CHAPTER 1 INTRODUCTION - TM-5-6115-593-12_11
Section II. DESCRIPTION AND DATA - TM-5-6115-593-12_12
Figure 1-1. Generator Set, Left Side
Figure 1-2. Generator Set, Right Side
Figure 1-3. Generator Set, Rear
Figure 1-4. Generator Set, Top
Figure 1-5. Remote Control Module
Figure 1-6. Automatic Control Module
Figure 1-7. Housing Kit, Installed on Generator Set
TABULATED DATA - TM-5-6115-593-12_20
TABULATED DATA (cont) - TM-5-6115-593-12_21
TABULATED DATA (cont) - TM-5-6115-593-12_22
TABULATED DATA (cont) - TM-5-6115-593-12_23
TABULATED DATA (cont) - TM-5-6115-593-12_24
TABULATED DATA (cont) - TM-5-6115-593-12_25
TABULATED DATA (cont) - TM-5-6115-593-12_26
TABULATED DATA (cont) - TM-5-6115-593-12_27
TABULATED DATA (cont) - TM-5-6115-593-12_28
TORQUE DATA
Figure 1-8. Fuel System Diagram
Figure 1-9. Instruction Plate Locations
Section III. SYSTEM OPERATION
DC ELECTRICAL AND CONTROL SYSTEM.
Engine Stopping
Engine Fault Indicators
AC POWER GENERATION AND CONTROL SYSTEM - TM-5-6115-593-12_36
AC POWER GENERATION AND CONTROL SYSTEM (cont) - TM-5-6115-593-12_37
AC POWER GENERATION AND CONTROL SYSTEM (cont) - TM-5-6115-593-12_38
AC POWER GENERATION AND CONTROL SYSTEM - TM-5-6115-593-12_39
COOLING SYSTEM - TM-5-6115-593-12_40
FUEL SYSTEM
CHAPTER 2 OPERATING INSTRUCTIONS - TM-5-6115-593-12_42
EXERCISE OF ENGINE ON STANDBY SERVICE - TM-5-6115-593-12_43
Figure 2-1. Engine Control Panel (Part of Control Cubicle)
Table 2-2. Generator Control Panel, Controls and Instruments
Figure 2-2. Generator Control Panel (Part of Control Cubicle)
Table 2-2. Generator Control Panel, Controls and Instruments-Continued - TM-5-6115-593-12_47
Table 2-2. Generator Control Panel, Controls and Instruments-Continued - TM-5-6115-593-12_48
Table 2-3. AC-DC Control Panel, Controls and Instruments
Figure 2-3. AC-DC Control Panel
Table 2-4. External Power Box Control Panel, Controls and Instruments
Figure 2-4. External Power Box Control Panel
Figure 2-5. Preparation for Starting (Sheet 1 of 3)
Figure 2-5. Preparation for Starting (Sheet 2 of 3)
Figure 2-5. Preparation for Starting (Sheet 3 of 3)
Figure 2-6. Starting Instructions (Sheet 1 of 3)
Figure 2-6. Starting Instructions (Sheet 2 of 3)
Figure 2-6. Starting Instructions (Sheet 3 of 3)
Figure 2-7. Stopping Instructions
Figure 2-8. Single Generator Unit, Operating Instructions
Figure 2-9. Preparation for Starting with Housing Kit Installed (Sheet 1 of
Figure 2-9. Preparation for Starting with Housing Kit Installed (Sheet 2 of 3)
Figure 2-9. Preparation for Starting with Housing Kit Installed (Sheet 3 of 3)
Figure 2-10. Starting Instructions when Ambient Temperature is from 40F to -25F (4.4C to -32C) and Housing Kit is Installed (Sheet 1 of 3)
Figure 2-10. Starting Instructions when Ambient Temperature is from 40F to -25F (4.4C to -32C) and Housing Kit is Installed (Sheet 2 of 3)
Figure 2-10. Starting Instructions when Ambient Temperature is from 40F to -25F (4.4C to -32C) and Housing Kit is Installed (Sheet 3 of 3)
Figure 2-11. Stopping Instructions with Housing Kit Installed
Figure 2-12. Single Generator Unit, Operating Instructions with Housing Kit Installed
Table 2-5. Remote Control Panel, Controls and Instruments
Figure 2-13. Remote Control Module Panel
Table 2-5. Remote Control Panel, Controls and Instruments-Continued - TM-5-6115-593-12_71
Table 2-5. Remote Control Panel, Controls and Instruments-Continued - TM-5-6115-593-12_72
Figure 2-14. Jumper Connections to be Removed when a Remote Control Module is Connected
Figure 2-15. Preparation for Starting Using Remote Control Module
Figure 2-16. Starting Instructions Using Remote Control Module (Sheet 1 of 2)
Figure 2-16. Starting Instructions Using Remote Control Module (Sheet 2 of 2)
Figure 2-17. Stopping Instructions Using Remote Control Module
