Telc2b3.tmp TM 5 6115 545 12 GENERATOR DIESEL ENGINE DRIVEN, TACTICAL SKID MTD., 60 KW, 3 PHASE, 4 WIR 120/208 AND 240/416 VOLTS, DOD MEP 006A, UTILITY CLASS, (NSN 00 118 1243) 105A, PRECISE 50/60 (6115 1252)

TM-5-6115-545-12 GENERATOR DIESEL ENGINE DRIVEN, TACTICAL SKID MTD., 60 KW, 3 PHASE, 4 WIR 120/208 AND 240/416 VOLTS, DOD MEP-006A, UTILITY CLASS, 5 (NSN 6115-00-118-1243) DOD MEP-105A, PRECISE CLASS, 50/60 (6115-00-118-1252) DOD MEP- TM-5-6115-545-12 Military Generators == MEP 105A

TM-5-6115-545-12_Operator_Maintenance TM-5-6115-545-12_Operator_Maintenance Military Generators == MEP 006A

User Manual: TM-5-6115-545-12 GENERATOR DIESEL ENGINE DRIVEN, TACTICAL SKID MTD., 60 KW, 3 PHASE, 4 WIR 120/208 AND 240/416 VOLTS, DOD MEP-006A, UTILITY CLASS, 5 (NSN 6115-00-118-1243) DOD MEP-105A, PRECISE CLASS, 50/60 (6115-00-118-1252) DOD MEP- Military Generators == MEP 115A

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reprint

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1

includes

through

ARMY
TM-5-6115-545-12
AIR FORCE
T0-35C2-3-444-1
NAVY
NAVFAC P-8-626-12
MARINE CORPS
TM-00038G-12

current
18.

TECHNICAL

MANUAL

OPERATOR AND 0RGANIZATIONAL
MAINTENANCE MANUAL

GENERATOR SET, DIESEL ENGINE DRIVEN, TACTICAL

SKID MTD., 60 KW, 3 PHASE, 4 WIRE, 120/208 AND 240/416 VOLTS

DOD MODELS

CLASS

HERTZ

MEP006A

UTILITY

50/60

6115-00-118-1243

MEP105A

PRECISE

50/60

6115-00-118-1252

MEP115A

PRECISE

400

NSN

6115-00-118-1253

Including Optional Kits
DOD

MODELS

F S N

N O M E N C L A T U R E

MEP006AWF

WINTERIZATION

KIT,

FUEL

KIT,

ELECTRIC

MEP006AWE

WINTERIZATION

M E P 0 0 6 A L M

LOAD

M E P 0 0 6 A W M

WHEEL

BANK

6115-407-8314

BURNING

6115-455-7693

KIT

6115-407-8322

MOUNTING

6115-463-9092

KIT

10 JUNE 1973
Published under authority of t h e
Departments

of

the

(Including

Air
U.

Force,
S.

the

Army,

Marine

Corps)

and

the

Navy

TM 5-6115-545-12
TO 35C2-3-444-1
NAVFAC P-8-626-12
TM 00038G-12

WARNING

DANGEROUS GASES (Cont)

All specific cautions and warnings contained in this
manual shall be strictly adhered to. Otherwise, severe
injury, death and/or damage to the equipment may
result.

Use extreme care, should a selenium rectifier
malfunction, to avoid inhalation of poisonous fumes.

HIGH VOLTAGE

are generated as a result of operation of the generator
set. Do not expose any part of the body to a high
pressure leak in the fuel or hydraulic system of the
generator set.

is produced when this generator set is in operation.

LIQUIDS UNDER PRESSURE

DEATH
or severe burns may result if personnel fail to observe
safety precautions. Do not operate this generator set
until the ground terminal stud has been connected to a
suitable ground. Disconnect the battery ground cable
before removing and installing components on the
engine or in the electrical control panel system.
Do not attempt to service or otherwise make any
adjustments, connections or reconnections of wires or
cables until generator set is shut-down and completely
de-energized.
DANGEROUS

GASES

Batteries generate explosive gas during charging;
therefore, utilize extreme caution, do not smoke, or
use open flame in vicinity when servicing batteries.
Slave receptacle is to be used when extra cranking
power is required for starting unit. Other methods are
not authorized, as arcing at batteries could occur.

Relieve pressure from radiator before removing
radiator cap.
NOISE
operating level of this generator can cause hearing
damage. Ear protectors, as recommended by the
medical or safety officer, must be worn when working
near this set.
WARNING
Hot refueling of generators while they are operating
poses a safety hazard and should not be attempted.
Hot engine surfaces and sparks produced from the
engine and generator circuitry are possible sources of
ignition. Severe injury, death, and/or damage to the
equipment may result.
CAUTION
DAMAGE

Exhaust discharge contains noxious and deadly fumes.
Do not operate generator sets in inclosed areas unless
exhaust discharge is properly vented to the outside.

to the equipment may result if personnel fail to
observe the cautions contained in this manual.

When filling fuel tank maintain metal to metal
contact between filler nozzle and fuel tank. Do not
smoke or use an open flame in the vicinity.

If generator set is shut-down by the operation of a
safety device, do not attempt to operate the unit until
the cause has been determined and eliminated.

Change 18 a/(b blank)

TM 5-6115–545-12
TO 35C2-3-444-1
NAVFAC P-8-626-12
TM 00038G-12
C 18
HEADQUARTERS,
DEPARTMENTS OF THE ARMY, NAVY AND AIR FORCE
AND HEADQUARTERS U.S. MARINE CORPS
WASHINGTON, D. C., 12 February 1991

CHANGE
NO. 18

Operator and Organizational Maintenance Manual
GENERATOR SET, DIESEL ENGINE DRIVEN, TACTICAL
SKID MTD., 60 KW, 3 PHASE, 4 WIRE, 120/208 AND 240/416 VOLTS
DOD MODEL

CLASS

HERTZ

MEP-006A
MEP-105A
MEP-115A

UTILITY
PRECISE
PRECISE

50/60
50/60
400

NSN
6115-00-116-1243
6115-00-118-1252
6115-00-118-1253

INCLUDING OPTIONAL KITS
NOMENCLATURE

FSN

WINTERIZATION KIT, FUEL BURNING
WINTERIZATION KIT, ELECTRIC
LOAD BANK KIT
WHEEL MOUNTING KIT

6115-407-8314
6115-455-7693
6115-407-8322
6115-463-9092

DOD MODEL
MEP006AWF
MEP006AWE
MEP006ALM
MEP006AWM

Approved for public release; distribution is unlimited
TM 5-6115-545-12/TO 35C2-3-444-1/NAVFAC P-8-626-12/TM 00038G–12, 10 June 1973, is
changed as follows:
1. Remove and insert pages as indicated below. New or changed text material is indicated by a
vertical bar in the margin. An illustration change is indicated by a miniature pointing hand.
Remove pages

Insert pages

a/(b blank)
2–1 and 2–2
3–3 and 3-4
3-8.1 /(3-8.2 blank)
3–15 and 3–1 6
3–19 through 3-22
3–105 and 3–106
3–115 and 3–116

a/(b blank)
2–1 and 2–2
3–3 and 3–4
3-8.1 /(3-8.2 blank)
3–15 and 3–16
3–19 through 3–22
3–105 and 3–106
3–115 through 3–118

2. Retain this sheet in front of manual for reference purposes.

TM 5–6115-545-12
TO 35C2-3-444-1
NAVFAC P-8-626-12
TM 00038G-12
C18
By Order of the Secretaries of the Army, Air Force, and Navy (Including the Marine Corps):
CARL E. VUONO
General, United States Army
Chief of Staff
Official:
THOMAS F. SIKORA
Brigadier General, United States Army
The Adjutant Genera/
MERRILL A. McPEAK
General USAF
Chief of Staff
Official:
CHARLES C. McDONALD
General, USAF
Commander, Air Force Logistics Command
DAVID E. BUTTORFF
Rear Admiral, CEC, US Navy
Commander
Navy Facilities Engineering Command
H.E. REESE
Executive Director
Marine Corps Research, Development and
Acquisition Command
DISTRIBUTION:
To be distributed in accordance with DA Form 12-25E, (qty rqr block no. 0859)

16 April 1984

DEPARTMENT OF THE ARMY TECHNICAL MANUAL

TM-5-6115-545-12

DEPARTMENT OF THE AIR FORCE TECHNICAL ORDER

TO-35C2-3-444-1

DEPARTMENT OF THE NAVY PUBLICATION

NAVFAC P-8-626-12

MARINE CORPS TECHNICAL MANUAL

TM-00038G-12
HEADQUARTERS

TECHNICAL MANUAL

DEPARTMENT OF THE ARMY
June 1973
WASHINGTON, 10
DC.,

OPERATOR AND ORGANIZATIONAL

MAINTENANCE MANUAL
Approved for public falease; distribution is unlimited.

GENERATOR SET, DIESEL ENGINE DRIVEN, TACTICAL
SKID MTD., 60 KW, 3 PHASE, 4 WIRE, 120/208 AND 240/416 VOLTS

D0D MODELS
MEPO06A
MEP105A
MEP115A

HERTZ
50/60
50/60
400

CLASS

UTILITY
PRECISE
PRECISE

FSN
6115-118-1243
6115-118-1252
6115-118-1253

INCLUDING OPTIONAL KITS
DOD MODELS
MEP006AWF
MEP006AWE
MEP006ALM
MEP006AWM

NOMENCLATURE
WINTERIZATION KIT,FUEL BURNING
WINTERIZATION KIT, ELECTRIC
LOAD BANK KIT
WHEEL MOUNTING KIT

FSN
—
6115-407-8314
6115-455-7693
6115-407-8322
6115-463-9092

TABLE OF CONTENTS

i

TM 5-6115-545-12
TO-35C2-3-444-1
NAVFAC P-8-626-12
TM-00038G-12
Page

Chapter
LIST

OF

ILLUSTRATIONS

.

.

.

.

.

.

.

.

.

.

.

General . . . . . . . . . . . . . . .
Description and Data . . . .

1-1
1-1

INSTALLATION AND OPERATION
INSTRUCTIONS . . . . . . . . . . . . . .

2-1

I
II
III
IV
V
VI

3

Service Upon Receipt of Material
Movement to New Worksite . . . .
Controls
and
Instruments
.
.
Operation Under Usual Conditions . . .
Operation Under Unusual
Conditions . . . . . . . . . . . . . . .
Operation of Auxiliary Material
Used in Conjunction with the
Equipment . . . . . . . . . . . . . . .

.
.
.
.

2-1
2-10
2-10
2-18

.

2-27

.

OPERATOR AND ORGANIZATIONAL
MAINTENANCE INSTRUCTIONS . . .
I

XI

Operator and organizational
Maintenance Repair Parts,
Tools and Equipment . . . . .
Lubrication . . . . . . . . . . . . . . . .
Preventive Maintenance Checks
and Services . . . . . . . . . . . . . . .
Operator’s
Maintenance.
.
Troubleshooting. . . . . . . . . . .
Field Expedient Repairs. . , . . . . . .
Radio Interference Suppression.
Organizational Maintenance
Procedures . . . . . . . . . . . . . .
Batteries and Related Parts . . . .
Muffler, Exhaust and Breather
Tubes . . . . . . . . . . . . . . . . . .
Convenience Receptacle. . . . .

XII

(Deleted)

XIII
XIV
XV
XVI

Plate and Sleeve Assembly. . . . . . . .
Paralleling Receptacles . . . . . . .
Generator Set Controls . . . . . . .
Engine Generator Set-Housing
Group . . . . . . . . . . . . . . .
Engine Generator and Chassis
Interconnecting Wiring
Harnesses . . . . . . . . . . . . . . . .
Load
Connection
Group.
.
.
Governor Control Unit
(MEP115A) . . . . . . . . . . . . . . .
Air Cleaner Assembly . , .
Relay
Table
Group
.
.
.
.
Generator Assembly. . . . . . . .
Day Tank and Fuel Filter
Assembly. . . . . . . . . . . . . . . .
Lifting Frame Assembly, Start Aid
Assembly and Fuel Transfer Pumps

II
III
IV
V

VI
VII
VIII
IX
X

XVII

XVIII
XIX
xx
XXI
XXII
XXIII
XXIV

ii

XXV
XXVI

Cooling Group. . . . . . . . . . .. . . .
Hydraulic Actuator and Sump
and Filter (C1ass 1 Sets
Only Except MEP115A)
XXVII
Engine
Assembly
.
XXVIII Alternator and Related Parts
XXIX
Speed Switch. . . . .
XXX
Oil Level Gage and Filter .
XXXI
Electric Starter and Adapter
XXXII
Lube Oil Filters and Sensors.
XXXIII Secondary Fuel Filter . .
XXXIV
Lube Oil Cooler . . . .
XXXV
Nozzle Holder Assemblies
andLines........
XXXVI
Diffuser and Turbocharter
XXXVII Water Pump and Fan . . .
XXXVIII Thermostat and Housing
XXXIX
Crankshaft and Pulley and
Vibration Dampener .
XL
Idler Pulley and Mounting
Bracket . . . . . . . . .
XLI
Intake Manifold . .
XLII
Exhaust Manifold
XLIII
Rocker Arm Shaft Assembly.
XLIV
Base Group and Related
Components.
.
.
.
XLV
Accessory Items . . . .

lNTRODUCTION . . . . . . . . . . . . . . . . . . . .
I
II

2

iii

iv

LIST OF TABLES
1

.

Change 15

2-32

3-1

.
.

3-1
3-1

.
.
.
.
.

3-6
3-6
3-20
3-27
3-28

.
.

3-29
3-29

.
.

3-31
3-32

A

.
.
,

3-35
3-36
3-37

.

3-60

.
.

3-60
3-60
3-72
3-72.3
3-72
3-74

.

3-74

.

3-77

3-81

3-84
3-87
3-87
3-91
3-92
3-93
3-93
3-94
3-96
3-96
3-100
3-103
3-103
3-106
3-106
3-108
3-110
3-110
3-112
3-116

AUXILIARY MATERIAL USED IN CONJUNCTION

I
II
III
IV
V

WITH THE EQUIPMENT . . . .

4-1

General . . . . . . . . . . . . .
Fuel Burning Winterization
Electric Winterization Kit.
Wheel Mounting Kit.
Load Bank . . . . . . . . . . . .

4-1
4-1
4-11
4-21
4-29

. . .
Kit.
. .
. .
. . .

APPENDIX
A

REFERENCES

.

A- 1

B

BASIC ISSUE ITEM LIST AND) ITEMS
TROOP INSTALLED OR
AUTHORIZED. . . . . . . . . . . . . .

B-1

.

.

.

.

.

.

.

.

.

.

.

.

.

.
.

B-1
B-2

.

B-2

.

B-3

)

C-1

Introduction . . . . . . . . . . . . . . . . .
Maintenance Allocation Chart.

C-1
C-2

INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1

I
II
III

C
.
.
.
.

Page

Chapter

Introduction . . . . . . . . . . . . . . .
Basic Issue Items . . . . . . . . . . . .
Items Troop Installed or
Authorized List . . . . . . . . .
IV
Maintenance and operating
Supplies . . . . . . . . . . . . . .
MAINTENANCE ALLOCATION CHART
( A R M Y a n d U S M C o n l y

I
II

TM 5-6115-545-12
TO-35C2-3-444-1
NAVFACP-8-626-12
TM-00038G-12
LIST OF ILLUSTRATIONS
Number
1-1.
1-2.
1-3.
1-4.
1-5.
1-6.
1-7.
1-8.
1-9.
1-10.
1-11.
1-12.
1-13.
1-14.
1-15.
1-16.
1-17.
1-18.
1-19.
1-20.
1-21.
1-22.

1-23.

1-24.
1-25.
1-26.
1-27.
1-28.
1-29.
1-30.
2-1A.
2.1.

Title
Engine Generator Set. Right Front.
Three Quarter View.
Engine Generator Set. Left Rear.
Three Quarter View..
Data Instruction Plate Locations
(2 Sheets) . . . . . . . . . . . . . . . . . .
Fuel System Diagram Instruction Plate . . . .
Lifting Instructions Instruction
Plate . . . . . . . . . . . . . . .
Operating Instructions Instruction
Plate . . . . . . . .. . . . . .
Service Instruction and System
Capacities Instruction Plate . .
Voltage Reconnection Instruction
Plate . . . . . . . . . . . . . . . . . . . . .
Operational Data Information
Plate (Mode I) . . . . . . . . . . . . . .
Operational Data Information
Plate (Mode II) . . . . . . . . . . . . . .
Battery Arrangement and Connections
Instruction Plate . . . . . . . . . . . . . .
Set I.D. Plate. . . . . . . . . . . . . . .
AC Troubleshooting Diagram
(Mode I)andPlate. . . . . . . . .
AC Troubleshooting Diagram
(Mode II)andPlate . . . . . . . . .
DC Troubleshooting Diagram
(Mode I) and Plate. . . . . . . . . . ..
DC Troubleshooting Diagram
(Mode II) and Plate . . . . . . . . . . ..
Schematic Wiring Diagram Class 1,
AC and Plate . . . . . . . . . . . .
Schematic Wiring Diagram Class 1,
DC and Plate . . . . . . . . . . . . . . .
Schematic Wiring Diagram Class 2,
AC andPlate . . . . . . . . . . . . . . . . . . . . . .
Schematic Wiring Diagram Class 2,
DC and Plate . . . . . . . . . . .. . . . . . . . ..
Kit Data and Instruction Plate
Location (2 Sheets) . . . . . . . . . . . . . . . . . . . . . .. . . . .. . .
Fuel Burning Winterization System
Diagram and Heater Control
Schematic Diagram Instruction Plate . . .
Electric Winterization System
Diagram and Electric Heater
Control Schematic Diagram
Instruction Plate . . . . . .
Load Bank Connection and Operation
Instruction Plate . . . . . . . . . . . . . . . . . . . .
Shipping Crate . . . . . . . . .
50/60 Hz Precise and Utility
Interconnecting Diagram . . . . . . . . . .
400 Hz Precise Interconnecting
Diagram. . . . . . . . . . . . .. . . . . . .
Hydraulic Flow Diagram . . . . . . . . .
Interconnection Wiring Diagram
50/60 Hz Precise and Utility
Interconnection Wiring Diagram
400 Hz. Precise and Utility . . . . . . . . . .
Noise Level Warning . . . . . . . . . .
Installation Plan . . . . . . . . . . .

Page

Number

Title

Page

Grounding Procedures (3 Sheets). . . . . .
Generator Load Terminal Board
Connections. . . . . . . . . . . . .
Voltage Conversion . . . . . . . . . . . . .
Generator Set Controls and
Instruments (6 Sheets) . . . . . . . . . . . . . . .
Preparation for Starting
(2 Sheets) . . . . . . . . . . . . . . . . .
Starting Instructions (2 Sheets) . . . . . . . . . . . . .
Stopping Instructions . . . . . . . . . . . . . . . . . .
Single Generator Unit, Operating
Instructions . . . . . . . . . . . . . . . . . . . . . . .. . . .
Parallel Generator Units Operating
Instructions . . . . . . . . . . . . . . . .
Fuel Burning Winterization Kit
Operating Instructions (2 Sheets) . . . . . . .
Electric Winterization Kit Operating
Instructions (2 Sheets). . . . . . . .
Wheel Mounting Kit Operation
Load Bank Operating Instructions
Lubrication Order (2 Sheets) . . . . . . . .
Oil Level Gage and Filler . . . . . . . . . .
Engine Lube Oil Filters . . . . . . . . .
Batteries and Slave Receptacles. . . . . . . . . .
Air Cleaner Service . . . . . . . . .
Fuel Filter and Strainer. . . . . . . .
Main Fuel Tank . . . . . . . . . . .. . . .
Hydraulic Sump and Filter . . . . . . . . . . . .
Secondary Fuel Filter . . . . . . . . . . .
Backwire of Fuel Injector Pump for
Class 2 0peration . . . . . . . . . . . . .
Interference Suppression Components
Removal and Installation . . . . . . . . . . . . . .
Exhaust and Breather System. . . . . . .
Convenience Receptacle . . . . . . . . . . . .
(Deleted) . . . . . . . . . . .. . . .
Plate and Sleeve Assembly . . . . . . . . . . . .
Paralleling Receptacles . . . . . . . . . . . . . . . . .
Generator Set Controls . . . . . . . . . . . .
Control Cubicle Assembly (2 Sheets) . . . . . . . . . . . .
Control Cubicle Schematic Diagram . . . . . . . . . . . .
Control Cubicle Wiring Diagram
(sheets) . . . . . . . . . . . . . . . . . .
Ammeter-Voltmeter Selector
Switch Schematic . . . . . . . . . . . . . . . . . . .
Housing Group (2 Sheets) . . . . . . . . . . . . .
Engine Generator and Chassis
Wiring Harness (2 Sheets) . . . . . . . . . . . . . . .
Load Connection Group . . . . . . . . . . . . . .
Terminal Clip Replacement . . . . . . . . . . . . . . .
Governor Control
Unit (MEP-115A) . . . . . . . . . . . . . . . . . .
Reconnections Board . . . . . . . . . . . . . . . .
Air Cleaner and Related Parts . . . . . . . . . .
Day Tank and Fuel Filter Assembly . . . . . . . .
Center Support and Related Parts . . . . . . . . . . .
Cooling Group and Related Parts . . . . . . . . . . . . .
Shutter Thermostat Replacement . . . . . . . . . . . . . .
Cooling Groups . . . . . . . . .. . . .
Hydraulic Actuator Servicing . . . . . . . . . . . . .
Hydraulic Sump and Filter . . . . . . . . . . . . . . . .

2-5

1-2

2-2.
2-3.

1-3
1-4
1-6
1-7

2-4.
2-5.
2-6.

1-8

2-7.
2-8.
2-9.

1-9

2-10.

1-10

2-11.

1-11

2-12.

1-12

1-23

2-13.
2-14.
3-1.
3-2.
3-3.
3-4.
3-5.
3-6.
3-7.
3-8.
3-9.
3-10.

1-25

3-11.

1-27

3-12.
3-13.
3-14.
3-15.
3-16.
3-17.
3-18.
3-19.
3-20.

1-13
1-14
1-17
1-19
1-21

1-29
1-31
1-33
1-35

3-21.
1-37
1-39
1-39

3-22.
3-23.
3-24.
3-24.1
3-24.2

1-41
1-43
1-45
1-47
1-49
2-4
2-4

3-25.
3-26.
3-27.
3-28
3-29.
3-30.
3-31.
3-32.
3-33.

2-8
2-9
2-11
2-19
2-23
2-23
2-24
2-25
2-28
2-30
2-33
2-34
3-2
3-4
3-5
3-11
3-14
3-15
3-16
3-18
3-19
3-29
3-30
3-32
3-33
3-34
3-35
3-36
3-38
3-29
3-51
3-55
3-59
3-63
3-68
3-70
3-72
3-72.2
3-72.3
3-73
3-75
3-79
3-80
3-82
3-83
3-85
3-86

Change 15 iii

TM 5-6115-545-12
TO-35C2-3-444-1
NAVFAC P-8-626-12
TM-00038G-12

LIST OF ILLUSTRATIONS (Cont)
Number
3-34.
3-35.
3-36.
3-37.
3-38.
3-38.1.
3-39.
3-40.
3-41.
3-42.
3-43.
3-44.
3-45.
3-46.
3-47.
3-48.
3-49.
3-50.
3-51.
3-52.
3-53.
4-1.

Title

Page

Drain Hose Removed . . . . . . . . . . 3-88
Belt Adjustment and Replacement . . . . . . 3-89
Alternator and Related Parts . . . . . . . . 3-90
Speed Switch . . . . . . . . . . . . . . . . . . 3-91
Oil Level Gage and Adapter and
Filler Elbow and Cap . . . . . . . 3-92
Electrical Starter Removal . . . . . . . . . 3-94
Secondary Fuel Filter Assembly . . . . . 3-95
Lube Oil Cooler . . . . . . . . . . . . . . . . . 3-97
Nozzle Holder and Line Assemblies. . . 3-99
Diffuser and Turbocharger . . . . . 3-101
Water Pump and Fan . . . . . . . . . . . . 3-104
Thermostat and Housing . . . . . . . . . . 3-105
Idler Pulley and Mounting Bracket . . . 3-107
Intake Manifold . . . . . . . . . . . . . . . . 3-109
Exhaust Manifold . . . . . . . . . . . 3-109
Rocker Arm Shaft Assembly . . . . . 3-111
Valve Locations . . . . . . . . . . . . . . . . 3-111
Base Group and Related Components . . . . . . . . . 3-113
Base Group . . . . . . . . . . . . . . . . . . . 3-114
Fuel Quantity Transmitter Set . . . . . . . . 3-115
Accessory Items with Attaching
Hardware . . . . . . . . . . . . . . . . . . . . 3-116
Fuel Burning Winterization Kit
(2 Sheets) . . . . . . . . . . . . . . . . . . . 4-3

Number
4-2.
4-3.
4-4.
4-5.
4-6.
4-7.
4-8.
4-9.
4-10.
4-11.
4-12.
4-13.
4-14.
4-15.
4-16.
4-17.
4-18.

Title

Page

Fuel Burning Winterization Kit
Control Box Lamp
Replacement . . . . . . . . . . . . . . 4-8
Fuel Regulator Valve Adjustment . . . . . 4-9
Adjusting Flame Switch . . . . . . . . 4-10
Thermostat Switch Replacement . . . . . . . . 4-10
Electric Winterization Kit
Schematic Wiring Diagram . . . . . . . . . 4-12
Electric Winterization Kit
(3 Sheets) . . . . . . . . . . . . . . . . . . . . . .
4-13
Coolant Pump Motor - Brush and
Connector Replacement . . . . . . . . . . 4-18
Electric Winterization Kit Control
Box Fuse and Lamp Replacement . . 4-20
Running Gear Assembly . . . . . . 4-22
Hand Lever and Bracket Assembly . . . . . . 4-24
Hub and Brake and Front Unit Axle
Assemblies (2 Sheets) . . . . . 4-26
Load Bank Schematic Diagram . . . . 4-31
Load Bank (2 Sheets) . . . . . 4-33
Fan and Motor Assembly . . . . . . 4-36
Wiring Diagram Load Bank . . . 4-39
Voltage Selector Switch Contact
Positions . . . . . . . . . . . . . . . . . 4-41
Load Selector Switch Contact
Positions . . . . . . . . . . . . . . . . . . 4-41

LIST OF TABLES
Number
1-1
2-1
2-2
3-1
3-2
3-3
4-1
4-2
4-3
4-4
4-5
4-6
4-7
4-8

iv

Change 13

Title

Page

Difference in Performance Characteristics . . . . . . . . . . 1-40
Freezing Points, Composition, and Specific Gravities of Military
Anti-freeze Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Fault Indicator Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Preventive Maintenance Checks and Services . . . . . . . . . . . . . . . . 3-7
Fault Indicator Test Points. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Preventive Maintenance Checks and Services . . . . . . . . . . . . . . . . . . 4-2
Fuel Burning Winterization Kit Troubleshooting . . . . . . . . . . . . . . 4-7
Electric Winterization Kit Preventive Maintenance Checks and Services . 4-17
Electric Winterization Kit Troubleshooting . . . . . . . . . . . . . 4-19
Wheel Mounting Kit Preventive Maintenance Checks and Services . . . . . . . . . 4-23
Wheel Mounting Kit Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Load Bank Preventive Maintenance Checks and Services . . . . . . . 4-35
Load Bank Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37

CHAPTER 1
INTRODUCTION
Section I. GENERAL
1-1. Scope.
a. These instructions are published for use by
personnel to whom the 60 KW Diesel Engine Driven
Generator Sets are issued. The 50/60 Hertz (Mode I)
Tactical Utility (Class 2) Set is used in application
where exact frequency is not required. The 50/60
Hertz, (Mode I) Tactical Precise (Class 1) and 400
Hertz, (Mode II) Tactical Precise Sets are used in
applications which demand precise frequency control.
This manual provides information on the operation
and organizational maintenance of the equipment.
Also included are descriptions of main units and their
functions in relationship to other components.
b. Demolition of material to prevent enemy use
will be in accordance with the requirement of
TM 750-244-3. (Procedures For Destruction of
Equipment to Prevent Enemy Use for U.S. Army).
c. Preservation for shipment and storage for
U. S. Air Force will be in accordance with T. O.
35-1-4. Shipment and storage for U.S. Army will
be in accordance with TB 740-97-2.
1-2. Forms and Records.
THIS TECHNICAL MANUAL IS USED BY THE
ARMY, AIR FORCE, NAVY AND MARINE CORPS.
THE USE OF FORMS IN COMPLIANCE WITH
DIRECTIVES AS STATED HEREIN WILL BE ACCOMPLISHED ONLY BY THE PERSONNEL OF
THE SERVICE TO WHICH THEY APPLY.

propriate specification/publications
for equipment maintenance forms and
records.
b. Report of errors, omissions, and recommendations for improvement of this publication by
the individual users is encouraged. Reports
should be submitted as follows.
(1) Air Force-AFTO Form 22 direct to:
Commander, Sacramento Air Materiel Area,
McClellan Air Force Base, ATTN: MMST, California,
95652, in accordance with T0-00-5-1.
(2) Army-DA Form 2028 directly to:
Commander, U. S. Army Troop Support Command, ATTN: AMSTR-MCTS, 4300 Good fellow
Boulevard, St. Louis, MO 63120-1798.
(3) Marine Corps- NAVMC Form 10772 direct to:
Commandant, U.S. Marine Corps, ATTN: Code
LMO, Washington, D. C., 20380.
(4) Navy-by letter direct to:
Commanding Officer, U.S. Navy, Ships Parts
Control Center, ATTN: Code 783, Mechanicsburg,
Pa., 17055.
NOTE
(Army only)
Applicable Army Forms, excluding
Standard Form 46 (United States
Government Motor Vehicles Operator’s
Identification Card) which is carried by
the operator, shall be kept in manual
compartment mounted on equipment.

a. Forms and Records used by the Army will
be only those prescribed by DA Pam 738750. Those used by the Marine Corps will
be those prescribed by TM 4700-15/1.
Other Service users should refer to apSection II DESCRIPTION AND DATA
1-3. Description.
a. General. The generator sets, military models
MEP105A, MEP006A and MEP115A (fig. 1-1 and 1-2),
are portable skid mounted self contained units. They
are provided with controls, instruments and acces series necessary for operation as a single unit or in
parallel with up to two other units of the same Class
and Mode. Each set is equipped with engine oil pan
heating elements and necessary connections for field
installation of winterization kits. The generator sets
may be mounted on trailers or wheel kits if desired.
In addition, to extend their capability, the sets have
been designed to accept and operate with the following kits: (See chapter 4 for Items 1 thru 4.)

(1) Load Bank.
(2) Fuel Burning Winterization.
(3) Electric Winterization.
(4) Wheel Mounting.
(5) Automatic Transfer Panel 50/60 Hz. Provides a means to monitor 60 Hz primary power and
automatically start and transfer the load to a standby
generator set in the event of abnormal primary power
fluctuation. (See Appendix A for technical manual. )

Change 12

1-1

Figure 1-1. Engine Generator Set. Right Front, Three Quarter View
(6) Automatic Transfer Panel 400 Hz. Provides
the capacity to start and transfer the load from an
operating 400 Hz generator set to a like standby set
in the event the operating sets load contactor opens
due to a fault condition (See Appendix A for technical
manual).
(7) Remote Control Box. Permits starting,
stopping and voltage adjustment of the generator set
from a remote location. (See Appendix A for technical manual).

1 - 2 C h a n g e

7

(8) Auxiliary Fuel Burning Winterization.
Provides a dependable external source of battery
power for starting of generator set in ambient
temperatures from -25°F. to -65°F. (See
Appendix A for technical manual. )
(9) Auxiliary Electric Winterization. Provides
a dependable external source of battery power for
starting of generator set in ambient temperatures
from -25°F. to -65°F. (See Appendix A for technical manual).

Figure 1-2. Engine Generator Set, Left Rear, Three Quarter View

b. Engine. The engine is a liquid-cooled, 6 cylinder, valve-inhead, 4 stroke cycle, turbo-charged, diesel engine.

1-4. Identification and Tabulated Data.

c. Generator. The 400 Hz generator is a 60 KW, brushless,
air-cooled rotating field generator.

a. Identification. The generator set has data and instructional
plates located throughout the set. Figure 1-3 locates these
plates, and figures 1-4 through 1-20 illustrate their content. Instruction plates for kits are located in figure 1-21, and figures 1-22
through 1-24 illustrate their content.

d. Generator. The 50/60 Hz generator is a 50/60KW,
brushless, air-cooled rotating field generator.

Change 11 1 - 3

1.

Fuel System Diagram Instruction Plate
(fig. 1-4)

2.

Lifting Instructions Instruction Plate (fig. 1-5)

3.

AC Troubleshooting Diagram (Mode I) and
Plate (fig. 1-13)
AC Troubleshooting Diagram (Mode II) and
Plate (fig. 1-14)

4.

Operating Instructions Instruction Plate
(fig. 1-6)

5.

Service Instructions and System Capacities
Instruction Plate (fig. 1-7)

6.

Voltage Reconnection Instruction Plate
(fig. 1-8)

7.

Operational Data Information Plate (Mode I)
(fig. 1-9)
Operational Data Information Plate (Mode II)
(fig. 1-10)

8.

Schematic Wiring Diagram Class 1, AC and
Plate (fig. 1-17)
Schematic Wiring Diagram Class 2, AC and
Plate (fig. 1 -19)

9.

Schematic Wiring Diagram Class 1, DC and
Plate (fig. 1-18)
Schematic Wiring Diagram Class 2, DC and
Plate (fig. 1-20)

10.

DC Troubleshooting Diagram (Mode I) and
Plate (fig. 1-15)
DC Troubleshooting Diagram (Mode II) and
Plate (fig. 1-16)

11.

Battery Arrangement and Connections
Instructions Plate (fig. 1-11)

12.

Set I.D. Plate (fig. 1 -12)

13.

Fuel Selector Valve Instruction Plate

Figure 1-3. Data Instruction Plate Locations (Sheet 1 of 2)
1-4

Figure 1-3.

Data Instruction Plate Locations (Sheet 2 of 2)

_b . Tabulated Data.
(1) Engine generator set (end item).
DOD drawing no. . . . . . 70-0105 (50/60 Hz precise)
70-0006 (50/60 Hz utility)
70-0115 (400h Hz precise)
Models :
Model . . . . . . . . . . . MEP105A (50/60 Hz precise)
Model . . . . . . . . . . . MEP006A (50/60 Hz utility)
Model . . . . . . . . . . . MEP115A (400 Hz precise)
Length . . . . . . . . . . . 87 inches
Width . . . . . . . . . . . 36 inches
Height . . . . . . . . . . . 59 inches
Weight dry (less kits and optional
equip. ) . . . . . . 4400 lbs (400 Hz set)

Weight dry (less kits and optional
equip.) . . . . . . 4300 lbs (50/60 HZ precise set)
Weight dry (less kits and optional
equip.) . . . . . . 4240 lbs (50/60 HZ utility set)
Operating temperature
range . . . . . . . . . . 125°F to -25°F (-25° to -65°F
with winterization systems)
Voltage output . . . . 120/208 volts and 240/416 volts
Power factor

. . . . 0.8

Size . . . . . . . . . . . . . . 60 KW 50 KW at 50 Hz)

1-5

b.

Tabulated Data. (Cont)

Firing order . . . . . . . . . . . . . . . 1-5-3-6-2-4

(2) Engine.

Rotation (viewed from
fan end) . . . . . . . . . . . . . . . . Clockwise

COD drawing no. . . . . . . . . . 70-1049
T y p e. . . . . . . . . . . . . . . . . . . . 6 cylinder, turbocharged
diesel
Fuel . . . . . . . . . . . . . . . . . . . . Diesel fuel W-F-800
JP-4 or JP-5

Cooling . . . . . . . . . . . . . . . . . . . . Circulating coolant
Cycle . . . . . . . . . . . . . . . . . . . . . . 4 stroke
Valves . . . . . . . . . . . . . . . . . . . . . 2 per cylinder
Maximum permissible exhaust
restriction . . . . . . . . . . . . . 2 inches of mercury
Brake horsepower

CAUTION
JP-4 and JP-5 fuel are considered
emergency fuels only.

Figure 1-4.

1-6

Change 7

1500 rpm . . . . . . . . . . . . . 100
1800 rpm . . . . . . . . . . . . . 120
2000 rpm . . . . . . . . . . . . . 130

Fuel System Diagram Instruction Plate

Figure 1-5. Lifting Instructions Instruction Plate
b. Tabulated Data. (Cont)
(3) Main generator (50/60 Hz tactical utility
and tactical precise).
DOD drawing no. . . . . . . . 70-1900
Type . . . . . . . . . . . . . . . Rotating field
synchronous, brushless
with integral exciter
KVA (Kilovolt amperes). ..62. 5/75
KW . . . . . . . . . . . . . . . 50/60
volts . . . . . . . . . . . . . . . 120/208 or 240/416
(Adjustable to 197/240
or 395/480, 60 Hz
fig. 1 -9)

Phases . . . . . . . . . . . . . . . 3
power factor . . . . . . . . . . . . 0.8
Hertz . . . . . . . . . . . . . . . . . 50/60
Cooling . . . . . . . . . . . . . . . Air
Degree of enclosure . . . . . . . Drip-proof
Lubrication . . . . . . . . . . . . . None required
Drive . . . . . . . . . . . . . . . . . Direct
Duty classification . . . . . . . . Continuous
Operating speed. . . . . . . . . . 1800 rpm for 60 Hz,
1500 rpm for 50 Hz

Amperes . . . . . . . . . . . . 208/104 (173/87 at 50 Hz)
1-7

Figure 1-6.

b. Tabulated Data. (Cont)
(4) Main generator (400 Hz, tactical precise).

