Operator and Organizational Maintenance PDF
Operator and Organizational Maintenance PDF
Operator and Organizational Maintenance PDF
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ARMY TECHNICAL MANUAL TM 5-6115-584-12
NAVY PUBLICATION navfac p-8-622-12
AIR FORCE TECHNICAL ORDER TO 35C2-3-456-1
MARINE CORPS TECHNICAL MANUAL tm 05682C-12
UK
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p \jfp *mi&
TECHNICAL MANUAL
NOV 21 1990
GOVERNMENT DOCUMENTS
GENERATOR SET, DIESEL ENGINE DRIVEN, TACTICAL SKID MTD 5KW, 1 PHASE
2 WIRE, 1 PHASE 3 WIRE, 3 PHASE 4 WIRE, 120, 120/240 AND 120/208 VOLTS
PUBLISHED UNDER THE AUTHORITY OF THE DEPARTMENTS OF THE ARMY, AIR FORCE, NAVY
£ AND HEADQUARTERS U.S. MARINE CORPS
JULY 1977
TM 5-6115-584-12
NAVFAC P-8-622-12
TO 35C2-3-456-1
TM 05682C-12
C 5
ANGE
CHANGE HEADQUARTERS, DEPARTMENTS
OF THE ARMY, NAVY AND AIR FORCE
NO . 5 HEADQUARTERS U.S. MARINE CORPS, WASHINGTON D.C. 17 June 1988
1. Remove and insert pages as indicated below. New or changed text material
is indicated by a vertical bar in the margin. An illustration change is indicated
by a miniature pointing hand.
By Order of the Secretaries of the Army, the Navy, and the Air Force ( Including the Marine Corps )
CARL E. VUONO
Official* General. United Slates 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
ALFRED G. HANSEN
General, USAF, Commander, Air Force
Logistics Command
J. J. WENT
Lieutenant General, USMC
Deputy Chiefof Staff for Installations and Logistics
DISTRIBUTION:
To be distributed in accordance with DA FOrm 12-25A, Operator and Unit Maintenance
requirements for Generator Set, Diesel Driven, Tactical, Skid Mounted, 120V, 120/240V,
120/208V, 5KW, 60HZ, 1PH/2 Wire, 1PH/3 Wire, 3PH/4 Wire (MEP-002A) (TM 5-6115-584
Series)
Army Technical Manual TM 5-6115-584-12
Navy Publication NAVFAC P-8-622-12
Air Force Technical Order TO 35C2- 3-456-1
Marine Corps Technical Manual TM 05682C-12
C 4
CHANGE
ANGE \ HEADQUARTERS
DEPARTMENTS OF THE ARMY, NAVY and AIR FORCE
NO • 4 J WASHINGTON, D.C., 14 April 1986
1. Remove and insert pages as indicated below. New or changed text material
is indicated by a vertical bar in the margin. An illustration change is indicated
by a miniature pointing hand.
By Order of the Secretaries of the Army, the Navy, and the Air Force:
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
EARL T. O'LOUGHLIN
General, USAF, Commander, Air Force
Logistics Command
GEORGE B. CRIST
Lieutenant General, USMC
Deputy Chiefof Stafffor Installations and Logistics
DISTRIBUTION:
To be distributed in accordance with DA For 12-25A, Operator and Organizational
Maintenance requirements for Generator Set, Diesel Driven, Tactical, Skid Mounted,
120V, 120/240V, 120/208V, 5KW, 60HZ, 1PH/2 Wire, 1PH/3 Wire, 3PH/4 Wire (MEP-002A).
TM 5-6115-584-12
NAVFAC P-8-622-12
TO 35C2-3-456-1
TM 05682C-12
C 3
CHANGE DEPARTMENTS OF THE ARMY, NAVY,
AIR FORCE AND MARINE CORPS
NO. 3 WASHINGTON, D.C., 8 October 1982
By Order of the Secretaries of the Army, the Navy, and the Air Force:
E. C. MEYER
General, United States Army
Official: Chief of Staff
ROBERT M. JOYCE
Major General, United States Army
The Adjutant General
W. M. ZOBEL
Rear Admiral, CEC, USNavy
Commander
Naval Facilities Engineering Command
JAMES P. MULLINS
General, USAF, Commander, Air Force
Logistics Command
H. A. HATCH
Lieutenant General, USMC
Deputy Chief of Staff for Installations and Logistics
DISTRIBUTION:
To be distributed in accordance with DA Form 12-25D, Operator Maintenance requirements for
Generator Sets, Engine Driven: 5 KW, 60 HZ
Marine Corps:
MARCORPS CODE: AGB
DEPARTMENT Of THE ARMY TECHNICAL MANUAL TM 5-6115-584-12
DEPARTMENT OF THE NAVY PUBLICATION" NAVFAC P-8-622-12
DEPARTMENT OF THE AIR FORCE TECHNICAL ORDER TO 35C2-3-456-1
MARINE CORPS TECHNICAL MANUAL TM 05682C-12
C2
3. File this change sheet in front of the publication for reference purposes
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
C2
By Order of the Secretaries of the Army, the Navy, and the Air Force:
BERNARD W. ROGERS
General, United State* Army
Official: ChiefofStaff
J. C. PENNINGTON
Major General, United States Army
The Adjutant General
D. G. ISELIN
Rear Admiral, CEC, U. S. Navy
Commander, Naval Facilities
Engineering Command
H. A. HATCH
Major General, U. S. Marine Corps
Deputy Chief of Staff for Installations and Logistics
Distribution:
Active Army:
To be distributed in accordance with DA Form 12-25D, Operator maintenance requirements for Gener
ator Sets, Engine Driven, 5 KW, 60 HZ.
Marine Corps:
MARCORPSCODE: AGB
TM 5-6115-584-12
NAVFAC P-8-622-12
TO 35C2-3-456-1
TM 05682C-12
C 1
By Order of the Secretaries of the Army, the Navy, and the Air Force:
BERNARD W. ROGERS
General, United States Army
Official: Chief of Staff
J. C. PENNINGTON
Brigadier General, United States Army
The Adjutant General
D. G. ISELIN
Rear Admiral, CEC, U. S. Navy
Commander,
Naval Facilities Engineering Command
H. A. HATCH
Major General, US Marine Corps
Deputy Chief of Stafffor Installations and Logistics
Distribution:
To be distributed in accordance with DA Form 12-25D, Operator Maintenance requirements for
Generator Sets, Engine Driven: 5 KW, 60 HZ.
l
♦
4
DEPARTMENT OF THE ARMY TECHNICAL MANUAL TM 5-6115-584-12
DEPARTMENT OF THE NAVY PUBLICATION NAVFAC P-8-622-12
DEPARTMENT OF THE AIR FORCE TECHNICAL ORDER TO-35C2-3-456-1
MARINE CORPS TECHNICAL MANUAL TM-05682C 12
HEADQUARTERS
DEPARTMENTS OF THE ARMY, NAVY, AIR FORCE, & USMC
WASHINGTON, D.C. 22 July 1977
GENERATOR SET, DIESEL ENGINE DRIVEN, TACTICAL SKID MTD 5KW. 1 PHASE
2 WIRE, 1 PHASE-3 WIRE, 3 PHASE-4 WIRE, 120, 120/240 AND 120/208 VOLTS
TABLE OF CONTENTS
Page
LIST OF EFFECTIVE PAGES v
LIST OF ILLUSTRATIONS vi
LIST OF TABLES vii
i
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TABLE OF CONTENTS (CONT)
Page
Section II. OPERATING UNDER UNUSUAL CONDITIONS 2-6
2-7. Operation in Extreme Heat 2-6
2-8. Operation in Extreme Cold (-25 °F, -32 °C) 2-6
2-9. Operation in Dusty or Sandy Areas 2-6
2- 10. Operation in Wet or Humid Areas 2-6
Section III. OPERATION USING NATO SLAVE CABLE 2-6.1
CHAPTER 3. OPERATOR MAINTENANCE INSTRUCTIONS 3-1
Section I. CONSUMABLE OPERATING AND MAINTENANCE SUPPLIES ... 3-1
3- 1. Consumable Supplies 3-1
Section II. LUBRICATION INSTRUCTIONS 3-1
3-2. General 3-1
3-3. Lubrication Order 3-1
Section III. PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) . 3-4
3-4. General 3-4
3-5. Correcting and Reporting Deficiencies 3-4
3-6. DeWmining PMCS Intervals 3-4
3-7. PMCS for Units in Continuous Operation 3-4
3-8. Preventive Maintenance Checks and Services 3-4
Section IV. TROUBLESHOOTING 3-5
3-9. General 3-6
3-10. Malfunctions Not Corrected By Use of the
Troubleshooting Table 3-6
Section V. OPERATOR MAINTENANCE PROCEDURES 3-8
3-11. Battery Assembly 3-8
3-12. Ground Rod and Fuel Drum Adapter Hold-Down Assembly 3-9
3-13. Fuel Tank Assembly 3-10
3-14. Shutter Box Assembly 3-10
3-15. Exhaust Muffler Assembly 3-13
3-16. Engine Starter Assembly 3-13
3-17. AC Output Control Box Assembly 3-14
3-18. Air Cleaner Assembly 3-14
3-19. Control Cubicle Assembly 3-17
3-20. Fuel System (Less Tank) 3-19
3-21. Control Cubicle Support Assembly, Speed Control and Engine
Control Wiring Harness 3-20
3-22. Engine Cooling System 3-21
3-23. Generator Assembly 3-23
3-24. Engine Assembly 3-23
3-25. Skid-Base Assembly 3-27
CHAPTER 4. ORGANIZATIONAL MAINTENANCE 4-1
Section I. SERVICE UPON RECEIPT OF MATERIAL 4-1
4-1. Inspecting and Servicing Generator Set 4-1
4-2. Installing Generator Set 4-2
Section II. MOVEMENT TO A NEW WORKSITE 4-4
4-3. Dismantling Generator Set for Movement 4-4
4-4. Reinstalling Generator Set After Movement 4-4
ii Change 5
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TABLE OF CONTENTS (CONT)
Page
Section III. REPAIR PARTS; SPECIAL TOOLS; SPECIAL TEST, MEASURE
MENT AND DIAGNOSTIC EQUIPMENT AND SPECIAL SUP
PORT EQUIPMENT 4-4
4-5. Special Tools and Equipment 4-4
4-6. Maintenance Repair Parts 4-4
Section IV. LUBRICATION INSTRUCTIONS 4-4
4-7. Lubrication 4-4
Section V. PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) . 4-5
4-8. PMCS, General 4-5
Section VI. TROUBLESHOOTING 4-6
4-12. Troubleshooting, General 4-6
4-13. Malfunctions Not Corrected By Use of the Troubleshooting
Table 4-6
Section VII. RADIO INTERFERENCE SUPPRESSION 4-10
4-14. General Methods for Proper Suppression 4-10
4-15. Radio Interference Suppression Components 4-10
Section VIII. MAINTENANCE OF ENGINE COOLING SYSTEM 4-12
4-16. Description and Function 4-12
4-17. Engine Cooling Assembly 4-12
Section IX. MAINTENANCE OF FUEL SYSTEM 4-16
4-18. Description and Function 4-16
4-19. Fuel Tank Assembly 4-16
4-20. Fuel Filter Assemblies and Strainer Assembly 4-17
4-21. Electric Fuel Pumps, Fuel Hoses and Auxiliary Solenoid Valve . . 4-21
4-22. Auxiliary Fuel Solenoid Valve 4-21
4-23. Fuel Shut-Off Solenoid Valve 4-21
Section X. MAINTENANCE OF ENGINE ELECTRICAL SYSTEM 4-24
4-24. Description and Function 4-24
4-25. Battery Assembly 4-24
4-26. Engine Starter Assembly 4-26
4-27. Battery Charging Alternator 4-29
4-28. Starter Lockout Switch and Gear 4-31
Section XI. MAINTENANCE OF OIL SYSTEM 4-33
4-29. Function and Description 4-33
4-30. Oil Cooler 4-33
4-31. Low Oil Pressure Switch 4-34
4-32. Oil Filter 4-36
4-33. Oil Pressure Gauge 4-37
Section XII. MAINTENANCE OF CONTROL SYSTEM 4-38
4-34. Description and Function 4-38
4-35. DC Control System 4-38
iii
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iv Change 5
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Reproduction for non- military use of the information or illustrations contained in this publication is not
permitted. The policy for military use reproduction is established for the Army in AR 380-5, for the Navy and
Marine Corps in OPNAVIN8T 5510. IB, and for the Air Force in Air Force Regulation 205-1.
Insert latest changed pages; dispose of superseded pages in accordance with applicable regulations.
NOTE: Ob a changed page, the portion of the text affected by the latest change la Indicated by a vertical line, or other
change symbol. In the outer margin of the page. Changes to Illustrations are Indicated by miniature pointing hands.
Changes to wiring diagrams are Indicated by shaded areas.
Page #Change
No. No.
Warning 0
Blank 0
1 - Til 0
Till Blank 0
1-1 - 1-11 0
1-12 Blank 0
1-13 - 1-15 0
1- 16 Blank 0
2- 1-2-6 0
3- 1 - 3-27 0
3-28 Blank 0
4- 1 - 4-58 0
4-60 Blank 0
A-l 0
A-2 Blank 0
B-l 0
B-2 Blank 0
- C-19 0
C-20 Blank 0
1 - Index 6 0
v
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NAVFAC P-8-622-12
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TM-05682C-12 LIST OF ILLUSTRATIONS
vi Change 5
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LIST OF TABLES
CHAPTER 1
INTRODUCTION
Section L GENERAL
Change A 1-1
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Section H. DESCRIPTION AND DATA
1-8. DESCRIPTION OF GENERATOR SET. The dc source consists of a 24 volt battery set (BT1
and BT2) that is kept charged by a battery charging;
This unit ls a 5 kilowatt, 60 Hertz Generator Set. It alternator (G2) and voltage regulator rectifier as
consists of a revolving field alternator powered by an sembly (A5). Fuse (Fl) protects the alternator from
air cooled diesel engine. See figures 1-1 and 1-2 for overload. Circuit breaker (CB2) protects the battery
the location of major components. charging system from overload. Slave receptable (J15)
permits an alternate external supply to be connected
a. Engine. to the battery circuit.
TS 6115-584 12/12
Figure 1-2. Engine Generator Set, Left-Front, Three-Quarter View
4
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2 -3-456-1
TM-05682C-12
and current under load and varies the exciter field either up WARRANTY:
or down to keep the generator field at such a value as to
maintain constant alternator output voltage. The regu DATE INSP:
lated voltage setting can be varied using the voltage adjust
rheostat (Rl). MFD BY: ONAN DIVISION OF ONAN CORP.
An ac receptacle (J14) is connected through a protective INSP STAMP:
circuit breaker (CB3) to provide 120 VAC.
(2) Operating Instruction Plate.
Outputs from the voltage regulator (A2) transformed
by transformers (Tl and T2) to a value suitable for input (a) Location. This plate is located on the side
to frequency transducer (A3) which energizes frequency of the control cubicle.
meter (M3).
(b) Content.
1-10. TABULATED DATA.
OPERATING INSTRUCTIONS
a. Identification and Instruction Plates (see figures
1-1 and 1-2). BEFORE STARTING SET
(1) Identification Plate. 1. Fill crankcase (do not overfill) and fuel tank.
Ensure that vent cap on underside of fuel filler
(a) Location. This plate is located on the side cap is open before starting generator.
of the control cubicle.
2. "WARNING" - Ground set to avoid shock
(b) Content. hazard.
US DEPARTMENT OF DEFENSE 3. Set batteries are negative ground.
GENERATOR SET DIESEL ENGINE 5KW 60 Hz STARTING SET
MODEL: MEP 002A 1. Move "MASTER SWITCH" to "PRIME &
RUN" position to allow fuel to prime set.
SER NO.:
2. Move "MASTER SWITCH" to "PREHEAT"
NSN: 6115-00-465-1044 position and hold for (1) minute.
REG NO.: NOTE: Preheat is not required when engine
is hot.
TM 5-6115-584-12
3. Move "MASTER SWITCH" to "START" posi
TO-35C2-3-456-1 tion and hold until engine fires continuously.
If engine does not start within 15 seconds
NAVFAC P-8-262-11 repeat steps 1 and 2.
TM-05682C-12 4. "MASTER SWITCH" will return to "PRIME
& RUN" position when released. If running
VOLTS: 120V 1 PH. from auxiliary fuel source, move "MASTER
120/240V 1PH. SWITCH" to "PRIME & RUN AUX FUEL"
120/208V 3PH. position.
PF: 0.8 5. After warm up. Check frequency and voltage
and adjust if necessary.
AMPS: 52,26,17.3
6. Move "AC CIRCUIT BREAKER" to "ON"
DRY WT: 960 LB position.
LG: 51 IN STOPPING SET
W: 32 IN 1. Move "AC CIRCUIT BREAKER" to "OFF"
position.
HGT: 37 IN
2. Move "MASTER SWITCH" to "OFF" position.
DATE MFG:
3. For emergency stop pull "DC CONTROL
CONTR NO; F04606-74-C-1133 CIRCUIT BREAKER."
Change 5 1-5
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NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
SERVICE INSTRUCTIONS
Lubricating
Fuels Oil Capacity
Ambient Capacity - 6.75 GAL (Less Filter)
Temperature Primary-Diesel Emergency-JP4 3.0QT
-65° to -25°F W-F-800 Grade DFA MIL-L-10295
-54° to-12°C
-25° to-10°F W-F-800 Grade DFl MIL-L-10295
-32° to-23°C
-10° to +30°F VV-F-800 Grade DFl For JP4 operation, see MIL-L-2104 Grade 10
-23° to -1°C Instruction Manual
Mode: 60 Hz
(2) Engine.
1-6 Change 5
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(3) Batteries.
Amp-Hrs: 45
(4) Fuel pumps.