Figure 2-18. Operating Instructions, Single Generator Unit Using Remote Control Module
Connecting the Automatic Control Module
Optional Uses
Figure 2-19. Automatic Control Module
Table 2-6. Automatic Control Module, Controls and Instruments
Table 2-6. Automatic Control Module, Controls and Instruments - Continued
Figure 2-21. Operating Instructions, Manually Operated in Parallel (Sheet 1 of 3)
DROOP PARALLELING
Figure 2-21. Operating Instructions, Manually Operated in Parallel (Sheet 3 of 3)
Section III. OPERATION UNDER UNUSUAL CONDITIONS - TM-5-6115-593-12_87
OPERATION IN SALT WATER AREAS
Section I. CONSUMABLE OPERATING AND MAINTENANCE SUPPLIES
Table 3-1. Consumable Operating and Maintenance Supplies - Continued
Section II. LUBRICATION INSTRUCTIONS - TM-5-6115-593-12_91
TABLE 3-2. OPERATOR/CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES - TM-5-6115-593-12_92
TABLE 3-2. OPERATOR/CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES - TM-5-6115-593-12_93
TABLE 3-3. OPERATOR/CREW TROUBLESHOOTING - TM-5-6115-593-12_94
TABLE 3-3. OPERATOR/CREW TROUBLESHOOTING - TM-5-6115-593-12_95
TABLE 3-3. OPERATOR/CREW TROUBLESHOOTING - TM-5-6115-593-12_96
TABLE 3-3. OPERATOR/CREW TROUBLESHOOTING - TM-5-6115-593-12_97
Section V. OPERATOR/CREW MAINTENANCE
Figure 3-1. Air Cleaner, Exploded view
MAINTENANCE OF RADIATOR ASSEMBLY
Figure 3-2. Fuel Transfer Pump Inspection Points
MAINTENANCE OF ETHER KIT
CHAPTER 4 ORGANIZATIONAL MAINTENANCE
INSTALLATION - TM-5-6115-593-12_104
Figure 4-2. Cooling System Drain and Shut -off Cock
Figure 4-3. Location of Engine Water Drains
Figure 4-4. Location of Engine Crankcase Drain and Drain Valve
Figure 4-5. Location of Fuel Tank Drain Cock
Table 4-1. Freezing Points, Composition, and Specific Gravities of Military Antifreeze
Figure 4-6. Installation Plan
Figure 4-7. Grounding Procedures (Sheet 1 of 3)
Figure 4-7. Grounding Procedures (Sheet 2 of 3)
Figure 4-7. Grounding Procedures (Sheet 3 of 3)
Slide Hammer Procedure
EQUIPMENT CONVERSION.
Figure 4-8. Output Voltage Conversion Connections
Section IV. LUBRICATION INSTRUCTIONS
Figure 4-8A. Crankcase Breather
Section V. PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
TABLE 4-2. ORGANIZATIONAL PREVENTIVE MAINTENANCE CHECKS AND SERVICES. - TM-5-6115-593-12_120
TABLE 4-2. ORGANIZATIONAL PREVENTIVE MAINTENANCE CHECKS AND SERVICES. - TM-5-6115-593-12_121
Table 4-3. Organizational Troubleshooting
Table 4-3. Organizational Troubleshooting -Continued - TM-5-6115-593-12_123
Table 4-3. Organizational Troubleshooting -Continued - TM-5-6115-593-12_124
Table 4-3. Organizational Troubleshooting -Continued - TM-5-6115-593-12_125
Table 4-3. Organizational Troubleshooting -Continued - TM-5-6115-593-12_126
Table 4-3. Organizational Troubleshooting -Continued - TM-5-6115-593-12_127
Table 4-3. Organizational Troubleshooting -Continued - TM-5-6115-593-12_128
Table 4-3. Organizational Troubleshooting -Continued - TM-5-6115-593-12_129
Table 4-3. Organizational Troubleshooting -Continued
Table 4-3. Organizational Troubleshooting -Continued - TM-5-6115-593-12_131
Table 4-3. Organizational Troubleshooting -Continued - TM-5-6115-593-12_132
Table 4-3. Organizational Troubleshooting -Continued - TM-5-6115-593-12_133
Table 4-3. Organizational Troubleshooting -Continued - TM-5-6115-593-12_134
Table 4-3. Organizational Troubleshooting -Continued - TM-5-6115-593-12_135
Section VIII. MAINTENANCE OF BATTERIES AND RELATED ITEMS
Figure 4-9. Batteries and Related Items, Exploded View
Figure 4-10. Battery Cable Fabrication
Section IX. MAINTENANCE OF MUFFLER AND EXHAUST
Section X. MAINTENANCE OF EXTERNAL POWER BOX ASSEMBLY
Figure 4-11. Muffler and Exhaust, Exploded View
Figure 4-12. External Power Box Assembly, Exploded View
LEGEND FOR FIGURE 4-12
Figure 4-13. External Power Box Assembly, Control Panel, Exploded View
PANEL MOUNTED RECEPTACLES.
