Chapter 1. Introduction - TM-5-6115-600-120017
Preparation for Storage and Shipment
Section II. Description and Data - TM-5-6115-600-120019
Figure 1-1. Generator Set, Right Front, Three Quarter View
Figure 1-2. Generator Set, Left Rear, Three Quarter View
Table 1-1. Tabulated Data
Table 1-1. Tabulated Data (cont) - TM-5-6115-600-120023
Table 1-1. Tabulated Data (cont) - TM-5-6115-600-120024
Table 1-1. Tabulated Data (cont) - TM-5-6115-600-120025
Table 1-1. Tabulated Data (cont) - TM-5-6115-600-120026
Table 1-1. Tabulated Data (cont) - TM-5-6115-600-120027
Table 1-1. Tabulated Data (cont) - TM-5-6115-600-120028
Table 1-1. Tabulated Data (cont) - TM-5-6115-600-120029
Table 1-1. Tabulated Data (cont) - TM-5-6115-600-120030
Table 1-1. Tabulated Data (cont) - TM-5-6115-600-120031
Table 1-1. Tabulated Data (cont) - TM-5-6115-600-120032
Table 1-1. Tabulated Data (cont) - TM-5-6115-600-120033
Table 1-1. Tabulated Data (cont) - TM-5-6115-600-120034
Table 1-1. Tabulated Data (cont) - TM-5-6115-600-120035
Table 1-1. Tabulated Data (cont) - TM-5-6115-600-120036
Table 1-1. Tabulated Data (cont) - TM-5-6115-600-120037
Table 1-1. Tabulated Data (cont) - TM-5-6115-600-120038
Table 1-1. Tabulated Data (cont) - TM-5-6115-600-120039
Table 1-1. Tabulated Data (cont) - TM-5-6115-600-120040
Table 1-1. Tabulated Data (cont) - TM-5-6115-600-120041
Table 1-1. Tabulated Data (cont) - TM-5-6115-600-120042
Table 1-1. Tabulated Data (cont) - TM-5-6115-600-120043
Figure 1-3. Location of Identification Plates
Table 1-2. Special Torque Data - TM-5-6115-600-120045
Figure 1-5. Fault Indicator Panel A9, Schematic Diagram
Figure 1-6. Fuel Burning Winterization Kit, Wiring Diagram
Figure 1-7. Fuel Burning Winterization Kit, Schematic Diagram
Figure 1-8. Electric Winterization Kit, Wiring Diagram
Figure 1-9. Electric Winterization Kit, Schematic Diagram
Chapter 2. Operating Instructions - TM-5-6115-600-120051
Figure 2-1. Location of Controls, Instruments, and Receptacles
Table 2-1. Generator Set, Controls and Indicators
Table 2-1. Generator Set, Controls and Indicators (cont) - TM-5-6115-600-120054
Table 2-1. Generator Set, Controls and Indicators (cont) - TM-5-6115-600-120055
Figure 2-2. Control Cubicle, Controls and Indicators
Table 2-2. Control Cubicle, Controls and Indicators
Table 2-2. Control Cubicle, Controls and Indicators (cont) - TM-5-6115-600-120058
Table 2-2. Control Cubicle, Controls and Indicators (cont) - TM-5-6115-600-120059
Table 2-2. Control Cubicle, Controls and Indicators (cont) - TM-5-6115-600-120060
Figure 2-3. Fault Indicator Panel, Controls
Table 2-3. Fault Indicator Panel, Controls and Indicators
Table 2-3. Fault Indicator Panel, Controls and Indicators (cont)
Figure 2-4. Voltage Conversion - TM-5-6115-600-120064
Figure 2-5. Starting Generator Set, Usual Conditions
Figure 2-6. Single Unit Operation
Operating teh Generator (Units in parallel)
Figure 2-7. Setting up for Parallel Operation
Figure 2-8. PArallel Operation Connection Diagram
Figure 2-9. Removing Generator Set From Parallel Operation
Section II. Operation of Auxiliary Equipment
Figure 2-11. Fuel Burning Winterization Kit, Controls and Indicators
Table 2-4. Fuel Burning Winterization Kit, Control and Indicators
Figure 2-12. Fuel Burning Winterization Kit,Operating Instructions
Figure 2-13. Electric Winterization Kit, Controls and Indicators
Figure 2-14. Electric Winterization Kit, Operating Instructions
Section III. Operation Under Unusual Conditions
Figure 2-15. Ether Starting, Operating Instructions
Operation in Sandy or Dusty Areas
Operation At High Altitudes
Figure 2-16. Emergency Operation (Battle Short) of Generator Set
Operation Using NATO Slave Cable
Chapter 3. Operator/Crew Maintenance Instructions
Section II. Lubrication Instructions
Figure 3-1. Lubrication Order
Figure 3-1. Lubrication Order (cont)
Section III. Preventive Maintenance Checks and Services - TM-5-6115-600-120089
Preventive Maintenance Checks and Services Table
Table 3-2. Operator Preventive Maintenace Checks and Services
Table 3-2. Operator Preventive Maintenace Checks and Services (cont)