Model: 244350
I
Fuel filter element: Part No. C-1125PL
Change 2 1-7
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Figure 1-3. Tie Down, Lifting, and Towing Provisions Crated Set
1-8
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
INJECTORS
RETURN FROM
INJECTORS
AUX
. FUEL LEVEL FUEL PUMP
V AUX FUEL
FLOAT FILLER SUPPLY
SWITCH ASS'Y FUEL
iSOLENOID X4
Change 5 1-9
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TM-05682C-12
t
I
1-10
TM 5-6115-584-12
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TM-05682C-12
P58U18
TRELAV rl?—Sr^w3 tz
*j P55H8 oov sot
7> s< ai Y
1 ? JM starTreu*
i
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
P5 P6 P7 P8
ENGINE AND GENERATOR AREA CONTROL
P16| CUBICLE
_ P65A DDDO AREA
O UJ a u.
S6 P64D CM
CO CO CO
> a. 0. a.
P3
PI
P13
P2
r
I P11
PA
I
i OUTPUT
BATTERY AREA i FUEL TANK AREA CONTROL BOX AREA
J.
NOTE
TS 6115-584-12/10
Figure 1-8. Generator Set Wiring Harness
1-13
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1-14 Change 5
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WIRE NO. FROM TO WIRE NO FROM TO WIRE NO FROM TO WIRE NO. FROM TO
D24A16 M5-2 S8-11 P55C10 J1-C TB4-14 P62D16 J2-A TB5-6 X17F16 S8-28 TB514
D25A16 M5 1 S8-21 P55D16 J2W TB4-13 P64A16 A1-4 TB5-8 X22C16 J2-b S8-18
D26A16 M4-1 S8-41 P64B16 M2-1 TB5-8 X23C16 J2-a S8-12
D26B16 J2-F S8-31 P55H16 DS2 1 TB4-12 P64C16 J2-D TB5-8 X29C16 J2-b S8-52
D27A16 M4-2 S8-61 P55J16 DS11 TB413 P64E16 MM TB5-8 X31D16 J2-k S8-54
D74A16 M3-2 A3- P55L16 JlD TB4-12 P66C16 J2-Q TB5-9 X34C18 J2-e TB5-4
D75A16 M3-1 A3+ P55N16 M2-2 TB4-12 P66D16 81-28 TB5-9 X34D16 S8-33 TB5-4
H52A12 K2-A2 TB4-7 P55P16 A1-2 TB414 P66E16 All TB5-9 X34E16 S8-57 TB5-4
H52B12 J2 P TB4-7 P55R16 JlF TB4-11 P66F16 J2-1 TB5-9 X35C16 J2-g S8-63
H52H12 J2 R TB4-8 P55U16 K2 X2 TB4-13 P67E16 J2 Z TB4-4 X39C16 J2-X A217
K51A12 J2-S K3-A2 P57A16 SI -27 TB4 10 P67F16 A2-12 TB4-4 X40C16 J2 Y A2-14
L58A16 S2-2 TB4-9 P57B16 A1-5 TB4 10 P67G16 T1-X2 TB4-4 X41A16 Rl 2 A2-8
L56B16 DS2-2 TB4 9 P57C16 A1-8 TB410 X9G16 J2-L TB5-12 X42A16 Rll A213
LS6C16 DS1-2 TB4-9 P58A16 K3-X1 A1-6 X9H16 A3-1 TB5-12 X43A16 T2-X2 A2-10
P50B10 J1-A TB4-5 P59C16 J2-M TB4 3 X9J16 T2-H1 TB5-12 X44A16 T2-X1 A2-11
P50C12 K2-A1 TB4-5 P60A16 A1-7 TB5-5 X9K16 T1-Hl TB5 12 X45A16 T1-Xl A2-15
P50D12 K3-A1 TB4-6 P60B16 A2-18 TB5-5 X12G16 J2-H TB5-13 X46A16 T1-X3 A2-16
P50E16 CB2-2 TB4-6 P60C16 J2-N TB5-5 X12H16 A3-2 TB5-13 PS9D16 K3-X2 TB4-3
P50F16 J2 C TB4-6 P61A16 S1-14 TB5-7 X12J16 T2-H2 TB5-13 P59E16 J2-J TB4-3
P53A16 CB2-1 TB511 P61B16 A1-3 TB5-7 X12K16 T1-H2 TB5 13
P53B16 Sill TB5-10 P61C16 J2F TB5-7 X14D17 J2-C S8-L5
P53C16 S1-25 TB511 P61E16 J2E TB5-7 X15D16 J2-d S8-24
P53D16 S2 1 TB5-11 P62A16 S117 TB5-6 X17D16 J2-K TB514
P54A16 S115 K2 XI P62B16 J2-B TB5-6 X17E16 S8-26 TB5-14
f
I
P54A "
P57A
P02A
P66D '
SI s?
9 9 99
X17E -O9OO9999
□26A X34D X17F. Q
D24At D25A, in□ L
X X X
"H
6 6 6 6 inu Q < CD < 0
Ml M2 X nX nX SX 0 Qs X
6 0 b 6 66 60 66666666
M3 DSI MS HI S8
NOTE
LAST TWO DIGITS IN "WIRE NO." INDICATE WIRE SIZE. THUS D24A16 IS A 16 GAUGE WIRE.
Figure 1-10. Control Cubicle Wiring Harness
{
TM 5-6115-584-12
NAVFACP-8-622-12
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TM-05682C-12
CHAPTER 2
OPERATING INSTRUCTIONS
Do not operate Generator Set in an enclosed Do not operate in excess of 200 hours continu
area unless the exhaust gases are piped to the ous with JP-4, MIL-J-5624 bulk fuel.
outside. Continued breathing of exhaust fumes
is dangerous. a. When starting a set with a dry fuel system or after a
filter drain or change:
Stay clear of all exposed electrical terminals
when Generator Set is operating. (1 ) Push in the DC circuit breaker.
Change 5 2-1
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(2) To prime fuel lines, slightly open one Drain Cock (5) When pump slows down, close Drain Cock and
item (1) on Filter item (10) nearest to Check Valve item move master switch to START.
(6). See Figure 4-11.
b. Move master switch to PREHEAT position and hold
(3) Move master switch to PRIME & RUN. for one minute.
NOTE
(4) The slowing of pump action indicates the fuel
system is primed. Preheat is not required when engine is warm.
2-2 Change 5
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Table 2-1. Generator Set Controls and Instruments
BATTERY Green — Good; Red — High or Indicates the degree of charge of the batteries.
INDICATOR Low ; Yellow — Charging Needle in left of green indicates discharged battery,
green area normal condition, red area indicates
extreme charge condition, or extreme discharge
condition.
Panel Light Shielded, bulb type, two used Illuminates control panel.
RUNNING TIME Hourmeter; 0 to 9,999.9 hours Indicates total operating time of Generator Set.
meter
Frequency Meter Range 55 to 65 Hz; 0.1 Hz scale Indicates frequency of Generator output.
divisions ; red mark at 60 Hz
% RATED CUR 0 to 133 percent range; red line Indicates percent of rated output current.
RENT METER at 100 percent, green line at 80
percent.
Voltmeter, AC 0 to 300 volt scale; suppressed Indicates Generator Set output voltage.
from 0 to 100 volts and linear
from 100 to 300 volts. Red marks
at 120, 208, and 240 volt points.
MASTER SWITCH Rotary switch, 5 positions, When placed in PREHEAT position, electrical
PREHEAT, OFF, PRIME & power is applied to glow plugs and preheaters on
RUN AUX. FUEL, PRIME & the engine to aid in cold engine starting. In OFF
RUN, and START position, all dc circuits are deenergized except panel
lights, and battery charging system. This position is
used to stop the unit under normal operation. The
PRIME & RUN AUX. FUEL position, is used when
set is running and auxiliary fuel system is being used
and also to prime entire fuel system before starting
if required. The PRIME & RUN position is used
when set is running and auxiliary fuel system is not
used and also to prime engine fuel system only
before starting if required. When placed in START
position, energizes engine cranking system for
engine starting, activates glow plugs and air heaters,
and by-passes protective devices.
DC CONTROL 7.5 AMP breaker Use for protecting dc circuit in case of short and
CIRCUIT also for emergency stopping; pull out to activate.
BREAKER
c. Place master switch in START position and d. Master switch will return to PRIME & RUN po
hold until engine comes to operating speed. If engine sition when released. If running from auxiliary fuel
does not start within 15 seconds repeat steps b and c. source, move master switch to PRIME & RUN AUX.
FUEL position.
120V
IPH
120/ t 120/
TBI 208V * ' » 240V
3PH IPH
O LI L2 L3 LO o
CAUTION:
DISCONNECT LOAD
BEFORE SWITCHING
% RATED
PANEL FREQUENCY CURRENT PANEL
LIGHT METER METER LIGHT VOLTMETER
BATTERY INDICATOR
PRIME AND
UXRUNFUEL ^.tftCWASf^
PULL0FOF< OFF
EMERGENCY
HEAT 1. !/ START|
MASTER SWITCH
VOLTASE ADJUST
AMMETER-VOLTMETER
SWITCH
© 0
' ' i i ' ' ' i
TS 61
g. Place AC circuit breaker in ON position. Adjust Observe percent rated current meter. Do not exceed
speed control to obtain 60 Hz. 5% load difference between phases. A 0.8 power factor
Table 2-2. Reconnection Switch Positions
Switch Position
Load Voltage and Phase Amps - Volts - Phase Measurement Across Terminals
120V 1 phase L3 L3-L1 1 L3-L1
120/240V 1 phase L3 L3-L0 1 L3-L0
120/208V 3 phase L1 L1-L2 3 L1-L2
L2 L2-L3 3 L2-L3
LS L3-L1 3 L3-L1
L3 L3-L0 3 L3-L0
2-4
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
load equals a 100% meter reading for maximum rated (5) Battery indicator should indicate yellow while
load. A 1.0 power factor load equals a 80% meter battery is charging, green when battery is fully
reading for maximum rated load. charged.
(2) Check fuel level gauge periodically. (7) Frequency meter should indicate 60 Hz (at
full rated load).
(3) Oil pressure gauge located on engine should
indicate 20 psi minimum.
(4) Check running time meter periodically in j. During operation, inspect for leaks, paying par
order to perform preventive maintenance check and ticular attention to engine fuel and oil lines and con
services at proper intervals. nections.
L3 LI
L3 ' \/g 2" N L2
TS 6116-564-12/2-4
Figure 2-4. Load Terminal and Reconnection Configuration
2-5
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
k. During operation, listen for unusual noises which 2-6. SHUTTING DOWN UNIT.
may indicate a pending malfunction.
a. Place AC circuit breaker in the OFF position.
2-5. OPERATING IN ALTERNATE MODES. b. To stop the Generator Set, place the master
switch in the OFF position.
CAUTION c. After operation of the Generator Set, perform
the inspection and service requirements as outlined
Disconnect load before switching. in preventive maintenance checks and services under
Operator Maintenance Instructions, Chapter 3.
This unit can be set for 120 volt - 1-phase, 120/240
volt - 1-phase, or 120/208 volt - 3-phase output. Ro d. Emergency Stop. To stop Generator Set in an
tate reconnection switch to desired output connection. emergency, pull out DC control circuit breaker (see
Refer to figure 2-2. figure 2-3).
2-7. OPERATION IN EXTREME HEAT. f. Hold master switch in START position for 2
minutes after engine comes to operating speed.
To ensure satisfactory operation under conditions of
extreme heat, accomplish the following: 2-9. OPERATION IN DUSTY OR SANDY AREAS.
a. Be sure that nothing obstructs air flow to and To ensure that the Generator Set will operate satis
from the unit. factorily in dusty or sandy areas, accomplish the fol
lowing:
b. Keep cooling fins clean.
a. Clean Generator Set frequently.
c. Inspect battery electrolyte level daily. Add dis
tilled water if necessary. b. Service air cleaner frequently. Check air re
striction indicator daily. If red signal is visible,
d. Keep generator free of dirt and grime. Be sure service the air cleaner. Be certain that all air cleaner
ventilating screens are free of obstructions. and intake manifold connections do not leak. Be cer
tain oil filler cap fits snugly.
2-8. OPERATION IN EXTREME COLD (-25° F.
-32°C). c. Change crankcase oil and oil filter frequently.
To ensure satisfactory operation under conditions of d. Store oil and fuel in dust-free containers.
extreme cold accomplish the following:
e. Make sure that Generator Set ground connection
a. Use correct lubricating oil in engine crankcase is free of dust and sand and connections are tight
for temperature conditions. (Refer to figure 3-1.) before starting the unit.
Change oil only when engine is warm.
2-10. OPERATION IN WET OR HUMID AREAS.
b. Use Arctic Grade diesel fuel.
To ensure that the Generator Set will operate satis
c. Keep batteries in a well charged condition. factorily in wet or humid areas, accomplish the fol
lowing:
d. Be certain air cleaner intake control is in cold
weather position. a. Keep fuel tank full to protect against moisture
condensation and accumulation.
e. Shutter blades should be fully closed for cold
engine, open only partially under light load, open b. Check wiring connectors for corrosion and wire
more as load increases. insulation for signs of deterioration.
2-6
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
Section III. OPERATION USING NATO SLAVE CABLE
WARNING The existing Army Slave Cable has end connectors with
two pins to mate with the Slave Receptacle on the
Before you use any cable, make sure the master Generator Set. The NATO Slave Cable has end connectors
battery switches and all electrical switches in with one pin. In order to utilize the NATO Slave Cable on
both the live and dead equipment are in the OFF The Generator Set, an Adapter Connector must be usedAS
position. If you attempt to install the cable into See Appendix B, Basic Issue Items List (BIIL) for Adapter
live operating equipment, arcing can occur. You ConnectorAS
can get burned and your cable will be damaged.
i
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
CHAPTER 3
Change 2 3-1
TM5-6115-584-12
NAVFAC P- 8- 622- 12
TO-35C2-3-456-1
TM-05682C-12
LUBRICATION ORDER
L05-6115-5S4-12
Intervals and the related man-hour times are t Relubricate after washing or fording.
operation. The man-hour time specified is the time required
to perform all the services prescribed for a particular interval.
The interval shall be changed to compensate for abnormal Clean parts with SOLVENT, dry-cleaning, or with OIL. fuel
operation and severe operating conditions or contaminated Diesel. Dry before lubricating.
lubricants. The interval may be extended during periods of
low level activity, commensurate with adequate preservation
precautions. Drain crankcase when hot. Fill and check level.
TS 6115-584 12/3-1(11
Figure 3-1. Lubrication Order (Sheet 1 of 2)
3-2
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-456-1
TM-05682C-12
-KEY-
EXPECTED TEMPERATURE
LUBRICANTS CAPACITY INTERVALS
Above +30°F + 30°Fto -10°F -10«FtO -65°F
OE-OIL, Engine. Heavy Duty 3 qt. w/o Filter Intervals
Crankcase given are
Oil Can Points 4 qt. w/Filter OE30 OE10 OES in hours
of
normal
OES-OIL, Engine. Sub-zero operation
Official:
PAUL T. SMITH BERNARD W. ROGERS
Major General, United States Army General. United States Army
The Adjutant General Chief of Staff
Official:
JAMES J. SHEPARD, COLONEL DAVID C. JONES, General, USAF
Commander, Air Force Logistics Command Chief of Staff
Official:
J.R. JONES E.B. FOWLER
Major General, U.S. Marine Corps Rear Admiral, United States Navy
Deputy Chief of Staff for Installations Commander, Naval Electronic
& Logistics Systems Command
3-3
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
NOTE
Within designated interval, these checks are to be performed in the order listed.
B-Before D-During A-After W-Weekly M-Monthly
Interval Procedures Equipment is
Item Item To Be Check for and have repaired Not Ready/
No. B D A W M Inspected or adjusted as necessary Available if:
NOTE
Perform lubrication prior to or in conjunction with
before PMCS. Refer to LO 5-6115-584-12. Keep your
unit clean by wiping of dirt and oil as you do PMCS.
3-4 Change 5
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
Table 3-2. Operator/Crew Preventive Maintenance Checks and Services (Cont.)
NOTE
Within designated interval, these checks are to be performed in the order listed.
B-Before D-During A-After W-Weekly M-Monthly
Interval Procedures Equipment is
Item Item To Be Check for and have repaired Not Ready/
No. B D A W M Inspected or adjusted as necessary Available if:
Generator set c. Check that grounding cable is installed and Cable is improp
(cont.) tight (para 4-2e, fig. 4-2). erly installed or
missing.
d. Check restriction indicator; if RED, clean Indicating
or replace air filter element, (para 3-18) RED
NOTE
During starting and operation, check restriction
indicator. Check for leaks, loose or cracked parts,
unusual noise, rough-running, excessive vibration,
lack of power, incorrect instrument readings, or
any indication of a failing or defective component.
If suspected, notify organizational maintenance.
Controls and Instruments will indicate within specified
instruments limits.
a. Battery Normal indication: yellow while charging, Indicating in
indicator green when fully charged. the Red.
b. Frequency Normal indication: 60 Hz (red line) with load Proper frequency
meter on generator. cannot be
maintained.
c. Percent rated Normal indication: Percent of load (output) on
current meter each phase. Not to exceed 100% load or 5% dif
ference between phases.
d. Voltmeter Normal indication: 120, 208 or 240 volts depend Desired voltage
ing on AMP Volt transfer switch position. cannot be obtained.
e. Oil pressure Normal indication: 20 to 45 psig at rated RPM. Oil pressure drops
gage below 16 psig.
f. Fuel gage Normal indication : Full
Fuel tank Fill tank upon completion of operation.
CAUTION
Dangerous gases. Do not smoke or use open
flame while servicing battery, due to possible
pressence of hydrogen, a highly explosive gas.
Change 5 3-5
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
Table 3-2. Operator/Crew Preventive Maintenance Checks and Services (Cont.)
NOTE
Within designated interval, these checks are to be performed in the order listed.
B- Before D-During A-After W-Weekly M-Monthly
NOTE
If the Generator Set is not going to be operated
for two weeks or more, disconnect the negative
cable from the battery. The Generator Set will
be ready to go upon reconnection of the negative
cable.
Even if the Generator Set is operated every day,
the battery may still run down. A run down
battery does not have time to be recharged. Run
the Generator Set for at least 30 minutes at rated
speed. Allow extra running time if the preheater
was used, or if starting took several tries.
• Batteries Check battery electrolyte levels. Proper level is 3/4 Air cleaner is
1 ' inch above plates. Use clean water (distilled if missing or un
available). serviceable. In
dicator indi
cates red.
