MTD 584 Betriebsanleitung

ARMY TECHNICAL MANUALTM 5-6115-584-12NAVY PUBLICATIONNAVFAC P-8-622-12AIR FORCE TECHNICAL ORDERTO 35C2-3-456-1MARlNE CORPS TECHNICAL MANUALTM 05682C-1

TM 5–6115–584–12NA\/FAC P-8-622-12TO-35C-2-3–456-1TM-05682C-12Section VI. TROUBLESHOOTING4-12. TROUBLESHOOTING, GENERAL. 4-13. MALFUNCTIONS NOT CORREC

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12Table 4.2. TroubleshootingMALFUNCTIONTEST OR INSPECTIONCORRECTIVE ACTION1. ENGINE FAILS TO

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12Table 4-2. Troubleshooting (Cont)MALFUNCTIONTEST OR INSPECTIONCORRECTIVE ACTION3. ENGINE C

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12Table 4-2. Troubleshooting (Cont)MALFUNCTIONTEST OR INSPECTIONCORRECTIVE ACTION9. ENGINE S

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12Table 4-2. Troubleshooting (Cont)MALFUNCTIONTEST OR INSPECTIONCORRECTIVE ACTION14. BATTERI

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12Figure 4-3. Primary Radio Interference Suppression Components (Sheet 1 of 2)4-11

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12Figure 4-3. Primary Radio Suppression Components (Sheet 2 of 2)Section VIII. MAINTENANCE O

(6)ing(2) Air Housing Duct Cover. Loosen hose clampand remove air housing duct cover (2) by remov-screws (1).(3) Shutter Assembly. Disconnect wiring t

TM5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12Figure 4-4. Shutter Assembly4-14Change 2

TM5-6115-584-12NAVFAC P-8-622-12TO-33C2-S-4S6-1TM-05682C-12(2) Install power unit assembly (6) into shutterassembly box (32) using screws (4) and spec

TM5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12Section IX. MAINTENANCE OF FUEL SYSTEM4-18. DESCRIPTION AND FUNCTION.a. Low Pressure System

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12Figure 4-7. Fuel Tank Assembly(4) Fuel Level Gauge. Engage threads of fuel(3) Check that d

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12other as secondary, plus there is one fuel strainer. If these filtersor strainer are plu

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-121. Nut (4)9. Drain valve2. Flatwasher (4)6. Fuel gauge10. Fuel tank3. Srap (2)7. Float swi

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12Figure • 4-8. Testing Float Switchother plus there is one fuel strainer. Ifor leaking val

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12Figure 4-9. Fuel Filterphysical damage. Replace element if necessary.Change primary elemen

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12heat. Flash point of solvent is 100° F to 138°F(38°C to 59°C).Clean parts in a well-ventil

TM 5-6115-584-12NAVFAC P-8-622-12c. Removal.(1) Fuel Filter Assembly (see figure 4-11). Drainfuel into a suitable container by opening drain valve(1).

TM 5-6115-584-12NAVPAC P-8-622-12TO-35C2-3-456-1TM-05682C-12Figure 4-12. Fuel Pump, Fuel Hoses and Solenoid4-22

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-11. Cover2. Gasket3. Strainer4. Magnet5. Fuel pumpTS 6115-58412/4-13Figure 4-13. Fuel Pump(2) Check for

Figure 4-15NAVFAC P-8-622-12TO-35C2-3-456-1TM 5-6115-584-12Section X. MAINTENANCE OF ENGINE ELECTRICAL SYSTEM4–24.DESCRIPTION AND FUNCTIONa. The engi

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1Figure 4–16. Installing Battery Cables.Change 104-25

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1NOTEAlways detach negative (–) cable firstand reattach it last.b. Battery Top (Hold–down) Frame (see f

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1Figure 4–18. Engine Starter InstallationChange 104–27

TM S-6115-584-12NAVFAC P-6-622-12TO-35C2-3-456-1support bracket (12) down and away from starter. OnStyle II Starter, support bracket is not fastened t

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1Figure 4-19. Testing Engine StarterChange 104-28.1

Figure 4-21.4-28.2Change 10TM 5-6115-584-12NAVFAC P-8-622-12TO 35C2-3-456-1

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1Figure 4–21 A. Inspecting Starter Brushes, Style II Starter(2) Install Solenoid. Refer to figure 4-22.

