MTD 114-112A Operations Instructions

ARMY TECHNICAL MANUALTM5-6115-585-12NAVY PUBLICATIONNAVFAC P-8-262-I 2AIR FORCE TECHNICAL ORDERTO-35C2-3-455-1MARINE CORPS TECHNICAL MANUALTM-05684C-1

TM5-6115-585-12NAVFAC P-8-623-12TO-35C2-3-455-1TM-05684C/05685B-12gasket between oil fill tube andthat dip-stick fits securely intoleaks.engine block.

TM5-6115-585-12NAVFAC P-8-623-12TO-35C2-3-455-1TM-05684C/05685B-12CHAPTER 4ORGANIZATIONAL MAINTENANCESection I. SERVICE UPON RECEIPT OF MATERIAL4-1.

TM5-6115-585-12NAVFAC P-8-623-12TO-35C2-3-455-1TM-05684C/05685B-12Figure 4-1. Uncrating Generator SetDo not smoke or use an open flame in the vicini-t

ing flammable gases or vapors. Use as few bends in thepipe and as short a pipe as possible. The exhaust pipeshould include a low point with suitable m

TM5-6115-585-12NAVFAC P-8-623-12TO-35C2-3-455-1TM-05684C/05685B-12Figure 4-2. Grounding Generator SetChange 4-3

TM5-6115-585-12NAVFAC P-8-262-12TO-35C2-3-455-1TM-05684C-12Section II. MOVEMENT TO A NEW WORKSITE4-3.a.DISMANTLING GENERATOR SET FOR MOVE-(6) On ASK e

TM5-6115-585-12NAVFAC P-8-262-12TO-35C2-3-455-1TM-05684C-12(10) Apply a thin coat of clean engine oil,(12) Pour 6.5 quarts of engine oil (see lubri-MI

TM5-6115-585-12NAVFAC P-8-262-12TO-35C2-3-455-1TM-05684C-12TABLE 4-1.ORGANIZATIONAL PREVENTIVE MAINTENANCE CHECKS AND SERVICES--continued4-6Change 5I

TM 5-6115-585-12NAVFAC P-8-623-12TO-35C2-3-455-1TM-05684C/05685B-12TABLE 4-1. ORGANIZATIONAL PREVENTIVE MAINTENANCE CHECKS AND SERVICES - continuedITE

TM 5-6115-585-12NAVFAC P-8-623-12TO-35C2-3-455-1TM-05684C/05685B-12Section VI. TROUBLESHOOTING4-12. TROUBLESHOOTING, GENERAL.4-13. MALFUNCTION NOT COR

TM5-6115-585-12NAVFAC P-8-262-12TO-35C2-3-455-1TM-05684C-12Table 4-2. TroubleshootingMALFUNCTIONTEST OR INSPECTIONCORRECTIVE ACTION1. ENGINE FAILS TO

TM5-6115-585-12NAVFAC P-8-262-12TO-35C2-3-455-1TM-05684C-12Table 4-2. Troubleshooting (Cont)MALFUNCTIONTEST OR INSPECTIONCORRECTIVE ACTION3.4.5.6.7.8.

TM5-6115-585-12NAVFAC P-8-623-12TO-35C2-3-455-1TM-05684C/05685B-12Table 4-2. Troubleshooting (Cont)MALFUNCTIONTEST OR INSPECTIONCORRECTIVE ACTION9. EN

TM5-6115-585-12NAVFAC P-8-262-12TO-35C2-3-455-1TM-05684C-12Table 4-2. Troubleshooting (Cont)MALFUNCTIONTEST OR INSPECTIONCORRECTIVE ACTION14. BATTERIE

TM5-6115-585-12NAVFAC P-8-262-12TO-35C2-3-455-1TM-05684C-12Figure 4-3. Primary Radio Interference Suppresion Components (Sheet 1 of 2)4-11

TM5-6115-585-12NAVPAC P-8-623-12TO-35C2-3-455-1TM-05684C/05684B-12Figure 4-3. Primary Radio Interference Supperssion Components (Sheet 2 of 2)Section

TM5-6115-585-12NAVFAC P-8-623-12TO-35C2-3-455-1TM-05684C-12(2) Air Housing Duct Cover. Remove air housingduct cover (2) by removing screws (1).(3) Shu

TM5-6115-585-12NAVFAC P-8-623-12TO-35C2-3-455-1TM-05684C/05685B-12Figure 4-4. Shutter Assembly4-14Change 2

(2) Install power unit assembly (6) into shutterassembly box (30) using screws (4) and special washer(5). Mount connector (3) using screws (1) and nut

TM5-6115-585-12NAVFAC P-8-623-12TO-35C2-3-455-1TM-05684C/05685B-12Section IX. MAINTENANCE OF FUEL SYSTEM4-18. DESCRIPTION AND FUNCTION.a. Low Pressure

TM5-6115-585-12NAVFAC P-8-262-12TO-35C2-3-455-1TM-05684C-12Figure 4-7. Fuel Tank Assembly(4) Fuel Level Gauge. Engage threads of fuel(3) Check that dr

TM5-6115-585-12NAVFAC P-8-623-12TO-35C2-3-455-1TM-05684C/05685B-12Figure 4-8. Testing Float Switchother as secondary, plus there is one fuel strainer.