NOTE
Fuel system temperature must be above freezing
when draining water and sediment.
3-6 Change 5
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
NOTE
Before you use this table, be sure you have performed all applicable operating checks.
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
1. ENGINE FAILS TO CRANK WHEN MASTER SWITCH IS HELD IN THE START POSITION.
Step 1. Check to see that dc control circuit breaker on Control Panel is depressed (paragraph 2-4).
Depress button to set circuit breaker. If breaker will not stay depressed, notify higher level
of maintenance.
Step 2. Inspect for loose, corroded, or broken battery cables or starter ground cable (paragraph 3-11).
If loose, corroded, or broken battery cables and starter ground cable are found, notify
higher level of maintenance.
Step 3. Check to see that electrolyte (liquid) level in each battery cell is above the top of the plates
(paragraph 3-11).
Open drains on the bottom of fuel filters and fuel strainer, and drain sediment and water.
If necessary, drain fuel system and use fresh clean fuel supply.
Step 3. Inspect for loose fuel fittings or bad fuel lines (paragraph 3-20).
If fuel lines are loose, cracked or show signs of leaking, notify higher level of maintenance.
Step 2. Check air cleaner assembly to see that inlet shutter assembely is in proper position for either
COLD WEATHER or NORMAL WEATHER operation (paragraph 3-18).
t
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Step 2. Check to see that shutters on shutter box have fully opened (paragraph 3-14).
Step 4. Low oil pressure will cause engine to shut down. Check oil level (paragraph 3-24).
Remove any restriction from intake port. Check and if necessary clean or replace air
cleaner filter
Step 3. Check load on Generator by checking % rated current meter on control panel (paragraph 3-19).
Step 1 . Inspect for oil leaks especially at front and rear oil seals, at oil pan gasket and dipstick cap
(paragraph 3-24).
Change 5 8-7
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
Table 3-3. Troubleshooting (Cont)
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
CAUTION I
Disconnect load before switching.
Step 2. Check load terminal board (paragraph 3-17).
Make certain load leads are attached to the correct load terminals. Make certain
connections are clean and tight.
If engine speed cannot be brought down so that Generator operates at 60 Hz, check
external governor linkage for binding or notify higher level maintenance
(paragraph 3-21).
3-11. BATTERY ASSEMBLY. (3) Inspect battery top frames (5), bottom frame (12),
and tray (13) for corrosion or physical damage. Check to
a. Inspect (see figure 3-2). see that frame is held securely in place and that all
attaching hardware, nut (7), washer, (8), screw (14), washer
(1) Inspect battery cable terminal connectors (2), (10) and (15), and bolt (9), is securely in place. Check that frame is free
(11) for corrosion, deterioration, or physical damage. Inspect of electrolyte.
battery terminal covers (16) for proper installation and physical
condition. Replace if cracked, split or torn. (4) Inspect battery (6) for leaks or cracks. Check top
of battery and battery caps for cleanliness. Check bat
(2) Inspect cables (1), (3), and (4) for breaks, damage and tery electrolyte (liquid) level. Level should be
deteriorated insulation.
3-8 Change 5
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-456-1
TM-05682C-12
3/4 inch above top of plates. Check that battery caps 3-12. GROUND ROD AND FUEL DRUM ADAPTER
are not loose. HOLD-DOWN ASSEMBLY.
b. Clean. a. Removal (see figure 3-3 ).
(1) Clean terminal connectors (2), (4), (10) and (11), (1) Ground Rod and Fuel Drum Adapter. Loosen
batteries (6) and frame using a low sodium solution and screws (1) and lockwashers (2). Slide three piece ground
wipe dry with a clean cloth. Notify higher level of main rod (3) out of hold-down assembly (4), then slide out
tenance if terminals, cables, batteries or frame is damaged. fuel drum adapter (5).
c. Service. (2) Hold-down adapter. Grasp hold-down assembly
(4) and remove screw (1) and lockwasher (2). Remove
(1) Fill batteries (6) with clean distilled water to a
level of 3/4 inch above top of plates. hold-down assembly.
Change 5 3-9
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3 456-1
TM-05682C-12
(caution"
Do not over-tighten screws as damage to
hold-down assemblies may occur.
(2) Ground Rods and Fuel Drum Adapter. Slide fuel
drum adapter (5) and three piece ground rod assembly (3)
between hold-down assemblies (4) and skid base (6).
Tighten screws (1).
3-13. FUEL TANK ASSEMBLY.
(2) Fuel Tank. Visually check fuel tank (4) for dents
or leaks. Check that filler cap (8) fits securely onto tank and
that filler cap and surrounding area is clean. Clean using
solvent and clean cloth.
(3) Fuel Level Gauge. Check fuel level gauge (6) for
physical damage. Check that gauge shows FULL when tank
is full, and EMPTY when tank is empty. Notify higher level
of maintenance for replacement of fuel level gauge.
1. Screw (2) 4. Hold-down assembly (2) (4) Float Switch. Inspect float switch (7) for physi
2. Lockwasher (2) 5. Fuel drum adapter cal damage. Check that float switch is properly attached to
3. Ground rod 6. Skid-base tank.
Figure 3-3. Ground Rod and Fuel Drum Adapter Hold-Down (5) Fittings. Inspect three fittings (5) for physical
damage. Check that fittings are secured to fuel tank. Notify
higher level of maintenance of leaky or damaged fittings.
b. Cleaning and Inspection.
(6) Fuel Drain Valve. Inspect drain valve (9) for
(1 ) Ground Rod. Inspect ground rod for damage and physical damage. Check that valve operates properly. If not,
corrosion. Pay particular attention to the threaded portions notify higher level of maintenance.
of each piece, making certain the three pieces can be
properly assembled. (7) Filler Cap Assembly. Inspect filler cap (8) for
physical damage. Ensure that vent on underside of filler
cap is open before starting generator.
(2) Fuel Drum Adapter. Inspect adapter (5) for
cleanliness and condition of threaded portions. Clean 3-14. SHUTTER BOX ASSEMBLY.
adapter with cleaning solvent and dry.
a. Inspect (see figure 3-5).
(3) Hold-down. Check hold-down assembly (4) for (1 ) Shutter Assembly. Check shutter assembly with
physical damage and check condition of hardware (1 unit running under normal operating conditions. When
and 2). engine is cold, shutter assembly should be fully closed.
When engine warms up, shutter assembly should be fully
open at 140° F (60° C) or above at full rated load. Make
c. Installation. certain shutter assembly is free of dirt and oil which could
cause shutters to stick.
3-10 Change 5
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
1. Strap (2)
2. Nut (4) 5. Fitting (3) 8. Filler cap
3. Flatwasher (4) 6. Fuel level gauge 9. Drain valve
4. Fuel tank 7. Float switch 10. Skid-base
TS 6115 584-12/3-4
(2) Bracket Assembly. Check bracket assembly flat and straight. Check to see that shutters close se
(1) for secure mounting to shutter (4) and shutter box curely and that they can be easily opened by hand.
(10). Brackets (11) should turn freely on bearings (12)
without excessive play. (4) Thermo Power Unit. Check thermo power unit
(7) located on inside of shutter assembly to see that
it is free of dirt, grease, or physical damage. Notify
(3) Shutters. Check shutters (4) to see that they higher level of maintenance for replacement of thermo
are free of dirt or grease. Check to see shutters are power unit.
3-11
TM 5-6115-584-12
NAVFAC P-8-6 22-12
TO-35C2-3-456-1
TM-05682C-12
3-12
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
3-15. EXHAUST MUFFLER ASSEMBLY. Check to see that exhaust is not obstructed and there
is no evidence of leaks.
WARNING
3-16. ENGINE STARTER ASSEMBLY.
Do not touch muffler assembly while unit is
running or immediately after shutdown, as a. Cleaning and Inspection (see figure 3-7). Clean
severe burns may result. engine starter (1) by removing loose dirt with a stiff
nonmetallic brush. Clean off remaining dirt and oil
a. Inspect (see figure 3-6). Manually open shutter with dry cleaning solvent (Fed. Spec. P-D-680). In
assembly and check that muffler assembly (3) is spect starter to see that electrical connections (4)
securely fastened to unit Check that nuts (2) and lock are clean and tight. Check to see that mounting bolts
tabs (1) attaching muffler to unit are in place. (2) are tight. Check starter (1) for physical damage.
3-13
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
1. Starter
2. Mounting bolts (4)
3. Mounting bracket
4. Electrical terminals (5)
5. Flywheel housing
TS 6116484-12/3-7
Figure 3-7. Electric Starter
1. 120VAC outlet 4. Electrical
cover (2) connectors (4)
3-17. AC OUTPUT CONTROL BOX ASSEMBLY. 2. Latches (2) 5. Load terminal board
3. Load terminal cover 6. Load terminal (4)
a. Inspect (see figure 3-8). TS 6116484-12/34
(1) Control Box Assembly. Check box assembly Figure 3-8. AC Output Control Box Assembly
for cracks, dents, or other physical damage. Inspect
to see that covers (1) for both 120 volt ac outlets
operate properly. Check latches (2) securing load
terminal board cover (3). Check to see that cover (3) Check that clamp (17) attaching dust cap (18) to hous
for load terminal board opens and closes properly. ing is secure and arrows on dust cap are pointing up.
Check to see that electrical connectors (4) are clean Check that two clamps (7) holding cold weather
and securely mounted. operation intake hose (19) are secure.
(2) Load Terminal Board Assembly. Check con (2) Bracket Assembly. Inspect bracket assembly
dition of load terminal board (5) and load terminals (1) to see that it is securely fastened to generator
(6) for cleanliness and tightness. Make certain that housing (2). Check that capscrews (3) and lockwashers
the load leads are secured to terminals. (4) which attach bracket to generator housing, and
three spacers (5) are in place.
3-18. AIR CLEANER ASSEMBLY. (3) Inlet Shutter (see figure 3-10). Check inlet
shutter (6) to see that it slides easily from COLD
a. Inspect on Equipment (see figure 3-9). WEATHER to NORMAL WEATHER position and back.
(1) Housing. Inspect housing (8) for dirt, grease, (4) Air Flow Indicator (see figure 3-10). Check
dents or other physical damage. Check to see that air flow indicator (7) for dirt, grease, or physical
housing is securely attached to bracket assembly (1). damage.
3-14
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
b. Removal and Service. (2) Air Cleaner Element (see figure 3-10). Every
1000 operating hours, or more frequently as condi
(1) Dust Cap (see figure 3-10). Every 100 oper tions dictate, or when red warning on air Bam in
ating hours (more frequently in dusty areas) service dicator becomes visible, clean or replace air cleaner
dust cap (1) by removing cap from air cleaner hous element (4). To remove the element remove dust cap
ing (5), removing rubber seal (9), and cleaning out (1) and seal (9). Remove wing nut (2), seal (3) and
any dirt or debris. The clamp (10) is loosened to re remove element (4). To clean element, direct dry
move dust cap and seal. clean air up and down pleats on the inside of the ele
ment. (See figure 3-11.) If element is very dirty, wash
it by soaking in mild detergent and water. Soak for
CAUTION fifteen minutes or more. Rinse element thoroughly
with clean water from hose (maximum pressure 40
psi). Air dry completely a minimum of 24 hours be
Do not use compressed air of more than 100 fore re -using. Do not dry with compressed air or
psi on the air cleaner element. heat over 150° F (66° C).
3-16
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
(2) Panel Light Assemblies (DS1 and DS2). In (13) Control Cubicle Box. Inspect box for phys
spect panel light assemblies (1) for cracked or miss ical damage.
Change 3 3-17
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
b. Service. damage. Check for leaks especially around fuel line fittings
(12), drains (1), and where bowl joins the head. Check that
(1) Panel Light. Panel lamp cover can be removed fuel filter assemblies are securely attached to mounting
for cleaning by turning them counterclockwise when bracket (16) and that bracket is securely attached to
viewed from front. bracket support on skid-base.
(2 ) Panel Lamps. Panel lamps are screw in base types
and are replaceable.
3-20. FUEL SYSTEM (LESS TANK). (2) Fuel Strainer Assembly (see figure 3-13). In
spect strainer assembly (11) for dents or other physical
a. Inspect (see figure 1-1). damage. Check for leaks especially around fuel line fittings
(12), drain (1), or where the bowl joins the head. Check
(1) Fuel Filter Assemblies (see figure 3-13). Inspect that strainer assembly (11) is securely attached to mounting
two fuel filter assemblies (10) for dents or other physical bracket (16).
-6
—7
u
3-19
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
1. Screw (4)
2. Lockwasher (4)
3. Flatwasher (4)
4. Vibration mount (4)
5. Control Cubicle
a. Inspect.
3-20 Change 5
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
freely. Check that speed control is properly attached (2) Blower Housing Assembly. Inspect blower
to governor assembly. housing assembly (32) for dents or other physical
damage. Check that blower housing assembly is
3-22. ENGINE COOLING SYSTEM. properly secured to engine. With engine running
check for noise which would indicate blower wheel
a. Inspect (see figure 3-17). is rubbing against blower housing assembly or blower
grille.
(1) Shroud Assembly. Inspect shroud assembly
(11) and door panel (12) for dents or other physical
damage. Inspect hinge attaching air housing panel (12)
to see that it swings freely. Check to see that shroud (3) Blower Housing Grille Assembly. Inspect
assembly and door panel are properly secured to grille (29) for dents or other physical damage and
engine. that grille is properly secured to engine.
3-21
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
TS 6115-584-12/3-17(1)
3-22
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
1. Generator assembly 3. Screen guard d. Engine Mounting Assemblies (see figure 3-19).
2. End bell 4. Housing Inspect engine mounts (13) for deterioration or
physical damage. Check for accumulations of dirt,
TS 6115-584 12/3 18 fuel, or oil. Check that mounts are securely attached
to engine and to skid-base with all mounting hardware
Figure 3-18. Generator Assembly in place.
3-23
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
1. Intake manifold
2. Screw (2) 6. Washer (2) 10. Spacer (2)
3. Lock tab (2) 7. Lead 11. Adapter
4. Gasket 8. Heater (2) 12. Gasket
5. Screw (2) 9. Washer (4) 13. Engine mounting assembly
TS 6115-584-12/3 19
Figure 3-19. Intake Manifold Assembly
3-24
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
VALVE
CLOSED
VALVE OPEN
1. Gasket 3. Body 6. Switch
2. Bolt 4. Drain 7. Leads
5. Adapter TO «1 12/3-11
Figure 3-21. 00 Filter and Oil Pressure Switch
SKID-BASE
DRAIN
HOSE IN USE
TO 6llt-CM-U/MO
Inspect to see that there is no dirt or oil underneath lens in i. Engine Stop Solenoid (see figure 3-22). Inspect stop
dicating that gauge is no longer properly sealed. Check to see solenoid (1) for dents or other physical damage. Check that
that pointer is not bent or damaged. Check that markings on solenoid is securely attached to cylinder shroud bottom pan
gauge are readable. Check to see that meter is fastened secure with two screws (2) and lockwashers (3). Check that electrical
ly to engine. connections (4) to solenoid are clean and tight.
h. Flexible Oil Lines (see figure 1-1). Inspect flexible oil lines j. Oil Dip-Stick and Housing (see figure 1-1). In
to the oil pressure gauge and the oil cooler for physical damage. spect oil dip-stick and housing (9) for physical dam
Check for leaks especially around fittings. age. Check for leaks especially at gasket between
TS6115-584-12/3-23
3-26 Change 4
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
WARNING
(4) Inspect ground wire and ground rod for physical Figure 3-24. Ground Stud
damage and check that connections are tight.
CHAPTER 4
ORGANIZATIONAL MAINTENANCE
4-1. INSPECTING AND SERVICING GENERATOR (4) Check engine intake and exhaust systems (fig
SET. ure 1-2) to make certain they are unobstructed by
foreign material.
a. Unloading Equipment. (5) Check that main fuel tank drain cock (figure
1-2) is closed.
(1) The dry weight of the engine Generator Set is
960 pounds. A crane, fork lift, or similar lifting (6) Remove all preservative material except for
device or fabricated skids must be used to unload the preservative crankcase oil.
equipment. The equipment must be kept in the UP
position while unloading. WARNING
(9) Check crankcase oil level (paragraph 3-2) If louvers are used at the air entrance, increase the
and add oil as necessary (paragraph 3-3) in accord duct work size by 25 to 50 percent. Install a gas-tight
ance with the lubrication order (figure 3-1). metal pipe exhaust from the exhaust outlets to the
outside of the installation. The termination of the
4-2. INSTALLING GENERATOR SET. exhaust pipe shall be such that hot gases or sparks
will be discharged harmlessly and will not be directed
a. General. The engine Generator Set should be in against combustible material or into an area con
stalled on a site clear of obstacles, with ample venti taining flammable gases or vapors. Use as few bends
lation and level within ±15 degrees maximum. in the pipe and as short a pipe as possible. The ex
haust pipe should include a low point with suitable
b. Outdoor Installation. When preparing for a per means for draining of condensate. Provide metal
manent installation, be sure the base is solid enough shields, 12 inches larger in diameter than the ex
to support the weight of the unit. See figure 1-4 for haust pipe where the line passes through flammable
dimensions of the base. Select a location where there walls. Wrap the exhaust pipe with asbestos if there
will be sufficient space on all sides for servicing and is any danger of anyone touching it.
operation of the engine Generator Set. When prepar
ing a temporary installation, move the engine Gener
ator Set as close to the worksite as practical. Use [^ftRNINGj
suitable planks, logs, or other material for a base in
an area where the ground is soft. Do not operate the engine Generator Set in an
enclosed area unless the exhaust gases are
c. Indoor Installation, Keep the area well ventilated piped to the outside. Inhalation of exhaust
at all times, so that the engine Generator Set will re fumes will result in serious illness or death.
ceive a maximum supply of air. If a free supply of
fresh air is not available, provide duct work which d. Leveling. The Generator Set is a portable unit
will assure at least 1350 cubic feet of air per minute. and is designed to operate satisfactorily up to 15°
4-2
TM 5-6115-584-12
NAVFAC P-8-62212
TO-35C2-3-456-1
TM-05682C-12
out-of-level. Set up the unit as level as possible and grounding method must be supplemented by an addi
keep it as level as possible during operation. tional driven metal rod ground or a buried metal
plate ground. A driven metal ground rod must have a
minimum diameter of 5/8 inch if solid or 3/4 if pipe,
e. Grounding. The Generator Set must be grounded and driven to a minimum depth of 8 feet. A buried
prior to operation. The ground can be, in order of metal ground plate must have a minimum area of 9
preference: (1) an underground metallic water piping square feet, minimum thickness of 1/4 inch, and be
system, (2) a driven metal rod, or (3) a buried metal buried at a minimum depth of 4 feet. The ground lead
plate (figure 4-2). If the effectively grounded portion must be at least No. 6 AWG (American Wire Gauge)
of the buried metallic water pipe is less than 10 feet copper wire. Ground rods are available as optional
due to insulated sections or joints, this preferred equipment.
