CHAPTER 1 INTRODUCTION - TM-5-6115-593-12_11Section II. DESCRIPTION AND DATA - TM-5-6115-593-12_12Figure 1-1. Generator Set, Left SideFigure 1-2. Generator Set, Right SideFigure 1-3. Generator Set, RearFigure 1-4. Generator Set, TopFigure 1-5. Remote Control ModuleFigure 1-6. Automatic Control ModuleFigure 1-7. Housing Kit, Installed on Generator SetTABULATED DATA - TM-5-6115-593-12_20TABULATED DATA (cont) - TM-5-6115-593-12_21TABULATED DATA (cont) - TM-5-6115-593-12_22TABULATED DATA (cont) - TM-5-6115-593-12_23TABULATED DATA (cont) - TM-5-6115-593-12_24TABULATED DATA (cont) - TM-5-6115-593-12_25TABULATED DATA (cont) - TM-5-6115-593-12_26TABULATED DATA (cont) - TM-5-6115-593-12_27TABULATED DATA (cont) - TM-5-6115-593-12_28TORQUE DATAFigure 1-8. Fuel System DiagramFigure 1-9. Instruction Plate LocationsSection III. SYSTEM OPERATIONDC ELECTRICAL AND CONTROL SYSTEM.Engine StoppingEngine Fault IndicatorsAC POWER GENERATION AND CONTROL SYSTEM - TM-5-6115-593-12_36AC POWER GENERATION AND CONTROL SYSTEM (cont) - TM-5-6115-593-12_37AC POWER GENERATION AND CONTROL SYSTEM (cont) - TM-5-6115-593-12_38AC POWER GENERATION AND CONTROL SYSTEM - TM-5-6115-593-12_39COOLING SYSTEM - TM-5-6115-593-12_40FUEL SYSTEMCHAPTER 2 OPERATING INSTRUCTIONS - TM-5-6115-593-12_42EXERCISE OF ENGINE ON STANDBY SERVICE - TM-5-6115-593-12_43Figure 2-1. Engine Control Panel (Part of Control Cubicle)Table 2-2. Generator Control Panel, Controls and InstrumentsFigure 2-2. Generator Control Panel (Part of Control Cubicle)Table 2-2. Generator Control Panel, Controls and Instruments-Continued - TM-5-6115-593-12_47Table 2-2. Generator Control Panel, Controls and Instruments-Continued - TM-5-6115-593-12_48Table 2-3. AC-DC Control Panel, Controls and InstrumentsFigure 2-3. AC-DC Control PanelTable 2-4. External Power Box Control Panel, Controls and InstrumentsFigure 2-4. External Power Box Control PanelFigure 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 InstructionsFigure 2-8. Single Generator Unit, Operating InstructionsFigure 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 InstalledFigure 2-12. Single Generator Unit, Operating Instructions with Housing Kit InstalledTable 2-5. Remote Control Panel, Controls and InstrumentsFigure 2-13. Remote Control Module PanelTable 2-5. Remote Control Panel, Controls and Instruments-Continued - TM-5-6115-593-12_71Table 2-5. Remote Control Panel, Controls and Instruments-Continued - TM-5-6115-593-12_72Figure 2-14. Jumper Connections to be Removed when a Remote Control Module is ConnectedFigure 2-15. Preparation for Starting Using Remote Control ModuleFigure 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 ModuleFigure 2-18. Operating Instructions, Single Generator Unit Using Remote Control ModuleConnecting the Automatic Control ModuleOptional UsesFigure 2-19. Automatic Control ModuleTable 2-6. Automatic Control Module, Controls and InstrumentsTable 2-6. Automatic Control Module, Controls and Instruments - ContinuedFigure 2-21. Operating Instructions, Manually Operated in Parallel (Sheet 1 of 3)DROOP PARALLELINGFigure 2-21. Operating Instructions, Manually Operated in Parallel (Sheet 3 of 3)Section III. OPERATION UNDER UNUSUAL