ONAN DJC MEP 003A Manual

ARMY TECHNICAL MANUAL TM5-6115-585-12
NAVY PUBLICATION NAVFAC P-8-262-I 2
AIR FORCE TECHNICAL ORDER TO-35C2-3-455-1

MARINE CORPS TECHNICAL MANUAL T M - 0 5 6 8 4 C - 1 2
TECHNICAL MANUAL
OPERATOR AND ORGANIZATIONAL

MAINTENANCE MANUAL
GENERATOR SET, DIESEL ENGINE DRIVEN, TACTICAL SKID MTD 1OKW,1 PHASE
-2 WIRE, 1 PHASE -3 WIRE, 3 PHASE -4 WIRE, 120, 120/240 AND 120/208 VOLTS
DOD MODEL C LASS HERTZ NSN
MEP-003A UTILITY 6 0 6115-00-465-1030
This copy is a reprint which includes current
pages from Changes 1 through 4
PUBLISHED UNDER THE AUTHORITY OF THE DEPARTMENTS OF THE ARMY, AIR FORCE, NAVY
AND HEADQUARTERS U.S. MARINE CORPS
JULY 1977
TM 5-6115-585-12
NAVFAC P-8-262-12
TO-35C2-3-455-1
TM-05684C-12
WARNING
HIGH VOLTAGE
D E A T H
to
to
be to
DANGEROUS GASES
LIQUIDS UNDER HIGH PRESSURE
NOISE
WARNING
ARMY TM 5-6115-585-12
NAVFAC P-8-623-12
AIR FORCE TO-35C2-3-455-1
MARINE CORPS TM-05684C/05685B-12
C12
C H A N G E H E A D Q U A R T E R S
DEPARTMENTS OF THE ARMY, NAVY AND AIR FORCE

A N D H E A D Q U A R T E R S U . S . M A R I N E C O R P S
N O . 1 2
WASHINGTON, D.C., 27 APRIL 1992
Operator and Organizational Maintenance Manual
GENERATOR SET, DIESEL ENGINE DRIVEN, TACTICAL SKID MTD, 10KW

1 PHASE-2 WIRE, 1 PHASE-3 WIRE, 3 PHASE-4 WIRE
120, 120/240 AND 120/208 VOLTS
DOD MODEL CLASS H E R T Z N S N
MEP-003A UTILITY 6 0 6115-00-465-1030
MEP-112A UTILITY 400 6115-00-465-1027
Approved for public release; Distribution is unlimited
TM 5-6115-585-12, NAVFAC P-8-623-12, TO 35C2-3-455-1, TM 05684C/05685B-12, 25 July 1977 is
changed as follows:
1. Remove and insert pages as indicated below. New or changed text material is indicated by a vertical bar in
the margin. An illustration change is indicated by a miniature pointing hand.
Remove pages Insert pages
C-17 and C-18 C-17 and C-18
2. Retain this sheet in front of manual for reference purposes.

ARMY TM 5-6115-585-12
NAVFAC P-8-623-12
AIR FORCE TO-35C2-3-455-1
MARINE CORPS TM-05684C/05685B-12
C 1 2
By Order of the Secretaries of the Army , Air Force, and Navy (Including the Marine Corps):
GORDON R. SULLIVAN
Genera/, United States Army
Official: Chief of Staff
MILTON H. HAMILTON
Administrative Assistant to the
Secretary of the Army
01066
MERRILL A. McPEAK
General USAF
Chief of Staff
Official:
CHARLES C. McDONALD
General, USAF
Commander, Air Force Logistics Command
DAVID E. BOTTORFF
Rear Admiral, CEC, US Navy
Commander
Navy Facilities Engineering Command
H.E. REESE
Deputy for Support
Marine Corps Research, Development and
Acquisition Command
DISTRIBUTION:
To be distributed in accordance with DA Form 12–25E, (qty rqr block no. 0868).
TM 5-6115-585-12
NAVFAC P-8-262-12
TO-35C2-3-455-1
TM-05684C-12
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. Disconnect the battery ground cable before removing and installing
components on the engine or in the electrical control panel system. Remove all
rings, watches, and other jewelry when performing maintenance on this equipment.
Loose fitting clothing should be secured to prevent it catching in moving parts. Do
not attempt to service or otherwise make any adjustments, connections or recon-
nections of wires or cables until Generator Set is shut-down and completely de-
energized.
DANGEROUS GASES
Batteries generate explosive gas during charging; therefore,

utilize extreme caution. Do not smoke, or use open flame
in the vicinity of the Generator Set when servicing batteries.
E x h a u s t d i s c h a r g e c o n t a i n s n o x i o u s a n d d e a d l y f u m e s . DO
not operate Generator Sets in enclosed areas unless exhaust
discharge is properly vented to the outside.
Exhaust discharge contains noxious and deadly fumes. Do not operate Generator
Sets unenclosed areas unless exhaust discharge is properly vented to the outside.
To avoid sparking between filler nozzle and fuel tank, always maintain metal to
metal contact between filler nozzle and fuel tank when filling fuel tank.
D O not smoke or use open flame in the vicinity of the Generator Set while fueling.
LIQUIDS UNDER HIGH PRESSURE
are generated as a result of operation of the Generator Set. Do not expose any
part of the body to a high pressure leak in the fuel injection system.
NOISE
Operating level of this generator can cause hearing damage. Ear protectors, as
recommended by the medical or safety officer, must be worn when working near
this set.
WARNING
Clean parts in a well-ventilated area. Avoid inhalation of solvent fumes and pro-
longed exposure of skin to cleaning solvent. Wash exposed skin thoroughly. Dry
cleaning solvent (Fed. Spec. P-D-680) used to clean parts is potentially dangerous
to personnel and property. Do not use near open flame or excessive heat. Flash
point of solvent is 100°F. to 138°F. (38°C. to 59°C.).
Change 5 a/(b blank)

DEPARTMENT OF THE ARMY TECHNICAL MANUAL TM5-6115-585-12
DEPARTMENT OF THE NAVY PUBLICATION NAVFAC P-8-623-12
DEPARTMENT OF THE AIR FORCE TECHNICAL ORDER TO-35C2-3-455-1
MARINE CORPS TECHNICAL MANUAL TM-0568 4C12/05685B-12
HEADQUARTERS
DEPARTMENTS OF THE ARMY, NAVY, AIR FORCE, & USMC
WASHINGTON, D.C. 25 JULY 1977
OPERATOR’S AND ORGANIZATIONAL

M A I N T E N A N C E M A N U A L
GENERATOR SET, DIESEL ENGINE DRIVEN, TACTICAL SKID MTD 10KW, 1 PHASE
-2 WIRE, 1 PHASE -3 WIRE, 3 PHASE -4 WIRE, 120, 120/240 AND 120/208 VOLTS
DOD MODEL CLASS HERTZ NSN
MEP-003A UTILITY 60 6115-00465-1030
MEP-112A UTILITY 400 6115-00-465-1027
TABLE OF CONTENTS
Page
LIST OF EFFECTIVE PAGES.... . . . . . . . . . . . . . . . . . . . . . v

LIST OF ILLUSTRATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . vi
LIST OF TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
CHAPTER 1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Section I. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1-1. Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1-2. Limited Applicability . . . . . . . . . . . . . . . . . . . . . 1-1
1-3. Maintenance Forms and Records . . . . . . . . . . . . . . . 1-1
1-4. Reporting of Errors . . . . . . . . . . . . . . . . . . . . . . 1-1
1-5. Levels of Maintenance Accomplishment . . . . . . . . . . . 1-1
1-6. (A, MC) Destruction of Material to Prevent Enemy Use . . . 1-1
1-7. (A, F, MC) Administrative Storage . . . . . . . . . . . . . . 1-1
1-8. Preparation for Shipment and Storage . . . . . . . . . . . . 1-1
Section II. DESCRIPTION AND DATA . . . . . . . . . . . . . . . . . . . . . . 1-2
1-9. Description of Generator Set . . . . . . . . . . . . . . . . . 1-2

1-10. Tabulated Data . . . . 1-5
CHAPTER 2. OPERATING INSTRUCTIONS 2 - 1
Section I. OPERATING PROCEDURE . 2-1
2-1. General . . . . . . . 2-1

2-2. Power Connections . 2-1
2-3. Equipment Reconnection . . . . . . . . . . . . . . . . . . . 2-1
2-4. Starting Generator Set . . . . . . . . . . . . . . . . . . . . 2-1
2-5. Operating in Alternate Modes . . . . . . . . . . . . . . . . . 2-6
2-6. Shutting Down Unit . . . . . . . . . . . . . . . . . . . . . . . 2-6
Change 2 i
TM5-6115-585-12
NAVFAC P-8-262-12
TO-35C2-3-455-1
TM-05684C-12
TABLE OF CONTENTS (CONT)
Page
Section II. OPERATING UNDER UNUSUAL CONDITIONS . . . . . . . . . . . . 2-6
2-7. Operation in Extreme Heat . . . . . . . . . . . . . . . . . . 2-6

2-8. Operation in Extreme Cold (-25° F, -32° C) . . . . . . . . . 2-6
2-9. Operation in Dusty or Sandy Areas . . . . . . . . . . . . . . 2-6
2-10. Operation in Wet or Humid Areas . . . . . . . . . . . . . . 2-6
CHAPTER 3. OPERATOR MAINTENANCE INSTRUCTIONS . . . . . . . . 3-1
Section I. CONSUMABLE OPERATING AND MAINTENANCE SUPPLIES . . . 3-1
3-1. Consumable Supplies . . . . . . . . . . . . . . . . . . . . . 3-1
Section II. LUBRICATION INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . 3-1
3-2. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3-3. Lubrication Order . . . . . . . . . . . . . . . . . . . . . . . 3-1
Section III. PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) . . 3-4
3-4. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3-5. Correcting and Reporting Deficiencies . . . . . . . . . . . . 3-4
3-6. Determining PMCS Intervals . . . . . . . . . . . . . . . . . 3-4
3-7. PMCS for Units in Continuous Operation . . . . . . . . . . . 3-4
3-8. Preventive Maintenance Checks and Services . . . . . . . . 3-4
Section IV. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3-9. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

3-10. Malfunctions Not Corrected By Use of the Troubleshooting
Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Section V. OPERATOR MAINTENANCE PROCEDURES . . . . . . . . . 3-8
3-11. Battery Assembly . . . . . . . . . . . . . . . . . . . . . . . 3-8

3-12. Ground Rod and Fuel Drum Adapter Hold-Down Assembly . . 3-9
3-13. Fuel Tank Assembly . . . . . . . . . . . . . . . . . . . . . 3-10
3-14. Shutter Box Assembly . . . . . . . . . . . . . . . . . . . . . 3-10
3-15. Exhaust Muffler Assembly . . . . . . . . . . . . . . . . . . 3-13
3-16. Engine Starter Assembly . . . . . . . . . . . . . . . . . . . 3-13
3-17. AC Output Control Box Assembly . . . . . . . . . . . . . . . 3-14
3-18. Air Cleaner Assembly . . . . . . . . . . . . . . . . . . . . 3-14
3-19. Control Cubicle Assembly . . . . . . . . . . . . . . . . . . . 3-17
3-20. Fuel System (Less Tank) . . . . . . . . . . . . . . . . . . . 3-19
3-21. Control Cubicle Support Assembly, Speed Control and
Engine Control Wiring Harness . . . . . . . . . . . . . . . 3-20
3-22. Engine Cooling System . . . . . . . . . . . . . . . . . . . . 3-21
3-23. Generator Assembly . . . . . . . . . . . . . . . . . . . . . . 3-23
3-24. Engine Assembly . . . . . . . . . . . . . . . . . 3-23
3-25. Skid-Base Assembly . . . . . . . . . . . . . . . . . . . . . 3-27
CHAPTER 4. ORGANIZATIONAL MAINTENANCE . . . . . . . . . . . . . . . . . 4-1
Section I. SERVICE UPON RECEIPT OF MATERIAL . . . . . . . . . . . . 4-1
4-1. Inspecting and Servicing Generator Set . . . . . . . . . . . . 4-1

4-2. Installing Generator Set. . . . . . . . . . . . . . . . . . . . 4-2
Section II. MOVEMENT TO ANEW WORKSITE . . . . . . . . . . . . . . . . . 4-4
4-3. Dismantling Generator Set for Movement . . . . . . . . . . 4-4

4-4. Reinstalling Generator Set After Movement . . . . . . . . . 4-4
i i
TM 5-6115-585-12
NAVFAC P-8-262-12
TO-35C2-3-455-1
TM-05684C/05685B-12
Page
Section III. REPAIR PARTS SPECIAL TOOLS; SPECIAL TEST, MEASURE-
MENT AND DIAGNOSTIC EQUIPMENT AND SPECIAL
SUPPORT EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4-5. Special Tools and Equipment.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4-6. Maintenance Repair Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Section IV. LUBRICATION INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

4-7. Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Section V. PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS). 4-5

4-8. PMCS, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Section VI. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6.1

4-12. Troubleshooting, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6.1
4-13. Malfunctions Not Corrected By Use of the Troubleshooting
Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6.1
Section VII. RADIO INTERFERENCE SUPPRESSION . . . . . . . . . . . . . . . . . . . . . . . . 4-10

4-14. General Methods for Proper Suppreseion . . . . . . . . . . . . . . . . . . . . . 4-10
4-15. Radio Interference Suppression Components . . . . . . . . . . . . . . . . . . 4-10
Section VIII. MAINTENANCE OF ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . 4-12

4-16. Description and Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
4-17. Engine Cooling Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Section IX. MAINTENANCE OF FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

4-18. Description and Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
4-19. Fuel Tank Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
4-20. Fuel Filter Assemblies and Strainer Aseembly . . . . . . . . . . . . . . . . 4-17
4-21. Electric Fuel Pumps, Fuel Hoses and Auxiliary Solenoid Valve . . 4-21
4-22. Auxiliary Fuel Solenoid Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
4-23. Fuel Shut-Off Solenoid Valve... . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Section X. MAINTENANCE OF ENGINE ELECTRICAL SYSTEM . . . . . . . . . . . . 4-24

4-25. Battery Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
4-26. Engine Starter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
4-27. Battery Charging Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
4-28. Starter Lockout Switch and Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
Section XI. MAINTENANCE OF OIL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33

4-29. Function and Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
4-30. Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
4-31. Low Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
4-32. Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36
4-33. Oil Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
Section XII. MAINTENANCE OF CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 4-38

4-35. DC Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
Change 6 iii
TM 5-6115-585-12
NAVFAC P-6-623-12
TO-35C2-3-455-1
TM-05682C/05885B-12
Page
Section XII. MAINTENANCE OF CONTROL SYSTEM (CONT):

4-36. AC Instrumentation System . . . . . . . . . . . . . . . . . . . . . . 4 - 3 8
4-37. Load Terminal Board Assembly . . . . . . . . . . . . . . . . . . . . . 4-41
4-38. Control Cubicle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 4-42
Section XIII. MAINTENANCE OF ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 4 5

4-39. Description and Function . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 4 5
4-40. Exhaust Muffler Assemblies . . . . . . . . . . . . . . . . . . . . . . . 4 - 4 5
4-41. Air Cleaner Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 4 7
4-42. Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 4 7
4-43. Intake Manifold Assembly . . . . . . . . . . . . . . . . . . . . . . . . 4 - 4 9
4-44. Rocker Arm Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-45. Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 4 9
.
4 - 4 9
4-46. Valve Rocker Arms . . . . . . .. . . . . . . . . . . . . . . . . . . . .
4 - 4 9
4-47. Injector Nozzle Assembly and Fuel Lines . . . . . . . . . . . . . . .
4-48. Glow Plug Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 5 1
4-49. Oil Drain Hose and Valve . . . . . . . . . . . . . . . . . . . . . . . . 4 - 5 1
4-50. Oil Pan-Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 5 3
4-51. Oil Fill Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 5 3
4-52. Engine Mounting Assembly...... . . . . . . . . . . . . . . . . . 4 - 5 3
4 - 5 3
Section XIV. MAINTENANCE OF GENERATOR ASSEMBLY . . . . . . . . . . . . . 4 - 5 5
4-54. Generator/Exciter Assembly . . . . . . . . . . . . . . . . . . . . . . . . 4 - 5 6
4-55. Screen-Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 5 6
Section XV. MAINTENANCE OF SKID-BASE . . . . . . . . . . . . . . . . . . . . . . . . 4 - 5 6

4-57. Skid-Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 5 6
CHAPTER 5 MATERIAL USED IN CONJUNCTION WITH DOD STANDARD
10KW DIESEL ENGINE DRIVEN, MODEL MEP-003A and
MEP-112A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 - 1
Section I. AUXUILLARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 - 1
5-1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 - 1
Section II. ACOUSTIC SUPPRESSION KIT . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 2
5-2. Acoustic Suppression Kit . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 2

5-3. Cover Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 2
5-4. Top Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 8
5-5. Left Panel Assembly with Side Closure Assembly . . . . . . . . . 5 - 1 0
5-6. Right Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 1 2
5-7. Rear Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 1 4
5-8. Exhaust Plenum Assembly . . . . . . . . . . . . . . . . . . . . . . . . 5 - 1 6
5-9. Left Support Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 1 6
5-10. Right Support Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 1 8
5-11. Front Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 1 8
5-12. Side Closure Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 - 2 1
5-13. Rear Closure Assembly . . . . . . . . . . . . . . . . . . . . . . . . . .
5-14. 5 - 2 1
Rear Flap Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 - 2 3
i v Change 8
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NAVFAC P-8-623-12
TO-35C2-3-455-1
TM-05682C/05685B-12
Page
Section III. ACOUSTIC SUPPRESSION KIT REPAIR . . . . . . . . . . . . . . . . 5-25
5-15. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25

5-16. Panel Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
5-17. Latch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
5-18. Catch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
5-19. Rubber Flap Replacement . . . . . . . . . . . . . . . . . . . . . . . 5-27
5-20. Hinges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
5-21. Captive Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
5-22. Front Panel Silencer . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
APPENDIX A. REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
APPENDIX B. ITEMS TROOP INSTALLED OR AUTHORIZED LIST . . . . . . B-1
APPENDIX C. MAINTENANCE ALLOCATION CHART . . . . . . . . . . . . . . . . C-1
Section I. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1

II. MAINTENANCE ALLOCATION CHART . . . . . . . . . . . . . . . . C-3
III. TOOLS, TEST AND SUPPORT EQUIPMENT
REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-18
IV. EXPLANATIONS OF REFERENCE CODES . . . . . . . . . . . . . . C-19
APPENDIX D. ADDITIONAL AUTHORIZATION LIST . . . . . . . . . . . . . . . . . D-1
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INDEX 1
iv.1/(iv.2 blank)
TM 5-6115-585-12
NAVFAC P-8-623-12
To-35C2-3-455-1
TM-05684C/05685B-12
LIST OF ILLUSTRATIONS
Figure Title Page
1-1. Engine Generator Set Right-Rear, Thee-Quarter View . . 1-3
1-2. Engine Generator Set Left-Front, Three-Quarter View . . . 1-4
1-2.1. Engine Generator Set Left-Front Three-Quarter View (MEP-112A) . . . . . . . . . . . . . . . . 1-4.1
1-2.2. Engine Generator Set, Left Front, Three-Quarter View (MEP-112A Only), with
Acoustic Suppression Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4.2
1-3. Tie Down, Lifting, and Towing Provisions Crated Set(MEP003A) . . . . . . . . . . . . . . . . . 1-8
1-4. Installation Plans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
1-5. Fuel Syetam Schematic . . . . . . . . . . : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
1-6. Eletrical Cable Schematic.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
1-7. Generator Set Electrical Schematic (MEP-003A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
1-7.1. Generator Set Electrical Schematic (MEP-112A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12.1
1-8. Generator Set Wiring Harneas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
1-9. AC Output Control Box Wiring Harness (MEP-003A) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
1-9.1. AC Output Control Box Wiring Harness (MEP-112A) . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14.1
1-10. Control Cubicle Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
2-1. Load Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2-2. Reconnection switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2-3. Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2-4. Load Terminal and Reconnection Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
3-1. Deleted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3-2. Battery Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
3-3. Ground Rod and Fuel Drum Adapter Pipe Hold-Down . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
3-4. Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
3-5. Shutter and Thermo Power Element Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3-6. Exhaust Muffler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
3-7. Electric Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
3-8. AC Output Control Box Aseembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
3-9. Air Cleaner and Shroud Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
3-10. Air Cleaner Aseembiy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
3-11. Cleaning Air Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
3-12. Control Cubicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
3-13. Fuel Filters and Fuel Strainer Aseembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
3-14. Fuel Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
3-15. Control Cubicle Support Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
3-16. Speed Control Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
3-22
3-17. Engine Cooling Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-18. Generator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
3-19. Intake Manifold Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
3-20. Oil Drain Hoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
3-21. Oil Filter and Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
3-22. Engine Stop Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
3-23. Battery and Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
3-24. Ground Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
4-1. Uncrating Generator Set..... . . . . . . . . . . . . . . . . . . 4-2
4-2. Grounding Generator Set..... . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4-3. Primary_Radio Interference Suppression Components . . . . . . . . . . . . . . . . . . . . . . . 4-11
4-4. Shutter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
4-5. Adjusting Shutters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
4-6. Adjusting Thermo Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
4-7. Fuel Tank Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
4-8. Testing Float Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
4-9. Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
4-10. Fuel Strainer Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
4-11. Fuel Filter and Fuel Strainer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Change 8 v
TM 5-6115-585-12
NAVFAC P-8-623-12
TO-35C2-3-455-1
TM-05684C/05685B-12
LIST OF ILLUSTRATIONS
Figure Title Page
4-12. Fuel Pump, Fuel Hoses and Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

4–13. Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
4-14. Adjusting Fuel Shut–Off Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
4–15. Fuel Solenoid Test Set–Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
4-16. Installing Battery Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–25
4–17. Testing Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–26
4-18. Engine Starter installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–27
4–19. Testing Engine Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–28.1
4–20. Testing Field Coil, Style II Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–28.2
4–21. Inspecting Engine Starter Brushes, Style I Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–28.2
4–21 A. Inspecting Engine Starter Brushes, Style II Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–28.3
4–22. Engine Starter Assembly, Style l Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–28.4
4–22A. Engine Starter Assembly, Style ll Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–28.4
4–23. Battery Charging Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
4-24. Testing Battery Charging Regulator/Rectifier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–31
4–25. Lockout Switch and Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
4–26. Adjusting Starter Lockout Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–33
4-27. Pressure Oil System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
4-28. Oil Cooler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
4-29. Replacing Oil Cooler Hoses (Early Model MEP–003A only) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–35
4–29.1. Replacing Oil Cooler Hoses (Current Model MEP-003A and MEP-112A) . . . . . . . . . . . . . . . . 4–36
4–30. Oil Filter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–36.1
4–31. Replacing Oil Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–37
4–32. Load Terminal Board Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–39
4–32.1. Terminal Clip Replacement.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–40
4-33. Control Cubicle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41
4-33.1. Relay K1 lnternal Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42.2
4-34. Removing Control Cubicle Support Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43
4-35. Control Cubicle Test Set–Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44
4-36. Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46
4-37. Exhaust Muffler and Air Cleaner Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-48
4-38. Rocker Arm Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-49
4-39. Cleaning Rocker Arm Cover Oil Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50
4-40. Checking and Adjusting Rocker Arm to Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–51
4-41. Cylinder Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-52
4-42. Oil Fill Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–53
4-43. Engine Mounting Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54
4-44. Generator Screen-Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-55
4-45. Skid–Base Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–57
5-1. Instruction and Rating Plates... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3
5–2. Cover Assembly, Removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–7
5–3. Top Panel Assembly and Exhaust Plenum, Removal and Installation . . . . . . . . . . . . . . . . . . . . 5–9
5-4. Left Panel Assembly and Side Closure Assembly, Removal and Installation . . . . . . . . . . . . . . 5–11
5-5. Right Panel Assembly, Removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–13
5-6. Rear Panel Assembly, Removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–15
5–7. Left Support Assembly, Removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–17
5–8. Right Support Assembly, Removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–19
5-9. Front Panel Assembly, Removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–20
5–10. Rear Enclosure Assembly, Removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–22
5–11. Rear Flap Assembly, Removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–24
5–12. Replacement of ASK Hardware items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–28
vi Change 11
TM 5-6115-585-12
NAVFAC P-8-623-12
TO-35C2-3-455-1
TM-05682C/05685B-12
LIST OF TABLES (CONT)
Table Page
2-1. Generator Set Controls and Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2-2. Reconnection Switch Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
3-1. Consumable Operating and Maintenance Supplies . . . . . . . . . . . . . . . . . . . 3-1
3-2. Preventive Maintenance Checks and Services . . . . . . . . . . . . . . . . . . . . . . . 3-4.1
3-3. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
4-1. Preventive Maintenance Checks and Services . . . . . . . . . . . . . . . . . . . . . . . 4-5
4-2. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4-3. Master Switch Continuity Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42
4-4. Voltmeter-Ammeter Range Selector Switch Continuity Check . . . . . . . . . . . 4-42.1
vii/(viii blank)
TM5-6115-585-12
NAVFAC P-8-623-12
TO-35C2-3-455-1
TM-05684C/05685B-12
CHAPTER 1
INTRODUCTION
Section I. GENERAL
mander, US Army Troop Support and Materiel

1-1. SCOPE
Readiness Command, ATTN DRSTS-MPSD, 4300
This manual is for your use in operating and main- Goodfellow Boulevard, St. Louis, MO 63120.
taining the DOD Standard Generator Sets, 10KW
Diesel Engine Driven, Model MEP-003A and Model b . ( F ) A i r F o r c e - AFTO Form 22 directly to:
MEP-112A. It contains sections for operating proce- Commander, Sacramento Air Logistics Center, ATTN:
dures for operation under both normal and unusual MMEDT, McClellan Air Force Base, CA 95652, in
conditions; a section for lubrication instructions, in- accordance with TO-00-5-1.
cluding a Lubrication Order; a section for preventive
maintenance; a section for troubleshooting; and sec- c. (N) Navy - by letter directly to: Commanding
tions for both operator maintenance procedures and Officer, US Navy, Ships Parts Control Center, ATTN:
organizational maintenance procedures. Thoroughly Code 783, Mechanicsburg, PA 17055.
familiarize yourself with the unit before operating
or servicing. d. (MC) Marine Corps - by NAVMC Form 10772
directly to: Commandant Headquarters, US ‘Marine
1-2. LIMITED APPLICABILITY Corps, ATTN: Code LMA-1, WASH DC 20380.
Some portions of this publication are not applicable
to all services. These portions are prefixed to indi- 1-5. LEVELS OF MAINTANCE ACCOMPLISH-
cate the services to which they pertain: (A) for Army, M E N T .
(F) for Air Force, (N) for Navy, and (MC) for Marine
Corps. Portions not prefixed are applicable to all a. (A, MC) Army and Marine Corps users shall
services refer to the Maintenance Allocation Chart (MAC) for
tasks and levels of maintenance to be performed.
1-3. Maintenance Forms and Records b. (F) Air Force users shall accomplish mainte-
a. (A) Maintenance forms and records used by nance at the user level consistent with their capabil-
Army personnel are prescribed in TM 38-750. ity in accordance with policies established in AFM
66-1.
b. (F) Maintenance forms and records used by Air c. (N) Navy users shall determine their mainte-
Force personnel are prescribed in AFM-66-1 and the nance levels in accordance with their service direc-
applicable 00-20 Series Technical Orders. tives.
1-6. (A, MC) DESTRUCTION OF MATERIAL TO PRE-
c. (N) Navy users should refer to their service
peculiar directives to determine applicable mainte- VENT ENEMY USE.
nance forms and records to be used.
Army and Marine Corps personnel shall refer to TM
750-244-3 as a Source for procedures for the de-
d. (MC) Maintenance forms and records used by
Marine Corps personnel are prescribed in TM 4700- struction of material to prevent enemy use.
15/1.
e. (A) HAND RECEIPT. Hand receipts for the 1-7. (A, F,MC) ADMINISTRATIVE STORAGE.
End Item/Components of End Item (COEI), Basic Army personnel shall refer to TM 740-90-1, Ad-
Issue Items (BII), and Additional Authorization List ministrative Storage, for procedures for storage of
(AAL) items are published in a Hand Receipt Manual. this equipment. Air Force personnel shall refer to
The Hand Receipt manual numerical designator is TO 35-1-4, Processing and Inspection of Aerospace
the same es the related Technical Manual with the Ground Equipment, for storage and shipment of this
letters HR added to the number. These manuals are equipment. Marine Corps personnel shall refer to
published to aid in property accountability and are MCO P4450.7.
available through: commander, US Army Adjutant
General publications Center, ATTN: AGDL-OD,
1655 Woodson Road, St. Louis, MO 63114. 1-8. PREPARATION FOR SHIPMENT AND STORAGE
a. (A) Army - Refer to TB 740-97-2 and TM 740-
1-4. REPORTING OF ERRORS
90-1.
Report of errors, omissions, and recommendations b. (F) Air Force - Refer to TO 35-1 -4 for end item
for improvement of this publication by the individual
Generator Sets and to TO 38-1-5 for installed engine.
user is encouraged. Reports should be submitted as
follows: c. (N, MC) Navy and Marine Corps refer to indi-
a. (A) Army - DA Form 2028 directly to: Com- vidual Service directives for require-rents.
Change 4 1 - 1
TM5-6115-585-12
NAVFAC P-8-623-12
TO-35C2-3-455-1
TM-05684C/05685B-12
Section II. DESCRIPTION AND DATA
1-9. DESCRIPTION OF GENERATOR SET. used primarily for operating control and excitation
The MEP-003A is a 10 kilowatt, 60 Hertz Generator and (2) the ac output system to supply power to the
load.
Set. The MEP-112A is a 10 kilowatt, 400 Hertz Gen-
erator Set. Both consist of a revolving field alter- The dc source consists of a 24 volt battery set (BT1
nator powered by an air cooled diesel engine. See and BT2) that is kept charged by a battery charging
figures 1-1 and 1-2 for the location of major com- alternator (G2) and voltage regulator rectifier as-
ponent. These sets are not designed for parallel sembly (A5). Fuse (F1) protects the alternator from
operation. overload. Circuit breaker (CB2) protects the battery
charging system from overload. Slave receptacle (J15)
a. Engine. permits an alternate external supply to be connected
(1) The engine powering this Generator Set is a to the battery circuit.
4 cylinder, 4 cycle air cooled engine, with a 140 cubic (2) Operation, Placing MASTER SWITCH (S1) into the
inch (cu. in.) displacement. A mechanical governor PREHEAT position, the preheat relay K2 is activated to
keeps engine speed at 1800 revolutions per minute energize the heater elements (HR1 and HR2) and the engine
(RPM) under rated load conditions for the MEP-003A glow plugs (HR3, HR4, HR5, and HR6).
and at 2000 RPM for the MEP-112A.
(2) Fuel is supplied either from this unit’s self- Placing the MASTER SWITCH in the PRIME-RUN-
contained fuel tank or, by using an adapter, directly AUXILIARY position activates the fuel pumps E2 and
from a 55 gallon drum or other source. The fuel is E3 as well as the auxiliary fuel pump El. If the fuel
filtered by two cartridge type fuel filters and a single level is down, the fuel level switch S3 will be closed
fuel strainer, Two electric, self-priming fuel pumps and the auxiliary fuel solenoid will actuate permit-
pump fuel to the fuel injection pump which delivers ting fuel to be pumped into the tank.
the fuel at high pressure to fuel injection nozzles in
Placing the MASTER SWITCH (S1) into the PRIME-
the cylinder head. When auxiliary source. of fuel is
RUN position maintains power to the main fuel pumps
used, three electric fuel pumps are used.
but deactivates the auxiliary fuel pump.
(3) Two 12 volt “wet cell” batteries in series
supply power for a 24 volt electric starter and for (a) Start. Placing the MASTER SWITCH (Sl)
into the start position maintains the fuel pump cir-
glow plugs, located in the cylinder head, and two air
cuits and the preheat circuits to the glow plugs (HR3,
heaters located in the intake manifold, used for cold
weather starting. An alternator located beneath the HR4, HR5 and HR6) as well as to energize the gover-
blower wheel and completely separate from the m ain nor solenoid (K5) and start relay (K1). The crank re-
lay (K3) is energized, in turn energizing the start
alternator automatically recharges these batteries
when the engine is operating. solenoid (K6) and activating the starter (B1). The
governor brings the engine to speed, building up oil
b. Generator. pressure and closing oil pressure switch (S5). The
exciter field is flashed during this starting procedure.
The generator on the MEP-O03A is a four pole, re-
volving field type. The generator on the MEP-112A (b) Run. Placing the MASTER SWITCH (S1) in the
is a 24 pole, revolving field type, Alternating current, PRIME-RUN position keeps the governor solenoid (K5)
supplied by the exciter assembly, is rectified and energized thru the now closed oil pressure switch (S5) and fuel
used to create the revolving field. will be supplied to the engine as long as the oil pressure is nor-
mal and the high temperature switch (S4) is not activated by
A “solid-state” voltage regulator assembly auto- high temperature.
matically adjusts this current to obtain a constant
(±3%) voltage in the main stator (output) windings. (c) Stop. Placing the MASTER SWITCH (S1) in
the OFF position de-energizes the governor solenoid
c. Controls. (K5) shutting off fuel to stop the engine. High temper-
All operator controls and indicator gauges necessary ature or low oil pressure will also shut the. engine
down.
for running the engine Generator Set are located on
the control panel. In addition, an oil pressure gage
(3) AC Circuitry. The main alternator (G1) is
is located on the engine and a fuel level gage is wound with six pairs of coils that may be connected
located on the fuel tank. The speed control is lo- by the AC Reconnect switch (S6) into various com-
cated below the control panel. binations, the output of which is available at the load
Controls for selecting output voltage are located on terminal board (TB1). Circuit breaker (CB1) protects
the output control box. the alternator from overloads. The volt/ampere se-
lect switch (S8) permits switching voltmeter (MS) and
d. Generator Set Electrical System (see schematic ammeter (M4) to read the load current and voltage
figure 1-7). for the various arrangement of outputs.
(1) General. The generator set’s electrical sys- Voltage regulator (A2) and current voltage trans-
tem consists of two distinct systems (1) the dc system former CVT1 monitors the alternator output voltage
1-2 Change 4
TM5-6115-585-12
NAVFAC P-8-623-12
TO-35C2-3-45-1
TM-05684C/05685B-12
Figure 1-1. Engine Generator Set, Right-Rear, Three-Quarter View
Change 2 1-3
TM5-6115-585-12
NAVFAC P-8-623-12
TO-35C2-3-455-1
TM-05684C/05685B-12
Figure 1-2. Engine Generator Set, Left-Front, Three-Quarter View (MEP-003A-Only)
1-4 Change 2
TM5-6115-585-12
NAVFAC P-8-623-12
TO-35C2-3-455-1
TM-05684C/05685B-12
Figure 1-2.1. Engine Generator Set, Left-Front, Three-Quarter View (MEP-112A Only)
Change 8 1-4.1
TM5-6115-585-12
NAVFAC P-6-623-12
TO-35C2-3-455-1
TM-05684C/05685B-l2
Figure 1-2.2 Engine Generator Set, Left Front, Three-Quarter View (MEP-003A Only),
With Acoustic Suppression Kit
1-4.2 Change 8
TM 5-6115-585-12
NAVFAC P-8-623-12
TO-35C2-3-455-1
TM-05684C/05685B-12
and current under load and varies the exciter field either WARRANTY :
up or down to keep the generator field at such a value
as to maintain constant alternator output voltage. The DATE INSP :
regulated voltage setting can be varied using the voltage
adjust rheostat (R1 ). MFD BY: ONAN CORP.
On MEP-003A, an ac receptacle (J14 ) is connected through INSP STAMP:

