Chapter 1 Introduction - TM-5-6115-596-140015
Figure 1-1. Generator set, 4.2 KW.
Figure 1-1.1 Generator set, 4.2kw.
Reporting Equipment Improvement Recommendations
Definition of Locational Terms
Figure 1-2. Generator set - left front view.
Figure 1-3. Generator set - right rear view.
Generator Regulator - TM-5-6115-596-140022
Figure 1-3.1 Generator set - right rear view.
Time Totalizing Meter - TM-5-6115-596-140024
Figure 1-4. Generator set - top view.
Figure 1-4. 1 Generator set - top view.
Figure 1-5. Identification plates and signs.
Figure 1-5.1 Identification plates and signs.
Performance
Generator - TM-5-6115-596-140030
Generator Regulator - TM-5-6115-596-140031
Chapter 2 OPERATING INSTRUCTIONS - TM-5-6115-596-140033
Figure 2-1.1 Control panel.
Air Shutter Lever
Fuel Shutoff Valve - TM-5-6115-596-140036
Engine Choke Control Lever
Starting Rope and Pulley
Electrical Receptacles
Section II. PREVENTIVE MAINTENANCE CHECKS AND SERVICES
Daily Preventive-Maintenance Services. cont'd
Table 2-1. Daily Preventive Maintenansce Service
Section III. OPERATION UNDER USUAL CONDITIONS
FIGURE 2-8, SHIPPING AND STORAGE CONTAINER.
Break-In Services
Operating Under Usual Conditions
Applying Generator Load
Section IV. OPERATION AND MAINTENANCE UNDER UNUSUAL CONDITIONS
Maintenance problems
Winterization equipment cont'd
Figure 2-9. Cold weather cover.
Figure 2-10. Using blowtorch to heat preheater.
Extreme Hot Weather or Dust
Maintenance After Subjection to Water
Chapter 3 MAINTENANCE INSTRUCTIONS
Records and Reports
Lubrication Under Unusual Conditions
Proper Lubrication Levels
Table 3-1. Operator Troubleshooting
CHAPTER 4 ORGANIZATIONAL MAINTENANCE INSTRUCTIONS - TM-5-6115-596-140061
Section II. SERVICE UPON RECEIPT
SpeciaL lubricating
Special Conditions
Table 4-1. Organizational Preventive Maintenance Checks and Services - TM-5-6115-596-140065
Table 4-1. Organizational Preventive Maintenance Checks and Services cont'd
Section IV. TROUBLESHOOTING PROCEDURES - TM-5-6115-596-140067
Isolate the individual component
Table 4-2. Organizational Troubleshooting
Figure 4-1. Electrical test equipment.
Figure 4-2. Electrical schematic diagram.
Table 4-3. Electrical Circuit Numbers (generator sets, serial numbers 923-001 thru 923-553)
Table 4-3.1 Electrical Circuit Numbers (generator sets, serial numbers 929-001 thru 929-290)
Table 4-4. Electrical Troubleshooting (Generator Sets serial numbers 923-001 thru 923-553)
GENERATOR FAILS TO OPERATE cont'd
Table 4-4.1 Electrical Troubleshooting (Generator Sets serial numbers 929-001 thru 929-290)
GENERATOR FAILS TO OPERATE
Figure 4-3. Electrical system.
Figure 4-3.1 Electrical system.
Section V. ENGINE MAINTENANCE PROCEDURES - TM-5-6115-596-140081
Removal
Section VI. FUEL, AIR INTAKE, AND EXHAUST SYSTEM MAINTENANCE PROCEDURES
Draining Fuel Tank
Inspection of Fuel Tank
Figure 4-7. Fuel filter, valve, and hoses.
Fuel Hoses
Fuel Shutoff Valve - TM-5-6115-596-140088
Figure 4-8. Removing or installing mufflers.
Figure 4-9. Flanged manifolds.
Installation - TM-5-6115-596-140091
Section VII. ELECTRICAL SYSTEM MAINTENANCE PROCEDURES
Figure 4-10. Starter-generator drive belts
Control Panel Repair
Control Panel Controls
Engine Start Switch
Figure 4-11. Control panel removal points.
Legend - TM-5-6115-596-140098
Figure 4-11.1 Control panel removal points.
