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Содержание 6115-00-465-1027

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 13: ......

Страница 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...

Страница 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...

Страница 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...

Страница 17: ...1 1 1...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 25: ......

Страница 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...

Страница 27: ...4...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 45: ......

Страница 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...

Страница 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...

Страница 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...

Страница 49: ......

Страница 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...

Страница 51: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 85: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 139: ...OT 14 L...

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 145: ......

Страница 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...

Страница 147: ...1 1 1...

Страница 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...

Страница 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...

Страница 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...

Страница 151: ......

Страница 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...

Страница 153: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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Страница 163: ...PIN 033750 000...

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Onan 6115-00-465-1027, Техническое руководство

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Содержание 6115-00-465-1027

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