Figure 4-22.Figure 4-22A.4-28.4Change 10TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1

ARMYNAVYAIR FORCEMARINE CORPSCHANGENo. 6TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12C6HEADQUARTERSDEPARTMENTS OF THE ARMY, AIR FORCE,

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1Figure 4–23. Battery Charging Alternator(a) Tag and disconnect stator lead (1) fromstator at terminal

TM 5-6115-584-12NAVFAC P-8-622-12TO-35iC2-3-456-1Avoid operation of Generator Set formore than 3 minutes with engineblower housing removed, as enginew

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12Figure 4-24. Testing Battery Charging Regulator/Rectifier Assembly(3) Remove (see figure

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12Figure 4-25. Starter Lockout Switch and Gear Assemblycontinuity between connector (8) pins

TM 5-6115-584-12NAVPAC P-8-622-12TO-35C2-3-456-1TM-05682C-12(20) and spring (12). Slide gear (5) out throughopening in engine back plate. Clean any ga

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12 On ASK equppied4-31. LOW OIL PRESSURE SWITCH.generators, remove oil access door.a. Test o

TM 5-6115-584-12NAVEAC P-8-622-12TO-35C2-3-456-1TM-05682C-12Figure 4-29.Replacing Oil Cooler HosesChange 2 4-35

Figure 4-30. Oil Filter AssemblyTM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12d. Install. Install switch (11) in adapter (5) andb. Remov

TM 5-6115-584.12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12Figure 4-31. Replacing Oil Pressure Gauge4-33. OIL PRESSURE GAUGE.Iockwasher (9), clamp (4

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12MAINTENANCE OF CONTROL SYSTEM4-34. DESCRIPTIONSection XII.AND FUNCTION.NOTEAll symbols (CB

TM 5-6115-584-12NAVFAC P-8-622.12TO-35C2-3-456-1TM-05682C-12for correct readings of voltmeter and ammeter in allmeter indications will be obtained wit

TM 5.6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-124-37. LOAD TERMINAL BOARD ASSEMBLY.a. Load Terminal Removal (see figure 4-32).(1) Unlatch

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12Figure 4-33. Control Cubicle AssemblyChange 5 4-41

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-124-38. CONTROL CUBICLE ASSEMBLY.a. Test, On Equipment (see figure 4-33).NOTEWhen disconnect

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12Table 4-4. Voltmeter-Ammeter Range Selector Switch Continuity CheckSwitch PositionvoltsPha

Figure 4-33.1.d. Disassembly.(1) Panel Light Assemblies (DS1) and (DS2) (seefigure 4-33). Tag and detach two leads to each panellight assembly (DS1) a

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12Figure 4-34. Removing Control Cubicle Support Assembly(3) Battery Charging Indicator (M1).

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12(11) Relay (K2-K3). Disconnect battery. Tag anddisconnect four leads to relay. Remove two

(2) Place master switch in preheat position.Lamps L2 and L3 shall light indicating that the pre-heat circuitry is correct.(3) Place master switch in s

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12Figure 4-36. Engine Assembly (Sheet 1 of 2)4-46

NAVFAC P-8-622-12TM 5-6115-584-12TO-35C2-3-456-1TM-05682C-121. Blower housing2. Shutter assembly3. Oil cooler4. Oil filter5. Injection pump6. Starter7

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12Figure 4-37. Exhaust Muffler and Air Cleaner Assemblies4-48

4-43. INTAKE MANIFOLD ASSEMBLY.a. Test On Equipment (see figure 4-36). On ASK equippedgenerators, remove right panel assembly (para. 5-6). Remove hose

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12c. Bend lock tabs (14) down and remove four screws (13)attaching manifold to cylinder hea

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12Figure 4-40. Breather Assembly(2) Place screen (7) in valve (6) and install re-4-46. VALVE

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12Figure 4-41. Checking and Adjusting Rocker Arm to Valve ClearanceAlways check and adjust t

