TM-5-6115-585-34 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-5-6115-585-34

Chapter 1 Introduction
Section Ii. Description And Tabulated Data
Engine Accessories
Table 1-1. Torque Values (Ft-Lb Dry)
Table 1-1. Torque Values (Ft-Lb Dry) (Cont’d)
Table 1-2. Repair And Replacement Standards
Table 1-2. Repair And Replacement Standards (Cont)
Table 1-2. Repair And Replacement Standards (Cont)
Table 1-2. Repair And Replacement Standards (Cont)
Table 1-2. Repair And Replacement Standards (Cont)
Figure 1-1. Generator Set Electrical Schematic
Figure 1-1.1. Genarator Set Electrical Schematic
Table 2-1. Special Tools, Test And Support Equipment
Table 2-2. Fabricated Tools And Equipment
Table 2-2. Fabricated Tools And Equipment (Cont)
Table 2-2. Fabricated Tools And Equipment (Cont)
Section Ii. Troubleshooting
Table 2-3. Troubleshooting
Table 2-3. Troubleshooting (Cont)
Table 2-3. Troubleshooting (Cont)
Table 2-3. Troubleshooting (Cont)
Table 2-3. Troubleshooting (Cont)
Table 2-3. Troubleshooting (Cont)
Section Iii. General Maintenance
Figure 2-1. Speed Control Assembly
Figure 2-2. Disconnecting Engine From Generator
Figure 2-3. Lifting Engine
Generator Assembly
Figure 2-4. Lifting Engine And Generator Assembly
Chapter 3 Maintenance Of Cooling System
Figure 3-1. Engine Cooling System
Test.
Chapter 4 Maintenance Of Fuel System
Section I Description And Function
Figure 5-1. Electrical Starter Assembly Style I
Figure 5-2. Electrical Starter Assembly Style Ii
Figure 5-3. Pinion Gear Stopper Removal
Figure 5-4. Testing Armature For Grounds
Figure 5-8. Checking Armature Shaft Runout
Figure 5-9. Testing Brush Spring Tension Style I Starter Only
Figure 5-10. Testing Solenoid Switch
Reassembly Style I Starter
Figure 5-12. Brush Replacement Style I Starter Only
Figure 5-13 Checking Pinion Clearance Style I Starter
Figure 5-14. Checking Pinion Travel Style Ii Starter
Chapter 6 Maintenance Of Control System
Figure 6-1. Control Cubicle Wiring Harness
Table 6-1. Control Cubicle Wiring Harness
Table 6-1. Control Cubicle Wiring Harness (Cont)
Table 6-2. 10kw Generator Set Wiring Harness
Figure 6-2. Generator Set Wiring Harness
Table 6-3. Ac Output Control Box Wiring Harness (Mep-003a Only)
Table 6-3. Ac Output Control Box Wiring Harness (Mep-003a Only) (Cont)
Table 6-3.1. Ac Output Control Box Wiring Harness (Mep-112a Only)
Table 6-3.1. Ac Output Control Box Wiring Harness (Mep-112a Only)
Ac Output Control Box Wiring Harness
Figure 6-3. Control Cubilcle (Sheet 1 Of 2)
Figure 6-3. Control Cubicle (Sheet 2 Of 2)
Figure 6-4. Testing Voltage Regulator
Figure 6-5. Ac Voltage Regulator Schematic
Figure 6-5.1. Ac Voltage Regulator Schematic
Figure 6-7. Ac Output Control Box Test Setup
Table 6-5. Reconnection Switch Continuity
Figure 6-7.1. Cvt And Ct Wiring
Figure 6-8. Ac Control Box Removal
Table 6-6. Testing Bridge Assembly (60 Hz Only)
Figure 6-9 Output Control Assembly (Sheet 1 Of2)
Figure 6-9. Ac Output Control Assembly (Sheet 2 Of 2)
Figure 6-10. Ac Output Control Assembly (Switch, Receptacle And Circuit Breaker)
Figure-6-10.1 Switch Assembly, Rotary
Figure 6-10.2 Switch Assembly, Rotary
Figure 6-11. Bridge Rectifier Assembly A-4
Chapter 7 Maintenance Of Engine
Figure 7-1. Injector Fuel Lines
