Onan 6115-00-465-1027 Technical Manual Download Page 66

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Summary of Contents for 6115-00-465-1027

Page 1: ...This is a reproduction of a library book that was digitized by Google as part of an ongoing effort to preserve the information in books and make it universally accessible https books google com...

Page 2: ...IVEN 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 00 465 1030 LIBRARY PIDERMAN PUBLIC DOCUMENTS...

Page 3: ...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 f...

Page 4: ...240 AND 120 208 VOLTS DOD MODEL CLASS HERTZ NSN MEP 003A MEP 112A UTILITY UTILITY 60 400 6115 00 465 1030 6115 00 465 1027 TM 5 6115 585 34 NAVFAC P 8 623 34 TO 35C2 3 455 2 TM 05684C 05685B 34 25 Jul...

Page 5: ...ear Admiral CEC US Navy Commander Naval Facilities Engineering Command Official LEW ALLEN JR General USAF Chief of Staff VAN L CRAWFORD JR Colonel USAF Director of Administration H A HATCH Major Gener...

Page 6: ...S DOD MODEL CLASS HERTZ NSN MEP 003A UTILITY 60 6115 00 465 1030 TM 5 6115 586 34 NAVFAC P 8 623 34 TO 35C2 3 455 2 TM 05684C 34 July 1977 is changed as follows 1 Remove and insert pages as indicated...

Page 7: ...C PENNINGTON Major General United States Army The Adjutant General DAVID C JONES General USAF Chief of Staff Official Jack R BENSON Colonel USAF Director of Adminsitration V J WALLS Acting Deputy Chie...

Page 8: ...UTILITY 400 6115 00 465 1027 TABLE OF CONTENTS Page LIST OF EFFECTIVE PAGES LIST OF ILLUSTRATIONS LIST OF TABLES INTRODUCTION iv V vi 1 1 CHAPTER 1 Section I GENERAL 1 1 1 1 1 2 1 3 1 4 1 5 Scope Lim...

Page 9: ...h 3 1 3 1 CHAPTER 4 MAINTENANCE OF FUEL SYSTEM 4 1 Section 1 DESCRIPTION AND FUNCTION 4 1 4 1 General 4 1 Section I MAINTENANCE OF FUEL TANK 4 1 4 2 Fuel Tank 4 1 CHAPTER 5 MAINTENANCE OF STARTING SYS...

Page 10: ...y Pass Valve 7 14 Gear Cover Assembly 7 15 Governor Cup 7 16 Camshaft Assembly and Tappets 7 17 Crankshaft and Main Block Bearings 7 18 Fuel Injection Pump 7 19 Cylinder Block 7 20 Fuel Injector O 7 9...

Page 11: ...e Flywheel and Ring Gear Assembly Governor Linkage Adjustsment Timing Port and Port Closing Mark Measuring Top Dead Center Testing Oil Cooler Battery Charge Alternator and Blower Wheel Resistively Loa...

Page 12: ...y Winding Data MEP 003A Generator Frame Assembly Winding Data MEP 112A Exciter Rotor Assembly Winding Data Generator Rotor Winding Data MEP 003A Generator Rotor Winding Data MEP 112A Adjusting R3 Resi...

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Page 14: ...RECORDS d MC Marine Corps by NAVMC form 10772 directly to Commandant US Marine Corps ATTN Code LMA 1 WASH DC 20380 I a A Maintenance forms and records used by Army personnel are prescribed in TM 38 7...

Page 15: ...r Coil Conductor 72 5220 052 to 064 36 1 4 24 2 1 11 1 strand of 17 AWG magnet wire 0 677 0 068 ohms Model MEP 112A DOD Drawing No 72 5272 Number of Slots 108 Pitch of Coil 1 4 Turns per Coil 2 Conduc...

Page 16: ...e Manufacturer Model Type Onan 147 0333 PSU single plunger multi outlet gear and cam block mounted Drive Type Mounting DOD Drawing No Volts Watts Input Pressure Orifice Size 72 5069 24 vdc 12 w 20 psi...

Page 17: ...1 1 1...

Page 18: ...bolt 44 46 Oil cooler mounting screws 20 22 Blower wheel mounting screw 65 70 Intake manifold mounting screws 13 15 Injector nozzle mounting screws 17 18 Glow plug 10 15 Governor arm locking screw 32...

Page 19: ...aring journal diameter 2 2427 2 2435 0 001 Main bearing journal clearance 0 0012 0 0037 0 0047 Main bearing journal out of round 0 0005 0 001 Main bearing journal taper 0 0004 0 0015 Connecting rod jo...

Page 20: ...rnal runout in vee blocks 0 004 Bearing clearance 0 0012 0 0037 0 0057 End Thrust 0 0070 0 0390 0 0450 Backlash camshaft to crank gear 0 005 0 0100 0 0120 PISTON 0 0062 0 0082 0 010 Clearance in cylin...