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12Figure 4-42. Cylinder Head Assembly4-53

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12plug is clean and tight. Check for leakage where theglow plug enters cylinder head.b. Test

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12Figure 4-44. Engine Mounting Assembly4-55

TM 5-6115-584-12NAVFAC P-8-622-12Section XIV. MAINTENANCE OF GENERATOR ASSEMBLYTO-35C2-3-456-1TM-05682C-124-53. DESCRIPTION AND FUNCTION.semi-conducto

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12voltage, that is higher or lower than the Generator Setb. Remove (see figure 4-45), Remove

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12Figure 4-46. Skid-Base Assembly4-58

(b) Refer to paragraph 4-38 and install con-trol cubicle.(2) Battery Frame Bottom and Tray.(a) Position battery tray (12) and bottomframe(11) on skid-

TM 5-6115-584-12NAVFAC P-8-622-12TO 35C2-3-456-1TM-05682C-12CHAPTER 5MATERIEL USED IN CONJUNCTION WITH DOD STANDARD GENERATORSET, 5KW DIESEL ENGINE DR

TM 5-6115-584-12NAVFAC P-8-622-12TO 35C2-3-456-1TM-05682C-12Section II.ACOUSTIC SUPPRESSION KIT5-2.ACOUSTIC SUPPRESSION KIT.The acoustic suppression k

TM 5-6115-584-12NAVFAC P-8-622-12TO 35C2-3-456-1TM-05682C-12OPERATING INSTRUCTIONSBEFORE STARTING SET1.INSURE MAIN CIRCUIT BREAKER IS OFF.2.REMOVE ASK

TM 5-6115-584-12NAVFAC P-8-622-12TO 35C2-3-456-1TM-05682C-125-4Figure 5-1.Instruction and Rating Plates (Sheet 2)Change 7

TM 5-6115-584-12NAVFAC P-8-622-12TO 35C2-3-456-1TM-05682C-12Figure 5-1.Instruction and Rating Plates (Sheet 3)Change 75-5

TM 5-6115-584-12NAVFAC P-8-622-12TO 35C2-3-456-1TM-05682C-125-6Figure 5-1.Change 7Instruction and Rating Plates (Sheet 4)

TM 5-6115-584-12NAVFAC P-8-622-12TO 35C2-3-456-1TM-05682C-12Figure 5-2.Cover Assembly, Removal and Installation14Change 7 5-7

TM 5-6115-584-12NAVFAC P-8-622-12TO 35C2-3-456-1TM-05682C-12b.Installation.See figure 5-2.Replace cover assemblyconsisting of top panel assembly, left

TM 5-6115-584-12NAVFAC P-8-622-12TO 35C2-3-456-1TM-05682C-12Fiqure 5-3.Top Panel Assembly and Exhaust Plenum,Removal and InstallationChange 7 5-9

TM 5-6115-584-12NAVFAC P-8-622-12TO 35C2-3-456-1TM-05682C-12(2) Remove seven screws (7) and locknuts (8), and 14washers (9 and 10) securing top panel

TM 5-6115-584-12NAVFAC P-8-622-12TO 35C2-3-456-1TM-05682C-12Figure 5-4.Left Panel Assembly, Removal and InstallationChange 7 5-11

TM 5-6115-584-12NAVFAC P-8-622-12TO 35C2-3-456-1TM-05682C-12b.Installation.See figure 5-4. Install left panelassembly to left support assembly, side c

TM 5-6115-584-12NAVFAC P-8-622-12TO 35C2-3-456-1TM-05682C-12Figure 5-5.Right Panel Assembly, Removal and InstallationChange 75-13

TM 5-6115-584-12NAVFAC P-8-622-12TO 35C2-3-456-1TM-05682C-12b.Installation.See figure 5-5.Install right panelassembly to right support assembly, rear

TM 5-6115-584-12NAVFAC P-8-622-12TO 35C2-3-456-1TM-05682C-12Figure 5-6.Rear Panel Assembly, Removal and InstallationChange 7 5-15