a protective circuit breaker (CB3) to provide 120 VAC.
(2) Operating Instruction Plate.
1-10. TABULATED DATA.
(a) Location. This plate is located on the side of
a. Identification and Instruction Plates (see figures 1-1 the control cubicle.
and 1-2 ).
(b) Content.
(1) Identification Plate.
OPERATING INSTRUCTIONS
(a) Location. This plate is located on the side of
the control cubicle. BEFORE STARTING SET
(b) Content. 1. Insure output circuit breaker is off.
US DEPARTMENT OF DEFENSE 2. Fill crankcase (do not overfill) and fuel tank.
Ensure that vent on underside of fuel filler cap
GENERATOR SET DIESEL ENGINE 10KW 60 H Z is open before starting generator.
MODEL: MEP-O03A 3. “WARNING” – Ground set to avoid shock.

hazard.
GENERATOR SET DIESEL ENGINE 10KW 400Hz
4. Set batteries are negative ground.
MODEL: MEP-112A
STARTING SET
NSN: 6115-00-465-1030 (MEP-003A)
1. Move “MASTER SWITCH” to “PRIME &
NSN: 6115-00-465-1027 (MEP-112A) RUN” position to allow fuel to prime set.
2. Move “MASTER SWITCH” to “PREHEAT”
TM 5-6115-585-12
position end hold for (1) minute.
TO-35C2-3-455-1 NOTE: Preheat is not required when engine is
hot.
NAVFAC P-8-623-12
3. Move “MASTER SWITCH” to “START” posi-
TM-05684C/05685B-12 tion and hold until engine fires continuously.
If engine does not start within 15 seconds,
VOLTS: 120V 1PH. repeat steps 1 and 2.
120/240V 1PH. 4. “MASTER SWITCH” will return to “PRIME &
120/208V 3PH.
RUN” position when released. If running from
auxiliary fuel source, move “MASTER
PF: 0.8
SWITCH” to “PRIME & RUN AUX FUEL”
position.
AMPS: 104, 52,34.7
5. After warm up. Check frequency and voltage
DRY WT: 1220 LB (MEP-003A) and adjust if necessary.
6. M o v e " A C C i r c u i t B r e a k e r " t o " O N "
DRY WT: 1325 LB (MEP-112A)
position.
LG: 62 IN
STOPPING SET
W: 32 IN 1. Move “AC CIRCUIT BREAKER” to “OFF”
position.
HGT: 37 IN
2. Move “MASTER SWITCH” to “OFF” position.
CONTR NO: F04606-74-C-1133 (MEP-003A)
3. For emergency stop Pull “DC CONTROL
CONTR NO: DAAK70-78-C-0177 (MEP-112A) CIRCUIT BREAKER-.” -
Change 6 1 - 5
TM5-6115-585-12
NAVFAC P-8-823-12
TO-35C2-3-455-1
TM-05684C/05685B-12
SERVICE INSTRUCTIONS
Lubricating
Fuels 0il Capacity
Ambient Capacity- 12.5 GAL (Less Filter)
Temperature Primary-Diesel Emergency-JP4 5. 5QT
-65° to -25ºF VV- F-800 Grade DFA MIL-L-10295

-54” to -12°C
-25° to -10°F VV- F-800 Grade DF1 MIL-L-10295

-32° to -23 °C
-10° to -30°F VV-F-800 Grade DF1 For JP4 operation, see MIL-L-2104 Grade 10
-23°to -1°C Instruction Manual
+30° to +1OO°F W-F-800 Grade DF2 MIL-L-2104 Grade 30

-1° to +38°C
+100° to +125°F VV- F-800 Grade DF2 MIL-L-2104 Grads 30

+38° to +52 °C
b. Tabulated Data for Generator Set.
(1) Generator Set.
Manufacturer: . . . . . . . . . . . . . . . . . . . . . . . . . . . Onam Corp.
Model, Rated Frequency . . . . . . . . . . . . . . . . . . . . . MEP-003A, 60 H Z
Model, Rated Frequency . . . . . . . . . . . . . . . . . . . . . MEP-112A, 400 Hz
Operating temperature range:

without external heat -25° to +125°F, -32° to 462°C
with external heat . . -65° to -25°F, -54° to -32°C
Maximum Rated Output: 10Kw (0.8 power factor)

(0-5000 ft above sea level)
Voltage: . . . . . . . . 120V. (single phase, 2 wire)

120/240V. (single phase, 3 wire)
120/208V. (3-phase, 4 wire)
Fuel capacity: . . . . . 12.5 gallons (47.3 liters)
Dimensions and weights: MEP-003A MEP-1124

overall length . . . . . . . . . . . . 62 in. (157.5 cm.) 62 in. (157.5 cm.)
overall width . . . . . . . . . . . . 32 in. (81.3 cm.) 32 in. (81.3 cm.)”
overall height . . . . . . . . . . 37 in. (94 cm.) 37 in. (94 cm.)
net weight empty . . . . . . . . . . 1220 lb (553.4 kg) 1325 lb (601 kg)
net weight filled . . . . . . . . . . 1360 lb (616.9 kg) 1455 lb (660 kg)
shipping weight . . . . . . . . . . . 1283.5 lb (582.2 kg) 1450 lb (658 kg)
cubage . . . . . . ... ... 42.5 cu. ft. (1.2 cubic meters) 42.5 cu. ft. (1.2 cubic meters)
Dimensions and weights with ASK Installed (MEP-003A) (MEP-112A)

overall length . . . . . . . . . . . . . . . . . . 69 in. 175.3 cm) 69 in. 175.3 cm)
overall width . . . . . . . . . . . . . . . . . . . 36 in. 91.4 cm) 36 in. 91.4 cm)
overall height . . . . . . . . . . . . . . . . . . 39 in. (99 cm) 39 in. (99 cm)
net weight empty . . . . . . . . . . . . . . . 1365 lb (619.7 kg) 1470 lb (667.4 kg)
net weight fllled . . . . . . . . . . . . . . . . 1505 lb (683.3 kg) 1600 lb (726.4 kg)
shipping weight . . . . . . . . . . . . . . . . 1365 lb (61 9.7 kg) 1470 lb (667.4 kg)
cubage . . . . . . . . . . . . . . . . . . . . . . 55 cu ft (1.6 cubic meters) 55 cu ft (1.6 cubic meters)
1 - 6 Change 8
TM5-6115-585-12
NAVFAC P-8-623-12
TO-35C2-3-455-1
TM-05684C/05685B-12
Ventilation requirements
(across the generator set) . . . . . 1350 CFM at 1800 RPM 1600 CFM at 2000 RPM
(2) Engine.
Manufacturer: . . . . . . . . . . . . . . . . . . . . . . . . . . Onan Corp.
Type: . . . . . . . . . . . . . . . . . . . . . .. four stroke cycle, air cooled, diesel
Number of cylinders: . . . . . . . . . . . . . . . . . . .. four
Change 8 1-6.1 /(1.6.2 blank)

TM5-6115-585-12
NAVFAC P-8-623-12
TO-35C2-3-455-1
TM-05684C/05685B-12
Displacement: . . . . . . . . . . . . . . . . . . . . . . . . . . 140 cu. in. (2294 cc.)
Compression ratio: . . . . . . . . . . . . . . . . . . . . . . . . . 19:1
Horsepower, 0-5000 ft above sea level . . . . . . . . . . . . . . 16@1800 RPM

18@2000 RPM
Lubricating oil capacity: . . . . . . . . . . . . . . . . . . . . . . 5.5qts, 6.5qts if filter is changed

(5. 2 liters, 6.2 liters if filter is
changed)
Governor: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . internal flyball, external adjust-

ment
Maximum battery charge rate . . . . . . . . . . . . . . . . . . . not less than 6.5 ampere
Starting motor voltage: . . . . . . . . . . . . . . . . . . . . . . . 24 VDC
(3) Batteries.
Type: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6TN (per MS35000-3)
Voltage: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 VDC
Amp-Hrs: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
(4) Fuel pumps.
Manufacturer: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bendix Corp.
Part No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 480517
Ground Polarity: . . . . . . . . . . . . . . . . . . . . . . . . . . Negative
(5) Fuel filters.
Manufacturer: . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fram Corp.
Model: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244350
Fuel filter element: . . . . . . . . . . . . . . . . . . . . . . . . . Part No. C1125PL
(6) Fuel strainer.
Model: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244344
Fuel strainer element: . . . . . . . . . . . . . . . . . . . . . . . Part No. 35070
(7) Air cleaner.
Manufacturer: . . . . . . . . . . . . . . . . . . . . . . . . . . . . Donaldson Co., Inc.

Model: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . KAXOO-3851
Air cleaner element: . . . . . . . . . . . . . . . . . . . . . . . . Part No. P1O 1222
(8) Engine oil filter.

Model: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170429
Oil filter element: . . . . . . . . . . . . . . . . . . . . . . . . . . . Part No. CH6PL
Change 2 1-7
TM5-6115-585-12
NAVFAC P-8-623-12
TO-35C2-3-455-1
TM-05684C/05685B-12
Figure 1-3. Tie Down, Lifting, and Towing Provisions Crated Set (MEP-003A)
1-8 Change 2
TM5-6115-585-12
NAVFAC P-8-262-12
TO-35C2-3-455-1
TM-05684C-12
Figure 1-5. Fuel System Schematic
Figure 1-4. Installation Plans
1-9
TM5-6115-585-12
NAVFAC P-8-262--12
TO-35C2-3-455-1
TM-05684C-12
1-10
TM 5-6115-585-12
NAVFAC P-8-623-12
TO-35C2-3-455-1
TM-05684C/05685B-12
Figure 1-8. Generator Set Wiring Harness
C h a n g e 4 1-13
TM 5-6115-585-12
NAVFAC P-8-623-12
TO-35C2-3-455-1
TM-05684C/05685B-12
Figure 1-9. AC Output Control Box Wiring Harness (MEP-003A Only)
1-14 Change 6
TM5-6115-585-12
NAVFAC P-8-623-12
TO-35C2-3-455-1
TM-05684C/05685B-12
Figure 1-9.1. AC Ouptut Control Box Wiring Harness (MEP-112A Only)

Change 4 1-14.1/(1-14.2 blank)
TM5-6115-585-12
NAVPAC P-8-623-12
TO-35C2-3-455-1
TM05684C/05685B12
Figure 1-10. Control Cubicle Wiring Harness
Change 5 1-15/(1-16 blank)

TM 5-6115-585-12
NAVFAC P-8-623-12
TO-35C2-3-455-1
TM-05684C/05685B-12
CHAPTER 2
OPERATING INSTRUCTIONS
Section I. OPERATING PROCEDURE
2-1. G E N E R A L Stay clear of all exposed electrical ter-

minals when Generator Set is operating.
a. This chapter contains instructions for opera-
tion, power and control connections. Location and Remove all rings, watches and other
function of controls and indicators and safety precau- jewelry when performing maintenance on
tions are also provided. this equipment. Loose fitting clothing
should be secured to prevent it from
b. Refer to table 3-2 and perform “Before Opera-
catching in moving parts.
tion” Preventive Maintenance Checks and Services
before operating the Generator Set. 2-2. P O W E R CONNECTIONS.
c. Before operating set, check for proper installa-

tion. See Chapter 4, Section I.
BEFORE ATTEMPTING TO CONNECT
d. Table 2-1 describes the Generator Set controls LOAD CABLES, MAKE SURE THE
and instruments (see figure 2-3). GENERATOR SET IS NOT
OPERATING, ALL SWITCHES ARE IN
THE OFF OR OPEN POSITION AND
THE SET IS GROUNDED.
All personnel involved in the operation or
maintenance of the Generator Set should To connect load cables to Generator Set, attach load
become thoroughly familiar with the safe- leads to terminals located in output control box as re-
ty precautions prior to performing opera- quired. See figure 2-1.
tion or maintenance procedures.
2-3. E Q U I P M E N T RECONNECTION.
Prior to connection of load cables, make
sure all switches are in OFF or OPEN posi-
tion, the Generator Set is not operating. When selecting position 120V, 1 PH unit is
in 2 wire configuration. A situation
Inspect the Generator Set ground connec-
can/may exist in allowing a double fault to
tion prior to starting the unit. Electrical
occur. To eliminate this possibility the
defects in load lines or load equipment can
reconnection switch will be rewired by
cause death by electrocution when contact
using a AWG #4 wire jumper between ter-
is made with an ungrounded system.
minals #LO and #6 of section 9.
Do not smoke or carry an open flame when
Before operating unit, be certain voltage and frequen-
servicing the batteries or fuel tank. Exer-
cy rating of the load matches that of the Generator
cise extreme care to prevent electrical arc-
Set. If the output voltage of the Generator Set must
ing in the area of the batteries.
be changed to match a particular load, rotate recon-
Battery electrolyte contains sulfuric acid nection switch located on Reconnection Panel to
and can cause severe burns. Handle it with desired output connections. See figure 2-2.
care. If the electrolyte comes in contact
2-4. S T A R T I N G G E N E R A T O R S E T ( S E E
with the body, eyes, or clothing, rinse im-
FIGURE 2-3).
mediately with clean water. Avoid spilling
electrolyte on painted surfaces. Do not
work alone or smoke when servicing
Do not operate in excess of 200 hours con.
batteries.
tinuous with JP-4. MILJ-5624 bulk fuel.
Do not operate Generator Set in an enclos- Do not use either to aid in starting unit.
ed area unless the exhaust gases are piped Hearing protection is required.
to the outside. Continued breathing of ex-
haust fumes is dangerous.
Change 6 2-1
TM5-6115-585-12
NAVFAC P-8-623-12
TO-35C2-3-455-1
TM-05684C/05685B-12
a. When starting a set with a dry fuel system or after a

filter drain or change:
(1) Push In DC circuit breaker.
(2) Make sure the vent on the underside of the fuel

filler cap is open.
(3) On ASK equipped generators, open air Intake door,
(4) To prime fuel lines, slightly open plug (1, fig. 4-9)
on head (8) on filter assembly nearest check valve (6,
fig. 4-11).
(5) Move master switch to PRIME& RUN.
(6) When pump slows down, and no more bubbles

appear around plug, tighten plug (1, fig. 4-9).
NOTE
Preheat is not required when engine is

warm.
b. Move master switch to PREHEAT position and hold

for one minute.
2-2 Change 8
TM 5-6115-585-12
NAVFAC P-8-623-12
TO-35C2-3455-1
TM-05684C/05685B-12
Table 2-1. Generator Set Controls and Instruments

Control Description Function
BATTERY Green - fully charged: Yellow - Indicates the degree of charge of the batteries. Needle
INDICATOR charging: Red - Under or over in the green area indicates fully charged between 26
charging and 30 volts. Needle in yellow area indicates charging
condition between 20 and 26 volts. Needle in red area
indicates an under charge or an over charge condition.
Panel Light Shielded, bulb type, two used Illuminates control panel.
RUNNING TIME Hourmeter; 0 to 9,999.9 hours Indicates total operating time of Generator Set.
meter
Frequency Meter Range 55 to 65 Hz; 0.1 Hz scale Indicates frequency of Generator output.
Model MEP-003A divisions; red mark at 60 Hz
Frequency Meter Range 380 to 420 Hz; 1 Hz scale Indicates frequency of Generator output.
Model MEP-112A divisions; red mark at 400 Hz
%RATED CUR- 0 to 133 percent range; red line at Indicates percent of rated output current.
RENT METER 100 percent, green line at 0 percent
Voltmeter, AC O to 300 volt scale; suppressed from Indicates Generator Set output voltage.
O to 100 volts and linear from 100
to 300 volts. Red marks at 120, 208,
and 240 volt points.
VOLTAGE AD- Rheostat Adjusts Generator Set output voltage. Clockwise to

JUST RHEOSTAT increase and counterclockwise to decrease.
AMMETER- Rotary switch Used to select phase, voltage and current combination
VOLTMETER for reading on ammeter and voltmeter.
TRANSFER
SWITCH
PANEL LIGHT Toggle switch; ON-OFF Controls panel lights.

SWITCH
MASTER SWITCH Rotary switch, 5 positions, PRE- When placed in PREHEAT position, electrical power is
HEAT, OFF, PRIME & RUN applied to glow plugs and preheater on the engine to
AUX. FUEL, PRIME& RUN, and aid in cold engine starting. In OFF position, alI dc cir-
START cuits are deenergized except panel lights, and battery
charging system. This position is use to stop the unit
under normal operation. The PRIME & RUN AUX.
FUEL position is used when set is running and auxil-
iary fuel system is being used and also to prime entire
fuel system before starting if required. The PRIME&
RUN position is used when set is running and auxiliary
fuel system is not used and also to prime engine fuel
system only before starting if required. When placed in
START position, energizes engine cranking system for
engine starting, activates glow plugs and air heaters,
and by-passes protective devices.
DC ONTROL 7.5 AMP breaker Used for protecting dc circuit in case of short and also
CIRCUIT for emergency stopping; pull out to activate.
BREAKER
Change 10 2-2.1 /(2-2.2 blank)

TM 5-6115-585-12
NAVFAC P-8-623-12
TO-35C2-3-455-1
TM-05684C/05685B-12
Table 2-1. Generator Set Controls and Instruments (Cont)
Control Description Function
OIL PRESSURE Located on oil fill side of Indicates engine oil pressure.
GAUGE engine. 0-50 pounds per
square inch (psi)
RECONNECTION Located on output con- Used to select 120V, 1 phase; 120/240V,

SWITCH trol box. Three position 1 phase; or 120/208V, 3 phase output for
rotary switch. Generator Set.
c. Place master switch in START position and d. Master switch will return to PRIME & RUN
hold until engine comes to operating speed. If engine position when released. If running from auxiliary fuel
does not start within 15 seconds repeat steps b and c. source, move master switch to PRIME& RUN AUX.
If engine cranks too slow utilize slave receptacle (J14) FUEL position.
for extra cranking power.
e. Check oil pressure on engine mounted gage.
NOTE Oil pressure should be at least 20 psi minimum.
If engine does not come to operating speed Check frequency on frequency meter on control panel
within 15 seconds, a minimum of 30 and adjust governor if necessary, using speed con-
seconds cooling period must be observed trol (19, figure 1-1). Refer to paragraph 1-10.b. for
before attempting another start. rated frequency. Pulling speed control knob out will
Figure 2-1. Load Terminals Figure 2-2. Reconnection Switch
C h a n g e 6 2-3
TM 5-6115-585-12
NAVFAC P-8-623-12
TO-35C2-3-455-1
TM-05684C/05685B-12
Figure 2-3. Control Panel

increase frequency, pushing speed control knob in will h. Place ammeter-voltmeter transfer switch in
decrease frequency. For fine control turn knob CW to position to check percent rated current for either
increase and CCW to decrease. 1-phase 120 V. output, l-phase 120/240 V. output, or
3-phase 120/208 V. O Utput. See table 2-1 and figure
f. Place ammeter-voltmeter transfer switch in
2-3.
position corresponding to the position of the reconnec-
tion switch. Adjust voltage adjust rheostat to desired NOTE
voltage as read on voltmeter. Turn rheostat clockwise For 3-phase output each of the four posi-
to increase voltage or counterclockwise to decrease tions indicated in table 2-2 must be
voltage. checked.
g. Place AC circuit breaker in ON position. Adjust Observe percent rated current meter. Do not exceed
speed control to obtain full load frequency per 5% load difference between phases. A 0.8 power factor
paragraph 1-10.b.
Table 2-2. Reconnection Switch Positions
2-4 Change 2
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NAVFAC P-8-623-12
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TM-05684C/05685B-12
load equals a 100% meter reading for maximum rated (5) Battery indicator should indicate yellow
load. A 1.0 power factor load equals a 80%. meter while battery is charging, green when battery is fully
reading for maximum rated load. charged.
i. During operating of the Generator Set observe (6) AC voltmeter should indicate 120V., 208V. or
the following. 240V. depending on load connection.
(1) Check 9. rated current meter. (7) Frequency meter should indicate 60 Hz
(2) Check fuel level gage periodically. (MEP-003A) or 400 Hz (MEP-112A) at rated load.
j. During operation, inspect for leaks, paying par-

(3) Oil pressure gage located on engine should in-
dicate 20 psi minimum. ticular attention to engine fuel and oil lines and
connections.
(4) Check running time meter periodically in
order to perform preventive maintenance check-and
services at proper intervals.
Figure 2-4. Load Terminal and Reconnection Configuration
Change 2 2 - 5
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NAVFAC P-8-262-12
TO-35C2-3-455-1
TM-05684C/05685B-12
k. During operation, listen for unusual noises 2-6. SHUTTING DOWN UNIT.
which may indicate a pending malfunction.
a. Place AC circuit breaker in the OFF position.
2-5. OPERATING IN ALTERNATE MODES.
b. To stop the Generator Set, place the master
switch in the OFF position.
When selecting position 120V, 1 PH unit is c. After operation of the Generator Set, perform
in 2 wire configuration. A situation the inspection and service requirements as outlined in
can/may exist in allowing a double fault to preventive maintenance checks and services under
occur. To eliminate this possibility the Operator Maintenance Instructions, Chapter 3.
reconnection switch will be rewired by us-
d . E m e r g e n c y S t o p . To stop Generator Set in an
ing a AWG #4 wire jumper between ter-
emergency, pull out DC control circuit breaker (see
minals #LO and #6 of section 9.
figure 2-3).
CAUTION
e. If generator set is not going to be operated for
Disconnect load before switching. two weeks or more, disconnect the negative cable from
the battery. The generator set will be ready to go upon
This unit can be set for 120 volt–1-phase, 120/240
reconnection of the negative cable.
volt—1-phase, or 120/208 volt—3-phase output.
Rotate reconnection switch to desired output connec-
tion. Refer to figure 2-2.
Section II OPERATION UNDER UNUSUAL CONDITIONS
2-7. OPERATION IN EXTREME HEAT. f. Hold master switch in START position for 2
minutes after engine comes to operating speed.
To ensure satisfactory operation under conditions of
extreme heat, accomplish the following. 2-9. OPERATION IN DUSTY OR SANDY
AREAS.
a. Be sure that nothing obstructs air flow to and
from the unit. To ensure that the Generator Set will operate satisfac-
torily in dusty or sandy areas, accomplish the
b. Keep cooling fins clean.
following
c. Inspect battery electrolyte level daily. Add
a. Clean Generator Set frequently.
distilled water if necessary.
b. Service air cleaner frequently. Check air restric-
d. Keep generator free of dirt and grime. Be sure
tion indicator daily. If red signal is visible, service the
ventilating screens are free of obstructions.
air cleaner. Be certain that all air cleaner and intake
2-8. OPERATION IN EXTREME COLD (-25°F, manifold connections do not leak. Be certain oil filler
-32°C). cap fits snugly.
To ensure satisfactory operation under conditions of c. Change crankcase oil and oil filter frequently.
extreme cold accomplish the following
d. Store oil and fuel in dust-free containers.
a. Use correct lubricating oil in engine crankcase
e. Make sure that Generator Set ground connec-
for temperature conditions. (Refer to figure 3-1.)
tion is free of dust and sand and connections are tight
Change oil only when engine is warm.
before starting the unit.
b. Use Arctic Grade diesel fuel.
2-10. OPERATION IN WET OR HUMID AREAS.
c. Keep batteries in a well charged condition.
To ensure that the Generator Set will operate satisfac-
d. Be certain air cleaner intake control is in cold torily in wet or humid areas, accomplish the following
weather position.
e. Shutter blades should be fully closed for cold

engine, open only partially under light load, open more
as load increases.
2-6 Change 6
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NAVFAC P-8-623-12
TO-35C2-3-455-1
TM-05684C-12
a. Keep fuel tank full to protect against moisture

condensation and accumulation.
b.. Check wiring connectors for corrosion and wire

insulation for signs of deterioration..
2-11. OPERATION USING NATO SLAVE CABLE.
T h e existing A r m y Slave Cable has end

connectors with two p i n s t o m a t e w i t h the
Slave Receptacle on the Generator Set [figure
1 - 1 ] . The NATO Slave Cable has end connectors
with one pin. In order to utilize the NATO
Slave Cable on the Generator Set. an Adapter
Connector must be used. See Additional
Authorization List [AAL] for Adaptor Connector.
Before using either cable. make sure

the master battery switches and all
electrical switches in both the live
and dead equipment are in the OFF position.
IF attempting to install the cable into
live operating equipment, arcing can
occur. Personal injury or damage to
equipment may occur.
Change 5 2-6.1/(2-6.2 blank)

TM 5-6115-585-12
NAVFAC P-8-623-12
TO-36C2-3-455-1
TM-05682C/0568B-12
CHAPTER 3
OPERATOR MAINTENANCE INSTRUCTIONS
Section I. CONSUMABLE OPERATING AND MAINTENANCE SUPPLIES
3-1. CONSUMABLE SUPPLIES.
Table 3-1 contains all consumable supplies and the

required quantities necessary for operating and main-
taining this Generator Set.
Table 3-1. Consumable Operating and Maintenance Supplies
(1) (2) (3) (4) (5) (6)

Qty Required Qty Required
Component National Stock for Initial for 8 Hours
Application Number Description Operation Operation Notes
Tank, Fuel 9130-00-256-8613 JP-4, MIL-J-5624, 12.5 Gal. 8.72 Gal. Emergency
Bulk only
FUEL OIL, DIESEL

as follows:
9140-00-286-5294 Regular Grade, DF2 12.5 Gal. 8.72 Gal.
9140-00-286-5286 Winter Grade, DF1 12.5 Gal. 8.72 Gal.
9140-00-286-5283 Artic Grade, DFA 12.5 Gal. 8.72 Gal.
Crankcase OIL, LUBRICATING

five gallon pail as
follows:
9150-00-265-9435 Grade OE 30, MIL-L- 6.5 Qt.