GROUND STUD
TS 611S-M4-12/4-2
4-3
TM 5-6115-584-12
NAVFAC P-8-622 12
TO-35C2-3-456-1
Section II. MOVEMENT TO A NEW WORKSITE
TM-05682C-12
4-3. DISMANTLING GENERATOR SET FOR MOVE (6) Disconnect negative battery cable from bat
MENT. tery.
a. Preparation for Movement. (7) Disconnect any other hoses, lines or cables,
if used.
(1) Disconnect the load cables.
(8) Close and secure all doors and panels.
(2) Remove exhaust pipe extension if used.
b. Movement. Preferred means of movement is to
(3) Make certain vent on underside of fuel filler transport. Towing for short distances is permissible
cap is closed. if terrain is suitable.
(4) Refer to the Items Troop Installed or Author 4-4. REINSTALLING GENERATOR SET AFTER
ized List (Appendix B and make sure all items are on
the equipment. MOVEMENT.
(5) Disconnect the ground lead from the ground Refer to paragraph 4-2 for reinstallation after move
stud. ment to a new worksite.
NOTE (6) Remove bolt (2) and pull oil filter body (3) loose
from oil filter adapter (5).
Insure that crankcase is hot before draining
oil.
(7) Discard gasket (4) and oil filter element (6). |
b. Oil Change (see figure 3-20).
(8) Wipe inside of oil filter body (3) clean with a rag.
(1) With drain valve closed, disconnect oil drain
hose from the plug on the skid-base.
(9) Wipe inside of adapter (6), clean with a rag. In- I
sure that the gasket groove is free of foreign material. In- I
(2) Open drain valve and drain oil into a con spect gaskets (7) and (10), retainer (8) and spring (9). I
tainer having at least a 4 quart capacity. Replace damaged components. I
44 Change 3
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
(10) Apply a thin coat of clean engine oil, (12) Pour 6.5 quarts of engine oil (see lubri
MIL-L-2104 to a new gasket (4). Install new gasket cation order for proper grade of oil) into oil fill tube
(4) in groove of adapter (5). (9, figure 1-1).
(11) Assemble components on through belt (2) in (13) Check oil level with dip-stick.
the order shown in figure 4-30. Position body (3) with
drain plug (1) down on adapter (5). Tighten through bolt (14) After 5 minutes of engine operation, check
(2)tol3^2ft-lb. crankcase oil level and bring oil level to full mark.
Change 5 4-5
TM 5-6U5-5R4-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
PROCEDURES EQUIPMENT IS
ITEM ITEM TO BE Check for and have repaired Not Ready/
NJL_ w M H INSPECTED or adjusted as necessary Available 1f:
4-6 Change 5
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
Step 2. Inspect battery and starter cables for corrosion and loose connections.
Replace starter.
Step 3. Inspect for clogged fuel strainer element or fuel filter elements (paragraph 4-20).
Clean strainer element; replace fuel filter elements.
4-7
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Remove obstructions.
6. ENGINE HAS EXCESSIVE OIL CONSUMPTION.
Step 1. Check air cleaner element.
4-8
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
Table 4-2. Troubleshooting (Cont)
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
4-9
TM 5-6115-584-12
NAVFAC P-8-6 22-12
TO-35C2-3-456-1
TM-05682C-12
Table 4-2. Troubleshooting (Cont)
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Replace fuse.
Step 2. Check for bad battery or batteries (paragraph 4-25).
4-14. GENERAL METHODS FOR PROPER SUP function it is to supress radio interference. The pri
PRESSION. mary suppression components are shown in figure
4-3.
Essentially, suppression is attained by providing a low
resistance path to ground for stray currents. The
methods used include shielding the ignition and high-
frequency wires, grounding the frame with bonding
straps, and using filtering systems.
b. Secondary Suppression Components. These com
4-15. RADIO INTERFERENCE SUPPRESSION COM ponents have radio interference suppression functions
PONENTS. which are incidental or secondary to their primary
function. They are the internal-external tooth lock-
a. Primary Suppression Components. The primary washers on the fuel pumps and battery charging reg
suppression components are those whose primary ulator-rectifier.
4-10
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
4. Capacitor
The engine has a pressure air cooling system. Fins a. Inspection on Equipment (see figure 3-17).
on the engine blower draw air into the front of the en (1) Check shutters on shutter assembly (4) for
gine housing and force it past the cylinders and out cleanliness and obstructions. Check blower housing
the right side of the engine. The engine air outlet
(32) externally and internally at engine blower for | |
uses a shutter assembly to control engine temper
ature. Part of the air is directed thru the air cleaner cleanliness and obstructions.
at cold temperatures. A thermo power unit controls (2) Open panel (12) by opening latches (14) and
shutter opening which limits air flow when the engine check that panel hinge works properly. With panel
is cold. When the engine air temperature reaches open, check engine fins for cleanliness and obstruc
approximately 120" F (49° C), the shutters begin to tions to airflow.
open. The shutters are completely open at 140° F
(60° C). The cooling system contains a high temper b. Removal.
ature cut-out switch that shuts down the engine in
case the engine temperature reaches 394°F (201°C). (1) Disconnect negative lead from batteries.
4-12 Change 3
TM5-6115-584-12
NAVFAC P-8-622- 12
TO-35C2-3-456-1
TM-05682C-12
(2) Air Housing Duct Cover. Loosen hose clamp (1) and nuts (2). Remove screws (4) and special washer
(6) and remove air housing duct cover (2) by remov (5) attaching thermo unit assembly (6) to shutter as
ing screws (1). sembly and remove thermo power unit assembly. Be
careful plunger does not fall out of thermo unit as
(3) Shutter Assembly. Disconnect wiring to ther sembly.
mal switch at connector plug (5) on outside of shutter
assembly. Remove capscrews (3) attaching shutter (2) Shutters. Remove eight screws (7) and washers
assembly to engine and blower housing (33). Care (8) attaching shutters (9 and 10) to bracket assem
fully pull shutter assembly (4) away from muffler blies (11, 12 and 13). Remove shutters. Remove nuts
(40) until lead from connector (5) to high tempera (14) washer (15) and shutter torsion springs (6).
ture cutout switch (38) becomes accessible. Discon Brackets (12) can now be removed. Remove bracket
nect leads from high temperature cutout switch (38) bearings (17). Remove screws (19) and remove bear
and remove shutter assembly (4). ing (17) and washer (18), brackets (11 and 13).
(3) Brackets.
(4) Remove screws (33 and 34) and remove front
shroud (36). (a) Remove clips (20) that retain lower rod
(21) in bracket (11) and pivot arm (22). Remove lower
rod and bracket (9). Remove bracket bearing, screw
(5) Shroud Assembly. Open latches (14), remove (19) and remove bearing (17) and washer (18).
screws (7), and washers (8), lift panel (9) and shroud
(11) as an assembly from the engine and blower hous (b) Remove nut (23), clip (24) and ball arm as
ing (33). sembly (25). Remove bracket (12) and associated
bearing (17), washer (18) and screw (19) using pro
cedure as in paragraph (a) above.
(6) Baffles and Shrouds. Remove rear shroud
(22) by removing screw (17), screw (15), washer (16), (c) Remove pivot arm (22) by removing nut
screws (20 and 18) and tie bars (19 and 21). Remove (26), lockwasher (27), flatwasher (28), washer (29),
baffle (25) by removing nuts (23) and J bolt (24). bearings (30) and bolt (31).
(1) Inspect the engine fins and the housing as (a) Reassemble pivot arm (22) using bolt (3l),
semblies for debris and remove as necessary. Clean bearings (30), washer (29), flatwasher (28), lockwasher
using detergent, clean cloth and brush. (27) and nut (26).
(2) Disconnect leads and remove high tempera (b) Mount bracket (13) to box (32) using bear
ture cutout switch from cylinder head. Check continuity ings (17), lockwasher (18), and screw (19). Be careful
between two terminals while heating switch with its not to confuse bracket (13) with bracket (12). Connect
mounting stud submerged in oil. When the temperature ball arm assembly (25) to bracket (13) and pivot arm
of the oil reaches 394 ±10° F (201 ±5°C) the switch (22) using clip (24) and nut (23).
should open. Switch should close when temperature
drops below 394 ±10° F (201 ±5°C). If switch does not (c) Mount bracket (11) along with bearing (17),
perform as indicated, replace. lockwasher (18) and screw (19). Ensure that bracket
is mounted so that shutter divider acts as inside stop.
Mount lower rod (21) to bracket (11) and pivot arm
d. Disassembly of Shutter Assembly (see figure (22) using clips (21).
4-4).
(d) Install brackets (12), bearings (17) and lock
(1) Shutter Thermo Power Unit Assembly. Re washer (18). Ensure that lower bracket is mounted so
move electrical connector (3) by removing screws that shutter divider acts as inside stop.
4-13
TM5-6115-584-12
NAVFAC P- 8-622-1 2
TO-35C2-3-456-1
TM-05682C-12
TS 61
Figure 4-4. Shutter Assembly
4-14 Change 2
TM5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
(?) Install power unit assembly (6) into shutter (2) Blower Housing. Install blower housing (32)
assembly box (32) using screws (4) and special washer on engine using screws (30 and 31).
(5). Mount connector (3) using screws (1) and nuts (2).
(3) Blower Grille Assembly. Install grille (29)
(3) Shutters. Mount torsion spring (16) using nut (14) on blower housing (32) using screws (26) and re
■ and washer (15). Mount shutters using screws (7) and tainers (27).
| washers (8). Ensure that adequate clearance between
shutter and shutter box sides is maintained and that (4) Baffles and Shrouds. Install shroud (22) using
brackets (12) are seated against shoulder of bearing (17) screws (15 and 17) and washer (16). Install rear shroud
| prior to tightening screws (7). Check shutter to ensure (36) using screw (33), clip (35) and screw (34). Install
they will fully open and close without binding. baffle (25) with hook bolt (24) and nut (23).
Change 3 4-15
TM5-6115-584-12
NAVFAC P-8- 622-12
TO-35C2-3-456-1
TM-05682C-12
4-18. DESCRIPTION AND FUNCTION. (5) Loosen filler cap and remove filler cap (4) and
strainer (5).
a. Low Pressure System (see Schematic figure
1-5).
d. Cleaning and Inspection.
(1) Fuel pump may draw fuel from an external
source to fill set tank or set tank may be filled man (1) Tank. Clean tank exterior using suitable sol
ually. If an external fuel source is selected, a float vent and clean cloth and brush. Inspect tank for
valve assembly in the set tank maintains the fuel signs of physical damage. If damaged refer to higher
level in the tank. Two other fuel pumps (in series) level of maintenance.
draw fuel from the set tank and force the fuel through
a primary strainer, two filters, and a check valve (2) Fuel Level Gauge. Check that fuel level gauge
assembly, to the injection pump. face is clean and readable. Check that as cork float
is moved up and down, the meter movement rotates.
b. High Pressure System. (3) Float Switch. Inspect terminal connector for
damage to threads. Check to see that float slides on
(1) Fuel injection pump forces the fuel, under shaft without binding. Clean with suitable solvent if
high pressure, to the fuel injection nozzles. The in required.
jection nozzles provide fuel to each combustion
chamber of the engine. Unused fuel is returned from (4) Fittings. Inspect fittings for good leak-free
the injectors to the fuel tank. A cam and gear on the seating on tank and check threads for physical damage.
camshaft drives the fuel injection pump. The gear
drives the pump face gear, providing fuel distribution (5) Fuel Drain Valve Assembly. Check that drain
to each cylinder in the proper order. The cam oper valve does not leak and threads for physical damage.
ates the pump plunger, pressurizing fuel to the noz
zles. A control sleeve meters fuel by controlling the
length of time the plunger spill port is closed, main e. Test.
taining pressure, and therefore, the amount of fuel
delivered in each stroke. The pintle type injection (1) Float Switch. Remove float switch (6) from
nozzles are conventional inward opening with ad tank (9). Using an ohmmeter, check for continuity
justable opening pressure. They are factory adjusted between terminals A and B of switch (see figure
to open at 1900 to 1950 psi. 4-8). Switch should show no continuity when float is
up. Switch should close when float drops to 2-7/8
±3/16 inch from threaded collar of float switch. Re
4-19. FUEL TANK ASSEMBLY. place switch if it does not operate properly.
a. Inspection on Equipment. Refer to paragraph (2) Tank. If tank shows signs of physical dam
3- 13a. age or leaks refer to higher level of maintenance.
b. Removal (see figure 4-7). Drain fuel into suit
able container by opening drain valve. Tag and dis f. Reassembly (see figure 4-7).
connect fuel hoses from fuel tank fittings. Disconnect
electrical lead from electrical connector (10). Re (1) Fuel Drain Valve. Engage threads of fuel
move nut (1) and flatwasher (2) from straps (3) on drain valve assembly (8) 1/2 turn into fuel tank
outside of fuel tank. Remove tank from skid-base. adapter (11). Coat threads with sealing compound
MIL-S- 22473. Tighten valve assembly into adapter
c. Disassembly. (1D.
(1) Fuel Level Gauge. Unscrew and remove fuel (2) Fittings. Engage threads of fitting (7) 1/2 turn
level gauge (5) using tools only on the hex portion of into fuel tank (9). Coat threads with sealing com
the gauge. pound MIL-S- 22473. Tighten fittings into tank. Fit
tings should face Generator Set for proper connection
(2) Float Switch. Unscrew collar and disconnect of fuel lines. Attach fuel lines to fittings.
electrical connector (10) if not previously discon
nected. Unscrew and remove float switch (6) using
tools only on the square portions of the switch. (3) Float Switch. Engage threads of float switch
(6) 1/2 turn into tank (9). Coat threads with sealing
(3) Unscrew and remove fittings (7). compound MIL-S- 22473. Tighten float switch (6) into
tank using tools only on square portion of switch. At
(4) Holding pipe adapter (11) with a wrench, un tach electrical lead to connector (10) on top of float
screw and remove drain valve (8). switch and tighten.
4-16
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
(4) Fuel Level Gauge. Engage threads of fuel (3) Check that drain valve is closed before filling
level gauge (5) 1/ 2 turn into tank (9). Coat threads tank with proper grade of fuel.
with sealing compound MIL-S-22473. Tighten float
level gauge into tank using tools only on hex portion NOTE
of gauge. Install filler cap (4) and strainer (5) into tank After each time fuel filters or strainer is
drained or elements replaced, purge air from
fuel system by moving master switch on con
g. Installation. trol panel to PRIME & RUN position. This
should activate the fuel transfer pump and
(1) Install straps (3) onto the skid-base and se force trapped air back to the vented fuel tank.
cure with nut (1) and flatwasher (2) on inside of skid-
base only. 4-20. FUEL FILTER ASSEMBLIES AND STRAINER
(2) Position fuel tank assembly onto skid-base, ASSEMBLY.
position straps over tank assembly and secure with There are two identical fuel filter assemblies (see
nut (1) and flatwasher (2). figure 3-13), one which acts as the primary and the
4-17
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
TS 61154M-12/44
Figure -4- 8. Testing Float Switch
other as secondary, plus there is one fuel strainer. If or leaking fittings and hoses, leaking valves and leak
these filters or strainer are plugged, fuel flow will be ing at bowl and head interface.
restricted and the engine may not run properly.
Periodic maintenance is required for this assembly. b. Service.
(1) Fuel Filters (see figure 4-9). Remove plug
a. Inspection (on Equipment). (1), open drain cock (2) and drain fuel into suitable
container. Remove bolt assembly (3), gasket (4) and
(1) Fuel Filter Assemblies and Strainer Assem filter body (5). Remove filter element (6) and gasket
bly. Inspect the assembly for secure mounting, loose (7). Inspect element for ruptures, clogs or other
4-18
TM 5-6115-584-
NAVFAC P-8-62:
TO-35C2-3-456-
TM-05682C-12
— 10
1. Nut 6. Retainer
1. Plug 5. Filter body 2. Washer 7. Strainer element
2. Drain cock 6. Filter 3. Stud 8. Nut
3. Bolt 7. Head gasket 4. Drain cock 9. Gasket
4. Gasket 8. Head 5. Body 10. Head
TS 6115-684-12/4-9 TS 61 15-584- 12/4-1
Figure 4-9. Fuel Filter Figure 4-10. Fuel Strainer Element
physical damage. Replace element if necessary. (2) Fuel Strainer Element (see figure 4-10
Change primary element every 500 operating hours, Open drain valve (4) and drain fuel into suitable cor
and secondary filter elements every 1000 operating tainer. Remove nut (1) and washer (2) attaching boc
hours. Replace filter element (6), gasket (7), filter (5) to head (10) and remove body and gasket (9). Re
body (5), gasket (4), and bolt assembly (3). Close drain move retainer (6) and remove strainer element (7
cock (2) and install plug (1). Inspect element for physical damage or clogging.
4-1
TM 5-6115-584-12
NAVFAC P-8-6 22-12
TO-35C2-3-456-1
TM-05682C-12
c. Removal (see figure 4-12). b. Test (on Equipment) (see figure 4-15).
(1) Fuel Hoses. Tag and remove fuel hoses (1, 2, (1) Tag and remove the solenoid harness leads
3 and 4) by unscrewing at fittings (5, 15 and 16). Keep (1). Figure 4-14.
4-21
TM 5-6115-584-12
TO-35C2-3-456-1
TM_05682C-12
4-22
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
1. Cover
2. Gasket
3. Strainer
4. Magnet
5. Fuel pump
4-24. DESCRIPTION AND FUNCTION. a. Battery Cables (Including Jumper Cable) (see figure 4-16).
