guide
5120-219-8404 or Equal
1 8-H
H
Remover & Replacer, Insert Valve Seat
5120-473-7393 or Equal
19-H
H
Grinding Set, Valve Seat
4910-473-6437 or EquaI
20-B-H
F
Tool Kit, Diesel Injector Repair
4910-317-8265 or Equal
21-H
H
Indicator, Connecting Rod Alignment
4910-733-2487 or Equal
22-H
H
Caliper Micrometer, Outside O“ thru 1”
5120-540-2978 or Equal
23-H
H
Compressor,
5120-250-6055 or Equal
24-H
H
Expander, Piston Ring
5120-894-0758 or Equal
25-H
H
Caliper, Micrometer, Outside 2“ thru 3“
5210-221-1745 or Equal
26-F-B
H
Compressor Tester Gage
4910-00-870-6283 or Equal
27-B-H
F
Gage, Depth, Micrometer
5210-00-542-4602 or Equal
27-F-B
H
Adapter
4910-00-870-2127 or Equal
1-
D-18
Maintenance
Category
Change 9
Piston
Ring
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
ALPHABETICAL INDEX
Subject
A
AC Instrumentetion System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Acoustic Suppression Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Instruction and Rating Plates... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal and Installation Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-36
5-2
5-3 thru 5-14,
F5-2 thru F5-12
6-16 thru 5-22,
F5-13
F3-8
3-17
F1-9
1-7
F3-10
3-18,4-41
3-18,4-41
3-18,4-41
4-41
F3-9
F3-11
4-22
4-22
5-1
Repair and Replacement of Hardware items. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AC Output Contro lBox Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AC Output Control Box Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Administrative Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Cleaner Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Impaction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Cleaner and ShroudAssembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Filter Element, cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Auxiliary Fuel Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test, On Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Auxiliary Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B
. . . . . . . . . . . . . . . . . . .
F4-17
Battery Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F3-2
3-11
3-11
4-25
4-25
4-25
4-25
F4-16
F4-23, 4-27
4-27
4-27
4-27
4-27
F4-24
F3-23
F4-40, 4-45
Batteries, Testing . . . . . . . . . . . . . . . .
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Installing . . . . . . . . . . . .
.
Battery Charging Alternator . . . . . . . . . .
.
Inspection . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . .
.
Replacement . . . . . . . . . . . . . . . . .
.
.
Test . . . . . . . . . . . . . . . . . . . . .
Battery Charging Regulator/Rectifier Assembly, . . . . . .
Battery and frame . . . . . . . . . . . . . . . . . . . . . .
Breather . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . .
Repair . . .
Replacement
Test . . . .
Battery
Cables,
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c
Consumable Operating and Maintenance Supplies
Control Cubicle Assembly . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . .
Service . . . . . . . . . . . . . . . . . . .
Test Bench . . . . . . . . . . . . . . . . .
Test, On Equipment . . . . . . . . . . . . .
Control Cubicle Support Assembly . . . . . . .
Inspection . . . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . .
Control Cubicle Test Set-Up . . . . . . . . . .
Control Cubicle Wiring Harness
Control System, Description and Function . . . . . . .
Cylinder Head Assembly . . . . . . . . . . . . .
T3-1, 3-1
F3-12, F4-33
4-38
4-38
3-19
4-38
4-38
3-19
4-36
4-38
F3-15
3-21
F4-34
F4-35
F1-10
4-34
F4-42
Change 7
Index 1
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
ALPHABETICAL INDEX
(CONT)
Subject
D
DC Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Destructionof Material to Prevent Enemy Use . . . . . . . . . . . . . . . . . . . .