Page 21: ...idth in head 1 16 3 32 1 8 0 433 0 439 0 500 Top of valve recessed below cylinder head deck Valve seat angle Valve Face Angle VALVE EXHAUST 45 44 N A N A 45 44 Head diameter 1 307 1 317 N A Stem diame...

Page 22: ...0 920 Load closed 45 lb 49 lb 40 lb Load open 87 2 lb 97 2 lb 80 lb OIL PUMP BODY Shaft bore diameter main 0 338 0 343 0 002 Shaft bore diameter idler 0 308 0 309 0 002 Pump gear bore diameter 0 884...

Page 23: ...erator and Organizational Maintenance Manual m Engine Repair and Replacement Standards Table 1 2 lists manufacturer s sizes tolerances andmaxi mum allowable wear and clearances 1 Safety Devices n Sche...

Page 24: ...HR3 T64 12 13 14 P73A 16 AS P71A16 P68A16 P 68116 TB61 T862 TB4 5 6 HR2 P69A16 P69816 HR1 2H52K12 H52212 HS2H12 J3 B J2 R PSOK 2 PSSW2 J15 K 6 K3 BTI BT2 KSIB12 KSIA12 P50D12 P55Y2N A 12 5 TB7 STARTER...

Page 25: ......

Page 26: ...B12 H52A12 P50C12 Wh A2 AI 8 J2 P T84 7 FI R2 P73A16 P71A16 TB4 5 6 12 J3 B H52J12 H52H12 K6 J2 R K3 K51B12 4KS1A12H250012 J2 S A2 AI r P50K2 L AS P68A16 P68816 TB6 1 02 P69A16 P69B16 TB6 2 P55W2 J15...

Page 27: ...4...

Page 28: ...tains fabrication instructions for all tools which must be fabricated by intermediate or depot personnel for maintenance of this unit 2 2 TOOLS AND EQUIPMENT Table 2 1 Special Tools Test and Support E...

Page 29: ...ricate fixture as shown below Drill F 0 255 in 0 262 in depth thru countersink 60 incl to 0 332 in diameter Tap 0 3125 18 UNC 2B depth thru Two holes located within 0 005 in of true position Sketch or...

Page 30: ...ctions Fabricate tool to dimensions shown below Sketch or Diagram 1 4 R 1 2 DIA 1 4 9 1647 1 1 8 21 4 12 0 Nomenclature Reference No or NSN Material Required 5 16 cold rolled steel Compression adapter...

Page 31: ...icated Tools and Equipment Cont Nomenclature Reference No or NSN Material Required Crankshaft gear driver Steel pipe 3 16 wall thickness Fabrication Instructions Fabricate tool to dimensions shown bel...

Page 32: ...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...

Page 33: ...Replace brush springs if necessary Step 4 Check for worn commutator high mica paragraph 5 2 Refinish commutator or replace armature including commutator 3 SLOW STARTER SPEED Step 1 Check for dirty co...

Page 34: ...h 7 20 Step 2 Check for poor compression See malfunction 14 Step 3 Incorrect timing Retime engine paragraph 7 18 6 ENGINE MISFIRES Step 1 Check for poor compression See malfunction 14 Step 2 Check for...

Page 35: ...des paragraph 7 9 Replace guides valves and seals Step 2 Check for worn or sticking piston rings paragraph 7 10 Replace rings if necessary Step 3 Check for air leaks to crankcase Replace gaskets and s...

Page 36: ...s Step 1 Check for loose cylinder head paragraph 7 9 Properly tighten head Step 2 Check for leaky head gasket paragraph 7 9 Replace gasket Step 3 Check for broken valve spring paragraph 7 9 Replace br...

Page 37: ...ace rotor if necessary Step 5 Check generator rotor flashing circuit paragraph 6 9 Replace diode CR2 or bridge rectifier Step 6 Check generator stator for open shorted or grounded windings paragraph 8...

Page 38: ...regulator Step 2 Check voltage adjust rheostat R1 Replace rheostat R1 if necessary 19 FREQUENCY METER M3 FAILS TO REGISTER Step 1 Check transformers T1 and T2 paragraph 6 4 Replace bad transformers St...

Page 39: ...cing Electronic Components 1 Tag wires before removal to facilitate proper reconnection DRY CLEANING SOLVENT P D 680 or P S 861 used to clean parts is potentially danger ous to personnel and property...

Page 40: ...nifold Remove air cleaner and bracket assembly from top of generator 9 Connect a suitable lifting device and support engine 5 Disconnect fuel line from fuel filter at fuel check valve Disconnect flexi...

Page 41: ...figure 2 3 lock washers 5 flatwashers 4 and nuts 6 to attach engine mounts to skid base 1 Screw 8 2 Lock plate 4 3 Pressure plate 4 4 Fan 5 Nut 12 6 Lockwasher 12 7 Engine 8 Generator housing 9 Flywhe...