Section IV. Troubleshooting - TM-5-6115-600-120094
Table 3-3. Troubleshooting, Operator
Table 3-3. Troubleshooting, Operator (cont) - TM-5-6115-600-120096
Table 3-3. Troubleshooting, Operator (cont) - TM-5-6115-600-120097
Table 3-3. Troubleshooting, Operator (cont) - TM-5-6115-600-120098
Table 3-3. Troubleshooting, Operator (cont) - TM-5-6115-600-120099
Table 3-3. Troubleshooting, Operator (cont) - TM-5-6115-600-120100
Section V. Operator/Crew Maintenance Instructions
Figure 3-2. Batteries, Servicing
Set Controls and Instrumentation
Douglas Kit Arm Puller
Seal Installer and puller
Figure 3-3. Fuel Filler Cap and Strainer
Ether System - TM-5-6115-600-120107
Exhaust and Breather System
Inspection of Air Cleaners
General Cleaning
Chapter 4. Organizational Maintenance
Figure 4-1. Shipping Crate
Figure 4-2. Location of Fill and Drain Points and Drain Valves
Table 4-1. Freezing Points, Composition, and Specific Gravities of Military Antifreeze Material
Figure 4-3. Noise Level Warning Sign
Figure 4-4. Installation Plan
Figure 4-4. Installation Plan (cont)
Figure 4-5. Ground Procedure
Auxiliary Fuel Connection
Figure 4-6. Fuel Connections
Figure 4-7. Load Cable Connections
Section II. Movement to a New Work Site - TM-5-6115-600-120124
Section IV. Lubrication Instructions
Figure 4-8. Lubricating Oil Filter, Servicing
Section V. Preventive Maintenance Checks and Services
Table 4-2. Organizational Preventive Maintenance Checks and Services
Table 4-2. Organizational Preventive Maintenance Checks and Services (cont) - TM-5-6115-600-120129
Table 4-2. Organizational Preventive Maintenance Checks and Services (cont) - TM-5-6115-600-120130
Table 4-2. Organizational Preventive Maintenance Checks and Services (cont) - TM-5-6115-600-120131
Table 4-2. Organizational Preventive Maintenance Checks and Services (cont) - TM-5-6115-600-120132
Section VI. Troubleshooting - TM-5-6115-600-120133
Table 4-3. Troubleshooting, Organizational
Table 4-3. Troubleshooting, Organizational (cont) - TM-5-6115-600-120135
Table 4-3. Troubleshooting, Organizational (cont) - TM-5-6115-600-120136
Table 4-3. Troubleshooting, Organizational (cont) - TM-5-6115-600-120137
Table 4-3. Troubleshooting, Organizational (cont) - TM-5-6115-600-120138
Table 4-3. Troubleshooting, Organizational (cont) - TM-5-6115-600-120139
Table 4-3. Troubleshooting, Organizational (cont) - TM-5-6115-600-120140
Table 4-3. Troubleshooting, Organizational (cont) - TM-5-6115-600-120141
Table 4-3. Troubleshooting, Organizational (cont) - TM-5-6115-600-120142
Table 4-3. Troubleshooting, Organizational (cont) - TM-5-6115-600-120143
Table 4-3. Troubleshooting, Organizational (cont) - TM-5-6115-600-120144
Table 4-3. Troubleshooting, Organizational (cont) - TM-5-6115-600-120145
Table 4-3. Troubleshooting, Organizational (cont) - TM-5-6115-600-120146
Table 4-3. Troubleshooting, Organizational (cont) - TM-5-6115-600-120147
Table 4-3. Troubleshooting, Organizational (cont) - TM-5-6115-600-120148
Table 4-3. Troubleshooting, Organizational (cont) - TM-5-6115-600-120149
Section VII. Radio Interference Suppression
Figure 4-9. Radio Interference Suppression Components, Removal and Installation
Section VII. Maintenance of Housing
Figure 4-10. Housing, exploded View
Figure 4-10. Housing, exploded View (cont)
Legend for Figure 4-10
Figure 4-11. Instalaltion of Door Seals
COVERS
Radiator Grille
Section IX. Maintenance of DC Electrical and Control System
Starter Motor Protection
Engine Fault Indicators
Ether Starting
Batteries And related Components
Figure 4-13. Batteries and Rollout Tray, Exploded View
Alternator and Fan Belts
Figure 4-14. Battery Cables and Slave Receptacles, Removal and Installation
Figure 4-15. Alternator and fan Belts, removal and installation
Battery Charging Alternator - TM-5-6115-600-120168
Cleaning and Inspection - TM-5-6115-600-120169
Figure 4-16. Battery Charging Alternator, Test and Adjustment
Figure 4-17. Battery Charging Alternator and Mounting Group, Removal and Installation
On Generator Set Test - TM-5-6115-600-120173
Figure 4-18. Wiring Harnesses, removal and installation