Replacement. - TM-5-6115-593-12_146
Figure 4-14. Contactors K107, K108, K109 and Main Circuit Breaker CB2, Schematic
Figure 4-15. Main Circuit Breaker, CB2
Installation - TM-5-6115-593-12_149
PLATE AND SLEEVE ASSEMBLY - TM-5-6115-593-12_150
HARNESS ASSEMBLY - TM-5-6115-593-12_151
Section XI. MAINTENANCE OF AC-DC CONTROL BOX ASSEMBLY
Figure 4-17. AC-DC Control Box Assembly, Exploded View
LEGEND FOR FIGURE 4-17
Figure 4-18. AC-DC Control Box Assembly, Component Panel Assembly, Exploded View
LEGEND FOR FIGURE 4-18
Figure 4-19. AC-DC Control Box Assembly Component Panel Assembly, Exploded View
SHORTING PLUG
POTENTIOMETER R103
WEATHER STRIPPING
Figure 4-20. Control Cubicle, (Sheet 1 of 3 )
Figure 4-20. Control Cubicle, (Sheet 2 of 3)
Figure 4-20. Control Cubicle, (Sheet 3 of 3)
LEGEND FOR FIGURE 4-20
Figure 4-21. Control Cubicle, Engine Panel, Exploded View
LEGEND FOR FIGURE 4-21
Figure 4-22. Control Cubicle, Generator Panel, Exploded View (Sheet 1 of 2)
Figure 4-22. Control Cubicle, Generator Panel, Exploded View (Sheet 2 of 2)
LEGEND FOR FIGURE 4-22
Section XII. MAINTENANCE OF CONTROL CUBICLE
ENGINE OIL PRESS
HARNESS ASSEMBLY - TM-5-6115-593-12_172
Section XIII. MAINTENANCE OF AIR CLEANER
Figure 4-23. Air Cleaner and Related Parts
AIR SHUT-OFF VALVE
Section XIV. MAINTENANCE OF TOOL BOX ASSEMBLY
Figure 4-24. Tool Box Assembly
Section XVI. MAINTENANCE OF SUPPORT FRAME ASSEMBLY
Figure 4-25. Document Compartment
Figure 4-26. Support Frame Assembly
Figure 4-27. Radiator Assembly, Exploded View
Figure 4-28. Fan Belt Adjustment and Replacement, Code A
Fan Belt Replacement
Section XVIII. MAINTENANCE OF FUEL LINES AND FITTINGS
Replacement. - TM-5-6115-593-12_185
Figure 4-29. Fuel Lines (Sheet 1 of 2)
Figure 4-29. Fuel Lines (Sheet 2 of 2)
Figure 4-30. Preheat Installation (Sheet 1 of 2)
Figure 4-30. Preheat Installation (Heater) (Sheet 2 of 2)
Section XX. MAINTENANCE OF FUEL TRANSFER PUMP
FILTER AND STRAINER
Section XXI. MAINTENANCE OF FUEL TANK ASSEMBLY
Figure 4-31. Fuel Transfer Pump Installation, Exploded View
Figure 4-32. Fuel Transfer Pump Contactor K20
Figure 4-33. Fuel Tank Assembly, Exploded View
Figure 4-35. Liquid Quantity Transmitter
Section XXII. MAINTENANCE OF INTERCONNECTING ELECTRICAL WIRING HARNESS
Figure 4-36. Generator and Reconnection Board
Figure 4-37. Electric Hydraulic Actuator
Section XXV. MAINTENANCE OF ETHER KIT
Section XXVI. MAINTENANCE OF ENGINE ASSEMBLY
Figure 4-39. Ether Installation
Figure 4-40. Engine Components (Sheet 1 of 2)
Figure 4-40. Engine Components (Sheet 2 of 2)
Figure 4-41. Water Pump Belt Adjustment
Figure 4-42. Speed Switch
Figure 4-43. Oil Level Sight Gauge and Filler
PRESSURE SWITCH.
Figure 4-44. Starter Assembly.
Figure 4-46. Pressure Switches
LUBE OIL COOLER
Figure 4-47. Oil Filters
Figure 4-48. Secondary Fuel Filter
Figure 4-49. Lube Oil Cooler
TURBOCHARGER - TM-5-6115-593-12_215
Figure 4-50. Fuel Injector
Figure 4-51. Turbocharger
Replace hoses and clamps
Figure 4-52. Water Pump and Idler Pulley Assembly
Figure 4-53. Thermostat Removal
THERMOSTAT
TEMPERATURE SWITCH
Figure 4-55. Coolant Temperature Switch
EXHAUST MANIFOLD
Figure 4-56. Intercooler
Figure 4-57. Exhaust Manifold
Figure 4-58. Water Manifold
Figure 4-59. Rocker Arm and Shaft Assembly
Section XXVII. MAINTENANCE OF BASE ASSEMBLY
REPLACEMENT OF TERMINALS, FITTINGS AND HOSES
Figure 4-60. Base Assembly, Exploded View
LEGEND FOR FIGURE 4-60
BREATHER LINES AND FITTINGS
Figure 4-61. Breather Lines and Fittings
CHAPTER 5 AUXILIARY EQUIPMENT USED IN CONJUNCTION WITH THE GENERATOR SET
Figure 5-1. Remote Control Module
Table 5-1. OPERATOR/CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES, REMOTE CONTROL MODULE
Table 5-2. Remote Control Module Troubleshooting (Operator/Crew Level)
Table 5-2. Remote Control Module Troubleshooting (Operator/Crew Level)-Continued - TM-5-6115-593-12_239
Table 5-2. Remote Control Module Troubleshooting (Operator/Crew Level)-Continued - TM-5-6115-593-12_240
Table 5-3. Remote Control Module Troubleshooting (Organizational Level)
Table 5-3. Remote Control Module Troubleshooting (Organizational Level)-Continued - TM-5-6115-593-12_242
Table 5-3. Remote Control Module Troubleshooting (Organizational Level)-Continued - TM-5-6115-593-12_243
Table 5-3. Remote Control Module Troubleshooting (Organizational Level)-Continued - TM-5-6115-593-12_244
Figure 5-2. Remote Control Module, Plate Assembly
Figure 5-3. Remote Control Module, Annunciator Control Assembly
Section III. REMOTE CONTROL CABLE ASSEMBLY - TM-5-6115-593-12_247
Section IV. AUTOMATIC CONTROL MODULE
ORGANIZATIONAL TROUBLESHOOTING
Table 5-4. OPERATOR/CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES, AUTOMATIC CONTROL MODULE