TM5-6115-585-12NAVFAC P-8-262-12TO-35C2-3-455-1TM-05684C-12Figure 4-9. Fuel FilterFigure 4-10. Fuel Strainer Element(2) Fuel Strainer Element (see fig

warningTM5-6115-585-12NAVFAC P-8-262-12TO-35C2-3-455-1TM-05684C-12Clean parts in a well-ventilated area. Avoidinhalation of solvent fumes and prolonge

TM5-6115-585-12NAVFAC P-8-623-12TO-35C2-3-455-1TM-05684C/05685B-12c. Removal.(1) Fuel Filter Assembly (see figure 4-11). Drainfuel into a suitable con

TM5-6115-585-12NAVFAC P-8-262-12TO-35C2-3-455-1TM-05684C-121. Hose assembly8.2. Hose assembly9.3. Hose assembly 4. Hose assembly11.5. Connector1

Figure 4-13. Fuel Pump4-23. FUEL SHUT-OFF SOLENOIDa. Inspect (on Equipment) (see figure 4-14). On ASK equippedgenerators, remove right panel assemb

4-25.TM 5-6115-585-12NAVFACP-8-623-12TO–35C2–3-455-1TM-05684C/05685B-12Figure 4–15. Fuel Solenoid Test Set–Up.Section X. MAINTENANCE OF ENGINE ELECTR

TM5-6115-585-L2NAVFAC P-8-623-12TO-35C2-3-455-1TM-05684C/05685B-12Tag and disconnect cables from starter case andstarter solenoid. Remove jumper betwe

TM 5-6115-585-12NAVFAC P-8–623-12TO–35C2–3-455-1TM-05684C/05685B-12Figure 4–16. Installing Battery Cables.Change 114–25

TM 5-6115-585-12NAVFAC P-8-623-12TO-35C2-3-455-1TM-05684C/05685B-12negative battery cable (–) to the ground terminal “G” ofthe starter. See figure 4–1

TM 5-6115–585-12NAVFAC P-8-623-12TO-35C2-3-455-1TM-05684C/05685B-12Figure 4–18. Engine Starter installationChange 114-27

TM 5-6115-585-12NAVFAC P-8-623-12TO-35C2-3-455-1TM-05684C/05685B-12(3) Connect voltmeter as shown in figure4–19, Test b. If battery voltage (24 volts)

Figure 4-19.TM 5-61 15–585-12NAVFAC P–8-623-12TO–35C2-3-455-1TM-05684C/05685B-12Change 114-28.1

TM 5-6115-585-12NAVFAC P–8-623-12TO-35C2-3-455-1TM-05684C/05685B-12Figure 4–20. Testing Field Coil, Style II StarterFigure 4–21. Inspecting Starter Br

NAVFAC P-8-623-12TO-35C2-3-455-1TM 5-6115-585-12TM-05684C/05685B-12Figure 4–21 A. Inspecting Starter Brushes, Style II Starterd. Bench Test.(1) Starte

TM 5-6115–585-12NAVFAC P–8-623-12TO-35C2-3-455-1TM-05684C/05685B-12Figure 4–22. Engine Starter Assembly, Style I StarterFigure 4-22A. Engine Starter A

TM-05684C/05685B-12TM 5-6115-585-12NAVFACP-8-623-12TO–35C2–3-455-1Figure 4–23. Battery Charging AlternatorChange 114-29

TM 5-6115-585-12NAVFACP-8-623-12TO–35C2–3-455-1TM-05684C/05685B-12NOTENOTESolenoid mounting screw removalmay require the use of an impact typedriver.(

TM5-6115-585-12NAVFAC P-8-623-12TO-35C2-3-455-1TM-05684C/05685B-12—,––— ——Figure 4-24. Testing Battery Charging Regulator/Rectifier Assembly(3) Remove

TMS-6115-585-12NAVFAC P-8-262-12TO-35C2-3-455-1TM-05684C-12Figure 4-25. Lockout Switch and Gearcontinuity between connector (8) pins A and B on leadc.

TM5-6115-585-12NAVFAC P-8-623-12TO-35C2-3-455-1TM-05684C/05685B-12(20) and spring (12). Slide gear (5) out through openingin engine back plate. clean

Figure 4-28.Figure 4-30 Figure 4-27.4-31.TM5-6115-585-12NAVFACP-8-623-12TO-35C2-3-455-1TM-05684C/05685B-124-34 Change 8

TM5-6115-585-12NAVFAC P-8-623-12TO-35C2-3-455-1TM-05684C/05685B-12Figure 4-29. Replacing Oil Cooler Hoses(Early Model MEP-003A Only)Change 2 4-35

TM5-6115-585-12NAVFAC P-8-623-12TO-35C2-3-455-1TM-05684C/05685B-12Figure 4-29.1. Replacing Oil Cooler Hoses(Current Model MEP-003A and Model MEP-112A)

TM5-6115-585-12NAVFAC P-8-623-12TO-35C2-3-455-1TM-05684C/05685B-12Figure 4-30. Oil Filter Assemblyd. Install. Install switch (11) in adapter (5) andb.

