TM-5-6115-634-14-and-P
ARMY
TM5-6115-634-14&P
TECHNICAL MANUAL
NAVY PUBLICATION
NAVFAC
P-8-647-14&P
AIR FORCE TECHNICAL ORDER
T O - 3 5 C 2 - 3 - 4 4 5 - 1 4
MARINE CORPS TECHNICAL MANUAL
TM-6115-14&P/1
TECHNICAL
OPERATOR,
UNIT,
GENERAL
INCLUDING
POWER
REPAIR
PU
(NSN
AND
DIESEL
KW,
(DIRECT
MAINTENANCE
PARTS
TRAILER
20
INTERMEDIATE
SUPPORT)
UNIT,
DRIVEN,
AND
MANUAL
AND
MANUAL
SPECIAL
TOOLS
LIST
ENGINE
MOUNTED,
60
HZ
794/G
6115-01-242-1665)
Approved
for
public
HEADQUARTERS,
16
release.
Distribution
is
DEPARTMENT
AUGUST
unlimited.
OF
1988
THE
ARMY
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
TO-35C2-3-445-14
TM-6115-14&P/1
a
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
TO-35C2-3-445-14
TM-6115-14&P/1
b
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
TO-35C2-3-445-14
TM-6115-14&P/1
c
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
TO-35C2-3-445-14
TM-6115-14&P/1
d
TM 5-6115-634-14&P
NAVFAC P-8-647-14&P
TO-35C2-3-445-14
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e/(f blank)
TM 5-6115-634-14&P
NAVFAC P-8-647-14&P
TO-35C2-3-445-14
C 6
CHANGE
HEADQUARTERS
DEPARTMENTS OF THE ARMY, NAVY AND AIR FORCE
WASHINGTON, D.C., 28 April 1997
NO. 6
OPERATOR, UNIT, AND INTERMEDIATE (DIRECT
AND GENERAL SUPPORT) MAINTENANCE MANUAL, INCLUDING
REPAIR PARTS AND SPECIAL TOOLS LIST
POWER UNIT, DIESEL ENGINE DRIVEN, TRAILER MOUNTED, 20 KW, 60 HZ
PU 794/G
(NSN 6115-01-242-1665)
DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited
TM 5-6115-634-14&P/NAVFAC P-8-647-14&P/TO-35C2-3-445-14, 16 August 1988, is changed as
follows:
1.
Remove and insert pages as indicated below. New or changed text material is indicated by a vertical bar
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Remove pages
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F-53 and F-54
2.
Insert pages
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Retain this sheet in front of manual for reference purposes.
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TM 5-6115-634-14&P
NAVFAC P-8-647-14&P
TO-35C2-3-445-14
C6
By Order of the Secretaries of the Army, Navy, and Air Force (including the Marine Corps):
DENNIS J. REIMER
General, United States Army
Chief of Staff
Official:
Administrative Assistant to the
Secretary of the Army
03170
RONALD R. FOGELMAN
General, USAF
Chief of Staff
Official :
HENRY VICCELLIO, JR.
General, USAF
Commander, Air Force Materiel Command
J. E. BUFFINGTON
Rear Admiral, CEC, US Navy
Commander
Navy facilities Engineering
Command
M. K. HAYDEN
Colonel, USMC
Director, Program Support
Marine Corps Systems Command
DISTRIBUTION:
To be distributed in accordance with DA Form 12-25-E, block no. 3869, requirements for
TM 5-6115-634-14&P.
TM 5-6115-634-14&P
NAVFAC P-8-647-14&P
TO-35C2-3-445-14
C5
HEADQUARTERS
CHANGE
DEPARTMENTS OF THE ARMY, NAVY AND AIR FORCE
WASHINGTON, D.C., 1 February 1994
NO. 5
Operator, Unit, and Intermediate (Direct and General Support)
Maintenance Manual
Including Repair Parts and Special Tools List
POWER UNIT, DIESEL ENGINE DRIVEN,
TRAILER MOUNTED, 20 KW, 60 HZ PU 794/G
(NSN 6115-01-242-1665)
DISTRIBUTION STATEMENT A:
Approved for public release, distribution is unlimited.
TM 5-6115-634-14&P/NAVFAC P-8-647-14&P/TO-35C2-3-445-14, 16 August 1988, is
changed as follows:
1.
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
i and ii
2-11 and 2-12
i and ii
2-11 and 2-12
Retain this sheet in front of manual for reference purposes.
TM 5-6115-634-14&P
NAVFAC P-6-647-14&P
TO-35C2-3-445-14
C5
By Order of the Secretaries of the Army, Air Force, and Navy:
GORDON R. SULLIVAN
General, United States Army
Chief of Staff
Official:
MILTON H. HAMILTON
Administrative Assistant to the
Secretary of the Army
06117
MERRILL A. McPEAK
General, USAF
Chief of Staff
RONALD W. YATES
General, USAF
Commander, Air Force Materiel Command
DAVID E. BOTTORFF
Rear Admiral, CEC, US Navy
Commander
Navy Facilities Engineering
Command
DISTRIBUTION:
To be distributed in accordance with DA Form 12-25-E, block no. 3869, requirements for
TM 5-6115-634-14&P.
TM 5-6115-634-14&P
NAVFAC P-8-647-14&P
TO-35CC2-3-445-14
TECHNICAL MANUAL
NO. 5-6115-634-14&P
HEADQUARTERS
DEPARTMENTS OF THE ARMY, NAVY AND AIR FORCE
WASHINGTON, D.C., 16 August 1988
OPERATOR, UNIT, AND INTERMEDIATE (DIRECT
AND GENERAL SUPPORT) MAINTENANCE MANUAL, INCLUDING
REPAIR PARTS AND SPECIAL TOOLS LIST
POWER UNIT, DIESEL ENGINE DRIVEN, TRAILER MOUNTED, 20 KW, 60 HZ
PU 794/G
(NSN 6115-01-242-1665)
REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS
You can help improve this manual. If you find any mistakes, or if you know of a way to improve
these procedures, please let us know. Mail your letter or DA Form 2028 (Recommended
Changes to Publications and Blank Forms), or DA Form 2028-2 located in the back of this
manual directly to: Commander, US Army Aviation and Troop Command, ATTN:
AMSAT-I-MP, 4300 Goodfellow Blvd., St. Louis, MO 63120-1798. You may also submit your
recommended changes by E-mail directly to <mpmt%[email protected]>.
A reply will be furnished directly to you. Instructions for sending an electronic 2028 may be
found at the back of this manual immediately preceding the hard copy 2028.
DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited.
TABLE OF CONTENTS
Page
HOW TO USE THIS MANUAL
CHAPTER 1
Section I
Section II
Section Ill
Section IV
CHAPTER 2
Section I
Section II
Section III
Section IV
CHAPTER 3
Section I
Section II
Section III
iii
INTRODUCTION
GENERAL INFORMATION
EQUIPMENT DESCRIPTION AND DATA
PRINCIPLES OF OPERATION
SERVICE UPON RECEIPT
1-1
1-1
1-3
1-7
1-7
2-1
OPERATING/INSTRUCTIONS
DESCRIPTION AND USE OF OPERATORS
CONTROLS AND INDICATORS
PREVENTIVE MAINTENANCE CHECKS AND SERVICES
OPERATION UNDER USUAL CONDlTlONS
OPERATION UNDER UNUSUAL CONDITIONS
2-1
2-1
2-10
2-18
3-1
3-1
3-1
3-3
OPERATOR MAINTENANCE
LUBRICATION INSTRUCTIONS
TROUBLESHOOTING PROCEDURES
MAINTENANCE PROCEDURES
Change
6
I
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Page
Chapter 4
UNIT MAINTENANCE INSTRUCTIONS
REPAIR PARTS AND SPECIAL TOOLS, TEST,
MEASUREMENT AND DIAGNOSTIC EQUIPMENT (TMDE)
AND SUPPORT EQUIPMENT
Section II
PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
Section III TROUBLESHOOTING
Section IV MAINTENANCE PROCEDURES
Section
4-1
I
Chapter 5
INTERMEDIATE DIRECT SUPPORT MAINTENANCE
INSTRUCTIONS
4-1
4-1
4-5
4-7
5-1
REPAIR PARTS, SPECIAL TOOLS, TEST, MEASUREMENT
AND DIAGNOSTIC EQUIPMENT (TMDE) AND SUPPORT EQUIPMENT 5-1
PREVENTIVE MAINTENANCE CHECKS AND SERVICES
Section II
5-1
5-1
Section III TROUBLESHOOTING
MAINTENANCE PROCEDURES
Section IV
5-6
PREPARATION FOR STORAGE AND SHIPMENT
Section V
5-61
Section I
Chapter 6
Section I
Section II
REPAIR PARTS, SPECIAL TOOLS, TEST MEASUREMENT AND
DIAGNOSTIC EQUIPMENT (TMDE) AND SUPPORT EQUIPMENT
MAINTENANCE
6-1
6-1
APPENDIX G
APPENDIX H
REFERENCES
MAINTENANCE ALLOCATION CHART
COMPONENTS OF END ITEM AND BASIC
ISSUE ITEMS LIST
ADDITIONAL AUTHORIZATION LIST (AAL) ITEMS
EXPENDABLE/DURABLE SUPPLIES AND
MATERIALS LIST
UNIT, INTERMEDIATE DIRECT SUPPORT AND
INTERMEDIATE GENERAL SUPPORT REPAIR
PARTS AND SPECIAL TOOLS LIST
ILLUSTRATED LIST OF MANUFACTURED ITEMS
TORQUE LIMITS (IF APPLICABLE)
F-1
G-1
H-1
INDEX
ALPHABETICAL
INDEX 1
APPENDIX A
APPENDIX B
APPENDIX C
APPENDIX D
APPENDIX E
APPENDIX F
ii
INTERMEDIATE GENERAL SUPPORT MAINTENANCE INSTRUCTIONS 6-1
INDEX
A-1
B-1
C-1
D-1
E-1
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
TO-35C2-3-445-14
TM-6115-14&P/1
HOW TO USE THIS MANUAL
The front cover index will assist YOU in quickly locating information. It
identifies information frequently used by the operator and maintenance
Each item appearing on the front cover is boxed and identified by
personnel.
topic and page number in the manual where the information is located. The page
in the manual in conjunction with the front cover has a black box on the edge
of the page. Bend the manual in half and follow the margin index to the page
with the black edge marker.
A complete, Alphabetical, subject index is located in the back of the manual
and separate sequential indexes appear before each chapter. These indexes
should help you in locating information under most likely looked for names.
Entries within the table of contents which duplicate the entries on the front
cover index are highlighted with a box.
iii/(iv Blank)
TM 5-6115-634-14&P
NAVFAC P-8-647-14&P
TO-35C2-3-445-14
CHAPTER 1
INTRODUCTION
CHAPTER INDEX
Page
1-1
1-3
1-7
1-7
Subject Index
General Information
Equipment Description and Data
Principles of Operation
Service Upon Receipt
Section I.
GENERAL INFORMATION
1-1. Scope
a. This manual is pubfished for the information and
guidance of personnel to whom the power unit, PU
794/G, is issued, It contains instructions for operation,
unit, direct support and general support maintenance
including repair parts and special tool lists for items of
the PU 794/G not covered in other technical manuals.
b. The PU 794/G provides 20 kW, 60 Hz precise
power. The PU 794/G consists of a modified MEP
004A 15 kW, 60 Hz generator mounted on a modified
M200A1 trailer.
c. Refer to TM 5-6115-464 series manuals for
generator set basic operation and maintenance and
TM 9-2330-205-14&P for the trailer.
d. Some portions of this publication are not applicaMe 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.
1-2. Maintenance Forms, Records and Reports.
a. (A) Maintenance forms and records used by
Army personnel are prescribed by DA Pam 738-750.
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 users should refer to their service-peculiar directives to determine applicable maintenance
forms and records to be used.
d. (MC) Maintenance forms and records used by
Marine Corps personnel are prescribed by
TM4700-15/1
e. Reports of errors, omissions and recommendations for improvement of this manual by its user is
encouraged. Such reports should be submitted by
various service personnel as follows:
(1) Army. DA Form 2028 direct to: Commander, U.S. Army Aviation and Troop Command, ATTN:
AMSAT-I-MP, 4300 Goodfellow Blvd., St. Louis, MO
63120-1798.
(2) Navy. By letter direct to: Commanding Office, Naval Construction Battalion Center, ATTN:
Code 15741, Port Hueneme, CA 93043-5000.
(3) Air Force. AFT0 From 22 direct to: Commander, Sacramento Air Logistics Center (AFLC),
ATTN: SM-ALC-MMEDTA, McClellan AFB, CA
95652-5609.
(4) Marine Corps. NAVMC 10772 direct to:
Commanding General, U.S. Marine Corps, Marine
Corps Logistics Base (Code 850) Albany, GA
31704-5000.
Change
4
1-1
TM5-6115-634-14&P
HAVFAC P-8-647-14&P
TO-35C2-3-445-14
TM-6115-14&P/1
1-3. Destruction to Prevent Enemy Use
Demolition of the PU 794/G to prevent
enemy use will be in accordance with the
requirements of TM750-244-3. Refer to
TM750-244-6 for trailer destruction procedures.
1-4. (A) Reporting Equipment
Improvement Recommendations (EIR)
If your PU 794/G needs improvement, let
us know. Send us an EIR. You, the user,
are the only one who can tell us what
you do not like about your equipment.
TABLE 1-1.
1-6.
Let us know why you do not like the
design. Put it on SF 368 (Quality Deficiency Report). Mail it to us at:
Commander, U.S. Army Troop Support Command, ATTN: AMSTR-QX, 4300 Goodfellow
Blvd., St. Louis, MO 63120-1798. We
will send you a reply.
1-5. Nomenclature Cross-Reference
Refer to Table 1-1 for nomenclatures
which deviate or shorten the official
nomenclature. The common name and the
official nomenclature is provided to
prevent misunderstandings.
NOMENCLATURE CROSS REFERENCE LIST
Common Name
Official Nomenclature
PU 794/G
Power Unit, Diesel Engine
Driven, Trailer Mounted,
20 kW, 60 Hz, PU 794/G
M200A1 trailer
Chassis, Trailer: Generator,
2 1/2 Ton, 2-wheel, modified
M200A1
Generator set
Generator Set, Diesel Engine
Driven, 15 kW modified to
20 kW, 60Hz
List of Abbreviations
Refer to Table 1-2 for a list of nonstandard abbreviations used in this
manual .
TABLE 1-2.
Hz
kg
km/h
kPa
kW
n-m
1-2
LIST OF NONSTANDARD ABBREVIATIONS
Centimeter
Degree Celsius
Degree Fahrenheit
Hertz
Kilograms
Kilometer per hour
Kilo Pascals
Kilowatt
Newton-meter
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
TO-35C2-3-445-14
TM-6115-14&P/1
1-7. Glossary
Refer to Table 1-3 for a glossaryof
terms. This table gives the manual user
definitions not provided in Tables 1-1
and 1-2.
TABLE 1-3.
Toxic
Poisonous
Electrolyte
A mixture of sulfuric acid and water used
in the batteries.
Isochronous
Recurring at regular intervals
Section II.
1-8.
GLOSSARY
EQUIPMENT DESCRIPTION AND DATA
Equipment Characteristics,
Capabilities and Features
a. Description: The PU 794/G consists of a modified M200A1 trailer
chassis, auxiliary assemblages and a
modified 15 kW, 60 Hz, generator set
(MEP-004A). The modifications are not
intended or designed to be removed. The
modifications are as follows:
(1) The PU 794/G is rated at 20
kW .
(2) The engine generator assembly
is mounted on shock isolator mounts to
reduce noise transmission.
(3) The fan and shrouding were
replaced with an improved fan and guard
for better cooling and noise reduction.
(4) A muffler is added to a new
combustion air intake filter housing and
the exhaust system is modified to reduce
noise.
(5) The top of the set was raised
to enclose the muffler and sound suppression material is added to the inside of
the housing.
(6) Devices for electromagnetic
pulse protection (EMP) have been added.
(7) A remote control unit for the
PU 794/G is furnished for mounting inside
a communications shelter and will start,
stop and parallel two power units. The
remote control unit indicates set running,
contactor closed, low fuel and phase
relation for paralleling.
(8) To facilitate remote paralleling, the PU 794/G has a remote speedsetting isochronous governor, permissive
paralleling relay, under- frequency and
undervoltage protective devices, associated
control and power cables, junction boxes
and switches.
b. Features: The PU 794/G provides
20 kW, 60 Hz power and has noise reduction to 65 db(A) in any direction when
measured at seven meters. The unit is
EMP protected. The unit can be operated
from the generator set controls or from
It can be
the remote control unit.
operated as a single unit or paralleled
with another PU 794/G for load transfer.
Two PU 794/G’s are not to be continuously operated in parallel. The power
unit can be operated while being towed.
1-9. Location and Description of Major
Components
Refer to Figure 1-1 and 1-2 for the location of major components of the PU 794/G.
For components not discussed in this
paragraph, refer to TM5-6115-464-12 for
the generator set components and TM92330-205-14&P for the components of the
trailer.
1-3
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
TO-35C2-3-445-14
TM-6115-14&P/1
Figure 1-1.
l-4
Curbside View PU 794/G
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
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TM-6115-14&P/1
Figure 1-2.
Roadside View PU 794/G
1-5
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
TO-35C2-3-445-14
TM-6115-14&P/1
a. Exhaust Silencer: Replaces the
existing muffler to decrease exhaust
noise during operation.
b. Enclosure Extension: Added to
raise the top of the generator set to
house the new exhaust silencer.
c. Exhaust Baffles: Noise absorbing
baffles that reduces exhaust air noise
during operation.
d. Air Cleaner Assembly: Includes a
resonant chamber to reduce air flow noise.
e. Intake Baffles: Noise absorbing
baffles that reduces intake air noise
during operation.
o. Remote Control Unit: Furnished
for remote control operations. Will
start, stop and parallel two PU 794/G’s.
The panel indicates set running, contactor closed, low fuel and phase synchronization for paralleling.
p. Cable Tray: Stores the power and
ground cables when not in use.
1-10. Tabulated Data
a. Generator Set. Refer to TM5-6115464-12 and TM5-6115-464-34 technical
manuals for additional information concerning Generator Set, DOD Model MEP004A.
ENGINE
f. Connector Plate: Provides an
external connection for power and remote
control cables.
g. Shorting Plug:
tion.
Permits local opera-
h. Remote Functions Assembly: Provides interface between the generator
set and the remote control unit.
i. Fender Kit Assembly: The fender
assembly is fitted to the trailer frame
and provides a platform work area for
personnel.
Personnel Platform: A retractable
platform is mounted at the rear of the
trailer frame and provides a platform
work area for personnel.
Manufacturer
Model
DOD Drawing
Number
Type
Rated Horsepower
Cooling System
Capacity
Crankcase
Capacity
Fuel Tank
Capacity
Electrical
System
k. Hand Brake Levers: The two hand
brake levers were moved from under the
trailer frame and mounted on the front
steps of the fender assembly.
Manufacturer
l. Cable Reel: Stores the control
cables and parallel cables of the PU 794/G
during movement or storage.
DOD Drawing
Number
Type
Junction Box: Provides a common
junction for power and control of two
power units when operating in parallel.
Load Capacity
1-6
4 cylinder, 4 cycle,
liquid-cooled
diesel
41 continuous @
1800 rpm
18.6 quarts
(22.2 liters)
8.0 quarts (7.6
liters)
15.0 gallons (56.7
liters)
24 VDC, negative
ground
GENERATOR
Current Rating
n. Battery Box: External battery box
relocates the batteries for easier operator maintenance.
White Engines, Inc.
Hercules Engine
Division
D198-ERX51
72-2222
Power Factor
Electric Machinery
Company
72-2400
Rotating field,
synchronous,
Brushless
(1800 rpm) 20 kW @
60 Hz
(1800 rpm) 69.4 amps
@ 120/208 VAC, 3ph.
0.8
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TO-35C2-3-445-14
TM-6115-14&P/1
b. Trailer. The trailer is a modified M200A1, 2 1/2 ton, 2-wheel trailer.
Towing Facilities
Towing Vehicle
Brakes
Handbrakes
Tires
Voltage (lighting)
Lunette
5-ton 6x6
Air over
hydraulic
Mechanical,
handlever
controlled
Pneumatic,
normal use 35
psi (3.16 kg/sq
cm). In mud,
snow and sand
use 15 psi
(1.06 kg/sq
cm).
24 VDC
Section III.
1-11.
Principles of Operation
The PU 794/G provides 20 kW, 60 HZ precise power. It is noise suppressed and
EMP protected. It is designed to be
operated and paralleled remotely from a
distance up to 100 feet (30.48 M). The
Section IV.
Figure 1-3 shows the
c. PU 794/G
data plates identifying the
PU 794/G.
Length
Width
Height
Weight
181 inches (459.74 cm)
97 inches (246.34 cm)
98 inches (248.92 cm)
6440 lbs (2921.18 kg)
Operating Range
-1O°F to 110°F (-24°C to 43°C) at
sea level
-lO°F to 95°F (-24°C to 35°C) up to
3000 feet (914.4 M)
Maximum 150 (26 percent) slope from
the level in any direction
PRINCIPLES OF OPERATION
trailer can be towed over prepared roads
at a maximum speed of 55 mph (88.5 km/h),
and over unimproved roads at a maximum
speed of 30 mph (48.3 km/h). It will
ford hard-bottom water crossings to any
depth that can be negotiated by the towing
vehicle.
SERVICE UPON RECEIPT
1-12. Unpacking/Uncrating the PU 794/G
a. Remove the packing list from the
right front side of the crate and set
aside.
b. Using metal cutters, cut the band
from around the crate.
c. Remove the crate from the top of
the generator set.
d. Cut the barrier paper along the
base of generator set.
g. Lift the generator and remove the
plywood shipping base from the trailer.
h. Set the generator back on the
trailer and reinstall the mounting
bolts.
i. Remove the packing material from
the battery box, cable tray, accessory
box , and the document box compartment.
j.
Remove the bands and plywood cap
from the cable reels.
e. Remove the barrier paper and dessicant bags.
k. Use the packing list and inventory
the accessories. Report any discrepancies to your supervisor.
f. Remove the mounting bolts that
mount the generator to the trailer.
1. Remove all packing/cushioning
material from the cables and tools.
1-7
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
TO-35C2-3-445-14
TM-6115-14&P/1
Figure 1-3.
1-8
Identification Plates
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
TO-35C2-3-445-14
1-13. Inspecting and Servicing PU 794/G
a. Inspection
(1) Make a complete visual inspection of
the exterior of the PU 794/G for evidence of damage.
(2) Open the control panel access doors
and inspect the control panel for damage.
(3) Open the generator compartment
access doors and inspect each component for
obvious signs of damage and corrosion.
(4) Open the engine compartment access
doors and inspect the engine and its components
for visible damage.
(5) Inspect the air cleaner assembly and
exhaust openings for any obstruction.
(6) Open the battery box cover and
inspect the batteries for damage.
b. Servicing
(1) Remove the depreservation guide from
the document box. The depreservation guide
explains what was done to the equipment prior to
packaging and a brief description of what has to
be done to place the unit into operation. Perform
services as required by the depreservation guide.
(2) Remove the batteries from the battery
box. Refer to TM 9-6140-200-14 to activate the
dry charge batteries. Install the batteries.
(3) Perform the before operation preventive maintenance checks and services listed in
chapter 2.
(4) Refer to TM 5-6115-464-12 and flush
the cooling system.
1-14. Installation.
a. PU 794/G.
(1) Position the PU 794/G on as level surface as possible, not to exceed 15° (26 percent)
slope.
Prior to separating the PU-794/G
from the prime mover open the accessory box and remove the ground
rod sections, slide hammer rod, and
the ground wire assembly. The accessory box cannot be accessed
when the curbside handbrake is engaged. Failure to do so may result
in serious injury or equipment damage.
To gain entry to the accessory box
the curbside handbrake must be
disengaged. Be sure the wheels
are blocked and leg supports down
before disengaging the handbrake.
When finished using the accessory
box be sure curbside handbrake is
engaged. Failure to observe this
warning may result in serious personal injury or damage to equipment.
Wheels must be blocked,
and leg supports down in
position before operating
ment. Failure to do so may
serious injury.
brakes set
support
the equipresult in
(2) Set the hand brakes and block the
wheels securely to prevent movement.
(3) Pull landing leg supports down and
adjust length for firm contact with the ground.
b. External Fuel Line Connections. When the
PU 794/G is to be operated for long intervals, frequent refilling of the fuel tank can be eliminated by
obtaining fuel from an external source (such as a
55 gallon diesel fuel drum). Refer to TM 5-6115464-12.
Change 3
1-9
TM5-6115-634-14&P
NAVFAC P-5-647-14&P
TO-35C2-3-445-14
(1) Connect one end of the auxiliary fuel
line to the PU 794/G auxiliary fuel supply connection located below the integral tank filler cap (Figure 1-4).
(2) Connect other end of the auxiliary fuel
line to the auxiliary fuel source.
1-10
(3) Position the fuel selector valve in the
AUXILIARY position (figure 1-4).
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
TO-35C2-3-445-14
Figure 1-4. External Line Connections
Change 3
1-10.1/(1-10.2 blank)
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TM-6115-14&P/1
CHAPTER 2
OPERATION/INSTRUCTIONS
CHAPTER INDEX
Page
Subject Index
Operator Controls and Indicators
Preventive Maintenance Checks and Services (PMCS)
Operation Under Usual Conditions
Operation Under Unusual Conditions
Section I.
2-1.
DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS
Operator Controls and Indicators
a . Generator Set. Refer to
TM-6115-464-12 for operator controls
and indicators for the generator set.
Refer to TM9-2330b. Trailer.
205-14&P for operator controls and indicators for the M200A1 trailer.
c. PU
2-1
2-1
2-10
2-18
794/G
(1) Figure 2-1 shows the location
of power and control connections for the
junction box.
(2) Figure 2-2 shows the controls
and indicators of the remote control
unit.
LOW FUEL - Lights when the
fuel level drops below 1/4
tank.
ENG RUNNING - Lights when
the engine has attained
running speed.
CONTACTOR CLOSED -Indicates
that the output contactor
of the power unit is closed.
FREQ ADJUST - Adjusts the
frequency of the respective
sets for parallel operation.
ENGINE: START, STOP Starts and stops the engine.
OPEN, CLOSE CONTACTOR:
Opens and closes the main
load contactor.
BATTLE SHORT: ON, OFF Permits emergency operation
by bypassing the protective
circuits except short circuit
and over speed.
SYN LIGHT - Synchronizing
lights indicate when the two
power units are in phase with
one another.
Section II. PREVENTIVE MAINTENANCE CHECKS AND SERVICES
2-2. Operator Preventive Maintenance
Checks and Services (PMCS)
a. To ensure that the PU 794/G 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. Deficiencies discovered during
operation of the unit shall be noted for
future correction, to be made as soon as
operation has ceased. Stop operation
immediately if a deficiency is noted
during operation which would damage the
equipment. All deficiencies and shortcomings shall be recorded together with
the corrective action on the applicable
form at the earliest possible opportu-
2-1
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Figure 2-1.
2-2
Junction Box Connections
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TM-6115-14&P/1
Figure 2-2.
Remote Control Unit Controls and Indicators
2-3
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nity. Army and Navy users shall accomplish the necessary preventive maintenance services listed and described in
paragraph 2-2.b. Air Force users shall
refer to the applicable inspection manuals
and work card sets in the TO-35C2-3 Series
for periodic requirements and Table 2-1
for detailed procedures. Marine Corps
users should refer to the current issue
of TM-11275-15/3A.
b. Table 2-1 contains a tabulated
listing of preventive maintenance checks
and services which must be performed
before, during, and after operation by
the operator. The item numbers are
listed consecutively and indicate the
sequence of minimum requirements.
c. Perform the checks and services in
Table 2-1 at the specified intervals.
Keep in mind the following:
(1) Do your “Before (B)” PMCS
before operating the PU 794/G. Pay
attention to the notes, cautions and
warnings.
ing” means to monitor the generator,
trailer and power distribution unit and
related parts.
(3) Do your “After (A)” PMCS
immediately after shutting down operPay attention to notes, cautions
ation.
and warnings.
(4) Leakage def initions 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.
(2) Do your “During (D)” PMCS
while the PU 794/G is operating. “DurTABLE 2-1.
2-4
OPERATOR/CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES
TM5-6115-634-14&P
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TM-6115-14&P/1
TABLE 2-1. OPERATOR/CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES (CONT’D)
2-5
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TABLE 2-1. OPERATOR/CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES (CONT’D)
2-6
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TABLE 2-1.
OPERATOR/CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES (CONT’D)
2-7
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TM-6115-14&P/1
TABLE 2-1. OPERATOR/CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES (CONT’D)
2-8
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NAVFAC P-8-647-14&P
T0-35C2-3445-14
TABLE 2-1. OPERATOR/CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES (CONT'D)
Change 1
2-9
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NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TABLE 2-1. OPERATOR/CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES (CON’D)
Section III. OPERATION UNDER USUAL CONDITION
2-10
Change 3
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NAVFAC P-6-647-14&P
T0-35C2-3-445-14
minimum depth of 4 feet (1.22 M). The ground lead
must be at least No. 4 AWG copper wire. Refer to
“Operating Under Unusual Conditions” for ground
connections during mobile operation.
(3) Release curbside handbrake. Remove
ground rod section, the slide hammer rod and the
ground wire assembly from the accessory box.
Remove the slide hammer from the front of the
trailer.
(4) Ground the PU 794/G.
Wheels must be blocked, brakes set
and leg supports down in support
position be fore operating the equipment. Failure to do so may result in
serious injury.
(a) Connect ground wire assemblies to
the ground stud on the connector plate of each
generator set. Select a spot on the ground
between trailers to install the ground rod.
*U.S. GOVERNMENT PRINTING OFFICE: 1993- 755-028/80139
Change 3
2-10.1 /(2-10.2 blank)
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Nuts must be tight on the slide
hammer rod. Loose hardware may
result in serious injury.
The slide hammer striker plate
and top nut must be tightened
to the end of the threads on the
slide hammer rod. The slide
hammer rod and ground rod section
must make firm contact inside the
ground rod coupler. Damage to
rods, plate and couplers could
result if left loose.
NOTE
If the slide hammer is assembled,
go to step (c).
(2). Tighten firmly against the striker
plate (1). Connect the ground rod coupler
(5) to the bottom of the slide hammer
rod (2). Connect the ground rod section
(6) to the other end of the ground rod
coupler (5). Tighten the ground rod
section (6) to make firm contact with
the slide hammer rod (2).
(c) Remove nut (4) from the
top of the slide hammer rod (2) if necessary, and place the slide hammer (7) on
top of the slide hammer rod. Slide down
until it rests on the striker plate (1).
Attach nut (4) to the top of the slide
hammer rod. Tighten to the end of the
threads.
(d) While holding in a vertical position, lift the slide hammer
(7). Slide it downward to drive the
ground rod section (6) into the ground.
Continue driving the ground rod section
(6) until approximately 4 inches (10
centimeters) remains above ground level.
(e) Disconnect the slide
hammer assembly (8) from the ground rod
coupler (5).
(f) Attach the ground rod
section (6) to the ground rod coupler
(5). Attach another ground rod coupler
(5) to the top of a new ground rod section (6). Connect the slide hammer
assembly (8) to the new ground rod
coupler (5).
(g) Repeat steps (d), (e)
and (f) until at least 8 feet (2.4
meters) of ground rod is buried. Disconnect nut (4), and remove the slide
hammer (7) from the slide hammer assembly (8). Disconnect the top ground rod
coupler (5).
(b) Connect the slide hammer
striker plate (1) to bottom of the slide
hammer rod (2). Tighten to the end of
threads. Connect lockwasher (3) and nut
(4) to bottom of the slide hammer rod
(h) Store the slide hammer
assembly (8) and unused ground rod in
the accessory box. Reset curbside handbrake. Secure the slide hammer to the
steel bar on front of the trailer with
lock pin.
2-11
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NAVFAC P-8-647-14&P
TO-35C2-3-445-14
(i) Connect a damp (9) to top of the ground
rod and reconnect the ground rod coupler (5). Connect
loose end of the ground wire assembly to the damp.
Tighten the damp screw (10). Ensure that all ground
wire connections are tight.
(5) Deleted.
c. Cable Connections for two PU 794/Gs.
NOTE
b. Cable Connections for a single PU 794/G
When making cable connections, PU
794/6 must be shut down. Failure to
observe this warning could result in
death by electrocution.
(1) Remove all the cables from the reel and
tray.
(2) Connect the 5-foot (1.52 meters) control
cable between the control connector on the connector
plate and the control connection on the junction box for
unit 1 (Figure 2-3).
(3) Connect the 100-foot (30.46 meters) control cable to the remote connector on the junction box.
Connect the other end of the control cable to the control cable connection on the front of the shelter (Figures 2-3 and 2-4).
(4) Connect one end of the power cable to the
power connector on the generator (not on the junction
box), and the other end of the power cable to the connector on the shelter.
Two PU 794’s are not to be continuously operated in parallel, only to
transfer power.
When making cable connections,
both PU 794/Gs must be shut down
due to feedback from and operating
unit. Failure to observe this warning
could result in death by electrocution.
(1) Connect the first PU 794/G following paragraph b. above. Designate this unit as unit number 1.
All connections to the junction box will be made at this
unit.
(2) Connect the grounding wire of the second
PU 794/G to the ground rod of the first PU 794/G.
(3) Connect the 25-foot (7.62 meters) control
cable from the control connector on the connector
plate of unit 2 to the unit 2 control connection of the
junction box on unit 1 (Figure 2-5).
(4) Connect the 25-foot (7.62 meters) power
cable between the power connector on the connector
plate of unit 2 and the unit 2 power connection of the
junction box on unit 1 (Figure 2-5)
All pins are live on the junction box
power connectors.
Power connections on the junction
box should not be used for single unit
operation.
All connectors are hot when used. Do
not remove caps from unused hocks.
2-12
Change 6
(5) Connect the 25-foot (7.62 meters) parallel
cable to the parallel connectors on both unit 1 and unit
2 (Figures 2-3 and 2-5).
(6) At both generator sets place the PARALLEL
OPERATION/SINGLE UNIT OPERATION switch on
the generator control panel to the PARALLEL OPERATION position.
2-4. Initial Adjustments
Perform the PMCS in Table 2-1 before operating the
PU 794/G.
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
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TM-6115-14&P/1
Figure 2-3.
Cable Connections Locations - PU 794/G
2-13
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-146P/1
Figure 2-4. Cable Connections Locations - Shelter
2-14
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T0-35C2-3-445-14
TM-6115-14&P/1
Figure 2-5.
Cable Connection for Two PU 794/G’s
2-15
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T0-35C2-3-445-14
TM-6115-14&P/1
2-5. Single Unit Operating Procedures
a.
Starting the PU 794/G From the
Remote Control Unit
(2) Allow the PU 794/G to operate
for 3 minutes with no load applied.
(3) Place the ENGINE switch in
the STOP position.
(1) Perform before operation PMCS.
(4) Perform after operation PMCS.
(2) Ensure the PU 794/G has been
cabled for single unit operation according to paragraph 2-3.b.
(3) Using the remote control unit
for SET No. 1 (Figure 2-2), place the
ENGINE switch in the START position and
hold until the ENG RUNNING light is
illuminated for five seconds. Release
the switch.
NOTE
If the ENG RUNNING light does
not illuminate in 15 seconds,
place the ENGINE switch in the
STOP position. Wait at least
15 seconds before attempting
to start again. Attempt to
two more times. If the unit
fails to start, refer to
troubleshooting procedures.
NOTE
When the PARALLEL OPERATION/
SINGLE UNIT OPERATION switch
is in the PARALLEL OPERATION
position, hold the BATTLE
SHORT switch in the ON
position until the CONTACTOR
CLOSED light illuminates.
(4) Hold the CONTACTOR switch in
the CLOSE position until the CONTACTOR
CLOSED light illuminates. Release the
switch.
(5) Frequency can be adjusted by
using the FREQ ADJUST control on the
remote control unit while another person
is watching the frequency meter on the
power unit.
b.
Stopping the PU 794/G From the
Remote Control Unit.
(1) Place the CONTACTOR switch in
the OPEN position.
2-16
c.
Starting-Operating-Stopping
PU 794/U From the Generator
Set Controls.
Hearing protection is required
when working in the area of the
PU 794/G when engine is running
with access doors open.
Failure to do so could result
in hearing loss.
(1) Perform before operation PMCS.
(2) Ensure PU 794/G has been cabled
for single unit operation according to
paragraph 2-3.b.
(3) Remove one end of the 5-foot
(1.52 meters) control cable from the
control connector on the connector plate.
(4) Remove the shorting plug from
the storage shorting-connector on the
connector place.
(5) Connect the shorting plug in
the control connector on the connector
plate.
(6) Refer to the operating plate
located on the inside of the generator
control right door panel for startingoperating-stopping the PU 794/G.
(7) After stopping generator,
remove shorting plug from the control
connector of the connector plate.
(8) Install shorting plug in the
storage shorting-connector on the connector plate.
(9) Install free end of 5-foot
(1.52 meters) control cable in the control connector of the connector plate.
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TM-6115-14&P/1
(10) Perform after operation PMCS.
2-6.
Remote Operation of Two
Pu 794/G’s.
(2) Allow the PU 794/G unit 1 to
operate without a load for 3 minutes.
(3) Place the ENGINE switch of
SET No. 1 in the STOP position.
f.
Disregard the paralleling
instructions on the inside
of the control panel door.
a.
2-7.
Perform after operatin PMCS.
Preparation for Movement
Perform before operation PMCS.
b. Ensure the PU 794/G’s have been
cabled for two PU 794/Gs according to
paragraph 2-3c.
c. Start PU 794/G unit 1 from the
remote control unit according to paragraph 2-5.a. (2) through (4). Unit 1 is
now supplying power for normal operation.
d. To transfer load, for maintenance,
start PU 794/G unit 2 from the remote
control unit as follows:
(1) Start PU 794/G unit 2 by
placing the SET No. 2 ENGINE switch on
the remote control unit in the START
position and hold until the ENG RUNNING
lamp lights.
(2) Turn the FREQ ADJUST control
for SET No. 2 slowly until the SYN LIGHT
changes intensity at 3 to 5 second intervals.
(3) Watch the light carefully.
When the light achieves the dimmest
point, move the CONTACTOR switch to the
CLOSE position and hold until the CONTACTOR CLOSED lamp lights.
(4) The two PU 794/Gs are now
sharing the load.
(1) Place the CONTACTOR switch of
SET No. 1 in the OPEN position.
Lethal voltages are present
at the load connection board
of the generator set during
Do not attempt to
operation.
connect or disconnect load
leads while the generator set
is operating. Do not attempt
to connect or disconnect load
leads with the generator set
shut down and the load connected to another power source,
or while the generator set is
paralleled to another unit
which is operating. Serious
injury or death by electrocucould result.
a. Disconnect the cables from the
shelter, the junction box and the connector plate.
b. Disconnect the ground wire from
the connector plate and ground rod.
c. Store the power cables and ground
wire in the cable pan. Store the control cables and paralleling cable on the
cable reel.
d.
Remove the ground rod.
(1) Release the curbside handbrake. Remove the slide hammer (1) from
the front of the trailer. Remove the
slide hammer assembly (2) from the accessory, box.
(2) Remove the nut (3) from the
slide hammer assembly and place slide
hammer over the rod (5).
2-17
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Nuts must be tight on the slide
hammer rod. Loose hardware may
result in serious injury.
(3) Place the striker plate (4)
on the slide hammer assembly and replace
the nut (3) on the slide hammer rod.
(4) Connect the slide hammer
assembly (2) and slide hammer with the
striker plate at the top to the ground
rod coupler (6).
(5) Use the Slide hammer to lift
the ground section from the ground.
(6) Disconnect the ground rod and
remove nut (7).
(7) Remove the slide hammer from
the slide hammer assembly and store it
on the front of the trailer.
(8) Return the nut (7) to slide
hammer assembly and store the assembly
in the accessory box. Reset curbside
handbrake.
Section IV.
OPERATION UNDER UNUSUAL CONDITIONS
2-8. Mobile Operations
In mobile operations, the PU 794/G supplies power while being towed over the
highway. The operation of the PU 794/G
is the same as normal operation. Two
units cannot be paralleled while in
mobile operation. The equipment being
powered must be grounded to the generator set of the PU 794/G. Care must be
taken in the routing of the power, control and ground cables from the PU 794/G
to the shelter to preclude damage while
the vehicle is moving. To prepare for
mobile operation connect the cables as
follows:
a. Connect the ground cable to the
GROUND stud on the connector plate
(Figure 2-3).
2-18
b. Connect the 5-foot (1.52 meter)
power cable between the power connector
of the connector plate and unit 1 power
connector on the junction box (Figure
2-3).
c. Connect the 25-foot (7.62 meter)
power cable to the load connector of the
junction box (Figure 2-3).
d. Remove the shorting plug and store
in the storage shorting plug connector
on the connector plate (Figure 2-3).
e. Connect the 5-foot (1.52 meter)
control cable between the connector
plate control connector and the unit 1
control connection on the junction box
(Figure 2-3).
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f. Connect the 100-foot (30.48 meter)
control cable to the remote connector on
the junction box (Figure 2-3).
i. Connect the cables to the respective connectors on the equipment to be
used (Figure 2-4).
g. Route the ground cable, power
cable, and control cable along the side
of the generator set toward the tongue
of the trailer (Figure 2-6).
j. Tie or fasten the excess cable to
the towing vehicle to allow turning and
to prevent damage to the cable.
h. Fasten the cables to the trailer
with the straps on the trailer frame
(Figure 2-6).
2-19
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Figure 2-6.
2-20
Cable Routing For Mobile Operation
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CHAPTER 3
OPERATOR MAINTENANCE
CHAPTER INDEX
Page
Subject Index
3-1
3-1
3-3
Lubrication Instructions
Troubleshooting Procedures
Maintenance Procedures
Section I.
3-1.
LUBRICATION INSTRUCTIONS
Lubrication
The lubrication instructions for the
generator set are contained in L05-6115464-12. The lubrication instructions
Section II.
for the trailer are contained. in
TM9-2330-205-14&P.
TROUBLESHOOTING PROCEDURES
3-2. Troubleshooting
Table 3-1 lists the common malfunctions
that may occur during operation or maintenance of the PU 794/G or its components. Test/inspections and corrective
actions should be performed in the order
in which they are listed. This manual
cannot cover all possible malfunctions
that may occur under the many conditions
If a specific malfuncof operation.
tion, test, or corrective action is not
covered, notify your supervisor.
3-1
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Table 3-1.
TROUBLESHOOTING
MALFUNCTION
TESTOR INSPECTION
CORRECTIVE ACTION
CANNOT OPERATE THE POWER UNIT FROM THE REMOTE CONTROL UNIT.
Step 1.
Check control cable connectors for tightness.
Tighten connectors.
Step 2.
Check battery cables.
Report loose cables to unit maintenance.
Step 3.
Disconnect remote control cable and insert shorting plug.
Start the generator set using GENERATOR set controls.
If generator starts, the remote control unit or cable is faulty.
Report to unit maintenance.
If generator does not start, refer to TM5-6115-464-12.
3-2
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TM-6115-14&P/1
Section III.
MAINTENANCE PROCEDURES
3-3. Operator Maintenance
The instructions in this section are
published for the information and guidance of personnel operating the
PU 794/G. Deficiencies noted during
inspection which are beyond the maintenance scope of the operator shall be
reported to higher level maintenance.
MAINTENANCE OF THE CABLE REEL ASSEMBLY
3-4 Service Cable Reel
This Task Covers: a.
b.
Inspection
Service
Tools
Wire Brush
Inspection
Inspect the cable reel for damage, and
missing hardware. Report any deficiency
to organization maintenance.
Service
Clean the cable reel assembly using a
wire brush.
INSPECTION OF FIRE EXTINGUISHER
3-5.
Fire Extinguisher
This
Task
Covers:
a. Inspection
Weighing
b.