Table 5-5. Automatic Control Module Troubleshooting (Operator/Crew Level)
Table 5-6. Automatic Control Module Troubleshooting (Organizational Level)-Continued - TM-5-6115-593-12_252
Table 5-6. Automatic Control Module Troubleshooting (Organizational Level)-Continued - TM-5-6115-593-12_253
Table 5-6. Automatic Control Module Troubleshooting (Organizational Level)-Continued - TM-5-6115-593-12_254
ORGANIZATIONAL MAINTENANCE OF THE HOUSING KIT
Table 5-7. OPERATOR/CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES, HOUSING KIT
Figure 5-4. Actuator Control Relay Assembly
Figure 5-5. Housing Kit, Installed on Generator Set
APPENDIX A REFERENCES - TM-5-6115-593-12_259
APPENDIX A REFERENCES - CONTINUED
APPENDIX B BASIC ISSUE ITEM LIST AND ITEMS TROOP INSTALLED OR AUTHORIZED LIST
Section II. INTEGRAL COMPONENTS OF END ITEM
Figure B-1. Basic Issue Items
APPENDIX C MAINTENANCE ALLOCATION CHART
EXPLANATION OF COLUMNS IN SECTION III. - TM-5-6115-593-12_265
SECTION II. MAINTENANCE ALLOCATION CHART - TM-5-6115-593-12_266
SECTION II. MAINTENANCE ALLOCATION CHART (Cont) - TM-5-6115-593-12_267
SECTION II. MAINTENANCE ALLOCATION CHART (Cont) - TM-5-6115-593-12_268
SECTION II. MAINTENANCE ALLOCATION CHART (Cont) - TM-5-6115-593-12_269
SECTION II. MAINTENANCE ALLOCATION CHART (Cont) - TM-5-6115-593-12_270
SECTION II. MAINTENANCE ALLOCATION CHART (Cont) - TM-5-6115-593-12_271
SECTION II. MAINTENANCE ALLOCATION CHART (Cont) - TM-5-6115-593-12_272
SECTION II. MAINTENANCE ALLOCATION CHART (Cont) - TM-5-6115-593-12_273
SECTION II. MAINTENANCE ALLOCATION CHART (Cont) - TM-5-6115-593-12_274
SECTION II. MAINTENANCE ALLOCATION CHART (Cont) - TM-5-6115-593-12_275
SECTION II. MAINTENANCE ALLOCATION CHART (Cont) - TM-5-6115-593-12_276
SECTION II. MAINTENANCE ALLOCATION CHART (Cont) - TM-5-6115-593-12_277
SECTION II. MAINTENANCE ALLOCATION CHART (Cont) - TM-5-6115-593-12_278
Section III. TOOLS, TEST AND SUPPORT EQUIPMENT REQUIREMENT
Section IV. REMARKS - TM-5-6115-593-12_280
Section II. ADDITIONAL AUTHORIZATION LIST
FO-1 DC Schematic (Sheet 1 of 4)
FO-1. DC Schematic (sheet 2 of 4)
FO-1 DC Schematic (sheet 3 of 4)
FO-1 DC Schematic (sheet 4 of 4)
FO-2 AC Schematic (Sheet 1 of 2)
FO-2 AC Schematic (Sheet 2 of 2)
FO-3 DC Wiring Diagram (Sheet 1 of 5)
FO-3 DC Wiring Diagram (Sheet 2 of 5)
FO-3 DC Wiring Diagram (Sheet 3 of 5)
FO-3 DC Wiring Diagram (Sheet 4 of 5)
FO-3 DC Wiring Diagram (Sheet 5 of 5)
FO-4 AC Wiring Diagram (Sheet 1 of 4)
FO-4 AC Wiring Diagram (Sheet 2 of 4)
FO-4 AC Wiring Diagram (Sheet 3 of 4)
FO-4 AC Wiring Diagram (Sheet 4 of 4)
FO-5 AC / DC Control Box (Sheet 1 of 4)
FO-5 AC / DC Control Box (Sheet 2 of 4)
FO-5 AC / DC Control Box (Sheet 3 of 4)
FO-5 AC / DC Control Box (Sheet 4 of 4)
FO-6 External Power Box Wiring Diagram (Sheet 1 of 3)
FO-6 External Power Box Wiring Diagram (Sheet 2 of 3)
FO-6 External Power Box Wiring Diagram (Sheet 3 of 3)
FO-7 Unit Control Box Wiring Diagram (Sheet 1 of 4)
FO-7 Unit Control Box Wiring Diagram (Sheet 2 of 4)
FO-7. Unit Control Box Wiring Diagram (Sheet 3 of 4)
FO-7. Unit Control Box Wiring Diagram (Sheet 4 of 4)
FO-8. Remote Control Module Schematic
FO-9. Remote Control Module Wiring Diagram (Sheet 1 of 2)
FO-9. Remote Control Module Wiring Diagram (Sheet 2 of 2)
FO-10. Generator Reconnection Box Wiring Diagram
FO-11. Engine Accessories Wiring Diagram (Sheet 1 of 2)
FO-11. Engine Accessories Wiring Diagram (Sheet 2of 2)
FO-12. Automatic Control Module AC Schematic (Sheet 1 of 2)
FO-12. Automatic Control Module AC Schematic (Sheet 2 of 2)
FO-13. Automatic Control Module Wiring Diagram(Sheet 1 of 3)
FO-13. Automatic Control Module Wiring Diagram(Sheet 2 of 3)
FO-13. Automatic Control Module Wiring Diagram (Sheet 3 of 3)
FO-14. Remote Control Module Interconnect Wiring Diagram
FO-15. Automatic Control Module Interconnect Wiring Diagram
FO-16. Louver Control Schematic
FO-17. Louver Control Schematic
Section II. DESCRIPTION AND DATA - TM-5-6115-593-12_12
Figure 1-1. Generator Set, Left Side
Figure 1-2. Generator Set, Right Side
Figure 1-3. Generator Set, Rear
Figure 1-4. Generator Set, Top
Figure 1-5. Remote Control Module
Figure 1-6. Automatic Control Module
Figure 1-7. Housing Kit, Installed on Generator Set
TABULATED DATA - TM-5-6115-593-12_20
TABULATED DATA (cont) - TM-5-6115-593-12_21
TABULATED DATA (cont) - TM-5-6115-593-12_22
TABULATED DATA (cont) - TM-5-6115-593-12_23
TABULATED DATA (cont) - TM-5-6115-593-12_24
TABULATED DATA (cont) - TM-5-6115-593-12_25
TABULATED DATA (cont) - TM-5-6115-593-12_26
TABULATED DATA (cont) - TM-5-6115-593-12_27
TABULATED DATA (cont) - TM-5-6115-593-12_28
TORQUE DATA
Figure 1-8. Fuel System Diagram
Figure 1-9. Instruction Plate Locations
Section III. SYSTEM OPERATION
DC ELECTRICAL AND CONTROL SYSTEM.