Figure 4-18. Wiring Harnesses, removal and installation (cont) - TM-5-6115-600-120175
Figure 4-18. Wiring Harnesses, removal and installation (cont) - TM-5-6115-600-120176
Figure 4-18. Wiring Harnesses, removal and installation (cont) - TM-5-6115-600-120177
Figure 4-18. Wiring Harnesses, removal and installation (cont) - TM-5-6115-600-120178
Speed Switch and Magnetic Pickup
Low Oil Pressure Switch Op
On Generator Set Test - TM-5-6115-600-120181
Figure 4-19. Engine Electrical Control Elements, Removal and Installation
Figure 4-19. Engine Electrical Control Elements, Removal and Installation (cont)
DC Control Circuit Breaker CB1
Figure 4-20. Electronic Component Assembly, A27, Relay Removal and Installation
Starter Assembly - TM-5-6115-600-120187
Figure 4-22. Starter and Solenoid, Test
Figure 4-23. Starter and Solenoid, removal and Installation
Figure 4-24. Starter Drive Assembly, Pinion Clearance Adjustment
Fuel Shutdown Solenoid L1
Section X. Maintenance of Set Controls and Instrumentation
Figure 4-26. Fault Indicator Assembly A9, exploded view
Figure 4-27. Fault Indicator Assembly A9, Test Setup
Control Box Assembly A3
Table 4-4. Fault Indicator Assembly A9, Procedural Analysis
Volts AC Meter M9
Kilowatts Meter M7
Hertz (Frequency) Meter M6 and Frequency Transducer A2.
Toggle Switches
Figure 4-30. Hertz Meter M6 and Frequency Transducer A2, removal and Replacement
Panel Lights
Oil Pressure Gage M1
Coolant Temperature Gage M2
Battery Charging Ammeter M4
Figure 4-38. Manual Speed Control, removal and Installation
Installation - TM-5-6115-600-120207
Relay Assembly A4
Wiring Harnesses - TM-5-6115-600-120209
Fuel Level Transmitter MT3
Section XI. Maintenance of AC Electrical Control System
Single Unit Operation
Parallel Operation
Miscellaneous
Tactical Relay Assembly A29
Figure 4-39. Reconnection Board Assembly and Load Board Assembly, Removal and Installation
Disassembly - TM-5-6115-600-120217
Main Circuit Breaker Assembly CB2
Figure 4-40. Reconnection Board Assembly, Exploded view
Load Terminal Board
Figure 4-41. Circuit Breaker Assembly CB2, Removal and Installation
Control Relays K1 and K6
Fuseholders
Figure 4-42. Convenience Receptacle Assembly, Exploded View
Section XII. Maintenance of Fuel System
Fuel Transfer Pumps B2 and B3 (Electric)
Figure 4-43. Electric Fuel Transfer Pumps, exploded view
Figure 4-44. Primary Fuel Filter and Strainer Assembly and Fuel Solenoid Valve, Exploded View
Secondary Fuel Filter - TM-5-6115-600-120230
Figure 4-45. Secondary Fuel Filter, Service and Replacement
Fuel System Bleeding
Service - TM-5-6115-600-120233
Fuel Level Switches FL1 and FL2
Figure 4-46. Fuel Level Switch and Day Tank, exploded view
Ether System - TM-5-6115-600-120237
Figure 4-47. Ether System, exploded view
Fuel Injection Pump - TM-5-6115-600-120239
Figure 4-48. Fuel Injection Lines, removal and replacement
Figure 4-49. Fuel Injection Valves, removal and replacement
Section XIII. maintenance of Exhaust and Breather System
Figure 4-50. Exhaust and Breather System, exploded view
Replacement of Breather Tube and Hose
Section XIV. Maintenance of Cooling System
Figure 4-51. Radiator and Shutter Assembly
Legend for Figure 4-51
Radiator Shutter Assembly
Figure 4-52. Shutter Control, Adjustment
Replacement of Radiator, Grille, and Shutter Assembly
Disassembly and Reassembly of Shutter Control Assembly
Figure 4-53. Shutter Control Assembly, exploded view
Shutter Thermostat
Coolant Thermostat
Figure 4-55. Coolant Thermostat, replacement and testing
Replacement of Fan Guards
Figure 4-56. Fan Belts, adjustment and replacement
Section XV. Maintenance of Lifting and Support System
Figure 4-57. Replacement of Lifting Frame
Replacement of Control Panel Supports
Figure 4-58. Replacement of Control Panel Supports
Section XVI. Maintenance of Power Generation System
Section XVII. Maintenance of Engine
Figure 4-60. Air Filters
Governor Throttle Linkage
Figure 4-61. Turbocharger Replacement
GOVERNOR
Figure 4-63. Governor, Replacement
Fan Assembly
Oil Cooler
Exhaust Manifold
Figure 4-67. Exhaust Manifold, removal and installation
Cylinder Head Assembly
