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CHAPTER 1 INTRODUCTION - TM-5-6115-584-12_35
(A, F, MC) ADMINISTRATIVE STORAGE
Section II. DESCRIPTION AND DATA - TM-5-6115-584-12_37
Figure 1-1. Engine Generator Set, Right-Rear, Three-Quarter View
Figure 1-2. Engine Generator Set, Left-Front, Three-Quarter View
Figure 1-2.1. Engine Generator Set with Acoustic Suppression Kit
TABULATED DATA - TM-5-6115-584-12_43
SERVICE INSTRUCTIONS
Engine - TM-5-6115-584-12_45
Batteries - TM-5-6115-584-12_47
Figure 1-3. Tie Down, Lifting, and Towing Provisions Crated Set
Figure 1-4. Installation Plans
FIGURE 1-6 ELECTRICAL CABLE SCHEMATIC
Figure 1-7. Generator Set Electrical Schematic
Figure 1-8. Generator Set Wiring Harness
Figure 1-9. AC Output Control Box Wiring Harness
Figure 1-10. Control Cubicle Wiring Harness
CHAPTER 2 OPERATING INSTRUCTIONS
STARTING GENERATOR SET
TABLE 2-1 GENERATOR SET CONTROLS AND INSTRUMENTS
Table 2-1. Generator Set Controls and Instruments (Cont)
Table 2-2. Reconnection Switch Positions
Figure 2-4. Load Terminal and Reconnection Configuration
Section II. OPERATION UNDER UNUSUAL CONDITIONS - TM-5-6115-584-12_63
CHAPTER 3 OPERATOR MAINTENANCE INSTRUCTIONS Section I. CONSUMABLE OPERATING AND MAINTENANCE SUPPLIES
Section III. PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
Table 3-2. Operator/Crew Preventive Maintenance Checks and Services (Cont.) - TM-5-6115-584-12_68
Table 3-2. Operator/Crew Preventive Maintenance Checks and Services (Cont.) - TM-5-6115-584-12_69
Table 3-2. Operator/Crew Preventive Maintenance Checks and Services (Cont.) - TM-5-6115-584-12_70
Table 3-3. Troubleshooting (Cont) - TM-5-6115-584-12_71
Figure 3-2. Battery Assembly
FUEL TANK ASSEMBLY.
Figure 3-4. Fuel Tank
Figure 3-5. Shutter and Thermo Power Element Assembly
Figure 3-6. Exhaust Muffler Assembly
AC OUTPUT CONTROL BOX ASSEMBLY
Figure 3-9. Air Cleaner and Shroud Assembly
Figure 3-10. Air Cleaner Assembly
CONTROL CUBICLE Assembly
Figure 3-12. Control Cubicle
Figure 3-13. Fuel Filters and Fuel Strainer Assembly
Figure 3-14. Fuel Pump Assembly
Figure 3-16. Speed Control Assembly
Figure 3-17. Engine Cooling Assembly
Figure 3-17. Engine Cooling Assembly CONT.
Figure 3-19. Intake Manifold Assembly
Figure 3-22. Engine Stop Solenoid
Figure 3-23. Battery and Frame
SKID- BASE ASSEMBLY
CHAPTER 4 ORGANIZATIONAL MAINTENANCE
Figure 4-1. Uncrating Generator Set
Figure 4-2. Grounding Generator Set
Section II. MOVEMENT TO A NEW WORKSITE
Section V. PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) - TM-5-6115-584-12_96
TABLE 4-1. ORGANIZATIONAL PREVENTIVE MAINTENANCE CHECKS AND SERVICES--continued
TABLE 4-1. ORGANIZATIONAL PREVENTIVE MAINTENANCE CHECKS AND SERVICES--continued
Section VI. TROUBLESHOOTING - TM-5-6115-584-12_100
Table 4.2. Troubleshooting
Table 4-2. Troubleshooting (Cont) - TM-5-6115-584-12_103
Table 4-2. Troubleshooting (Cont) - TM-5-6115-584-12_104
Table 4-2. Troubleshooting (Cont) - TM-5-6115-584-12_105
Figure 4-3. Primary Radio Interference Suppression Components
Figure 4-3. Primary Radio Interference Suppression Components CONT.
