Section III. GENERAL MAINTENANCE

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. This section contains general maintenance instruc- tions which are the responsibility of direct support and general support maintenance personnel. You will find that these instructions apply to several assem- blies or components. They would otherwise have to be repeated throughout the chapter. 2-7. GENERAL MAINTENANCE PROCEDURES, a. Work Guidelines. (1) Make sure the work area is clean before you disassemble the pump or engine. (2) Make sure that materials needed for the maintenance task are at hand. These may include cleaning solvents, lubricants, buckets, or other con- tainers for cleaning or keeping components separated, clean wiping cloths, and, of utmost importance, the proper tools. DRY CLEANING SOLVENT, P-D-680 or P-S- 861, used to clean parts is potentially danger- ous to personnel and property. Avoid repeated and prolonged skin contact. DO NOT use near open flame or excessive heat. Flash point of solvent is 100º to 138° F (38° to 60° C). (3) Clean the exterior of the engine and pump before disassembly to keep foreign matter from bearings, gears, and other machine-surfaced parts which are subject to scoring and other such damage. Use a cloth dampened with cleaning solvent (fed. spec. P-D-680). Compressed air used for cleaning and drying purposes can create airborne particles that may enter the eyes. Pressure shall not exceed 30 psig and use only with adequate chip guards and goggles. (4) If compressed air is used to clean parts, you should make sure it is free of dirt and other con- taminants. (5) Protect disassembled parts from dust, blowing sand, and moisture which can cause rapid wear and deterioration of bearings, gears, and other machine parts. b. Seals and Gaskets. Replace seals and gaskets of all components disassembled. This will greatly reduce the possibility of leaking and will help prevent the entry of dust and dirt after reassembly. c. Care of Bearings. (1) Clean ball and roller bearings by placing them in a wire basket and immersing in a container of fresh cleaning solvent. Agitate the bearings in the solvent to remove all traces of old lubricant. (2) After cleaning the bearings, dry them with clean compressed air. Take care to prevent spinning the bearings when using a compressed air jet. (3) Dip the cleaned bearings in clean engine oil and immediately wrap them in lint-free paper to protect them from dust and other foreign matter. d. Replacing Electronic Components. (1) Tag wires before removal to facilitate proper reconnection. (2) When soldering use heat sink between solder- ing pencil and electronic component to prevent damage to the component. (3) Do not use excessive heat when soldering on printed circuit boards to prevent damage to board. e. Fuel System Maintenance. The fuel injectors and fuel pump are manufactured to extremely tight toler- ances. Even small amounts of dust or water in the fuel system can damage these components. Conse- quently it is of great importance that dirt be kept out of the fuel lines and fittings during disassembly and assembly. All openings should be taped, plugged, or capped immediately after disassembly. If dirt does accidentally enter a component, it should be washed in clean fuel oil before reassembly. Section IV. REMOVAL AND INSTALLATION OF MAJOR COMPONENTS 2-8. CONTROL CUBICLE. 2-9. ENGINE ASSEMBLY. a. Removal. Refer to Operator and Orguizational Matitanance Manual. a. Remove. On ASK equipped generators, refer to the Operator and Organizational Maintenance Manual, remove cover assembly, and perform the following steps. b . I n s t a l l a t i o n . R e f e r t o O p e r a t o r a nd Organizational Maintenance Manual. (1) Disconnect and remove batteries. 2-12 Change 6