Engine Stopping
Engine Fault Indicators
AC POWER GENERATION AND CONTROL SYSTEM - TM-5-6115-593-12_36
AC POWER GENERATION AND CONTROL SYSTEM (cont) - TM-5-6115-593-12_37
AC POWER GENERATION AND CONTROL SYSTEM (cont) - TM-5-6115-593-12_38
AC POWER GENERATION AND CONTROL SYSTEM - TM-5-6115-593-12_39
COOLING SYSTEM - TM-5-6115-593-12_40
FUEL SYSTEM
CHAPTER 2 OPERATING INSTRUCTIONS - TM-5-6115-593-12_42
EXERCISE OF ENGINE ON STANDBY SERVICE - TM-5-6115-593-12_43
Figure 2-1. Engine Control Panel (Part of Control Cubicle)
Table 2-2. Generator Control Panel, Controls and Instruments
Figure 2-2. Generator Control Panel (Part of Control Cubicle)
Table 2-2. Generator Control Panel, Controls and Instruments-Continued - TM-5-6115-593-12_47
Table 2-2. Generator Control Panel, Controls and Instruments-Continued - TM-5-6115-593-12_48
Table 2-3. AC-DC Control Panel, Controls and Instruments
Figure 2-3. AC-DC Control Panel
Table 2-4. External Power Box Control Panel, Controls and Instruments
Figure 2-4. External Power Box Control Panel
Figure 2-5. Preparation for Starting (Sheet 1 of 3)
Figure 2-5. Preparation for Starting (Sheet 2 of 3)
Figure 2-5. Preparation for Starting (Sheet 3 of 3)
Figure 2-6. Starting Instructions (Sheet 1 of 3)
Figure 2-6. Starting Instructions (Sheet 2 of 3)
Figure 2-6. Starting Instructions (Sheet 3 of 3)
Figure 2-7. Stopping Instructions
Figure 2-8. Single Generator Unit, Operating Instructions
Figure 2-9. Preparation for Starting with Housing Kit Installed (Sheet 1 of
Figure 2-9. Preparation for Starting with Housing Kit Installed (Sheet 2 of 3)
Figure 2-9. Preparation for Starting with Housing Kit Installed (Sheet 3 of 3)
Figure 2-10. Starting Instructions when Ambient Temperature is from 40F to -25F (4.4C to -32C) and Housing Kit is Installed (Sheet 1 of 3)
Figure 2-10. Starting Instructions when Ambient Temperature is from 40F to -25F (4.4C to -32C) and Housing Kit is Installed (Sheet 2 of 3)
Figure 2-10. Starting Instructions when Ambient Temperature is from 40F to -25F (4.4C to -32C) and Housing Kit is Installed (Sheet 3 of 3)
Figure 2-11. Stopping Instructions with Housing Kit Installed
Figure 2-12. Single Generator Unit, Operating Instructions with Housing Kit Installed
Table 2-5. Remote Control Panel, Controls and Instruments
Figure 2-13. Remote Control Module Panel
Table 2-5. Remote Control Panel, Controls and Instruments-Continued - TM-5-6115-593-12_71
Table 2-5. Remote Control Panel, Controls and Instruments-Continued - TM-5-6115-593-12_72
Figure 2-14. Jumper Connections to be Removed when a Remote Control Module is Connected
Figure 2-15. Preparation for Starting Using Remote Control Module
Figure 2-16. Starting Instructions Using Remote Control Module (Sheet 1 of 2)
Figure 2-16. Starting Instructions Using Remote Control Module (Sheet 2 of 2)
Figure 2-17. Stopping Instructions Using Remote Control Module
Figure 2-18. Operating Instructions, Single Generator Unit Using Remote Control Module
Connecting the Automatic Control Module
Optional Uses
Figure 2-19. Automatic Control Module
Table 2-6. Automatic Control Module, Controls and Instruments
Table 2-6. Automatic Control Module, Controls and Instruments - Continued
Figure 2-21. Operating Instructions, Manually Operated in Parallel (Sheet 1 of 3)
DROOP PARALLELING
Figure 2-21. Operating Instructions, Manually Operated in Parallel (Sheet 3 of 3)