Power factor . . . . . . . . 0.8
Coating . . . . . . . . . .. Air

DOD drawing no. . . . . . 70-1901

Degree of enclosure . . . . . . Drip-proof

Type . . . . . . . . . . . . . Rotating field synchronous,
brushless with integral
exciter

Lubrication . . . . . . . . . . . . None required
Drive . . . . . . . . . . . . . . . . Direct

KVA (Kilovolt Amperes) . . . 75

Duty classification . . . . . . . Continuous

KW . . . . . . . . . . . . . . . ..60

Operating speed . . . . . . . . .2000 rpm

Hertz . . . . . . . . . . . . . . . . 400
Volts . . . . . . . . . . . . . l20/208 or 240/416
(Adjustable to 197/229 or
395 458 - fig, 1-10)

(5) Fuel level switch (day tank).
DOD drawing no. . . . . . 70-1594

Amperes . . . . . . . . . . 208/104

Type . . . . . . . . . . . . . Float
Current . . . . . . . . . . 3.0 amperes at
6 to 32 Vdc

Phases . . . . . . . . . . . . 3

Pressure . . . . . . . . . . 0 to 150 psi

1 - 8 Change 3

Figure 1-7. Service Instructions and System Capacities Instruction Plate

b. Tabulated

Data. (Cont)

Switch contact data

When fuel level drops below 5.75 ± 0.12 inches from top of tankUpper and lower switches are closed.
(6) Engine accessories.

Normal fuel level is 2.00±0.12 inches from top of tank.
(a)

Open continuity exists between connector pins A-B (upper
switch) and C-D (lower switch).
When fuel level drops below 2.75±0.12 inches from top of tankUpper switch is closed and lower switch opens.

Fuel transfer pumps.

Model (MS) . . . . . . . . . . . . . . . MS5132-2
Volts . . . . . . . . . . . . . . . . . . . . .24dc
psi(max) . . . . . . . . . . . . . . . . . .7
Delivery (max) . . . . . . . . . . . . .18 gallons per hr
Change 11

1-9

Figure 1-8. Voltage Reconnection Instruction Plate
( d ) Battery charging alternator.

b . Tabulated Data. (Cent)
(b) Turbocharger.

DOD drawing no. . . . . .69-780-2

Drive . . . . . . . . . . . . . . . Engine exhaust

Type drive . . . . . . . .. Belt

Type . . . . . . . . . . . . . . . Impeller

Rating

(c) Electric starter.

volts . . . . . . . . . . . ..24

Service parts type no. . . . . MS53011-1

Amperes . . . . . . . . ..35

volts . . . . . . . . . . . . . . . . 24 dc

Operating temperature
range . . . . . . . . . . . -65° F to + 175° F

Rotation at drive end .

. . Clockwise

Torque . . . . . . . . . . . 22 ft-lbs (rein) at 400
amperes, 4.0 volts
Pinion data
Pinion teeth . . . . . . . . 12 tooth (on 13 tooth blank)
Engagement . . . . . . . . Positive engagement indexing drive with overrunning
clutch
1-10

Charge rate . . . . . . . 0 to 2 amperes adjustable
with fully charged battery
Fuse . . . . . . . . . . . . . Style AGC40, 32 volts,
40 amperes
Current output . . . . . . 0 to 15 amperes,
1900-4000 rpm
at rated temperature

Figure 1-9. Operational Data Information Plate (Mode I)
—b. Tabulated Data. (Cent)
(e)
— Oil cooler.
Type . . . . . . . . . Permanent tubular element

Switch Configuration
A . . .

1 circuit N. O.

B . . .

1 circuit N. C.

Pressure Range:
(f)
— Radiator.
DOD drawing no . . . 70-1126
Capacity . . . . . . . 15 quarts
P r e s s u r e . . . . . . . 7 psi
(g) —Water Pump.
Type . . . . . . . . . Belt driven
(h) Safety devices:
—1.

Low oil pressure switch.

DOD part no. . . . . 70-1309
Contact Rating
A . . . 10 amperes 28 volt dc resistive
B . . . 10 amperes 125 volt ac resistive

500 psi maximum
Pressure Setting
A . . .
B . . .

A-D circuit trip at 18-22 psi decreasing
(N. O.)
B-C circuit trip at 18-22 psi decreasing
(N. C.)

2 . Coolant high temperature switch.
DOD drawing no. . . 69-697-3
Rating
volts . . . . . . . . . . . 28 dc
Current . . . . . . . . . 10 amperes
Trip temperature . . . . 222° F ± 3° F
3. Overspeed switch.
DOD drawing no . . . . .

70-1105-1 (400 Hz)
70-1105-2 (50/60 Hz)
Change 1

1-11

Figure 1-10. Operational Data Information Plate (Mode II)
b. Tabulated Data. (Cont)
—
Type. . . . . . . . . . Speed sensitive, manual reset

( 1 ) Primary fuel filter and strainer
assembly.

Overspeed trip . . . . 2400 to 2450 rpm, engine speed; DOD drawing no. . . . 70-507
1200 to 1225 rpm, switch speed
(m)
.— Secondary fuel filter.
Element trip speed . . S9-1 set - 290-310 rpm,
Cartridge. . . . . . . . . C-1125PL
automatic reset 190-210 rpm.
. .
(all sets)
(n)
— Ether tank.
S9-2 set -825-850 (400 Hz)
rpm, automatic reset 725-750
rpm. Set -590-610 rpm (50/
60 Hz) automatic reset 490510 rpm.
S9-3 set -1200-1225 rpm,
manual reset. (all sets)
(i) Oil filters (2).
Type . . . . . . . . . . Replaceable element
(j) Batteries (2).
Service part type no. . MS35000-3
volts . . . . . . . . . 12 dc
Connections . . . . . . series for 24 volts
(k)
— Ether solenoid.
DOD drawing no . . . . 70-1609
Volts . . . . . . . . .24dc
1 - 1 2 Change 1

DOD drawing no. . . . 70-1608
Capacity (fluid ounces,
ethyl ether) . . . . . 26.7
(o)
— Lube oil pressure transmitter.
DOD drawing no. . . . 69-779
Voltage rating . . . . . 24 Vdc
Pressure range . . . . 0-120 psi
Resistance
0.0 to
1.5 to
14.5 to
28.0 to

(ohms) pressure (psi)
1.0 ------ 0
3.0 ------ 10
16.5 ----- 60
31.0 ----- 120

( p ) Temperature

transmitter.

DOD drawing no. . . . 69-781
Voltage rating . . . . . 24 Vdc
Temperature range . . 120° F to 280° F

Figure 1-11. Battery Arrangement and Connections Instruction Plate
b.

Tabulated Data. (Cont)

Resistance (ohms)

(9) Lubricating system.
Type system . . . . . . . . . . . Full flow, circulating
pressure

2360 ± 10 percent at 120° F
Oil pump type
710 ± 5 percent at 200° F
310 ± 8 percent at 280° F
(7) Capacities.
Fuel tank . . . . . . . . 55 gallons
Usable fuel . . . . . . ..50 gallons
Engine crankcase. . . .20 quarts
Engine cooling system . . . . . . 33.5 quarts
Hydraulic governor system
(See fig. 1-28.) . . . . . . . . 5 quarts
(8) Cooling system.
stabilized coolant
temperature
(minimum) . . . . . .180° F
Water pump type . . . . Centrifugal, belt driven

Oil pressure range,
hot, at rated
speed . . . . . . . . . . . . . .

Gear, positive
displacement

30-55 psi

Pressure regulation
governed by . . . . . . . . . . Regulation valve
Nominal oil capacities:
Oil change . . . . . . . . . . . . .20 quarts
Crankcase and
oil filters . . . . . . . . . . .26 quarts
Lubricating oil
filters . . . . . . . . . . . . . Dual full flow
(10) Valve data.
Valve lash adjustment.
Intake valve clearance (hot) . . 0.015 inch

Change 3

1-13

Figure 1-12. Set I. D. Plate
b . Tabulated Data. (Cont)
(13) Belt deflections.
Intake valve
clearance (cold) . . . . 0.018 inch
Exhaust valve
clearance (hot) . . . . 0.015 inch
Exhaust valve
clearance (cold). . . . 0.018 inch
(11) Governor (mechanical).
Type . . . .. ..
Variable speed, flyball
Regulation . . . . . . . 2-3%
(12) Torque data.
NOTE
Torque values with threads lubricated
with engine oil.
Exhaust manifold screws.25 ft - lbs (12 ft lb
increments)

Fan drive belt . . . . . . 9/32 inch at 12 to
14 lb force (measured at
center point between pulleys)
Alternator belt . . . . . 9/64 inch at 3 to
5-1/4 lb force (measured
center point between pulleys)
(14) Shipping dimensions and weights (fig. 1-25).
108 inches crated
87 inches uncrated

Length

Width . . . . . . . . . . . . . . . . . . . ..48 inches crated
36 inches uncrated
Height . . . . . . . . . . . . . . . . . . 72 inches crated
59 inches uncrated
Weight (50/60 Hz utility set) . . . . . 4740 lbs (approx)
(crate included)

Engine lube oil filter
assembly mounting screws . . . . . 50 ft - lbs

Weight (50/60 Hz precise set) . . . . 4800 lbs (approx)
(crate included)

Intake manifold securing
capscrews . . . . . . . . . . . . . . .33 ft - lbs

Weight (400 Hz set) . . . . . . . . . . . 4900 lbs (approx)
(crate included)

L OW oil pressure
switch . . . . . . . . .20 ft - lbs

Volume . . . . . . . . . . . . . . . . . ..216 cubic feet
(15) Optional equipment.

Injector hold-down
13 ft - lbs
capscrews . . . . . . (6 ft lb increments)
Turbocharger locknuts . . . . . . . . . 21 ft - lbs
Water pump mounting screws . . . . . 33 ft - lbs
Fan to pump mounting screws . . . . 35 ft - lbs
1-14
Change 1

(a)
— Fuel burning winterization kit.
DOD drawing no. . . . . . . . . . . . 70-1297
Volts . . . . . . . . . . . . . . . . . . . . .24Vdc

& Tabulated Data. (Cent)
Amperes (above 30°F) . . . . . . . . . . . . . . . . . . . .. Start 14.5.
run 5.0
Amperes (below 30 IF) . . . . . . . . . . . . . . . . . . . .. Start 17.5.
run 7.5
Fuel consumption . . . . . . . . . . . . . . . . . . . . . . . ..21 -23cc/min
(700F)

(17) Maintenance and operating supplies.
Refer to Appendix B for a complete list of maintenance and operating supplies required for initial operation.
1-5. Difference in Models
This manual covers generator sets model MEPO06A, MEP105A,
and ME P1 15A. Model ME PO06A is a 50/60 Hz utility set (Class
2 Model MEP105A is a 50/60 Hz precise set (Class I Mode I), and
model MEP115A is a 400 Hz precise set (Class I Mode II).

Duty cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..continuous
(b).
— Electric winterization kit.
DOD drawing no . . . . . . . . . . . . . . . . . . . . . . . ...70-1299
Input power . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..205 t0240 volts
50/60 or 400 Hz
single phase
Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...14.6/12.5 amperes
at 205/240 Vac
Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thermostat shutoff at 1500F +5°
on at 130 °F~50

@ Wheel mounting kit.
DOD drawing no . . . . . . . . . . . . . . . . . . . . . . . ...70-1256
Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..50001bs
Max speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..5mph onpaved
surfaces
Tmmangle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..40 °pivot
Tire pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . ..60psi

@ Load bank.

The difference between precise and utility 50/60 Hz and 400 Hz
generator sets are noted in the appropriate paragraphs throughout the manual. Figures 1-26 and 1-27 show the harness interconnection for these models. These differences are summarized as
follows:
~ The generator used on models MEPO06A and MEP105A is a
50/60 Hz generator. That used in Model MEP115A is a 400 Hz
generator.
~ The governor used on model MEP105A is an electrohydraulic governor consisting of a governor control unit, load
measuring unit and hydraulic sump, filter, pump and actuator
(See fig. 1-28). An electric governor is used on model MEP115A.
The governor control unit on MEP105A is 50/60 Hz, and 400 Hz
on MEP1 15A. The load measuring unit however is used on all
models. Frequency is controlled by a rheostat on the control
panel on MEP115A and MEP105A unit. The governor used on
model MEPO06A is a mechanical governor which is integral with
the fuel injection pump. Frequency is adjusted by a manual
speed control.
g The same special relay box is used on models ME P105A
and MEPO06A, but model MEP105A also has a precise relay box.
The precise relay box contains a frequency selector switch, under
frequency relay, undervoltage relay, permissive paralleling relay,
governor feedback capacitor and frequency adjust fixed resistors.
The special relay box used on model MEP1 15A contains the same
components as that used on models ME PO06A and ME P105A,
and also those contained in the precise relay box with the excep
tion of the frequency selector switch.

DOD drawing no . . . . . . . . . . . . . . . . . . . . . . . ...70-1271
Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..30KW
Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64/42 amperes
Input voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . ..120/2080r
240/416, 3-phase, 4
wire
(16) Wiring diagrams. (figs. 1-13 thru 1-20: 1-29 and 1-30)

< The control cubicle contains some componets which are
different on the various models.
g The exciter regulator assembly and the cross current
transformer, on the current transformer assembly, are different
on model MEP1 15A to those on the other two models.
& The differences in performance characteristics of the various
models are shown in table 1-1.

Change 11

1-15/(1-16

blank)

TM 5-6115-545-12

Figure 1-31.1

Change

11

1-18.1/(1-18.2

blank)

TM 5-6115-545-12

Figure 1-15.1 Troubleshooting Diagram, MEP115A

C h a n g e 1 1 1-22.1 /(1-22.2 blank)

Figure 1-17. Schematic Wiring Diagram
Class 1, AC and Plate
Change 1 1-25/(1-26 blank)

TM 5-6115-545-12

Figure 1-17.1 Schematic Wiring Diagram, MEP 115A
Change 11

1-26.1 /(1-26.2 blank)

Figure 1-18.

Schematic Wiring Diagram
Class 1, DC and Plate
Change 1 1-27/(1-28 blank)

TM 5-6115-545-12
TO-35C2-3-444-1
NAVFAC P-8-626-12
TM-00038G-12

Figure 1-18.1 Schematic Wiring Diagram, MEP 115A

Change 14 1-28.1/(1-28.2

blank)

Figure 1-19. Schematic Wiring Diagram
Class 2, AC and plate
Change 1 1-29/(1-30 blank)

Figure 1-20.

Schematic Wiring Diagram
Class 2, DC and Plate
Change 1 1-31/(1-32 blank)

1. Load Bank Connection and Operation Instruction Plate (fig. 1-24).
2. Electric Winterization System Diagram and Electric Heater Control Schematic Diagram
Instruction Plate (fig. 1-23).
3. Fuel Burning Winterization System Diagram and Heater Control Schematic Diagram
Instruction Plate (fig. 1-22).
4. Remote Operation Instruction Plate.

Figure 1-21. Kit Data and Instruction Plate Location (Sheet 1 of 2)
1-33

Figure 1-21. Kit Data and Instruction Plate Location (Sheet 2 of 2)
1-34

Figure 1-22. Fuel Burning Winterization System
Diagram and Heater Control Schematic
Diagram Instruction Plate
Change 1 1-35/(1-36 blank)

Figure 1-23. Electric Winterization System Diagram
and Electric Heater Control Schematic
Diagram Instruction Plate
1-37/(1-38 blank)

Figure 1-24. Load Bank Connection and Operation Instruction Plate

Figure 1-25. Shipping Crate

Change 3 1 - 3 9

Table 1-1. Differences in Performance Characteristics
MEP006A

MEP105A

MEP115A

1. Voltage
(a) Dip with application of
rated load.

20% max.

15% max.

12% max.

(b) Rise with rejection of
rated load.

20% max.

15% max.

12% max.

(c) Dip or rise with application of simulated
motor load.

40% max.

30% max.

25% max.

(d) Adjustment range

50 Hz +2.5%
-10%

50 Hz +2.5%
-10%

400 Hz +10%
-5%

60Hz +15%
-5%

60Hz +15%
-5%

2 to 3%

Within

Within

± 0. 25%

±0.25%

Within

Within

Within

2% bandwidth

0.5% bandwidth

0.5% bandwidth

Within

Within

Within

3% bandwidth

1% bandwidth

1% bandwidth

(d) Undershoot with application of rated load.

3% max.

1.5% max.

1.5% max.

(e) Recovery after application
of rated load.

Within

Within

Within

3 seconds

1 second

1 second

(f) Overshoot with rejection
of rated load.

4% max.

1.5% max.

1.5% max.

(g) Recovery after rejection
of rated load.

Within

Within

Within

3 seconds

1 second

1 second

(h) Drift (60° F change).

1%

0.5%

0.5%

(i) Adjustment range

45-65 Hz

50 Hz

390 to 420 Hz

2. Frequency
(a) Regulation.

(b) Short term steady state
stability.
(c) Long term steady state
stability.

48 to 52 Hz
(Manual)

60 Hz
58 to 62 Hz

1-40

Figure 1-26. 50/60 Hz Precise and Utility
Interconnecting Diagram
Change 1 1-41/(1-42 blank)

Figure 1-27. 400 Hz Precise
Interconnecting Diagram
Change 1 1-43/(1-44 blank)

Figure 1-28. Hydraulic Flow Diagram (MEP105A)

Change 11

1-45/(1-46

blank)

TM 5-6115-545-12
TO 35C2-3-444-l
NAVFAC P-8-626-12
TM-00038G-12
CHAPTER 2
INSTALLATION AND OPERATING INSTRUCTIONS
Section I. SERVICE UPON RECEIPT OF MATERIEL

2-1.

Unloading Equipment.

The dry weight of the engine generator set is 4240 pounds
(50/60 Hz utility set), 4300 pounds (50/60 Hz precise set) or
4400 pounds (400 Hz set). A crane, fork lift or similar lifting
device or fabricated skids must be used to unload the equipment.
The equipment must be kept in the UP position while unloading.
WARNING
Do not use a lifting device with a capacity of less
than 6,000 pounds. Do not allow the crated
generator set to swing while it is suspended. Failure
to observe this warning may result in serious injury
or death to personnel.
2-2. Unpacking the Equipment.
a. Before unpacking, move the engine generator set as near
as possible to the location where it will be operated.
CAUTION
Exercise care in the use of bars, hammers, and
similar tools while uncrating the unit to avoid
damaging the equipment.
b. Remove the top and then the sides of the crate
(fig. 1-25).
c. Remove barrier bag, dessicant bags, and shipping
material from engine generator set.
d. Disconnect engine generator set from crate skid by
removing carriage bolts, nuts, washers, and lift set off of skid
crate.
2-3. Inspecting and Servicing the Equipment.
a. Preparation. Prepare the engine generator set for
inspection and operation as outlined in the following paragraphs.
For Army users refer to DA Form 2258.
b. Inspection.

Inspection is to be performed as follows:

(1) Inspect radiator for damage and foreign material
(table 3-l).
(2) Inspect all air cleaner connections for tightness and
damage.
(3) Check fan belts and alternator drive belt for correct
adjustment (table 3-1 )
(4) Check engine intake (fig. 3-5) and exhaust systems
(fig. 3-12) to make certain they are unobstructed by foreign
material.

(5) Inspect the fuel, water and coolant lines for cracks,
leaks, or other damage (table 3-l).
(6) If cooling system shutoff cock (21, fig. 3-29) and/or
crankcase drain plug (11, fig. 3-50) have been removed, install
them properly. Check that these drain cocks are closed. Check
that oil cooler drain plug is installed.
(7) Check that main fuel tank drain cock (fig. 3-7) and
day tank drain cock (36, fig. 3-27) are closed.
(8) Make a thorough visual inspection of the entire
engine generator set for loose or missing mounting hardware, or
damaged or missing parts. Report all damaged or missing parts
on DD Form 6.
(9) (AF Only) Assure that the noise level warning sign
is stenciled on the top half of both rear (generator end of set)
side doors as shown on fig. 2-1 A.
c. Servicing. Servicing of the equipment is to be
performed as follows:
WARNING
Do not smoke or use an open flame in the vicinity
when filling fuel tank.
WARNING
Hot refueling of generators while they are operating
poses a safety hazard and shall not be attempted.
Hot engine surfaces and sparks produced from the
engine and generator circuitry are possible sources of
ignition. Severe injury, death and/or damage to
equipment may result.
(1) Fill fuel tank with appropriate fuel through filler
neck and set FUEL SELECTOR VALVE (A, fig. 2-5) to SET
TANK position to connect main fuel tank to electrical fuel
pumps. If an auxiliary source of fuel is to be used in operating
the engine generator set, connect fuel hose to AUXILIARY
FUEL CONNECTION and set FUEL SELECTOR VALVE to
AUXILIARY position.
(2) Fill radiator with arctic antifreeze solution, the
standard coolant for this engine generator set, in accordance
with table 2-1. In case of emergency, water with rust inhibitor
can be used. Depreservation of the cooling system includes
draining the cooling system (para 3-41) and cleaning the system
with low pressure steam or, if steam is not available, with hot
water. Depreservation requires that the coolant in the lube oil
cooler also be drained and refilled (para 3-199).

Change 18 2 - 1

Table 2-1. Freezing Points, Composition, and Specific Gravities of Military Antifreeze Materials.

Pints of
inhibited
glycol per
gallons of
coolant

Lowest
expected
ambient
temperature
o
F

1

2

3

+20

1½

+10

2

Compound, antifreeze

Ethylene glycol
coolant solution
specific gravity

Arctic2

68oF3

Issued full strength
and ready mixed for
o

o

1.022
1.036

0

2¾

0 to -65 F temperatures

1.047

-10

3¼

for both initial

1.055

-20

3½

installation and

1.062

-30

4

replenishment of

1.067

-40

4¼

losses.

1.073

-50

Arctic

-60

antifreeze

WITH WATER OR

-75

preferred

ANY OTHER SUBSTANCE

DO NOT DILUTE

Maximum protection is obtained at 60 percent by volume (4.8 pints of ethylene glycol per gallon of solution.)

Military Specification MI L-A-11755 Arctic type, nonvolatile antifreeze compound is intended for use in the cooling system of liquid-cooled
internal combustion engines. It is used for protection against freezing primarily in Arctic regions where the ambient temperature remains
for extended periods close to -40 oF or drops below, to as low as -75°F.

Use an accurate hydrometer. To test hydrometer, use 1 part ethylene glycol antifreeze to 2 parts water. This should produce a hydrometer
reading of 0oF. Fasten a tag near the radiator tiler cap indicating the type antifreeze,
WARNING
Do not smoke or use an open flame in the vi.
cinity when servicing batteries. Batteries
generate hydrogen, a highly explosive gas.
Electrolyte contains sulfuric acid and can
cause severe burns. Handle it with care. If
the solution comes in contact with the body,
eyes or clothing, rinse immediately with
clean water. Avoid spilling electrolyte on
painted surfaces.

Slave receptacle is to be used
when extra cranking power is
required for starting unit.
Other methods are not authorized, as

arcing

at

batteries

could occur.
(3) Batteries are shipped in a dry state. Battery electrolyte
must be requisitioned separately. To activate the battery remove
cell caps and fill battery cells with electrolyte. Make sure vent
holes in cell caps are open, and replace caps.

2-2

Change 12

The electrolyte level must be rechecked approximately 30
minutes after initial filling as the plates and separators will absorb the solution, thus, resulting in a low level. If the battery is
not used within 12 hours after initial filling,it should be put on
a charger and brought up to the correct specific gravity. Test
batteries as described in paragraph 8-82b. for the ambient temperature in effect.
(4) Check crankcase oil level (para3-3c.) and add oil as
necessary (para 3-4c. ) in accordance with the lubrication order
(fig. 3-l). Depreservation requires that the crankcase be drained
and refilled (para 3-46).
(4a) Class 1 sets only. (MEP105A). Check hydraulic oil level
and add oil as necessary in accordance with the lubrication order
(fig. 3-1).
(5) Perform the before operation preventive maintenance
services specified in table 3-1.
2-4. Installation of Separately Packed Components.
No separately packed components are shipped with generator
sets.

WARNING

2-5. Installation and Setting-up Instructions.
a . General. The engine generator set should be
installed on a level site, clear of obstacles, and with
ample ventilation. The site must be within 25 feet
of any paralleled generator set, 25 feet of any auxiliary fuel supply and 500 feet of any remote control
area.
b . Outdoor Installation. When preparing for a
permanent installation, be sure the base is solid
enough to support the weight of the unit. See figure
2-1 for dimensions of the base. Select a location
where there will be sufficient space on all sides for
servicing and operation of the engine generator set.
When preparing a temporary installation, move the
engine generator set as close to the worksite as
practical. Use suitable planks, logs, or other
material for a base in an area where the ground is
soft .
c . Indoor Installation. Keep the area well ventilated at all times, so that the engine generator set
will receive a maximum supply of air. If a free
supply of fresh air is not available, provide duct
work, with an opening at least as large as the radiator,
to the outside of the installation. If louvers are used
at the air entrance, increase the duct work size by
25 to 50 percent. Loosen the screw and nut which
secure the weather cap to the exhaust outlet and re move the weather cap. Install a gas-tight metal pipe
exhaust from the exhaust outlet to the outside of the
installation. The termination of the exhaust pipe
shall be such that hot gases or sparks will be dis charged harmlessly and will not be directed against
combustible material or into an area containing
flammable gases or vapors. Use as few bends in
the pipe and as short a pipe as possible. The exhaust pipe should include a low point with suitable
means for draining of condensate. Provide metal
shields, 12 inches larger in diameter than the exhaust pipe where the line passes through flammable
walls. Wrap the exhaust pipe with asbestos if there
is any danger of anyone touching it. Refer to figure
2-1 for dimensions, air flow requirements and floor
loading requirements.

Do not operate the engine generator set in an
enclosed area unless the exhaust gases are
piped to the outside. Inhalation of exhaust
fumes will result in serious illness or death.
d . Leveling, The engine generator set is a
portable unit and is designed to operate satisfactorily
up to 15° out-of-level. Set up the unit as level as
possible and keep it as level as possible during
operation.
e. Grounding. The engine generator set must be
grounded prior to operation. The ground can be, in
order of preference, (1) an underground metallic
water piping system, (2) a driven metal rod or
(3) a buried metal plate (fig. 2-2). If the effectively
grounded portion of the buried metallic water pipe
is less than 10 feet due to insulated sections or
joints, this preferred grounding method must be
supplemented by an additional driven metal rod
ground or a buried metal plate ground. A driven
metal ground rod must have a minimum diameter
of 5/8 inch if solid or 3/4 inch if pipe, and driven
to a minimum depth of 8 feet. A buried metal
ground plate must have a minimum area of 9 square
feet, minimum thickness of 1/4 inch, and be buried
at a minimum depth of 4 feet. The ground lead
must be at least No. 6 AWG (American Wire Gauge)
copper wire. Ground rods are available as optional
equipment. The procedures for making a ground
connection are shown in figure 2-2.
f. Generator Load Connections. Instructions
for making the required generator load connections
are designated in figure 2-3.
2-6. Equipment Conversion.
a. Conversion instructions for equipment operation at 120/208 Vac or 240/416 Vac are given in
figure 2-4.
b . Conversion instructions for equipment operation of 50 or 60 Hz are given in figure 2-6.
c . Conversion instructions for remote operation
by removal and relocation of the control cubicle are
given in paragraph 2-23.

Figure 2-1A. Noise level warning.
Change 2

2-3

2-4

Figure 2-1.

Figure 2-2. Grounding Procedures (Sheet 1 of 3)
C h a n g e 3 2-5

Figure 2-2. Grounding Procedures (Sheet 2 of 3)
2-6 Change 3

TM 5-6115-545-12
TO-35C2-3-444-1
NAVFAC P-8-626-12
TM-00038G-12

Figure 2-2.

Grounding Procedures (Sheet 3 of 3)
Change 3 2 - 7

TM 5-6115-545-12
TO-35C2-3-444-1
NAVFAC P-8-626-12
TM-00038G-12

WARNING
LETHAL VOLTAGES ARE PRESENT AT THE LOAD CONNECTION BOARD OF
THE GENERATOR SET DURING OPERATION. DO NOT ATTEMPT TO CONNECT OR DISCONNECT LOAD LEADS WHILE THE GENERATOR SET IS
DO NOT ATTEMPT TO CONNECT OR DISCONNECT LOAD
OPERATING.
LEADS WITH THE GENERATOR SET SHUTDOWN AND THE LOAD CONNECTED
TO ANOTHER POWER SOURCE, OR WHILE THE GENERATOR SET IS
PARALLELED TO ANOTHER THAT IS OPERATING. WHEN MAKING ANY
ELECTRICAL CONNECTIONS, MAKE SURE THE DC CONTROL CIRCUIT
BREAKER (FIG. 2-5) IS OPEN AND THE NEGATIVE BATTERY TERMINAL
IS DISCONNECTED.

TO PREVENT WATER AND MOISTURE DAMAGE TO CABLE,
ROUTE THE POWER CABLE THROUGH THE LEATHER OR CANVAS BOOT.
AFTER THE END OF THE BLACK INSULATION IS INTO THE BOOT,
SECURE THE BOOT AROUND THE CABLE BY PULLING THE DRAW STRING.
NEXT ROUTE THE CABLES OVER THE TERMINAL BOARD. THEN DOWN
AND AROUND TO THE PROPER TERMINAL.

ONE OR MORE SINGLE-PHASE
COMBINATION WITH 3-PHASE
PHASE MUST NOT EXCEED 33
THE ENGINE GENERATOR SET

NOTE
LOADS CAN BE SERVED ALONE OR IN
LOADS, BUT THE LOAD ON ANY ONE
PERCENT OF THE CURRENT RATING OF
(PHASE BALANCE IS 5 PERCENT).

STEP 1. 208V OR 416V SINGLE-PHASE LOAD CONNECTIONS. USING WRENCH PROVIDED, CONNECT
FIRST LOAD TO L1 AND L2. CONNECT SECOND LOAD TO L2 AND L3. CONNECT THIRD LOAD TO
L1 AND L3.
STEP 2. 120V OR 240V SINGLE-PHASE LOAD CONNECTIONS. CONNECT FIRST LOAD TO L1 AND L0.
CONNECT SECOND LOAD TO L2 and L0. CONNECT THIRD LOAD TO L3 AND L0.
STEP 3. 3-PHASE LOAD CONNECTIONS. THE PHASE SEQUENCE OF THE ENGINE GENERATOR SET
OUTPUT IS L1-L2-L3 AND INSURE THAT THE EXTERNAL LOAD IS APPROPRIATELY CONNECTED.
Figure 2-3.
2 - 8 Change 14

Generator Load Terminal Board Connections

TM 5-6115-545-12
TO-35C2-3-444-1
NAVFAC P-8-626-12
TM-00038G-12

Figure 2-3.1.

Parallel Connection

Change

14 2-8.1

TM 5-6115-545-12
TO-35C2-3-444-1
NAVFAC P-8-626-12
TM-00038G-12

Figure 2-3.2. Parallel Connection.
2-8.2

Change 13

Figure 2-4.

Voltage Conversion
Change 7 2-9

Section II. MOVEMENT TO NEW WORKSITE
(5) Disconnect the ground lead from the
ground terminal stud (fig. 2-2).

Dismantling for Movement.

2-7.

WARNING

(6) Disconnect any other external hoses,
lines and cables, if used.

Make certain that engine generator set is
not operating in a standby mode, or connected to a parallel bus.

(7) Close and secure all doors and panels.
b. Movement.

a. Preparation for Movement.
(1) Disconnect the load cables from the load
terminal board (fig. 2-3) and tag for identification.
(2) Remove the exhaust pipe extension, if
used .
(3) Drain fuel (fig. 3-7) and coolant (para
3-41) if transportation by railroad is anticipated
or the distance to be traveled is great.

(2) If the engine generator set is to be
moved a long distance, or if the terrain is
unsuitable for towing, prepare engine generator
set for moving as described in paragraph 2-7 a.
2-8.

(4) Refer to the basic issue item list
(Appendix B) and make sure that all items are
present and properly stowed.

Section III.

(1) If the engine generator set is to be
moved only a short distance and the terrain is
suitable, attach a suitable towing device to the
towing openings of the engine generator set and
tow the engine generator set to the new worksite.

Reinstallation after Movement.

Refer to paragraph 2-5 for reinstallation after
movement to a new worksite.

CONTROLS AND INSTRUMENTS

2-9. General.

2-10.

This section describes and illustrates the various
controls and instruments required for generator
set operation.

The purpose of the generator set controls and
instruments and the normal and scale readings of
the instruments are illustrated in figure 2-5.

2-10

Controls and Instruments.

Figure 2-5. Generator Set Controls and Instruments (Sheet l of 6)
C h a n g e 3 2-11

Figure 2-5. Generator Set Controls and Instruments (Sheet 2 of 6)
2-12

Figure 2-5. G e n e r a t o r Set Controls and Instruments (Sheet 3 of 6)
Change l

2-13

Figure 2-5.

2-14

Change 12

Figure 2-5. Generator Set Controls and Instruments (Sheet 5 of 6)
Change 1

2-15

Figure 2-5. Generator Set Controls and Instruments (Sheet 6 of 6)

2-16

Table 2-2. Fault Indicators Function
INDICATOR
(Fig. 2-5)

FUNCTION

LOW OIL PRESSURE

Lights if oil pressure drops below 20 ± 2 psi.

COOLANT HIGH TEMP

Lights if coolant temperature rises above
222 ± 3° F.

OVERSPEED

Lights if engine rpm reaches 2400 to 2450 rpm.

NO FUEL

Lights if fuel in day tank falls to level permitting
only one minute of engine operation.

SHORT CIRCUIT

Lights if output reaches 425 ± 25% of rated current.

OVER LOAD

Lights if any phase current exceeds 110% of
rated load.

UNDER VOLT

Lights (Class 1 sets only) instantaneously if output
falls below 48 volts, or 6 ± 2 sec after output
reaches 99 ± 4 volts.

UNDER FREQ

Lights on (Class 1 sets only) when output freq drops
to: Mode I - 46 ± 1 Hz for 50 Hz operation, 55 ± 1
Hz for 60 Hz operation, Mode II - 370 ± 5 Hz for
400 Hz.

REVERSE POWER

Lights if power flow into set exceeds 20% of rated
value.

OVER VOLT

Lights if output voltage rises above 153 ± 3 volts.

Change 1

2-17

Section IV. OPERATION UNDER USUAL CONDITIONS
2-11. General.

2-14. Operation of Equipment.

a . Instructions in this section are provided for
information and guidance of personnel responsible
for operation of the engine generator set.

a. Single Engine Generator Set Operation.
See-fig. 2-9 for single engine generator set operating
instructions.

b . The operator must know how to perform every
operation of which the engine generator set is capable.
This section gives instructions on starting and stopping the engine generator set, operation of the generator set and coordinating the basic motions to perform
the specific tasks for which the equipment is designed. Since nearly every job presents a different
problem, the operator may have to vary procedures
to fit the individual job.

b . Parallel Operation of Engine Generator Sets,
See-fig. 2-10 for parallel operation instructions for
up to 3 engine generator sets of the same class,
mode and size.

2-12. Starting.
a . Preparation for Starting. Instructions to be
followed when preparing to start the engine generator set are shown in figure 2-6. Preventive maintenance procedures to be performed before operation are given in table 3-1.
b . Starting. After performing the preparation
for starting procedure of paragraph 2-12a, start the
engine generator set as shown in figure 2-7. If the
engine will not start or if any other abnormality is
observed, notify organizational maintenance
personnel.

c. Emergency Operation. If any emergency
situation requires continued operation of the engine
generator set after being shut down by one of the
safety device electrical circuits (para 2-13 b), the
BATTLE SHORT switch (fig. 2-7) can be used to
override all safety devices except the overspeed and
short circuit operation of this switch is as follows:
(1) Place BATTLE SHORT switch in OFF
position.
(2) Hold START-RUN-STOP switch in START
POSITION and start engine (fig. 2-7).
(3) Lift cover and push BATTLE SHORT
switch to ON position.
(4) Release START switch and push BATTLE
SHORT switch to OFF position as soon as possible
after emergency has passed.