Page 42: ...AC P 8 262 12 TO 35C2 3 455 2 TM 05684C 34 2 3 Dan 1 Engine 2 Engine mount 2 3 Screw 8 4 Flatwasher 8 5 Lockwasher 8 6 Nut 8 7 Skid base assembly 8 Engine lifting bracket TS 6115 586 34 2 3 Figure 2 3...

Page 43: ...engine and generator assembly as one unit then removing generator assembly from engine b Align fan 4 adapter plate and flywheel 9 using pilot studs 1 Disconnect three wiring assemblies from connectors...

Page 44: ...3 Ground stud 4 Generator support 5 Screw 8 6 Nut 8 7 Lockwasher 8 8 Flatwasher 8 9 Screw 4 10 Lockwasher 4 11 Flatwasher 4 12 Screw 8 13 Flatwasher 8 14 Lockwasher 8 15 Nut 8 16 Engine support 2 17 E...

Page 45: ......

Page 46: ...ts 2 are securely mounted to shutters 3 Check that bracket bearings are not excessively worn Refer to Operator and Organizational Maintenance Manual 2 Bracket Assemblies Replace bracket 2 or bearings...

Page 47: ...L 1 Tat 1 Shutter assembly 2 Bracket assembly 4 3 Shutter 2 4 Air housing panel 5 Air housing panel and door 6 Grille 7 Blower housing 8 Engine shroud 9 Air duct cover 10 Leads 2 11 High temperature s...

Page 48: ...o 300 F 149 C minimum Repeat continuity check in 2 above b Test 5 If continuity does not exist replace with a new switch 1 Using an oil pot tester and peanut oil heat oil to 394 10 F 201 5 C c Install...

Page 49: ......

Page 50: ...roper order The cam operates the pump plunger pressurizing fuel to the nozzles A control sleeve meters fuel by controlling the length of time the plunger spill port is closed maintaining pressure and...

Page 51: ......

Page 52: ...sconnect connector and grommet 4 CAUTION 2 Remove cotter pin 5 and pin 6 from yoke 26 Remove screws 7 lockwashers 8 and remove solenoid switch 9 Do not saturate armature or field coils with solvent as...

Page 53: ...crew 4 8 Lockwasher 4 9 Solenoid switch 10 Thru bolt 2 11 Lockwasher 2 12 Back plate assembly 13 Brush washer 14 Brush spring 4 15 Brush assembly 16 Screw 3 17 Lockwa sher 3 18 Brush holder 19 Frame a...

Page 54: ...262 12 TO 35C2 3 455 2 TM 05684C 34 PULL CURRENT DRAW TEST A A B SI 25 AMP 24V HOLD CUR RENT DRAW TEST B B Si A 6 AMP 24V TOTAL CURRENT DRAW TESTC B SI JUMPER Alif 24V TS 6115 585 34 5 2 Figure 5 2 T...

Page 55: ...armature in the growler turn the growler on and 1 Armature 2 Growler 3 Hack saw blade TS 6115 585 34 5 4 Figure 5 4 Testing Armature for Shorted Coils run a steel strip over the armature surfaces If a...

Page 56: ...r 2 Armature 3 Commutator Figure 5 5 Checking Commutator Runout 1 Armature 2 Dial indicator Figure 5 6 Testing Armature Shaft Runout NAVFAC P 8 262 12 TO 35C2 3 455 2 TM 05684C 34 4 Lathe TS 6115 585...

Page 57: ...t A Current should not exceed 16 amps b Measure the hold in coil draw using Test B Current should not exceed 6 amps c Total hold and pull current draw using Test C is 22 amps Total current draw should...

Page 58: ...figure 5 9 Install new brushes as follows NOTE a Using rosin core solder and a soldering iron or heavy duty soldering gun tin the remaining sections of the original brush lead Use care in undercutting...

Page 59: ...d ware on the solenoid switch 9 Connect solenoid 9 and yoke 26 with pin 6 Retain pin 6 with cotter pin 5 Install boot 24 and retainer 23 over yoke 26 ger of TS 6115 585 34 5 10 Figure 5 10 Checking Pi...

Page 60: ...n the harness Repair consists of replacing wires as required 4 AC Voltmeter M5 18 figure 6 3 Attach test ac voltmeter in parallel across terminals with panel ac voltmeter M5 Operate Generator Set and...

Page 61: ...A3 2 T2 H2 TI H2 P57C16 P58A16 P59C 16 P60 116 A1 8 K3 X2 J2 J 41 7 TB5 12 TB5 12 TB5 12 TB5 12 XA2A16 X43A16 X44A16 X45A16 X46A16 P59D16 P59E16 1 51 i jull 1 50FT 150FT 1 53110 13 11 CH3 2 JU C k 1 T...

Page 62: ...ed red red red 9 41 15 5 46 5 MS25036 112 332 1819 MS25036 153 MS25036 107 MS25036 107 MS25036 153 M 25036 107 37 P53B16 P53C16 P53016 P54A16 16 16 16 16 red red red red 46 44 MS25036 107 MS25036 107...