Tools
Scale
Inspection
Inspect the fire extinguisher for damage and missing hardware. Report any
deficiency to unit maintenance.
3-3
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Weighing
Weigh the fire extinguisher monthly to insure that it is sufficiently
Fully charged, the fire extinguisher weighs 7.75 pounds filled and
charged.
5.0 pounds empty.
3-4
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NAVFAC P-8-647-14&P
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CHAPTER 4
UNIT MAINTENANCE INSTRUCTIONS
CHAPTER INDEX
Page
Subject Index
Repair Parts, Special Tools, Test, Measurement, and
Diagnostic Equipment (TMDE) and Support Equipment
Preventive Maintenance Checks and Services (PMCS)
Troubleshooting
Maintenance Procedures
4-1
4-1
4-5
4-7
4-1. Scope
Unit maintenance for the PU 794/G is
described in Sections I through IV. For
trailer maintenance instructions, refer
to TM9-2330-205-14&P, and for the generator set, refer to TM5-6115-464-12.
Section I. REPAIR PARTS AND SPECIAL TOOLS, TEST, MEASUREMENT,
AND DIAGNOSTIC EQUIPMENT (TMDE) AND SUPPORT EQUIPMENT
4-2. Special Tools and Equipment
Special tools for the generator
set are listed in TM5-6116-464-24P.
Tools required to perform unit maintenance are listed in Appendix C of
TM5-6115-464-12.
b. Trailer repair parts are listed
and illustrated in TM9-2330-205-14&P.
c. Repair parts are listed and illustrated in Appendix F (RPSTL) covering
unit maintenance of the PU 794/G.
4-4.
b. Special tools for the trailer are
listed in TM9-2330-205-14&P.
c. For authorized common tools and
equipment refer to the Modified Table of
Organization and Equipment (MTOE) applicable to your unit.
4-3.
Fabricated Tools and Equipment
There is no requirement to fabricate
tools for unit maintenance of the
PU 794/G. Refer to Appendix G of this
manual for the listing of tools and
equipment required.
Repair Parts
Generator set repair parts are
listed and illustrated in TM5-6115-464-24P.
Section II.
PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
4-5. General PMCS
To insure that the PU 794/G 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.
Deficiencies discovered during operation
of the unit shall be noted for future
correction, to be made as soon as operation has ceased. Stop operation immediately if a deficiency is noted during
operation which would damage the equipment. All deficiencies and shortcomings
4-1
TMS-6115-634-14&P
NAVFAC P-8-847-14&P
TO-35C2-3-445-14
shall be recorded together with the corrective
action on the applicable form at the earliest
possible opportunity. Army and Navy users shall
accomplish the necessary preventive maintenance
services listed and described in paragraph 4-6.
Air Force users shall refer to the applicable
inspection manuals and work card sets in the
TO-35C2-3 Series for periodic requirements and
Table 4-1 for detailed procedures.
4.6. PMCS Procedures
Table 4-1 contains a tabulated listing of preventive
maintenance checks and services which must be
performed on the PU 794/G by unit maintenance
personnel. Table 4-1 consists of five columns
containing the following information:
a. Item Number.
Checks and services are
numbered in the order of performance. These
numbers will be entered in the TM number
column on DA Form 2404 when recording the
results of PMCS.
b. Interval. The interval columns are headed
W, M, S, and A. Bullets indicate the proper check
periods.
c. Item to be Inspected. Items listed in this
column are divided into groups by the portion
of equipment of which they are part. Item to
be inspected will be identified by its common
name.
d. Procedures.
This column contains all
information required to accomplish the checks
and services.
Table 4-1. UNIT PREVENTIVE MAINTENANCE CHECKS AND SERVICES
*U. S. Government Printing Office: 1990-754-029/20183
4-2
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
4-3
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
Table 4-1.
4-4
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
Table 4-1. UNIT PREVENTIVE MAINTENANCE CHECKS AND SERVICES (CONT)
Section III.
4-7.
TROUBLESHOOTING
General Procedures
This section contains troubleshooting
and corrective action procedures authorized at the unit maintenance level, see
Appendix B, MAC.
4-8. Troubleshooting
Table 4-2 lists malfunctions that may
occur during operation or maintenance of
the PU 794/G and components. Test,
checks, inspections, and corrective
actions should be performed in the order
listed. If a malfunction beyond the
scope of unit maintenance is discovered,
report the malfunction to direct support
maintenance. For troubleshooting procedures on the generator set, refer to
TM5-6115-464-12. For troubleshooting
procedures on the trailer, refer to
TM9-2330-205-14&P.
4-5
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
Table 4-2.
PU 794/G, TROUBLESHOOTING PROCEDURES
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
1.
PU 794/G WILL NOT START USING REMOTE CONTROL UNIT, BUT STARTS WITH
SHORTING PLUG INSTALLED.
PU 794/G must be shut down before checking cable
connectors.
Failure to do so could result in
serious injury or death by electrocution.
Step 1.
Connect 5-foot control cable from connector plate to unit 2
control connection on junction box. Attempt to start unit
with SET No. 2 controls on remote control unit.
PU 794/G must be shut down before disconnecting
remote control unit. Serious injury or death by
electrocution could result if procedure is
performed with power unit running.
If the unit starts, the remote control unit is faulty.
Replace the remote control unit.
PU 794/G must be shut down before performing all
tests. Failure to do so could result in serious
injury or death by electrocution.
Step 2.
Test the control
box.
cables, remote control cable and junction
Replace faulty cable or junction box.
Step 3.
If unit still will not start, the remote functions box
assembly is faulty.
Report to intermediate direct support maintenance.
4-6
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
Table 4-2.
PU 794/6, TROUBLESHOOTING PROCEDURES (CONT)
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
2.
APPROPRIATE INDICATOR LAMP DOES NOT ILLUMINATE AT REMOTE CONTROL UNIT.
Step 1.
Check indicator lamp for open filament.
Replace lamp if filament is open.
Step 2.
Refer to FO-2 and test control cables and junction box for
continuity in indicator lamp circuit.
Replace faulty cable or junction box.
Step 3.
Test remote control unit.
Replace faulty remote control unit.
Step 4.
If indicator lamp still does not illuminate, remote functions
box assembly is faulty.
Report to intermediate direct support maintenance.
Section IV.
4-9. General Instructions
This section provides organizational
maintenance instructions for the
MAINTENANCE PROCEDURES
PU 794/G. Each maintenance function
will be performed with the PU 794/G shut
down and negative battery cable disconnected, except where otherwise stated.
4-7
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
MAINTENANCE OF BATTERY BOX ASSEMBLY
4-10. REPLACE BATTERY
This task covers: a. Removal
b. Inspection
c. Installation
INITIAL SETUP
General Safety Instructions
Tools
General Mechanic’s Tool Kit
5180-00-177-7033
Materials/Parts
Battery
96906-MS35000-3 (2 ea)
Equipment Conditions
Reference
Para. 4-9 General Instructions.
REMOVAL
1.
2.
REMOVE BATTERY RETAINER.
a.
Remove three nuts (1) flat
washers (2) and rods (3).
b.
Lift off battery retainer (4).
REMOVE BATTERIES.
NOTE
When removing battery
cables, always disconnect
the negative cable first.
4-8
a.
Remove cable clamp from negative terminal (5) and move to
side of battery box (6).
b.
Remove cable clamp from positive terminal (7) and move to
side of battery box (6).
Electrolyte and battery corrosion
can cause injury to you. Be careful
not to splash electrolyte on yourself
or the equipment.
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
4-10.
REPLACE BATTERY (cont)
c.
Remove cable assembly (8)
from the batteries.
d.
Lift out batteries (9) one at
a time.
INSPECTION
INSPECT BATTERIES.
Refer to TM9-6140-200-14 for
inspection and servicing of
batteries.
INSTALLATION
1.
2.
REPLACE BATTERIES.
a.
Individually place batteries
(9) into battery box (6).
b.
Connect cable assembly (8) to
battery terminals as shown.
c.
Connect positive battery
cable clamp (7) to positive
terminal.
d.
Connect negative battery
cable clamp (5) to negative
terminal.
REPLACE BATTERY RETAINER.
a.
Thread three rods (3) into
bottom brackets.
b.
Place battery retainer (4)
over the three rods (3).
c.
Install three washers (2) and
nuts (1).
4-9
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
MAINTENANCE OF BATTERY BOX ASSEMBLY
4-11.
REPLACE BATTERY CABLES
This task covers: a. Removal
b. Fabrication
c. Installation
INITIAL SETUP
Tools
General Mechanic’s Tool Kit
5180-00-177-7033
Materials/Parts
Battery cables
97403-13228E3368-1 and -2
REMOVAL
REMOVE BATTERY CABLE.
a.
Remove nut (1), lockwasher (2),
and cable lead from negative
battery terminal connector.
Remove nut (3), lockwasher (4),
and cable lead fom positive
battery terminal connector.
Carefully pull the cables from
the battery box.
b. Open the engine access door
(right side) and secure it to
latch provided. Remove nut
(5), lockwasher (6), and positive cable lead from starter
solenoid. Remove screw (7),
lockwasher (8), and negative
cable lead from starter
mounting plate.
c.
4-10
Open engine access door (left
side) and secure it to latch
provided. Remove the connector
strain reliefs from the skid
base and remove the cables.
Equipment Conditions
Reference
Para. 4-9 General Instructions.
NOTE
Always remove the negative lead from the
battery terminal first.
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
4-11.
REPLACE BATTERY CABLES (cont)
FABRICATION
REPLACE BATTERY CABLE.
Replacement of the battery
cables is by fabrication (see
Appendix G).
INSTALLATION
INSTALL BATTERY CABLE.
NOTE
The negative cable
lead is marked with
black shrink tubing
and the positive
cable lead is marked
with red shrink
tubing.
a.
Get a new set of battery cables
and route cables through the
skid base assembly, with connector ends for batteries outwards, and secure the connector
strain reliefs to the skid base.
b.
Secure the negative cable lead
(see note), to the starter
mounting plate with screw (7),
and lockwasher (8). Secure the
positive cable lead to the
starter solenoid with lockwasher (6) and nut (5).
c.
Route the cables through the
bushing on the battery box.
Secure the positive lead to
the positive battery terminal
connector with lockwasher (4)
and nut (3). Secure the negative lead to the negative
battery terminal connector
with lockwasher (2) and nut
(1). Inspect all connections
to ensure the connections are
tight.
4-11
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
MAINTENANCE OF BATTERY BOX ASSEMBLY
4-12.
REPLACE BATTERY BOX
This task covers: a. Removal
b. Installation
INITIAL SETUP
Tools
General Mechanic’s Tool Kit
5180-00-177-7033
Materials/Parts
Battery Box Assembly
97403-13228E3358
REMOVAL
1.
2.
REMOVE BATTERY CABLES.
a.
Remove cable clamp (1) from
positive and negative battery
cables (2).
b.
Feed battery cables (2) out
of battery box.
REMOVE BATTERY BOX.
Remove four screws (3), flat
washers (4), lockwashers (5),
and nuts (6).
INSTALLATION
1.
INSTALL BATTERY BOX.
a.
Place battery box over mounting holes on fender.
b.
Install four screws (3), flat
washers (4), lockwashers (5),
and nuts (6).
4-12
Equipment Conditions:
Reference
Para. 4-10 Remove Batteries
from Battery Box.
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
4-12. RELACE BATTERY BOX (cont)
2.
INSTALL BATTERY CABLES.
a.
Feed positive and negative
battery cables (2) through rear
cable opening in battery box.
b.
Install battery terminal
clamps (1), on positive and
negative cables (2).
NOTE
FOLLOW ON MAINTENANCE:
Install Batteries
(Para. 4-10).
4-13
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
MAINTENANCE OF BATTERY BOX ASSEMBLY
4-13. REPLACE BATTERY BOX COVER
This task covers: a. Removal
b. Installation
INITIAL SETUP
Tools
Equipment Conditions:
Reference
Para. 4-10 Remove Batteries from
Battery Box.
General Mechanic’s Tool Kit
5180-00-177-7033
Materials/Parts
Battery Box Cover
97403-13228E3360
REMOVAL
Remove the five screws (1),
washers (2) and nuts (3), holding cover and hinge (4) to the
battery box.
INSTALLATION
Position new cover and hinge (4)
to line up holes and install
five screws (1), washers (2)
and nuts (3).
NOTE
FOLLOW ON MAINTENANCE: Install
Batteries (Para. 4-10).
4-14
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
MAINTENANCE OF INTAKE BAFFLE ASSEMBLY
4-14. REPLACE INTAKE BAFFLE ASSEMBLY
This task covers: a. Removal
b. Installation
INITIAL SETUP
Tools
General Safety Instructions
General Mechanic’s Tool Kit
5180-00-177-7033
Materials/Parts
Baffle Assembly, Intake
97403-13228E1877
The baffle assembly is too bulky and
heavy for one person to remove without
possible damage. Get help to lift or
carry assembly. Failure to do so may
result in serious injury.
Equipment Conditions:
Reference
Para. 4-9 General Instructions.
REMOVAL
REMOVAL BAFFLE ASSEMBLY, INTAKE.
a.
Remove two bottom screws (1),
and flatwasher (2).
b.
Remove two top screws (1)
and flatwashers (2).
NOTE
When removing the right and left
side screws, one person should hold
the intake baffle assembly front to
keep the baffle asembly weight off
of the screws being removed.
c.
Remove four screws (1), flatwashers (2), left and right
side.
d.
Remove intake baffle assembly
(3) and attached gasket (4).
4-15
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
4-14. REPLACE INTAKE BAFFLE ASSEMBLY (cont)
INSTALLATION
INSTALL INTAKE BAFFLE ASSEMBLY.
a.
Position intake baffle assembly
and align the screw holes.
b.
Install one top screw (1),
and flatwasher (2) on each
side.
c.
Install remaining 10 screws
(1), and flatwashers (2), top,
right, left, and bottom of
intake baffle assembly.
d.
Tighten 12 screws.
4-16
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
MAINTENANCE OF INTAKE BAFFLE ASSEMBLY
4-15. REPLACE GRID
This task covers: a. Removal
b. Inspection
c. Installation
INITIAL SETUP
Tools
General Mechanic’s Tool Kit
5180-00-177-7033
Equipment Conditions:
Reference
Para. 4-9 General Instructions.
Materials/Parts
Grid
97403-132289E1878
Channel End
97403-13228E3366-1
Center Baffle
97403-13228E1880
REMOVAL
1.
Remove 10 screws (1), 20 flat
washers (2), 10 lockwashers (3),
and 10 nuts (4) and remove grid
(5).
2.
Remove five center intake baffles
(6) and two channel end insulation
baffles (7) by sliding them out of
the baffle assembly intake (8).
INSPECTION
1. Visually inspect grid (5) for dirt.
Service by cleaning grid with a
soft brush.
2.
Visually inspect five center intake
baffles (6) and two channel end
insulation baffles (7) for dirt.
Service interior of baffle assembly
intake by cleaning with a soft
brush.
4-17
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
4-15. REPLACE GRID (cont)
3. Replace damaged grid and/or center
intake baffles and channel end
insulation baffles.
INSTALLATION
1.
Insert two channel end insulation
baffles (7) and five center intake
baffles (6) by sliding them into
baffle assembly intake (8).
2. Install grid (5) with 10 screws
(1), 20 flat washers (2), 10
lockwashers (3), and 10 nuts (4).
4-18
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
MAINTENANCE OF INTAKE BAFFLE ASSEMBLY
4-16.
REPLACE FLANGE, BOTTOM, LOWER AND UPPER SIDE
This task covers: a. Removal
b. Installation
INITIAL SETUP
Tools
General Mechanic’s Tool Kit
5180-00-177-7033
Equipment Conditions:
Reference
Para. 4-14 Baffle Assembly, Intake
Removed.
Materials/Parts
Flange Bottom
97403-13228E1950
Flange Lower Side
97403-13228E1943
Flange Upper Side
97403-13228E1921
REMOVAL
1.
REMOVE FLANGE BOTTOM.
Remove four screws (1) and
lockwashers (2) and remove
bottom flange (3).
2.
REMOVE FLANGE LOWER SIDE.
Remove two screws (4) and
lockwashers (5) and remove
lower side flange (6).
3.
REMOVE FLANGE UPPER SIDE.
Remove three screws (4) and
and lockwashers (5) and remove
upper side flange (7).
INSTALLATION
1.
INSTALL FLANGE UPPER SIDE.
Install upper side flange (7)
with three screws (4) and
lockwashers (5).
4-19
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
4-16. REPLACE FLANGE, BOTTOM, LOWER AND UPPER SIDE (cont)
2.
INSTALL FLANGE LOWER SIDE.
Install lower side flange (6)
with two screws (4) and
lockwashers (5).
3.
INSTALL FLANGE BOTTOM.
Install bottom flange (3) with
four screws (1) and lockwashers
(2).
NOTE
FOLLOW ON MAINTENANCE: Install
Intake Baffle Assembly (Para.
4-14).
4-20
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
MAINTENANCE OF CONNECTOR PLATE
4-17.
REPLACE CONNECTOR PLATE
This task covers: a. Removal
b. Installation
INITIAL SETUP
Tools
General Mechanic’s Tool Kit
5180-00-177-7033
Equipment Conditions:
Reference
Para. 4-9 General Instructions.
Materials/Parts
Connector Plate
97403-13228E1902
NOTE
Replacement of the connector
plate requires removal of
the mounted cable heads and
generator ground. Proceed
is follows:
REMOVAL
1.
OPEN LEFT REAR ACCESS DOOR.
Open door access, left rear on
generator set, to allow easy
access to rear of connector
plate.
2.
REMOVE GROUND CABLE.
a.
Remove brass nut (1), selflocking.
b.
Tag and remove ground wires
(3) and three flat washers
(2).
4-21
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
4-17. REPLACE CONNECTOR PLATE (cont)
3. REMOVE POWER CABLE HEAD.
a.
Remove surge suppressors (4),
by removing three screws (5),
lockwashers (6), flat washers
(7) and nuts (8).
b. Remove four screws (9) and nuts
(10).
c.
Backout power cable head (11)
from the connector plate (12).
4. REMOVE PARALLELING/CONTROL CABLE
HEADS.
5.
a.
At the front of the connector
plate (12), remove the locking
nuts (13) from the two cable
heads.
b.
Remove each cable head from
the connector plate (12).
REMOVE CONNECTOR PLATE.
a.
Remove six screws (14) and
lockwashers (15) and remove
connector plate (12).
b.
Remove connector ALT, receptacle (16), by removing four
screws (17) and nuts (18)
w/captive washer.
c,
Remove ground terminal (19)
by removing brass nut (20).
d.
Remove nameplate GROUND (21)
by removing two screws (22).
INSTALLATION
1.
INSTALL PLATE CONNECTOR.
a.
4-22
Install nameplate GROUND with
two screws (22).
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
4-17.
2.
3.
4.
REPLACE CONNECTOR PLATE (cont)
b.
Install ground terminal (19)
with brass nut (20).
c.
Install connector ALT receptacle (16) with four screws
(17), and nuts (18).
d.
Install connector plate (12)
with six screws (14), and lockwashers (15).
INSTALL PARALLEL/CONTROL CABLE
HEADS.
a.
Insert each cable head into
the connector plate (12).
b.
Install the locking nut (13)
onto each cable head and
tighten.
REPLACE POWER CABLE HEAD.
a.
Insert the power cable head
(11) into the connector plate
(12).
b.
Install three surge suppressors
(4) with screws (5), lockwashers
(6), flat washers (7) and nuts
(8).
c.
Secure the power cable by installing four screws (9), nuts
(10) and captive washers.
INSTALL GROUND CABLE.
Install ground cable with two
washers (2) and brass nut (1),
self-locking.
5.
CLOSE LEFT REAR ACCESS DOOR.
NOTE
FOLLOW ON MAINTENANCE: Connect
Negative Battery Cable (Para.
4-10).
4-23
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
MAINTENANCE OF ACCESS DOORS
4-18.
REPLACE FRONT ACCESS DOORS
This task covers: a. Removal
b. Installation
INITIAL SETUP
Tools
Equipment Conditions:
Reference
Para. 4-9 General Instructions.
General Mechanic’s Tool Kit
5180-00-177-7033
Materials/Parts
Door, Access, Right Front
97403-13228E3379
Door, Access, Left Front
97403-13228E3378
REMOVAL
REMOVE FRONT ACCESS DOORS.
a. Open doors (1).
b.
Remove eight screws (2),
lockwashers (3) and nuts (4)
from hinges (5) and remove
doors (l).
INSTALLATION
INSTALL FRONT ACCESS DOORS.
a. Position hinges (5) against
brackets (6) and align holes.
b.
Install eight screws (2),
lockwashers (3) and nuts (4).
c.
Close doors (1).
NOTE
FOLLOW ON MAINTENANCE: Connect
Negative Battery Cable (Para.
4-10).
4-24
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
MAINTENANCE OF ACCESS DOORS
4-19.
REPLACE SIDE ACCESS DOORS, LEFT AND RIGHT
This task covers: a. Removal
b. Installation
INITIAL SETUP
General Safety Conditions
Tools
General Mechanic’s Tool Kit
5180-00-177-7033
Removal and installation of access
doors is awkward. Get help in
help in holding the doors. Failure
to do so could result in serious
injury.
Materials/Parts
Door, Access, Left Rear
97403-13228E3363-3
Door, Access, Right Rear
97403-13228E3363-2
Door, Access, Forward
97403-13228E3363-1 (2 ea)
Equipment Conditions:
Reference
Para. 4-9 General Instructions.
REMOVAL
REMOVAL LEFT AND RIGHT SIDE ACCESS
DOORS.
Remove 24 screws (1) and lockwashers (2) from four hinges
(3). Remove four access doors
(4) from generator housing (5).
INSTALLATION
INSTALL LEFT AND RIGHT SIDE ACCESS
DOORS.
a.
Install four access doors (4)
onto generator housing (5).
b.
Install 24 screws (1) and lockwashers (2) into housing (5)
through four hinges (3).
NOTE
FOLLOW ON MAINTENANCE: Connect
Negative Battery Cable (Para. 4-10).
4-25
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
MAINTENANCE ASSEMBLY GENERATOR SET, TOP REAR
4-20. REPLACE TOP REAR COVER
This task covers: a. Removal
b. Installation
INITIAL SETUP
Tools
General Safety Instructions
General Mechanic’s Tool Kit
5180-00-177-7033
Materials/Parts
Sealing Compound
Top Rear Housing, Generator Set
97403-13228E3376
Equipment Conditions:
Reference
Para. 4-19 Remove Side Access Doors,
Left and Right.
REMOVAL
1.
REMOVE RAIN CAP AND EXHAUST
PLATE.
a.
Loosen rain cap retaining
clamp screw (1) and lift off
rain cap (2),
b.
Remove exhaust plate (3),
by removing four screws (4),
and lockwashers (5).
2. REMOVE TOP REAR COVER.
a. Remove four screws (6), lockwashers (7), flatwashers (8)
and nuts (9) around rear
edge.
b.
4-26
Remove six screws,
lockwashers (11).
and
The rear cover is somewhat awkward
to remove. Get help to lift the
cover off the generator set.
Failure to do so would result in
serious injury.
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
4-20.
REPLACE TOP REAR COVER (cont)
c. Remove five screws (12), lockwashers (13) and flat washers
(14).
d.
Remove top rear cover (15).
INSTALLATION
1.
2.
INSTALL TOP REAR COVER.
a.
Place top rear cover (15) on
top of generator set. Match
the mounting holes on the center
and rear support cross members.
b.
Install four screws (6), lockwashers (7), flat washers (8)
and nuts (9) around rear edge.
c.
Install five screws (12), lockwashers (13) and flat washers
(14) on top rear cover (15).
d.
Install six screws (10) and
lockwashers (11).
REPLACE RAIN CAP AND EXHAUST PLATE.
a. Coat the bottom of the exhaust
plate (3) with sealing compound.
Place the exhaust plate (3) over
the exhaust, install four screws
(4) and lockwashers (5).
b.
Place the rain cap (2) over the
exhaust with the rain cap (2)
in the closed position. Tighten the clamp screw (1).
NOTE
FOLLOW ON MAINTENANCE: Install Side
Access Doors, Left and Right (Para.
4-19).
4-27
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
MAINTENANCE OF REAR HOUSING GENERATOR SET FRAME
4-21. REPLACE REAR HOUSING FRAME
This task covers: a. Removal
b. Installation
INITIAL SETUP
General Safety Instructions
Tools
General Mechanic’s Tool Kit
5180-00-177-7033
Materials/Parts
Housing, Generator Set, Rear
97403-13228E1901
Equipment Conditions:
Reference
Para. 4-14 Remove Baffle, Air Intake.
Para. 4-20 Remove Cover, Top Rear.
Para. 4-17 Remove Connector Plate.
TM5-6115-464-12
Remove Door Access, Control Panel
Para. 3-134.
TM5-6115-464-34
Removal Control Cubicle Assembly
Para. 4-2.
Remove Fault Locating Indicator
Para. 4-3.
REMOVAL
REMOVE REAR HOUSING FRAME.
Remove four screws (1), lockwashers
(2) and nuts (3) at the bottom
right and left side of the rear
housing frame (4) and remove it.
4-28
The removal/installation of the rear
housing frame requires two persons
one to hold the housing upright while
the mounting hardware is being
removed. Failure to do so could
result in serious injury.
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
4-21.
REPLACE REAR HOUSING FRAME (cont)
INSTALLATION
INSTALL REAR HOUSING FRAME.
Position rear housing frame (4)
over angle brackets (5) and
install four screws (1),
lockwashers (2) and nuts (3).
NOTE
FOLLOW ON MAINTENANCE:
Replace Fault Locating Indicator
(TM5-6115-464-34, Para. 4-3).
Replace Control Cubicle Assembly
(TM5-6115-464-34, Para. 4-2).
Replace Door Access, Control Panel
(TM5-6115-464-12, Para. 3-134).
Install Connector Plate (Para.
4-17).
Install Cover, Top Rear (Para.
4-20).
Install Baffle, Air Intake (Para.
4-14).
4-29
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
MAINTENANCE EXHAUST BAFFLE ASSEMBLY
4-22. REPLACE BAFFLE ASSEMBLY
This task covers: a. Removal
b. Installation
INITIAL SETUP
General Safety Instructions
Tools
General Mechanic’s Tool Kit
5180-00-177-7033
Materials/Parts
Baffle Assy, Exhaust
97403-13228E1958
Equipment Conditions:
Reference
Para. 4-9 General Instructions.
REMOVAL
REMOVE EXHAUST BAFFLE ASSEMBLY.
a. Remove four nuts (1), lockwashers (2), flat washers (3)
and screws (4).
b.
Remove exhaust baffle assembly
(5) from top support by
lifting up and backwards.
INSTALLATION
INSTALL EXHAUST BAFFLE ASSEMBLY.
a. Install exhaust assembly onto
top support pins (6).
b.
4-30
Install four screws (5), flat
washers (4), lockwashers (3),
and nuts (2).
Baffle assembly is too bulky and heavy
for one person to remove. Get help
to lift or carry assembly. Failure
to do so may result in serious injury.
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
MAINTENANCE OF EXHAUST BAFFLE ASSEMBLY
4-23.
REPLACE EXHAUST BAFFLE MOUNTING BRACKETS
This task covers: a. Removal
b. Installation
INITIAL SETUP
Tools
General Mechanic’s Tool Kit
5180-00-177-7033
Equipment Conditions:
Reference
Para. 4-22 Remove Exhaust Baffle Assembly.
Materials/Parts
Flange Top Exhaust Baffle Assy
97403-13228E1964
Flange Side Angle Exhaust Baffle Assy
97403-13228E1965 (2 ea.)
Flange Bottom Exhaust Baffle Assy
97403-13328E1966
REMOVAL
1.
REMOVE TOP FLANGE.
Remove five screws (1) and lockwashers (2) and remove top flange
(3).
2.
REMOVE BOTTOM FLANGE.
Remove three screws (1) and
lockwashers (2) and remove
bottom flange (4).
3.
REMOVE SIDE ANGLE FLANGE.
Remove 10 screws (1) and
lockwashers (2) and remove
two side angle flanges (5).
INSTALLATION
1.
INSTALL SIDE ANGLE FLANGE.
Install two side angle flanges
(5) with 10 screws (1) and
lockwashers (2).
4-31
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
4-23. REPLACE EXHAUST BAFFLE MOUNTING BRACKETS (cont)
2.
INSTALL BOTTOM FLANGE.
Install bottom flange (4) with
three screws (1) and lockwashers (2).
3.
INSTALL TOP FLANGE.
Install top flange (3) with
five screws (1) and lockwashers (2).
NOTE
FOLLOW ON MAINTENANCE: Install
Exhaust Baffle Assembly (Para.
4-22) .
4-32
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
MAINTENANCE OF TOP FRONT COVER, GENERATOR SET
4-24.
REMOVE TOP FRONT COVER
This task covers: a. Removal
b. Installation
INITIAL SETUP
Tools
General Safety Instructions
General Mechanic’s Tool Kit
5180-00-177-7033
The front cover is large and awkward
to remove. Get help to lift the
cover off of the generator set.
Failure to do so could result in
serious injury.
Materials/Parts
Top Front Cover, Generator Set
97403-13228E3375
Equipment Conditions:
Reference
Para. 4-19 Remove Side Access
Doors, Left and Right.
REMOVAL
1.
REMOVE TOP FRONT COVER.
a.
Remove five screws (1), lockwashers (2) and flat washers
(3).
b.
Remove 11 screws (4), lockwashers (5), flat washers (6)
and nuts (7) around front
edge.
c.
Remove six screws (8) and
lockwashers (9).
d.
Remove top front cover (10)
from generator set.
4-33
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
4-24. REMOVE TOP FRONT COVER (cont)
2. REMOVE DOOR ACCESS RADIATOR
FILLER.
a. Remove two screws (11), lockwashers (12) and nuts (13).
b. Remove access door (14).
INSTALLATION
1. INSTALL DOOR ACCESS RADIATOR
FILLER.
a. Position access door (14) in
place and line up mounting
holes.
b.
2.
Install two screws (11), lockwashers (12) and nuts (13).
INSTALL TOP FRONT COVER.
a. Place top front cover (10) on
top of generator set to match
mounting holes on center and
front support cross members.
b.
Install five screws (1), lockwashers (2) and flat washers
(3) at center support lifting
frame.
c.
Install 11 screws (4), lockwashers (5), flatwashers (6)
and nuts (7) at front edge
of cover.
d.
Install six screws (8) and
lockwashers (9).
NOTE
FOLLOW ON MAINTENANCE: Install
Side Access Doors, Left and Right
(Para, 4-19).
4-34
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
MAINTENANCE OF FRONT FRAME HOUSING, GENERATOR SET
4-25.
REPLACE FRONT FRAME
This task covers: a. Removal
b. Installation
INITIAL SETUP
Tools
Equipment Conditions:
Reference
Para. 4-22 Remove Baffle Assy Exhaust.
Para. 4-24 Remove Assy Gen Set Top Front.
Para. 4-18 Remove Front Access Doors.
TM5-6115-464-12
Remove Radiator Para. 3-88.
General Mechanic’s Tool Kit
5180-00-177-7033
Materials/Parts
Front Housing, Generator Set
13228E1884
REMOVAL
REMOVE FRONT FRAME.
Remove six screws (1), flat
washers (2), lockwashers (3)
and nuts (4), right and left
side of front frame (5) and
remove.
INSTALLATION
INSTALL FRONT FRAME.
Position front frame (5) on
skid and install six screws
(2), flat washers (3), lockwashers (4) and nuts (5),
right and left side of frame.
NOTE
FOLLOW ON MAINTENANCE:
Replace Radiator (TM5-6115-464-12,
Para. 3-88).
Install Front Access Doors (para. 4-18).
Install Assy Gen Set Top Front
(Para. 4-24).
Install Baffle Assy Exhaust (Para. 4-22).
4-35
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
MAINTENANCE OF EXHAUST SILENCER SYSTEM
4-26.
REPLACE SILENCER
This task covers: a. Removal
b. Installation
INITIAL SETUP
General Safety Instructions
Tools
General Mechanic’s Tool Kit
5180-00-177-7033
Materials/Parts
Silencer, Exhaust
97403-A-22-960-XX
Equipment Conditions:
Reference
Para. 4-20 Remove Generator
Set, Top Rear.
REMOVE
1.
2.
REMOVE TUBE ASSEMBLY.
a.
Loosen clamp (1).
b.
Remove top of tube assembly
(2) from silencer (3).
REMOVE SILENCER.
a.
Remove four screws (4), washers
(5), lockwashers (6) and nuts
(7).
b.
Lift silencer (3) up and out of
top rear of the generator set.
INSTALLATION
1.
REPLACE SILENCER.
a.
4-36
Position the silencer support
bracket mounting holes under-
During removal, allow time for
silencer and tube assembly to cool
before handling. Failure to do so
could result in serious injury.
Silencer weighs approximately
65 pounds. Get help to remove
silencer.
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
4-26.
REPLACE SILENCER (cont)
neath the support center
lifting frame mounting holes.
b.
2.
Install silencer (3) with four
screws (4), washers (5), lockwashers (6) and nuts (7).
REPLACE TUBE ASSEMBLY.
a.
Place clamp (1) over silencer
(3) inlet.
b.
Insert top of tube assembly (2)
into silencer (3) inlet and
tighten clamp (l).
NOTE
FOLLOW ON MAINTENANCE: Install
Generator Set, Top Rear (Para.
4-20) .
4-37
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
MAINTENANCE OF SILENCER EXHAUST SYSTEM
4-27.
REPLACE FLEXIBLE TUBE ASSEMBLY AND GASKET
This task covers: a. Removal
b. Installation
INITIAL SETUP
General Safety Instructions
Tools
General Mechanic’s Tool Kit
5180-00-177-7033
During removal, allow time for the
exhaust tube assembly to become cool
before handling. Failure to do so
could result in serious injury.
Materials/Parts
Gasket
30554-72-2057
Tube Assembly, Flexible
55996-DP-1306-2
Equipment Conditions:
Reference
Para. 4-9 General Instructions.
REMOVAL
REMOVE TUBE ASSEMBLY AND GASKET.
a.
Loosen clamp (1).
b.
Remove two screws (2)
washers (3).
and lock-
c. Remove tube assembly (4) and
gasket (5).
INSTALLATION
INSTALL TUBE ASSEMBLY AND GASKET.
a.
4-38
Place gasket (5) and then tube
assembly (4) onto the exhaust
manifold.
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
4-27.
REPLACE FLEXIBLE TUBE ASSEMBLY AND GASKET (cont)
b.
Install two screws (2) and
lockwashers (3).
c.
Place clamp (1) over end of
silencer inlet tube.
d.
Install free end of tube assembly (4) into muffler inlet and
tighten clamp (1).
4-39
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
MAINTENANCE AIR CLEANER SYSTEM
4-28. REPLACE AIR CLEANER HOUSING
This task covers: a. Removal
b. Installation
INITIAL SETUP
Tools
General Safety Instructions
General Mechanic’s Tool Kit
5180-00-177-7033
To avoid dropping the air filter
housing, get help to hold the
housing in place while removing
or replacing the top mounting
hardware.
Materials/Parts
Filter Housing
97403-13338E1894
Equipment Conditions:
Reference
Para. 4-32 Remove Filter Element.
TM5-6115-464-34
Remove Fault Indicator Panel
Para. 4-3.
REMOVAL
1.
REMOVE AIR INLET HOSE.
To remove air inlet hose (1),
loosen clamp (2). Pull air
inlet hose from back of air
cleaner housing (3).
2.
REMOVE AIR BREATHER HOSE.
To remove air breather hose
(4), depress spring clamp (5)
and remove hose from rear of
air cleaner housing (3).
3.
REMOVE SWITCH PRESSURE.
Remove cannon plug (6) from
the pressure switch (7) and
remove the pressure switch by
unthreading.
4-40
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
4-28 REPLACE AIR CLEANER HOUSING (cont)
4.
AIR CLEANER HOUSING.
a.
Remove cable clamp (8) from air
cleaner housing (3).
b.
Remove the air cleaner housing
(3) by removing four screws
(9), lockwashers (10) and
hex nuts (11).
INSTALLATION
1.
2.
3.
INSTALL AIR CLEANER HOUSING.
a.
Position air cleaner housing
(3) mounting brackets, so
mounting holes are in line
with mounting holes in the
center support section (12).
b.
Install the air cleaner
housing (3), by installing
four screws (9), lockwashers
(10) and hex nuts (11).
c.
Install cable clamp (8) on
air cleaner housing (3).
INSTALL SWITCH PRESSURE.
a.
Install the pressure switch
(7) into its threaded hole.
b.
Connect cannon plug (6) to
the pressure switch (7).
INSTALL AIR BREATHER HOSE.
a.
Place the spring clamp (5) onto
the air breather hose (4),
approximately one-inch from the
end.
b.
Fit the air breather hose (4)
onto the air inlet and slide
the spring clamp (5) over the
inlet to secure the hose.
4-41
TM-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
4-28 REPLACE AIR CLEANER HOUSING (cont)
4. INSTALL AIR INLET HOSE.
a.
Place the metal clamp (2) over
the air inlet hose (1) approximately one-inch from the end.
b. Fit the air inlet hose (1) onto
the air cleaner housing air
inlet pipe, and secure air
inlet hose (1) by moving the
clamp (2) over the air inlet
pipe and tightening the clamp
(1).
NOTE
FOLLOW ON MAINTENANCE:
Replace Fault Indicator Panel
(TM5-6115-464-34, Para. 4-3).
Install Filter Element (Para.
4-32).
4-42
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
MAINTENANCE AIR CLEANER SYSTEM
4-29.
REPLACE AIR INLET HOSE
This task covers: a. Removal
b. Installation
INITIAL SETUP
Tools
General Mechanic’s Tool Kit
5180-00-177-7033
Equipment Conditions:
Reference
Para. 4-9 General Instructions.
Materials/Parts
Air Inlet Hose
97403-13228E1885
Clamp
96906-MS35842-13
REMOVAL
REMOVE AIR INLET HOSE.
a.
Loosen two hose clamps (1) and
slide them back over the air
inlet hose (2).
b.
Remove the air inlet hose (2)
from the air cleaner housing
(3) and the air inlet adapter
(4).
INSTALLATION
REPLACE AIR INLET HOSE.
a.
Place a hose clamp (1) over
each end of the air inlet
hose (2).
b.
Connect the air inlet hose (2)
to the air cleaner housing (3)
and the air inlet adapter (4).
4-43
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
4-29. REPLACE AIR INLET HOSE (cont)
c.
4-44
Move each clamp (1) over the
mounting surface of the hose
ends and tighten the clamps
(1).
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
MAINTENANCE AIR CLEANER SYSTEM
4-30. REPLACE AIR BREATHER HOSE
This task covers: a. Removal
b. Installation
INITIAL SETUP
Tools
General Mechanic’s Tool Kit
5180-00-177-7033
Equipment Condition:
Reference
Para. 4-9 General Instructions.
Para. 4-28 Remove Air Inlet Hose.
Materials/Parts
Hose
30554-72-2050-2
Clamp
96906-MS39326-17
REMOVAL
REMOVE THE AIR BREATHER HOSE.
a. Open the spring clamps (1) and
move clamps back over the air
breather hose (2).
b.
Remove the air breather hose
(2) from the air cleaner
housing (3) and the air
breather (4).
INSTALLATION
REPLACE THE AIR BREATHER HOSE.
a.
Place a spring clamp (1) over
each end of the air breather
hose (2).
b.
Connect the air breather hose
(2) to the air breather
housing (3) and the air
breather (4).
4-45
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
4-30. REPLACE AIR BREATHER HOSE (cont)
c. Slide the spring clamps (1)
over the matting ends of the
air breather hose (2) and
release clamps (1).
NOTE
FOLLOW ON MAINTENANCE:
Replace Air Inlet Hose (Para. 4-28).
Connect Negative Battery Cable
(Para. 4-10).
4-46
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
MAINTENANCE AIR CLEANER SYSTEM
4-31.
REPLACE AIR INLET ADAPTER AND GASKET
This task covers: a. Removal
b. Installation
INITIAL SETUP
Tools
General Mechanic’s Tool Kit
5180-00-177-7033
Equipment Condition:
Reference
Para. 4-9 General Instructions.
Materials/Parts
Adapter Air Inlet
97403-13228E1917
Gasket
97403-40819
REMOVAL
1.
2.
REMOVE AIR INLET HOSE.
a.
Loosen the clamp (1) from
adapter air inlet (2) and
slide clamp back over the
air inlet hose (3).
b.
Remove the air inlet hose (3)
from the air inlet adapter (2).
REMOVE ADAPTER AIR INLET.
a.
Remove two screws (4) and lockwashers (5).
b.
Remove adapter air inlet (2)
and gasket (6) from intake
manifold cover (7).
INSTALLATION
1.
INSTALL ADAPTER AIR INLET AND GASKET.
a.
Place a gasket (6) and adapter
air inlet (2) on intake manifold
cover (7).
4-47
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
4-31. REPLACE AIR INLET ADAPTER AND GASKET (cont)
b.
2.
Install two screws (4) and
lockwashers (5).
INSTALL AIR INLET HOSE.
Connect air inlet hose (3) onto
adapter air inlet (2), slide
clamp (1) over mating surface
and tighten.
NOTE
FOLLOW ON MAINTENANCE: Connect
Negative Battery Cable (Para. 4-10).
4-48
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
MAINTENANCE AIR CLEANER SYSTEM
4-32. REPLACE FILTER ELEMENT
This task covers: a. Removal
b. Inspection
c. Service
d. Installation
INITIAL SETUP
General Safety Instructions
Tools
General Mechanic’s Tool Kit
5180-00-177-7033
Materials/Parts
Do not clean air filter element in
gasoline or other petroleum solvents.
Detergent
Filter Element
30554-70-4020
Bar Retainer
97403-13228E1883
Do not use compressed air to dry a
wet filter.
Equipment Conditions:
Reference
Para. 4-9 General Instructions.
When using compressed air, use eye
protection and to not direct air
toward skin. Pressure should not
exceed 30 psig. Failure to observe
this warning could result in
serious injury.
REMOVAL
REMOVE FILTER ELEMENT.
a.
Remove two screws (1), lockwashers (2), nuts (3) and
retainer bar (4).
b.
Remove filter element (5).
INSPECTION
INSPECT THE FILTER ELEMENT.
Place a light behind the filter
element and check for holes,
tears or other defects. Replace
if defective.
4-49
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-148P/1
4-32. REPLACE FILTER ELEMENT (cont)
SERVICE
SERVICE THE FILTER ELEMENT.
a. Soak and agitate filter element
for 15 minutes in a solution of
warm water and mild detergent.
b. Rinse filter element until clean
and air dry.
c.
The filter element may also be
cleaned with low pressure
(30 psig max) compressed air.
INSTALLATION
INSTALL FILTER ELEMENT.
Place the filter (5) into
position on the air filter
housing (6), and install
retaining bar (4) with two
screws (1), lockwashers (2)
and nuts (3).
NOTE
FOLLOW ON MAINTENANCE: Repl ace
Negative Battery Cable (Para. 4-10).
4-50
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
MAINTENANCE REMOTE FUNCTION BOX ASSEMBLY
4-33.
INSPECT REMOTE FUNCTIONS BOX ASSEMBLY
This task covers:
a. Inspection
INITIAL SETUP
Equipment Conditions:
Reference
Para. 4-9 General Instructions.
Tools
General Mechanic’s Tool Kit
5180-00-177-7033
INSPECTION
INSPECT REMOTE FUNCTIONS BOX
ASSEMBLY.
a. Open roadside rear access door
on power unit.
b.
Visually inspect remote functions box assembly (1) for
damage and loose hardware.
c.
Inspect cable harness connections (2) for tightness.
NOTE
FOLLOW ON MAINTENANCE: Connect
Negative Battery Cable (Para.
4-10).
4-51
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
MAINTENANCE OF ENGINE FAN
4-34. REPLACE FAN
This task covers: a. Removal
b. Installation
INITIAL SETUP
Equipment Conditions:
Reference
Para. 4-9 General Instructions.