2-13. Stopping.
NOTE
a . Normal Stopping. (See figure 2-8). Preventive
maintenance procedures to be performed after equipment operation are given in table 3-1.
b . Stopping by Safety Devices. The engine generator set is equipped with safety device electrical
circuits that will automatically stop the engine and
simultaneously open the main ac contactor in case
of; (1) high coolant temperature, (2) low oil pressure,
(3) engine overspeed, (4) over-voltage or, (5) no fuel.
A short circuit, overload, or reverse power protective relay will automatically open the main ac contactor but will not stop the engine. On precise class
1 engine generator sets only, under voltage and under
frequency relay protective circuits will similarly
open the main ac contactor but will also not stop the
engine. A specific FAULT INDICATOR (fig. 2-5)
will light when any of these abnormal conditions occur.
Refer to table 2-2 for the specific criteria for which
these safety device electrical circuits operate. Once
the engine generator set has been stopped due to the
action of one of these safety devices, the problem
must be corrected before the engine generator set is
placed back in operation.
c. Emergency Stopping. To stop the engine
generator set in an emergency, open DC CONTROL
CIRCUIT BREAKER (fig. 2-8).

2-18 Change 12

The BATTLE SHORT switch
may be actuated, as necessary,
any time the engine generator
set is operating.

d. Load Connections for Parallel Operation.
NOTE
Prior to attempting parallel operation,
ensure all generator sets have the same
frequency and voltage output.
WARNING
Lethal voltages are present at the load
terminal board of the generator set
during operation. Do not attempt to
connect or disconnect load leads while
the generator set is operating. Do not
attempt to connect or disconnect load
leads with the generator set shut down
and the load connected to another power

source, or while the generator set is
paralleled to another set which is operating.

(4) Connect the load to terminals
marked L1, L2, L3 and L0 (figure 2-3).
NOTE

WARNING
Do not attempt to connect the paralleling cable while either or both of
the sets to be paralleled is operating.
Make sure that there is no input to the
load from another source. Failure to
observe this warning may result in
death by electrocution.
CAUTION
Precise generator sets equipped with
the electric governor system cannot be
paralleled with sets that have the
electro hydraulic governor system.
(1) If the generator sets are to
share a load greater than the KW rating of a single set, connect load terminal boards as shown in figure 2-3A.
This arrangement allows for sharing or
transferring of the load between generator sets.
(2) Open the left access door to
the set compartment and remove the
safety cover from the terminal board
(figure 2-3).
(3) Insert load leads through
plate and sleeve assembly (figure 2-3)
located to the left of the generator
set air intake.

NOTE
The load terminal boards will accommodate 2-wire single phase and 4-wire
three phase loads. One or more single
phase loads can be served alone or in
combinations with three phase loads; but
the load on any one phase must not exceed 100 percent of the current rating
of that phase. Be sure that wire sizes
are correct for load to be carried.

Make certain that the load terminal
boards of the sets to be paralleled are
connected properly. Reading left to
right, phase rotation for the phase
loads is L1, L2, L3. Be sure L1 is
connected to L1, L2 is connected to L2,
etc.
(5) Connect load leads and paralleling cables as shown in figures 2-3A
and 2-3B.
NOTE
After load connection, tighten binding
nuts with plastic/phenolic box end
wrench and install safety cover.
NOTE
Paralleling of tactical precise generator sets requires that paralleling cables be installed and the shorting plug
located on one of the paralleling receptacles of each generator set be removed.
2-15. Exercise of Engine on Standby Service.
A diesel engine on standby service that is customarily operated under optimum conditions should be
exercised at least every 30 days. However, under
environmental conditions involving extreme temperatures, humidity, dust, sand, etc., it maybe found
necessary to shorten the interval between exercise
periods teas often as weekly. Exercise period
should be long enough to enable the engine to attain
normal operating temperature (160°-200°F) while
carrying, if possible, at least 50 percent of its
normal load. To exercise engine, proceed as
follows:
a . Perform the preparation for starting instruction shown in figure 2-6. Make complete visual
inspection of unit to be sure it is in operating condition.
b . Start engine as shown in figure 2-7. After an
acceptable warm-up period, run engine at rated speed
with whatever load is available, up to full load, for

Change 12

2-18.1/(2-18.2

blank)

Figure 2-6.

Change 11

2-19

Figure 2-6. Preparation for Starting (Sheet 2 of 2)

2-20

Figure 2-7. Starting Instructions (Sheet 1 of 2)

Change 12

2-21

Step 6. ALLOW ENGINE TO WARM UP TO NORMAL OPERATING TEMPERATURE (100 - 150 OF) WITH
NO LOAD APPLIED.
CAUTION
TO PREVENT ENGINE CARBON DEPOSITS DO NOT RUN ENGINE-GENERATOR
SETS FOR MORE THAN 5 MINUTES AT GOVERNED SPEED WITHOUT LOAD.
STEP 7. RESET FAULT INDICATOR LIGHTS BY PRESSING TEST OR RESET SWITCH. IF FAULT
INDICATORS, ARE EXTINGUISHED AFTER BEING RESET, PROCEED WITH STEP (8). IF ANY FAULT
INDICATOR LIGHTS, THE INDICATED FAULT (TABLE 2-2) MUST BE CORRECTED BEFORE PROCEEDING .
STEP 8.
SITION.
TACTOR.

CLOSE MAIN AC CONTACTOR BY MOMENTARILY PLACING CKT BKR SWITCH IN CLOSE POMOMENTARILY PLACING CKT BKR SWITCH IN OPEN POSITION WILL OPEN THE AC CON-

AMBIENT AIR TEMPERATURE BELOW MINUS 25° F
STEP 1. PREHEAT ENGINE COOLANT AND LUBRICATING OIL USING EITHER THE FUEL BURNING
OR ELECTRIC WINTERIZATION KIT CONTROLS AS SHOWN IN FIGURES 2-11 and 2-12 RESPECTIVELY .
STEP 2.
25° F.

PERFORM STARTING PROCEDURE OF STEPS 1 THROUGH 8 SPECIFIED FOR ABOVE MINUS

Figure 2-7.

2-22

Change 3

Starting Instructions (Sheet 2 of 2)

NORMAL
STEP 1. OPEN MAIN AC CONTACTOR BY MOMENTARILY PLACING CKT BRK SWITCH IN OPEN POSITION.
STEP 2. ALLOW 3 MINUTES TO ELAPSE AFTER PERFORMING STEP 1 AND PLACE START-RUN-STOP
SWITCH IN STOP POSITION.
STEP 3. AFTER ENGINE STOPS, REMOVE DC CONTROL POWER BY OPENING DC CONTROL CIRCUIT
BREAKER.
EMERGENCY
PULL DC CONTROL CIRCUIT BREAKER.

ME 6115-545-12/2-8 C3

Figure 2-8. Stopping Instructions
Change 3 2-23

STEP 1.

PREPARE ENGINE GENERATOR SET FOR STARTING (FIG. 2-6).

STEP 2.

START ENGINE GENERATOR SET (FIG. 2-7).

STEP 3. ROTATE AMPS-VOLTS SELECTOR SWITCH TO EACH PHASE POSITION WHILE OBSERVING AC
AMMETER. IF MORE THAN 100% RATED CURRENT IS INDICATED IN ANY PHASE POSITION, REDUCE
THE LOAD.
STEP 4. IF MORE THAN THE 100% PERCENT LOAD IS INDICATED ON THE KILOWATT METER, REDUCE
THE LOAD.

ME 6115-545-12/2-9

Figure 2-9. Single Generator Unit, Operating Instructions
2-24

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.

Panel illumination light
Air cleaner condition indicator
Frequency meter
Kilowatt meter
Volts-amps transfer switch
AC ammeter
AC voltmeter
Low oil pressure indicator
Coolant high temperature indicator
Overspeed indicator
No fuel indicator
Short circuit indicator
Overload indicator
Under voltage indicator
Under frequency indicator
Reverse power indicator
Over voltage indicator
Fault location indicator fuse
Test or reset switch

20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.

DC circuit breaker
Manual speed control
Battle short switch
Battle short indicator
Voltage adjust rheostat
Synchronizing lights
Operations switch
Voltage sensing switch
Panel light switch
Frequency adjust rheostat
Circuit breaker switch
Circuit breaker indicator
Start-run-stop switch
Engine primer switch
Running time meter
Battery charge ammeter
Fuel level gauge
Oil pressure gauge
Coolant temperature gauge

Figure 2-10. Parallel Operation (Load Sharing and Load Transfer) (Sheet 1 of 5 )
Change 12

2-25

A - PARALLEL OPERATION (LOAD SHARING)
STEP 1. THE FIRST SET STARTED SHALL BE DESIGNATED AS “ON-LINE” AND THE SETS IN PARALLEL OPERATION SHALL BE DESIGNATED “ON-COMING.” WITH ALL SETS SHUT DOWN INSTALL
THE PARALLELING CABLE AND CONNECT THE LOAD TERMINAL BOARDS AS DESCRIBED IN FIGURE
2-3A. CHECK THAT THE VOLTAGE RECONNECTION BOARDS (FIGURE 2-4) OF THE SETS ARE IDENTICALLY POSITIONED.
CAUTION
DO NOT PLACE THE CIRCUIT BREAKER SWITCH ON ANY OF THE GENERATOR SETS IN THE CLOSE POSITION UNTIL SPECIFICALLY DIRECTED TO DO SO. CLOSING THE CIRCUIT BREAKER SWITCH AT
ANY OTHER TIME MAY SEVERELY DAMAGE ONE OR MORE OF THE GENERATOR SETS.
CAUTION
CHECK THAT THE MAIN POWER SWITCH (FIGURE 2-3.2) AT THE LOAD
IS OPEN BEFORE ATTEMPTING TO PLACE A GENERATOR SET ON LINE.

STEP 2. START THE GENERATOR SETS AS DESCRIBED IN FIGURES 2-6 AND 2-7. DO NOT PERFORM STEP 8 OF FIGURE 2-7.
STEP 3. HOLD THE CKT BRK SWITCH (FIGURE 2-5) OF THE “ON-LINE” SET IN THE CLOSE POSITION UNTIL THE CKT BRK INDICATOR LIGHT ILLUMINATES. PLACE THE OPERATION SWITCH
IN THE PARALLEL POSITION.
STEP 4. ADJUST THE VOLTAGE ON BOTH SETS TO THE REQUIRED VALUE. ADJUST THE FREQUENCY OF THE “ON-LINE” SET TO THE REQUIRED VALUE. PLACE THE OPERATION SWITCH OF THE
“ON-COMING” SET IN THE PARALLEL POSITION.
NOTE
OBSERVE THE SYNCHRONIZING LIGHTS OF THE “ON-COMING” SET.
THE LIGHTS SHOULD GO ON AND OFF SIMULTANEOUSLY. IF THE
LIGHTS GO ON AND OFF ALTERNATELY, SETS ARE OUT OF PHASE.
STOP BOTH SETS AND CORRECT INTERCONNECTION CABLES AS DESCRIBED IN (FIGuRE 2-3.1). IF THE PROBLEM PERSISTS, REFER TO NEXT HIGHER LEVEL OF MAINTENANCE.
STEP 5. ADJUST THE FREQUENCY OF THE “ON-COMING” SET A LITTLE HIGHER THAN THE “ONLINE” SET. THEN REDUCE THE FREQUENCY SLOWLY WITH THE FREQUENCY ADJUST RHEOSTAT UNTIL THE SYNCHRONIZING LIGHTS REMAIN ON OR OFF AT 2 TO 3 SECOND INTERVALS.
STEP 6. CAREFULLY OBSERVE THE SYNCHRONIZING LIGHTS OF THE “ON-COMING” SET AND, AT
THE INSTANT BOTH LIGHTS GO DARK, PLACE THE CKT BRK SWITCH OF THE “ON-COMING” SET TO
THE CLOSE POSITION. WHEN THE CKT BRK INDICATOR LIGHT ILLUMINATES, THE SETS ARE OPERATING IN PARALLEL.

Figure 2-10. Parallel Operation (Load Sharing and Load Transfer) (Sheet 2 of 5)

2-26 Change 12

CAUTION
THE KILOWATT METER AND AC AMMETER INDICATE PERCENTAGES AND
DO NOT INDICATE TRUE KW AND AMPERE READINGS.
STEP 7. WITH NO EXTERNAL LOAD ON THE PARALLELED SETS, ADJUST THE FREQUENCY ADJUST
RHEOSTAT OF THE “ON-COMING” SET UNTIL BOTH RATED LOAD METERS (KILOWATT) READ ZERO.
ADJUST THE VOLTAGE ADJUST RHEOSTAT OF THE “ON-COMING SET UNTIL THE PERCENT OF RATED
CURRENT METERS (AMMETERS) ON BOTH SETS READ ZERO. TURNING COUNTERCLOCKWISE WILL DECREASE READINGS.
STEP 8. APPLY LOAD TO THE SETS. THE KILOWATT LOAD SHOULD DIVIDE SO THAT THE LOAD
ON EACH SET IS EQUAL. IF THE LOAD AND CURRENT ARE NOT SHARED EQUALLY, ADJUST THE
VOLTAGE AND FREQUENCY RHEOSTATS OF THE “ON-COMING” SET UNTIL LOAD AND CURRENT ARE
DIVIDED EQUALLY BETWEEN THE GENERATOR SETS.
STEP 9. THE CURRENT SHOULD DIVIDE SO THAT THE OBSERVED DIFFERENCE BETWEEN THE CURRENT ON ANY PHASE BETWEEN THE “ON-LINE” AND “ON-COMING” SETS IS NOT MORE THAN 20
PERCENT. IF THE READINGS ARE NOT WITHIN 20 PERCENT, NOTIFY HIGHER LEVEL MAINTENANCE.
NOTE
IF THE REVERSE POWER INDICATOR OF EITHER SET ILLUMINATES
AND THE MAIN LOAD CONTACTOR OPENS, OPEN THE MAIN POWER
SWITCH AND REPARALLEL THE GENERATOR SETS.
CAUTION
WHEN GENERATOR SETS ARE BEING OPERATED IN PARALLEL, ONE OR
MORE OPERATORS MUST REMAIN WITH THE SETS TO MONITOR THE RATED LOAD AND CURRENT METERS.
NOTE
TWO OR MORE GENERATOR SETS CAN BE OPERATED IN PARALLEL.
PARALLELING PROCEDURES-ARE THE SAME AS THOSE DESCRIBED
ABOVE. ONE GENERATOR AT A TIME IS BROUGHT ON LINE.
CAUTION
PRIOR TO REMOVAL OF GENERATOR SETS FROM PARALLEL OPERATION,
MAKE SURE THE LOAD DOES NOT EXCEED THE FULL LOAD RATING OF
GENERATOR SETS(S) REMAINING ON LINE.
STEP 10. TO REMOVE A GENERATOR SET FROM PARALLEL OPERATION, PLACE THE CIRCUIT
BREAKER SWITCH OF THE SET IN THE OPEN POSITION. STOP THE SET AS DESCRIBED IN FIGURE
2-8.
B - PARALLEL OPERATION (LOAD TRANSFER)
THE FOLLOWING METHOD OF PARALLEL OPERATION IS TO BE USED WHEN IT IS NECESSARY TO
TRANSFER THE LOAD FROM ONE SET TO THE OTHER WITHOUT INTERRUPTING POWER.
Figure 2-10. Parallel Operation (Load Sharing and Load Transfer) (Sheet 3 of 5)
Change 12

2-26.1

NOTE
VISUALLY CHECK THAT THE POWER CABLE AND PARALLEL CABLE ARE
IN ACCORDANCE WITH FIGURE 2-3B. IF THE CABLES ARE NOT ATTACHED AS INDICATED, SHUT DOWN THE “ON-LINE” SET AND FOLLOW INSTRUCTIONS IN PARAGRAPH 2-14D.
CAUTION
DO NOT ATTEMPT LOAD CONNECTS IN PARAGRAPH 2-14D UNLESS ALL
SETS ARE OFF AND NO OTHER EXTERNAL VOLTAGE IS APPLIED TO
THE LOAD.
STEP 1. THE SET IN OPERATION SHALL BE DESIGNATED AS “ON-LINE” AND THE SETS PLACED
IN PARALLEL OPERATION SHALL BE DESIGNATED “ON-COMING.”
STEP 20 PLACE THE OPERATIONS SWITCH (FIGURE 2-5) ON BOTH SETS IN THE PARALLEL OPERATION POSITION.
CAUTION
DO NOT CLOSE THE CIRCUIT BREAKER SWITCH AFTER STARTING THE
“ON-COMING” SET AS SERIOUS DAMAGE TO ONE OR BOTH GENERATOR
SETS MAY RESULT.
STEP 3. REFER TO FIGURE 2-6 AND 2-7 (DO NOT PERFORM STEP 8 OF FIGURE 2-7), AND START
THE “ON-COMING” SET.
STEP 4. NOTE THE VOLTAGE INDICATED ON THE “ON-LINE" SET. ADJUST THE VOLTAGE OF THE
“ON-COMING" SET TO THE VOLTAGE NOTED ON THE “ON-LINE” SET.
STEP 5. ADJUST THE FREQUENCY OF THE “ON-COMING” SET TO A HIGHER VALUE THAN THAT OF
THE “ON-LINE” SET.
STEP 6. SLOWLY REDUCE THE FREQUENCY OF THE “ON-COMING” SET UNTIL THE SYNCHRONIZING
LIGHTS (FIGURE 2-5) FLASH AT 2 TO 3 SECOND INTERVALS.
CAUTION
DO NOT PLACE THE CIRCUIT BREAKER SWITCH OF THE “ON-COMING”
SET IN THE CLOSE POSITION WHILE THE SYNCHRONIZING LIGHTS
ARE LIT AS DAMAGE TO ONE OR BOTH GENERATOR SETS MAY RESULT.
STEP 7. CAREFULLY WATCH THE SYNCHRONIZING LIGHTS OF THE “ON-COMING” SET. AT THE
INSTANT BOTH LIGHTS GO DARK, MOVE THE CIRCUIT BREAKER SWITCH OF THE “ON-COMING” SET
TO THE CLOSE POSITION.
STEP 8. ADJUST THE VOLTAGE AND FREQUENCY RHEOSTATS OF THE “ON-COMING” SET UNTIL
LOAD AND CURRENT ARE DIVIDED EQUALLY BETWEEN THE TWO GENERATOR SETS.
STEP 9.

MOVE THE CIRCUIT BREAKER SWITCH OF THE “ON-LINE” SET TO THE OPEN POSITION.

STEP 10. PLACE THE OPERATIONS SWITCH OF THE “ON-COMING” SET TO THE SINGLE UNIT OPERATION POSITION.
Figure 2-10. Parallel Operation (Load Sharing and Load Transfer) (Sheet 4 of 5)
2-26.2

Change 12

STEP 11. READJUST VOLTAGE AND FREQUENCY OF THE “ON-COMING” SET AS NECESSARY.
STEP 12.

REFER TO FIGURE 2-8 AND STOP THE “ON-LINE” SET.

Figure 2-10. Parallel Operation (Load Sharing and Load Transfer) (Sheet 5 of 5)

Change 12

2-26.3

1. Panel illumination light
2. Air cleaner condition indicator
3. Frequency meter
4. Kilowatt meter
5. Volts-amps transfer switch
6. AC ammeter
7. AC voltmeter
8. Low oil pressure indicator
9. Coolant high temperature indicator
10. Overspeed indicator
11. No fuel indicator
12. Short circuit indicator
13. Overload indicator
14. Under voltage indicator
15. Under frequency indicator
16. Reverse power indicator
17. Over voltage indicator
18. Fault location indicator fuse
19. Test or reset switch

Figure 2-10A.

20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.

DC circuit breaker
Manual speed control
Battle short switch
Battle short indicator
Voltage adjust rheostat
Synchronizing lights
Operations switch
Voltage sensing switch
Panel light switch
Frequency adjust rheostat
Circuit breaker switch
Circuit breaker indicator
Start-run-stop switch
Engine primer switch
Running time meter
Battery charge ammeter
Fuel level gauge
Oil pressure gauge
Coolant temperature gauge

Parallel Operation of Tactical Utility Generator Sets
(Load Sharing and Load Transfer) (Sheet 1 of 4)

2-26.4

Change 12

A - PARALLEL OPERATION OF TACTICAL UTILITY GENERATOR SETS (LOAD SHARING)
STEP 1. THE FIRST SET STARTED SHALL BE DESIGNATED AS “ON-LINE” AND THE SETS IN PARALLEL OPERATION SHALL BE DESIGNATED “ON-COMING.” WITH ALL SETS SHUT DOWN CONNECT
THE LOAD TERMINAL BOARDS AS DESCRIBED IN FIGURE 2-3. CHECK THAT THE VOLTAGE RECONNECTION BOARDS (FIGURE 2-4) OF THE SETS ARE IDENTICALLY POSITIONED.
CAUTION
DO NOT PLACE THE CIRCUIT BREAKER SWITCH ON ANY OF THE
GENERATOR SETS IN THE CLOSE POSITION UNTIL SPECIFICALLY DIRECTED TO DO SO. CLOSING THE CIRCUIT BREAKER
SWITCH AT ANY OTHER TIME MAY SEVERELY DAMAGE ONE OR
MORE OF THE GENERATOR SETS.
CAUTION
CHECK THAT THE MAIN POWER SWITCH (FIGURE 2-3.2) AT THE
LOAD IS OPEN BEFORE ATTEMPTING TO PLACE A GENERATOR SET
ON LINE.
STEP 2. START THE GENERATOR SETS AS DESCRIBED IN FIGURES 2-6 AND 2-7.
FORM STEP 8 OF FIGURE 2-7.

DO NOT PER-

STEP 3. HOLD THE CKT BRK SWITCH (FIGURE 2-5) OF THE “ON-LINE” SET IN THE CLOSE POSITION UNTIL THE CKT BRK INDICATOR LIGHT ILLUMINATES. PLACE THE OPERATION SWITCH IN
THE PARALLEL POSITION.
STEP 4. SET “VOLT-AMPS TRANSFER SWITCH” IN THE LI-LO POSITION. ADJUST THE VOLTAGE
ADJUST RHEOSTAT UNTIL THE AC VOLTMETER INDICATES 122 VOLTS FOR THE 120/208 CONNECTION AND 244 VOLTS FOR THE 240/416 CONNECTION. ADJUST MANUAL SPEED CONTROL UNTIL
THE FREQUENCY METER INDICATES 61 HERTZ. PLACE THE OPERATION SWITCH OF THE “ON-COMING” SET IN THE PARALLEL POSITION.
NOTE
OBSERVE THE SYNCHRONIZING LIGHTS OF THE “ON-COMING” SET.
THE LIGHTS SHOULD GO ON AND OFF SIMULTANEOUSLY IF THE
LIGHTS GO ON AND OFF ALTERNATELY, SETS ARE OUT OF PHASE.
STOP BOTH SETS AND CORRECT INTERCONNECT CABLES (FIGURE
2-3.1). IF PROBLEM PERSISTS, REFER TO NEXT HIGHER LEVEL
OF MAINTENANCE.
STEP 5. ADJUST THE MANUAL SPEED CONTROL OF THE “ON-COMING” SET UNTIL THE SYNCHRONIZING LIGHTS, SIMULTANEOUSLY, REMAIN ON OR OFF AT 2 TO 3 SECOND INTERVALS.
STEP 6. CAREFULLY OBSERVE THE SYNCHRONIZING LIGHTS OF THE “ON-COMING” SET AND, AT
THE INSTANT BOTH LIGHTS GO DARK, PLACE THE CKT BRK SWITCH OF THE “ON-COMING” SET TO
THE CLOSE POSITION. WHEN THE CKT BRK INDICATOR LIGHT ILLUMINATES, THE SETS ARE OPERATING IN PARALLEL.

Figure 2-10A.

Parallel Operation of Tactical Utility Generator Sets
(Load Sharing and Load Transfer) (Sheet 2 of 4)
Change 12

2-26.5

STEP 7. WITH NO EXTERNAL LOAD ON THE PARALLELED SETS, ADJUST THE MANUAL SPEED CONTROL OF THE “ON-COMING” SET UNTIL BOTH PERCENT POWER METERS (KILOWATT) INDICATE
ZERO . ADJUST THE VOLTAGE ADJUST RHEOSTAT OF THE “ON-COMING” SET UNTIL THE PERCENT
OF RATED CURRENT METERS (AMMETERS) ON BOTH SETS INDICATE ZERO. TURNING COUNTERCLOCKWISE WILL DECREASE READINGS.
STEP 8. APPLY LOAD TO THE SETS. THE KILOWATT LOAD SHOULD DIVIDE SO THAT THE LOAD
ON EACH SET IS EQUAL. IF THE LOAD AND CURRENT ARE NOT SHARED EQUALLY, ADJUST THE
LOAD BY OBSERVING THE SET WHICH HAS THE HIGHER READING ON THE KILOWATT METER. DECREASE THE ENGINE SPEED OF THIS SET BY ADJUSTING COUNTERCLOCKWISE THE MANUAL SPEED
CONTROL IN SMALL INCREMENTS. INCREASE THE ENGINE SPEED OF THE SET WITH THE LOWER
KILOWATT READING BY ADJUSTING CLOCKWISE THE MANUAL SPEED CONTROL IN SMALL INCREMENTS.
ADJUSTMENTS SHOULD BE MADE BETWEEN BOTH SETS UNTIL THE KILOWATT METERS ARE BALANCED.
STEP 9. THE CURRENT SHOULD DIVIDE SO THAT THE OBSERVED DIFFERENCE BETWEEN THE CURRENT ON ANY PHASE BETWEEN THE “ON-LINE” AND “ON-COMING” SETS IS NOT MORE THAN 20
PERCENT. IF THE READINGS ARE NOT WITHIN 20 PERCENT, NOTIFY HIGHER LEVEL MAINTENANCE.
CAUTION
WHEN GENERATOR SETS ARE BEING OPERATED IN PARALLEL, ONE
OR MORE OPERATORS MUST REMAIN WITH THE SETS TO MONITOR THE
RATED LOAD AND CURRENT METERS. MAKE FURTHER ADJUSTMENTS
AS REQUIRED TO MAINTAIN EQUAL LOAD ON THE PARALLELED SETS.
CAUTION
PRIOR TO REMOVAL OF GENERATOR SET FROM PARALLEL OPERATION,
MAKE SURE THE LOAD DOES NOT EXCEED THE FULL LOAD RATING OF
SETS(S) REMAINING ON LINE.
STEP 10. TO REMOVE A GENERATOR SET FROM PARALLEL OPERATION, PLACE THE CIRCUIT BREAKER SWITCH OF THAT SET IN THE OPEN POSITION. STOP THE SET AS DESCRIBED IN FIGURE 2-8.
B - PARALLEL OPERATION (LOAD TRANSFER)
THE FOLLOWING METHOD OF PARALLEL OPERATION IS TO BE USED WHEN IT IS NECESSARY TO
TRANSFER THE LOAD FROM ONE SET TO THE OTHER WITHOUT INTERRUPTING POWER.
NOTE
VISUALLY CHECK THAT THE POWER CABLE AND PARALLEL CABLE ARE
IN ACCORDANCE WITH FIGURE 2-3.2. IF THE CABLES ARE NOT ATTACHED AS INDICATED, SHUT DOWN THE “ON-LINE” SET AND FOLLOW
INSTRUCTIONS IN PARAGRAPH 2-14D.
CAUTION
DO NOT ATTEMPT LOAD CONNECTS IN PARAGRAPH 2-14D UNLESS ALL
SETS ARE OFF AND NO OTHER EXTERNAL VOLTAGE IS APPLIED TO
THE LOAD.

Figure 2-l0.l. Parallel Operation of Tactical Utility Generator Sets
(Load Sharing and Load Transfer) (Sheet 3 of 4)
2-26.6

Change 12

STEP 1. THE SET IN OPERATION SHALL BE DESIGNATED AS “ON-LINE” AND THE SETS PLACED
IN PARALLEL OPERATION SHALL BE DESIGNATED “ON-COMING.”
STEP 2. PLACE THE OPERATIONS SWITCH (FIGURE 2-5) ON BOTH SETS IN THE PARALLEL OPERATION POSITION.
CAUTION
DO NOT CLOSE THE CIRCUIT BREAKER SWITCH AFTER STARTING THE
“ON-COMING” SET AS SERIOUS DAMAGE TO ONE OR BOTH GENERATOR
SETS MAY RESULT.
STEP 3. REFER TO FIGURE 2-6 AND 2-7 (DO NOT PERFORM STEP 8 OF FIGURE 2-7), AND START
THE “ON-COMING” SET.
STEP 4. NOTE THE VOLTAGE INDICATED ON THE “ON-LINE” SET. ADJUST THE VOLTAGE OF THE
“ON-COMING” SET TO THE VOLTAGE NOTED ON THE “ON-LINE” SET.
STEP 5. ADJUST THE FREQUENCY OF THE “ON-COMING” SET TO A HIGHER VALUE THAN THAT OF
THE “ON-LINE” SET.
STEP 6. SLOWLY REDUCE THE FREQUENCY OF THE “ON-COMING” SET UNTIL THE SYNCHRONIZING
LIGHTS FLASH AT 2 TO 3 SECOND INTERVALS.
CAUTION
DO NOT PLACE THE CIRCUIT BREAKER SWITCH OF THE “ON-COMING”
SET IN THE CLOSE POSITION WHILE THE SYNCHRONIZING LIGHTS ARE
LIT AS DAMAGE TO ONE OR BOTH GENERATOR SETS MAY RESULT.
STEP 7. CAREFULLY WATCH THE SYNCHRONIZING LIGHTS OF THE “ON-COMING” SET. AT THE
INSTANT BOTH LIGHTS GO DARK, MOVE THE CIRCUIT BREAKER SWITCH OF THE “ON-COMING” SET
TO THE CLOSE POSITION.
STEP 8. ADJUST THE VOLTAGE AND FREQUENCY RHEOSTATS OF BOTH SETS UNTIL LOAD AND CURRENT ARE DIVIDED EQUALLY BETWEEN THE TWO GENERATOR SETS,AS EXPLAINED IN FIGURE
2-10.1, PARAGRAPH A, STEPS 7 AND 8.
STEP 9.

MOVE THE CIRCUIT BREAKER SWITCH OF THE “ON-LINE” SET TO THE OPEN POSITION.

STEP 10. PLACE THE OPERATIONS SWITCH OF THE “ON-COMING” SET TO THE SINGLE UNIT OPERATION POSITION.
STEP 11. READJUST VOLTAGE AND FREQUENCY OF THE “ON-COMING” SET AS NECESSARY.
STEP 12. REFER TO FIGURE 2-8 AND STOP THE “ON-LINE” SET.

Figure 2-10.1. Parallel Operation of Tactical Utility Generator Sets
(Load Sharing and Load Transfer) (Sheet 4 of 4)
Change 12

2-26.7/(2-26.8 blank)

the period of time required to obtain two consecutive
water temperature readings of 160° F minimum,
taken at a 15-minute interval. Then continue t o
operate engine for 30 minutes. Check and correct
any coolant or oil leaks.
c.
Stop engine as shown in figure
2-8. If the accumulated hours of operation during the above exercise periods
do not total 300 hours (recommended lube
filters and lubricating oil change peri-

od) during a six-month period, it is
recommended that the filters and lubrieating oil be changed (para 3-4). If
the accumulated hours of operation during the above exercise periods do not
total 100 hours (recommended fuel filter
change period) during a 12-month period,
it is recommended that the fuel filter
element be replaced (para 3-160).

Section V. OPERATION UNDER UNUSUAL CONDITIONS
2-16. Operation in Extreme Cold (Below- 25°F).

2-17. Operation in Extreme Heat (up to + 125° F).

a. General. The engine generator set is designed
to operate in temperatures down to - 25°F without
winterization equipment. To operate successfully at
temperatures below -25° F, the engine must be heated
by integrally mounted electric winterization heating
equipment (fig. 2-12) which receives auxiliary power
from an external source or by a fuel burning winterization system (fig. 2-11). Operate fuel burning winterization system for 55 minutes or until fuel burning
winterization system cycles off. Operate electric winterization for 5 hrs.

a. Keep the cooling system free from rust and
scale. If necessary, add an approved rust inhibitor.
Keep cooling system filled with clean, approved
coolant. Avoid, if possible, the use of alkaline water
or salt water, which cause the accumulation of rust
and scale. Inspect the belts for proper adjustment.
Be sure that the engine generator set is free of dust
and dirt. Check for obstructions in the cooling fins
of the radiator and make sure shutter controls are
operating properly.

b . Fuel System. Keep the fuel tank as full as possible to prevent condensation of moisture. Be sure
the proper grade of fuel is used for existing temperatures. Service the fuel filters and strainers (para
3-34b) more frequently than normal. Remove ice,
snow, and moisture from the filler cap and filler
neck. At end of day’s operation, drain water from
fuel tank (fig. 3-7) and from the fuel filters (para 3-56).

b . Lubricate the engine in accordance with the
instructions in paragraph 3-3 and 3-4.

c . Engine Electrical System. Clean the batteries
and cables and inspect for cracked or damaged cases.
Be sure the battery terminals are tight, clean, and
lightly greased. See that the battery cap vent holes
are open. The electrolyte level must be 3/8 inch
above the plates. To prevent the batteries from freezing, see that they are kept fully charged. Inspect all
electrical wiring for cracks, breaks, and fraying.
Tighten loose connections.
NOTE

After adding water to the batteries
in freezing temperatures, run the
engine for at least an hour to thoroughly mix the water with the
electrolyte.
d . Lubrication. Lubricate the engine generator set
in accordance with instructions in paragraphs 3-3 and
3-4.
e . Cooli ng System. Inspect the level of the coolant
in the radiator. Inspect the cooling system for leaks,
aying particular attention to gaskets and hose connections. Verify that antifreeze mixture is in accordance with table 2-1.
f . Air Cleaner. Refer to paragraph 3-32 for proper
maintenance of air cleaner.

c. Do not fill the fuel tank too full; allow sufficient
room for fuel expansion.
d . Inspect battery electrolyte level daily. The
plates should be covered with 3/8 inch of water. Add
water if necessary.
WARNING
Exhaust discharge contains noxious and deadly fumes. Do not
operate generator sets in inclosed areas unless exhaust discharge is properly vented to
the outside.
Check that the engine generator
—e.
set is free of air-flow restrictions.
When operating indoors, make provisions
for adequate ventilation and the venting of exhaust fumes to the outside. TO
prevent excessive back pressure, it is
recommended that an exhaust extension
of flexible tubing be no longer than 20
feet (maximum).
f. Keep external surface of engine clean.
g. The unit should be allowed to run at no load to
allow the engine to cool prior to shutdown.
2-18. Operation in Dusty or Sandy Areas.

Change 12

2-27

NOTE
ELECTRIC AND FUEL BURNING WINTERIZATION KITS CAN NOT
BE OPERATED SIMULTANEOUSLY.
STARTING
STEP 1. CHECK FUEL SUPPLY AND TURN MANUAL HEATER FUEL SHUT-OFF VALVE (A) TO O N
STEP 2. OPEN BOTH COOLANT SHUTOFF VALVES LOCATED NEXT TO LUBE OIL COOLER (B) AND
THERMOSTAT ASSEMBLY (C).
STEP 3. OPEN COOLANT SELECTOR VALVE (D) BY PLACING HANDLE (IN 3-O’CLOCK POSITION)
POINTING TOWARDS FUEL BURNING HEATER.

Figure 2-11. Fuel Burning Winterization Kit Operating Instructions (Sheet 1 of 2)

2-28

Change 12

E - HEATER CONTROL PANEL
STEP 4. PRESS HEATER CIRCUIT BREAKER AND PRESS THE PRESS-TO-TEST INDICATOR, INDICATOR
LAMP SHALL LIGHT.
STEP 5. SET ON - OFF SWITCH TO ON. INDICATOR LAMP SHALL LIGHT WHEN HEATER GOES INTO RUN
CYCLE (APPROXIMATELY THREE MINUTES). OPERATE HEATER FOR 50 MINUTES OR UNTIL CYCLE
OPERATION OCCURS AS INDICATED BY EXTINGUISHING OF INDICATOR LAMP.
NOTE
IF INDICATOR LAMP DOES NOT LIGHT IN APPROXIMATELY FOUR MINUTES,
SET ON-OFF SWITCH TO OFF. WAIT THREE MINUTES BEFORE ATTEMPTING
TO RESTART HEATER.
STOPPING
STEP 1. SET ON-OFF SWITCH TO OFF. INDICATOR LAMP SHALL REMAIN ILLUMINATED UNTIL HEATER
COMPLETE PURGE CYCLE (APPROXIMATELY 4-1/2 MINUTES).
STEP 2. AFTER INDICATOR LAMP EXTINGUISHES, REENERGIZE BREAKER.
STEP 3. CLOSE BOTH COOLANT SHUTOFF VALVES (B AND C).
STEP 4. TURN MANUAL HEATER FUEL VALVE TO OFF.
STEP 5. PLACE COOLANT SELECTOR VALVE (D) HANDLE (IN 9-O'CLOCK POSITION) POINTING DIRECTLY
AWAY FROM FUEL BURNING HEATER.

ME 6115-545-12/2-11(2) C1

Figure 2-11.