2104
9150-00-265-9428 Grade OE 10, MIL-L- 6.5 Qt.
2104
9150-00-242-7603 Grade OES 6.5 Qt.
Batteries 681O-00-249-9354 Electrolyte 3.2 Gal.
Section II. LUBRICATION INSTRUCTIONS
3-2. GENERAL. quire lubrication and also the proper lubricant to be
To prevent excessive wear and insure continued 3-3. LUBRICATION ORDER.

operation, lubrication of certain moving parts on this
unit is required. The Lubrication Order reproduced Lubricate generator set as instructed in Lubrication
in this section shows the areas of this unit which re- Order LO 5-6115-565-12
Change 8 3-1/(3-2 Blank)
All text and illustration on pages 3-2 and 3-3 have been deleted.
TM5-6115-585-12
NAVFAC P-8-623-12
TO-35C2-3-455-1
TM-05684C/05685B12
Section III. PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
3-4. GENERAL. NOTE
To ensure that the Generator Set is ready for operation at all times
it must be inspected systematically, so that defects may be dis- Leakage definitions for operator/crew
covered and corrected before they result in serious damage or PMCS shall be classified as follows:
failure, The necessary preventive maintenance checks and services
that are to be performed by the Operator personnel are listed and Class I Seepage of fluid (as indicated by wetness or
described in paragraph 3-8. For ASK equipped generators, checks discoloration) not great enough to form drops.
and services will be limited to those areas that can be inspected
through ASK access doors. Class II Leakage of fluid great enough to form drops but not
enough to cause drops to drip from item being
checked/inspected.
3-5. CORRECTING AND REPORTING DEFI- Class Ill Leakage of fluid great enough to form drops that fall
CIENCIES. from the item being checked/inspected.
Defects discovered during operation will be noted

for future correction. Stop operation imediately if
a deficiency is noted which would damage the equip-
ment or is a safety hazard. All deficiencies and
short comings will be recorded together with the Equipment operation is 14 allowable with minor
corrective actions taken on the applicable form. Ieakage (Class I or II). Of course, you must
consider the fluid capacity in the item/system being
Marine Corps users should refer to current issue of
checked/inspected. When in doubt, notify your
TM 4700-15/1. supervisor.
When operating with Class I or Class II Ieaks,

3-6. DETERMINING PMCS INTERVALS. continue to check fluid Ievels as required.
Certain Operator PMCS on this unit should be per-
formed on a per hour of operation - basis. The
running time motor on the control panel should be
used to determine the Generator Set operating time.
3-7. PMCS FOR UNITS IN CONTINUOUS OPERATION.
For PMCS performed on an operating time basis,

perform PMCS as close as possible to the time in-
tervals indicated. For units in continuous operation,
perform PMCS before startlng operation if contin-
uous operation will extend service Interval past that
which is showen.
3-8. PREVENTIVE MAINTENANCE CHECKS

SERVICES.
Table 3-2 contain tabulated listing of PMCS which

shall he performed by the Operator personnel. The
item numbers are listed Consecutively and indicate
the sequance of minimum requirements.
3-4 Change 8
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NAVFAC P-S-623-12
TO-35C2-3-455-1
TM-05684C/05085B-12
Table 3-2. OPERATOR/CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES
Change 7 3-4.1
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NAVFAC P-8-623-12
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Table 3-2. OPERATOR/CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES–CONT
3-4.2 C h a n g e 8
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NAVFAC P-8-623-12
TO-35C2-3-455-1
TM-05684C/05685B-12
Table 3-2. OPERATOR/CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES - CONT
Change 1 0 3-4.3/(3-4.4 blank)

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

OF THE TROUBLESHOOTING TABLE.
This section contains troubleshooting information for
locating and correcting operating troubles which may
develop in the Generator Set. Each malfunction for
an individual component unit, or system is followed This manual cannot list all malfunctions that may
by a list of tests or inspections which will help you o c c u r , nor all tests or inspections and corrective
to determine probable causes and corrective actions actions. If a malfunction is not listed or cannot be
to take. Y OU should perform the test/inspections and corrected by listed corrective actions, notify your
corrective actions in the order listed. supervisor.
C h a n g e 7 3-5
TM5-6115-585-12
NAVFAC P-8-262-12
TO-35C2-3-455-1
TM-05684C-12
Table 3-3. Troubleshooting
NOTE
Before you use twistable, be sure you have performed all applicable operating checks.
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
1. ENGINE FAILS TO CRANK WHEN MASTER SWITCH IS HELD IN THE START POSITION.
Step 1. Check to see that dc control circuit breaker on Control Panel is depressed (paragraph
2-4).
Depress button to set circuit breaker. If breaker will not stay depressed, notify
higher level of maintenance.
Step 2. Inspect for loose, corroded, or broken battery cables or starter ground cable (paragraph
3-11).
[ a ] I f l o o s e , c o r r o d e d , or broken battery cables and starter ground cable are

found, notify higher level maintenance.
[b] Use slave receptacle when extra cranking power is required.
Step 3. Check to see that electrolyte (liquid) level in each battery cell is above the top of the
plates (paragraph 3-11).
If electrolyte level is below top of plates, notify higher level maintenance.
2. ENGINE CRANKS NORMALLY BUT FAILS TO START.
Step 1. Check for empty fuel tank (paragraph 3-13).
If fuel tank is low or empty, fill.
Step 2. Check for sediment or water in both fuel filters and fuel strainer (paragraph 3-20).
Open drains on the bottom of fuel filters and fuel strainer, and drain sediment and
water. If necessary, drain fuel system and use fresh clean fuel supply.
Step 3. Inspect for loose fuel fittings or bad fuel lines (paragraph 3-20).
If fuel lines are loose, cracked or show signs of leaking, notify higher level main-
tenance.
Step 4. Check governor linkage for obstructions or binding (paragraph 3-21).
Remove any obstruction or notify higher level of maintenance.
3. ENGINE STARTS BUT DOES NOT RUN SMOOTHLY (MISFIRES, LOCKS, OR MAKES UNUSUAL
NOISES).
Step 1. Check steps 2 and 3 under ENGINE CRANKS NORMALLY BUT FAILS TO START above.
Perform corrective action as necessary.
Step 2. Check air cleaner assembly to see that inlet shutter assembly is in proper position for
either COLD WEATHER or NORMAL WEATHER operation (paragraph 3-18).
Push knob and slide assembly into proper position.
Step 3. Inspect exhaust muffler assembly for obstructions (paragraph 3-15).
Remove obstruction if possible or notify higher level maintenance.
3-6 Change 5
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NAVFAC p-8-623-12
TO-35C2-3-455-1
TM-05684C/05685B-12
Table 3-3. Troubleshooting (Cent)
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
4. ENGINE STARTS AND RUNS NORMALLY BUT SUDDENLY “STOPS. “
Step 1. Check fuel level indicated by gauge on fuel tank (paragraph 3-13).
Add fuel if necessary.
Step 2. Check to see that shutters on shutter box have fully opened (paragraph 3-14).
Refer to next higher level of maintenance.
Step 3. Check to see that blower housing grille and engine cooling fins are clean (paragraph 3-22)
Refer to next higher level of maintenance.
Step 4. Low oil pressure will cause engine to shut down. Check oil level (paragraph 3-24).
Add correct weight oil, if necessary.
Step 5. Check that vent on under side of fuel filler cap is open (paragraph 3-13).
Clear vent hole.
5. ENGINE RUNS BUT EMITS BLACK SMOKE IN EXHAUST.
Step 1. Check air cleaner assembly to see that inlet shutter assembly is in proper position for
either COLD WEATHER or NORMAL WEATHER operation (paragraph 3-18).
Push knob and slide assembly into proper position.
Step 2. Check for restricted air intake. Red signal on air flow indicator should be visible
(paragraph 3-18).
Remove any restriction from intake port. Check and if necessary replace air
cleaner filter.
Step 3. Check load on Generator by checking % rated current meter on control panel (paragraph
3-19).
Notify immediate supervisor:
6. ENGINE RUNS WITH EXCESSIVE OIL CONSUMPTION.
Step 1. Inspect for oil leaks especially at front and rear oil seals, at oil pan gasket and dipstick
cap (paragraph 3-24).
Notify higher level maintenance.
Step 2. Check for red warning signal on air flow indicator indicating a dirty air cleaner filter
(paragraph 3-18).
Clean or replace filter. Reset air flow indicator by pushing reset button.
Step 3. Check for air leaks to crankcase (loose oil filler cap, leaks at gaskets, etc) (paragraph
3-24).
Tighten oil filler cap or notify higher level of maintenance.
3-7
TM 5-6115-585-12
NAVFAC P-8-623-12
TO-35C2-3-455-1
TM-05684C/05685B-12 Table 3–3. Troubleshooting (Cont)
3-11. BATTERY ASSEMBLY.

a. Inspect (see figure 3–2). On generators equipped The 6TN and 6TL batteries can be mixed or matched.
with acoustic suppression (ASK), remove batteries access However, maintenance–free batteries cannot be mixed or
door. matched with military batteries. The 6TN and or the 6TL
(1) Inspect battery cable terminal connectors (2), batteries will perform properly in hot weather as long as
(10) and (11) for corrosion, deterioration, or physical electrolyte levels are carefully monitored. If the electrolyte
damage. Inspect battery terminal covers (12) for proper expands and causes the level to rise, some fluid must be
installation and physical condition. Replace if cracked, split
removed. If the level becomes too low due to evaporation,
or tom.
distilled water may be used to obtain the proper level. A
(2) Inspect cables (1), (3) and (4)) for breaks,
good grade of drinking water (excluding mineral waters)
damage and deteriorated insulation.
may be used if distilled water is not available.
(3) Inspect battery top frames (5), bottom frame
(12), and tray (13) for corrosion or physical damage. Check
Electrolyte (NSN S 6810-00-249-9354 and
to see that batteries are held securely in place and that all
6810-00-843-1640) have a specific gravity of 1.280 and
attaching hardware nut (7), washer (8), screw (14), washer
(15) and bolt (9) are securely in place. should be used in these batteries. Do NOT adjust the
electrolyte in wet batteries to a lower specific gravity.
(4) Inspect battery (6) for leaks or cracks. Check

Battery electrolyte can cause severe bums
to the skin. Always flush exposed parts of top of battery and battery caps for cleanliness. Check battery
the skin with water as quickly as possible. electrolyte (liquid) level. Level should be
3-8 Change 9
TM 5-6115-585-12
NAVFAC P-8-623-12
TO-35C2-3-445-1
TM-05684C/05685B-12
Figure 3-2. Battery Assembly
about 3/8 inch above top of plates. Check that battery c. Service.
caps are not loose and that vent holes are free of
obstructions. (1) Fill batteries (6) with clean distilled water to a level of
3/8 inch above top of plates. In freezing weather run engine a
minimum of one hour after adding water.
b. Clean.
3-12. GROUND ROD AND FUEL DRUM ADAPTER PIPE
HOLD-DOWN ASSEMBLY.
a. Removal (see figure 3-3). On ASK equipped generators,
remove oil access door and fuel filter access door.
Be sure that none of the neutralizing solution
enters the battery cells. (1) Ground Rod and Fuel Drum Adapter Pipe.
Loosen screws (1), lockwaahers (2). Slide ground rod pieces
(3) out of hold-down assembly (4), then slide out fuel drum
(1) Clean terminal connectors (2), (10) and (11), adapter pipe (5).
batteries (6) and frame using a suitable neutralizing agent
and wipe dry with a clean cloth. Notify higher level main- (2) Hold-down adapter. Grasp hold-down assembly
tenance if terminals, cables, batteries or frame is damaged. (4) and remove screw (1) and lockwaeher (2). Remove hold-
Protect battery terminals with a light coat of silicone base down asseembly.
grease.
Change 8 3-9
TM5-6115-585-12
NAVFAC P-8-623-12
TO-35C2-3-455-1
TM-05684C/05685B-12
Do not over-tighten screws as damage to

hold-down assemblies may occur.
3-13. F U E L T A N K A S S E M B L Y .
a. Cleaning and Inspection (see figure 3-4).
(1) Fuel Tank Strap Assemblies. Inspect both

straps (1) for damage that would prevent them from
securely holding fuel tank (4) to skid-base (10).
Check that both straps are tight. Tighten Straps by
tightening nuts (2) and washers (3) securing each
strap to skid-base.
(2) Fuel Tank. Visually check fuel tank (4) for

dents or leaks. Check that filler (8) fits securely
onto tank and that filler cap and surrounding area is
clean. Clean using solvent and clean cloth.
(3) Fuel Level Gage. Check fuel level gage(6)

for physical damage. Check that gage shows FULL
when tank is full, and EMPTY when tank is empty.
Notify higher level maintnenance for replacement of
fuel level gage.
(4) Float Switch. Inspect float switch (7) for phys-

ical damage. Check that float switch is properly at-
Figure 3-3. Ground Rod and Fuel Drum tached to tank.
Adapter Pipe Hold-Down
(3) Fittings. Inspect three fittings (5) for physical
damage. Check that fittings are secured to fuel tank.
Notify higher level maintenance of leaky or damaged
b. Cleaning and Inspection. fittings.
(1)Ground Rod. Inspect ground rod for damage (6) Fuel Drain Valve. Inspect drain valve (9) for
and corrosion. Pay particular attention to the threaded physial damage. Check that valve operates properly.
portions of each piece, making certain the pieces can If not, notify higher level maintenance.
be properly assembled.
(7) Filler Cap Assembly Inspect filler cap (8) for physical
damage. Check that vent on underside of cap opens and closes
(2) Fuel Drum Adapter Pipe. Inspect pipe (5) for
easily. Ensure that vent on underside of filler cap is open before
c l e a n l i n e s s a n d condition of threaded portions. Clean starting generator.
pipe with cleaning solvent and dry.
3-14. S H U T T E R B O X A S S E M B L Y .
(3) Hold-down. Check hold-down assembly (4) for
physical damage and check condition of hardware (1 a. Inspect (see figure 3-5).
and 2).
c. Installation.
(1) Hold-down. Position lockwashers (2) on Do not operate unit if shutter assembly is not
screws (1) and insert into holes in skid-base (6). operating properly.
Position hold-down assemblies (4) against skid-base
(6), then start screw (1). (1) Shutter Assembly. Check shutter assembly with
unit running under normal operating conditions. When
engine is cold, shutter assembly should be fully closed.
(2) Ground Rod and Fuel Drum Adapter Pipe.
When engine warms up, shutter assembly should be fully
Slide fuel drum adapter pipe (5) and ground rod (3). open at 14°F (60°C) or above at full rated load. Make
between hold-down assemblies (4) and skid-base certain shutter assembly is free of dirt and oil which could
(6). Tighten screws (1). cause shutters to stick.
3-10 Change 8
TM5-6115-585-12
NAVFAC P-8-262-12
TO-35C2-3-455-1
TM-05684C-12
Figure 3-4. Fuel Tank
(2) Bracket Assembly. Check bracket assembly flat and straight. Check to see that shutters close se-
(1) for secure mounting to shutter (4) and shutter box curely and that they can be easily opened by hand.
(10). Brackets (11) should turn freely on bearings (12)
without excessive play. (4) Thermo Power Unit. Check thermo power unit
(7) located on inside of shutter assembly to see that
it is free of dirt, grease, or physical damage. Notify
(3) Shutters. Check shutters (4) to see that they higher level of maintenance for replacement of thermo
are free of dirt or grease. Check to see shutters are power unit.
3-11
TM5-6115-585-12
NAVFAC P-8-623-12
TO-35C2-3-455-1
TM-05684C/05685B-12
Figure 3-5. Shutter and Thermo Power Element Assembly
3-12 Change 2
TM5-6115-585-12
NAVFAC P-8-623-12
TO-35C2-3-455-1
TM-05684C/05685B-12
Figure 3-6. Exhaust Muffler Assembly
3-15. EXHAUST MUFFLER ASSEMBLY. NOTE

Mount 45° elbows (12) on the mufflers (3) to deflect
exhaust heat away from the batteries.
Do not touch muffler assembly while unit is 3-16. ENGINE STARTER ASSEMBLY.
running or immediately after shutdown, as
a. Cleaning and Inspection (see figure 3-7). On ASK
severe burns may result.
equipped generators, remove BATTERIES access door.
a. Inspect (see figure 3-6). Manually open shutter Clean engine starter (1) by removing loose dirt with a
assembly and check that muffler assembly (3) is stiff nonmetallic brush. Clean off remaining dirt and oil
securely fastened to unit. Check that nuts (2) and lock with dry cleaning solvent (Fed. Spec. P-D-680). Inspect
tabs (1) attaching muffler to unit are in place. starter to see that electrical connections (4) are clean
and tight. Check to see that mounting bolts (2) are tight.
Check to see that exhaust is not obstructed and there Check starter (1) for physical damage.
is no evidence of leaks.
Change 8 3-13
TM5-6115-585-12
NAVFAC P-8-623-12
TO-35C2-3-455-1
TM-05684C/05685B-12
Figure 3-7. Electric Starter
3-17. AC OUTPUT CONTROL BOX ASSEMBLY.
a. Inspect (see figure 3-8).
(1) Control Box Assembly. Check box assembly Figure 3-8. AC Output Control Box Assembly
for cracks, dents, or other physical damage. Inspect
to see that covers (1) for both 120 volt ac outlets
operate properly (MEP-003A only). Check latches (2)
securing load terminal board cover (3). Check to see Check that clamp (17) attaching dust cap (18) to hous-
that cover (3) for load terminal board opens and ing is secure and arrows on dust cap are pointing up.
closes properly. Check to see that electrical connec- Check that two clamps (7) holding cold weather
tors (4) are clean and securely mounted. operation intake hose (19) are secure.
(2) Load Terminal Board Assembly. Check con- (2) Bracket Assembly. Inspect bracket assembly
dition of load terminal board (5) and load terminals (1) to see that it is securely fastened to generator
(6) for cleanliness and tightness. Make certain that housing (2). Check that capscrews (3) and lockwashers
the load leads are secured to terminals. (4) which attach bracket to generator housing, and
three spacers (5) are in place.
3-18. AIR CLEANER ASSEMBLY. (3) Inlet Shutter (see figure 3-10). Check inlet
shutter (6) to see that it slides easily from COLD
a. Inspect on Equipment (see figure 3-9). On ASK equipped WEATHER to NORMAL WEATHER position and back.
generators, open AIR INTAKE and AIR CLEANER access doors.
(1) Housing. Inspect housing (8) for dirt, grease, (4) Air Flow Indicator (see figure 3-10). Check
dents or other physical damage. Check to see that air flow indicator (7) for dirt, grease, physical dam-
housing is securely attached to bracket assembly (1). age, or if the red flag is visible.
3-14 Change 8
TM5-6115-585-12
NAVFAC P-8-262-12
TO-35C2-3-455-1
TM-05684C-12
Figure 3-9. Air Cleaner and Shroud Assembly
3-15
TM5-6115-585-12
NAVFAC P-8-623-12
TO-35C2-3-455-1
TM-05684C/05685B-12
b. Removal and Service. (2) Air Cleaner Element (see figure 3-10). Every
12 months, 1000 operating hours, or when red warn-
(1) Dust Cap (see figure 3-10). Every 100 oper- ing on air flow indicator becomes visible, whichever
ating hours (more frequently in dusty areas) service comes first, clean or replace air cleaner element
dust cap (1) by removing cap from air cleaner hous- (4). To remove the element remove dust cap (1) and
ing (5), removing rubber seal (9), and cleaning out seal (9). Remove wing nut (2), seal (3) and remove
any dirt or debris. The clamp (10) is loosened to re- element (4). To clean element, direct dry clean air
move dust cap and seal. up and down pleats on the inside of the element. (See
figure 3-11.) If element is very dirty, wash it by
soaking in mild detergent and water. Soak for fifteen
minutes or more. Rinse element thoroughly with
clean water from hose (maximum pressure 40 psi).
Air dry completely a minimum of 24 hours before
Do not use compressed air of more than 100 re-using. Do not dry with compressed air or heat
psi on the air cleaner element. over 150°F (66°C).
Figure 3-10. Air Cleaner Assembly
3-16 Change 2
TM5-6115-585-12
NAVFAC P-8-623-12
TO-35C2-3-455-1
TM-05684C/05685B-12
ing lamp covers. Check that electrical connections

are clean and tight.
(3) Panel Light Switch. Operate lamp switch (2)

to check that lamps are operable.
(4) Meters. Battery Indicator (M1), Hourmeter

(M2), Frequency Meter (M3), Percent Current Meter
(M4) and AC Voltmeter (M5). Inspect meter glass to
see that it is not cracked. Check to see the meter
face is clean and readable. Check to see that pointer
is not bent. Check to see that electrical connections
are clean and tight.
(5) DC Control Circuit Breaker (CB2). Inspect

circuit breaker for physical damage. Inspect electri-
cal connections to see that they are clean and tight.
Check to see that when button on breaker is pushed
in or pulled out, it will remain in that position.
(6) Master Rotary Switch (S1). Inspect switch for

physical damage. Inspect electrical connections to
see that they are clean and tight. Check to see that
when placed in the OFF, PRIME & RUN AUX FUEL,
or PRIME & RUN positions the switch will remain in
position. Check to see that when placed in the PRE-
HEAT position and released, switch returns to OFF
Figure 3-11. Cleaning Air Filter Element position. With DC Control Circuit Breaker (CB2)
pulled out (unit will not crank), check to see that when
released from START position the switch will auto-
matically return to PRIME & RUN position.
(7) Panel Light Switch (S2). Inspect switch for

Do not re-use element more than twice. Do physical damage. Inspect for clean and tight elec-
not re-use element if it has even the slightest trical connections. Check to see that switch will re-
rupture. main in both ON and OFF positions.
c. Installation. (8) Range Selector Switch (S6). Inspect switch for

physical damage. Inspect for clean and tight elec-
(1) Air Cleaner Element. Slide element (4, figure trical connections. Check to see that switch will re-
3-10) over stud in housing (5), install seal (3) on wing main in each of the six switch positions.
nut (2) and secure element with wing nut (2). Hand
tighten wing nut. Install seal (9) and dust cap (1). Be (9) Voltage Adjust Rheostat (R1). Inspect rheo-
certain “Top” on dust cap faces up. Retighten clamp stat for physical damage. Inspect for clean and tight
(10) to secure dust cap. Depress reset button (8) to electrical connections. Note rheostat position and
reset indicator (7). check that rheostat moves smoothly thru its range.
Return rheostat to previously noted position.
3-19. CONTROL CUBICLE ASSEMBLY.
(10) AC Voltage Regulator (A2). Visually inspect
a. Inspect (see figure 3-12). board and components for signs of overheating,
cleanliness and physical damage. Inspect for clean
(1) Control Cubicle Assembly. Inspect cubicle for and tight connections to the board and that board is
dirt, grease or physical damage which might affect securely mounted.
operation of the unit. Loosen three fasteners holding
control panel to permit access to the inside of the (11) Transformers (T1 and T2). Inspect trans-
cubicle. Check to see that all parts mounted to the formers for physical damage, cleanliness and that
cubicle are secure and all hardware is in place. electrical connections are clean and tight.
Check that all instruments and controls operate nor-
mally when unit is running. Check for broken or badly (12) Wiring Harness. Inspect wiring harness for
insulated harness wires and, if necessary, refer to physical damage such as broken or frayed wires or
higher level of maintenance. damaged insulation.
(2) Panel Light Assemblies (DS1 and DS2). In- (13) Control Cubicle Box. Inspect box for phys-
spect panel light assemblies (1) for cracked or miss- ical damage.
Change 2 3-17
TM5-6115-585-12
NAVFAC P-8-262-12
TO-35C2-3-455-1
TM-05684C-12
Figure 3-12. Control Cubicle
3-18
TM 5-6115-585-12
NAVFAC P-8-623-12
TO-35C2-3-455-1
TM-05684C/05685B-12
b. Service. Inspect two fuel filter assemblies (10) for dents or other
physical damage. Check for leaks especially around fuel line
(1) Panel Light. Panel lamp cover can be removed fittings (12), drains (1), and where bowl joins the head. Check
for cleaning by turning them counterclockwise when that fuel filter assemblies are securely attached to mounting
viewed from front. bracket (16) and that bracket is securely attached to bracket
support on skid-base.
(2) Panel Lamps. Panel lamps are screw in base
types and are replaceable.
3-20. FUEL SYSTEM (LESS TANK). (2) Fuel Strainer Assembly (see figure 3-13).
Inspect strainer assembly (11) for dents or other phys-
a. Inspect (see figure 1-1). ical damage. Check for leaks especially around fuel
line fittings (12), drain (1), or where the bowl joins the
(1) Fuel Filter Assemblies (see figure 3-13). On ASK head. Check that strainer assembly (11) is securely
equipped generators, remove FUEL FILTERS access door. attached to mounting bracket (16).
Figure 3-13. Fuel Filters and Fuel Strainer Assembly
Change 8 3-19
TM 5-6115-585-12
NAVFAC P-8-623-12
TO-35C2-3-455-1
TM-05684C/05685B-12
(3) Fuel Pump Assemblies (Three) (see figure

3-14). Inspect fuel pumps (1) for dents or other phys-
ical damage. Check for leaks especially around hose
assembly fittings (2). Check that fuel pumps are se-
curely a t t a c h e d t o m o u n t i n g b r a c k e t ( 3 ) a n d t h a t
mounting bracket is securely attached to bracket sup-
port on skid-base. Inspect electrical leads to fuel
pumps to see that wires and connectors are not
broken, frayed, or damaged. Check that connectors
are tightly connected. Check that cap (4) on auxiliary
fuel pump inlet is securely in place when unit is not
being run from auxiliary fuel supply.
(4) Fuel Hoses. Inspect fuel hoses (2, 3 and 4,

figure 3-13) for leaks or physical damage. Check to
see that fuel hose fittings are securely tightened in
place.
b. Service.
(1) Fuel Filter Assemblies (see figure 3-13). Daily

before and after operation, open drain valves (1) and drain
water and sediment from assemblies.
(2) Fuel Strainer Assembly. Daily, before and after

operation, open drain valves (1) and drain water and sedi-
ment from strainer assembly (11).
Figure 3-15. Control Cubicle Support Assembly
3-21. C O N T R O L C U B I C L E S U P P O R T A S S E M B L Y ,
SPEED CONTROL AND ENGINE CONTROL
WIRING HARNESS.
a. Inspect.
(1) Vibration Mounts (Four) (see figure 3-15).

Inspect vibration mounts for deterioration or physi-
cal damage. Inspect mounts to see that they are free
of dirt, fuel, or oil. Check to see that mounts are
securely attached to control cubicle support on skid-
base. If mounts are faulty, refer to higher level of
maintenance.
(2) Engine Control Wiring Harness Assembly. On ASK
equipped generators, open or remove all access doors. Inspect
wiring harness for broken or frayed wires. Check for wires with
damaged or deteriorated insulation. Check that all connectors and
terminals are clean and tight.
(3) Speed Control Assembly (see figure 3-16). On ASK

equipped generators, lift motor speed control flap. Inspect to see
that speed control is firmly attached to unit. Check that speed
Figure 3-14. Fuel Pump Assembly control moves in and out freely. If speed control is loose, refer to
higher level maintenance.
3-20 Change 8
TM5-6115-585-12
NAVFAC P-8-623-12
TO-35C2-3-455-1
TM-05684C/05685B-12
Figure 3-16. Speed Control Assembly
3-22. ENGINE COOLING SYSTEM. damage. Check that blower housing assembly is
properly secured to engine. With engine running
a. Inspect (see figure 3-17). On ASK equipped generators, check for noise which would indicate blower wheel
inspection is limited to parts of shroud assembly visible through is rubbing against blower housing assembly or blower
access doors.
grille. (For units without ASK.)
(1) Shroud Assembly. Inspect shroud assembly (11) and
door panel (12) for dents or other physical damage. Inspect
hinge attaching door panel (12) to see that it swings freely. (3) Blower Housing Grill Assembly. Inspect grille (30)
Check to see that shroud assembly and door panel are prop- for dents or other physical damage and that grille is properly
erly secured to engine. secured to engine. (For unite without ASK.)
(2) Blower Housing Assembly. Inspect blower

housing assembly (33) for dents or other physical
Change 8 3-21
TM5-6115-585-12
NAVFAC P-8-262-12
TO-35C2-3-455-1
TM-05684C-12
Figure 3-17. Engine Cooling Assembly (Sheet 1 of 2)
3-22
TM5-6115-585-12
NAVFAC P-8-623-12
TO-35C2-3-455-1
TM-05684C/05685B-12
Figure 3-17. Engine Cooling Assembly (Sheet 2 of 2)
3-23. GENERATOR ASSEMBLY. debris and free of dents or cracks. Check that screen-guard
is securely fastened in place over opening in generator
On ASK equipped generators, inspection is limited to screen housing-stator assembly. Inspect end-bell (2) to see that it is
guard areas visible through access doors. Inspect screen clean and free of cracks or other physical damage. Check
guard (3, figure 3-18) to see that it is clean and free of that openings in end-bell and end-bell cover are free of
debris. Check that end-bell is securely attached to generator
housing.
3-24. ENGINE ASSEMBLY.
a. Lifting Attachment (sea figure 3-17). On ASK equipped

generators, open air intake door. Inspect for cracks or other
physical damage. Check that mounting screws (37) are secure.
NOTE
On ASK aquipped generators, if intake manifold is

suspected of possible problems, refer to higher level
of maintenance.
b. Intake Manifold Assembly (see figure 3-19). Inspect intake

manifold (1) for cracks or physical damage. Check that manifold
is properly secured to cylinder head and mounting screws (5)
and lock tabs (3) are in place.
c. Oil Drain Hose (see figure 3-20). On ASK equipped
generators, remove oil access door. Inspect oil drain hose for
physical damage. Check that drain valve operates properly and
does not leak when closed. Check that oil drain hose is properly
stored when not in use.
d. Engine Mounting Assemblies (Two) (see figure 3-19). On

ASK equipped generators, remove oil access door and batteries
access door. Inspect engine mounts (13) for deterioration or
physical damage. Check for accumulation of dirt, fuel, or oil.
Check that mounts are securely attached to engine and to skid-
Figure 3-18. Generator Assembly bsse with all mounting hardware in place.
Change 8 3-23
TM5-6115-585-12
NAVFAC P-8-262-12
TO-35C2-3-455-1
TM-05684C-12
Figure 3-19. Intake Manifold Assembly
3-24
TM5-6115-585-12
NAVFAC P-8-262-12
TO-35C2-3-455-1
TM-05684C-12
Figure 3-21. Oil Filter and Oil Pressure Switch
Figure 3-20. Oil Drain Hose
e. Oil Filter Assembly (see figure 1-1). Inspect oil

filter assembly for dents or other physical damage.
Check for leaks especially at gasket (1, figure 3-21)
between body (3) and adapter (5) and between bolt (2)
and body (3). Check to see that drain plug (4) is se-
curely in place and does not leak.
f. Oil Pressure Switch (see figure 3-21). Inspect oil

pressure switch (6) for dents or other physical dam-
age. Check that switch is securely mounted to oil
filter adapter (5). Check for leaks where switch (6)
attaches to adapter (5). Check that both electrical
connections (7) to switch (6) are tight and free of cor-
rosion.
g. Oil Pressure Gauge Assembly (see 45, figure