Section III. OPERATION UNDER UNUSUAL CONDITIONS - TM-5-6115-593-12_87
OPERATION IN SALT WATER AREAS
Section I. CONSUMABLE OPERATING AND MAINTENANCE SUPPLIES
Table 3-1. Consumable Operating and Maintenance Supplies - Continued
Section II. LUBRICATION INSTRUCTIONS - TM-5-6115-593-12_91
TABLE 3-2. OPERATOR/CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES - TM-5-6115-593-12_92
TABLE 3-2. OPERATOR/CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES - TM-5-6115-593-12_93
TABLE 3-3. OPERATOR/CREW TROUBLESHOOTING - TM-5-6115-593-12_94
TABLE 3-3. OPERATOR/CREW TROUBLESHOOTING - TM-5-6115-593-12_95
TABLE 3-3. OPERATOR/CREW TROUBLESHOOTING - TM-5-6115-593-12_96
TABLE 3-3. OPERATOR/CREW TROUBLESHOOTING - TM-5-6115-593-12_97
Section V. OPERATOR/CREW MAINTENANCE
Figure 3-1. Air Cleaner, Exploded view
MAINTENANCE OF RADIATOR ASSEMBLY
Figure 3-2. Fuel Transfer Pump Inspection Points
MAINTENANCE OF ETHER KIT
CHAPTER 4 ORGANIZATIONAL MAINTENANCE
INSTALLATION - TM-5-6115-593-12_104
Figure 4-2. Cooling System Drain and Shut -off Cock
Figure 4-3. Location of Engine Water Drains
Figure 4-4. Location of Engine Crankcase Drain and Drain Valve
Figure 4-5. Location of Fuel Tank Drain Cock
Table 4-1. Freezing Points, Composition, and Specific Gravities of Military Antifreeze
Figure 4-6. Installation Plan
Figure 4-7. Grounding Procedures (Sheet 1 of 3)
Figure 4-7. Grounding Procedures (Sheet 2 of 3)
Figure 4-7. Grounding Procedures (Sheet 3 of 3)
Slide Hammer Procedure
EQUIPMENT CONVERSION.
Figure 4-8. Output Voltage Conversion Connections
Section IV. LUBRICATION INSTRUCTIONS
Figure 4-8A. Crankcase Breather
Section V. PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
TABLE 4-2. ORGANIZATIONAL PREVENTIVE MAINTENANCE CHECKS AND SERVICES. - TM-5-6115-593-12_120
TABLE 4-2. ORGANIZATIONAL PREVENTIVE MAINTENANCE CHECKS AND SERVICES. - TM-5-6115-593-12_121
Table 4-3. Organizational Troubleshooting
Table 4-3. Organizational Troubleshooting -Continued - TM-5-6115-593-12_123
Table 4-3. Organizational Troubleshooting -Continued - TM-5-6115-593-12_124
Table 4-3. Organizational Troubleshooting -Continued - TM-5-6115-593-12_125
Table 4-3. Organizational Troubleshooting -Continued - TM-5-6115-593-12_126
Table 4-3. Organizational Troubleshooting -Continued - TM-5-6115-593-12_127
Table 4-3. Organizational Troubleshooting -Continued - TM-5-6115-593-12_128
Table 4-3. Organizational Troubleshooting -Continued - TM-5-6115-593-12_129
Table 4-3. Organizational Troubleshooting -Continued
Table 4-3. Organizational Troubleshooting -Continued - TM-5-6115-593-12_131
Table 4-3. Organizational Troubleshooting -Continued - TM-5-6115-593-12_132
Table 4-3. Organizational Troubleshooting -Continued - TM-5-6115-593-12_133
Table 4-3. Organizational Troubleshooting -Continued - TM-5-6115-593-12_134
Table 4-3. Organizational Troubleshooting -Continued - TM-5-6115-593-12_135
Section VIII. MAINTENANCE OF BATTERIES AND RELATED ITEMS
Figure 4-9. Batteries and Related Items, Exploded View
Figure 4-10. Battery Cable Fabrication
Section IX. MAINTENANCE OF MUFFLER AND EXHAUST
Section X. MAINTENANCE OF EXTERNAL POWER BOX ASSEMBLY
Figure 4-11. Muffler and Exhaust, Exploded View
Figure 4-12. External Power Box Assembly, Exploded View
LEGEND FOR FIGURE 4-12
Figure 4-13. External Power Box Assembly, Control Panel, Exploded View
PANEL MOUNTED RECEPTACLES.