4-37TM5-6115-585-12NAVFAC P-8-262-12TO-35C2-3-455-1TM-05684C-12Figure 4-31. Replacing Oil Pressure Gauge4-33. OIL PRESSURE GAUGE.On ASK equipped gener

TM5-6115-585-12NAVFAC P-8-262-12TO-35C2-3-455-1TM-05684C-12Section XII.MAINTENANCE OF CONTROL SYSTEM4-34. DESCRIPTION AND FUNCTION.NOTEAll symbols (CB

Change 8 4-39TM 5-6115-585-12NAVFAC P-8-623-12TO-35C2-3-455-1TM-05682C/05685B-12for correct readings of voltmeter and ammeterindications will be obta

4-40 Change 8TM 5-6115-585-12NAVFAC P-8-623-12TO-35C2-3-455-1TM-05682C/05685B-124-37. LOAD TERMINAL BOARD ASSEMBLY.a. Load Terminal Removal (see figu

Figure 4-33.TM5-6115-585-12NAVFAC P-8-623-12TO-35C2-3-455-1TM-05684C/05685B-12Change 84-41

4-42 Change 10TM 5-6115-585-12NAVFAC P-8-623-12TO-35C2-3-455-1TM-05684C/05685B-124-38. CONTROL CUBICLE ASSEMBLY.a. Test, On Equipment (see figure 4-33

TM 5-6115-585-12NAVFAC P-8-623-12TO-35C2-3-455-1TM-05684C/05685B-12Table 4-4. Voltmeter-Ammeter Range Selector Switch Continuity CheckSwitch PositionV

TM5-6115-565-12NAVFAC P-8-623-12TO-35C2-3-455-1TM-05684C/05685B-12(3) Relay Assembly (A1). Inspect relay assembly(5) for physical damage. Check that e

Change 54-43TM5-6115-585-12NAVFAC P-8-262-12TO-35C2-3-455-1TM-05684C-12Figure 4-34. Removing Control Cubicle Support Assembly(3) Battery Charging Ind

TM5-6115-585-12NAVFAC P-8-262-12TO-35C2-3-455-1TM-05684C-12(11) Relay (K2-K3). Disconnect battery. Tag anddisconnect four leads to relay. Remove two s

(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

4-46Figure 4-36.TM5-6115-585-12NAVFAC P-8-262-12TO-35C2-3-455-1TM-05684C-12

TM5-6115-585-12NAVFAC P-8-623-12TO-35C2-3-455-1TM-05684C/05685B-121.2.3.4.5.7.8.9.6.10.11.12.13.14.15.16.Blower housingShutter assemblyOil coolerOil f

4-48TM5-6115-585-12NAVFAC P-8-262-12TO-35C2-3-455-1TM-05684C-12Figure 4-37. Exhaust Muffler and Air Cleaner Assemblies.

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

figure 4-38) figure 3-9) figure 4-38) figure 4-39 figure 4-38) figure 4-41) 4-46. figure 4-40) 4-45. 4-44. figure 4-40TM5-6115-585-12NAVFAC P-8-623-1

Figure 4-40. figure 4-41) figure 4-40. figure 4-41.4-47.4-48.TM5-6115-585-12NAVFAC P-8-262-12T0-35C2-3-455-1TM-05684C-124-51

TM5-6115-585-12NAVFAC P-8-262-12TO-35C2-3-455-1TM-05684C-12Figure 4-41. Cylinder Head Assembly4-52

figure 4-41) figure 3-20) figure 4-42) figure 4-43) (para. 5-3) (para. 5-4)4-49.4-50.4-51.4-52.TM5-6115-585-12NAVFAC P-8-623-12TO-35C2-3-455-1TM-0568

TM5-6115-585-12NAVFAC P-8-262- 12TO-35C2-3-455-1TM-05684C-12Figure 4-43. Engine Mounting Assembly4-54

4-53. (see figure 1-1)TM 5-6115-585-12NAVFAC P-8-623-12TO-35C2-3-455-1TM-05684 C/05685B-12Section XIV. MAINTENANCE OF GENERATOR ASSEMBLYFigure 4-44.

figure 1-1) para 5-3 Section XV. figure 1-1.) figure 4-45 figure 4-45) figure 4-45) para 5.3) paragraph 4-25 figure 4-44) paragraph 4-36 figure 4-45

TM5-6115-585-12NAVFAC P-8-623-12TO-35C2-3-455-1TM-05684C/05685BFigure 4-45. Skid Base Assembly.Change 44-57

TM5-6115-585-12NAVFAC P-8-262-12TO35C2-3-455-1TM-05684C-12(b) Refer to paragraph 4-38 and Install con-trol cubicle.(2) Battery Frame Bottom and Tray.(

TM 5-6115-585-12NAVFAC P-8-623-12TO 35C2-3-455-1TM-05684C/05685B-12CHAPTER 5MATERIEL USED IN CONJUNCTION WITH DOD STANDARD GENERATORSET, 10KW DIESEL E

TM 5-6115-585-12NAVFAC P-8-623-12TO 35C2-3-455-1TM-05682C/05685B-12Section II.ACOUSTIC SUPPRESSION KIT5-2.ACOUSTIC SUPPRESSION KIT.The acoustic suppre