4-35
1-6
E
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F3-7
F1-6
F4-36
4-42
4-39
3-24, 4-42
4-42
4-42
F3-17
4-17
4-17
4-16
4-17
3-22, 4-17
4-17
4-17
4-17
4-17
4-24
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,
F1-2.1
F1-2
F1- 1
F4-44
4-52
4-52
4-52
4-52
4-52
F4-18, F4-22
3-16, 4-26
4-26
4-26
4-26
4-26
4-26
F4-21
F4-19
F4-20
F3-22
3-21
F4-37
F3-6
3-15, 4-40
4-40
4-40
Float Switch, Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F4- 8
F4- 9
Electric Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Cable Schematic. . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description and Function . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Cooling System.. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description and Function.. . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Electrical System, Description and Function. . . . . . . . . . . . . .
Engine Generator Set
Engine Generator Set with Suppression Kit . . . . . . . . . . . . . . .
Left-Front, Three-Quarter View . . . . . . . . . . . . . . . . . . . . . .
Right-Rear, Three-QuarterView . . . . . . . . . . . . . . . . . . . . .
Engine Mounting Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Starter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test, Bench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test, Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Engine Starter Brushes, Inspecting . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Starter, Testing . . . . . . . . . . . . . . . . . . . . .
Engine Starter Wiring Diagram. . . . . . . . . . . . . . . . .
Engine Stop Solenoid . . . . . . . . . . . . . . . . . . . . . .
Engine Wiring Harness, Inspection . . . . . . . . . . . . . . .
Exhaust Muffler and Air Cleaner Assemblies . . . . . . . . .
Exhaust Muffler Assemblies . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . .
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F
INDEX 2
Change 7
Section II.
GROUP NO.17
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
TM5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
Section III. TOOLS, TEST AND SUPPORT EQUIPMENT REQUIREMENTS
REFERENCE
CODE
MAINTENANCE
CATEGORY
1-B
2-I
O
F
3-B
4-B
O
O
5-B
6-I
7-H
8-H
9-H
10-I-J
11-H
F
F
F
F
F
F
F
12-I
13-H
14-H
15-B
16-H
17-H
18-H
19-H
20-B-H
21-H
22-H
23-H
24-H
25-H
26-F-B
27-B-H
27-F-B
F
F
F
F
H
H
H
H
F
F
H
F
F
H
H
F
H
D-18
NOMENCLATURE
TOOL
NUMBER
Tester, Battery Electrolyte Solution
Torch Outfit, Cutting and Welding Tool
Set LI W67706
Multimeter
Thermometer, Self Indicating 50-400 Degrees F Range
Test Set Armature
Tool Kit, Electrical Connector Repair
Hoist, Chain, 3 Ton
Trestle, Hoist, Portable 5 Ton
Multimeter, Split Core
Ohmmeter
Puller Attachment Component of Puller
Kit 5180-701-8046
Soldering Outfit, Electric
Wrench, Torque 1/2” Drive
Lifter, Valve Spring
Tester, Spring Resiliency
Grinding Machine, Valve Face
Remover & Replacer, Valve Guide
Remover & Replacer, Insert Valve Seat
Grinding Set, Valve Seat
Tool Kit, Diesel Injector Repair
Indicator, Connecting Rod Alignment
Caliper, Micrometer, Outside 0” thru 1”
Compressor, Piston Ring
Expander, Piston Ring
Caliper, Micrometer, Outside 2” thru 3”
Compressor Tester Gage
Gage, Depth, Micrometer
Adapter
6630-171-5126 or Equal
3433-357-6311 or Equal
6685-527-7867 or Equal
6625-233-1459 or Equal
5180-876-9366 or Equal
3950-292-9879 or Equal
3950-449-7005 or Equal
6625-892-1497 or Equal
6625-581-2466 or Equal
5180-711-6753 or Equal
3439-853-8760 or Equal
5120-640-6364 or Equal
5120-239-8686 or Equal
5120-449-8028 or Equal
4910-540-4679 or Equal
5120-219-8404 or Equal
5120-473-7393 or Equal
4910-473-6437 or Equal
4910-317-8265 or Equal
4910-733-2487 or Equal
5120-540-2978 or Equal
5120-250-6055 or Equal
5120-894-0758 or Equal
5210-221-1745 or Equal
4910-00-870-6283 or Equal
5210-00-542-4602 or Equal
4910-00-870-2127 or Equa1
Change 11
*U.S. GOVERNMENT PRINTING OFFICE: 1992 - 311-831/61210
PIN # 032551-011
TM5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