CONDITIONS - TM-5-6115-593-12_87OPERATION IN SALT WATER AREASSection I. CONSUMABLE OPERATING AND MAINTENANCE SUPPLIESTable 3-1. Consumable Operating and Maintenance Supplies - ContinuedSection II. LUBRICATION INSTRUCTIONS - TM-5-6115-593-12_91TABLE 3-2. OPERATOR/CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES - TM-5-6115-593-12_92TABLE 3-2. OPERATOR/CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES - TM-5-6115-593-12_93TABLE 3-3. OPERATOR/CREW TROUBLESHOOTING - TM-5-6115-593-12_94TABLE 3-3. OPERATOR/CREW TROUBLESHOOTING - TM-5-6115-593-12_95TABLE 3-3. OPERATOR/CREW TROUBLESHOOTING - TM-5-6115-593-12_96TABLE 3-3. OPERATOR/CREW TROUBLESHOOTING - TM-5-6115-593-12_97Section V. OPERATOR/CREW MAINTENANCEFigure 3-1. Air Cleaner, Exploded viewMAINTENANCE OF RADIATOR ASSEMBLYFigure 3-2. Fuel Transfer Pump Inspection PointsMAINTENANCE OF ETHER KITCHAPTER 4 ORGANIZATIONAL MAINTENANCEINSTALLATION - TM-5-6115-593-12_104Figure 4-2. Cooling System Drain and Shut -off CockFigure 4-3. Location of Engine Water DrainsFigure 4-4. Location of Engine Crankcase Drain and Drain ValveFigure 4-5. Location of Fuel Tank Drain CockTable 4-1. Freezing Points, Composition, and Specific Gravities of Military AntifreezeFigure 4-6. Installation PlanFigure 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 ProcedureEQUIPMENT CONVERSION.Figure 4-8. Output Voltage Conversion ConnectionsSection IV. LUBRICATION INSTRUCTIONSFigure 4-8A. Crankcase BreatherSection V. PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)TABLE 4-2. ORGANIZATIONAL PREVENTIVE MAINTENANCE CHECKS AND SERVICES. - TM-5-6115-593-12_120TABLE 4-2. ORGANIZATIONAL PREVENTIVE MAINTENANCE CHECKS AND SERVICES. - TM-5-6115-593-12_121Table 4-3. Organizational TroubleshootingTable 4-3. Organizational Troubleshooting -Continued - TM-5-6115-593-12_123Table 4-3. Organizational Troubleshooting -Continued - TM-5-6115-593-12_124Table 4-3. Organizational Troubleshooting -Continued - TM-5-6115-593-12_125Table 4-3. Organizational Troubleshooting -Continued - TM-5-6115-593-12_126Table 4-3. Organizational Troubleshooting -Continued - TM-5-6115-593-12_127Table 4-3. Organizational Troubleshooting -Continued - TM-5-6115-593-12_128Table 4-3. Organizational Troubleshooting -Continued - TM-5-6115-593-12_129Table 4-3. Organizational Troubleshooting -Continued Table 4-3. Organizational Troubleshooting -Continued - TM-5-6115-593-12_131Table 4-3. Organizational Troubleshooting -Continued - TM-5-6115-593-12_132Table 4-3. Organizational Troubleshooting -Continued - TM-5-6115-593-12_133Table 4-3. Organizational Troubleshooting -Continued - TM-5-6115-593-12_134Table 4-3. Organizational Troubleshooting -Continued - TM-5-6115-593-12_135Section VIII. MAINTENANCE OF BATTERIES AND RELATED ITEMSFigure 4-9. Batteries and Related Items, Exploded ViewFigure 4-10. Battery Cable FabricationSection IX. MAINTENANCE OF MUFFLER AND EXHAUSTSection X. MAINTENANCE OF EXTERNAL POWER BOX ASSEMBLYFigure 4-11. Muffler and Exhaust, Exploded ViewFigure 4-12. External Power Box Assembly, Exploded ViewLEGEND FOR FIGURE 4-12Figure 4-13. External Power Box Assembly, Control Panel, Exploded ViewPANEL MOUNTED RECEPTACLES.Replacement. - TM-5-6115-593-12_146Figure 