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ARMY TECHNICAL MANUAL

TM5-6115-585-34

NAVY PUBLICATION

NAVFACP-8-262-12

AIR FORCE TECHNICAL ORDER

TO-35C2-3-455-2

MARINE CORPS TECHNICAL MANUAL

TM-05684C-34

TECHNICAL MANUAL

INTERMEDIATE (FIELD) (DIRECT AND GENERAL SUPPORT)

AND DEPOT LEVEL MAINTENANCE MANUAL

GENERATOR SET, DIESEL ENGINE DRIVEN, TACTICAL SKID MTD 10KW, 1 PHASE

-2 WIRE, 1 PHASE -3 WIRE,3PHASE -4 WIRE, 120, 120/240 AND 120/208 VOLTS

DOD MODEL CLASS

HERTZ

NSN

MEP-003A UTILITY

60 6115-00-465-1030

This copy is a reprint which includes current

pages from Changes 1 through 9.

PUBLISHED UNDER THE AUTHORITY OF THE DEPARTMENTS OF THE ARMY,

AIR FORCE, NAVY, AND HEADQUARTERS U.S. MARINE CORPS

JULY 1977

Summary of content (192 pages)

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ARMY TECHNICAL MANUAL TM5-6115-585-34 NAVY PUBLICATION NAVFACP-8-262-12 AIR FORCE TECHNICAL ORDER TO-35C2-3-455-2 MARINE CORPS TECHNICAL MANUAL TM-05684C-34 TECHNICAL INTERMEDIATE AND (FIELD) DEPOT MANUAL (DIRECT LEVEL AND GENERAL MAINTENANCE SUPPORT) MANUAL GENERATOR SET, DIESEL ENGINE DRIVEN, TACTICAL SKID MTD 10KW, 1 PHASE -2 WIRE, 1 PHASE -3 WIRE,3PHASE -4 WIRE, 120, 120/240 AND 120/208 VOLTS DOD MODEL CLASS HERTZ NSN MEP-003A UTILITY 60 6115-00-465-1030 T h i s c o p y p a
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TM5-6115-585-34 NAVFAC P-8-262-12 TO-35C2-3-455-2 TM-05684C-34 WARNING All specific cautions and warnings contained in this manual shall be strictly adhered to. Otherwise, severe injury, death and/or damage to the equipment may result. HIGH VOLTAGE is produced when this Generator Set is in operation. DEATH or severe burns may result if personnel fail to observe safety precautions. Do not operate this Generator Set until the ground terminal stud has been connected to a suitable ground.
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TM 5-6115-585-34 NAVFAC P-8-623-34 TO-35C2-3-455-2 TM-05684C/05685B-34 C9 HEADQUARTERS, DEPARTMENTS OF THE ARMY, NAVY AND AIR FORCE AND HEADQUARTERS U.S. MARINE CORPS WASHINGTON, D. C., 4 MAY 1992 CHANGE NO.
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TM 5-6115-585-34 NAVFAC P-8-623-34 TO-35C2-3-455-2 TM-05684C/05685 B-34 C9 By Order of the Secretaries of the Army, Air Force, and Navy (Including the Marine Corps): GORDON R. SULLIVAN General, United States Army Chief of Staff Official: Milton H. Hamilton MILTON H. HAMILTON Administrative Assistant to the Secretary ot the Army 01110 MERRILL A. McPEAK General USAF Chief of Staff Official: CHARLES C. McDONALD General, USAF Commander, Air Force Logistics Command DAVID E.
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20 March 1991
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14 June 1989
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16 April 1984
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DEPARTMENT OF THE ARMY TECHNICAL MANUAL DEPARTMENT OF THE NAVY PUBLICATION DEPARTMENT OF THE AIR FORCE TECHNICAL ORDER MARINE CORPS TECHNICAL MANUAL TM5-6115-585-34 NAVFAC P-8-623-34 TO-35C2-3-455-2 TM-05684C/05685B-34 HEADQUARTERS DEPARTMENTS OF THE ARMY, NAVY, AIR FORCE, & USMC WASHINGTON, D.C.
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TM5-6115-585-34 NAVFAC P-8-262-12 TO-35C2-3-455-2 TM-05684C/05685B-34 TABLE OF CONTENTS (CONT) Page Section III. Section IV. CHAPTER 3. Section I. Section II. CHAPTER 4. Section I. Section II. CHAPTER 5. Section I. Section II. CHAPTER 6. Section Section ii I. II. GENERAL MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . 2-12 2-6. 2-7. General Maintenance . . . . . . . . . . . . . . . . . . . . . . General Maintenance Procedures . . . . . . . . . . . . . . .
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TM 5-6115-585-34 NAVFAC P-8-623-34 TO-35C2-3-455-2 TM-05684C/05685B-34 TABLE OF CONTENTS (CONT) Page CHAPTER 7. MAINTENANCE OF ENGINE. . . . . . . . . . . . . . . . . . . . . 7-1 Section I. DESCRIPTION AND FUNCTION. . . . . . . . . . . . . . . . . . . . 7-1 7-1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 ENGINE EXTERNAL ASSEMBLY.. . . . . . . . . . . . . . . . . . 7-1 7-2. 7-3. 7-4. 7-5. 7-6. 7-7. 7-8. Section II. Section III. CHAPTER 8. Section I.
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TM 5-6115-585-34 NAVFAC P-8-623-34 TO-35C2-3-455-2 TM-05684C/05685B-34 TABLE OF CONTENTS (CONT) Page CHAPTER 1 0 . Section I . Section I I . MATERIAL USED IN CONJUNCTION WITH DOD STANDARD GENERATOR SET, 10KW DIESEL ENGINE, MODEL MEP-003A AND MEP-112A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 10-1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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TM 5-6115-585-34 NAVFAC P-8-623-34 TO-35C2-3-455-2 TM-05684C/05685B-34 LIST OF ILLUSTRATIONS Figure l–l. 1–1.1 2–1. 2-2. 2-3. 2-4. 3-1. 5-1. 5-2. 5-3. 5-4. 5-5. 5-6. 5-7. 5-8. 5-9. 5-10. 5-11. 5–12. 5-13. 5-14. 6-1. 6-2. 6-3. 6-4. 6-5. 6-5.1. 6-6. 6-6.1. 6-7. 6-8. 6-9. 6-10. 6-11. 7-1. 7-2. 7-3. 7-3.1. 7-4. 7-5. 7-6. 7-7. 7–8. 7-8.1. 7-9. 7-10. 7-11. 7-12. 7-13. 7-14. 7-15. 7-16. 7-17. 7-18. 7-19. 7-20. 7-21. Page Title Generator Set Electrical Schematic (MEP-003A) . . . . . . . . . . . . . . . . . . .
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TM 5-6115-585-34 NAVFAC P-8-623-34 TO-35C2-3-455-2 TM-05684C/05685B-34 Figure 7–22. 7–23. 7-24. 7-25. 7-26. 7-27. 7-28. 7-29. 7-30. 7-31. 7-32. 7–33. 7-34. 7-35. 7-36. 7–37. 7-38. 7–39. 7-40. 7-41. 7-42. 7-43. 7-44. 7-45. 7-46. 7-47. 8-1. 8-2. 8-3. 8-4. 8-5. 9-1. 9-2. 10-1. 10-2. 10-3. 10-4. 10-5. 10-6. LIST OF ILLUSTRATIONS (CONT) Title Gear CoverComponents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear Cover Inspection . . . . . . . . . . .
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TM5-6115-585-34 NAVFAC P-8-262-12 TO-35C2-3-455-2 TM-05684C/05685B-34 CHAPTER 1 INTRODUCTION Section I. GENERAL 1-1. SCOPE. 1-4. REPORTING OF ERRORS. This manual is for your use in maintaining the DOD Standard Generator Set, 10KW Diesel Engine Driven, Models MEP-003A and MEP-112A. It contains sections for general maintenance, including troubleshooting, and removal and installation of major components, and maintenance of individual components of the unit.
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TM5-6115-585-34 NAVFAC P-8-623-34 TO-35C2-3-455-2 TM-05684C/05685B-34 c. Main Generator. Exciter field voltage andcurrent versus load, see the following: Exciter Percent of Rated Load 10-.8PF, 120 V Volts Amps 0.96 o 17.8 25 21.7 0.56 50 25.5 0.66 0.77 75 29.8 0.87 100 34.0 1.0 125 38.7 d. Generator Frame Assembly. Model . . . . . . . . . . . . . . . . . . . .MEP-003A DOD Drawing No. . . . . . . . . . . . 72-5270 Number of Slots ........ . . . ...60 Pitch of Coil . . . . . . . . . . . . . . . .
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TM5-6115-585-34 NAVFAC P-8-623-34 TO-35C2-3-455-2 TM-05684C/05685B-34 k. Engine Accessories. (1) Fuel injection pump. Manufacturer . . . . . . . . . . . . .. Onan Model . . . . . . . . . . . . . . . .147-0333 Type . . . . . . . . . . PSU, single plunger multi outlet Drive Type . . . . . . . . . . . .gear and cam Mounting . . . . . . . . . . . block mounted (4) Battery charging alternator. Refer to Operator and Organizational Maintenance Manual. (5) Fuel solenoid valve. DOD Drawing No. . . . . . . . . . . .
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TM5-6115-585-34 NAVFAC P-8-623-34 TO-35C2-3-455-2 TM-05684C/05685B-34 Table 1-1. Torque Values (Ft-Lb Dry) Torque Range (Cadmium Plated) (Ft-Lb Dry) Item Min. Max. Connecting rod bolt . . . . . . . . . . . . . . 27 29 Cover-rocker box . . . . . . . . . . . . . . 7 8 Exhaust manifold nuts . . . . . . . . . . . . 11* 13* Flywheel mounting screw . . . . . . . . . . . 54 58 Gearcase cover . . . . . . . . . . . . . . . . 15 17 Rear bearing plate . . . . . . . . . . . . . .