Figure 7-2. Speed Control Assemlby And Governor Control Assemlby
Figure 7-3. Engine Flywheel And Ring Gear Assembly
Figure 7-3.1. Governor Linkage Adjustment
Figure 7-6. Testing Oil Cooler
Figure 7-7. Battery Charge Alternator And Blower Wheel
Figure 7-8. Resistively Loading The Batteries
Section Iii. Engine Internal Assemblies
Figure 7-8.1. Testing Engine Compression
Cylinder Head
Figure 7-9. Cylinder Head Removal
Figure 7-10. Valve Spring Removal
Figure 7-11. Cylinder Head Assembly
Figure 7-12. Valve Seat Replacement
Figure 7-13. Cylinder Head Bolt Tightening Sequence
Figure 7-14. Piston And Connecting Rod
Figure 7-15. Crankshaft Pistons And Connecting Rod (Sheet 1 Of 2)
Figure 7-15. Crankshaft Pistons And Connecting Rod (Sheet 2 Of 2)
Figure 7-17. Connecting Rod And Bushings
Figure 7-18. Connecting Rod Installation
Figure 7-19. Oil Pump Removal (Sheet 1 Of 2)
Figure 7-19. Oil Pump Removal (Sheet 2 Of 2)
Figure 7-21. Internal Engine Assemlby (Sheet 1 Of 2)
Figure 7-22. Gear Cover Components
Figure 7-23. Gear Cover Inspection
Figure 7-24. Governor Cup Assembly
Figure 7-25. Camshaft Bearing Installation
Figure 7-27. Timing Gear Backlash
Figure 7-28. Crankshaft Gear Removal
Figure 7-30. Crankshaft Bearing Installation
Figure 7-32. Injection Pump
Figure 7-33a. Pump Installed
Figure 7-34. Disassembly Of Fuel Injection Pump (Sheet 1 Of 2)
Figure 7-34. Disassembly Of Fuel Injection Pump (Sheet 2 Of 2)
Figure 7-36. Delivery Valve Test Assembly
Figure 7-37. Inspecting Tappet
Figure 7-39. Control Unit Assembly
Figure 7-40. Checking Plunger Sleeve Alignment
Figure 7-42. Injection Pump Installation
Figure 7-43. Delivery Valve
Table 7-1. Button Code Letter And Size
Cylinder Block.
Figure 7-45. Injector Nozzle Removal
Figure 7-46. Fuel Injector
Figure 7-47. Centering Sleeve Installation
Section Ii. Maintenance
Figure 8-1. Generator Exploded View (Sheet 1 Of 2)
Figure 8-1. Generator Exploded View (Sheet 2 Of 2)
Testing Generator Stator
Figure 8-2. Testing Exciter Rotor
Reassembly.
Figure 8-3. Generator Frame Assembly Winding Data
Figure 8-3.1. Genarator Frame Assembly Winding Data
Figure 8-4.Exciter Rotor Assembly Winding Data
Figure 8-5. Generator Rotor Winding Data
Figure 8-5.1.Generator Rotor Winding Data
Section Iii. Operational Tests
Figure 9-1. Adjusting R3 Resistor
Test Procedure.
Section I. Auxiliary Equipment
Section Ii. Acoustic Suppression Kit Installation
Table 10-1. Acoustic Suppression Kit Parts And Required Hardware
Figure 10-1. Relocation Of Trailer Items To Accommodate Ask Installation
Preliminary Procedures
Figure 10-2. Installation Of Right Support Assembly, Rear Panel Assembly, And Rear Flap Assembly
Left Support Assembly
Figure 10-3. Installation Of Left Support Assembly
Rear Flap Assembly
Exhaust Plenum Assembly
Figure 10-4. Installation Of Rear Closure Assembly And Exhaust Plenum Assembly
Right Panel Assembly (Long Side)
Figure 10-5. Installation Of Right Panel Assembly
Figure 10-6. Installation Of Left Panel, Side Closure, Front Panel And Top Panel Assemblies
Front Panel Assembly
Top Panel Assembly
Appendix A References
Alphabetical Index
Alphabetical Index (Cont)
Alphabetical Index (Cont)
Alphabetical Index (Cont)

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