TM-5-6115-585-34 Generator Set Diesel Engine Driven Tactical Skid Mtd 5 KW 1 Phase 2 Wire 1 Phase-3 Wire 3 Phase-4 Wire 120 120/240 and 120/208 Volts Manual

CHAPTER 1 INTRODUCTION - TM-5-6115-585-34_27
Section II. DESCRIPTION AND TABULATED DATA
Engine Accessories
Table 1-1. Torque Values (Ft-Lb Dry)
Table 1-1. Torque Values (Ft-Lb Dry) (Contd)
Table 1-2. Repair and Replacement Standards - TM-5-6115-585-34_33
Table   1-2.   Repair   and   Replacement   Standards   (Cont) - TM-5-6115-585-34_35
Table   1-2.   Repair   and   Replacement   Standards   (Cont) - TM-5-6115-585-34_36
Table   1-2.   Repair   and   Replacement   Standards   (Cont) - TM-5-6115-585-34_37
Table   1-2.   Repair   and   Replacement   Standards   (Cont) - TM-5-6115-585-34_38
Figure 1-1. Generator Set Electrical Schematic
Figure 1-1.1. Genarator Set Electrical Schematic
Table 2-1. Special Tools, Test and Support Equipment
Table   2-2.   Fabricated   Tools   and   Equipment - TM-5-6115-585-34_42
Table   2-2.   Fabricated   Tools   and   Equipment   (Cont) - TM-5-6115-585-34_43
Table   2-2.   Fabricated   Tools   and   Equipment   (Cont) - TM-5-6115-585-34_44
Section II. TROUBLESHOOTING - TM-5-6115-585-34_45
Table 2-3. Troubleshooting
Table   2-3.   Troubleshooting   (Cont) - TM-5-6115-585-34_47
Table 2-3. Troubleshooting (Cont) - TM-5-6115-585-34_48
Table 2-3. Troubleshooting (Cont) - TM-5-6115-585-34_49
Table 2-3. Troubleshooting (Cont) - TM-5-6115-585-34_50
Table 2-3. Troubleshooting (Cont) - TM-5-6115-585-34_51
Section III. GENERAL MAINTENANCE
Figure   2-1.   Speed   Control   Assembly
Figure 2-2. Disconnecting Engine from Generator
Figure 2-3. Lifting Engine
GENERATOR ASSEMBLY - TM-5-6115-585-34_56
Figure 2-4. Lifting Engine and Generator Assembly - TM-5-6115-585-34_57
CHAPTER 3 MAINTENANCE OF COOLING SYSTEM
Figure   3-1.   Engine   Cooling   System
Test. - TM-5-6115-585-34_61
CHAPTER 4 MAINTENANCE OF FUEL SYSTEM
Section I DESCRIPTION AND FUNCTION
Figure 5-1. Electrical Starter Assembly STYLE I
Figure 5-2. Electrical Starter Assembly STYLE II
Figure 5-3.    Pinion Gear Stopper Removal - TM-5-6115-585-34_68
Figure 5-4.    Testing Armature for Grounds
Figure 5-8.    Checking Armature Shaft Runout
Figure 5-9.    Testing Brush Spring Tension STYLE I Starter Only
Figure 5-10. Testing Solenoid Switch
Reassembly Style I Starter
Figure 5-12.    Brush Replacement STYLE I Starter Only
Figure 5-13 Checking Pinion Clearance STYLE I Starter
Figure 5-14.   Checking Pinion Travel STYLE II Starter - TM-5-6115-585-34_76
CHAPTER 6 MAINTENANCE OF CONTROL SYSTEM - TM-5-6115-585-34_77
Figure   6-1.   Control   Cubicle   Wiring   Harness
Table 6-1. Control Cubicle Wiring Harness - TM-5-6115-585-34_79
Table 6-1. Control Cubicle Wiring Harness (Cont)
Table 6-2. 10KW Generator Set Wiring Harness
Figure 6-2. Generator Set Wiring Harness - TM-5-6115-585-34_82
Table 6-3. AC Output Control Box Wiring Harness (MEP-003A Only)
Table 6-3. AC Output Control BOX Wiring Harness (MEP-003A Only) (Cont)
Table 6-3.1. AC Output Control Box Wiring Harness (MEP-112A Only)
Table 6-3.1. AC Output Control Box Wiring Harness (MEP-112A Only)
AC OUTPUT CONTROL BOX WIRING HARNESS
Figure 6-3. Control Cubilcle (sheet 1 of 2)
Figure 6-3. Control Cubicle (Sheet 2 of 2) - TM-5-6115-585-34_89
Figure 6-4. Testing Voltage Regulator
Figure 6-5. AC Voltage Regulator Schematic - TM-5-6115-585-34_91
Figure 6-5.1. AC Voltage Regulator Schematic
Figure 6-7. AC Output Control Box Test Setup
Table 6-5. Reconnection Switch Continuity
Figure 6-7.1. CVT and CT Wiring
Figure 6-8. AC Control Box Removal - TM-5-6115-585-34_96
Table 6-6. Testing Bridge Assembly (60 Hz Only)
Figure 6-9 Output Control Assembly (Sheet 1 of2)
Figure 6-9. AC Output Control Assembly (Sheet 2 of 2) - TM-5-6115-585-34_99
Figure 6-10. AC Output Control Assembly (Switch, Receptacle and Circuit Breaker)
Figure-6-10.1 Switch Assembly, Rotary
Figure 6-10.2 Switch Assembly, Rotary
Figure 6-11. Bridge Rectifier Assembly A-4