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TM 5-6115-585-34 NAVFAC P-8-623-34 TO-35C2-3-455-2 TM-05684C/05685B-34 Table 1-1. Torque Values (Ft-Lb Dry) (Cont’d) Torque Range (Cadmium Plated) (Ft-Lb Dry) Item Acoustic Suppression Kit Right Support Assembly Mounting Screws . . . . Left Support Assembly Mounting Screws . . . . . Rear Panel Assembly Mounting Screws . . . . . . Rear Flap Assembly Mounting Screws . . . . . . . Rear Closure Assembly Mounting Screws . . . . . Side Closure Assembly Mounting Screws . . . . .
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TM 5-6115-585-34 NAVFAC P-8-623-34 TO-35C2-3-455-2 TM-05684C/05685B-34 Table 1-2. Repair and Replacement Standards (All values in inches unless otherwise specified.) Manufacturer Dimensions and Tole r a n c e s Component Minimum Maximum Maximum Allowable Wear Limit CYLINDER BLOCK: Cylinder bore diameter 3.5005 0.005 Cylinder bore out of round 0.001 0.001 Cylinder bore taper 0.001 0.002 3.4993 Main bearing bore - less bearings 2.4365 2.4375 2.
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TM5-6115-585-34 NAVFAC P-8-262-12 TO-35C2-3-455-2 TM-05684C-34 Table 1-2. Repair and Replacement Standards (Cont) Manufacturer Dimensions and Tolerances Component Minimum Maximum Maximum Allowable Wear Limit CONNECTING ROD (Cont): Connecting rod side clearance 0.0020 0.0160 0.0160 Piston pin bushing bore - less bushing 1.043 1.045 1.0455 Piston pin bushing bore 0.9903 0.9906 0.001 2.2500 1.1875 2.2505 1.1880 0.002 0.002 1.185 1.189 0.
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TM5-6115-585-34 NAVFAC P-8-262-12 TO-35C2-3-455-2 TM-05684C-34 Table 1-2. Repair and Replacement Standards (Cont) Manufacturer Dimensions and Tolerances Minimum Component Maximum Maximum Allowable Wear Limit PISTON RING (Cont): Clearance in groove - oil control 0.0020 0.0030 0.0050 Gap 0.0100 0.0200 0.0400 Head diameter 1.307 1.317 N/A Stem diameter - tapered 0.3391/0.3381 0.3420/0.3410 0.002 Stem to guide clearance 0.0030/0.0050 0.0012/0.0032 0.
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TM5-6115-585-34 NAVFAC P-8-262-12 TO-35C2-3-455-2 TM-05684C-34 Table 1-2, Repair and Replacement Standards (Cont) 1-7
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TM5-6115-585-34 NAVFAC P-8-262-12 TO-35C2-3-455-2 TM-05684C-34 Table 1-2. Repair and Replacement Standards (Cont) Manufacturer Dimensions and Tolerances Component Minimum Maximum Maximum Allowable Wear Limit FLYWHEEL: Face runout, total 0.0053 Pilot bore eccentricity 0.0020 FLYWHEEL HOUSING: Attaching face deviation 0.0113 Housing bore eccentricity 0.005 ROCKER ARM MECHANISM: Tappet adjusting screw torque 4 ft-lbs 10 ft-lbs CYLINDER HEAD: Warpage (longitudinally) 0.001 0.
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TM 5-6115-585-34 NAVFAC P-8-623-34 TO 35C2-3-455-2 TM-05684C/05685B-34 Figure 1-1.
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TM-6115-585-34 NAFAC P-8-623-34 TO-35C2-3-455-2 TM-05684C/05685B-34 Figure 1-1.1. 1-10.1/(1-10.
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TM 5-6115-585-34 NAVFAC P-8-623-34 TO-35C2-3-455-2 TM-05684C/05685B-34 CHAPTER 2 GENERAL MAINTENANCE INSTRUCTIONS Section I. REPAIR PARTS, SPECIAL TOOLS, TEST, MEASUREMENT, AND DIAGNOSTIC EQUIPMENT (TMDE), AND SUPPORT EQUIPMENT 2-1. REPAIR PARTS. Table 2-1 contains a list of all special tools, test and support equipment needed to maintain this unit.
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TM5-6115-585-34 NAVFAC P-8-262-12 TO-35C2-3-455-2 TM-05684C-34 Table 2-2. Fabricated Tools and Equipment Nomenclature Pump mounting fixture Reference No. or NSN Material Required 0.375” cold rolled steel Fabrication Instructions: Fabricate fixture as shown below. Drill “F” (0.255 in.-0.262 in.) depth thru countersink 60° incl. to 0.332 in. diameter. Tap 0.3125-18 UNC-2B depth thru. Two holes located within 0.005 in. of true position.
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TM5-6115-585-34 NAVFAC P-8-623-34 TO-35C2-3-455-2 TM-05684C/05685B-34 Table 2-2. Fabricated Tools and Equipment (Cont) Nomenclature Reference No. or NSN Valve spring depressor Material Required 1/4” cold rolled steel Fabrication Instructions: Fabricate tool to dimensions shown below. Sketch or Diagram: Nomenclature Compression adapter mounting studs Reference No.
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TM 5-6115-585-34 NAVFAC P-8-623-34 TO-35C2-3-455-2 TM-05684C/05685B-34 Table 2-2. Fabricated Tools and Equipment (Cont) Nomenclature Crankshaft gear driver Material Required Reference No. or NSN Steel pipe 3/16” wall thickness Fabrication Instructions: Fabricate tool to dimensions shown below by sawing pipe to correct length.
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TM 5-6115-585-34 NAVFAC P-8-623-34 TO-35C2-3-455-2 TM-05684C/05685B-34 Table 2-2. Fabricated Tools and Equipment (Cont) Nomenclature Reference No. or NSN Camshaft/crankshaft gear puller ring Material Required Steel, round, CD Fabrication Instructions: Make puller according to dimensions shown below. Sketch or Diagram: Section II. TROUBLESHOOTING 2-4. GENERAL. This section contains troubleshooting information for locating and correcting operating troubles which may develop in the Generator Set.
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TM 5-6115-585-34 NAVFAC P-8-623-34 TO-35C2-3-455-2 TM-05684C/05658B-34 Table 2-3. Troubleshooting MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION 1. STARTER MOTOR DOES NOT TURN-HIGH CURRENT DRAW. Step 1. Check starter for grounded switch, terminals, or field (paragraph 5-2). Replace any grounded component. Step 2. Check for frozen armature shaft bushing (paragraph 5-2). Replace bushing and, if necessary, armature. 2. STARTER DOES NOT TURN-NO CURRENT DRAW. Step 1.
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TM5-6115-585-34 NAVFAC P-8-262-12 TO-35C2-3-455-2 TM-05684C-34 Table 2-3. Troubleshooting (Cont) MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION 4. STARTER WILL NOT ENGAGE FLYWHEEL. Step 1. Check starter clutch (bendix) and pinion (paragraph 5-2). Repair or replace as necessary. Step 2. Check for damaged ring gear (paragraph 7-4). Replace ring gear if necessary. 5. ENGINE WILL NOT START WHEN CRANKED. Step 1. Check for faulty injection caused by dirty fuel. Replace with clean fuel. Service fuel filters.
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TM5-6115-585-34 NAVFAC P-8-262-12 TO-35C2-3-455-2 TM-05684C-34 Table 2-3. Troubleshooting (Cont) MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION 8. LOW OIL PRESSURE (CONT). Step 2. Check for worn oil pump (paragraph 7-11). Replace pump. Step 3. Check for worn engine bearings (paragraph 7-17). Replace worn bearings. 9. HIGH OIL PRESSURE Step 1. Check to see if oil by-pass is stuck closed (paragraph 7-13). Clean or replace oil by-pass valve and spring. Step 2. Check for clogged oil passages.
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TM5-6115-585-34 NAVFAC P-8-262-12 TO-35C2-3-455-2 TM-05684C-34 Table 2-3. Troubleshooting (Cont) MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION 13. METALLIC KNOCKING, CLICKING, OR POUNDING FROM CRANKCASE OR CYLINDER BLOCK. Step 1. Check for worn or loose comecting rod bearings (paragraph 7-10). Replace bearings if necessary. Step 2. Check for loose piston and connecting rod assembly (paragraph 7-10). Repair or replace assembly. 14. LOW ENGINE COMPRESSION.