Installation - TM-5-6115-596-140100
Wiring Harnesses and Cables
Removal and Installation of Wiring Harness
Legend - TM-5-6115-596-140103
Figure 4-12.1 Control panel, exploded view.
Figure 4-13. Connectors and receptacles.
Figure 4-14. Wiring harness leads.
Figure 4-15. Generator-to-regulator wiring harness.
Inspection and Repair - TM-5-6115-596-140108
Power Receptacle Wiring Harness
Figure 4-16. Power receptacle wiring harness
Figure 4-16.1 Power receptacle wiring harness.
Inspection and Repair - TM-5-6115-596-140112
Chapter 5 DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE INSTRUCTIONS
Table 5-1. Direct Support and General Support Preventive Maintenance Checks and Services
Section IV. TROUBLESHOOTING PROCEDURES - TM-5-6115-596-140115
Table 5-2. Symptom Index
Table 5-3. Direct and General Support Troubleshooting
Table 5-3. Direct and General Support Troubleshooting cont'd - TM-5-6115-596-140118
Table 5-3. Direct and General Support Troubleshooting cont'd - TM-5-6115-596-140119
Table 5-3. Direct and General Support Troubleshooting cont'd - TM-5-6115-596-140120
Section V. ENGINE MAINTENANCE PROCEDURES - TM-5-6115-596-140121
Figure 5-1. Engine removal points.
Legend - TM-5-6115-596-140123
Installation - TM-5-6115-596-140124
Engine Belt Drive Sheave and Adapter
Section VI. FUEL TANK MAINTENANCE PROCEDURES
Figure 5-3. Fuel tank.
Testing Fuel Tank
Testing Fuel Tank. cont'd
Section VII. STARTER-GENERATOR MAINTENANCE PROCEDURES
Figure 5-4. Adjusting generator voltage.
Figure 5-5. Starter-generator removal points.
Inspection and Repair - TM-5-6115-596-140133
Figure 5-6. Starter-generator belt drive sheave and bushing exploded view
Disassembly of Starter-Generator
Figure 5-7. Startergenerator -- exploded view.
Legend - TM-5-6115-596-140137
Disassembly of Starter-Generator cont'd
Cleaning
Ball Bearings
Armature
Figure 5-8. Testing armature for grounds.
Figure 5-9. Testing armature for short circuits
Figure 5-10. Testing brush spring tension.
Repair
Figure 5-11. Lathe tool properly shaped for commutator turning.
Figure 5-13. Armature mounted in lathe.
Undercutting Mica
Assembly - TM-5-6115-596-140149
Assembly cont'd
Run-In of Generator Brush
Figure 5-16. Electrical test setup for brush run-in.
Starter-Generator Repair and Overhaul Standards
Figure 5-18. Repair and overhaul standard points of measurement for starter-generator.
Table 5-4. Starter-Generator Repair Standards
Section VIII. GENERATOR-REGULATOR MAINTENANCE PROCEDURES
Disassembly
Figure 5-19. Generator regulator removal points.
Figure 5-19.1 Regulator removal points.
Figure 5-20. Generator-regulator exploded view.
Legend - TM-5-6115-596-140162
Table 5-5. Generator Regulator Circuit Values
Assembly - TM-5-6115-596-140164
Generator Regulator Resilient Mounts
Figure 5-21. Generator regulator resilient mounts.
Shipping Instructions
Inspection upon Receipt
Inspection upon Receipt.
Appendix A REFERENCES - TM-5-6115-596-140171
REFERENCES
APPENDIX B MAINTENANCE ALLOCATION CHART
Adjust
Rebuild
Column 5, Tools and Equipment
Column 4, National/NATO Stock Number
APPENDIX A REFERENCES - TM-5-6115-596-140178
Table
APPENDIX C ADDITIONAL AUTHORIZATION LIST
Section III. ADDITIONAL AUTHORIZATION LIST
APPENDIX A EXPENDABLE SUPPLIES AND MATERIALS LIST
Section II. EXPENDABLE SUPPLIES AND MATERIALS LIST
APPENDIX E TORQUE LIMITS
TM-5-6115-596-14 Generator Set: Gasoline Engine Driven 4.2 KW 150 AMP 28V DC Model DC 4.2 - ORD /28 (6115-00-857-1397) Manual
Figure 1-1. Generator set, 4.2 KW.