Tools
General Mechanic’s Tool Kit
5180-00-177-7033
#1 Common Tool Kit
TBD
Materials/Parts
Fan, Engine
97403-13228E1887
REMOVAL
REMOVE ENGINE FAN.
Remove four screws (1) and
lockwashers (2) and remove fan
(3).
INSTALLATION
INSTALL ENGINE FAN.
Install fan (3), two screws
(1) and lockwashers (2).
NOTE
FOLLOW ON MAINTENANCE: Connect
Negative Battery Lead (Para.
4-10).
4-52
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
MAINTENANCE OF ENGINE V-BELT
4-35. REPLACE V-BELT
This task covers: a. Removal
b. Installation
INITIAL SETUP
Equipment Conditions:
Reference
Para. 4-9 General Instructions.
Tools
General Mechanic’s Tool Kit
5180-00-177-17033
Materials/Parts
Belt, V, Engine
96906-MS51O66-57
REMOVAL
REMOVE ENGINE V-BELT.
Loosen battery charging alternator retaining screw (1) and
push alternator close to
engine. Remove V-belt (2)
from alternator (3), fan (4)
and engine (5) pulleys.
INSTALLATION
INSTALL ENGINE V-BELT.
Install V-belt (2) onto engine
(5), fan (4) and alternator
(3) pulleys. Pull engine
alternator away from engine to
put tension on V-belt (2).
Tighten alternator retaining
screw (1).
NOTE
FOLLOW ON MAINTENANCE: Connect
Negative Battery Cable (Para.
4-10).
4-53
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
MAINTENANCE OF FAN GUARD, LEFT AND RIGHT
4-36. REPLACE FAN GUARD, LEFT AND RIGHT
This task covers: a. Removal
b. Installation
INITIAL SETUP
Equipment Conditions:
Reference
Para. 4-9 General Instructions.
Tools
General Mechanic’s Tool Kit
5180-00-177-7033
Materials/Parts
Fan Guard, Right
97403-13228E1891
Fan Guard, Left
97403-13228E1892
Plate, Fan
97403-13228E1918
REMOVAL
REMOVE FAN GUARDS.
a.
Remove six screws (1) and
lockwashers (2).
b.
Remove fan guards (3), left and
right and fan plate (4).
INSTALLATION
INSTALL FAN GUARDS.
a. Position fan plate (4) against
radiator.
b.
Install two fan guards (3),
six screws (1) and lockwashers
(2).
NOTE
FOLLOW ON MAINTENANCE: Connect
Negative Battery Cable (Para.
4-10) .
4-54
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
MAINTENANCE OF DOCUMENT BOX
4-37. REPLACE DOCUMENT BOX
This task covers: a. Removal
b. Installation
INITIAL SETUP
Tools
General Mechanic’s Tool Kit
5180-00-177-7033
Equipment Conditions:
Reference
Para. 4-9 General Instructions.
Materials/Parts
Box, Document
97403-13228E3364
Bracket, Document
97403-13328E3367-1
Bracket, Document
97403-13228E3367-2
REMOVAL
1.
REMOVE DOCUMENT BOX.
a. Remove four screws (1) and
lockwashers (2) from document
box brackets (3).
b.
Remove document box (4) with
brackets (3) from front skid
(5).
2. REMOVE BRACKETS FROM DOCUMENT BOX.
a.
Remove four screws (6), lockwashers (7) and nuts (8).
b.
Remove two brackets (3).
INSTALLATION
1.
INSTALL BRACKETS TO DOCUMENT BOX.
Install two brackets (3), four
screws (6), lockwashers
(7) and nuts (8).
4-55
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
4-37. REPLACE DOCUMENT BOX (cont)
2.
INSTALL DOCUMENT BOX.
a.
Place document box (4) with
brackets (3) over mounting
holes on skid (5).
b.
Install four screws (1) and
lockwashers (4).
NOTE
FOLLOW ON MAINTENANCE: Connect
Negative Battery Cable (Para.
4-10).
4-56
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
MAINTENANCE OF THE SKID BASE ASSEMBLY
4-38. INSPECT SKID BASE ASSEMBLY
This task covers:
a. Inspection
INITIAL SETUP
Tools
Equipment Conditions:
Reference
Para 4-9 General Instructions.
General Mechanic’s Tool Kit
5180-00-177-7033
# 1 Common Tool Kit
TBD
INSPECTION
INSPECT THE SKID BASE ASSEMBLY
Visually inspect the skid base
(1) for cracks, corrosion and
defective welds.
NOTE
FOLLOW ON MAINTENANCE: Connect
Negative Battery Cable (Para.
4-10).
4-57
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
MAINTENANCE OF JUNCTION BOX
4-39. INSPECT, TEST AND REPLACE JUNCTION BOX ASSEMBLY
This task covers: a. Inspection
b. Test
c. Removal
d. Installation
INITIAL SETUP
Tools
General Mechanic’s Tool Kit
5180-00-177-7033
Materials/Parts
Junction Box Assembly
97403-13228E1872
Cover Enclosure
97403-13228E1936
INSPECTION
INSPECT JUNCTION BOX ASSEMBLY.
a. Visually inspect the junction
box (1) for damaged connectors,
loose mounting hardware or
cracks.
b.
Visually inspect the interior
of the junction box (1) for
dampness or water by removing 16
screws (2), lockwashers (3) and
cover (4).
c. Inspect the gasket (5) for
deterioration or tears.
d.
Replace cover (4) by installing
16 screws (2) and lockwashers (3).
TEST
TEST JUNCTION BOX ASSEMBLY.
Refer to FO-2 power unit schematic and troubleshooting
4-58
Equipment Conditions:
Reference
Para. 4-9 General Instructions.
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
4-39.
INSPECT, TEST AND REPLACE JUNCTION BOX ASSEMBLY (cont)
diagram, make continuity meter
measurements of power and control wiring harness, pin-topin and pin-to-ground. When
open condition or short to
ground is observed, replace the
junction box.
REMOVAL
REMOVE JUNCTION BOX ASSEMBLY.
a.
Remove four screws (6), lockwashers (7) and nuts (8).
b.
Remove the junction box.
INSTALLATION
INSTALL JUNCTION BOX ASSEMBLY.
a.
Place the junction box onto
the trailer, matching up the
mounting holes.
b.
Install four screws (6),
lockwashers (7), and nuts (8).
NOTE
FOLLOW ON MAINTENANCE: Connect
Negative Battery Cable (Para.
4-10) .
4-59
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
MAINTENANCE OF CABLE REEL ASSEMBLY
4-40. REPLACE CABLE REEL ASSEMBLY
This task covers: a. Removal
b. Installation
INITIAL SETUP
Tools
General Mechanic’sTool Kit
5180-00-177-7033
Materials/Parts
Cable Reel Assembly
97403-13228E1873
REMOVAL
REMOVE CABLE REEL ASSEMBLY.
a.
Remove cables from cable reel
assembly (1).
b.
Remove cable reel assembly
(1) by removing four screws
(2), lockwashers (3) and
nuts (4).
c.
Remove support bracket (5)
by removing two screws (6),
washers (7) and nuts (8).
INSTALLATION
INSTALL CABLE REEL ASSEMBLY.
a. Install support bracket (5)
by installing two screws (6),
washers (7) and nuts (8).
b.
4-60
Install cable reel assembly
(1) onto trailer by installing
four screws (7), washers (3)
and nuts (4).
Equipment Conditions:
Reference
Para. 4-9 General Instructions.
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
4-40.
REPLACE CABLE REEL ASSEMBLY (cont)
NOTE
FOLLOW ON MAINTENANCE: Connect
Negative Battery Cable (Para.
4-10) .
4-61
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
MAINTENANCE PULLER BRACKET
4-41.
REPLACE PULLER BRACKET
This task covers:
a. Inspection
b. Installation
INITIAL SETUP
Equipment Conditions:
Reference
Para. 4-9 General Instructions.
Tools
General Mechanic’s Tool Kit
5180-00-177-7033
Materials/Parts
Bracket Puller
97403-13228E3387
REMOVAL
REMOVE PULLER BRACKET.
Remove two nuts with captive
washer (1) and screws (2).
Remove puller bracket (3) and
chain (4) from trailer curbside
front step (5).
INSTALLATION
INSTALL PULLER BRACKET.
Place puller bracket (3) over
mounting holes on curbside
front step (5).
Secure chain
(4) to left hand screw (2)
and Install two screws (2)
and nuts with captive washer
(1).
NOTE
FOLLOW ON MAINTENANCE: Connect
Negative Battery Cable (Para.
4-10) .
4-62
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
MAINTENANCE OF FENDER AND WALKWAY
4-42. REPLACE FRONT STEP, CURBSIDE AND ROADSIDE
This task covers: a. Removal
b. Installation
INITIAL SETUP
Tools
General Safety Instructions
General Mechanic’s Tool Kit
5180-00-177-7033
Materials/Parts
Step Front Curbside
97403-13228E3389
Step Front Roadside
97403-13228E1903
Spacer Plates
97403-13228E1267-1 and -2
Due to the bulk and weight of the
front steps, a minimum of two
persons are required to move them.
Failure to do so could result in
serious injury.
When removing mounting hardware
brace or hold the step so it will
not drop.
Equipment Conditions:
Reference
Para. 4-12 Remove Battery Box.
Para. 4-41 Remove Puller-Bracket.
Para. 4-53 Remove Fire Extinguisher
Bracket.
TM9-2330-205-14&P
Remove Handbrake Cover Assembly
Section IX.
REMOVAL
1.
REMOVE FRONT STEP ROADSIDE.
a.
Remove four 1-3/4 inch screws
(1), eight flat washers (2) and
four self-locking nuts (3).
b.
Remove two 1-inch screws (4),
four flat washers (5) and two
self-locking nuts (6).
c.
Remove 1-1/4 inch screw (7).
two flat washers (8) and selflocking nut (9).
4-63
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
4-42. REPLACE FRONT STEP, CURBSIDE AND ROADSIDE (cont)
d. Remove seven 1-inch screws
(10), 14 flat washers (11) and
seven self-locking nuts (12)
and remove roadside front step
(13).
2.
REMOVE FRONT STEP CURBSIDE.
a. Remove two gas can brackets (14)
from curbside front step (15) by
removing eight screws (16), 16
flat washers (17) and eight
self-locking nuts (18).
b.
Perform steps 1a through 1d
above to remove the curbside
front step (15).
INSTALLATION
1.
2.
INSTALL FRONT STEP, ROADSIDE.
a.
Install roadside front step (13)
with four 1-3/4 inch screws (1),
eight flat washers (2) and four
self-locking nuts (3).
b.
Install seven 1-inch screws
(10), 14 flat washers (11) and
seven self-locking nuts (12).
c.
Install two 1-inch screws (4),
four flat washers (5) and
two self-locking nuts (6).
d.
Install 1-1/4 inch screw
(7), two flat washers (8)
and self-locking nut (9).
INSTALL FRONT STEP, CURBSIDE.
a. Perform steps 2a through 2d,
above, to install the curbside
front step (15).
b.
4-64
Install gas can brackets (14) by
installing eight screws (16),
16 flat washers (17) and eight
self-locking nuts (18).
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
4-42.
REPLACE FRONT STEP, CURBSIDE AND ROADSIDE (cont)
NOTE
FOLLOW ON MAINTENANCE:
Replace Handbrake Lever Assembly
(TM9-2330-205-14&P, Section IX).
Install Fire Extinguisher Bracket
(Para. 4-53).
Install Puller Bracket (Para.
4-41).
Install Battery Box (Para. 4-12).
4-65
TM-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
MAINTENANCE OF FENDER, ROADSIDE, CURBSIDE
4-43.
REPLACE FENDER, ROADSIDE AND CURBSIDE
This task covers: a. Removal
b. Installation
INITIAL SETUP
Tools
General Safety Instructions
General Mechanic’s Tool Kit
5180-00-177-7033
Materials/Parts
Fender, Roadside
97403-13214E1264
Fender, Curbside
97403-13214E1263
Equipment Conditions:
Reference
Para. 4-9 General Instructions.
REMOVAL
1.
REMOVE FENDER, ROADSIDE.
a. Remove five 1-1/4 inch screws
(1), 10 flat washers (2) and
five self-locking nuts (3).
b. Remove seven 1-inch screws (4),
14 flat washers (5) and
seven self-locking nuts (6).
c.
Remove five 1-inch screws (7),
flat washers (8) and five
self-locking nuts (9) and
remove roadside fender (10).
2. REMOVE FENDER, CURBSIDE.
a. Perform steps 1a through 1c,
above, to remove curbside
fender (11).
4-66
Due to the bulk and weight of the
fenders, a minimum of two persons
are required to move them. Failure
to do so could result in serious
injury.
When removing mounting hardware
brace or hold the step so it will
not drop.
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
4-43. REPLACE FENDER, ROADSIDE AND CURBSIDE (cont)
INSTALLATION
1. INSTALL FENDER, ROADSIDE.
a. Set roadside fender (10) into
position and hold in place.
2.
b.
Install five 1-inch screws (7),
10 flat washers (8) and five
self-locking nuts (9).
c.
Install seven 1-inch screws
(4), 14 flat washers (5) and
seven self-locking nuts (6).
d.
Install five 1-1/4 inch screws
(1), 10 flat washers (2) and
five self-locking nuts (3).
INSTALL FENDER, CURBSIDE.
Perform steps 1a through 1d to
install curbside fender (11).
NOTE
FOLLOW ON MAINTENANCE: Connect
Negative Battery Cable (Para.
4-10).
4-67
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
MAINTENANCE OF REAR STEP, ROADSIDE, CURBSIDE
4-44. REPLACE REAR STEP, ROADSIDE AND CURBSIDE
This task covers: a. Removal
b. Installation
INITIAL SETUP
Tools
General Safety Instructions
General Mechanic’s Tool Kit
5180-00-177-7033
Materials/Parts
Step Rear, Roadside
97403-13214E1876
Step Rear, Curbside
97403-13214E1259
Equipment Conditions:
Reference
Para. 4-9 General Instructions.
REMOVAL
1. REMOVE REAR STEP, ROADSIDE.
a. Remove ten 1-inch screws (1), 20
flat washers (2) and 10 selflocking nuts (3).
b. Remove five 1-inch screws (4),
10 flat washers (5) and selflocking nuts (6) and remove
roadside rear step (7).
2. REMOVE REAR STEP, CURBSIDE.
Perform steps 1a and 1b
to remove curbside rear
step (8).
4-68
Due to the bulk and weight of the
rear steps, a minimum of two persons
are required to move them. Failure
to do so could result in serious
injury.
When removing mounting hardware,
brace or hold the step so it will
not drop.
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
4-44.
REPLACE REAR STEP, ROADSIDE AND CURBSIDE (cont)
INSTALLATION
1.
2.
INSTALL REAR STEP, ROADSIDE.
a.
Place roadside rear step (7)
into position and hold in place.
b.
Install five 1-inch screws (4),
10 flat washers (5) and five
self-locking nuts (6).
c.
Install ten 1-inch screws (1),
20 flat washers (2) and 10
self-locking nuts (3).
INSTALL REAR STEP, CURBSIDE.
Perform steps 1a through 1C
to install curbside rear step
(8).
NOTE
FOLLOW ON MAINTENANCE: Connect
Negative Battery Cable (Para.
4-10).
4-69
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
MAINTENANCE OF PLATFORM, TAIL GATE
4-45. REPLACE PLATFORM TAILGATE
This task covers: a. Removal
b. Installation
INITIAL SETUP
General Safety Instructions
Tools
General Mechanic’s Tool Kit
5180-00-177-7033
Due to the bulk and weight of the tail
gate, a minimum of two persons are
required to move it. Failure to do so
could result in serious injury.
Materials/Parts
Platform, Tail Gate
97403-13214E1298
When removing mounting hardware brace
or hold the step so it will not drop.
Equipment Conditions:
Reference
Para. 4-9. General Instructions.
REMOVAL
REMOVE PLATFORM TAIL GATE.
Remove two screws (1), four
flat washers (2) and two selflocking nuts (3) and remove
tailgate platform (4).
INSTALLATION
INSTALL PLATFORM TAIL GATE.
a. Position tailgate platform (4)
into place where the mounting
holes line up.
b.
Install two screws (1), four
flat washers (2) and two selflocking nuts (3).
NOTE
FOLLOW ON MAINTENANCE: Connect
Negative Battery Cable (Para.
4-10).
4-70
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
MAINTENANCE OF CABLE STORAGE PAN
4-46. REPLACE CABLE STORAGE PAN
This task covers: a. Removal
b. Installation
INITIAL SETUP
Tools
General Mechanic’s Tool Kit
5180-00-177-7033
Equipment Conditions:
Reference
Para. 4-9 General Instructions.
Materials/Parts
Pan, Cable Storage
97403-13228E3402
Bracket, Cable Pan
97403-13228E3399
REMOVAL
REMOVE CABLE STORAGE PAN.
a.
Remove two 1-inch screws (1),
four flat washers (2) and two
nuts (3).
b.
Remove two 1-3/4 inch screws
(4), four flat washers (5) and
two nuts (6) and remove cable
storage pan (7).
INSTALLATION
INSTALL CABLE STORAGE PAN.
storage pan (7) to
by installing two
four flat washers
nuts (3).
a.
Mount cable
bracket (8)
screws (1),
(2) and two
b.
Mount cable storage pan (7,) to
trailer chassis (9) by installing
two 1-3/4 inch screws (4),
four flat washers (5) and two
nuts (6).
4-71
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
4-46. REPLACE CABLE STORAGE PAN (cont)
NOTE
FOLLOW ON MAINTENANCE: Connect
Negative Battery Cable (Para.
4-10).
4-72
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
MAINTENANCE OF REMOTE CONTROL UNIT
4-47. TEST AND REPLACE REMOTE CONTROL UNIT
This task covers: a. Test
b. Replacement
INITIAL SETUP
Tools
General Mechanic’s Tool Kit
5180-00-177-7033
Equipment Conditions:
Reference
Para. 2-5 Single Unit Operating
Procedures.
Materials/Parts
Remote Control Unit
97403-13228E1869
Control Cable, 100 ft.
97403-13228E1946
TEST
TEST REMOTE CONTROL UNIT.
Operate the generator from
the remote control unit (1).
All controls and indicators
should function as described in
operating procedures. Shut
down the generator.
REPLACEMENT
REPLACE REMOTE CONTROL UNIT.
If any control or indicator
does not function, replace
the remote control unit (1) by
disconnecting the control
cable from the bottom of
the unit.
4-73
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
MAINTENANCE OF CONTROL CABLE, 100 FT.
4-48. TEST AND REPLACE CONTROL CABLE
This task covers: a. Removal
b. Test
c. Installation
INITIAL SETUP
Tools
General Mechanic’s Tool Kit
5180-00-177-7033
Multimeter
6625-01-139-2512
Materials/Parts
Control Cable, 100 ft.
97403-13228E1946
REMOVAL
REMOVE 100 FT. CONTROL CABLE.
Disconnect control cable connectors from the junction box
and remove the remote control
unit. Refer to Figures 2-3 and
2-5.
TEST
TEST 100 FT. CONTROL CABLE.
a.
Use a multimeter and test for
pin-to-pin continuity (O ohms).
Test for open circuit (infinite
ohms) between each pin and pinto-connector at both ends of
the cable.
b.
If an open or short occurs
within the cable assembly,
replace the cable.
4-74
Equipment Conditions:
Reference
Para. 4-9 General Instructions.
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
4-48. TEST AND REPLACE CONTROL CABLE (cont)
INSTALLATION
INSTALL 100 FT, CONTROL CABLE.
Connect control cable connectors to the junction box and to
the remote control unit. Refer
to Figures 2-3 and 2-5.
NOTE
FOLLOW ON MAINTENANCE: Connect
Negative Battery Cable (Para.
4-10).
4-75
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
MAINTENANCE OF CABLE ASSEMBLY POWER 25 FT.
4-49. TEST AND REPLACE POWER CABLE, 25 FT.
This task covers: a. Removal
b. Test
c. Installation
INITIAL SETUP
Tools
General Mechanic’s Tool Kit
5180-00-177-7033
Multimeter
6625-01-139-2512
Materials/Parts
Cable Assembly, Power, 25 ft.
97403-13228E1944-2
REMOVAL
REMOVE 25 FT. POWER CABLE.
Disconnect power cable connectors from the junction box on
the first power unit and from
the connector plate on the
second power unit. Refer to
Figures 2-3 and 2-5.
TEST
TEST 25 FT. POWER CABLE.
a.
Use a multimeter and test for
pin-to-pin continuity (O ohms).
Test for open circuit (infinite
ohms) between each pin and pinto-connector at both ends of
the cable.
b.
If an open or short occurs
within the cable assembly,
replace the cable.
4-76
Equipment Conditions:
Reference
Para. 4-9 General Instructions.
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
4-49. TEST AND REPLACE POWER CABLE, 25 FT. (cont)
INSTALLATION
INSTALL 25 FT. POWER CABLE.
Connect power cable
to the junction box
first PU and to the
plate on the second
connectors
on the
connector
PU.
NOTE
FOLLOW ON MAINTENANCE: Connect
Negative Battery Cable (Para.
4-10).
4-77
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
MAINTENANCE OF POWER CABLE, 5 FT.
4-50. TEST POWER CABLE, 5 FT.
This task covers: a. Test
INITIAL SETUP
Equipment Conditions:
Reference
Para. 4-9 General Instructions.
Tools
General Mechanic’s Tool Kit
5180-00-177-7033
Multimeter
6625-01-139-2512
Materials/Parts
Power Cable, 5 ft.
97403-13228E1944-1
TEST
TEST POWER CABLE, 5 FT.
a. Use a multimeter and test for
pin-to-pin continuity (O ohms).
Test for open circuit (infinite
ohms) between each pin and pinto-connector at both ends of
the cable.
b.
If an open or short occurs
within the cable assembly,
replace the cable.
NOTE
FOLLOW ON MAINTENANCE: Connect
Negative Battery Cable (Para.
4-10).
4-78
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
MAINTENANCE OF CONTROL CABLES, 5 FT. AND 25 FT.
4-51. TEST CONTROL CABLE, 5 FT. AND 25 FT.
This task covers: a. Test
INITIAL SETUP
Tools
Equipment Conditions:
Reference
Para. 4-9 General Instructions.
General Mechanic’s Tool Kit
5180-00-177-7033
Multimeter
6625-10-139-2512
Materials/Parts
Control Cable, 5 ft.
97403-13228E1945-1
Control Cable, 25 ft.
97403-13228E1945-2
TEST
TEST CONTROL CABLE, 5 FT. AND 25 FT.
a.
Use a multimeter and test for
pin-to-pin continuity (O ohms).
Test for open circuit (infinite
ohms) between each pin and pinto-connector at both ends of
the cable.
b.
If an open or short occurs
within either cable assembly,
replace the cable.
NOTE
FOLLOW ON MAINTENANCE: Connect
Negative Battery Cable (Para.
4-10).
4-79
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
MAINTENANCE OF CABLE PARALLELING
4-52. TEST PARALLELING CABLE
This task covers: a. Test
INITIAL SETUP
Tools
Equipment Conditions:
Reference
Para. 4-9 General Instructions.
General Mechanic’s Tool Kit
5180-00-177-7033
Multimeter
6625-01-139-2512
Materials/Parts
Paralleling Cable
97403-13228E1947
TEST
TEST PARALLELING CABLE.
a. Use a multimeter and test for
pin-to-pin continuity (O ohms).
Test for open circuit (infinite
ohms) between each pin and pinto-connector at both ends of
the cable.
b.
If an open or short occurs
within the cable assembly,
replace the cable.
NOTE
FOLLOWON MAINTENANCE: Connect
Negative Battery Cable (Para.
4-10).
4-80
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-146P/1
MAINTENANCE OF EXTINGUISHER, FIRE
4-53. REPLACE FIRE EXTINGUISHER
This task covers: a. Removal
b. Installation
INITIAL SETUP
Tools
General Mechanic’s Tool Kit
5180-00-177-7033
Equipment Conditions:
Reference
Para. 4-9 General Instructions.
Materials/Parts
Bracket, Fire Ext.
97403-13214E1235
Extinguisher, Fire
97403-13228E3394
REMOVE
1.
REMOVE FIRE EXTINGUISHER.
Unstrap fire extinguisher (1)
and remove.
2.
REMOVE FIRE EXTINGUISHER BRACKET.
Remove two screws (2), four
flat washers (3) and two selflocking nuts (4) and remove
fire extinguisher bracket (5).
INSTALLATION
1.
INSTALL FIRE EXTINGUISHER BRACKET.
Install fire extinguisher
bracket (5) with two screws
(2), four flat washers (3)
and two selflocking nuts (4).
2.
INSTALL FIRE EXTINGUISHER.
Set fire extinguisher (1) into
bracket and close strap.
4-81
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
4-53. REPLACE FIRE EXTINGUISHER (cont)
NOTE
FOLLOW ON MAINTENANCE: Connect
Negative Battery Cable (Para.
4-20) .
4-82
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
CHAPTER 5
INTERMEDIATE DIRECT SUPPORT MAINTENANCE INSTRUCTIONS
CHAPTER INDEX
Subject Index
Page
Repair Parts, Special Tools, Test, Measurement
and Diagnostic Equipment (TMDE) and Support Equipment
Preventive Maintenance Checks and Services
Troubleshooting
Maintenance Procedures
Preparation for Storage and Shipment
Section I.
5-1.
REPAIR PARTS, SPECIAL TOOLS, TEST, MEASUREMENT AND DIAGNOSTIC
EQUIPMENT (TMDE) AND SUPPORT EQUIPMENT
General
TM9-2330-205-14&P for generator set and
trailer TMDE.
This chapter provides instructions for
intermediate direct support maintenance
on the PU 794/G as authorized by the
Maintenance Allocation Chart (MAC),
Appendix B. Refer to TM5-6115-464-34
for maintenance tasks performed on the
Generator Set.
5-2.
5-3.
Repair Parts
Repair parts are listed and illustrated
in the Repair Parts and Special Tools
List (RPSTL), Appendix F. See TM5-6115464-24P and TM9-2330-205-14&P for generator set and trailer repair parts.
Special Tools and Equipment
5-4.
Test, measurement and diagnostic equipment (TMDE) and support equipment including electrical test equipment and standard
gages are listed in Appendix B, Section
III. Refer to TM5-6115-464-24P and
Section II.
5-5.
5-1
5-1
5-1
5-6
5-61
Fabricated Tools and Equipment
No fabricated tools and equipment are
required for intermediate direct support
maintenance on the PU 794/G.
PREVENTIVE MAINTENANCE CHECKS AND SERVICES
General
Preventive maintenance checks and services are performed by unit maintenance
Refer to Chapter 4 for
personnel.
instructions.
Section III.
5-6.
General
This section contains troubleshooting
and corrective actions performed at the
intermediate direct support maintenance
level as authorized by the MAC, Appendix B.
TROUBLESHOOTING
5-7.
Troubleshooting
Table 5-1 lists the common malfunctions
of the PU 794/G that must be corrected
at the intermediate direct support maintenance level. Refer to TM5-6115-464-34
5-1
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
for troubleshooting the generator set
diesel engine and main generator assembly,
and TM9-2330-205-14&P for troubleshooting
the trailer. Fold outs FO-2 through
Table 5-1.
FO-6 are troubleshooting schematic diagrams for use as necessary during troubleshooting.
TROUBLESHOOTING
MALFUNCTION
TESTOR INSPECTION
CORRECTIVE ACTION
1.
REMOTE CONTROL UNIT INOPERATIVE
Refer to para. 5-29 and test remote control unit.
Replace faulty components.
2.
REMOTE FUNCTIONS BOX ASSEMBLY INOPERATIVE
Step 1.
Refer to para. 5-20 and test for continuity in wiring harness
from J29B to J29C.
If open circuits exist, replace the wiring harness.
Step 2.
Refer to para. 5-19, and test for continuity in the wiring
harness from J29A to J29 and JA.
If open circuits exist, replace the wiring harness.
Step 3.
Refer to para. 5-22, and test relays KA, KB, KC, KD and KE.
Replace faulty relay.
If relays are functional and fault still exists, replace
the remote functions box assembly.
3.
SPECIAL RELAY ASSEMBLY INOPERATIVE
Step 1.
Refer to para. 5-25 and test special relay assembly.
If faulty components are found, send to intermediate
general support maintenance.
Step 2.
Refer to figure 5-1, and test for continuity in wiring from
connector JA to TB102 and A5.
If an open circuit exists , repair wiring as necessary.
Step 3.
Refer to figure 5-1, and check for continuity in wiring between
connectors, terminal boards and switches.
If an open circuit exists, repair or replace the special
relay assembly.
5-2
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
Figure 5-1.
Special Relay Assembly Wiring Harness (Sheet 1 of 3)
5-3
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
Figure 5-1.
5-4
Special Relay Assembly Wiring Harness (Sheet 2 of 3)
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
Figure 5-1.
Special Relay Assembly Wiring Harness (Sheet 3 of 3)
5-5
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
Section IV.
MAINTENANCE PROCEDURES
5-8. General
This section provides PU 794/G maintenance procedures for intermediate direct
support (DS) maintenance personnel.
5-6
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
MAINTENANCE OF GENERATOR SET, 20 KW
5-9. TEST GENERATOR SET 20 KW
This task covers: Test
INITIAL SETUP
Tools
General Safety Instructions
General Mechanic’s Tool Kit
5180-00-177-7033
Materials/Parts
Fuel/oil
Equipment Conditions:
Reference
TM5-6115-464-34.
Prior to performing any operational
test, ensure that the generator set
is serviced with the correct fuel,
oil and coolant as listed on the
data plate.
TEST
Test the Generator Set, 20 kW,
in accordance with Chapter 7 of
TM5-6115-464-34. The rated
load for this generator set is
20 kW.
5-7
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
MAINTENANCE OF INTAKE BAFFLE ASSEMBLY
5-10.
REPAIR INTAKE BAFFLE
This task covers: a. Removal
b. Repair
c. Installation
INITIAL SETUP
Tools
General Mechanic’s Tool Kit
5180-00-177-7033
Materials/Parts
Baffle Housing
97403-13228E1881
Grid Intake
97403-13228E1878
Channel End Baffle
97403-13228E3366-1
Baffle Center Intake
97403-13228E1880
Gasket
97403-13228E1940 (2 ea)
REMOVAL
1.
2.
REMOVE INTAKE GRID.
a,
Remove 10 screws (1) flat
washers (2), lock washers (3)
and nuts (4).
b.
Remove grid screen (5).
REMOVE CENTER AND END BAFFLES.
a.
Slide out the two end baffles
(6).
b. Slide out the five center
baffles (7).
3. REMOVE GASKET.
The gasket material located on
both mating surfaces of the
5-8
Equipment Conditions:
Reference
Para. 4-14 Remove Baffle
Assembly Intake.
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
5-10.
REPAIR INTAKE BAFFLE (cont)
baffle housing (8) will be
removed only when found
damaged.
REPAIR
Repair of the grid screen, end
and center baffles and gaskets
is accomplished by replacement.
INSTALLATION
a.
Install gasket material as
required.
b.
Install center (7) and end (6)
baffles by sliding into baffle
housing (8).
c.
Install grid screen (5) by installing 10 screws (1) flat
washers (2), lock washers (4)
and nuts (5).
NOTE
FOLLOW ON MAINTENANCE: Install
Baffle Assembly Intake (Para.
4-14) .
5-9
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
MAINTENANCE OF THE ACCESS DOORS
5-11.
REPAIR OF THE ACCESS DOORS
This task covers: Repair
INITIAL SETUP
Equipment Conditions:
Reference
Para. 4-18 Remove Access Door.
Tools
General Mechanic’s Tool Kit
5180-00-177-7033
#1 Common Tool Kit
TBD
Materials/Parts
Door, Access
97403-13228E3363-2
Seal, Door
30554-69-771
REPAIR
1.
REPAIR THE ACCESS DOORS.
a.
Remove any dents or bends from
the access doors (1).
b.
Replace torn or deteriorated
door seals (2).
NOTE
FOLLOW ON MAINTENANCE: Install
Access Door (Para. 4-18).
5-10
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
MAINTENANCE OF GENERATOR SET TOP COVER REAR ASSEMBLY
5-12.
REPAIR OF GENERATOR SET TOP REAR COVER
This task covers: a. Removal
b. Repair
c. Installation
INITIAL SETUP
Tools
General Mechanic’s Tool Kit
5180-00-177-7033
Equipment Conditions:
Reference
Para. 4-20 Remove Top Rear Cover.
Materials/Parts
Rear Housing Generator Set
97403-13228E3376
Insulation
97403-13228E3373-4
97403-13228E3373-2
97403-13228E3373-5
97403-13228E3373-6
Retainer Insulation
97403-13228E3372
REMOVAL
1.
REMOVE INSULATION.
a.
Remove seven rivets (1) holding
retainer bracket (2) to rear
cover housing (3).
b.
Remove insulation (4).
c.
Remove two pieces of insulation
(5) by sliding out of housing
(3).
d.
Remove insulation (6) and (7)
by sliding out of housing (3).
REPAIR
1.
REPAIR INSULATION.
Repair of all insulation is
accomplished by replacement.
5-11
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
5-12.
REPAIR OF GENERATOR SET TOP REAR COVER (cont)
INSTALLATION
1.
INSTALL INSULATION.
a.
Install two pieces of
insulation (5) by sliding into
housing (3).
b.
Install insulation (6) and
(7) by sliding into housing
(3).
c. Install insulation (4) and
retainer bracket (2) by
sliding into housing (3).
d.
Install seven rivets (1).
NOTE
FOLLOW ON MAINTENANCE: Install
Top Rear Cover (Para. 4-20).
5-12
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
MAINTENANCE OF GENERATOR SET REAR HOUSING, FRAME
5-13.
REPAIR OF REAR HOUSING FRAME
This task covers: a. Inspection
b. Repair
INITIAL SETUP
Equipment Conditions:
Reference
Para. 4-21 Remove Rear Housing
Frame.
Tools
General Mechanic’s Tool Kit
5180-00-177-7033
Materials/Parts
Housing Generator Set Rear Frame
97403-13228E1901
INSPECTION
INSPECT REAR HOUSING.
a.
Visually inspect all weld nuts
for stripped threads.
b.
Visually inspect rear housing
(1) for bends or cracks.
REPAIR
REPAIR REAR HOUSING FRAME.
a.
Use standard shop practice for
correcting any defects found
under inspection.
b.
Repair of the rear housing
frame (1) is accomplished by
replacement.
NOTE
FOLLOW ON MAINTENANCE: Install
Rear Housing Frame (Para. 4-21).
5-13
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
MAINTENANCE OF EXHAUST BAFFLE ASSEMBLY
5-14. REPAIR OF EXHAUST BAFFLE ASSEMBLY
This task covers:
Repair
INITIAL SETUP
Tools
General Mechanic’s Tool Kit
5180-00-177-7033
#1 Common Tool Kit
TBD
Materials/Parts
Housing, Baffle
97403-13228E1959
Gasket
97403-13228E1940
Flange, Top
97403-13228E1964
Flange, Side
97403-13228E1965 (2 ea)
Flange, Bottom
97403-13228E1966
Baffle Bar
97403-13228E1960
Channel, End Baffle
97403-13228E3366-2
Hang Plate
97403-13228E1963
Baffle, Center
97403-13228E1962
REPAIR
REPAIR THE EXHAUST BAFFLE ASSEMBLY.
a.
The top flange (1), bottom
flange (2) and side flanges
(3, 4) are repaired by
welding, straightening and
other normal maintenance shop
procedures.
b.
Repair the baffle assembly
gasket (5) by replacing it
with a new gasket.
5-14
Equipment Conditions:
Reference
Para. 4-22 Remove Exhaust
Baffle Assembly.
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
5-14.
REPAIR OF EXHAUST BAFFLE ASSEMBLY (cont)
c.
Replace all damaged mounting
hardware.
d.
Remove baffle bar (6) by removing three nuts (7), washers
(8) and screws (9).
e.
Remove two end baffles (10) and
five center baffles (11) from
baffle housing (12).
f.
Replace with new parts as
required.
9*
Remove two hang plates (13) by
removing four nuts (14), lockwashers (15), flat washers
(16) and screws (17) from the
baffle housing assembly (12).
h.
Replace with new parts as
required.
NOTE
FOLLOW ON MAINTENANCE: Install
Exhaust Baffle Assembly (Para.
4-22) .
5-15
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
MAINTENANCE OF GENERATOR SET, TOP FRONT ASSEMBLY
5-15. REPAIR GENERATOR SET TOP FRONT
This task covers: a. Removal
b. Repair
c. Installation
INITIAL SETUP
Tools
General Mechanic’s Tool Kit
5180-00-177-7033
Materials/Parts
Housing Generator Set
97403-13228E1953
Insulation
97403-13228E3373-1
97403-13228E3373-2
97403-13228E3373-3
Retainer, Insulation
97403-13228E3372
Door, Access
30554-72-2121
REMOVAL
1.
REMOVE ACCESS DOOR.
Remove two screws (1), lockwashers (2) and nuts (3)
from access door (4).
2. REMOVE INSULATION.
a.
Remove retainer bracket (5) and
insulation (6) by removing
seven rivets (7).
b. Remove two pieces of insulation
(8) by sliding out.
c.
5-16
Remove two pieces of insulation
(9) by sliding out.
Equipment Conditions:
Reference
Para. 4-24 Remove Top Front Cover.
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
5-15.
REPAIR GENERATOR SET TOP FRONT (cont)
REPAIR
1.
REPAIR INSULATION.
Repair of all insulation is
accomplished by replacement.
2.
REPAIR DOOR ACCESS.
Repair is accomplished by
replacement.
INSTALLATION
1.
2.
INSTALL INSULATION.
a.
Install insulation (8) by sliding into housing (10).
b.
Install insulation (9) by sliding into housing (10).
c.
Install insulation (6) and
retainer bracket (5) by sliding
into housing.
d.
Install seven rivets (7) into
housing (10) and retainer
bracket (5).
INSTALL ACCESS DOOR.
Install two screws (1), lockwashers (2) and nuts (3).
NOTE
FOLLOW ON MAINTENANCE: Install
Top Front Cover (Para. 4-24).
5-17
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
MAINTENANCE OF GENERATOR SET FRONT HOUSING
5-16. REPAIR GENERATOR SET FRONT HOUSING
This task covers: a. Inspection
b. Removal
c. Repair
d. Installation
INITIAL SETUP
Tools
General Mechanic’s Tool Kit
5180-00-177-7033
Materials/Parts
Housing, Generator Set
97403- 13228E1884
Sound Panel, Housing
97403-13228E3380
INSPECTION
INSPECT FRONT HOUSING.
a.
Visually inspect front housing
(1) for bends and cracks.
b.
Inspect all weld nuts for
stripped threads.
c.
Inspect sound panels (2) for
deterioration
REMOVAL
REMOVE SOUND PANEL
The sound panels (2) are held
in place by adhesive and must
be scrapped off the housing (1)
and the surfaced cleaned.
5-18
Equipment Conditions:
Reference
Para. 4-25 Remove Front Frame.
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
5-16.
REPAIR GENERATOR SET FRONT HOUSING (cont)
REPAIR
REPAIR FRONT HOUSING
a.
Use standard shop practice for
correcting mechanical defects.
b.
Repair of the sound panels is
accomplished by replacement.
INSTALLATION
INSTALL SOUND PANEL.
The sound panels (2) are adhesive backed with edge seal.
Peel off the seal and press
the panel into place.
NOTE
FOLLOW ON MAINTENANCE: Install
Front Frame (Para. 4-25).
5-19
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
MAINTENANCE OF CONTROL WIRING HARNESS
5-17.
REPAIR OF CONTROL WIRING HARNESS
This task covers: a. Removal
b. Test
c. Repair
d. Installation
INITIAL SETUP
Tools
General Mechanic’s Tool Kit
5180-00-177-7033
Multimeter
6625-01-139-2512
Equipment Conditions:
Reference
Para. 4-9 General Instructions.
General Safety Instructions
Materials/Parts
Control Wiring Harness
97403-13228E1909
Connector, Receptacle
97403-13228E1949
Connector J45
81349-D38999/24-F-D-5S
Connector P15
96906-MS31O6R2O-29P
REMOVAL
REMOVE CONTROL WIRING HARNESS.
a.
Disconnect connector P-15 (1)
from special relay assembly
J15 (2).
b.
Disconnect the SS2R connector
(3) from the SS2P connector
(4).
c.
Remove the nut from connector
J45 and remove the cable
connector from the connector
plate (5).
d.
Remove the control wiring harness by feeding it down through
the relay table and out of the
generator set.
5-20
To avoid short circuits which could
damage equipment or injure personnel,
always disconnect negative battery
cable before performing maintenance
on the electrical system.
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
5-17.
REPAIR OF CONTROL WIRING HARNESS (cont)
TEST
TEST CONTROL WIRING HARNESS.
a.
Use a multimeter and wire
running list, test for pin-topin continuity. Also test for
open circuit between each pin
and pin-to-connector.
b. When an open or short within
the cable assembly occurs,
repair or replace the wiring
harness.
5-21
TM-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
5-17.
REPAIR OF CONTROL WIRING HARNESS (cont)
REPAIR
REPAIR CONTROL WIRING HARNESS.
Use standard shop procedures
when repairing the control
wiring harness.
INSTALLATION
INSTALL THE CONTROL WIRING HARNESS.
a.
Install the control wiring harness by feeding connector P15
(1) up through the relay table
and connect P-15 (1) to J15
(2) on the special relay
assembly.
b.
Connect the SS2R connector (3)
to the SS2P connector (4).
c.
Install the cable connector in
the connector plate (5) and
replace the nut on connector
J45.
NOTE
FOLLOW ON MAINTENANCE: Connect
Negative Battery Cable (Para.
4-10).
5-22
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
MAINTENANCE OF POWER WIRING HARNESS
5-18.
REPAIR OF POWER WIRING HARNESS
This task covers: a. Test
b. Removal
c. Repair
d. Installation
INITIAL SETUP
Tools
General Mechanic’s Tool Kit
5180-00-177-7033
Multimeter
6625-01-139-2512
Equipment Conditions:
Reference
Para. 4-9 General Instructions.
General Safety Instructions
Materials/Parts
Harness Wiring Power
97403-13228E1951
Connector
96906-MS17346R36N77S
Surge Protector
97403-13228E1908
Terminal Ring
97403-13228E3388
Live voltages are present while the
generator set is operating. Be careful not to physically touch exposed
power wiring of power connector with
the body. Serious injury or death
by electrocution could result.
TEST
TEST THE POWER WIRING HARNESS.
a.
Start up the generator set.
Refer to para 2-5.
b.
Rotate the voltage meter selector switch through all positions and observe proper phaseto-neutral voltages.
c.
When a voltage is not observed
for any switch position the
power wiring harness is defective.
d.
Shut down the generator set.
5-23
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
5-18.
REPAIR OF POWER WIRING HARNESS (cont)
To avoid short circuits which
could damage equipment or injure personnel, always disconnect negative battery cable
before performing maintenance
on the electrical system.
e.
Use a multimeter and test for
continuity from all wire ends
(individually) to the J29M
connector (see wire list).
f. Use multimeter and test connector pins A, B and C to
housing of surge protectors
A1, A2, and A3 for open condition. (see wire list)
g.
5-24
When an pin or short occurs
within the cable assembly,
repair or replace the wiring
harness.
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
5-18.
REPAIR OF POWER WIRING HARNESS (cont)
REMOVAL
REMOVE POWER WIRING HARNESS FROM
THE LOAD TERMINAL.
a.
Tag and remove the wire leads
from the load terminal, L1 (1),
L2 (2), L3 (3) and LO (4).
b.
Remove the power connector J29M
and the surge protectors A1,
A2, A3 from the plate connector. Refer to para 4-17.
REPAIR
REPAIR WIRING HARNESS.
Use standard shop procedures
when repairing the power wiring
harness.
INSTALLATION
INSTALL THE POWER WIRING HARNESS.
a.
Refer to para 4-17 and install
the power connector J29M and
the surge protectors to the
plate connector.
b.