Page 63: ...5036 107 MS25036 153 MS25036 107 MS25036 153 MS25036 107 X12616 X12H16 X12 16 X12K16 16 16 16 16 black black black black 23 19 16 MS25036 107 MS25036 107 MS25036 107 MS25036 153 MS25036 107 MS25036 15...

Page 64: ...9 53 36 31 MS25036 113 35 55 P55M16 P55S16 P58B16 P59B16 16 16 16 16 red red red red 47 47 P60D16 P61D16 P61F16 P62C16 16 16 16 16 red red red red 31 20 20 5 26 P62E16 P63A16 P64016 P65A16 16 16 16 16...

Page 65: ...6 P2 b P2 a P2 h P2 k P11 E P11 S P11 C P11 G P55M16 P55S16 P58B16 P59B16 P60D16 P61D16 P61 F16 P62616 P2 N P2 F P2 E P2 B P11 K P7 P8 P4 A X34B16 X35B16 X39B16 X40B16 P2 e P2 g P2 X P2 Y P11 P P11 D...

Page 66: ...5 MS25036 115 MS25036 115 MS25036 115 16 5 16 16 5 15 X6A8 X7A8 X7B8 XTD16 X8A8 X8B8 8 8 8 16 8 8 black black black black black black 12 13 5 MS25036 115 MS25036 115 MS25036 115 MS25036 115 MS25036 10...

Page 67: ...18 figure 6 3 Tag and disconnect two leads from meter Remove three screws nuts and lockwashers attaching meter to control panel and remove meter d Meters replace 1 Frequency Meter M3 16 figure 6 3 Po...

Page 68: ...MS25036 107 MS25036 107 MS25036 115 MS25036 115 X6A8 X7B8 X7D16 X8B8 8 8 16 8 black black black black 15 12 13 5 18 MS25036 115 MS25036 115 MS25036 115 MS25036 108 MS25036 153 MS25036 115 MS25036 115...

Page 69: ...ck 7 22 16 14 5 MS25036 107 MS25036 153 MS25036 107 MS25036 153 MS25036 108 MS25036 153 MS25036 153 X34A16 X35A16 X36A16 X37A16 16 16 16 16 black black black black 17 19 28 28 MS25036 153 MS25036 153...

Page 70: ...ge regulator is limited to replacing defective components Refer to the schematic figure 6 5 for proper values c Install Mount control box 1 to skid base 10 using screws 8 washers 9 and screws 3 lock w...

Page 71: ...34 36 57 55 TM 05684C 34 TO 35C2 3 455 2 NAVFAC P 8 262 12 49 38 33 3 9 42 lu 40 A 35 48 3 0 E S 12 10 56 53 GENERATOR 47 18 2 7 2 2 28 21 17 TS 6115 585 3 4 6 3 1 Figure 6 3 C ontrol Cubicle S heet...

Page 72: ...t linear reactor 15 for physical damage Check that electrical connections are clean and tight Check that reactor is securely attached to side panel of output control box 3 AC Circuit Breaker CB1 see f...

Page 73: ...V VOLTMETER AC0 150V 2 150V VOLTMETER DC 0 15V 2 FULL SCALE RESISTOR 10 OHMS 20 WATT RESISTOR 2500 OHMS 2 WATT FUSE 5 AMP SWITCH 250V 5A AC MIN SWITCH 250V 1A AC MIN TEST AND CALIBRATION Vy AC INPUT V...

Page 74: ...Q3 CIO 12uf 50V C9 3 3uf 50V RI OS 1101 69K 1 2 W 150uf 5 0V CII CRI CR2 CR3 CR5 R9 15082 01 2 120 47uf 2 00V C4 100K R2 IK IW RI6 22K R14 NO 180 R15 ZIK 3 4 W IK IW C2 RI3 0 68uf 200V C3 47uf 2 00V...

Page 75: ...K How CR6 18V CII 150 UF A LUM R6 39K QI 2N2905 Q2 2N1711 17 ISCR4 SCR5 Q3 2N3584R8 100 SRIO 1690 TE C9 3 3 UF CIO 12 UF Figure 6 5 1 AC Voltage Regulator Schematic MEP 112A CRI 6 8V C R 8 15 R9 150 C...

Page 76: ...5A16 X36A16 X37A16 J11 P J11 D L1 1 L1 3 X31A X48A XIOD X8D16 X9B8 X9016 X9E16 X9L12 X10A8 X10B8 X10016 X11A8 X11B8 X11016 X12A8 CB3 2 TB2 5 S6 10 TB2 5 X38A16 X39A16 X40A16 X47A16 L1 5 J11 F J11 T A4...