The engine is cranked by a 24 volt starting motor (see figure (1) Test. Test battery cables for continuity. Replace any
1-7). When the starting motor solenoid is energized, a core pulls cable that does not show continuity.
in, shifting the pinion into engagement with the engine flywheel
ring gear. At the same time, contacts in the solenoid close to (2) Remove. Remove negative battery cable from negative
provide a circuit for the starting motor. Two 12 volt batteries ( -) battery terminal. Remove positive ( + ) battery cable from
in series are used. Controls for this starting circuit are located positive battery terminal.
in the control cubicle. A battery alternator is utilized to main
tain the battery charge. The stator is mounted on the engine NOTE
block and the permanent magnet rotor is mounted into the air
cooling system blower. Solid state diode rectifiers convert the Always detach negative (1) cable first and reattach it
alternating current generated in the stator to direct current last.
for battery charging.
Tag and disconnect cables from starter case and starter
4-25. BATTERY ASSEMBLY. solenoid. Remove jumper between batteries. Clean battery,
starter, and starter solenoid terminals thoroughly and install
new cables as given below.
CAUTION
(3) Replace. Attach jumper cable between negative ( -) ter
minal of one battery and positive ( + ) terminal of the other bat
tery. Tighten terminal connectors securely. Attach positive
Metal objects making contact between the positive and battery cable to stud on starter solenoid. Attach negative bat
negative battery terminals, or between the positive bat tery cable to stud on starter case (see figure 4-16). Attach
tery terminal and the generator frame can cause FIRE positive cable to positive terminal on one battery and negative
or EXPLOSION. Always keep the battery terminal cable to negative terminal on the other battery. Tighten ter
covers on the battery terminals. See Figure 3-23. minal connectors securely.
4-24 Change 4
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
TS 8115-5M12/4 16
4-26 Change 3
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
TESTA
switch (5) to field terminal (13). Remove nut and 4-27. BATTERY CHARGING ALTERNATOR.
washer from field terminal (14) on solenoid (5). Re
move pin (11). Remove solenoid switch (5) by remov a. Battery Alternator Stator (see figure 4-23).
ing screws (4). Remove lead (12) from solenoid (5)
and terminal (9). (1) Remove blower housing (see paragraph4-17).
(2) Install Solenoid. Refer to figure 4-22. Con (2) Inspect The presence of the blower wheel
nect lead (12) to terminal (9) on solenoid (5). Connect limits inspection of the battery alternator to inspec
plunger (2) to yoke (3) with pin (11). Connect starter ting that two leads (1) from stator (2) are free of
field to solenoid (5) at terminal (14) with nut and damage and are not rubbing against blower wheel and
washer, do not tighten. Connect solenoid switch (5) are securely connected to terminal block (3) located
to motor (7) with screws (4). Connect lead (12) be on engine back plate (4).
tween solenoid (5) and terminal (13). Tighten nut in
solenoid terminal (14). WARNING
FUSE
REMOVED
TS 6116 SM-12/4-24
(3) Remove (see figure 4-23). Disconnect and tag (1) Inspect. Inspect terminal block (3) for physi
leads on regulator/ rectifier assembly. Remove screws cal damage. Check that electrical connections to block
(7), washers (6) and nuts (6) attaching assembly to are clean and tight. Check that block is securely
sngine back plate and remove assembly. fastened to engine back plate (4).
(4) Replace. Attach assembly to engine back plate (2) Test. Tag and disconnect leads to terminal
jvith three screws (7), six lockwashers (8), and three block. Check to see that there is no continuity be
luts (6). Attach tagged leads from assembly. tween terminals on terminal block and ground.
(3) Replace. Tag and disconnect leads at termi
nal block. Remove two screws and nuts attaching
c. Battery Charger Circuit Fuse (see figure 4-23). block to engine plate and remove block. Attach new
terminal block to engine back plate with two screws
(1) Inspect. Inspect fuse (9) for physical damage. and nuts. Connect previously tagged leads to ter
Check that end caps on fuse are free of corrosion. minal block. Remove tags.
Check that fuse is properly mounted in fuse holder.
4-28. STARTER LOCKOUT SWITCH AND GEAR
(2) Test. Test fuse (9) for continuity using an ASSEMBLY.
ohmmeter. Replace fuse that does not show con
tinuity. a. Inspect (see figure 4-25). Disconnect negative
battery cable. Remove wing nut (1) and cover (3) and
(3) Replace. Remove fuse holder cap and remove inspect switch contact points between contact spring
fuse. Install new fuse in fuse holder body and attach (15) and adjusting screw (14) for physical damage.
fuse holder cap.
b. Test. With engine off, disconnect switch at
d. Terminal Block (see figure 4-23). connector (8). Using an ohmmeter, test that there is
Change 3 4-31
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
12 3 1
continuity between connector (8) pins A and B on lead c. Remove. Disconnect switch lead from connector
from switch. Reconnect switch, operate engine at (8). Remove two screws (9) and lockwashers (10)
operating speed, disconnect connector (8) and attaching switch to engine back plate. Carefully re
between pins A and B on switch, check that switch is move switch taking care not to lose thrust plunger
open (no continuity).
4-32 Change 3
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
4-29. FUNCTION AND DESCRIPTION. damage. Inspect seal (1A, figure 4-28) and replace
if damaged. Blower housing must be removed to
The diesel engine has pressure lubrication to all inspect cooler and hoses.
working parts (see figure 4-27). The oil system
includes oil intake cup, gear type oil pump, bypass b. Service. Every 500 operating hours clean oil
valve, oil pressure gauge, low oil pressure shutoff, cooler fins with air gun (50 psi) held 12 inches away
full-flow oil filter, oil cooler, and passages to de from the fins. Every 2500 operating hours remove
liver oil throughout the engine. Oil is held in the oil oil cooler and flush in both directions using solvent
base, and forced through the oil filter and oil cooler at 25 psi.
by the pump. Lines leading to the rocker housing,
passages through the block to crankshaft and front c. Remove. Remove blower housing. Disconnect oil
camshaft bearing, crankshaft passages to connecting cooler hoses at valve of oil filter adapter (see figure
rod bearings and connecting rod passages to piston 4-29). Drain cooler into suitable container. Remove
pin bushings complete the oil system network. The four machine screws (3, figure 4-28) and special U-
bypass valve controls oil pressure by allowing excess shaped washers (4) attaching oil cooler (1) and oil
oil to flow directly back to the crankcase. cooler seal (1A) to mounting plate (2) and remove
cooler (1). Remove and check hoses. Plug hose
4-30. OIL COOLER. if not used immediately.
a. Inspect (see figure 4-28). Inspect oil cooler (1) d. Replace. Install oil cooler (1) and oil cooler
for physical damage. Visually check for leaks where seal (1A) on mounting plate (2) and secure with screws
oil cooler is connected to oil hoses (figure 4-29). (3) and special U-shaped washers (4). Attach oil
Check that cooler is securely fastened to mounting hoses to cooler as shown ln figure 4-29. Replace
plate (2, figure 4- 28) and that plate is securely fastened blower housing shown infigure 4-29. Replace blower
to engine. Inspect oil hoses for leaks and physical housing. Replace any oil lost.
Change 2 4-33
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
BVPASS VALVE
OIL PUMP
OIL PAN
TS 811S-58402M 27
4-34 Change 3
TM 5-6115-584-12
NAVFAC P-8-6 22-12
TO-35C2-3-456-1
TM-05682C-12
Change 2 4-35
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
d. Install. Install switch (11) in adapter (5) and b. Remove. Drain oil filter into suitable container
tighten. Use wrench on square portion of switch base. by removing drain plug (1). Loosen through bolt (2)
Connect leads at terminals 1 and 2. and remove body (3). Remove and discard filter (6)
and gasket (4).
c. Replace. Clean filter mounting area in adapter
4-32. OIL FILTER. (5) and inside of body (3). Install new element (6)
in body (3). Install new gasket (4) in groove of
a. Service (see figure 4-30). Every 100 operating adapter (5). Position body (3) (drain down) with ele
hours replace oil filter element. Clean inside of ment installed on adapter (5) and secure with through
bowl while filter is removed. Replace defective hoses. bolt (2). Tighten through bolt 10 to 15 ft-lb.
4-36
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
- MAINTAIN
4-33. OIL PRESSURE GAUGE. lockwasher (3), clamp (4) and remove oil pressure gauge
and bracket. Remove fitting (5) and nuts (6) attaching
a. Test. Attach a pressure gauge of known accuracy gauge (7) to mounting bracket (8) and remove gauge (7).
between flexible oil line and unit pressure gauge.
Operate unit for 1/2 hour and check that both gauges
read the same. At rated RPM the normal oil pressure is c. Replace. Install oil pressure gauge (7) on mounting
20 to 45 PSI which is dependent on air and engine bracket (8) with nuts (6) two on each side of bracket (8).
temperature, grade of oil, and wear tolerance of engine. Maintain gap between gauge and bracket as indicated on
If the unit pressure gauge is in error by more than 5 lb, figure 4-31. Position oil pressure gauge and bracket on
replace. engine and install clamp (4), lockwasher (3) and screw (2).
b. Remove (see figure 4-32). Disconnect and drain oil Connect and tighten oil line (1).
line (1) top oil pressure gauge (7). Remove screw (2),
Change 3 4.37
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
Section XII. MAINTENANCE OF CONTROL SYSTEM
4-34. DESCRIPTION AND FUNCTION. When the master switch is placed in position 5,
marked START on the control panel, circuits are com
NOTE pleted between terminals 11-13, 11-14, 11-15, 25-27,
25-28. The circuits between 11-13, 11-14, 11-15
All symbols (CB2, S1, etc.) are the same as activate the engine fuel pumps, apply power to one side
used on the wiring diagram, figure 1-7, and of an open contact of relay Kl and activate the pre
elsewhere throughout the manual. heat circuit as described in previous positions of the
switch. The circuit between 25-28 of the master
4-35. DC CONTROL SYSTEM. switch bypasses the safety devices which are capable
of stopping the engine. Bypassing the low oil pressure
Operation of the dc control system is as follows. safety device (S5) is essential until the engine has
Operator controlled dc functions are all contained in sufficient cil pressure to close its contacts. By
three items mounted on the control panel. These are passing the safety device completes a circuit to the
the dc circuit breaker (CB2), the master switch (S1), engine fuel solenoid and relay coil (Kl). Energizing
and the panel light switch (S2) (see figure 4-33). the start relay (Kl) completes a circuit through the
contacts of (Kl) to the running time meter, and to
a. The dc circuit breaker (CB2) controls all dc one side of the low oil pressure switch. The circuit
power to the unit. When it is de -energized (pulled between 25-27 of the master switch applies battery
out), all dc control circuits are de -energized, except voltage to the field flash resistor through diode (CR2).
the battery charging system which is self protected This action applies field flashing current to the
by fuse (Fl). This breaker can be used for emer exciter field. It also applies power through diode
gency stopping of the unit. (CR1), which prevents starting set when the battery
polarity is reversed, and the closed contacts of the
b. The master switch (S1) controls all starting and start disconnect switch (S7) to the crank relay coil
operating of the set under normal conditions. It is a (K3). When the crank relay contacts close, a circuit
five position rotary switch with the extreme position is completed to the starter solenoid (K6), which
in either direction being a momentary position. The closes and starts the cranking motor. With the
five positions control set operates as follows. When engine fuel solenoid energized and the starting motor
the master switch is placed in position 1, marked cranking the engine, the engine should start and ac
PREHEAT on control panel, a circuit is completed celerate toward the speea setting of the governor.
between terminals 11 and 15 of the master switch, When engine speed passes approximately 1000 RPM
this applies power to the coil of the preheat relay the start disconnect switch contact opens de-ener
(K2). When the preheat relay contacts close, power is gizing the crank relay (K3) and in turn the start
then applied to the glow plugs and preheaters on the solenoid and starting motor. With the engine ac
engine. This position of the switch should be used for celerating and ac voltage building up, the governor
starting any time the engine is cold, or has not been will take control of the engine and the voltage regu
run for sometime. The normal period for preheating lator will bring voltage to the value set by voltage
is 1 minute, but can be as long as 1 minute 30 seconds adjust rheostat. By the time the Generator Set is
as conditions dictate. This switch position is momen under control of the regulator and governor, the
tary so that the preheat circuit remains activated engine oil pressure will be sufficient to permit re
only as long as the operator holds the switch in turning master switch (S1) to the PRIME & RUN or
PREHEAT or START position. When the master switch PRIME & RUN AUX. FUEL position depending on
is placed in position 2, marked OFF on control panel, desired set operation. The set will now be operating
all dc circuits are de-energized except the panel under control of the voltage regulator and governor
lights, battery indicator, and the battery charging but without any load. As stated above, the set is now
system. This position is used to stop the set under ready to accept a load. Placing the ac circuit breaker
normal operation. When the master switch is placed in the ON position connects the selected generator
in position 3, marked PRIME & RUN AUX. FUEL on output to the set load terminals. The breaker can be
control panel, circuits are completed between ter opened manually or by automatic action of the internal
minals 11-13, 11-14, 11-17 of the master switch. relay trip device in the case of an overload or a
This applies power to the engine fuel pumps, and the short circuit. The panel light switch activates the
auxiliary fuel system and also to one side of an panel lights when placed in the ON position.
open contact of relay (Kl). This position is used when
the set is running and the auxiliary fuel system is
being used, and also to prime the entire fuel system 4-36. AC INSTRUMENTATION SYSTEM.
before starting. Position 4 of the master switch,
marked PRIME & RUN on the control .panel, is the Operation of the ac instrumentation system which
same as position 3 except that the circuit between consists primarily of ammeter voltmeter and am
terminals 11-17, of the master switch is not made. meter-voltmeter transfer switch is as follows. The
This position is used when the set is running and the function of the ammeter-voltmeter transfer switch
auxiliary fuel system is not being used, and also to (S8) and the meter switching section of the re-
prime the engine fuel system only before starting. connection switch (S6) is to provide the connections
4-38
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
lor correct readings of voltmeter and ammeter in all meter indications will be obtained with the ammeter-
voltage connections and to ensure that the secondaries voltmeter transfer switch (S8) in positions 5 or 6,
of the current transformers are never open circuited. which are single phase positions. It also ensures the
This combination also ensures that when the Gen reverse of this condition for positions 1, 2, 3, and 4
erator Set is connected for 3 phase operation that no of switch (S8).
Change 5 4-39
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C112
4-37. LOAD TERMINAL BOARD ASSEMBLY. (5) Latch door.
a. Load Terminal Removal (see figure 4-32). c. Replacement of Lost or Broken Terminal Clip
(Retainer Safety Clip). The terminal clip is a component of
(1) Unlatch door (3). both the load terminal and the ground terminal. If the ter
minal clip is lost or broken, fabricate as follows:
(2) Remove screws (1), lockwasher (2), and cover
and door assembly (3). (1) Requisition bulk wire NSN 9505-00-804-3814
(0.042 inch diameter) for the ground terminal (ground
(3) Remove screws (4) and lockwashers (5). stud). Requisition bulk wire NSN 9505-01-049-0144 (0.050
inch diameter) for the load terminal.
(4) Carefully lift terminal board (6) and tag and
disconnect leads from load terminals (7) by removing (2) Cut off about 3 inches of the wire, short enough
nut (11), lockwasher (10) and flatwasher (9). to keep the clips from touching another terminal or the
generator frame in the open or closed position.
( 5 ) Remove load terminal ( 7 ) from terminal board ( 6 )
by removing nut (8), flatwasher (12) and lockwasher (13). (3) Slip the wire through the hole in the terminal.
b. Load Terminal Installation (see figure 4-32). (4) Hold the terminal as shown (Detail A, figure
4-32.1) and bend both ends of the wire straight up keeping
(1) Install load terminal (7) to terminal board (6) the wire in as straight a line as you can with terminal body.
by installing lockwasher (13), flatwasher (12) and nut (8).
(5) Bend the wire into back-to-back 90°
(2) Connect leads to terminals (7) by installing (Detail B, figure 4-32.1) so that the legs of both angles are
flatwashers (9), lockwashers (10) and nut (11). about one-half inch long.
(3) Install lockwashers (5) and screws (4). (6) Bend the ends of each 90° angle down and
around into a U-shape (Detail C, figure 4-32.1) so that if
(4) Install door assembly (3), lockwashers (2) and done properly, the clip will hold the nut when it is un
screws (1). screwed to install the cable (Detail D, figure 4-32.1).
DETAIL C DETAIL D
Figure 4-32.1. Terminal Clip Replacement
4-40 Change 5
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
Change 5 4-41
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
4-38. CONTROL CUBICLE ASSEMBLY. (5) Hour Meter (M2). Operate Generator Set. Check
hour meter against a known accurate time source. Replace
a. Test, On Equipment (see figure 4-33 ). meter if necessary.
NOTE (6) Battery Charging Indicator (Ml). Connect meter
capable of reading at least 28 volts dc from terminal on
When disconnecting leads from terminals, battery charging indicator to ground. Operate Generator
tape leads to prevent electrical shorts. Set. With the pointer on indicator pointing in the low or
first green section of the dial, test meter should read 22-28
(1) Control Cubicle. Perform operational test on volts dc. Replace indicator if necessary.
control cubicle, checking for proper operation in each
of the Generator Set's three modes using a voltmeter (7) DC Control Circuit Breaker (CB2). Operate
of known accuracy. Check that ac output voltage indicated Generator Set. Pull circuit breaker (CB2). If generator does
on control panel matches output voltage at terminal board. not come to an emergency stop, stop the unit using master
Check that Generator Set does come to an EMERGENCY switch and replace breaker.
STOP when dc control circuit breaker (figure 2-3) is pulled.
Test individual components of the control cubicle as CAUTION
given below. See figure 4-33 for location of components. [
Disconnect battery cable before making checks,
(2) With the generator operating at rated speed unless otherwise noted.
or 60 Hz, flash the generator field by placing the master
switch on the control cubicle in the start position. If the (8) Master Switch (Si). Disconnect battery. Tag
generator voltage fails to build up after flashing, the control and disconnect seven leads to master switch. Using an
cubicle may be defective. ohmmeter, check for continuity between terminals for
each of the five switch positions as given in table 4-3.