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TM5-6115-585-34 NAVFAC P-8-262-12 TO-35C2-3-455-2 TM-05684C-34 Table 2-3. Troubleshooting (Cont) MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION 15. STICKING VALVES (CONT). Step 3. Check clearance between valve stem and guide (paragraph 7-9). Correct clearance. 16. ENGINE RUNS NORMALLY BUT GENERATOR HAS NO OUTPUT. Step 1. Check voltage regulator (paragraph 6-6). Repair or replace regulator. Step 2. Check exciter field (stator) for open or shorted windings (paragraph 8-2). Replace stator if necessary.
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TM5-6115-585-34 NAVFAC P-8-623-34 TO-35C2-3-455-2 TM-05684C/05685B-34 Table 2-3. Troubleshooting (Cont) MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION 18. HIGH GENERATOR OUTPUT VOLTAGE (NO LOAD). Step 1. Check for voltage regulator failure. Remove voltage regulator lead wire X39C16 from terminal 17. If voltage goes even higher, the voltage regulator is good. Test and repair defective regulator (paragraph 6-6). Step 2. Check voltage adjust rheostat (R1). Replace rheostat (Rl) if necessary. Step 3.
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TM 5-6115-585-34 NAVFAC P-8-623-34 TO-35C2-3-455-2 TM-05684C/05685B-34 Section III. GENERAL MAINTENANCE 2-6. GENERAL MAINTENANCE. should make sure it is free of dirt and other contaminants. This section contains general maintenance instructions which are the responsibility of direct support and general support maintenance personnel. You will find that these instructions apply to several assemblies or components. They would otherwise have to be repeated throughout the chapter.
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TM 5-6115-585-34 NAVFAC P-8-623-34 TO-35C2-3-455-2 TM-05684C/05685B-34 (2) Tag and disconnect battery cables and ground cable from starter. (3) Tag and disconnect wiring harness and electrical leads from engine. (4) Disconnect air cleaner holes from shutter assembly and intake manifold. Remove air cleaner and bracket assembly from top of generator. (7) Disconnect and remove fuel tank. (8) Disconnect speed adjustment assembly (see figure 2-1). Loosen nut (1) and lockwasher (2) and slide from bracket (5).
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TM 5-6115-585-34 NAVFAC P-8-623-34 TO-35C2-3-455-2 TM-05684C/05685B-34 (e) Remove twelve nuts (5) and lockwashers (6) attaching generator housing (8) to engine(7). (11) Remove four screws (3, figure 2-3), lockwashers (5), flatwashers (4) and nuts (6) attaching each engine mount (2) to skid-base (7). Lift engine free of Generator Set. b. Installing Engine-Generator Assembly. (1) Attach generator to engine. (a) Install two 1/4-20 x 2 in.
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T M 5 - 6 1 1 5 - 5 8 5 - 3 4 NAVFAC P-8-623-34 T O - 3 5 C 2 - 3 - 4 5 5 - 2 TM-05684C/05685B-34 Figure 2-3.
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TM5-6115-585-34 NAVFAC P-8-623-34 TO-35C2-3-455-2 TM-05684C/05685B-34 c. Installing Engine. (1) This installation procedure is to be followed if the engine has been removed and the generator has been left mounted on the skid-base. (2) Lift engine into place on skid-base using engine lifting bracket (8, figure 2-3). Leave about a 6 inch space between the generator and the engine.
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TM5-6115-585-34 NAVFAC P-8-262-12 TO-35C2-3-455-2 TM-05684C-34 Figure 2-4.
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TM 5-6115-585-34 NAVFAC P-8-623-34 TO-35C2-3-455-2 TM-05684C/05685B-34 CHAPTER 3 MAINTENANCE OF COOLING SYSTEM Section I. DESCRIPTION AND FUNCTION 3-1. GENERAL. The engine has a pressure air cooling system. Fins on the engine blower draw air into the front of the engine housing and force it past the cylinders and out the right side of the engine. A separate blower on the generator rotor draws air into the rear of the gener- ator and forces it out openings near the engine.
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TM5-6115-585-34 NAVFACP-8-623-34 TO-35C2-3-455-2 TM-05684C/05685B-34 Figure 3-1.
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TM5-6115-585-34 NAVFAC P-8-623-34 TO-35C2-3-455-2 TM-05684C/05685B-34 (3) If continuity exists, replace with a new switch. The high temperature cutout switch must be removed and tested semiannually (500 hours). b. Test. Oil to (1) Using an oil pot tester and peanut oil, heat 394° ± 10ºF (201° ± 5°C). (2) Immerse threads and bottom surface of switch in oil. After a minimum of 1 minute, use an ohmmeter and check continuity between terminals on switch.
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TM5-6115-585-34 NAVFAC P-8-623-34 TO-35C2-3-455-2 TM-05684C/05685B-34 CHAPTER 4 MAINTENANCE OF FUEL SYSTEM Section I. DESCRIPTION AND FUNCTION 4-1. GENERAL. The engine fuel system consists of two pressure system; the low pressure system and the high pressure system. In the low pressure system, a fuel pump may draw fuel from an external source to till set tank or set tank may be filled manually.
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TM5-6115–585–34 NAVFAC P-8-623-34 TO-35C2-455-2 TM-05684C/05685B-34 CHAPTER 5 MAINTENANCE OF STARTING SYSTEM Section I. DESCRIPTION AND FUNCTION 5-1. GENERAL The engine is cranked by a 24 volt electric starter. when the starter motor solenoid is energized, the solenoid core pulls in, shifting the pinion gear into engagement with the engine flywheel ring gear. The starting motor is protected from overspeeding by an overrunning clutch.
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Change 8 TM5-6115-585-34 NAVFACP-8-623-34 TO-35C2-455-2 TM-05684C/05685B-34 5-2 Figure 5-1.
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Figure 5-2.
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TM5-6115-585-34 NAVFACP-8-623-34 TO-35C2-455-2 TM-05684C/05685B-34 (4) Remove the through studs (9), remove screws (10) and rear cover (11). (5) Raise the brush springs (12) lift the brushes (13) and remove brush holder (14). (6) Remove stator (frame assembly) (15), rear bearing (16), armature (17) and armature front bearing (18). (7) Remove screws (19), cover (20), retaining ring (21), flat washer (22) and spacer (23). (8) Remove screw (24) freeing the center bracket (25).
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TM5-6115-585-34 NAVFACP-8-623-34 TO-35C2-455-2 TM-05684C/05685B-34 Figure 5-4. Testing Armature for Grounds Figure 5-5. Testing Armature for Shorted Coils (2) Testing Armature. (a) Testing Armature for grounds. Touch armature shaft and the end of each commutator bar with a pair of ohmmeter leads. There should be no continuity. If continuity is indicated between any commutator bar and armature shaft, it indicates a grounded armature. Replace grounded armature. See figure 5-4.
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TM5-6115-585-34 NAVFAC P-8-623-34 TO-35C2-455-2 TM-05684C/05685B-34 (d) Testing Commutator Runout. Place the armture in a test bench and check runout with a dial indicator. See figure 5-7. When commutator runout exceeds 0.004 inch, commutator should be refaced. After refacing commutator, check that it meets minimum specifications. Check and if necessary, undercut mica as given under repair. (e) Testing Armature Shaft Runout. Place armature in a test bench and check shaft runout with a dial indicator.
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TM5-6115-585-34 NAVFACP-8-623-34 TO-35C2-455-2 TM-05684C/05685B-34 (3) Testing Field Coils. See Operator and Organizational Maintenance Manual. See Operator and (4) Testing Brushes. Organizational Maintenance Manual. (5) Testing Brush Springs. Style I Starter. (see figure 5-9). Measure brush spring with tension meter. Push the brush and take reading just as the brush projects a little from the brush holder. On a new brush, the spring tension should be 32 to 40 ounces.
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T M 5 - 6 1 1 5 - 5 8 5 - 3 4 NAVFACP-8-623-34 T O - 3 5 C 2 - 4 5 5 - 2 TM-05684C/05685B-34 5 - 8 Change 8 Figure 5-10.