Page 77: ...32A16 CTI 2C CB1 5 X33A16 CTI 10 S6 14 X34A16 J11 P S6 A33 X35A16 J11 D S6 A53 X36A16 Ll 1 CVTI H1 X37A16 L1 3 CVTI H3 X38A16 L1 5 CVTI H5 X39A16 J11 F CVTI C1 X40A16 J11 T CVTI C2 X47A16 A4 X1 CVTI X...

Page 78: ...that all hinges covers and latches operate properly Check that all nameplates are in place Check that side access cover is always in place when box is not being actively serviced b Test 9 Bridge Rect...

Page 79: ...262 12 TO 35C2 3 455 2 TM 05684C 05685B 34 2 ZE 10 1 Control box 2 Connectors 4 3 Screw 2 4 Washer 2 5 Bevel washer 2 6 Washer 2 7 Nut 2 8 Screw 4 9 Washer 8 10 Skid base T3 6116 685 10 Figure 6 8 AC...

Page 80: ...ove wiring from trans formers and switch Disassemble transformers by removing screws 4 and nuts 5 8 Bridge Rectifier Assembly see figure 6 9 Tag and remove leads to rectifier assembly 23 Re move nuts...

Page 81: ...5 585 34 NAVFAC P 8 262 12 TO 35C2 3 455 2 TM 05684C 34 7 W O 25 15 25 10 9 8 23 20 21 24 17 14 18 17 11 12 19 13 17 22 000 2 3 16 TS 6115 585 34 6 9 1 Figure 6 9 AC Output Control Assembly Sheet 1 of...

Page 82: ...Ti and CVT1 Assemble transformers 6 and 7 figure 6 9 with screws 4 and nuts 5 Attach tagged wires to transformers and reconnection switch 1 figure 6 10 Refer to wiring diagram figure 1 1 Install trans...

Page 83: ...2 Control box 3 Screw 4 4 Lockwasher 4 5 Screw 2 6 Spacer 2 7 Lockwasher 2 8 Nut 2 9 Main breaker 10 Screw 6 11 Circuit breaker 12 Screws 2 13 Receptacle 14 Screws 4 15 Nuts 4 16 Cover 17 Gasket 18 Sc...

Page 84: ...2 5340 MFR RI TAAR CR2O TOCR21 400 HZ 2 3 2 5 1 5 CRI CR2 CR3 8 2 B2 3 6 JIZ 2 2A CR4 CR5 CR6 5 110 J9 A4 6 RI 8 60 HZ 1 AC output control box 2 Bridge rectifier assembly 60 Hz 2A Bridge rectifier ass...

Page 85: ......

Page 86: ...lines 7 figure 7 1 between injector pump 1 and injector nozzles 2 Remove tags Install return line 5 and manifold 4 Install fittings 6 on injector nozzles 2 and install re turn lines 3 between fittings...

Page 87: ...85B 34 2 1 Fuel injection pump 2 Injector nozzles 4 3 Fuel lines injector nozzle return 4 4 Fuel return manifold 5 Fuel line manifold to fuel pump 6 Fitting 4 7 Fuel lines injector pump to injector no...

Page 88: ...er pin 6 Pin 7 Nut 8 Nut 9 Lockwasher 10 Clamp 11 Speed control cable 12 Control bracket 13 Screw 2 14 Lockwasher 2 15 Nut 2 16 Droop adjust ratchet 17 Spring 18 Maximum speed screw 19 Control arm TM...

Page 89: ...AC P 8 262 12 2 0 10 11 6 1 1 Flywheel and ring gear 2 Crankshaft 3 Screw 4 Washer 5 Flywheel housing 6 Screw 4 7 Lockwasher 4 8 Flatwa sher 4 9 Stud 1 2 10 Pointer 11 Screw 2 TS 6115 586 341 3 Figure...

Page 90: ...ustment Perform the follow ing steps to establish governor overshoot and under shoot balancing external linkage movements within the range of governor internal parts 1 Start engine and with no load ad...

Page 91: ...n timing port on side of flywheel housing 5 figure 7 3 The timing pointer 10 should be in exact alignment with P C mark on flywheel If pointer is not in align ment move pointer and remark generator ad...

Page 92: ...damper assemblies These washers must remain in the same ar rangement of the originally assembled set or the function of the dampers will be impaired 7 7 BLOWER WHEEL ASSEMBLY c Repair Blower wheel and...

Page 93: ...and remove the blower housing Remove blower wheel assembly 4 figure 7 7 per paragraph 7 7 Remove rotor mounting screws 9 and lockwashers 10 attaching rotor 11 to blower wheel 4 and remove rotor 11 b...

Page 94: ...ove items 4 through 11 from cylinder head 13 CAUTION a Compression Test Diesel engines have very close clearances Too much oil squirted into the cylinder may cause a hydrostatic lock and damage the pi...

Page 95: ...12 7 6 5 3 2 1 Compressor tester goge 2 Nut 2 3 Compression adapter mounting studs 2 4 Wochor 2 5 Retainer flange 6 Compression adapter 7 Gosket 8 Adapter 9 Goakot 10 Ho chucd 11 Gasket 12 Cylinder I...