(3) Voltage Adjust Rheostat (Rl). Turn the Am If continuity is not found for each set of terminals listed,
meter Voltmeter transfer switch to its various positions. replace master switch.
For each position of the switch, turn voltage adjust rheostat
to its extreme positions. Voltage readings should be as (9) Panel Light Switch (S2). Tag and disconnect
follows. Voltage adjust range shall be between 205 and two leads to panel light switch. Using an ohmmeter,
220V for the 120/208V, 3 phase, 4 wire connection. test for continuity between terminals on switch. With
Between 114 and 126V for the 120V, 1 phase, 2 wire the switch in the OFF position, there should be no
connection. Between 228 and 252V for the 120/240V,
1 phase, 3 wire connection.
Table 4-3. Master Switch Continuity Check
(4) Panel Light Assemblies (DS1) and (DS2). With
a good incandescent lamp in place and 24 vdc present Check for Continuity
at terminals of panel light (panel light switch ON) check Switch Position Between Terminals
that lamps do not light.
PREHEAT 11-15
NOTE OFF NONE
RUN AUX FUEL 11-13-17
Be certain panel light switch is OFF before RUN 11-13
installing or replacing panel light assembly. START 11-13-15 25-27-28
4-42 Change 5
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
Table 4-4. Voltmeter-Ammeter Range Selector Switch Continuity Check
Switch Position
Volte Phase Amps Check for Continuity Between Terminals
L1-L2 3 L1 11-15 21-23 31-33 41-46-47 51-52
L2-L3 3 L2 11-17 21-24 31-33 41-42-47 51-53
L3-L1 3 L3 11-17-18* 21-25 31-33 41-42-43 51-54
L3-L0 3 L3 11-18 21-26 31-33 41-42-43 51-55
L3-L1 1 L3 11-12 21-27 31-37 41-42-43-45 51-56
L3-L0 1 L3 11-12 21-28 31-37 41-43-45-46 51-57
• Terminal 17 is jumped to terminal 18.
continuity. With the switch in the ON position, there (13) Wiring Harness - Test wiring harness by using
should be continuity. Replace switch if necessary. an ohmmeter checking continuity of each wire. Perform
point to point checks between points indicated on figure
1-10. Wiring harness need not be totally disconnected
(10) Ammeter - Voltmeter Transfer Switch (S8). for checking continuity.
Tag and disconnect sixteen leads to range selector switch. (14) Transformer (Tl ) (see figure 4-33). Tag and dis
Check for continuity between terminals for each of the six connect five leads to transformer Tl. Using an ohmmeter
switch positions as given in table 4-4. If continuity is not check primary winding by measuring resistance from
found for each set of terminals listed, replace switch. terminal H1 to H2. Resistance should be 18.6 ohms ± 1.86
ohms. Check secondary winding by measuring resistance
from terminal X1 to X3. Resistance should be 1.6 ohms ±
(11) Relays (Kl), (K2), (K3), Assembly A-l, CR-1, .16 ohms. If either of the windings do not show the proper
and CR-2. Open circuit breaker (CB2). Disconnect bat resistance, replace transformer.
tery cable. Tag, disconnect and tape terminals lugs of
the following: Al and A2 on crank relay (K3), Al and A2 (15) Transformer (T2) (see figure 4-33), Tag and dis
on preheat relay (K2), and Al-4 and Al-3 on relay as connect four leads to transformer T2. Check primary wind
sembly Al. Tag and disconnect terminals Al-5, Al-6, ing by measuring resistance from terminal Hi to H2.
Al-7, and Al-8 on relay assembly Al. Test for shorted Resistance should be 155 ohms ± 15.5 ohms. Check second
or open diodes CR-1 and CR-2 by using an ohmmeter. Con ary winding by measuring resistance from terminal X1 to
nect positive lead of the ohmmeter to Al-5 and negative X2. Resistance should be 18.8 ohms ± 1.88 ohms. If either
lead to Al-6, ohmmeter should indicate high resistance, of the windings do not show the proper resistance, replace
then reverse the leads and ohmmeter should indicate low transformer.
resistance. Connect positive lead of the ohmmeter to b. Remove.
Al-7 and negative lead to Al-8, ohmmeter should read
high resistance. Replace defective diodes that fail the (1) Control Cubicle. Tag and detach two connectors
above test. Reconnect wire to Al-5, Al-6, Al-7, and for wiring harness from control cubicle (see figure 1-2).
Al-8 to Al relay assembly. Reconnect battery cable, Remove screw (6, figure 4-34) and nut (8) attaching ground
close circuit breaker (CB2). Hold master switch in START strap to cubicle support frame. Remove four screws (2),
position and using an ohmmeter check for continuity lockwashers (3) and flatwashers (4) attaching control
between terminals Al and A2 on crank relay K3 and Al-3 cubicle to vibration mounts (5) and remove cubicle (1).
and Al-4 on Al relay assembly. Continuity should end
when master switch is released. Repeat test for preheat c. Inspect.
relay K2 holding master switch in PREHEAT position.
Replace defective relays. Reconnect wires to relay K2, (1) Inspect the control cubicle assembly per
K3 and Al relay assembly. paragraph 3-19.
(2) Frequency Transducer (A3) (see figure 4-33).
(12) Terminal Board Assemblies (TB4) and (TB5). Inspect transducer for physical damage. Check to see that
Tag and disconnect leads to terminal boards. Test from the electrical connections to transducer are clean and tight.
each terminal to ground for shorts. Replace board if any Check to see that transducer is securely attached to the
terminal shows continuity to ground. control cubicle.
Change 5 4-42.1
TM 5-6115-584 12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
COtL APROX
300 OHM
4-42.2 Change 5
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
(3) Battery Charging Indicator (Ml). Tag and Remove switch knob by loosening two setscrews.
disconnect lead to indicator. Remove two lockwashers Remove nut attaching switch to control panel and
and nuts and retainer holding meter in place and remove switch. Install new switch as given above.
remove indicator.
(4) DC Control Circuit Breaker (CB2). Discon (8) Voltage Adjust Rheostat (Rl). Tag and dis
nect two leads to breaker. Remove two screws connect two leads to rheostat. Remove rheostat knob
attaching breaker to control panel and remove breaker. by loosening two alien setscrews. Remove nut and
washer attaching rheostat to panel and remove rheostat
(5) Master Switch (S1). Disconnect battery. Tag (9).
and disconnect seven leads to master switch. Re
move switch knob by loosening two setscrews. Remove (9) Transformer (Tl). Tag and disconnect five
nut attaching switch to control panel and remove
leads to transformer. Remove four screws and
switch. lockwashers attaching transformer to control cubicle
and remove transformer.
(6) Panel Light Switch (S2). Tag and disconnect
two leads to switch. Remove nut attaching switch
to control panel and remove switch. (10) Transformer (T2). Tag and disconnect four
leads to transformer. Remove two screws and lock
(7) Ammeter - Voltmeter Transfer Switch (S8). Tag washers attaching transformer to cubicle and remove
and disconnect sixteen leads to range selector switch. transformer.
Change 3 4-43
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
(11) Relay (K2-K3). Disconnect battery. Tag and (10) Terminal Board Assemblies (TB4) and CTB5).
disconnect four leads to relay. Remove two screws Attach board to control cubicle with two screws and
and nuts attaching relay to control cubicle. nuts. Attach tagged leads to board (if necessary, refer
to schematic, figure 1-10).
(12) Terminal Board Assemblies (TB4 and TB5).
Tag and disconnect leads to terminal boards. Remove (11) Voltage Adjust Rheostat (Rl). Attach rheostat
two screws and nuts attaching board to control cubicle (9) to control panel with nut and lockwasher pro
and remove board. vided with rheostat. Make certain that rheostat aligns
with slot on panel. Push rheostat knob onto shaft and
NOTE attach using two alien screws. Attach two tagged
leads to rheostat per wiring diagram, figure 1-7.
TB4 has 27 leads and TB5 has 36 leads,
(12) Transformer (Tl). Attach transformer to
e. Assembly. control cubicle with four screws and nuts. Connect
five tagged leads to (Tl) per wiring diagram, figure
(1) Panel Light Assemblies (DS1 and DS2). Attach 1-7.
new light assembly to control panel with the nut and
lockwasher supplied with each assembly. Attach two (13) Transformer (T2). Attach transformer to
tagged leads to each panel light (if necessary refer control cubicle with four screws and nuts. Connect
to wiring diagram, figure 1-7). four tagged leads to (T2) per wiring diagram, figure
1-7.
(2) Hour Meter (M2). Attach hour meter to control
panel with three screws, lockwashers, and nuts pro f. Bench Test. Connect the control cubicle as shown
vided with meter. Attach two tagged leads to meter in figure 4-35 and proceed as follows.
(if necessary, refer to wiring diagram, figure 1-7).
(1) Position switches as follows:
(3) Battery Charging Indicator (Ml). Slide battery
charging indicator into opening in control panel. Place (a) Master switch-stop
retainer over back of indicator and secure with two
lockwashers and nuts. Attach lead to indicator (if (b) Panel light switch-off
necessary, refer to wiring diagram, figure 1-7).
(c) Sl-closed
(4) DC Control Circuit Breaker (CB2). Attach
circuit breaker to control panel with the two screws. (d) S2-open
Reconnect tagged leads to breaker (if necessary, refer
to wiring diagram, figure 1-7).
CONTROL BOX
(5) Master Switch (S1). Attach master switch to + BT
control panel with nut and key ring provided with
switch. Make certain key on key ring aligns with slot HUH
in control panel. Push switch knob onto shaft and
attach with two alien screws. Attach seven tagged
leads to switch (if necessary, refer to wiring dia -©-
gram, figure 1-7). L4
(2) Place master switch in preheat position. (9) Place master switch in the stop position.
Lamps L2 and L3 shall light indicating that the pre All lamps shall be out indicating that all stop circuits
heat circuitry is correct. are correct.
(3) Place master switch in start position. Lamps (10) Place panel light switch in the on position.
LI, L2, L3, L4, L5 and L6 shall light indicating that Panel lights shall be on indicating that the panel light
all circuits for starting are correct. circuit is correct.
(4) With the master switch in the start position, (11) Reposition all switches as in step 1 and dis
open switch S1. Lamp L1 shall extinguish indicating connect test setup.
that the start disconnect circuitry is correct.
(12) Test CR1 and CR2 as follows:
(5) With the master switch in the start position.
Close switch 82 and then, place the master switch in (a) Remove wires from terminals 6 and 7 of
the prime and run position. Lamps L2 and L3 shall Al.
extinguish. Lamps LA, L5 and L6 shall remain lit
indicating that the prime and run circuitry are cor (b) Measure forward and backward resistance
rect. of CR1 between terminals 5 and 6 of Al. Resistance
should read high in one direction and low in the other.
(6) With the master switch in the prime and run If not, CR1 is bad.
position and lamps L4, L5 and L6 lit open switch S2.
Lamp L4 shall extinguish indicating that the engine (c) Measure forward and backward resistance
protective devices circuit and the prime circuit is of CR2 between terminals 7 and 8 of Al. Resistanci
correct. should read high in one direction and low in the other
If not, CR2 is bad.
(7) Repeat the procedure of step 5, except that
the master switch shall be placed in the prime and
run aux fuel position after closing switch S2. Lamps g. Install.
L4, L5, L6 and L7 shall remain lit indicating that
the prime and run aux fuel circuitry is correct. (1) Control Cubicle. Attach control cubicle (1
figure 4-34) to four vibration mounts (5) with fou
(8) With the master switch in the prime and run screws (2), lockwashers (3), and flatwashers (4]
aux fuel position and lamps L4, L5, L6 and L7 lit Attach ground strap (7) to cubicle support fram
open switch S2. Lamp L4 shall extinguish indicating with screw (6) and nut (8). Attach two connector
that the engine protective devices circuit and the from wiring harness to connectors on back of contrc
prime circuit is correct. cubicle.
4-46
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
TS 6115-584-12/4-38(2)
Figure 4-36. Engine Assembly (Sheet 2 of
(1) Air Cleaner Assembly. Check air cleaner b. Test. Operate engine with no load on Generator
assembly for corrosion, broken or dented components Set, until it warms up to normal operating tem
or split hoses. perature indicated by shutters being in an inter
mediate position between open and closed. Check oil
b. Remove. pressure. Oil pressure should be 20-45 psi. Check
frequency on frequency meter. Frequency should be
(1) Air Cleaner Assembly. Loosen hose clamps approximately 60 Hz indicating that engine speed is
(9 and 11) attaching two air intake hoses (10 and 12) about 1800 RPM. Apply full rated load to engine.
to housing and detach hoses. Remove screws (13), Check that governor adjusts engine quickly, smoothly,
lockwashers (14) and remove air cleaner and bracket and without excessive hunting. Check that exhaust is
and spacers (15). Remove air flow indicator (16) by normal under load. Check that engine runs without
turning counterclockwise. excessive fuel or oil consumption. Check that no
unusual noise is heard. Inability of engine to meet
(2) Remove nut (17), lockwashers (18), screw these tests may indicate engine malfunctioning. See
(19) and separate air cleaner (20) and bracket (21). Troubleshooting, Section VI.
d. Install. NOTE
(1) Air Cleaner Assembly (see figure 4-37). Engine lifting attachment is for lifting engine
Install air cleaner (20) on bracket (21) and secure alone. Do not use this attachment for lifting
with screws (19), lockwashers (18) and nuts (17). engine if generator is still attached. Use the
Install air flow indicator (16) on air cleaner. set lifting eye for this purpose (see figure 1-1).
4-47
TM 5-6115-584-12
NAVFAC P-8-6 22-12
TO-35C2-3-456-1
TM-05682C-12
4-48
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
4-43. INTAKE MANIFOLD ASSEMBLY. and tight. While engine is operating, check for leaks
especially at the gasket (15, figure 4-36) between
a. Test, On Equipment (see figure 4-36). Remove manifold and cylinder head and the gasket (25) between
hose between intake manifold and air cleaner to the manifold heater adapter (24) and the manifold.
permit visual inspection of heater coils (18). Place Drop oil from an oil can or hold piece of thin paper
master switch (see figure 2-3) in the PREHEAT posi on point suspected of leaking. If leak exists, oil will
tion. Good coils should start to heat within one minute. be sucked in or paper will be sucked against leaking
Release switch as soon as coil begins to heat. Replace area.
a bad heater.
c. Remove. Tag and disconnect leads (17 and 19)
from heaters (18) and remove heaters (18). Remove
b. Inspect. Inspect heater for physical damage. lead (19) by removing screw (20), washers (21 and
Check that electrical connections to heater are clean 22) and spacer (23). Remove adapter (24) and gasket
a. Inspect (see figure 4-40). Inspect exterior of (1) Assemble filter (10) and cup (11) in breather
breather for damage. Inspect that tube (2) is securely tube (12).
4-50
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
(2) Place screen (7) in valve (6) and install re 4-46. VALVE ROCKER ARMS.
tainer (8).
a. Inspect (see figure 4-41). Inspect rocker arms
(3) Assemble valve (6) on breather tube (12) with for physical damage or excessive wear.
packing (9) between them.
b. Adjust. Check and adjust the rocker arm to
(4) Install insulators (5) on breather assembly proper valve clearance every 500 operating hours.
and install clamp (4) over insulators (5). Correct valve clearance is .010 inch for intake valve
and .007 inch for exhaust valve.
(5) Tighten screw (3).
Always check and adjust the valve tappet clearance head. Correct valve clearance is 0.010 for intake
when the engine is at an ambient of approximately valve, 0.007 for exhaust valve.
70° F (18° C). Remove rocker cover and proceed as
follows: (4) To adjust the valve clearance for No. 2 cyl
inder, turn the blower wheel clockwise 180° until the
CAUTION letter "B" appears in the timing port and adjust valves
as given in step 3.
Turn blower wheel clockwise only. (5) Install rocker cover and tighten screws 7 to
8 ft-lb.
(1) Using 5/ 8" socket wrench and extension, turn
the blower wheel clockwise until No. 1 cylinder is on 4-47. INJECTOR NOZZLE ASSEMBLY AND FUEL
its compression stroke, which follows the closing of LINES.
its intake valve. See figure 4-41 for identification of
intake valve assembly. a. Inspect.
(2) Continue clockwise rotation until the letter (1) Injector Nozzle Assembly (see figure 4-42).
"A" appears in the timing port on the side of the Inspect for leaking fuel. Inspect fuel fittings for tight
generator adapter. This puts No. 1 cylinder in the ness.
power stroke with both valves closed.
(2) Fuel Lines. Inspect fuel lines for leaks and
damage to fittings.
(3) By using a feeler gauge, check the clearance
between the rocker arm and the valve stem cap. See 4-48. GLOW PLUG ASSEMBLIES.
figure 4-41. Increase or reduce the clearance until
the proper gap is established, adjusting with the lock- a. Inspect (see figure 4-42). Inspect glow plugs for
nut which secures the rocker arm to the cylinder physical damage. Check that electrical lead to glow
4-52
TM 5-6115-584-12
NAVFAC P-8-6 22-12
TO-35C2-3-456-1
TM-05682C-12
4-53
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
plug is clean and tight. Check for leakage where the
glow plug enters cylinder head.
CAUTION
4-55
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
Section XIV. MAINTENANCE OF GENERATOR ASSEMBLY
4-53. DESCRIPTION AND FUNCTION. semi-conductor diodes mounted on two heat sinks, a
voltage regulator and current-voltage transformers.