Figure 1-1.1 Generator set, 4.2kw.
Reporting Equipment Improvement Recommendations
Definition of Locational Terms
Figure 1-2. Generator set - left front view.
Figure 1-3. Generator set - right rear view.
Generator Regulator - TM-5-6115-596-140022
Figure 1-3.1 Generator set - right rear view.
Time Totalizing Meter - TM-5-6115-596-140024
Figure 1-4. Generator set - top view.
Figure 1-4. 1 Generator set - top view.
Figure 1-5. Identification plates and signs.
Figure 1-5.1 Identification plates and signs.
Performance
Generator - TM-5-6115-596-140030
Generator Regulator - TM-5-6115-596-140031
Chapter 2 OPERATING INSTRUCTIONS - TM-5-6115-596-140033
Figure 2-1.1 Control panel.
Air Shutter Lever
Fuel Shutoff Valve - TM-5-6115-596-140036
Engine Choke Control Lever
Starting Rope and Pulley
Electrical Receptacles
Section II. PREVENTIVE MAINTENANCE CHECKS AND SERVICES
Daily Preventive-Maintenance Services. cont'd
Table 2-1. Daily Preventive Maintenansce Service
Section III. OPERATION UNDER USUAL CONDITIONS
FIGURE 2-8, SHIPPING AND STORAGE CONTAINER.
Break-In Services
Operating Under Usual Conditions
Applying Generator Load
Section IV. OPERATION AND MAINTENANCE UNDER UNUSUAL CONDITIONS
Maintenance problems
Winterization equipment cont'd
Figure 2-9. Cold weather cover.
Figure 2-10. Using blowtorch to heat preheater.
Extreme Hot Weather or Dust
Maintenance After Subjection to Water
Chapter 3 MAINTENANCE INSTRUCTIONS
Records and Reports
Lubrication Under Unusual Conditions
Proper Lubrication Levels
Table 3-1. Operator Troubleshooting
CHAPTER 4 ORGANIZATIONAL MAINTENANCE INSTRUCTIONS - TM-5-6115-596-140061
Section II. SERVICE UPON RECEIPT
SpeciaL lubricating
Special Conditions
Table 4-1. Organizational Preventive Maintenance Checks and Services - TM-5-6115-596-140065
Table 4-1. Organizational Preventive Maintenance Checks and Services cont'd
Section IV. TROUBLESHOOTING PROCEDURES - TM-5-6115-596-140067
Isolate the individual component
Table 4-2. Organizational Troubleshooting
Figure 4-1. Electrical test equipment.
Figure 4-2. Electrical schematic diagram.
Table 4-3. Electrical Circuit Numbers (generator sets, serial numbers 923-001 thru 923-553)
Table 4-3.1 Electrical Circuit Numbers (generator sets, serial numbers 929-001 thru 929-290)
Table 4-4. Electrical Troubleshooting (Generator Sets serial numbers 923-001 thru 923-553)
GENERATOR FAILS TO OPERATE cont'd
Table 4-4.1 Electrical Troubleshooting (Generator Sets serial numbers 929-001 thru 929-290)
GENERATOR FAILS TO OPERATE
Figure 4-3. Electrical system.
Figure 4-3.1 Electrical system.
Section V. ENGINE MAINTENANCE PROCEDURES - TM-5-6115-596-140081
Removal
Section VI. FUEL, AIR INTAKE, AND EXHAUST SYSTEM MAINTENANCE PROCEDURES
Draining Fuel Tank
Inspection of Fuel Tank
Figure 4-7. Fuel filter, valve, and hoses.
Fuel Hoses
Fuel Shutoff Valve - TM-5-6115-596-140088
Figure 4-8. Removing or installing mufflers.
Figure 4-9. Flanged manifolds.
Installation - TM-5-6115-596-140091
Section VII. ELECTRICAL SYSTEM MAINTENANCE PROCEDURES
Figure 4-10. Starter-generator drive belts
Control Panel Repair
Control Panel Controls
Engine Start Switch
Figure 4-11. Control panel removal points.
Legend - TM-5-6115-596-140098
Figure 4-11.1 Control panel removal points.