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TM 5-6115–585-34 NAVFAC P-8-623-34 TO-35C2-455-2 TM-05684C/05685B-34 h. Reassembly Style I Starter (see figure 5-1) (1) Soak sleeve bearing (36) in SAE 10 oil for 15 minutes before assembly of stater. (2) Press bearing (36) into pinion housing (28). (3) Slide drive assembly (35) onto the armature shaft. Slide stop and position lock ring (34) in its groove on the armarure shaft. Pull step over lock ring. A bearing puller tool may be required. (4) Install thrust washer (27) on the end of the armature shaft.
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TM5-6115-585-34 NAVFACP-8-623-34 TO-35C2-455-2 TM-05684C/05685B-34 Figure 5-11. Undercutting Mica Figure 5-12.
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TM5-6115-585-34 NAVFAC P-8-623-34 TO-35C2-455-2 TM-05684C/05685B-34 (8) Slide spring (35), pinion gear(34) and Stopper (33) onto shaft. Position retaininq ring (32) in groove on shaft and pull stopper over ring to secure it. A bearing puller tool may be required. (9) Place bearings (16) and (18) on the armature shaft, and insert armature into the center bracket. Slide Stator (15) over armature and into center bracket. Align stator to bracket by fitting tab on stator into notch on center bracket.
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TM5-6115-585-34 NAVFAC P-8-623-34 TO-35C2-455-2 TM-05684C/05685B-34 Figure 5-14. Checking Pinion Travel STYLE II Starter (e) If adjustment of pinion gear travel is required, remove screws (1) lift off solenoid (3). Adjust pinion travel by adding or removing mounting spacers (2). Increasing the number of washers will decrease maximum travel distance; and removing washers will increase maximum travel distance. NOTE Solenoid mounting scerw removal may require the use of a impact type driver.
PAGE 77
TM5-6115-585-34 NAVFAC P-8-623-34 TO-35C2-3-455-2 TM-05684C/05685B-34 CHAPTER 6 MAINTENANCE OF CONTROL SYSTEM Section I. DESCRIPTION AND FUNCTION 6-1. DC CONTROL SYSTEM. 6-3. VOLTAGE REGULATOR. Refer to the Operator and Organizational Maintsnance Manual for the description and function of the dc control system. Excitation current is controlled through the static type automatic voltage regulator.
PAGE 78
TM-5-6115-585-34 NAVFAC P-8-623-34 TO-35C2-3-455-2 TM-056684C/05685B-34 Figure 6-1.
PAGE 79
TM5-6115-585-34 NAVFAC P-8-623-34 TO-35C2-3-455-2 TM-05684C-34 Table 6-1. Control Cubicle Wiring Harness NOTE All wires are copper, 600V, per MIL-W-5086/2. Wire No. Gauge Marking Color D24A16 D25A16 D26A16 D26B16 16 16 16 16 black black black black 13 13 10 24 MS25036-154, MS25036-107 MS25036-154, MS25036-107 MS25036-154, MS25036-107 MS25036-107 D27A16 D74A16 D75A16 H52A12 16 16 16 12 black black black red 10.5 31.5 32 9.
PAGE 80
TM5-6115-585-34 NAVFAC P-8-623-34 TO-35C2-3-455-2 TM-05684C-34 Table 6-1. Control Cubicle Wiring Harness (Cont) Marking Color Length in Inches Gauge P61C16 P61E16 P62A16 P62B16 16 16 16 16 red red red red 19.5 19.5 42 19.5 MS25036-107 MS25036-107 MS25036-107, MS25036-107 P62D16 P64A16 P64B16 P64C16 16 16 16 16 red red red red 19.5 9.5 41 21.
PAGE 81
TM5-6115-585-34 NAVFAC P-8-623-34 TO-35C2-3-455-2 TM-05684C-34 Table 6-2. 10KW Generator Set Wiring Harness NOTE All wires are copper, 600V, per MIL-W-5086/2. Length in Inches Wire No. Gauge Marking Color D26C16 H52C12 H52J12 K51B12 16 12 12 12 black red red red 31 53 53 35 P50A10 P50G16 P55B10 P55E16 10 16 10 16 red red red red 39 53 36 31 P55M16 P55S16 P58B16 P59B16 16 16 16 16 red red red red 35 55 47 47 P60D16 P61D16 P61F16 P62C16 16 16 16 16 red red red red 31 20 20.
PAGE 82
TM5-6115-585-34 NAVFAC P-8-262-12 TO-35C2-3-455-2 TM-05684C-34 Figure 6-2.
PAGE 83
TM5-6115-585-34 NAVFAC P-8-623-34 TO-35C2-3-455-2 TM-05684C/05685B-34 Table 6-3. AC Output Control Box Wiring Harness (MEP-003A Only) NOTE All wires are copper, 600V, per MIL-W-5086/2. Wire No. Gauge Marking Color D26D16 D26E16 D26F16 D26G16 16 16 16 16 black black black black 21 17 17 32 MS25036-107 MS25036-107, MS25036-108 MS25036-107, MS25036-108 MS25036-107, MS25036-153 D26H16 D26J16 D26K16 P55F16 16 16 16 16 black black black red 15 3.
PAGE 84
TM 5-6115-585-34 NAVFAC P-8-623-34 TO-35C2-3-455-2 TM-05684C/05685B-34 Table 6-3. AC Output Control B OX Wiring Harness (MEP-003A Only) (Cont) Wire No. Gauge Marking Color Length in Inches Terminal Lugs X29A16 X30A16 X30B16 X30C16 16 16 16 16 black black black black 19.5 14 15 32 MS25036-153 MS25036-153, MS25036-107 MS25036-107, MS25036-108 MS25036-153, MS25036-107 X31A16 X31B16 X32A16 X33A16 16 16 16 16 black black black black 7 22 16 14.
PAGE 85
TM 5-6115-585-34 NAVFAC P-8-623-34 TO-35C2-3-455-2 TM-05684C/05685B-34 Table 6-3.1. AC Output Control Box Wiring Harness (MEP-112A Only) NOTE All wires are copper, 600V, per MIL-W-5086/2. Wire No. Gauge Marking Color D26D16 D26E16 D26F16 D26G16 16 16 16 16 black black black black 21 17 17 32 MS25036-107 MS25036-107, MS25036-108 MS25036-107, MS25036-108 MS25036-107, MS25036-153 D26H16 D26J16 D26K16 P59G16 16 16 16 16 black black black red 15 3.
PAGE 86
TM5-6115-585-34 NAVFAC P-8-623-34 TO-35C2-3-455-2 TM-05684C/05685B-34 Table 6-3.1. AC Output Control Box Wiring Harness (MEP-112A Only) 6-8.2 Wire No. Gauge Marking Color Length in Inches Terminal Lugs X29A16 X30A16 X30B16 X30C16 16 16 16 16 black black black black 19.5 14 15 32 MS25036-153 MS25036-153, MS25036-107 MS25036-107, MS25036-108 MS25036-153, MS25036-107 X31A16 X31B16 X32A16 X33A16 16 16 16 16 black black black black 7 22 16 14.
PAGE 87
TM 5-6115-585-34 NAVFACP-8-623-34 TO-35C2-3-455-2 TM-05684C/05685B-34 c. Remove. (1) Tag and disconnect harness leads to voltage regulator (39). (2) Remove nuts (38) attaching voltage regulator from control box (57) and remove voltage regulator. d. Test, Bench (see figure 6-4). (1) Connect ac voltage regulator to test circuit and test as shown in figure 6-4. Transformers T1 and T2 are located in the control cubicle (see figure 6-3, items 34 and 37) and may be disconnected and used for this test.
PAGE 88
TM5-6115-585-34 NAVFAC P-8-262-12 TO-35C2-3-455-2 TM-05684C-34 6-10 Figure 6-3.
PAGE 89
TM5-6115-585-34 NAVFAC P-8-623-34 TO-35C2-3-455-2 TM-05684C/05685B-34 1: Screw 2. Nut 3. Holder 4. Terminal (2) 5. Hook 6. Screw 7. Nut 8. Clamp 9. Fastener pin (3) 10. Grommet (3) 11. Stud (3) 12. Battery indicator 13. Lampholder (2) 14. Lamp (2) 15. Hourmeter 16. Frequency meter 17. Percent rated current meter 18. AC Voltmeter 19. Knob (3) 20. Rheostat 21. Switch 22. Switch 23. Switch 24. Screw (2) 25. Circuit breaker 26. Nut(4) 27. Screw (4) 28. Panel 29. Nut 30. Screw 31. Strap 32. Screw (2) 33.
PAGE 90
TM5-6115-585-34 NAVFACP-8-623-34 TO-35C2-3-455-2 TM-05684C/05685B-34 Figure 6-4.
PAGE 91
Figure 6-5.
PAGE 92
Change 7 TM5-6115-585-34 NAVFACP-8-623-34 TO-35C2-3-455-2 TM-05684C/05685B-34 6-14 Figure 6-5.1.
PAGE 93
TM5-6115-585-34 NAVFAC P-8-623-34 TO-35C2-3-455-2 TM-05684C/05685B-34 resistance of each of the three windings in the reactor by checking resistance between terminals 1 and 2, 3 and 4, 5 and 6. Resistance for each winding must be 13.5 ohms plus or minus 1.35, if not replace reactor. (6) Connector Assemblies. Test for continuity between each pin and case for shorts to ground. (7) Current Voltage Transformer (CVT1). Using an ohmmeter check three primary windings of transformer (figure 1-1, 6-7.
PAGE 94
TM5-6115-585-34 NAVFACP-8-623-34 TO-35C2-3-455-2 TM-05684C/05685B-34 Table 6-5.
PAGE 95
TM5-6115-585-34 NAVFACP-8-623-34 TO-35C2-3-455-2 TM-05684C/05685B-34 TM5-6115-585-34 NAVFACP-8-623-34 TO-35C2-3-455-2 TM-05684C/05685B-34 Figure 6-7.1. CVT and CT Wiring Change 5 6-16.
PAGE 96
TM5-6115-585-34 NAVFACP-8-623-34 TO-35C2-3-455-2 TM-05684C/05685B-34 Figure 6-8. AC Control Box Removal 6-16.
PAGE 97