Install the L1 (1), L2 (2), L3 (3)
and LO (4) wire leads to the load terminal.
NOTE
FOLLOW ON MAINTENANCE: Connect
Negative Battery Cable (Para.
4-10).
5-25
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
MAINTENANCE OF THE WIRING HARNESSES
5-19.
TEST AND REPLACE SPECIAL RELAY ASSEMBLY TO REMOTE FUNCTIONS BOX
ASSEMBLY WIRING HARNESS
This task covers: a. Removal
b. Test
c. Repair
d. Installation
INITIAL SETUP
Tools
General Mechanic’s Tool Kit
5180-00-177-7033
Multimeter
6625-01-139-2512
Equipment Conditions:
Reference
Para. 4-9 General Instructions.
General Safety Instructions
Materials/Parts
Wiring Harness
97403-13228E1911
Connector, Plug
96906-MS31O6R24-28P
Connector Plug
96906-MS31O6R22-19P
Connector, Plug
96906-MS5086R145-6P
REMOVAL
REMOVE WIRING HARNESS BETWEEN
SPECIAL RELAY BOX AND REMOTE
FUNCTIONS BOX ASSEMBLY.
a.
Remove connector P29A (1) from
the remote functions box
assembly (2) at J29A (3).
b.
Remove connector P29 (4) and
PA (5) from the special relay
box (6) at J29 (7) and JA (8).
c.
Remove the wiring harness (9)
from the generator set.
5-26
To avoid short circuits which could
damage equipment or injure personnel,
always disconnect negative battery
cable before performing maintenance
on the electrical system.
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
5-19. TEST AND REPLACE SPECIAL RELAY ASSEMBLY TO REMOTE FUNCTIONS BOX
ASSEMBLY WIRING HARNESS (cont)
5-27
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
5-19. TEST AND REPLACE SPECIAL RELAY ASSEMBLY TO REMOTE FUNCTIONS BOX
ASSEMBLY WIRING HARNESS (cont)
b.
Use a multimeter and test for
open circuit between pins and
pin-to-connector.
c.
When opens or shorts occur,
repair wiring harness.
REPAIR
REPAIR WIRING HARNESS.
a.
Use standard shop procedures
when repairing the wiring
harness.
b.
If not repairable, fabricate
(see Appendix G).
INSTALLATION
INSTALL WIRING HARNESS.
a.
Connect P29A (1) connector to
the remote functions box
assembly (2) at J29A (3).
b.
Install connectors P29 (4) and
PA (5) to the special relay
box (6) at J29 (7) and JA (8).
NOTE
FOLLOW ON MAINTENANCE: Connect
Negative Battery Cable (Para.
4-10).
5-28
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
MAINTENANCE OF THE WIRING HARNESSES
5-20.
TEST AND REPLACE REMOTE FUNCTIONS BOX ASSEMBLY TO CONNECTOR PANEL
WIRING HARNESS
This task covers: a. Removal
b. Test
c. Repair
d. Installation
INITIAL SETUP
Tools
General Mechanic’s Tool Kit
5180-00-177-7033
Multimeter
6625-01-139-2512
Equipment Conditions:
Reference
Para. 4-9 General Instructions.
General Safety Instructions
Materials/Parts
Wiring Harness
97403-13228E191O
Connector, Socket
96906-MS3456W24-28S
Connector Elec.
81349-D38999/24FH21S
To avoid short circuits which could
damage equipment or injure personnel,
always disconnect negative battery
cable before performing maintnenace
on the electrical system.
REMOVAL
REMOVE WIRING HARNESS.
a.
Disconnect P29B (1) connector
on wiring harness (2) at the
remote functions box assembly
(3) from J29B (4).
b.
Remove the nut from connector
J29C and remove the cable
connector from the connector
plate (5).
TEST WIRING HARNESS.
a.
Use the wire running list.
and a multimeter to test for
continuity from pin-to-pin.
5-29
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
5-20. TEST AND REPLACE REMOTE FUNCTIONS BOX ASSEMBLY TO CONNECTOR PANEL
WIRING HARNESS (cont)
5-30
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
5-20.
TEST AND REPLACE REMOTE FUNCTIONS BOX ASSEMBLY TO CONNECTOR PANEL
WIRING HARNESS (cont)
b.
Use a multimeter and test for
open circuit between pins and
pin-to-connector.
c.
When opens or shorts occur,
repair wiring harness.
REPAIR
REPAIR WIRING HARNESS.
a. Use standard shop procedures
when repairing the wiring
harness.
b.
If not repairable, fabricate
(see Appendix G).
INSTALLATION
INSTALL WIRING HARNESS.
a. Install connector P29B (1) onto
the remote functions box
assembly (3) at J29B (4).
b.
Install the cable connector in
the connector plate (5) and
replace the nut on connector
J29C .
NOTE
FOLLOW ON MAINTENANCE: Connect
Negative Battery Cable (Para.
4-10).
5-31
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
MAINTENANCE OF THE WIRING HARNESSES
5-21.
TEST AND REPLACE SS2P TO CONVENIENCE RECEPTACLE WIRING HARNESS
This task covers: a. Removal
b. Test
c. Repair
d. Installation
INITIAL SETUP
General Safety Instructions
Tools
General Mechanic’s Tool Kit
5180-00-177-7033
Multimeter
6625-01-139-2512
Materials/Parts
Wiring Harness
97403-13228E1913
Connector, Plug
97403-13228E1948
Equipment Conditions:
Reference
TM5-6115-464-12
Remove Convenience Receptacle and
Circuit Breaker Para. 3-124.
REMOVAL
REMOVE CONVENIENCE WIRING HARNESS.
a.
Disconnect SS2P connector from
SS2R connector.
b.
Remove wire XN9B from the
circuit breaker (1) and wire
XN12B from the receptacle (2).
5-32
To avoid short circuits which could
damage equipment or injure personnel,
always disconnect negative battery
cable before performing maintenance
on the electrical system.
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
5-21.
TEST AND REPLACE SS2P TO CONVENIENCE RECEPTACLE WIRING HARNESS (cont)
TEST
TEST CONVENIENCE WIRING HARNESS.
a.
Use a multimeter and test for
continuity between pins, also
test for open circuit between
pins.
b.
When open or short occurs,
repair wiring harness.
REPAIR
REPAIR WIRING HARNESS.
a.
Use standard shop procedures
when repairing the wiring
harness.
b.
If not repairable, fabricate
(see Appendix G).
INSTALLATION
INSTALL CONVENIENCE WIRING HARNESS.
a.
Connect wire XN12B to the
receptacle and wire XN9B to
the circuit breaker.
b.
Connect connector SS2P to connector SS2R.
NOTE
FOLLOW ON MAINTENANCE: Install
Convenience Receptacle and Circuit
Breaker (TM5-6115-464-12, Para.
3-124.)
5-33
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
MAINTENANCE OF THE REMOTE FUNCTIONS BOX ASSEMBLY
5-22.
REPAIR THE REMOTE FUNCTIONS BOX ASSEMBLY
This task covers: a. Test
b. Repair
c. Removal
d. Install
INITIAL SETUP
Tools
General Mechanic’s Tool Kit
5180-00-177-7033
#1 Common Tool Kit
TBD
Multimeter
6625-01-139-2512 (2 ea)
Materials/Parts
Relay
96906-M5757/23-O03
TEST
TEST THE REMOTE FUNCTIONS BOX
RELAY.
a.
Remove the remote functions box
cover (1) by removing eight
screws (2), lockwashers (3) and
flat washers (4).
b.
Set up an electric relay for
testing as shown in test one.
c.
Adjust voltage on the power
supply between +1.5 Vdc and
+7.0 Vdc.
d.
The ohmmeter on M2 should read
infinity indicating an open
circuit. Replace the relay if
this reading is not shown.
e.
Increase voltage on the power
supply to +18 Vdc.
5-34
Equipment Conditions:
Reference
Para. 4-9 General Instructions.
General Safety Instructions
NOTE
Two tests are required to determine
serviceability of the relays. A
24 Vdc adjustable power supply and
two multimeters are required to test
the relay.
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
5-22.
REPAIR THE REMOTE FUNCTIONS BOX ASSEMBLY (cont)
f. The ohmmeter on M2 should drop
to O indicating a closed circuit. Replace the relay if
this reading is not shown.
g.
Change the test setup to test
two as shown in the figure.
h.
Repeat steps (c) through (f).
i.
Readings on M2 should be the
same as test one; if not,
replace the relay.
j.
Repeat steps (b) through (i)
for four remaining relays.
REPAIR
REPAIR THE REMOTE FUNCTIONS BOX
ASSEMBLY.
Repair of the remote functions
box assembly is accomplished by
replacing any of the five
relays that is malfunctioning.
If relays are not malfunctioning replace remote
functions box assembly.
REMOVAL
REMOVE THE REMOTE FUNCTIONS BOX
ASSEMBLY.
a.
Refer to para. 5-19 and para.
5-20 and remove connectors
J29A and J29B.
b.
Remove four nuts (5), lockwashers (6), flat washers (8)
and screws (7).
c.
Lift the remote functions box
assembly (9) from the mounting
bracket (10).
5-35
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
5-22. REPAIR THE REMOTE FUNCTIONS BOX ASSEMBLY (cont)
INSTALLATION
INSTALL THE REMOTE FUNCTIONS BOX
ASSEMBLY.
a. Install four flat washers (8),
screws (7), lockwashers (6) and
nuts (5) into the bracket (10)
and remote functions box
assembly (9).
b. Refer to para. 5-19 and para.
5-20 and reconnect connectors
J29A and J29B.
c. Install eight flat washers (4),
lockwashers (3) and screws (2)
into the remote functions box
cover (1).
d. Secure all mounting hardware.
NOTE
FOLLOW ON MAINTENANCE: Connect
Negative Battery Cable (Para.
4-10).
5-36
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
MAINTENANCE OF CURRENT TRANSFORMER
5-23. MAINTENANCE OF CURRENT TRANSFORMER ASSEMBLIES
This task covers: a. Removal
b. Inspection
c. Testing
d. Installation
INITIAL SETUP
Tools
General Mechanic’s Tool Kit
5180-00-177-7033
Multimeter
6625-01-139-2512
Equipment Conditions:
Reference
Para. 4-9 General Instructions.
TM5-6115-464-34
Remove Control Cubicle Assembly
Para. 4-2.
Materials/Parts
Current Boost Transformer
30554-72-2216
Instrumentation Transformer
30554-70-1172
Cross Current Transformer
30554-72-2330
REMOVAL
1.
2.
REMOVE REMOTE FUNCTIONS BOX
ASSEMBLY AND BRACKET AND RECONNECTION BOARD COVER.
a.
Refer to para. 5-19 and para.
5-20 and remove connectors
J29A and J29B.
b.
Remove four bolts (1) and
washers (2) and remove remote
functions box assembly and
bracket (3) and reconnection
board cover (4).
REMOVE TRANSFORMER ASSEMBLIES.
a.
Tag and disconnect electrical
leads from transformer assemblies.
b.
Tag and record routing and
polarity of generator leads
through transformer windows.
Then disconnect and remove
the leads.
5-37
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
5-23. MAINTENANCE OF CURRENT TRANSFORMER ASSEMBLIES (cont)
c.
Remove four nuts (5), lockwashers (6), bolts (7), and
current boost transformer (8).
NOTE
Do not remove mounting brackets unless inspection reveals
damage and replacement is
necessary.
d.
Remove four screws and washer
assemblies (9), flat washers
(10), and two mounting brackets
(11).
e.
Remove six screws (12) and flat
washers (13), and instrumentation transformer assembly (14).
f. Remove two nuts (15), screws
(16), lockwashers (17), and
cross-current compensation
transformer (18).
NOTE
Do not remove mounting brackets unless inspection reveals
damage and replacement is
necessary.
g.
Remove four screws (19) and
flat washers (20), and two
mounting brackets (21).
INSPECTION
INSPECT TRANSFORMERS
a.
Visually inspect transformers
for cracks, corroded terminals,
and evidence of shorting.
b. The transformers must be replaced if above conditions are
found.
5-38
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
5-23.
MAINTENANCE OF CURRENT TRANSFORMER ASSEMBLIES (cont)
TESTING
TEST TRANSFORMER ASSEMBLIES.
a.
Test current boost transformer
as follows:
(1) Use an ohmmeter to test
for 0.19 ohms between A1
and A2, B1 and B2, C1 and
C2.
(2) Apply 7 Vac 60 Hz to secondary winding. Exciter
current should be 75
milliamperes maximum.
(3) Replace the transformer if
test steps (1) or (2)
above failed.
b.
Test instrumentation transformer as follows:
(1) Use an ohmmeter to test
for 0.11 ohms between
terminals A1 and A3, B1
and B2, C1 and C2.
(2) Apply 10 Vac 60 Hz to secondary winding. Exciter
current should be 50
milliamperes maximum.
(3) Replace transformer if
test steps b. (1) or (2)
failed.
c.
Test cross-current compensation
transformer as follows:
(1) Use an ohmmeter to test
for 0.3 ohms between terminals A1 and A2.
(2) Apply 10 Vac 60 Hz to
secondary winding. Exciter current should be 50
milliamperes maximum.
5-39
TM-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
5-23. MAINTENANCE OF CURRENT TRANSFORMER ASSEMBLIES (cont)
(3) Replace transformer if
test steps c. (1) or (2)
failed.
INSTALLATION
1.
INSTALL TRANSFORMER ASSEMBLIES.
a.
Install two mounting brackets
(21), if removed, and secure
with four screws (19) and flat
washers (20).
b.
Install cross-current compensation transformer (18) and
secure with two screws (16),
lockwashers (17), and nuts
(15).
c.
Install instrumentation transformer assembly (14), and
secure with six screws (12) and
flat washer (13).
d.
Install mounting brackets (11),
if removed, and secure with
four screws (9) and flat
washers (10).
e.
Install current boost transformer (8) and secure with
four screws (7), lockwashers
(6), and nuts (5).
f.
Route generator leads through
transformer windows while
observing polarity as noted
during removal. See transformer wiring table. Connect
the leads to voltage reconnection
board. Remove tags. Retie
wire bundles through the
coils.
g.
Connect electrical leads to
transformer assemblies.
Remove tags.
5-40
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
5-23.
2.
MAINTENANCE OF CURRENT TRANSFORMER ASSEMBLIES (cont)
INSTALL REMOTE FUNCTIONS BOX
ASSEMBLY AND BRACKET AND RECONNECTION BOARD COVER
a.
Install reconnection board
cover (4) and remote functions
box assembly and bracket (3)
with four bolts (1) and
washers (2).
b.
Refer to para. 5-19 and para.
5-20 and reconnect connectors
J29A and J29B.
NOTE
FOLLOW ON MAINTENANCE: Install
Control Cubicle Assembly
(TM5-6115-464-34, Para. 4-2).
Connect Negative Battery Cable
(Para. 4-10).
5-41
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
MAINTENANCE OF THE CRANKSHAFT PULLEY
5-24. REPLACE CRANKSHAFT PULLEY
This task covers: a. Removal
b. Installation
INITIAL SETUP
Tools
Equipment Conditions:
Reference
Para. 4-35 Remove Engine V-belt.
General Mechanic’s Tool Kit
5180-00-177-7033
#1 Common Tool Kit
TBD
Materials/Parts
Pulley Crankshaft
97403-13228E1893
REMOVAL
1.
REMOVE CRANKSHAFT PULLEY.
a.
Remove nut (1), lockwasher
(2), pulley washer (3) and
pin (4).
b.
Remove pulley (5) from pulley
shaft.
INSTALLATION
1.
INSTALL CRANKSHAFT PULLEY.
a.
Install new pulley (5) onto
pulley shaft.
b.
Install pin (4), pulley washer
(3), lockwasher (2) and nut (1)
onto pulley shaft.
c.
Tighten the nut (1) to 125 ftlb (172.5 n-m).
NOTE
FOLLOW ON MAINTENANCE: Install
Engine V-belt (Para. 4-35).
5-42
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
MAINTENANCE OF SPECIAL RELAY ASSEMBLY
5-25. TEST SPECIAL RELAY ASSEMBLY
This task covers: a. Removal
b. Test
c. Installation
INITIAL SETUP
Tools
General Mechanic’s Tool Kit
5180-00-177-7033
Solder/Desolder Kit
3439-00-460-7198
Multimeter
6625-01-139-2512
Equipment Conditions:
Reference
Para. 4-9 General Instructions.
TM5-6115-464-34
Remove Static Exciter and Voltage
Regulator Assembly Para. 5-13.
Materials/Parts
Special Relay Assembly
97403-13228E1904
REMOVAL
REMOVE SPECIAL RELAY ASSEMBLY FROM
RELAY TABLE.
a.
Tag and disconnect wiring harnesses from special relay
assembly connectors.
b.
Remove six screws (1), lockwashers (2), nuts (3) and remove the special relay
assembly from relay table in
generator set.
c.
Disassemble only as necessary
to test for faulty components.
d.
Remove two screw and captive
washer assemblies (4) and remove chassis (5) from special
relay assembly (6).
5-43
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
5-25. TEST SPECIAL RELAY ASSEMBLY (cont)
TEST
TEST SPECIAL RELAY ASSEMBLY
NOTE
When a component or assembly
fails during the following test
procedures, refer the special
relay assembly to higher level
maintenance.
NOTE
Components shown removed are
for identification and relative
locations only. Actual removal
is not required.
a.
5-44
Use an ohmmeter to test potentiometer (7) as follows:
(1)
Connect ohmmeter leads
between wiper terminal and
either outer terminal.
(2)
Rotate adjustment at an
even rate from full
counter-clockwise to full
clockwise.
Meter indication should change at even
rate from O to 12 ohms.
(3)
Refer to wire run list and
test wiring harness wires
for continuity.
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
5-25.
TEST SPECIAL RELAY ASSEMBLY (cont)
b. Test the dc relay assembly (8)
as follows:
(1)
Apply 24 Vdc to terminals
6 and 15 then use an
ohmmeter to test for continuity across terminals
5 and 17, and an open
circuit across terminals
4 and 17, and 3 and 13.
(2)
Remove the 24 Vdc from
terminals 6 and 15, and
apply the 24 Vdc to terminals 13 and 15. Use the
ohm meter to test for continuity across terminals
1 and 14 and 2 and 3.
(3)
Remove the 24 Vdc from
terminals 13 and 15.
(4)
Place the ohmmeter probes
across terminals 10 and
12, and record the meter
indication.
Reverse the
probes on terminals 10
and 12, and record the
indication.
Resistances
indicated should be high
in one direction and low
in the other.
(5)
Repeat the above test,
using terminals 24 and 21.
(6)
Use the ohmmeter to test
resistance across terminals 7 and 8 for approximately 7.5 K ohms resistance.
(7)
Repeat step (6) to test
resistance across terminals 19 and 20 for same
meter indications.
(8)
Apply 120 Vac to terminals
18 and 22 and use the ohm
meter to test resistance
across terminals 7 and 8,
and 19 and 20. Meter
5-45
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
5-25. TEST SPECIAL RELAY ASSEMBLY (cont)
should indicate approximately 2.5K ohms, across
terminals 7 and 8, and 19
and 20.
(9) Use the ohmmeter to test
resistor R3 for 1.5K ohms.
c.
Inspect instrument shunt (9)
for burns and corrosion.
d.
Inspect relay K3 (10) for
cracked casing and evidence
of shorting.
e. Inspect the special current
transformer (11) for burns and
evidence of shorting. Use an
ohmmeter to test for continuity
across windings.
f.
Use ohmmeter to test diode
assembly (12) using procedure
steps b(4) and (5).
g.
Use ohmmeter to test fixed
resistors (13) and (14) for
7.5 ohms.
INSTALLATION
INSTALL SPECIAL RELAY ASSEMBLY.
5-46
a.
Install chassis (5) on special
relay assembly (6) and secure
with two screw and captive
washer assemblies (4).
b.
Install special relay assembly
on relay table and secure with
six screws (1), lockwashers (2)
and nuts (3).
c.
Connect wiring harnesses to the
special relay connectors, and
remove the tags.
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
5-25.
TEST SPECIAL RELAY ASSEMBLY (cont)
NOTE
FOLLOW ON MAINTENANCE: Install
Static Exciter and Voltage Regulator Assembly (TM5-6115-464-34,
Para. 5-13). Connect Negative
Battery Cable (Para. 4-10).
5-47
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
MAINTENANCE OF THE ISOLATORS, FRONT AND REAR
5-26.
INSPECT ISOLATORS
This task covers:
a. Inspection
INITIAL SETUP
Tools
None
Materials/Parts
None
Equipment Conditions:
Reference
Para. 4-9 General Instructions.
5-48
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
MAINTENANCE OF THE LIFTING FRAME
5-27.
REPLACE LIFTING FRAME
This task covers: a. Removal
b. Installation
INITIAL SETUP
Tools
General Mechanic’s Tool Kit
5180-00-177-7033
#1 Common Tool Kit
TBD
Materials/Parts
Clevis
90202-XBN8190
Bracket, Angle
30554-72-2012
Support, Center
97403-13228E1890
Support, Right
97403-13228E1889
Support, Left
97403-13228E1888
Equipment Conditions:
Reference
Para. 4-12 Remove Rear Housing Frame.
Para. 4-25
Remove
Front Frame.
Para. 4-26 Remove Tube Assembly and
Silencer.
Para. 4-28 Remove Air Cleaner
Housing.
TM5-6115-464-12
Remove Fuel Lines and Fittings Para.
3-83.
TM5-6115-464-34
Remove Day Tank Assembly Para. 3-18.
Remove Fuel Injection Pump Assembly
Para. 3-20.
REMOVAL
NOTE
It is not necessary to completely
disassemble the lifting frame to
replace a single part. Only those
parts requiring repair or replacement need be removed.
1.
REMOVE LIFTING FRAME
a.
Remove four nuts (1),
lockwashers (2),
flat washers (3),
and screws (4).
b.
Remove four nuts (5), lockwashers (6), spacers (7), flat
washers (8) and screws (9).
5-49
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
5-27. REPLACE LIFTING FRAME (cont)
c.
Lifting frame may now be
removed from the skid base
(10).
2. REMOVE CENTER SUPPORT BRACKET.
a.
Remove four nuts (11), lockwashers (12), flat washers
(13) and screws (14).
b.
Remove four nuts (15), lockwashers (16), flat washers
(17) and screws (18).
c. The center support (19), right
support (20), left support (21)
and lifting clevis (22) are now
separated.
INSTALLATION
1.
2.
INSTALL CENTER SUPPORT BRACKET.
a.
Position center support (19),
right support (20), left support (21) and lifting clevis
(22) for installation.
b.
Install four flat washers (17),
screws (18), lockwashers (16)
and screws (15).
c.
Install four flat washers
(13), screws (14), lockwashers
(12) and nuts (11).
INSTALL LIFTING FRAME.
a.
Position lifting frame on skid
base (10) for installation.
b.
Install four flat washers (6),
screws (5), spacers (7), lockwashers (8) and screws (9).
c.
Install four flat washers (3),
screws (4), lockwashers (2)
and nuts (1).
5-50
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
5-27.
REPLACE LIFTING FRAME (cont)
NOTE
FOLLOW ON MAINTENANCE: Install
Fuel Injection Pump Assembly (TM56115-464-34, Para. 3-20).
Install Day Tank Assembly (TM56115-464-34, Para. 3-18).
Install Fuel Lines and Fittings
(TM5-6115-464-312, Para 3-83).
Install Air Cleaner Housing (Para.
4-28) .
Install Tube Assembly and Silencer
(Para 4-26).
Install Front Frame (Para. 4-25).
Install Rear Housing Frame (Para.
4-21).
5-51
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
MAINTENANCE OF JUNCTION BOX
5-28. JUNCTION BOX MAINTENANCE
This task covers: Test
INITIAL SETUP
Tools
Equipment Conditions:
Reference
Para. 4-39 Remove Junction Box
Assembly.
General Mechanic’s Tool Kit
5180-00-177-7033
Megohmeter
TBD
Materials/Parts
Junction Box
97403-13228E1872
TEST INSULATION OF POWER AND
CONTROL WIRING HARNESSES.
a.
Refer to MIL-HDBK-705B method
301.16 and use a megohmeter to
test all leads individually for
insulation breakdown.
b. The junction box must be
repaired or replaced if tests
indicates faulty insulation on
any wire.
NOTE
FOLLOW ON MAINTENANCE: Install
Junction Box Assembly (Para.
4-39) .
5-52
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
MAINTENANCE REMOTE CONTROL UNIT
5-29.
TEST AND REPAIR REMOTE CONTROL UNIT
This task covers: a. Test
b. Repair
INITIAL SETUP
Tools
Materials/Parts
General Mechanic’s Tool Kit
5180-00-177-7033
Multimeter
6625-01-139-2512
Solder/Desolder Kit
3439-00-460-7198
Remote Control Unit
97403-13228E1869
TEST
1.
2.
TEST INDICATOR LIGHT ASSEMBLIES.
a.
Remove LOW FUEL, ENG RUNNING
and CONTACTOR CLOSED lamps.
Use an ohmmeter to test the
lamps for burned out filaments.
Replace turned out lamps.
b.
Remove SYN LIGHT lamps. Use
an ohmmeter to test the lamps
for burned out filaments.
Replace burned out lamps.
TEST SWITCHES, CONTROLS AND WIRING
HARNESS.
NOTE
Refer to FO-2 for the following
procedures.
a.
Connect ohmmeter leads across
J29D pins A and B. Toggle S18
to RUN position. Meter indication should be O ohms.
b.
Connect ohmmeter leads across
Toggle
J29D, pins A and C.
and hold S18 to START position.
Meter indication should be O ohms.
5-53
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
5-29. TEST AND REPAIR REMOTE CONTROL UNIT (cont)
c.
Connect ohmmeter leads across
J29D pins A and D. Toggle and
hold S20 to CLOSE position.
Meter indication should be O
ohms.
d.
Connect ohmmeter
J29D pins A and
hold S20 to OPEN
Meter indication
O ohms.
e.
Connect ohmmeter leads across
J29D pins A and F. Toggle and
hold S22 to ON position. Meter
indication should be O ohms.
f.
Connect ohmmeter leads across
J29D pins V and U. Toggle S19
to RUN position. Meter indication should be O ohms.
g.
Connect ohmmeter leads across
J29D, pins V and T. Toggle
and hold S19 to START position.
Meter indication should be O
ohms.
h.
Connect ohmmeter leads across
J29D pins V and S. Toggle and
hold S21 to CLOSE position.
Meter indication should be O
ohms.
i.
Connect ohmmeter
J29D pins V and
hold S21 to OPEN
Meter indication
O ohms,
j.
Connect ohmmeter leads across
J29D pins V and P. Toggle and
hold S23 to ON position. Meter
indication should be O ohms.
k.
Connect ohmmeter leads across
J29D pins a and d . Meter indication should be 500 ohms.
l.
Repeat step 2.k. above using
J29D pins g and W.
5-54
leads across
E. Toggle and
position.
should be
leads across
R. Toggle and
position.
should be
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
TEST AND REPAIR REMOTE CONTROL UNIT (cont)
5-29.
m.
Connect ohmmeter across J29D
pins b and d then rotate FREQ
ADJUST (set no. 1) from fully
counter-clockwise to fully
clockwise. Meter indication
should change smoothly from
O-to-500 ohms.
n.
Repeat step 2.m. above, using
J29D pins f and W.
o.
Use the multimeter to test for
continuity between J29D pins B
and Y, G and H, H and J, n and
p, V and i, N and M, M and L,
and g and k.
p.
If any test step (2.a through
2.o) failed, the unit must be
repaired.
REPAIR
REPAIR CONTROLS AND INDICATORS
a.
Repair by replacing faulty
controls and indicators as
follows:
(1) Remove six screws (1) that
secures the control panel
(2) to the housing.
(2) Remove ring nut (3), from
J29D connector (4) and
carefully push connector
inwards from port.
(3) Remove control panel (2)
and wiring harness from
housing.
b.
Remove ENGINE START/STOP, CONTACTOR CLOSE/OPEN and BATTLESHORT ON/OFF switches.
5-55
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
5-29. TEST AND REPAIR REMOTE CONTROL UNIT (cont)
NOTE
All switches are removed in the
same manner. The BATTLESHORT
ON/OFF switch has one additional
part which will be identified in
the following steps.
(1) Tag and disconnect electrical leads from switch
terminals.
(2) Remove nut (5), lockwasher
(6), locking ring (7),
switch guard (8) for
BATTLESHORT ON/OFF switch
only, switch (9) and nut
(10). Retain mounting
hardware.
c. Install ENGINE START/STOP, CONTACTOR CLOSE/OPEN and BATTLESHORT ON/OFF switches.
NOTE
All switches are installed in the
same manner. The BATTLESHORT ON/
OFF switch has one additional part
which will be identified in the
following steps.
(1) Obtain replacement switch
(9). Install nut (10) on
switch (9), switch guard
(8) BATTLESHORT ON/OFF
switch only, locking ring
(7) , lockwasher (6) and
nut (5).
(2) Reconnect tagged electrical leads to switch terminals.
d.
Replace FREQ ADJUST rheostats
as follows:
(1) Tag and disconnect wire
leads from R32 terminals.
(2) Remove knob (11) , nut and
washer assembly (12), and
rheostat (13) from panel.
5-56
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
5-29.
TEST AND REPAIR REMOTE CONTROL UNIT (cont)
(3) Install rheostat (13) on
panel. Secure with nut
and washer assembly (12).
Then install knob (11).
e.
Replace ENG RUNNING, CONTACTOR
CLOSED and LOW FUEL light
assemblies as follows:
(1) Tag wire leads connected
to terminals.
(2) Use solder/desolder kit to
remove solder from connector terminals and disconnect the wires.
(3) Remove nut (14), lockwasher (15), and light
assembly (16) from panel.
(4) Install light assembly
(16) and secure it to
panel with nut (14) and
lockwasher (15).
(5) Connect wires to terminals
and solder connections in
accordance with MIL-STD454, requirement 5.
f.
Replace SYN LIGHT assembly as
follows:
(1)
Tag and disconnect wire
leads connected to terminals.
(2)
Remove nut (17), tooth
washer (18), flat washer
(19), light assembly (20),
and flat washer (21) from
panel.
(3)
Get a replacement light
assembly (20) and install
flat washers (21) and
(19), tooth washer (18)
and nut (17).
(4)
Connect wires to terminals.
5-57
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
5-29. TEST AND REPAIR REMOTE CONTROL UNIT (cont)
5-58
g.
Inspect all connections for
compliance with FO-2 wiring
diagram. Then remove tags.
h.
Replace wiring harness as
follows:
(1)
Tag and mark wires connected to switches, controls and indicators.
(2)
Remove ring nut (3) from
J29D connector (4). Remove
wiring harness.
(3)
Get a new wiring harness
to tag and mark wires to
tag and mark wires to
exact match with the old
wiring harness.
(4)
Connect wires to controls,
switches, and indicators
per tags. Ensure all connections are in accordance
with the schematic diagram
(FO-2).
(5)
Solder connections to indicators in accordance
with MIL-STD-454.
(6)
Secure wiring harness with
wire straps.
(7)
Install connector J29D (4)
to with ring nut (3).
(8)
Install control panel (2)
to housing and secure with
six screws (1).
(9)
Test the remote control
unit by operating the
generator set in the
remote mode.
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
MAINTENANCE OF THE FIRE EXTINGUISHER
5-30.
FIRE EXTINGUISHER MAINTENANCE
This task covers: a. Inspection
b. Test
c. Replace
d. Service
INITIAL SETUP
Tools
General Mechanic’s Tool Kit
5180-00-177-7033
Equipment Conditions:
Reference
Para. 4-53 Remove Fire Extinguisher.
Materials/Parts
Extinguisher, Fire
97403-13228E3394
INSPECTION
1.
INSPECT THE FIRE EXTINGUISHER.
a.
Visually inspect for a broken
seal, damaged handle or broken
test sight guage.
TEST
1.
TEST THE FIRE EXTINGUISHER.
a.
Visually check the test sight
guage. Sight gauge should read
in green area or good area, depending on type of extinguisher
supplied.
b.
Weigh extinguisher. Acceptable
weight should appear on data
plate.
5-59
TM-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
5-30. FIRE EXTINGUISHER MAINTENANCE (cont)
REPLACE
1. REPLACE THE FIRE EXTINGUISHER.
If during testing of the fire
extinguisher defects are
found, replace the fire
extinguisher.
SERVICE
1.
SERVICE THE FIRE EXTINGUISHER.
Service of fire extinguisher
is accomplished through installation facilities
engineers or service and
supply units.
NOTE
FOLLOW ON MAINTENANCE: Install
Fire Extinguisher (Para. 4-53).
5-60
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
Section V.
PREPARATION FOR STORAGE AND SHIPMENT
5-31. Storage
Storage for the PU 794/G is intend
limited to 180 day storage or less. To
place the unit in administrative storage,
5-32.
Preparation for Shipment
The PU 794/G can be shipped by rail, air
or sea without damage to the unit. The
secure all tools and equipment in the
designated place. Refer to AR 750-1.
The PU 794/G has no special storage
requirements.
PU 794/G will be packaged for shipment
in accordance with MIL-G-28554B, Level A
packing instructions.
5-61/(5-62 Blank)
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
CHAPTER 6
INTERMEDIATE GENERAL SUPPORT MAINTENANCE INSTRUCTIONS
CHAPTER INDEX
Page
Subject Index
6-1
6-1
Repair Parts, Special Tools Equipment
Maintenance
Section I. REPAIR PARTS, SPECIAL TOOLS, TEST MEASUREMENT
AND DIAGNOSTIC EQUIPMENT (TMDE) AND SUPPORT EQUIPMENT
6-1.
General
Refer to Chapter 5 for instructions on
repair parts, special tools and equipment.
Section II.
6-2. General Instructions
Instructions for maintenance and repair
of components of the PU 794/G are pro-
MAINTENANCE
vided in this section. Refer to TM56115-464-34 for instructions on the
repair of the diesel engine generator
and accessories.
6-1
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
MAINTENANCE OF THE GENERATOR SET, 20 KW
6-3. REPLACE THE GENERATOR SET
This task covers: a. Removal
b. Installation
INITIAL SETUP
General Safety Instructions
Tools
General Mechanic’s Tool Kit
5180-00-177-7033
Lifting Device, 5-ton Capacity
Do not use a lifting device of
less than 10,000 lb. capacity.
Materials/Parts
Generator Set 20 kW
97403-13228E1868
Equipment Conditions:
Reference
Para. 4-9 General Instructions.
REMOVAL
REMOVE GENERATOR SET.
6-2
a.
Remove eight nuts (1), lockwashers (2), bolts (3) and
flat washers (4) .
b.
Attach lifting device to the
generator set (5).
c.
Be sure the lifting device is
properly attached to the generator set at the lifting
clevises (6).
d,
Lift the generator set (5) from
the trailer (7).
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
REPLACE THE GENERATOR SET (cont)
6-3.
INSTALLATION
INSTALL GENERATOR SET.
a.
Place a new generator set (5)
onto the trailer (7), and align it
with the mounting holes.
b.
Install eight flat washers (4),
bolts (3), lockwasher (2) and
nuts (1).
NOTE
FOLLOW ON MAINTENANCE: Connect
Negative Battery Cable (Para.
4-10).
6-3
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
MAINTENANCE OF SPECIAL RELAY ASSEMBLY
6-4. REPLACE FAULTY COMPONENT OF SPECIAL RELAY ASSEMBLY
This task covers: a. Removal
b. Replacement
c. Installation
INITIAL SETUP
Tools
Materials/Parts
General Mechanic’s Tool Kit
5180-00-177-7033
Solder/Desolder Kit
3439-00-460-7198
Special Relay Assembly
97403-13228E1904
REMOVAL
REMOVE CHASSIS FROM SPECIAL RELAY
ASSEMBLY.
Remove two screw and captive
washer assemblies (1) and
remove chassis (2) from special
relay assembly (3).
REPLACEMENT
REPLACE FAULTY COMPONENT IN SPECIAL
RELAY ASSEMBLY.
a.
Solder/desolder harness wires
as necessary using MIL-STD-454.
b.
Replace faulty potentiometer:
(1) Tag and remove wires from
faulty potentiometer (4).
(2) Remove nut (5) and remove
faulty potentiometer (4).
(3) Install new potentiometer
(4) and secure with nut
(5).
(4) Attach wires to potentiometer (4).
6-4
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
REPLACE FAULTY COMPONENT OF SPECIAL RELAY ASSEMBLY (cont)
6-4.
c.
Replace faulty wiring harness:
(1) Remove all wires of faulty
wiring harness (6). (Not
shown).
(2) Attach new wiring harness
(6) using wiring diagram
figure 5-1.
d.
Replace faulty dc relay
assembly:
(1) Tag and remove wires from
faulty dc relay assembly
(7).
(2) Remove four screws (8) and
remove faulty dc relay
assembly (7).
(3) Install new dc relay assembly (7) and secure with
four screws (8).
(4) Attach wires to new dc
relay assembly (7).
e.
Replace faulty instrument shunt:
(1) Tag and remove wires from
faulty instrument shunt
(9).
(2) Remove two screws (10) and
remove faulty instrument
shunt (9).
(3) Install new instrument
shunt (9) and secure with
two screws (10).
(4) Attach wires to new instrument shunt (9).
6-5
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
REPLACE FAULTY COMPONENT OF SPECIAL RELAY ASSEMBLY (cont)
6-4.
f. Replace faulty K3 relay:
(1) Tag and remove wires from
faulty K3 relay (11).
(2) Remove two screws (12) and
nuts (13) and remove faulty
K3 relay (11).
(3) Install new K3 relay (11)
and secure with two screws
(12) and nuts (13).
(4) Attach wires to new K3
relay (11).
g.
Replace faulty special current
transformer:
(1) Tag and remove wires from
faulty special current
transformer (14).
(2) Remove two screws (15)
and nuts (16) and remove
faulty special current
transformer (14).
(3) Install new special current transformer (14) and
secure with two screws
(15) and nuts (16).
(4) Attach wires to new
special current transformer (14).
h.
Replace faulty diode assembly:
(1) Remove two screws (17)
from terminal board (18)
and remove faulty diode
assembly (19).
(2) Secure new diode assembly
(19) on terminal board
(18) with two screws (17).
i.
Replace R31 fixed resistor:
(1) Tag and remove wires from
faulty R31 fixed resistor.
6-6
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
6-4. REPLACE FAULTY COMPONENT OF SPECIAL RELAY ASSEMBLY (cont)
(2) Remove two screws (21),
washers (22) and nuts (23)
to remove bracket assembly
(24) and faulty R31 fixed
resistor (20).
(3) Remove faulty R31 fixed
resistor (20) from bracket
assembly.
(4) Install new R31 fixed
resistor (20) into bracket
assembly (24).
(5) Install bracket assembly
(24) with new R31 fixed
resistor (20) and secure
with two screws (21),
washers (22) and nuts
(23).
(6) Attach wires to new R31
fixed resistor (20).
j.
Replace faulty R35 fixed resistor using steps in i. to remove
and install items (26) through
(29).
INSTALLATION
INSTALL SPECIAL RELAY ASSEMBLY IN
CHASSIS.
Install special relay assembly
(3) in chassis (2) and secure
with two screw and captive
washer assemblies (1).
6-7
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
MAINTENANCE OF ISOLATORS, FRONT AND REAR
REPLACE ISOLATORS
6-5.
This task covers: a. Removal
b. Installation
INITIAL SETUP
Tools
General Mechanic’s Tool Kit
5180-00-177-7033
#1 Common Tool Kit
TBD
Lifting Device
Materials/Parts
Isolator, Front
81860-508-4NS
Isolator, Rear
8186O-51O-2NS
REMOVAL
1.
2.
REMOVE FRONT ISOLATORS.
a.
Remove four front isolator
mounting screws (1) and lockwashers (2).
b.
Attach a lifting device and
lift the engine assembly until
isolators are clear of the
skid.
c.
Remove two nuts (3), bushings
(4), snubing washers (5),
isolators (6), flat washers
(7), screws (8) and lockwashers
(9).
REMOVE REAR ISOLATORS.
a.
6-8
Remove four rear isolator
mounting screws (10) and lockwashers (11).
Equipment Conditions:
Reference
Para. 4-21 Remove Rear Housing Frame.
Para. 4-25 Remove Front Frame.
TM5-6115-464-34
Remove Engine Assembly Para. 2-6.
Remove Generator Assembly Para. 2-7.
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
REPLACE ISOLATORS (cont)
6-5.
b.
Attach a lifting device and
lift the alternator assembly
until the isolators are clear
of the skid.
c.
Remove two nuts (12), snubing
washers (13), flat washers
(14), isolators (15) and screws
(16).
INSTALLATION
1.
2.
INSTALL FRONT ISOLATORS.
a.
Install two screws (8), lockwashers (9), flat washers (6),
isolators (5), snubing washers
(5), bushings (4) and nuts (3).
b.
Using lifting device, lower
engine onto skid.
c.
Install four mounting screws
(1) and Iockwashers (2).
INSTALL REAR ISOLATORS.
a.
Install two screws (16),
isolators (15), flat washers
(14) snubing washers (13) and
and nuts (12).
b.
Using lifting device, lower the
alternator onto the skid.
c.
Install four screws (10) and
lockwashers (11).
NOTE
FOLLOW ON MAINTENANCE: Install
Generator Assembly (TM5-6115-46434, Para. 2-7).
Install Engine Assembly (TM5-6115464-34, Para. 2-8).
Install Front Frame (Para. 4-25).
Install Rear Housing Frame (Para.
4-21).
6-9
TM-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
MAINTENANCE OF THE SKID BASE ASSEMBLY
6-6. REPLACE THE SKID BASE ASSEMBLY
This task covers: a. Removal
b. Installation
INITIAL SETUP
Equipment Conditions:
Reference
Para. 6-3 Remove Generator Set.
Para. 4-21 Remove Rear Housing Frame.
Para. 4-25 Remove Front Frame.
Para. 5-27 Remove Lifting Frame.
Tools
General Mechanic’s Tool Kit
5180-00-177-7033
#1 Common Tool Kit
TBD
Materials/Parts
Skid Base
97403-13228E1899
REMOVAL
REMOVE THE ENGINE AND ALTERNATOR.
For removal of the engine,
alternator assemblies and fuel
tank from skid base (1), refer
to para. 6-5 and TM5-6115-46434.
INSTALLATION
INSTALL THE ENGINE AND ALTERNATOR.
For installation of the engine,
alternator assemblies and fuel
tank to skid base (1), refer to
para. 6-5 and TM5-6115-464-34.
NOTE
FOLLOW ON MAINTENANCE: Install
Lifting Frame (Para. 5-27).
Install Front Frame (Para. 4-25).
Install Rear Housing Frame (Para.
4-21).
Install Generator Set (Para. 6-3).
6-10
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MAINTENANCE OF JUNCTION BOX
6-7. JUNCTION BOX REPAIR
This task covers: a. Removal
b. Installation
INITIAL SETUP
Tools
General Mechanic’s Tool Kit
5180-00-177-7033
Materials/Parts
Housing, Junction Box
97403-13228E1935
Cover, Enclosure
97403-13228E1936
Wiring Harness, Control
97403-13228E1933
Wiring Harness, Power
97403-13228E1934
REMOVAL
1.
PLACE JUNCTION BOX ASSEMBLY ON A
CLEAN FLAT SURFACE.
2.
REMOVE ENCLOSURE COVER.
a.
Remove 16 screws (1), washers
(2) and cover (3) from housing (4).
b.
Remove gasket (5) as required.
NOTE
Disassemble only as necessary
to replace faulty components.
3.
REMOVE CONTROL WIRING HARNESS.
a.
Tag wiring harness connectors
and mark tags for connector
positions on housing.
6-11
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6-7. JUNCTION BOX REPAIR (cont)
b.
Remove three nut and washer
assemblies (6), that secure
the wiring harness connectors
to the housing and remove the
wiring harness (7).
4. REMOVE POWER WIRING HARNESS.
a. Tag wiring harness connectors
and mark tags for connector
positions on housing.
b. Remove twelve screws (8), nuts
(9) and washers (10) that
secure the wiring harness connectors to the housing and
remove the wiring harness (11).