Fuel Burning Winterization Kit Operating Instructions (Sheet 2 of 2)
Change 1 2-29

A - RECEPTACLE J49

B -COOLANT SELECTOR VALVE

C - SHUTOFF VALVE

D - SHUT OFF VALVE

STARTING
NOTE
ELECTRIC AND FUEL WINTERIZATION KITS CAN NOT BE OPERATED SIMULTANEOUSLY.
STEP 1. INSURE THAT A 205-240 VOLT, 50/60 OR 400 HZ, SINGLE PHASE SOURCE OF EXTERNAL POWER TO ELECTRIC WINTERIZATION KIT RECEPTACLE 49 (A) HAS BEEN CONNECTED,
STEP 2. PLACE COOLANT SELECTOR VALVE (B) HANDLE (IN 12-0’CLOCK POSITION) POINTING
STRAIGHT UP.
STEP 3. OPEN BOTH COOLANT SHUTOFF VALVES (C & D) LOCATED NEXT TO LUBE OIL COOLER AND
THERMOSTAT ASSEMBLY.
ME 6115-545-12/2-12 (1)
2-30

Figure 2-12. Electric Winterization Kit, Operating Instructions (Sheet 1 of 2)

E - ELECTRIC HEATER CONTROL BOX

STEP 4. CLOSE CIRCUIT BREAKER (E) AND SET ON-OFF SWITCH TO ON, CHECK THAT POWER ON AND
HEATER ON INDICATORS LIGHT.
STEP 5. COOLANT IS NOW BEING HEATED AND PUMP IS OPERATING.
STOPPING
STEP 1. SET ON-OFF SWITCH TO OFF AND OPEN CIRCUIT BREAKER. POWER ON AND HEATER ON
INDICATORS SHOULD BE EXTINGUISHED.
STEP 2. PLACE COOLANT SELECTOR VALVE (A) HANDLE (IN 9-O’CLOCK POSITION) POINTING
DIRECTLY AWAY FROM FUEL BURNING HEATER.

Figure 2-12.

Electric Winterization Kit. Operating Instructions (Sheet 2 of 2)
2-31

a. Where water is available, keep the immediate
area wetted down. Keep the unit as clean as possible,
paying special attention to the screens and grilles.
b . Clean filters and strainers more frequently
than under normal conditions. Be sure that all lubricant containers are tightly sealed and stored in
an area free from dust and sand.
c. Take all necessary precautions to keep dirt and
grit out of the fuel tank.

2-21. Operation at High Altitudes.
The engine generator set will operate at elevations
up to 5,000 feet above sea level without special adjustment or reduction in load. At 8, 000 feet above
sea level, the 50/60 kw rating is reduced to 45 54
kw. Since higher altitudes also increase the possibility of freezing, the coolant antifreeze protection
should be checked (table 2-1) and the batteries should
be tested (paragraph 3-82 b). A reduction in the load
may be also be necessary since engines are more
likely to overheat at high altitudes.

2-19. Operation Under Rainy or Humid Conditions.
2-22. Operation in Snow.
Keep the fuel tank full to prevent forming of condensation. During dry periods when the set is not
operating, open the doors and allow the set to dry out.
Drain water and sediment from fuel tank (fig. 3-7)
more frequently,
2-20. Operation in Salt Water Areas.
a. Salt water causes corrosive action on metal.
Care must be taken to avoid equipment contact with
salt water. If contact is made, or if the unit is exposed to salt spray, wash the generator set frequently
with clean. fresh water.
b . Remove rust or other corrosion and paint all
damaged preprinted surfaces in accordance with services requirements.

Keep the fuel tank full to prevent forming of condensation. Drain water and sediment from fuel tank (fig.
3-7) more frequently. Check coolant antifreeze protection (table 2-1) and test the batteries (para 3-82b).
Insure that drifting snow does not obstruct normal –
cooling air flow.
2-23. Control Cubicle Removal for Remote Operation.
The set is designed for operation with the control panel
located up to 500 feet from the set.
If a remote location is desired, prepare a suitable location for mounting the panel. Disconnect and remove
wiring harness (1, Fig. 3-17) and control cubicle assembly (7). Fabricate a new cable of required length
using wire compatible with the connectors P1 and P2.

Section VI. OPERATION OF AUXILIARY MATERIAL USED IN CONJUNCTION WITH THE EQUIPMENT
2-24. General.
This section contains operating instructions for all
kits and auxiliary equipment. Included are the fuel
burning winterization kit, electric winterization kit,
wheel mounting kit, and load bank.
2-25. Fuel Burning Winterization Kit.
The fuel burning winterization kit is utilized to preheat engine coolant and lubricating oil in extreme
cold weather. The fuel burning winterization kit is
installed as described in paragraph 4-4. In ambient
temperature of -65° F, the kit should be placed in
operation a minimum of 55 minutes prior to starting.
Operating time may be reduced or increased for
warmer or colder temperatures, respectively. Operating instructions for the fuel burning winterization
kit are shown in figure 2-11.
2-26. Electrical Winterization Kit.
The electrical winterization kit consists of a heat exchanger, control box, coolant pump, thermostat and
accessories. The primary purpose of the kit is to
maintain the set in a heated condition, at any ambient

2-32

Change 12

temperature from 125° F. to -65° F. to enable it to
accept 75% of rated load in one step within 20 seconds
after starting action is initiated. The coolant temperature is thermostatically controlled at 130° F. to
150° F.
The kit can also be used to warm the Generator Set for
initial starting within 5 hours at any ambient temperature down to -65°F.
Power for operation of the kit may be obtained from
any power source that supplies 205 to 240 volts at
50, 60 or 400 Hz single phase. For electrical winterization kit operating instructions refer to Fig. 2-12.
2-27. Wheel Mounting Kit.
The wheel mounting kit provides a means of mobility
for the generator set. The maximum towing speed is
5 mph on paved surfaces. Operation of the wheel
mounting kit is illustrated in figure 2-13.
2-28. Load Bank.
The load bank provides up to 50% of the rated load of
the generator set to compensate for underrated loads.
Operating instructions for the load bank are illustrated
in figure 2-14.

STEP 1.

RELEASE TOWBAR LOCK AND CONNECT TOWBAR AND SAFETY CHAIN TO THE TOWING VEHICLE.

STEP 2. RELEASE PARKING BRAKE HANDLE AND TOW GENERATOR SET TO DESIRED LOCATION.
STEP 3. ENGAGE PARKING BRAKES AND REMOVE TOWBAR AND SAFETY CHAINS FROM THE TOWING
VEHICLE.
STEP 4. RAISE TOWBAR UNTIL TOWBAR LOCK ENGAGES.

ME

6115-545-12/2-13

Figure 2-13. Wheel Mounting Kit Operation

2-33

Figure 2-14.

2-34

CHAPTER 3
OPERATOR AND ORGANIZATIONAL MAINTENANCE INSTRUCTIONS
Section I. OPERATOR AND ORGANIZATIONAL MAINTENANCE
REPAIR PARTS, TOOLS, AND EQUIPMENT
3-1. Tools and Equipment.
a . Basic Issue (Army). Tools and repair parts
issued with or authorized for use with the engine
generator set are listed in the basic issue items list,
Appendix B of this manual.
b . Special Tools. No special tools or equipment

are required by operator or organizational maintenance personnel for maintenance of the engine generator set.
3-2. Organizational Maintenance Repair Parts (Army).
Organizational maintenance repair parts are listed
and illustrated in the publications listed in Appendix A.

Section II. LUBRICATION
3-3. General Lubrication Information.
WARNING

To avoid accidental engine cranking
or startup, set CKT BRK switch
(fig. 2-5) to OPEN position and disconnect cable from battery negative
terminal, prior to servicing the
engine generator set. Reconnect
cable at completion of service
procedures.
a. This paragraph contains a reproduction of the
lubrication order and lubrication instructions which
are supplemental to, and not covered in the lubrication order.
b . The lubrication order shown in figure 3-1 is an
exact reproduction of the approved lubrication order.
Refer to DA Pam 310-4 (Army) for the current LO.
c. The oil level gage (fig. 3-2) is the shielded
type which allows the operator to check oil level while
the engine is either stopped or running. The gage is
stamped on both sides to indicate two different oil
level locations. The engine RUNNING side is stamped
ADD, FULL, and RUNNING. The engine STOPPED
side is stamped ADD, FULL, and STOPPED.
CAUTION
Use appropriate ADD and FULL
marks depending upon whether
the engine is stopped or running.
d. The engine cannot be operated safely when the
oil level has dropped to the add mark on the oil level
gage, oil must be added to raise its level to the full
mark. When oil level is at the full mark, the proper
amount of oil is in the crankcase. Never fill crankcase above full marks.
e. A seal in the oil level gage cap prevents oil
from leaking to the outside of the engine and foreign
material from entering. For these reasons, the

gage must be kept tight on the level gage adaptor.
Each time oil is changed, inspect the seal to make
certain it is in good condition.
f . The purpose of the breather tubes
2, 6, & 8, fig. 3-12.1) is to vent the
inside of the engine thus preventing
pressure buildup and removing harmful
vapors from the crankcase , gear train,
and valve compartment . Fumes are redirected into the air intake system and
burned in the combustion of the engine.
If the tubes become clogged, vapors are
trapped within the engine, and pressure
buildup could force oil past crankcase
seals, oil level gauge or cylinder head
cover gasket.
3-4. Detailed Lubrication information.
a . General. Keep all lubricants in closed containers and store in a clean, dry place away from
external heat. Allow no dust, dirt or other foreign
material to mix with the lubricants. Keep all
lubrication equipment clean and ready for use.
NOTE
When changing oil, drain valve
must be open to drain crankcase
and closed before refilling.
(1) Lubricating oil must be in accordance
with the requirements of figure 3-1. Keep oil free
of water and abrasives by proper handling and
storage.
(2) Before each period of operation, check
oil level in the crankcase. If necessary, add oil
to bring level to full mark on the oil level gage,
Inspect engine for evidence of oil leaks and make
necessary repairs.
(3) After each operation interval of 100 hours,

Change 12 3-1

TM5-6115-545-12

3-2

Change 12

Figure 3-1.

Lubrication Order (Sheet 1 of 2)

Figure 3-1.

Lubrication Order (Sheet 2 of 2)

Change 12

3-3

TM 5-6115-545-12
TO 35C2-3-444-1
NAVFAC P-8-626-12
TM 00038G-12

Figure 3-2. Oil Level Gage and Filler
remove breather tubes (2, 6 & 8, fig. 3-12.1) from the valve
cover, crankcase, oil separator and air intake system. Clean
inside of tubes with cleaning solvent, blow out with compressed
air, and replace on engine and oil separator.
b. Cleaning. Keep all external parts not requiring
lubrication clean of lubricants. Before lubricating equipment,
wipe all lubrication points free of dirt and grease. Clean all
lubrication points after lubrication to prevent accumulation of
foreign matter.

(4) Install the drain plug, close the oil drain valve and
fill the crankcase with 26 quarts of the specified grade of
lubricant to the FULL mark on the oil level gage. Use the side
of the oil level gage stamped STOPPED.
(5) Place dead crank switch (49, fig. 3-27) in the off
(down) position and crank engine for 15 seconds, then place
dead crank switch in on (up) position.
(6) Start and operate the engine for approximately 5
minutes.
(7) Stop the engine and allow several minutes for the oil
to drain back to the crankcase before checking the oil level.

c. Oil Level.
CAUTION
To prevent overfill of the oil sump, remove oil filler
cap when checking oil with set running.
(1) Crankcase oil level must be checked frequently.
(2) Oil may require changing more frequently than
usual because of contamination by dilution and because sludge
formation will increase under cold weather operation conditions.

(8) Using the oil level gage, (fig. 3-2) check the oil
level and add oil as necessary to raise the level even with the
FULL mark on the oil level gage.
(9) Observe the engine for oil leakage. Repair oil leaks
before continuing operation.
d. Oil Filter Service See figure 3-3 and service the oil
filters as follows:
CAUTION

(3) Before draining the oil system, operate the engine
until a minimum coolant temperature of 160° F is obtained.
Shut engine off, open the engine oil drain valve and remove the
oil drain plug from the skid and allow the oil to drain into
appropriate container. Refer to para 3-4 d. for oil filter service.

3-4 Change 18

Disconnect negative lead from battery prior to
servicing oil falter.
(1) Drain oil filter by removing plug (l). Drain oil into
appropriate container.

1.
2.
3.
4.
5.
6.

Plug
Screw
Washer
Gasket
Screw
Washer

7.
8.
9.
10.
11.
12.

Filter body
Filter element
Header
Gasket
Retaining Ring
Adapter

13.
14.
15.
16.
17.
18.

Washer
Oil Seal
Spring
Switch
Nipple
Transmitter

19.
20.
21.
22.
23.

Nipple
Cap
Plug
Connector
Gasket

Figure 3-3. Engine Lube Oil Filters
3-5

(2) Remove screw (5), and washer (6), and
remove filter body (7) and filter element (8) as an
assembly from the header (9).
(3) Remove filter element (8) from filter body
(7). Remove and discard filter element (8) and
gasket (10).
(4) Thoroughly wash and dry interior of filter
body (7), header (9), and surrounding area. Install
the new filter element (8) and gasket (10) in filter
body (7) using reverse procedure of disassembly.
(5) Replace plug (1) in filter body (7).

(6) Tighten screw (5) to a torque of 45 to 50
ft. - lbs.
(7) Add oil as described in paragraphs 3-4 c
(4) through 3-4 c (9).
(8) Place dead crank switch (49, fig. 3-27) in
off (down) position and crank engine in 15 second
cranks followed by 3 minute rests until oil pressure
gauge shows pressure. Then place dead crank switch
in on (up) position
(9) Observe the engine lube oil filter for oil
leakage and be certain that filter body (7) and gasket
(10) are properly installed.

Section III. PREVENTIVE MAINTENANCE CHECKS AND SERVICES

3-5. General.
To insure that the engine generator set is ready for
operation at all times, it must be inspected systematically so that defects may be discovered and corrected before thay result in serious damage or failure. The necessary preventive maintenance services
to be performed are listed and described in paragraphs 3-6 and 3-7. Item numbers indicate the sequence of minimum inspection requirements. Defects
discovered during operation of the unit shall be noted
for future correction, to be made as soon as operation
has ceased. Stop operation immediately if a deficiency is noticed which would damage the equipment
if operation were continued. Air Force users shall
refer to the applicable inspection manuals and work
card sets in T. O. 35C2-3-Series for periodic preventive maintenance requirements and table 3-1
for detailed procedures. Marine Corps users should
refer to the current issue of TM 11275-15/1.
3-6. Daily Preventive Maintenance Checks and
Services (Army and Navy).

b. The item numbers are listed consecutively and indicate the sequence of
minimum requirements. R e f e r t o t a b l e
3-1.1 for the preventive maintenance
services.

3-7.1. Perform weekly as well as before
PMCS if:
a. You are the assigned operator and
have not operated the item since the
last weekly inspection.
b. You are operating the item for
the first time.
3-7.2. Leakage definitions for operator/
crew PMCS shall be classified as follows :
CLASS I

Table 3-1 contains a tabulated listing of Preventive maintenance services which must be performed daily by the operator. The item numbers
are listed consecutively and indicate the sequence of
minimum requirements.
3-7. Monthly and Semi-annual Preventive Maintenance Checks and Services (Army and Navy).
a . Table 3-1.1 contains a tabulated
listing of preventive maintenance checks
and service: which must be performed by

organizational maintenance personnel at
monthly and semi-annual intervals.

3-6

Change 1 2

Seepage of fluid (as indicated by wetness or discoloration) not great enough to form
drops.

CLASS II Leakage of fluid great enough
to form drops but not enough
to cause drops to drip from
item being checked/inspected.
CLASS III Leakage of fluid great enough
to form drops that fall from
the item being checked/inspected.

Section IV. OPERATOR’S MAINTENANCE
3-8. General.

3-10. Slave Receptacle Inspection.

Instructions in this section are provided to assist the
operator in maintaining the engine generator set.

A slave receptacle (17, fig. 3-4) is located in a
receptacle box on the forward left side of the housing.
Inspect the slave receptacle for loose mounting,
loose electrical connections, loose covers, corrosion
and other damage.

3-9. Batteries.
a . Inspection. See figure 3.4 and remove screws
(9),and washers (10) and studs (8) which attach battery tray (11) to base and slide storage batteries and
trays (11) out. Inspect storage batteries for cracks
and leaks. Check for loose cables (1, 2 and 3) and
mountings and excessive corrosion.
Refer to table 3-1. Fill to 3/8 inch
b. Service.
above plates. In freezing weather, run engine a minimum of 1 hour after adding distilled water. Apply
grease to cable connectors.

3-11. Muffler, Exhaust Pipe and Breather System Inspection
Inspect muffler and exhaust pipes (fig.
3-12) and breather
system (Fig. 3-12.1) for crocks, leaks, breaks, loose mounting,

and other damage.
3-12. Convenience Receptacle Assembly
Inspection.
Inspect convenience receptacles assembly (fig. 3-13)
and components for loose mounting, loose covers,
corrosion and other damage.

Change 12

3-6.1/(3-6.2

blank)

TM 5-6115-545-12
TO-35C2-3-444-1
NAVFAC P-8-626-12
TM-00038G-12
Table 3-1. OPERATOR/CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES

B – BEFORE OPERATION

D – DURING OPERATION

A – AFTER OPERATION

INTERVAL
ITEM
NO.

B

D
—

A

ITEM TO BE
INSPECTED

PROCEDURES

EQUIPMENT WILL
BE REPORTED NOT
READY (RED) IF:

Do not attempt to service
(make adjustments, connections, reconnection of wires
or cables) or correct anything
inside the generator set until
the generator set is shut down
and completely de-energized.

Generator Set

1

Equipment operation is allowable with minor leakages
(Class I or II). Of course, you
must consider the fluid capacity in the item/system being
checked/inspected. When in
doubt, notify your supervisor.

●

When operating with Class I
or Class II leaks, continue to
check fluid levels as required
in your PMCS.

●

Class III leaks should be reported to your supervisor or
organizational maintenance,

Visually inspect unit for fuel, oil,
coolant, and hydraulic leaks. Check
for proper levels.

Class III oil, coolant,
and hydraulic fluid are
found during inspection

Visually inspect the generator
f o r m i s s i n g , loose or damaged
parts and hardware , and for
unusual wear or deterioration.

●

●

●

●

Dead Crank Switch

Check for proper ground connection.
(Para. 2-5e, fig. 2-2).

Generator set not
properly grounded.

Place dead crank switch in the run
position.

If switch
malfunctions.

Change 13

3-7

TM 5-6115-545-12
TO-35C2-3-444-1

NAVFAC P-8-626-12
TM-00038G-12
Table 3-1. OPERATOR/CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES (Cent)

B – BEFORE OPERATION

D – DURING OPERATION

A – AFTER OPERATION

INTERVAL
ITEM
NO.

2

3-8

B

D

A

ITEM TO BE
INSPECTED

PROCEDURES

EQUIPMENT WILL
BE REPORTED NOT
READY (RED) IF:

●

Batteries

Remove corrosion and apply grease
to cable connectors. Tighten loose
cables and mountings. Inspect for
cracks and leaks. Fill batteries to
3/8 inch above the plates. Clean
vent hole in filler cap before installing. In freezing weather run engine
a minimum of 1 hour after adding
water.

Cable connections
cannot be tightened,
or battery is cracked
or leaking.

●

Fuel Selector Valve

Turn fuel selector valve to the
correct position.

Fuel selector valve is
inoperable.

Controls and instruments:

Instruments shall indicate within
specified limits. (Fig. 2-5)

a. Battery charging
ammeter

Green portion of scale

Ammeter does not
indicate charging
current.

b. Coolant temp gage

180° to 200° F

Temp exceeds 200° F.

c. Voltmeter

120/208 - 240/416

Voltage cannot be
properly adjusted.

d. Oil pressure gage

30 to 55 psi

Pressure is below
30 psi.

e. A.C. ammeter

Indicates percentage of applied
current. Not to exceed 100%

Meter is
nonfunctional.

f. Wattmeter

Indicates applied load. Not to
exceed 100%.

Meter is
nonfunctional.

g. Frequency meter

400 Hz - 50/60 Hz

Frequency cannot be
properly adjusted.

●

Change 13

TM 5-6115-545-12
TO 35C2-3-444-1
NAVFAC P-8-626-12
TM 00038G-12
Table 3-1. OPERATOR/CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES

B - BEFORE OPERATION

ITEM
NO.

INTERVAL
B

D

A

●

3

4

●

5

●

●

●

ITEM TO BE
INSPECTED

A - AFTER OPERATION

D -DURING OPERATION

EQUIPMENT WILL
BE REPORTED NOT
READY (RED) IF

PROCEDURES

h. Fault indicator
panel

All lights out during operation. Check bulb operation using test or reset switch on panel.

Fuel tank

Fill fuel tank at completion of operation. (Fig. 1-2;
para 2-16b, 2-17c, 2-19, and 2-22)

Oil level

Check engine oil and add as required as indicated by
oil level gage. (Fig. 3-2; para 3-4a, 3-4b, 3-4c,
(l-9))

Fuel filters and
strainers

Check for leaks. Drain water and sediment.

Fault light will not extinguish when switch is placed
to TEST RESET position,
then released.

Class III leakage is detected.

NOTE
In freezing weather, drain shortly
after operation. Allow to drain
until fuel runs clear.

6

•

●

Day Tank

Drain water and sediment.
NOTE
In freezing weather, drain shortly
after operation. Allow to drain
until fuel runs clear.

Change 18

3-8.1 /(3.8-2 blank)

Table 3-1.1.

INTERVAL
ITEM
NO.

—M

H

ORGANIZATIONAL PREVENTIVE MAINTENANCE CHECKS AND SERVICES
W-WEEKLY (40 HOURS)
M-MONTHLY(1O0 HOURS)
ITEM TO BE
INSPECTED

S-SEMIANNUAL (500 HOURS)
H-HOURS (AS INDICA TED) EQUIPMENT WILL
BE REPORTED NOT
PROCEDURES
READY (RED) IF:

Fluid level

Check fluid levels.

a. Lubricating oil

Check oil and add as required.
(Fig. 3-1; 3-2)

b. Hydraulic
sump

Check and add fluid as required.
(Fig. 3-44)

c. Cooling
system

Check coolant level. Proper level
is 2 inches below filler neck.
(Para 2-3 c 2).

2

Fuel tank

Drain water and sediment from
fuel tank. (Fig. 1-4; para 3-62b2)
Note: In freezing weather, tank
should be drained shortly after
operation.
Close drain cocks as
soon as clean fuel begins to run
out.

3

Fuel filters and
strainers

Drain water and sediment from
filters and strainers.
Note: In freezing weather, filters and strainers should be
drained shortly after operation.
Close drain cocks as soon as
clean fuel begins to run out.
(Fig. 1-1; para 3-6 and 3-9)

4

Batteries

Check battery electrolyte level.
(Para 3-9) Perform a hydrometer
check of the battery electrolyte
prior to adding distilled water.
Recharge or replace battery if
specific gravity reading is low.
(Para 3-82 b)

5

Day tank

Drain water and sediment from day
tank.
Note: In freezing weather, tank
should be drained shortly after
operation. Close drain cock as
soon as clean fuel begins to run
out. (Para 3-33 b)

6

Generator
set

Inspect entire unit for loose,
damaged, or missing parts; and
unusual wear or deterioration.

1

Change 6

3-9

Table. 3-1.1.

ORGANIZATIONAL PREVENTIVE MAINTENANCE CHECKS AND SERVICES--continued
W-WEEKLY (40 HOURS)
M-MONTHLY(1O0 HOURS )

ITEM
NO.

—s

H

7

8

●

9

ITEM TO BE
INSPECTED

S-SEMIANNUAL (500 HOURS)
H-HOURS (AS INDICI ED)
EQUIPMENT WILL
BE REPORTED NOT
PROCEDURES
READY (RED) IF:

V-belts

Inspect for worn, frayed, oil
soaked, or cracked belts. Check
adjustment of V-belts. Proper adjustment for fan belt is a
deflection of 9/32 inch with application of 12-14 lb pressure
midway between accessory drive
pulley. For alternator drive
belt, a deflection of 9/64 inch
with application of 3-5 lb pressure midway between alternator
pulley and accessory drive pulley.
(Fig. 3-35)

Air filters

This unit is equipped with an air
filter condition indicating light
that will indicate when the filter
elements need cleaning. Clean
elements when necessary as indicated by the light.

Deleted.

10

●

Engine oil

Drain engine oil and refill.
(Para 3-4c)
Change lubricating oil every 300
hours or 6 months.

11

Oil filters

Replace lubricating oil filters.
(Para 3-4d)
Change lubricating oil filters
every 300 hours or 6 months.

12

Fuel filters
and strainer:

Replace primary and secondary fuel
filters, and clean fuel strainers
every 100 hours.
(Para 3-34, 3-36, and 3-165 a)

13

●

Hydraul ic
sump

Drain and refill hydraulic sump.
(Para 3-44)

14

●

Hydraul ic
filter

Replace hydraulic filter.
(Para 3-45)

15

●

Hydraulic
actuator

Clean actuator filter screen.
(Para 3-175)

3-10

Change 7

Figure 3-4. Batteries and Slave Receptacles
Change 12

3-11

3-13. (Deleted)
3-14. Plate and Sleeve Assembly Inspection.
Inspect plate and sleeve assembly (fig. 3-15) for
tears, dents and other damage.

3-19. AC Ammeter.
a. Inspection. Inspect ac ammeter (8, fig. 3-18)
for cracks, breaks, corroded and/or loose terminals,
and other damage.
b . Adjustment. With generator off, adjust ac
ammeter zero control until pointer is at zero.

3-15. Paralleling Receptacles Inspection.

3-20. Frequency Meter.

Inspect the paralleling receptacles (fig. 3-16) for
loose electrical connection, loose mounting, bent
pins, cracks, breaks, corrosion, and other damage.
Inspect the connector leads for broken or frayed
insulation and other damage.

Inspect freq meter (7, fig. 3-18) for cracks, breaks,
loose and/or corroded terminals, and other damage.

3-16. DC Circuit Breaker Inspection and Fault
Indicator Lamp Test.
Inspect DC CONTROL CIRCUIT BREAKER (27, fig.
3-17) for loose mounting, loose electrical connections, or damage and check lamp operation as
follows:
a. Close DC CONTROL CIRCUIT BREAKER
(fig. 2-5).
b. Set START-RUN-STOP switch to RUN,
c. Set and hold fault indicator TEST OR RESET
switch to test and check that all fault indicators
light.
b. Set START-RUN-STOP switch to RUN.
c. Set and hold fault indicator TEST OR RESET
switch to test and check that all fault indicators
light.

3-21. Control Cubicle Panel Switches Inspection.
Inspect switches on the control cubicle panel (96,
fig. 3-18), for cracks, breaks, corroded terminals,
loose electrical connections, loose mounting, and
other damage.
3-22. Control Cubicle Panel Gages Inspection.
Inspect gages on the control cubicle panel (96, fig.
3-18), for cracks, breaks, corroded terminals,
loose electrical connection, loose mounting, and
other damage.
3-23. Running Time Meter Inspection.
Inspect RUNNING TIME meter on the control cubicle
panel (96, fig. 3-18), for cracks, breaks, corroded
terminals, loose electrical connections, loose
mounting, and other damage.
3-24. Battery Charge Ammeter Inspection.
Inspect BATTERY CHG AMMETER (77, fig. 3-18)
on the control cubicle panel for cracks, breaks,
corroded terminals, loose electrical connections,
loose mounting, and other damage.
3-25. Panel Light Assemblies.
a. Inspection.
—

3-17. AC Voltmeter.

(1) Inspect lens (17, fig. 3-18) for cracks,
breaks, loose mounting.

a. Inspection. Inspect ac voltmeter (42, fig. 3-18)
for cracks, breaks, corroded and/or loose terminals,
and other damage.

(2) Inspect lamp (24, fig. 3-18) for breaks or
loose mounting.
b.
— Test and Replacement.

b. Adjustment. With generator off, adjust voltmeter zero control until the pointer is at zero.

(1) Close DC circuit breaker.
(2) Set PANEL LIGHT switch to ON position.

3-18. Kilowatt Meter.

(3) If any panel lamps do not light, replace
lamp.

a. Inspection. Inspect kilowatt meter (39, fig.
3-18) for cracks, breaks, corroded and/or loose
terminals, and other damage.

3-26. Press-to-Test Light Assemblies.

b . Adjustment. With generator off, adjust kilowatt meter zero control until pointer is at zero.

(1) Inspect lens (26 and 33, fig. 3-18) for cracks,
breaks, loose mounting.

3 - 1 2 Change 1

a.
— Inspection.

Table 3-2. Fault Indicator Test Points
Fault indicator
LOW OIL PRESSURE

12-D

OVER SPEED

12-E

COOLANT HIGH TEMP

12-K

NO FUEL

12-L

SHORT CIRCUIT

12-F

UNDER VOLTAGE

12-G

REVERSE POWER

12-H

OVER LOAD

12-M

UNDER FREQ

12-N

OVER VOLT

12-I

(2) Inspect lamps (31 and 38, fig. 3-18) for
breaks or loose mounting.
b.

Pin no.

3-32. Air Cleaner Assembly.
a . Inspection.

Test and Replacement,
(1) (Deleted)
(1) Close DC circuit breaker.
(2) Press press-to-test light assemblies.

(3) If lamp doesn’t light, unscrew lens and
replace lamp.
(4) Re-install lens.
3-27. Synchronizing Light Assembly Inspection.
Remove lens and inspect lamp (of synchronizing lights
(16, fig. 3-18) for damage or loose mounting.
3-28. Door Holders Inspection
Open door and inspect door holder (85, fig. 3-18)
for damage.
3-29. Crosspin Assembly Inspection.
Open door to gain access to rear of control cubicle
panel and examine crosspin (94, fig. 3-18) for
damage.
3-30. Control Cubicle Door Inspection.
Open door and inspect both sides for damage.
3-31. Housing Group Inspection.
Inspect engine generator set doors for proper operation. Inspect doors, covers, and panels for loose
mounting, dents or other damage (fig. 3 -22).

(2) (Deleted)
(3) Inspect air cleaner condition switch for
loose mounting, loose connector wires, and other
damage.
(4) Inspect air cleaner filter element for
signs of blockage, holes, and other damage.
b . Service. Service the air cleaner as described
and illustrated in figure 3-5.
3-33. Day Tank Assembly.
a . Inspection. Inspect the day tank assembly
(fig. 3-27) for cracks, breaks, holes, loose electrical connector and other damage.
b.
Service. Service the day tank
—
assembly at intervals shown in table
3-1.1, item 5 and proceed as follows:
Open the drain cock (36) at the bottom
of the day tank and let the tank drain
until clean fuel is seen, then close
the drain cock.
3-34. Fuel Filter and Strainer Assembly.
a . Inspection. Inspect fuel filter and strainer
assembly (fig. 3-6) for leaks, cracks, breaks, dents
and other damage.
Change 12

3-13

STEP
STEP
STEP
STEP

1.
2.
3.
4.

REMOVE WING NUTS AND RETAINER.
CAREFULLY REMOVE DIRTY FILTER ELEMENT.
CLEAN INSIDE OF HOUSING.
CLEAN FILTER ELEMENT BY EITHER METHOD A OR B
DESCRIBED BELOW.
CAUTION
DO NOT CLEAN IN GASOLINE OR
OTHER PETROLEUM SOLVENT.

METHOD A.
COMPRESSED AIR
DIRECT COMPRESSED AIR (100 PSI MAX.) THROUGH PANEL OPPOSITE DIRECTION
OF ARROWS ON ELEMENT DECAL OR OPPOSITE AIRFLOW DIRECTION.
METHOD B.
WASHING WITH WATER
SOAK 15 MINUTES IN WATER AND MILD DETERGENT. RINSE UNTIL CLEAN. AIR DRY
DO NOT USE COMPRESSED AIR.
STEP 5.
STEP 6.

INSTALL FILTER ELEMENT.
INSTALL WING NUTS AND RETAINER AND TIGHTEN WING NUTS
FINGER TIGHT.

Figure 3-5.
3-14 C h a n g e

7

Air Cleaner Service

bottom of filter and strainer and allow to drain into
suitable container.
(2) Remove filter body (3) from header (4) by
removing screw (5) and gasket (6).
(3) Remove and discard filter cartridge (7) and
gasket (8). Unscrew nut (9) from stud (10) and remove strainer body (12) and gasket (13).
(4) Remove retainer (14) and strainer element
(15).
(5) Clean the strainer element (15) and all parts
including interior of strainer body (12) with cleaning
solvent Federal Specification P-D-680.
(6) Dry with compressed air or lint free cloth.
(7) See figure 3-6 and install new filter cartridge (7) and gasket (8) and replace fuel filter and
strainer in reverse order of removal.
3-35. Start Aid Assembly.
a . Inspection. Inspect ether tank (8, fig.. 3-28),
solenoid valve, and tank bracket for loose mounting,
dents, loose fittings, and other damage.
b . Servicing. Either tank must be replaced by
Organizational Maintenance personnel when empty
(tank weighs 2 lbs. 4 oz. when full; 1 lb. when
empty). Service the starting aid assembly as follows:
WARNING
Be careful not to inhale ether gas
as drowsiness and unconsciousness
may result.
(1) Disconnect atomizer (2, fig. 3-28) and
tube (1) from intake manifold and solenoid valve
adapter (3).
(2) Crank engine and momentarily actuate
ENGINE PRIMER switch while an observer watches
adapter opening. If no spray is observed, notify
Organizational Maintenance personnel.

1. Drain Cock
2. Drain Cock

3.
4.
5.
6.
7.
8.

Filter body
Header
Screw
Gasket
Filter cartridge
Gasket

9.
10.
11.
12.
13.
14.
15.

Nut

Stud
Nut
Strainer body
Gasket
Retainer
Strainer element

(3) Clean atomizer and tube with a source of
compressed air.
3-36. Filler Cap, Gasket and Strainer.
a . Inspection. (See fig. 3-7)
(1) Inspect main fuel tank cap and strainer for
breaks, cracks, holes or other evidence of damage.

Figure 3-6. Fuel Filter and Strainer
b.
Service. S e r v i c e t h e f u e l f i l ter assembly at intervals shown in table 3-1.1, item 12, and proceed as follows :

(2) Inspect main fuel tank cap gasket for tears
or deterioration. Check that valve opening in cap I S
clear of obstruction.
(3) Inspect fuel tank filler hose for leaks.
cracks, loose mounting, deterioration or other evidence of damage.

(1) Open the drain cocks (1 and 2, fig. 3-6) at
Change 12

3-15

TM 5-6115-545-12
TO 35C2-3-444-1
NAVFAC P-8-626-12
TM 00038G-12

Figure 3-7. Main Fuel Tank
(4) Inspect main fuel tank vent hoses for cracks, loose
mounting, deterioration or other evidence of damage.
b. Service. (See fig. 3-7.)
(1) Remove main fuel tank cap, gasket, and strainer.

3-40. Shutter and Shutter Thermostat Inspection.
Verify that the linkage connecting the shutter control assembly
(10, fig. 3-30), which houses the shutter thermostat (6) to the
shutter (2, fig. 3-31 ) is secure and not damaged. Check
thermostat housing for cracks, leaks or other damage.
3-41. Radiator.

(2) Clean all metal parts and dry thoroughly.
(3) Replace a damaged or defective gasket.
(4) Replace a damaged or defective main fuel tank
strainer.

a. Inspection. Inspect the radiator assembly (35, fig. 3-29)
for leaks.
b. Service.
(1) Service the radiator as follows:

3-37. Fuel Transfer Pump.
WARNING
Inspect fuel transfer pumps (37 and 38, fig. 3-28) for leaks,
loose correctors, dents, cracks and other damages.
3-38. Radiator Grille.
Inspect radiator grille (fig. 3-31) for dirt, foreign matter, cracks,
dents, leaks, and other damage.

Scalding can result from steam in the coolant system
escaping when the radiator cap is removed. Always
allow coolant to cool and remove the radiator cap
slowly to permit any pressure to escape.
( a ) Open radiator cap access door and remove cap.

3-39. Fan Guard Inspection.

( b ) Refer to Table 2-1 for proper coolant and fill
radiator until coolant level is two inches below filler neck.

Inspect the LH and RH fan guards (25 and 26, fig. 3-29) for
dirt, cracks, dents or other damage.

( c ) Fasten tag near radiator cap indicating date, type
of coolant and level of protection.

3-16 Change 18

NOTE
At the time the cooling system is required to
be drained, the coolant in the lube oil cooler
should also be drained as described in paragraph 3-199 b.
(d) To drain the radiator place suitable container to collect
coolant. Remove radiator cap.
(e) Open radiator shutoff cock (21) and drain radiator
coolant into container. Needle valve (9, fig. 3-34) should be also
opened to drain the engine block.
(f) Close shutoff cock (21, fig. 3-29) and close needle
valve (9, fig. 3-34).