TM5-6115-585-34 NAVFAC P-8-623-34 TO-35C2-3-455-2 TM-05684C/05685B-34 Table 6-6. Testing Bridge Assembly (60 Hz Only) To Test Diode Check Resistance in Both Directions Between Terminals A4-CR1 2-5 A4-CR2 1-5 A4-CR3 3-5 A4-CR4 2-4 A4-CR5 1-4 A4-CR6 3-4 c. Removal. (1) Reconnection Switch (S6) and Transformers (CT1 and CVT1). Due to the large number of wires connected to these items, they are removed from the control box with the wiring connected.
PAGE 98
TM5-6115-585-34 NAVFACP-8-262-12 TO-35C2-3-455-2 TM-05684C-34 Figure 6-9 Output Control Assembly (Sheet 1 of2) 6-18
PAGE 99
TM 5-6115-585-34 NAVFAC P-8-623-34 TO-35C2-3-455-2 TM-05684C/05685B-34 1. Screw (1O) 2. Lockwasher (10) 3. Nut (10) 4. Screw (2) 5. Nut (2) 6. Transformer 7. Transformer 8. Screw(6) 9. Lockwasher (6) 10. Load terminal board 11. Screw (4) 12. Lockwasher (4) 13. Access panel 14. Screws (4) 15. Linear reactor 16. Screw (12) 17. Nut(12) 18. Connector (3) 19. Screw (4) 20. Nut (4) 21. Connector 22. Nut (4) 23. Bridge rectifier assembly 24. Output control box 25. Load terminal (4) Figure 6-9.
PAGE 100
Change 2 TM5-6115-585-34 NAVFACP-8-623-34 TO-35C2-3-455-2 TM-05684C/05685B-34 6-20 Figure 6-10.
PAGE 101
TM5-6115-585-34 N A V F A C P - 8 - 6 2 3 - 3 4 T O - 3 5 C 2 - 3 - 4 5 5 - 2 TM-05684C/05685B-34 Figure 6-10.1 Change 7 6-20.
PAGE 102
TM5-6115-585-34 NAVFACP-8-623-34 TO-35C2-3-455-2 TM-05684C/05685B-34 Figure 6-10.2 6-20.
PAGE 103
TM5-6115-585-34 NAVACP-8-623-34 TO-35C2-3-455-2 TM-05684C/05685B-34 Figure 6-11.
PAGE 104
PAGE 105
TM5-6115-585-34 NAVFAC P-8-623-34 TO-35C2-3-455-2 TM-05684C/05685B-34 CHAPTER 7 MAINTENANCE OF ENGINE Section L DESCRIPTION AND FUNCTION 7-1. GENERAL. The engine is a four cylinder, air-cooled, overhead valve, fuel injected, diesel. End crankshaft and camshaft bearings are press fit one piece bearings. The center crankshaft bearing is a two piece split bearing. Crankshaft end play is adjusted by using correct shim between rear bearing plate and cylinder block.
PAGE 106
TM5-6115-585-34 NAVFACP-8-623-34 TO-35C2-3-455-2 TM-05684C/05685B-34 Figure 7-1.
PAGE 107
Figure 7-2.
PAGE 108
TM5-6115-585-34 NAVFACP-8-262-12 TO-35C2-3-455-2 TM-05684C-34 7-4 Figure 7-3.
PAGE 109
TM5-6115-585-34 NAVFAC P-8-623-34 TO-35C2-3-455-2 TM-05684C/05685B-34 e. Replace. Using screws (13, figure 7-2), lockwashers (14), and nuts (15), attach governor control bracket (12) to engine back plate. Attach speed control cable (11) to governor arm (3) with pin (6) and cotter pin (5). Attach governor arm (3) and governor linkage (1) between governor and fuel injection pump (2).
PAGE 110
TM5-6115-585-34 NAVFAC P-8-623-34 TO-35C2-3-455-2 TM-05684C/05685B-34 Top Dead Center. This can be measured on top of exhaust valve stem with a dial indicator (see figure 75). NOTE As the piston comes up to Top Dead Center there is very little change in the dial indicator reading and extreme care should be used to establish the exact Top Dead Center. Zero the dial indicator. Rotate flywheel in opposite direction (clockwise) to a point where the dial indicator will indicate approximately 0.200 inch.
PAGE 111
TM5-6115-585-34 NAVFAC P-8-262-12 TO-35C2-3-455-2 TM-05684C/05685B-M Figure 7-7. Battery Charge Alternator and Blower Wheel (1) Plug the oil cooler outlet using suitable plug. (2) Connect the oil cooler in suggested test setup (see figure 7-6). (3) Apply 25 psi air pressure to the oil cooler. (4) Close the valve and monitor the pressure. A drop in air pressure indicates a leak in the oil cooler. 7-7. BLOWER WHEEL ASSEMBLY. a. Inspect (see figure 7-7).
PAGE 112
TM5-6115-585-34 NAVFAC P-8-623-34 TO-35C2-3-455-2 TM-05684C/05685B-34 7-8. BATTERY CHARGE ALTERNATOR. a. Inspect (see figure 7-7). (1) Refer to Operator and Organizational Maintenance Manual and remove blower housing. (2) Check stator wiring and voltage regulator wiring for loose connections or shorts. Check fuse F 1 (16). (2) With generator running, disconnect batteries leaving 12 ohm resistor load in circuit to generator. The alternator should provide a dc voltage between 24 and 28.5 volts. c. Removal.
PAGE 113
TM 5-6115-585-34 NAVFAC P-8-623-34 TO-35C2-3-455-2 TM-05684C/05685B-34 d. Clean and Inspect. Clean blower wheel, stator and rotor with clean dry cloth. Inspect stator and rotor for signs of friction wear. Check stator wires for breaks, looseness and good insulation. e. Test. (1) Rotor. The rotor is a permanent magnet assembly and should not deteriorate. (2) Stator. Using an ohmmeter, check the stator for open circuitry. High pot test the stator to ground for short circuits at 1070 volts. f. Install.
PAGE 114
TM 5-6115-585-34 NAVFAC P-8-623-34 TO-35C2-3-455-2 TM-05684C/05685B-34 1. Compressor tester gage 2. Nut (2) 3. Compression adapter mounting studs (2) 4. Washer (2) 5. Retainer flange 6. Compression adapter 7. Gasket 8. Adapter 9. Gasket 10. Heat shield 11. Gasket 12. Cylinder injection opening 13. Cylinder head Figure 7-8.1.
PAGE 115
TM 5-6115-58S-34 NAVFAC P-8-623-34 TO-35C2-3-455-2 TM-05684C/05685B-34 7-9. CYLINDER HEAD. a. Removal (see figure 7-9). (1) Remove. Refer to the Operator and Organizational Maintenance Manual and remove air shutter assembly and intake and exhaust manifold, muffler and shroud assembly. Remove engine lifting bracket, rocker cover and gasket, fuel nozzles, and connecting oil lines to cylinder head.
PAGE 116
TM5-6115-585-34 NAVFAC P-8-623-34 TO-35C2-3-455-2 TM-05684C/05685B-34 Figure 7-9. Cylinder Head Removal 7-10.
PAGE 117
TM5-6115-585-34 NAVFAC P-8-262-12 TO-35C2-3-455-2 TM-05684C-34 Figure 7-10.
PAGE 118
TM5-6115-585-34 NAVFACP-8-262-12 TO-35C2-3-455-2 TM-05684C-34 Figure 7-11.
PAGE 119
TM5-6115-585-34 NAVFAC P-8-623-34 TO-35C2-3-455-2 TM-05684C/05685B-34 Be careful not to cut into counterbore bottom. See figure 7-12. Thoroughly clean valve seat counterbore and remove’ any burrs from the edges. Drive new valve seat inserts into place. Be certain that each seat rests solidly on bottom of counterbore at all points. To make installation easier, heat cylinder head in an oven at 325°F (163°C) for about l/2-hour. Face each new seat to a 45° angle.
PAGE 120
TM5-6115-585-34 NAVFACP-8-623-34 TO-35C2-3-455-2 TM-05684C/05685B-34 Figure 7-13.
PAGE 121
TM5-6115-585-34 NAVFACP-8-262-12 TO-35C2-3-455-2 TM-05684C-34 Figure 7-14.
PAGE 122
TM5-6115-585-34 NAVFACP-8-262-12 TO-35C2-3-455-2 TM-05684C-34 7-16 Figure 7-15.
PAGE 123
TM5-6115-585-34 NAVFAC P-8-262-12 TO-35C2-3-455-2 TM-05684C-34 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Oil base Gasket Screw (10) Lockwasher (10) Washer (10) Bolt (8) Bearing (8) Cap (4) Connecting rod (4) Piston assembly (4) Front camshaft bearing 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. Center cam-shaft bearing Rear camshaft bearing Plug Retaining ring Crankshaft washer Crankshaft gear Packing Rear bearing plate Screw (6) Lockwasher (6) Crankshaft end bearing (2) Gasket 24. 25. 26. 27. 28. 29. 30.
PAGE 124
TM5-6115-585-34 NAVFAC P-8-262-12 TO-35C2-3-455-2 TM-05684C-34 If pin is excessively loose, install a new piston and pin assembly. NOTE Piston and pins are matched sets and are not procured separately. (3) Rings. Place each piston ring into its cylinder bore and using a feeler gauge measure gap dimensions. Gap is shown in Table l-2 If gap is under 0.010 inch, file as follows: (a) Place file in vise. (b) Grasp piston ring in both hands.
PAGE 125
TM5-6115-585-34 NAVFAC P-8-262-12 TO-35C2-3-455-2 TM-05684C-34 NOTE After installation of new connecting rod or main bearings, clearances should be checked using plastic gauge. (5) Install oil base (1, figure 7-15) with a new gasket (2) using screws (3), lockwasher (4) and washer (5). (6) Install cylinder heads using proper bolt tightening sequence (see figure 7-13). 7-11. OIL PUMP. a. Remove. (1) Refer to paragraph 7-14 and remove gear cover.
PAGE 126
