SECTION IV. REMOVAL AND INSTALLATION OF MAJOR COMPONENTS

Figure 2-1. Removing and Installing Helical Coil Thread Inserts

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 SECTION IV. REMOVAL AND INSTALLATION OF MAJOR COMPONENTS 2-14. GENERAL. This section contains removal and installation procedures for the engine, generator G1,fuel tank and load circuit breaker CB101. 2-15. ENGINE REMOVAL AND INSTALLATION. a. Remove. The engine is removed through the front of the generator set using an overhead crane or hoist, rated for 15,000 pounds (6800 kg) with a minimum height clearance of 124 inches (3175 mm). Proceed as follows (1) Disconnect load cables from output terminals, place on safety stands and tag output terminal to ensure generator set is not connected to load bus during generator removal. (2) Set maintenance lockout switch to MAINTENANCE and safety tag. (3) Disconnect cable from UTILITY POWER receptacle and safety tag UTILITY POWER receptacle to ensure cable is not connected during engine removal. (4) Remove batteries in accordance with paragraph 3-9 of the Operator and Organizational Maintenance Manual. (5) Drain the cooling and lubrication systems in accordance with paragraphs 3-3 and 3-12 of the Operator and Organizational Maintenance Manual. (6) Disconnect the oil prelube hoses and bypass filter hose from the engine block, and oil pan in accordance with paragraphs 4-65 and 4-71 of the Operator and Organizational Maintenance Manual. (7) Disconnect the oil drain valve and hose from the oil pan in accordance with paragraph 4-67 of the Operator and Organizational Maintenance Manual. (8) Disconnect the hoses from the crankcase breathers. (9) Disconnect the radiator hoses to the water pump, thermostat housings, and aftercooler in accordance with paragraphs 4-54, 4-55, and 4-57 of the Operator and Organizational Maintenance Manual. (10) Disconnect the coolant preheater hoses from the water pump and cylinder head (coolant transfer tubes) in accordance with paragraph 4-61 of the Operator and Organizational Maintenance Manual. (11) Disconnect the ether installation from the engine in accordance with paragraph 450 of the Operator and Organizational Maintenance Manual. (12) Disconnect the fuel lines from the fuel filters, fuel return port on the cylinder block, and clamps holding the lines to the engine in accordance with paragraphs 4-47 and 4-48 of the Operator and Organizational Maintenance Manual. (13) Disconnect the EMERGENCY SHUTDOWN cable from the engine emergency manual fuel shut off valve and from the cable clamps securing the cable to the engine in accordance with paragraph 4-51 of the Operator and Organizational Maintenance Manual. (14) Remove the engine wiring harness in accordance with paragraph 4-22 of the Operator and Organizational Maintenance Manual. (15) Remove the ac and dc lights and conduits above the engine in accordance with figure 3-9 and paragraph 4-35 of the Operator and Organizational Maintenance Manual. (16) Remove radiator shutter and radiator in accordance with paragraph 4-55 of the Operator and Organizational Maintenance Manual. Remove fan and pulley guards in accordance with paragraph 4-59 of the Operator and Organizational Maintenance Manual. (17) Remove the mufflers in accordance with paragraph 4-86 of the Operator and Organizational Maintenance Manual. (18) Remove the exhaust system components that connect the mufflers to the turbocharger outlets in accordance with paragraph 3-15 of the Operator and Organizational Maintenance Manual. 2-22

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