Section IV. EXPIANATION OF REFERENCE CODES
REMARKS
REFERENCE CODE
A-A
Visual Inspection
B-B
Hydrometer Test
C-B
Operational Test
D-I
Weld and Straighten
E-B
Thermometer Test
F-B, C-D,
H, I-J
In accordance with Procedure in Applicable TM
G-A
Inspect for Minimum Length
H-B
Growler Test
I-B
Test for known Voltage
J-I
Fabricate New Harness
K-D
Adjust after Repair or Replacement
L-B
Continuity Test
M-D
Zero Adjustment
N-C
Replace Element
o-c
Drain Condensation
P-B
Insulation Breakdown and Continuity Tests
Q-K
Rewind
R-A
Visual Audible and Physical Heat Detection
S-D
Adjust to Specification in Applicable TM
T-D
Adjust Injector Pressure Setting
U-B
Pressure Test
V-I
Includes Replacing Valves and Springs
W-B
Spring Tension and Length
Change 2
D-19/(D-20
blank)
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
ALPHABETICAL INDEX
Paragraph,
Figure, Table,
Number
Subject
A
AC Instrumentation System... . . . . . . . . . . . . . . . . . . . . . . . . . . .
AC Output Control Box Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AC Output Control Box Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . .
Administrative Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Cleaner Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Cleaner and Shroud Assembly.. . . . . . . . . . . . . . . . . . . . . . . . . .
Air Filter Element, Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ammeter - Voltmeter Transfer Switch Continuity Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Auxiliary Fuel Solenoid Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test, On Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-36
F3-8
3-17
F1-9
1-7
F3-10
3-18, 4-41
3-18, 4-41
3-18, 4-41
4-41
F3-9
F3-11
T4-4
4-22
4-22
B
Batteries, Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Cables, Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Charging Alternator . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Charging Regulator/Rectifier Assembly, Testing . . . . . . . . . . .
Battery and Frame . . . . . . . . . . .
Breather . . . . . . . . .
.
...*..
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●
✎
✎
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✎✎✎☛
✎
✎
...00
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...*.
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..0
F4-17
F3-2
3-11
3-11
4-25
4-25
4-25
4-25
F4-16
F4-23, 4-27
4-27
4-27
4-27
4-27
F4-24
F3-23
F4-40, 4-45
c
Consumable Operating and Maintenance Supplies . . . . . . . . . .
Control Cubicle Assembly
Assembly . . . . . .
Disassembly . . . . .
Inspection . . . . . .
Installation . . . . .
Removal . . . . . .
Service . . . . . . .
Test, Bench . . . . .
Test, On Equipment .
Control Cubicle Support Assembly . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing, . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Cubicle Test Set-Up . . . . . . . . . . . . . . . . . . . .
Control Cubicle Wiring Harness . . . . . . . . . . . . . . . . . .
Control System, Description and Function . . . . . . . . . . . . .
Cylinder Head Assembly . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . .
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T3-1, 3-1
F3-12, F4-33
4-38
4-38
3-19
4-38
4-38
3-19
4-38
4-38
F3-15
3-21
F4-34
F4-35
F1-10
4-34
F4-42
Change 3
Index 1
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
ALPHABETICAL INDEX (CONT)
Paragraph,
Figure, Table,
Number
Subject
D
DC Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Destruction of Material to Prevent Enemy Use . . . . . . . . . . . . . . . . . . . .
4-35
1-6
E
Electric Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Cable Schematic.. . . . . . . . . . . . . . . . . . . . . . . . .
Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description and Function . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description and Function . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Electrical System, Description and Function . . . . . . . . . . . . .