Replacement. - TM-5-6115-593-12_146
Figure 4-14. Contactors K107, K108, K109 and Main Circuit Breaker CB2, Schematic
Figure 4-15. Main Circuit Breaker, CB2
Installation - TM-5-6115-593-12_149
PLATE AND SLEEVE ASSEMBLY - TM-5-6115-593-12_150
HARNESS ASSEMBLY - TM-5-6115-593-12_151
Section XI. MAINTENANCE OF AC-DC CONTROL BOX ASSEMBLY
Figure 4-17. AC-DC Control Box Assembly, Exploded View
LEGEND FOR FIGURE 4-17
Figure 4-18. AC-DC Control Box Assembly, Component Panel Assembly, Exploded View
LEGEND FOR FIGURE 4-18
Figure 4-19. AC-DC Control Box Assembly Component Panel Assembly, Exploded View
SHORTING PLUG
POTENTIOMETER R103
WEATHER STRIPPING
Figure 4-20. Control Cubicle, (Sheet 1 of 3 )
Figure 4-20. Control Cubicle, (Sheet 2 of 3)
Figure 4-20. Control Cubicle, (Sheet 3 of 3)
LEGEND FOR FIGURE 4-20
Figure 4-21. Control Cubicle, Engine Panel, Exploded View
LEGEND FOR FIGURE 4-21
Figure 4-22. Control Cubicle, Generator Panel, Exploded View (Sheet 1 of 2)
Figure 4-22. Control Cubicle, Generator Panel, Exploded View (Sheet 2 of 2)
LEGEND FOR FIGURE 4-22
Section XII. MAINTENANCE OF CONTROL CUBICLE
ENGINE OIL PRESS
HARNESS ASSEMBLY - TM-5-6115-593-12_172
Section XIII. MAINTENANCE OF AIR CLEANER
Figure 4-23. Air Cleaner and Related Parts
AIR SHUT-OFF VALVE
Section XIV. MAINTENANCE OF TOOL BOX ASSEMBLY
Figure 4-24. Tool Box Assembly
Section XVI. MAINTENANCE OF SUPPORT FRAME ASSEMBLY
Figure 4-25. Document Compartment
Figure 4-26. Support Frame Assembly
Figure 4-27. Radiator Assembly, Exploded View
Figure 4-28. Fan Belt Adjustment and Replacement, Code A
Fan Belt Replacement
Section XVIII. MAINTENANCE OF FUEL LINES AND FITTINGS
Replacement. - TM-5-6115-593-12_185
Figure 4-29. Fuel Lines (Sheet 1 of 2)
Figure 4-29. Fuel Lines (Sheet 2 of 2)
Figure 4-30. Preheat Installation (Sheet 1 of 2)
Figure 4-30. Preheat Installation (Heater) (Sheet 2 of 2)
Section XX. MAINTENANCE OF FUEL TRANSFER PUMP
FILTER AND STRAINER
Section XXI. MAINTENANCE OF FUEL TANK ASSEMBLY
Figure 4-31. Fuel Transfer Pump Installation, Exploded View
Figure 4-32. Fuel Transfer Pump Contactor K20
Figure 4-33. Fuel Tank Assembly, Exploded View
Figure 4-35. Liquid Quantity Transmitter
Section XXII. MAINTENANCE OF INTERCONNECTING ELECTRICAL WIRING HARNESS
Figure 4-36. Generator and Reconnection Board
Figure 4-37. Electric Hydraulic Actuator
Section XXV. MAINTENANCE OF ETHER KIT
Section XXVI. MAINTENANCE OF ENGINE ASSEMBLY
Figure 4-39. Ether Installation
Figure 4-40. Engine Components (Sheet 1 of 2)
Figure 4-40. Engine Components (Sheet 2 of 2)
Figure 4-41. Water Pump Belt Adjustment
Figure 4-42. Speed Switch
Figure 4-43. Oil Level Sight Gauge and Filler
PRESSURE SWITCH.
Figure 4-44. Starter Assembly.
Figure 4-46. Pressure Switches
LUBE OIL COOLER
Figure 4-47. Oil Filters
Figure 4-48. Secondary Fuel Filter
Figure 4-49. Lube Oil Cooler
TURBOCHARGER - TM-5-6115-593-12_215
Figure 4-50. Fuel Injector
Figure 4-51. Turbocharger
Replace hoses and clamps
Figure 4-52. Water Pump and Idler Pulley Assembly
Figure 4-53. Thermostat Removal
THERMOSTAT
TEMPERATURE SWITCH
Figure 4-55. Coolant Temperature Switch
EXHAUST MANIFOLD
Figure 4-56. Intercooler
Figure 4-57. Exhaust Manifold
Figure 4-58. Water Manifold
Figure 4-59. Rocker Arm and Shaft Assembly
Section XXVII. MAINTENANCE OF BASE ASSEMBLY
REPLACEMENT OF TERMINALS, FITTINGS AND HOSES
Figure 4-60. Base Assembly, Exploded View
LEGEND FOR FIGURE 4-60
BREATHER LINES AND FITTINGS
Figure 4-61. Breather Lines and Fittings
CHAPTER 5 AUXILIARY EQUIPMENT USED IN CONJUNCTION WITH THE GENERATOR SET
Figure 5-1. Remote Control Module
Table 5-1. OPERATOR/CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES, REMOTE CONTROL MODULE
Table 5-2. Remote Control Module Troubleshooting (Operator/Crew Level)
Table 5-2. Remote Control Module Troubleshooting (Operator/Crew Level)-Continued - TM-5-6115-593-12_239
Table 5-2. Remote Control Module Troubleshooting (Operator/Crew Level)-Continued - TM-5-6115-593-12_240
Table 5-3. Remote Control Module Troubleshooting (Organizational Level)
Table 5-3. Remote Control Module Troubleshooting (Organizational Level)-Continued - TM-5-6115-593-12_242
Table 5-3. Remote Control Module Troubleshooting (Organizational Level)-Continued - TM-5-6115-593-12_243
Table 5-3. Remote Control Module Troubleshooting (Organizational Level)-Continued - TM-5-6115-593-12_244
Figure 5-2. Remote Control Module, Plate Assembly