Brackets
Figure 4-4. Shutter Assembly
Adjustments - TM-5-6115-584-12_110
Section IX. MAINTENANCE OF FUEL SYSTEM - TM-5-6115-584-12_111
Figure 4-7. Fuel Tank Assembly
Figure 4-8. Testing Float Switch - TM-5-6115-584-12_113
Figure 4-7. Fuel Tank Assembly
Figure 4-8. Testing Float Switch - TM-5-6115-584-12_115
Figure 4-9. Fuel Filter
Figure 4-11. Fuel Filters and Fuel Strainer Assembly
ELECTRIC FUEL P U M P S . F U E L A N D AUXILIARY SOLENOID VALVE
Figure 4-12. Fuel Pump, Fuel Hoses and Solenoid - TM-5-6115-584-12_119
Figure 4-14. Adjusting Fuel Shut-Off Solenoid
Section X. MAINTENANCE OF ENGINE ELECTRICAL SYSTEM
Figure 416. Installing Battery Cables - TM-5-6115-584-12_122
ENGINE STARTER ASSEMBLY
Figure 418. Engine Starter Installation - TM-5-6115-584-12_124
Repair. Style I Starter
Figure 4-19. Testing Engine Starter
FIGURE 4-20 TESTING FIELD COIL, STYLE II STARTER
Figure 421 A. Inspecting Starter Brushes, Style II Starter
Figure 4-22 ENGINE STARTER ASSEMBLY, STLYE I STARTER
Figure 423. Battery Charging Alternator
Battery Charging
Figure 4-24. Testing Battery Charging Regulator/Rectifier Assembly
Figure 4-25. Starter Lockout Switch and Gear Assembly
Section XI. 4-29. FUNCTION AND DESCRIPTION The diesel engine has pressure Iubrication to all working parts (see figure 4-27). The oil system includes oil intake cup, gear type oil pump, bypass valve, oil pressure gauge, low oil pressure shutoff, full-flow oil filter, oil coder, and passages to de- liver oil throughout the engine. Oil is held in the oil base, and forced through the oil filter and oil cooler by the pump. Lines leading to the rocker housing, passages through the block to crankshaft and front camshaft bearing, crankshaft passages to connecting rod bearings and connecting rod passages to piston pin bushings complete the oil system network The bypass valve controls oil pressure by allowtng excess oil to flow directly back to the crankcase. 4-30. OIL COOLER a. Inspect (see figure 4-28). On ASK equipped generators, remove ASK cover assembly (para 5-3). Inspect oil cooler (1) for physical damage. Visually check for leaks where oil cooler is connected to oil hoses (figure 4-29). Check that cooler Is securely fastened to mounting plate (2, figure 4-28) and that plate is securely fastened to engine. Inspect all hoses for Figure 4-26. Adjusting Starter Lockout Switch MAINTENANCE OF OIL SYSTEM
Figure 4-27. Pressure Oil System
Figure 4-29. Replacing Oil Cooler Hoses
Figure 4-30. Oil Filter Assembly - TM-5-6115-584-12_137
Figure 4-31. Replacing Oil Pressure Gauge - TM-5-6115-584-12_138
DC CONTROL SYSTEM
Figure 4-32. Load Terminal Board Assembly - TM-5-6115-584-12_140
LOAD TERMINAL BOARD ASSEMBLY - TM-5-6115-584-12_141
Figure 4-33. Control Cubicle Assembly
CONTROL CUBICLE ASSEMBLY - TM-5-6115-584-12_143
Table 4-4. Voltmeter-Ammeter Range Selector Switch Continuity Check - TM-5-6115-584-12_144
Relay Assembly
Figure 4-34. Removing Control Cubicle Support Assembly
Figure 4-35. Control Cubicle Test Set-Up - TM-5-6115-584-12_147
Section XIII. MAINTENANCE OF ENGINE
Figure 4-36. Engine Assembly
Figure 4-36. Engine Assembly CONT.
Figure 4-37. Exhaust Muffler and Air Cleaner Assemblies
INTAKE MANIFOLD A S SEMBLY.
ROCKER ARM COVERS
Figure 4-40. Breather Assembly
Figure 4-41. Checking and Adjusting Rocker Arm to Valve Clearance
Figure 4-42. Cylinder Head Assembly
Figure 4-43. Oil Fill Tube
Figure 4-44. Engine Mounting Assembly
Section XIV. MAINTENANCE OF GENERATOR ASSEMBLY - TM-5-6115-584-12_159
Section XV. MAINTENANCE OF SKID-BASE
Figure 4-46. Skid-Base Assembly
Battery Frame Bottom and Tray
CHAPTER 5 MATERIEL USED IN CONJUNCTION WITH DOD STANDARD GENERATOR SET, 5KW DIESEL ENGINE DRIVEN, MODEL MEP-002A
Section II. ACOUSTIC SUPPRESSION KIT
OPERATING INSTRUCTIONS
Figure 5-1. Instruction and Rating Plates
Figure 5-1. Instruction and Rating Plates CONT.
Figure 5-1. Instruction and Rating Plates CONT.