Page 96: ...ve push rod 15 and remove cylinder heads If heads stick rap sharply with a soft hammer Do not use a pry Do not strike the cooling fins 5 Remove push rod shield 17 andpackings 16 spring 18 and washers...

Page 97: ...8 2 Ball 8 3 Rocker arm 8 4 Screw 10 5 Plate 2 6 Screw 12 7 Washer 12 8 Cylinder head 2 9 Block 10 Gasket 2 11 Valve stem lock 16 12 Valve spring retainer 8 13 Spring 8 14 Exhaust valve 4 15 Push rod...

Page 98: ...8 262 12 TO 35C2 3 455 2 TM 05684C 34 5 2 3 1 Lov 1 Valve spring compressor 2 Nut 3 Rocker arm stud 4 Valve spring retainer 5 Valve stem 6 Valve spring 7 Cylinder head TS 6115 585 34 7 10 Figure 7 10...

Page 99: ...10 id 8 1 Valve rotator 4 2 Spring retainer lock 8 3 Spring retainer 4 4 Seal 2 5 Valve spring 4 6 Intake valve guide 2 7 Valve seat 4 8 Intake valve 2 9 Exhaust valve guide 2 10 Exhaust valve 2 11 Ro...

Page 100: ...at Replacement 3 Refer to Operator and Organizational Maintenance Manual and install mufflers CAUTION Install push rod with longer shouldered end toward rocker arm 4 Install push rods 15 figure 7 9 ro...

Page 101: ...TM 5 6115 585 34 NAVFAC P 8 623 34 TO 35C2 3 455 2 TM 05684C 056858 34 5 3 11 10 8 2 18 0116 07 13 Figure 7 13 Cylinder Head Bolt Tightening Sequence 7 14 Change 4...

Page 102: ...10 37 9 1 Compression ring plated 2 2 Compression ring 3 Oil ring expander 4 Oil ring 5 Retaining ring 2 6 Piston pin 7 Piston 8 Connecting rod assembly 9 Bolt 2 10 Cap 11 Bearing 2 12 Connecting rod...

Page 103: ...TO 35C2 3 455 2 NAVFAC P 8 262 12 O g 1 5 16 11 25 26 10 26 9 34 0 0 0 0 0 26 29 25 24 32 14 13 12 23 O o33 30 31 22 1929 28 18 2 7 2 2 0 2 1 3 TS 6115 585 34 7 15 1 Figure 7 15 C rankshaft Pistons a...

Page 104: ...er 5 CAST IRON OIL CONTROL RING GAP 2 Remove screws 13 figure 7 19 lockwasher 12 bracket 11 and remove oil cup assembly 10 3 Remove cylinder head paragraph 7 9 and remove all carbon at the top of the...

Page 105: ...center Ream bushing I D to obtain the proper clearance Check bore in connecting rod Bore must be open Check connecting rod alignment on a standard align ment fixture 2 Install rings and oil ring expa...

Page 106: ...nstall see figure 7 19 1 Install gear 16 retaining washer 15 and lockring 14 2 Fill pump intake and outletwith oil to be sure it is primed 3 Mount pump on engine using screws 17 and lockwashers 18 All...

Page 107: ...TM5 6115 585 34 o TM 05684C 34 TO 35C2 3 455 2 NAVFAC P 8 262 12 16 oO 19 8 20 10 11 12 13 27 26 21 25 24 22 2 5 TS 6115 585 3 4 7 19 1 Figu re 7 19 O il Pum p Remo val S heet 1 o f 2...

Page 108: ...to 0 3380 inch 2 Spring free length should be 2 5 16 inches 1 16 inch Spring force should be 2 25 0 11 pounds when spring is compressed to a length of 1 3 16 inches e Installation 1 Assemble spring 2...

Page 109: ...6115 585 34 TM 05684C 34 TO 35C2 3 455 2 NAVFAC P 8 262 12 B e r l i n O O O 27 17 16 22 14 11 12 13 2 4 2 5 2 6 O O O 28 TS 6115 585 34 7 21 1 Figure 7 21 I nternal Engine Assembly S heet 1 o f 2 7...

Page 110: ...ring 17 Camshaft gear 18 Key 19 Screw 3 20 Lockwasher 3 21 Screw 2 22 Back plate 23 Gasket 24 Plug 25 Rear camshaft bearing 26 Center camshaft bearing 27 Front camshaft bearing 28 Tappet 8 TS 6115 58...

Page 111: ...ess new bearings and oil seal into place 1 Work governor shaft to check for binding and see that governor shaft end thrust ball is in place see figure 7 23 2 Turn governor yoke so smooth side convex s...

Page 112: ...t center pin but should be replaced if excessively loose or wobbly Check distance the center pin extends from the camshaft gear this dis tance must be 25 32 inch to give proper travel dis tance for th...