INSTALLATION
1.
2.
INSTALL POWER WIRING HARNESS.
a.
Get a new wiring harness and
tag the connectors to match
the tags on wiring harness
removed in step 4.
b.
Line up connector mounting
holes with holes provided in
housing and secure with twelve
screws (8), washers (10), and
nuts (9). Remove tags.
INSTALL CONTROL WIRING HARNESS.
a.
3.
Get a new wiring harness (7)
and tag the connectors to match
tags on wiring harness removed in step 3.
INSTALL ENCLOSURE COVER.
Install gasket (5) if required,
and cover (3) and secure to
housing (4) with 16 screws (1)
and washers (2).
6-12
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JUNCTION BOX REPAIR (cont)
6-7.
b.
Insert connectors in holes
provided in housing and secure
with three nuts and washers (6)
provided with harness connectors. Remove tags.
6-13
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
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TM-6115-14&P/1
MAINTENANCE OF MODIFIED TRAILER-M200A1
REPLACE THE M200A1 TRAILER
6-80
This task covers: a. Removal
b. Installation
INITIAL SETUP
Tools
General Mechanic’s Tool Kit
5180-00-177-7033
Equipment Conditions:
Reference
Para. 6-2 General Instructions.
Materials/Parts
Modified Trailer
97403-13228E1870
REMOVAL
REMOVE GENERATOR SET FROM TRAILER.
a.
Remove eight nuts (1), lockwashers (2), bolts (3) and
washers (4).
b. Attach a lifting device to the
generator set (5).
c.
Be sure that the lifting device
is properly attached to the
generator set (5) at the lifting clevises (6).
d.
Lift the generator set (5) from
the trailer (7).
INSTALLATION
INSTALL GENERATOR ON NEW TRAILER.
a. Install the generator set (5)
onto the replacement trailer
(7), and aline it with mounting
holes.
6-14
Do not use a lifting device of
less than 10,000 lb. capacity.
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
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TM-6115-14&P/1
6-8. REPLACE THE M200A1 TRAILER (cont)
b.
Install eight washers (4),
bolts (3), lockwashers (2)
and nuts (1).
NOTE
FOLLOW ON MAINTENANCE: General
Instructions (Para. 6-2).
6-15/(6-16 Blank)
TM5-6115-634-14&P
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TM-6115-14&P/1
APPENDIX A
REFERENCES
A-1 .
SCOPE
This appendix lists all forms, field
manuals, technical manuals and
miscellaneous publications referenced in
this manual.
A-2.
FORMS
Equipment Inspection and Maintenance Worksheet . . . . . . . . DA Form 2404
Quality Deficiency Report . . . . . . . .. . . . . . . . . . . . . . . . SF 368
Reports of Errors, Omissions and Recommendations . . . DA Form 2028(A)
AFTO Form 22(F)
NAVMC 10772(MC)
A-3. TECHNICAL MANUALS
Hand Receipt Manual, MEP-004A, Generator Set . . . . . . . . . . TM5-6115-464-HR (A)
Intermediate (Field) (Direct and General Support) . . . . . . TM5-6115-464-34 (A)
and Depot Level Maintenance Manual, MEP-004A
TO-35C2-3-445-2 (F)
Generator Set
NAVFAC-P-8-624-34 (N)
TM-07523A34 (M)
Maintenance Forms and Records . . . . . . . . . . . . . . . . . . . . . . . . . AFM-66-1 (F)
TM4700-15/1 (M)
Operator and Unit Maintenance Manual . . . . . . . . . . . . . . . . . . TM5-6115-464-12 (A)
MEP-004A, Generator Set
TO-35C2-3-445-1 (F)
NAVFAC P-8-624-12 (N)
TM-07523A-12 (M)
Operator’s, Organizational, Direct Support and . . . . . . . . TM9-6140-200-14 (A)
Maintenance Manual for Lead-acid Storage Batteries
Operator, Unit, Direct Support and General Support . . . . TM9-2330-205-14&P (A)
Maintenance (including Repair Parts and Special Tools
List), trailer, chassis, M200Al
Organizational Care, Maintenance and Repair of . . . . . . . . TM9-261O-2OO-24 (A)
Pneumatic Tires, Inner Tubes and Radial Tires
Portable Fire Extinguisher for Army Users . . . . . . . . . . . . . TM5-42OO-2OO-1O
Principles and Technical Characteristics of USMC . . . . . . TM-11275-15/3A (M)
Engineering Equipment
Procedures for Destruction of Equipment to Prevent
Enemy use - Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM750-244-3
- Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM750-244-6
A-1
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
A-3.
TECHNICAL MANUALS (Continued)
Unit, Intermediate (Field) (Direct Support and . . . . . . . . TM5-6115-464-24P (A)
TO-35C2-3-445-4 (F)
General Support) and Depot Maintenance Repair Parts
NAVFAC P-8-624-24P (N)
and Special Tools Lists (RPSTL), MEP-004A Generator
A-4. MISCELLANEOUS PUBLICATIONS
Classification, Reclassification, Issue and Reporting
Maintenance Training, Aircraft . . . . . . . . . . . . . . . . . . AR 700-42 (A)
Generator Sets, Electrical, Measurements and . . . . . . . . . . . . . MIL-H-DAK-705
Instrumentation
Generator Sets, Mobile Electric Power and Supplemental . . . . MIL-G-28554B
Equipment; Packaging of
Identification Marking of U.S. Military Property . . . . . . . . . . MIL-STN-130
Lubrication Order, MEP-004A Generator Set . . . . . . . . . . . .. . L05-6115-464-12(A)
LO-07523A-12(M)
The Army Maintenance Management System (TAMMS) . . . . . . . . . . DA PAM 738-750
Oil Sampling Requirement . . . . . . . . . . . . . . . . . . . . . . TB43-O21O(A)
Painting and Preserving
. . . . . . . . . . . . . . . . . . . MIL-T-704
Soldering Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MIL-STD-454
Terminal Splice Standards . . . . . . . . .
. . . . . .. . . . . . MIL-T-7928
Wiring, Aerospace Vehicle . . . . .... . . . . . . . . . . . . . . . MIL-W-5088
A-2
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
APPENDIX B
MAINTENANCE ALLOCATION CHART
Section I.
B-1 .
General.
a. This section provides a general
explanation of all maintenance and
repair functions authorized at various
maintenance levels.
b. The Maintenance Allocation Chart
(MAC) in Section II designates overall
authority and responsibility for the
performance of maintenance functions on
PU 794/G. It does not include the
generator set or trailer components
except modifications included in TM56115-464-12 and TM9-330-205-14&P. The
application of the maintenance functions
to the end item or component will be
consistent with the capacities and capabilities of designated maintenance
levels.
c. Section III lists the tools and
test equipment (both special tools and
common tool sets) required for each
maintenance function as referenced from
Section II.
d. Section IV contains supplemental
instructions and explanatory notes for a
particular maintenance function.
B-2. Maintenance Functions. Maintenance functions will be limited to and
defined as follows:
a. Inspect. To determine the serviceability of an item by comparing its
physical, mechanical and/or electrical
characteristics with established standards through examination (e.g., sight,
sound, or feel).
b. Test. To verify serviceability by
measuring the mechanical, pneumatic,
hydraulic, or electrical characteristics
of an item and comparing those characteristics with prescribed standards.
c. Service. Operations required
periodically to keep an item in proper
INTRODUCTION
operating condition, i.e., to clean
(includes decontaminate, when required),
preserve, drain, paint, or to replenish
fuel, lubricants, chemical fluids, or
gases.
d. Adjust. To maintain or regulate,
within prescribed limits, by bringing
into proper or exact position, or by
setting the operating characteristics to
specified parameters.
e. Aline. To adjust specified variable elements of an item to bring about
optimum or desired performance.
To determine and cause
f. Calibrate.
corrections to be made or to be adjusted
on instruments or test, measuring and
diagnostic equipments used in precision
measurement. Consists of comparisons 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.
g. Remove/Install. To remove and
install the same item when required to
perform service or other maintenance
Install may be the act of
functions.
emplacing, seating, or fixing into
position a spare or repair part of
module (component or assembly) in a
manner to allow the proper functioning
of an equipment or system.
h. Replace. To remove an unserviceable item and install a serviceable
counterpart in its place. “Replace” is
authorized by the MAC and is shown as
the third position code of the SMR code.
i. Repair. The application of maintenance services, including fault location/troubleshooting, removal/installation, disassembly/assembly procedures
and maintenance actions to identify
troubles and restore serviceability to
B-1
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an item by correcting specific damage,
fault, malfunction, or failure in a
part, subassembly module (component or
assembly), end item, or system.
j. Overhaul. That maintenance effort
(service/action) prescribed to restore
an item to a completely serviceable/
operational condition as required by
maintenance standards in appropriate
technical publications (i.e., DMWR).
Overhaul is normally the highest degree
of maintenance performed by the Army.
Overhaul does not normally return an
item to like new condition.
k. Rebuild. Consists of those
services/actions necessary for the
restoration of unserviceable equipment
to a like new condition in accordance
with original manufacturing standards.
Rebuild is the highest degree of
materiel maintenance applied to Army
The rebuild operation inequipment.
cludes the act of returning to zero
those age measurements (hours/miles,
etc.) considered in classifying Army
equipment/components.
6-3. Explanation of Columns in the MAC,
Section II.
a. Column 1, Group Number. Column 1
lists functional group code numbers the
purpose of which is to identify maintenance significant components, assemblies, subassemblies and modules with
the next higher assembly. End item
group number shall be “00”.
b. Column 2, Component/Assembly.
Column 2 contains the names of components, assemblies, subassemblies and
modules for which maintenance is
authorized.
c. Column 3, Maintenance Function.
Column 3 lists the functions to be performed on the item listed in Column 2.
(For detailed explanation of these
functions, see paragraph B-2.)
d. Column, 4, Maintenance Level.
Column 4 specifies (by listing of a work
time figure in the appropriate subcol-
B-2
umn(s)), the level of maintenance authorized to perform the function listed
in Column 3. This figure represents the
active time required to perform that
maintenance function at the indicated
level of maintenance. If the number or
complexity of the tasks within the listed
maintenance function vary at different
maintenance levels, appropriate work
time figures will be shown for each
level. The work time figure represents
the average time required to restore an
item (assembly, subassembly, component,
module, end item, or system) to a serviceable condition under typical field operating conditions. This time includes
preparation time (including any necessary
disassembly/assembly time), troubleshooting/fault location time and quality
assurance/quality control time; in addition, to the time required to perform
the specific tasks identified for the
maintenance functions authorized in the
maintenance allocation chart. The symbol
designations for the various maintenance
levels are as follows:
C . . . . . Operator or Crew
O . . . . . Unit Maintenance
F . . . . . Intermediate Direct Support
Maintenance
H . . . . . Intermediate General Support
Maintenance
L . . . . . Specialized Repair Activity
(SRA)
D . . . . . Depot Maintenance
e. Column 5, Tools and Equipment.
Column 5 specifies, by code, those common
tool sets (not individual tools) and
special tools, TMDE and support equipment
required to perform the designated function.
f. Column 6, Remarks. This column
shall, when applicable, contain a letter
code, in alphabetic order, which shall
be keyed to the remarks contained in
Section IV.
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B-4 Explanation of Columns in Tool and
Test Equipment Requirements, Section
III.
d. Column 4, National Stock Number.
The national stock number of the tool or
test equipment.
a. Column 1, Reference Code. The
tool and test equipment reference code
correlates with a code used in the MAC,
Section II, Column 5.
e. Column 5, Tool Number. The manufacturer’s part number.
b. Column 2, Maintenance Category.
The lowest category of maintenance authorized to use the tool or test equipment.
c. Column 3, Nomenclature. Name or
identification of the tool or test equipment.
B-5. Explanation of Columns in Remarks,
Section IV.
a. Column 1, Reference Code. The
code recorded in column 6, Section II.
b. Column 2, Remarks. This column
lists information pertinent to the maintenance function being performed as indicated in the MAC, Section II.
B-3
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Section II. MAINTENANCE ALLOCATION CHART
B-4
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MAINTENANCE ALLOCATION CHART - CONTINUED
B-5
TM5-6115-634-14&P
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T0-35C2-3-445-14
TM-6115-14&P/1
MAINTENANCE ALLOCATION CHART - CONTINUED
B-6
TM5-6115-634-14&P
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T0-35C2-3-445-14
TM-6115-14&P/1
MAINTENANCE ALLOCATION CHART - CONTINUED
B-7
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TM-6115-14&P/1
SECTION Ill. TOOL AND TEST EQUIPMENT REQUIREMENTS
5810-00-177-7033
6625-01-139-2512
3439-00-460-7198
B-8
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APPENDIX C
COMPONENTS OF END ITEM AND BASIC ISSUE ITEMS LIST
Section I.
C-1. Scope
This appendix lists components of end
items and basic issue items necessary to
inventory items that are required for
safe and efficient operation.
ment (TOE/MTOE) authorization of the end
item.
The following provides an explanation of
columns found in the tabular listings:
(1)
Column (1).
Illustration
Number (Illus. Number). This column
indicates the number of the illustration
in which the item is shown.
C-2. General
The components of end item and basic
issue items lists are divided into the
following sections:
a. Section II. Components of End
Item. This listing is for informational
purposes only, and is not the authorization to requisition replacements. These
items are part of the end item, but are
removed and separately packaged for
transportation or shipment. As part of
the end item, these items must be with
the end item whenever it is issued or
transferred between property accounts.
Illustrations are furnished to assist
you in identifying the items.
b. Section III. Basic Issue Items.
These are the minimum essential items
required to place the PU 794/G in operation, to operate it, and to perform
emergency repairs. Although shipped
separately packaged, BII must be with
the PU 794/G during operation and whenever it is transferred between property
accounts. The illustrations will assist
you with hard-to-identify items. This
manual is your authority to request/
requisition replacement 611, based on
Table of Organization and Equipment/
Modified Table of Organization and Equip-
Section II.
INTRODUCTION
(2) Column (2). National Stock
Number.
Indicates the national stock
number assigned to the item and will be
used for requisitioning purposes.
(3) Column (3). Description.
Indicates the national item name, and if
required, a minimum description to identify and locate the item. The last line
for each item indicates the federal
supply code for manufacturer (FSCM)
followed by the part number. If item
needed differs for different models of
this equipment, the model is shown under
the ‘USABLE ON’ heading in this column.
(4) Column (4). Unit of Measure
(U/M) . Indicates the measure used in
performing the actual operational/maintenance function. This measure is
expressed by a two-character alphabetical abbreviation (e.g., ea, in, pr).
(5) Column (5). Quantity Required
(Qty Req ). Indicates the quantity of
the item authorized to be used with/on
the equipment.
COMPONENTS OF END ITEM
Not applicable.
C-1
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Figure C-1.
C-2
Basic Issue Items
Section III.
BASIC ISSUE ITEMS
TM5-6115-634-14&P
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TM-6115-14&P/1
5220-00-559-9618
7240-00-177-6154
2910-00-066-1235
5120-01-013-1676
5975-00-878-3791
C-3/(C-4 Blank)
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APPENDIX D
ADDITIONAL AUTHORIZATION LIST ITEMS
Section I.
D-1. Scope.
This appendix lists additional items
authorized for support of the system.
D-2.
General.
This list identifies items that do not
have to accompany the system and that do
not have to be turned in with it. These
items are all authorized to you by CTA,
MTOE, TDA, or JTA.
D-3. Explanation of Listing.
National stock numbers, descriptions and
quantities are provided to help you idenSection II.
INTRODUCTION
tify and request the additional items
you require to support this equipment.
The items are listed in alphabetical
sequence by item name under the type
document (that is, CTA, MTOE, TDA, or
JTA) which authorizes the items(s) to
you .
If the item you require differs between
serial numbers of the same model, effective serial numbers are shown in the
last line of the description. If the
item required differs for different
models of this equipment, the model is
shown under the “Usable On” heading in
the description column.
ADDITIONAL AUTHORIZATION LIST ITEMS
Not applicable.
D-1/(D-2 Blank)
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APPENDIX E
EXPENDABLE/DIRABLE SUPPLIES AND MATERIALS LIST
Section I.
E-1.
Scope
This appendix lists expendable supplies
and materials you will need to operate
and maintain the Power Distribution
Center. These items are authorized to
you by CTA 50-970 Expendable Items
(except Medical, Class V, Repair Parts,
and Heraldic Items).
INTRODUCTION
measure is expressed by a two-character
alphabetical abbreviation (e.g., ea, in,
If the unit of measure differs
pr).
from the unit of issue, requisition the
lowest unit of issue that will satisfy
your requirements.
H - Intermediate General Support
Maintenance
D - Depot Maintenance
E-2. Explanation of Columns
a. Column(1)-Item Number. This number is assigned to the entry in the
listing and is referenced in the narrative instructions to identify the
material (e.g., “Use cleaning compound,
item 5, App. D“).
b. Column(2)-Level. This column
identifies the lowest level of maintenance that requires the listed item.
c. Column(3)-National Stock Number.
This is the national stock number
assigned to the item; use it to request
or requisition the item.
d. Column(4)-Description. Indicates
the Federal item name and, if required,
a description to identify the item. The
last line for each item indicates the
Federal Supply Code for Manufacturer
(FSCM) in parentheses followed by the
part number.
(enter as applicable)
C - Operator/Crew
O - Unit Maintenance
F - Intermediate Direct Support
Maintenance
Section II.
e. Column(5)-Unit of Measure (U/M).
Indicates the measure used in performing
the actual maintenance function. This
EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST
Not applicable.
E-1/(E-2 Blank)
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TM-6115-14&P/1
APPENDIX F
UNIT, INTERMEDIATE DIRECT SUPPORT AND
INTERMEDIATE GENERAL SUPPORT
REPAIR PARTS AND SPECIAL TOOLS LIST
Section I.
INTRODUCTION
F-1. Scope.
a. This RPSTL lists and authorizes
spares and repair parts; special tools;
special test, measurement, and diagnostic (TMDE); and other special support
equipment required for performance of
unit, intermediate direct support, and
intermediate general support maintenance
of the PU794/G. It authorizes the
requisitioning, issue, and disposition
of spares, repair parts and special
tools as indicated by the source, maintenance and recoverability (SMR) codes.
b. This RPSTL lists only those new
parts required to upgrade the MEP-103A,
Precise, Generator Set, Diesel Engine
Driven, Tactical Skid Mounted, 15 kW, 3
Phase, 4 wire, 120/208 and 240/416 volts
to a 20 kW Generator Set. When parts
are not listed in this RPSTL, refer to
TM5-6115-464-24&P.
F-2.
General.
In addition to Section I, Introduction,
this Repair Parts and Special Tools List
is divided into the following sections:
a. Section II - Repair Parts List. A
list of spares and repair parts authorized by this RPSTL for use in the performance of maintenance. The lists also
includes parts which must be removed for
replacement of the authorized parts.
Parts lists are composed of functional
groups in ascending alphanumeric sequence,
with the parts in each group listed in
ascending figure and item number sequence.
Bulk materials are listed by item name
in FIG BULK at the end of the section.
Repair parts kits or sets are listed
separately in their own functional group
within Section II. Repair parts for
repairable special tools are also listed
in the section.
b. Section III - Special Tools List.
A list of special tools, special TMDE,
and other special support equipment
authorized by this RPSTL (as indicated
by Basis of Issue (BOI) information in
DESCRIPTION AND USABLE ON CODE (UOC)
column) for the performance of maintenance.
c. Section IV - National Stock Number
A list, in
and Part Number Index.
National Item Identification Number
(NIIN) sequence, of all National stock
numbered items appearing in the listings,
followed by a list in alphanumeric
sequence of all part numbers appearing
in the listing. National stock numbers
and part numbers are cross-referenced to
each illustration figure and item number
appearance.
F-3. Explanation of Columns (Section II
and III).
Indicates
a. ITEM NO. (Column (1)).
the number used to identify items called
out in the illustration.
The Source,
SMR CODE (Column (2))
Maintenance. and Recoverability (SMR)
code is a 5-position code containing
supply/requisitioning information, maintenance category authorization criteria,
and disposition instruction, as shown in
the following breakout:
F-1
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
*Complete Repair: Maintenance capacity,
capability, and authority to perform all
corrective maintenance tasks of the
“Repair” function in a use/user
environment in order to restore
serviceability to a failed item.
(1) Source Code. The source code
tells you how to get an item needed for
maintenance, repair, or overhaul of an
end item/equipment. Explanations of
source codes follows:
Code
- Item procured and stocked for
anticipated or known usage.
PB
- Item procured and stocked for
isurance purposed because essentiality dictates that a minimum
quantity be available in the
supply system.
PD
F-2
PE
- Support equipment procured and
stock for initial issue or outfitting to specified maintenance
repair activities.
PF
- Support equipment which will not
be stocked but which will be
centrally procured on demand.
PG
- Item procured and stocked to
provide for sustained support
for the life of the equipment.
It is applied to an item peculiar to the equipment which
because of probable discontinuance or shutdown of production facilities would prove
uneconomical to reproduce at a
later time.
KD
- An item of depot overhaul/repair
kit and not purchased separately.
Depot kit defined as a kit that
provides items required the time
of overhaul or repair.
KF
- An item of a maintenance kit and
not purchased separately. Maintenance kit defined as a kit
that provides an item that can
be replaced at organizational or
Definition
PA
PC
Not subject to automatic replenishment.
- Item procured and stocked, and
which otherwise would be coded
PA except that it is deteriorative in nature. Support item,
excluding support equipment,
procured for initial issue or
outfitting and stocked only for
subsequent or additional initial
issues or outfittings. Not
subject to automatic replenishment.
- Support item, excluding support
equipment, procured for initial
issue or outfitting and stocked
only for subsequent or additional
initial issues or outfittings.
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
Code
Definition
AH
intermediate levels of maintenance.
KB
Item included in both a depot
overhaul/repair kit and a Maintenance kit.
MO
Item to be manufactured or
fabricated at organizational
level.
MF
Item to be manufactured or
fabricated at intermediate maintenance levels.
Air Force - Intermediate (*)
Army - Direct Support (*)
Marine Corps - 4th Echelon
Navy - Afloat
MH
Item to be manufactured or
fabricated intermediate maintenance levels.
Air Force - Intermediate (*)
Army - General Support (*)
Marine Corps - 4th Echelon
Navy - Ashore
MG
MD
Item to be manufactured or fabricated at both afloat and ashore
intermediate maintenance levels
- Navy use only.
Item to be manufactured or
fabricated at depot maintenance
level.
AO
Item to be assembled at organizational level.
AF
Item to be assembled at intermediate maintenance levels.
Air Force - Intermediate (*)
Army - Direct Support (*)
Marine Corps - 3rd Echelon
Navy - Afloat
- Item to be assembled at intermediate maintenance levels.
Air Force - Intermediate (*)
Army - General Support (*)
Marine Corps - 4th Echelon
Navy - Ashore
AG
- Item to be assembled at both
afloat and ashore intermediate
maintenance level - Navy use
only.
AD
- Item to be assembled at depot
maintenance levels.
NOTE : For USAF and the USA Safe(*)
guard Program, only Code “F” will be
used to denote intermediate maintenance.
On joint programs use of either code F
or H by the joining service will denot
intermediate maintenance USAF and the
USA Safeguard Program.
XA
- Do not requisition an “XA’’-coded
item. Order its next higher
assembly. (Also refer to NOTE
below.)
XB
- If an “XB” item is not available
from salvage, order it using the
FSCM and part number given.
XC
- Installation drawing, diagram,
instruction sheet, field service
drawing, that is identified by
manufacturer’s part number.
XD
- Item is not stocked. Order an
“XD’’-coded item through normal
supply channels using the FSCM
and part number given, if no NSN
is available.
NOTE : Cannibalization or controlled
exchange, when authorized, may be used
as a source of supply items with the
above source codes, except for those
source coded “XA” or throse aircraft
support items restricted by requirements
of AR 700-42.
(2) Maintenance Code. Maintenance
codes tells you the level(S) of maintenance authorized to USE and REPAIR sup-
F-3
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
port items. The maintenance codes are
entered in the third and fourth positions
of the SMR Code as follows:
(a) the maintenance code
entered in the third position tell you
the lowest maintenance level authorized
to remove, replace, and use an item.
The maintenance code entered in the third
position will indicate authorization to
one of the following levels of maintenance.
Code
Application/Explanation
C
Crew or operator maintenance
done within unit or aviation
unit maintenance.
O
Unit or aviation unit category
can remove, replace, and use the
item.
F
H
Direct support or aviation intermediate level can remove, replace,
and use the item.
General support level can
remove, replace, and use the
item.
L
Specialized repair activity can
remove, replace, and use the
item.
D
Depot level can remove, replace,
and use the item.
(b) The maintenance code
entered in the fourth position tells
whether or not the item is to be
repaired and identifies the lowest
maintenance level with the capability to
do complete repair (i.e., perform all
authorized repair functions.) (NOTE:
Some limited repair may be done on the
item at a lower level of maintenance, if
authorized by the Maintenance Allocation
Chart (MAC) and SMR codes.) This position will contain one of the following
maintenance codes.
F-4
Code
Application/Explanation
O
Unit or (aviation unit) is the
lowest level that can do complete
repair of the item.
F
Direct support or aviation intermediate is the lowest level that
can do complete repair of the
item.
H
General support is the lowest
level that can do complete
repair of the item.
L
Specialized repair activity
(designate the specialized repair
activity) is the lowest level
that can do complete repair of
the item.
D
Depot is the lowest level that
can do complete repair of the
item.
Z
Nonrepairable. No repair is
authorized.
B
No repair is authorized. (No
parts or special tools are
authorized for the maintenance
of a “B” coded item). However,
the item may be reconditioned by
adjusting, lubricating, etc., at
the user level.
(3) Recoverability Code. Recoverability codes are assigned to items
to indicate the disposition action on
unserviceable items. The recoverability
code is entered in the fifth position of
the SMR Code as follows:
Recoverability Application/Explanation
Codes
Z
Nonreparable item.
When unserviceable,
condemn and dispose of
the item at the level
of maintenance shown
in 3d position of SMR
Code.
O
Reparable item. When
uneconomically repar-
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
Recoverability Application/Explanation
Codes
able, condemn and
dispose of the item at
unit or aviation unit
level.
F
H
O
L
A
Reparable item. When
uneconomically reparable, condemn and
dispose of the item at
the direct support or
aviation intermediate
level.
Reparable item. When
uneconomically reparable, condemn and
dispose of the item at
the general support
level.
Reparable item. When
beyond lower level
repair capability,
return to depot. Condemnation and disposal
of item not authorized
below depot level.
Reparable item. Condemnation and disposal
not authorized below
specialized repair
activity (SRA).
Item requires special
handling or condemnation procedures because
of specific reasons
(e. g., precious metal
content, high dollar
value, critical material, or hazardous
material). Refer to
appropriate manuals/
directives for specific
instructions.
c. FSCM Column 3
Supply Code for Manufacturer (FSCM) is a
5-digit numeric code which is used to
identify the manufacturer, distributor,
or Government agency, etc., that supplies
the item.
d. PART NUMBER (Column (4)). Indicates
the primary number used by the manufacturer
(individual, company, firm, corporation,
or Government activity), 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.
NOTE : When you use a NSN to requisition an item, the item you receive may
have a different part number from the
part ordered.
DESCRIPTION AND USABLE ON CODE
(UOC) (Column (5)). This column
includes the following information:
(1) The Federal item name and,
when required, a minimum description to
identify the item.
(2) Items that are included in
kits and sets are listed below the name
of the kit or set.
(3) Spare/repair parts that make
up an assembled item are listed immediately following assembled item line
entry.
(4) Part numbers for bulk
materials are referenced in this column
in the line item entry for the item to
be manufactured/fabricated.
(5) When the item is not used
with all serial numbers of the same
model, the effective serial numbers are
shown on the last line(s) of the description (before UOC).
(6) The usable on code, when
applicable (see paragraph 5, Special
information).
(7) In the Special Tools List
section, the basis of, issue (BOI)
appears as the last line(s) in the entry
for each special tool, special TMDE, and
other special support equipment. When
density of equipments supported exceedes
density spread indicated in the basis of
issue, the total authorization is
increased proportionately.
F-5
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
F-6
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
and subassembly groups, and listings are
divided into the same groups.
(2) Second. Find the figure
covering the assembly group or subassembly group to which the item
belongs.
Identify the item on
(3) Third.
the figure and note the item number.
(4) Fourth. Refer to the Repair
Parts List for the figure to find the
part number for the item number noted on
the figure.
(5) Fifth. Refer to the Part
Number Index to find the NSN, if
assigned.
find the pertinent National Stock Number
or Part Number. The NSN index is in
National Item Identification Number
(NIIN) sequence (see 4.1(1)). The part
numbers in the Part Number index are
listed in ascending alphanumeric
sequence (see 4.b). Both indexes crossreference you to the illustration figure
and item number of the item you are
looking for.
(2) Second. After finding the
figure and item number, verify that the
item is the one you’re looking for, then
locate the item number in the repair
parts list for the figure.
F-7. Abbreviations.
Not Applicable.
b. When National Stock Number or Part
Number is known:
(1) First. Using the Index of
National Stock Numbers and Part Numbers,
F-7
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
Figure F-1.
F-8
Battery Box Assembly, Batteries and Cables
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
SECTION II.
REPAIR PARTS LIST
(3)
USHC
(4)
b.
REPL
9S1 FACTOR
NAT IONAL
STOCK
NUHBER
(2)
SNR COOE
(1)
ILLUSTRATION
a,
F18.
NO,
b.
ITEH
NO.
h
b.
c.
d.
ARMY
AIR
FORCE
NAVY
USMC
1
1
HFOZZ
1
2
PAFZZ
S970-00-914-3111
1
3
PAFZZ
5940-00-115-2684
8*
(6)
(5)
DESCRIPTION
UMBLE
ON
CODE
REF NUN8ER
k IIFR CODE
(7)
(8)
QTV
lNC
IN
UIH UNIT
ECT
EA
1
SLEEVIN6, INSULATION
H23053/S-109-2 81349
ECT
FT
1
TERMINAL LU6
M20659-118
ECT
EA
2
9b90b
ECT
EA
1
ECT
FT
8
ECT
EA
1
CABLE, MTTERV,
1322SE3368-1
MANUFACTURE FROM
97403
1
4
Phm
CONNECTOR, STRAIN
2535
59730
1
s
P#FZZ
CABLE
111348611-14
81349
1
b
HFOZZ
1
7
PAFZZ
5970-00-914-311s
SLEWNS,INSULATION
H23053/5-109-O S1349
ECT
FT
1
1
8
PAFZZ
594040-115-2bB4
TERHINAL LUG
HS20659-llS
ECT
EA
2
9b90b
CONNECTOR, STRAIN
2535
ECT
EA
1
59730
CABLE
lf1348b11-14
ECT
FT
s
S1349
NUT, PLAIN HEIASON
RS519b7-S
ECT
HD
7
96906
HASHER,LOCK
RSW3&4b
ECT
HD
7
9b90b
RETAINER, BATTERV
1322 BE33bl
ECT
EA
1
97403
ROO,THREAOED
12-2067-1
ECT
EA
3
30ss4
LEA0,STORA6E BATRV
70-1S824
ECT
EA
1
30554
1
1
1
1
I
1
1
9
10
11
12
13
14
15
CABLE, BATTERY
i3228EZ3b8-2
MANUFACTURE FROM!
PAFZZ
XAOZZ
PAOZZ
PADZZ
531 O-OO-732-O55E
5310-004s7-9541
PAOZ Z
PAon
Phozz
s30b-ol-197-173a
b140-01-2094410
MC
OTV
PER
EOUIP
97403
F-9
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
(1)
ILLUSTRATION
1,
~la,
10,
b,
ITEM
No,
1
lb
1
1
1
1
1
1
1
I
1
1
F-10
17
10
19
20
21
22
8*
ARRY
P#o12
Pfloll
(2)
(3)
SHR COOE
USMC
b.
AIR
FORCE
c,
d.
a.
NAVY
USNC
SSI
b.
REPL
FhCTOR
(4)
NATIONAL
STOCK
NUIISER
$940-00-s494s83
S94040-S4945S1
PAoll
10001
Pnozl
Pbozz
PAOZZ
S31O-OO-7614SS2
5310-00-S82-S9bS
S30S-00-0b8-0501
23 , KBOZZ
24
23
2b
P#ozz
XBOZZ
PAOZZ
(5)
[b)
(7)
(m
DESCRIPTION
S30S-00-942-2196
USABLE
ON
COOE
REF NURSER
k HFR COOE
TERMINAL, LU6
HS7SO04-2
96906
TERMINAL, LU6
HS7SO04-1
9b90b
BATTERY, STORM
HS3SOO0-3
9b90h
MTTERY,BM MSV
1322SE3W
97403
NUT, HEMSON
HSS19b7-2
96906
MSHER,LOCK
Ns3s33&44
W06
SCREii,CAPf HEMSON
19S9072S-S
9b90b
COVER, BATTERY,BO1
13228E3360
97403
BUSHINS, INSULATING
69-570-1
305s4
BOX, MTTERV
13228E33S9
97403
SCREN,CAP,HEKA60N
HS9072W0
9b90b
aTY
lHC
IN
WI UNIT
ECT
Efi
2
ECT
EA
2
ECT
EA
2
ECT
EA
1
ECT
HD
s
ECT
Ho
s
ECT
HO
s
ECT
EA
1
ECT
EA
1
ECT
EA
1
ECT
HO
4
USNC
m
PER
EWIP
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
Figure F-2.
Generator Set
F-11
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
(2)
MR CODE
(1)
ILLUSTRATION
b.
:ik
No,
2
2
2
2
2
a.
ITEM
ARHV
No.
1
2
3
4
s
PAHZZ
PMzz
Pm
PAHIZ
POHOD
b.
AIR
FORCE
c.
d.
NAVV
USMC
(3)
USNC
(4)
ho
REPL
551 FACTOR
NATIONAL
STOCK
NU14BER
a.
5310-00-004-5030
5310-0042046S3
S310-00-9S1-7209
(s)
DESCRIPTION
(b)
USABLE
ON
REF NUMBER
b IIFR CODE
COOE
NUT,HEI
ltS51967-20
9b90b
M5HER,LIXK
NS3S33B-SO
96906
MSHER,FLAT
M27103-22
9h90b
SCREN,CAP,HEXMON
1322BE18b7-3
91403
BEN SET20KW, 60HZ
[email protected]
91403
QTV
INC
IN
Ulfl UNIT
ECT
HD
s
ECT
HD
s
ECT
HO
B
ECT
En
B
ECT’
EA
1
NOTE :
See TM 5-6115-464-24P
for component parts.
F-12
(7)
(a)
USMC
OTY
PER
E9UII
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
Figure F-3.
F-13
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
:i6.
w,
b.
ITEH
NO.
3
1
s
3
3
3
3
3
3
3
3
2
3
4
s
b
7
6
9
10
(3(
USHC
(4)
b.
REPL
SS1 FACTOR
NATIONAL
STOCK
NUHEiR
(2)
SHR CODE
(1)
ILLUSTRATION
de
ARIIY
Pm
Pfiozz
Pholz
b.
AIR
FORCE
co
d.
NAVY
Llsnc
a,
S305-00-060-0S02
5310-00-S82-5965
5310-00-609-40S6
PBOPF
Phozz
Phozz
P40ZZ
PAOZZ
XBOZZ
Xsozz
S310-00-934-9737
5310-00-04S-3299
S31O-OO4O9-SS44
S3bS-00-964-b195
(6)
(5I
DESCRIPTION
(7)
QTV
USABLE
INC
ON
IN
COOE
UIH UNIT
REF NUltBER
&HFR CODE
SCREH, CAP, HEM60N
RS90725-6
9b90b
H14SHER,LOCK
IIS3S336-44
9b90b
WHER ,FLAT
HS27163-10
96906
BAFFLE,MSY INThKE
13226Ef877
97403
NUT, PLAIN, HEKMON
HS3Sb49-2f12
9b90b
HASHER, LOCK
NS3S338-42
9b90b
WASHER, FLAT
HS27163-7
96906
SCREH,MCHINE
HS3S206-247
9b90b
SRID, INTAKE
1322 SE1S7S
91403
CHANNEL, END BAFFLE
13226E33bb-1
97403
ECT
HD
18
ECT
HD
21
ECT
HO
12
ECT
Ed
1
ECT
Ho
10
ECT
HO
10
ECT
HD
20
ECT
HO
10
ECT
EA
1
ECT
EA
2
3
Ii
PAOZZ
BIIFFLE,CENTER INTAK
91403
13226E1S80
ECT
EA
s
s
12
Phozz
INSULATION
1322BE1942-1
ECT
EA
2
97403
MFFLE,HOUSIN6,
1322SE1S61
ECT
EA
1
97403
6ASKET
13226E 1940
ECT
EA
2
97403
FLANSE , 60TTOH,
1322SE19S0
ECT
EA
1
97403
FLANSE,SIOE,LOHER,
13226E1943
ECT
EA
t
91403
3
3
3
3
F-14
13
14
1s
lb
K60FZ
IAFZZ
Xsozz
XSozz
(8)
USMC
OTY
PER
EWJIP
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
(3)
WC
[4)
bt
REPL
SS1 FACTOR
NATIONAL
STOCK
NUflSER
(2)
SHR COOE
(1)
ILLU8TRMION
a,
F16,
NO,
b,
ITEH
NO.
3
17
XBOZZ
3
lB
PAOZZ
4.
ARM
b.
AIR
FORCE
c.
d.
NAVY
UBHC
a.
5305-00-06B4500
(5)
DESCRIPTION
(6)
USABLE
ON
CODE
REF NUMBER
k HFR CODE
FLAN6E,SIDE,UPPER,
13228E1921
97403
SCREH ,CAP , HEM60N
tlS9072S-3
9b90b
(7)
QTV
INC
IN
U/l! UNIT
ECT
EA
1
ECT
HD
3
(a)
USMC
OTV
PER
EQUIP
F-15
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
Figure F-4.
F-16
Connector Plate
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
(2)
SNR CODE
(1)
ILLUSTRATION
a,
F16,
NO.
b,
Iml
NO,
4
1
4
4
4
4
4
4
4
4
4
4
4.
4
4
2
3
4
5
b
7
8
9
10
11
12
13
14
48
ARM
Pnolz
Pholl
b.
AIR
FORCE
(3)
USMC
c.
d.
a*
NWV
WC
SS1
b.
REPL
FACTOR
NATIONAL
STOCK
NUMBER
5305-00-0684500
5310-00-502-596S
XBozz
Pnoll
PAOZZ
S31O-OO-O63-736O
530S-00-0S4-bbSS
PA021
PAOU
PA021
5935-01 -12S-134S
PA(IZZ
PMll
Pnoll
KBOZZ
Pkoll
PAOll
(5)
DESCRIPTION
(4)
S935-01-07b4602
5305-00-253-WS
9905-00-4774137
S310-00-697-bOS2
531 O-OO-O4S421B
(6)
(7)
(8)
QTY
USABLE
INC
ON
IN
CODE
WI! UNIT
REF NU14BER
& IIFR CODE
SCREH,CAP,HEM60N
HS9072S-3
9b90b
WiSHER,LOCK
HSSS33M4
9b90b,
PLATE, CONNECTOR
1322SE1902
97403
NUT, PLAIN, ASSEMBLED
S1l-0b1800-00
7S199
SCREW, MCHINE
14SS19S7-31
96906
CONN,RECEPTACLE
13228E1952
9740s
CAP MSV,PROTECTIVE
1322SE33S5
97403
CAP ASSY,PROTECT IVE
10-552943-239
77S20
PLUS, SHORTIN6,
1322 SE3363
97403
COVER, ELECTRICAL
Ml 73SOC3b
9b90b
SCREH, DRIVE
HS2131E-21
9b90b
PLATE, IOENT
13211 Eb7S0
97403
NUT , HEXA60N
14S3Sb91-Sb
96906
HASHER,FLAT
HS1S795-91S
96906
ECT
HO
b
ECT
HD
b
ECT
EA
1
ECT
EA
4
ECT
HO
4
ECT
Eh
1
ECT
EA
1
ECT
EA
1
ECT
EA
1
ECT
EA
1
ECT
HD
2
ECT
EA
1
ECT
EA
1
ECT
EA
3
4
1s
PAOIZ
5310-01 -017-3S7b
NUT, SELFAOCKINS
TLF-1213-S-JAH S24SS
ECT
EA
1
4
lb
Pholl
S940-01-00%4763
TERHINAL,LOAD
b9-b92-l
ECT
EA
1
USMC
BTY
PER
EQUIP
30ss4
L
F-17
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
Figure F-5.
F-18
Access Doors
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
(2)
(3)
SIIR CODE
Usnc
(1)
ILLUSTRATION
b.
ITEM
NO.
5
i
Paul
5305-00-068-0S00
SCREU,CAP,HEKAWN
HS9072S-3
9b90b
s
2
Pfiou
S310-00-Sf12-S9bS
NASHER,LOCK
Hs3s33&44
9b90b
OOOR,ACCESS
1322EE33b3-2
91403
DMIR,hCCESS
1322BE3363-3
91403
s
s
5
3
4
!
b
Am
b.
AIR
FORCE
c.
d.
NhVV
USM
ae
b,
REPL
SS1 FhCTOR
USABLE
on
CODE
4*
F16.
N&
5
a.
NATIONAL
STOCK
NUMBER
ISWF
IWF
PflFZZ
REF IWER
k HFR CODE
S320-00+03-10bO RIVET, BLIND
H2424311-SS02
13228E19bl
s
7
i3228E33b3-1
3
s
s
5
5
e
9
10
11
12
PAOH
lBWF
lBOZ1
ISOFF
Isozz
5310-00-7b14SB2
QTY
‘INC
IN
U/H UNIT
ECT
HD
S2
ECT
HD
32
ECT
EA
i
ECT
EA
1
ECT
EA
(0)
Uslw
OTY
PER
EQUIP
4
ECT
EA
1
ECT
EA
2
ECT
HO
8
ECT
EA
1
ECT
EA
1
ECT
EA
1
ECT
EA
1
97403
DOOR, ACCESS ,
KSWF
(7)
S1349
PLATE, INSTRUCTION
X8F1Z
(6)
(s)
DESCRIPTION
(4)
97403
NUT ,HEKASON
HSS1967-2
9b90b
DOOR ,ACCESS ,
1322SE3379
97403
BRACKET, ACCESS DOOR
1322 SE33B2-2
97403
DOOR, ACCESS,
1322 SE337S
97403
BRACKET, ACCESS DOOR
1322 SE33S2-1
97403
F-19
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
Figure F-6.
F-20
Generator Set Top Rear Cover
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
TO-35C2-3-445-14
TM-6115-14-14&P/1
F T
(4)
ILLUSTRflTION
—
a,
F180
No,
)0
r
[TM
10,
AIR
FORCE
—
b
BHR CODE
c,
NAVY
r
USMC
1,
SS1
—
1,
IEPL
~ACTOR
NATIONAL
STOCK
NUMBER
b
b
b
b
b
b
2
3
5305-00468-0s00
4
5310-00-5E2-S965
s
531 O-OO+O9-4OSB
5310-00-7b148B2
b
7
5305-00-068-0502
8
ITV
NC
N
INIT
Ill!
— —
ECT
EA
1
ECT
EA
1
ECT
HD
s
ECT
HD
9
ECT
HD
5
ECT
HD
4
ECT
HD
4
ECT
EA
1
RIVET, BLIND
H242431 l-Ab02 01349
ECT
HD
7
)LfiTE,
1
USASLE
ON
CODE
tEF NUIWR
k HFR CODE
~~H~sT
1322BE33Sb
b
;EN SET, ASSV COVER
1 S22SE337b
97403
SCREH,CAP,HEXAS4ZII
H89072S-3
9b90b
WASHER, LOCK
IISSSS3B-44
9b90b
HMHER,FLAT
HS271S3-10
9b90b
NUT , HEM60N
NSS19b7-2
9b90b
SCREN,CAP,HEXA80N
HS9072SA
9b90b
HOUSING, GEM SET,
13228E1954
97403
9
b
10
RETAINER, INSULATION
97405
1322 flE3372
ECT
EA
1
b
11
INSULATION
1S22SE3373-2
ECT
EA
1
97403
INSULATION
1322EE33734
ECT
EA
1
9740s
INSULATION
13228E3373-5
ECT
EA
1
77403
INSULATION
13229E3S73-4
ECT
EA
2
97403
b
b
5320-00-S50-32b6
12
13
14
—
—
NC
ITV
~ER
[QUIP
97403
h
b
r
DESCR1PTION
USHC
. —
F-21
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
Figure F-7.