Engine Generator Set
Left-Front, Three-Quarter View . . . . . . . . . . . . . . . . . . . . .
Right-Rear, Three-Quarter View . . . . . . . . . . . . . . . . . . . .
Engine Mounting Assembly . . . .
Disassembly . . . . . . . . . .
Inspection . . . . . . . . . . .
Installation . . . . . . . . . .
Reassembly . . . . . . . . . .
Removal . . . . . . . . . . . .
Engine Starter Assembly . . . . .
Cleaning and Inspection . . .
Installation . . . . . . . . . .
Removal . . . . . . . . . . . .
Repair . . . . . . . . . . . . .
Test, Bench . . . . . . . . . .
Test, On Equipment . . . . .
Engine Starter Brushes, Inspecting
Engine Starter, Testing . . . . . .
Engine Starter Wiring Diagram . .
Engine Stop Solenoid . . . . . . .
Engine Wiring Harness., Inspection
–.
Exhaust Muffler and Air Cleaner Assemblies . . . . . . . . . . . . . . . .
Exhaust Muffler Assemblies . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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F3-7
F1-6
F4-36
4-42
4-39
3-24, 4-42
4-42
4-42
F3-17
4-17
4-17
4-16
4-17
3-22, 4-17
4-17
4-17
4-17
4-17
4-24
F1-2
F1-1
F4-44
4-52
4-52
4-52
4-52
4-52
F4-18, F4-22
3-16, 4-26
4-26
4-26
4-26
4-26
4-26
F4-21
F4-19
F4-20
F3-22
3-21
F4-37
. . . .
. . . .
F3-6
. . . .
3-15, 4-40
4-40
. . . .
4-40
. . . .
. . . .
. . . .
F
Float Switch, Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INDEX 2
F4- 8
F4- 9
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
ALPHABETICAL INDEX (CONT)
Paragraph,
Figure, Table,
Number
Subject
F (CONT)
Fuel Filter and Strainer Assembly. . . . . . . . . . . . . . . . . . . . . . . . . F3-13, F4-11
4-20
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-20
Installation . . . . . . . . . . . . . . . . . . . . . . . . .
4-20
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-20
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-14, F4-13
F4-12
Fuel Pump, Fuel Hoses and Solenoid . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Pumps and Hoses
4-21
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-21
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-21
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-21
Test, On Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F4-14
Fuel Shut-Off Solenoid, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Shut-Off Solenoid
4-23
Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-23
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-23
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-23
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-23
Test, On Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F4-15
Fuel Solenoid Test Set-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F4-10
Fuel Strainer Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-18
Fuel System, Description and Function . . . . . . . . . . . . . . . . . . . . . . .
3-20
Fuel System (Less Tank), Inspection . . . . . . . . . . . . . . . . . . . . . . . . .
F1-5
Fuel System Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F3-4, F4-7
Fuel Tank Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-13, 4-19
Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-19
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-13, 4-19
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-19
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-19
Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
G
Generator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description and Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator/Exciter Assembly, Inspection . . . . . . . . . . . . . . . . . . . . . . .
Generator Screen-Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator Set
Controls and Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dismantling for Movement. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Servicing on Receipt . . . . . . . . . . . . . . . . . . . . . . .
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation Plans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Re-installing after Movement . . . . . . . . . . . . . . . . . . . . . . . . . .
Tabulated Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Urcrating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Glow Plug Assemblies
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F3-18
4-53
3-23
4-54
F4-45
T2-1
1-9
4-3
F1-7
F4-2
4-1
4-2
F1-4
4-4
1-10
F4-1
F1-8
4-48
4-48
4-48
4-48
Change 3
INDEX 3
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
ALPHABETICAL INDEX(CONT)
Paragraph,
Figure, Table,
Number
Subject
G (CONT)
Ground Rod and Fuel Drum Adapter Hold-Down Assembly . . . . . . . . . . . . .
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . .
Removal
Ground Stud. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F3-3
3-12
3-12
3-12
F3-24
I
Injector Nozzle Assembly and Fuel Lines, Inspection . . . . . . . . . . . . .
Intake Manifold Assembly . . . . : . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test, On Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
4-47
F3-19
4-43
4-43
4-43
4-43
4-43
Levels of Maintenance Accomplishment . . . . . . . . . . . . . . . . . . .
Load Terminal Board Assembly. . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Load Terminal and Reconnection Configuration . . . . . . . . . . . . . . .
Load Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lockout Switch and Gear . . . . . . . . . . . . . . . . . . . . . . . . . . .
Low Oil Pressure Switch
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test, Bench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test, On Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication Instructions
Operator/Crew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Organizational . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
1-5
F4-32
4-37
4-37
F2-4
F2-1
F4-25
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
4-31
4-31
4-31
4-31
. . . .
. . . .
. . . .
3-2
4-7
F3-1, 3-3
Maintenance Forms and Records . . . . . . . . . . . . . . . . . . . . . .
Maintenance Repair Parts . . . . . . . . . . . . . . . . . . . . . . . . . .
Manual
Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Scope . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . .
Master Switch Continuiti Check . . . . . . . . . . . . . . . . . . . . . .
. . . . .
. . . . .
. . . . .
. . . . .
. . . . .
Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Cooler Hoses, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Drain Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Drain Hose and Valve, Replacement . . . . . . . . . . . . . . . . . . . . .
Oil Fill Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INDEX 4
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
1-3
4-6
1-2
1-1
T4-3
F4-28
4-30
4-30
4-30
4-30
F4-29
F3-20
4-49
F4-43
4-51
4-51
TM5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
ALPHABETICAL INDEX (CONT)
Paragraph,
Figure, Table,
Number
Subject
O (CONT)
Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . .
Service . .
Oil Filter and Oil Pressure Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pan-Base, Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pressure Gauge
Removal . . . . . . . . . . . . . . . . . . . . . . .
Replacement
Test
Oil, System, Description and Function
Operating Procedures
Equipment Reconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating in Alternate Modes . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation in Dusty or Sandy Areas. . . . . . . . . . . . . . . . . . . . . . .
Operation in Extreme Cold . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation in Extreme Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation in Wet or Humid Areas. . . . . . . . . . . . . . . . . . . . . . .
Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shutting Down Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting Generator Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F4-30
4-32
4-32
4-32
F3-21
4-50
4-33
F4-31, 4-33
4-33
4-29
2-3
2-1
2-5
2-9
2-8
2-10
2-2
2-6
2-4
P
1-8
Preparation for Shipment or Storage . . . . . . . . . . . . . . . . . . . . . . . . .
F4-27
Pressure Oil System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
T3-2, T4-1
Preventive Maintenance Checks and Services . . . . . . . . . . . . . . . . . . . .
Operator/Crew
3-5
Correcting and Reporting Deficiencies . . . . . . . . . . . . . . . . . . .
3-6
Determining Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-7
Units in Continuous Operation . . . . . . . . . . . . . . . . . . . . . . . .
Organizational
4-9
Determining Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8
General
4-10
Units in Continous Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F4-3
Primary Radio Interference Suppression Components . . . . . . . . . . . . . . . .
R
Radio Interference Suppression Components . . . . . . . . . . . . . . . . . . . . .
General Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reconnection Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reconnection Switch Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reporting Of Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rocker Arm Cover Oil Line, Cleaning . . . . . . . . . . . . . . . . . . . . . . . .
Rocker Arm Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rocker Arm to Valve Clearance, Checking and Adjusting . . . . . . . . . . . . . .
4-15
4-14
F2-2
T2-2
1-4
F4-39
F4-38
4-44
4-44
4-44
4-44
F4-41
INDEX 5
TM5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
ALPHABETICAL INDEX (CONT)
Paragraph,
Table,
Number
Figure,
Subject
s
Screen-Guard
Inspection . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . .
Repair . . . . . . . . . . . . . . . . . . . . .
Shutter Assembly . . . . . . . . . . . . . . . . . .
Shutter Box Assembly, Inspection . . . . . . . . .
Shutter and Thermo Power Element Assembly . . .
Shutters, Adjusting . . . . . . . . . . . . . . . . .
Skid-Base . . . . . . . . . . . .
Cleaning . . . . . . . . . .
Description and Function . .
Inspection . . . . . . . . . .
Installation . . . . . . . . .
Removal . . . . . . . . . .
Repair . . . . . . . . . . .
Special Tools . . . . . . . . . .
Speed Control . . . . . . . ..O
Inspection . . . . . . . . . .
Starter Lockout Switch Adjusting
Starter Lockout Switch and Gear
Adjustment .
Inspection . .
Removal . .
Repair . . .
Replacement
Test . . . . .
Starting Procedure
.
.
.
.
.
.
.
. .
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
. . . . . . . . . .....
. . . . . . . . . . ..
. . . . . . . . . . . . . . .
. . . . . . . . . . . . . . .
. . . . . . . . . . . . . .
. . . . . . . . . . . . . . .
. . .. . . . ....
. . . . . . . . . . . . . . .
. . . . . . . ..
. . . . . . . . . . . . . . .
. . . . . . . . . ...
. . . . . . . . . . . . .
. . . . . . . . . . . . ..
. . . . . . . . . .. . . .
. . . . . . . . . . . . ..
. . . . . . .. ....
. . . . . . . . . . . ...
. . . . . . . . . . . ...
. . . . . . . . . . . .
4-55
4-55
4-55
4-55
F4-4
3-14
F3-5
F4-5
F4-46
3-25
4-56
3-25, 4-57
4-57
4-57
4-57
4-5
F3-16
3-21
F4-26
.
.
.
.
.
.
.
. . .
. . .
. . . .
. . . . .
. . . . .
. . . . .
. . . . .
. . . .....
. . . . . .
. . . . . . .
. . . . . . . . .
. . . . . . . . .
. . . . . . . . .
. . . . . . . . .
.
.
.
.
.
.
.
4-28
4-28
4-28
4-28
4-28
4-28
F2-3
.
.
.
.
.
. . . . . . . . . . . . . .
. . . . . . . . . . . . .
. . . . . . . . . . . . . . .
. . . . . . ... . . . . . . .
.................
.
.
.
.
.
F4-6
F1-3
T3-3, T4-2
3-9
4-12
Valve Rocker Arms
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-46
4-46
T
Thermo Unit, Adjusting . . . . . . . . . . . . . . . .
Tie Down, Lifting, and
Towing Provisions Crated Set
Troubleshooting
.....................
Operator
General . . . . . . . . . . . . .
Organizational, General . . . . . . . . . . . . .
v
Index 6
Change 3
TM5-6115-586-12
NAVFAC P-8-622
TO-35C2-3-456-1
TM-05682C-12
By Order of the Secretaries of the Army, the Navy, and the Air Force:
I
BERNARD W. ROGERS
General, United States Army
Chief of Staff
Official:
PAUL T. SMITH
Major General, United States Army
The Adjutant General
D. G. ISELIN
Rear Admiral, CEC, U. S. Navy
Commander,
Naval Facilities Engineering Command
Official:
DAVID C. JONES, General, USAF
Chief of Staff
JAMES J. SHEPARD, Colonel, USAF
Director of Administration
W. R. JOHNSON
Brigadier General, U. S. Marine Corps
Acting Deputy Chief of Staff for Installation and Logistics
Distribution:
To be distributed in accordance with DA Form 12-25D, Operator maintenance requirements for Generator
Sets, Engine Driven: 5 KW, 60 HZ.
* Us. Govmt@mm PRINTING OFFICE : 19940- 300-769 ( 22286)
PIN:
032551-011