Page 113: ...ine making sure tappets 28 are in place on push rods Align timing marks on camshaft gear and crankshaft gear see figure 7 26 Check gear lash see figure 7 27 c Installation 7 Install oil base per parag...

Page 114: ...o paragraph 7 10 and remove oil base 1 Refer to Operator and Organizational Maintenance Manual and remove blower housing 9 Refer to paragraph 7 11 and remove oilpump cup assembly 2 Refer to paragraph...

Page 115: ...e 7 30 2 Bearings Replace bearings if clearances are greater than limits see table 1 2 or if bearings are worn grooved or broken 2 Install thrust washers 25 figure 7 15 on locking pins see figure 7 30...

Page 116: ...then use a steel shimof proper thickness and an 0 005 inch thick gasket on each side of shim This avoids excessive gasket compression and maintains bolt torque Shims are available in 0 005 0 010 0 01...

Page 117: ...he side of the pump mounting flange figure 7 33 These values are important in timing a new pump to the engine b Disassembly see figure 7 34 All work on in jection equipment MUST be performed in the cl...

Page 118: ...INSTALLER X 1 1XX CAREFULLY REMOVE INTERNAL RETAINER TO REMOVE BUTTON O RING KEEPS TAPPET IN DURING HANDLING SU U BUTTON WITH CODE NUMBER OR LETTER STAMPED ON IT TO REACH BUTTON GRIP INTO TAPPET GROOV...

Page 119: ...5c2 3 455 2 TM 05684C 34 15 16 27 18 29 O o 9 0 9 28 m 8 10 11 26 0DDDDD 12 24 25 17 34 23 35 22 30 21 19 13 20 14 O M D 3 31 32 36 40 5 6 39 33 38 37 Ts 6115 506 347 3A 1 Figure 7 34 Disassembly of F...

Page 120: ...our head retaining screws 15 and the four head retaining clamps 16 Carefully rest tappet on clean surface and using shaft head hammer pump body assembly until hydraulic head assembly separates from bo...

Page 121: ...b Attach test fixture TSE 76226 3 to amanual ly operated Nozzle Test Stand NOTE d If the delivery valve assembly is leaky the delivery valve seat may be lapped to its corres ponding seat in the de ery...

Page 122: ...area figure 7 37 Replace the tappet if wear indentations exceed 0 002 The tappet thickness measured between the plunger button contact surface and the cam contact area must be 0 207 or larger 6 The p...

Page 123: ...that the face gear has been correctly assembled to the hydraulic head 18 Insert pin 37 figure 7 34 and flatwasher 38 into lower hole of lever on control unit assembly 4 and secure with lockwasher 39 a...

Page 124: ...etaining plate as shown in figure 7 39 using two tab washers and two screws Torque screws to 20 25 inch pounds and bend locking tabs over screws NOTE TS 6115 686 31 7 41 Figure 7 41 Pressure Testing I...

Page 125: ...pump inlet Connect fuel return line 8 Connect each fuel outlet line to the proper pump outlet see paragraph 7 2 9 Connect governor linkage to governor arm d Check for fuel leakage between top of hous...

Page 126: ...stallation above Example Formula 3 Timing Method 2 Flowing the Pump Port closing dimension of old pump removed from engine 1 093 a Install a Number 12 or M timing button in injection pump and install...

Page 127: ...ne inch counterclockwise so that P C mark is below timing pointer hole timing pointer coincides with the P C mark stamped on flywheel the injection pump button thickness is correct If the P C mark on...

Page 128: ...e or rebore the cylinder to fit the next available oversize piston Pistons and rings are available in 0 005 0 010 0 020 0 030 and 0 040 inch oversize If cylinders do not need re finishing remove any e...

Page 129: ...12 TO 35C2 3 455 2 TM 05684C 34 10 8 7 OOO 6 5 3 2 s o 1 Screw 2 2 Washer 2 3 Retainer 4 Fuel jector 5 Gasket 6 Adapter 7 Gasket 8 Heat shield 9 Gasket 10 Cylinder head TS 6115 585 34 7 45 Figure 7 4...

Page 130: ...se valve should slide back to seat without aid when assembly is held at 45 degree angle If necessary work valve into nozzle body Using dry compressed air blow out fuel inlet 14 f Inspect Inspect tappe...

Page 131: ...ing to prevent it from binding between nozzle and cap nut and tighten nozzle cap nut to 50 to 55 ft lbs 7 Adjust opening pressure of nozzle see para graph 7 20c i Installation 1 Make sure old gasket m...

Page 132: ...e or in questionable condition can be removed and replaced as follows a Unsolder wires from diodes b Install new diode and attaching hardware Tighten nut 40 figure 8 1 only finger tight 3 Testing Diod...

