TM5-6115-585-12NAVFAC P-8-623-12TO-35C2-3-455-1TM-05684C/05685B-121.2.3.4.5.7.8.9.6.10.11.12.13.14.15.16.Blower housingShutter assemblyOil coolerOil filterInjection pumpIntake manifold assemblyStarterExhaust mufflerGovernorAir cleaner assemblyOil dip-stick and fillerScrew (2)Washer (2)Shockmount (2)Spacer (2)Bracket17. Rocker cover (2)18. Intake manifold19. Screw (4)20. Lock tab (4)21. Gasket (2)22. Lead23. Heater (2)24. Lead25. Screw (2)26. Washer (2)27. Washer (4)28. Spacer (4)29. Adapter30. Gasket31. Engine shroud and doorpanelTS 6115-585-12/4-36(2)Figure 4-36. Engine Assembly (Sheet 2 of 2)NOTEUpper and lower nut must bein small increments so thatflat against adapters.tightened evenlymuffler will layBend lock tabs (2) up to secure nuts (1).4-41. AIRCLEANER ASSEMBLY.a. Inspect (see figure 4-37). On ASK equipped generators,open air intake door and air cleaner door.(2) Install air cleaner, bracket and spacers (15) ongenerator housing and secure with lockwashers (14) andscrews (13). Install hoses (10 and 12) and secure with clamps(9) and (11).4-42. ENGINEASSEMBLY.a. Inspect (see figure 1-1). Inspect engine for loose con-nections, leaks in oil and fuel systems, and free action of allmoving parts. Check that engine is securely mounted to skid-base. On ASK equipped generators, inspections of the engineassembly are limited to components accessible through theaccess doors.(1) Air Cleaner Assembly. Check air cleanerassembly for corrosion, broken or dented componentsor split hoses.b. Remove.(1) Air Cleaner Assembly. Loosen hose clamps(9 and 11) attaching two air intake hoses (10 and 12)to housing and detach hoses. Remove screws (13),lockwashers (14) and remove air cleaner and bracketand spacers (15). Remove air flow indicator (16) byturning counterclockwise.(2) Remove nut (17), lockwashers (18), screw(19) and separate air cleaner (20) and bracket (21).c. Repair.(1) Air Cleaner Assembly. Weld and straightenair cleaner housing as necessary.(2) Mounting Bracket (see figure 4-37). If bracket(21) is split or bent, weld and straighten bracket asnecessary. After completing repairs, check thatbracket securely attaches air cleaner to set.d. Install.(1) Air Cleaner Assembly (see figure 4-37).Install air cleaner (20) on bracket (21) and securewith screws (19), lockwashers (18) and nuts (17).Install air flow indicator (16) on air cleaner.b. Test. Operate engine with no load on GeneratorSet, until it warms up to normal operating tem-perature indicated by shutters being in an inter-mediate position between open and closed. Check oilpressure. Oil pressure should be 20-45 psi. Checkfrequency on frequency meter. Frequency should beapproximately 60 Hz (MEP-003A) or 400 HZ ( M E P -112A). Apply full rated load to engine. Check thatgovernor adjusts engine quickly, smoothly, and with-out excessive hunting. Check that exhaust is normalunder load. Check that engine runs without excessivefuel or oil consumption. Check that no unusual noiseis heard. Inability of engine to meet these tests mayindicate engine malfunctioning. See Troubleshooting,Section VI.c. Service. Service engine according to the schedulegiven in table 4-1, Preventive Maintenance Checksand Services.d. Adjust. The only engine adjustments applicableto this level of maintenance are to the valve rockerarms stop solenoid. and starter lockout switch.NOTEEngine lifting attachment is for lifting enginealone. Do not use this attachment for liftingengine if generator is still attached. Use theset lifting eye for this purpose (see figure 1-1).Change 84 - 47
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