Figure 4-68. Valve Cover, Removal and Installation
Figure 4-69. Valve Lash Adjustment
Chapter 5. Auxiliary Equipment Used in Conjunction with the End Item
Figure 5-1. Fuel Burning Winterization Kit, Removal and Installation
Figure 5-1. Fuel Burning Winterization Kit, Removal and Installation (cont)
Preventive Maintenance Checks and Services (PMCS)
Table 5-1. Fuel Burning Winterization Kit, Operator/Crew Preventive Maintenance Checks and Services
Table 5-2. Fuel Burning Winterization Kit, Oragnizational Preventive Maintenance Checks and Services
Operator Maintenance Procedures
Table 5-3. Fuel Burning Winterization Kit, Operator/Crew Troubleshooting
Table 5-4. Fuel Burning Winterization Kit, Organizational Troubleshooting
Table 5-4. Fuel Burning Winterization Kit, Organizational Troubleshooting (cont)
Figure 5-2. Fuel Burning Winterization Kit Heater Assembly, Service
Figure 5-3. Fuel Burning Winterization Kit Heater Assembly, Maintenance
Limit Switch
Wiring Harnesses - TM-5-6115-600-120290
Thermostat Switch - TM-5-6115-600-120291
Figure 5-5. Heater Control Box to Fuel Burning Heater, Wiring Harness
Figure 5-6. Special relay Box to Fuel Burning Heater Control Box, Wiring Harness
Control Box Assembly
Figure 5-7. Fuel Burning WinterizationKit Control Box Assembly, Partially Exploded View
Figure 5-8. Fuel Burning Winterization Kit Control Box, Lamp Replacement
Section II. Electric Winterization Kit - TM-5-6115-600-120297
Figure 5-9. Electric Winterization Kit
Figure 5-9. Electric Winterization Kit, Removal and Installation
Preventive Maintenance Checks and Services - TM-5-6115-600-120300
Table 5-5. Electric Winterization Kit, Operator/Crew Preventive Maintenance Checks and Services
Table 5-6. Electric Winterization Kit, Organizational Preventive Maintenance Checks and Services
Table 5-7. Electric Winterization Kit, Operator/Crew Troubleshooting
Table 5-8. Electric Winterization Kit, Organizational Troubleshooting
Table 5-8. Electric Winterization Kit, Organizational Troubleshooting (cont)
Coolant Pump and Motor
Figure 5-10. Coolant Pump and Motor Assembly
Thermostat Switch - TM-5-6115-600-120308
Figure 5-12. Control Box to Electric Heater, Wiring Harness
Electric Winterization Control Box, Wiring Harness, Power Switch, Fuse holder, Fuse Light Assembly, and Indicating Lamps
Figure 5-13. Electric Winterization Kit Control box,partially exploded view
Install Control Box
Appendix A. References - TM-5-6115-600-120313
Appendix A. References (cont) - TM-5-6115-600-120314
Appendix A. References (cont) - TM-5-6115-600-120315
Appendix B. Items Troop Installed or Authorized and maintenance and operating Supplies List
Maintenance Code - TM-5-6115-600-120318
Explanation of Columns in the tabular List of maintenance and Operating Supplies
Section II. Items Troop Installed or Authorized
Section II. Items Troop Installed or Authorized (cont)
Section III. Maintenance and Operating Supplies
Section III. Maintenance and Operating Supplies (cont)
Appendix C. Maintenance Allocation Chart
Explanation of Columns in Section III - TM-5-6115-600-120326
Explanation of Columns in Section IV
Section II. Maintenance Allocation Chart - TM-5-6115-600-120328
Section II. Maintenance Allocation Chart (cont) - TM-5-6115-600-120329
Section II. Maintenance Allocation Chart (cont) - TM-5-6115-600-120330
Section II. Maintenance Allocation Chart (cont) - TM-5-6115-600-120331
Section II. Maintenance Allocation Chart (cont) - TM-5-6115-600-120332
Section II. Maintenance Allocation Chart (cont) - TM-5-6115-600-120333
Section II. Maintenance Allocation Chart (cont) - TM-5-6115-600-120334
Section III. Tools, Test and Support Equipment Requirements - TM-5-6115-600-120335
Section III. Tools, Test and Support Equipment Requirements (cont)
Section IV. Remarks - TM-5-6115-600-120337
Section IV. Remarks (cont) - TM-5-6115-600-120338
Section IV. Remarks (cont) - TM-5-6115-600-120339
Appendix D. Additional Authorization List
Section II. Additional Authorization List - TM-5-6115-600-120342
TM-5-6115-600-12 Generator Set Diesel Engine Driven Tactical Skid Mtd. 100 Kw. 3 Phase 4 Wire 120/208 and 240/416 Volts Manual