(3) Soak new filter element in clean hydraulic oil conforming
to Military Specification MIL-H-5606 to remove air trapped in
filter material.
(4) Install new preformed packing (8) and backup rings (9).
(5) Apply a light coat of hydraulic oil to the preformed packing (8), and backup rings (9), header (10), and the threads of the
filter body (6).
(6) Install new element in filter body (6) and fill bowl with
clean hydraulic fluid. Install filter body (6) in header (10) and
tighten. Lockwire header to filter body on the threads of the
filter body.
3-46. Engine Assembly Service.

3-42. Hydraulic Cooler (MEP105A Only) Inspection.
Refer to table 3-1 and service the engine crankcase as follows:
Inspect fins and lines of hydraulic cooler (19, fig. 3-29) for cracks,
breaks, dents, leaks, loose mounting and other damage.
3-43. Hydraulic Sump (MEP105A Only) Inspection.
Inspect hydraulic actuator (fig. 3-32) for loose mounting, loose hose connections, loose connectors, loose linkage, and other damage.
3-44. Hydraulic Sump (MEP105A Only).
a. Inspection. Inspect hydraulic sump (1, fig. 3-8) for cracks,
leaks, breaks and other damage. Inspect filler cap (3) for secure
fitting. Inspect seal on tiller cap (3) for excessive wear and other
damage. Inspect hydraulic sump sight glass (2) for legibility of
marking, loose fitting, and other damage. Inspect hydraulic sump
for cracks, loose mounting, leaks and other damage.
b. Service. To service hydraulic sump (1, fig. 3-8) refer to table
3-1 and proceeds as follows:
(1) Check oil level; level should be up to sight glass (2, fig.
3-8).

a. Check crankcase lubricating oil level using oil level gage
(fig. 3-2).
b. Remove engine lubricating oil filler cap and add oil as
required to obtain full level on oil level gage. See figure 3-1 for
proper lubricating oil.
c. To drain the crankcase, remove plug and place suitable
container at drain hose.
d. Open engine lubricating shutoff cock valve and drain oil into
container.
e. Close shutoff cock and replace plug.
f. To refill the crankcase; remove the oil filler cap and add oil
until crankcase is full; verify crankcase is full by checking oil level gage.
3-47. Fan Belts Inspection
Inspect drive belts (fig. 3-35) for signs of wear, damage or oil
soaking.
3-48. Battery Charging Alternator Inspection.

(2) Remove tiller cap (3). Add hydraulic oil conforming to
Military Specification MIL-H-5606 to obtain proper level.

Inspect battery charging alternator (fig. 3-36) for cracks, loose
mounting, dents, loose or damaged connector, and other defects.

(3) To drain tank, place suitable container beneath drain plug
(4) and remove drain plug. Repeat step (2) to refill sump tank.

3-49. Speed Switch Inspection.

3-45. Hydraulic Filter (MEP105A Only).

Inspect speed switch (fig. 3-37) for loose mounting, loose connector and other damage.

a. Inspection. Inspect hydraulic filter (fig. 3-8) for cracks,
breaks, and other damage.

3-50. Angle Adapter Inspection.

b. Service. To service the hydraulic filter refer to table 3-1 and
figure 3-8 and proceed as follows:

Inspect angle adapter (fig. 3-38) for loose mounting, breaks,
cracks and other damage.

(1) Cut lockwire (5). Remove filter body (6) and filter element
(7). Discard filter element.

3-51. Hydraulic Pump and Drive Assembly (MEP105A Only) Inspection.

(2) Clean filter body with cleaning solvent, Federal Specification P-D-680 and dry thoroughly.

Inspect hydraulic pump and drive assembly (fig. 1-2) for leaks
and loose mounting.

Change 11

3-17

1. Hydraulic sump
2. Sight glass
3. Filler cap
4. Drain plug
5. Lockwire

6. Filter body
7. Filter element
8. Preformed packing
9. Backup rings
10. Header

Figure 3-8. Hydraulic Sump and Filter (MEP105A)

3-52. Oil Level Gage and Filler Inspection.

3-53. Starter Assembly Inspection.

See figure 3-2 and proceed as follows:

Inspect starter assembly for cracks, dents, loose, damaged or
missing parts, loose mounting, loose electrical connections, and
other damage.

a. Inspect oil level gage legibility of marking, loose
fitting and other damage.
b. Inspect oil filler cap for secure fitting.

3-54. Oil Pressure Transmitter Inspection.
Inspect transmitter (18, fig. 3-3) for leaks, cracks, loose mounting,
loose electrical connection and other damage.

c. Inspect seal on oil filler cap for excessive wear, and
other damage.

3-55. Lube Oil Filter Assemblies Inspection.

d. Inspect oil filler for cracks, loose mounting, and other
damage.

Inspect lube oil filters (fig. 3-3) for leaks, cracks, breaks, dents
and other damage.

3-18

Change 11

TM 5-6115-545-12
TO 35C2-3-444-1
NAVFAC P-8-626-12
TM 00038G-12

1. Drain cock
2. Bleed screw
3. Capscrew

7. Filter element
8. Bowl

4. Gasket
5. Header
6. Gasket

Figure 3-9. Secondary Fuel Filter
3-56. Secondary Fuel Filter.

(1) Uncouple line from day tank at filter, and
raise line above day tank level.

a. Inspection. Inspect secondary fuel filter
(fig. 3-9) for breaks or cracks. Inspect threaded
parts for damage or stripped threads.

filter.

b . Service. To service the fuel filter proceed
as follows:

(3) Open bleed screw (2) remove capscrew (3)
and remove and discard gasket (6) and filter element.

(2) Open drain cock (1, fig. 3-9) and drain

3-19

TM 5-6115-545-12
TO 35C2-3-444-1
NAVFAC P-8-626-12
TM 00038G-12
(4) Clean interior of bowl (8) with cleaning solvent
Federal Specification P-D-680. Dry with compressed air or lint
free cloth.
(5) Install new filter element (7) and new gasket (6) in
the reverse order of removal.
(6) Close drain cock (l), and bleed fuel filter and
recouple fuel line to fuel filter.
c. Fuel System Bleeding Procedure.

3-61. Oil Pan Assembly Inspection.
a. Inspect oil heater coolant line connections for leaks
around fittings, loose line connections, cracks, and other
damage.
b. Inspect drain fitting, valve, hose connections and plug
for leaks, cracks, loose mounting, and other damage.
c. Inspect hose for deterioration, tears and other damage.
Inspect oil pan for cracks, dents, leaks and other damage.

(1) Open bleed screw (2) on secondary filter,
(2) Depress the DC Circuit Breaker (20, fig. 2-10A).
(3) Place the battle short switch to the ON position
(22, fig. 2-10A).

3-62. Main Fuel Tank.
a. Inspection.
(1) Inspect main fuel tank (fig. 3-7) for loose mounting.

(4) Place the start-run-stop switch to the run position
(32, fig. 2-10A).
(5) Observe fuel coming from top of secondary filter.
When air free fuel is flowing, tighten bleed screw (2).
(6) Place the start-run-stop switch to stop position
(32, fig. 2-10A),
(7) Open the DC Circuit Breaker (20, fig. 2-10A).
(8) Place the battle short switch to the OFF position
(22, fig. 2-10A),
3-57. Fuel Injection Pump Inspection.
Inspect fuel injection pump (fig. 1-1 ) for dents, cracks, breaks,
leaky connections and other damage.
3-58. Water Pump Inspection.
a. Inspect water pump (18, fig. 3-43) for leaks, cracks,
breaks, loose mounting and other damage.
b. With engine running check that excessive noise is not
heard from water pump.

(2) Inspect main fuel tank for leaks, cracks, breaks and
other damage.
(3) Inspect fuel quantity transmitter gasket and electrical
connection.
(4) Refer to paragraph 3-36 a for fuel tank cap, gasket
and strainer inspection procedure.
b. Service.
(1) Refer to paragraph 3-36 b for fuel tank cap, gasket
and strainer servicing procedure.
(2) Connect auxiliary fuel line (fig. 1-1) to hose
connector at end of fuel tank drain valve (fig. 3-7), located at
the engine end of the fuel tank. Drain into suitable container.
Open drain cock and allow water and sediment to completely
drain off. Close drain cock when clean fuel runs out.
(3) Add fuel as required.
3-63. Paralleling Cable Inspection.

3-59. Fan Inspection.
Inspect fan for cracks, breaks, loose mounting and other
damage.
3-60. Temperature Transmitter Inspection.
Inspect coolant temperature transmitter (10, fig, 3-44) for leaks,
cracks, loose mounting, loose electrical connections and other
damage.

3-20 Change 18

Inspect the parallel cable (fig. 1-1 ) for loose connections,
damaged connectors/pins, loose mounting, damaged cable, and
other damage.
3-64. Auxiliary Fuel Line Inspection.
Inspect the auxiliary fuel line (fig. 1-1) for loose connections,
leaks, cracks, breaks, and other damage.

TM 5-6115-545-12
TO 35C2-3-444-1
NAVFAC P-8-626-12
TM 000838G-12
Section V. TROUBLESHOOTING
3-65. General
Table 3-3 provides information useful in diagnosing and
correcting unsatisfactory operation or failure of the engine
generator set and its components. Each malfunction stated is
followed by a list of the probable causes of the trouble. The
corrective action recommended is described opposite the
probable cause. Any trouble beyond the scope of organizational
maintenance shall be reported to the next higher level of

maintenance. The engine generator set must be completely
serviced with fuel, coolant, and lubricating oil. Before
troubleshooting, check that all electrical connections are correct
and operating controls are in the correct positions.
NOTE
Air Force and Navy users are authorized to perform
maintenance within the scope of their capability.

Table 3-3 Troubleshooting
MALFUNCTION
1.

Engine fails to crank
when START-STOPRUN switch is moved
to START position.

PROBABLE CAUSE

CORRECTIVE ACTION

a.

Improper starting
procedure.

a.

Perform starting procedure as described in
paragraph 2-12.

b.

Batteries weak,

b.

Recharge or replace batteries (para 3-82).
Refer to page 2-14, fig. 2-5c and page 2-21,
step 1, prior to replacing batteries.

c.

Batteries improperly
installed.

c.

Connect batteries as indicated in figure 3-4.

d.

Defective, corroded or loose
battery cables.

d.

Tighten all loose connections and clean corrosion
from all terminals. (Refer to item 16, table 3-1.)

Defective or loose

control

e.

Inspect control wires and repair or tighten
as necessary.

f.

Defective DC CONTROL
CIRCUIT BREAKER.

f.

Replace DC CONTROL CIRCUIT BREAKER
(para 3-100).

g.

Defective START-RUN-STOP
switch

g.

Replace START-RUN-STOP switch (para 3-119).

h.

Defective speed switch

h.

Replace defective speed switch (para 3-186).

a.

Improper starting procedure.

a.

Perform starting procedure as described in
paragraph 2-12.

b.

Fuel supply exhausted

b.

Fill fuel tank or use auxiliary fuel supply
(para 2-3).

c.

Water in fuel supply

c.

Drain fuel system, service with proper grade of
fuel (para l-4b).

d.

Air in fuel system.

d.

Bleed fuel system (para 3-56c).

e.

Restricted fuel supply line.

e.

Clean restriction or replace tine.

f.

Defective day tank float
switch.

f.

Replace float switch (para 3-159).

g.

Defective fuel solenoid
valve.

g.

Replace fuel solenoid valve (para 3-158).

h.

Clogged fuel fitter and
strainer elements,

h.

Service filter and strainer (para 3-34).

i.

Clogged secondary filter
element.

i.

Service filter (pars 3-197).

i.

Defective nozzle holder

i.

Replace nozzle holder assembly (para 3-201).

k.

Clogged air intake system.

k.

Service air filter assembly (fig. 3-5).

e.

wires.

2. Engine cranks but will
not start.

assembly.

Change 18 3-21

TM 5-6115-545-12
TO 35C2-3-444-1
NAVFAC P-8-626-12
TM 00038G-12
Table 3-3 Troubleshooting (Cont)

1.

3.

4.

5.

6.

Engine runs when START
-RUN-STOP SWITCH is
held in START position
but stops when switch
is set to RUN.

Engine runs erratitally or misfires

Engine exhaust
excessively black

Engine exhaust white
or blue.

3-22 Change 18

CORRECTIVE ACTION

PROBABLE CAUSE

MALFUNCTION

Contaminated or improper
grade of fuel.

l.

Drain fuel supply, service with proper grade
of fuel (para l-4b).

m.

Speed switch not reset
after overspeed shutdown.

m.

Reset speed switch by depressing reset button
on back end of switch.

n.

Open or defective dead
crank switch.

n.

Close switch (49, fig. 3-27) and test for
continuity. Replace if defective.

o.

Closed fuel shutoff lever
(Class I only).

o.

Open lever for fuel inlet to injection pump.

a.

Switch not held in start
position sufficient amount
of time to enable engine to
exceed 600 rpm.

a.

Hold in start for a longer period (para 2-12).

b.

Defective speed switch.

b.

Replace speed switch (para 3-186).

c.

Defective START-RUNSTOP switch.

c.

Replace switch (para 3-119).

d.

Defective oil pressure switch.

d.

Replace oil pressure switch (para 3-194).

e.

High coolant temperature.

e.

Refer to malfunction item 11.

a.

Contaminated or improper
fuel.

a.

Drain fuel system and fill with proper fuel
(para 1-4).

b.

Air in fuel system.

b.

Bleed fuel lines (pars 3-56).

c.

Restricted fuel fines.

c.

Clean fuel lines.

d.

Defective nozzle holder
assembly.

d.

Replace nozzle holder assembly (para 3-201).

e.

Dirty air cleaner.

e.

Service air filters (fig. 3-5).

f.

Defective turbocharger.

f.

Replace turbocharger (para 3-203).

a.

Improper fuel.

a.

Drain fuel system and fill with proper fuel (para 1-4).

b.

Clogged air intake

b.

Service sir filter assembly (fig. 3-5).

c.

Defective turbocharger.
Clogged turbo.

c.

Replace turbocharger (para 3-203).

d.

Generator set overloaded.

d.

Reduce load to rated level.

e.

Improper timing.

e.

Correct timing.

a.

Improper fuel.

a.

Drain fuel system and fill with proper fuel (para 1-4).

b.

Engine operating temperature
too low due to faulty thermostat.

b.

Replace thermostat (para 3-209).

c.

Oil level too high.

c.

Drain crankcase until proper level is indicated
on oil level gage (para 3-4).

d.

Defective nozzle holder
assembly.

d.

Replace nozzle holder assembly (para 3-201).

e.

improperly adjusted valves.

e.

Adjust valves (para 3-220).

Table 3-3. Troubleshooting (Cont)

PROBABLE CAUSE

MALFUNCTION

CORRECTIVE ACTION

—a.

Oil level too low.

a.

Add oil until proper level is indicated on oil
level gage (para 3-4).

b.

Defective oil pressure
gage.

b.

Replace gage (para 3-121).

—c.

Defective oil pressure
transmitter.

c.

Replace transmitter (para 3-193).

—d.
—e.

Clogged lube oil filters.

Service filters (para 3-4).

Improper viscosity oil

—d.
e.

—f.
g.

Worn oil pump.

—f.

Replace oil pump.

Worn bearings.

g.

Replace bearings.

—a.

Improper turbocharger
lubrication.

—a.

Clean turbocharger oil passages (para 3-203).

b.
—

Loose turbocharger end
plates.

b.

Tighten end plate screws (para 3 -203).

—a .

Loose turbocharger
end plates.

—a.

Tighten turbocharger end plate screws
(para 3-203).

b.

Defective turbocharger
housing.

—b.

Inspect housing. Replace turbocharger
(para 3-203).

10. High oil pressure
indicated on oil
pressure gage.

—a.

See b, c and e from
malfunction 7.

—a.

See b.
— c and —e of malfunction 7.

b.
—

Oil pressure regulator.

—b.

Replace oil pressure regulator

11. High coolant temperature indicated on
coolant temperature
gage.

—a.
b.
—

Coolant level low.

—a.
b.
—

Add coolant (para 3-41).

—c.
—d.

Lube oil level low.

—c.
—d.

Add lube oil (fig. 3-l).

7.

oil pressure indicated on oil pressure
gage.

LOW

8. Noisy turbocharger.

9.

Turbocharger
oil.

leaks

High coolant temperature
due to incorrect coolant.

Defective or improperly
adjusted fan belts.

Drain crankcase and fill with proper lube oil
(fig. 3-l).

Check for proper coolant mixture. Correct
or replace as necessary (para 3-41).

Adjust or replace fan belts (para 3-183).

—e.

Insufficient heat transfer
through radiator.

—e.

Check
Check
Insure
12,300

f.
—

Defective coolant
thermostat.

f.

Replace thermostat (para 3-209).

g.

Defective water pump.

g.

Replace water pump (para 3-206).

—h.
i.

Clogged radiator.

h

Replace radiator (para 3-172).

Generator set overloaded.

i.

Check that the generator load does not exceed the ratings specified on the kilowatt
capacity nameplate 70-1345 (M2), 70-1346
(Ml).

j.

Defective coolant temperature transmitter.

j.

Replace transmitter (para 3-209).

—k.

Defective coolant temperature gage.

k.

Replace gage (para 3-120).

that air inlet doors are open.
shutter operation (para 3-171).
that there is at least 10.200 CFM or
CFM cu. ft. air supply (fig. 2-l).

C h a n g e 3 3-23

Table 3-3. Troubleshooting (Cont)

MALFUNCTION
1 1 . (Deleted)
12. Low coolant temperature indicated on
coolant temperature
gage.

13. Battery charging
ammeter shows no
charging when batteries are low or
discharged.

14. Battery charging
ammeter indicates
excessive charging
rate after prolonged
operation.

15. Ac voltmeter does
not indicate any
set voltage,

3 - 2 4 Change 1

PROBABLE CAUSE
l. & m. (Deleted)
Defective coolant thermoa.
—
stat.

CORRECTIVE ACTION
l . & m . (Deleted)
a. replace thermostat (para 3-209).

b—.

Defective or improperly
adjusted radiator
shutter and control
assembly.

b—.

Adjust or replace shutter or control assembly
(para 3-171).

c.
—

Defective coolant temperature transmitter.

c.

Replace transmitter (para 3-209).

d.
—

Defective coolant
temperature gage.

d.
—

Replace gage (para 3-120).

a.
—

Blown alternator fuse.

a.
—

Replace fuse located at back end of alternator.

b.
—

Improperly adjusted
alternator.

b—.

Adjust alternator (para 3-184).

c.
—

Defective or improperly
adjusted alternator belt.

c.

Adjust or replace belt (para 3-183).

d.
—

Defective

d.
—

Replace alternator - (para 3-184).

e.
—

Defective battery
charging ammeter.

e.
—

Replace ammeter (para 3-124).

f.
—

Open wire in charging
circuit.

f.
—

Find open wire and repair.

a.
—

Improperly adjusted
alternator.

a.
—

Adjust alternator (para 3-184).

b— .

Defective

b—.

Service or replace batteries (para 3-82).

c.
—

Low resistance or short
to ground.

c.
—

Inspect wiring and repair as necessary.

d.

Defective

d.

Replace alternator (para 3-184).

e.
—

Defective battery
charging ammeter.

e.
—

Replace ammeter (para 3-108).

a.
—

Defective speed switch.

a.

Replace speed switch (para 3-186).

b—.

Defective VOLTS-AMPS
selector switch.

b—.

Replace switch (para 3-11 2).

c.
—

Defective ac voltmeter.

c.
—

Replace voltmeter (para 3-105).

alternator.

batteries.

alternator.

Table 3-3. Troubleshooting (Cont)
MALFUNCTION

PROBABLE CAUSE
Defective VOLTAGE
ADJUST rheostat.

16. Ac voltage too high
or too low.
17. Ac voltmeter indicates voltage but
frequency is off
scale to left.
18. Ac voltage
fluctuates.

19. Erratic frequency
indicator on frequency meter.

20. Frequency meter
fails to register.

Replace rheostat (para 3-110).

a.

Engine speed too low.

a.

Adjust frequency adjust control (precise).
Increase speed manually (utility).

b.

Defective meter or
transducer.

b.

Replace meter and transducer (para 3-111).

a.

Loose electrical
connection.

a.

Inspect harness and connectors and repair
(para 3-139).

b.

Defective VOLTS-AMPS
switch.

b.

Replace switch (para 3-112).

c.

Defective VOLTAGE
ADJUST rheostat.

c.

Replace Rheostat (para 3-110).

d.

Defective ac voltmeter.

d.

Replace meter (para 3-105).

a.

Air in fuel.

a.

Bleed fuel system (para 3-56).

b.

Defective nozzle holder
assembly.

b.

Replace nozzle holder assembly (para 3-201).

c.

Improperly adjusted
valves.

c.

Adjust valves (para 3-220).

d.

Defective frequency
transducer or frequency meter.

d.

Replace transducer and meter (para 3-111).

a.

Frequency meter
defective.

a.

Replace meter and transducer (para 3-111).

b.

Frequency transducer
defective.

b.

Replace frequency meter and transducer
(para 3-111).
Replace meter (para 3-106).

Kilowatt meter defective,

21. Kilowatt. meter fails
to register.
22. Engine generator set
shuts down, NO FUEL
indicator illuminates,
but sufficient fuel remains in main tank
for operation.

CORRECTIVE ACTION

a.

Defective day tank
float switch.

a.

Replace float switch (para 3-159).

b.

Defective fuel solenoid
valve.

b.

Replace solenoid valve (para 3-158).

c.

Clogged fuel filter or
strainer.

c.

Service filter and strainer. (para 3-34).

d.

Clogged fuel transfer
pump screens.

d.

Service fuel transfer pumps (para 3-165).

e.
—

Defective fuel transfer
pumps.

e.

Replace pumps (para 3-165).

3-25

Table 3-3. Troubleshooting (Cont)
PROBABLE CAUSE

MALFUNCTION

CORRECTIVE ACTION

23. Engine generator set
shuts down, HIGH
COOLANT TEMP
indicator illuminates
but coolant temperature is normal.

Defective coolant
temperature switch.

Replace switch (para 3-209).

24. Engine generator set
shuts down, low oil
pressure indicator
illuminates, but oil
pressure is normal.

Defective oil pressure
switch.

Replace switch (para 3-194).

25. Engine generator set
shuts down, over speed indicator illuminates, but engine
speed is normal.

Defective overspeed
switch.

Replace switch (para 3-186).

26. All meters read correctly except volt meter reads off scale
high.

Defective voltage adjust
rheostat.

Replace rheostat (para 3-110).

27. Circuit breaker
switch is closed and
indicator does not
light.
28. Main AC contactor
(CB2) will not close.

3-26

Change 8

a.

Defective load circuit
breaker switch.

a.

Replace circuit breaker switch (para 3-117).

b.

Lamp burned out.

b.

Replace lamp (para 3-26).

Main AC contactor (CB2)
defective.

Measure continuity of coil pins A and B. If no
continuity, replace contactor (para 3-141).

Section

3 - 6 6 .

F I E L D

VI.

E X P E D I E N T

G e n e r a l .

Organizational

R E P A I R S

Expedient

T r o u b l e

maintenance

cur while the engine

WARNING

level troubles may oc-

generator

set is operating

in
Do not add coolant to

the field where supplies and repair parts are not
available

and normal corrective
When

performed.
ing expedient

radiator until pressure

action cannot be

this condition

exists,

the follow-

has been relieved.

repairs may be used in emergencies
Equip-

upon the decision of the unit commander.
ment so repaired

must be removed

as soon as possible and properly

Water pump leaks.

Loosen radiator cap so as
to

from operation

relieve

pressure.

inue engine

repaired before

as frequently
Fuel

is

not

to maintain

assembly
Fuel tank strainer

Run engine

element

with defective

defective.

element

generator

(para

set,

With

placement.

until

is obtained

3-71.

Engine

Heat

Up.

3-34).
Expedient Remedy

Smoke.

Trouble

Expedient

Remedy

Badly worn fan belt.

Continue

engine operation

with defective
Defective

exhaust

pipe.

Run engine

generator

with defective
until

(para

belt

is ob-

is obtained,

or until

engine can be shut down.

3-86).

Frequently
belt

Engine

fan belt

installed until replacement

set

exhaust pipe

replacement

tained

3-69.

can

shut

down for water pump re-

Trouble
Filled

until engine

be conveniently

strainer

installed

replacement

water level

above top of radiator coil

Expedient Remedy

Housing

to radiator
as necessary

Strained.

Trouble

3-68.

Cont-

operation

adding coolant

being placed in operation again.
3-67.

Remedy

(Para

observe fan
3-183.

)

Overheating.
3-72.
Expedient

Trouble

Shutter control

assembly

If the engine

is running

too hot, manually

not operational.

Engine
and

Remedy

Cranks

Runs

But

Will

Erratically

Trouble

Not
or

Start

or

Expedient Remedy

open

shutter with the lever to

Clogged

fuel filter.

Shut down engine

keep shutters open until

fuel filter

the engine

strainer element

is normally

3 - 3 4 b ) .

ance

air, If available,

reason.

and remove

cartridge and

shut down for n>aintenor other

Starts

Misfires.

( p a r a

Use compressed
or shake

vigorously, to clear ob 3-70.

Loss

of

Coolant.

struction.
continue
Expedient

Trouble

Reassemble

placement

Remedy

and

operation until reparts are ob -

tained.
Leaking coolant

hose.

If necessary shut down
engine,
tightly

drain coolant,
wrap leaky area

Clogged fuel transfer

Shut down engine

pump screen.

pump screen

of hose with plastic elec tricians
toring
while

tape.

Keep

repaired
engine

Use compressed
available,

moni-

hose area

Reassemble

hose is

radiator.

Liberally
putty,

vigor-

obstruction.

and continue

operation until replacement

obtained.

Leaking

3-165).

air, if

or shake

OUSIY, to clear

is operating

until replacement

and remove

(para

parts are obtained.

apply

or other

epoxy, tar,
nonsoluble

substance to leaking
of radiator.

area

Let dry.

Defective

fuel line.

Shut down engine and tightly
wrap area of line leak with
plastic

electrician’s

tape.

Keep monitoring

repaired
is operating

Fill radiator and operate

line while engine

engine until replacement

until a replacement

radiator is obtained.

is obtained.

fuel line

3 - 2 7

3-72.

Engine
and

Cranks

Runs

But

Will

Erratically

Not

or

Start

or

Trouble

Starts

Misfires.

Expedient

tape.
Expedient

Trouble

Remedy

Keep

monitoring

re-

paired line while engine is
operating

If repaired

Remedy

(Cont)

fuel line leaks,

and a replacement

oil line is obtained.

shut down engine.
3-74.
Shut down engine

Clogged air filter.

move filter element
3 - 5 ) .

(fig.

Use compressed

if available,

Reassemble
operation

Shows

Trouble

Expedient

obstruction.

Battery charging

alter-

Continue

nator defective.

and continue

ing alternator

until replacement

replacement

connect
( p a r a

fuel selector
3 - 1 6 6 ) .

3 - 2 8 )

(24).

assembly

(21,

Use

3-75.

of

Frequency

Control

(Class

1

Expedient

Governor

Sets

Only).

Remedy

Shut down the engine genera-

system fails

tor set and disconnect

to operate properly.

Keep

governor control

moni-

Remove cover

fuel line

(fig.

(12,

l-l).

fig.

3-17).

Loosen screw (13) and move

is operating

until a replacement

plugs

J17 and J21 on the electrical

to comp-

reconnected

while engine

Loss

Trouble

(15) connection

connection.

charging alter-

hose

tape as necessary
lete

or

fig.

and plastic electrician’s

toring

until

valve

directly to hose as-

sembly

installed
is obtained

nator service or repair.

Connect

hose assembly

operation

until engine can be shut down

Shut down engine and dis -

valve,

Remedy

engine

for battery
fuel selector

Charge.

with defective battery charg -

parts are obtained.

Defective

No

air,

or shake vigor

ously, to clear

Charging Ammeter

Battery

and re-

fuel pump lever all the way

fuel

selector valve

is obtained.

forward and tighten screw,

If reconnected

fuel line leaks,

Move actuator

shut down engine.

retracted

linkage

position.

to the

Operate

set as class 2 unit until fault
3 - 7 3 .

Engine

Shuts

Indicator

D o w n and

LOW

OIL

in governor system can be

PRESSURE

corrected.

Lights.

Trouble

Expedient

NOTE

Remedy
If actuator

Defective

oil line.

linkage

main in retracted position dis -

leak with plastic electrician’s

connect

actuator

wire arm

(3,

down position

Section

3-76.

General

Methods

Used

to

VII.

Attain

RADIO

INTERFERENCE

Proper

b.

Suppression.

Secondary

components

suppression

is attained

by providing a

low resistance path to ground for the stray currents.
The methods used include
wires,

shielding

Suppression

Interference

a.

Primary

function
exciter

3-78.

Suppression

Components.

Suppression

Components.

contains

(EMI) suppression

suppression

on this generator

compo-

set,

Replacement

of

Suppression

Components.

Fuel Pumps.

assembly.

Replace fuel pumps with integral

suppression

paragraph

components as des -

3-165.

The

Battery

alternator

Charging

with integral

described in

Alternator.

Replace

RFI suppression

p a r a g r a p h

the

diodes as

3 - 1 8 4 .

assembly to suppress

this

contactor,

day tank solenoid valve, battery

The fuel pumps, main

and load bank (if installed)

primary suppression components.
3 - 2 8

or secondary to their

No secondarv

—
b.

an Electromagnetic

EMI from

ing alternator

These

suppression

The

is to suppress radio interference.

Interference

function.

radtr.irds for loose

IooEe terminal

connecllt)ns.

.1 . Inspect

c o n n e c t o r s

o t h e r

f o r

b e n t

o r

b r o k e n

p i n s

I n s p e c t

w i r i n g

Hz

[he

two

bent

or broken

b. Inspect

d a m a g e .

r e l a y s

f o r

c o r r o s i o n

l o o s e
a n d

{he

50 60 Hz switch

for loose

mcmnting.

cor;’osion and other damage.

3-151.
d .

(50

pin; and other ciaml:e.

I n s p e c t

a n d

1

nluuntin:,

corrosion. and other

damage.

c .

Precise

Inspection.

m o u n t i n g ,
o t h e r

Special

Relay

Assembly

(50

60

Hz)

Inspection.

l o o s e

d a m a g e .

C h a n g e

7

3 - 7 3

a, Loosen

the two top screws

which

secure

the

a. Loosen

cov;r to the front panel.
b. Remove
frofit panel

the bottom two screws

and let the

b. Remove

slide down, then remove.

c. Inspect
loo;e

the

mounting,

cross
loose

current
wiring,

adjust

control

corrosion,

for

the terminal

e. Inspect

transformer

Ioo;e connections,
&

Inspect

boards

connections,

ren~ adjust

wiring

for

for loose

ing~ loose

corrosion,

terminal

loose connections,

and

f. Inspect

~.
loose

mounting,

relay assembly for dents,

loose connectors,

Inspect

the

relays

wiring

relay assembly

with bottom two screws.

for loose mounting,
and other

for fraying,

loose

~ Tighten

top two screws.

Relay

front panel

Assembly

(400

Hz)

Inspection.

XXII.

3-153.

GENERATOR

Load

Measuring

loose

assembly is used to generate
Maintenance

by sliding

Generator

b. Inspect

c. Listen
—
3-156.

Unit

( f i g .

1 - 1 )

due to overheat,

Generator

Bearing

in this posi -

DAY

TANK

AND

G e n e r a l .

on day tank and

The day tank is used to gravity
pump. The fuel supplied

to the day tank from the main tank passes through the
strainer

3 - 7 4

and primary fuel

filter.

frame

refer to next

for cracks,

and

in operation.

Inspection.

bearing

Examine

wear, or discoloration

feed fuel to the fuel injector

damage.

for excessive
Inspect ac generator

This section contains information

breaks,

and other

for unusual nowes while

tion cover plate.

XXIII.

unit for dents,

connector,

ac generator

hea~ by placing an open hand on the generator end

Section

Inspection.

level.

bell. If the hand cannot be maintained

assembly.

under

oth~r damage.

Inspection.

a. Inspect ac generator

the panel

it to special relay

elec-

at the organizational

level consists of the following inspections.

fuel filter

damage.

ASSEMBLY

tion for one minute,

General.

3 - 1 5 7 .

for dents,

and other

top two screws.

higher maintenance

3-155.

and

assembly with bottom two screws.

Section

power.

corrosion,

relay assembly

the~op two screws and securing

loose mounting,

trical

loose

damage.

connectors,

Inspect the load measuring

The generator

and other damage.

by sliding front panel under the top
i. Replace

3-154.

and

for loose mounting,

corrosion,

h. Inspect the special

Special

for corrosion,

and other

two screws and securing it to special

3-152.

boards for loose mount-

connections,

corrosion,

loo;e mounting,

i. Tighten

loose wiring,

other damage.

damage.

~. Replace

and cross cur-

mounting,

and other damage.

cofiections,

the special

sharing adjust

controls for loose

~. Inspect transformer

damage.

other damage.

~. Inspect

and let the

other damage.

mounting,

and other

fraying,

two screws

d. Inspect the terminal

mount-

and other damage.

for loose

corrosion,

the bottom

c. Inspect the load

and other

corrosion,

~. Inspect

which secure the

frofit panel slide down then remove.

damage.

ing, loose terminal

the two top screws

cov;r to the front panel.

The strainer

and

FUEL

FILTER

by removing

bearing

inspec-

for signs of

due to overheating.

ASSEMBLY

primary

fuel filter prevent

entering

the day tank.

foreign particles

from

A solenoid valve on the main

tank is used to control the flow of fuel to the day tank.
The solenoid valve is controlled

by the float level

switch which is actuated by the level of the fuel in
the day tank.

1.

Hose assy

14.

Hose assy

2.

Elbow

15.

Hose assy

3.

Reducer

16.

Clamp

4.

Hose assy

17.

Screw

5.

Connector

18.

Nut

6.

Reducer

19.

Clamp

7.

Screw

20.

Screw

2 8 A .

:

32:
*Note:

Heater

fuel

Washer

43.

Screw

Elbow

44.

Nut

45.

Washer

Plug*
shutoff valve

fuel winterization

Washer

21.

Nut

33.

Tee

Screw

22.

Clamp

34.

Solenoid

8B.

Washer

23.

Bracket

35.

9.

Fuel

24.

Hose assy

36.

Connector

25.

Screw

37.

10.

Screw
Washer

Nipple

49.

Dead crank switch

Drain cock

50.

Bracket

Reducer

51.

Bracket

Screw

26.

Bracket

38.

Float

Nut

27.

Screw

39.

Elbow

13.

Clamp

28.

Nut

40.

Elbow

3-158.

See

Solenoid

figure

3-27

Day

Tank

Valve.

and

Fuel

b.
—

and proceed as follows:

a.

Inspection.
mounting,

other damage.

Inspect
dents,

solenoid

breaks,

valve

stripped

valve

switch

Filter

Assembly

Testing.

Test solenoid

(1) Disconnect
solenoid

loo;e

(34)

Screw
Nut

47.

11”

3-27.

4 6 A .

48.

12.

Figure

46.

if

kit installed

8.

assy

Elbow
Day tank

~;;jed)

8A.

filter

41.
42.

electrical

valve

(34) as follows:

connector

on

valve (34).

for

threads

or

(2)
terminals

Intermittently
on the

apply

solenoid

24

valve

volts

to

connector

the
and

C h a n g e

1 3 - 7 5

listen

for evidence

- noid action

of solenoid

is heard, replace

(3) Reconnect

actuation.

the electrical

(5) Install

If no sole-

the solenoid

valve (34).

moval

c.

connector.

float

switch

(38) using above

re-

steps in reverse order.

Removal

and Replacement.

Replace

the day

tati– (42) as follows:
c.

Removal

sol=noid

valve

and

Replacement.

To

repltice

the
(1)

(34) proceed as follows:

(1) Open drain

cock(36)

(42) and drain talk coutents

Removal.

(~) Open drain cock (36) on bottom

on bottom of day tank

ir,to a suitable contain-

of day

tank (42) and drain tank contents into a suitable
container.

er.

(2) Disconnect

and tag electrical

(b) Tag

connectors

from the float switch (38)
., and the solenoid valve

nectors

(34).

(34).

(3) Disconnect

and disconnect

frfim float switch

(~) Unscrew

fuel lines from day tank.

the

the electrical

con-

(38) and solenoid valve

float

switch

(38) from the

day tank (42) and lift the float switch assembly
(4) Disconnect
and remove

fuel line attached

to elbow (31)

from the tank.

elbow from tee (33).
(d) Discomect
NOT E

(42) and s~lenoid

If fuel winterizat ion kit is installed,
disconnect

(~)

lines

from day tank

Remove

the

four

screws

(25)

and

wash-

ers (28A) which secure day tank (42) to bracket (51)

heater fuel shutoff valve

and remove day tank.

(32) from tee (33).

(5) Remove

fuel

valve (34)

(2)

the four screws (25) and washers

(28A) which secure day tank (42) to bracket (51) and

Replacement.

Install

day

using the removal steps in reverse

tank

(42)

by

order.

remove day tank.
(6) Remove

tee (33) from solenoid

valve

(34).

3-160.

Fuel

Filter

Assembly

Removal

and

Replace-

m e n t .
(7) Unscrew

and remove

solenoid

valve (34)
To replace the fuel filter assembly, see

from day tank (42).