TM 5-6115-585-12NAVFAC P-8-623-12TO 35C2-3-455-1TM-05684C/05685B-12Figure 5-1.Instruction and Rating Plates (Sheet 1 of 4) 5-3Change 8

5-4TM 5-6115-585-12NAVFAC P-8-623-12TO 35C2-3-455-1TM-05682C/05685B-12Figure 5-1.Instruction and Rating Plates (Sheet 2) Change 8

TM 5-6115-585-12NAVFAC P-8-623-12TO 35C2-3-455-1TM-05684C/05685B-12Figure 5-1.Instruction and Rating Plates (Sheet 3)Change 85-5

TM 5-6115-585-12NAVFAC P-8-623-12TO 35C2-3–455-1TM-05682C/05685B-12Figure 5-1.Instruction and Rating Plates (Sheet 4)5-6Change 8

TM 5-6115-585-12NAVFAC P-8-623-12TO 35C2-3-455-1TM-05684C/05685B-12Figure 5-2.Cover Assembly, Removal and Installation5-7Change 8

TM 5-6115-585-12NAVFAC P-8-623-12TO 35C2-3-455-1TM-05682C/05685B-12b.Installation. See figure 5-2.Replace cover assemblyconsisting of top panel assemb

TM 5-6115-585-12NAVFAC P-8-623-12TO 35C2-3-455-1TM 05684C/05685B-12Figure 5-3.Top Panel Assembly and Exhaust Plenum,Removal and Installation5-9Change

TM 5-6115-585-12NAVFAC P-8-623-12TO 35C2-3-455-1TM-05682C/05685B-12(2)Remove seven screws (7) and locknuts (8), and 14washers (9 and 10) securing top

TM 5-6115-585-12NAVFAC P-8-623-12TO 35C2-3-455-1TM-05684C/05685B-12Figure 5-4.Left Panel Assembly and Side Closure Assembly,Removal and InstallationCh

TM 5-6115-585-12NAVFAC P-8-623-12TO 35C2-3-455-1TM-05682C/05685B-12b.Installation. See figure 5-4.Install left panel withside closure assembly to top

TM 5-6115-585-12NAVFAC P-8-623-12TO 35C2-3-455-1TM-05684C/05685B-12Figure 5-5.Right Panel Assembly, Removal and InstallationChange 8 5-13

TM 5-6115-585-12NAVFAC P-8-623-12TO 35C2-3-455-1TM-05682C/05685B-12b.Installation.See figure 5-5. Install right panelassembly to right support assembl

TM 5-6115-585-12NAVFAC P-8-623-12TO 35C2-3-455-1TM-05684C/05685B-12Figure 5-6.Rear Panel Assembly, Removal and InstallationChange 85-15

TM 5-6115-585-12NAVFAC P-8-623-12TO 35C2-3-455-1TM-05682C/05685B-12(3)Install two screws (1) and washers (2) securingright panel assembly (3) to rear

TM 5-6115-585-12NAVFAC P-8-623-12TO 35C2-3-455-1TM-05684C/05685B-12Figure 5-7.Left Support Assembly, Removal and InstallationChange 85-17

TM 5-6115-585-12NAVFAC P-8-623-12TO 35C2-3-455-1TM-05682C/05685B-12(2) Torque screws (8) to 26 ±2 ft-lbs dry.(3)Replace left panel assembly (6) with s

TM 5-6115-585-12NAVFAC P-8-623-12TO 35C2-3-455-1TM-05684C/05685B-12Figure 5-8.Right Support Assembly, Removal and InstallationChange 85-19

TM 5-6115-585-12NAVFAC P-8-623-12TO 35C2-3-455-1TM-05682C/05685B-12Figure 5-9.Front Panel Assembly, Removal and Installation5-20Change 8

TM 5-6115-585-12NAVFAC P-8-623-12TO 35C2-3-455-1TM-05684C/05685B–12(2)Install four screws (1) and washers (2) securingfront panel assembly (3) to top

TM 5-6115-585-12NAVFAC P-8-623-12TO 35C2-3-455-1TM-05682C/05685B-12Figure 5-10.Rear Closure Assembly, Removal and Installation5-22Change 8

TM 5-6115-585-12NAVFAC P-8-623-12TO 35C2-3-455-1TM-05684C/05685B-125-14.REAR FLAP ASSEMBLY.a.Removal.See figure 5-11.Remove rear flap assemblyfrom ski

TM 5-6115-585-12NAVFAC P-8-623-12TO 35C2-3-455-1TM-05682C/05685B-12Figure 5-11.Rear Flap Assembly, Removal and Installation5-24Change 8

TM 5-6115-585-12NAVFAC P-8-262-12TO-35C2-3-455-1TM-05684C-12WARNINGAll specific cautions and warnings contained in this manual shall be strictlyadhere

TM 5-6115-585-12NAVFAC P-8-623-12TO 35C2-3-455-1TM-05684C/05685B-12SECTION III.ACOUSTIC SUPPRESSION KIT REPAIR5-15.GENERAL.The local safety office and

TM 5-6115-585-12NAVFAC P-8-623-12TO 35C2-3-455-1TM-05682C/05685B-12(c)Apply adhesive backed teflon tape to leftsupport assembly top surface (slotted s