TM 5-6115-584-12NAVFAC P-8-622-12TO 35C2–3-456–1TM-05682C-12(3)Install two screws (1) and washers (2) securingright panel assembly (3) to rear panel a

TM 5-6115-584-12NAVFAC P-8-622-12TO 35C2-3-456-1TM-05682C-12Figure 5-7.Left Support Assembly, Removal and InstallationChange 75-17

TM 5-6115-584-12NAVFAC P-8-622-12TO 35C2-3-456-1TM-05682C-12(3) Install left panel assembly (5) as described inparagraph 5-5.(4)Install access plate (

TM 5-6115-584-12NAVFAC P-8-622-12TO 35C2-3-456-1TM-05682C-12Figure 5-8.Right Support Assembly, Removal and InstallationChange 75-19

TM 5-6115-584-12NAVFAC P-8-622-12TO 35C2-3-456-1TM-05682C-12Figure 5-9.Front Panel Assembly, Removal and Installation5-20Change7

TM 5-6115-584-12NAVFAC P-8-622-12TO 35C2-3-456-1TM-05682C-125-12. SIDE CLOSURE ASSEMBLY.a.Removal.See figure 5-10.Remove side closureassembly from rea

TM 5-6115-584-12NAVFAC P-8-622-12TO 35C2-3-456-1TM-05682C-12Figure 5-10.Side Closure Assembly, Removal and Installation5-22Change 7

TM 5-6115-584-12NAVFAC P-8-622-12TO 35C2-3-456-1TM-05682C-12Figure 5-11.Rear Closure Assembly, Removal and InstallationChange 75-23

TM 5-6115-584-12NAVFAC P-8-622-12TO 35C2-3-456-1TM-05682C-12(4)Remove four screws (13) and locknuts (14), andeight washers (15 and 16) securing rear c

TM 5-6115-584-12NAVFAC P-8-622-12TO 35C2-3-456-1TM-05682C-12Figure 5-12.Rear Flap Assembly, Removal and InstallationChange 75-25

TM 5-6115-584-12NAVFAC P-8-622-12TO 35C2-3-456-1TM-05682C-12SECTION III.ACOUSTIC SUPPRESSION KIT REPAIR5-15.GENERAL .WARNINGThe local safety office an

TM 5-6115-584-12NAVFAC P-8-622-12TO 35C2-3-456-1TM-05682C-12(c)Apply adhesive backed teflon tape to leftsupport assembly top surface (slotted surface

TM 5-6115-584-12NAVFAC P-8-622-12TO 35C2-3-456-1TM-05682C-12d.Install ASK replacement components by following theapplicable installation procedures ou

TM 5-6115-584-12NAVFAC P-8-622-12TO 35C2-3-456-1TM-05682C-12Figure 5-13.Replacement of ASK Hardware ItemsChange 75-29

TM 5-6115-584-12NAVFAC P-8-622-12TO 35C2-3-456-1TM-05682C-125-20.HINGES .The following procedures are for hinge replacement on the toppanel assembly a

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12APPENDIX AREFERENCES1.2.3.4.5.PAINTING:T.O. 35-1-3TM 43-0139RADIO SUPPRESSION:MIL-STD-461M

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12APPENDIX BCOMPONENTS OF END ITEMS LISTSection I. INTRODUCTIONB-1. SCOPE.This appendix list

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12Section II. INTEGRAL COMPONENTS OF END ITEM(1) (2) (3)(4)(5) (6) (7)Illustration(a) (b)Nat

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12APPENDIX CADDITIONAL AUTHORIZATION LISTSection I. INTRODUCTIONC-1. SCOPE.in with it. These

TM5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12APPENDIX DMAINTENANCE ALLOCATION CHARTSection I. INTRODUCTIOND-1. GENERAL.a. This section p

TM5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12original manufacturing standards. Rebuild is per-formed only when required by operational c

01 02 03Section II.TM5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12D-3

Section II. 03 04TM5-6115-584-12NAVFAC P-8-622-12TM-05682C-12D-4

04Section II.TM 5-6115-584-12NAVFAC P-8-622.12TO-35C2-3-456-1TM-05682C-12[D-5

04 05 06Section II.TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12D-6

Section II. 06 07TM5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12D-7

07 08Section II.TM5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12D-8Change 2