3 - 2 7
(8) Install
sequence

3-159.

new solenoid

valve (34) in reverse
NOT E

of removal procedures.

Day

Tank

and

Float

Refer to p a r a g r a p h

Switch

3 - 3 4 for prc -

cedure’s to replace
See

figure

of fuel filter

3 - 2 7 and proceed as follows:

a. Inspection.

Inspect

the

float

switch

(38)

which

is iiiounted

on the day tank (42) for loose connector

(10),

mounting,

loose

f i g u r e

and proceed as follows:

and other

a.
—

assembly.

Removal.

(1) Open drain

damage.

filter element

cocks

on fuel filter

assembly

(9) and drain into suitable container.
~.

Testing.

‘Test the float switch (38) as
(2) Clean

follows:

dirt

from filter

head,

filter

body

and surrounding area.
(1) Remove

connector

(10) from

float
(3) Disconnect

switch (38).

remove
(2) Remove

float

switch

(3) Connect

an ohmmeter

fuel filter

hose assemblies

(1 and 4) and

assembly (9) by removing the

four screws (7) and washers(8).

(38) from day tank

(42).
b.
between

D of the connector (10) and verify continuity when
the bottom float is placed at its bottom position and
verify open circuit

(2)

(4) Connect

an ohmmeter

and B of the connector

between

verify open circuit
t ion.

9

blv
. (9).
. .

pins A

(10) and verify continuity

when the top float is placed at its bottom position

C h a n g e

(1) See
assembly

f i g u r e

3 - 2 7

and replace fuel filter

(9) in the reverse order of removal.

when float is placed at its top

position.

3 - 7 6

Installation.

pina C and

and

when float is placed at its top posi-

Close

drain

cocks

on

fuel

filter

assem-

Section

XXIV.

LIFTING

FRAME

A N D

3 - 1 6 1 .

F U E L

ASSEMBLY,

T R A N S F E R

START

ASSEMBLY

P U M P S

G e n e r a l .

(Q) Check
outlined

The center support is located

AID

operation

of ether tank (8) as

in step (2) above.

at the center of the

housing and provides a means of lifting the generator set by use of a clevis located

on each side of

(s) Connect

tube (1) to adapter

(3) on

solenoid valve (4).

the top of the center support. The start aid assembly

mounted on the center support, is used as

an aid in starting the engine at temperatures
40° F. This system

is controlled

below

by the ENGINE

PRIMER switch on the control cubicle

panel when

the engine is being cranked aml the START-RUNSTOP switch

is in the START

the ENGINE PRIMER
ated,

under

these conditions,

ether is injected

Each

one metered

(4) operation

in step (3), disconnect

was not

solenoid connector

and check for 24 volts dc at the pins of its mating
connector
actuated

each time the ENGINE PRIMER switch is

with the engine cranked.

time
actu-

shot of

(6) If 24 volts dc is measured
place the solenoid valve

in step (5), re-

(4) as follows:

into the engine air intake system.

This section also contains
tenance of the electric
are utilized

position.

switch is momentarily

(5) If solenoid valve
verified

information

fuel transfer

(~) Remove

for main-

pumps which

two screws

(9) and nuts (10)

which secure the solenoid valve (4) to the framework.

to transfer fuel from the main fuel

tank to the day tank.
~) while holding ether tank (8) securely,
3-162.

Start

Aid

open bracket (7) and remove the tank and attached

Assembly.

solenoid valve as an assembly.
a .

I n s p e c t i o n .

sol=nold

valve

ing, dents,
~.

I n s p e c t

( 4 )

loose

ether tank

(8,

fig.

3-28)
(c) Remove

and bracket (7) for loose mount-

fittings,

and other

Testi w and Replacement.

(~) Install the new solenoid
adapter

(1) Disconnect tube

(1,

adapter (3) and install

fig.

3-28)

in a

new solen~id valve.

damage.

from adap-

valve (4) with

using two screws (9) and nuts (10). Do not

tighten screws (9) securely.

ter (3) on solenoid valve (4),
(g) Connect
WARNING

tube

(1) to adapter

(3) on

solenoid valve (4) and tighten the solenoid valve
mounting screws (9) securely.

Be careful n~t to inhale
(f) Screw a new ether tank (8) into the

ether gas as drowsiness
and unconsciousness

may

solenoid ~itlve (4).

result.
(g) Close bracket
(2) Crank

the engine

and momentarily

and release the ENGINE PRIMER
server watches the solenoid
spray of ether is observed,

valve

actuate

switch, while
(4) opening.

for audible

valve (4) operation

perform

step (3).

evidence

of solenoid

while the ENGINE PRIMER

switch is repeatedly

(7) If 24 volts dc was not measured
(5), test the ENGINE PRIMER
(Refer to

3-163.

Lifting

valve

fied in step (3), replace

(~) Open

in step

switch and replace

paragraph

3-118a.)

Frame.

actuated.
a. Inspection. See

(4) If solenoid

tank

an obIf no

if defective.
(3) Listen

(7) to secure ether

(8).

(4), operation

is veri-

ether tank (8) as follows:

bracket

lift~W

Re

f i g u r e

(8 1) for breaks,

ing, corrosion
b.

(7).

irame

3 - 2 8

and inspect

cracks,

loose

mount-

and rust.

lacement.

Replace

clevis

(80)

in

accord-

ante
-with
+8.
figure
@) Unscrew
valve (4) and remove

ether tank

(8) from solenoid
3-164.

ether tank.

Filler

Cap,

Gasket,

Strainer,

and

Hose

Replacement.
(c) Install new ether tank (8) using above
procedure–in

See

reverse.

figure

3-28

(items 39 thru 59 and proceed as

follows:
WARNING
a. Remove
Be careful not to inhale
drowsiness

ether gas as

and unconsciousness

item

(39). Items

(40) and

(42)

will

co~e out together.

may result.
3 - 7 7

b. see p a r a g r a p h

3 - 8 7 and remove oil separator (85).

(3) Disconnect

c. Remove nuts (82), clamp and bracket (84), nuts (83), and

tube

assembly

(30) from

both

fuel pumps (37 and 38).

screws (W.
d. Remove
(50T Loosen

screws
clamps

e. Remove

(49),

washers

and remove

clamp

(44)

(51)

and

nuts

hoses (47 and48).

and remove

filler

(4) Remove

neck

(43L

four screws (34) and nuts (35)

which secure fuel pumps.

(5) To

reassemble,

reverse

the

disassembly

sequence.

f. Remove

remainder

of items

in

sequential

3-166.

Fuel

Selector

Valve

and

Lines

Replacement.

ordir.
See
~. InSt._dl

3 - 1 6 5 .
See

in reverse

F u e l

figure

a.

sequence

T r a n s f e r
3-28

of removal.

(1) Twist and remove

cover and gasket

from body of fuel pump (3’7 and 38).

remove

filter from fuel

pump

body.

Specification

(25),

(15),

(17),

(21),

(23),

(22),

(27),

(28)

fig.

3-28:

KEY

Servicing.

(3) Wash

filter with cleaning

P-D-680

(4) Inspect

solvent

Federal

and dry thoroughly.

filter

and

gasket

for tears.

Re-

filter and gasket.

(5) Position

filter,

and gasket in fuel

pump

body and secure with cover.

~.

Testing.

Test

each

fuel

pump

(37

and

38)

one at a time as follows:

(1) Disconnect

fuel hose assemblies

from

fuel pumps.

(2) Connect top (inlet) of fuel pump to a fuel
source.

(3) Connect
a clean

bottom

(outlet)

of fuel

pump

to

empty container.

(4) Connect
receptacle

bracket.

a 24-Vdc power supply to male

and ground,

requirements

observing ground polarity

(+ or -) as stamped

Fuel pump

should

on fuel pump

deliver

hour of fuel with zero pressure.
inoperative,

18 gallons

If fuel pump

there may be an open circuit

wire lead assembly.
after

rechecking

place

the fuel pump.

If fuel

electrical

(5) At completion

pump

in the

does not operate

test connection,

of test,

per
is

reconnect

re-

fuel

hose assemblies to fuel pump (37 and 38).

c.

Replacement.

and-proceed

See

figure

3-28

(detail A)

as follows:

(1) Disconnect

connectors

on fuel

pumps

(37 and 38).

(2) Disconnect
3 - 7 8

Change

9

(16),
and

(18),

(29),

item num-

(20),

as

(19),

required.

hose

assemblies

(24).

to

1.

Tube

47.

Hose

2.

Atomizer

48.

Hose

3.

Adapter

49.

Screw

4.

Solenoid valve

50.

Nut

5.

Screw

51,

Washer

6.

Nut

52.

Hose

6A.

Nut

53.

Tee

7.

Bracket

54.

Hose

7A.

Strap

55.

Tee

8.

Ether tank

56.

Hose
Hose

Screw

57.

10.

Nut

58.

Tee

lOA.

Nut

59.

Hose

9.

place defective

3 - 2 8 and remove and replace

(24),

P u m p s .

and proceed as follows:

(2) Carefully

f i g u r e

bers

11.

Screw

60.

Screw

12.

Nut

61.

Nut

13.

Cap and chain

62.

Washer

14.

Adapter

63.

15.

Hose assembly

16.

Elbow

64.

17.

Elbow

65.

Nut

18.

Hose assembly

66.

Washer

19.

Elbow

67.

Bracket

20.

Elbow

68.

Screw

21.

Hose assembly

69.

Nut

22.

Elbow

70.

Washer

23.

Elbow

71.

Tail pipe bracket

24.

Hose assembly

72.

Rivet

73.

Load bank support
bracket
Screw

Fuel selector valve

25.

Connector

26.

Elbow

27.

Screw

74.

Screw

28.

Nut

75.

Nut

29.

Fuel selector valve

76.

Cap and chain

30.

Tube assembly

77.

Cotter pin

31.

Elbow

78.

Nut

32.

Elbow

79.

Bolt

33.

Elbow

80.

Clevis

34.

Screw

80A.

Nut

35.

Nut

80B.

Washer

36.

(Deletefi)

80C.

Screw

37.

Fuel pump

80D.

Nut

38.

Fuel pump

80E.

Washer,

39.

Fuel cap

80F. Washer,

40.

Fuel cap gasket

80G.

Screw

41.

Hook

81.

Lifting frame

42.

Strainer

82.

Nut

43.

Filler neck

83.

Nut

44.

Clamp

84.

Clamp and bracket

45.

Fillerneck hose

85.

Oil separator

46.

Clamp

86.

Screw

instruction

plate

flat
bevel

Figure 3-28. Center Support and Related Parts
Change 7

3-79

3-80 Change 9

Figure 3-29.

Section

XXV.

C O O L I N G

G R O U P

CAUTION
3 - 1 6 7 .

G e n e r a l .

The cooling system consists
and shutter controls,
tings, and linkage

of a radiator,

and the

to connect

necessary
these

lines, fit-

components.

The shutter is controlled by the shutter control
thermostat,
See

f i g u r e

which

can

also

be

Check temperature of water with a reliable thermometer. DO not overheat.

shutter

operated

manually.

(5) Observe thermostat (6) as temperature of
the water increases.
If the thermostat (6) is func tioning properly, it should begin to open at 160° F
and be fully open at 202° F.

3 - 2 9 to remove hoses and other related

parts.

(6) Thermostat
(6) is not adjustable. If it does
not operate within the above limits it must be replaced,

3 - 1 6 8 .

G r i l l e .
b. Replacement.

~. Replacemerit.

Replace

grille

( 7 8 ,

f i g .

3 - 2 2 )

as follows:

(1)

(1)

(~) Remove screws

(76,

fig.

3-22)

and cage

(Q) Remove

2 screws

(79) which

(2) Installation.

Install

grille

in

cock

Repair.

Repair
and

grille

(78) by

corners.

corrosion and repaint
ance with services

a.
—

(b) Loosen hose clamp (4) which secures
lower hosF (6) to the shutter control assembly.
(c) Remove nuts 1 , f i g . 3 - 3 0 ) which secure
shutter assembly to contro\ assembly (10) and remove the rod (2) from control assembly (10).

reverse

order

straightening

Remove

prepainted

rust or other

surfaces in accord-

requirements.

and washers

fitti~-,

elbow,

(15

and

17,

fig.

7 screws

(24)

25
and 26) to radiator
[
move both fan guards.

(2) Installation.

which

secure

fan

f i g .

3 - 3 0 )

and

coupling

drain

hose.

fig.

3-30)

(3,

and

3-171.

in reverse

the thermostat

( 6 ,

Shutter

Assembly.

Testing.

Test shutter

(2,

fig.

3-31)

as follows:

order of removal.
(1) Verify

b. Repair. Repair fan guard (25 and 26) by
Remove rust or other
strZig htemng cross members.
corrosion and repaint

Install

in reverse order of removal steps.

shroud (36) and rea.
—

preprinted

surfaces in accord-

ance with service requirements.
Shutter

(17) and remove

3-29)

(16 and 18) on the hy-

guards

3-170.

valve,

3 - 3 1 )

coupling fitting and remove thermostat (6).

the two clamps

(3) Re-install

drain

f i g .

(5) with attached

(e) Remove two nuts

cooler lines to the fan guards (25 and 26).

(2 Remove

of radiator

shutter control assembly

( 3 ,

shutter control assem-

studs (4) w“hich secure the control assembly to the

(1) Remove the 2 screws
which secure

(4) which secure

bly (5) to the bottom

G u a r d .

Replacement.

draulic

Removal.

(~) Remove the two screws

cross members

(6) as

(21).

of removal.

F a n

thermostat

secure

grille at each side and remove grille (78).

3 - 1 6 9 .

the

(a) Drain radiator assembly ( 3 5 , f i g . 3 - 2 9 )
by removfig the radiator cap and opening shutoff

Removal.

nuts (77) which secure grille (78) at top and bottom.

~.

Replace

follmws:

closed

position,

that

shutter (2) changes

when the engine

from

a

is cold, to an

open position when the engine is at operating

temp-

eratures.
(2) Verify

Thermostat.

shutter (2) opens and closes freely

when operated manually.
a.
—

Testing.
(1) To test shutter thermostat

tion, verify that the shutters

( f i g .

3 - 3 0 ) opera -

on the shutter assembly

b.

Adjustment.

ma~ual

With

shutter control

the engine

cold and the

in the closed

position ad-

change from a closed position when the engine is cold,
and to an open position when the engine is at operating

just the nuts on the shutter assembly

temperature.

Check

(2) Remove the thermostat
(Refer to

paragraph

b

( 6 ,

f i g .

3 - 3 0 ) .

shaft to assure that the shutters

mersed but not touching

evenly

water

fully.

below).

S u s p e n d
thermostat (6) in a container of
w a t e r . T h e r m o s t a t must be completely im-

(4) Heat

link

that with manual shutter control in open posi-

tion, the shutters are opened

c.
( 3 )
c l e a n

threaded

are fully closed.

bottom of container.

gradually

and stir

Replacement.

Replace

the shutter(2)

as

foll;ws:

(1)

Removal.

so heat is
(~) Remove ~rille as described in

distributed.

p a r a g r a p h

3-168a.
—

C h a n g e

1

3-81

1.

Nut

4.

stud

7.

Packing

2.

Rod

5.

Gasket

8.

Nut

3.

Nut

6.

Thermostat

9.

Piston

Figure

(~) Remove nuts ( 1 ,
shutter assembly

threaded

fig.

3-30.

3-30)

Shutter

Thermostat

10.

Control

assy

Replacement

(~) Perform steps (s) through @) of

which secure

rod (2) to control assem-

W

graph

p a r a -

3 - 1 7 0 b (1).

bly (10).
(c) Loosen hose clamp
(~) Remove
( 1 ,

1A ,

fig.

radiator

remove

the 8 screws and washers

(1,

fig.

3-29)

and

up–per hose (3) from radiator.

3 - 3 1 ) w~ch secure shutter (2) to the

(17), and remove

(y) Remove shutter as described in

the shutter (2).

p a r a g r a p h

3 - 1 7 1 .
(2) Installation.

Install

shutter

(2) in the

re(s) Remove six screws

verse order of removal.

( 8 4 ,

and nuts (85) which secure the battery
3 - 1 7 2 .

f i g .

3 - 2 2 )

access door

(86) to the lower front housing (93) and remove

R a d i a t o r .

battery access door (86).
a. Replacement.
fig.

To replace

the radiator

( 1 7 ,
~) Perform steps ~ through ~ of

3 - 3 1 ) proceed as follows:

p a r a g r a p h

3 - 8 7 .
(1)

Removal.
(g) Remove
(~) Position

radiator

3 - 8 2

coolant.

Change

9

suitable

container

to collect

10 screws

(55) and nuts (56)

which secure the housing top front (57) in the front
and rear.

1.

Screw

5.

fA.

Washer

6.

Shutter

control

assy

9.

Gasket

10.

Screw

14.

Washer

15.

Cap
Drain

2.

Shutter

7.

Screw

11.

(Delete)

16.

3.

Screw

7A.

Washer

12.

Shroud

17.

4.

Washer

8.

(Delete)

13.

Figure

(Q) Remove

12 screws

3-31.

RH

Cooling

radiator

(58) and cage nuts

(j) Remove

7 screws

sides, and remove

remove both fan guards.

(i) Remove the 2 screws

(15

and

17,

fig.

whi~h secure the two clamps (16 and 18) on

hose

Radiator

3-4)

(24)

(25 and 26) to radiator

(k) Disconnect
fig.

support

Group

fan guards

3 - 2 9 )

radiator

support

(59) which secure the housing top front (57) on the
the cover.

LH

which

secure

shroud (36) and

wiring connections

( 1 4 ,

Z the battery slave receptacles.

the hydraulic cooler lines to the fan guards (25 and
26).

C h a n g e

9 3-83

3-173.

(!) Remove 4 screws ( 8 9 a n d 9 1 , f i g . 3 - 2 2 ) and cage nuts (90

Hydraulic

Cooler.

and 92) which secure the lower front housing (93) to the left and
right hand housing corner posts (138 and 139).

The hydraulic cooler is used on Class 1 sets only.

a. Service. To service the hydraulic cooler ( 1 9 , f i g . 3 - 2 9 )
.—
proceed as follows:

(@ Remove 4 screws (94 and 97) and nuts (95 and 98) which
secure the upper front housing (96) to the left and right hand
housing corner posts and remove upper front housing (96).

(1) Check that the mounting screws (1.5 and 17) are secure.
(g) Perform steps ~ through ~ of p a r a g r a p h

3-86.
(2) Clean dirt off fins.

(g) Remove 10 screws (141 and 148) which secure the front
~ Replacement. To replace the hydraulic cooler ( 1 9 , f i g . 3 - 2 9 )

left and right hand housing corner posts (138 and 139) to the radi-

proceed as follows:

ator support.

(1) Removal.

(p) Remove 4 screws (140 and 147) which secure th bottom
of the left and right hand housing corner posts (138 and 139) to
the radiator support, and remove corner posts.

(q) Position suitable container to receive hydraulic oil
drained from hoses and tubing when disconnected.

(q) Remove 6 screws ( 3 1 , f i g . 3 - 2 9 ) , 12 bevel washers (32),
washer (33) and nuts (34) which secure the RH and LH radiator

@) Disconnect hose (7) from elbow (8)

supports (37 and 38) at the top of the skid base (39).
(g) Remove elbow (8) from connector (9) and remove
connector from flare nut (10).

(1) Remove 8 screws (27), 16 washers (28 and 29) and 8 nuts
(30) which secure the RH and LH racliator supports (37 and 38) to
the sides of skid base (39).

(~) Disconnect hose (11) from connector (12) and remove
connector from adapter (13).

(~) Remove radiator assembly (35), RH and LH radiator
supports (37 and 38) and radiator shroud (36) from skid base (39).

(s) Disconnect adapter (13) from return line (14).
(~ Remove screw (15) and clamp (16) which secure return

(~) Remove 8 screws and washers ( 7 , 7 A , f i g . 3 - 3 1 ) and
nuts (8) which secure radiator (17) and shroud (12) to RH and LH

line to RH fan guard (26).

radiator supports (13 and 14) and remove supports.
@ Remove screw (17) and clamp (18) which secure input
line to LH fian guard (25), and remove hydraulic cooler (19).

(y) Remove screws (9) and washers (10) which secure
radiator 17) to shroud (12) and remove the shroud and radiator.

(2) Installation.
(2) Installation.

Install hydraulic cooler (19) in reverse order

of removal, Replenish hydraulic sump with hydraulic oil.

Install radiator assembly component using

the removal steps as applicable in reverse order.

Section

XXVI.

HYDRAULIC

ACTUATOR

(MEP105A

AND

SUMP

AND

FILTER

ONLY)
a. Disconnect hose ( 6 , f i g . 3 - 3 2 ) from elbow (7) and remove

3-174. General (See fig. 1-28.)

el~ow (7) and packing (8).
a. The hydrwdic actuator is utilized on precise engine
ge;emtor sets. The actuator regulates the engine fuel injection
system in order to maintain rated speed for all load conditions.

b. The hydraulic sump is mounted on the left side of the
engine, on Class 1 precise generator sets. The sump acts as a

Q, Disconnect reducer expander (9) w-ith packing (10) from
filter plug (11).

c. Remove filter plug (11) and packing (12) from hydraulic
actuator.

reservoir for the hydraulic oil pump, used to supply hydraulic
power to the hydraulic actuator.

~, Clean filter plug (11) with cleaning solvent, Federal
Specification P-D-680, and dry thoroughly.

c. The hydrmdic oil filter is mounted on the sump and provides
pr%ection against contaminant

in the hydraulic oil pressure

system.

e.
— Inspect filter screen for tears, holes, irregularity of mesh, or
other damage,

$ Replace cleaned filter plug (1 1), if serviceable, or install a
3-175.

Hydraulic

3 - 8 4

Actuator

C h a n g e

Service.

1 1

new plug and reassemble in the reverse order of removal.

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.

Throttle linkage
Nut self-locking
Lever arm
Return Adapter
Connector J25
Hose
Elbow assembly bulkhead
Packing
Reducer expander
Packing
Filter plug
Packing
Connector J24
Piston

Figure 3-32. Hydraulic Actuator Servicing (MEP105A)

3-176. Removal, of Sump and Filter.

d. See figure 3-33 and remove sump and filter as illustrated.

a. Remove plug (1, fig. 3-33) on sump tank (21). Drain sump
and discard oil.
3-177. Cleaning and Inspection of Sump and Filter.
b. Remove hose assembly (2) from elbow assembly (7). Remove
two loop clamps and associated hardware front of engine.
c. Remove hose assembly (3) from elbow assembly (7) and from
elbow assembly (3A).

a. Cleaning.
—
(1) Flush sump tank (21) thoroughly with hot water or steam
under pressure.

Change 11

3-85

Figure 3-33.

3-86

Change 11

(2) Clean sumv tank and filter thorou~hlv with
cleani~

solvent,

Fe~eral

Specification

[3)
Ins~ect
.,.
3-178.

b.
—

filter

for damze.
<.

P-D--680.
Installation.

Inspection.
a. See
(1) Inspect

threaded

(2) Inspect

sump tank (21) for cracks

filt=r

areas for damage.

~.

3 - 1 7 9 .

Connect

c.
—

XXVII.

E N G I N E

hydraulic

(5) With

and components generate

the

oil, MIL-H-5606.

engine

running observe

(fig.

2-5)

BATTERY

for proper charging

indication.

power to drive the generator.
3-181.

3-180.

lines.

Fill sump with hydraulic

CHG AMMETER

mechanical

and install sump tank (21) and

A S S E M B L Y

G e n e r a l .

The engine assembly

3 - 3 3

or

distort ion.

Section

f i g u r e

in reverse order of removal.

Engine

Assembly

Drain

Hoses.

Testing.
To remove and install the oil pan drain hose assem-

a. Testing.

To

test

the

engine

assembly

proceed

as Follows:

figure

(1) With engine

running,

by observing COOLANT
(fig.

bly and the water block drain hcse assembly.

test for overheating

TEMPERATURE

indicator

3-34

See

and proceed as follows:

a. Remove

oil drain

hose (3) by removing

clamps

(1 ;nd 2).

2-5).
b. Unscrew
(2) With

engine running test for proper oil

and remove

(5) =nd connector

nipple

(4) shutoff

cock

(6).

pressure by observing OIL PRESSURE indicator
(fig.

c. Disconnect

2-5).

water drain

hose (7) from

nipple

(8)

and–remove water drain hose (7).
(3) With engine running test by listening for
engine knocks,

excessive

black,

observe

gray, or blue

exhaust

e. Install

for

rectified

XXVIII.

ALTERNATOR

is a 24 volt, continuous output,
and constructed

extra long periods of reliable

AND

RELATED

tension,

on bearings.

The alternator

alternator belt
force against

stator laminations

between

nator and frames,

not against the

with a single belt.

The idler,

(3) Retighten

the water

capscrew

the alternator

adjusting

(4) To obtain proper

fan belt (9) ten-

sion loosen the idler pulley adjusting

See

Drive

figure

(5) Tighten

and proceed as follows:

capscrew
~.

bracket

capscrew

(6) and move idler pulley (4) as required.

Belts.

3-35.

brace

(5).

by the crankshaft pulley

with an identical matched pair of belts.

3-183.

alter-

is driven by the crank-

pump and the fan mounted on the water pump pulley
are driven simultaneously

apply

end frames.

Both front and rear bearings are sealed and lubri -

shaft pulley

drain hose in

PARTS

When adjusting

diode

to provide

service with minimum

The rotor is mounted

for life.

and needle

(8

CAUTION

unit, designed

maintenance.

nipple

of removal.

G e n e r a l .

The alternator

cated

remove

oil drain hose and wate:

rev~e.

Inspect lens and

and damage.

Testing.

During load bank testing

observe that indicating

(3)

load reject

remove nut (37), washer (38),

in reverse

(9,

light for 100SC

( p a r a

light lights.

positions.

and nut (39) tagging leads before removing
switch.

fnstall

switch

and make continuity

check of switch positions,

switch

breaker.

Remove cover

and inspect indicating
connections,

To

circuit

Light.

lamp for looseness
fig.

tags.

order of removal.

(1)

corrosion,

and other damage.

(40,

and remove

switch (40) for positive action

Check for loose connections.

between positions.
Check

Remove cover

load reject

before

reverse

Switch.

Inspection.

and inspect

leads

To replace the circuit
(3)
Replacement.
breaker ( 4 8 , f i g . 4 - 1 4 ) , remove screws (47) and tag
leads

b. Load Reject
-—

R?connect

a n d

lead reje@

(49

Replacement.

through

nut (51),

54,

washer

fore removing

order of removal.

fig.

To replace

4- 1 4 ) ,

(52),

and

base (54).

indicating

remove

nut (53),

light

lens (49), bulb(50),
tagging

leads

be-

Install in reverse order of

removal.
c.
—

Fan and Motor Assembly.
(1) Inspection. Remove

and inspec-t-rnciuntin~
terioration

cover

grommets

and looseness, wiring

and check fan brushes for wear.
(2) fan guard
material,

(43,

fig.

4-14),

( 9 ,

(5,

f i g .

fig.

overheating

fan blade

and air outlet for foreign

assembly

o%-scrvti-fhrough

(3) Replacement.
4-15),

4 - 4 2

b.

( p a r a

fan ward that fan blade

To replace

remove tan guard

nut (41) and

screw

(43,

Remove cover

reject

relay

connections

for loose

(9,

fig.

4-14),

mounting,

and

damage,

for looseness.

Testing.

Higher level of maintenance

is

c.

(42).

Loo.?en

Higher level of maintenance

is

f i g u r e

fan blade
fig.

Replacement.

req~ired.

( 2 ,

4 - 1 4 ) by resetscrews

a.
f i g .

Terminal

Board.

Impection.
4 - 1 4 )

nectioiis,

fnspect the terminal board

( 6 4 ,

f o r loose nl&nting, loose electrical con-

cracks,

breaks,

and

other

damage.

4 - 1 5 ) securing fan blade (2) and remcwe

blade from motor shaft. To replace
fig.

load

and wiring

4-46.

f i g .

Relay.

req~ired.

4 - 1 5 .

( 1 ,

Reject

Inspection.

ins~ect

for unusual noises, signs of

and other damage.

rotates clockwise with air flow as shown on

moving

Load

a.

leads for fraying,
Inspect

(2) Testing. During’ load bank testing

fig.

4-45.

ior de-

and fan blade for damage and looseness.

Inspect motor

4 - 4 2 b . )

4 - 1 4 )

4-14)

4-15),

grommets

renlove fan and motor assembly

b.

( 5 ,

(46,

fig.

( 6 4

Replace,
f i g .

[]cmt.

4 - 1 4 ) ,

To repIace the terminal

r e m o v e

board

nut (57), screw (58), washer

(59) and spacer
terminal

terminal

nut (61),

order of re-

moval.

at a higher

are tested

and replaced

Thermostat

(1)

Remove

one end of heating

(2) Test

Switch.

open, replace
a. Inspection. Remove cover
ins~ect

thermostat

wiring

connections.

b.

nut which secures harness lead to
element

and remove

lead from

elem,3nt.

level of maintenance.

4-47.

Testing,

nut

(62), and screw (63). Install in reverse
Diodes

b.

(60) tagging leads before removing

board (64), Remove

( 1 6 ,

f i g .

4 - 1 4 )

for proper

and

(3) Measure

(4)

(1) See f i g u r e s

4-13,

4-14,
with

and

4-16

paragraph

and rec.

container

with clean

resistance

below.

Reconnect

continuity.

If

between

4 - 1 4 ) ,

oil having

terminals.

Re.

10 ohms,

lead.

Replacement.
( 8 8 , f i g .

ging leads
(2) Fill suitable

for

sistance should be approximately

operation.

Testing.

move switch in accordance

element
element.

and

switch (85) for loose mounting
Test

heating
heating

To replace

the heating

elements

remove nut (86) and screw (87) tag-

before

removing

elements.

Install

in re-

verse order of removal.

a flash point above 600°F.

(3) Suspend thermostat
oil. Aiso, suspend

switch

a thermometer

(4) Connect multimeter

in container

in container

of

4 - 4 9 .

between switch terminals.

See f i g u r e s

1-1,

and proceed

as follows:

WARNING

~. Refer to

Ensure oil in container has a flash point
exceeding

R e m o v a l .

of oil.
1-2,

1-21,

p a r a g r a p h

1-26

2 - 1 3

b. Set % LOAD SELECTOR

or

1-27,

and

4-13,

and stop generator

set.

SWITCH to OFF.

600° F, oil is heated gradually,

and necessary fire precautions are taken.
c. Disconnect
(5) Heat container

of oil gradually, and stir so

f i g .

(6) Observe multimeter

and thermometer

for

indication of infinity (open switch) below 4500F +
150F. At 4500F + 150F, multimeter shall indicate

special

d. Disconnect

infinity

oil to cool,

{switch

open)

multimeter

shall indi-

special

at 351°F * 15°F.

Connect

cable

rel~y box receptacle

70-1212

plug P51

f. Disconnect

Replacement.
4-14)

To

remove

screw (84) tag~ing

replace

thermostat

plug

P51

to tactical

J51.

load bank four-wire

(13Tfrom load terminal
fig.

purpose cable

Replace

if defective.

(85,

plug P50

relay box receptacle

froti cable 70-1212 plug P51.

e.

c.

purpose cable

from tactical

(switch closed).

(7) Permit
cate

4 - 1 4 )

J50.

heat is evenly distributed.

continuity

( 6 ,

power cable

board terminals

(fig.

3-24).

switch

nut (82), washer (83), and

leads before removing

~. Remove load bank four-wire power cable

switch.

fig.

Install switch in reverse order of removal.

( 1 3 ,

4 - 1 4 ) and special purpose cable (6) from the gene-

rator set through the plate and sleeve assembly hole
4-48.

Heater

(fig.

Elements.
wARNING

h. Remove
f i g .

Ensure heater

elements

bank is disconnected

are cold and load

from generator

a. Inspection. Remove cover
insfiect heater
loose

electrical

elements

( 1 6 ,

f i g .

cracks,

power cable

( 1 3 ,

at rear top left side of housing. Replace

screws

in housing after removal of cables and clamps.

4 - 1 4 )

breaks,

load bank four-wire

4 - 1 4 ) and special purpose cable (6) from loop

clamps

set.

and

(88) for loose mounting.

connections,

3-15).

cor-

i.

Remove

six

screws,

12

lockwashers,

and

six

nut~ securing load bank to set housing and remove
load bank from housing.

rosion, and other damage.

4-43/(4-44

blank)

A P P E N D I X

A

R E F E R E N C E S

A - 1 .

Fire

Protection.

TB

5-4200-200-10

Hand

Portable

Fire

Extinguisher

Approved

for

Army

U s e r s .

A - 2 .

Lubrication.

C 9 1 0 0 - I L

Identification

List

for

Fuels,

Lubricants,

Oils

and

W a x e s .

LO

A - 3 .

5-6115-545-12

Lubrication

Order.

Painting.

T . O .

3 5 - 1 - 3

Painting

and

Marking

of

USAF

Aerospace

for

Field

Use.

Ground

Equipment.

T M

A - 4 .

A - 5 .

Radio

9 - 2 1 3

Painting

Instructions

Suppression.

M I L - S T D - 4 6 1

Radio

Interference

Suppression.

TM

Radio

Interference

Suppression.

11-483

Maintenance.

T . O .

0 0 - 2 5 - 2 2 5

Repair

of

External

Power

Cables,

Aerospace

Ground

Equipment.

T.O.

00-25-234

General

Shop

Practice

Maintenance

T . O .

1 - 1 - 1

Cleaning

T . O .

1 - 1 - 2

Corrosion

of

and

Requirements

Test

Aerospace

Control

of

for

Electric

the

Repair,

Equipment.

Equipment.

and

Treatment

for

Aerospace

Equipment.

T . O .

1 - 1 A - 1 4

Installation
tronic

Practices

T . O .

3 1 - 1 - 7 5

General

T . O .

3 5 - 1 - 1 1

Organization,
for

T . O .

3 5 - 1 - 1 2

Maintenance

FSC

3 5 - 1 - 2 6

3 5 - 1 - 5 2 4

and

and

and

Procedures

Elec-

Depot

Level

Maintenance

Equipment.

for

Cleaning

for

FSC

Aerospace

Criteria

6115

Aerospace

Equipment.

Equipment

cable

and

Practices.

Non-Airborne

Repair/Replacement

USAF

Electric

Equipment.

Ground

T . O .

Aircraft

Intermediate

6115

Components
Ground

T . O .

for

Wiring.

to

FSC

TM

9-1870-1

Care

TM

9-2610-200-20

Organizational

Registration
6115

Maintenance

Pneumatic

Care,
Tires

Number

System

Appli-

Equipment.

of

Pneumatic

Maintenance
and

Inner

Tires.

and

Repair

of

Tubes.

A - 1

TM

9-2610-200-34

Direct

Support

Depot

T . O .

TB

3 6 Y 3 2 - 1 - 1 4 2

750-651

Care

Use

and

of

in

D A

P a m

7 3 8 - 7 5 0

T M

5 - 6 1 1 5 - 5 4 5 - 1 2

The

and

G.

Rebuild)

S.

Maintenance

Antifreeze

Engine

Army

Operator

of

Tires

and

Manual

and

Pneumatic

Solutions

Cooling

(Including

Inner

Tubes.

Tires.

Cleaning

Compounds

Systems.

Maintenance

and

Maintenance

Pneumatic

Management

Organizational

Systems.

Maintenance

Manual.

T . O . 3 5 C 2 - 3 - 4 4 4 - 1
N A V F A C

P - 8 - 6 2 6 - 1 2

TM00038G-12

TM

5-6115-545-34

T . O .

3 5 C 2 - 3 - 4 4 4 - 2

N A V F A C

Depot

(Field)

(Direct

Maintenance

and

General

Support)

and

Manual.

P - 8 - 6 2 6 - 3 4

T M

0 0 0 3 8 G - 3 5

T M

5 - 6 1 1 5 - 5 4 5 - 2 4 P

T . O .

Intermediate

3 5 C 2 - 3 - 4 4 4 - 4

N A V F A C

P - 8 - 6 2 6 - 2 5 P

Organizational,
Support,
Special

Intermediate

and

Depot

Tools

List.

(Field),

Direct

Maintenance

Repair

and

General

Parts

and

S L - 4 - 0 0 0 3 8 G
T M

9 - 6 1 4 0 - 2 0 0 - 1 5

Operation

and

Organizational,

Maintenance
TM

5-6115-588-14

Operator,

3 5 C A - 1 - 1 1 1

and

T . O .

N A F A C

P - 8 - 6 0 1

T M - 6 1 1 5 - 1 5 / 4

Shipment

and

T . O .

Repair

Auxiliary

Equipment

Intermediate
and

Parts

Generator

and

Lead

Depot

and

15

Depot
Acid

Type.

(Field)

Maintenance

Special

Through

Tools

200

KW,

(Direct
Manual

List

for

DOD

Sets.

storage.

3 5 - 1 - 4

Processing

and

Equipment

T . O .

Support)

Including

Field.