TM 5-6115-585-12NAVFAC P–8-623-12TO 35C2-3-455-1TM-05684C/05685B-12d.Install ASK replacement components by following theapplicable installation proced

TM 5-6115-585-12NAVFAC P-8-623-12TO 35C2-3-455-1TM-05682C/05685B-12Figure 5-12.Replacement of ASK Hardware Items5-28Change 8

TM 5-6115-585-12NAVFAC P-8-623-12TO 35C2-3-455-1TM-05684C/05685B-125-20.HINGES.The followinq procedures are for hinqe replacement on the toppanel asse

1.2.3.4.5.TM5-6115-585-12NAVFAC P-8-262- 12TO-35C2-3-455-1TM-05684C-12APPENDIX AREFERENCESPAINTING:T.O. 35-1-3Painting and marking of USAF Aerospace G

TM5-6115-585-12NAVFAC P-8-262-12TO-35C2-3-455-1TM-05684C-12(1)SMRCodePACZZPACZZPACZZPACZZPACZZPACZZAPPENDIX BITEMS TROOP INSTALLED OR AUTHORIZED LIST(

TM5-6115-585-12NAVFAC P-8-262-12TO-35C2-3-455-1TM-05684C-12APPENDIX CMAINTENANCE ALLOCATION CHARTSection I. INTRODUCTION1. GENERAL.a. This section pro

TM5-6115-585-12NAVFAC P-8-262- 12TO-35C2-3-455-1TM-05684C-12original manufacturing standards. Rebuild is per-formed only when required by operational

Section II.GROUP NO. 01GROUP NO. 02GROUP NO. 03TM5-6115-585-12NAVFAC P-8-262-12TO-35C2-3-455-1TM-05684C-12C-3

Section II.GROUP NO. 03 GROUP NO. 04TM5-6115-585-12NAVFAC P-8-262-12TO-35C2-3-455-1TM-05684C-12C-4

Section II.GROUP NO. 04TM5-6115-585-12NAVFAC P-8-262-12TO-35C2-3-455-1TM-05684C-12Change 4C-5

Section II.GROUP NO. 04GROUP NO. 05GROUP NO. 06TM5-6115-585-12NAVFAC P-8-262-12TO-95C2-3-455-1TM-05684C-12C-6Change 4

Section II.GROUP NO. 06GROUP NO. 07TM5-6115-585-12NAVFAC P-8-262-12TO-35C2-3-455-1TM-05684C-12C-7

Section II.GROUP NO. 07GROUP NO. 08TM5-6115-585-12NAVFAC P-8-262-12TO-35C2-3-455-1TM-05684C-12C-8

Section II.GROUP NO. 08GROUP NO. 09TM5-6115-585-12NAVFAC P-8-262-12TO-35C2-3-455-1TM-05684C-12C-9

Section II.GROUP NO. 09GROUP NO. 10GROUP NO. 11 GROUP NO. 12M5-6115-585-12NAVFAC P-8-262-12TO-35C2-3-455-1TM-05684C-12C-10

Section II.GROUP NO. 12GROUP NO. 13GROUP NO. 14TM 5-6115-585-12NAVFAC P-8-623-12TOO-35C2-3-455-lTM-05684C/05685B-12Change 7C-11

Section II.GROUP NO. 14TM5-6115-585-12NAVFAC P-8-262-12TO-35C2-3-455-1TM-05684C-12C-12

Section II.GROUP NO. 14GROUP NO. 15TM5-6115-585-12NAVFAC P-8-262-12TO-35C2-3-455-1TM-05684C-12Change 4C-13

Section II.GROUP NO. 15TM 5-6115-585-12NAVFAC P-8-623-12TO-35C2-3-455-1TM-05684/C-/05685B12Change 10C-14

Section II.GROUP NO. 15TM5-6115-565-12NAVFAC P-8-262-12TO-35C2-3-455-1TM-05684C-12C-15

Section II.GROUP NO. 15GROUP NO. 16TM 5-6115-585-12NAVFAC P-8-262-12TO-35C2-3-455-1TM-05684C-12C-16Change 10

Section II.GROUP NO. 16GROUP NO. 17TM5-6115-585-12NAVFAC P-8-623-12TO-35C2-3-455-1TM-05684C/05685B-12Change 8C-16.1/(C-16.2 blank)

Section II.GROUP NO. 17TM5-6115-585.12NAVFAC P-8-623-12TO-35C2-345-1TM-05684C/05685B-12C-17

TM5-6115-585-12NAVFAC P-8-623-12TO-35C2-3-455-1TM-05684C/0568B-12Section III. TOOLS, TEST AND SUPPORT EQUIPMENT REQUIREMENTSC-18Change 12

TM5-6115-585-12NAVFAC P-8-262-12TO-35C2-3-455-1TM-05684C-12Section IV. EXPLANATION OF REFERENCE CODESREFERENCE CODEREMARKSA-AVisual InspectionB-BHydro

TM5-6115-585-12NAVFAC P-8-623-12TO-35C2-3-455-1TM-05684C/05685B-12APPENDIX DADDITIONAL AUTHORIZATION LISTSection I. INTRODUCTIOND-1. SCOPE.in with it.