Section II. 08 09TM 5-6115-584-12NAVFAC P-8-622-12TO35C2-3-456-1TM-05682C-12D-9

Section II. 09 10 11 12TM5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12D-10 Change 2

Section II. 12 13 14TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12D-11

14Section II.TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12WWIW3A0ZIIVd3M‘1’-IVLSNIN!X’IVILsrmlvF3XAI13SLLS3’11L33dSNlok0:Gi● ON dflO?K

Section II. 14 15TM 5-6115-584-13NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12D-13

15Section II.TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-lTM-05682C-l2D-14Change 9

Section II. 15TM5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12D-15

Section II. 16 15TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12D-16Change 9

Section II. 16 17TM 5-6115-584-12NAVFAC P-8-622-12TM-05682C-12TO-35C2-3-456-1D-16.1/(D-16.2 blank)

Section II. 17TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12D-17

TM5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-lTM-05682C-12Section III. TOOLS, TEST AND SUPPORT EQUIPMENT REQUIREMENTS1-ReferenceMaintenanceToolCode C

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12ALPHABETICAL INDEXSubjectAC Instrumentetion System . . . . . . . . . . . . . . . . . . . .

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12ALPHABETICAL INDEX (CONT)SubjectDDC Control System . . . . . . . . . . . . . . . . . . . .

GROUP NO.17Section II.TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12

REFERENCECODEMAINTENANCECATEGORYNOMENCLATURETOOLNUMBERTM5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12Section III. TOOLS, TEST AND SUPPORT

TM5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12Section IV. EXPIANATION OF REFERENCE CODESREFERENCE CODEA-AB-BC-BD-IE-BF-B, C-D,H, I-JG-AH-

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12ALPHABETICAL INDEXSubjectAAC Instrumentation System... . . . . . . . . . . . . . . . . .

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12ALPHABETICAL INDEX (CONT)SubjectDDC Control System . . . . . . . . . . . . . . . . . . . .

ALPHABETICAL INDEX (CONT)SubjectTM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1F (CONT)Fuel Filter and Strainer Assembly. . . . . . . . . . . . . . .

1-34-6TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12ALPHABETICAL INDEX(CONT)Paragraph,Figure, Table,SubjectNumberG (CONT)Ground Rod and

1

ALPHABETICAL INDEX (CONT)TM5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12Paragraph,Figure, Table,NumberSubjectO (CONT)Oil Filter . . . . .

TM5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12ALPHABETICAL INDEX (CONT)SubjectsScreen-GuardInspection . . . . . . . . . . . . . . . . . .

TM5-6115-586-12NAVFAC P-8-622TO-35C2-3-456-1TM-05682C-12By Order of the Secretaries of the Army, the Navy, and the Air Force:BERNARD W. ROGERSIGeneral

PIN: 032551-011

DEPARTMENT OF THE ARMY TECHNICAL MANUALTM 5-6115-584-12DEPARTMENT OF THE NAVY PUBLICATIONNAVFAC P-8-622-12DEPARTMENT OF THE AIR FORCE TECHNICAL ORDERT

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12Section SectionCHAPTERSectionSectionSectionSectionSectionCHAPTERSectionSectionII.III.3.I.I

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12SectionSectionSectionSectionSectionSectionSectionSectionSectionSectionIII.IV.V.VI.VII.VIII

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12Section XII.SectionXIII.Section XIV.Section XV.CHAPTER 5SectionI.SectionII.TABLE OF CONTEN

TM 5-6115-584-12NAVFAC P-8-622-12TO -35C2-3-456-1TM-05662C-12Section III.APPENDIX A.APPENDIX B.SectionI.II.III.APPENDIX C.SectionI.II.APPENDIX D.Secti

ARMY TM 5-6115-584-12NAVFAC P-8-622-12AIR FORCE TO-35C2-3-456-1MARINE CORPS TM-05682C-12C11CHANGEHEADQUARTERSDEPARTMENTS OF THE ARMY, NAVY AND AIR FOR

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12Reproduction for non-military use of the information or illustrations contained in this pu