3-17). Inspect glass lens to see that it is not cracked. Figure 3-22. Engine Stop Solenoid
3-25
TM5-6115-585-12
NAVFAC P-8-623-12
TO-35C2-3-455-1
TM-05684C/05685B-12
Inspect to see that there is no dirt or oil underneath i. Engine Stop Solenoid (see figure 3-22). Inspect
lens indicating that gage is no longer properly sealed. stop solenoid (1) for dents or other physical damage.
Check to see that pointer is not bent or damaged. Check that solenoid is securely attached to cylinder
Check that markings on gage are readable. Check to shroud bottom pan with two screws (2) and lockwash-
see that meter is fastened securely to engine. ers (3). Check that electrical connections (4) to sole-
noid are clean and tight.
h. Flexible Oil Line (see figure 3-17). Inspect
flexible oil line to the oil pressure gage (45) for j. Oil Dip-Stick and Oil Fill Tube (see figure
physical damage. Check for leaks especially around 4-42). Inspect oil dip-stick and oil fill tube for
fittings. physical damage. Check for leaks especially at
Figure 3-23. Battery and Frame
3-26 Change 5
TM5-6115-585-12
NAVFAC P-8-623-12
TO-35C2-3-455-1
TM-05684C/05685B-12
g a s k e t b e t w e e n o i l f i l l t u b e a n d engine block. Check

t h a t d i p - s t i c k f i t s s e c u r e l y i n t o oil fill tube with no
leaks.
3-25. SKID-BASE ASSEMBLY.
Battery electrolyte can cause severe burns to

the skin. Always flush exposed parts of the
skin with water as quickly as possible.
a. Inspect (see figure 3-23).
(1) Battery Frame Bottom. On ASK equipped generators,

remove BATTERIES access door. Inspect battery frame bottom
(6) for dents, cracks, corrosion, or other physical damage. Check
to see that battery frame bottom is free of corrosion.
(2) Battery Tray. Check to see that battery tray

(8) is free of corrosion. Check that battery tray is
securely attached to skid-base (9) with screw.
(3) Ground Stud (see figure 3-24). On ASK equipped genera-

tors, lift rear penal flap and inspect ground stud for deformed
threads, corrosion, or other physical damage. Check that ground
stud is securely attached to skid-base. Check that connection to
stud are clean and tight.
b. Cleaning. Remove corrosion with a suitable neutralizing

agent. Wipe dry with a clean cloth.
Figure 3-24. Ground Stud

TM5-6115-585-12
NAVFAC P-8-623-12
TO-35C2-3-455-1
TM-05684C/05685B-12
CHAPTER 4
ORGANIZATIONAL MAINTENANCE
Section I. SERVICE UPON RECEIPT OF MATERIAL
4-1. I N S P E C T I N G AND SERVICING GENEATOR (4) Check engine intake and exhaust systems (fig-
SET. ure 1-2) to make certain they are unobstructed by
foreign material.
a. Unloading Equipment.
(5) Check that main fuel tank drain cock (figure
1-2) is closed.
(1) A crane, fork lift, or similar lifting device
or fabricated skids must be used to unload the (6) Remove all preservative material except for
equipment. The equipment must be kept in the UP preservative crankcase oil.
position while unloading.
Do not smoke or use an open flame in the

vicinity when filling fuel tank.
Do not use a lifting device with a capacity of NOTE
less than 1500 pounds. Do not allow the crated
Generator Set to swing while it is suspended. On generators equipped with acoustic suppression
Failure to observe this warning may result in kit (ASK), route auxiliary fuel line under rear flap on
serious injury or death to personnel. skid to auxiliary fuel pump.
b. Unpacking. (7) Fill fuel tank with appropriate fuel and set
MASTER SWITCH (figure 2-3) to RUN position to con-
nect main fuel tank to electrical fuel pumps. If an
(1) Before unpacking, move the engine Generator auxiliary source of fuel is to be used in operating the
Set as near as possible to the location where it will
engine Generator Set, connect fuel hose to AUXILIARY
be operated.
FUEL, CONNECTION and set MASTER SWITCH to
RUN AUX FUEL position.
Exercise care in the use of bars, hammers,

and similar tools while uncrating the unit to
avoid damaging the equipment. Do not attempt to remove sealing particles
that have fallen inside the battery as
(2) Remove the top and then the sides of the damage to the battery could occur.
crate (figure 4-1).
(8) Batteries are shipped in a dry state. If
(3) Remove barrier bag, dessicant bags, and ship- batteries are hermetically sealed, destroy sealing
ping material from engine Generator Set. device inside each cell by tapping with a blunt in-
strument. Battery electrolyte must be requisition-
(4) Disconnect engine Generator Set from crate ed separately. To activate the battery, remove all
skid by removing carriage bolts, nuts, washers, and caps and fill battery cells with electrolyte. Elec-
lift engine Generator Set off skid. trolyte level should be 3/8 inch above top of plates
for each cell. Make sure vent holes in caps are
c. Service and Inspection. open, and replace caps. Connect batteries as
shown in figure 4-16.
(1) Prepare the engine Generator Set for in-
spection and servicing as outlined in the following NOTE
paragraphs. For Army users, refer to D A F o r m 2 2 5 8 .
The electrolyte level must be rechecked approx-
(2) Make a thorough visual inspection of the en- imately 30 minutes after initial filling as the
tire Generator Set for loose or missing hardware or platas end separator will absorb the solution,
damaged or missing parts. Report all damaged or thus resulting in a low level. If the battery is not
missing parts on DD Form 6. to be used within 12 hours after initial filling, it
should be put on a charger and brought up to
(3) Inspect all air cleaner connections for tight- the correct specific gravity. Test batteries as
ness and damage. deecribed in paragraph 4-25c, for the ambient
temperature in effect.
(3.1) On ASK equipped generators, inspect ASK for damage.
Check that exhaust plenum is clear of debris.
Change 8 4-1
TM5-6115-585-12
NAVFAC P-8-623-12
TO-35C2-3-455-1
TM-05684C/05685B-12
Figure 4-1. Uncrating Generator Set
b. Outdoor Installation. When preparing for a per-

manent installation, be sure the base is solid enough to
support the weight of the unit. See figure 1-4 for dimen-
sions of the bas. Seclect a location where there will be
Do not smoke or use an open flame in the vicini- sufficient space on all sides for servicing and operation
ty when servicing batteries. Battaries generate of the engine Generator Set. When preparing a tem-
hydrogen, a highly explosive gas. Electrolyte porary installation, move the engine Generator Set as
contains sulphuric acid and can cause severe close to the worksite as practical. Use suitable planks,
burns. Handle it with care. If the solution comes logs, or other material for a base in an area where the
in contact with the body, eyes or clothing, rinse ground is soft.
immediately with clean water. Avoid spilling
electrolyte on painted surfaces. c. Indoor Installation. Keep the area wall ventilated
at all times, so that the engine Generator Set will
receive a maximum supply of air. If a free supply of
(9) Check crankcase oil level (paragraph 3-2) and fresh air is not available, provide duct work which will
add oil as necessary (paragraph 3-3) in accordance with assure the required ventilation (refer to paragraph 1-
the lubrication order (figure 3-1). 10.b.(1).). If louvers are used at the air entrance, in-
crease the duct work size by 25 to 50 percent. Install a
4-2. I N S T A L L I N G G E N E R A T O R S E T . gas-tight metal pipe exhaust from the exhaust outlets
to the outside of the installation. The termination of
a. General. The engine Generator Set should be in- the exhaust pipe shall be such that hot gases or sparks
stalled on a site clear of obstacles, with ample ventila- will be discharged harmlessly and will not be directed
tion and level within ±15 degrees maximum. against combustible material or into an area contain-
4-2 Change 4
TM5-6115-585-12
NAVFAC P-8-623-12
TO-35C2-3-455-1
TM-05684C/05685B-12
ing flammable gases or vapors. Use as few bends in the d. Leveling. The Generator Set is a portable unit
pipe and as short a pipe as possible. The exhaust pipe and is designed to operate satisfactorily up to 15º out-
should include a low point with suitable means for of-level. Set up the unit as level. Set up the unit as level
draining of condensate. Provide metal shields, 12 in- as possible and keep it as level as possible during
ches larger in diameter than the exhaust pipe where the operation.
line passes through flammable walls. Wrap the exhaust
pipe with asbestos if there is any danger of anyone e. Grounding. The Generator Set must be grounded
touching it. prior to operation. The ground can be, in order of
preference: (1) an underground metallic water piping
system, (2) a driven metal rod, or (3) a buried metal
plate (figure 4-2). If the effectively grounded portion of
the buried metallic water pipe is less than 10 feet due to
insulated sections or joints, this preferred grounding
method must be supplemented by an additional driven
Do not operate the engine Generator Set in an metal rod ground or a buried metal plate ground. A
enclosed area unless the exhaust gases are driven metal ground rod must have a minimum
piped to the outside. Inhalation of exhaust diameter of 5/8 inch if solid or 3/4 if pipe, and driven
fumes will result in serious illness or death. to a minimum depth of 8 feet. A buried metal ground
plate must have a minimum area of 9 square feet,
minimum thickness of 1/4 inch, and be buried at a
minimum depth of 4 feet. The ground lead must be at
least No. 6 AWG (American Wire Gauge) copper wire.
Change 4 4.2.1/(4-2.2 blank)

TM5-6115-585-12
NAVFAC P-8-623-12
TO-35C2-3-455-1
TM-05684C/05685B-12
Figure 4-2. Grounding Generator Set
C h a n g e 4 - 3
TM5-6115-585-12
NAVFAC P-8-262-12
TO-35C2-3-455-1
TM-05684C-12
Section II. MOVEMENT TO A NEW WORKSITE
4-3. DISMANTLING GENERATOR SET FOR MOVE- (6) On ASK equipped generators, remove batteries access
MENT. door. Disconnect negative battery cable from battery.
a. Preparation for Movement. (7) Disconnect any other hoses, lines or cables,
if used.
(1) Disconnect the load cables.
(8) Close and secure all doors and panels.
(2) Remove exhaust pipe extension if used.
b. Movement. Preferred means of movement is to
(3) Make certain vent on underside of fuel filler transport. Towing for short distances is permissible
cap is closed. if terrain is suitable.
(4) Refer to the Items Troop lnstalled or Author-
4-4. R E I N S T A L L I N G GENERATOR SET AFTER
ized List (Appendix B and make sure all items are on
MOVEMENT.
the equipment.
(5) Disconnect the ground lead from the ground Refer to paragraph 4-2 for reinstallation after move-
stud. ment to a new worksite.
Section III. REPAIR PARTS; SPECIAL TOOLS; SPECIAL TEST, MEASUREMENT

AND DIAGNOSTIC EQUIPMENT AND SPECIAL SUPPORT EQUIPMENT
4-5. SPECIAL TOOLS AND EQUIPMENT. 4-6. MAINTENANCE REPAIR PARTS.
Repair parts and equipment are listed and illustrated

Special tools are listed in Appendix C, section III. in the repair parts and special tools list manual
covering organizational maintenance for this Gener-
ator Set.
Section IV. LUBRICATION INSTRUCTIONS
4-7. L U B R I C A T I O N .
a. Lubrication Order. Lubrication instructions for (5) Open drain plug (1, figue 4-30) and drain
the Generator Set are contained in L05-6115-585-12. oil filter oil into a container having at least a 1
quart capacity.
(6) Remove through bolt (2) and pull oil filter

(F) Air Force lubrication instructions appear in the body (3) loose from oil filter adapter (5).
applicable work card set in the TO 35C2-3-1-426
series. (7) Discard gasket (4) and oil filter element
(6).
b. Oil Change (see figure 3-20). On ASK equipped generators,

remove oil access door. (8) Wipe inside of oil filter body (3 clean with a
rag.
(1) With drain valve closed, disconnect oil drain
hose from the plug on the skid-base.
(9) Wipe inside of adapter (5) clean with a
rag. Insure the gasket groove is free of foreign
material. Inspect gaskets (7) and (10) to be sure
(2) Open drain valve and drain oil into a con- they are not torn or frayed. Check that retainer (8),
tainer having at least a 7 quart capacity. and spring (9) are not deformed. Replace damaged
components.
(3) Close drain valve.
(4) Connect oil drain hose to plug on skid-base.
4-4 Change 8
TM5-6115-585-12
NAVFAC P-8-262-12
TO-35C2-3-455-1
TM-05684C-12
(10) Apply a thin coat of clean engine oil, (12) Pour 6.5 quarts of engine oil (see lubri-
MIL-L-2104 to a new gasket (4) Install new gasket cation order for proper grade of oil) into oil fill tube
(4) in groove of adapter (5). (9, figure 1-1).
(11) Assemble components on through belt (2) in (13) Check oil level with dip-stick.
the order shown in figure 4-30. Position body (3) with
drain plug (1) down on adapter (5). Tighten through bolt (14) After 5 minutes of engine operation, check
crankcase oil level and bring oil level to full mark.
(2) to 13± 2ft-lb dry.
Section V. PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
4-8. P M C S , G E N E R A L . 4-9. Determining PMCS Intervals. Organizational

PMCS on this unit should be performed on a - per
To ensure that the Generator Set is ready for operation hours of operation - basis. The running time meter
at all times, it must be inspected systematically so defects on the control panel should be used to determine the
may be discovered and corrected before they result in Generator Set operating time.
serious damage, failure or safety hazard. The necessary
preventive maintenance checks and services that are to 4-10. PMCS for Units in Continuous Operation. For
be performed by Organizational personnel are listed and PMCS performed on an operating time basis, per-
described in the following paragraphs. Defects discovered form PMCS as close as possible to the time intervals
during operation will be noted for future correction. Stop indicated. For units in continuous operation, perform
operation immediately if a deficiency is noted which would PMCS before starting operation if continuous opera-
damage the equipment or present a safety hazard. All tion will extend service interval past that which is
faults will be recorded together with the corrective actions shown.
taken on the applicable form. Air Force users shall refer
to the applicable inspection manuals and work card sets 4-11. (A. N, MC) Preventive Maintenance Checks and
in the TO 35C2-3-1-426 series for periodic requirements. Services. Table 4-1 contains a tabulated listing of
Marine Corps users should refer to current issue of TM PMCS which shall be performed by Organizational
4700-15/1. On ASK equipped generators, full or partial personnel. The item numbers are listed consecutively
removal of ASK may be necessary to perform PMCS. and indicate the sequence of minimum requirements.
Table 4-1. ORGANIZATIONAL PREVENTIVE MAINTENANCE CHECKS AND SERVICES
Change 8 4-5
TM5-6115-585-12
NAVFAC P-8-262-12
TO-35C2-3-455-1
TM-05684C-12
TABLE 4-1. ORGANIZATIONAL PREVENTIVE MAINTENANCE CHECKS AND SERVICES--continued
PROCEDURES EQUIPMENT IS
ITEM TO BE Check for and have repaired Not Ready/
INSPECTED Available if:
Open drains on fuel strainer,

and primary and secondary filters.
Drain water and sediment (para
3-20). Allow to drain until fuel
runs clean.
Fuel Tank Open drain on fuel tank and drain

water and sediment (para 3-13).
Allow to drain until fuel runs
clean.
Lubricating Change lubricating oil and filter

Oil and Fil- every 100 hours of operation
ter (L.O., fig. 3-1).
Fuel Strain- Clean fuel strainer e v e r y 3 0 0

er hours of operation ( p a r a 4 - 2 0 ) .
Primary Fuel Service primary f i l t e r e v e r y 5 0 0

Filter hours of operation ( p a r a 4 - 2 0 ) .
Secondary Service secondary filter every

Fuel Filter 1000 hours (para 4-20).
Batteries Perform a hydrometer test on

batteries every 300 hours, or
quarterly. Refer to para 4-25c
for test procedures.
Crankcase Inspect breather tube every 500

Breather hours, clean as necessary (para
4-45).
Dust caps Clean out dust caps on air

on air cleaner assembly (every 100
cleaner operating hours or more fre-
quently under unusual condi-
tions.)
Air cleaner Clean every 1000 operating Air cleaner

hours or as conditions dic- is missing or
tate. Replace air cleaner unserviceable.
every 2000 operating hours.
4-6 Change 5
TM 5-6115-585-12
NAVFAC P-8-623-12
TO-35C2-3-455-1
TM-05684C/05685B-12
TABLE 4-1. ORGANIZATIONAL PREVENTIVE MAINTENANCE CHECKS AND SERVICES - continued
W - WEEKLY (40 HOURS)

INTERVAL M - MONTHLY (100 HOURS) H - HOURS (AS INDICATED)
PROCEDURES EQUIPMENT IS
ITEM ITEM TO BE Check for and have repaired Not Ready/
NO. W M H INSPECTED or adjusted as necessary Available if:
12 500 Bonding Strap Remove bolts from both ends of bonding

(Engine to strap (see item 1, Fig 4-3) and inspect
skid base) for corrosion on the bonding strap or
mating surfaces of the engine and skid
base. Clean surfaces and replace strap.
13 500 Rocker Arm Service rocker covers every 500

Covers operating hours (para 4-44).
14 500 Valve Rocker Adjust the rocker arm to proper

Arms valve clearance every 500
operating hours (para 4-46).
Change 10 4-6.1/(4-6.2 blank)

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

OF THE TROUBLESHOOTING TABLE.
This section contains troubleshooting information for locat-
ing and correcting operating troubles which may develop in This manual cannot list all malfunctions that may occur, nor
the Generator Set. Each malfunction for an individual com- all tests or inspections and corrective actions. If a malfunc-
ponent unit or system is followed by a list of tests or inspection is not listed or cannot be corrected by listed corrective
tions which will help you to determine probable causes and actions, notify your supervisor.
corrective actions to take. You should perform the tests/
inspections and corrective actions in the order listed.
Change 10 4-6.3/(4-6.4 blank)

TM5-6115-585-12
NAVFAC P-8-262-12
TO-35C2-3-455-1
TM-05684C-12
Table 4-2. Troubleshooting
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
1. ENGINE FAILS TO CRANK WHEN MASTER SWITCH IS HELD IN THE START POSITION.
Step 1. Use slave receptacle when extra cranking power is required.
Step 2. Test batteries (paragraph 4-25).
Replace defective batteries. Check battery alternator fuse and replace if necessary.
S t e p 3 . Inspect battery and starter cables for corrosion and loose connections.
Clean or tighten cables.
S t e p 4 . Test “START’’ position of master switch (paragraph 4-38).
Replace defective master switch.
step 5. Inspect and test for open starter solenoid switch or for short to ground (paragraph 4-26).
Replace defective solenoid.
S t e p 6 . Inspect and test starter lockout switch (paragraph 4-28).
Adjust switch points if they are not closing or replace defective switch.
2. STARTER TURNS BUT WILL NOT ENGAGE ENGINE.
Step 1. Inspect starter drive assembly (paragraph 4-26).
Clean drive assembly if it is sticking.
Step 2. Inspect starter drive gear assembly for worn or broken teeth (paragraph 4-26).
Replace starter.
3. ENGINE CRANKS NORMALLY BUT FAILS TO START.
Step 1. Test stop solenoid for correct operation (paragraph 4-23).
Replace bad solenoid.
Step 2. Inspect fuel pumps for clogged strainers (paragraph 4-21).
Replace strainer element.
Step 3. Inspect for clogged fuel strainer element or fuel filter elements (paragraph 4-20).
Clean strainer element; replace fuel filter elements.
Step 4. Check for clogged fuel lines to injector pump.
Clean or replace clogged fuel lines.
Step 5. Test for worn or damaged fuel pumps (paragraph 4-21).
Replace bad pumps.
Step 6. Inspect and test intake manifold heaters (paragraph 4-43).
Replace bad heaters.
C h a n g e 5 4 - 7
TM5-6115-585-12
NAVFAC P-8-262-12
TO-35C2-3-455-1
TM-05684C-12
Table 4-2. Troubleshooting (Cont)
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
3. ENGINE CRANKS NORMALLY BUT FAILS TO START (Cont).
Step 7. Inspect and test glow plug assemblies (paragraph 4-48).
Replace bad glow plugs.
4. ENGINE STARTS BUT DOES NOT RUN SMOOTHLY (MISFIRES, KNOCKS, OR MAKES UNUSUAL
NOISES).
Step 1. Check steps 1, 2, 3, 4 and 5 under ENGINE CRANKS NORMALLY BUT FAILS TO
START above.
Perform corrective action as necessary.
Step 2. Check valve to rocker arm clearance (paragraph 4-46).
Adjust clearance if necessary.
5. LOW ENGINE POWER ESPECIALLY UNDER HEAVY LOAD.
Step 1. Check steps 1, 2, 3, 4 and 5 under ENGINE CRANKS NORMALLY BUT FAILS TO
START above.
Perform corrective actions as necessary.
Step 2. Check air cleaner assembly for obstructions (paragraph 4-41).
Remove obstructions.
6. ENGINE HAS EXCESSIVE OIL CONSUMPTION.
Step 1. Check air cleaner element.
Clean or replace element if necessary.
Step 2. Check breather pipe (paragraph 4-45).
Clean or replace breather pipe.
7. LOW OIL PRESSURE.
Step 1. Check oil level (paragraph 4-51).
Add oil if required.
Step 2. Check oil pressure gauge (paragraph 4-33).
Replace a bad gauge.
8. HIGH OIL PRESSURE.

Step 1. Check oil.
Add proper grade of oil.
Step 2. Check oil pressure gauge (paragraph 4-33).
Replace gauge if necessary.
4-8
TM5-6115-585-12
NAVFAC P-8-623-12
TO-35C2-3-455-1
TM-05684C/05685B-12
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
9. ENGINE SHUTS DOWN.
Step 1. Check oil level (paragraph 4-51).
Add proper grade of oil.
Step 2. Check for restricted air cooling system (paragraph 4-41).
Clean restrictions from system.
Step 3. Check for overload on generator.
Keep generator load within set capability.
Step 4. Check low oil pressure switch (paragraph 4-31).
Replace a bad switch.
Step 5. Check thermo over heat switch (paragraph 4-17c).
Replace a bad switch.
10. ENGINE VIBRATES.
Step 1. Engine mounts loose or bad (paragraph 4-52).
Tighten mounting or replace as necessary.
Step 2. Check for loose blower wheel.
Tighten blower wheel.
Step 3. Check valve clearance (paragraph 4-46).
Reset valve clearance.
11. LOW GENERATOR OUTPUT VOLTAGE (NO LOAD).
Step 1. Low engine speed.
Set engine speed to achieve no-load frequency (paragraph 1-10.b.).
Step 2. Check voltage adjust rheostat (R1) setting (paragraph 4-38).
Set rheostat (R1) for proper output voltage.
12. HIGH GENERATOR OUTPUT VOLTAGE (NO LOAD).
Step 1. Check voltage adjust rheostat (R1) setting (paragraph 4-38).
Set rheostat (R1) for proper output voltage.
13. AC CIRCUIT BREAKER (CB1) WILL NOT CLOSE.
Step 1. Check for short circuit load.
Remove short circuit.
Change 2 4-9
TM5-6115-585-12
NAVFAC P-8-262-12
TO-35C2-3-455-1
TM-05684C-12
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
14. BATTERIES DO NOT RETAIN CHARGE.
Step 1. Check for blown alternator protection fuse (F1) (paragraph 4-27).
Replace fuse.
Step 2. Check for bad battery or batteries (paragraph 4-25).
Replace defective battery.
Section VII. RADIO INTERFERENCE SUPPRESSION
4-14. G E N E R A L M E T H O D S FOR PROPER SUP- function it is to supress radio interference. The pri-
PRESSION. mary suppression components are shown in figure
4-3.
Essentially, suppression is attained by providing a low
resistance path to ground for stray currents. The
methods used include shielding the ignition and high-
frequency wires, grounding the frame with bonding
straps, and using filtering systems.
b. Secondary Suppression Components. These com-
4-15. R A D I O I N T E R F E R E N C E S U P P R E S S I O N C O M - ponents have radio interference suppression functions
PONENTS. which are incidental or secondary to their primary
function. They are the internal-external tooth lock-
a. Primary Suppression Components. The primary washers on the fuel pumps and battery charging reg-
suppression components are those whose primary ulator-rectifier.
4-10
TM5-6115-585-12
NAVFAC P-8-262-12
TO-35C2-3-455-1
TM-05684C-12
Figure 4-3. Primary Radio Interference Suppresion Components (Sheet 1 of 2)

4-11
TM5-6115-585-12
NAVPAC P-8-623-12
TO-35C2-3-455-1
TM-05684C/05684B-12
Figure 4-3. Primary Radio Interference Supperssion Components (Sheet 2 of 2)
Section VIII. MAINTENANCE OF ENGINE COOLING SYSTEM
4-17. ENGINE COOLING ASSEMBLY.

4 - 1 6 . DESCRIPTION AND FUNCTION. a. Inspection (See figure 3-17). On ASK equipped generators,
refer to para 5-3 and 5-8 and remove ASK cover assembly and
The engine has a pressure air cooling system. Fins exhaust plenum assembly. Check that ASK front panel assembly
on the engine blower draw air into the front of the en- is clear of debris.
gine housing and force it past the cylinders and out (1) Check shutters on shutter assembly (4) for
the right side of the engine. The engine air outlet cleaniness and obstructions. Check blower housing
uses a shutter assembly to control engine temper- (33) externally and internally at engine blower for
ature. Part of the air is directed thru the air cleaner cleanliness and obstructions.
at cold temperatures. A thermo power unit controls
(2)Open panel (12) by opening latches (14) and
shutter opening which limits air flow when the engine
is cold. When the engine air temperature reaches check that panel hinge works properly. With panel
approximately 120°F (49°C), the shutters begin to open, check engine fins for cleanliness and obstruction
open. The shutters are completely open at 140°F to airflow.
(60°C). The cooling system contains a high temper- b. Removal.
ature cut-out switch that shuts down the engine in
case the engine temperature reaches 394°F (201°C). (1) Disconnect negative lead from batteries.
4-12 Change 8
TM5-6115-585-12
NAVFAC P-8-623-12
TO-35C2-3-455-1
TM-05684C-12
(2) Air Housing Duct Cover. Remove air housing (1) and nuts (2). Remove screws (4) and special washer
duct cover (2) by removing screws (1). (5) attaching thermo unit assembly (6) to shutter as-
sembly and remove thermo power unit assembly. Be
(3) Shutter Assembly. Disconnect wiring to ther- careful plunger does not fall out of thermo unit as-
mal switch at connector plug (5) on outside of shutter sembly.
assembly. Loosen hose clamp (6) and disconnect air
intake hose from shutter assembly (4). Remove cap- (2) Shutters. Remove eight screws (7) attaching
screws (3) attaching shutter assembly to engine and shutters (8) to bracket assemblies (9, 10 and 11). Re-
blower housing (33). Carefully pull shutter assembly move shutters. Remove nuts (12) washer (13) and
(4) away from muffler (44) until lead from connector shutter torsion springs (14). Brackets (11) can now be
(5) to high temperature cutout switch (42) becomes removed. Remove bracket bearings. Remove screws
accessible. Disconnect leads from high temperature (17) and remove bearing (15) and washer (16), brackets
cutout switch (42) and remove shutter assembly (4). (9 and 10).
(4) Remove screws (37), washers (38), spacers (3) Brackets.

(40) and shock-mounts (39) and remove lifting bracket
(41). (a) Remove clips (18) that retain lower rod
(19) in bracket (9) and pivot arm (20). Remove lower
(5) Remove screws (34) and remove front shroud rod and bracket (9). Remove bracket bearing, screw
(36). (17) and remove bearing (15) and washer (16).
(6) Shroud Assembly. Open latches (14), remove (b) Remove nut (21), clip (22) and ball arm as-
screws (7), and washers (8), lift panel (9) and shroud sembly (23). Remove bracket (10) and associated
(11) as an assembly from the engine and blower hous- bearing (15), washer (16) and screw (17) using proce-
ing (33). dure as in paragraph (a) above.
(7) Baffles and Shrouds. Remove baffles (16) and (c) Remove pivot arm (20) by removing nut
(17) by removing screw (15). Remove rear shroud (24), lockwasher (25), flatwasher (26), washer (27),
(23) by removing screw (20), screw (18), washer (19), bearings (28) and bolt (29).
screw (34) and bracket (22). Remove baffles (26) by
removing nuts (24) and J bolt (25).
e. Test.
(8) Blower Grille Assembly. Remove screws (27)
and retainers (28) and remove grille (30). (1) Thermo Power Unit Assembly. Immerse the
thermo unit into a container of oil while monitoring
(9) Blower Housing. Remove screws (31) attach- the oil temperature. Plunger of thermo unit should
ing housing (33) to engine and remove screw (32) at- start to extend when temperature reaches 120°F (49°
taching housing to oil cooler support bracket. Remove C). Total extension at 140°F (60°C) should be at least
housing (33). 13/64 inch. Replace thermo unit if it does not operate
properly.
(10) Refer to paragraph 4-30 and remove oil
cooler and base. Remove screw (34), clip (35) and
shroud (36). f. Reassembly of Shutter Assembly.
c. Cleaning and Testing. (1) Brackets.
(1) Inspect the engine fins and the housing as- (a) Reassemble pivot arm (20) using bolt (29),
semblies for debris and remove as necessary. Clean bearings (28), washer (27), flatwasher (26), lockwasher
using detergent, clean cloth and brush. (25) and nut (24).
(2) Disconnect leads and remove high tempera- (b) Mount bracket (10) to box (30) using bear-
ture cutout switch from cylinder head. Check continuity ings (15), lockwasher (16), and screw (17). Be careful
between two terminals while heating switch with its not to confuse bracket (10) with bracket (9). Connect
mounting stud submerged in oil. When the temperature ball arm assembly (23) to bracket (10) and pivot arm
of the oil reaches 394 ±10°F (201 ±5°C) the switch (20) using clip (22) and nut (21).
should open. Switch should close when temperature
drops below 394 ± 10°F (201 ± 5°C). If switch does not (c) Mount bracket (9) along with bearing (15),
perform as indicated, replace. lockwasher (16) and screw (17). Ensure that bracket
is mounted so that shutter divider acts as inside stop.
Mount lower rod (19) to bracket (9) and pivot arm (20)
d. Disassembly of Shutter Assembly (see figure using clips (18).
4-4).
(a) Install brackets (11), bearings (15) and lock-
(1) Shutter Thermo Power Unit Assembly. Re- washer (16). Ensure that lower bracket is mounted so
move electrical connector (3) by removing screws that shutter divider acts as inside stop.
4-13
TM5-6115-585-12
NAVFAC P-8-623-12
TO-35C2-3-455-1
TM-05684C/05685B-12
Figure 4-4. Shutter Assembly
4-14 Change 2
TM5-6115-585-12
NAVFAC P-8-623-12
TO-35C2-3-455-1
TM-05684C/05685B-12
(2) Install power unit assembly (6) into shutter (2) Blower Housing. Install blower housing (33)
assembly box (30) using screws (4) and special washer on engine using screws (31 and 32).
(5). Mount connector (3) using screws (1) and nuts (2).
(3) Blower Grille Assembly. Install grille (30)
on blower housing (33) using screws (27) and re-
(3) Shutters. Mount torsion spring (14) using nut
tainers (28). (For units without ASK.)
(12) and washer (13). Mount shutters using screws (7).
Ensure that adequate clearance between shutter and (4) Baffles and Shrouds. Install shroud (23) using
shutter box sides is maintained and that brackets (11) screws. (18 and 20) and washer (19). Install rear shroud
are seated against shoulder of bearing (15) prior to (36) wing clip (35) and screws (34). Install baffles
tightening screws (7). Check shutter to ensure they will (16) and (17) using screws (15). Install baffle (26)
fully open and close without binding. with hook bolt (25) and nut (24).
(5) Shroud Assembly. Install door panel (12) and

g. Adjustments. shroud (11) as an assembly to the engine and blower
housing (33) using screws (7) and washers (8). Close
(1) Shutters (see figure 4-5). Disconnect rod latches (14).
from upper shutter. Adjust ball joint until upper
shutter closes tightly on lower shutter when lower (6) Lifting Bracket. Install lifting bracket (41)
with spacers (40), mounts (39), washers (38) and
shutter is held closed. Re-attach rod to upper shutter.
Screws (37).
(7) Shutter Assembly. Install shutter assembly (4)
(2) Thermo Unit (see figure 4-6). With Generator on engine and blower housing (33) using capscrews (3).
Set at 70°F, (21°C) loosen thermo unit guide-mounting Connect air intake hose to shutter assembly using
screws, the mounting holes in the shutter box are hose clamp (6). Connect connector plug to thermo unit
slotted. Slide the assembly to a position where the connector receptacle (5).
thermo unit plunger rests on roll pins with shutters
closed. Tighten mounting screws. (8) Air Housing Duct Cover. Mount air housing
duct cover (2) to shutter assembly (4) using screws
h. Installation (see figure 3-17). (l).
(1) Install shroud (38). clip (35) and screw (34). (9) On ASK equipped generators, refer to paragraphs
Install oil cooler and base as described in paragraph 5-3 and 5-8 and replace ASK cover assembly and exhaust
plenum.
4-30.
Figure 4-5. Adjusting Shutters Figure 4-6. Adjusting Thermo Unit
Change 8 4-15
TM5-6115-585-12
NAVFAC P-8-623-12
TO-35C2-3-455-1
TM-05684C/05685B-12
Section IX. MAINTENANCE OF FUEL SYSTEM
4-18. DESCRIPTION AND FUNCTION. (5) Loosen filler cap and remove filler cap (4) and
strainer (5).
a. Low Pressure System (see Schematic figure
1-5).
d. Cleaning and Inspection.
(1) Fuel pump may draw fuel from an external
source to fill set tank or set tank may be filled man- (1) Tank. Clean tank exterior using suitable sol-
ually. If an external fuel source is selected, a float vent and clean cloth and brush. Inspect tank for
valve assembly in the set tank maintains the fuel signs of physical damage. If damaged refer to higher
level in the tank. Two other fuel pumps (in series) level of maintenance.
draw fuel from the set tank and force the fuel through
a primary strainer, two filters, and a check valve (2) Fuel Level Gage. Check that fuel level gage
assembly, to the injection pump. face is clean and readable. Check that as cork float
is moved up and down, the meter movement rotates.
b. High Pressure System. (3) Float Switch. Inspect terminal connector for
damage to threads. Check to see that float slides on
(1) Fuel injection pump forces the fuel, under shaft without binding. Clean with suitable solvent if
high pressure, to the fuel injection nozzles. The in- required.
jection nozzles provide fuel to each combustion
chamber of the engine. Unused fuel is returned from (4) Fittings. Inspect fittings for good leak-free
the injectors to the fuel tank. A cam and gear on the seating on tank and check threads for physical damage.
camshaft drives the fuel injection pump. The gear
drives the pump face gear, providing fuel distribution (5) Fuel Drain Valve Assembly. Check that drain
to each cylinder in the proper order. The cam oper- valve does not leak and threads for physical damage.
ates the pump plunger, pressurizing fuel to the noz-
(6) Strainer. Invert and clean with solvent.
zles. A control sleeve meters fuel by controlling the
length of time the plunger spill port is closed, main- e. Test.
taining pressure, and therefore, the amount of fuel
delivered in each stroke. The pintle type injection (1) Float Switch. Remove float switch (6) from
nozzles are conventional inward opening with ad- tank (9). Using an ohmmeter, check for continuity
justable opening pressure. They are factory adjusted between terminals A and B of switch (see figure
to open at 1900 to 1950 psi. 4-8). Switch should show no continuity when float is
up. Switch should close when float drops to 2-7/8
±3/16 inch from threaded collar of float switch. Re-
4-19. FUEL TANK ASSEMBLY< place switch if it does not operate properly.
a. Inspection on Equipment. Refer to paragraph (2) Tank. If tank shows signs of physical dam-
3-13a. age or leaks refer to higher level of maintenance.
b. Removal (see figure 4-7). Drain fuel into suitable container
by opening drain valve. Tag and disconnect fuel hoses from fuel f. Reassembly (see figure 4-7).
tank fittings. Disconnect electrical lead from electrical connector
(10). Remove nut (1) and flatwasher (2) from straps (3) on out-
side of fuel tank. Remove tank from skid-base. On ASK equipped (1) Fuel Drain, Valve. Engage threads of fuel
generators, remove top panel, left panel and side closure assem- drain valve assembly (8) 1/2 turn into fuel tank
blies (para. 5-4 and 5-5). adapter (11). Coat threads with sealing compound
ML-S-22473. Tighten valve assembly Into adapter
c. Disassembly. (11).
(1) Fuel Level Gage. Unscrew and remove fuel