CHAPTER 7 MAINTENANCE OF ENGINE
Figure 7-1. Injector Fuel Lines
Figure 7-2. Speed Control Assemlby and Governor Control Assemlby
Figure 7-3. Engine Flywheel and Ring Gear Assembly
Figure 7-3.1. Governor Linkage Adjustment
Figure 7-6. Testing Oil Cooler
Figure 7-7. Battery Charge Alternator and Blower Wheel - TM-5-6115-585-34_111
Figure 7-8. Resistively Loading the Batteries - TM-5-6115-585-34_112
Section III. ENGINE INTERNAL ASSEMBLIES - TM-5-6115-585-34_113
Figure 7-8.1. Testing Engine Compression
CYLINDER HEAD
Figure 7-9. Cylinder Head Removal
Figure 7-10. Valve Spring Removal
Figure 7-11. Cylinder Head Assembly
Figure 7-12. Valve Seat Replacement - TM-5-6115-585-34_119
Figure 7-13. Cylinder Head Bolt Tightening Sequence
Figure 7-14. Piston and Connecting Rod
Figure 7-15. Crankshaft Pistons and Connecting Rod (sheet 1 of 2)
Figure 7-15. Crankshaft Pistons and Connecting Rod (Sheet 2 of 2) - TM-5-6115-585-34_123
Figure 7-17. Connecting Rod and Bushings
Figure 7-18. Connecting Rod Installation
Figure 7-19. Oil pump Removal (Sheet 1 of 2) - TM-5-6115-585-34_126
Figure 7-19. Oil Pump Removal (Sheet 2 of 2)
Figure 7-21. Internal Engine Assemlby (sheet 1 of 2)
Figure 7-22. Gear Cover Components
Figure   7-23.   Gear   Cover   Inspection - TM-5-6115-585-34_130
Figure 7-24. Governor Cup Assembly - TM-5-6115-585-34_131
Figure 7-25. Camshaft Bearing Installation - TM-5-6115-585-34_132
Figure 7-27. Timing Gear Backlash
Figure   7-28.   Crankshaft   Gear   Removal - TM-5-6115-585-34_134
Figure 7-30. Crankshaft Bearing Installation - TM-5-6115-585-34_135
Figure 7-32. Injection Pump - TM-5-6115-585-34_136
FIGURE 7-33A. PUMP INSTALLED
Figure 7-34. Disassembly of fuel Injection Pump (Sheet 1 of 2)
Figure 7-34. Disassembly of Fuel Injection Pump (Sheet 2 of 2) - TM-5-6115-585-34_139
Figure 7-36. Delivery Valve Test Assembly - TM-5-6115-585-34_140
Figure 7-37. Inspecting Tappet
Figure   7-39.   Control   Unit   Assembly - TM-5-6115-585-34_142
Figure 7-40. Checking Plunger Sleeve Alignment - TM-5-6115-585-34_143
Figure 7-42. Injection Pump Installation
Figure   7-43.   Delivery   Valve - TM-5-6115-585-34_145
Table 7-1. Button Code Letter and Size
CYLINDER BLOCK.
Figure   7-45.   Injector   Nozzle   Removal
Figure 7-46. Fuel Injector - TM-5-6115-585-34_149
Figure 7-47. Centering Sleeve Installation
Section   II.   MAINTENANCE - TM-5-6115-585-34_151
Figure 8-1. Generator Exploded View (Sheet 1 of 2)
Figure 8-1. Generator Exploded View (Sheet 2 of 2) - TM-5-6115-585-34_153
Testing   Generator   Stator
Figure 8-2. Testing Exciter Rotor
Reassembly. - TM-5-6115-585-34_156
Figure 8-3. Generator Frame Assembly Winding Data
Figure 8-3.1. Genarator Frame Assembly Winding Data
Figure 8-4.Exciter Rotor Assembly Winding Data
Figure   8-5.   Generator   Rotor   Winding   Data
Figure 8-5.1.Generator Rotor Winding Data
Section III. OPERATIONAL TESTS
Figure 9-1. Adjusting R3 Resistor
Test Procedure.
Section I. AUXILIARY   EQUIPMENT
SECTION II. ACOUSTIC SUPPRESSION KIT INSTALLATION
Table 10-1. Acoustic Suppression Kit Parts and Required Hardware
Figure 10-1. Relocation of Trailer Items to Accommodate ASK Installation
PRELIMINARY PROCEDURES - TM-5-6115-585-34_171
Figure 10-2. Installation of Right Support Assembly, Rear Panel Assembly, and Rear Flap Assembly
Left Support Assembly
Figure 10-3. Installation of Left Support Assembly
Rear Flap Assembly - TM-5-6115-585-34_175
Exhaust Plenum Assembly - TM-5-6115-585-34_176
Figure 10-4. Installation of Rear Closure Assembly and Exhaust Plenum Assembly
Right Panel Assembly (Long Side)
Figure 10-5. Installation of Right Panel Assembly
Figure 10-6. Installation of Left Panel, Side Closure, Front Panel and Top Panel Assemblies
Front Panel Assembly - TM-5-6115-585-34_181
Top Panel Assembly - TM-5-6115-585-34_182
APPENDIX A REFERENCES - TM-5-6115-585-34_183
ALPHABETICAL   INDEX - TM-5-6115-585-34_185

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