Preparation for Storage and Shipment
Section II. Description and Data - TM-5-6115-600-120019
Figure 1-1. Generator Set, Right Front, Three Quarter View
Figure 1-2. Generator Set, Left Rear, Three Quarter View
Table 1-1. Tabulated Data
Table 1-1. Tabulated Data (cont) - TM-5-6115-600-120023
Table 1-1. Tabulated Data (cont) - TM-5-6115-600-120024
Table 1-1. Tabulated Data (cont) - TM-5-6115-600-120025
Table 1-1. Tabulated Data (cont) - TM-5-6115-600-120026
Table 1-1. Tabulated Data (cont) - TM-5-6115-600-120027
Table 1-1. Tabulated Data (cont) - TM-5-6115-600-120028
Table 1-1. Tabulated Data (cont) - TM-5-6115-600-120029
Table 1-1. Tabulated Data (cont) - TM-5-6115-600-120030
Table 1-1. Tabulated Data (cont) - TM-5-6115-600-120031
Table 1-1. Tabulated Data (cont) - TM-5-6115-600-120032
Table 1-1. Tabulated Data (cont) - TM-5-6115-600-120033
Table 1-1. Tabulated Data (cont) - TM-5-6115-600-120034
Table 1-1. Tabulated Data (cont) - TM-5-6115-600-120035
Table 1-1. Tabulated Data (cont) - TM-5-6115-600-120036
Table 1-1. Tabulated Data (cont) - TM-5-6115-600-120037
Table 1-1. Tabulated Data (cont) - TM-5-6115-600-120038
Table 1-1. Tabulated Data (cont) - TM-5-6115-600-120039
Table 1-1. Tabulated Data (cont) - TM-5-6115-600-120040
Table 1-1. Tabulated Data (cont) - TM-5-6115-600-120041
Table 1-1. Tabulated Data (cont) - TM-5-6115-600-120042
Table 1-1. Tabulated Data (cont) - TM-5-6115-600-120043
Figure 1-3. Location of Identification Plates
Table 1-2. Special Torque Data - TM-5-6115-600-120045
Figure 1-5. Fault Indicator Panel A9, Schematic Diagram
Figure 1-6. Fuel Burning Winterization Kit, Wiring Diagram
Figure 1-7. Fuel Burning Winterization Kit, Schematic Diagram
Figure 1-8. Electric Winterization Kit, Wiring Diagram
Figure 1-9. Electric Winterization Kit, Schematic Diagram
Chapter 2. Operating Instructions - TM-5-6115-600-120051
Figure 2-1. Location of Controls, Instruments, and Receptacles
Table 2-1. Generator Set, Controls and Indicators
Table 2-1. Generator Set, Controls and Indicators (cont) - TM-5-6115-600-120054
Table 2-1. Generator Set, Controls and Indicators (cont) - TM-5-6115-600-120055
Figure 2-2. Control Cubicle, Controls and Indicators
Table 2-2. Control Cubicle, Controls and Indicators
Table 2-2. Control Cubicle, Controls and Indicators (cont) - TM-5-6115-600-120058
Table 2-2. Control Cubicle, Controls and Indicators (cont) - TM-5-6115-600-120059
Table 2-2. Control Cubicle, Controls and Indicators (cont) - TM-5-6115-600-120060
Figure 2-3. Fault Indicator Panel, Controls
Table 2-3. Fault Indicator Panel, Controls and Indicators
Table 2-3. Fault Indicator Panel, Controls and Indicators (cont)
Figure 2-4. Voltage Conversion - TM-5-6115-600-120064
Figure 2-5. Starting Generator Set, Usual Conditions
Figure 2-6. Single Unit Operation
Operating teh Generator (Units in parallel)
Figure 2-7. Setting up for Parallel Operation
Figure 2-8. PArallel Operation Connection Diagram
Figure 2-9. Removing Generator Set From Parallel Operation
Section II. Operation of Auxiliary Equipment
Figure 2-11. Fuel Burning Winterization Kit, Controls and Indicators
Table 2-4. Fuel Burning Winterization Kit, Control and Indicators
Figure 2-12. Fuel Burning Winterization Kit,Operating Instructions
Figure 2-13. Electric Winterization Kit, Controls and Indicators
Figure 2-14. Electric Winterization Kit, Operating Instructions
Section III. Operation Under Unusual Conditions
Figure 2-15. Ether Starting, Operating Instructions
Operation in Sandy or Dusty Areas
Operation At High Altitudes
Figure 2-16. Emergency Operation (Battle Short) of Generator Set
Operation Using NATO Slave Cable
Chapter 3. Operator/Crew Maintenance Instructions
Section II. Lubrication Instructions
Figure 3-1. Lubrication Order
Figure 3-1. Lubrication Order (cont)
Section III. Preventive Maintenance Checks and Services - TM-5-6115-600-120089
Preventive Maintenance Checks and Services Table
Table 3-2. Operator Preventive Maintenace Checks and Services
Table 3-2. Operator Preventive Maintenace Checks and Services (cont)
Section IV. Troubleshooting - TM-5-6115-600-120094