(2) Fittings. Engage threads of fitting (7) 1/2 turn
level gage (5) using tools only on the hex portion of into fuel tank (9). Coat threads with sealing com-
the gage. pound MIL-S-22473. Tighten fittings into tank. Fit-
tings should face Generator Set for proper connection
(2) Float Switch. Unscrew collar and disconnect of fuel lines. Attach fuel lines to fittings.
electrical connector (10) if not previously discon-
nected. Unscrew and remove float switch (6) using
tools only on the square portions of the switch. (3) Float Switch. Engage threads of float switch
(6) 1/2 turn into tank (9). Coat threads with sealing
(3) Unscrew and remove fittings (7). compound ML-S 22473. Tighten float switch (6) into
tank using tools only on square portion of switch. At-
(4) Holding pipe adapter (11) with a wrench, un- tach electrical lead to connector (10) on top of float
screw and remove drain valve (8). switch and tighten.
4-16 Change 8
TM5-6115-585-12
NAVFAC P-8-262-12
TO-35C2-3-455-1
TM-05684C-12
Figure 4-7. Fuel Tank Assembly
(4) Fuel Level Gauge. Engage threads of fuel (3) Check that drain valve is closed before filling
level gauge (5) 1/2 turn into tank (9). Coat threads tank with proper grade of fuel.
with sealing compound MIL-S-22473. Tighten float
level gauge into tank using tools only on hex portion NOTE
of gauge. Install filler cap (4) and strainer (5) into tank
After each time fuel filters or strainer is
(9).
drained or elements replaced, purge air from
fuel system by moving master switch on con-
g. Installation.
trol panel to PRIME & RUN position. This
should activate the fuel transfer pump and
(1) Install straps (3) onto the skid-base and se-
force trapped air back to the vented fuel tank.
cure with nut (1) and flatwasher (2) on inside of skid-
base only.
4-20. FUEL FILTER ASSEMBLIES AND STRAINER
(2) Position fuel tank assembly onto skid-base, position ASSEMBLY.
straps over tank assembly and secure with nut (1) and flat-
washer (2). On ASK equipped generators, install side There are two identical fuel filter assemblies (see
figure 3-13), one which acts as the primary and the
closure, left panel and top panel assemblies (para. 5-4 and
5-5). Change 8 4-17
TM5-6115-585-12
NAVFAC P-8-623-12
TO-35C2-3-455-1
TM-05684C/05685B-12
Figure 4-8. Testing Float Switch
other as secondary, plus there is one fuel strainer. If or leaking fittings and hoses, leaking valves and leak-
these filters or strainer are plugged, fuel flow will be ing at bowl and head interface.
restricted and the engine may not run properly.
Periodic maintenance is required for this assembly. b. Service.
(1) Fuel Filters (see figure 4-9). On ASK equipped
a. Inspection (on Equipment). On ASK equipped generators, generators, remove right panel assembly (para 5-6).
remove FUEL FILTERS access door. Remove plug (1), open drain cock (2) and drain fuel Into
suitable container. Remove bolt assembly (3), gasket (4)
(1) Fuel Filter Assemblies and Strainer Assem- and filter body (5). Remove filter element (6) and
bly. Inspect the assembly for secure mounting, loose gasket (7). Inspect element for ruptures, clogs or other
4-18 Change 8
TM5-6115-585-12
NAVFAC P-8-262-12
TO-35C2-3-455-1
TM-05684C-12
Figure 4-9. Fuel Filter Figure 4-10. Fuel Strainer Element
physical damage. Replace element if necessary. (2) Fuel Strainer Element (see figure 4-10).
Change primary element every 500 operating hours, Open drain valve (4) and drain fuel into suitable con-
and secondary filter elements every 1000 operating tainer. Remove nut (1) and washer (2) attaching body
hours. Replace filter element (6), gasket (7), filter (5) to head (10) and remove body and gasket (9). Re-
body (5), gasket (4), and bolt assembly (3). Close drain move retainer (6) and remove strainer element (7).
cock (2) and install plug (1). Inspect element for physical damage or clogging.
4-19
TM5-6115-585-12
NAVFAC P-8-262-12
TO-35C2-3-455-1
TM-05684C-12
heat. Flash point of solvent is 100°F to 138°F

(38° C to 59° C).
Clean parts in a well-ventilated area. Avoid Every 300 operating hours, clean strainer element
inhalation of solvent fumes and prolonged ex- (7) by soaking in dry cleaning solvent (Fed. Spec
posure of skin to cleaning solvent. Wash ex- P-D-680) and dry thoroughly using a clean dry cloth.
posed skin thoroughly. Dry cleaning solvent Replace strainer element (7) on stud (3) and secure
(Fed. Spec P-D-680) used to clean parts is with retainer (6). Position gasket (9) and body (5) on
potentially dangerous to personnel and prop- head (10) and secure with washer (2) and nut (1).
erty. Do not use near open flame or excessive Close drain cock (4).
Figure 4-11. Fuel Filters and Fuel Strainer Assembly
4-20
TM5-6115-585-12
NAVFAC P-8-623-12
TO-35C2-3-455-1
TM-05684C/05685B-12
c. Removal. hoses clean and plug to prevent contamination. Dis-

(1) Fuel Filter Assembly (see figure 4-11). Drain connect electrical connector (22) at solenoid valve (6).
fuel into a suitable container by opening drain valve
(l). Disconnect fuel lines (2, 3 and 4) and drain fuel (2) Fuel Pumps. Tag and disconnect electrical
lines. Remove elbow (5), check valve (6) and C O U P - lead from each fuel pump at connector on wiring
ling (7). Plug fuel lines to prevent accumulation of harness. Remove nuts (7), lockwashers (8 and 11) and
foreign material. screws (9) attaching each pump (12 and 13) and pump
lead (10) to bracket (21) and remove pumps.
(2) Remove screws (8) and lockwasher (9) at-
taching each filter assembly (10) and strainer as-
(3) Remove solenoid valve (6) from fittings (16
sembly (11) to mounting bracket and remove filter or and 17) and remove fitting (5) from solenoid valve.
strainer assembly. Remove inlet and outlet fittings
(12). Be careful when removing fittings not to dam-
(4) Remove fittings (14, 15, 16 and 17) from fuel
age housing. pumps. Remove nuts (18), lockwasher (19), screw (20)
(3) Remove nuts (13), lockwashers (14), screws and remove bracket (21).
(15) and remove bracket (16).
d. Installation.
(4) Inspect check valve (6) for cleanliness. Us-
ing a clean punch depress check valve from seat (op- (1) Position bracket (21) on frame and secure
posite end of arrow) and check for free movement with screws (20), lockwashers (19) and nuts (18).
and reseating upon release. Replace check valve if
it does not move freely. (2) Install fuel fittings (17, 16, 15, 14 and 5) in
fuel pumps (12 and 13).
d. Installation.
(1) Position bracket (16) on frame and secure (3) Turn solenoid valve (6) onto fuel pump outlet
with screws (15), lockwashers (14) and nuts (13). fittings (16 and 17) and position on fuel pump as shown
in figure 4-12.
(2) Position fuel filter assembly (10) or fuel
strainer (11) on bracket (16) and secure with lock- (4) Install fuel pumps (12 and 13) on bracket (21)
washers (9) and screws (8). and secure with screws (9), washers (8 and 11) and
nuts (7). Reconnect electrical leads to wiring harness’
(3) Install coupling (7), check valve (6) and elbow and fuel solenoid valve.
(5) On fuel line (4). Make sure arrow on check valve
points toward coupling (7). (5) Install and tighten fuel hoses (4, 3, 2 and 1).
(4) Connect fuel lines (4, 3 and 2). Tighten drain

valve (1) in each filter assembly and strainer assemb- 4-22. AUXILLARY FUEL SOLENOID VALVE.
ly.
a. Test on Equipment. On ASK equipped generators, remove
(5) On ASK equipped generator, install ASK right panel
assembly (para. 5-6). fuel access door and perform the following procedures.
NOTE (1) Ensure output pressure of auxiliary fuel pump
When installing hose assembly (2), dean using fuel, making is 6 to 7 psi and fuel level in set tank is below 1/2
sure all dirt is removed. full. Disconnect harness at solenoid valve connector.
Place master switch in PRIME RUN and AUX position.
4-21. E L E C T R I C F U E L P U M P , H O S E S AND Ensure voltage between points A and B on harness
AUXILIARY 30 SOLENOID VALVE. connector is 24 VDC. Reconnect harness to solenoid
valve. Test output pressure at output side of solenoid
a. Testing on Equipment. Perform operational teat valve. Pressure should be same as output pressure
for each pump individually. Each pump shroud pump of auxiliary fuel pump, if not replace solenoid valve.
at 6 to 7 psi as registered on an accurate fuel pres-
sure gauge. Connect fuel pressure gauge to output
port of pump. Turn master switch to PRIME AND
RUN position. Pressure gauge should register 6 to 7
psi. Replace defective pumps.
A radio interference suppression diode is
b. Service (see figure 4-13). On ASK equipped generators, mounted within the solenoid valve. The anode
remove fuel access door. Remove cover (1), gasket (2) and of the diode is connected to terminal A with the
strainer (3). Be careful not to lose magnet (4). Every 500 oper- cathode connected to terminal B of the solenoid
ating hours replace gasket (2) and strainer (3) in both main valve. When connecting 24 volts dc across the
pumps and auxiliary pump. Ensure that chamfered surface of solenoid terminals, be sure to connect the
magnet (4) is up prior to installation of new strainer and gasket. positive (+) lead to terminal B and the negative
(-) lead to terminal A.
c. Removal (see figure 4-12).
(1) Fuel Hoses. Tag and remove fuel hoses (1, 2, (2) With 24 volts dc applied across solenoid ter-
3 and 4) by unscrewing at fittings (5.15 and 16). Keep minals A and B, the solenoid should draw approxi-
mately 1/2 ampere, if not replace solenoid valve.
Change 8 4-21
TM5-6115-585-12
NAVFAC P-8-262-12
TO-35C2-3-455-1
TM-05684C-12
1. Hose assembly 8. Lockwasher (3) 16. Elbow (3)

2. Hose assembly 9. Screw (3) 17. Connector
3. Hose assembly 10. pump lead (3) 18. Nut (4)
4. Hose assembly 11. Lockwasher (3) 19. Lockwasher (4)
5. Connector 12. Fuel pump (2) 20. Screw (4)
6. Auxillary fuel solenoid valve 13. Auxillary fuel pump 21. Bracket
7. Nut (3) 14. Cap 22. Connector
15. Elbow (3)
Figure 4-12. Fuel Pump, Fuel Hoses and Solenoid

4-22
TM5-6115-585-12
NAVFAC P-8-623-12
TO-35C2-3455-1
TM-05684C/05685B-12
(3) With switch (S1) closed the plunger should

actuate and the current draw should be 0.25 ampere dc.
(4) If plunger does not actuate or if meter reads
above 0.35 amperes replace solenoid.
C . Remove (see figure 4-14). Tag and disconnect
harness leads (1). Remove the shut-off solenoid by
removing screws (9) and Iockwashers (10).
d. Installation. Mount shut-off solenoid using

screws (9) and lockwashers (10). Reconnect previously
tagged and removed harness wires (1).
e. Adjust. The solenoid plunger (3) should be adjusted so it

fully stops injection when in the deenergized position. With engine
running at full rated load, clearance between plunger (3) and control
arm (4) should be at least 1/8 inch. To adjust the plunger length,
loosen jam nut (6) on bottom of plunger. Turn knurled headscrew
(5). Lock jam nut (6) after correct adjustment. On ASK equipped
generators, install right panel assembly (para. 5-6).
Figure 4-13. Fuel Pump
4-23. FUEL SHUT-OFF SOLENOID
a. Inspect (on Equipment) (see figure 4-14). On ASK equipped

generators, remove right panel assembly (para. 5-6). Check that
electrical connections (1) are secure and clean. Check that rubber
boot (11 ) is clean and not broken. Check that governor and pump
linkage moves freely and is clean.
b. Test (on Equipment) (see figure 4-15).

(1) Tag and remove the solenoid harness leads
(l). Figure 4-14.
Switch S2 in figure 4-16 must be closed during

initial activation of solenoid to prevent in-rush
currents from damaging the dc ammetar. Open
switch S2 after solenoid activation to permit dc
ammeter to function.
(2) Connect the solenoid into test setup (figure 4-

15).
Figure 4-14. Adjusting Fuel Shut_Off Solenoid
Change 8 4-23
TM 5-6115-585-12
NAVFACP-8-623-12
TO–35C2–3-455-1
TM-05684C/05685B-12
Figure 4–15. Fuel Solenoid Test Set–Up.

Section X. MAINTENANCE OF ENGINE ELECTRICAL SYSTEM
4–24. DESCRIPTION AND FUNCTION.
a. The engine is cranked by a 24 volt electric

starting motor (see figure 1–7). When starting motor Metal objects making contact be-
solenoid is energized, the solenoid core pulls in, shift- tween the positive and negative
ing the pinion gear into engagement with the engine battery terminals, or between the
flywheel ring gear. At the same time, contacts in the positive battery terminal and the gen-
solenoid close to provide a circuit for the starter. The erator frame can cause FIRE or
starting motor is protected from overspeeding by an EXPLOSION, Always keep the bat-
tery terminal covers on the battery
overrunning clutch. Two 12 volt batteries in series are terminals. See Figure 3–2,
used. The starting switch for this starting circuit is lo-
cated in the control cubicle, A blower wheel alternator BATTERY ASSEMBLY.
is utilized to maintain the battery charge. The stator is Battery Cables (Including Jumper Cable). On
mounted on the engine block and the permanent mag- ASK equipped generators, remove BATTERIES ac-
net rotor is mounted into the air cooling system blower. cess door.
Solid state diode rectifiers convert the alternating cur- (1) Test. Test battery cable for continuity, Re-
rent generated in the stator to direct current for battery
place any cable that does not show continuity,
charging.
(2) Remove. Remove negative battery cable
from negative (–) battery terminal. Remove positive
b. A new (Style II) gear–reduction electric starter
(+) battery cable from positive battery terminal.
will be installed on engines manufactured during 1990;
and will be available as a replacement when the origi- Tag and disconnect cables from starter case and
nal starter, (Style I ) is no longer available. The Style II starter solenoid. Remove jumper between batteries.
starters are interchangeable with the Style I starter. Clean battery, starter, and starter solenoid terminals
thoroughly and install new cables as given below.
c. Slave receptacle is used to supply external (3) Replace. Attach jumper cable between
cranking power and as an output receptacle for other negative (–) terminal of one battery and positive (+) ter-
equipment. Refer to Figure 4–34 for removal and in- minal of the other battery. Attach positive battery cable
stallation of slave receptacle. to the “B” Terminal stud on starter solenoid. Attach
4–24 Change 1 1
TM5-6115-585-L2
NAVFAC P-8-623-12
TO-35C2-3-455-1
TM-05684C/05685B-12
Tag and disconnect cables from starter case and

starter solenoid. Remove jumper between batteries.
Clean battery, starter, and starter solenoid ter-
minals thoroughly and install new cables as given
above.
(3) Replace. Attach jumper cable between nega-
tive (-) terminal of one battery and positive (+) ter-
minal of the other battery. Tighten terminal con-
nectors securely. Attach positive battery cable to
stud on starter solenoid. Attach negative battery cable
to stud on starter case (see figure 4-16). Attach posi-
tive cable to positive terminal on one battery and
negative cable to negative terminal on the other bat-
tery. Tighten terminal connectors securely.
Change 5 4-24.1/(4-24.2 blank)

TM 5-6115-585-12
NAVFAC P-8–623-12
TO–35C2–3-455-1
TM-05684C/05685B-12
Figure 4–16. Installing Battery Cables.
Change 11 4–25
TM 5-6115-585-12
NAVFAC P-8-623-12
TO-35C2-3-455-1
TM-05684C/05685B-12
negative battery cable (–) to the ground terminal “G” of cell of battery separately using a hydrometer. Remove
the starter. See figure 4–16. Attach positive cable cap from one cell and draw fluid from that cell into hy-
(+) to positive terminal on one battery and negative ca- drometer. Hydrometer must register a specific gravity
ble (–) to negative terminal on the other battery. of 1.260 to 1.280. If specific gravity is below 1.260,
Tighten all terminal connectors securely. charge battery. See figure 4–17. Replace fluid into cell
and replace cap. Check each battery cell using this
NOTE
procedure. If one or more cells in a battery will not take
Always detach negative (–) cable first a charge, replace battery.
and reattach it last.
(2) Remove. Remove battery cables and top
b. Battery Top (Hold–down) Frame (see figure
frames, a and b above. Remove batteries from battery
3-2).
frame.
(1) Remove. Tag and disconnect battery ca-
bles (1 and 3) and jumper cable (4) from batteries (6). (3) Replace. Place batteries in battery frame
Remove six nuts (7) and flatwashers (8) holding top with negative (–) terminals toward control panel end of
frame (5) in place, and remove top frame. If hook bolts generator and positive (+) terminals toward blower
(9) do not need replacing, they need not be removed. housing end of generator. Install battery top frame and
battery cables as outlined above.
(2) Replace. Hook six bolts (9) onto bottom
frame (6). Place top frame (5) over batteries (6) mak-
ing certain hook bolts slide through the top frame.
Secure top frame in place with six flatwashers (8) and
nuts (7). Reattach battery cables (1 and 3) and jumper
cable (4).
(3) Repair. Straighten battery top frames

making certain they fit securely over batteries and hold
batteries in place.
c. Storage Batteries.
Battery electrolyte can cause severe

burns to the skin. Always flush ex-
posed parts of the skin with water as
quickly as possible.
The 6TN and 6TL batteries can be mixed or matched.
However, maintenance–free batteries cannot be
mixed or matched with military batteries. The 6TN and
or the 6TL batteries will perform properly in hot weather
as long as electrolyte levels are carefully monitored. If Figure 4–17. Testing Batteries
the electrolyte expands and causes the level to rise,
some fluid must be removed. If the level becomes too 4–26. ENGINE STARTER ASSEMBLY.
low due to evaporation, distilled water maybe used to
obtain the proper level. A good grade of drinking water a. Test. On equipment (see figure 4–19). On
(excluding mineral waters) may be used if distilled ASK equipped generators, remove batteries access
water is not available. door.
Electrolyte (NSNs 6810–00–249–9354 and (1) Make sure batteries are fully charged and
6810–00-843-1640) have a specific gravity of 1.280 that all battery and starter cables are serviceable and
and should be used in these batteries to a lower spe- properly installed.
cific gravity.
(2) Connect voltmeter as shown in figure
(1) Test. Charge battery for a sufficient time 4–19, Test a. If voltage is indicated, solenoid maybe
for battery to be fully charged (1 to 2 hours). Test each defective. Proceed to step (4).
4-26 Change 11
TM 5-6115–585-12
NAVFAC P-8-623-12
TO-35C2-3-455-1
TM-05684C/05685B-12
Figure 4–18. Engine Starter installation
Change 11 4-27
TM 5-6115-585-12
NAVFAC P-8-623-12
TO-35C2-3-455-1
TM-05684C/05685B-12
(3) Connect voltmeter as shown in figure (b) Style II Starter. Refer to figure 4-22A.
4–19, Test b. If battery voltage (24 volts) is not indi- Inspect solenoid switch (3) for cracks, dents, or other
cated, the starter (B1) may be defective. Proceed to physical damage. Check to see that the electrical ter-
step (4). minals are clean and free of corrosion. Check that
solenoid switch (3) is securely fastened to the starter
(4) Momentarily connect a jumper as shown motor (4), with screws (1).
in figure 4–19, Test b. Voltmeter reading should drop
to zero and starter should crank engine. If voltmeter
(3) Inspecting Drive Assembly. Refer to fig-
does not drop to zero, solenoid is defective. If voltme-
ure 4–22 for Style I Starter and figure 4–22A for Style II
ter reading does drop to zero but starter fails to crank
engine, starter is defective. Starter. Inspect drive gear for cracks or chipped teeth.
Check that gear and spring of drive moves freely, and
b. Removal (see figure 4–18). On ASK equipped returns to rear position when released.
generators remove batteries access door. Tag and
disconnect leads (1) thru (6). On Style I Starters, re- (4) Inspecting Brushes.
move nut (7), lockwasher(8), screw (9). Loosen but do
not remove screw (10), Iockwasher (11) and swing
(a) Style I Starter. Refer to figure 4-21.
support bracket (12) down and away from starter, On
Remove two through bolts (1) and lift end plate (2)
Style II Starter, support bracket is not fastened to the
away from frame. Lift brush tension springs (3) and lift
starter, loosen screw (10), Iockwasher (11) and swing
each brush (4) from holder for inspection. Check brush
support bracket down and away.
face for deep surface pits, cracks, or excessive chip-
ping. Measure brush length. See figure 4–21. When
brush is worn to length less than 1/4 inch, notify higher
Support bracket and associated hard- level maintenance for replacement of brushes (4).
ware must remain with engine at all Clean area around brushes and commutator and dry
times! It provides support for Style I with low pressure compressed air. Lift brush springs
Starters that may be used to replace
(3) and insert brushes (4) in brush holder. Reposition
Style II Starters during Operator and
Organizational maintenance. The end plate (2) on frame and insert and tighten through
support bracket and associated hard- bolts (1) securely.
ware is supplied on all engines
manufactured with either the Style I or
(b) Style II Starter. Refer to figure 4-21A.
Style II Starters.
Remove two nuts (1) and flat washers (2), lift off termi-
Support starter (15) and remove screws (13), lock nal assembly (3). Remove the two through studs (4),
washers (14) attaching starter to flywheel housing screws (5) and carefully lift off cover (6), leaving the
(17). Slide starter out of housing. brush holder (7) in place on the armature commutator.
Lift brush tension springs (8) and lift each brush (9)
c. Cleaning and Inspection of Starter Solenoid, from holder for inspection. Check brush face for deep
Drive Assembly and Starter Brushes. surface pits, cracks, or excessive chipping. Next
measure brush length. See figure 4–21A. When brush
(1) Cleaning Starter. Refer to paragraph
is worn to length less than 11.0 mm (0.433 inch), re-
3–16a.
placement is required. When Negative brushes are
worn, replacement is by installing a new brush holder
(2) Inspecting Solenoid Switch,
(7) which includes these brushes. When the Positive
(a) Style I Starter. Refer to figure 4-22. brushes are worn, replacement in by installing a new
Inspect solenoid switch (1) for cracks, dents, or other stator (10). Individual brushes are NOT available for
physical damage. Check to see that the electrical ter- replacement. Clean area around the brushes and
minals are clean and free of corrosion, Check that the commutator with dry and low pressure compressed air.
rubber boot (2) on plunger (3), cotter pin (4), clevis pin Lift brush springs (8) and inserft brushes (9) in brush
(5), and yoke (6) are in good condition. Check that holder(7). Reposition cover (6), fasten screws (5), in-
plunger (3) and yoke (6) operate freely. Check that so- sert through studs (4) and tighten securely. Place
lenoid switch (1) is securely fastened to the starter terminal assembly (3) on studs and fasten with flat
motor (8), with screws (14). washers (2) and nuts (1). Tighten securely.
4-28 Change 11
TM 5-61 15–585-12
NAVFAC P–8-623-12
TO–35C2-3-455-1
TM-05684C/05685B-12
C h a n g e 1 1 4-28.1
TM 5-6115-585-12
NAVFAC P–8-623-12
TO-35C2-3-455-1
TM-05684C/05685B-12
Figure 4–20. Testing Field Coil, Style II Starter
Figure 4–21. Inspecting Starter Brushes, Style I Starter
4-28.2 Change 11
TM 5-6115-585-12
TM-05684C/05685B-12
Figure 4–21 A. Inspecting Starter Brushes, Style II Starter
d. Bench Test. and Iockwasher holding lead (12) on small solenoid

switch terminal. Remove nut and Iockwasher from
(1) Starter Assembly. Refer to paragraph
negative terminal (9) freeing lead (12). Remove nut
4–26a.
and lockwasher from solenoid field terminal (11). Re-
(2) Field Coil. move cotter pin (4) and clevis pin (5) from plunger (3)
and yoke (6). Remove screws (14) and lift solenoid
(a) Connect continuity tester as shown In
figure 4–18, Test c. An open circuit indicates a defec- switch (1) from frame (8). Retain hardware from termi-
nals for solenoid installation, see following paragraph.
tive field coil.
(b) Connect tester for continuity as shown (2) Install Solenoid. Refer to figure 4-22.
in figure 4–19, Test d. Continuity indicates that the field Place solenoid (1) on frame (8) and move to rear until
coil is shorted to the field frame. field terminal (11 ) enters field coil lead strap. Install nut
and Iockwasher, do not tighten. Install screws (14), do
(3) Field Coil. Style II Starter.
not tighten. Align the plunger (3) on yoke (6) and insert
(a) Connect tester for continuity between clevis pin (5) and secure with cotter pin (4). Install lead
the field coil brushes as shown in figure 4–20, Test C. (12) on small solenoid terminal and on negative termi-
An open circuit indicates a defective field coil. nal (9) Secure with nuts and Iockwashers. Tighten nut
and Iockwasher on field terminal (11), and screws (14).
(b) Connect tester for continuity between
a field brush and stator frame as shown in figure 4–20, f. Repair. Style II Starter.
Test D. Continuity indicates that the field coil is shorted
to the frame. (1) Remove Solenoid. If solenoid is defec-
tive, remove as follows: Refer to figure 4–22A.
e. Repair. Style I Starter.
Remove nut and Iockwasher on terminal (M) freeing
(1) Remove Solenoid. If solenoid is defective, lead (L). Remove screws (1), solenoid switch (3) and
remove as follows: Refer to figure 4-22. Remove nut spacers (2). Retain hardware from terminal (M).
Change 11 4–28.3
TM 5-6115–585-12
NAVFAC P–8-623-12
TO-35C2-3-455-1
TM-05684C/05685B-12
Figure 4–22. Engine Starter Assembly, Style I Starter
Figure 4-22A. Engine Starter Assembly, Style II Starter
4-28.4 Change 11
TM 5-6115-585-12
NAVFACP-8-623-12
TO–35C2–3-455-1
Figure 4–23. Battery Charging Alternator
Change 11 4-29
TM 5-6115-585-12
NAVFACP-8-623-12
TO–35C2–3-455-1
TM-05684C/05685B-12
NOTE NOTE
Solenoid mounting screw removal Rotate Stator so wires come off the
may require the use of an impact type top. Place clamp on top of oil pump.
driver. Run wire over top of oil pump.
(2) Install Solenoid. Refer to figure 4-22A.