F-22
Generator Set Rear Housing
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
(3)
USMC
(4)
b.
REPL
SS1 FACTOR
NATIONAL
STOCK
NUMBER
(2)
SltR CODE
(1)
[ILLUSTRATION
1,
~lso
loo
b.
lTE!I
NO.
7
i
Pboll
5310-00-761-6882
7
2
PAoll
5310-00-582-S96S
7
7
7
7
7
7
3
4
s
b
7
B
a.
ARHV
PAOZZ
b.
AIR
FORCE
c.
d,
NAVY
USMC
a.
S30S40460-0S00
XBOIZ
Pholl
PAOIZ
Pholl
XBOFF
530b-00-22b-4B2S
5310-00-407-9Sbb
5310-00-s80-7744
(5J
DESCRIPTION
(b)
USABLE
ON
CODE
REF NUWR
k NFR CODE
NUT , HEM60N
HS51967-2
9b90b
WASHER ,LOCK
HS3533B-44
9b90b
SCREN, CAP, HEXMON
NS9072S-3
9b90b
HOUSIN6, SEN SET,
13228E3377
97403
SCREN,CAP,HEXMN
MS9072B32
9b90b
NMHER,LOCK
HSSS33B-4S
9b90b
NUT, HEXMN
HSSi9b7-S
9b90b
REAR HOUSINS , SENSET
1322SE1901
97403
(7)
(8)
m
INC
IN
WI UNIT
ECT
Ho
2
ECT
HO
4
ECT
HD
4
ECT
EA
1
ECT
HD
14
ECT
HO
14
ECT
HO
14
ECT
EA
1
Usltc
OTV
PER
EOUIP
F-23
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
Figure F-8.
F-24
Exhaust Baffle Assembly
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
{1)
lLLUSTRdTIDN
d,
FIS.
NO,
b.
ITEM
No,
8
1
a
B
8
s
0
s
B
8
8
B
s“
s
a
s
8
2
3
4
s
b
7
B
9
10
11
12
13
14
1s
lb
(31
Usllc
(2)
SltR CODE
4,
ARM
PbFll
b,
AIR
FORCE
c,
d,
a,
NAVY
USHC
SS1
b.
REPL
FACTOR
(4)
NATIONAL
STOCK
NLMBER
5320-00-303-1060
lBFZZ
Mm
PAOZZ
Phozz
S30S-00-2254S43
S31O-OO-SS2-S965
XBOFZ
P40ZZ
531040-761 -68S2
KBOZZ
IBOZZ
XBOZZ
PAOZZ
PAOZZ
Phozz
PAOZZ
Phozz
MOZZ
5310-00-s00-7744
S3104O-4O7-9W
S30640-22W499
S31O-OO-O81-42I9
(s)
DESCRIPTION
(6)
USASLE
ON
CODE
REF NUflSER
t llFR CODE
RIVET, BLINO
t12424311-B502
81349
PLATE, IDENT
1322SE1S79
97403
PLATE, INFORMATION
1322BE19S6
97403
9CREH , CAP , HEXA60N
IW9072S-S
94906
HASHER,LDCK
HS3S3SB-44
9b90b
SAFFLE ASSY,EXHAUST
1322SE19SB
97403
NUT, HEMBOM
RS519b7-2
9b90b
BAFFLE SAR
1322BE1960
97403
BAFFLE , CENTER,
1322SE1962
97403
CHANNEL,ENO BAFFLE
1322SE3366-2
97403
INSULATION
1322SE1942-2
97403
NUT , HEMSON
HS51967-S
%90&
WHER, LOCK
RS3S33S-4S
9b90b
SCREW ,CAP,HEXASON
HS9072S-34
9b90b
WHER,FLAT
flS271S3-i2
9b90b
HAM PLATE
1322BE1963
97403
(7)
(e)
QTV WC ~
lNC QTV
IN
PER
WI UNIT EQUIP
ECT
EA
s
ECT
EA
1
ECT
EA
1
ECT
HO
7
ECT
HD
7
ECT
EA
1
ECT
HD
3
ECT
EA
1
ECT
EA
s
ECT
EA
2
ECT
EA
2
ECT
HD
4
ECT
HD
4
ECT
HD
4
ECT
HO
4
ECT
EA
2
I
F-25
TM-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
;iao
NO.
b.
fTEH
NO.
8
17
X80FF
8
18
P40ZZ
a
8
8
F-26
19
20
21
(3)
USMC
{4)
b,
REPL
SS1 FACTOR
NATIONAL
STOCK
NUHSER
(2)
SIIR CODE
(1J
ILLUSTRATION
a,
ARM
KBOZ1
Xsou
XBOZ1
b.
AIR
FORCE
C*
d.
NAVY
USMC
4.
(s)
DESCRIPTION
530S-00-22S-3S43
USABLE
ON
CODE
REF MIMER
k HFR CODE
HOUSIN6, SRFFLE ,
1322SE19S9
(6)
(7)
OTY
INC
IN
UIH UNIT
ECT
EA
1
ECT
HO
8
ECT
EA
2
ECT
EA
1
ECT
EA
1
97403
SCREH , CAP, HEXMDN
RS9072kS
9b90b
FLAN6E,S1OE,EXIWST
1322BE19bS
97403
FLAN6E, TOP ,EXHAUST
13220E1964
97403
FLAN6E, BOTTOM
i3228E19b6
9140s
(a)
USMC
OTY
PER
EOUIP
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
Figure F-9.
Generator Set Top Front Cover
F-27
TM-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
(2)
(31
EM CODE
USHC
(1)
ILLUSTRATION
;i80
NO,
b.
ITE14
NO,
9
1
9
9
9
9
9
9
9
9
9
2
3
4
s
b
7
a
9
10
4.
ARHY
Pnou
P40Z1
P40u
PAOZZ
PAou
da
NAVY
USMC
do
ho
REPL
SS1 FACTOR
NhTIONAL
STOCK
NUIWER
S30S-00-068-OSOO
S31O-OO-W2-S96S
5310-oo-so9-405e
S310-00-7bl-b882
S30S-00-0bLOS02
PAOZZ
PAFZZ
9
12
PAFZZ
XBOZl
5320-00-B50-32bb
611 S41-213-S791
. ---- ,
F-28
[7)
OTY
INC
IN
Ulm UNIT
ECT
EA
1
ECT
HD
7
ECT
HO
Is
ECT
HO
s
ECT
HD
13
ECT
HO
11
ECT
EA
1
ECT
EA
2
ECT
EA
2
ECT
EA
1
RETMNER, INSULATION
97403
13228E3372
ECT
EA
1
RIVET, BLIND
H2424311-M02
ECT
HD
7
ECT
EA
1
SEN SET, ASSV
1322EE3375
PAFZZ
XBFll
USABLE
ON
CODE
REF NUltBER
k HFR CODE
[BFU
11
13
C,
(b)
!s)
(8)
DESCRIPTION
XDW
9
9
b,
MR
FORCE
(4)
97403
SCREH,CAP,HEXASON
IIS9072S-3
9b90b
WIER,LOCK
HSSS3W44
9b90b
HASHER,FLhT
IIS271E3-10
9b90b
NUT, HEXA60N
RSS19b7-2
9b90b
SCREM,ChP , HEXMON
RS9072S-b
9b90b
HOUWS, EiEN SET,
13229E1953
97403
INSULATION
1S228E3373-1
97403
Insulation
1322EE3373-3
97403
INSULATION
13228E3373-2
97403
DOOR +ICCESS,
72-2121
0i349
303s4
USMC
OTV
PER
EQUIP
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
Figure F-10.
Generator Set Front Housing
F-29
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
(4)
ILLUSTRATION
—
4*
FM,
No,
—
10
10
10
10
10
—
F-30
rITEH
NO,
‘r
hIR
FORCE
c,
r
—
NAVY
USMC
;s1 ‘ACTOR
—
1,
1.
IEPL
NAT ION#L
STOCK
NUMBER
5S06-00-226+25
1
2
5310-00-407-?S66
3
531040-s00-7744
4
s
—
Ii T (s)
(5)
DESCRIPTION
Usnc
SfIR CODE
USABLE
ON
CODE
REF NUMBER
& HFR COOE
SCREH,C14P,HEM60H
HS9072M2
9b?Ob
tiASHER,LOCK
HS35338-45
96906
NUT, HEXMON
HS51967-S
9b90b
HOUSINS , 6EN SET,
13228E1S84
97403
SOUNO PMEL,HOUS IN6
13228E3380
97403
Ill
ITV
NC
N
INIT
—
ECT
HO
b
ECT
Ho
b
ECT
HD
b
ECT
LA
1
ECT
in
2
—
UMC
m
PER
EQUIP
— —
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
TO-35C2-3-445-14
TM-6115-14&P/1
Figure F-11.
Power Wiring Harness and Control Wiring Harness
F–31
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
10
~le.
40.
b,
ITEM
NO.
11
1
PAOZZ
11
2
PAOU
11
11
11
11
11
3
4
s
b
7
a,
ARRV
Pwz
Phozz
P40U
PAOZZ
e
PfiFZZ
11
9
PhFZZ
10
(4)
b,
MR
FORCE
c,
d,
b.
REPL
551 FhCTOR
NATIOML
STOCK
NIMBER
NAVV
USMC
a,
S306-00-22S-S499
5310-oo-so940se
S31040-S82-596S
S31O-OO-761-6882
530s-oo-059-3hho
S31O-O1-O12-3S95
HDFFF
11
11
(3)
Uslfc
(2)
S?lR CODE
(1)
[LLU9TRATION
5920-00-033-0266
PAFZZ
(5)
DESCRIPTION
(6)
(7)
QTV
USABLE
INC
ON
IN
CODE
U/m UNIT
REF NUltBER
k HFR CODE
SCREM,CAP,HEMGON
HS9072544
94904
ECT
HD
3
HASHER,FLAT
HS27I83-10
96906
ECT
HD
3
tMHER,LOCK
HS35338-44
Yb90b
ECT
HO
3
NUT, HEMSON
HSS19b7-2
9b90b
ECT
HD
3
.SCREH,MCH[NE
HSS19SE-64
96906
ECT
HO
4
NUT, PLAIN
69-S61-6
303s4
ECT
EA
4
HARNESS , HIRIN6,PONER
1322SE19S1
97403
ECT
EA
1
CONNECTOR,ELEC
RS1734kR3bN77S 96906
ECT
EA
1
SUR6E,PROTECTOR
2301-SS
ECT
EA
3
23kb3
TERIIINAL,R1N6,
F-666-121
EC!
EA
98410
11
11
PAFZZ
5970-00-S12-2967
SLEEVIN6,1NSULAT ION
!12SOS3/5-1084 81349
ECT
FT
v
11
12
PAFZZ
597040-91 S-9186
SLEEV1N6,1NSUL4TION
H2SOW5-108-2 81349
ECT
FT
v
11
13
PAFZZ
3970-00-944-1329
SLEEVIN6,1NSULATION
H230S3/5-108-b E1349
ECT
FT
v
11
14
PAFZZ
6145-00-970-6595
HIRE, ELECTRICAL,
!MOS412-4-9
ECT
FT
v
ECT
EA
1
ECT
EA
i
11
1s
HOFFF
11
lb
PAFZZ
F-32
01348
HIRIN6 HARNESS ,CONTROL
97403
13228E1909
MANUFACTURE FROlh
S935-01-07S-9S03
CONNECTOR,PLU6
HS345bH20-29P
96906
(0)
USMC
QTV
PER
EOUIP
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
ILLUSTRATIOM
b,
a,
;ik
ITEH
No.
NO.
11
11
11
11
11
11
11
11
17
18
19
20
21
22
23
24
b.
c.
d,
a,
b,
NW
U5HC
SSI
REPL
FACTOR
MR
ARHV
FORCE
STOCK
NUNSER
PAFIZ
PAFn
P4FZZ
Phozz
597s-00-11 1-3208
597%00-944-1499
614S-00-S70460S
S31O-OO-73245S8
HFOZZ
11
25
PAOZ1
11
24
Pnozz
CONNECTOR,ELEC
03E999124FDSS
81349
(8)
CONN,RECEPTMLE
13228E1949
97403
STRAP, TIEDOBN
HS33b7-S-9
W90b
STRAP ,CABLE
H63368-1-9A
9b90b
QTY Ustlc
lNC OTV
IN
PER
U/n UNIT EOUIP
ECT
EA
1
ECT
EA
1
ECT
HO
v
ECT
HD
1
ECT
FT
v
ECT
HD
1
ECT
Ed
1
ECT
E4
1
SLEEVINS INSULATION
l!230$3/5-108-9 S1349
ECT
FT
1
NIRE,ELECTRICAL,
ECT
FT
v
HIRE, ELECTRICAL ,
[email protected]
81349
NUT, PLAIN HEM60H
HSS19b7-S
9b90b
TERI!INAL, RIN6,
F-666-12X
b14s40-s7a-b59s
USABLE
ON
CODE
REF NUMBER
k HFR COOE
HIRE,6AOUND
1322SE1900
HMIFACTURE FROHI
PAFZZ
(7)
DESCRIPTION
NATIONAL
PAFzl
PAFZZ
(&)
I
WC
M CODE
H508b/2-4-9
97403
9B41O
01348
F-33
TM-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
Figure F-12.
F-34
Wiring Harnesses
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
T
(4)
a,
FM
No,
r
ITEM
Ho.
a,
ARHY
12
1
HFFFF
12
2
PAFll
12
12
12
12
s
4
s
b
USRC
SNR CODE
1LLU9TRATION
r
bIR
FORCE
co
NW
zUSHC
—
i,
SS1
—
1.
tEPL
fhCTOR
NATIONAL
STOCK
NUHUER
REF NUHBER
k HFR CODE
S93S-00-S48-1529
S93541-147-3902
PhFZZ
593S-00-622-2924
Phfzz
5975-00-944-1499
PAFZZ
7
i97%o&i i 1-3200
PhFZZ
12
e
ltFFFF
12
9
PAFZl
12
10
bi4S-00-570-bkOS
12
11
PhFZZ
12
12
PhFzz
12
13
5975-00-944-1499
5935 -00-b22-2929
5975-00-1114208
14
PAFZZ
6145-00-578405
IIFFFF
urn
—
EA
1
ECT
EA
1
ECT
Eh
1
ECT
HO
i
ECT
HD
v
ECT
FT
v
ECT
EA
1
ECT
HD
1
ECT
EA
1
CONNECTOR , ELEC
D3S999/24FH21S 81349
ECT
ER
1
STRAP, TIEDOMN
ECT
HD
v
ECT
FT
v
ECT
EA
1
9b90b
CONNECTOR,PLW
IW3456M22-19P
9b90b
CONNECTOR,PLU8
RS34S6H14S4P
9b90b
STRAP,CMLE
14S3Jb8-i-9A
9b90b
STRAP, TIEDOUN
HIRE, ELECTRICAL,
H50W2-lb-9
9b90b
81349
STRhP,CABLE
HS33b&i-9h
9b90b
CONNECTOR, PLUG
llS34Sbti24-28S
9b90b
W IRE, ELECTRICAL,
MOOb/2-lb-9
)TY
‘ER
;aw
— —
ECT
CONNECTOR,PLU6
HSJ4S6124-2SP
HIRINS HARNESS, SS2P
TO CONVENIENCE RCPT
13228 E1913
—
MC
1
M33b7-5-9
12
ITY
NC
N
INIT
EA
HIRIN6 HARNESS
REMOTE FUNCT IONS BOX ASSY
TO CONNECTOR PANEL
91403
1322SE191O
MANUFACTURE FROMI
PAF21
F
ECT
lM3b7-S-9
12
USABLE
ON
COOE
ltIRIN6 HARNESS,
5P RELAY MSV TO REHOTE
FUNCTIONS BOX ASSY
13228E1911
97403
HANUFhCTURE FROHI
Phm
m-
OESCRIPTION
9b90b
01349
97403
— — —
F-35
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
(2)
(3)
SNR CODE
USNC
(1)
lLLU8TRhTIOM
t9
FIB*
No,
b,
ITEH
No,
4*
ARM
b.
AIR
FORCE
c.
do
NW
USHC
1.
b.
REPL
SS1 FACTOR
(4)
(6)
(5)
(7)
NATIONAL
STOCK
NURSER
m
USABLE
[NC
OH
IN
COOE
Uli! Ut41T
REF MIMER
k RFR COOE
flANUFACTURE FROHI
12
12
1s
16
PAFIZ
P4F1Z
CONNECTOR,PLU6
13229E1940
614s-oo-s7&b60s
12
12
F-36
17
18
19
PhFZZ
PhFll
PhFZZ
S97S-00-1114208
S940-01-013-S297
S97$O0-944-1499
ECT
M
1
ECT
FT
v
ECT
HD
v
ECT
EA
2
ECT
HD
1
9740s
HIRE ,ELECTRICAL,
MSOEb/2-lb-9
12
(8)
DESCRIPTION
S1S49
STRAP, TIEDONN
HSS367-S-9
96906
TERHf ML ,LU6,
HS2S03b-lS3
9b90b
STRAP, (WE
I!SS36G1-9A
96906
USMC
QTV
PER
ESUIP
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
Figure F-13.
Silencer and Exhaust System
F-37
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
10
:!60
100
b.
Inn
NO,
13
1
13
13
13
13
13
13
13
13
13
13
13
2
3
4
s
b
7
6
9
&*
ARHY
Phozz
PAOZ1
Pm
P80U
12
b,
kIR
FORCE
co
d,
a.
NAVY
Usftc
SS1
b,
REPL
FACTOR
(4)
NATIONAL
STOCK
NWER
530S-00-068-0500
S31O-OO-SQ2-596S
S34041424-9937
5315-00-0b3-901b
Pnozz
PAOZZ
Pkozl
Pnozz
Pnoz2
10 % PAOZZ
11
(3)
Usnc
(2)
SltR CODE
(1)
ILLUSTRATION
5305-00-9644196
5310-00-0S24b32
5305-00-071-1787
5310-00-2094965
5340-00-b2b-9402
IBOIZ
Phozz
S33040-630-3559
13
13
13
13
F-38
13
14
15
lb
17
Pfiozz
P#ozz
Phozz
Phozz
XBOZZ
530540-543-2419
531 O-OO-O6OAOO4
5310-oo-b37-954t
531040-732-0556
USABLE
ON
CODE
REF NUHBER
t HFR CODE
SCREH,CAP ,HEM60N
HS90725-3
96906
W4ER,LOCK
HS35338-44
9b90b
CtiP,PROTECTIVE
72-2033
SOSS4
PIN, SPRIN6
NMSblC&22
8020s
CLMPASSV, EXHNJST
1322EE3365
97403
SCREH,MCHINE
HS3S20b-2S0
9b90b
NUTkCAPTIVE WASHER
511-061600-00
78189
SCREH,CAP,HEX
RS90725-Bb
9b90b
WMHER,LOCK
ns3533s47
9b90b
CLAMP , LOOP
U250
01652
TUBE ASSV, FLEXISLE
DP-130b-2
5599b
MSKET
72-2057
13
(6)
(s)
DESCRIPTION
(7)
OTV
[NC
IN
UIH UNIT
ECT
Ho
2
ECT
HD
2
ECT
EA
1
ECT
EA
1
ECT
EA
1
ECT
HD
4
ECT
HO
4
ECT
EA
2
ECT
HD
2
ECT
EA
1
ECT
EA
1
ECT
EA
1
ECT
EA
4
ECT
HD
4
ECT
HD
4
ECT
HD
4
ECT
EA
1
30554
SCREH,CAP , HEMSON
HS9072S-bl
9b90b
iiASHER,FLAT
HS27163-14
9b90b
WMHER,LOCK
RS353364b
9b90b
NUT, PL41N HEMSON
HSS19b7-6
9b90b
SILENCER, EXHAUST
A-22-9b0-XX
97403
(0)
USHC
QTV
PER
EQUIP
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
TO-35C2-3-445-14
TM-6115-14&P/1
Figure F-14.
Air Cleaner System
F-39
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
a,
FIS.
NO,
b,
m
NO,
ARM
14
1
Pnozz
14
14
14
14
14
14
14
14
14
14
14
14
14
14
14
F-40
2
3
4
s
b
7
s
9
10
11
12
Is
14
1s
lb
(3)
USMC
(4)
b,
REPL
SSI FACTOR
NATIONAL
STOCK
NUMBER
(2)
SNR CODE
(1)
ILLUSTR8TIDN
4,
b.
#lR
FORCE
co
d.
NAVY
USNC
a.
4730-00-909-S627
PAO1l
Pdoll
Phou
S30S-00-071-17S7
S310-00-209-09bS
Mou
Pnozz
PAou
PAW
PAOZZ
PAou
Pfiozz
S330-00-2314b33
4730-00-s414ss4
4720-00-b2S-2202
S310-00-76148S2
531040-M2-S9b5
S30S-00-22S-3S43
KBFZZ
Phozz
Phozz
S930-00-430-3S32
S3OS-OO-O71-2S1O
Xsozz
PADIZ
294040-4b3-13b2
(s)
DESCRIPTION
(6)
(7)
WY
USABLE
INC
ON
IN
CODE
WI UNIT
REF NUMBER
k RFR CODE
CLMP,HOSE
IISJSS42-13
9490b
HOSE, NON-NETALLIC,
1322SS1S8S
97403
SCREH,CAP,HEI
tlS9072S-S6
9b90b
MSHER,LOCK
ns3s33s47
9b90b
fiDhPTER,#lR INLET
1322SS1917
9740s
MSKET,141R INLET
40819
97403
CL14HP,SPRINS,HOSE
NS3932b-17
9b90b
HOSE , PREFORMED
72-20S0-2
30s54
NUT, HEMSON
MSS1967-2
9b90b
WIER,LDCK
HS3S33S-44
9b90b
SCREH,CAP,HEXMON
HS9072&S
9b90b
HOUSINS, AIR FILTER
1322SEIS94
97403
SHITCH,PRESSURE
70-1s10
305s4
SCREH,CAP,HEX
HS9072S-13
9b90b
RETMNER,AIR FILTER
1322SE1SB3
97403
FILTER, ELEIIIENT
704020
30ss4
ECT
EA
2
ECT
M
1
ECT
EA
2
ECT
HO
2
ECT
EA
1
ECT
Eh
1
ECT
EA
2
ECT
EA
1
ECT
HD
b
ECT
HO
b
ECT
ND
4
ECT
EA
1
ECT
EA
1
ECT
EA
2
ECT
Eh
1
ECT
EA
1
(8)
USRC
OTV
PER
EQUIP
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
Figure F-15.
Remote Functions Box Assembly
F-41
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
;ia.
NO.
b,
ITEH
NO.
15
1
15
2
Is
1s
3
4
a.
ARMY
PhFll
Pholl
bo
AIR
FORCE
co
d.
bo
REPL
SS1 FACTOR
NATIONAL
STOCK
NUMBER
NW
USMC
ae
530540-0b&0500
5310-00-SS2-S96S
PSFFF
s
PhFn
1s
b
XBF2Z
7
(4)
XBFZl
15
1s
(3)
Usnc
(2)
SIIR CODE
(1)
ILLUSTRATION
PAFZZ
5305-00-03b49bB
594s-00-43s-1s33
(s)
DESCRIPTION
(b)
USABLE
ON
CODE
REF NIMBER
b HFR CODE
(7)
OTV
lNC
IN
U/n UNIT
ECT
HD
4
ECT
HO
4
ECT
EA
1
ECT
EA
SCREU,ASSEHBLED NAS
13214E3290-18
30SS4
ECT
EA
12
CDVER,ENCLOSURE
1322BE1923
ECT
EA
1
97403
RELAY
W51123403
ECT
Eh
9b90b
SCREH , CAP, HEXMON
RS9072S-3
9b90b
HASHER,LOCK
HSS3330-44
96906
BRACKET, REHOTE
1322SE1922
97403
S01 ,REHOTE FUNCTION
1322EE190b
97403
1s
8
P4F11
530S-00-191-6226
SCREN,MSEIISLEO MS
Pls121-b4
4S722
ECT
EA
1s
9
PAFll
S310-00-934-97S1
NUT,HEI
HS3S650-302
ECT
HD
9b90b
ENCLOSURE ,
1322BE19S1
ECT
EA
1
97403
COVER , RE-CONNECTI IIN
72-214S
ECT
EA
1
30ss4
RIVET, BLIND
1424243 /lBS03
ECT
EA
4
S1349
PLATE, CAUTION
1322BE1939
ECT
EA
1
91403
15
1s
1s
15
F-42
10
11
12
13
XAFZZ
XBFZZ
PAFll
WFZZ
5320-o~-lss-b120
(8)
USMC
WY
PER
EQUIP
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
Figure F-16. Engine Belt, Fan and Pulley
F-43
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
(1)
MWR4TIOM
;6’
so,
b,
ITE14
so.
ARHV
lb
1
Phou
tb
lb
M
lb
2
3
4
s
4.
Pholl
(2)
(3)
SI!R CODE
Usflc
b.
AIR
FORCE
Ca
da
Mvv
US14C
a.
b.
REFL
SS1 FflCTOR
(4)
NATIONAL
STOCK
MIMER
!30b-00-22b-402S
S31O-OO-4O7-9S64
PBOZZ
PA02Z
PAOZZ
(s)
ib
lb
lb
F-44
b
7
8
9
Pnozz
Pholz
S31O-OO-42O4O64
S3104O-4OO449S
53b$O0-015-bSOO
531540-S44-3662
lBFZ1
Pholz
(7)
30S0-00-S17-4SS6
QTY
UMBLE
INC
ON
IN
CODE
Uin UNIT
NSF NUMBER
k RFR CODE
SCREH,CAP,HEXASON
HS90728-32
9Ho&
WIER,LOCK
Rs3s33#-4s
96906
FAN, EN61NE
1322EE1S07
97403
NUT, PLAIN, HEXASON
202S6S6
2S26S
MSHER,LOCK
lSb9h
lb
(6)
(a)
DESCRIPTION
WISHER, PULLEY
2072694
ECT
HD
4
ECT
HD
4
ECT
EA
1
ECT
Ed
1
ECT
EA
1
ECT
M
1
ECT
HO
2
ECT
EA
1
ECT
EA
1
2S26S
2S263
PIN, SPRINS
llSlb3b2-b2
96906
PULLEY, CRANKSHAFT
1322BEIS93
97403
BELT, V, ENSINE
HSS1066-S7
96906
USRC
OTY
PER
EQUIP
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
Figure F-17.
Fan Guard, Left and Right
F-45
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
:ik
ND,
b.
ITEH
NO,
(3) ‘
USMC
(4)
b.
REPL
SS1 FACTOR
NATIONAL
STOCK
NUMBER
(2)
SMR CODE
(1)
1IMSTRN1OM
a.
ARIIY
b.
AIR
FORCE
co
~e
NAVY
USMC
~~
17
i
PROZZ
5305-00-068-0500
17
2
PAO1l
5310-00-SS2-59b5
17
t7
17
F-46
3
4
s
18011
IBDZ1
IBOFZ
(5)
DESCRIPTION
(6)
USABLE
ON
CODE
REF NUNBER
k HFR CODE
SCREN,CAP, HEM60N
!!S90725-3
9b90b
MSHER,LOCK
HS3S33S44
9490b
SUhRD,FAN,RIBNT
1322SE1S91
97403
SUARD,FAN,LEFT
1322SE1892
9740s
PLATE, FAN
1322SE1918
97403
[7)
OTY
INC
IN
Ull! UNIT
ECT
HO
b
ECT
HD
b
ECT
EA
1
ECT
Ea
1
ECT
EA
1
(8)
USHC
QTV
PER
EQUIP
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
Figure F-18.
Special Relay Assembly (Sheet 1 of 3)
F-47
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
Figure F-18.
F-48
Special Relay Assembly (Sheet 2 of 3)
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
Figure F-18.
Speical Relay Assembly (Sheet 3 of 3)
F-49
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
(2I
(J)
SHR COOE
UBmc
(1)
LLUSTMTION
16.
w
b.
ITEM
NO.
la
1
1,
10
18
10
10
18
10
2
3
4
s
b
7
a,
b.
AIR
c,
do
4*
b,
REPL
AR19V
FORCE
NAvv
USNC
SS1 FhCTOR
NATIONAL
STOCK
NUNBEli
mm
PhFZZ
Phfu
PhFZZ
Pnozz
(6)
(7)
S30S-00-0bS4S02
5310-00-0b7-b3W
S31O-OO-SO9-4OW
S305-00-Ob&OSOO
S310-00-5B2-S9bS
USABLE
ON
CODE
REF NUNBER
k NFR CODE
OTV
INC
IH
U/m UNIT
ECT
EA
1
ECT
EA
1
ECT
ND
3
ECT
HO
b
ECT
HD
k
ECT
HD
3
ECT
HD
b
COVER, SPECML RELAY
97403
13228E190S
ECT
EA
1
RELAY ASW,SPECML
1322SE1904
97401
CHASSIS
72-2231
SOSS4
SCREII,CAP,HEXA60N
HS9072S-b
M90b
WIER,LOCK
Ra4s90449
9b90b
HASNER,FL8T
HS27183-10
9b90b
SCREN,CAP,HEMSDN
NS9072S4.
9b90b
ttMHER,LOCK
HSS333S-44
9b90b
18
s
XBFZZ
18
9
PdHZZ
S30S40-191-b22b
SCREH,ASSEHBLEO HAS
45722
PlS121-b4
ECT
EA
2
1s
10
PAHZZ
S30S-00-03B-30S9
SCREH k MASHER ASSV
45722
P1S121-3
ECT
EA
32
18
11
PAHZZ
5310-00-934-9739
NUT, PLAIN, HEXA60N
9b90b
M3Sb4%242
ECT
HD
32
lB
12
PAHZZ
5310-00-934-9747
NUT, PLAIN, HEXASON
lK35b49-2b2
9b90b
ECT
HD
24
1s
13
PAHZZ
530$O043b-b9b0
SCREH,MSEHBLED HAS
13214E3290-lS
30S54
ECT
EA
24
10
14
PhHZZ
5935-01 -17b-1708
COVER, CONN. RCPT
HS2S043-22DA
ECT
EA
1
ECT
HO
10
ECT
HD
2
1s
1s
PhHZZ
S310-004S2-3b32
F-50
lb
PAHU
531040-s09-ss44
9b90b
NUTkCAPTIVE HASHER
S1l-081SO040
1s
(e)
DESCRIPTION
PBFMI
Pm
(s)
(4)
HASHER, FLAT
HS271B3-7
7s189
9b90b
UBNC
QTV
PER
EQUIP
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
(1)
[LLUSTRhTIOM
—
(2)
SMR CODE
—
a,
I-
mm
USHC Ssl
— —
r
DESCRIPTION
4.
:16,
Uoo
—
ITEH
NO,
AMY
18
17
PAW
5305-00-9844193
SCREW, HACH, PANHD
9b90b
tlS3S20b-249
18
10
PM1l
530S-004b84SO0
SCREW, MACHINE
HS35206-243
hlR
FORCE
c,
!EPL
MC1O
m vi m-
(4)
T-
10
I-
(3)
MC
NATIONAL
STOCK
NURSER
w
—
ITV
[NC
x
IN1l
—
ECT
HD
2
ECT
MD
4
USABL[
ON
CODE
REF NUHSER
k HFR COOE
9bfOb
18
19
P4Hlr
S30S-00-9S44194
SCREW, HACH, PANHD
l183520b-24b
9b90b
ECT
HO
2
18
20
PAHZZ
bb2540-S92-4342
SHUNT INSTRRNT(R13)
HSA200
03776
ECT
EA
1
18
21
PAHZZ
5310-00-0b3-73b0
NUT, PLAIN, ASSEHSLEO
511-0blSO040 7S189
ECT
EA
s
18
22
PAHzl
6110-00-201401s
DC RELAY WV
69-76S
EC1
EA
1
91742
RELAY
M241b6-Dl
ECT
EA
1
9b90b
HIR1N6 HARNESS,
1322 flE3374
ECT
EA
i
97403
ECT
EA
1
ECT
EA
1
ECT
EA
1
ECT
EA
2
ECT
M
2
ECT
1A
2
ECT
m
2
ECT
m
2
—
—
la
18
18
10
10
18
10
18
18
10
—
23
24
2s
2b
27
20
29
30
31
32
PAHZZ
3945-00-s35-7478
MDHHH
)AHZ z
f925+l-i544)2b5
MHZ1
i935-01-197-2b25
MHZZ
i935-ol-071-0331
MHIZ
i93S-01-223-15b3
MHZ 1
~935-Ot-22b-S3b5
‘AH1l
935-01-211-4440
Altzz
93541-199-4442
Alizz
935-01 -229-Q140
— -
Usnc
OTY
PER
EQUIP
CONNECTOR,ELEC
ltS3452H20-27S
9b90b
CONNECTOR,ELEC
RS3452W3b-7S
9b90b
CONNECTOR,ELEC
RS3452HIS-llS
9b90b
CONNECTOR,ELEC
flS3452H14S-bS
9b90b
CONNECTOR,ELEC
HS3452W32-7P
9b90b
CONNECTOR,ELEC
HS3452W20-29S
9b906
CONNECTOR, ELEC
HS34S2H22-19S
9b90b
CONNECTOR,ELEC
HS3452H24-28S
9b90b
F-51
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
(2)
SNR COOE
(1 I
ILLUSTRATION
;iso
NO,
b,
ITEM
NO,
10
J3
10
1s
1s
1s
Is
1s
le
1s
34
3!
36
a.
hRHV
PMll
PAH1l
PAHZZ
P4HZZ
37 ~ p~~lz
30
39
40
4i
PAHZ1
P4HZZ
PAHZZ
Pntm
b.
AIR
FORCE
(3)
USHC
co
d.
a.
NdVV
USMC
SS1
b.
REPL
FACTOR
(5)
DESCRIPTION
(4)
NATIONAL
STOCK
NUMER
S93S-01-202-6206
S9S341-196-1094
594040-204-S9bb
5940-00-S37-Ib29
S940-00-283-S2S0
S940-00-143-4794
5940-00-143477s
594040425-5041
5940-00-143-4171
18
1s
42
43
44
PAHZZ
PhHIZ
PAHZZ
530s-00-ss9-3001
S940-00-9SW09b
b15040-S19-2714
1s
4s
4b
PPHll
59bl-00-lbS-2903
2
ECT
EA
2
ECT
EA 143
ECT
EA
1s
ECT
En
4
ECT
Eh
2
ECT
HD
s
ECT
Ps
4
ECT
EA
4
ECT
HD
4
ECT
EA
2
ECT
M
4
ECT
EA ‘1
ECT
EA
1
INSULAT ION SLEEV INS
TYPEF, FORHU S1349
ECT
FT
1
TERHINAL LUS,
M2S03b-102
ECT
EA
2
CONNECTOR,ELEC
NS34S2N3b-7P
9b90b
TERMINAL LUB,
HS2SO36-102
9b90b
TERMINAL LUS,
14S2S03b-149
9b90b
TERHINAL LUS,
lfS2S03b-10b
9b90b
TERHINAL LU6,
ltS2S03b-112
9b90b
TERHINAL LU6 ,
RS2S03b-lSb
9b90b
TERNINAL LU6,
M1714s-b
9b904
TERMINAL LUS,
47
PAHZZ
18
4s
PAHZZ
F-52
5940-00-204-S9bb
9b90b
SCREN,HACHINE
HS3S20b-231
9b90b
TERHINAL SOARD
3STB20
S1349
JUHPER, TERHINAL BRO
S3330
97403
SEHICONDUCTOR
lNSb19
1s
QTV
INC
IN
u/H UNIT
Eh
9690b
DIDDE ASSEMBLY
1322SE1920
hHHIZ
(7)
ECT
CONNECTOR,ELEC
HS3452H28-12S
601J
1s
USWE
ON
COOE
REF NUHSER
k RFR CODE
HS2S03b-lS7
1s
(b)
14099
9b90b
(8)
USMC
OTY
PER
EQUIP
TM 5-6115-634-14&P
NAVFAC P-6-647-14&P
TO-35C2-3-445-14
(2)
(3)
SMR CODE
USMC
(1)
ILLUSTRATION
a
b
FIG
NO.
ITEM
NO.
ARMY
18
49
PAHZZ
18
18
18
18
18
18
18
50
51
52
53
54
55
56
a
PAHZZ
PAHZZ
PAHZZ
PAHZZ
PAHZZ
PAHZZ
PAHZZ
b
c
d
a
(7)
(8)
DESCRIPTION
b
REPL
AIR
FORCE NAVY USMC SS1 FACTOR
(6)
(8)
(5)
(4)
NATIONAL
STOCK
NUMBER
5905-00-860-6276
5905-00-642-1955
5905-00-843-2809
5905-01-021-9133
5935-01-175-8419
5935-01-005-9925
5310-00-082-1404
5950-00-601-6296
USABLE
ON CODE
FIEF NUMBER
& MFR CODE
BRACKET ASSEMBLY
MS75009-33
96906
RESISTOR, FIXED
RW33V100
81349
RESISTER FlXED
RW33V150
81349
RESISTOR, VARIABLE
RP0025-21206BA
30554
COVER, CONN
MS25043-18DA
96906
PLUG, CHAIN ASSY
72-2241
30554
WASHER, FLAT
MS27183-6
96906
TRANSFORMER, CURRENT
72-2204
30554
QTY
USMC
INC
QTY
IN
PER
U/M UNIT EQUIP
ECT
EA
2
ECT
EA
1
ECT
EA
1
ECT
EA
1
ECT
EA
1
ECT
EA
1
ECT
HD
1
ECT
EA
1
Change
6
F-53
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
TO-35C2-3-445-14
TM-6115-14&P/1
Figure F-19.
F-54
Isolators, Front and Rear
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
(1)
lLLUSTRATIM
a.
FM.
No.
b,
ITEH
No,
19
1
2
19
3
19
19
19
19
19
19
19
19
19
19
19
19
19
4
5
b
7
8
9
10
11
12
13
14
15
(3)
(21
SHR CODE
a.
ARMY
b,
AIR
FORCE
USRC
—
:,
ic--
—
WY
—
Usllc
Ssl
—
—
4,
PAM z
(4)
NATIONAL
STOCK
NWBER
S30SA10-942-2196
Pnozl
5310-004s7-9!41
Pswz
S30S40-071-2078
PAFZZ
5310-00-584-S272
PAFIZ
S3104O-SO9-S998
lBHZZ
PSHZZ
P8HZZ
P~Fzz
S31O-O1-O7O-21OS
‘9HZZ
!305-00-7S2-94S9
WHZZ
i305-00-72447b0
‘BHZZ
)BHZZ
MHZ 1
!31040-B20Ab53
MHZ I
nlo40-oo4-so38
(s)
OESCRIPTIOti
SCREH,CAP, NEMSON
MS9072S40
9&90b
MSHER,LOCK
lts3533&4b
9b90b
SCREH,CAP,HEX
IIS90728-122
9b90b
MSHER,LOCK
tts35338-48
9b90b
WASHER ,FLAT
HS27183-18
?b90b
ISOLATOR , FRONT
508-4NS
818b0
HftSHER, SNUBBIN6,
13228E3392-I
97403
WSHINS,FRONT
1322SE1930
9740J
WT,PLA1N,HEM60N
t!s51967-i4
9k90b
;CREH, CAP, HEX
HS90728-b6
96906
;CREH, CAP, HEX
HS90725-174
9b90b
[SOLATOR,REAR
S1O-2NS
01860
MSHER, SNUBBIN6 ,
1S228E3392-2
97403
WIER,LOCK
HS3533E-SO
96906
iUT, HEX
ltSSi9b7-20
—
USMLE
ON
CODE
REF NUHBER
& HFR CODE
E
-m-
ITY
:NC
N
JIH INI’
— —
UBHC
QTY
PER
EQUIP
iii-
ECT
HD
4
ECT
HO
s
ECT
EA
2
ECT
HD
2
ECT
HO
2
ECT
EA
2
ECT
EA
2
ECT
EA
2
ECT
EA
2
ECT
HD
4
ECT
EA
2
ECT
EA
2
ECT
M
2
ECT
HD
2
ECT
HD
2
96906
—
F-55
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
Figure F-20.
F-56
Document Box, Lifting Frame and Skid Base
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
(2)
(3)
SltR CODE
WC
(1)
ILLUSTRATION
—
4*
)*
1.
c,
—
a,
Fls,
r
[TEN
[0.
UR
ORCE
NAVY
WC
Ssl hCTOfi
—
No.
20
20
20
20
20
20
20
20
20
20
20
20
NATIONAL
STOCK
NUHSER
5305-00-071-2069
2
20
20
—
1
20
20
EPL
(4)
5310-00-584-S272
3
5310-00-s09-s998
4
5310-01470-2105
5
I91O+-2464923
b
1
s
9
10
11
!31 0-00-399-0995
12
i306-00-22b-4S25
13
i31040-407-95hb
14
i31 040-s80-7744
1s
lb
—
T) T 7ii-
(s}
OESCRIPTION
—
ITV
NC
H
INIT
—
ECT
HO
20
ECT
HO
20
ECT
HQ
20
ECT
EA
20
ECT
EA
2
ECT
EA
2
ECT
EA
2
ECT
EA
1
ECT
EA
1
ECT
EtI
4
ECT
EA
4
ECT
HO
8
ECT
HO
s
ECT
HO
4
ECT
EA
1
ECT
EA
1
—
—
USMLE
ON
CODE
REF NUHSER
k IIFR CODE
SCREW ,CAP , HEX
!!S90728-113
9b90b
HASHER ,LOCK
ns3533&4s
9b90b
HASHER,FLAT
HS271S3-18
96906
NUT, PLAIN, HEXA6DN
HSW9b7-14
9b90b
BRACKET ,CLEVIS,
72-2014
30ss4
CLEVIS
WN8190
90202
BRACKET ,AN6LE ,
72-2012
30554
WPPORT , CENTER ,
1322SE1S90
97403
;UPPORT,R16HT,
1322SE 1SS9
97403
WPPORT, LEFT
13228E1S8S
97403
MSHER,SEVELEO
380s
0574s
;CREW ,CIIP,HEXMON
RS9072S-32
9b90b
IASHER ,LOCK
HS3S33S-45
9b90b
KtT ,HEXA60N
HSS19b7-5
96906
IR6CKET , DOCUMENT ,
13228E3S67-2
97403
IRACKET , DOCUHENT ,
1322SE33b7-1
97403
JIH
USHC
9TY
PER
EOUIP
F-57
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
(2}
(1)
ILLUSTRATION
:;s,
NO*
b,
ITEM
No,
20
17
20
F-58
10
(3)
WC
(4)
b.
REPL
SS1 FACTOR
NATIONAL
STOCK
NUflSEil
SHR CODE
a.
ARM
lSQ1l
WHIZ
b,
AIR
FORCE
c,
d,
NW
WC
4,
(s)
(6) (7)
(s)
DESCRIPTION
OTV
USABLE
INC
ON
IN
CODE
U/m UNIT
REF NURSER
b 14FR CODE
S01 , DOCUHENT,
13228E33b4
?7403
SKIO BASE
1322SE1S99
9740X
ECT
EA
1
ECT
EA
I
Usmc
m
PER
EQUIP
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
Figure F-21.
Junction Box Assembly
F-59
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
(2)
m CODE
(1)
ILLUSTRATION
a,
m
NO,
b,
[TM
No,
MnY
21
1
PAFZZ
21
2
NOHH
21
3
4
21
21
21
21
21
21
21
21
s
b
7
8
9
10
11
a,
PW1
PAHll
b.
