Section III. GENERAL MAINTENANCE
2-6. GENERAL MAINTENANCE.
This section contains general maintenance instruc-
tions which are the responsibility of direct support
and general support maintenance personnel. You till
find that these instructions apply to several assem-
blies or components. They would otherwise have to
be repeated throughout the chapter.
2-7. GENERAL MAINTENANCE PROCEDURES
a. Work Guidelines.
(1) Make sure the work area is clean before you
disassemble the pump or engine.
(2) Make sure that materials needed for the
maintenance task are at hand. These may include
cleaning solvents, lubricants, buckets, or other con-
tainers for cleaning or keeping components separated,
clean wiping cloths, and, of utmost importance, the
DRY CLEANING SOLVENT, P-D-680 or P-S-
861, used to clean parts is potentially danger-
ous to personnel and property. Avoid repeated
and prolonged skin contact. DO NOT use near
open flame or excessive heat. Flash point of
solvent is 100° to 138° F (38 ° to 60 ° C).
(3) Clean the exterior of the engine and pump
before disassembly to keep foreign matter from
bearings, gears, and other machine-surfaced parts
which are subject to scoring and other such damage.
Use a cloth dampened with cleaning solvent (fed. spec.
Compressed air used for cleaning and drying
purposes can create airborne particles that may
enter the eyes. Pressure shall not exceed 30 psi
and use only with adequate chip guards and
capped immediately after disassembly. If dirt does
accidentally enter a component, it should be washed
in clean fuel oil before reassembly.
Section IV. REMOVAL AND INSTALLATION OF MAJOR COMPONENTS
(4) If compressed air is used to clean parts, you
should make sure it is free of dirt and other con-
(5) Protect disassembled parts from dust, blowing
sand, and moisture which can cause rapid wear and
deterioration of bearings, gears, and other machine
b. Seals and Gaskets. Replace seals and gaskets of
all components disassembled. This wilI greatly reduce
the possibility of leaking and will help prevent the
entry of dust and dirt after reassembly.
c. Care of Bearings.
(1) Clean ball and roller bearings by placing them
in a wire basket and immersing in a container of
fresh cleaning solvent. Agitate the bearings in the
solvent to remove all traces of old lubricant.
(2) After cleaning the bearings, dry them with
clean compressed air. Take care to prevent spinning
the bearings when using a compressed air jet.
(3) Dip the cleaned bearings in clean engine oil
and immediately wrap them in lint-free paper to
protect them from dust and other foreign matter.
d. Replacing Electronic Components.
(1) Tag wires before removal to facilitate proper
(2) When soldering use heat sink between solder-
ing pencil and electronic component to prevent damage
to the component.
(3) Do not use excessive heat when soldering on
printed circuit boards to prevent damage to board.
e. Fuel System Maintenance. The fuel injectors and
fuel pump are manufactured to extremely tight toler-
ances. Even small amounts of dust or water in the
fuel system can damage these components. Conse-
quently it is of great importance that dirt be kept out
of the fuel lines and fittings during disassembly and
assembly. All openings should be taped, plugged, or
2-8. CONTROL CUBICLE.
2-9. ENGINE ASSEMBLY.
a. Removal. Refer to Operator and Organizational
a. Remove. On ASK equipped generators, refer to Operator
and Organizational Maintenance Manual and remove cover
assembly to perform the following steps.
b . I n s t a l l a t i o n .
R e f e r t o O p e r a t o r a n d
Organizational Maintenance Manual.
(1) Disconnect and remove batteries.
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C h a n g e 6