TM 5-6115-585-12NAVFAC P-8-623-12TO-35C2-3-455-1TM-05682C/0568B-12F4-41INDEX 1ALPHABETICAL INDEXSubjectAAC Instrumentation System . . . . . . . . . .

TM6-6115-585-12NAVFAC P-8-262-12TO-95C2-3-455-1TM-05684C-12SubjectALPHABETICAL INDEX (CONT)Paragraph,Figure, Table,NumberDDC Control System . . . . .

TM5-6115-585-12NAVFAC P-8-262-12TO-35C2-3-455-1TM-05684C-12ALPHABETICAL INDEX (CONT)Paragraph,Figure, Table,SubjectNumberF (CONT)Fuel Filter and Strai

TM5-6115-585-12NAVFAC P-8-262-12TO-35C2-3-455-1TM-05684C-12ALPHABETICAL INDEX (CONT)Paragraph,G (CONT)Ground Rod and Fuel Drum Adapter Hold-Down Assem

TM5-6115-585-12NAVFAC P-8-262-12TO-35C2-3-455-1TM-05684C-12ALPHABETICAL lNDEX (CONT)Paragraph,Figure, Table,SubjectNumberO (CONT)Oil Filter . . . . .

TM5-6115-585-12NAVFAC P-8-262-12TO-35C2-3-455-1TM-05684C-12ALPHABETICAL INDEX (CONT)Paragraph,Figure, Table,SubjectsScreen-GuardInspection . . . . . .

TM 5-6115-585-12NAVFAC P-8-262-12TO 35C2-3-455-1TM 05684C-12By Order of the Secretaries of the Army, the Navy, and the Air Force:BERNARD W. ROGERSGene

TM 5-6115-585-12NAVFAC P-8-262-12TO-35C2-3-455-1TM-05684C-12WARNINGAll specific cautions and warnings contained in this manual shall be strictlyadhere

DEPARTMENT OF THE ARMY TECHNICAL MANUALTM5-6115-585-12DEPARTMENT OF THE NAVY PUBLICATIONNAVFAC P-8-623-12DEPARTMENT OF THE AIR FORCE TECHNICAL ORDERTO

ARMY TM 5-6115-585-12NAVFAC P-8-623-12AIR FORCE TO-35C2-3-455-1MARINE CORPS TM-05684C/05685B-12 C12CHANGEHEADQUARTERSDEPARTMENTS OF THE ARMY, NAVY A

TM5-6115-585-12NAVFAC P-8-262-12TO-35C2-3-455-1TM-05684C-12TABLE OF CONTENTS (CONT)SectionCHAPTERSectionSectionSectionSectionSectionCHAPTERSectionSect

SectionSectionSectionSectionSectionSectionSectionSectionSection SectionIII.IV.V.VI.VII.VIII.IX.X.XI.XII.TM 5-6115-585-12NAVFAC P-8-262-12TO-35C2-3-45

TM 5-6115-585-12NAVFAC P-6-623-12TO-35C2-3-455-1TM-05682C/05885B-12TABLE OF CONTENTS (CONT)Section XII.Section XIII.Section XIV.Section XV.CHAPTER 5S

TM 5-6115-585-12NAVFAC P-8-623-12TO-35C2-3-455-1TM-05682C/05685B-12SectionIII.APPENDIX A.APPENDIX B.APPENDIX C.Section I.II.III.IV.APPENDIX D.INDEX .

Figure1-1.1-2.1-2.1.1-2.2.1-3.1-4.1-5.1-6.1-7.1-7.1.1-8.1-9.1-9.1.1-10.2-1.2-2.2-3.2-4.3-1.3-2.3-3.3-4.3-5.3-6.3-7.3-8.3-9.3-10.3-11.3-12.3-13.3-14.3-

TM 5-6115-585-12NAVFAC P-8-623-12TO-35C2-3-455-1TM-05684C/05685B-12Figure4-12.4–13.4-14.4–15.4-16.4–17.4-18.4–19.4–20.4–21.4–21 A.4–22.4–22A.4–23.4-24

LIST OF TABLES (CONT)TableTM 5-6115-585-12NAVFAC P-8-623-12TO-35C2-3-455-1TM-05682C/05685B-12Page2-1.2-2.3-1.3-2.3-3.4-1.4-2.4-3.4-4.Generator Set Con

TM5-6115-585-12NAVFAC P-8-623-12TO-35C2-3-455-1TM-05684C/05685B-12CHAPTER 1INTRODUCTIONSection I. GENERAL1-1. SCOPE This manual is for your us

TM5-6115-585-12NAVFAC P-8-623-12TO-35C2-3-455-1TM-05684C/05685B-12Section II. DESCRIPTION AND DATA1-9.The Set. DESCRIPTION OF GENERATOR SET.MEP-0

MILTON H. HAMILTONARMY TM 5-6115-585-12NAVFAC P-8-623-12AIR FORCE TO-35C2-3-455-1MARINE CORPS TM-05684C/05685B-12C12By Order of the Secretaries of th

TM5-6115-585-12NAVFAC P-8-623-12TO-35C2-3-45-1TM-05684C/05685B-12Figure 1-1. Engine Generator Set, Right-Rear, Three-Quarter ViewChange 2 1-3