AIR
FORCE
c,
d.
NAVV
Usllc
(3)
USHC
(4)
b.
REPL
Ssl FAC1OR
NATIONAL
STOCK
NWER
a.
5S05-00-22S-9081
s30540-9s4-b193
S31O-OO-O45-3299
XSHU
PfiHIZ
P4HZZ
P4H1Z
PN4rr
PhHZi
PflHll
5J1O-OO-934-9157
S30S-01-OOb-2052
S3104O4774797
(s)
OESCRIPTIOH
(A)
(7)
QTV
USABLE
INC
Oa
Ill
CODE
U/m UNIT
REF NUNBER
t IIFRCOOE
SCW ,CAP HEX
RS9072S-3b
9b90b
JUNCTIONSOX hSSV
1322SS1872
9140J
SCREti,19ACHINE
IMSS204-24S
9b90b
MSHER,LOCK
HS3S338-42
9b90b
COVER, ENCLOSURE
1322SE19Sb
9140s
SASKET
13228E1938
9740s
ShSKET
1S228E193E
97403
NUT, PLAIN .HEXA60N
HS3S649-2E2
9b90b
SCREW, MCHINE
HSS1S494S
9b90b
NUT, SELFAOCKIN6
HS21044N3
9b90b
COVER , ELEC CONN
D3S999/21FS39S
S1349
ECT
HO
2
ECT
EA
1
ECT
HD
10
ECT
HD
19
ECT
Eb
1
[Cl
EA
3
ECT
EA
2
ECT
HO
2
ECT
En
12
Ecl
HD
12
ECT
EA
1
21
12
PMrr
COVER,ELEC CONN
03S999/23FH21P S1349
ECT
EA
2
21
13
PbHZl
COVER, ELEC CONN
HS17349N3bS
ECT
EA
3
WIRING HARNESS, CONTROL
13228 E1933
97403
ECT
EA
1
21
14
HOHHH
9b90b
21
14A
PAHZZ
STRAP, CABLE, ADJUSTABLE
14 S3368- 1-9
96906
ECT
EA
1
21
148
PAHZZ
STRAP, CABLE
MS3367-5-9
ECT
EA
AR
96906
WIRE, ELECTRICAL
MS5086/2-20-9
ECT
EA
AR
B1349
.21
14C
MDHZZ
21
14D
PAHZZ
CONNECTOR, ELECTRICAL
D38999/24FH21P B1349
ECT
EA
2
21
14E
PAHZZ
CONNECTOR, ELECTRICAL
D38999/247C39S 83149
ECT
EA
1
F-60
(a)
Usnc
OTY
PER
EOUIP
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
(2)
(1)
6.
FM,
so.
21
21
r
89
lTER
NO*
—
ARRV
1s
HDHZ1
PAHZZ
15B
PAHZZ
15C
PAHZZ
15D
PAOZZ
15F
15G
lb
—
b,
AIR
FORCE
—
c.
T-
WV
USRC
—
a.
E-WI!
—
15A
,5E
21
(3)
USRC
w colts
Ssl
VCTO
in
(4)
N#TIONM
STOCK
NUltSER
usmE
ON
CODE
REF NURBER
k HFR COOE
—
5970-01-182-7761
MFHZZ
PAHZZ
ECT
HIRIN6 HARNESS,PHR
1322SE1934
9740s
INSULATION
M23053/5-108-O
81349
—
—
OTY
INC
IN
USMC
OTY
PER
EOUII
.
Jim UN1’
— —
M
1
EA
AR
CONNECTOR, ELECTRICAL
MS17346R36N77S
96906
ECT
EA
1
INSULATION
M23053/5-110-o
ECT
EA
AR
ECT
EA
AR
EA
AR
EA
7
EA
2
EA
1
81349
TAPE
130C
75037
ECT
NIRE, ELECTRICAL
N5086/2-4-9
81349
SPLICE
J-389
98410
ECT
ECT
96906
HOUSIN6,JUNCTION BO
9140s
13229E1935
(awl
m-
ECT
CONNECTOR
MS17346R36N77P
PAHZZ
T)
DESCRIPTION
ECT
—
—
—
F-61
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
Figure F-22.
F-62
Cable Reel Assembly
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
(3)
USHC
(4)
b!
REPL
SS1 FACTOR
NAT IONhL
STDCK
NUMBER
(2)
SHR CODE
(1)
lLLUSTRhTION
1.
:16.
to.
b,
ITEM
NO.
22
1
P4011
530S-00-06S-0S11
22
2
Pholz
s310-oo-b37-9s4i
22
22
22
22
22
22
22
s
4
s
b
7
8
9
a.
ARMY
PAall
b.
AIR
FORCE
c.
d*
NAVY
USHC
a,
531040-732-0550
XBOZZ
Xsolz
PAOZZ
Phozz
Pnozz
Pnozz
S30540-993-lSS1
S310-QO-B09-BS4b
5310-01-012-3595
(b)
(s)
DESCRIPTION
(7)
OTY
USABLE
INC
ON
IN
CODE
IM UNIT
REF NUHBER
kllFR CODE
SCREH,CAP,HEX
l!S90720-b2
9b90b
HMHER,LOCK
HSSS33S-46
96906
NUT, PLAIN HEM60N
HSS19b7-B
9b90b
CASLE REEL MSEIWLY
13228E1873
9740s
SRKT SPT,CABLE REEL
13228E3371
97403
SCREH,MCH,PAN HO
MS3S207-2b7
9b90b
UMHER,FLAT
19S271S’3-B
96906
NUT, PLAIN
b9-5bi-b
30554
STRAP, NYLON,
13228 El E8b-1
97403
ECT
HD
b
ECT
HO
b
ECT
HD
b
ECT
EA
1
ECT
EA
1
ECT
HO
8
ECT
nx
lb
ECT
m
8
ECT
EA
4
(B)
USMC
QTV
PER
EQUIP
F-63
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
Figure F-23.
F-64
Modified Trailer M200A1, Puller Bracket and Storage Pan
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
(4)
ILLUSTRATION
h
NO,
r
4,
ITEM
Moo
ARMY
25
1
PAozl
23
2
Paozz
23
23
25
23
3
4
5
b
b.
MR
FORCE
c,
NAVY
TUsnc
—
b,
5S1
—
0
EPL
ACTOM
NATIONAL
STOCK
WISER
5305-00466-0511
S3104O-O8O-6OO4
Pboll
S31O-OO-W7-4652
Keozz
2590-00-473-6331
Phozz
S30S-00-909-743S
Pnozz
S31O-O1-O12459S
F
{5)
OESCRIPTIOM
WC
SHR CODE
USABLE
ON
CODE
REF NUHBER
k HFR CODE
SCREH,CAP ,HEX
HS9072&62
9b90b
HASHER,FLhT
HS271S3-14
9b90b
NUT , SELF-LOCKIN6
lt651922-17
9b90b
BRACKET ASSEMBLY
13211 E1492-1
9740J
SCREM,HACH,P14N HD
MS3S207-2b4
9b90b
NUT, PLAIN
69-5bl-b
30ss4
ii- iiiirY
Isltc
tic
)TY
)ER
ml?
—
N
In
—
NIT
—
ECT
HD
B
ECT
HD
lb
ECT
HD
4
ECT
EA
2
ECT
HD
2
ECT
EA
2
23
7
Phozz
CHAIN, SMH,t30
TYPE II CLASS 3$1348
ECT
EA
1
23
8
P40ZZ
PIN, HAIR, COTTER
1322SE3390
ECT
EA
1
97403
BRACKET, PULLER
1322SE33S7
ECT
E&
1
97403
BOLT, MCHINE
INS9072S-37
ECT
EA
2
9b90b
NASHER,FLAT
HS271B3-12
ECT
HD
B
96906
NMHER, LOCK
MS3S33S-45
ECT
HD
4
9b90b
NUT , HEKMDN
HS519b7-5
ECT
HO
2
9b90b
SCREH,CAP,HEX
INS9072S-114
ECT
HD
2
96906
NIWHER, FLAT
HS271U3-lE
ECT
HD
4
9b906
ECT
Eh
2
—
—
23
23
23
23
23
23
23
23
?
10
11
12
13
14
15
16
XBOZZ
Phozz
5306-00-225-S501
PAOZZ
531040481-4219
Phozz
53i0-00-407-9Sbb
Phozz
5310-00-s80-7744
PAOZZ
5305-00-071-2070
PAOZZ
5310-00-s09-5998
PhFZZ
53 IO-O1-O7O-21OS
NUT ,PLAIN,HEM60N
lNSS19b7-14
—
—
9b90b
F-65
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
1,
w,
so.
b.
ITEH
NO.
ARHV
23
17
P4011
23
23
23
23
23
23
23
23
23
23
23
23
23
23
23
18
19
20
21
22
23
24
21
2b
27
2s
29
30
31
32
(3)
US14C
(4)
b.
REPL
SS1 FACTOR
NATIONAL
STOCK
NUHBER
(2)
WIR CODE
(1)
ILLUSTRATION
a,
b.
AIR
FORCE
C*
d.
NAVY
USNC
a.
5306-00-223-6499
IBOZZ
PAOIZ
PAOZZ
P&ozl
330%oo-9a9-7434
S310-00-609-6S46
S31041-O12-3S9S
PAOZZ
non
PAOll
xBou
PAOZZ
S30S-00-984-Sb91
421040 -223-4SS7
530s-00-993-1s40
PAOZZ
PAOIZ
PAOZZ
PAOZZ
PAO1l
Xsozz
530s-00-993-1ss1
S30b-00-225-649Q
S31O-OO-O67-7493
531040-904-3EOb
2540-00-903-3S03
(s)
DESCRIPTION
(6)
OTV
USABLE
INC
ON
IN
CODE
Ulll UNIT
REF NU14BER
k RFR CODE
SCREW, CAP, NEM60N
IW0725-34
9b90b
PAN, CABLE STORA6E
1322BE3402
97403
SCREH,HACHINE
HS3S207-2b3
9b90b
HMHER,FLAT
HS27183-6
96906
NUT,PMN
b9-5bi4
SOSS4
STRAP, NVLON
1322EElS~b-2
97403
SRACKET,CABLE PAN
1S22SE3399
91403
SCREN,HACH,PAN HD
NSSS206-311
9b90b
SRACKET,FIRE EXT
13214 E1235
97403
SCREW ,IMCH,PAN HO
HS3S207-2bS
9b90b
STRAP, NYLON,RMLS
i322SElSEb-3
97403
SCREH,ttACH,PIIN HO
llS3S207-2b7
9b90b
SCREH, CAP, HEX
14S9072S-33
9b90b
WASHER , FLAT
HS271B3-13
9b90b
NUT, SELF40CK1N6
HSS1922-9
9b90b
ACCESSDRY BOX
13214E12S6
97403
ECT
Ho
2
ECT
~
II
ECT
HD
4
ECT
Rx
11
ECT
EA
a
ECT
EA
4
ECT
EA
1
ECT
EA
lb
ECT
EA
1
ECT
HD
3
ECT
EA
4
ECT
HO
1
ECT
HD
4
ECT
HD
4
ECT
HD
4
ECT
EA
1
1
F-66
(7)
(8)
WC
QTV
PER
EWIP
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
—.
4,
b,
FIQ,
No*
ITEM
Moo
23
33
(3)
(2 I
SRR COOS
(1)
lLLUSTRhTIOM
b.
AIR
FORCE
F Fi-
(41
DESCRIPTION
c,
d.
WV
WC
—
a,
SS1
—
NATIOML
STOCK
NMSER
USASLE
ON
CODE
REF NUHBER
k ltFRCOOE
rRAILER,H200Al
1322SE1870
XBHH
ECT
ITY
NC
N
INI’
—
USHC
QTY
PER
EQUIP
1
97403
NOTE
;ee TM 9-2330 -20514&P for component
mrts.
—
—
F-67
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
TO-35C2-3-445-14
TM-6115-14&P/1
Figure F-24.
F-68
Fender and Step Assemblies
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
;ism
NO.
b.
ITEH
NO.
24
1
24
24
24
24
24
24
24
24
24
24
24
24
24
24
24
2
3
4
s
b
7
s
9
10
11
12
13
14
1s
lb
(3)
USHC
(2)
SNR COOE
{1)
ILLUSTRATION
a,
ARMY
PAozl
Pholz
Pnozz
XBOZZ
Pnozz
PAOZZ
Paozz
b.
m
FORCE
co
d.
a,
W/v
USMC
SSI
b,
REPL
FACTOR
(4)
NATIONAL
STOCK
NUPISER
530S-00-939-9204
$310-00-s09-ss33
5310-00-0b7-b3Sb
2S10-00-926-3S17
530S40-071-20b9
S31O-OO-SO9-S998
S3104O-22S4993
Xson
Ksozz
Pnozz
P40ZZ
Pfiolz
PAOZZ
PAOZZ
Phozz
PAOU
5305 -oo-06e-osll
5310-oo-oao-boo4
S310-00-087-4bS2
530b-00-22S-S499
5310-00-0S14219
S310-00-9E44EOb
S34041-lSb-b142
(s)
OESCRIPTIOM
(b)
USABLE
ON
COOE
REF NUHEER
& HFR CODE
SCREM,CAP,HEX
14S9072S-187
9b90b
MASHER,FLAT
IIS271S3-23
9b?Ob
NUT, SELF40CKIN8
HSS1922-S7
9b90b
PLATFORM, TAIL6ATE
13214E1298
97403
SCREH,CAP,HEI
t4S90728-113
94906
HASHER,FLAT
HS27iS3-18
9b90b
NUT, SELFAOCK1N6
HSS1922-33
9b90b
BRACKET , RISHT HAND
1322 SE1S74
97403
SRACKET,LEFT HAND
1322SE1S7S
97403
SCREH,CAP,HEX
RS9072S-b2
9b90b
HASHER ,FLAT
MS271S3-14
9b90b
NUT, SELFAOCKIN6
flS51922-17
9b90b
SCREN,CAP,HEXA60N
RS9072S-34
9b90b
HASHER,FLAT
HS27183-12
9b90b
NUT, SELFMCKINS
HSS1922-9
9b90b
ANCHOR ,PLATFORII
13214 E1303
97403
(7}
(a)
aTv
INC
Usllc
QTY
IN
PER
WI! UNIT EOUI~
ECT
El
2
ECT
EA
4
ECT
EA
2
ECT
EA
1
ECT
Ho
b
ECT
Ho
b
ECT
EA
b
ECT
EA
1
ECT
EA
1
ECT
HO
b.
ECT
HO
b
ECT
HO
b
ECT
HD
36
ECT
HO
S6
ECT
HO
7s
ECT
Eh
2
F-69
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
:iB.
NO,
b,
ITE14
No,
(3)
Usnc
(2)
MR CODE
(1)
ILLUBTMTION
a.
ARM
bMR
FORCE
co
~,
fi~
NAVY
Usmc
SBI
b,
REPL
FACTOR
NATIONAL
BTOCK
NURSER
USABLE
ON
CODE
REF NIMBER
& NFR COOE
24
17 XBOZZ
BRACKET, STEP,REAR
13214E1309-1
91403
24
18
IBOZ1
STEP, RMR,ROADSIDE
13228E1B76
91403
24
19
XBOZ1
STEP, REAR, CURBSIDE
13214E12S9
97403
24
20
PAOZZ
S306-00-25S-SS00
SCREH,CAP,HEK
IW072S+
9b90b
24
21
Xsozz
251 O-O1-19W273
FENDER, CURBSIDE
13214E12b3
97403
24
22
180ZZ
2S10-01-213-3242
FENOER,ROADSIDE
13214E12b4
91403
24
23
Pnozz
S305-00-22S-9081
SCREH,CAP HEX
HS9072Sdb
9b90b
24
24
PAOZ1
S306-00-22S-S503
SCREN, CAP ,HEX
HS90725-39
9b90b
STEP, FRONT, CURSSIOE
13228E3389
97403
STEP, FRONT ROADSIDE
1322BE1903
97403
SPACER, PLATE
iJ2i4E12b7-2
9740s
SPACER, PLATE
13214Et2b7-1
97403
24
24
24
24
24
24
24
F-70
2s
26
27
28
29
30
31
XBOZZ
lBOZZ
XBOZZ
XBOZZ
XBOZ1
XBOZZ
XBFZZ
5365-00-94S-5998
536$00-944-2692
(6)
[s)
DESCRIPTION
(4)
CHANNEL
13214E1463
91403
13214E1268
97403
t322SElS71
97403
CHANNEL
CHASSIS
(7)
;OTV
INC
IN
UM UNIT
ECT
Eh
2
ECT
EA
1
ECT
EA
1
ECT
HD
10
ECT
EA
1
ECT
EA
1
ECT
HD
2
ECT
EA
B
ECT
EA
1
ECT
Eh
1
ECT
EA
1
ECT
EA
2
ECT
EA
1
ECT
EA
1
ECT
EA
1
(a)
USMC
QTV
PER
EOUII
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
Figure F-25.
F-72
Remote Control Unit
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
(2)
SNR CODE
ILLUSTRATION
1,
;ie.
No,
ml
10,
2s
1
2s
2
2s
3
a.
},
ARMY
\IR
:ORCE
co
NAVV
m
ii- ii--
m
—
ITY
NC
N
NIT
—
ECT
Eh
1
SCREH,ASSEHBLED W
13214E3290-IB
30S54
ECT
EA
b
PANEL ,RE140TE CTRL
1322BE191S
ECT
EA
1
(4)
(5)
DESCRIPTION
USMC
r
—
a,
USMC
SSI
—
1,
IEPL
‘Aclol
NATIONAL
STOCK
NUMBER
REF NUHSER
k HFR CODE
REHOTE CTRL UNIT
13228E1S69
530S-004S64960
USASLE
ON
CODE
b21040-B31+247
L16HT, INDICATOR
51-3S02-01317-20 72bi9
ECT
EA
2
23
s
$240-00-143-3060
LMP, INCANDESCENT
w4-lol/130
ECT
EA
2
81348
2!
b
53SS-00-916-2060
KNOB, CONTROL , PLMTZ
96906
HS91S28-0F2B
ECT
EA
2
2s
7
)90s-00465-7855
RHEOSTAT
H22-04-OOISIFO 81349
ECT
EA
2
2s
8
!930-00-615-6731
SIMRD,SW ITCH
19S2S224-1
ECT
EA
2
96906
LISHT,ASSV,RED
LH73/lLL12RN2
ECT
EA
2
S1349
\21040-717-2900
2s
10
h210-00-724-2447
L16HT,MSY,SREEN
LH73/1-LC12SN2 S1349
ECT
EA
4
2s
11
\240-00-080-2012
LAHP, INCANDESCENT
ltS2S237-327AS15 96906
ECT
EA
k
25
12
!930-00-68S-1629
WTCH,TOSSLE
RS24S23-23
ECT
EA
2
96906
SHI TCH, TUSSLE
M24S23-27
ECT
EA
2
96906
WIT CH,TOSSLE
HS27407-2
ECT
EA
2
9h90b
UIRIN6 HARNESS,
13228E3370
ECT
EA
1
97403
—
—
2s
2s
25
13
j930-00-bS3-1633
!93040-9064477
14
15
—
ER
QUIP
—
97403
4
9
ITV
97403
25
2s
Isltc
F-73
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
(2)
(3)
SRR coos
Im
(1J
ILLUSTRATION
;ie.
de
b,
c.
d.
MM
m
FORCE
SW
Usllc
a,
b,
RWL
SS1 FSCTOR
!
STOCX
NuMER
!io
MO,
25
15A
PAFZZ
25
15B
PAFZZ
5940-00-557-1629
25
15C
PAFZZ
5975-00-944-1499
25
II
PAFZZ
F-74
I
I II
7
m
Mtlomsl
m
15D
(s)
DUCRIPTION
(4)
5975-00-111-3208
USASLE
on
CODE
REf SUIPBER
k IVR COOE
TERMINAL LUG
NS25036-102
96906
TERMINAL LUG
MS25036- 149
96906
STRAP
MS3368-1-9A
96906
STRAP
MS3367-5-9
96906
UIRE, ELECTRICAL
M5086/2-20-9
96906
INC
IN
U/n
w’
ECT
EA
30
ECT
EA
6
ECT
EA
1
ECT
EA
AR
ECT
CONNECTOR, ELECTRICAL PLUG
038999 /24-FG39P 81349
ECT
HOUSING, RMOTE CNTRL
13228 E1914
97403
ECT
(a)
Usnc
OTY
PER
EQUIP
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
Figure
F-76
F-26.
Interconnection
Cables
TM-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
—
;ik
NO.
ii-
ARHY
—
—
2!
1
24
24
24
2h
24
2b
2b
2b
2b
2b
2b
2b
2b
2b
2b
—
a,
lTEPI
NO,
{3)
USMC
(2)
SHR CODE
(1)
ILLUSTRATION
b,
AIR
FORCE
—
co
z--
—
a,
NAVV
—
USMC
—
Ss
—
2
c-?EPL
FACT(
(4)
NATIONAL
STOCK
NUMBER
5310-00-0574s73
4
530$00454-M49
S3b$01-0R2-303b
s
b
1
S31O-OO-177-1332
8
9
5310-00457-0573
10
130S-00-0S4-5b49
11
12
i93S-01474-4602
13
14
I3104O-I77-1332
1s
i31040457-0S73
lb
,305 JJ0-0S4-5b49
—
——
G
5 -iii-
M
—
)TV
[NC
N
INI’
—
ECT
El
1
ECT
EA
2
ECT
HO
2
ECT
HO
2
ECT
E#
2
ECT
EA
2
ECT
EA
1
ECT
EA
2
ECT
HO
2
ECT
HO
2
ECT
EA
2
ECT
M
2
ECT
M
1
ECT
;~
2
ECT
4D
2
ECT
ID
2
—
—
USMLI
ON
CODE
IEF NU14BER
I 14FR CODE
—
5310-00-177-13~2
3
(s)
DESCRIPTION
ABLE ,CONTROL, 100FT
13228E1946
97403
LOCKNUT
HS17830-04C
9690b
W4ER,FLAT
NA8b20C4
S020S
SCREH,HACH,PAH HO
HSS19S7-lS
9b90b
RIN6 RETAININ6
7SSO02A7780-1
07990
OUST COVER
D3S999/32H21R
01349
ABLE , POHER,2SFT
1322tiE1944-2
97403
LOCKNUT
HS17830-04C
9b90b
MASHER , FLAT
NASb20C4
S020S
SCREN,IMCH,P14N HO
IIS51957-15
9b90b
RIN6, RETAININB
67025S-90
Ob324
COVER, ELECTRICAL
HS17350C3b
9b90b
IBLE,POHER,SFT
1322QE1944-1
97403
LOCKNUT
IIS17S30-04C
9b90b
HASHER , FLAT
NfiSb20C4
S0205
SCREW, MCH, PhN HD
HSS19S7-lS
9b90b
US14C
OTV
PER
EQuIP
F-77
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
1,
~16.
10,
b.
ITEH
NO.
2b
17
2b
2b
2b
2b
2b
2b
2b
2b
18
19
20
21
22
23
24
2s
2b
2b
2b
27
Zb
2b
26
28
29
30
a*
ARMY
(4)
b.
AIR
FORCE
c’
d.
b.
REPL
SS1 FACTOR
NATIONAL
STOCK
NUHBER
NhVV
USHC
a.
PAOZZ
Phou
591541 -07b-4b02
PBOOO
PAou
Pfiozl
Pkou
Pdozz
531 O-OO-I77-1332
5310-004s7-0s73
530$00-0S4-5b49
S3b5-01-0B2-303b
PAOZZ
PAon
PAon
Phozz
5310-00-177-1332
531040-0574573
5305-00-034 -5b49
53b541-0B2403b
PAou
31
PBODD
26
32
Mou
RIN6, RETAININS
670258-90
Ob324
COVER, ELECTRICAL
HS17350C3b
9b90b
CABLE , CONTROL,SFT
1S22SE194S-1
97403
LOCKNUT
M17B30-04C
9b90b
HASNER,FLAT
NMb20C4
8020s
SCREW, MCH , PAN HO
HSS19S7-15
9b90b
R!N6 RETAIN1N6
7S3002A77E0-1
079%
5310-00-177-1332
EA
2
ECT
EA
2
ECT
EA
1
ECT
EA
2
ECT
HD
2
ECT
HD
2
ECT
EA
2
ECT
EA
2
ECT
EA
1
97403
ECT
9b90b
HASHER,FLAT
NMb20C4
S0205
SCREH, MACH, PAN HD
HSS19S7-15
9b90b
RIN6 RETA1NIN6
7SSO02b7780-1
S7990
DUST COVER
D3S999132M23R
S1349
LOCKNUT
M17B3044C
ECT
81349
LOCKNUT
HS17B30-04C
CABLE, PAMLLELIN6
1322BE1947
(7)
OTV
USABLE
INC
ON
IN
CODE
WI! UNIT
REF NLMBER
k HFR COOE
CABLE ,CONTROL , 2SFT
1322SE 1945-2
PSODO
(h)
(s)
DESCRIPTION
DUST CDVER
D3S997132W23R
Paon
2b
F-78
(3)
USHC
(2)
WI CODE
(1)
[LLUSTRt4T10N
‘EA~ z
ECT
HQ
2 .
ECT
i Ho
2
ECT
EA
2
ECT
EA
2
ECT
EA
1
ECT
EA
2
97403
9b90b
(8)
Usmc
OTY
PER
EOUIP
1.
1.
1.
),
us,
ITEM
10.
lRHV
iIR
:ORCE
10,
(3)
USHC
(2)
SRR CODE
(1)
:LLUSTRhTION
c,
#
W/v
SHC
—
.
SI
—
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
—
ii ii--})
(4)
DESCRIPTION
rY
1.
IEPL
‘ACTOR
NATIONAL
STOCK
WISER
UMSLE
ON
CODE
EF NUMBER
HFR CODE
2b
33
310-004574573
WASHER , FLAT
NASb20C4
S0205
2b
34
305-00-0S4-5b49
SCREN, MCI+, PAN HD
HS519S7-15
96906
RIN6, RETAININ6
S702S0-5S
Ob324
DUST COVER
D38999132H1SR
81349
2b
2b
—
Ib541-254-b47h
3s
3b
—
Ic
i
‘H
—
(11
—
ECT
ID
2
ECT
ID
2
ECT
A
2
ECT
,A
2
—
—
Isilc
ITY
‘ER
:auIP
F-79
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
Figure F-27.
F-80
Accessories and Schematics
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
(1)
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REF NUMBER
L MFR CODE
EITINBUWNER,FIRE
13228E3394
97403
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B3BA7S11
09b47
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iS211E7S41
97403
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1322BE1927
97403
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1322SS1926
97403
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1322BE192E
97403
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1322BE192S
97403
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?74-144
45225
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3598
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13228E3384
97403
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F-81
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
(1)
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—
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—
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k lfFR CODE
—
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PAFZi
WQ-01-t02-17k:
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7s037
CABLE,S CONDUCTOR
13222E1432
97403
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13222E1434
91403
1322BE1882
97403
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13228E19T2
97403
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PA.UZ
1322SE1938
97403
1322SE1940
97403
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F-82
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130C s/41N
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DESCRIPTION
USNC
z—
(4)
72040421-2202
NSULhTION
1322SE1942-1
97403
NSULATION
1322BE1942-2
97403
NSULAT!ON
1322BE3373-1
97403
NSULATIDN
1322aE3373-2
97403
NBULATION
1322S23S73-3
97403
ISULATIDN
13228E33734
91403
ISULATIOM
i32M33734
97403
:NSULATIW
lS22tE33734
91403
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72-20S0-2
30s54
ECT
v
ECT
v
ECT
v
ECT
v
ECT
v
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v
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v
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TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
(1)
ILLUSTRATION
;is.
M.
b.
ITEH
NO,
(2)
SHR CODE
a.
ARHY
b.
AIR
FORCE
(3)
USHC
c.
d,
a,
N4VY
IJBNC
SSI
b.
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FACTOR
(4)
NATIONAL
STOCK
NWISER
MD1l
(s)
DESCRIPTION
597040-740-2971
SLEEVIN6,1NSULATION
f1230S3/5-107-9
ECT
FT
v
ECT
FT
v
ECT
FT
v
S1349
SLEEVING, INSULATION
lt230S3/5-10S-O S1349
ECT
FT
v
PADZZ
5970-00-91 s-9186
SLEEVING, INSULATION
R2SOS3/S-100-2 S1S49
ECT
FT
v
.!!4)22
S970-00-944-1329
SLEEVIN6, INSULATION
14230S3/S-109A 81349
ECT
FT
v
SLEEVING, INSULATION
M23053/5-108-9
81349
ECT
FT
v
PAOZZ
s970-oo-914-311e
SLEEVIN6, INSULATION
H230S3/5-109-O 81349
ECT
FT
v
PA02Z
S970-00-914-3117
SLEEVING, INSULATION
R230S31S-109-2 01S49
ECT
FT
v
PAOZZ
5970-0041 s-1300
SLEEVIN6, INSULATION
l!23053/S-110-O 81349
ECT
FT
v
14011
5970-00422-277S
SLEEVING, INSULATION
l1230S3/S-110-9 81349
ECT
FT
v
PAOZZ
S970-QO-B12-1358
SLEEVINS, INSULATION
19230S3/S-111-9 81349
ECT
FT
v
Pwll
S320-00-6S0-3266
R IVET,BLIND
H2424311-A602
ECT
HO
v
61349
R IVET,BLINO
R2424311-BS02
ECT
EA
v
S1349
ECT
EA
v
ECT
FT
v
ECT
FT
v
ECT
FT
v
PA DZZ
PAOZZ
PA Ozz
PA DZZ
S32O-OO-3O3-1O6O
6145-01 -0S7-1271 H IRE, ELECTRICM ,
HS08b/2-12-2
b 14S-00:162-S846
b 14S-00-570-660S
61349
W IRE, ELECTRICAL
lfS06b12-lb-O
B1349
U IRE ,ELECTRICAL ,
HSOSb12-Ib-9
B1349
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f150S6/2-16-O
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PER
EOLIIP
S1349
5970-00-612-2947
PRoll
(B)
QTY
INC
IN
M UNIT
PADZZ
PAOZZ
4
(7)
24600
CABLE
Hls4sb/1-14
PADZZ
USABLE
ON
COOE
REF NUMBER
k NFR COOE
CABLE,37 COWOUCTOR
99s-14s
PAOZZ
(h)
51349
i
F-83
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
TO-35C2-3-445-14
TM-6115-14&p/1
—
L
—
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(2)
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(1)
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1= 1-1-- F
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10,
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USMC
b.
REPL
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—
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(s)
DESCRIPTION
141
NATIONAL
STOCK
NuRSER
REF NUHBER
b flFRCOOE
PAD2Z
114s40-s51-s50s
HIRE, ELECTRICAL
nsow2-20-9
PADZZ
14540 -57 E4595
WIRE, ELECTRICAL,
HSOW2-4-9
PADZZ
)70-01-158-515’?
ILOIN6 COMPOUND
P4011
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on
CODE
INC ~
IN
[P
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iCT
SL\V
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S1349
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8134s
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HIL+24041
si349
030-00481-2339
iALIN6 CORPOUNO
l!lL-5-22473
81s49
PAFll
975-QO-074-2072
IRAP, CMLE
IIS3367-1-9
96906
PAFZZ
97540-111-3208
lRAP, TIEOOUN
Pls33h7-5-9
9b90b
PAF1l
i97wo-944-i499
TRAP, CABLE
HS336S-1-9h
9MOb
PAoll
4720A)N01-9299
Phozl
614s-00-39s-s795
PnFzz
3439-00-273-2534
F-84
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ECT
ST
ECT
)
I
ECT
D
/
ECT
o
t
1“
ECT
FT
v
ilRE,ELECTRICAL
wk343c06DlT S1348
ECT
FT
v
SOLOER
ECT
LB
v
ECT
EA
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RS52130M206R
SNbOHRP2
96906
S134B
Phozz
ThPE , UOTH
TYPE 11
PAO1l
CH141 N, SM4,#30
TYPE 1! CLASS S 8134i
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TAPE,PKS , WATERPROOF
TYPE IV
ECT
R
v
—
—
7510 -01-12B-1187
PAOZ
—
iCT
—
— —
S134S
01349
J
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
SECTION III.
Not app
SPECIAL TOOLS LIST
cable.
SECTION IV. NATIONALSTOCK ANDPARTNUMBER INDEX
STOCK NUMBER
5310-00-004-5038
5310a0-004+038
5365-00-015+800
5920-00+33+266
530540-036-6968
5305-00-036-6968
5305+0+36+968
5305-004)38+089
5310+0-045+3299
5310-00+45<299
5310-00-045-5218
5310-00-052+632
5310 -00+52< 632
530540-054-5649
5305-004544649
5305-00454-5649
5305-00-054+649
5305-00+54-5649
5305404544649
5305-00-054&655
531040+57-0573
5310-00-057+573
5310-00-0574573
5310-00+57+573
5310-00+57-0573
5310-00+57-0573
5305-00+59-3660
531040+63–7360
5310-00-063-7360
5315-00-063-9016
2910-00+66-1235
5310-00-067-6356
5310-00-067+357
5305-00+68-0500
5305-00-068-0500
5305-00-068+500
5305-00-068+500
5305+0+684)500
5.305-00468-0500
5305-00+68-0500
5305-00-068-0500
5305-00+68-0500
5305+0+68-0500
5305+0468+500
5305 A30+68-0501
5305+0+68-0502
5305-00-068-0502
5305-00-068-0502
5305-00468-0502
FIGURE
NO.
ITEM
NO.
2
19
16
11
15
18
25
18
3
21
4
13
18
26
26
26
26
26
26
4
26
26
26
26
26
26
1
15
6
9
5
11
4
18
13
27
24
18
3
4
5
6
7
9
13
15
17
18
18
1
3
6
9
18
13
2
10
6
4
14
7
15
4
10
16
22
28
34
5
3
9
15
21
27
33
5
4
21
4
3
3
4
18
1
1
3
3
2
1
1
1
6
18
22
1
7
6
3
STOCK NUMBER
5305 A30-068+51 1
5305+0+68+51 1
5305-00-068-0511
5305-00+71-1787
5305+0-071-1787
5305+ OA71-2069
5305-00-071-2069
5305-00471-2070
530540 q71–2078
5305-00+71-2510
5975-00+74-2072
6240-00+80-2012
5310-00-080-6004
5310-00-080-6004
5310 -00<80+004
8030-00+81-2339
5310-00+814219
5310-00+814219
5310-00+)814219
5310+0+82–1404
5310-00+874652
5310-004)874652
5310-00-087-7493
5975+0–111–3208
5975-00-111-3208
5975-00-111-3208
5975-00-111-3208
5975-00-111-3208
5940-00-115-2684
5940 -00-1 15–2684
6240-00-143-3060
594040–143+775
5940-00-1434777
5940-00-1434794
6145-00-16245848
5961-00-165-2903
5310-00-177-1332
5310-00-177-1332
5310-00-177-1332
5310-00-177-1332
5310-00-177-1332
5310-00-177-1332
7240-00-177-6154
5305-00-191+.226
5305-00-191-6226
6110-00-201+015
5940-00-204-8966
5940-00-204-8966
5310+0–209-0965
FIGURE
NO.
ITEM
NO.
22
23
24
13
14
20
24
23
19
14
1
10
8
3
1
5
14
3
14
BULK
25
13
23
24
BULK
8
23
24
18
23
24
23
11
12
12
12
BULK
1
1
25
18
18
18
BULK
18
26
26
26
26
26
26
27
15
18
18
18
18
13
1
11
14
2
11
15
11
14
55
3
12
30
19
6
12
17
3
8
5
39
41
38
46
2
8
14
20
26
32
;
9
22
35
48
9
F-85
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
STOCKNUMBER
5310-00-209+965
42 10-00-223+857
5305-00-2254843
53054)0-225-3843
5305-00-2254843
5310-00-225-6993
530640-2254498
5306-00-2254499
5306-00-2254499
530640 -225 -s499
5306-00-225-8499
5306-00-225+50 1
5306-00-225-8503
5305-00-225-9081
5305-00-225-9081
5306-00-2264825
5306-00-2264825
5306-00-2264825
5306+0-2264825
5330-00-231-6633
5305-00-253+615
5306-00-255-8500
3439 -00-273 ~2536
5940-00-283+280
5320-00+03-1060
5320-00+03-1060
5320-00+03-1060
6145-00-395-8799
5310-00-399-0995
5310+0+00+495
4720-00401-9299
5310-00407-9566
5310+0407–9566
5310-00-407-9566
5310+0407–9566
5310+0407–9566
5310-00407-9566
5310-00420-6064
5930-00430-532
5945-00435-1833
2940-00463-1362
2590-00-473-6331
9905+04774137
3030-00-517-4586
6150-00+19-2714
4730-00--541-6584
5305-00-543-2419
5935-00-548-1529
5940-00-549-6581
5940-004494583
5940+0-557-1629
6145-00-%78-6595
6145-00-578-6595
6145-004784595
614540478-6605
6145-00-578-6605
F-86
FIGURE
NO.
ITEM
NO.
14
23
8
4
25
1:
24
23
8
11
23
24
23
24
21
24
7
10
16
20
14
4
24
BULK
18
5
8
BULK
BULK
20
16
BULK
1:
11
7
29
14
1
17
13
10
24
1
23
5
1
1
12
6
11
20
37
5
1
11
5
7
8
10
16
20
23
16
14
15
14
23
4
16
18
14
13
12
1
1
18
11
1:
2
2
13
12
4
13
7
16
4
12
9
44
7
13
2
17
16
36
14
26
BUhi
11
12
21
7
STOCK NUMBER
6145-00-578-6605
6145-00-5784605
6145-00478-6605
5310-00-582+965
5310-00-582+965
5310-00+82+965
5310-00+82+965
5310-004824965
5310-00-582+965
5310-00+82+965
5310-00-5824965
53104IO-582+965
5310-004824965
5310-00-582+965
5310-00+82+965
5310+0+82+965
5310-00+82+965
531040-584+272
5310404844272
5950-00-601+296
5930-00415-6731
5935-00422-2924
5935-00-622-2929
4720-00-625-2202
472040+25–2202
5340-00-626-9402
5330-00430-3559
531040-637-9541
5310-00-637-9541
5310-00-637-9541
5310+0+)37-9541
5905+0+42–1955
5905-00-665-7855
5930-00+83-1629
5930-00+83-1633
6210-00-717-2900
6210-00-724-2447
530540–724-6760
5310-00-7324558
5310-00-732+558
531 O-OO-732-O558
531 O-OO-732-O558
5970-00-740-2971
5310-00-761+882
531 OA3O-761+882
5310-00-761-6882
5310-00-761+882
5310-00-761+882
5310+0–761+882
5310-00-761-6882
531 O-OO-761+882
5305-00-782-9489
5310-00+09+058
531 O+ O+IO94O58
5310-00+094058
FIGURE
NO.
12
12
BULK
1
3
4
5
6
7
8
9
11
13
14
15
17
18
19
20
18
25
12
12
14
BULK
13
13
1
13
19
22
18
25
25
25
25
25
19
1
11
13
22
BULK
1
5
6
7
8
9
11
14
19
3
6
9
ITEM
NO.
13
16
21
2
2
2
4
2
5
3
3
2
10
2
2
7
4
2
56
8
4
10
8
10
12
12
15
2
2
50
7
12
13
1:
11
11
22
16
3
20
8
;
7
5
4
9
10
3
5
4
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
STOCK NUMBER
5310-00+094058
5310-00-8094058
531 O+IO+O9-5998
531 O+ OA3O9-5998
531 O-OO+O9-5998
5310-00+09-5998
5310+0+09-8533
5310-00-809-8544
5310+0+09-8544
5310-00+09-8546
5310-00+09-8546
5970+0+12–1358
5970+0+12–2967
5970-00+12-2967
5970-00415-1300
5310-00-8204653
5310-00+204653
5970+0-822-2775
5940-00-825-5041
621 O-OO+31+247
5905-00-843-2809
5315-00+344-3662
5320+0+50–3266
5320+0-850-3266
.5320 -00+350-3266
6145-00-851+505
5945-00-855-7478
5905-00+60-6276
5310-00477-5797
5975-00+178-3791
5310+0-880-7744
531 O+ O+!8O-7744
5310+0+80–7744
5310-00480-7744
531 O-OO+8O-7744
5305+0+89-3001
6625 -00 A392-4342
5310-00+97-6082
2540-00-903-3503
5930-00-906-3477
4730-00-909-8627
5970-00-914-3117
5970-00-914-3117
5970-00-914-3118
5970-00-914-3118
5970-00-915-9186
5970-00-915-9186
5355-00-916-2060
2510-00-926+517
5310-00-934-9739
531040–934–9747
5310-00-934-9751
5310-00-934-9757
5310-00-934-9757
5305+0–939–9204
FIGURE
NO.
ITEM
NO.
11
18
19
20
23
24
24
3
18
22
23
BULK
11
BULK
BULK
2
19
BULK
18
25
18
16
6
9
BULK
BULK
18
18
21
27
7
8
10
20
23
18
18
4
23
25
14
1
BULK
1
BULK
11
BULK
25
24
18
18
15
3
21
24
2
5
5
3
15
6
2
7
16
7
20
11
2
14
40
4
51
7
9
12
23
49
10
9
7
12
3
14
13
42
20
13
32
14
;
7
12
6
4
11
12
9
5
8
1
STOCK NUMBER
5305-00-942-2196
5305-00-942-2196
5970-00-944-1329
5970-00-944-1329
5975-00-944-1499
5975-00-944-1499
5975-00-944-1499
5975-00-944-1499
5975-00-944-1499
5365 -UO-944-2692
5365-00-945-5998
5310-00-951-7209
5940-00-983-6096
5310-00-984-3806
5310-00-984-3806
5305-00-984-5691
5305-00-984-6193
“5305-00-984-6193
5305-00-984-6194
5305+0–984-6195
5305-00-984-6198
530540–989-7434
5305-00-989-7435
5305+0-993-1848
5305g0–993–1851
5305-00-993-1851
59354)1+05-9925
5305-01-006-2052
5940-01-4)094763
5310-01+)12-3595
5310 -1-012q595
5310--01+12-3595
53104)1+12+3595
512041-013-1676
5940-01+313-8287
5310-01-017+876
5905-01+)21-9133
53404)1+324-9937
5310-01+70-2105
5310-01+370-2105
5310-01470-2105
5935-01-071+331
5935-01475-9503
5935-01-0764602
5935-01+764602
5935-014764602
5365-01+)824036
5365+1-0824036
5365-01+)82-3036
6145-01-087-1271
7510-01-128-1187
5935-01-128-1348
5935+1-147+902
5925-01-154+265
5320+1-155-6120
FIGURE
NO,
ITEM
NO.
1
19
11
BULK
11
12
12
12
BULK
24
24
2
18
23
24
23
18
21
18
3
13
23
23
23
22
23
18
21
4
11
22
23
23
27
12
4
18
13
19
20
23
18
11
4
26
26
26
26
26
BULK
BULK
4
12
18
15
26
1
13
20
5
9
19
28
27
3
43
31
15
24
17
3
19
8
6
19
5
26
6
28
54
9
16
6
8
6
21
1:
15
52
3
9
4
16
27
16
10
12
18
5
23
29
8
2:
12
F-87
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
FIGURE
NO.
ITEM
NO.
5340-01-156-6142
24
16
5970-01-158-5159
5935-01-1754419
593541-176-1708
5970-01-182-7761
2510-01-195-4273
5935-01-196-1094
5306-01-197-1738
5935-01-197-2625
5935-01-1994442
BULK
18
18
BULK
24
18
1
18
18
STOCK NUMBER
F-88
53
14
21
34
14
26
31
STOCK NUMBER
5935-01-202-6206
6140-01-209+410
5935 -Q1-2114440
2510-01-213-3242
6115-01-213+791
5935-01-223-1563
5935-01-226-8365
5935+1–229-0140
491 O-O1-246-O923
5365-01-2544476
FIGURE
NO.
ITEM
NO.
