9-43. INTAKE MANIFOLDS MAINTENANCE

TM-9-6115-604-34 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
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TM 9-6115-604-34 NAVFAC P-8-633-34 (15) Fill the cooling system in accordance with the Operator and Organizational Maintenance Manual. j. Test. (1) Ensure that the cooling system has been filled completely and that the coolant level in the radiator has been adjusted in accordance with the Operator and Organizational Maintenance Manual. CAUTION Do not allow test air pressure to exceed 15 psi (104 kPa) during the following test or damage to cooling system components or the after cooler Itself may result. CAUTION Do not perform the following test on a hot engine. (2) Using a radiator cap adapter, pressurize the cooling system to 10 to 15 psi (69 to 104 kPa) for approximately 5 minutes. (3) Inspect the aftercooler for leaks in accordance with steps (a), (1), (2), (5), and (7). (4) Tighten leaking lines and fittings, or repair in accordance with steps (b) through (i), above. Repair a leaking core in accordance with steps (b) through (i), above. 9-43. INTAKE MANIFOLDS MAINTENANCE a. Remove. (1) Remove aftercooler in accordance with paragraph 9-42. (2) Remove the capscrews (1 and 41, Figure 9-78), lockwashers (2), and washers (3) securing the air balance connections (42). Remove the air balance connections, and remove and discard the gaskets (43). (3) Remove the capscrews (1), lockwashers (2), washers (3), raise the crossover housings (4) slightly, and remove and discard the gaskets (5). (4) Remove the capscrews (44), lockwashers (2), washers (3), and remove the intake manifolds (46 and 47). Leave the damps (45) attached to the harness and ether lines. (5) Remove and discard the gaskets (48) and rubber sleeves (49). b. Clean and Inspect. WARNING Dry cleaning solvent PD680, Type Ill, or equivalent, Is flammable and moderately toxic to the skin, eyes, and respiratory tract. Assure adequate ventilation. Skin, eye, and respiratory protection Is required to avoid Injury to personnel. (1) Clean all parts in dry cleaning solvent, PD-680, Type ll, or equivalent Clean all traces of the old gaskets from the mating surfaces. (2) Inspect the capscrews (1, 41, and 44, Figure 9-78) for damaged or stripped threads. Repair slightly damaged threads by chasing. Replace stripped capscrews. (3) Inspect the threaded holes in the intake manifolds (46 and 47)for damage or stripping. Repair damaged or stripped holes in accordance with paragraph 2-12. (4) Visually inspect the intake manifolds (46 and 47) and air balance connections (42) for cracks and warped gasket surfaces. Repair or replace in accordance with step c, below. (5) Check the intake manifolds (46 and 47) and air balance connections (42) for cracks and porosity using dye penetrate, MIL-1-25135, inspection in accordance with MIL-1-6866. Repair or replace cracked or porous parts in accordance with step c, below. 9-139

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