TM5-6115-585-12NAVFAC P-8-623-12TO-35C2-3-455-1TM-05684C/05685B-12Figure 1-2. Engine Generator Set, Left-Front, Three-Quarter View (MEP-003A-Only)1-4

TM5-6115-585-12NAVFAC P-8-623-12TO-35C2-3-455-1TM-05684C/05685B-12Figure 1-2.1. Engine Generator Set, Left-Front, Three-Quarter View (MEP-112A Only)Ch

TM5-6115-585-12NAVFAC P-6-623-12TO-35C2-3-455-1TM-05684C/05685B-l2Figure 1-2.2 Engine Generator Set, Left Front, Three-Quarter View (MEP-003A Only),

and current under load and varies the exciter field eitherup or down to keep the generator field at such a valueas to maintain constant alternator out

TM5-6115-585-12NAVFAC P-8-823-12TO-35C2-3-455-1TM-05684C/05685B-12SERVICE INSTRUCTIONSFuelsAmbientCapacity- 12.5 GALTemperaturePrimary-DieselEmergency

TM5-6115-585-12NAVFAC P-8-623-12TO-35C2-3-455-1TM-05684C/05685B-12Ventilation requirements(across the generator set) . . . . .1350 CFM at 1800 RPM1600

TM5-6115-585-12NAVFAC P-8-623-12TO-35C2-3-455-1TM-05684C/05685B-12(3)(4)(5)(6)Displacement: . . . . . . . . . . . . . . . . . . . . . . . . . . Compre

TM5-6115-585-12NAVFAC P-8-623-12TO-35C2-3-455-1TM-05684C/05685B-12Figure 1-3. Tie Down, Lifting, and Towing Provisions Crated Set (MEP-003A)1-8Change

TM5-6115-585-12NAVFAC P-8-262-12TO-35C2-3-455-1TM-05684C-12Figure 1-5. Fuel System SchematicFigure 1-4. Installation Plans1-9

Figure 1-6.-12TM5-6115-585-12NAVFAC P-8-262-TO-35C2-3-455-1TM-05684C-121-10

TM 5-6115-585-12NAVFAC P-8-623-12TO-35C2-3-455-1TM-05684C/05685B-12Figure 1-8. Generator Set Wiring Harness 1-13 Change 4

1-14Change 6TM 5-6115-585-12NAVFAC P-8-623-12TO-35C2-3-455-1TM-05684C/05685B-12Figure 1-9. AC Output Control Box Wiring Harness (MEP-003A Only)

TM5-6115-585-12NAVFAC P-8-623-12TO-35C2-3-455-1TM-05684C/05685B-12Figure 1-9.1. AC Ouptut Control Box Wiring Harness (MEP-112A Only)Change 41-14.1/(1-

TM5-6115-585-12NAVPAC P-8-623-12TO-35C2-3-455-1TM05684C/05685B12Figure 1-10. Control Cubicle Wiring HarnessChange 51-15/(1-16 blank)

warningcautionTM 5-6115-585-12NAVFAC P-8-623-12TO-35C2-3-455-1TM-05684C/05685B-12CHAPTER 2OPERATING INSTRUCTIONSSection I.OPERATING PROCEDURE2-1. GEN

TM5-6115-585-12NAVFAC P-8-623-12TO-35C2-3-455-1TM-05684C/05685B-12a. When starting a set with a dry fuel system or after afilter drain or change:(1) P

Control Description FunctionBATTERYGreen - fully charged: Yellow -Indicates the degree of charge of the batteries. NeedleINDICATORcharging: Red - Unde

TM 5-6115-585-12NAVFAC P-8-623-12TO-35C2-3-455-1TM-05684C/05685B-12Table 2-1. Generator Set Controls and Instruments (Cont)ControlDescriptionFunctionO

TM 5-6115-585-12NAVFAC P-8-623-12TO-35C2-3-455-1TM-05684C/05685B-12Figure 2-3.Control Panelincrease frequency, pushing speed control knob in willdecre

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

warningTM 5-6115-585-12NAVFAC P-8-262-12TO-35C2-3-455-1TM-05684C/05685B-12k. During operation, listen for unusual noiseswhich may indicate a pending m

cautionTM5-6115-585-12NAVFAC P-8-623-12TO-35C2-3-455-1TM-05684C-12a. Keep fuel tank full to protect against moisturecondensation and accumulation.b..

(1)ComponentApplicationTank, FuelCrankcaseBatteriesCHAPTER 3OPERATOR MAINTENANCE INSTRUCTIONSSection I. CONSUMABLE OPERATING AND MAINTENANCE SUPPLIES3

CAUTIONTM5-6115-585-12NAVFAC P-8-623-12TO-35C2-3-455-1TM-05684C/05685B12Section III. PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)3-4. GENERAL.NOT

para 4-2e fig. 4-2 para 3-18 para 3-20TM 5-6115-585-12NAVFAC P-S-623-12TO-35C2-3-455-1TM-05684C/05085B-12Table 3-2. OPERATOR/CREW PREVENTIVE MAINTENA

para 2-4h para 4-20 para 4-20TM 5-6115-585-12NAVFAC P-8-623-12TO-35C2-3-455-1TM-05684C/05685B-12Table 3-2. OPERATOR/CREW PREVENTIVE MAINTENANCE CHECK