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12Figure1-1.1-2.1-2.11-3.1-4.1-5.1-6.1-7.1-8.1-9.1-10.2-1.2-2.2-3.2-4.3-1.3-2.3-3.3-4.3-5.3-

TM 5-6115-584-12NAVFAC P-6-622-12TO-35C2-3-456-1Figure4-12.4-13.4-14.4-15.4-16.4-17.4-18.4-19.4-20.4-21.4-21A.4-22.4-22A.4-23.4-24.4-25.4-26.4-27.4-28

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1Table2-12-2.3-1.3-2.3-3.4-1.4-2.4-3.4-4.LIST OF TABLESTitleGenerator Set Controls and InstrumentsRecon

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12ICHAPTER 1INTRODUCTIONSection I. GENERAL1-1. SCOPE.This manual is for your use in operatin

TM 5-6115-584-12NAVFAC P-8622-12TO-35C2-3-456-1TM-05682C-121-6. (A, MC) DESTRUCTION OF MATERIALTO PREVENT ENEMY USE.Army and Marine Corps personnel sh

1-9TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12Section II. DESCRIPTION AND DATA DESCRIPTION OF GENERATOR SET.This unit is a 5 kilowatt

“TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12Figure 1-1. Engine Generator Set, Right-Rear, Three-Quarter View1-3

ARMY TM 5-6115-584-12NAVFAC P-8-622-12AIR FORCE TO-35C2-3-456-1MARINE CORPS TM-05682C-12C11By Order of the Secretaries of the Army, Air Force, and Nav

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12Figure 1-2. Engine Generator Set, Left-Front, Three-Quarter View1-4

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05662C-121. AIR INTAKE5. AIR CLEANER2. EXHAUST PLENUM6. BATTERIES3. OIL7. COOLING AIR INTAKE4. FUEL

and current under load and varies the exciter field either upor down to keep the generator field at such a value as tomaintain constant alternator out

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12SERVICE INSTRUCTIONSFuelsAmbientCapacity-6.75 GALTemperaturePrimary-DieselEmergency-JP4Lub

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12Ventilation requirements (total): . . . . . . . . . . . . . . . . . . 1350 CFM at 1800 RP

(3)(4)(5)(6)Displacement: . . . . . . . . . . . . . . . . . . . . . . . . . . . .Compression ratio: . . . . . . . . . . . . . . . . . . . . . . . . .H

TM5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12Figure 1-3. Tie Down, Lifting, and Towing Provisions Crated Set1-8

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12Figure 1-4. Installation PlansFigure 1-5. Fuel System SchematicChange 5 1-9

Figure 1-6.TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-121-10

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12Figure 1-7. Generator Set Electrical Schematic.Change 91-11/(1-12 blank)

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-ITM-05682C-12Figure 1-8. Generator Set Wiring Harness1-13

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12Figure 1-9. AC Output Control Box Wiring Harness1-14Change 5

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12Figure 1-10. Control Cubicle Wiring HarnessChange 51-15/(1-16 blank)

.

TM 5–6115-584-12NAVFAC P–8-622-12TO-35C2-3-456-1TM-05682C-12CHAPTER 2OPERATING INSTRUCTIONSSection I. OPERATING PROCEDURE2-1. GENERAL.a. This chapter

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12(2)(3)(4)(5)(6)Ensure vent on underside of fuel filler cap is open.Open air intake access

Table 2-1.TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12Change 92-2.1/(2-2.2 blank)

Figure 2-1.. Load TerminalsFigure 2-1.Figure 2-2. TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12Table 2-1. Generator Set Controls and In

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12Figure 2-3. Starting Procedurepushing speed control knob in will decrease frequency.Texth.

load equals a 100% meter reading for maximum ratedload. A 1.0 power factor load equals a 80% meterreading for maximum rated load.i. During operating o

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12k. During operation, listen for unusual noiseswhich may indicate a pending malfunction.2-5

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12CHAPTER 3OPERATOR MAINTENANCE INSTRUCTIONSSection I. CONSUMABLE OPERATING AND MAINTENANCE

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12Section III. PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)3-4. GENERAL.To ensure that

