ARMY TM 9-6115-643-24
AIR FORCE TO 35C2-3-445-22
f. Attach lifting harness to engine and overhead hoist. Take up slack.
g. With aid of an assistant, lift engine from engine stand and position engine on skid base, aligning mounting holes,
brackets and generator to flywheel housing.
h. Install bolts (42) and Iockwashers (43), tightening bolts (42) slowly to ensure even and proper seating of generator
housing lip to flywheel housing. Torque bolts (42) to 31 ft-lbs (42 Nm).
i. Secure engine support bracket (5) to skid base with bolts (4), snubbing washers (3), washers (2), and nuts(1).
Torque bolts (4) to75ft-lbs(102 Nm).
j .
Align scribe mark on generator drive disc and engine flywheel, and install bolts (40) and Iockwashers (41) securing
generator drive disc to engine flywheel. Torque bolts (40) to 35 ft-lbs (47 Nm).
k. Install screen/cover (39) on generator case with screw (38) and washer (37).
l. Loosen nuts (23) and (27), adjust bolts (25) to obtain 0.5 inch (1 2.7 mm) minimum clearance with skid base. Torque
nuts (23) and (27) to 150 ft-lbs (204 Nm).
m. Install support (10, FIGURE 3-15) on right side panel with bolts (12) and assembled nuts (11).
n. Install load output terminal board assembly (8) on supports (9) and (10) with bolts (5), Iockwashers (6), and wash-
ers (7).
o. Secure ground strap (4) to skid base with bolt (3), Iockwashers (2) and nut (1).
p. Position engine electrical harness and connect electrical leads to battery charging alternator (1, FIGURE 3-14),
starter solenoid (2), starter motor (3), and coolant high temperature switch (4) on left side of engine. Remove tags.
q. Connect coolant drain hose (6) at engine block drain valve (7) and tighten clamp (5).
r. Remove caps and connect fuel line (19, FIGURE 3-13) to fuel transfer pump (13).
s. Remove caps, connect fuel return line (21) and tighten clamp (20) at engine fuel filter (9).
t.
Install fuel filter/water separatorassembly(18) on engine with bolts (16), washers (17), Iockwashers (15), and nuts
(14).
u. Remove caps and connect fuel line(12) to fuel transfer pump (13).
v. Remove caps, connect hose (11) and install clamp (10) at fuel filter/water separator assembly (18).
w. Remove caps and connect fuel line (8) to engine fuel filter (9).
x. Connect electrical leads to fuel injection pump governor actuator (7), DEAD CRANK switch (6), magnetic pickup
(5), coolant temperature sender (4), oil pressure sender (3), low oil pressure switch (2), and glow plug contactor
(1). Remove tags.
y. Connect oil drain hose (2, FIGURE 3-12) to engine oil pan and tighten clamp(1).
z. Position air intake hoses (2, 3, and 4, FIGURE 3-11) in generator set and tighten clamps (1).
aa. With aid of an assistant, position left rear side housing panel (4, FIGURE 3-10) and lower side panel (1 2) on gener-
ator set.
ab. Secure left rear side panel (4) to skid base with bolts (1), Iockwashers (2), and washers (3).
ac. Secure lower left side panel (12) to front housing and skid base with bolts (5) and (10), washers (7) and (11), lock-
washers (6) and (9), and nuts (8).
ad. Connect battery cables (3, FIGURE 3-9) and slave cables (4) to NATO slave receptacle (5) with bolts(1) and lock-
washers (2).
ae. Connect auxiliary fuel pump (7, FIGURE 3-8) and fuel float module (8) electrical connectors and remove tags.
af. Remove caps and connect fuel hose (4) to fuel line (5).
ag. Remove caps and connect hose (3) to fuel filler paneI assembly (6) and tighten clamp (2).
ah. Remove caps and connect fuel filler panel assembly (6) to fuel tank and tighten clamp (1).
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