4-14. Contactors K107, K108, K109 and Main Circuit Breaker CB2, SchematicFigure 4-15. Main Circuit Breaker, CB2Installation - TM-5-6115-593-12_149PLATE AND SLEEVE ASSEMBLY - TM-5-6115-593-12_150HARNESS ASSEMBLY - TM-5-6115-593-12_151Section XI. MAINTENANCE OF AC-DC CONTROL BOX ASSEMBLYFigure 4-17. AC-DC Control Box Assembly, Exploded ViewLEGEND FOR FIGURE 4-17Figure 4-18. AC-DC Control Box Assembly, Component Panel Assembly, Exploded ViewLEGEND FOR FIGURE 4-18Figure 4-19. AC-DC Control Box Assembly Component Panel Assembly, Exploded ViewSHORTING PLUGPOTENTIOMETER R103 WEATHER STRIPPINGFigure 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 4-20Figure 4-21. Control Cubicle, Engine Panel, Exploded ViewLEGEND FOR FIGURE 4-21Figure 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 4-22Section XII. MAINTENANCE OF CONTROL CUBICLEENGINE OIL PRESS HARNESS ASSEMBLY - TM-5-6115-593-12_172Section XIII. MAINTENANCE OF AIR CLEANERFigure 4-23. Air Cleaner and Related PartsAIR SHUT-OFF VALVESection XIV. MAINTENANCE OF TOOL BOX ASSEMBLYFigure 4-24. Tool Box AssemblySection XVI. MAINTENANCE OF SUPPORT FRAME ASSEMBLYFigure 4-25. Document CompartmentFigure 4-26. Support Frame AssemblyFigure 4-27. Radiator Assembly, Exploded ViewFigure 4-28. Fan Belt Adjustment and Replacement, Code AFan Belt Replacement Section XVIII. MAINTENANCE OF FUEL LINES AND FITTINGSReplacement. - TM-5-6115-593-12_185Figure 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 PUMPFILTER AND STRAINERSection XXI. MAINTENANCE OF FUEL TANK ASSEMBLYFigure 4-31. Fuel Transfer Pump Installation, Exploded ViewFigure 4-32. Fuel Transfer Pump Contactor K20Figure 4-33. Fuel Tank Assembly, Exploded ViewFigure 4-35. Liquid Quantity TransmitterSection XXII. MAINTENANCE OF INTERCONNECTING ELECTRICAL WIRING HARNESSFigure 4-36. Generator and Reconnection BoardFigure 4-37. Electric Hydraulic ActuatorSection XXV. MAINTENANCE OF ETHER KITSection XXVI. MAINTENANCE OF ENGINE ASSEMBLYFigure 4-39. Ether InstallationFigure 4-40. Engine Components (Sheet 1 of 2)Figure 4-40. Engine Components (Sheet 2 of 2)Figure 4-41. Water Pump Belt AdjustmentFigure 4-42. Speed SwitchFigure 4-43. Oil Level Sight Gauge and FillerPRESSURE SWITCH.Figure 4-44. Starter Assembly.Figure 4-46. Pressure SwitchesLUBE OIL COOLERFigure 4-47. Oil FiltersFigure 4-48. Secondary Fuel FilterFigure 4-49. Lube Oil CoolerTURBOCHARGER - TM-5-6115-593-12_215Figure 4-50. Fuel InjectorFigure 4-51. TurbochargerReplace hoses and clampsFigure 4-52. Water Pump and Idler Pulley AssemblyFigure 4-53. Thermostat RemovalTHERMOSTATTEMPERATURE SWITCHFigure 4-55. Coolant Temperature SwitchEXHAUST MANIFOLDFigure 4-56. IntercoolerFigure 4-57. Exhaust ManifoldFigure 4-58. Water ManifoldFigure 4-59. Rocker Arm and Shaft AssemblySection XXVII. MAINTENANCE OF BASE ASSEMBLYREPLACEMENT OF TERMINALS, FITTINGS AND HOSESFigure 4-60. Base Assembly, Exploded ViewLEGEND FOR FIGURE 4-60BREATHER LINES AND FITTINGSFigure 4-61. Breather Lines and FittingsCHAPTER 5 AUXILIARY EQUIPMENT USED IN CONJUNCTION WITH THE GENERATOR SETFigure 5-1. Remote Control ModuleTable 5-1. OPERATOR/CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES, REMOTE CONTROL MODULETable 