TM5-6115-585-34 NAVFACP-8-262-12 TM-05684C-34 T O - 3 5 C 2 - 3 - 4 5 5 - 2 7-20 Figure 7-19.
PAGE 127
TM5-6115-585-34 NAVFAC P-8-262-12 TO-35C2-3-455-2 TM-05684C-34 1. 2. 3. 4. 5. 6. 7. 8. 9. Gear cover Gasket Screw (4) LockWasher (4) Washer (4) Screw Lockwasher Oil base Gasket 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. oil pump Oil cup assembly Bracket Lockwasher Screw Lock ring Washer Gear Screw (2) Lockwasher (2) 21. 22. 23. 24. 25. 26. 27. Back plate Rear bearing plate Oil by-pass valve Screw (2) Screw (2) Lockwasher (4) Oil filter adapter Gasket TS 6115-585-34/7-19 (2) Figure 7-19.
PAGE 128
TM5-6115-585-34 NAVFACP-8-262-12 TO-35C2-3-455-2 TM-05684C-34 7-22 Figure 7-21.
PAGE 129
TM5-6115-585-34 NAVFAC P-8-262-12 TO-35C2-3-455-2 TM-05684C-34 Figure 7-21. Figure 7-22.
PAGE 130
TM5-6115-585-34 NAVFAC P-8-262-12 TO-35C2-3-455-2 TM-05684C-34 cover (6) to crankcase. Tape crankshaft keyway to prevent damage to seal. To loosen gear cover, tap it with a soft hammer. Remove gasket (7). board so seal boss is supported. Insert new seal from inside with rubber lip and closed case toward outside of gear cover and drive it flush with outside surface, d. Reassemble. c. Disassemble and Inspect. (1) Governor Shaft (see figure 7-22).
PAGE 131
TM5-6115-585-34 NAVFAC P-8-623-34 TO-35C2-3-455-2 TM-05684C/05685B-34 e. Install (see figure 7-21). with (1) Pack the cavity between the two oil seal lips grease per MIL-G-23827. (2) Tape keyway and sharp edges on crankshaft to protect the oil seal during installation. (3) Mount gear cover (6) on engine using new and flatwasher (3). Tighten mounting screws to specified torque. See table 1-1. Before tightening screws, be sure stop pin is in governor hole.
PAGE 132
TM5-6115-585-34 NAVFAC P-8-623-34 TO-35C2-3-455-2 TM-05684C/05685B-34 (12) Remove back plate (22) and gasket (23) by removing screws (19), screws (21) and lockwashers (20). (13) Camshaft Bearings. The camshaft bearings (25, 26 and 27, figure 7-21) should be replaced if clearance to camshaft is greater than specified, bearings show cracks breaks, burrs, excessive wear, or other defects. The camshaft to bearing clearance should be 0.0012 to 0.0037 inch.
PAGE 133
TM5-6115-585-34 NAVFAC P-8-262-12 TO-35C2-3-455-2 TM-05684C-34 Figure 7-26. Crankshaft and Camshaft Gear Timing Marks (12) Refer to Operator and Organizational Maintenance Manual and install rocker arm covers. (13) Refer to paragraph 2-9 and install engine. (14) Refer to Operator and Organizational Maintenance Manual and install blower housing. Figure 7-27. Timing Gear Backlash 7-17. CRANKSHAFT AND MAIN BLOCK BEARINGS. a. Removal (see figure 7-15). (8) Refer to paragraph 7-10 and remove oil base.
PAGE 134
TM5-6115-585-34 NAVFAC P-8-262-12 TO-35C2-3-455-2 TM-05684C-34 Figure 7-28. Crankshaft Gear Removal (14) Remove center main bearing housing (29) and center bearings (31 and 32) and remove crankshaft (33) through rear opening in crankcase. Figure 7-29. Crankshaft Peening (4) Mask off connecting rod bearing areas. b. Clean and Inspect. d. Installation. (1) Crankshaft. Clean crankshaft and blowout all oil passages. Check journals for out-of-round, taper, grooving or ridges.
PAGE 135
TM5-6115-585-34 NAVFAC P-8-623-34 TO-35C2-3-455-2 TM-05684C-34 Figure 7-30. Crankshaft Bearing Installation during installation. Mount and secure rear bearing plate (19). (7) Check crankshaft end play (see figure 7-31). Use enough rear bearing plate shims to provide 0.010 to 0.015 inch end play. If more than 0.010 inch total thickness is required then use a steel shim of proper thickness and an 0.005 inch thick gasket on each side of shim. This avoids excessive gasket compression and maintains bolt torque.
PAGE 136
TM5-6115-585-34 NAVFAC P-8-623-34 TO-35C2-3-455-2 TM-05684C/05685B-34 (14) Refer to paragraph 7-8 and install alternator stator. (15) Refer to paragraph 7-7 and install blower wheel. (16) Refer to paragraph 7-9 and install cylinder heads. (17) Refer to Operator and Organizational Maintenance Manual and install blower housing. 7-18. FUEL INJECTION PUMP. a. Removal (see figure 7-32).
PAGE 137
TM5-6115-585-34 NAVFACP-8-623-34 TO-35C2-3-455-2 TM-05684C/05685B-34 Figure 7-33A Change 6 7-31
PAGE 138
TM5-6115-585-34 NAVFACP-8-623-34 TO-35C2-3-455-2 TM-05684C/05685B-34 7-32 Figure 7-34.
PAGE 139
TM5-6115-585-34 NAVFAC P-8-262-12 TO-35C2-3-455-2 TM-05684C-34 1. Retaining plate screw (2) 2. Tab washer (2) 3. Control unit retaining plate and stop assembly 4. Control unit assembly 5. Plunger sleeve pin 6. Pump housing 7. Cap nut 8. Gasket 9. Delivery valve holder 10. Valve spring 11. Delivery valve assembly 12. Valve spacer 13. Locating screw 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26.
PAGE 140
TM5-6115-585-34 NAVFAC P-8-262-12 TO-35C2-3-455-2 TM-05684C-34 Figure 7-36. Delivery Valve Test Assembly (a) Insert the delivery valve spring (1) and the delivery valve holder (2). Tighten the delivery valve holder to a torque of 70-75 ft-lbs. Figure 7-36 illustrates the components that are to be assembled to test fixture TSE 76226 (3). (b) Attach test fixture TSE 76226 (3) to a manually operated Nozzle Test Stand.
PAGE 141
TM5-6115-585-34 NAVFAC P-8-262-12 TO-35C2-3-455-2 TM-05684C-34 (10) Plunger sleeve pin (5) must fit snug but must be free to rotate in control unit assembly. NOTE New part clearance is 0.0002-0.00081". If clearance exceeds 0.0015”, replace control unit assembly. d. Reassembly (see figure 7-34). NOTE Replace all copper and “O" ring gaskets. (1) After all parts have been thoroughly cleaned and inspected and after all worn units have been replaced, dip the individual parts in clean fuel oil.
PAGE 142
TM5-6115-585-34 NAVFAC P-8-262-12 TO-35C2-3-455-2 TM-05684C-34 (4) Apply a thin coat of petroleum jelly to the thrust washer (29, figure 7-34) and assemble it to the hub on the face gear (28). (5) Carefully center spring ring (27) on hydraulic head assembly. (6) Position the face gear (28) and thrust washer (29) over the end of the plunger and align the head of the plunger sleeve pin with its mating slot located on the inside of the face gear (28).
PAGE 143
TM 5-6115-585-34 NAVFAC P-8-623-34 TO-35C2-3-455-2 TM-05684C/05685B-34 (20) Place pump in horizontal position with control unit bore (36 ) facing up. (21 ) Center the plunger sleeve (34) in the control unit bore (36 ). Position plunger sleeve pin (5) so that the flats align with the groove in the control sleeve (34) and the electric pencil mark (dot ) faces the top of the pump. (22 ) Insert control unit assembly (4) into housing (6), pressing gently until control unit seats. Do not use force.
PAGE 144
TM 5-6115-585-34 NAVFAC P-8-623-34 TO-35C2-3-455-2 TM-05684C/04685B-34 NOTE A fuel inlet stud can be fabricated with a 1/4” .18 NPT pipe die. High pressure tubing must be used between the Nozzle Test Stand and the pump assembly. NOTE Always check to make sure that all external connections are tight and that the Nozzle Test Stand is in good order. (8) Slowly operate the Nozzle Test Stand until a pressure of 400 psi is achieved. A rapid drop in pressure indicates that a leak is present.
PAGE 145
TM5-6115-585-34 NAVFAC P-8-262-12 TO-35C2-3-455-2 TM-05684C-34 (2) Timing Method 1. This is a means for calculating the correct button thickness before the pump is installed. It requires the port closing dimensions and button thickness from the pump being replaced. Substitute the dimensions for those in the formula below and calculate the new button thickness. Determine the button code letter from table 7-1. NOTE Always use button thickness closest to this dimension.