Figure 5-3. Remote Control Module, Annunciator Control Assembly
Section III. REMOTE CONTROL CABLE ASSEMBLY - TM-5-6115-593-12_247
Section IV. AUTOMATIC CONTROL MODULE
ORGANIZATIONAL TROUBLESHOOTING
Table 5-4. OPERATOR/CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES, AUTOMATIC CONTROL MODULE
Table 5-5. Automatic Control Module Troubleshooting (Operator/Crew Level)
Table 5-6. Automatic Control Module Troubleshooting (Organizational Level)-Continued - TM-5-6115-593-12_252
Table 5-6. Automatic Control Module Troubleshooting (Organizational Level)-Continued - TM-5-6115-593-12_253
Table 5-6. Automatic Control Module Troubleshooting (Organizational Level)-Continued - TM-5-6115-593-12_254
ORGANIZATIONAL MAINTENANCE OF THE HOUSING KIT
Table 5-7. OPERATOR/CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES, HOUSING KIT
Figure 5-4. Actuator Control Relay Assembly
Figure 5-5. Housing Kit, Installed on Generator Set
APPENDIX A REFERENCES - TM-5-6115-593-12_259
APPENDIX A REFERENCES - CONTINUED
APPENDIX B BASIC ISSUE ITEM LIST AND ITEMS TROOP INSTALLED OR AUTHORIZED LIST
Section II. INTEGRAL COMPONENTS OF END ITEM
Figure B-1. Basic Issue Items
APPENDIX C MAINTENANCE ALLOCATION CHART
EXPLANATION OF COLUMNS IN SECTION III. - TM-5-6115-593-12_265
SECTION II. MAINTENANCE ALLOCATION CHART - TM-5-6115-593-12_266
SECTION II. MAINTENANCE ALLOCATION CHART (Cont) - TM-5-6115-593-12_267
SECTION II. MAINTENANCE ALLOCATION CHART (Cont) - TM-5-6115-593-12_268
SECTION II. MAINTENANCE ALLOCATION CHART (Cont) - TM-5-6115-593-12_269
SECTION II. MAINTENANCE ALLOCATION CHART (Cont) - TM-5-6115-593-12_270
SECTION II. MAINTENANCE ALLOCATION CHART (Cont) - TM-5-6115-593-12_271
SECTION II. MAINTENANCE ALLOCATION CHART (Cont) - TM-5-6115-593-12_272
SECTION II. MAINTENANCE ALLOCATION CHART (Cont) - TM-5-6115-593-12_273
SECTION II. MAINTENANCE ALLOCATION CHART (Cont) - TM-5-6115-593-12_274
SECTION II. MAINTENANCE ALLOCATION CHART (Cont) - TM-5-6115-593-12_275
SECTION II. MAINTENANCE ALLOCATION CHART (Cont) - TM-5-6115-593-12_276
SECTION II. MAINTENANCE ALLOCATION CHART (Cont) - TM-5-6115-593-12_277
SECTION II. MAINTENANCE ALLOCATION CHART (Cont) - TM-5-6115-593-12_278
Section III. TOOLS, TEST AND SUPPORT EQUIPMENT REQUIREMENT
Section IV. REMARKS - TM-5-6115-593-12_280
Section II. ADDITIONAL AUTHORIZATION LIST
FO-1 DC Schematic (Sheet 1 of 4)
FO-1. DC Schematic (sheet 2 of 4)
FO-1 DC Schematic (sheet 3 of 4)
FO-1 DC Schematic (sheet 4 of 4)
FO-2 AC Schematic (Sheet 1 of 2)
FO-2 AC Schematic (Sheet 2 of 2)
FO-3 DC Wiring Diagram (Sheet 1 of 5)
FO-3 DC Wiring Diagram (Sheet 2 of 5)
FO-3 DC Wiring Diagram (Sheet 3 of 5)
FO-3 DC Wiring Diagram (Sheet 4 of 5)
FO-3 DC Wiring Diagram (Sheet 5 of 5)
FO-4 AC Wiring Diagram (Sheet 1 of 4)
FO-4 AC Wiring Diagram (Sheet 2 of 4)
FO-4 AC Wiring Diagram (Sheet 3 of 4)
FO-4 AC Wiring Diagram (Sheet 4 of 4)
FO-5 AC / DC Control Box (Sheet 1 of 4)
FO-5 AC / DC Control Box (Sheet 2 of 4)
FO-5 AC / DC Control Box (Sheet 3 of 4)
FO-5 AC / DC Control Box (Sheet 4 of 4)
FO-6 External Power Box Wiring Diagram (Sheet 1 of 3)
FO-6 External Power Box Wiring Diagram (Sheet 2 of 3)
FO-6 External Power Box Wiring Diagram (Sheet 3 of 3)
FO-7 Unit Control Box Wiring Diagram (Sheet 1 of 4)
FO-7 Unit Control Box Wiring Diagram (Sheet 2 of 4)
FO-7. Unit Control Box Wiring Diagram (Sheet 3 of 4)
FO-7. Unit Control Box Wiring Diagram (Sheet 4 of 4)
FO-8. Remote Control Module Schematic
FO-9. Remote Control Module Wiring Diagram (Sheet 1 of 2)
FO-9. Remote Control Module Wiring Diagram (Sheet 2 of 2)
FO-10. Generator Reconnection Box Wiring Diagram
FO-11. Engine Accessories Wiring Diagram (Sheet 1 of 2)
FO-11. Engine Accessories Wiring Diagram (Sheet 2of 2)
FO-12. Automatic Control Module AC Schematic (Sheet 1 of 2)
FO-12. Automatic Control Module AC Schematic (Sheet 2 of 2)
FO-13. Automatic Control Module Wiring Diagram(Sheet 1 of 3)
FO-13. Automatic Control Module Wiring Diagram(Sheet 2 of 3)
FO-13. Automatic Control Module Wiring Diagram (Sheet 3 of 3)
FO-14. Remote Control Module Interconnect Wiring Diagram
FO-15. Automatic Control Module Interconnect Wiring Diagram
FO-16. Louver Control Schematic
FO-17. Louver Control Schematic
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Integrated Publishing, Inc. - A (SDVOSB) Service Disabled Veteran Owned Small Business
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