TM 5-6115-585-12NAVFAC P-8-623-12TO-35C2-3-455-1TM-05684C/05685B-12Table 3-2. OPERATOR/CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES - CONT3-4.3/(3-

TM5-6115-585-12NAVFAC P-8-262-12TO-35C2-3-455-1TM-05684C-12Section IV. TROUBLESHOOTING3-9. GENERAL.3-10. MALFUNCTIONS NOT CORRECTED BY USEOF THE TROUB

TM5-6115-585-12NAVFAC P-8-262-12TO-35C2-3-455-1TM-05684C-12Table 3-3. TroubleshootingNOTEBefore you use twistable, be sure you have performed all appl

TM 5-6115-585–12NAVFAC p-8-623-12TO-35C2-3-455-1TM-05684C/05685B-12Table 3-3. Troubleshooting (Cent)MALFUNCTIONTEST OR INSPECTIONCORRECTIVE ACTION4. E

warning paragraph 3-17 paragraph 3-21TM 5-6115-585-12NAVFAC P-8-623-12TO-35C2-3-455-1TM-05684C/05685B-12Table 3–3. Troubleshooting (Cont)3-11. BATTERY

TM 5-6115-585-12NAVFAC P-8-623-12TO-35C2-3-445-1TM-05684C/05685B-12Figure 3-2. Battery Assemblyabout 3/8 inch above top of plates. Check that batteryc

TM5-6115-585-12NAVFAC P-8-623-12TO-35C2-3-455-1TM-05684C/05685B-12Figure 3-3. Ground Rod and Fuel DrumAdapter Pipe Hold-Downb. Cleaning and Inspection

TM5-6115-585-12NAVFAC P-8-262-12TO-35C2-3-455-1TM-05684C-12Figure 3-4. Fuel Tank(2) Bracket Assembly. Check bracket assemblyflat and straight. Check t

TM5-6115-585-12NAVFAC P-8-623-12TO-35C2-3-455-1TM-05684C/05685B-12Figure 3-5. Shutter and Thermo Power Element Assembly3-12Change 2

TM5-6115-585-12NAVFAC P-8-623-12TO-35C2-3-455-1TM-05684C/05685B-123-15. EXHAUST MUFFLER ASSEMBLY.Figure 3-6. Exhaust Muffler AssemblyDo not touch muff

TM5-6115-585-12NAVFAC P-8-623-12TO-35C2-3-455-1TM-05684C/05685B-12Figure 3-7. Electric Starter3-17. AC OUTPUT CONTROL BOX ASSEMBLY.a. Inspect (see fig

TM5-6115-585-12NAVFAC P-8-262-12TO-35C2-3-455-1TM-05684C-12Figure 3-9. Air Cleaner and Shroud Assembly3-15

TM5-6115-585-12NAVFAC P-8-623-12TO-35C2-3-455-1TM-05684C/05685B-12b. Removal and Service.(2) Air Cleaner Element (see figure 3-10). Every(1) Dust Cap

TM5-6115-585-12NAVFAC P-8-623-12TO-35C2-3-455-1TM-05684C/05685B-12Figure 3-11. Cleaning Air Filter ElementDo not re-use element more than twice. Donot

TM5-6115-585-12NAVFAC P-8-262-12TO-35C2-3-455-1TM-05684C-12Figure 3-12. Control Cubicle3-18

TM 5-6115-585-12NAVFAC P-8-623-12TO-35C2-3-455-1TM-05684C/05685B-12b. Service.(1) Panel Light. Panel lamp cover can be removedfor cleaning by turning

TM 5-6115-585-12NAVFAC P-8-623-12TO-35C2-3-455-1TM-05684C/05685B-12(3) Fuel Pump Assemblies (Three) (see figure3-14). Inspect fuel pumps (1) for dents

TM5-6115-585-12NAVFAC P-8-623-12TO-35C2-3-455-1TM-05684C/05685B-12Figure 3-16. Speed Control Assembly3-22. ENGINE COOLING SYSTEM.damage. Check that b

TM5-6115-585-12NAVFAC P-8-262-12TO-35C2-3-455-1TM-05684C-12Figure 3-17. Engine Cooling Assembly (Sheet 1 of 2)3-22

TM5-6115-585-12NAVFAC P-8-623-12TO-35C2-3-455-1TM-05684C/05685B-12Figure 3-17. Engine Cooling Assembly (Sheet 2 of 2)3-23. GENERATOR ASSEMBLY.On ASK

TM5-6115-585-12NAVFAC P-8-262-12TO-35C2-3-455-1TM-05684C-12Figure 3-19. Intake Manifold Assembly3-24

TM5-6115-585-12NAVFAC P-8-262-12TO-35C2-3-455-1TM-05684C-12Figure 3-21. Oil Filter and Oil Pressure SwitchFigure 3-20. Oil Drain Hosee. Oil Filter Ass

TM5-6115-585-12NAVFAC P-8-623-12TO-35C2-3-455-1TM-05684C/05685B-12Inspect to see that there is no dirt or oil underneathlens indicating that gage is n