Support new solenoid (3) and original spacer(s), en-
gage solenoid plunger on Iever(yoke), secure using
(a) Tag and disconnect stator lead (1) frcm
new screws (1).
stator at terminal block (3) Check between two stator
g. Install Starter. Refer to figure 4–18. Slide leads for approximately 0.6 ohms continuity. If open cr
starter into opening in flywheel housing (17). Make shorted, notify higher level of maintenance. Check for
certain starter lies flat against housing. Attach starter continuity between each lead and ground. If continuity
to housing with screws (13) and Iockwashers (14). For is found, notify higher level of maintenance.
Style I Starter, swing support bracket(12) into position
(b) With the stator leads (1) disconnected,
at back of the starter, and attach with screw (9), nut (7)
check voltage across two leads (1) from stator. Voltage
and Iockwasher (8). Tighten screw (10) and lock
should be in a range of 30–35 volts AC with the engine
washer (11) securing support bracket (12) to engine
operating normally at 1800 RPM. If voltage is less than
block. Replace tagged leads per diagram, figure 4–18.
30 volts AC, stator on magnets in rotor may be defec-
Remove tags.
tive. Refer to higher level of maintenance for
4–27. B A T T E R Y C H A R G I N G A L T E R N A T O R . replacement of stator or rotor. Reconnect stator leads
(1).
a. Battery Alternator Stator (see figure 4–23).
On ASK equipped generators, remove ASK cover as-
sembly (para 5–3).
(1) Remove blower housing (see paragraph

4–17). Avoid operation of Generator Set for
more than 3 minutes with engine
(2) Inspect. The presence of the blower blower housing removed, as engine
wheel limits inspection of the battery alternator to in- will overheat.
specting that two leads (1) from stator (2) are free of
b. Battery Charging Regulator/Rectifier Assem-
damage and are not rubbing against blower wheel and
bly (see figure 4-23).
are securely connected to terminal block (3) located on
engine back plate (4). (1) Inspect. Inspect regulator/rectifier as-
sembly (5) for physical damage. Check that leads from
assembly to terminal block (3) are not damaged or
frayed. Check that assembly Is securely mounted to
engine back plate (4).
(2) Test.
Avoid contact with blower wheel while
testing battery alternator voltage. (a) Test stator as given In paragraph
4–27A above to see that it is operating correctly.
(3) Test.
(b) Remove fuse (9, figure 4-23) and con-
nect a 10 amp ammeter across the fuse holder
terminals as shown in figure 4–24. With engine operat-
ing normally at 1800 RPM, charge rate shou!d be no
less than 6.5 amps when loaded by a discharged bat-
Do not operate unit more than 3 min- tery. Charge rate should taper-off as battery becomes
utes with blower housing removed.
charged.
NOTE
Observe proper polarity when making

current test.
4-30 Change 11
TM5-6115-585-12
NAVFAC P-8-623-12
TO-35C2-3-455-1
TM-05684C/05685B-12
—,––— ——
Figure 4-24. Testing Battery Charging Regulator/Rectifier Assembly
(3) Remove (see figure 4-23). Disconnect and tag (1) Inspect. Inspect terminal block (3) for physi-
leads on regulator/rectifier assembly. Remove screws cal damage. Check that electrical connections to block
(7), washers (8) and nuts (6) attaching assembly to are clean and tight. Check that block is securely
engine back plate and remove assembly. fastened to engine back plate (4).
(4) Replace. Attach assembly to engine back plate (2) Test. Tag and disconnect leads to terminal
with three screws (7), six lockwashers (8), and three block. Check to see that there is no continuity be-
nuts (6). Attach tagged leads from assembly. tween terminals on terminal block and ground.
(3) Replace. Tag and disconnect leads at terminal
block. Remove two screws and nuts attaching block to
c. Battery Charger Circuit Fuse (see figure 4-23).
engine plate and remove block. Attach new terminal block
to engine back plate with two screws and nuts. Connect
(1) Inspect. Inspect fuse (9) for physical damage.
previously tagged leads to terminal block. Remove tags. Or
Check that end caps on fuse are free of corrosion.
Check that fuse is properly mounted in fuse holder. ASK equipped generators, install ASK cover assembly (para.
5-3).
(2) Test. Test Test (9) for continuity using an 4-28. S T A R T E R L O C K O U T S W I T C H A N D G E A R .
ohmmeter. Replace fuse that does not show con- On ASK equipped generators, remove oil access door.
tinuity.
a. Inspect (see figure 4-25). Disconnect negative battery
(3) Replace. Remove fuse holder cap and remove cable. Remove wing nut (1) and cover (3) and inspect
fuse. Install new fuse in fuse holder body and attach switch contact points between contact spring (15) and
fuse holder cap. adjusting screw(14) for physical damage.
b. Test. With engine off, disconnect switch at
d. Terminal Block (see figure 4-23). connector (8). Using an ohmeter, test that there is
Change 8 4 - 3 1
TMS-6115-585-12
NAVFAC P-8-262-12
TO-35C2-3-455-1
TM-05684C-12
Figure 4-25. Lockout Switch and Gear
continuity between connector (8) pins A and B on lead c. Remove. Disconnect switch lead from connector
from switch. Reconnect switch. operate engine at (8). Remove two screws (9) and lockwash ers (10)
operating speed, disconnect connector (8) and attaching switch to engine back plate. Carefully re-
between pins A and B on switch. check that switch is move switch taking care to to lose thrust plunger
open (no continuity).
4-32
TM5-6115-585-12
NAVFAC P-8-623-12
TO-35C2-3-455-1
TM-05684C/05685B-12
(20) and spring (12). Slide gear (5) out through opening
in engine back plate. clean any gasket (13) material
from switch and back Plate.
d. Repair. Repair starter lockout switch by raplac-

ing found to be defective under inspection.
e. Replace. Make certain spacer (16) is on shaft and

slip timing gear (5) through opening in engine back
plate. Make certain that shaft seats properly in gear
cover and that gear teeth are properly meshed. Place
thrust plunger (20) and spring (12) in gear shaft. Slide
switch and gasket (13) over shaft and attach to engine
back plate with two screws (9) and lockwashers (10).
Use a new gasket (13) between switch and engine back
plate. Reconnect electrical connector (8).
f. Adjust. With engine stopped, remove cover retaining

wing nut (1) and remove cover (3). Turn adjusting screw
(14) clockwise until points open. Turn adjusting screw
counterclockwise until points just close (see figure 4-26).
Start engine and disconnect switch from wiring harness at
connector (8, figure 4-25). Adjust adjusting screw for a
0.040 point gap. Replace cover (3) and wing nut (1).
Reconnect connector (8).
Be sure two wires are recessed in slot of housing

before tightening cover down. Figure 4-26. Adjusting Starter Lockout Switch
Section XI. MAINTENANCE OF OIL SYSTEM
4-29. FUNCTION AND DESCRIPTION.. for leaks and physical damage. inspect seal (1A, figure 4-28)
and replace if damaged. Blower housing must be removed to
The diesel engine has pressure lubrication to all inspect cooler and hoses.
working parts (see figure 4-27). The oil system
includes oil intake cup, gear type oil pump, bypass.
valve, oil pressure gage, low oil pressure shutoff, b. Service Every 500 operating hours clean oil cooler
full-flow oil filter, oil cooler, and passages to de- fins with air gun (50 psi) held 12 inches away from the
liver oil throughout the engine. Oil is held in the oil fine. Every 2500 operating hours remove oil cooler and
base, and forced through the oil filter and oil cooler flush in both directions using solvent at 25 psi.
by the pump. Lines leading to the rocker housing,
passages through the block to crankshaft and front c. Remove. Remove blower housing. Disconnect
camshaft bearing, crankshaft passages to connecting oil cooler hoses at valve of oil filter adapter (see
rod bearings and connecting rod passages to piston figure 4-29). Drain cooler into suitable container.
pin bushings complete the oil system network. The Remove machine screws (3, figure 4-28) and hex
bypass valve controls oil pressure by allowing excess nuts (4) attaching oil cooler (1) and oil cooler seal
oil to flow directly back to the crankcase. (1A) to mounting plate (2) and remove cooler (1).
Remove and check hoses. Plug hose if not used im-
4-30. OIL COOLER. mediately.
a. Inspect (see figure 4-28). On ASK equipped generators, d. Replace. install oil cooler (1) and oil cooler sea (1A) on
remove ASK cover assembly (para. 5-3). Inspect oil cooler(1) mounting plate (2) and secure with screws (3) and hex nuts (4).
for physical damage. Visually check for leaks where oil cooler Attach oil hoses to cooler as shown in figure 4-29 or 4-29.1.
Is connected to oil hoses (figure 4-29 or 4-29.1). Check that Replace blower housing shown in figure 4-29 or 4-29.1. Replace
cooler is securely fastened to mounting plate (2, figure 4-28) blower housing. Replace any oil lost. On ASK equipped. gener-
and that plate is securely fastened to engine. Inspect oil hoses ators, replace ASK cover assembly (para 5-3).
Change 8 4-33
TM5-6115-585-12
NAVFACP-8-623-12
TO-35C2-3-455-1
TM-05684C/05685B-12
4-34 Change 8
TM5-6115-585-12
NAVFAC P-8-623-12
TO-35C2-3-455-1
TM-05684C/05685B-12
Figure 4-29. Replacing Oil Cooler Hoses

(Early Model MEP-003A Only)
Change 2 4-35
TM5-6115-585-12
NAVFAC P-8-623-12
TO-35C2-3-455-1
TM-05684C/05685B-12
Figure 4-29.1. Replacing Oil Cooler Hoses

(Current Model MEP-003A and Model MEP-112A)
4-36 Change 2
TM5-6115-585-12
NAVFAC P-8-623-12
TO-35C2-3-455-1
TM-05684C/05685B-12
Figure 4-30. Oil Filter Assembly
d. Install. Install switch (11) in adapter (5) and b. Remove. Drain oil filter into suitable container
tighten. Use wrench on square portion of switch base. by removing drain plug (1). Loosen through bolt (2)
Connect leads at terminals 1 and 2. and remove body (3). Remove and discard filter (6)
and gasket (4).
4-32. OIL FILTER.
c. Replace. Clean filter mounting area in adapter (5) and
On ASK equipped generators, remove oil access door. inside of body (3). Install new element (6) in body (3). Install new
gasket (4) in groove of adapter (5). Position body (3) (drain
a. Service (see figure 4-30). Every 100 operating hours down) with element installed on adapter (5) and secure with
replace oil filter element. Clean inside of bowl while filter is through bolt (2). Tighten through bolt 10 to 15 ft-lb dry.
removed. Replace defective hoses.
Change 8 4.36.1 /(4.36.2 blank)

TM5-6115-585-12
NAVFAC P-8-262-12
TO-35C2-3-455-1
TM-05684C-12
Figure 4-31. Replacing Oil Pressure Gauge
4-33. OIL PRESSURE GAUGE. sure gauge and bracket. Remove fitting (5) and nuts
(6) attaching gauge (7) to mounting bracket (8) and
On ASK equipped generators, remove oil access door. remove gauge (7).
a. Test. Attach a pressure gauge of known accuracy

between flexible oil line and unit pressure gauge. Operate unit c. Replace. Install oil pressure gauge (7) on mount-
for 1/2 hour and check that both gauges read the same. At ing bracket (8) with nuts (6) two on each side of
rated rpm the normal oil pressure range is 20 to 45 psi which bracket (6). Maintain gap between gauge and bracket
is dependent on sir and engine temperature, grade of oil, and as indicated on figure 4-31. Position oil pressure
wear tolerances on the engine. If the unit pressure gauge is gauge and bracket on engine and install clamp (4),
in error by more than 5 lb, replace. lockwasher (3) and screw (2). Connect and tighten
oil line (1).
b. Remove (see figure 4-31). Disconnect and drain
oil line (1) to Oil pressure gauge (7). Remove screw
(2), lockwasher (3), clamp (4) and remove oil pres-
TM5-6115-585-12
NAVFAC P-8-262-12
TO-35C2-3-455-1
TM-05684C-12
Section XII. MAINTENANCE OF CONTROL SYSTEM
4-34. DESCRIPTION AND FUNCTION. When the master switch is placed in position 5,
marked START on the control panel, circuits are com-
NOTE pleted between terminals 11-13, 11-14, 11-15, 25-27,
25-28. The circuits between 11-13, 11-14, 11-15
All symbols (CB2, S1, etc. ) are the same as activate the engine fuel pumps, apply power to one side
used on the wiring diagram, figure 1-7, and of an open contact of relay K1 and activate the pre-
elsewhere throughout the manual. heat circuit as described in previous positions of the
switch. The circuit between 25-28 of the master
4-35. DC CONTROL SYSTEM. switch bypasses the safety devices which are capable
of stopping the engine. Bypassing the low oil pressure
Operation of the dc control system is as follows. safety device (S5) is essential until the engine has
Operator controlled dc functions are all contained in sufficient oil pressure to close its contacts. By-
three items mounted on the control panel. These are passing the safety device completes a circuit to the
the dc circuit breaker (CB2), the master switch (S1), engine fuel solenoid and relay coil (K1). Energizing
and the panel light switch (S2) (see figure 4-33). the start relay (K1) completes a circuit through the
contacts of (K1) to the running time meter, and to
a. The dc circuit breaker (CB2) controls all dc one side of the low oil pressure switch. The circuit
power to the unit. When it is de-energized (pulled between 25-27 of the master switch applies battery
out), all dc control circuits are de-energized, except voltage to the field flash resistor through diode (CR2).
the battery charging system which is self protected This action applies field flashing current to the
by fuse (Fl). This breaker can be used for emer- exciter field. It also applies power through diode
gency stopping of the unit. (CR1), which prevents starting set when the battery
polarity is reversed, and the closed contacts of the
b. The master switch (Sl) controls all starting and start disconnect switch (S7) to the crank relay coil
operating of the set under normal conditions. It is a (K3). When the crank relay contacts close, a circuit
five position rotary switch with the extreme position is completed to the starter solenoid (K6), which
in either direction being a momentary position. The closes and starts the cranking motor. With the
five positions control set operates as follows. When engine fuel solenoid energized and the starting motor
the master switch is placed in position 1, marked cranking the engine, the engine should start and ac-
PREHEAT on control panel, a circuit is completed celerate toward the speed setting of the governor.
between terminals 11 and 15 of the master switch, When engine speed passes approximately 1000 RPM
this applies power to the coil of the preheat relay the start disconnect switch contact opens de-ener-
(K2). When the preheat relay contacts close, power is gizing the crank relay (K3) and in turn the start
then applied to the glow plugs and preheaters on the solenoid and starting motor. With the engine ac-
engine. This position of the switch should be used for celerating and ac voltage building up, the governor
starting any time the engine is cold, or has not been will take control of the engine and the voltage regu-
run for sometime. The normal period for preheating lator will bring voltage to the value set by voltage
is 1 minute, but can be as long as 1 minute 30 seconds adjust rheostat. By the time the Generator Set is
as conditions dictate. This switch position is momen- under control of the regulator and governor, the
tary so that the preheat circuit remains activated engine oil pressure will be sufficient to permit re-
only as long as the operator holds the switch in turning master switch (S1) to the PRIME & RUN or
PREHEAT or START position. When the master switch PRIME & RUN AUX. FUEL position depending on
is placed in position 2, marked OFF on control panel, desired set operation. The set will now be operating
all dc circuits are de-energized except the panel under control of the voltage regulator and governor
lights, battery indicator, and the battery charging but without any load. As stated above, the set is now
system. This position is used to stop the set under ready to accept a load. Placing the ac circuit breaker
normal operation. When the master switch is placed in the ON position connects the selected generator
in position 3, marked PRIME & RUN AUX. FUEL on output to the set load terminals. The breaker can be
control panel, circuits are completed between ter- opened manually or by automatic action of the internal
minals 11-13, 11-14, 11-17 of the master switch. relay trip device in the case of an overload or a
This applies power to the engine fuel pumps, and the short circuit. The panel light switch activates the
auxiliary fuel system and also to one side of an panel lights when placed in the ON position.
open contact of relay (K1). This position is used when
the set is running and the auxiliary fuel system is
being used, and also to prime the entire fuel system 4-36. AC INSTRUMENTATION SYSTEM.
before starting. Position 4 of the master switch,
marked PRIME & RUN on the control panel, is the Operation of the ac instrumentation system which
same as position 3 except that the circuit between consists primarily of ammeter voltmeter and am-
terminals 11-17, of the master switch is not made. meter-voltmeter transfer switch is as follows. The
This position is used when the set is running and the function of the ammeter-voltmeter transfer switch
auxiliary fuel system is not being used, and also to (S8) and the meter switching section of the re-
prime the engine fuel system only before starting. connection switch (S6) is to provide the connections
4-38
TM 5-6115-585-12
NAVFAC P-8-623-12
TO-35C2-3-455-1
TM-05682C/05685B-12
for correct readings of voltmeter and ammeter indications will be obtained with the ammeter-
in all voltage connections and to ensure that voltmeter transfer switch (S8) in position 5 or
the secondaries of the current transformers are 6, which are single phase positions. It also
never open circuited. This combination also ensures the reverse of this condition for
ensures that when the Generator Set is positions 1,2, 3, and 4 of switch (S8).
connected for 3 phase operation that no meter
Figure 4-32. Load Terminal Board Assembly

TM 5-6115-585-12
NAVFAC P-8-623-12
TO-35C2-3-455-1
TM-05682C/05685B-12
4-37. LOAD TERMINAL BOARD ASSEMBLY. (5) Latch door.
a. Load Terminal Removal (see figure 4-32). c. Replacement of Lost or Broken Terminal Clip
(Retainer Safety Clip). The terminl clip is a component of
(1) Unlatch door (3). both the load terminal and the ground terminal. If the ter-
minal clip is lost or broken, fabricate as follows:
(2) Remove screws (1), lockwasher (2), and cover
and door assembly (3). (1) Requisition bulk wire NSN 9505-00-804-3814
(0.042 inch diameter) for the ground terminal (ground
(3) Remove screws (4) and lockwasher (5). stud). Requisition bulk wire NSN 9505-01-049-0144 (0.050
inch diameter) for the load terminal.
(4) Carefully lift terminal board (6) and tag and
disconnect leads from load terminals (7) by removing (2) Cut off about 3 inches of the wire, short enough
nut (11), lockwasher (10) and flatwasher (9). to keep the clips from touching another terminal or the
generator frame in the open or closed position.
(5) Remove load terminal (7) from terminal board (6)
by removing nut (8), flatwasher (12) and lockwasher (13). (3) Slip the wire through the hole in the terminal.
b. Load Terminal Installation (see figure 4-32). (4) Hold the terminal as shown (Detail A, figure
4-32.1) and bend both ends of the wire straight up keeping
(1) Install load terminal (7) to terminal board (6) the wire in as straight a line as you can with terminal body.
by installing lockwasher (13), flatwasher (12) and nut (8).
(5) Bend the wire into back-to-back 90º angles
(2) Connect leads to terminals (7) by installing (Detail B, figure 4-32.1) so that the legs of both angles are
flatwashers (9), lockwashers (10) and nut (11). about one-half inch long.
(3) Install lockwashers (5) and screws (4). (6) Bend the ends of each 90° angle down and
around into a U-shape (Detail C, figure 4-32.1) so that if
(4) Install door assembly (3), lockwashers (2) and done properly, the clip will hold the nut when it is un-
screws(1). screwed to install the cable (Detail D, figure 4-32.1).
Figure 4-32.1. Terminal Clip Replacement

TM5-6115-585-12
NAVFAC P-8-623-12
TO-35C2-3-455-1
TM-05684C/05685B-12
Change 8 4-41
TM 5-6115-585-12
NAVFAC P-8-623-12
TO-35C2-3-455-1
TM-05684C/05685B-12
4-38. CONTROL CUBICLE ASSEMBLY. (5) Hour Meter (M2). Operate Generator Set.
Check hour meter against a known accurate time source.
a. Test, On Equipment (see figure 4-33). Replace meter if necessary.
NOTE (6) Battery Charging Indicator (M1). Connect

meter capable of reading at least 35 volts DC from terminal
When disconnecting leads from terminals, tape on battery charging indicator to ground. Operate Generator
leads to prevent electrical shorts. Set. With the needle in the yellow area, the meter should read
between 18 and 27.5 volts. With the needle in the green area,
(1) Control Cubicle. Perform operational test on the meter should read between 24.5 and 31.5 volts. NOTE:
control cubicle, checking for proper operation in each of the The apparent overlap in voltage between the yellow high and
Generator Set’s three modes using a voltmeter of known green low is the result of a plus or minus 1.5 volt meter
accuracy. Check that ac output voltage indicated on control tolerance.
panel matches output voltage at terminal board. Check that
Generator Set does come to an EMERGENCY STOP when (7) DC Control Circuit Breaker (CB2). Operate
dc control circuit breaker (figure 2-3) is pulled. Test individ- Generator Set. Pull circuit breaker (CB2). If generator does
ual components of the control cubicle as given below. See not come to an emergency stop, stop the unit using master
figure 4-33 for location of components. switch and replace breaker.
(2) With the generator operating at rated fre- CAUTION

quency, flash the generator field by placing the master switch
on the control cubicle in the start position. If the generator Disconnect battery cable before making checks,
voltage fails to build up after flashing, the control cubicle unless otherwise noted.
may be defective.
(8) Master Switch (S1). Disconnect battery. Tag
(3) Voltage Adjust Rheostat (R1). Turn the and disconnect seven leads to master switch. Using an ohm-
Ammeter Voltmeter transfer switch to its various positions. meter, check for continuity between terminals for each of the
For each position of the switch, turn voltage adjust rheostat five switch positions as given in table 4-3. If the continuity is
to its extreme positions. Voltage reading should be as fol- not found for each set of terminals listed, replace master
lows. Voltage adjust range shall be between 205 and 220V switch.
for the 120/208V, 3 phase, 4 wire connection. Between 114
and 126V for the 120V, 1 phase, 2 wire connection. Between (9) Panel Light Switch (S2). Tag and disconnect
228 and 252V for the 120/240V, 1 phase, 3 wire connection. two leads to panel light switch. Using an ohmmeter, test for
continuity between terminals on switch. With the switch in
(4) Panel Light Assemblies (DS1) and the OFF position, there should be no continuity. With the
(DS2). With a good incandescent lamp in place and 24 vdc switch in the ON position, there should be continuity.
present at terminals of panel light (panel light switch ON), Replace switch if necessary.
check that lamps do light.
Table 4-3. Master Switch Continuity Check
NOTE
Check for Continuity
Be certain panel light switch is OFF before Switch Position Between Terminals
installing or replacing panel light assembly.
PREHEAT 11-15
OFF NONE
RUN AUX FUEL 11-13-17
RUN 11-13
START 11-13-15 25-27-28
TM 5-6115-585-12
NAVFAC P-8-623-12
TO-35C2-3-455-1
TM-05684C/05685B-12
Table 4-4. Voltmeter-Ammeter Range Selector Switch Continuity Check
Switch Position
Volts Phase Amps Check for Continuity Between Terminals
L1-L2 3 L1 11-15 21-23 31-33 41-46-47 51-52

L2-L3 3 L2 11-17 21-24 31-33 41-42-47 51-53
L3-L1 3 L3 11-17-18* 21-25 31-33 41-42-43 51-54
L3-LO 3 L3 11-18 21-26 31-33 41-42-43 51-55
L3-L1 1 L3 11-12 21-27 31-37 41-42-43-45 51-56
L3-LO 1 L3 11-12 21-28 31-37 41-43-45-46 51-57
* Terminal 17 is jumped to terminal 18.
(10) Ammeter-Voltmeter Transfer Switch (S8). (14) Transformer (T1) (see figure 4-33). Tag and
Tag and disconnect sixteen leads to range selector switch. disconnect five leads to transformer T1. Using an ohm-
Check for continuity between terminals for each of the meter check primary winding by measuring resistance
six switch positions as given in table 4-4. If continuity from terminal H1 to H2. Resistance should be 18.6
is not found for each set of terminals listed, replace switch. ohms ± 1.86 ohms. Check secondary winding by measuring
resistance from terminal X1 to X3. Resistance should
(11) Relays (K1), (K2), (K3), relay assembly (A1), diodes be 1.6 ohms ± .16 ohms. If either of the windings do not
(CR1) and (CR2) (see figures 1-7 and 4-33). Open circuit breaker show the proper resistance. replace transformer.
(CB2). On ASK equipped generators, remove batteries access
door. Disconnect battery cable. Tag, disconnect and tape the (15) Transformer (T2) (see figure 4-33). Tag and
following terminal lugs: A1 and A2 on crank relay (K3), preheat disconnect four leads to transformer T2. Check primary
relay (K2), and A1-4 and A1-3 on relay assembly A1. Tag and winding by measuring resistance from terminal H1 to H2.
disconnect terminals A1-5, A1-6, A1-7, and A1-8 on relay assembly Resistance should be 155 ohms ± 15.5 ohms. Check sec-
A1. Tact diodes CR1 and CR2 for shorted or open condition with
ondary winding by measuring resistance from terminal Xl
ohmmeter. Check CR1 by connecting positive lead of ohmmeter
to A1-5 and negative lead to A1-6. Ohmmeter should indicate to X2. Resistance should be 18.8 ohms ± 1.88 ohms. If
high resistance. Reverse ohmmeter leads. Ohmmeter should read either of the windings do not show the proper resistance,
low resistance. If either CR1 or CR2 fails the above test, the replace transformer.
diode is defective and must be replaced. Reconnect terminals to
A1-5, A1-6, A1-7, and A1-8 on relay assembly A1. Reconnect b. Remove.
battery cable. Close circuit breaker (CB2). Hold master switch (1) Control Cubicle. On ASK equipped generators, remove
in START position and using an ohmmeter check for continuity rear panel assembly (para. 5-7). Open air intake door. Tag and
between terminals A1 and A2 on crank relay K3, and continuity detach two connectors for wiring harness from control cubicle (see
between A1-3 and A1-4 on relay assembly A1. Continuity should figure 1-2). Remove screw (6, figure 4-34) and nut (8) attaching
end when master switch is released, Repeat the above continuity ground strap to cubicle support frame. Remove four screws (2),
test for preheat relay K2 while holding master switch in Iockwashers (3) and flatwashers (4) attaching control cubicle to
PREHEAT position. If either K2 or K3 fail the continuity test, the vibration mounts (5) and remove cubicle (1).
relay is defective and must be replaced. Reconnect terminals A1
and A2 to relay K2 and K3, and terminals A1-4 and A1-3 to
relay assembly A1. c. Inspect.
(12) Terminal Board Assembly (TB4) and (TB5). Tag and
disconnect leads to terminal boards. Test from each terminal to (1) Inspect the control cubicle assembly per
ground for shorts. Replace board if any terminal shows continuity paragraph 3-19.
to ground.
(2) Frequency Tranducer (A3) (see figure 4-33).
NOTE Inspect transducer for physical damage. Check to see that
On ASK equipped generators, access to J1 and J2 the electrical connections to transducer are clean and tight.
is through air intake door. Check to see that transducer is securely attached to the
control cubicle.
(13) Wiring Harness. Test wiring harness by using an
ohmmeter checking continuity of each wire. Perform point to
point checks between points indicated on figure 1-10. Wiring
harness need not be totally disconnected for checking continuity.
Change 8 4-42.1
TM5-6115-565-12
NAVFAC P-8-623-12
TO-35C2-3-455-1
TM-05684C/05685B-12
(3) Relay Assembly (A1). Inspect relay assembly
(5) for physical damage. Check that electrical connections
to as embly are clean and tight. Check that assembly is
securely attached to control cubicle.
(4) Relay (K1). Inspect relay (6) for physical

damage and continuity (see figure 4-33.1). Remove relay
from socket and inspect for bent or missing pins. Check
that relay is secured to socket with two screws.
Figure 4-33.1. Relay K1. Internal Connection Diagram
d. Disassembly.
(1) Panel Light Assemblies (DS1) and (DS2)

(see figure 4-33). Tag and detach two leads to each panel
light assembly (DS1) and (DS2). Remove nut and lock-
washer securing light assembly to control panel and remove
light assembly.
(2) Hour Meter (M2). Tag and disconnect two

leads to hour meter. Remove three screws, lockwashers,
and nuts attaching hour meter to control panel and remove
meter.
4-42.2 Change 8
TM5-6115-585-12
NAVFAC P-8-262-12
TO-35C2-3-455-1
TM-05684C-12
Figure 4-34. Removing Control Cubicle Support Assembly
(3) Battery Charging Indicator (M1). Tag and setscrews. Remove nut attaching switch to control
disconnect lead to indicator. Remove two lockwashers panel and remove switch. Install new switch as given
and nuts and retainer holding meter in place and above.
remove indicator.
(4) DC Control Circuit Breaker (CB2). Discon- (8) Voltage Adjust Rheostat (R1). Tag and
nect two leads to breaker. Remove two screws disconnect two leads to rheostat. Remove rheostat
attaching breaker to control panel and remove breaker. knob by loosening two allen setscrews. Remove nut
and washer attaching rheostat to panel and remove
(5) Master Switch (S1). Disconnect battery. Tag rheostat (9).
and disconnect seven leads to master switch. Re-
move switch knob by loosening two setscrews. Remove (9) Transformer (T1). Tag and disconnect five
nut attaching switch to control panel and remove leads to transformer. Remove four screws and
switch. lockwashers attaching transformer to control cubicle
and remove transformer.
(6) Panel Light Switch (S2). Tag and disconnect
two leads to switch. Remove nut attaching switch (10) Transformer (T2). Tag and disconnect four
to control panel and remove switch. leads to transformer. R e m o v e t w o s c r e w s a n d
(7) Ammeter-Voltmeter Transfer Switch (S8). lockwashers attaching transforrner to cubicle and
Tag and disconnect sixteen leads to range selector remove transformer.
switch. Remove switch knob by loosening two
TM5-6115-585-12
NAVFAC P-8-262-12
TO-35C2-3-455-1
TM-05684C-12
(11) Relay (K2-K3). Disconnect battery. Tag and (10) Terminal Board Assemblies (TB4) and (TB5).
disconnect four leads to relay. Remove two screws Attach board to control cubicle with two screws and
and nuts attaching relay to control cubicle. nuts. Attach tagged leads to board (if necessary, refer
to schematic, figure 1-10).
(12) Terminal Board Assemblies (TB4 and TB5).
Tag and disconnect leads to terminal boards. Remove (11) Voltage Adjust Rheostat (R1). Attach rheostat
two screws and nuts attaching board to control cubicle (9) to control panel with nut and lockwasher pro-
and remove board. vided with rheostat. Make certain that rheostat aligns
with slot on panel. Push rheostat knob onto shaft and
NOTE attach using two allen screws. Attach two tagged
leads to rheostat per wiring diagram, figure 1-7.
TB4 has 27 leads and TB5 has 36 leads.
(12) Transformer (T1). Attach transformer to
e. Assembly. control cubicle with four screws and nuts. Connect
five tagged leads to (T1) per wiring diagram, figure
(1) Panel Light Assemblies (DS1 and DS2). Attach 1-7.
new light assembly to control panel with the nut and
lockwasher supplied with each assembly. Attach two (13) Transformer (T2). Attach transformer to
tagged leads to each panel light (if necessary refer control cubicle with four screws and nuts. Connect
to wiring diagram, figure 1-7). four tagged leads to (T2) per wiring diagram, figure
1-7.
(2) Hour Meter (M2). Attach hour meter to control
panel with three screws, lockwashers, and nuts pro- f. Bench Test. Connect the control cubicle as shown
vided with meter. Attach two tagged leads to meter in figure 4-35 and proceed as follows.
(if necessary, refer to wiring diagram, figure 1-7).
(1) Position switches as follows:
(3) Battery Charging Indicator (M1). Slide battery
charging indicator into opening in control panel. Place (a) Master switch-stop
retainer over back of indicator and secure with two
lockwashers and nuts. Attach lead to indicator (if (b) Panel light switch-off
necessary, refer to wiring diagram, figure 1-7).
(c) S1-closed
(4) DC Control Circuit Breaker (CB2). Attach
circuit breaker to control panel with the two screws. (d) S2-open
Reconnect tagged leads to breaker (if necessary, refer
to wiring diagram, figure 1-7).
(5) Master Switch (S1). Attach master switch to

control panel with nut and key ring provided with
switch. Make certain key on key ring aligns with slot
in control panel. Push switch knob onto shaft and
attach with two allen screws. Attach seven tagged
leads to switch (if necessary, refer to wiring dia-
gram, figure 1-7).
(6) Panel Light Switch (S2). Attach panel light

switch to control panel with nut and key ring. Make
certain key on key ring aligns with slot in control
panel. Attach two tagged leads to switch (if necessary,
refer to wiring diagram, figure 1-7).
(7) Voltmeter-Ammeter Range Selector Switch