Batteries,

Organizational,

General

Family

A - 6 .

Storage

3 8 - 1 - 5

Processing
craft

Inspection

for

and

Storage

Inspection

Gasoline

and

of

Aerospace

and

Shipment.

of

Diesel

Ground

Non-Mounted,
Engines

for

Non-Air-

Storage

and

Shipment.

T B

7 4 0 - 9 7 - 2

Preservation
Shipment

TM

A - 7 .

740-90-1

Destruction

T M

of

Administrative

7 5 0 - 2 4 4 - 3

Radioactive

TB

Procedures

750-248

1 2

Equipment

for

Storage

of

Equipment.

for

Destruction

of

Equipment

to

Prevent

U s e .

Instructions

by

C h a n g e

Mechanical

Storage.

Material

and

A - 2

USAMEC

Material.

E n e m y

A - 8 .

of
and

for

Disposal
U.S.

Army

Safe
of

Handling,

Maintenance,

Storage,

Radioactive

Commodities

Managed

Mobility

Equipment

Command.

A P P E N D I X

BASIC

ISSUE

T R O O P

(SECTIONS

ITEM

I N S T A L L E D

I,

II,

AND

Section

B - 1 .

I.

III

B

LIST

AND

O R

ITEMS

A U T H O R I Z E D

NOT

Applicable

minimum
the

This

appendix

driven
ator

or

lists

generator

for

basic

authorized
set,

operation.

issue

which
and

items,

items

accompany

required

installation,

by

or

quantity

supply

be

available

in

system.

troop

the

the

USAF)

INTRODUCTION

S c o p e .

installed

TO

diesel

(2)

crew/oper-

operator’s

main-

level

of

item.

Maintenance
maintenance

The

code,

indicates

authorized

maintenance

level

to

the

install

code

lowest
the

listed

is:

tenance.
C o d e
B - 2 .

Explanation

G e n e r a l .
C

This

basic

issue

authorized
plies

is

list

items,

and

divided

items

troop

maintenance

into

the

installed

and

following

C r e w / O p e r a t o r

or

operating

sup-

(3)

sections

or
a . Basic

Issue

alphabetical
with

and

sequence,

which

b . Items
Section
which

must

Troop

III.

A

at the

accompany

Items

end

c . Maintenance

and

IV.

plies

required

of

item,

li s t i n g

A

items

turned

discretion

the

of

for

Section

or

A

are

with

the

item.

List

salvage.

Operating

subject

Supplies
and

The

Explanation

following

the

tabular

II,

and

Section

of

R

Applied

Items

ment

may
to

Items

of

-

Sec

operating

-

S

Repair

sup-

ment

Troop

explanation

Installed

Items
or

of

columns

List,

Maintenance,

Authorized

List,

-

will

be

used

on

and

special

at

and

test

equip-

economically

general

tools,

support

DSU

Number.

equipeconom-

GSU

are

activ-

furnished

basis.

This

assigned

requisitioning

are

and

exchange

number

test

which

normally

an

Stock

for

and

levels.

which

s to c k

(assemblies

tools

considered

direct

reparable

supply

t h eF e d e r a l

and

eral

Recoverability

Source

item.

code,

Source

indicates

codes

the

source

for

column
to

the

indicates

item

and

purposes.

d .

the
of

Repair

parts,

equipment

for

supply

use

special

supplied

at

tools

from

system

indicated

and

and

Unit

or

ft,

upon
pr,

Quantity

Only).

This

stocked

for

cause

the

tiality

of

special

which

the

are

insurance

combat
end

which

the

description

Fedof

the

the

the

A

the

2

character

amount

allowances

or
are

alpha-

quantity
based,

etc.

Furnished

f . Quantity

parts,

(U/M).

indicating

column

with

Authorized

equipment

indicates

additional

With

Equipment
th e

indicates

quantity

(BIIL
of

an

item

equipment.

maintenance

levels.

Repair

column

any

Measure

ea,

furnished

authorized

of

item

,

e .

test

GSA/DSA

This

and

abbreviation

the

e.g.

name

required.

betic

are

Explanation

Army

item

item

C o d e

P 2

un-

recovery

non-recoverable.

parts

assemblies

and

b . Federal

in

Section

(SMR):

(1)

P

are

parts,

c . Description.

listed

whether

for

III.

a . Source,
Code(s)

are

special

at

and

ically

by

Issue

coded

repair

which

reparable

be

operation.

an

Basic

to

components),

Columns.

provides

list

indicates

returned

are:

maintenance

maintenance

be

Explanation

ities
B-3.

not

codes

C o d e

item.

initial

y

code,

should

Items

Recoverability

-

of

commander

NOT

in

items

furnished

sequence

unit

are

list,

end

Authorized

the

but

II.

which

in

a l p h a be t i c a l

in

with

tion

-

Installed

list,
end

in

of

be

the

turned

List

Recoverability

serviceable

or
item

tools

and

procured
purposes
military
dictates

test

tity
of
m e n t .

and

th e

Authorized

Only).
item

T his

(Items

column

authorized

to

be

Troop

Installed

indicates

t he

or

quan-

used

with

the

equip-

Items

List

Only).

be-

essenthat

a

g . Illustration
This

column

(Basic

is divided

as

Issue

folIows:

B - 1

(1) Figure Number. Indicates the figure number of the illustration in which the items is shown.

quantities required for an average 8 hours of operation.

(2) Item Number. Indicates the callout number
used to reference the item in the illustration.

f . Notes, Column 6. This column indicates informative notes keyed t o data appearing in a preceding column.

B-4. Explanation of Columns in the Tabular List of
Maintenance and Operating Supplies - Section IV.

B-5. Special Information. (Not applicable).

a. Component Application, Column 1. This
colimn identifies the component application of each
maintenance or operating supply item.

B-6. Abbreviations.

b . Federal Stock Number, Column 2. This
column indicates the Federal stock number assigned
to the item and will be used for requisitioning purposes.
c. Description, Column 3. This column indicates the item name and brief description.
d . Quantity Required for Initial Operation,
Column 4. This column indicates the quantity of
each maintenance or operating supply item required
for inttial operation of the equipment.
e. Quantity Required for 8 Hours Operation,
Column 5. This column indicates the estimated

Abbreviation:

Explanation:

hv- duty
deg
ea
hd
ID
in
lb(s)
max
nom
oz
sgl
w/

heavy-duty
degree
each
head
inside diameter
inch
pound(s)
maximum
nominal
ounce
single
with

Section II. BASIC ISSUE ITEMS
(1)

(2)

I

SMR I FEDERAL STOCK
NUMBER
CODE

PAC

7520-559-9618

PAC

5935-00-322-8959

(4)

(3)
DESCRIPTION

I

I REF NO. & MFR
CODE

USABLE
ON CODE

Case, Maintenance and Operational Manual
Adapter Connector

UNIT
OF
MEAS

(5)

(6)

(7)

QTY
INC
IN
UNIT

QTY
FURN
WITH
EQUIP

ILLUSTRATION
(A)
(B)
ITEM
FIG
NO. I NO.

ea
ea

1
1

Section III. ITEMS TROOP INSTALLED OR AUTHORIZED LIST
(1)

(2)

(3)

SMR
CODE

FEDERAL STOCK
NUMBER

DESCRIPTION

1
PAC

4910-273-3663

REF NO. & MFR
CODE

USABLE
ON CODE

(4)

(5)

UNf T
OF
MEAS

QTY AUTH

GAGE: tire pressure, 10 to 160 lbs range.
(See parts manual)

ea

1

PAC

4930-360-2801

GREASE GUN hand, lever operated, 16 oz.

ea

1

PAC

5120-224-4045

HAMMER, I-LAW machinist ball pean,
1 -1/4 lb head,

ea

1

HOSE ASSEMBLY grease gun, hydraulic
coupling one end, other end male connection, 1/8 in NPTF, 3/16 in ID hose,
19-1 1/32 in overall length.

ea

PAC

B-2

4930-141-8311

Change 12

Section

III.

ITEMS

TROOP

INSTALLED

OR

(2)

(1)

AUTHORIZED

LIST

(cont)

(3)

(4)

(5)

DESCRIPTION
SMR

FEDERAL STOCK

UNIT

CODE

NUMBER

OF

4930-262-8868

PAC

USABLE

CODE

ON CODE

OILER,

5120-223-7396

PAC

REF NO. & MFR

HAND

Pump,

capacity,

flexible

PLIERS,

SLIPJOINT

comb w/cutter,
PAC

5975-878-3791

PAC

5120-293-3176

ROD,

WRENCH

16 oz.

spout.
straight

ea

1

ea

1

ea

1

ea

1

nose,

ASSEMBLED

SCREWDRIVER,

5120-240-5328

PAC

fed

MEAS

6 in long.

GROUND,

wide, blade

force

QTY AUTH

FLAT TIP tip 1/4 in

4 in long.

OPEN

END,

hd, 22-112 deg angle,

ADJUSTABLE:

sgl-

hv- duty, 8 in nom,

19 overall, O.947 in max jaw opening.

Section

IV.

MAINTENANCE

(2)

(1)

COMPONENT

FEDERAL

APPLICATION

STOCK NUMBER

AND

OPERATING

SUPPLIES

(4)

(3)
DESCRIPTION

(5)

QUANTITY

QUAN~TY

REQUfRED

REQUIRED

F/INITIAL

F/8 HRS

OPERATION

OPERATION

50 gal

(6)

NOTES

FUEL OIL - DIESEL

FUEL TANK
9140-286-5294(1)

Regular Grade DF 2

55 (4)

9140-286-5286(1)

Winter Grade DF 1

55 (4)

for additional

9140-286-5283(1)

Artic Grade DF A

55 (4)

uisitioning data.

2910-209-4997(1)

Ether Bottle

&

JP=5

ctmsiclertd
91 30-256-8613(1)

(2) See C-6800-IL

-fuel

~fi

for additional

are

fuel onlv
JP4-MIL-T-5b24

req-

ui sitioning data.

memencv
55 (4)

(3) See current

JP5-MIL-T-5624
OIL LUBRICATING

CRANKCASE

req-

1
f! AL?TION

JP-4

(1) See C-91 OO-IL

9150-188-9858(1)

OE/HDO

30 (3) 5 Gal

9150-189-6727(1)

OE/HDO

10 (3) 1

Qt

cation.

20 (6)

Pail

20 (6)

Can

20 (6)

(4) Fuel

system

9150-265-9436(1)

OE/HDO

30 (3) 55 Gal

Drum

20 (6)

capacity.

(in

915!3-191-2772(1)

OE/HDO

10 (3) 55 Gal

Drum

20 (6)

gallons)

(3) 55 Gal Drum

20 (6)

91

91

50-242-7603(1)

50-242-7604(1)

(3) 5 Gal Pail

OES

OES

LO

for grade appli-

(5) Cooling system
OIL,

GOVERNOR
9150-223-4134(1)

OHA,

HYDRAULIC
MIL-H-5606

1

Gal

Can

capacity.

5 qts

(in

quarts)

ANTIFREEZE

RADIATOR
6850-181-792

Antifreeze,
/
6ww-174-1806(2)
Antifreeze,

inhibited

34 (5)

(6) Requires

Artic

34 (5)

quarts to fill
crankcase,

26

lines

and filters.

BATTERY

6810-249-9354(2)

ELECTROLYTE

(7) Requires

4 (7)

4 gal-

lons to fill batteries.

C h a n g e

3 B-3/B-4

blank)

APPENDIX C
MAINTENANCE ALLOCATION CHART
Section I. INTRODUCTION
ARMY and USMC only
C-1. General.
a. This section provides a general explanation of
all maintenance and repair functions authorized at
various maintenance levels.
b . Section II designates overall responsibility for
the performance of maintenance functions on the
identified end item or component. The implementation of the maintenance functions upon the end item
or component will be consistent with the assigned
maintenance functions.
c. Section III lists the tools and test equipment
required for each maintenance function as referenced from Section II.
d. Section IV contains supplemental instructions,
explanatory notes and/or illustrations required for
a particular maintenance function.
C-2. Explanation of Columns in Section II.
a. Group Number. Column 1. The assembly
group is a numerical group assigned to each assembly in a top down breakdown sequence. The applicable assembly groups are listed on the MAC in disassembly sequence beginning with the first assembly removed in a top down disassembly sequence.
b . Group Title. Column 2. This column contains
a brief description of the components of each assembly group.
c . Maintenance Functions, Column 3. This
column lists the various maintenance functions (A
through K) and indicates the lowest maintenance
category authorized to perform these functions. The
symbol designations for the various maintenance
categories are as follows
C - Operator or crew
O - Organizational maintenance
F - Direct support maintenance (DS)

B - Test. To verify serviceability and to detect electrical or mechanical failure by use of test
equipment.
C - Service. To clean, to preserve, to charge,
and to add fuel, lubricants, cooling agents, and air.
If it is desired that elements, such as painting and
lubricating, be defined separately, they may be so
listed.
D - Adjust. To rectify to the extent necessary
to bring into proper operating range.
E - Align. To adjust specified variable elements of an item to bring to optimum performance.
F - Calibrate. To determine the corrections
to be made in the readings of instruments or test
equipment used in precise measurement. Consists
of the comparison of two instruments, one of which
is a certified standard of known accuracy, to detect
and adjust any discrepancy in the accuracy of the instrument being compared with the certified standard.
G - Install. To set up for use in an operational
environment as an emplacement, site, or
vehicle.
H - Replace. To replace unserviceable items
with serviceable like items.
I - Repair. Those maintenance operations
necessary to restore an item to serviceable condition
through correction of material damage or a specific
failure. Repair may be accomplished at each category of maintenance.
J - Overhaul. Normally, the highest degree of
maintenance performed by the Army in order to minimize time work in process is consistent with quality
and economy of operation. It consists of that maintenance necessary to restore an item to completely
serviceable condition as prescribed by maintenance
standards in technical publications for each item of
equipment. Overhaul normally does not return an
item to like new, zero mileage, or zero hour condition.

H - General support maintenance (GS)
D - Depot maintenance
The maintenance functions are defined as follows
A - Inspect. To determine serviceability of an
item by comparing its physical, mechanical, and
electrical characteristics with established standards.

K - Rebuild. The highest degree of material
maintenance consists of restoring equipment as
nearly as possible to new condition in accordance
with original manufacturing standards. Rebuild is
performed only when required by operational considerations or other paramount factors and then only at
the depot maintenance category. Rebuild reduces to
zero the hours or miles the equipment, or component
C-1

thereof,

lowest level of maintenance

has been in use.

authorized

to use the

tool or test equipment.
d.

Tools

and

Equipment.

Column4.

This

column
c.

is Crovided for referencing by code t he tools and test
eq;ipment,

(Section

III)

tenance functions ( S e c t i o n

Nomenclature.

ideiitificatlon

requi-red to perform the mainII).

d. Tool
e.

Remarks.

Column

5.

This

column

by code t he remarks

for–referencing

inent to the maintenance

is

fac~urer’s

provided

Explanation

of

Number.

Columns

Code.

column

lists

the

in

Section

Explanation

This column

of

Columns

in

Section

IV.

consists

Code.

This

column

consists

erences to S e c t i o n

column 5 and the second letter references

the T & TE requirements

tenance function

represents

the item

letter is representative

column on

the specific

tenance

main-

Maintenance

Category.

II.

The first letter references

column

a main-

3, A through K.

Generator

This

column

lists

information

per-

tini%t to th e maintenance

function being performed,

as indicated on the MAC,

Section

MAINTENANCE

Set

Family

60

KW,

and

ALLOCATION

USMC

II.

Tactical,

MAINTENANCE
—

G
R

1
.

CHART

only

Precise

and

Utility,

50/60

and

400

Hz

— (4)

(3)

(2)

(1)

II.

This column shows the

ARMY
DOD

function,

b. Remarks.

A through K on

Section

For

two

is to be used with. The

of columns

the MAC.

b.
—

of

letl%rs separafed by a dash, both of which are ref-

of a

num%er and a letter separated by a dash. The num-

letter

Stock

III.

ber references
the MAC. The

manu-

functions.

a. Reference
a. Reference

This

code and part number, or Federal

Number of tools and-test equipment.

( S e c t i o n IV) pert-

C-4.
C-3.

This column lists the name or

of th e tool or test equipment.

(5)

FUNCTIONS

TOOLS

O
U

AND

GROUP TITLE

P

REMARKS

IQUIPMENT
N

4
rY
d
•1
—

O .

0 1

Batteries

and Related Items

D

Muffler,

Exhaust,

A-

A, B-B

A-A

Nave Receptacle
0 2

1-B

and

Breather

Pipes
Muffler

A-A

Exhaust

A-A

Breather
0

3

Convenience

Circuit
0

4

A-A

Pipes

A-A

Receptacle

Breaker

o

G-B

(Deleted)

0 5

Plate & Sleeve Assembly

A-A

0 6

Paralleling Receptacles

A-A

0 7

Generator
Circuit

C-2

Change

Set Controls
Breaker DC

1

D

G-B

(1)

MAINTENANCE
G
R

(4)

(3)

(2)

A

3

(5)

FUNCTIONS

H

TOOLS

O
U
AND

GROUP TITLE

P

*
u
w
g

N

*

G

i

i

A-A

o

o

o

A- A, D-B,

~
7

Manual

Speed C-d

EQUIPMENT

z
E
a

O .

0

:
<

REMARKS

~

(Cont)
Fhult IncMcatcw

E- I
Lamp8

c

0

lnlee

o

0

0

0

0

D-B

Voltmeter AC

c

0

0

F-D

Wattmeter

AC

c

F

0

D-

Wattmeter

Cowerter

o

F

0

D-B

AC

c

F

0

D-

Rheoetats/potenuometer

o

o

0

Frequency Meter

c

F

0

FYequency

o

F

0

2-B

G-B

switches

c

o

0

2-B

G-B

Gauges

c

0

0

D-B

Hourmeter

c

0

0

D-B

Ammeter

c

0

0

D-B

Relay Assembly

o

F

0

Terminal

0

‘kxdml Box Aesembly

Ammeter

lkanechcer

DC

Beard

panel LigM Assembly

c

Lamp

Air Cleaner

Battle

Clrcult

LigM

Short 1A*

Breaker LigM

mc LlgMs

c

c

c

c

2-B

B,

B,

F-D

F-D

G-B

D-B

0
c

0

c

0

c

0

c

0

c

0

c

0

c

0

c

0

0

0

c - 3

(1)

(2)

(4)

(3)
MAINTENANCE

(5)

FUNCTIONS

G
R
O

x
—

U

E
—

-i
—

5
~

&l

GROUP TITLE

E
N
g

o .

TOOLS

AND
6

P

—
07

z
—

$
cd
H
—

a
z
—

o

0

~
&
W
Z
—

REMARKS

3QUIPMEW

Control Box Assembly

(cont)
Lamp

0 8

0 9

Door Holder

c

0

Cross Pin

c

0

Door

c

0

Harness

o

0

0

Doors

c

0

F

3-1

1-1

Covers

c

0

F

3-1

1-1

Panels

c

0

F

3-1

1-1

0

0

2-B,4-X

A-A,J-K

Housing Group

Engine, Generator and Chassis
Interconnecting

o

0

Wiring

A-A,G-B,
J-K

Harnesses
1 0

11

Load Connection Group

Main Load Contactor

0

Load Term Bd Assembly

0

Current Xfmr Assembly

0

Reconnection Board

0

0

F

A-A,D-B

0

0

A-A

F

F

F

0

o

0

D

0

F

F

F

Control

0

F

0

Actuator

0

F

F

Magnetic Pick Up

0

2-B

A-A,K-B

Governor Control Unit

Electro-Hydraulic

2-B,D,I

L-B,C-l

Electric

12

Air Cleaner Ass’y
Element

1 3

F

c

A-A

c

:

A-A

Relay Table Group

Tactical Relay Assembly

o

F

F

F

2-B

K-B

Precise Relay Assembly

0

F

F

F

2-B

K-B

Special Relay Assembly

0

F

F

H

2-B

K-B

i’

~

F

i’

2-B

2-B

Excitation Assembly
Exciter

C - 4

C h a n g e

1 5

TM

5-6115-545-12

TO-35C2-3-444-1
NAVFAC

P-8-626-12

TM-00038G-12

( 1 )

(3)

(2)

MAINTENANCE

(4)

(5)

FUNCTIONS

G
A
—

R

H

TOOLS

o
GROUP TITLE

u
P

AND

N

5

o .

~

REMARKS

M

&
c1

~

EQUIPMENT

A
a

—
1 3

Relay Table Group

(Cont)
Voltage Regulator

F

F

2–B,

D–B

5–I, J

Load Measuring Unit

1 4

Generator Assembly

o

F

0

F

E–I

6,7–H,

D–B

8–B
9–I, J

Bearing

0

Rectifier Rotating

F

F

F

10– H

N–A

F

2–B,

G–B

11–1

1 5

Fan Generator

F

Rotor Assembly

F

F

F

2–B

O–B, P–K

Stator Exciter Assembly

F

F

F

2-B

O–B, P–K

Stator Generator Assembly

F

F

F

2–B

O–B, P–K

Solenoid Valve

o

o

o

2–B

G–B

Day Tank

c

F

Day Tank and Fuel Filter
Assembly

Float Switch

0

0

Q–C

0

c

c

0

Start Aid Assembly

c

c

0

Filler Cap, Gasket and

c

c

0

Fuel Filter Assembly

1 6

o

c

Q–C

Lifting Frame Assembly

Strainer

1 7

Hoses

c

0

Lifting Frame

o

F

Fuel Transfer Pump

c

0

o

o

Cooling Group
Grill

c

0

Fan Guard

c

0

Change

13

C-5

TM

5-6115-545-12

TO-35C2-3-444-1
NAVFAC

P-8-626-12

TM-00038G-12

(1)

(4)

(3)

(2)

MAINTENANCE

(5)

FUNCTIONS

G
:

R
O

F
—

GROUP TITLE

U
P

AND
L1
b
*
b
n
q

N
O .

TOOLS

w
c)
-j

REMARKS

EQUIPMENT

a
a!
—

1 7

Shutter Thermostat

c

o

Shutters Assembly

c

0

Radiator

c

0

c

0

c

F

Sump

c

o

Filter

c

0

12–B

R–B

(Cont)

Hydraulic

Cooler

1 8

Hydraulic Actuator

1 9

Hydraulic

2 0

D–B

14–B–D

D–B, T–D

Sump and Filter

F

6–H,7– H

D–B

c

o

15–D

V–D

c

0

2–B,

D–B, V–E

Engine Assembly

Belts, Fan

Alternator/Battery

Charging

u–c

16– B,D

2–B, ll– H

G–B

F

2–B

G–B

F

F

2–B

G–B

F

F

2–B,16– B

D–B

c

F

17–B

W–B, X–D

c

o

2 – B, 18,

G–B, Y–D

Diodes

F

F

Brush ASSY

F

F

Rotor

F

Field Assembly
Voltage Regulator (DC)

Hydraulic Pump & Drive
Assembly

Speed Switch and Drive

Speed Switch

19–D

Adapter

c

F

Tach Drive

F

F

c

o

Starter Assembly

c

0

Brushes

E

F

Oil Level Gage and Filler

Electric Starter and Adapter

C-6

Change

13

2–B

D–B

AA–A

(1)

(2)

(3)
MAINTENANCE FUNCTIONS

(4)

(5)

TOOLS
REMARKS

GROUP T~LE
2QUIPME~

20
(Cont)

Solenoid Starter

2-B

D-B

Armature Starter

22-B

AB-B

Xmtr, Pressure

2-B

G-B

Switch, Pressure

2-B

G-B

Drive Starter
Field Assembly
Oil Filter and Sensors

Filter Assembly, Oil

AC-C

AC-C

Secondary Fuel Filter
Lube Oil Cooler
Relief Valve
Nozzle Holder Assemblies
and Lines
Nozzle Holders

23- B,
D- I

AE-D

Lines
L- B,QI

Pump, Fuel Injection
Diffuser and Turbocharger
Diffuser
Turbocharger
Water Pump and F%n
Pump
Fan
Thermostat and Housing
Thermostat

12-B

R-B

Xmtr, Temperature

2-B

G-B

Switch, Temperature

2-B

G-B
Change

8

C-7

D

( 1 )

(4)

(3)

(2)

MMNTENANCE

G
R

(5)

FUNCTIONS
—
H

‘TOOLS

O
U

REMARUS

GROUP TITLE

P

5
j

N
O

.

2

0

( C o n t )

ZQUIPMENI

A
w
&
—
Dampener,

Vibration and

Crankshaft

F

Pulley

Idler Pulley Assembly

o

Intake Manifold

0

EXhSUSt Manifold

0

Engine

F

FYcmt Support

Oil Pan Assembly

F

011 pump

H

Flywheel end Housing

Flywheel Assembly

Eungcear

H

Flywheel

H

Housiw

H

Timing

Gear

and

Cover

H

Cylinder Head and Vslve
Operating Mechanism

Rocker Arm Shaft Assem.

F

bly

Rocker Arm Assembly

F

21-D

V-D

Pushrod

F

Cylinder Head Assembly

F

24-1,25-

AF-1

Valves Intake and Exkuet

F

26-1

D-B

qx’ings Valvw

F

27-H

AG-B

Seats Intake and Exhaust

H

28-H

Guides Valve

H

29-H

Head,

H

valves

Cylinder

Lifters,

camshaft
C - 8

Change

8

Valve

H

H

(4)

(3)

(2)

(1)

(5)

MAINTENANCE FUNCTIONS
G
R

c

TOOLS

O
U

REMARKS

GROUP TITLE

P

9

lQUIPMEIW

5
m
ha
a

N
O .
—
2 0
Piston snd I@s
(Cont)
Pietun P&

Camecting

30-A

31- A,

Rod

32-H

Rod Beu’tng

33-A

Plstal Rtngs

34- A,
35-H

Plstal

36-H

Crankshaft snd mock
33, 37-A,

Cylinder Sleeves

38-H

M a i n

B e a r i n g s

33- A,
37-A

Craukshatt

Brg,

39-A

I

33, 30- A

camshaft

Cylinder Block

2 1

)

)

AH-K

2sss Graup

sensor,

‘Iknk,

2-B

Fuel

D-B

I- I

Fuel

Skid Base

2 2

Jccessory Items

Psralleltng Cable

Fuel Line,

2 3

F

A- A, J-K

Auxilisry

Farts Kits

Garket

Set, Vslve Grindlw

Gasket Set, Intermediate

Hit,

Starter

Kit, Starter Relsy

mt,

Brush,

Electric

C h a n g e

8 C - 9

(3)

(2)

(1)

MAINTENANCE
G
R

4

(4)

(5)

FUNCTIONS

i

I

TOOLS

O
R E M A R K S

u

GROUP TITLE

P

cLI
w
tJ

N
O .

g

w
u
~

EQUIPMENT
~

A
w
a

w
a

—
2 3

Kit, Starter

Solenoid

(Cont)
Ktt, Gasket Set, Fuel

Kit, Water

Pump

Pump

Gasket Set, Oil Pan

Kit, Cylinder

2 4

Jot Used

2 5

Vinterization

Sleeve

Kit Fuel

c

o

F

Box Assembly

0

0

F

0

F

D-B

o

D-B

Burning

Control

Light Assembly
Lamp

Circuit

Breaker

0

Power Switch

Heater Assembly

D-B

F

2-B

G-B

F

2-B

G-B

c

F

F

F

0

F

0

F

2-B

G-B

Receptacle Assembly

0

o

2-B

G-B

Igniter Assembly

0

0

8-B

Switch,

F

F

2-B

Wiring Harnesses

0

o

c

Coolant Pump and Motor Ass

F

F

F

F

F

F

Valve

Assembly,

Terminal

Switch,

Regulator

Board

Limit

Flame

Pump

Motor Assembly

F

F

Relief Valve

C - 1 0

2-B

F

F

Fan

F

F

M&M

F

F

F

D-B

G- B, V-D

A- A, J-K

8-B

MAINTENANCE FUNCTIONS
—

G
R

H
—

O
U

M
u
4
d
&
w
E
—

N
O .

Thermostat

TOOLS

AND

GROUP TITLE

P

2 5

(5)

(4)

(3)

(2)

(1)

Switch

0

REMARKS

EQUIPMENr

2-B

D-B

(Cont)
Burner Chamber

F

Heat

F

Exchanger

Hoses, Lines and Fittings

2 6

0

Ieater Kit, Winterization

0

D-B

Electric

Coolant Pump & Motor Assy

0

Pump

F

Relief Valve

D-B

F

Motor

F

E- I

D-B

Heating Elements

o

0

0

Thermostat

Switch

0

0

0

Hoses and Fifflngs

c

Wiring Harness

c

0

0

o

0

0

Electric

8-B

2-B

D-B

0

A- A, J-K

Winterization

Control

Box

2-B

Wiring Hmmess

F

‘iYansformers

F

F

F

2-B

Relay

F

F

F

2-B

F

F

2-B

o

F

F

2-B

G-B

Power Switch

0

F

F

2-B

G-B

Fuse Holder

0

2-B

G-B

Semi Conductors

Circuit

Breaker

Fuse
Light Assembly

Indicating lamps

0

F

J-K

G-B

F

o

0

0

F

D-B

c

0

D-B

C - 1 1

MAINTENANCE
—

G
R

A

B

(5)

(4)

(3)

(2)

(1)

FUNCTIONS

H

I

TOOLS

O
U
P

REMARKS

GROUP TITLE
H
u
w
&

N

H

a
G

c

c

F

o

Wheels and Tires

c

c

0

0

Bearings Wheel

o

0

Brakes

0

a

0

F

~

2 8

EQUIPMENT
5

g

E
E
E

o .

2 7

:
4

Kit-Wheel

Mounting

Load Bank

40-B

Al-B

0

o

c1

0

0

o

0

0

(1

2-B

G-B

Switch, Load Reject

0

0

o

2-B

G-B

Fan and Motor Assembly

0

0

F

Wiring Harnesses

D-B

A- A, J-K

Control Panel Assembly

Switches,

Rotary

Brushes

0

F

Fan Blade and Guard

0

o

Grommets,

0

0

Circuit

Mounting

Breaker

0

0

0

Indicating Light

0

0

0

0

0

F

F

Lamp

Load Reject Relay

0

Terminal

0

Board

Diodes

Thermostat

Heater

C - 1 2

Elements

0

F

E- I

2-B

G-B

2-B

K-B

2-B

G-B

2-B

G-B

o
F

F

o

o

0

0

Section

III.

MAINTENANCE

ARMY

For

DOD

T O O L

Generator

A N D

T E S T

and

ALLOCATION

USMC

Sets,

60

CHART

only

KW,

50/60

E Q U I P M E N T

and

400

Hz

R E Q U I R E M E N T S
-.

REFERENCE
CODE

1-B

MAINTENANCE

NUMBER

o

Tester,

Battery Elect- Rolyte Solution

(Component

2-B

TOOL

NOMENCLATURE

CATEGORY

0

of Tool Set L/x Tl 31 52)

Multimeter

6630-171-5126
or Equal

6625-581-2036
or Equal

3-I

F

Torch Outfit, Cutting and Welding
(Tool

4-K

o

Set L/I W67706)

Tool Kt, Electrical

3433-357-6311
or Equal

Connector

Repair

5180-876-9336
or Equal

5-D-I-J

F

6625-643-1740

Oscilloscope

or Equal

6-H

F

Hoist,

Chain,

3 Ton

3950-292-9879
or Equal

7-H.

F

Trestle,

Hoist,

Portable,

5 Ton

3950-449-7005
or Equal

8-B

F

Multimeter,

Split

Core

6625-892-1497
or Equal

9-I-J

F

6625-581-2466

Ohmmeter

or Equal

1O-H

F

Puller Attachment

(Component

of

Puller Kit 5180-701 -8046)

11-1

F

Soldering

Outfit,

Electric

5180-711-6753
or Equal

3439-853-8760
or Equal

12-B

o

Thermometer,

Self-Indicating

50-400 Degree

F

Test

Stand,

or Equal

4940-152-2107

Actuator

(Class 1 only)

15-D

6685-527-7867

Deleted

13

14-B-D

F. Range

o

Scale,

or ~qWd~

Dial Indicating,

O-50 lb

6670-254-4634
or Equal

16-B-D

0

Test Set, Generator

and Voltage

Regulator

17-B

F

4~10-270.37~0
or Eqval

Test Gage and Hose Ay

4910-774-9343
f. r ~ql]a]

18-D

F

Tachometer,

Stroboscopic

6630-892-1510
w Yjual

Change

3 C - 1 3

REFERENCE
CODE
19-D

NOMENCLATURE

MAINTENANCE

TOOL
NUMBER

CATEGORY
F

4910-912-3960

Test Stand, Ignition Magneto

or Equal
I
20-I

o

Tester Spring Resiliency

6635-449-3750
or Equal

21-D

F

Gage,

5120-221-1999

Thickness

or Equal

22-B

F

Test

Set, Armature

6625-233-1459
or Equal

23-B-~1

F

Tool Kit, Diesel

Injector

Repair

4910-317-8265
or Equal

24-I

F

Grinding

Kt, Valve

4910-473-6437

Seat

or Equal

25-H

F

Wrench,

Torque

5120-542-5577
or Equal

26-I

F

Grinding

Machine,

Valve

Face

4910-540-4679
or Equal

27-H

F

Lifter,

Valve

5120-239-8686

Spring

or Equal
28-H

H

Remover

and Replacer,

Insert Valve

5120-473-7393
or Equal

Seat
29-H

H

Remover

30-A

H

Caliper

and Replacer,

Valve Guide

5120-219-8404
or Equal

Micrometer,

Outside

or Equal

1 “ thru 2“
31 -A

H

Indicator,

5210-243-2933

Connecting Rod Alignment

4910-733-2487
or Equal

32-H

H

Wrench,

Torque

5120-640-6364
or Equal

33-A

H

Gage

Set,

Telescoping

5120-473-9350
or Equal

34-A

H

Gage, ~ Thickness

5210-517-8097
or Equal

35-H

H

Compressor, Piston Ring

5120-894-0753
or Equal

36-H

H

Expander,

Piston

Ring

5120-393-0549
or Equal

37-A

H

Caliper,

5120-255-7564

Micrometer

or Equal
38-H

H

Puller,

Mechanical,

Sleeve
39-A

H

Caliper,

Cylinder,

5120 -417 -’2952
or Equal

Micrometer

5210-221-1934
or Equal

40-B

C - 1 4

c

Gage,

Tire

Pressure

4910-204-3170
or Equal

Section

IV.

MAINTENANCE

ARMY

REFERENCE

and

ALLOCATION

USMC

CHART

only

REMARKS

CODE
A-A

Visual Inspection

B-B

Hydrometer

C-I

Cover Components Only

D-B

Operational

E-I

Repair by Replacement

F-D

Zero Adjust

GB

Continuity

H-C

Deleted

I-I

Weld and Straighten

J-K

Fabricate

K-B

Test for Known Voltage

L-B,

D&I

Test

Test

of Components

Test

New Harness

In Accordance

at Terminals

with Procedures in Applicable

M-D

Deleted

N-A

Visual,

O-B

Insulation Breakdown and Continuity Tests

P-K

Rewind

Q-C

Drain Condensation

R-B

Thermometer

S-B

Deleted

T-D

Adjust after Replacement

u-c

Check Fluid Level

V-D

Adjust to Specifications

W-B

Test Pressure

X-D

Adjust Pressure

Y-D

Overspeed Only

Z-D

Deleted

M-A

Inspect for Minimum

A&B

Growler Test

Audible

TM

and Physical Heat Detection

Test

or Repair

in Applicable

TM

Output
Output

Length

C - 1 5

REFERENCE

REMARKS

CODE

C - 1 6

AC-C

Replace

Element

AD-D

Deleted

AE-D

Adjust Injector

AF-I

Includes

AG B

Spring Tension and Length

AH- K

Include Replacement

AI-B

Pressure

Pressure Setting

Replacing

Test

Valves and Springs

of Sleeves

A L P H A B E T I C A L

I N D E X
P a r a g r a p h ,
Figure,

Subject

Table,

N u m b e r

A

Abbreviations
A c c e s s o r y

.

.

.

B - 6

.

I t e m s

A c c e s s o r y
General.
H o s e

F 3 - 5 3

I t e m s

.

.

.

.

A s s e m b l y

Cable

Storage

.

A d j u s t i n g

3 - 2 2 8

.

Paralleling
Space

3 - 2 2 7

Assembly.

.

F l a m e

3 - 2 2 6

.

.

.

.- .

.

S w i t c h

.

.

M i c r o - S w i t c h

.

.

.

.

.

.

.

3 - 2 2 9
F 4 - 4

A d j u s t m e n t
F l a m e
Fuel

Regulator

F u e l

Air

.

.

.

R e g u l a t o r

V a l v e

T a p p e t

Cleaner

Service

Alternator

.

Battery

.

.

.

Adjustment

Drive

Belts

.

.

.

.

.

.

.

4 - 1 0

.

.

.

F 4 - 3
3 - 2 2 0

.

F 3 - 5

.

.

.

.

F 3 - 3 6
3 - 1 8 4

Alternator
and

.

.

.

Parts

.

Charging

Belt

General

.