Table 3-3. Troubleshooting, Operator
Table 3-3. Troubleshooting, Operator (cont) - TM-5-6115-600-120096
Table 3-3. Troubleshooting, Operator (cont) - TM-5-6115-600-120097
Table 3-3. Troubleshooting, Operator (cont) - TM-5-6115-600-120098
Table 3-3. Troubleshooting, Operator (cont) - TM-5-6115-600-120099
Table 3-3. Troubleshooting, Operator (cont) - TM-5-6115-600-120100
Section V. Operator/Crew Maintenance Instructions
Figure 3-2. Batteries, Servicing
Set Controls and Instrumentation
Douglas Kit Arm Puller
Seal Installer and puller
Figure 3-3. Fuel Filler Cap and Strainer
Ether System - TM-5-6115-600-120107
Exhaust and Breather System
Inspection of Air Cleaners
General Cleaning
Chapter 4. Organizational Maintenance
Figure 4-1. Shipping Crate
Figure 4-2. Location of Fill and Drain Points and Drain Valves
Table 4-1. Freezing Points, Composition, and Specific Gravities of Military Antifreeze Material
Figure 4-3. Noise Level Warning Sign
Figure 4-4. Installation Plan
Figure 4-4. Installation Plan (cont)
Figure 4-5. Ground Procedure
Auxiliary Fuel Connection
Figure 4-6. Fuel Connections
Figure 4-7. Load Cable Connections
Section II. Movement to a New Work Site - TM-5-6115-600-120124
Section IV. Lubrication Instructions
Figure 4-8. Lubricating Oil Filter, Servicing
Section V. Preventive Maintenance Checks and Services
Table 4-2. Organizational Preventive Maintenance Checks and Services
Table 4-2. Organizational Preventive Maintenance Checks and Services (cont) - TM-5-6115-600-120129
Table 4-2. Organizational Preventive Maintenance Checks and Services (cont) - TM-5-6115-600-120130
Table 4-2. Organizational Preventive Maintenance Checks and Services (cont) - TM-5-6115-600-120131
Table 4-2. Organizational Preventive Maintenance Checks and Services (cont) - TM-5-6115-600-120132
Section VI. Troubleshooting - TM-5-6115-600-120133
Table 4-3. Troubleshooting, Organizational
Table 4-3. Troubleshooting, Organizational (cont) - TM-5-6115-600-120135
Table 4-3. Troubleshooting, Organizational (cont) - TM-5-6115-600-120136
Table 4-3. Troubleshooting, Organizational (cont) - TM-5-6115-600-120137
Table 4-3. Troubleshooting, Organizational (cont) - TM-5-6115-600-120138
Table 4-3. Troubleshooting, Organizational (cont) - TM-5-6115-600-120139
Table 4-3. Troubleshooting, Organizational (cont) - TM-5-6115-600-120140
Table 4-3. Troubleshooting, Organizational (cont) - TM-5-6115-600-120141
Table 4-3. Troubleshooting, Organizational (cont) - TM-5-6115-600-120142
Table 4-3. Troubleshooting, Organizational (cont) - TM-5-6115-600-120143
Table 4-3. Troubleshooting, Organizational (cont) - TM-5-6115-600-120144
Table 4-3. Troubleshooting, Organizational (cont) - TM-5-6115-600-120145
Table 4-3. Troubleshooting, Organizational (cont) - TM-5-6115-600-120146
Table 4-3. Troubleshooting, Organizational (cont) - TM-5-6115-600-120147
Table 4-3. Troubleshooting, Organizational (cont) - TM-5-6115-600-120148
Table 4-3. Troubleshooting, Organizational (cont) - TM-5-6115-600-120149
Section VII. Radio Interference Suppression
Figure 4-9. Radio Interference Suppression Components, Removal and Installation
Section VII. Maintenance of Housing
Figure 4-10. Housing, exploded View
Figure 4-10. Housing, exploded View (cont)
Legend for Figure 4-10
Figure 4-11. Instalaltion of Door Seals
COVERS
Radiator Grille
Section IX. Maintenance of DC Electrical and Control System
Starter Motor Protection
Engine Fault Indicators
Ether Starting
Batteries And related Components
Figure 4-13. Batteries and Rollout Tray, Exploded View
Alternator and Fan Belts
Figure 4-14. Battery Cables and Slave Receptacles, Removal and Installation
Figure 4-15. Alternator and fan Belts, removal and installation
Battery Charging Alternator - TM-5-6115-600-120168
Cleaning and Inspection - TM-5-6115-600-120169
Figure 4-16. Battery Charging Alternator, Test and Adjustment
Figure 4-17. Battery Charging Alternator and Mounting Group, Removal and Installation
On Generator Set Test - TM-5-6115-600-120173
Figure 4-18. Wiring Harnesses, removal and installation
Figure 4-18. Wiring Harnesses, removal and installation (cont) - TM-5-6115-600-120175