(S8). Attach range selector switch to control panel
with nut and key ring. Make certain key on key ring
aligns with slot in control panel. Push switch knob
onto shaft and attach with two allen screws. Attach
sixteen tagged leads to switch (if necessary, refer to
wiring diagram, figure 1-7).
(8) Relay (K1). Plug new relay into socket on

relay assembly A1 and secure with two screws.
(9) Relay (K2 and K3). Attach relay to control

cubicle with two screws and nuts. Reconnect four
tagged leads per wiring diagram, figure 1-7. Figure 4-35. Control Cubicle Test Set-Up
4-44
TM5-6115-585-12
NAVFAC P-8-623-12
TO-35C2-3-455-1
TM-05684C/05685B-12
(2) Place master switch in preheat position. (9) Place master switch in the stop position.
Lamps L2 and L3 shall light indicating that the pre- All lamps shall be out indicating that all stop circuits
heat circuitry is correct. are correct.
(3) Place master switch in start position. Lamps (10) Place panel light switch in the on position.
L1, L2, L3, L4, L5 and L6 shall light indicating that Panel lights shall be on indicating that the panel light
all circuits for starting are correct. circuit is correct.
(4) With the master switch in the start position, (11) Reposition all switches as in step 1 and dis-
open switch S1. Lamp L1 shall extinguish indicating connect test setup.
that the start disconnect circuitry is correct.
(12) Test CR1 and CR2 as follows:
(5) With the master switch in the start position.
Close switch S2 and then, place the master switch in (a) Remove wires from terminals 6 and 7 of
the prime and run position. Lamps L2 and L3 shall A1.
extinguish. Lamps L4, L5 and L6 shall remain lit
indicating that the prime and run circuitry are cor- (b) Measure forward and backward resistance
rect. of CR1 between terminals 5 and 6 of A1. Resistance
should read high in one direction and low in the other.
(6) with the master switch in the prime and run If not, CR1 is bad.
position and lamps L4, L5 and L6 lit open switch S2.
Lamp L4 shall extinguish indicating that the engine (c) Measure forward and backward resistance
protective devices circuit and the prime circuit is of CR2 between terminals 7 and 8 of A1. Resistance
correct. should read high in one direction and low in the other.
If not, CR2 is bad.
(7) Repeat the procedure of step 5, except that
the master switch shall be placed in the prime and
run aux fuel position after closing switch S2 Lamps. g. Install.
L4, L5, L6 and L? shall remain lit indicating that
the prime and run aux fuel circuitry is correct. (1) Control Cubicle. Attach control cubicle (1, figure 4-34) to
four vibration mounts (5) with four screws (2), lockwashers (3), and
(8) With the master switch in the prime and run flatwashers (4). Attach ground strap (7) to cubicle support frame
aux fuel position and lamps L4, L5, L6 and L7 lit with screw (6) and nut (8). Attach two connectors from wiring har-
open switch S2. Lamp L4 shall extinguish indicating ness to connectors on back of control cubicle. On ASK equipped
that the engine protective devices circuit and the generators, install rear panel assembly (para. 5-7).
prime circuit is correct.
Section XIII. MAINTENANCE OF ENGINE
4-39. DESCRIPTION AND FUNCTION t 4-40. EXHAUST MUFFLER ASSEMBLY
(See figure 4-36.) The engine assembly is a four

cylinder, air cooled, overhead valve, fuel injected a. Inspect (see figure 4-37). If engine exhaust is
diesel equipped with; a blower housing (1) and a noisy or if exhaust gases are detected from shutter
shutter assembly (2) used to direct and control assembly, indications are that muffler (3) or gaskets
cooling air, an oil cooler (3) and gear type oil pump (4) and (6) may be defective.
used to cool and circulate lubricating oil in the
engine, a replaceable cartridge type oil filter (4) to
remove contaminants from the lubricating oil, fuel b. Remove. Remove shutter assembly as outlined
injection pump (5) to supply metered fuel to the in paragraph 4-17. Bend lock tabs (2) down and
engine combustion cylinders through fuel injectors remove four nuts (1) holding muffler (3) in place.
located in the cylinder heads, air intake manifold (6) Remove lock tabs (2), mufflers (3), mufflfer gaskets (4).
and heaters that receive combustion air from the adapters (5) and adapter gaskets (6) from each
external air cleaner (10) and heat the combustion air cylinder head.
if required, starter motor (7) coupled to the engine
drive gear for cranking the engine for starting, cor-
rosion resistant exhaust mufflers (8) to reduce engine c. Replace. Place gaskets (6), adapters (5) in place
exhaust noise, and a mechanical governor used on each cylinder head. Slide new muffler gaskets (4),
to maintain rated frequency under varying load. muffler (3), and lock tabs (2) over studs (7) in cyl
inder head and secure to cylinder head with nuts (1).
Change 8 4-45
TM5-6115-585-12
NAVFAC P-8-262-12
TO-35C2-3-455-1
TM-05684C-12
TM5-6115-585-12
NAVFAC P-8-623-12
TO-35C2-3-455-1
TM-05684C/05685B-12
1. Blower housing 17. Rocker cover (2)

2. Shutter assembly 18. Intake manifold
3. Oil cooler 19. Screw (4)
4. Oil filter 20. Lock tab (4)
5. Injection pump 21. Gasket (2)
6. Intake manifold assembly 22. Lead
7. Starter 23. Heater (2)
8. Exhaust muffler 24. Lead
9. Governor 25. Screw (2)
10. Air cleaner assembly 26. Washer (2)
11. Oil dip-stick and filler 27. Washer (4)
12. Screw (2) 28. Spacer (4)
13. Washer (2) 29. Adapter
14. Shockmount (2) 30. Gasket
15. Spacer (2) 31. Engine shroud and door
16. Bracket panel
TS 6115-585-12/4-36(2)
Figure 4-36. Engine Assembly (Sheet 2 of 2)
NOTE (2) Install air cleaner, bracket and spacers (15) on

generator housing and secure with lockwashers (14) and
screws (13). Install hoses (10 and 12) and secure with clamps
Upper and lower nut must be tightened evenly (9) and (11).
in small increments so that muffler will lay
flat against adapters. 4-42. ENGINE ASSEMBLY.
Bend lock tabs (2) up to secure nuts (1). a. Inspect (see figure 1-1). Inspect engine for loose con-
nections, leaks in oil and fuel systems, and free action of all
4-41. AIR CLEANER ASSEMBLY. moving parts. Check that engine is securely mounted to skid-
base. On ASK equipped generators, inspections of the engine
a. Inspect (see figure 4-37). On ASK equipped generators, assembly are limited to components accessible through the
open air intake door and air cleaner door. access doors.
(1) Air Cleaner Assembly. Check air cleaner b. Test. Operate engine with no load on Generator
assembly for corrosion, broken or dented components Set, until it warms up to normal operating tem-
or split hoses. perature indicated by shutters being in an inter-
mediate position between open and closed. Check oil
b. Remove. pressure. Oil pressure should be 20-45 psi. Check
frequency on frequency meter. Frequency should be
(1) Air Cleaner Assembly. Loosen hose clamps approximately 60 Hz (MEP-003A) or 400 H Z ( M E P -
(9 and 11) attaching two air intake hoses (10 and 12) 112A). Apply full rated load to engine. Check that
to housing and detach hoses. Remove screws (13), governor adjusts engine quickly, smoothly, and with-
lockwashers (14) and remove air cleaner and bracket out excessive hunting. Check that exhaust is normal
and spacers (15). Remove air flow indicator (16) by under load. Check that engine runs without excessive
turning counterclockwise. fuel or oil consumption. Check that no unusual noise
is heard. Inability of engine to meet these tests may
(2) Remove nut (17), lockwashers (18), screw indicate engine malfunctioning. See Troubleshooting,
(19) and separate air cleaner (20) and bracket (21). Section VI.
c. Repair. c. Service. Service engine according to the schedule
given in table 4-1, Preventive Maintenance Checks
(1) Air Cleaner Assembly. Weld and straighten and Services.
air cleaner housing as necessary.
d. Adjust. The only engine adjustments applicable
(2) Mounting Bracket (see figure 4-37). If bracket to this level of maintenance are to the valve rocker
(21) is split or bent, weld and straighten bracket as arms stop solenoid. and starter lockout switch.
necessary. After completing repairs, check that
bracket securely attaches air cleaner to set.
d. Install. NOTE
(1) Air Cleaner Assembly (see figure 4-37). Engine lifting attachment is for lifting engine
Install air cleaner (20) on bracket (21) and secure alone. Do not use this attachment for lifting
with screws (19), lockwashers (18) and nuts (17). engine if generator is still attached. Use the
Install air flow indicator (16) on air cleaner. set lifting eye for this purpose (see figure 1-1).
Change 8 4-47
TM5-6115-585-12
NAVFAC P-8-262-12
TO-35C2-3-455-1
TM-05684C-12
Figure 4-37. Exhaust Muffler and Air Cleaner Assemblies.

TM5-6115-585-12
NAVFAC P-8-623-12
TO-35C2-3-455-1
TM-05684C/05685B-12
4-43. INTAKE MANIFOLD ASSEMBLY. and tight. While engine is operating, check for leaks
especially at the gasket (21, figure 4-36) between
a. Test. On Equipment (see figure 4-36). On ASK equipped manifold and cylinder head and the gasket (30) between
generators, remove right panel assembly (para. 5-6). Remove the manifold heater adapter (29) and the manifold.
hose between intake manifold and air cleaner to permit visual Drop oil from an oil can or hold piece of thin paper
inspection of heater coils (23). Place master switch (see figure on point suspected of leaking. If leak exists, oil will
2-3) in the PREHEAT position. Good coils should start to heat be sucked in or paper will be sucked against leaking
within one minute. Release switch as soon as coil begins to heat. area.
Replace a bad heater.
c. Remove. Tag and disconnect leads (22 and 24)
from heaters (23) and remove heaters (23). Remove
b. Inspect heater for physical damage. leads (24) by removing screw (25), washers (26 and
Check that electrical connections to heater are clean 27) and spacer (28). Remove adapter (29) and gasket
Figure 4-38. Rocker Arm Covers

Change 8 4-49
TM5-6115-585-12
NAVFAC P-8-623-12
TO-35C2-3-455-1
TM-05684C/05685B-12
(30). Bend lock tabs (20) down and remove four screws (19)
attaching manifold to cylinder heads and remove manifold
(18). Clean away any gasket material (21) stuck to cylinder
heads or manifold.
Figure 4-39. Cleaning Rocker Arm Cover Oil Line
4-50 Change 10
TM5-6115-585-12
NAVFAC P-8-262-12
T0-35C2-3-455-1
TM-05684C-12
4-51
TM5-6115-585-12
NAVFAC P-8-262-12
TO-35C2-3-455-1
TM-05684C-12
Figure 4-41. Cylinder Head Assembly
4-52
TM5-6115-585-12
NAVFAC P-8-623-12
TO-35C2-3-455-1
TM-05684C/05685B-12
Figure 4-42. Oil Fill Tube
Change 8 4-53
TM5-6115-585-12
NAVFAC P-8-262- 12
TO-35C2-3-455-1
TM-05684C-12
Figure 4-43. Engine Mounting Assembly

4-54
TM 5-6115-585-12
NAVFAC P-8-623-12
TO-35C2-3-455-1
TM-05684 C/05685B-12
Section XIV. MAINTENANCE OF GENERATOR ASSEMBLY
Figure 4-44. Generator Screen-Guard

4-55
TM 5-6115-585-12
NAVFAC P-8-623-12
TO-35C2-3-455-1
TM-05684C/05685B-12
4-56
TM5-6115-585-12
NAVFAC P-8-623-12
TO-35C2-3-455-1
TM-05684C/05685B
Figure 4-45. Skid Base Assembly.
Change 4 4-57
TM5-6115-585-12
NAVFAC P-8-262-12
TO35C2-3-455-1
TM-05684C-12
(b) Refer to paragraph 4-38 and Install con- (b) See paragraph 4-25 and install batteries
trol cubicle. and battery hold-downs.
(2) Battery Frame Bottom and Tray. (3) Slave Receptacle. Install bracket (23) with
(a) Position battery tray (12) and bottom frame screws (22). Install slave receptacle (21) on bracket
with screws (18), lockwashers (20) and nuts (19).
(11) on skid-base (24). Attach by installing nuts (5 and Install leads (17) on slave receptacle as tagged. Re-
9), lockwashers (6 and 10), bevel washers (7) and move tags.
screws (4 and 8).
(4) Ground Stud. Install ground stud (16) on skid-base (24)
NOTE with Iockwasher (14) and nut (13). Install leads(15 and 17) on
ground stud (16) with Iockwasher (14) and nut (13). On ASK
Bevel washers are only on the four bolts at equipped generator sets refer to chapter 5 and install entire
the outside of the skid-base. ASK assembly.
4-58 Change 8
TM 5-6115-585-12
NAVFAC P-8-623-12
TO 35C2-3-455-1
TM-05684C/05685B-12
CHAPTER 5
MATERIEL USED IN CONJUNCTION WITH DOD STANDARD GENERATOR
SET, 10KW DIESEL ENGINE DRIVEN, MODELS MEP-003A AND MEP-112A
Section I. AUXILIARY EQUIPMENT

5-1. GENERAL .
This chapter describes all Organizational Level Maintenance pro-
cedures for auxiliary equipment (kits) which are used in con-
junction with the generator set. Any effects of the auxiliary
equipment on the operation or maintenance procedures for the
generator set are identified in the procedures where they occur.
Change 8 5-1
TM 5-6115-585-12
NAVFAC P-8-623-12
TO 35C2-3-455-1
TM-05682C/05685B-12
Section II. ACOUSTIC SUPPRESSION KIT
5-2. ACOUSTIC SUPPRESSION KIT.

The acoustic suppression kit (ASK) is an add-on enclosure that
reduces the noise level from the DOD Standard Generator Set, 10KW
Diesel Engine Driven, Models MEP-003A and MEP-112A. The control
cubicle and ac output control box assembly are not covered and
the fuel tank is only partially covered. Other controls or areas
requiring frequent service can be reached through top panel and
right and left panel access doors. All ASK plates are shown in
figure 5-1.
5-3. COVER ASSEMBLY.
a. Removal. See figure 5-2. Remove cover assembly
consisting of top panel, left and right panels, front panel and
side closure assemblies as follows:
(1) Remove four screws (1) and washers (2) securing
left panel assembly (3) to left support assembly (4).
(2) Remove two screws (5) and locknuts (6), and four
washers (7 and 8), securing side closure assembly (9) to rear
closure assembly(10).
(3) Remove six screws (11) and washers (12) securing
right panel assembly (13) to right support assembly (14).
(4) Remove two screws (15) and washers (16) securing
right panel assembly (13) to rear panel assembly (17), and remove
two screws (18) and locknuts (19), and four washers (20 and 21)
securing right panel assembly (13) to rear closure assembly (10).
(5) Remove three screws (22) and locknuts (23), and
six washers (24 and 25) securing top panel assembly (26) to rear
closure assembly (10).
WARNING
The ASK Cover assembly is heavy. Four people are

required to lift cover. Failure to follow safety
rules could result in personal injury.
(6) Lift and remove cover assembly from generator set.
5-2 Change 8
TM 5-6115-585-12
NAVFAC P-8-623-12
TO 35C2-3-455-1
TM-05684C/05685B-12
Figure 5-1. Instruction and Rating Plates (Sheet 1 of 4)

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

Change 8
TM 5-6115-585-12
NAVFAC P-8-623-12
TO 35C2-3-455-1
TM-05684C/05685B-12

Change 8 5-5
TM 5-6115-585-12
NAVFAC P-8-623-12
TO 35C2-3–455-1
TM-05682C/05685B-12
5-6 Change 8
TM 5-6115-585-12
NAVFAC P-8-623-12
TO 35C2-3-455-1
TM-05684C/05685B-12
Figure 5-2. Cover Assembly, Removal and Installation
Change 8 5 - 7
TM 5-6115-585-12
NAVFAC P-8-623-12
TO 35C2-3-455-1
TM-05682C/05685B-12
b. Installation. See figure 5-2. Replace cover assembly

consisting of top panel assembly, left and right panel assem-
blies, front panel and side closure assemblies on generator as
follows:
WARNING
The ASK Cover assembly is heavy. Four people are
required to lift cover. Failure to follow safety
rules could result in personal injury.
(1) Position cover assembly on generator set.
(2) Install three screws (22) and locknuts (23), and

six washers (24 and 25) securing top panel assembly (26) to rear
(3) Torque screws (22) to 16 ±2 ft-lbs dry.
(4) Install two screws (18) and locknuts (19), and
four washers (20 and 21) securing right panel assembly (13) to
rear closure assembly (10) and install two screws (15) and
washers (16) securing right panel assembly (13) to rear panel
assembly (17).

(6) Torque screws (15) to 18 ±2 in.-lbs dry.
(7) Install six screws (11) and washers (12) securing

(9) Install two screws (5) and locknuts (6), and four
washers (7 and 8) securing side closure assembly (9) to rear
(11) Install four screws (1) and washers (2) securing
5-4. TOP PANEL ASSEMBLY.

Removal. See figure 5-3. Remove top panel assembly
from left, right and front panel assemblies, and side and rear
closure assemblies as follows:
(1) Remove 13 screws (1) and washers (2) securing top
panel assembly (3) to left panel assembly (4), right panel
assembly (5) and front panel assembly (6).
5-8 Change 8
TM 5-6115-585-12
NAVFAC P-8-623-12
TO 35C2-3-455-1
TM 05684C/05685B-12
Figure 5-3. Top Panel Assembly and Exhaust Plenum,

Removal and Installation
Change 8 5 - 9
TM 5-6115-585-12
NAVFAC P-8-623-12
TO 35C2-3-455-1
TM-05682C/05685B-12
(2) Remove seven screws (7) and locknuts (8), and 14
washers (9 and 10) securing top panel assembly (3) to side
closure assembly (11) and rear closure assembly (12).
(3) Lift off top panel assembly (3).
b. Installation. See figure 5-3. Install top panel
assembly to left, right and front panel assemblies, and to side
and rear closure assemblies as follows:
(1) Position top panel assembly (3) on left panel
assembly (4), right panel assembly (5), front panel assembly (6),
side closure assembly (11), and rear closure assembly (12).
(2) Install seven screws (7) and locknuts (8), and 14
washers (9 and 10) securing top panel assembly (3) to side
closure assembly (11) and rear closure assembly (12).

(4) Install 13 screws (1) and washers (2) securing top
panel assembly (3) to left panel assembly (4), right panel
assembly (5), and front panel assembly (6).
5-5. LEFT PANEL ASSEMBLY WITH SIDE CLOSURE ASSEMBLY.
a. Removal. See figure 5-4. Remove left panel assembly
with side closure assembly from top panel, front panel, left
support and rear closure assemblies as follows:
(1) Remove top panel assembly (1) as described in
paragraph 5-4.
(3) Remove three screws (6) and washers (7) securing

left panel assembly (4) to front panel assembly (8).
closure assembly (14) and lift off left panel assembly (4) with
side closure assembly (13) .
(5) Remove three screws (15) and locknuts (16),
six washers (17 and 18) securing side closure assembly (13
left panel assembly (4).
5-10 Change 8
TM 5-6115-585-12
NAVFAC P-8-623-12
TO 35C2-3-455-1
TM-05684C/05685B-12
Figure 5-4. Left Panel Assembly and Side Closure Assembly,

Removal and Installation
Change 8 5-11
TM 5-6115-585-12
NAVFAC P-8-623-12
TO 35C2-3-455-1
TM-05682C/05685B-12
b. Installation. See figure 5-4. Install left panel with

side closure assembly to top panel, front panel, left support and
rear closure assemblies as follows:
(1) Install three screws (15) and locknuts (16) and

six washers (17 and 18) securing side closure assembly (13) to
left panel assembly (4).
(3) Position left panel assembly (4) with side closure

assembly (13) on generator and install two screws (9) and lock–
nuts (10) and four washers (11 and 12) securing side closure
assembly (13) to rear closure assembly (14).
(5) Install three screws (6) and washers (7) securing
left panel assembly (4) to front panel assembly (8).
(9) Install top panel assembly (1) as described in

paragraph 5-4.
5-6. RIGHT PANEL ASSEMBLY.
a. Removal. See figure 5-5. Remove right panel assembly
from right support assembly, rear panel assembly, front panel
assembly, top panel assembly and rear closure assembly as
follows:
(2) Remove three screws (5) and washers (6) securing

right panel assembly (3) to front panel assembly (7).
(3) Remove five screws (8) and washers (9) securing
right panel assembly (3) to top panel assembly (10).
(4) Remove two screws (11) and two locknuts (12), and
four washers (13 and 14) securinq riqht panel assembly (3) to
rear closure assembly (15) and remove two screws (16)and washers
(17) securing right panel assembly (3) to rear panel assembly
(18) and remove right panel asssembly (3) .
5-12 Change 8
TM 5-6115-585-12
NAVFAC P-8-623-12
TO 35C2-3-455-1
TM-05684C/05685B-12
Figure 5-5. Right Panel Assembly, Removal and Installation
Change 8 5-13
TM 5-6115-585-12
NAVFAC P-8-623-12
TO 35C2-3-455-1
TM-05682C/05685B-12
b. Installation. See figure 5-5. Install right panel

assembly to right support assembly, front panel assembly, top
panel assembly, rear closure assembly and rear panel assembly as
follows:
(1) Position right panel assembly (3) on right support
assembly (4) and install two screws (11) and locknuts (12), and
four washers (13 and 14) securing right panel assembly (3) to
rear closure assembly (15) and install two screws (16) and
washers (17) securing right panel assembly (3) to rear panel
assembly (18).
(4) Install five screws (8) and washers (9) securing
right panel assembly (3) to top panel assembly (10).
(6) Install three screws (5) and washers (6) securing

right panel assembly (3) to front panel assembly (7).
(8) Install six screws (1) and washers (2) securing
5-7. REAR PANEL ASSEMBLY.

a. Removal. See figure 5-6. Remove rear panel assembly
from control cubicle support frame and right panel assembly as
follows:
(1) Remove two screws (1) and washers (2) securing

right panel assembly (3) to rear panel assembly (4) and remove
rear panel assembly (4).
(2) Remove four screws (5) and locknuts (6), and eight
washers (7 and 8) securing rear panel assembly (4) to control
cubicle support frame (9).
b. Installation. See figure 5-6. Install rear panel

assembly to control cubicle support frame and right panel
assembly as follows:
(1) Position rear panel assembly (4) on control

cubicle support frame (9) and install four screws (5) and
locknuts (6), and eight washers (7 and 8) securing rear panel
assembly (4) to control cubicle support frame (9).
5-14 Change 8
TM 5-6115-585-12
NAVFAC P-8-623-12
TO 35C2-3-455-1
TM-05684C/05685B-12
Figure 5-6. Rear Panel Assembly, Removal and Installation
Change 8 5-15
TM 5-6115-585-12
NAVFAC P-8-623-12
TO 35C2-3-455-1
TM-05682C/05685B-12
(3) Install two screws (1) and washers (2) securing

right panel assembly (3) to rear panel assembly (4).
5-8. EXHAUST PLENUM ASSEMBLY.
a. Removal. See figure 5-3. Remove exhaust plenum
assembly from shutter assembly as follows:

paragraph 5-4.
(2) Remove four screws (13) and locknuts (14), and
eight washers (15 and 16) securing exhaust plenum assembly (17)
to shutter assembly (18) and lift off exhaust plenum assembly
(17).
b. Installation. See figure 5-3. Install exhaust plenum
assembly on shutter assembly as follows:
(1) Position exhaust plenum assembly (17) on shutter
assembly (18) and install four screws (13) and locknuts (14), and
eight washers (15 and 16) securing exhaust plenum assembly (17)
to shutter assembly (18).
paragraph 5-4.
5-9. LEFT SUPPORT ASSEMBLY.
a. Removal. See figure 5-7. Remove left support assembly
from skid as follows:
access plate (3) to AC output control box (4).
(2) Remove top panel assembly (5), as described in

paragraph 5-4.
(3) Remove left panel assembly (6) with side closure

assembly (7) as described in paragraph 5-5.
(4) Loosen four screws (8) and slide out left support
assembly (9) from under skid (10).
b. Installation. See figure 5-7. Install left support
assembly onto skid as follows:
(1) With four screws (8) loosened, slide left support
assembly (9) between skid (10) and bevel washers (11).
5-16 Change 8
TM 5-6115-585-12
NAVFAC P-8-623-12
TO 35C2-3-455-1
TM-05684C/05685B-12
Figure 5-7. Left Support Assembly, Removal and Installation

Change 8 5-17
TM 5-6115-585-12
NAVFAC P-8-623-12
TO 35C2-3-455-1
TM-05682C/05685B-12
(3) Replace left panel assembly (6) with side closure

assembly (5) as described in paragraph 5-5.
(4) Replace top panel assembly (5) as described in
paragraph 5-4.
(5) Replace four screws (1) and washers (2) securing
access plate (3) to AC output control box (4).
5-10. RIGHT SUPPORT ASSEMBLY.

a. Removal. See Figure 5-8. Remove right support
assembly from skid and right panel assembly as follows:
(1) Remove right panel assembly (1) as described in
paragraph 5-6.
(2) Loosen six screws (2) securing right support
assembly (3) to skid (4) and slide out right support assembly (3)
from under skid (4).
b. Installation. See figure 5-8. Install right support
(1) With six screws (2) loosened, slide right support
assembly (3) between skid (4) and bevel washers (5).
(3) Replace right side panel (1) as described in

paragraph 5-6.
5-11. FRONT PANEL ASSEMBLY.

a. Removal. See figure 5-9. Remove front panel assembly
from right, left, and top panel assemblies as follows:
the front panel assembly (3) to top panel assembly (4).
front panel (3) to left panel assembly (7) and right panel
assembly (8).
(3) Remove front panel assembly (3).
b. Installation. See figure 5-9. Install front panel

assembly to right, left and top panel assemblies as follows:
(1) Position front panel assembly (3) to right and
left panel assemblies (8 and 7) and secure with six screws (5)
and washers (6).
5-18 Change 8
TM 5-6115-585-12
NAVFAC P-8-623-12
TO 35C2-3-455-1
TM-05684C/05685B-12
Figure 5-8. Right Support Assembly, Removal and Installation
Change 8 5-19
TM 5-6115-585-12
NAVFAC P-8-623-12
TO 35C2-3-455-1
TM-05682C/05685B-12
Figure 5-9. Front Panel Assembly, Removal and Installation

5-20 Change 8
TM 5-6115-585-12
NAVFAC P-8-623-12
TO 35C2-3-455-1
TM-05684C/05685B–12
front panel assembly (3) to top panel assembly (4).
(3) Torque screws (1 and 5) to 18 ±2 in.-lbs dry.
5-12. SIDE CLOSURE ASSEMBLY.

Refer to paragraph 5-5 for removal and installation procedures.
5-13. REAR CLOSURE ASSEMBLY.

a. Removal. See figure 5-10. Remove rear closure
assembly from control box support, side closure assembly, right
panel and top panel assemblies as follows:
paragraph 5-4.
washers (4 and 5) securing rear closure assembly (6) to right
panel assembly (7).
(4) Remove four screws (13) and locknuts (14), and
eight washers (15 and 16) securing rear closure assembly (6) to
mounting brackets (17) and remove rear closure assembly (6).
b. Installation. See figure 5-10. Install rear closure

assembly to control box support, side closure assembly, right
panel and top panel assemblies as follows:
(1) Install four screws (13) and locknuts (14), and
eight washers (15 and 16) securing rear closure assembly (6) to
mounting brackets (17).
washers (4 and 5) securing rear closure assembly (6) to right
panel assembly (7).
(4) Torque screws (2, 13, and 8) to 16 ±2 ft-lbs dry.
paragraph 5-4.
Change 8 5-21
TM 5-6115-585-12
NAVFAC P-8-623-12
TO 35C2-3-455-1
TM-05682C/05685B-12
Figure 5-10. Rear Closure Assembly, Removal and Installation
5-22 Change 8
TM 5-6115-585-12
NAVFAC P-8-623-12
TO 35C2-3-455-1
TM-05684C/05685B-12
5-14. REAR FLAP ASSEMBLY.

a. Removal. See figure 5-11. Remove rear flap assembly
from skid as follows:
(1) Remove three screws (1) and locknuts (2), and six
washers (3 and 4) securing rear flap assembly (5) to skid (6).
(2) Remove rear flap assembly (5).
b. Installation. See figure 5-11. Install rear flap

(1) Position rear flap assembly (5) on skid (6) and
install three screws (1) and locknuts (2), and six washers (3
and 4).
Change 8 5-23
TM 5-6115-585-12
NAVFAC P-8-623-12
TO 35C2-3-455-1
TM-05682C/05685B-12
Figure 5-11. Rear Flap Assembly, Removal and Installation
5-24 Change 8
TM 5-6115-585-12
NAVFAC P-8-623-12
TO 35C2-3-455-1
TM-05684C/05685B-12
SECTION III. ACOUSTIC SUPPRESSION KIT REPAIR
5-15. GENERAL.
The local safety office and Preventative Medicine

Support Activity must be consulted prior to initial
CARC painting.
This section provides repair procedures for the Acoustic Suppres-

sion Kit (ASK). Repair of the ASK at all levels of Maintenance
is limited to replacement of panel assemblies and replacement of
hinges, latches, catches, captive nuts, rubber flaps and the
front panel silencer assembly. After repair is accomplished,
paint needed areas in accordance with MIL-STD-704 using paints
colors green 383, brown 383, and black as required by FED-
STD-595.
5-16. REPLACEMENT OF ASK COMPONENTS.
a. Refer to Table 3-2 for inspection of ASK components for
damage and to determine if replacement is necessary.
b. Remove the ASK component to be replaced by following
the applicable removal procedures outlined in Section II.
c. Prior to replacement of the rear panel, left support,
right support, side closure and rear closure assemblies, adhesive
backed teflon tape must be applied to the new assemblies as
follows:
(1) Rear Panel Assembly (refer to figure 5-6, item 4).
(a) Wipe surface clean.
(b) Cut a 11 3/4 in. length of adhesive backed

teflon tape from supplied bulk material.
(c) Apply adhesive backed teflon tape to the
right edge of rear panel assembly (edge with captive nuts). Use
hand pressure to remove air bubbles.
(d) Clear tape from captive nut openings.
(2) Left Support Assembly (refer to figure 5-7,

item 9).
(b) Cut a 61 in. length of adhesive backed teflon

tape from supplied bulk material.
Change 8 5-25
TM 5-6115-585-12
NAVFAC P-8-623-12
TO 35C2-3-455-1
TM-05682C/05685B-12
(c) Apply adhesive backed teflon tape to left

support assembly top surface (slotted surface which mounts
against underside of skid). Use hand pressure to remove air
bubbles.
(d) Clear tape from slotted openings.