Figure 5-2. Cover Assembly, Removal and Installation
TOP PANEL ASSEMBLY - TM-5-6115-584-12_171
Fiqure 5-3. Top Panel Assembly and Exhaust Plenum, Removal and Installation
Remove seven screws
Figure 5-4. Left Panel Assembly, Removal and Installation
Torque screws
Figure 5-5. Right Panel Assembly, Removal and Installation
Installation - TM-5-6115-584-12_177
Figure 5-6. Rear Panel Assembly, Removal and Installation
EXHAUST PLENUM ASSEMBLY - TM-5-6115-584-12_179
Figu re 5-7. Left Support Assembly, Removal and Installation
RIGHT SUPPORT ASSEMBLY
Figure 5-8. Right Support Assembly, Removal and Installation
Figure 5-9. Front Panel Assembly, Removal and Installation
SIDE CLOSURE ASSEMBLY
Figure 5-10. Side Closure Assembly, Removal and Installation
Figure 5-11. Rear Closure Assembly, Removal and Installation
REAR FLAP ASSEMBLY - TM-5-6115-584-12_187
Figure 5-12. Rear Flap Assembly, Removal and Installation
SECTION III. ACOUSTIC SUPPRESSION KIT REPAIR
REPLACEMENT OF ASK COMPONENTS - TM-5-6115-584-12_190
LATCH REPLACEMENT
Figure 5-13. Replacement of ASK Hardware Items
HINGES
APPENDIX A REFERENCES - TM-5-6115-584-12_194
APPENDIX B COMPONENTS OF END ITEMS LIST
Section II. INTEGRAL COMPONENTS OF END ITEM
APPENDIX C ADDITIONAL AUTHORIZATION LIST
APPENDIX D MAINTENANCE ALLOCATION CHART
EXPLANATION OF COLUMNS IN SECTION III - TM-5-6115-584-12_201
SECTION II. MAINTENANCE ALLOCATION CHART - TM-5-6115-584-12_202
SECTION II. MAINTENANCE ALLOCATION CHART CONT. - TM-5-6115-584-12_203
SECTION II. MAINTENANCE ALLOCATION CHART CONT. - TM-5-6115-584-12_204
SECTION II. MAINTENANCE ALLOCATION CHART CONT. - TM-5-6115-584-12_205
SECTION II. MAINTENANCE ALLOCATION CHART CONT. - TM-5-6115-584-12_206
SECTION II. MAINTENANCE ALLOCATION CHART CONT. - TM-5-6115-584-12_207
SECTION II. MAINTENANCE ALLOCATION CHART CONT. - TM-5-6115-584-12_208
SECTION II. MAINTENANCE ALLOCATION CHART CONT. - TM-5-6115-584-12_209
SECTION II. MAINTENANCE ALLOCATION CHART CONT. - TM-5-6115-584-12_210
SECTION II. MAINTENANCE ALLOCATION CHART CONT. - TM-5-6115-584-12_211
SECTION II. MAINTENANCE ALLOCATION CHART CONT. - TM-5-6115-584-12_212
SECTION II. MAINTENANCE ALLOCATION CHART CONT. - TM-5-6115-584-12_213
SECTION II. MAINTENANCE ALLOCATION CHART CONT. - TM-5-6115-584-12_214
SECTION II. MAINTENANCE ALLOCATION CHART CONT. - TM-5-6115-584-12_215
SECTION II. MAINTENANCE ALLOCATION CHART CONT. - TM-5-6115-584-12_216
SECTION II. MAINTENANCE ALLOCATION CHART CONT. - TM-5-6115-584-12_218
Section III. TOOLS, TEST AND SUPPORT EQUIPMENT REQUIREMENTS - TM-5-6115-584-12_219
ALPHABETICAL INDEX - TM-5-6115-584-12_220
ALPHABETICAL INDEX (CONT) - TM-5-6115-584-12_221
SECTION II. MAINTENANCE ALLOCATION CHART CONT. - TM-5-6115-584-12_222
Section III. TOOLS, TEST AND SUPPORT EQUIPMENT REQUIREMENTS - TM-5-6115-584-12_223
Section IV. EXPIANATION OF REFERENCE CODES
ALPHABETICAL INDEX - TM-5-6115-584-12_226
ALPHABETICAL INDEX (CONT) - TM-5-6115-584-12_227
ALPHABETICAL INDEX (CONT) - TM-5-6115-584-12_228
ALPHABETICAL INDEX (CONT) - TM-5-6115-584-12_229
ALPHABETICAL INDEX (CONT) - TM-5-6115-584-12_230
ALPHABETICAL INDEX (CONT) - TM-5-6115-584-12_231
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