Figure 4-18. Wiring Harnesses, removal and installation (cont) - TM-5-6115-600-120176
Figure 4-18. Wiring Harnesses, removal and installation (cont) - TM-5-6115-600-120177
Figure 4-18. Wiring Harnesses, removal and installation (cont) - TM-5-6115-600-120178
Speed Switch and Magnetic Pickup
Low Oil Pressure Switch Op
On Generator Set Test - TM-5-6115-600-120181
Figure 4-19. Engine Electrical Control Elements, Removal and Installation
Figure 4-19. Engine Electrical Control Elements, Removal and Installation (cont)
DC Control Circuit Breaker CB1
Figure 4-20. Electronic Component Assembly, A27, Relay Removal and Installation
Starter Assembly - TM-5-6115-600-120187
Figure 4-22. Starter and Solenoid, Test
Figure 4-23. Starter and Solenoid, removal and Installation
Figure 4-24. Starter Drive Assembly, Pinion Clearance Adjustment
Fuel Shutdown Solenoid L1
Section X. Maintenance of Set Controls and Instrumentation
Figure 4-26. Fault Indicator Assembly A9, exploded view
Figure 4-27. Fault Indicator Assembly A9, Test Setup
Control Box Assembly A3
Table 4-4. Fault Indicator Assembly A9, Procedural Analysis
Volts AC Meter M9
Kilowatts Meter M7
Hertz (Frequency) Meter M6 and Frequency Transducer A2.
Toggle Switches
Figure 4-30. Hertz Meter M6 and Frequency Transducer A2, removal and Replacement
Panel Lights
Oil Pressure Gage M1
Coolant Temperature Gage M2
Battery Charging Ammeter M4
Figure 4-38. Manual Speed Control, removal and Installation
Installation - TM-5-6115-600-120207
Relay Assembly A4
Wiring Harnesses - TM-5-6115-600-120209
Fuel Level Transmitter MT3
Section XI. Maintenance of AC Electrical Control System
Single Unit Operation
Parallel Operation
Miscellaneous
Tactical Relay Assembly A29
Figure 4-39. Reconnection Board Assembly and Load Board Assembly, Removal and Installation
Disassembly - TM-5-6115-600-120217
Main Circuit Breaker Assembly CB2
Figure 4-40. Reconnection Board Assembly, Exploded view
Load Terminal Board
Figure 4-41. Circuit Breaker Assembly CB2, Removal and Installation
Control Relays K1 and K6
Fuseholders
Figure 4-42. Convenience Receptacle Assembly, Exploded View
Section XII. Maintenance of Fuel System
Fuel Transfer Pumps B2 and B3 (Electric)
Figure 4-43. Electric Fuel Transfer Pumps, exploded view
Figure 4-44. Primary Fuel Filter and Strainer Assembly and Fuel Solenoid Valve, Exploded View
Secondary Fuel Filter - TM-5-6115-600-120230
Figure 4-45. Secondary Fuel Filter, Service and Replacement
Fuel System Bleeding
Service - TM-5-6115-600-120233
Fuel Level Switches FL1 and FL2
Figure 4-46. Fuel Level Switch and Day Tank, exploded view
Ether System - TM-5-6115-600-120237
Figure 4-47. Ether System, exploded view
Fuel Injection Pump - TM-5-6115-600-120239
Figure 4-48. Fuel Injection Lines, removal and replacement
Figure 4-49. Fuel Injection Valves, removal and replacement
Section XIII. maintenance of Exhaust and Breather System
Figure 4-50. Exhaust and Breather System, exploded view
Replacement of Breather Tube and Hose
Section XIV. Maintenance of Cooling System
Figure 4-51. Radiator and Shutter Assembly
Legend for Figure 4-51
Radiator Shutter Assembly
Figure 4-52. Shutter Control, Adjustment
Replacement of Radiator, Grille, and Shutter Assembly
Disassembly and Reassembly of Shutter Control Assembly
Figure 4-53. Shutter Control Assembly, exploded view
Shutter Thermostat
Coolant Thermostat
Figure 4-55. Coolant Thermostat, replacement and testing
Replacement of Fan Guards
Figure 4-56. Fan Belts, adjustment and replacement
Section XV. Maintenance of Lifting and Support System
Figure 4-57. Replacement of Lifting Frame
Replacement of Control Panel Supports
Figure 4-58. Replacement of Control Panel Supports
Section XVI. Maintenance of Power Generation System
Section XVII. Maintenance of Engine
Figure 4-60. Air Filters
Governor Throttle Linkage
Figure 4-61. Turbocharger Replacement
GOVERNOR
Figure 4-63. Governor, Replacement
Fan Assembly
Oil Cooler
Exhaust Manifold
Figure 4-67. Exhaust Manifold, removal and installation
Cylinder Head Assembly
Figure 4-68. Valve Cover, Removal and Installation