B-BeforeTM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3456-1TM-05682C-12Table 3-2. Operator/Crew Preventive Maintenance Checks and Services (Cont.)NOTEWith

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12B-BeforeTable 3-2. Operator/Crew Preventive Maintenance Checks and Services (Cont.)NOTEWit

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12Table 3-3. Troubleshooting (Cont)MALFUNCTIONTEST OR INSPECTIONCORRECTIVE ACTION4, ENGINE S

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12Table 3-3. Troubleshooting (Cont)MALFUNCTIONTEST OR INSPECTIONCORRECTIVE ACTION7. GENERATO

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-121. Cable6, Battery (2)2. Connecter (2)11. Terminal7. Nut (4)12. Bottom frame3. Cable8. Wa

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-121. Screw (2)4. Hold-down assembly (2)2. Lockwasher (2)5. Fuel drum adapter3. Ground rod6.

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-121. Strap (2)2. Nut (4)5. Fitting (3)8. Filler cap3. Flatwasher (4)6. Fuel level gauge9. Dr

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-121. Bracket Assembly (4)5. Screw (2)9. Washer2. Screw (8)6. Lockwasher (2)3. Washer (8)10.

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-121. Lock tab (2)5. Adapter (2)8. Oil pressure gauge2. Nut (4)6. Adapter gasket (2)9. Oil ho

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-121. Starter2. Mounting bolts (4)3. Mounting bracket4. Electrical terminal (5)5. Flywheel ho

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-121. Bracket assembly7. Hose clamp2. Generator housing8. Air cleaner housing3. Capscrews (6)

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12b. Removal and Service.(2) Air Cleaner Element (see figure 3-10).Every1000 operating hours

Figure 3-11. Cleaning Air Filter ElementDo not re-use element more than twice. Donot re-use element if it has even the slightestrupture.c. Installatio

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-121. Panel light (2)7. Voltmeter2. Panel light switch8. DC control circuit breaker3. Battery

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12b. Service(1) Panel Light. Panel lamp cover can be re-moved for cleaning by turning them

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12(3) Fuel Pump Assemblies (Three) (see figure3-14). Inspect fuel pumps (1) for dents or oth

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12-1. Knob4. clamp2. Nut5. Nut3. support6. Cotter pin9. Engine backplate TS 6115-584-12/3-16

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12Figure 3-17. Engine Cooling Assembly (Sheet 1 of 2)3-22

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-121. Screw (6)22. shroud2. Air duct cover23. Nut3. Screw (4)24. Hook bolt4. Shutter assembly

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12Figure 3-19. Intake Manifold Assembly3-24

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12Figure 3-21. Oil filter and Oil Pressure SwitchFigure 3-20. Oil Drain Hosee. Oil Filter As

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12Inspect to see that there is no dirt or oil underneath lens in-dicating that gauge is no l

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12housing and engine block. Check that dip-stick fitssecurely into housing with no leaks.3-2

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1CHAPTER 4ORGANIZATIONAL MAINTENANCESection I. SERVICE UPON RECEIPT OF MATERIAL4-1. INSPECTING AND SERV

TM 5-6115-584-12NAVPAC P-8-622-12TO-35C2-3-456-1Figure 4-1. Uncrating Generator Set(9) Check crankcase oil level (paragraph 3-2)and add oil as necessa

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12out-of-level. Set up the unit as level as possible andgrounding method must be supplemente

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12Section II. MOVEMENT TO A NEW WORKSITE4.3 DISMANTLING GENERATOR SET FOR MOVE-MENT.a. Prepa

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-456-1TM-05682C-12(10) Apply a thin coat of clean engine oil,MIL-L-2104 to a new gasket (4). Install new gaske

para 4-45 para 4-20 para 4-20 para 4-20 fig, 3-1 para 3-13 para 3-20 para 4-25cTM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12TABLE 4-1.

TM 5-6115-584-12NAVFAC P-8-622-12TO-35C2-3-456-1TM-05682C-12TABLE 4-1. ORGANIZATIONAL PREVENTIVE MAINTENANCE CHECKS AND SERVICES--continuedITEMNO.M121