18
1
18
24
9
18
18
18
20
26
33
15
30
22
13
28
29
32
6
35
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
PART
NUMBER
72–2057
72–2067–1
72–2121
72–2204
72–2241
FSCM
FIG.
NO.
ITEM
NO.
30554
13
12
30554
“30554
30554
30554
1
9
18
18
14
13
56
54
PART
NUMBER
FSCM
FIG.
NO.
ITEM
NO.
755002 A7780–1
755002 A7780–1
755002 A7780-1
838A7511
87990
87990
87990
09647
26
26
26
27
5
23
29
2
F-89
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
PART
NUMBER
MS90725-3
MS90725+
MS90725+
‘MS90725-3
MS90725+
MS90725-3
MS90725-3
MS90725-3
MS90725<
MS90725-34
MS9072544
MS90725-34
MS90725+34
MS90725+35
MS90725+6
MS90725+6
MS90725+7
MS90725q9
MS90725+
MS90725-6
MS90725-6
MS90725-6
MS90725+
MS90725+0
MS90725+0
MS9072546
MS90725-86
MS90728-113
MS90728-113
MS90728-122
MS90728-13
MS9072842
MS90728-32
MS90728+2
MS90728+2
MS90728+33
MS90728+1
MS90728+2
MS90728+2
MS90728+2
MS90728-66
MS90728q
MS90728-+
MS90728+
MS91528+F2B
MSA200
NAS561C8-22
NAS620C4
NAS620C4
NAS620C4
NAS620C4
NAS620C4
NAS620C4
P15121+
P15121-64
F-90
FSCM
FIG.
NO.
ITEM
NO.
PART
NUMBER
FSCM
96906’
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
03776
80205
80205
80205
80205
80205
80205
80205
45722
45722
4
5
6
7
9
13
15
17
18
8
11
23
24
24
21
24
23
24
1
3
6
9
18
1
19
13
14
20
24
19
14
7
10
16
20
23
13
22
23
24
19
8
8
14
25
18
13
26
26
26
26
26
26
13
15
1
1
3
3
2
1
1
1
6
14
1
17
13
20
1
23
10
24
22
1
7
6
3
26
1
8
3
1
5
3
14
5
1
1
12
29
13
1
1
10
10
4
18
11
6
20
4
3
9
15
21
27
33
10
8
P15121-64
P74–144
QQ-W+43C06B1T
RPO025–2120GBA
RW33V1OO
RW33V150
SN60WRP2
TLF–1213-B-JAM
TYPE IV
U250
W–L–101/130
XBN8190
1o--552943-239
130C 3/41N
13211E1492-1
13211E6730
13211E7541
13214E1235
13214E1256
13214E1263
13214E1264
13214E1267–1
13214E1267–2
13214E1298
13214E1303
13214E3290–18
13214E3290–18
13214E3290–18
1569A
1N5619
202568A
2301-38
287269A
3598
3805
38TB20
40819
51--3502+1317-20
511+61800<0
511-06180040
511+81800+0
511-081800+0
601J
69–561+5
69–561+
69–561+5
69–561+
69-692-1
69–768
70–1310
70–1582-6
70-4020
72–2050–2
72–2050–2
72–2053
45722
45225
81348
30554
81349
81349
81348
82458
81349
01652
81348
90202
77820
75037
97403
97403
97403
97403
97403
97403
97403
97403
97403
97403
97403
30554
30554
30554
28265
14099
28265
23663
28265
07464
05748
81349
97403
72619
78189
78189
78189
78189
83330
30554
30554
.30554
30554
30554
93742
30554
30554
30554
30554
30554
30554
FIG.
NO.
18
27
BULK
18
18
18
BULK
4
BULK
13
25
20
4
BULK
23
4
27
23
23
24
24
24
24
24
24
15
18
25
16
18
16
11
16
27
20
18
14
25
4
18
13
18
18
11
22
23
23
4
18
14
1
14
14
BULK
13
ITEM
NC).
9
8
52
50
51
15
10
5
6
8
4
12
3
::
:;
28
27
4
16
5
13
2
5
46
4
9
6
9
11
43
6
4
4
21
7
15
44
6
8
6
21
16
22
13
15
16
8
3
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
PART
NUMBER
FSCM
FIG.
NO.
ITEM
NO.
MS3452W24–28S
MS3452W28–12S
MS3452W32–7P
MS3452W36–7P
MS3452W36–7S
MS3456W14S-6P
MS3456W20–29P
MS3456W22–19P
MS3456W24–28P
I’IS3456W24-28S
MS35206-231
MS35206–243
MS35206-245
MS35206–246
MS35206–247
MS35206–249
MS35206-250
MS35206+11
MS35207–263
MS35207–264
MS35207–265
MS35207–267
MS35207-267
MS35338-42
MS3533842
MS3533844
MS3533844
PLS3533844
MS3533844
MS35338-44
MS3533844
MS3533844
MS3533844
MS3533844
MS3533844
MS3533844
MS3533844
MS3533844
FLS3533844
MS3533845
MS35338--45
MS3533845
MS3533845
MS3533845
MS3533845
MS3533846
MS3533846
MS35338-46
MS3533846
MS3533847
MS35338+7
MS3533848
MS3533848
MS35338-50
MS35338450
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
18
18
18
18
18
12
11
12
12
12
18
18
21
18
3
18
13
23
23
23
23
22
23
3
21
1
3
4
5
6
7
8
9
11
13
14
15
17
18
7
8
10
16
20
23
1
13
19
22
13
14
19
20
2
19
32
33
29
34
26
4
16
3
2
10
42
18
3
19
8
17
6
24
19
5
26
6
28
6
4
21
2
2
2
4
2
5
3
3
2
10
2
2
7
6
13
2
2
13
12
12
15
2
2
9
4
4
2
2
14
PART
NUMBER
MS35649–242
MS35649–262
MS35649–282
MS35649–282
MS35650-302
MS35691+6
MS35842–13
MS39326-17
MS45904+59
MS51066+7
MS51849&5
MS51922–17
MS51922–17
MS51922–33
MS51922–57
MS51922–9
MS5192241
MS51957–15
MS51957–15
MS51957–15
MS51957–15
MS51957–15
MS51957~15
MS51957+1
MS51958+4
MS51967–14
MS51967–14
MS51967–14
MS51967–2
MS51967–2
MS51967–2
MS51967–2
MS51967–2
MS51967–2
MS51967–2
MS51967–2
MS51967–20
MS51967–20
MS51967–5
MS51967-5
MS51967+
MS51967+
MS51967-6
MS51967+
MS51967-8
MS51967+
MS51967+3
MS521301A206R
MS75004–1
MS75004–2
MS75009+33
MS90725–114
MS90725–174
MS90725–187
MS90725+
FSCM
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96!306
96906
96906
96906
96906
96906
96906
96906
96906
96506
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
FIG.
NO.
ITEM
NO.
18
18
3
21
15
4
14
14
18
16
21
23
24
24
24
23
24
26
26
26
26
26
26
4
11
19
20
23
1
5
6
11
12
5
8
9
13
1
7
4
9
9
3
12
7
.3
31
15
4
10
16
22
28
34
5
5
9
4
16
20
8
6
:
9
11
14
2
19
7
8
10
20
23
1
11
13
22
BULK
1
1
18
23
19
24
3
+
5
4
9
1
15
7
12
3
14
13
11
22
16
3
17
16
49
14
11
1
18
F-91
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
PART
NUMBER
G70258-68
LH73/1-LC12GN2
LH73/l LL12RN2
M22+4-00181FD
M23053/5-107-9
M23053I5-108-o
M23053/5-108-O
M23053/5-108-2
M23053/5-108-2
M23053/5-108.4
M23053/5-108-6
M23053/5-109+2
M23053/5-109-O
M23053/5-109-2
M23053/5-109-2
M23053/5-110-O
M23053/5-llC)-9
!423053/5-1114
M24243/1-A602
M24243/1-A602
M24243/1-A602
M24243/1-B502
M24243/1-B502
M24243/1-B502
M24243/lB503
M5086/2–12–2
M5086/2–16+1
M5086/2–16–9
M5086/2–16–9
M5086/2–16–9
M5086/2–16-9
M5086/2–16–9
M5086/2–20-9
M5086/24-9
M5086/2+–9
M5086/24-9
M5757/23-003
MIL-M-24041
MIL-S-22473
MS15795–918
MS16562+2
MS17143-6
MS17350C36
MS17350C36
MS17350C36
MS17830-04C
MS17830-04C
MS17830-04C
MS17830+4C
MS17830-04C
MS1783044C
MS20659-118
MS20659-118
MS21044N3
MS21318-21
F-92
FIG.
ITEM
FSCM
NO.
NO.
06324
81349
81349
81349
81349
x
25
25
81349
81349
81349
81349
81349
81349
81349
81349
81349
81349
81349
81349
81349
81349
81349
81349
81349
81349
81349
81349
81349
81349
81349
81349
81349
81349
81349
81349
81348
81348
81348
96906
81349
81349
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
;;
BULK
11
BULK
11
BULK
11
BULK
1
BULK
1
BULK
BULK
BULK
BULK
6
9
BULK
:
BULK
15
BULK
BULK
11
12
12
12
BULK
BULK
11
11
BULK
15
BULK
BULK
4
16
18
4
26
26
26
26
26
26
26
26
1
1
21
4
9
7
11
12
13
7
2
9
12
5
1
12
21
7
13
16
14
26
7
14
7
40
10
12
18
2
8
::
26
32
3
8
10
11
PART
NUMBER
MS24166-D1
MS24523–23
MS24523-27
MS25036–102
MS25036–102
MS25036–106
MS25036–112
MS25036-149
MS25036-153
MS25036–156
MS25036–157
MS25043-18DA
MS25043–22DA
MS25224–1
MS25237+27AS15
MS27183-10
MS27183-10
MS27183-10
MS27183–10
MS27183–10
M.S27183-12
MS27183–12
MS27183–12
MS27183–13
MS27183–14
MS27183–14
MS27183–14
MS27183–18
MS27183–18
MS27183–18
MS27183–18
MS27183–22
MS27183–23
MS27183+
MS27183–7
MS27183–7
MS271834
MS27183+
MS27407–2
MS3367–1–9
MS3367-5+
MS3367-5+J
MS3367+4
MS3367-5-9
MS3367-5-9
MS3368-l+A
MS3368-1-9A
MS3368-1–9A
MS3368-1-9A
MS3368-l+A
MS3452W14S4S
MS3452W18-llS
MS3452W20–27S
MS3452W20–29S
MS3452W22-19S
FSCM
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
FIG.
ITEM
NO.
NO.
18
25
25
18
18
18
18
18
12
18
18
18
18
25
25
3
6
9
11
18
8
23
24
23
13
23
24
19
20
23
24
2
24
18
3
18
22
23
25
BULK
11
12
12
23
12
13
35
48
37
38
36
18
39
41
53
14
8
11
3
5
4
2
5
15
11
14
30
14
2
11
5
3
15
6
3
2
55
7
16
7
20
14
19
6
12
17
BUii
11
12
12
12
BULK
18
18
18
18
18
20
5
9
19
28
27
25
30
31
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
APPENDIX G
ILLUSTRATED LIST OF MANUFACTURED ITEMS
6-1. Scope
This appendix includes complete instructions for making items authorized to be
manufactured or fabricated at intermediate direct support maintenance.
G-2. General
All bulk materials needed for manufacture at an item are listed by part
number or specification number in a
tabular list on the illustration.
G-3. Manufactured Items Illustrations
G-1
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
Figure G-1.
G-2
Fabrication of Battery Cables (Sheet 1 of 2)
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
13228E3368
NOTES :
1.
CRIMPED TERMINALS SHALL MEET THE PERFORMANCE REQUIREMENTS OF MIL-T-7928.
2.
SLIDE THE STRAIN RELIEF CONNECTOR ONTO THE CABLE BEFORE CRIMPING ON THE
TERMINAL-LUGS.
3.
All DIMENSIONS ARE SHOWN IN INCHES.
PARTS LIST
FIND
NO.
PART OR
IDENTIFYING NO.
QTY
REQD
NOMENCLATURE OR DESCRIPTION
SPECIFICATION
1
MS20659-118
2
TERMINAL LUG, CRIMP STYLE
2
MS23053/5-109-2
2
INSULATION SLEEVING, HEAT
SHRINKABLE RED
3
2535
4
M13486/1-14
AR
CABLE, COLOR BLK, SIZE 0
WIRE
MIL-C-13486/1
5
M23053/5-109-O
2
INSULATION SLEEVING, HEAT
SHRINKABLE, BLK
MIL-I-23053/5
Figure G-1.
I
1
I
CONNECTOR, STRAIN RELIEF
MIL-I-23053/5
I
Fabrication of Battery Cables (Sheet 2 of 2)
G-3
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
Figure G-2.
G-4
Fabrication of Special Relay Assembly to Remote Functions
Box Assembly Wiring Harness (Sheet 1 of 2)
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
13228E1911
NOTES:
1.
CONNECTOR PLUG SHALL BE STAMPED, AS INDICATED IN ACCORDANCE WITH
MIL-STD-130.
2.
ALL SOLDERED CONNECTIONS SHALL BE IN ACCORDANCE WITH MIL-STD-454,
REQUIREMENT 5.
3.
WIRE MARKING SHALL BE IN ACCORDANCE WITH MIL-W-5088 EXCEPT THAT
LENGTH BETWEEN GROUPS OF NUMBERS SHALL NOT EXCEED 6 INCHES.
4.
MARK “97403-13228E911” ONTO STRAP, FIND NO. 6 IN ACCORDANCE
WITH MIL-STD-130.
5.
BUNDLE ALL WIRES IN THE SAME RUN AT THREE INCH INTERVALS USING
STRAPS, FIND NO. 5.
6.
ALL DIMENSIONS ARE SHOWN IN INCHES.
Figure G-2.
Fabrication of Special Relay Assembly to Remote
Functions Box Assembly Wiring Harness (Sheet 2 of 2)
G-5
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
Figure G-3.
Fabrication of Remote Functions Box Assembly
to Connector Panel Wiring Harness (Sheet 1 of 2)
G-6
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
13228E1910
NOTES :
1.
CONNECTOR PLUG SHALL BE STAMPED, AS INDICATED IN ACCORDANCE WITH
MIL-STD-130.
2.
ALL SOLDERED CONNECTIONS SHALL BE IN ACCORDANCE WITH MIL-STD-454,
REQUIREMENT 5.
3.
WIRE MARKING SHALL BE IN ACCORDANCE WITH MIL-M-5088 EXCEPT THAT
LENGTH BETWEEN GROUPS OF NUMBERS SHALL NOT EXCEED 6 INCHES.
4.
MARK “97403-13228E191O” ONTON STRAP, FIND NO. 2 IN ACCORDANCE
WITH MIL-STD-130.
5.
BUNDLE ALL WIRES IN THE SAME RUN AT THREE INCH INTERVALS USING
STRAPS, FIND NO. 5.
6.
ALL DIMENSIONS ARE SHOWN IN INCHES.
PARTS LIST
FIND
NO.
PART OR
IDENTIFYING NO.
QTY
REQD
NOMENCLATURE OR DESCRIPTION
1
MS3106R24-285
1
CONNECTOR, ELECTRICAL P29B
2
MS3368-1-9A
1
STRAP, CABLE
3
M5086/2-16-9
4
D38999/24-F-H-215
5
MS3367-5-9
AR
STRAP, CABLE, ADJUSTABLE
6
SN60WRP2
AR
SOLDER, LEAD-Tin
Figure G-3.
AR
1
SPECIFICATION
WIRE, ELECTRICAL
NO. 16 AWG WHT
MIL-W-5086/2
CONNECTOR, ELECTRICAL P29C
MIL-C-38999/24
QQ-S-571
Fabrication of Remote Functions Box Assembly to
Connector Panel Wiring Harness (Sheet 2 of 2)
G-7
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
Figure G-4.
Fabrication of SS2P to Convenience Receptacle
Wiring Harness (Sheet 1 of 2)
G-8
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
13228E1913
NOTES :
1.
CONNECTOR PLUG SHALL BE STAMPED, AS INDICATED IN ACCORDANCE WITH
MIL-STD-130.
2.
CRIMPED TERMINATIONS SHALL MEET THE PERFORMANCE REQUIREMENTS OF
MIL-T-7928.
3.
WIRE MARKING SHALL BE IN ACCORDANCE WITH MIL-W-5088 EXCEPT THAT
LENGTH BETWEEN GROUPS OF NUMBERS SHALL NOT EXCEED 6 INCHES.
4.
INSTALL STRAPS, FIND NO. 3 AT 3.00 MAX INTERVALS.
5.
MARK “97403-13228E1913” ONTO STRAP, FIND NO. 5 IN ACCORDANCE WITH
MIL-STD-130.
6.
ALL DIMENSIONS ARE SHOWN IN INCHES.
PARTS LIST
FIND
NO.
PART OR
IDENTIFYING NO.
1
13228E1948
2
M5086/2-16-9
QTY
REQD
NOMENCLATURE OR DESCRIPTION
1
CONNECTOR, PLUG
AR
WIRE, ELECTRICAL
NO. 16 AWG, WHT
3
MS3367-5-9
AR
4
MS25036-153
2
TERMINAL, RING, INSULATED
NO. 8 STUD SIZE
5
MS3368-1-9A
1
STRAP, CABLE, ADJUSTABLE
Figure G-4.
SPECIFICATION
MIL-W-5086/2
STRAP, CABLE
Fabrication of SS2P to Convenience Receptacle
Wiring Harness (Sheet 2 of 2)
G-9
TM-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
Figure G-5.
G-10
Fabrication of Ground Wire (Sheet 1 of 2)
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
13228E1900
NOTES:
10
CRIMP CONNECTION SHALL MEET THE APPLICABLE REQUIREMENTS OF
MIL-STD-454, REQUIREMENT 19.
2.
REMOVE INSULATION FROM WIRE, FIND NO. 1 AS SHOWN.
3.
TIN IN ACCORDANCE WITH MIL-STD-454, REQUIREMENT 5, USING
SOLDER, FIND NO. 4.
4.
HOT STAMP “97403-13228E1900” IN ACCORDANCE WITH MIL-M-60903.
5.
ALL DIMENSIONS ARE SHOWN IN INCHES.
PARTS LIST
QTY
REQD
1
M5086/2-4-9
AR
WIRE, ELECTRICAL, 4 AWG,
WHT
2
F-666-12X
1
TERMINAL LUG, 4 AWG, 3/8
STUD SIZE
3
M23053-5-1O8-9
1
INSULATION SLEEVING, HEAT
SHRINKABLE, WHITE
MIL-I-23053-5
SOLDER, LEAD-TIN
QQ-S-571
—
1
4
SN60WRP2
Figure G-5.
AR
NOMENCLATURE OR DESCRIPTION
SPECIFICATION
PART OR
IDENTIFYING NO.
FIND
NO.
*
MIL-W-5086/2
Fabrication of Ground Wire (Sheet 2 of 2)
G-11/(G-12Blank)
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
APPENDIX H
TORQUE LIMITS (IF APPLICABLE)
This appendix will list standard torque
values and provide general information
and methods for applying torque. Special torque values and sequences will be
Table H-1.
indicated in the maintenance procedures
for applicable components (see Table
H-1).
SELF-LOCKING NUT BREAKWAY TORQUE VALUES
Minimum Breakaway
Minimum Breakaway
Thread Size
10-32
1/4-28
5/16-24
3/8-24
7/16-20
1/2-20
9/16-18
Torque (In.-Lbs.)
Thread Size
2.0
5/8-18
6.5
7/8-14
1-12
1-1/8-12
1-1/4-12
14.0
18.0
24.0
Torque (In.-Lbs.)
32.0
50.0
70.0
90.0
117.0
143.0
NOTE
To determine breakaway torque, thread nut onto screw or bolt
until at least two threads stick out. Nut shall not make
contact with a mating part. Stop the nut. Torque necessary
to begin turning nut again is the breakaway torque. Do not
reuse self-locking nuts that do not meet minimum breakaway
torque.
H-1/(H-2 Blank)
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
ALPHABETICAL INDEX
Para.,Table,
Figure Number
Subject
A
Abbreviations . . . . . . . . . . . . . . . . 1-6
Access Doors
Front
Inspection . . . ... . . . . . . . . . . T2-1
Maintenance . . . . . . . . . . . . . . . . 4-18
5-11
Side
Inspection . . . . . . . . . . . . . . . . .T2-1
Maintenance . . . . . . . . . . . . . . . 4-19
5-11
Adapter,Air Inlet,Maintenance . . . . . . 4-31
Air Breather Hose,Maintenance . . . . . . 4-30
Air Cleaner Housing
Inspection . . . . . . . . . . . . . . . . . T2-1
Maintenance . . . . . . . . . . . . . . . . 4-28
Air Inlet
Adapter,Maintenance . . . . . . . . . . . . 4-31
Hose,Maintenance . . . . . . . 4-29
Assembly,Generator Set
Cover,Top Rear
Inspection . . . . . . . . . . . . . T2-1
Maintenance . . . . . . . . . . . . . . 4-20
5-12
Top Front Cover
Inspection . . . . . . . . . . . . . . . . T2-1
Maintenance . . . . . . . . . . . . . . 4-24
5-15
B
Baffle Assembly
Exhaust
Inspection . . . . . . . . . . . . . . . . T2-1
Maintenance . . . . . . . .. . . . . . . . T4-1
4-22
5-14
Flanges,Intake,Maintenance . . . . . . . 4-16
Grid,Intake
Inspection . . . . . . . . . . . . . . . . . 4-15
Maintenance . . . . . . . . . . . . . . . 4-15
Intake
Inspection . . . . . . . . . . . . . . . . T2-1
Maintenance . . . .. . . . . . . . . . . T4-1
4-14
5-10
Subject
Para.,Table,
Figure Number
Mounting Brackets,Exhaust,
Maintenance . . . . . . . . . . . . . . .. . . 4-23
Base,Skid
Inspection . . . . . . . . . . . . . . 4-38
Maintenance . . . . . . . . . . . . . . . . . . 6-6
Battery
Box
Inspection . . . . . . . . . .. . . . . . T2-1
Maintenance . . . . . . . . . . . . . . . . 4-12
Box Assembly
Inspection . . . . . . . . . . . . . . . . . T2-1
Maintenance . . . . .. . . . . . . . . . 4-12
Box Cover Maintenance . . . . . . . . . . . . 4-13
Cables
Inspection . . . . . . . . . . . . . . . . T2-1
Maintenance . . . . . . . . . . . . . . 4-11
Inspection . . . . . . . . . . . . . . . . . T2-1
Maintenance . . . .. . . . . . . . . . T4-1
4-10
Belt,V,Engine
Inspection . . . . . . . . . . . . . . T2-1
Maintenance . . . . . . . . . . . . . . 4-35
Box
Battery
Inspection . . . . . . . . . . . . . . . T2-1
Maintenance . . . . . . . . . . . . . T4-1
4-10
Battery,Assembly
Inspection . . . . . . . . . . . . T2-1
Maintenance . . . . . . . . . . . . . 4-12
Cover,Battery,Maintenance. . . . . . . . 4-13
Document
Inspection . . . . . . . . . . . . . . T2-1
Maintenance . . . . . . . . . . . . . . 4-37
Junction,Assembly
Inspection . .. .. . . . . . . . . .. 4-39
Maintenance . . . . . . . . . . . . . . 4-39
5-28
6-6
Remote Functions,Assembly
Inspection . . . . . . . . . . . . . . . . 4-33
Maintenance . . . . . . . . . . . . . . 5-22
Troubleshooting . . . . . . . . . . T5-1
Bracket,Puller
Inspection . . . . . . . . . . . . . . . . . . T2-1
Maintenance . . . . . . . . . . . . . 4-41
Brackets,Mounting,Exhaust Baffle
Assembly,Maintenance . . . . . . . . . 4-23
Index
1
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
ALPHABETICAL INDEX (Continued)
Para.,Table,
Figure Number
Subject
C
Cable
Assembly,Power
Inspection . . . .
Maintenance . . . . .
Control,5Ft
Inspection .....
Maintenance . . . .
. . . . . . . . . . . . . T2-1
. . . . . . . . . . . . 4-49
. . . . . . . . . . T2-1
. . . . . . . . . . T2-1
4-51
Control,25Ft
Inspection. . . . . . . . . . . . . T2-1
Maintenance .. . . . . . . . . . . . T2-1
4-51
Control,100Ft
Inspection . . . . . . . . . . . . T2-1
Maintenance . . . . . . . . . 4-48
Paralleling
Inspection. . . . . . . . . . . T2-1
Maintenance . . .. . . . . T2-1
4-52
Power,5Ft
Inspection . .. . . .. . . . . . . . T2-1
Maintenance . . . . . . . . . . . T2-1
4-50
Reel Assembly
Inspection .. . . . . . . . . . . . . . T2-1
3-4
Maintenance . . . . . . . . . . . 3-4
4-40
Storage Pan
Inspection . . .
...
..
. T2-1
Maintenance . . . . . . . . .. 4-46
Cables,Battery
Inspection . . . . . . . . . . . . . . . T2-1
Maintenance . . . . . . . . . . 4-11
Connector Plate Maintenance . . . . . . . . 4-17
Control Cable
5Ft
Inspection . . . . . . . . . T2-1
Maintenance . . . . . . .. T2-1
4-51
25Ft
Inspection . . . . . . . . . . . . . T2-1
Maintenance . . . . . . . . . T2-1
4-51
100Ft
Inspection . . . . . . . . . . . . . . T2-1
Maintenance . . . . . .. . . . 4-48
Index
2
Para.,Table,
Figure Number
Subject
Control Unit,Remote
Inspection . . . . . . . . . . . . . T2-1
Maintenance . . . . . . . . . . . . .4-47
4-48
5-29
Troubleshooting . . . . . . . . . T3-1
T4-2
T5-1
Control Wiring Harness
Inspection ...... . . . . .... T2-1
Maintenance . . . . . . . . . . . 5-17
Controls and Indicators,Operator. . . 2-1
Cover,Battery Box,Maintenance . . . . . . 4-13
Cover Assembly,Generator Set
Top Rear
Inspection . . . . . . . . . . . . . T2-1
Maintenance .. . . . . . . . . . . . . . 4-20
5-12
Top Front
Inspection . . . . . .. . . . . . . . . . T2-1
Maintenance . . . . . . . . . . . 4-24
5-15
Crankshaft Puny Maintenance . . . . . . . 5-24
Curbside
Fender,Maintenance . . .. . . . . . . . . 4-43
Front Step,Maintenance . . . . . . . . . 4-42
Rear Step,Maintenance . . . . . . . . . . 4-44
Current Transformer . . . . . . . . . . 5-23
D
Data,Tabulated . . . . . . . . . . . . . . . . . . . 1-10
Destruction to Prevent Enemy Use... 1-3
Document Box
Inspection . . . . . . . . . . . . . . . . . . . . . . . T2-1
Maintenance . . . .. . . . . . . . . . . 4-37
Doors,Access
Front
Inspection . . . . . . . . . . . . . . . T2-1
Maintenance . . . . . . . . . . . . . . . . . . . . 4-18
5-11
Side
Inspection . . . . . . . . . . . . . . . . . . . . . T2-1
Maintenance . . . . . . . . . . . . . . . . . . . . 4-19
5-11
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
ALPHABETICAL INDEX (Continued)
Para. ,Table,
Figure Number
Subject
E
Engine
Belt,V
Inspection . . . . . . . . . . . .. T2-1
Maintenance . . . . . . . . . . . . . . 4-35
Fan
Inspection . . . . . . . . . . . . . T2-1
Maintenance . . . . . . . . . . . 4-34
Exhaust Baffle Assembly
Inspection . . . . . . . . . . . . . . . . . T2-1
Maintenance . . . . . . . . . . .. . T4-1
4-22
5-14
Mounting Brackets,Maintenance . . . . 4-23
Exhaust System Silencer
Inspection . . . . . . . . . . . . . . . T2-1
Maintenance . . . . . . . . . . . . 4-26
Extinguisher,Fire
Inspection . . . . . . . . . . . . . . . T2-1
Maintenance . . . . . . . . . . . . . 4-53
5-30
F
Fan,Engine
Inspection . .. . . . . . . . . . . . . . . . . . . T2-1
Maintenance . . . . . . . . . . . . 4-34
Fan Guard,Left and Right
Inspection . . . . . . . . . . . . . . . . T2-1
Maintenance . . . . . . . . . . . . .. 4-36
Fender,Curbside and Roadside,
Maintenance . . . . . . . . . . . . . . . . . 4-43
Filter Element
Inspection . . .. . . . . . . , . . . . . . . . T2-1
4-32
Maintenance . . . . . . . . . . . . . . . 4-32
Fire Extinguisher
Inspection . . . . . . . . . . . . . . . . . . T2-1
Maintenance . . . . . . . . . . . . . 4-53
5-30
Flanges,Intake Baffle Assembly,
Maintenance . . . . . . . . . . . . 4-16
Flexible Tube Assembly,
Maintenance . . . . . . . . . . . . . . 4-27
Forms,Records and Reports,
Para.,Table,
Figure Number
Maintenance . . . . , . . . . . . . . . . . . . . 1-2
Frame,Lifting
Inspection . . . . . . . . . . . . . . . . . T2-1
Maintenance . . . . . . . . . . . . . . 5-27
Front Access Doors
Inspection . . . . . . . . . . . . . T2-1
Maintenance .. . . . . . . . . . . . 4-18
5-11
Front Frame Housing,Generator Set
Inspection . . . . . . . . . . . . . . T2-1
Maintenance . . . . . . . . . . . 4-25
5-16
Front Isolators
Inspection . .... . . . ...... 5-26
Maintenance . . . . . . . . . . . . 6-5
Front Step,Curbside and Roadside,
Maintenance . . . . . . . . . . . . 4-42
Subject
G
Generator Set
Cover Assembly,Top Rear
Inspection . . . . . . . . . . T2-1
Maintenance . . . .. . . . . . 4-20
5-12
Front Frame Housing
Inspection . . . . . . . . . . . . . . . . T2-1
Maintenance . . . . . . . . . . .4-25
5-16
Rear Housing
Inspection . . . . . . T2-1
Maintenance . . . . . . . . . 4-21
5-13
20Kw,Maintenance . . . . . . . . . . . 5-9
6-3
1-7
Glossary . . . . . . . . . . . . . .. . . . . . .
Grid,Intake Baffle Assembly
Inspection . . . . . . . . . . . . . . . . . 4-15
Maintenance . . . . . . . . . . . . 4-15
Guard,Fan,Left and Right
Inspection . . . . . . . . . . . . . . . . . . . T2-1
Maintenance . . . . . . . . . . 4-36
Index
3
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
ALPHABETICAL INDEX (Continued)
Para.,Table,
Figure Number
Subject
H
Harness,Wiring
Control
Inspection . . . . . . . . . . . . . .
Maintenance . . . . . . . . . . .
Power
Inspection . . .. . ........ .
Maintenance . . . . . . . . . . . . .
Remote Functions Box Assembly
to Connector Panel
Inspection . . . . . . . . . .. . .
Maintenance . . . . .. . . . .
Special Relay Assembly to Remote
Functions Box
Inspection . . . . . . . . . . . . .
Maintenance . . . . . . . . . .
SS2P to Convenience Receptacle
Inspection . . . . . . . . . .
Maintenance . . . . . . . . .
Hose
Air Breather,Maintenance . . . . . .
Air Inlet,Maintenance . . . . . . . .
Housing,Generator Set
Front Frame
Inspection . . . . . . . . . . . .
Maintenance . . . . . . . .
T2-1
5-17
T2-1
5-18
T2-1
5-20
T2-1
5-19
T2-1
5-21
4-30
4-29
T2-1
4-25
5-16
Rear
Inspection . . . . . . . . . . . . . . T2-1
Maintenance . . . . . . . . . . 4-21
5-13
I
Indicators and Controls,Operator. . . 2-1
Inspection and Service,PU 794/G . . . . 1-13
Installation,PU 794/G . . . . . . . . . . 1-14
Intake Baffle Assembly
Flanges,Maintenance . . . . . . . 4-16
Grid
Inspection . . . . . . . . . . . . . . . 4-15
Maintenance . . . . . . . . . 4-15
Inspection . .. . . . . . . . . . . . T2-1
Maintenance . . . . . . . . . . . . T4-1
4-14
5-10
Index
4
Para.,Table,
Figure Number
Subject
Intermediate Direct Support
Maintenance . . . . . . . . . . . .. . . . 5-8
Preventive Maintenance Checks
and Services . . . . . . . . . . . 5-5
Troubleshooting .. . . . . . . . . . . . . 5-7
Intermediate General Support
Maintenance . . . . . . . . . . . . 6-2
Isolators,Front and Rear
Inspection . . . . . . . . . . . . . 5-26
Maintenance . . . . . . . . . 6-5
J
Junction Box Assembly
Inspection . . . . . . . . . . 4-39
Maintenance . . . . . . . . . . 4-39
5-28
6-7
L
Lifting Frame
Inspection . . . . . . . . . . T2-1
Maintenance . . . . .. . . . . 5-27
M
Maintenance
Forms,Records and Reports . . . . . . . . 1-2
Intermediate Direct Support . . . . . . 5-8
Intermediate General Support . . . . . 6-2
Operator . . . . . . . . . . . . . . . . . .
Unit . . . . . . . . . . .. . . . . . . . . . . 4-9
Major Components . . . . . . . . . . . 1-9
Mobile Operation . . . . . . . . . . . . 2-8
Modified Trailer M200A1
Inspection . . . . . . . . . . . . . T2-1
Maintenance . . . . .. . . . . . . 6-8
Mounting Brackets,Exhaust Baffle
Assembly,Maintenance . . . . . . . . . . 4-23
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
ALPHABETICAL INDEX (Continued)
Para.,Table,
Figure Number
Subject
0
Operation
Mobile . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Principles of . . . . . . . . . . . . . . . 1-11
Single Unit . . . . . . . . . . . . . . . . 2-5
Two Units . . . . . . . . . . . . . . 2-6
Operator
Controls and Indicators . . . . . . . . . . 2-1
Maintenance . . . . . . . . . . . . . . 3-3
Preventive Maintenance Checks
and Services ......... . . . . . . . 2-2
Troubleshooting . . . . . . . . .. . 3-2
P
Pan,Cable Storage
Inspection . . . . . .
. . T2-1
Maintenance . . . . . . . . . . . . . 4-46
Paralleling Cable
Inspection . . . . . . . . . . T2-1
Maintenance . . . . . . . . . . . T2-1
4-52
Platform,Tailgate,Maintenance . . . . . 4-45
Power Cable Assembly
Inspection . . . . . . . . . . . . . . T2-1
Maintenance . . . . . . . . . . . . . 4-49
Power Cable,5Ft
Inspection . . . . . . . . . . . . . . . T2-1
Maintenance . . . . . . . . . . . . . T2-1
4-50
Power Wiring Harness
Inspection . . . . . . . . . . . . . . . T2-1
Maintenance . . . . . . . . . . . . . 5-18
Preparation for Shipment . . . . . . . . . 5-32
Preparation for Storage . . . . . . 5-31
Preventive Maintenance Checks
and Services
Intermediate Direct Support . . . . . . 5-5
Operator . . . . . . . . . . . . . . 2-2
Unit . . . . . . . . . . . . . . . . . . . . . . . 4-6
Puller Bracket
Inspection . . . . . . . . . . . T2-1
Maintenance . . . . . . . . . . . . 4-41
Pulley,Crankshaft,Maintenance . . . . . 5-24
PU 794/G
Para.,Table,
Figure Number
Subject
Description . . . . . . . . . . . . . . . . .
Major Components . . . . . . . . . .
Preparation for Shipment . . . . . . .
Preparation for Storage . . . . . . . .
Principles of Operation . . . . . . .
Service Upon Receipt
Inspection and Service . . . . .
Installation . . . . . . . . . . .
Unpacking,Uncrating . . . . . .
Tabulated Data . . . . . . . . . . .
1-8
1-9
5-32
5-31
1-11
1-13
1-14
1-12
1-10
R
Rear Housing,Generator Set
Inspection . . . . . . . . . . . . . . . T2-1
Maintenance . . . . . . . . . . . 4-21
5-13
Rear Isolators
Inspection . . . . . . . . . . . . 5-26
Maintenance . . . . . . . . . . . . . 6-5
Rear Step,Curbside and Roadside,
Maintenance . . . . . . . . .. . . . . 4-44
Records,Reports and Forms,
Maintenance . . . . . . . . . . . . 1-2
Reel,Cable,Assembly
Inspection . . . . . . . . . . . . . . . T2-1
3-4
Maintenance . . . . . . . . . . . . . 3-4
4-40
Relay Assembly,Special
Inspection . . . . . . . . . . . . . T2-1
Maintenance . . . . . . . . . . 5-25
6-4
Troubleshooting . . . . . . . . . . . . . T5-1
Remote Control Unit
Inspection . .. . . . . . . . . . . . . . . . . . T2-1
Maintenance . . . . . . . . . . . . . 4-47
4-48
5-29
Troubleshooting . . . . . . . . . . . T3-1
T4-2
T5-1
Remote Functions Box Assembly
Inspection . . . . . . . . . . . . . . . . . 4-33
Maintenance . . . . . . . . . . . . . . 5-22
to Connector Panel Wiring Harness
Inspection . . . . .. . . . . . . . T2-1
Index
5
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
TO-35C2-3-445-14
TM-6115-14&P/1
ALPHABETICAL INDEX (Continued)
Para.,Table,
Figure Number
Subject
Maintenance . . . . . . . . . . . . . . . . 5-20
Troubleshooting . . . . . . . . . . . . . T5-1
Roadside
Fender,Maintenance . . . . . . . . . . . 4-43
Front Step,Maintenance . . . . . . . 4-42
Rear Step,Maintenance . . . .. . . . 4-44
S
Service Upon Receipt
Inspection and Service . . . . . . . . . . . 1-13
Installation . . . . . . . . . . . . . . . . . 1-14
Unpacking,Uncrating . .. . . . . . . . . 1-12
Shipment,Preparation for . . . . . . . . . 5-32
Side Access Doors
Inspection . . . . . . . . . . . . . . . T2-1
Maintenance . . . . . . . . . .. . . . . 4-19
5-11
Silencer,Exhaust System
Inspection . . . . . . . . . . . . . . . . T2-1
Maintenance . . . . . . . . . . . . . . . 4-26
Single Unit Operation . . . . . . . . . . . . . . 2-5
Skid Base
Inspection . . . . . . . . . . . . 4-38
Maintenance . . .. . . . . . . . . . . 6-6
Special Relay Assembly
Inspection . . . . . . . . . . . . . . . . T2-1
Maintenance . . . . . . . . . . . . . . . . 5-25
6-4
to Remote Functions Box Assembly
Wiring Harness
Inspection . . . .. . . . . . . . . .. T2-1
Maintenance . . . . . . . . . . . . . . 5-19
Troubleshooting . . .. . . . . . . . . . T5-1
SS2P to Convenience Receptacle
Wiring Harness
Inspection . . . .
. .... T2-1
Maintenance . . . .. . . . . . . . . . . 5-21
Storage
Pan,Cable
Inspection . . . . . . . . . . . . . . . T2-1
Maintenance . . . . .. . . . . . 4-46
Preparation for . . .. . . . . . . . . 5-31
Index
6
Para.,Table,
Figure Number
Subject
T
Tabulated Data............ . . . . . . 1-10
Tailgate Platform,Maintenance . . . .. . . 4-45
Top Front Cover Assembly,Generator
Set
Inspection . . . . . . . . . . . . . . . . T2-1
Maintenance . .. . . . . . . . . . . . . . . 4-24
5-15
Top Rear Cover Assembly,Generator
Set
Inspection . . . . . . . . . . . . . . . . T2-1
Maintenance . . . . . . . . . . . . . . 4-20
5-12
Trailer,Modified M200A1
Inspection . . . . . . . . . . . . . . . T2-1
Maintenance . . . . . . . . . . . . 6-8
Transformer,Current . . . . . .. . . . . . . . 5-23
Troubleshooting
Intermediate Direct Support . . . . . . 5-7
Operator . . . . . . . . . . . . . . 3-2
Unit . . . . . . . . . . . . . . . . . . . . 4-8
Tube,Fl exible,Assembly,
Maintenance . . . . . . . . . . . . . . . . . . 4-27
20kW Generator Set,Maintenance .. . . . 5-9
6-3
Two Units Operation . . . . . . . . . . . . 2-6
U
Unit
Maintenance . . . . . . . . . . . 4-9
Preventive Maintenance Checks
and Services . . . . . . . . . . . . . . 4-6
Remote Control
Inspection . . . .. . . . . . . . . . T2-1
Maintenance . . . . . . . . . . . . 4-47
4-48
5-29
Troubleshooting . . . . . . . . . . . . T3-1
T4- 2
T5-1
Troubleshooting . . . . . . . . . . . 4-8
Unpacking,Uncrating . . . . . . . . . . 1-12
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
ALPHABETICAL INDEX (Continued)
Para.,Table,
Figure Number
Subject
V
V Belt,Engine
Inspection . . . . . . . . . . . . . . . . . T2-1
Maintenance . . . . . . . . . . . . . . . . 4-35
W
Wiring Harness
Control
Inspection . .. . . . . . . . . . . . . T2-1
Maintenance . . . . . . . . . . . . . . 5-17
Power
Inspection . . . . . . . . . . . . . . T2-I
Maintenance . . . . . . . . . . . . 5-18
Special Relay Assembly to Remote
Functions Box Assembly
Inspection . . . . . . . . . . . . T2-1
Maintenance . . . . . . . . . . . . 5-19
SS2P to Convenience Receptacle
Inspection . . . . . . . . . . . . . . T2-1
Maintenance . . . . . . . . . . . . . . 5-21
Remote Functions Box Assembly
to Connector Panel
Inspection . . . . . . . . . . . . . . T2-1
Maintenance . . . . . . . . . . . . . 5-20
Index 7/(Index 8 Blank)
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
FO-1.
FUEL SYSTEM DIAGRAM
FP-1/(FP-2 blank)
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
F0-2.
FP-3
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
TO-35C2-445-14
TM-6115-14&P/1
FO-3.
GENERATOR SET AC CIRCUITS
TROUBLESHOOTING DIAGRAM (SHEET 1 OF 2)
FP-5/(FP-6 blank)
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
FO-3.
GENERATOR SET AC CIRCUITS
TROUBLESHOOTING DIAGRAM (SHEET 2 0F 2)
FP-7
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
T0-35C2-3-445-14
F0-4.
FP-9
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
FO-5.
GENERATOR SET AC CIRCUITS
SCHEMATIC DIAGRAM
FP-11/(FP-12 blank)
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
FO-6.
GENERATOR SET DC CIRCUITS
TROUBLESHOOTING DIAGRAM (SHEET 2 OF 2)
FP-13/(FP-14 blank)
TM5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
FO-6.
GENERATOR SET DC CIRCUITS
TROUBLESHOOTING DIAGRAM (SHEET 1 OF 2)
FP-15/(FP-16 blank)
ARMY TECHNICAL MANUAL
NAVY PUBLICATION
AIR FORCE TECHNICAL ORDER
MARINE CORPS TECHNICAL MANUAL
TM 5-6115-634-14&P
NAVFAC P-8-647-14&P
T0-35C2-3-445-14
TM-6115-14&P/1
By Order of the Secretaries of the Army, the Navy, and the Air Force:
Official:
CARL E. VUONO
General, United States Army
Chief of Staff
R.L. DILWORTH
Brigadier General, United States Army
The Adjutant General
J.P.JONES,JR.
Rear Admiral, CEC, US Navy
Commander
Naval Facilities Engineering Command
Official:
LARRY D. WELSH, General USAF
Chief of Staff
ALFRED G. HANSEN
General, USAF, Commander, Air Force
Logistics Command
H. E. REESE
Executive Director
Marine Corps Research, Development and
Acquisition Command
DISTRIBUTION:
To be distributed in accordance with DA Form 12-25A, Operator, Unit and Direct
Support and General Support Maintenance requirements for Generator Set, Diesel
Engine Driven, Trailer Mounted.
*U.S. GOVERNMENT PRINTING OFFICE 1988 - 554-169/87137
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