(3) Right Support Assembly (refer to figure 5-8,
item 3).
(b) Cut a 61 in. length of adhesive backed teflon

tape from supplied bulk material.
(c) Apply adhesive backed teflon tape to right
support assembly top surface (slotted surface which mounts
against underside of skid). Use hand pressure to remove air
bubbles.
(d) Clear tape from slotted openings.
(4) Side Closure Assembly (refer to figure 5-4,
item 13).
(b) Cut a 20 1/2 in. length and a 29 1/4 in.

length of adhesive backed teflon tape from supplied bulk
material.
(c) Apply adhesive backed teflon tape to top
edges (edges with four holes) and left edge (edge with three
holes). Use hand pressure to remove air bubbles.
(d) Clear tape from holes.

(5) Rear Closure Assembly (refer to figure 5-10,
item 6).
(b) Cut a 23 in. length and a 14 in. length of

adhesive backed teflon tape from supplied bulk material.
(c) Apply adhesive backed teflon tape to top edge

(edge with three holes) and right edge (edge with two holes which
contacts right panel assembly). Use hand pressure to remove air
bubbles.
(d) Clear tape from holes.
5-26 Change 8
TM 5-6115-585-12
NAVFAC P–8-623-12
TO 35C2-3-455-1
TM-05684C/05685B-12
d. Install ASK replacement components by following the

applicable installation procedures outlined in Section II.
5-17. LATCH REPLACEMENT.

The following procedures are for replacement of side closure door
latch assemblies. Figure 5-12 (Illustration A) shows a typical
latch assembly replacement.
Remove damaged latch assembly (1) by drilling out rivet

(2) using a No. 11 drill bit (0.191 dia.).
b. Install new latch assembly (1) with a 3/16 inch dia.
rivet (2) using hand riveter.
5-18. CATCH REPLACEMENT.

The following procedures are typical for replacement of all
access door catch assemblies. Figure 5-12 (Illustration B) shows
a typical catch assembly replacement using the left panel as an
example.
a. Remove damaged catch assembly (1) by drilling out

rivets (2) using a No. 11 drill bit (0.191 dia.).
b. Install new catch assembly (1) with four 3/16 inch dia.
rivets (2) using hand riveter.
5-19. RUBBER FLAP REPLACEMENT.

The following procedures are for replacement of all rubber flaps.
Figure 5-12 (Illustration C) shows a rubber flap replacement
using the rear flap assembly as an example.
a. Remove rubber flap (1) (and retainer(s) if provided)
from panel, support, or angle (2) by removing screws (3), washers
(4) and nuts (5) (or by drilling out rivets using a No. 11 drill
bit, 0.191 dia.). Save retainer(s) (if provided) for reuse.
b. Use old rubber flap as a pattern to cut a new flap from

bulk material and to mark new holes in flap for rivets or screws.
c. Drill out holes for rivets or screws in new rubber
flap. Use No. 11 (0.191 dia.) drill bit for rivet holes.
d. Install new rubber flap (1) (with old retainer(s) if
provided) on panel, support, or angle (2) with same number of
screws (3), washers (4) and nuts (5) (or 3/16 inch dia. rivets
using hand riveter).
Change 8 5-27
TM 5-6115-585-12
NAVFAC P-8-623-12
TO 35C2-3-455-1
TM-05682C/05685B-12
Figure 5-12. Replacement of ASK Hardware Items

5-28 Change 8
TM 5-6115-585-12
NAVFAC P-8-623-12
TO 35C2-3-455-1
TM-05684C/05685B-12
5-20. HINGES.
The followinq procedures are for hinqe replacement on the top
panel assembiy-access door. See figure 5-12. (Illustration D).
a. Remove hinge (1) from panel assembly (2) and access
door (3) by drilling out rivets (4 and 5) using a No. 11 drill
bit (0.191 dia.).
b. Install hinge (1) to access door (3) and panel assembly

(2) with same number of 3/16 inch dia. rivets (4 and 5) using
hand riveter.
5-21. CAPTIVE NUTS.

The following procedures are typical for replacement of captive
nuts installed in the left and riqht panel assemblies, rear Panel
assembly, and front panel assembly. see figure 5-12 (Illustra-
tion E) showing an example for replacement of captive nuts.
a. Remove captive nut (1) from panel (2) by squeezing

sides of cage with pliers. Pull out until nut is freed.
b. Install new captive nut (1) by squeezing sides of cage
with pliers until nut can be inserted into square opening in
panel (2).
5-22. FRONT PANEL SILENCER.
The following procedures are to be followed for replacement of
the silencer attached to the front panel. See figure 5-12
(Illustration F).
a. Remove nine rivets (1) securing silencer (2) to front

panel (3) by drilling out rivets using a No.11 drill bit (0.191
dia.).
b. Apply adhesive backed teflon tape to all four inside
edges of new silencer. Use hand pressure to remove air bubbles.
Clear tape from rivet holes. Locate silencer on front panel by
aligning rivet holes.
c. Install new silencer (2) to front panel (3) with nine

3/16 inch dia. rivets (1) using hand riveter.

TM5-6115-585-12
NAVFAC P-8-262- 12
TO-35C2-3-455-1
TM-05684C-12
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. 1-1-1 Cleaning of Aerospace Equipment.
T.O. 1-1-2 Corrosion Control and Treatment for Aerospace Equipment.
T.O. 35-1-11 Organization, Intermediate and Depot Level Maintenance or FSC 6115
Equipment.
T.O. 35-1-12 Components and Procedures for Cleaning Aerospace Ground Equipment.
T.O. 35-1-26 Repair/Replacement Criteria for FSC 6115 Aerospace Ground Equip-
ment.
T.O. 35-1-524 USAF Equipment Registration Number System Applicable to FSC 6115
Equipment.
TM5-764 Electric Motor and Generator Repair.

TM5-766 Electric Power Generation in the Field.
TM38-750 The Army Maintenance Management System.
TM5-6115-585-24P Organizational, Intermediate (field) Direct Support and General Sup-
port and Depot Maintenance Repair Parts List.
4. SHIPMENT AND STORAGE:

T.O. 35-1-4 Processing and Inspection of Aerospace Ground Equipment for Storage
and Shipment.
T.O. 38-1-5 Processing and Inspection of Non-Mounted, Non-Aircraft Gasoline and
Diesel Engines for Storage and Shipment.
5. DESTRUCTION OF MATERIAL:
TM 750-244-3 Procedures for Destruction of Equipment to Prevent Enemy Use.
A-1/ (A- 2 blank)

TM5-6115-585-12
NAVFAC P-8-262-12
TO-35C2-3-455-1
TM-05684C-12
APPENDIX B
ITEMS TROOP INSTALLED OR AUTHORIZED LIST
(1) (2) (3) (4) (5)
Unit
SMR Federal Stock of
Code Number Description Meas Qty Auth
PACZZ 7520-00-559-9618 Case, Maintenance and operational Manual EA 1
PACZZ 5975-00-878-3791 Rod, Ground w/attachments and wire EA 1
PACZZ 5120-01-013-1676 Slide Hammer, Ground EA 1
PACZZ 4210-00-555-8837 Extinguisher, Fire, Monobromotrifluoromethane w/mounting EA 1

bracket (charged replacement cylinder only NSN 4210-00-
708-0031). operating temperature range -50°F (-58°C) to
+120°F (+49°C).
Note: When inspection maintenance or replacement of cylin-

der on Walter Kidde Co. extinguisher is necessary, the
proper torque for swivel nut is not to exceed 160 inch pounds
maximum.
PACZZ 6140-00-179-8418 Boot, Battery Terminal EA 3
PACZZ 5935-00-322-8959 Adapter Connector EA 1
Change 5 B-1/(B-2 blank)

TM5-6115-585-12
NAVFAC P-8-262-12
TO-35C2-3-455-1
TM-05684C-12
APPENDIX C
MAINTENANCE ALLOCATION CHART
Section I. INTRODUCTION
1. GENERAL. The maintenance functions are defined as follows:
a. This section provides a general explanation of all A - INSPECT. To determine serviceability of an

maintenance and repair functions authorized at various item by comparing its physical, mechanical and
maintenance levels. electrical characteristics with established standards.
b. Section II designates overall responsibility for B - TEST. To verify serviceability and to detect
the performance of maintenance functions on the electrical or mechanical failure by use of test equip-
identified end item or component. The implementation ment.
of the maintenance functions upon the identified end
item or component will be consistent with the assigned C - SERVICE. To clean, to preserve, to charge and
maintenance functions. to add fuel, lubricants, cooling agents and air. (If it is
desired that elements, such as painting and lubri-
c. Section III lists the tools and test equipment cating, be defined separately, they may be so listed. )
required for each maintenance function as refer-
enced from Section II. D - ADJUST. To rectify to the extent necessary to
bring into proper operating range.
d. Section IV contains supplemental instructions or
explanatory notes required for a particular mainten- E - ALIGN. To adjust specified variable elements
ance function. of an item to bring to optimum performance.
F - CALIBRATE. To determine the corrections to

2. EXPLANATION OF COLUMNS IN SECTION II. be made in the readings of instruments or test equip-
ment used in precise measurement. Consists of the
a. Group Number. Column 1. The assembly group comparison of two instruments, one of which is a
number is a numerical group assigned to each assem- certified standard of known accuracy, to detect and
bly. The assembly groups are listed on the MAC in adjust any discrepancy in the accuracy of the instru-
disassembly sequence beginning with the first assem- ment being compared with the certified standard.
bly removed in a top down disassembly sequence.
G - INSTALL. To set-up for use in an operational
environment such as an emplacement, site or vehicle.
b. Assembly Group. Column 2. This column con-
tains a brief description of the components of each H - REPLACE. To replace unserviceable items with
assembly group. serviceable like items.
I - REPAIR. Those maintenance operations neces-

c. Maintenance Functions. Column 3. This column sary to restrore an item to serviceable condition
lists the various maintenance functions (A through K). through correction of material damage or a specific
The upper case letter placed in the appropriate failure. Repair may be accomplished at each level of
column indicates the lowest maintenance level author- maintenance.
ized to perform these functions. The active repair
time required to perform the maintenance function is J - OVERHAUL. Normally, the highest degree of
included directly below the symbol identifying the maintenance performed by the Army in order to
category of maintenance. The symbol designations for minimize time work is in process consistent with
the various maintenance levels are as follows: quality and economy of operation. It consists of that
maintenance necessary to restore an item to com-
C - Operator or Crew pletely serviceable condition as prescribed by main-
tenance standards in technical publications for each
O - Organizational Maintenance item of equipment. Overhaul normally does not return
an item to like new, zero mileage or zero hour con-
F - Direct Support Maintenance dition.
H - General Support Maintenance K - REBUILD. The highest degree of material

maintenance. It consists of restoring equipment as
D - Depot Maintenance nearly as possible to new condition in accordance with
C-1
TM5-6115-585-12
NAVFAC P-8-262- 12
TO-35C2-3-455-1
TM-05684C-12
original manufacturing standards. Rebuild is per- b. Maintenance Level. This column shows the lowest
formed only when required by operational consider- level of maintenance authorized to use the tool or
ations or other paramount factors and then only at test equipment.
the depot maintenance level. Rebuild reduces to zero
the hours of miles the equipment, or component c. Nomenclature. This column lists the name or
thereof, has been in use. identification of the tool or test equipment.
d. Tools and Equipment. Column 4. This column is
provided for referencing by code the tools and test d. Tool Number. This column lists the manufac-
equipment (Section III), required to perform the main- turer’s code and part number or federal stock num-
tenance functions (Section II). ber of tool or test equipment.
e. Remarks. Column 5. This column is provided

for referencing by code the remarks (Section IV) 4. EXPLANATION OF COLUMNS IN SECTION IV.
pertinent to the maintenance functions.
a. Reference Code, This column consists of two
3. EXPLANATION OF COLUMNS IN SECTION III. letters separated by a dash (entered from Column 5
of Section II). The first letter references Alpha
a. Reference Code. This column consists of a sequence in Column 5 and the second letter refer-
number and a letter separated by a dash. The number ences a maintenance function, Column 3 (A through K).
references the T&TE requirements listed in Section
II. The letter represents the specific maintenance b. Remarks. This column lists information per-
function the item is to be used with in Columns (A tinent to the maintenance function to be performed
through K) of Section II. (as indicated in Section II).
C-2
TM5-6115-585-12
NAVFAC P-8-262-12
TO-35C2-3-455-1
TM-05684C-12
C-3
TM5-6115-585-12
NAVFAC P-8-262-12
TO-35C2-3-455-1
TM-05684C-12
C-4
TM5-6115-585-12
NAVFAC P-8-262-12
TO-35C2-3-455-1
TM-05684C-12
Change 4 C-5
TM5-6115-585-12
NAVFAC P-8-262-12
TO-95C2-3-455-1
TM-05684C-12
C-6 Change 4
TM5-6115-585-12
NAVFAC P-8-262-12
TO-35C2-3-455-1
TM-05684C-12
C-7
TM5-6115-585-12
NAVFAC P-8-262-12
TO-35C2-3-455-1
TM-05684C-12
C-8
TM5-6115-585-12
NAVFAC P-8-262-12
TO-35C2-3-455-1
TM-05684C-12
C-9
M5-6115-585-12
NAVFAC P-8-262-12
TO-35C2-3-455-1
TM-05684C-12
C-10
TM 5-6115-585-12
NAVFAC P-8-623-12
TOO-35C2-3-455-l
TM-05684C/05685B-12
Change 7 C-11
TM5-6115-585-12
NAVFAC P-8-262-12
TO-35C2-3-455-1
TM-05684C-12
C-12
TM5-6115-585-12
NAVFAC P-8-262-12
TO-35C2-3-455-1
TM-05684C-12
Change 4 C-13
TM 5-6115-585-12
NAVFAC P-8-623-12
TO-35C2-3-455-1
TM-05684/C-/05685B12
C-14 Change 10
TM5-6115-565-12
NAVFAC P-8-262-12
TO-35C2-3-455-1
TM-05684C-12
C-15
TM 5-6115-585-12
NAVFAC P-8-262-12
TO-35C2-3-455-1
TM-05684C-12
C-16 Change 10
TM5-6115-585-12
NAVFAC P-8-623-12
TO-35C2-3-455-1
TM-05684C/05685B-12
Change 8 C-16.1/(C-16.2 blank)

TM5-6115-585.12
NAVFAC P-8-623-12
TO-35C2-345-1
TM-05684C/05685B-12
C-17
TM5-6115-585-12
NAVFAC P-8-623-12
TO-35C2-3-455-1
TM-05684C/0568B-12
Section III. TOOLS, TEST AND SUPPORT EQUIPMENT REQUIREMENTS
C-18 Change 12
TM5-6115-585-12
NAVFAC P-8-262-12
TO-35C2-3-455-1
TM-05684C-12
Section IV. EXPLANATION OF REFERENCE CODES
REFERENCE CODE REMARKS
A-A Visual Inspection
B-B Hydrometer Test
C-B Operational Test
D-I Weld and Straighten
E-B Thermometer Test
F-B, C-D, In accordance with Procedure in Applicable TM

H, I-J
G-A Inspect for Minimum Length
H-B Growler Test
I-B Test for known Voltage
J-I Fabricate New Harness
K-D Adjust after Repair or Replacement
L-B Continuity Test
M-D Zero Adjustment
N-C Replace Element
O-C Drain Condensation
P-B Insulation Breakdown and Continuity Tests
Q-K Rewind
R-A Visual, Audible and Physical Heat Detection
S-D Adjust to Specification in Applicable TM
T-D Adjust Injector Pressure Setting
U-B Pressure Test
V-I Includes Replacing Valves and Springs
W-B Spring Tension and Length
C-19/(C-20 blank)
TM5-6115-585-12
NAVFAC P-8-623-12
TO-35C2-3-455-1
TM-05684C/05685B-12
APPENDIX D
ADDITIONAL AUTHORIZATION LIST
Section I. INTRODUCTION
D-1. SCOPE. in with it. These items are authorized to you by CTA,
MTOE, TDA or JTA.
This appendix lists additional items you are authorized for
the support of the 10KW Generator Set
D-3. EXPLANATION OF LISTING.
D-2. GENERAL
National stock number, descriptions and quantities are
This list identifies items that do not have to accompany provided to help you identify and request the additional
the 10KW Generator Set and that do not have to be turned items you require to support this equipment.
Section II. ADDITIONAL AUTHORIZATION LIST
(1) (2) (3) (4)

NATIONAL
STOCK QTY
NUMBER DESCRIPTION U/M AUTH
6115-01-273-7376 Acoustic Suppression Kit KT 1
D-1/(D-2 blank)
TM 5-6115-585-12
NAVFAC P-8-623-12
TO-35C2-3-455-1
TM-05682C/0568B-12
ALPHABETICAL INDEX
Paragraph,
Figure, Table,
Subject Number
A
AC Instrumentation System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36
Acoustic Suppression Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Instruction and Rating Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-1
Removal and Installation Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 thru 5-14,
F5-2 thru F5-11
Repair and Replacement of Hardware Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 thru 5-22
F5-12
AC Output Control Box Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-8
lnspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
AC Output Control Box Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F1-9
Administrative Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Air Cleaner Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-10
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18, 4-41
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18, 4-41
Removal and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18, 4-41
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41
Air Cleaner and Shroud Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-9
Air Fitter Element, Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-11
Auxiliary Fuel Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Test, On Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Auxiliary Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
B
Batteries, Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-17

Battery Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-2
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Battery Cables, Installing.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-16
Battery Charging Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-23, 4-27
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
Battery Charging Regulator/Rectifier Assembly, Testing . . . . . . . . . . . . . . F4-24
Battery and Frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-23
Breather, Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45
c
Consumable Operating and Maintenance Supplies . . . . . . . . . . . . . . . . . . . T3-1, 3-1
Control Cubicle Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-12, F4-33
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Test, Bench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
Test, On Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
Control Cubicle Support Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . F3-15
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-21
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-34
Control Cubicle Test Set-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-35
Control Cubicle Wiring Harness . . . . . . . . . . . . . . . . . F1-10
4-34
F4-41
Change 8 INDEX 1
TM6-6115-585-12
NAVFAC P-8-262-12
TO-95C2-3-455-1
TM-05684C-12
ALPHABETICAL INDEX (CONT)

Paragraph,
Figure, Table,
Subject Number
D
DC Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35
Destruction of Material to Prevent Enemy Use . . . . . . . . . . . . . . . . . . . . 1-6
E
Electric Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-7

Electrical Cable Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F1-6
Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-36
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42
Description and Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24, 4-42
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42
Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-17
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
c l e a n i n g . . . . . . . . . . . . . . 4-17
Description and Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22, 4-17
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Engine Electrical System, Description and Function. . . . . . . . . . . . . . . . . 4-24
Engine Generator Set
Left-Front, Three-Quarter View(MEP-112A Only). . . . . . . . . . . . . . . . . . . . . F1-2.1
Left-Front Three-Quarter View, with Acoustic
Suppression Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F1-2.2
Right-Rear, Three-QuarterView . . . . . . . . . . . . . . . . . . . . . . . . F1-1
Engine Mounting Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-43
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-52
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-52
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-52
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-52
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-52
Engine Starter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-18, F4-22
Cleaning and Inspection 3-16, 4-26
Installation . . . . . . . . . . . . . . . . . . .... 4-26
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
Repair . . . . . . . . . . . . . . . . . . ●
4-26
Test, Bench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
Test, On Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
Engine StarterBrushes, Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . F4-21
Engine Starter, Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-19
Engine Starter Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . F4-20
Engine Stop Solenoid ...... . . . .... . ......
● ● . . . . . . . F3-22
Engine Wiring Harness, Inspection. . . . . . . . . . . . . . . . . . . 3-21
Exhaust Muffler Air CleanerAssemblies . . . . . . . . . . . . . . . . . . . . F4-37
Exhaust Muffler Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-6
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15, 4-40
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40
Replacement . . . . . . . . . . . . . ● . . . ... . ... ● . . 4-40
F
Float Switch, Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-8
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-9
INDEX 2 Change 8
TM5-6115-585-12
NAVFAC P-8-262-12
TO-35C2-3-455-1
TM-05684C-12

Paragraph,
Figure, Table,
Subject Number
F (CONT)
Fuel Filter and Strainer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . F3-13, F4-11

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-14, F4-13
Fuel Pump, Fuel Hoses and Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . F4-12
Fuel Pumps and Hoses
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
FuelShut-Off Solenoid, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-14
Fuel Shut-Off Solenoid Valve
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Fuel Solenoid Test Set-Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-15
Fuel Strainer Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-10
Fuel System, Description and Function . . . . . . . . . . . . . . . . . . . . . . . 4-18
FuelSystem (Less Tank), Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Fuel System Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F1-5
Fuel Tank Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-4, F4-7
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13, 4-19
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13, 4-19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Generator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-18

Description and Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-53
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Generator/Exciter Assembly, Inspection . . . . . . . . . . . . . . . . . . . . . . . 4-54
Generator Screen-Guard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-44
Generator Set
Controls and Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T2-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Dismantling for Movement.. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F1-7
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-2
Inspection and Servicing on Receipt . . . . . . . . . . . . . . . . . . . . . . . 4-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Installation Plans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F1-4
Re-installing after Movement . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Tabulated Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Uncrating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4- 1
Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F1-8
Glow Plug Assemblies
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-48
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-48
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-48
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-48
INDEX 3
TM5-6115-585-12
NAVFAC P-8-262-12
TO-35C2-3-455-1
TM-05684C-12

Paragraph,
G (CONT)
Ground Rod and Fuel Drum Adapter Hold-Down Assembly . . . . . . . . . . . . . F3-3

Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Ground Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-24
Injector Nozzle Assembly and Fuel Lines, Inspection . . . . . . . . . . . . . . . . 4-47

Intake Manifold Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-19
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43
Levels of Maintenance Accomplishment , . . . . . . . . . . . . . . . . . . . . . . 1-5

Load Terminal Board Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-32
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
Load Terminal and Reconnection Configuration . . . . . . . . . . . . . . . . . . . F2-4
Load Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-1
Lockout Switch and Gear.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-25
Low Oil Pressure Switch
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
Test, Bench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
Lubrication Instructions
Operator/Crew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Organizational . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Lubrication Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-1, 3-3
Maintenance Forms and Records . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Maintenance Repair Parts... . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Manual
Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Master Switch Continuity Check . . . . . . . . . . . . . . . . . . . . . . . . . . . T4-3
Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-28

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
Oil Cooler Hoses, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-29
Oil Drain Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-20
Oil Drain Hose and Valve, Replacement . . . . . . . . . . . . . . . . . . . . . . . 4-49
Oil Fill Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-42
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-51
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-51
INDEX 4
TM5-6115-585-12
NAVFAC P-8-262-12
TO-35C2-3-455-1
TM-05684C-12
ALPHABETICAL lNDEX (CONT)

Paragraph,
Figure, Table,
Subject Number
O (CONT)
Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-30

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
Oil Filter and Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . F3-21
Oil Pan-Base, Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50
Oil Pressure Gauge
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-31, 4-33
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
Oil System, Description and Function . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Operating Procedures
Equipment Reconnection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Operating in Alternate Modes . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Operation in Dusty or Sandy Areas . . . . . . . . . . . . . . . . . . . . . . . 2-9
Operation in Extreme Cold. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Operation in Extreme Heat. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Operation in Wet or Humid Areas . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Shutting Down Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Starting Generator Set... . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Preparation for Shipment or Storage . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Pressure Oil System. . . . . . . . . . . . . . . . . . . . . . . . . F4-27
Preventive Maintenance Checks and Services . . . . . . . . . . . . . . . . . . . . T3-2, T4-1
Operator
Correcting and Reporting Deficiencies . . . . . . . . . . . . . . . . . . . 3-5
Determining Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Units in Continuous Operation . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Organizational
Determining Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Units in Continuous Operation . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Primary Radio Interference Suppression Components . . . . . . . . . . . . . . . . F4-3
Radio Interference Suppression Components . . . . . . . . . . . . . . . . . . . . . 4-15

General Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Reconnection Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-2
Reconnection Switch Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T2-2
Reporting of Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Rocker Arm Cover Oil Line, Cleaning . . . . . . . . . . . ................. F4-39
Rocker Arm Covers . . . . . . . . . . . . . . . . . . . . . ................. F4-38
Inspection . . . . . . . . . . . . . . . . . . . . . . . . .................. 4-44
Removal . . . . . . . . . . . . . . . . . . . . . . . . ................. 4-44
Replacement . . . . . . . . . . . . . . . . . . . . . . ................. 4-44
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44
Rocker Arm to Valve Clearance, Checking and Adjusting . . . . . . . . . . . . . . . . . F4-40
INDEX 5
TM5-6115-585-12
NAVFAC P-8-262-12
TO-35C2-3-455-1
TM-05684C-12

Paragraph,
Figure, Table,
Subject Number
s
Screen-Guard
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-55
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-55
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-55
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-55
Shutter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-4
Shutter Box Assembly, Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Shutter and Thermo Power Element Assembly . . . . . . . . . . . . . . . . . . . . F3-5
Shutters, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4- 5
Skid-Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-45
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Description and Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-56
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25, 4-57
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-57
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-57
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-57
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Speed Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-16
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Starter Lockout Switch, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . F4-26
Starter Lockout Switch and Gear
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Starting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-3
T
Thermo Unit, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4-6
Tie Down, Lifting, and Towing Provisions Crated Set . . . . . . . . . . . . . . . . F1-3
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T3-3, T4-2
Operator General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Organizational, General. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Valve Rocker Arms

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46
Voltmeter-Ammeter Range Selector Switch Continuity Check . . . . . . . . . . . . T4-4
INDEX 6
TM 5-6115-585-12
NAVFAC P-8-262-12
TO 35C2-3-455-1
TM 05684C-12
By Order of the Secretaries of the Army, the Navy, and the Air Force:
BERNARD W. ROGERS
General, United States Army
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
DAVID C. JONES, General, USAF

AMES J. SHEPARD, Colonel, USAF

Director of Administration
W. R. JOHNSON
Brigadier General, U. S. Marine Corps
Acting Deputy Chief of Staff for Installations and Logistics
Distribution:
To be distributed in accordance with DA Form 12-25D, Operator maintenance requirements for Generator
Sets, Engine Driven: 10 KW, 60 HZ.

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ARMY TECHNICAL MANUAL TM5-6115-585-12

NAVY PUBLICATION NAVFAC P-8-262-I 2

AIR FORCE TECHNICAL ORDER TO-35C2-3-455-1

OPERATOR AND ORGANIZATIONAL

DOD MODEL C LASS HERTZ NSN

MEP-003A UTILITY 6 0 6115-00-465-1030

This copy is a reprint which includes current

pages from Changes 1 through 4

LIQUIDS UNDER HIGH PRESSURE

DEPARTMENTS OF THE ARMY, NAVY AND AIR FORCE

Operator and Organizational Maintenance Manual

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

DOD MODEL CLASS H E R T Z N S N

MEP-003A UTILITY 6 0 6115-00-465-1030

MEP-112A UTILITY 400 6115-00-465-1027

Approved for public release; Distribution is unlimited

TM 5-6115-585-12, NAVFAC P-8-623-12, TO 35C2-3-455-1, TM 05684C/05685B-12, 25 July 1977 is

the margin. An illustration change is indicated by a miniature pointing hand.

Remove pages Insert pages

C-17 and C-18 C-17 and C-18

2. Retain this sheet in front of manual for reference purposes.

is produced when this Generator Set is in operation.

Batteries generate explosive gas during charging; therefore,

LIQUIDS UNDER HIGH PRESSURE

Change 5 a/(b blank)

DEPARTMENT OF THE NAVY PUBLICATION NAVFAC P-8-623-12

DEPARTMENT OF THE AIR FORCE TECHNICAL ORDER TO-35C2-3-455-1

MARINE CORPS TECHNICAL MANUAL TM-0568 4C12/05685B-12

WASHINGTON, D.C. 25 JULY 1977

OPERATOR’S AND ORGANIZATIONAL

DOD MODEL CLASS HERTZ NSN

MEP-003A UTILITY 60 6115-00465-1030

MEP-112A UTILITY 400 6115-00-465-1027

LIST OF EFFECTIVE PAGES.... . . . . . . . . . . . . . . . . . . . . . v

Section I. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1-1. Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Section II. DESCRIPTION AND DATA . . . . . . . . . . . . . . . . . . . . . . 1-2

1-9. Description of Generator Set . . . . . . . . . . . . . . . . . 1-2

CHAPTER 2. OPERATING INSTRUCTIONS 2 - 1

Section I. OPERATING PROCEDURE . 2-1

2-1. General . . . . . . . 2-1

Section II. OPERATING UNDER UNUSUAL CONDITIONS . . . . . . . . . . . . 2-6

2-7. Operation in Extreme Heat . . . . . . . . . . . . . . . . . . 2-6

CHAPTER 3. OPERATOR MAINTENANCE INSTRUCTIONS . . . . . . . . 3-1

Section I. CONSUMABLE OPERATING AND MAINTENANCE SUPPLIES . . . 3-1

3-1. Consumable Supplies . . . . . . . . . . . . . . . . . . . . . 3-1

Section II. LUBRICATION INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . 3-1

3-2. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Section III. PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) . . 3-4

3-4. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Section IV. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

3-9. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Section V. OPERATOR MAINTENANCE PROCEDURES . . . . . . . . . 3-8

3-11. Battery Assembly . . . . . . . . . . . . . . . . . . . . . . . 3-8

CHAPTER 4. ORGANIZATIONAL MAINTENANCE . . . . . . . . . . . . . . . . . 4-1

Section I. SERVICE UPON RECEIPT OF MATERIAL . . . . . . . . . . . . 4-1

4-1. Inspecting and Servicing Generator Set . . . . . . . . . . . . 4-1

Section II. MOVEMENT TO ANEW WORKSITE . . . . . . . . . . . . . . . . . 4-4

4-3. Dismantling Generator Set for Movement . . . . . . . . . . 4-4