The generator (main alternator) (see figure 1-1) is The exciter armature and the bridge rectifier assem
a single bearing, splashproof, self-ventilated unit, with bly are mounted on the rotor shaft of the synchronous
a flange to attach to the engine flywheel housing. generator and are connected to the generator field
Major generator components are stator, rotor, and windings. The stator of the brushless exciter con
brushless exciter. The stator is composed of a com sists of field coils wound on the poles and attached
pressed stack of one piece laminations held in posi to the generator endbell. During operation of the
tion by stator bars welded axially on the outside generator, the three-phase power generated in the
diameter of the laminations. A steel wrapper welded rotating exciter armature is applied directly to the
to these bars provides the generator frame. The rotating rectifier assembly. The six diodes, mounted
generator windings each occupy two groups of slots on rotating heat sinks, are connected to forma three-
180 mechanical degrees apart. The generator rotor is phase, full-wave bridge. The direct current output of
composed of one piece rotor laminations, stacked, the bridge rectifier is applied to the rotating field
compressed, and held in position by copper damper of the generator. Thus, the two assemblies; exciter
bars welded to the copper end laminations. Rotor armature and synchronous field form a single rotating
windings are made of Type L2 Class 155 copper wire assembly, enabling electrical connections to be made
insulated from ground with MIL-I-22834A synthetic without the use of brushes, collector rings or com
bonded paper. The rotor is press fitted and keyed to mutator. Excitation current for the stationary field
the rotor shaft, and balanced. The brushless ro coils of the excitation unit is supplied by the synchron
tating exciter with rotating rectifier unit is used for ous generator, and controlled through the static type
providing excitation current to the rotating field of the automatic voltage regulator. The voltage regulator
generator. The complete excitation unit consists of continuously compares the output voltage of the
four basic component assemblies: a three-phase ro synchronous generator with a stable reference volt
tating armature, alternating current generator; a age. The difference between the two voltages con
three-phase full-wave bridge rectifier composed of six stitutes an error signal which indicates an output
4-56. DESCRIPTION AND FUNCTION. (b) Remove four screws (1, figure 4-46) and nuts
(2) attaching each mount in place and remove mounts (3).
(See figure 1-1.) The skid-base serves as a base for mount (2) Battery Frame and Tray Removal.
ing all major components of the Generator Set. Provisions
for towing or lifting with a forklift are built into the skid- (a) See paragraph 4-25 and remove battery hold-
base. Tie down rings are also provided. downs and batteries.
4-57. SKID-BASE. (b) Remove screws (4 and 8, figure 4-46), bevel
washers (7), lockwashers (6 and 10), and nuts (5 and 9).
Remove frame (11) and tray (12).
a. Inspect (see figure 4-46).
(3) Ground Stud. Remove nut (13) and lockwasher
(1) Vibration Mounts. Inspect vibration mounts (3) (14) attaching ground leads (15) from starter to ground
for cracked rubber and loose or missing hardware. stud (16). Remove nut (13) and lockwasher (14) attaching
ground stud to skid-base (24). Remove stud.
(2) Battery Frame Bottom. Inspect battery frame (4) Slave Receptacle. Tag and remove leads (17)
(11) for corrosion, bends, dents or broken welds. from slave receptacle (21). Remove receptacle (21) by
removing screws (18), nuts (19) and lockwashers (20).
(3) Battery Tray. Inspect battery tray (12) for Remove mounting bracket (23) by removing screws (22).
corrosion, or physical damage.
c. Repair.
(4) Ground Stud. Inspect ground stud (16) for (1) Battery Frame Bottom. Clean, weld and
physical damage to threads, nuts and washers. straighten battery frame as required.
(5) Tie Down Ring. Inspect tie down rings (25) (2) Battery Tray. Clean and straighten battery tray
for physical damage. Check that they are securely mounted as necessary.
to skid-base.
(3) Broken or Lost Terminal Clip (Retainer, Safety
Clip). For fabrication procedure, see Chapter 4, Section XII
(6) Skid-Base. Inspect skid-base (24) for physical Maintenance of Control System, paragraph 4-37.
damage. Check that skid-base is not bent or bowed.
d. Install (see figure 4-46).
b. Remove (see figure 4-46).
(1 ) Vibration Mounts. (1 ) Vibration Mounts.
(a) Refer to paragraph 4-38 and remove control (a) Position mounts (3) and install screws (1)
cubicle. and nuts (2).
Change 5 4-57
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
4-58
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
(b) Refer to paragraph 4-38 and install con (b) See paragraph 4-25 and install batteries
trol cubicle. and battery hold- downs.
(2) Battery Frame Bottom and Tray. (3) Slave Receptacle. Install bracket (23) with
screws (22). Install slave receptacle (21) on bracket
(a) Position battery tray (12) and bottom frame with screws (18), lockwashers (20) and nuts (19).
(11) on skid-base (24). Attach by installing nuts (5 and Install leads (17) on slave receptacle as tagged. Re
9), lockwashers (6 and 10), bevel washers (7) and move tags.
screws (4 and 8).
NOTE (4) Ground Stud. Install ground stud (16) on skid-
base (24) with lockwasher (14) and nut (13). Install
Bevel washers are only on the four bolts at leads (15 and 17) on ground stud (16) with lockwasher
the outside of the skid-base. (14) and nut (13).
4-59/(4-60 blank)
i
t
TM 5-6115-584-12
NAVFAC P-8-6 22-12
TO-35C2-3-456-1
TM-05682C-12
APPENDIX A
REFERENCES
L PAINTING:
2. RADIO SUPPRESSION:
3. MAINTENANCE:
T.O. 35-1-4 Processing and Inspection of Aerospace Ground Equipment for Storage
and Shipment.
T.O. 38-1-5 Processing and Inspection of Non-Mounted, Non-Aircraft Gasoline and
Diesel Engines for Storage and Shipment.
5. DESTRUCTION OF MATERIAL:
i
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
APPENDIX B
COMPONENTS OF END ITEMS LIST
Section I. INTRODUCTION
These are minimum essential items required to place the e. Location. The physical location of each item listed
5KW Generator Set in operation, to operate it and to per is given in this column. The lists are designed to inven
form emergency repairs. Although shipped separately tory all items in one area of the major item before moving
packed, they must accompany the Generator Set during on to an adjacent area.
operation and whenever it is transferred between account
able officers. The illustrations will assist you with hard-to- f. Quantity Required (Qty Reqd): This column lists
identify items. This manual is your authority to requisition the quantity of each item required for a complete major
replacement BII based on Table(s) of Organization and item.
Equipment (TOE)/Modification Table of Organization and
Equipment (MTOE) authorization of the end item. g. Quantity: This column is left blank for use during
inventory. Under the received column, list the quantity
B-3. EXPLANATION OF COLUMNS. you actually receive on your major item. The date columns
are for use when you inventory the major item at a later
a. Illustration: This column is divided as follows: date, such as for shipment to another site.
Change 2 B-l
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
Section H. INTEGRAL COMPONENTS OF END ITEM
NONE
B-2 Change 5
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
APPENDIX C
ADDITIONAL AUTHORIZATION LIST
Section I. INTRODUCTION
C-l. SCOPE. in with it. These items are authorized to you by CTA,
MTOE, TDA or JTA.
This appendix lists additional items you are authorized for
the support of the 5KW Generator Set
C-3. EXPLANATION OF LISTING.
C-2. GENERAL.
National stock number, descriptions and quantities are
This list identifies items that do not have to accompany provided to help you identify and request the additional
the 5KW Generator Set and that do not have to be turned items you require to support this equipment.
NONE
APPENDIX D
MAINTENANCE ALLOCATION CHART
Section I. INTRODUCTION
b. Section II designates overall responsibility for B - TEST. To verify serviceability and to detect
the performance of maintenance functions on the electrical or mechanical failure by use of test equip
identified end item or component. The implementation ment.
of the maintenance functions upon the identified end
item or component will be consistent with the assigned C - SERVICE. To clean, to preserve, to charge and
maintenance functions. to add fuel, lubricants, cooling agents and air. (If it is
desired that elements, such as painting and lubri
c. Section m lists the tools and test equipment cating, be defined separately, they may be so listed.)
required for each maintenance function as refer
enced from Section II. D - ADJUST. To rectify to the extent necessary to
bring into proper operating range.
d. Section IV contains supplemental instructions or
explanatory notes required for a particular mainten E - ALIGN. To adjust specified variable elemer' s
ance function. of an item to bring to optimum performance.
F - CALIBRATE. To determine the corrections to
D-2. EXPLANATION CF COLUMNS IN SECTION II. be made in the readings of instruments or test equip
ment used in precise measurement. Consists of the
a. Group Number. Column 1. The assembly group comparison of two instruments, one of which is a
number is a numerical group assigned to each assem certified standard of known accuracy, to detect and
bly. The assembly groups are listed on the MAC in adjust any discrepancy in the accuracy of the instru
disassembly sequence beginning with the first assem ment being compared with the certified standard.
bly removed in a top down disassembly sequence.
G - INSTALL. To set-up for use in an operational
environment such as an emplacement, site or vehicle.
b. Assembly Group. Column 2. This column con
tains a brief description of the components of each H - REPLACE. To replace unserviceable items with
assembly group. serviceable like items.
I - REPAIR. Those maintenance operations neces
c. Maintenance Functions. Column 3. This column sary to restrore an item to serviceable condition
lists the various maintenance functions (A through K). through correction of material damage or a specific
The upper case letter placed in the appropriate failure. Repair may be accomplished at each level of
column indicates the lowest maintenance level author maintenance.
ized to perform these functions. The active repair
time required to perform the maintenance function is J - OVERHAUL. Normally, the highest degree of
included directly below the symbol identifying the maintenance performed by the Army in order to
category of maintenance. The symbol designations for minimize time work is in process consistent with
the various maintenance levels are as follows: quality and economy of operation. It consists of that
maintenance necessary to restore an item to com
C - Operator or Crew pletely serviceable condition as prescribed by main
tenance standards in technical publications for each
O - Organizational Maintenance item of equipment. Overhaul normally does not return
an item to like new, zero mileage or zero hour con
F - Direct Support Maintenance dition.
H - General Support Maintenance K - REBUILD. The highest degree of material
maintenance. It consists of restoring equipment as
D - Depot Maintenance nearly as possible to new condition in accordance with
Change 2 D-l
TM5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
original manufacturing standards. Rebuild is per b. Maintenance Level. This column shows the lowest
formed only when required by operational consider level of maintenance authorized to use the tool or
ations or other paramount factors and then only at test equipment.
the depot maintenance level. Rebuild reduces to zero
the hours of miles the equipment, or component c. Nomenclature. This column lists the name or
thereof, has been in use. identification of the tool or test equipment.
d. Tools and Equipment Column 4. This column is
provided for referencing by code the tools and test d. Tool Number. This column lists the manufac
equipment (Section m), required to perform the main turer's code and part number or federal stock num
tenance functions (Section n). ber of tool or test equipment.
e. Remarks. Column 5. This column is provided
for referencing by code the remarks {Section IV) D-4. EXPLANATION OF COLUMNS IN SECTION IV.
pertinent to the maintenance functions.
a. Reference Code. This column consists of two
D-3. EXPLANATION OF COLUMNS INACTION gL letters separated by a dash (entered from Column 5
of Section n). The first letter references Alpha
a. Reference Code. This column consists of a sequence in Column 5 and the second letter refer
number and a letter separated by a dash. The number ences a maintenance function, Column 3 (A through K).
references the T&TE requirements listed in Section
n. The letter represents the specific maintenance b. Remarks. This column lists information per
function the item is to be used with in Columns (A tinent to the maintenance function to be performed
through K) of Section II. (as indicated in Section n).
D-2 Change 2
TM5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
A-A,
B-B D-I
A-A, A-A,
L-B
EQUIPMENT
2 a
« 7 7"
J, « «
M cnmaan
invHaaAO
HIVdaH
o ttvxsni
)3) aXYHHTIVO
H notiv
Q xsnrav
»H cm CM »H CM
O aoiAHas od od od ud od
•H CM ^ • OO
m xsax od od fcd od
fHtHiH »-« iH *4 r4 fH
1< xoadSNi od ud ud ud od od od od od o
Tank
AStrap
Fuel
s embly,
)HTop
Frame,
old-down)
| ATEMBLY,K
FVL
AROD
GRA-H
S EMBLY, Assembly
Hold-down
ABATTERY
S EMBLY Level
Fuel
Gauge,
8 3 Battery
Cables, 1)
Storage
Battery,
I Assembly
Rod Float
Switch,
Fuel
Tank,
< )3)
Fittings
1)
£ 'ON dflOHQ 3 S S
Change 2 D-3
Iw ■Oaim?bbnOh MICJ1„"00
«i IU11 *>aio\i NM
'
<"
00H -
REMARKS A-A,
C-B, A-A,
L-B A-A,
C-B A-A,
C-B A-A,
C-B, A-A,
C-B,
A-A,
I-B
)5)
A-A A-A K-D A-A -D -D
TOOLS EQUIPMENT
AND
)1)
3-B 3-B 3-B
-.0
K REBUILD D
-.0
J OVERHAUL H
I REPAIR 1.0
F
MFAUINTCENIAONCSE 0.0 0.1 8.0 0.0 0.1 0.0 0.0 0.0 0.0 0.0
H REPLACE O C O O C O O F F F
G INSTALL
)3) F CALIBRATE
E AUGN
0.1 0.1
c SERVICE C C
0.1 0.1 0.3 0.1 0.1 0.1 0.1 0.1 0.1 0.1
A INSPECT C c c C C C c c c c
CONTROL
CAUSBEIMCBLEY
AGROUP
S EMBLY Assembly,
Light
Panel
Filler
Assembly
Cap Incandescent
Lamp,
Valve,
Fuel
Drain Frequency
Meter,
Counbtircole
1) VDC
oltmeter, Ammeter,
AC AC
Voltmeter,
Meter
Hour
Cont'd
)1) d N GROUP 03
D
n § TO o -
REMARKS A-A,
L-B A-A,
L-B A-A,
L-B A-A,
L-B A-A,
L-B A-A,
L-B, A-A,
L-B A-A,
L-B A-A,
L-B
A-A,
I-B
)5)
1I
AND EQUIPMENT
TOOLS
W
3-B 3-B 3-B 3-B 3-B 3-B 3-B 3-B 3-B 3-B
K REBUILD
J OVERHAUL
(CONT)
CHART
AMLIL
ASection
IONCTAENTAINOCNE 1.0
I REPAIR H
FMUANICTEINAONCSE 0.0 0.3 0.1 0.3 0.1 0.1 0.3 0.0 0.3 0.0
H REPLACE O O O O O O F O F O
G INSTALL
)3) F CALIBRATE
E AUGN
0.1
D ADJUST F
C SERVICE
0.1 0.0 0.1 0.0 0.1 0.0 0.1 0.1 0.0 0.0
B TEST O o O O O O F O F O
0.1 0.1 0.1 0.1 0.1 0.1 0.0 0.1 0.1 0.1
A INSPECT C C C C C C F O O O
Control
DC
Breaker,
Circuit
T-l
TransASrmers,
ft
AS EMBLY
GROUP TAmp1Volt
rSwitch,
ansfer Master
Rotary,
Switch, AC
Voltage,
Regsfator, FTraenqsudeuncery,
Adj.
Voltage
Rheostat, A-l
ARelAS
s embly,
Light
Panel
Switch,
)J) K3
and
K2
Relay
Cont'd
)1) d 55 o6 D
~ 0000ifc-•o•s tOtO
z2 > - -
-as
X
REMARKS A-A,
L-B A-A,
L-B
A-A,
J-I J
L-B,
9)
A-A A-A A-A I-B A-A
TOOLS EQUIPMENT
AND
)1)
3-B --1 0-1 --1
0.8
K REBUILD D
0.8
J OVERHAUL H
MS)CONT)
AH.
CHART
LeINcOTtCEANiToNICnOEN 0.0 3.0 0.5 1.0 0.1
I REPAIR F F F H F
G INSTALL
)3) F CALIBRATE
E AUGN
D ADJUST
C SERVICE
TAssembly
Board
erminal Wiring
Assembly
Harnes Wiring
Assembly
Harnes Control
ASpeed
s embly, CONTROL
AS EMBLY
BOX
AGROUP
S EMBLY Assembly,
CBox
ontrol ALoad
Board
s embly,
CBox,
ounbtircole )4)
Con ector
Assembly
CONTROL
AS EMBLY
Counbtircole Control
Engine
(?)
Kl
Relay, AC
OUTPUT Terminal
Cont'd
S NO. GROUP D 05 0-
<H
i-J 9mIH9i«noo*MISS
L
c*f B
Mmi-i
L> £
o
►■o
REMARKS A-A,
L-B A-A,
L-B A-A,
L-B A-A,
L-B A-A,
L-B A-A,
L-B A-A,
D-I O-C
A-A,
A-A,
I-B A-A,
J-I
AND EQUIPMENT
TOOLS
)1)
--1
3-B, 3-B 3-B --1 3-B 3-B 3-B 3-B 0-1
K REBUILD
J OVERHAUL
(CONT)
CHAR1
ALMAn.
SIOeNCTcAEt1NAiNoOCNnE 0.5 0.8 1.5
I REPAIR F F F
MFAUINCTENIAONCES 0.1 0.1 0.8 3.0 0.8 0.3 0.3 0.8 1.1 0.0
H REPLACE F F F F F F F F F O
G INSTALL
(8) F He u
E <
D ADJUST
0.1
C SERVICE C
0.1 0.0 0.0 0.1 0.3 0.1 0.1 0.1 0.0 0.1
A INSPECT F F F F F F F F F C
Assembly,
Bridge
Printed Wiring
Assembly
Harnes CSwitch,
Rotary
on ection
AGROUP
S EMBLY Assembly,
TransASrmer )Less
Tank)
SYSTEM
FVL 1)
As embly,
Filter
Fuel
Circuit
Main
Breaker,
DA
Breaker,
Circuit
Conv
Receptacle,
Linear
Reactor,
Circuit
Board fcCVTl
CT1
Control
Box
Cont'd
i i 0V
0-
i-6115-584-12
FAC P- 8- 622- 12
35C2-3-456-1
05682C-12
A-A,
O-C C-B,
N-C A-A,
D-I A-A,
D-I A-A,
N-C A-A,
D-I
AND EQUIPMENT
TOOLS
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HIVdaH _ "> in
°© o0.