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TM5-6115-585-34 NAVFAC P-8-262-12 TO-35C2-3-455-2 TM-05684C-34 Table 7-1. Button Code Letter and Size Code No. Or Letter Part No. Size 16 s 147A186 0.134 15 R 147A187 0.131 14 P 147A188 0.128 13 N 147A189 0.125 12 M 147A190 0.122 1 A 147A147 0.119 2 B 147A148 0.116 3 c 147A149 0.113 4 D 147A150 0.110 5 E 147A151 0.107 (b) Remove delivery valve cap nut and delivery valve holder (figure 7-43).
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TM5-6115-585-34 NAVFAC P-8-623-34 TO-35C2-3-455-2 TM-05684C/05685B-34 properly. The delivery valve holder must be assembled with a twelve point wrench, and retorqued to 70-80 ft-lbs dry. The cap nut must be retroqued to 55-60 ft-lbs dry. On ASK equipped generators, refer to Operator and Organizational Maintenance Manual and install right panel and top panel assemblies. 7-19. CYLINDER BLOCK. (1) Steam clean cylinder block to remove deposits of oil and dirt.
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TM5-6115-585-34 NAVFACP-8-623-34 TO-35C2-3-455-2 TM-05684C/05685B-34 Figure 7-45.
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TM5-6115-585-34 NAVFAC P-8-623-34 TO-35C2-3-455-2 TM-05684C/05685B-34 sharp tools, emery paper, grinding powder, or abrasives of any kind. If necessary, clean outer surfaces of nozzle body (9) with a brass brush but, do not attempt to scrape carbon from nozzle surfaces, because severe damage to spray hole can result. Use a soft, oil soaked cloth to clean nozzle valve. Clean interior of nozzle cap nut. f. Inspect. Inspect tappet surfaces of injector body for nicks or roughening.
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TM5-6115-585-34 NAVFAC P-8-623-34 TO-35C2-3-455-2 TM-05684C/05685B-34 (3) Mount injector in a suitable holding fixture. (4) Assemble valve (7) and nozzle (9) and install on body (15). (5) Install nozzle cap nut (12) loosely. When tightening nozzle cap nut do not contact nozzle valve (7). (6) Place centering sleeve TSE 773 over nozzle for initial tightening.
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TM5-6115-585-34 NAVFAC P-8-623-34 TO-35C2-3-455-2 TM-05684C/05685B-34 CHAPTER 8 MAINTENANCE OF GENERATOR ASSEMBLY Section I. DESCRIPTION AND FUNCTION 8-1. GENERAL. Refer to Operator and Organizational Maintenance Manual for description and function of the generator. Section II. MAINTENANCE 8-2. GENERATOR MAINTENANCE. a.
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TM5-6115-585-34 N A V F A C P - 8 - 6 2 3 - 3 4 TO-35C2-3-455-2 TM-05684C/05685B-34 Figure 8-1.
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TM5-6115-585-34 NAVFAC P-8-623-34 TO-35C2-3-455-2 TM-05684C/05685B-34 1. Screw (2) 2. Nut (2) 3. Lockwasher (2) 4. Screen 5. Screw (4) 6. Lockwasher (4) 7. Cover 8. Screw (4) 9. Lockwasher (4) 10. Screw (8) 11. Lockwasher (8) 12. Packing 13. End bell assembly 14. Screw (4) 15. Lockwasher (4) 16. End bell 17. Stator assembly 18. Nut (2) 19. Screw (2) 20. Terminal board 21. Screw (8) 22. Lock plate (4) 23. Pressure plate (4) 24. Screw (8) 25. Lock plate 26. Ring 27. Disk 28. Fan 29. Screw 29A.
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TM5-6115-585-34 NAVFAC P-8-623-34 TO-35C2-3-455-2 TM-05684C/05685B-34 period of time. The applied voltage must not be so high as to injure the insulation unless the insulation was initially defective. (5) Results, Any evidence of insulation breakdown is cause for replacement of the equipment under test. (2) Apparatus. Use acceptable high potential test apparatus, following the operating instructions of the manufacturer. f. Winding Resistance Test. Perform winding re- (3) Procedure.
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TM5-6115-585-34 NAVFAC P-8-623-34 TO-35C2-3-455-2 TM-05684C/05685B-34 j. Reassembly. (1) Install diodes (42and43, figure 8-l) on heat sink and secure with lockwashers (41) and nuts (40). (2) For MEP-003, assemble shaft collar (34), bearing retainer (33), bearing (32) to the generator shaft using screw (29), lockwasher (30) and flatwasher (31).
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TM5-6115-585-34 NAVFAC P-8-262-12 TO-35C2-3-455-2 TM-05684C/05685B-34 (5) Mount coupling disc and fan assembly to the rotor assembly (52, MEP-113A, or 52A, MEP-112A) using screw (24) lock plate (25) and retaining ring (26). Bend lock tabs flat against head of screw (24). (6) Mount exciter stator (17) to end bell (16) using screws (14) and lockwashers (15). (7) Place “O” ring (12) into end bell bearing housing, attach terminal board (20) to the exciter stator using screws (19) and nuts (18).
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TM5-6115-685-34 NAVFACP-8-623-34 TO-35C2-8-455-2 TM-05684C/05685B-34 Figure 8-3.
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TM5-6115-585-34 NAVFACP-8-623-34 TO-35C2-3-455-2 TM-05684C/05685B-34 Figure 8-3.1. Change 2 8-8.1/(8-8.
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TM5-6115-585-34 NAVFACP-8-262-12 TO-35C2-3-455-2 TM-05684C-34 Figure 8-4.
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TM5-6115-585-34 NAVFACP-8-623-34 TO-35C2-3-455-2 TM-05684C/05685B-34 Figure 8-5.
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TM5-6115-585-34 NAVFACP-8-623-34 TO-35C2-3-455-2 TM-05684C/05685B-34 Figure 8-5.1.Generator Rotor Winding Data (MEP-112A) Change 2 8-12.1/(8-12.
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TM5-6115-585-34 NAVFAC P-8-623-34 TO-35C2-3-455-2 TM-05684C/05685B-34 CHAPTER 9 GENERATOR SET TEST AND INSPECTION AFTER REPAIR OR OVERHAUL Section I. GENERAL REQUIREMENTS 9-1. GENERAL INFORMATION, The activity performing the repair or overhaul is responsible for the performance of all applicable tests and inspections specified herein.
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TM5-6115-585-34 NAVFACP-8-623-34 TO-35C2-3-455-2 TM-05684C/05685B-34 Table 9-1. Test Schedule Test Test Method (MIL-STD-705) Instrument Requirements 513. 1C Accuracy shall be as follows: Record only the readings of the master and panel instruments at no-load, 50’% and 100% of rated load. Record the readings of the master and panel instruments at all voltage connections. Current indicator system, 10% max. Voltage indicator system - Initial accuracy 2.
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TM5-6115-585-34 NAVFAC P-8-262-12 TO-35C2-3-455-2 TM-05684C-34 (d) S2-open. (2) Place master switch in preheat position. Lamps L2 and L3 shall light indicating that the preheat circuitry is correct. (3) Place master switch in start position. Lamps L1, L2, L3, L4, L5 and L6 shall light indicating that all circuits for starting are correct. (4) With the master switch in the start position, open switch S1, lamp L1 shall extinguish indicating that the start disconnect circuitry is correct.
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TM 5-6115-585-34 NAVFAC P–8-623-34 TO 35C2-3-455-2 TM-05684C/05685B-34 CHAPTER 10 MATERIEL USED IN CONJUNCTION WITH DOD STANDARD GENERATOR 10KW DIESEL ENGINE DRIVEN, MODELS MEP-003A AND MEP-112A SET , Section I. 10-1. AUXILIARY EQUIPMENT GENERAL . This chapter describes all Direct Support procedures for auxilliary equipment (kits) which are used in conjunction with the generator set.
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TM 5-6115-585-34 NAVFAC P-8-623-34 TO 35C2-3-455-2 TM–05684C/05685B–34 SECTION II. 10-2. ACOUSTIC SUPPRESSION KIT INSTALLATION ACOUSTIC SUPPRESSION KIT. The 10K Acoustic Suppression Kit (ASK) is installed on generator sets in either the skid or trailer configuration. For the trailer mounted configuration, the ASK is installed on the Table trailer at the approximate location shown in figure 10-1. All required mounting .0-1 lists ASK parts and related hardware.