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_239Table 5-2. Remote Control Module Troubleshooting (Operator/Crew Level)-Continued - TM-5-6115-593-12_240Table 5-3. Remote Control Module Troubleshooting (Organizational Level)Table 5-3. Remote Control Module Troubleshooting (Organizational Level)-Continued - TM-5-6115-593-12_242Table 5-3. Remote Control Module Troubleshooting (Organizational Level)-Continued - TM-5-6115-593-12_243Table 5-3. Remote Control Module Troubleshooting (Organizational Level)-Continued - TM-5-6115-593-12_244Figure 5-2. Remote Control Module, Plate AssemblyFigure 5-3. Remote Control Module, Annunciator Control AssemblySection III. REMOTE CONTROL CABLE ASSEMBLY - TM-5-6115-593-12_247Section IV. AUTOMATIC CONTROL MODULEORGANIZATIONAL TROUBLESHOOTINGTable 5-4. OPERATOR/CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES, AUTOMATIC CONTROL MODULETable 5-5. Automatic Control Module Troubleshooting (Operator/Crew Level)Table 5-6. Automatic Control Module Troubleshooting (Organizational Level)-Continued - TM-5-6115-593-12_252Table 5-6. Automatic Control Module Troubleshooting (Organizational Level)-Continued - TM-5-6115-593-12_253Table 5-6. Automatic Control Module Troubleshooting (Organizational Level)-Continued - TM-5-6115-593-12_254ORGANIZATIONAL MAINTENANCE OF THE HOUSING KITTable 5-7. OPERATOR/CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES, HOUSING KITFigure 5-4. Actuator Control Relay AssemblyFigure 5-5. Housing Kit, Installed on Generator SetAPPENDIX A REFERENCES - TM-5-6115-593-12_259APPENDIX A REFERENCES - CONTINUEDAPPENDIX B BASIC ISSUE ITEM LIST AND ITEMS TROOP INSTALLED OR AUTHORIZED LISTSection II. INTEGRAL COMPONENTS OF END ITEMFigure B-1. Basic Issue ItemsAPPENDIX C MAINTENANCE ALLOCATION CHARTEXPLANATION OF COLUMNS IN SECTION III. - TM-5-6115-593-12_265SECTION II. MAINTENANCE ALLOCATION CHART - TM-5-6115-593-12_266SECTION II. MAINTENANCE ALLOCATION CHART (Cont) - TM-5-6115-593-12_267SECTION II. MAINTENANCE ALLOCATION CHART (Cont) - TM-5-6115-593-12_268SECTION II. MAINTENANCE ALLOCATION CHART (Cont) - TM-5-6115-593-12_269SECTION II. MAINTENANCE ALLOCATION CHART (Cont) - TM-5-6115-593-12_270SECTION II. MAINTENANCE ALLOCATION CHART (Cont) - TM-5-6115-593-12_271SECTION II. MAINTENANCE ALLOCATION CHART (Cont) - TM-5-6115-593-12_272SECTION II. MAINTENANCE ALLOCATION CHART (Cont) - TM-5-6115-593-12_273SECTION II. MAINTENANCE ALLOCATION CHART (Cont) - TM-5-6115-593-12_274SECTION II. MAINTENANCE ALLOCATION CHART (Cont) - TM-5-6115-593-12_275SECTION II. MAINTENANCE ALLOCATION CHART (Cont) - TM-5-6115-593-12_276SECTION II. MAINTENANCE ALLOCATION CHART (Cont) - TM-5-6115-593-12_277SECTION II. MAINTENANCE ALLOCATION CHART (Cont) - TM-5-6115-593-12_278Section III. TOOLS, TEST AND SUPPORT EQUIPMENT REQUIREMENTSection IV. REMARKS - TM-5-6115-593-12_280Section II. ADDITIONAL AUTHORIZATION LISTFO-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 SchematicFO-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 DiagramFO-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 DiagramFO-15. Automatic Control Module Interconnect Wiring DiagramFO-16. Louver Control SchematicFO-17. Louver Control Schematic