Page 133: ...685B 34 52F 52D 52E 52 C MITED 52B 52A 13 17 18 NA 10 20 19 1990 52 15 12 38 45 39 16 425048 51 45 36 9 35 40 51 43 34 33 50 49 THE 564687 32 31 30 32A 29 hol 32B 31A 000 Dool 1 2 TS 6115 585 34 8 1 1...

Page 134: ...ing harness from terminal board 20 Remove screws 19 and nuts 18 attaching ter minal board to exciter stator and remove terminal board e Testing Exciter Stator Field High Potential Test WARNING 5 Remov...

Page 135: ...the initially applied voltage will be not greater than 600 volts 2 Winding Resistance Test Performwinding re sistance test using a Kelvin bridge Follow the manu facturer s instructions given on the b...

Page 136: ...s 32B bearing 32A tothe generator shaftusing screw 20A lockwasher 30A and flatwasher 31A 3 Place rotor assembly into stator 53 2 For MEP 003 assemble shaft collar 34 bearing retainer 33 bearing 32 to...

Page 137: ...r shaft to be certain it rotates freely that bear ings are smooth and rotor does not rub against stator 7 Place O ring 12 into end bell bearing housing attach terminal board 20 to the exciter stator u...

Page 138: ...winding sing splices item 15 and insulate splices with sleeving item 16 Lace wires to coil ends and lace or tie coils at both ends at a min of every g sleeving item 2 item 4 shall be marked in accord...

Page 139: ...OT 14 L...

Page 140: ...WINDING DATA NO OF SLOTS 108 PITCH OF COIL 14 TURNS PER COIL 2 CONDUCTOR 5 STRANDS OF ITEM 2 RESISTANCE BETWEEN LEAD PAIRS T1 T4 T2 T5 T3 T6 T7 T10 T8 T11 AND T9 T12 071 007 OHMSAT25 C M 19 SHALL BE...

Page 141: ...11 9 A 19 14 11 51413 2 11 10 8 3 1716 14...

Page 142: ...T2 and T3 using splice item 16 Splices shall be insulated with sleeving item 17 Solder leads item 15 to diodes items 9 10 as shown in connection diagram 5 14 13 11 10 9 816 6520 321 35 34 4 All splic...

Page 143: ...19 0 m10 hms a 10n ion ion ey...

Page 144: ...item 1 using white lead and press into rotor item 2 starting at the teltale marked end Required pressure for final inch of shaft insertion shall be 2000 pounds min Shaft shall be insulated with min of...

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Page 146: ...ENDS AND AT REQUIRED LOCATIONS ADD WEIGHTS ITEM 14 1 AND 2 AND OR ITEM 16 AS REQUIRED USING HARDWARE ITEMS 15 AND 16 MAX STACK OR WEIGHTS PER SCREW SHALL BE 50 INCH 3 SPLICES SHALL BE INSTALLED IN ACC...

Page 147: ...1 1 1...

Page 148: ...nt clearance between engine Inspect to see that all wiring harnesses are properly connected and that all connectors are tight Check that all wires are secured away from moving parts which might damage...

Page 149: ...of 115 to 125 and 200 to 250V The error shall not exceed 3 and 5 volts respectively Frequency indicator system 0 5 maximum Voltage adjust range shall be between 197 6 and 218 4V for the 120 208V 3 ph...

Page 150: ...it and the prime circuit is correct 4 With the master switch in the start position open switch si lamp L1 shall extinguish indicating that the start disconnect circuitry is correct 5 With the master s...

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Page 152: ...ization Intermediate and Depot Level Maintenance for FSC 6115 Equipment Components and Procedures for Cleaning Aerospace Ground Equipment Repair Replacement Criteria for FSC 6115 Aerospace Ground Equi...

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Page 154: ...Installation Control Cubicle Removal Wiring Harness Control Unit Assembly Cooling System Description and Function Inspection Maintenance Crankshaft and Bearings Installation Crankshaft and Camshaft Ge...

Page 155: ...F7 46 F7 45 7 2 4 1 4 2 G Gear Cover Assembly Inspection General Maintenance Generator Assembly General Maintenance Removal Generator and Control Circuitry Test Generator Frame Assembly Winding Data...

Page 156: ...d Piston Ring Installation Piston Top Dead Center Measurement Plunger Sleeve Alignment Check 7 10 F7 14 F7 16 F7 5 F7 40 R Reconnection Switch Continuity Repair Parts Repair Standards Reporting of Err...

Page 157: ...Subject T Tabulated Data Test Schedule Timing Gear Backlash Timing Port and Port Closing Mark Torque Values Troubleshooting 1 7 T9 1 F7 27 F7 4 F7 44 T1 1 2 4 T2 3 V Valve Seat Replacement Valve Spri...

Page 158: ...CEC U S Navy Commander Naval Facilities Engineering Command DAVID C JONES General USAF Chief of Staff Official JAMES J SHEPARD Colonel USAF Director of Administration W R JOHNSON Brigadier General U...

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Page 163: ...PIN 033750 000...

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