O nvxsNi
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w Nonv
Q xsnrav
03 TS3T
SAtFuel
sraeimnebrly,
ASGREOMiBrLPY SElement,
Fuel
trainer AIR
CLEANER
AS EMBLY ShInlet
Assembly,
ut er
Pump
Assembly,
Fuel
Element,
Fuel
Filter )Lines,
Fuel
Flexible) Air
Housing,
Cleaner ADust
Cap
s embly,
Air
Filter
Cleaner Bracket
Assembly
1)
)Primary) )Electric)
Cont'd
3 "on dnoao s §
Change 2
REMARKS 1B
L-B,
)5)
A-A C-B D-I 1B A-B A-B A-B A-B R-A
TOOLS EQUIPMENT
AND
--
H
--I-J D-1
3-B,
)1) 1-H
3-B 3-B 3-B 3-B
18.0
K REBUILD D D D D D
-.0
J OVERHAUL H H H H H
0.1 0.5 0.1 0.8 0.8 1.8 1.8 1.0 0.5 1.5
FMUANICNTEINOANSCE H REPLACE O F O F F F F F F F
G INSTALL
)S) F CALIBRATE
E AUGN
D ADJUST
C SERVICE
/Exciter
Assembly
Generator GAesRotor
neramtbolry, EARxsecitetmfebirleyr,
GField,
eEnxecraitoer Assembly
Stator
Housing- EARotor
xscietmebrly,
Assembly
Scre n-Guard
GROUP
AS EMBLY AGSENEMRBALTOYR Shaft
Rotor
Bearing,
GEende-raBteolr ,
Flow
Air
Indicator,
1)
Generator Generator
Cont'd
Oo>>-.
£<?>£ ^'to
REMARKS
A-A,
D-I E-B,
1B A-A,
D-I A-A,
D-I
)5)
A-A A-A D-I D-I A-A
AND EQUIPMENT
TOOLS
)1)
0-1 1-B 0-1 0-0
K REBUIL1
J J OVERHJ"
G •J INSTAL
)3) F WH<CALIBR
E AUGN
D ADJUST O o
C w SERVIC
B TEST 0.1
O
Eh INSPEC 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1
A F F C C C C C C c
BAssembly,
rSahcukteter
COOLING
SYSTEM,
ENGINE
ASGROUP
EMBLY
SAHSUTEMEBLRY Panel,
Air
Housing
SAssembly
hut er EXHAUST
MUF LER
Shroud
Assembly
1) Coupling
Disc, Generator
Fan
Thermo
Unit
AS EMBLY
Shut ers Muf ler
Cont'd
REMARKS A-A,
D-I A-A,
D-I C-B
A-A, G-A,
L-B C-B
A-A, 1-
-D D-I
A-A,
)5)
C-B A-A -B
TOOLS EQUIPMENT
AND
8-H
V-H,
)1)
0-1 0-1 3-B 3-B 5-B 0-1
-.0
K REBUILD D
-.0
1.5 1.5
J OVERHAUL H H H
G INSTALL
)3) F CALIBRATE
0.0
E AUGN F
0.5
D ADJUST O
1.0
C SERVICE C
Blower
AHousing
s embly,
AGrille
Blower
s embly,
GROUP
AS EMBLY Set
GEngine,
enerator Gear
RFlywheel
& ing
STARTER
ELECTRIC Assembly
Starter AENGINE
S EMBLY,
Assembly
Brush Assembly
Drive
SSwitch
olenoid
1)
Aagpmhlv
AS EMBLY Armature EXTERNAL
Housing
Cont'd
A-A,
L-B A-A,
U-B K-D,
L-B
EQUIPMENT
S-B
M cninaan
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mvdaH
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MaIntake
Assembly,
nifold SLSwitch
and
toacrktoeurt
Assembly,
Wheel
Blower Oil,
Lines,
FOil
lexible,
AGROUP
S EMBLY
Cooler
Assembly,
Oil Assembly,
Gauge
Oil Fuel,
Lines,
Pump
to
Cooler
Oil
to
Pump
Housing,
Flywheel GAssembly
overnor
Heater,
Manifold
1)
Gear
As embly
Pres ure OH
Hoses,
Injector
Cont'd
S 'ON dllOHO s
Change 3
REMARKS
VA1-
L-
A1- A111-
)5) A1A
A1A A1A A-D
L- L-
-D EQUIPMEA1
DOD
K REBUILD D 1.0
J OVERHAUL H A.0
)COAT)
CVAR1
ALMAII.
-OIeCATc1EtIAi-oCAVn I F -.0
REPAIR
0.1
FMUAICAT1IE-A C-E V REPLACE -- F 0.A F 1.0 F 0.1 - 0.1 - 0.1 0 F 0.8 F -.5 F 0.5
G INSTALL
)1) F CALIBRATE
V ALIGN
0.1
A INSPECT C 0.1 F 0.1 0 1.0 0 0.1 0 0.1 0 0.1 0 0.1 0 0.1 F 0.- F
AAattery
Rotor,
lternator AStator,
Aattery
lternator Valve
Retainers,
&
Locks
Rocker
Assembly,
Cover Assembly
Head
Cylinder
VROUP
AASASVA Charger
Aattery
Fuse,
-top
Solenoid,
Fuel Regulator/Rectif er Aattery
As embly,
AASASVA,
VVI
Alock
1erminal
)- Rocker
Arm
Charging IA1ERA L Springs
Circuit
Arm
Cont'd
)1) d N GROUP - D
REMARKS
A-
A1- D T1D,
F-, -1D
)-) A1A A-J A1A A1A
-- F-
-D EQUIPMEA1
D-D 1-H
1--
---V
)1) A
11 H
161 1)H 111H
I)C-AT)
AM-ection
CHAR1
L -ACTAET.-CAE I REPAIR H 0.8 F 1.0 F -.0 H 0.8
FMAUIAC1EIA-CAES
V REPLACE F 1.0 F 1.0 F 1.5 - 0.A H -.0 D 1.0 F -.- F 0.- - 0.- F 1.0 - 0.-
G INSTALL
)A) F CALIBRATE
E ALIGN
D ADJUST F H 0.-
C SERVICE F - 0.-
A INSPECT F 0.- F 0.1 0 0.- 0 0.1 F 0.1 F 0.1 F 0.5 F 0.1 C 0.1 F 0.1 C 0.1
&
Intake
Valves,
Exhaust VAsolderembly,
&
Aozzle
GR-UP
AASASVA &
Intake
Seat,
Exhaust
As embly,
Pump
Fuel
As embly,
Plug
Glow As embly,
Filter
Oil
Vuide,
-tem
Valve Rod,
Push
Valve
Injector
Fuel Cylinder
Head,
)-) Valve
-pring Fill
-il
1ube,
Injection
Valves
Cont'd
)1) d N GROUP D
>oi
n tnc0 1ICT>tn ii
a■t
o GOStn O
■8102
1 ooi
H
1
REMARKS C-B
A-A,
)5) C-B 1I
N-C
TOOLS EQUIPMENT
AND -H-H
03-
H, --H
0-H,
(4) 0-
H 0A-
H
5 PQ us
5
)CONT)
CHART
ALMAOIn.
Section
CNATENIAONCE 0.5 0.5
P.Ws F F
0.0 0.1 1.0 0.3 1.8 1.0 0.5 1.8 1.0 1.8
FMUANICNTIENOANSCE F o F F F F F 0.- F F
H o O O
•J 5
(S)
E g <
0.0 0.3
B S3w O F
0.1 0.1 0.1 0.1 0.1 0.1 0.0 0.0 0.0 0.1 0.0
C F C O F F F F F F
H w O
GACup
osvermnborly, Assembly
Rod
Con ecting
Rod
C&
Piston
on ecting
GROUP
AS EMBLY Oil
PFUs ure,
Switch, OH
AAdapter
s embly, Oil
APump
s embly,
Filter
Oil
Element, Assembly
Piston
Drain
Oil
Hose, Oil
Pan-Base, Piston
Rings,
D Piston
Pin,
Filter
Cont'd
a) 6 Q D
<cn IUl 00oos■
1cn I K9
>L
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REMARKS A-A,
D-I A-A,
F-B A-A,
D-I
(5-
F-H A-A
AND EQUIPMENT
TOOLS 25-H,
13-H
(4-
25-H
2.0 10.0
5.0
K REBUILD H D D
1
0.8 2.0 0.8
B OVERHAUL F H H
M(CONT-
AII.
SCHART
LIeNOcTCEtANiTINoCOnEN
I REPAIR 2.0 0.8 0.3
F O O
MFAUINTCETNIAONCES 1.8 1.4 3.5 1.3 2.0 5.5 0.2 3.5 0.2
H REPLACE F F F F F F O F O 0.- O
G INSTALL
(3- F CALIBRATE
E AUGN
D ADJUST
0.2
C SERVICE O
0.3
B TEST F
0.4 0.1 0.3 0.2 0.8 0.8 0.1 0.2 0.1 0.1
A INSPECT F F F F F F O F C C
AMounting
Engine
s embly,
C&
Mraainnkshaft
Block
AGROUP
S EMBLY Assembly,
Cover
Gear Frame
Battery
Bottom,
AValve
Oil
s embly, ASKISDE-MBALSYE
CAssembly
amshaft
Cylinder
Block,
(2- Bearings,
Rod
Oil
Breather
Bearings Crankshaft
By-pass
Cont'd
S NO. GROUP 15
1-
as
n CO 3 00 O
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
3
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Change 2 D-17
TM 15-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
Section III. TOOLS, TEST AND SUPPORT EQUIPMENT REQUIREMENTS
D-18 Change 4
TM5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
Q-K Rewind
i
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
ALPHABETICAL INDEX
Paragraph,
Figure, Table,
Subject Number
A
AC Instrumentation System 4-36
AC Output Control Box Assembly F3-8
Inspection 3-17
AC Output Control Box Wiring Harness Tl-9
Administrative Storage 1-7
Air Cleaner Assembly F3-10
Inspection 3-18, 4-41
Installation 3-18, 4-41
Removal and Service 3-18, 4-41
Repair 4"41
Air Cleaner and Shroud Assembly F3-9
Air Filter Element, Cleaning F3-11
Ammeter - Voltmeter Transfer Switch Continuity Check T4-4
Auxiliary Fuel Solenoid Valve 4-22
Test, On Equipment 4-22
B
Batteries, Testing F4-17
Battery Assembly F3-2
Cleaning 3-11
Inspection 3-11
Removal 4-25
Repair 4-25
Replacement 4-25
Test 4-25
Battery Cables, Installing F4-16
Battery Charging Alternator F4-23, 4-27
Inspection 4-27
Removal 4-27
Replacement 4-27
Test 4-27
Battery Charging Regulator/Rectifier Assembly, Testing F4-24
Battery and Frame F3-23
Breather F4-40, 4-45
C
Consumable Operating and Maintenance Supplies T3-1, 3-1
Control Cubicle Assembly F3-12, F4-33
Assembly 4-Z8
Disassembly 4-38
Inspection 3-19
Installation 4-38
Removal 4-38
Service 3-19
Test, Bench 4-38
Test, On Equipment 4"38
Control Cubicle Support Assembly F3-15
Inspection 3-21
Removing F4-34
Control Cubicle Test Set-Up F4-35
Control Cubicle Wiring Harness Fl-10
Control System, Description and Function 4-34
Cylinder Head Assembly F4-42
Change 3 Index 1
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
ALPHABETICAL INDEX (CONT)
Paragraph,
Figure, Table,
Subject Number
F
Float Switch, Testing F4-8
Fuel Filter F4-9
INDEX 2
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
ALPHABETICAL INDEX (CONT)
Paragraph,
Figure, Table,
Subject Number
F (CONT)
Fuel Filter and Strainer Assembly F3-13, F4-11
Inspection 4-20
Installation 4-20
Removal 4-20
Service 4-20
Fuel Pump F3-14, F4-13
Fuel Pump, Fuel Hoses and Solenoid F4-12
Fuel Pumps and Hoses
Installation ' 4-21
Removal 4-21
Service 4-21
Test, On Equipment . 4-21
Fuel Shut-Off Solenoid, Adjusting F4-14
Fuel Shut-Off Solenoid
Adjustment 4-23
Inspection 4-23
Installation 4-23
Removal 4-23
Test, On Equipment 4-23
Fuel Solenoid Test Set-Up F4-15
Fuel Strainer Element F4-10
Fuel System, Description and Function 4-18
Fuel System (Less Tank), Inspection 3-20
Fuel System Schematic Fl-5
Fuel Tank Assembly F3-4, F4-7
Cleaning 3-13, 4-19
Disassembly 4-19
Inspection 3-13, 4-19
Installation 4-19
Reassembly 4-19
Test 4-19
G
Generator Assembly F3-18
Description and Function 4-53
Inspection 3-23
Generator/Exciter Assembly, Inspection 4-54
Generator Screen-Guard F4-45
Generator Set
Controls and Instruments T2-1
Description 1-9
Dismantling for Movement 4-3
Electrical Schematic Fl- 7
Grounding F4-2
Inspection and Servicing on Receipt 4-1
Installation 4-2
Installation Plans Fl-4
Re-installing after Movement 4-4
Tabulated Date 1-10
Uncrating F4- 1
Wiring Harness Fl-8
Glow Plug Assemblies
Inspection 4-48
Installation 4-48
Removal 4-48
Test 4-48
Change 3 INDEX 3
TM 5-6115-584-12
NAVFAC P- 8 -62 2 -12
TO-35C2-3-456-1
TM-05682C-12
ALPHABETICAL INDEX (CONT)
Paragraph,
Figure, Table,
Subject Number
G (CONT)
Ground Rod and Fuel Drum Adapter Hold-Down Assembly F3-3
Cleaning and Inspection 3-12
Installation 3-12
Removal 3-12
Ground Stud F3-24
I
Injector Nozzle Assembly and Fuel Lines, Inspection 4-47
Intake Manifold Assembly F3-19
Inspection 4-43
Installation 4-43
Removal 4-43
Repair 4-43
Test, On Equipment 4-43
L
Levels of Maintenance Accomplishment 1-5
Load Terminal Board Assembly F4-32
Installation 4-37
Removal 4-37
Load Terminal and Reconnection Configuration F2-4
Load Terminals F2-1
Lockout Switch and Gear F4-25
Low Oil Pressure Switch
Installation 4-31
Removal 4-31
Test, Bench 4-31
Test, On Equipment 4-31
Lubrication Instructions
Operator/Crew 3-2
Organizational 4-7
Lubrication Order F3-1, 3-3
M
Maintenance Forms and Records 1-3
Maintenance Repair Parts 4-6
Manual
Applicability 1-2
Scope 1-1
Master Switch Continuity Check T4-3
O
Oil Cooler F4-28
Inspection 4-30
Removal 4-30
Replacement 4-30
Service 4-30
Oil Cooler Hoses, Replacing F4-29
Oil Drain Hose F3-20
Oil Drain Hose and Valve, Replacement 4-49
Oil Fill Tube F4-43
Installation 4-51
Removal 4-51
rNDEX 4
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
ALPHABETICAL INDEX (CONT)
Paragraph,
Figure, Table,
Subject Number
O (CONT)
Oil Filter F4-30
Removal 4-32
Replacement . . . . 4-32
Service 4-32
Oil Filter and Oil Pressure Switch F3-21
Oil Pan-Base, Inspection 4-50
Oil Pressure Gauge
Removal 4-33
Replacement F4-31, 4-33
Test 4-33
Oil System, Description and Function 4-29
Operating Procedures
Equipment Reconnection 2-3
General 2-1
Operating in Alternate Modes 2-5
Operation in Dusty or Sandy Areas 2-9
Operation in Extreme Cold 2-8
Operation in Extreme Heat 2-7
Operation in Wet or Humid Areas 2-10
Power Connections 2-2
Shutting Down Unit 2-6
Starting Generator Set t 2-4
P
Preparation for Shipment or Storage 1-8
Pressure Oil System F4-27
Preventive Maintenance Checks and Services T3-2, T4-1
Operator/Crew
Correcting and Reporting Deficiencies 3-5
Determining Intervals 3-6
General 3-4
Units in Continuous Operation - 3-7
Organizational
Determining Intervals 4-9
General 4-8
Units In Continuous Operation 4-10
Primary Radio Interference Suppression Components F4-3
R
Radio Interference Suppression Components 4-15
General Methods 4-14
Reconnection Switch F2-2
Reconnection Switch Positions T2-2
Reporting of Errors 1-4
Rocker Arm Cover Oil Line, Cleaning F4-39
Rocker Arm Covers F4-38
Inspection 4-44
Removal 4-44
Replacement 4-44
Service 4-44
Rocker Arm to Valve Clearance, Checking and Adjusting F4-41
INDEX 5
TM 5-6115-584-12
NAVFAC P-8-622-12
TO-35C2-3-456-1
TM-05682C-12
Paragraph,
Figure, Table,
Subject Number
S
Screen-Guard
Inspection 4-55
Installation 4-55
Removal 4-55
Repair 4-55
Shutter Assembly F4-4
Shutter Box Assembly, Inspection 3-14
Shutter and Thermo Power Element Assembly F3-5
Shutters, Adjusting F4-5
Skid- Base F4-46
Cleaning 3-25
Description and Function 4-56
Inspection 3-25, 4-57
Installation 4-57
Removal 4-57
Repair 4-57
Special Tools 4-5
Speed Control F3-16
Inspection 3-21
Starter Lockout Switch, Adjusting F4-26
Starter Lockout Switch and Gear
Adjustment 4-28
Inspection 4-28
Removal • 4-28
Repair 4-28
Replacement 4-28
Test 4-28
Starting Procedure F2-3
T
Thermo Unit, Adjusting F4-6
Tie Down, Lifting, and Towing Provisions Crated Set Fl-3
Troubleshooting • T3-3, T4-2
Operator General 3-9
Organizational, General 4-12
V
Valve Rocker Arms
Adjustment 4-46
Inspection 4-46
Index 6 Change 3
TM 5-6115-586-12
NAVFAC P-8-622
TO-35C2-3-456-1
TM-05682C-12
By Order of the Secretaries of the Army, the Navy, and the Air Force:
BERNARD W. ROGERS
General, United States Army
Official: Chief of Staff
PAULT. SMITH
Major General, United States Army
The Adjutant General
D. G. ISELIN
Rear Admiral, CEC, U. S. Navy
Commander,
Naval Facilities Engineering Command
W. R. JOHNSON
Brigadier General, U. S. Marine Corps
Acting Deputy Chief of Staff for Installations and Logistics
Distribution:
To be distributed in accordance with DA Form 12-25D, Operator maintenance requirements for Generator
Sets, Engine Driven: 5 KW, 60 HZ.
*U.S. Government Printing Office; 1990-261-888/22708
i
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1