*ARMY TM 9-6115-584-24P TECHNICAL MANUAL UNIT, DIRECT SUPPORT, GENERAL SUPPORT AND DEPOT LEVEL MAINTENANCE REPAIR PARTS AND SPECIAL TOOLS LIST GENERATOR SET, DIESEL ENGINE DRIVEN, TACTICAL SKID MTD 5 KW, 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-002A UTILITY 60 6115-00-465-1044 *This manual supersedes TM 5-611 5-584-24P/NAVFAC P-8-622-24P/TO 35C2-3-456-4, dated 16 July 1979, including all changes. HEADQUARTERS DEPARTMENTS OF THE ARMY, NAVY AND THE AIR FORCE 31 AUGUST 1996
*ARMY TM 9-6115-584-24P TECHNICAL MANUAL HEADQUARTERS DEPARTMENTS OF THE ARMY, NAVY AND THE AIR FORCE NO. 9-6115-584-24P WASHINGTON, D.C., 31 AUGUST 1996 UNIT, DIRECT SUPPORT, GENERAL SUPPORT, AND DEPOT LEVEL MAINTENANCE REPAIR PARTS AND SPECIAL TOOLS LIST GENERATOR SET, DIESEL ENGINE DRIVEN, TACTICAL SKID MTD 5kW, 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-002A UTILITY 60 6115-00-465-1044 Current as of 31 August 1996 REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS You can help improve this manual. If you find any mistakes, or if you know of a way to improve these procedures, please let us know. Mail your letter or DA Form 2028 (Recommended Changesto Publications and Blank Forms), or DA Form 2028-2 located in the back of this manual directly to: Commander, US Army Aviation and Troop Command, ATTN: AMSAT-I-MP, 4300 Goodfellow Blvd., St. Louis, MO 63120-1798. You may also submit your recommended changes by E-mail directly to <mpmt%/avma28@st-louis-emh7.army.mil>. A reply will be fumished directly to you. For NAVY send letter directly to: Commanding Officer, Naval Construction Battalion Center, ATTN: Code 15 Port Hueneme, CA 93043. For Air Force, submit AFTO Form 22 (Technical Order System Publication Improvement Report and Reply) in accordance with paragraph 6-5, Section VI, T.O. 00-5-1. Forward to Commader, Sacramento Air Logistics Center. ATTN: TILBA, McClellan AFB, CA 95652-5990 DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited. *This manual supersedes TM 5-6115-584-24P/NAVFAC P-8-622-24P/TO 35C2-3-456-4, dated 16 July 1979, including all changes. i
ARMY TM 9-6115-584-24P TABLE OF CONTENTS Illus. Page Figure SECTION I INTRODUCTION Scope... 1 General... 1 Explanation of Columns... 1 Special Information... 5 How to Locate Repair Parts... 5 Abbreviations... 5 Federal Supply Codes for Manufacturers... 6 SECTION II. REPAIR PARTS LIST Group 01 Battery Assembly... 8 1 02 Ground Rod Assembly... 11 2 03 Fuel Tank Assembly... 13 3 04 Control Cubicle Assembly... 16 4 Control Cubicle Front Panel-Exploded View... 18 5 Control Cubicle Wiring Harness... 24 6 Relay Panel Assembly-Exploded View... 26 7 Voltage Regulator... 29 8 05 Wiring Harness and Speed Control Assembly... 37 10 06 Control Box Assembly, AC Output... 41 11 AC Control-Access Cover, Load Terminals and Current Transformers... 43 12 AC Control- Circuit Breakers, Rotary Switch and Duplex Receptacle... 47 13 AC Control-Wiring Harness, Rectifier Bridge and Identification Plates... 53 14 Bridge Rectifier Assembly... 57 15 07 Fuel System - Less Tank... 59 16 Fuel Filter Assembly... 61 17 Fuel Filter - Exploded View... 63 18 Fuel Strainer - Exploded View... 65 19 Fuel Pump Assembly-Exploded View... 67 20 08 Air Cleaner Assembly... 70 21 Air Cleaner- Exploded View... 72 22 09 Generator Assembly... 74 23 Generator Assembly - Exploded View... 77 24 Rotor Assembly - Exploded View... 82 25 10 Shutter Assembly... 87 26 Shutter Assembly - Exploded View... 89 27 11 Exhaust Muffler Assembly... 93 28 12 Engine Cooling System... 95 28 13 Electric Starter... 98 30 Starter - Exploded View... 101 31 &32 ii