Figure 4-69. Valve Lash Adjustment
Chapter 5. Auxiliary Equipment Used in Conjunction with the End Item
Figure 5-1. Fuel Burning Winterization Kit, Removal and Installation
Figure 5-1. Fuel Burning Winterization Kit, Removal and Installation (cont)
Preventive Maintenance Checks and Services (PMCS)
Table 5-1. Fuel Burning Winterization Kit, Operator/Crew Preventive Maintenance Checks and Services
Table 5-2. Fuel Burning Winterization Kit, Oragnizational Preventive Maintenance Checks and Services
Operator Maintenance Procedures
Table 5-3. Fuel Burning Winterization Kit, Operator/Crew Troubleshooting
Table 5-4. Fuel Burning Winterization Kit, Organizational Troubleshooting
Table 5-4. Fuel Burning Winterization Kit, Organizational Troubleshooting (cont)
Figure 5-2. Fuel Burning Winterization Kit Heater Assembly, Service
Figure 5-3. Fuel Burning Winterization Kit Heater Assembly, Maintenance
Limit Switch
Wiring Harnesses - TM-5-6115-600-120290
Thermostat Switch - TM-5-6115-600-120291
Figure 5-5. Heater Control Box to Fuel Burning Heater, Wiring Harness
Figure 5-6. Special relay Box to Fuel Burning Heater Control Box, Wiring Harness
Control Box Assembly
Figure 5-7. Fuel Burning WinterizationKit Control Box Assembly, Partially Exploded View
Figure 5-8. Fuel Burning Winterization Kit Control Box, Lamp Replacement
Section II. Electric Winterization Kit - TM-5-6115-600-120297
Figure 5-9. Electric Winterization Kit
Figure 5-9. Electric Winterization Kit, Removal and Installation
Preventive Maintenance Checks and Services - TM-5-6115-600-120300
Table 5-5. Electric Winterization Kit, Operator/Crew Preventive Maintenance Checks and Services
Table 5-6. Electric Winterization Kit, Organizational Preventive Maintenance Checks and Services
Table 5-7. Electric Winterization Kit, Operator/Crew Troubleshooting
Table 5-8. Electric Winterization Kit, Organizational Troubleshooting
Table 5-8. Electric Winterization Kit, Organizational Troubleshooting (cont)
Coolant Pump and Motor
Figure 5-10. Coolant Pump and Motor Assembly
Thermostat Switch - TM-5-6115-600-120308
Figure 5-12. Control Box to Electric Heater, Wiring Harness
Electric Winterization Control Box, Wiring Harness, Power Switch, Fuse holder, Fuse Light Assembly, and Indicating Lamps
Figure 5-13. Electric Winterization Kit Control box,partially exploded view
Install Control Box
Appendix A. References - TM-5-6115-600-120313
Appendix A. References (cont) - TM-5-6115-600-120314
Appendix A. References (cont) - TM-5-6115-600-120315
Appendix B. Items Troop Installed or Authorized and maintenance and operating Supplies List
Maintenance Code - TM-5-6115-600-120318
Explanation of Columns in the tabular List of maintenance and Operating Supplies
Section II. Items Troop Installed or Authorized
Section II. Items Troop Installed or Authorized (cont)
Section III. Maintenance and Operating Supplies
Section III. Maintenance and Operating Supplies (cont)
Appendix C. Maintenance Allocation Chart
Explanation of Columns in Section III - TM-5-6115-600-120326
Explanation of Columns in Section IV
Section II. Maintenance Allocation Chart - TM-5-6115-600-120328
Section II. Maintenance Allocation Chart (cont) - TM-5-6115-600-120329
Section II. Maintenance Allocation Chart (cont) - TM-5-6115-600-120330
Section II. Maintenance Allocation Chart (cont) - TM-5-6115-600-120331
Section II. Maintenance Allocation Chart (cont) - TM-5-6115-600-120332
Section II. Maintenance Allocation Chart (cont) - TM-5-6115-600-120333
Section II. Maintenance Allocation Chart (cont) - TM-5-6115-600-120334
Section III. Tools, Test and Support Equipment Requirements - TM-5-6115-600-120335
Section III. Tools, Test and Support Equipment Requirements (cont)
Section IV. Remarks - TM-5-6115-600-120337
Section IV. Remarks (cont) - TM-5-6115-600-120338
Section IV. Remarks (cont) - TM-5-6115-600-120339
Appendix D. Additional Authorization List
Section II. Additional Authorization List - TM-5-6115-600-120342
TM-5-6115-600-12 Generator Set Diesel Engine Driven Tactical Skid Mtd. 100 Kw. 3 Phase 4 Wire 120/208 and 240/416 Volts Manual
