ARMY TM 9-6115-645-24
AIR FORCE TO 35C2-3-444-12
MARINE CORPS TM 09244A/09245A-24/2
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3-7.3
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Connect hose (17) to water pump and tighten clamp (16).
Connect hose (15) at thermostat housing and tighten clamp (14).
Connect hose (19) at radiator drain valve (20) and tighten clamp (18).
Secure support rods (13) to front engine lifting bracket with bolts (11), washers (12), Iockwashers (10), and nuts
(9).
Install spacer (8) and fan (7) on water pump with bolts (5) and Iockwashers (6). Torque bolts (5) to 24 ft-lbs (33
Nm).
Install fan guard (4) on radiator assembly (23) with bolts (1), washers (2), and Iockwashers (3).
Using lifting device, position top housing section (10, FIGURE 3-4) on generator set.
Secure top housing section (10) to output box angle with bolt (9) and assembled nut (8).
Secure top housing section (10) to rear side panels with bolts (7) and assembled nuts (6).
Secure top housing section (10) to front housing with bolts (4), flat washers (5), Iockwashers (3), and nuts (2).
Connect exhaust pipe to turbocharger outlet and install clamp (1).
Install overflow bottle assembly (5, FIGURE 3-3) on right side of engine with bolts (3) and Iockwashers (4).
Connect hose (2) on overflow bottle assembly (5) and tighten clamp (1).
Position filler hose and panel assembly (5, FIGURE 3-2) in generator set. Connect filler hose and panel assem-
bly (5) to radiator (2) and tighten clamp (1).
Connect overflow hose (4) to filler hose and paneI assembly (5) and tighten clamp (3).
Install new ties (6) on radiator supports (7) to secure overflow hose (4).
Install top housing panel (7, FIGURE 3-1) with bolts (1) and (4), Iockwashers (2) and (5), and washers (3) and
(6).
Service coolant system, paragraph 2-1.2.2.
Service lubrication system, paragraph 2-1.2.4.
Install control box assembly, paragraph 2-19.4.
Connect negative battery cable and close battery access door.
Close all access doors.
Start generator set, check for leaks and proper operation.
Shut down generator set and service fluid levels as necessary.
Replacement.
Remove old engine assembly from generator set, paragraph 3-7.1.
Disconnect throttle lever cable (1, FIGURE 3-17) from fuel injection pump of old engine.
Remove throttle lever cable bracket (2), with cable (1) attached, from old engine and install on new engine.
Connect throttle lever cable (1) to fuel injection pump lever of new engine.
Remove the following from the old engine and install on new engine:
(1)
(2)
(3)
(4)
(5)
Oil sample valve and low oil pressure switch assembly (3, FIGURE 3-17).
Alternator guard (1, FIGURE 3-18). Use hardware from old engine.
Fuel filter drain valve assembly (2, FIGURE 3-18).
Oil drain line elbow (7, FIGURE 2-31) with hose (4) attached.
Mount bracket (14, FIGURE 2-25) with wire holder (10) and overflow bottle (5). Use hardware from old
engine.
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