ARMY TM 9-6115-584-24P Page Illus. Figure SECTION II. REPAIR PARTS (Continued) 14 Engine - External Assembly... 108 33 Flywheel and Housing... 111 34 Intake Manifold and Heater... 113 35 Blower Wheel, Alternator Stator, Regulator, Fuse and Terminal Block... 115 36 Blower Wheel - Exploded View... 118 37 Oil Cooler, Oil Lines and Fittings, Oil Pressure Gauge... 121 38 Governor Assembly... 124 39 Fuel Lines, Pump To and From Injector Nozzles... 126 40 Start Control Assembly - Exploded View... 128 41 Fuel Stop Solenoid... 131 42 15 Engine - Internal Assembly - Rocker Cover, Rocker Arms And Push-rods... 134 43 Cylinder Head Assembly - Exploded View... 137 44 Nozzle And Holder Assembly - Exploded View... 140 45 Oil Fill Tube Assembly And Oil Drain Hose... 142 46 Oil Filter Assembly - Exploded View... 144 47 Fuel Injector Pump... 147 48 Fuel Injector Pump - Exploded View... 149 49 Oil Base, Oil Pump... 153 50 Gearcase Assembly - Exploded View... 156 51 Camshaft Assembly, Cam And Oil Pump Gears... 158 52 Piston And Connecting Rod - Exploded View... 161 53 Rear Bearing Plate, Crankshaft, Bearing And Cylinder Block... 163 54 16 Skid Base Assembly - Exploded View... 172 55 Slave Receptacle Assembly... 177 56 5kw Acoustical Kit... 179 17 Acoustical Suppression Kit... 189 57 18 Bulk Material... 198 BULK SECTION III. SPECIAL TOOLS LIST... 99 58 SECTION IV. NATIONAL STOCK NUMBER AND REFERENCE NUMBER INDEX... 201 SECTION V. REFERENCE DESIGNATOR INDEX... 219 iii/(iv blank)
UNIT, DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE REPAIR PARTS AND SPECIAL TOOLS LIST SECTION I. INTRODUCTION ARMY TM 9-6115-584-24P 1. SCOPE. This RPSTL lists and authorizes spares and repair parts; special tools; special test, measurement, and diagnostic equipment (TMDE); and other special support equipment required for performance of unit, direct support and general support maintenance of the generator set. It authorizes the requisitioning, issue, and disposition of spares, repair parts and special tools as indicated by the source, maintenance and recoverability (SMR) codes. 2. GENERAL. In addition to this section, Introduction, this Repair Parts and Special Tools List is divided into the following sections: a. Section II.Repair Parts List. A list of spares and repair parts authorized by this RPSTL for use in the performance of maintenance. This list also includes parts which must be removed for replacement of the authorized parts. Parts lists are composed of functional groups in ascending alphanumeric sequence, with the parts in each group listed in ascending figure and item number sequence. Bulk materials are listed in item name sequence. Items are shown in the associated illustration(s)/figure(s). b. Section Ill. Special Tools List. A list of special tools, special TMDE, and other special support equipment authorized by this RPSTL (as indicated by Basis of Issue (BOI) information in DESCRIPTION AND USABLE ON CODE column) for the performance of maintenance. c. Section IV. Cross-Reference Index. A list, in National Item Identification Number (NIIN) sequence, of all National stock numbered items appearing in the listing, followed by a list in alphanumeric sequence of all part numbers appearing in the listings. National stock numbers and part numbers are cross referenced to each illustration figure and item number appearance. The figure and item number index lists figure and item numbers in alphanumeric sequence and cross references NSN, CAGEC and part number. 3. EXPLANATION OF COLUMNS (Section II AND Section III). a. ITEM NO. (Column (1)). Indicates the number used to identify items called out in the illustration. b. SMR Code (Column (2)). The Source, Maintenance, and Recoverability (SMR) code is a 5-position code containing supply/requisitioning information, maintenance category authorization criteria, and disposition instruction, as shown in the following breakout: * Complete Repair: Maintenance capacity, capability, and authority to perform all corrective maintenance tasks of the "Repair" function in a use/user environment in order to restore serviceability to a failed item. (1) Source Code. The source code tells you how to get an item needed for maintenance, repair, or overhaul of an end item/equipment. Explanations of source codes follows: 1