4 - 1 1

.

C l e a r a n c e

Related

.

.

V a l v e

.

and

Assembly

.

.

.

.

.

F 3 - 3 5

Replacement
.

.

.

.

.

3 - 1 8 3

.

.

.

3 - 1 8 2

.

.

.

B

Base

Group

and

Assembly
Base
Fuel

.

Related

.

Group

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

F 3 - 5 0

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

F 3 - 5 1

Installation

.

.

Tank

Components

.

Removal,

Cleaning

and

Inspection

Fuel

Quantity

Transmitter

Removal,

Fuel

Quantity

Transmitter

Test

General,

.

Related

Components

Skid
Basic

.

Base

Issue

Batteries

.

.

Batteries

.

Items

and

List,

Related

.

.

.

and

.

.

.

Slave

.

.

.

.

Replacement

3 - 2 2 3

3 - 2 2 1

.

.

3 - 2 2 5

F 3 - 5 2

.

.

.

Section

.

.

.
.

and

.

3 - 2 2 4
3 - 2 2 2

.

.

.

.

II

.

.

.

B - 2

Parts

.

.

.
.

Inspection

B a t t e r i e s
General

.
.

.

Testing

and

.

.

.

.

.

.

3 - 8 2

.

3 - 8 1

.

Receptacles

F 3 - 4

.

C

Controls

and

Instruments

Controls

and

General,

.

.

Convenience

2-10,

.

2 - 9

.

.

F 3 - 1 3

Replacement

,

3 - 8 9

.

.

.

.
.

Receptacle

Assembly

Circuit

Breaker

General

.

.

.

F2-5

Receptacle

Convenience
Box

,

Instruments
.

Replacement

.
.

.
.

Test
.

.

.
.

.
.

.

Replacement.

.

3 - 9 1

.

.

3 - 8 8

.

3 - 9 0

.
.

.
.

.
.

.
.

.
.

(Deleted)
(Deleted)

F 3 - 1 4

(Deleted)

3 - 9 4

(Deleted)

3 - 9 2
3 - 9 3

(Deleted)
Coolant

Pump M o t o r

- Brush

and

Connector

Replacement.

F 4 - 8

C h a n g e

1 I-1

ALPHABETICAL

Cooling

INDEX

(Cont)

Group

Cooling

Group,

Cooling

Group

Fan

Guard

General

.

.

.

.

.

Shutter

.

.

.

.

.

.

.

.

.

.

.

Inspection

.

.

.

.

.

.

.
.

and

.

.
.

.

.
.

.
.

.

Vibration
.

.

.

.

.

.

.
.

.

F 3 - 3 1

.

F 3 - 2 9

.

.

.

3 - 1 6 9

.

.

.

.

.

.

.

.

3 - 1 6 7
3 - 1 6 8

.

.

.

.
.

.

.

.

.

.

.

.

.

.

.

.

3 - 1 7 3

.

.

.

3 - 1 7 2

.

.

.

3 - 1 7 1

.

.

.

.

.

.

.
.

.

.

.

.

.

R e p l a c e m e n t

.

.
.

.

.
.

.
.

.

.

.

.
.

.

.

.

.
.

.

.

.
.

.

.

.

.
.

.

.
.

.

.
.

.

.
.

.

.
.
.

.

.
.

T h e r m o s t a t

.

.

.

.

.

Pulley

General

.

.

.

.
Parts

T h e r m o s t a t

S h u t t e r
Crankshaft

.

.

.
.

Assembly

S h u t t e r

.
.

.

.

.

Related

.

Cooler

Radiator

.

.

.

.

Hydraulic

.
and

.

.

Grille

.

.

.

.

.

.

3 - 1 7 0

.
.

F 3 - 3 0

.

Dampener

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

3 - 2 1 0

.

.

3 - 2 1 1

.

.

.

D

Data

Instruction

Day

Tank

Plate

Fuel

Day

Tank

Day

Tank

Fuel

Locations.

and

Float

and

and

Description

.

Difference

in

of

Diffusers

.

.

.

.

.

Models

.

.

.

.

.

F 1 - 3

.

.

.

.

.

.

.

.

.

and

.

.

.

.

.

.

.

.

.

.

F 3 - 2 7

.

Replacement

.

3 - 1 5 9

.

.
.

3 - 1 6 0

.

.

3 - 1 5 8

.

.

.

.

and

.

.

.

.

.

.

.

1 - 3

Tabulated

.

.

.

.

.

.

.

.

1 - 5

.

1 - 4

Data

.

Performance

.
.

.

.

.

.

.

A - 7

.

T 1 - 1

Characteristics

Turbocharger

.

.

.

.

.

.

.

Diffuser

General

.

Assembly
Removal

.

and

Exhaust

.

Data

in

Assembly

.

Filter

.

Material

Differences

.

.

Identification
Destruction

.

Assembly

Valve,

Description

.

Switch

Fuel

Filter

Solenoid

.

Assembly

.

.

.

.

.

Turbocharger,

.

.

.
.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

3 - 2 0 4

.

.

3 - 2 0 2

.

3 - 2 0 3

.

.

.

F 3 - 4 2

.

.
.

E

Electric

Starter

General

.

and

.

.

Starter

Assembly

Starter

Solenoid

Electric

.

.

.

.

.

.

.

.

.

.

.

Fuse

General

.

.

.

.

.

.

.

.

Operation

.

.

Preventive

.

.

.

.

.
.

.

.

.

.

.

Troubleshooting
Engine

.

Hoses

Engine

Assembly

General

.

.

.

.

.

.

.

F 4 - 7

.

.

.

.

.

.

.
.

.

.
.

.

.

F 4 - 9

.

.

4 - 1 7

.

.

4 - 1 8

.

2 - 2 6

.

and

.

.

.

.

Checks
.

.

4 - 2 0

.

Services

.

.

.

.

.

.

.

.

.

.

.

.

.

T 4 - 3

.

4 - 1 9

.

.

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.

.

.

4-21,

.

3 - 1 8 1

.

.

.

Testing.

.

.

Generator

.
and

.

.

.

.

Inspection,

Front,

.

.

.

.

and
.

.

.
.

Chassis

.

Test,

Generator
Rear,

.

.
.

.

General

Right

3 - 1 9 0
3 - 1 9 1

.

.

Generator

Left

.

.

Engine

Engine

.

F 4 - 6

Assembly

Drain

Engine

.

.

.

.

.

.

.
.

Replacement

.

.

Removal

.

3 - 1 8 9

.
.
.

.

.

.

Maintenance

Wiring

.

.

.

Preventive
.

.

.

Lamp

.
.

Maintenance

schematic

.

.

.

.

and
.

.

.

.

Kit

Box

Installation

.

.
.

.

Control
.

.

.

Winterization

Assembly

I - 2

Adapter
.

.

.
.

.

.

.

.

Repair

.

.

.
.

.
.

.

.

Wiring

.

.

and

.

.

.
.

.

.

.

Interconnecting

Chassis
.

.

.

.

.

.

.

.
.

Wiring

.

.

Replacement

.

.

.

.

.
.

.

.

.

.

3 - 1 8 0
.

3 - 1 7 9

Harnesses

Harnesses
.

.

.

.
.

.

.

F 3 - 2 3

.

.

.

.

.

.

3 - 1 3 8

.

.

.

3 - 1 3 9

Set

Three
Three

Quarter
Quarter

View
View

.

.
.

.
.

.
.

.
.

.
.

.
.

.
.

.
.

.
.

.

.

.

F 1 - 2

.

.

.

F 1 - 1

T4-4

ALPHABETICAL

Engine

Generator

General

.

.

Housing

Set

.

.

Group

R e m o v a l

Housing

.

.

.

.

.

.

a n d

.

.

(Cont)

Group

.

.

INDEX

.

.

.

.

.

.

.

.

.

.

.

.

R e p l a c e m e n t

.

.

.

.

.

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.

.

.

.

.

.

.

.

.

.

.

.

.

3 - 1 3 6
F 3 - 2 2
3 - 1 3 7

.

Equipment
Inspecting

and

Unloading.

.

.

.

,

.

.

.

Unpacking.

.

.

.

.

.

.

.

Equipment
Exhaust

servicing

Conversion.
and

.

Breather

.

.

.

Pipe

.

.

.

Manifold

Assembly.

.

.

.

and

.

E x p l a n a t i o n

o f

.

.

.

.

C o l u m n s

.

.

.

.
.

.

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.

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.

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.

.

.

.

.

.

.

2 - 3

.

.

.

.

.

.

.

.

2 - 1

.

.

.

.

2 - 2

.

.

.

.

.

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.

.

.

.

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.

.

.

.

.

.

.

.

.

.

.

.

.

.

.
.

.

.

.

.

.

Replacement.

.
.

.

.

.

.
.
.

.

General
Inspection

.

.

Exhaust

.

.

.

.

.

.

.

.

.

.

2 - 6

.

.

.

.

F 3 - 1 2

.

.

F 3 - 4 7

.

.

.

.

.

.

.

.

.

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.

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.

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.

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.

.

.

.

.

.
.

.

.

.

.

.

.

.

3 - 2 1 6
3 - 2 1 7
B - 3

.

Explanation

of

Columns

in

Section

II.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

C - 2

Explanation

of

Columns

in

Section

III

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

C - 3

Explanation

of

Columns

in

Section

IV

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

C - 4

Explanation
and

of

Columns

Operating

in

Supplies

the
-

Tabular

Section

List

IV.

.

of

.

Maintenance

.

.

.

B - 4

.

F

Fan

and

Motor

Fault

Indicator

Fault

Indicators

Field

Assembly.
Test

Function

Expedient

Battery

Engine

Heat

Fuel

Up

Not

General

.

.

Loss

of

Records

.

Burning

T3-2

.

.

.

.

.

.

.

.

.

.

.

T2-2

Not

.

.

.

.

.

.

.

Box

General,

.

.
and

.
.

.

.

.

.

.

.

.

.

.

.

.

.

.

Maintenance
.

.

.

Troubleshooting

.

.

.

.

.

.

.

.
.

.

.

.

.

.

.

.

.

.

.

.

.

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.

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.

.

.

.

.

.

.

.

.

.

.

.

.

.

.
.

.

.

.

3-72

.

3-69

.

.

.

.

.

.

.

.

.

.

.

of

Military

.

.

.

.

.

.

3-73

.

.

3-67

.

3-66

.

3-68

. .
.

.

.

.

.

3-75
A - 1

.

1-2

Materials

T2-1

.

Antifreeze

.

.
.

.

.

.
.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.
.

.

.

.

.

.

.

.

.

.

.

.

.
.

.

.

.

.

.

.

.

.

.

.
.

Gravities

.

.

.

.

.

.

.

.

.

.

.

.

.

.

Lights

.

.

.

.

.

Specific

.

3-71

.

.

.

.

.

.
.

.

.

.

.
.

Only)

.

and

.

.

Replacement
.

.

.
.

sets

.

.

.

Misfires

.

.

Kit
.

.

.

.

S m o k e . . .

.

.

or

.

.

.

.

.

Erratically

Indicator

.

1

.

.

3-74

.

and Runs

Pressure

.

.

.

Oil

.

(Class

.

.

.

.

.

.

.

Lamp

.

.

.

.

.

Starts

.

.

.

.

.

Low

Composition,

.

Control

.

.

.

.

.

.

Charge

or

.

Control
.

No

Start

.

w i t h

.

Shows

Will

Winterization

.

Removal

F4-15

.

.

Points,

Preventive

.

.

.

and

Operation

.

.

F i l l e d

.

Installation

.

.

.

Frequency

Assembly

.

.

.

.

Fuel

.

.

Strained

.

Forms

.

.

Down-and

Protection,

Freezing

.

.

Ammeter

.

.

H o u s i n g

Fire

.

Shuts

is

.

.

But

Overheating

Engine

.

.

.

Cranks

Engine

.

.

Repairs

Charging

Engine

.

Points

.

.

.

.

.

.

.

.

.

.
.
.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

F4-1

.

.

.

F4-2

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

4-3

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

4-4

.

.

.

.

.

.

.

2-25

.

.

4 - 6

.

.

4-5

.

.

4-7,

.

.

.

.

.
.

.

.

.
.

.
.

.

.

.

.
.

.

.
.

.

.
.

.

.

.

.
.

.

.

.

.
.

.

.

.

.

.

.

.

.

.

.

.

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.

.

.

.

.

.

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.

.

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.

.

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.

.

.

.

.

.

.
.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

T4-2

G

G e n e r a l

.

Generator
General

.

.

.

.

Generator

Bearing

Generator

Inspection

Generator

Load

Generator

Set

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

B-2,

C-1

.

AC

Voltmeter

.

.
.

.

.

.

.

Board

.
.

.

.

.

.

.

.

.

.

.

.

Connections

Replacement

AMPS-VOLTS

.

Replacement

Ammeter-Voltmeter

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.
.

.

.

.

.

.
.

.

.
.

.

.

.
.

.

.

.
.

.

.

.

.

.

.

.

.

.
.

.

.

.

.

.

.

.

.
.

.

.
.

.

.

.
.

.

.

.
.

.

.

3-154

.

.

3-156

.

.

.

.

.

.

.

.

.

.

3-155
F2-3

Controls

Ammeter

Battery

.

Inspection..

Terminal

AC

Assembly

.

Assembly

Selector

Selector
.

Charging

.

.

.
.

Ammeter

.
.

.

.
.

.
.

.

.
.

.

.

.

.

.

Schematic

.
.

.
.

Switch

Switch,
.

.
.

.

.

.

.

.

.

.

.

.

.

.
.

.

.

.

.

.

.

.

.
.

.

.

.
.

.

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.

.

.
.

.
.

.
.
.

.
.

.

.

.
.

.

.
.

.
.

.

.

.

.
.

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.
.

.
.

.
.

.

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.

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.

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.

.
.

.

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.
.

.
.

.
.
.

.

.
.

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.
.

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.

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.

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.

.
.

.
.

.

.

.

3-108
3-105
F3-21
3-112
F3-17
3-124
I-3

Generator

Set

Controls

(Cont)

Battle Short Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-116

Circuit Breaker Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-117

Box . . , , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-135

Control Box Relay Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-126

Control

Control Box Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Cubicle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Cubicle Panel Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-134
3-104,

Control Cubicle Schematic Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

F3-19

Control Cubicle Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

F3-20

Coolant Temperature Gage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crosspin Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DC Control Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-120
3-132
3-100,

3-131

Engine Primer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-118

Engine Start-Run-StopSwitch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-119

Fault

Indicator, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-103

Frequency Adjust Rheostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-109

Frequency Transducer and Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-111

Fuel Level Gage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-122

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-99

Kilowatt Meter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-106

Manual Speed Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-102

Oil Pressure Gage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-121

Single/Parallel Operation Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-115

Panel Light Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-128

Panel Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-113

Press-to-Test Light Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-129

Running Time Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-123

Synchronizing Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-130

Terminal Board Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-127

Voltage Adjust Rheostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-110

Voltage Sensing Switch, Local-Remote . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-114

Wattmeter Conversion Inspection and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-107

Wiring Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-101

Control

Unit

Air Cleaner and Related Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air

Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaner

General

.

.

.

.

.

.

.

Control

Unit

Governor

Control

Box

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Frequency

Adjust

Rheostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Procedures

Hand Lever and Bracket Assembly-. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heater

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.

Governor

Grounding

Elements . . . . . . . . . . . . . . . . . . .

. . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hub and Brake and Front Unit Axle Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic

Actuator

and

Sump

and

Filter

F3-26
3-147
3-145
3-146
3-146.1
F2-2

F4-11
4-48
F4-12

(MEP105AOnly)
. . . . . .

3-174

Hydraulic Actuator Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-175

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic

Actuator

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . .

Hydraulic Sump and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic

Sump

Cleaning
Drain

and

and

Hose

Filter

(MEP105A

Inspection

of

Sump

Only
and

Except

F3-32
F3-8

MEP115A)

Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Sump and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-177
F3-34
F3-33

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-178

Removal of Sump and Filter . . . . . . . . . . .

3-176

I

Pulley

and

Mounting

Bracket

Assembly. . . . . . . . . . . . . . . . . . . . . . . . .

I - 4

3-125

Door Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Governor

Idler

F3-18

3-133

C h a n g e 1 5

F3-45

ALPHABETICAL

INDEX

(Cont)

Idler Pulley and Mounting Bracket (Cont)
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-212

Inspection, Removal and Installation.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-213

Inspect, Test, Service, and Adjust Heater Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-9

Inspection
Auxiliary

Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-64

Angle Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel

3-50

Battery Charge Ammeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-24

Battery Charging Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-48

Control Cubicle Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-30

Control Cubicle Panel Gages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-22

Control Cubicle Panel Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-21

Convenience Receptacle Assembly.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-12

(Deleted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-13

Crankshaft Pulley Vibration Dampener . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-211

Crosspin Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-29

DC Circuit Breaker and Fault Indicator Lamp Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-16

Door Holders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-28

Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-59

Fan Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-47

Fan Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-39

Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-57

Housing Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-31

Hydraulic Actuator (MEP105A Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-43

Hydraulic Coler (MEP105A Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-42

Hydraulic Pump and Drive Assembly (MEP105A Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-51

Lube Oil Filters Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-55

Muffler Exhaust and Breather Pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-11

Oil Level Gage and Filler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-52

Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-61

Oil Pressure Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-54

Paralleling Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-63

Paralleling Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-15

Plate and Sleeve Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-14,F3-15

Rocker Arm Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-219

Skid Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-222

Slave Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-10

Starter Assembly. . . . . . .. . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..

3-53

Speed Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-49

Synchronizing Light Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-27

Temperature Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-60

Water

3-58

Inspection,

P u m p . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..

Repair

and

Replacement

Hoses and Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-25

Wiring Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-26

Inspection,

Testing,

Control

and

Replacement

Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Coolant Pump and Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-8,4-27
4-22

Heating Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-24

Nozzle Holder and Line Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

F3-41

Thermostat Stitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-23

Installation
And Setting -up Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-5

Hydraulic Actuator Sump and Filter (MEP105A Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-178

Load Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-39

Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-4

Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

F2-1

Of

Separately

Packed

Instruction Plate
Battery Arrangement and Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

F1-11

Electric Winterization System Diagram and Electric Heater Control Schematic Diagram . . . . . . . . . . . . . . . . . . .

F1-23

Fuel Burning Winterization System Diagram and Heater Control Schematic Diagram . . . . . . . . . . . . . . . . . . . . .

F1-22

Fuel System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

F1-4

Lifting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

F1-5

Lead Bank Connection and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

F1-24

C h a n g e

1 1

I - 5

ALPHABETICAL
Instruction

Plate

Instructions

Service

Instructions

Intake

(Cont)

(Cont)

Operating

Voltage

INDEX

.

Reconnection

.

.

.

and

.

.

.

.

System

.

.

.

.

.

Capacities

.

.

.

.

.

.

.

F1-6

.
.

F 1 - 7

.

F 1 - 8

.

Manifold
F 3 - 4 6

Assembly . . . . . . . . . . . . . . . . . . . . . . . .
General

.

.

Removal

.

and

5 0 / 6 0

.

.

Troop

.

.

.

and

.

.

.

.

.

.

.

.

3 - 2 1 4

.

.

3 - 2 1 5

.

.

.

.

Utility

.

Suppression

Replacement
Items

.
.

Precise

Precise

Interference

.

.

Diagram

HZ

Hz

.

Replacement

Interconnecting

400

.

.

.

.

.

.

.

.

.

.

.

F 1 - 2 6

.

F 1 - 2 7

Components

.

.

Installed

.

.

or

.

.

.

.

Authorized

.

List,

3 - 7 8

.
Section

III

.

.

B - 2

.

F 1 - 2 1

K

Kit

Data

and

Instruction

Plate

Location.

.

.

.

.

.

.

L

Lifting

Frame

Support

Filler

Cap,

Fuel

Gasket,

.

.

.

.

Frame

.

Aid

,

.

.

.
.

Transfer
.

Hose

.

Pumps

.

.

Replacement

Replacement
.

.

.

.
.

.

F 3 - 2 8
3 - 1 6 4
3 - 1 6 6

.

3 - 1 6 5

.

.

Assembly

.

.

3 - 1 6 1

.

.

.

3 - 1 6 3

.

.

.

3 - 1 6 2

.

.

.

.

.

and

Lines

.

Fuel

.

Bank
.

.

Kit

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

Diagram

.

Wiring

Harness

Main

.

.

.

.

Reject

.

Relay

.

.

of

Cooler

Fuel

.
.

.
.

Inspection

.

.

.

.
.

.

.

.

Services

T 4 - 7

.

.

4 - 4 9

.

F 4 - 1 3

.

4-41,

.

F 4 - 1 6
4 - 4 3

.

General

.

Low

Oil

Pressure

Filter

Assembly

Pressure

.

.

.

.

.

.

.

.

.

.

3 - 1 4 3

.

3 - 1 4 0

.

3 - 1 4 1
3 - 1 4 2

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.
.

.

.
.

.

.

.

3 - 1 4 4
F 3 - 2 5

.
.

4 - 4 5

.

F 4 - 1 8

Positions

Pump

.
.

.

F 3 - 2 4

.

.

.

for

Class

2

Operation

.

F 3 - 1 0

F 3 - 4 0

.

.

.

.

.

.

.

.

3 - 1 9 8

.

.

3 - 1 9 9

.

.

3 - 1 9 2

Switch.

3 - 1 9 4

.

Replacement

and
.

.

Contact

.
.

.

.

.

.

and

.

.

Injector

.

.

.

.

.
.

Filters
.

.

.

.

Board
.

Lube

Assembly

.

Switch

Lockwire

.

.

.

Assembly

Board

Selector

.

4 - 4 0

.

.

.

.

.

2 - 2 8

and

.

.

.

4 - 4 2

.
.

.
.

.

Board

Reconnection

Oil

.

.

.

.

4 - 3 9

.

.

.

.

4 - 3 8
.

.

.

.

4 - 4 4

.

.

Checks

.

.

.

.

Terminal

Oil

.

Contactor

Reconnection

.

Group

.

AC

Load

.
.

Transformer

G e n e r a l

.

.

F 4 - 1 4

.

.

.

.
.

.
.

.

.

.

.

Connection
.

.
.

Procedures

Diagram

Troubleshooting

Oil

.

.

Wiring

Current

.

Maintenance

Schematic

Assembly

.

M a i n t e n a n c e

Preventive
Removal

.

.

Maintenance

P r e v e n t i v e

Oil

.

A s s e m b l y

.

.

Operation

General

.

P a n e l

Installation

I - 6

.

Assembly

G e n e r a l

Lube

and

General

C o n t r o l

Load

Valve

P u m p s

.

and

Parts

Strainer,

T r a n s f e r

Assembly

Load

Assembly
Related

F u e l

Start

Load

Aid

and

Selector

Lifting

Load

Start

Center

.

.

Sensors
.

.

.

.

.

Shutdown
.

Transmitter

.

.

.
.

.

.
.

.

.

.

3 - 1 9 5

.

3 - 1 9 3

T4-8

ALPHABETICAL

INDEX

(Cont)

Lubrication
Detailed

Lubrication

Engine

Lube

General

Information

Oil

Filters

Lubrication

Lubrication

.

Lubrication

Order

.

.

.

Information

.

.

.

.

.

.

.

.
.

.

.

.

.

.

.

.

.

.

.

.

.
.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.
.

.

.

.

.

.

.

.

.

.

.
.

.

.

.

.

.

.

.

.

.
.

.

.

.

.

.

.
.

.

.

.

.

.

.

.

.

.

.

.

.

3 - 4

.

F 3 - 3
3 - 3

.

.

.

.

.

.

.

F 3 - 1

. . . . . . . .

F 3 - 2

.

.

.

Oil Level Gage and Filler . . . . . . . . . . . . . . . . . . ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.

.

.

.

.

.
.

.

.

.

.

.

.
.

.

.

.

.

.

.

.

A - 2

M

Maintenance

.

Maintenance
Material,

.

.

and

.

.

.

.

Operating

Service

upon

.

.

.

Supplies,

Receipt

.

.

.

Section

of

.

.

IV

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

A - 5

.

B - 2

.
.

.

.

.

4 - 2

M o v e m e n t
Dismantling

for

.

Reinstallation

after

Exhaust

and

Muffler,

.
.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

Breather

Pipes

-

.

.
.

.
.

.
.

General

.
.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

2 - 7

.

.

.

.

2 - 8

.

3 - 8 5

.

3 - 2 0 0

.

.

.

.

.

.

.

N
Nozzle

Holder

General

.

.

Inspection,
Nozzle

Assemblies

and

Lines

.

.

.

.

.

.

Testing,
Holder

and

.

.

.

and

Replacement

Line

Assemblies

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.
.

.
.

.

.
.

.

3 - 2 0 1

.

.

.

.

F 3 - 4 1

F 3 - 3 8

0

Oil

Level

Gage

and

G e n e r a l
Oil

Level

and

.

.

.

.

.

Adapter
.

.

.

and

.

.

.

. .

Filler

Elbow

.

.

.

.

.

.

.

.

and

Cap

.

.

.

.

.

.

.

.

.

.

.
.

.
.

.

.
.

.

.
.

.
.

.

.
.

.

.

.

.

.

3 - 1 8 7

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

3 - 1 8 8

Instructions

Electric

Winterization

Fuel

Burning

Load

Bank

Parallel

.

Kit

of

Electric

.

.

.

.

.

Units
Unit

Winterization

.

.

.

.

.
.

.

Auxiliary

Burning

.
Kit

Generator

Operation

.

Winterization

Generator

Single

Fuel

.

Gage

Replacement
Operation

Filler
.

.

.

.

.

.

Kit

.

.

.
.

.

.

.

.
.

.

.

.

.

.

.

.

.

.

in

Conjunction

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.
.

.
.

.

.

.

.
.

.

.

.

.
.

.

.

.

.

.

.
.

.

.
.

.

.

.

.

.

F 2 - 1 2

.

.

.

.

F 2 - 1 1

.

F 2 - 1 4

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

F 2 - 1 0

.

.

.

.

.

.

.

.

.

F 2 - 9

Equipment

.

.

.
.

.

the

.

.

.
.

.

.

with

.

.
.

.

.

.

.

.
.

.

.

.

.
.

.

.

.

.
.

.
.

.

.

.

.

.

.

.

used

.

.

.

.

.

.

Kit

.

.

.

Material

Winterization

.

.

.
.

.
.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

2 - 2 6

.

.

2 - 2 5
2 - 2 4

G e n e r a l
Load Bank
Wheel
Operation

Mounting

Bit

Under

.

.

.

Unusual

.

.

.

.

.

.

.

O p e r a t i o n
i n
Operation
in
Operation

in

Silt

Operation

in

Snow

Operation

Under
of

Water

Areas

.

Rainy

Under

Exercise

E x t r e m e
Extreme
.

.

Engine

.

.
.

Humid

.
.

of

Standby

Service

Equipment

for

Starting

.

.

.

Starting
.

.

.

.

Instructions .
.
.
.
.
.

Stopping

I)

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.
.

2 - 2 7

.

.
.

.
.

.

.
.

.

.

.

.

.

.

.

.

.
.

.
.

.
.

.

.
.

.

.

.

.

.

.

.

.

.

.

.
.

.
.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.
.

.
.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.
.

.
.

.
.

.

.

.

.

.

2 - 2 2

.

.

2 - 1 9

.

.

2 - 1 5

.

.
.

2 - 2 3
2
2
2
2
2

.

- 2 1
- 1 8
- 1 6
- 1 7
- 2 0

Conditions

on

Preparation

(Mode

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

2 - 1 1

Operation

Operational

.

( B e l o w
- 2 5 F) . . . . . . . . . . . . . . . . . . . . . . . . . .
(Up
to
+125 o F) . . . . . . . . . . . . . . . . . . . . .

Conditions

G e n e r a l

Starting
Sopping
.

.

o

C o l d
Heat
.

.

or

Usual

.

Conditions

Control
Cubicle
Removal
for
Remote
Operation
Operation
at
High
Altitudes
.
.
.
.
.
.
.
Operation in Dusty or Sandy Areas

Operation

2 - 2 8

. . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . .. . . .. . . . . . . . . . . . . . . . . . . .

.
.

.

.

2 - 1 2
F 2 - 7
2 - 1 3
F 2 - 8

Instructions
Data

2 - 1 4
F 2 - 6

Information P l a t e
.

.

.

.

.

.

.

(Mode II) . . . . . . . . . .

F 1 - 9
F 1 - 1 0
I - 7

ALPHABETICAL

Operator’s

INDEX

(Cont)

Maintenance

AC Ammeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-19

AC Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-17

Air

3-32

Cleaner

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-9

Day Tank Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-33

Engine Assembly Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-46

Filler Cap, Gasket and Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-36

Frequency Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-20

Fuel Filter and Strainer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-34,F3-6

Fuel Transfer Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-37

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-8

Hydraulic Sump (MEP105A Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-44

Hydraulic Filter (MEP105A Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-45

Kilowatt Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-18

Main Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-62,F3-7

Panel Light Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-25

Press-To-Test Light Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preventive Maintenance Checks and Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-26
T3-1

Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-41

Radiator Grille . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-38

Start Air Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-35

Secondary Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-56,F3-9

Organization Maintenance-General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-80

Organizational Maintenance Repair Parts (Army) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2

P

Painting

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A-3

Paralleling Receptacles

Plate

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

F3-16

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-97

Replacement

3-98

and

Sleeve

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Assembly
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

F3-15

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-95

Replacement

3-96

Assembly

Preventive

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance

Checks

and

Services

Daily (Army and Navy) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-6

Fuel Buring Winterization Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

T4-1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-5

Monthly and Semi-Annual (Army and Navy) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-7

Operators

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

T3-1

R

Radio

Interference

Suppression

General Methods Used to Attain Proper Suppression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Interference Suppression Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal and Installation

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacement and Suppression Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-76
3-77
F3-11
3-78

Radio Suppression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A-4

Radioactive Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A-8

Relay

Table

Group

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-148

Load Measuring Unit Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-153

Precise Relay Assembly Class l (50/60 Hz) Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-150

Special Relay Assembly (50/60 Hz) Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-151

Special Relay Assembly (400 Hz) Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-152

Tactical Relay Assembly Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-149

Replacement

I - 8

AC Ammeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-108

AC Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-105

C h a n g e

1 1

ALPHABETICAL

Replacement
Base
Batteries

a n d Related

.

.

.

.

.

.

B a t t e r y

T r a y

.

Breather

Pipe

.

Control

Pipe

Lines,

Gil

.

Receptacle
Secondary

Fuel

Shutter
Slave

Pump

Wiring

Harness

Arm

.

Inspection

Locations.

Valve

Tappet

Running

Gear

.

.

.

.

.

.

.

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3 - 2 2 4

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3 - 8 2

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3 - 8 3

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3 - 8 6

.

.

4 - 1 6

.

4 - 1 3

.

3 - 1 0 6
3 - 1 8 8

.
.

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3 - 1 2 9

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4 - 1 2

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3 - 1 3 3

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3 - 1 9 7
F 3 - 3 0
3 - 8 4
F 4 - 5

.

3 - 2 0 6

.

3 - 1 0 1 , 4 - 1 4

.

Assembly
.

.

.

.

.

Valve

.
.

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. .

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.

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.

.

Fan

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.

Filler

.

and

.
.

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.

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.
.

.

.

Shaft

Assembly
General

.

Switch

Water

.

.

.

Receptacle

Thermostat

.

.
.

.

Assembly

Filter

Thermostat

.

.

.

and

Assembly

.

.

.
.

.

Light

.

.

.

.

.
.

Gage

Press-To-Test

Rocker

.

Meter

Level

.

Fittings

Assembly

Kilowatt

.

.
.

.

.

and

Components

3 - 8 7

Cubicle .

Exhaust

Igniter

(Cont)

(Cont)

Group

Hose,

INDEX

.
.

.

.

.
.

.

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.

Adjustment
.

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.

Clearance

Assembly

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3 - 2 1 8

.

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3 - 2 1 9

.

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F 3 - 4 8

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.

F 3 - 4 9
3 - 2 2 0
F 4 - 1 0

S

Schematic

Wiring

F 1 - 1 7

C l a s s

l ,

a n d

P l a t e

.

.

.

AC,

Class

2,

and

Plate

.

.

.

F 1 - 1 9

D C ,

C l a s s

l ,

a n d

P l a t e

.

.

.

F 1 - 1 8

Class

2,

and

Plate

.

.

DC,
Scope

.

.

.

Secondary

.

.

Fuel

Assembly.

.

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.

.

Replacement

.

.

.

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.

.

.

I.D.

.

Shipment

and

Shipping

Crate

Special
Speed

4-l,

B-1

Filter

.

.

Plate.

F 1 - 2 0
1-1,

.

.

General

Set

Diagram

A C ,

.

.

.

.

Storage
.

.

.
.

.

.

.

.

(Not

3 - 1 9 6
3 - 1 9 7
F 1 - 1 2

.

.

A - 6

.

.

.

.

.

F 3 - 3 9

.

.

.

.

Information

.

.

.

.

.

F 1 - 2 5
B - 5

Applicable)

Switch

Assembly

.

.

.

.

.

and

.

.

F 3 - 3 7

.

.

.

.

3 - 1 8 5

Replacement

.

.

.

3 - 1 8 6

.

Testing

.
.

G e n e r a l

.

.

T

Terminal

Board

Testing

.

Control

Switch

Thermostat

Assembly
.

Fuse

and
.

.

.

.

.

Lamp
.

.

.

.

.

.

Housing

.

.

.

Testing
.

Equipment

.

.

.

.

.

Operational
and
.

.
.

.
.

.

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.

.

4 - 4 6

.

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.

4 - 2 8

.

.
.

.
.

.

.

3 - 1 8 6

.

.

4 - 1 5

.
.

F 3 - 4 4

.
.

.

3 - 2 0 7
3 - 2 0 8

Check

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

Installation

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

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.

.

.

3 - 2 0 9

.

.

.

.
.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

and

Removal,
and

.

.
and

Switch

.

.

Inspection
Thermostat

.

Switch

Thermostat

General,

.

Replacement

Box

Speed

Tools

.

and

.
.

.
.

.
.

.
.

.
.

.
.

.

.

.

.

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.

.
.

.
.

.
.

.

.

.

.

4 - 4 7

.

.

.

.

3 - 1

1 - 9

ALPHABETICAL

INDEX

(Cont)

Troubleshooting
G e n e r a l

.

.

.

.

.

Troubleshooting
Troubleshooting
AC,

(Mode

I)

AC,

(Mode

II)

DC,

(Mode

I)

DC,

(Mode

II)

.

.
.

3 - 6 5

.
.

T 3 - 3

.

Diagram
and

F 1 - 1 3

Plate

and
and

F 1 - 1 4

Plate

F 1 - 1 5

Plate

and

F 1 - 1 6

Plate

V

Voltage
Voltage

Selector

Conversion

.

Switch

Contact

Positions

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

F 4 - 1 7

.

.

.

F 2 - 4

F 3 - 4 3

W

Water

Pump

Assembly
General

.
.

and

Fan

.

.

.

.

Replacement

.
.

Wheel

Alignment

Wheel

Bearings

.

.

.

Wheel

Mounting

Kit

.

.

.

Preventive

.

.

and

.
.

.

.

.
.

.

.

.

.

.
.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

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.

.
.

.

.

.

.

.

.

3 - 2 0 6

.

.

.

.

.

.

.

4 - 3 6

.

.

.

.

.

4 - 3 4

Assembly

.

4 - 3 5

.

and

3 - 2 0 5

.

.

.

.

Lever

.

.

.

Procedures
.

.
.

Troubleshooting

I - 1 0

.

Maintenance

.

Preventive

Wheels

.

.

.

.

.

Bracket

Kit

Maintenance

Operation

.

.

.
.

.

Hand

.

.
.

.

.

.

.
.

.

and

.

.
.

.

Brakes

.

.
.

.

Wheel

General

.

.

.

.

.
.

.
.

.

.

.
.

.
.

.

.
.

.
.

.
.

.
.

Maintenance

Tires

.

.

.
.

.

.

.

.
.

.

.
.
.

.

.

.
.

.
.

.
.

.

.
.

.

.
.

.
.

.

.

.
.

.

.

.

.

Services

.
.

.

.

.

and

.
.

.
.

.

Checks

.

.
.

.

.
.

.

.

4 - 2 9

.

4 - 3 2

.

F 2 - 1 3
4 - 3 0

.
.

.

.

T 4 - 5

.

4-31,

.
.

.

.

4 - 3 3

T4-6

By Order of the Secretaries of the Army, the Navy, and the Air Force:

CREIGHTON W. ABRAMS
Official:
VERNE L. BOWERS
Major General, United States Army

General, United States Army
Chief of Staff

The Adjutant General
A. R. MARSCHALL

Rear Admiral, CEC, USN
Commander, Naval Facilities
Engineering Command
JOHN D. RYAN, General, USAF
Official:
DWIGHT W. COVELL, Colonel, USAF

Chief of Staff

Director of Administration
Distribution:
Army:
To be distributed in accordance with DA Form 12-25D, operator maintenance requirements for
Generator Sets: 60 KW, 60 HZ, Precise Power; 60 KW, 400 HZ Precise Power; 60 KW, 60 HZ,
Utility.
MARCORPS CODE:
AGC

PIN: 013548-000



---

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