Installation - TM-5-6115-596-140100
Wiring Harnesses and Cables
Removal and Installation of Wiring Harness
Legend - TM-5-6115-596-140103
Figure 4-12.1 Control panel, exploded view.
Figure 4-13. Connectors and receptacles.
Figure 4-14. Wiring harness leads.
Figure 4-15. Generator-to-regulator wiring harness.
Inspection and Repair - TM-5-6115-596-140108
Power Receptacle Wiring Harness
Figure 4-16. Power receptacle wiring harness
Figure 4-16.1 Power receptacle wiring harness.
Inspection and Repair - TM-5-6115-596-140112
Chapter 5 DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE INSTRUCTIONS
Table 5-1. Direct Support and General Support Preventive Maintenance Checks and Services
Section IV. TROUBLESHOOTING PROCEDURES - TM-5-6115-596-140115
Table 5-2. Symptom Index
Table 5-3. Direct and General Support Troubleshooting
Table 5-3. Direct and General Support Troubleshooting cont'd - TM-5-6115-596-140118
Table 5-3. Direct and General Support Troubleshooting cont'd - TM-5-6115-596-140119
Table 5-3. Direct and General Support Troubleshooting cont'd - TM-5-6115-596-140120
Section V. ENGINE MAINTENANCE PROCEDURES - TM-5-6115-596-140121
Figure 5-1. Engine removal points.
Legend - TM-5-6115-596-140123
Installation - TM-5-6115-596-140124
Engine Belt Drive Sheave and Adapter
Section VI. FUEL TANK MAINTENANCE PROCEDURES
Figure 5-3. Fuel tank.
Testing Fuel Tank
Testing Fuel Tank. cont'd
Section VII. STARTER-GENERATOR MAINTENANCE PROCEDURES
Figure 5-4. Adjusting generator voltage.
Figure 5-5. Starter-generator removal points.
Inspection and Repair - TM-5-6115-596-140133
Figure 5-6. Starter-generator belt drive sheave and bushing exploded view
Disassembly of Starter-Generator
Figure 5-7. Startergenerator -- exploded view.
Legend - TM-5-6115-596-140137
Disassembly of Starter-Generator cont'd
Cleaning
Ball Bearings
Armature
Figure 5-8. Testing armature for grounds.
Figure 5-9. Testing armature for short circuits
Figure 5-10. Testing brush spring tension.
Repair
Figure 5-11. Lathe tool properly shaped for commutator turning.
Figure 5-13. Armature mounted in lathe.
Undercutting Mica
Assembly - TM-5-6115-596-140149
Assembly cont'd
Run-In of Generator Brush
Figure 5-16. Electrical test setup for brush run-in.
Starter-Generator Repair and Overhaul Standards
Figure 5-18. Repair and overhaul standard points of measurement for starter-generator.
Table 5-4. Starter-Generator Repair Standards
Section VIII. GENERATOR-REGULATOR MAINTENANCE PROCEDURES
Disassembly
Figure 5-19. Generator regulator removal points.
Figure 5-19.1 Regulator removal points.
Figure 5-20. Generator-regulator exploded view.
Legend - TM-5-6115-596-140162
Table 5-5. Generator Regulator Circuit Values
Assembly - TM-5-6115-596-140164
Generator Regulator Resilient Mounts
Figure 5-21. Generator regulator resilient mounts.
Shipping Instructions
Inspection upon Receipt
Inspection upon Receipt.
Appendix A REFERENCES - TM-5-6115-596-140171
REFERENCES
APPENDIX B MAINTENANCE ALLOCATION CHART
Adjust
Rebuild
Column 5, Tools and Equipment
Column 4, National/NATO Stock Number
APPENDIX A REFERENCES - TM-5-6115-596-140178
Table
APPENDIX C ADDITIONAL AUTHORIZATION LIST
Section III. ADDITIONAL AUTHORIZATION LIST
APPENDIX A EXPENDABLE SUPPLIES AND MATERIALS LIST
Section II. EXPENDABLE SUPPLIES AND MATERIALS LIST
APPENDIX E TORQUE LIMITS
TM-5-6115-596-14 Generator Set: Gasoline Engine Driven 4.2 KW 150 AMP 28V DC Model DC 4.2 - ORD /28 (6115-00-857-1397) Manual