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TM 5-6115-585-34 NAVFAC P-8-623-34 TO 35C2-3-455-2 TM–05684C/05685B–34 Table 10-1. Item Acoustic Suppression Kit Parts and Required Hardware (Cent) Assembly Related Hardware Qty 7. Exhaust Plenum (W/hose & hose clamp) (13, fig. 10-4) 45° elbow 1-1/4” l/4"-20x3/4LG Hex Cap Screw 1/4” Washer 1/4” Locknut 2 4 8 4 8. Left Panel (Short Side) (2, fig. 10-6) Battery Terminal Covers Adhesive Backed Teflon Tape 4 1 a. Attaches to Left Support Assembly l/4"-20x3/4LG Hex Cap Screw 1/4” Washer 4 4 b.
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TM 5-6115-585-34 NAVFAC P-8-623-34 TO 35C2-3-455-2 TM–05684C/05685B–34 Figure 10-1.
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TM 5-6115-585-34 NAVFAC P-8-623-34 TO 35C2-3-455-2 TM–05684C/05685B-34 10-3. PRELIMINARY PROCEDURES. Prior to ASK installation, perform the following procedures: a. Refer to Operator and Organizational Maintenance Manual,paragraph 4-17, and remove the grille (30) from the engine blower housinq. Store qrille and attaching hardware at owning units facility. b. When ASK installation is to be performed on trailer mounted generator sets, ensure that generator set ground is connetted to trailer ground. c.
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TM 5-6115-585-34 NAVFAC P-8-623-34 TO 35C2-3-455-2 TM-05684C/05685B-34 Figure 10-2.
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TM 5-6115-585-34 NAVFAC P-8-623-34 TO 35C2-3-455-2 TM–05684C/05685B–34 (4) Cut a 61 in. length of adhesive backed teflon tape (as listed in Table 10-1, item 1). Apply adhesive backed teflon tape to a clean right support assembly top surface (surface that mounts against underside of skid frame). Use hand pressure to remove air bubbles. Clear teflon tape away from screw slots.
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TM 5–6115-585-34 NAVFAC P-8–623-34 TO 35C2-3–455-2 TM–05684C/05685B–34 Figure 10-3.
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TM 5-6115-585-34 NAVFAC P-8-623-34 TO 35C2-3-455-2 TM–05684C/05685B–34 CAUTION When drilling holes, care must be taken not to damage fuel lines. (1) Refer to figure 10-2, detail B and drill one 5/16 inch guide hole (12) in generator set control cubicle support frame (13) at location shown. (2) Using rear panel assembly (14) as template, align drilled guide hole (12) with bottom left rear panel assembly hole and mark location of three remaining holes in generator set control cubicle support frame (13).
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TM 5-6115-585-34 NAVFAC P-8-623-34 TO 35C2-3-455-2 TM–05684C/05685B–34 CAUTION When drilling holes, care must be taken not to damage control cubicle. (2) Refer to figure 10-4 and locate rear closure asSeat clips (3A) of rear sembly (1) behind mounting brackets (3). closure assembly (1) over mounting brackets (3), so that rear closure assembly (1) is positioned over vibration mount hardware. When positioned correctly, the rear closure assembly (1) is 1/4 inch higher than top of control cubicle (2).
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TM 5-6115-585-34 NAVFAC P-8-623-34 TO 35C2-3-455-2 TM-05684C/05685B-34 Figure 10-4.
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TM 5-6115-585-34 NAVFAC P-8-623-34 TO 35C2-3-455-2 TM-05684C/05685B–34 shutter assembly (15) with four screws (17), eight washers (18 and 19), and four locknuts (20) (listed in table 10-1, item 7). (5) (6) engine block. g. Torque screws (17) to 16 ±2 ft-lbs dry. Route drain hose (11) between batteries and Right Panel Assembly (Long Side). (1) Refer to figure 10-5 and clear out acoustic fill from holes in right panel assembly (1) using 3/8 inch diameter pin.
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TM 5–6115-585-34 NAVFAC P-8-623-34 TO 35C2-3-455-2 TM-05684C/05685B–34 Figure 10-5.
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TM5-6115-585-34 NAVFAC P-8-623-34 TO 35C2-3-455-2 TM-05684C/05685B-34 Figure 10-6.
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TM 5-6115-585-34 NAVFAC P-8-623-34 TO 35C2-3-455-2 TM-05684C/05685B–34 terminals; 2 red terminal covers for positive battery terminals and 2 black terminal covers for negative battery terminals (as listed in Table 10-1, item 8). Reconnect cable clamps to battery terminals. Cover cable clamps with terminal covers (3). (3) Clear out acoustic fill from holes in left panel assembly (2) using 3/8 inch diameter pin. (4) Cut a 20 1/2 in. length and a 29 1/4 in.
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TM 5-6115-585-34 NAVFAC P-8–623-34 TO 35C2-3-455-2 TM–05684C/05685B–34 k. Top Panel Assembly. Refer to figure 10-6 and clear out acoustic fill (1) from holes in top panel assembly (24) using 3/8 inch diameter pin. Locate top panel assembly (24) by aligning holes (2) in top panel assembly (24) with captive nuts in left panel assembly (2), right panel assembly (21) and front panel assembly (20), and with holes in side closure assembly (4) and rear closure assembly (15).
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TM5-6115-585-34 NAVFAC P-8-262-12 TO-35C2-3-455-2 TM-05684C-34 APPENDIX A REFERENCES 1. PAINTING: T.O. 35-1-3 Painting and marking of USAF Aerospace Ground Equipment. 2. RADIO SUPPRESSION: MIL-STD-461 Radio Interference Suppression. 3. MAINTENANCE: T.O. 00-25-225 T.O. 00-25-235 T.O. T.O. T.O. T.O. 1-1-1 1-1-2 31-1-75 35-1-11 T.O. 35-1-12 T.O. 35-1-26 T.O. 35-1-524 T.O. 34Y19-1-111 AFM 66-1 T.O. 35C2-3-1-426 Repair of External Power Cables, Aerospace Ground Equipment.
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TM5-6115-585-34 NAVFACP-8-623-34 TO-35C2-3-455-2 TM-05684C/05685B-34 ALPHABETICAL INDEX Paragraph, Figure, Table, Number Subject A 6-2 AC Instrumentation stem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Acoustic Suppression Kit, Tabulated Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Acoustic Suppression Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . .
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TM5-6115-585-34 NAVFAC P-8-262-12 TO-35C2-3-455-2 TM-05684C-34 ALPHABETICAL INDEX (CONT) Paragraph, Figure, Table, Number Subject E (CONT) Engine Control Circuitry Test . . . . . . . . . . . . . . . . . . . . . . Exciter Rotor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Winding Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . External Governor and Speed Control . . . . . . . . . . . . . . . . . . . . . . . . 9-6, F9-2 . . . . . . . . . . . . . . . . . .
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TM5-6115-585-34 NAVFAC P-8-262-12 TO-35C2-3-455-2 TM-05684C-34 ALPHABETICAL INDEX (CONT) Paragraph, Figure, Table, Number Subject L . . . . . 1-5 2-3 F2-4 T6-4 F7-35 Manual Limited Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance Forms and Records . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 1-1 1-3 Levels of Maintenance Accomplishment . . . . . . . . . . . . . . . .
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TM5-6115-585-34 NAVFAC P-8-262-12 TO-35C2-3-455-2 TM-05684C-34 ALPHABETICAL INDEX (CONT) Paragraph, Figure, Table, Number Subject T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 T9-1 F7-27 F7-4, F7-44 T1-1 2-4, T2-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-12 F7-10 6-3, 6-6 F6-5 F6-4 Wiring Harnesses, Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4 Tabulated Data . . . . . . . . . . . . . . . . . . . . . . . . . .
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TM 5-6115-585-34 NAVFAC P-8-262-12 TO 35C2-3-455-2 TM 05684C-34 By Order of the Secretaries of the Army, the Navy, and the Air Force: BERNARD W. ROGERS General, United States Army Chief of Staff Official: PAUL T. SMITH Major General, United States Army The Adjutant General D. G. ISELIN Rear Admiral, CEC, U. S. Navy Commander, Naval Facilities Engineering Command Official: DAVID C. JONES, General, USAF Chief of Staff JAMES J. SHEPARD, Colonel, USAF Director of Administration W. R.
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PIN: 033750-000