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

Open the PDF directly: View PDF .
Page Count: 325 [warning: Documents this large are best viewed by clicking the View PDF Link!]

ARMY TM-5-6115-545-12

AIR FORCE T0-35C2-3-444-1

This copy IS a reprint which includes currentNAVY NAVFAC P-8-626-12

pages from Changes 1 through 18.MARINE CORPS TM-00038G-12

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 NSN

MEP006AUTILITY 50/606115-00-118-1243

MEP105A PRECISE 50/606115-00-118-1252

MEP115A PRECISE 4006115-00-118-1253

Including Optional Kits

DOD MODELSNOMENCLATUREFSN

MEP006AWFWINTERIZATION KIT, FUEL BURNING6115-407-8314

MEP006AWEWINTERIZATION KIT, ELECTRIC6115-455-7693

MEP006ALMLOAD BANK KIT6115-407-8322

MEP006AWMWHEEL MOUNTING KIT6115-463-9092

Published under authority of the10 JUNE 1973

Departments of the Air Force, the Army, and the Navy

(Including U. S. Marine Corps)

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.

HIGH VOLTAGE

is produced when this generator set is in operation.

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.

Exhaust discharge contains noxious and deadly fumes.

Do not operate generator sets in inclosed areas unless

exhaust discharge is properly vented to the outside.

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.

TM 5-6115-545-12

TO 35C2-3-444-1

NAVFAC P-8-626-12

TM 00038G-12

Use extreme care, should a selenium rectifier

malfunction, to avoid inhalation of poisonous fumes.

LIQUIDS UNDER PRESSURE

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.

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

to the equipment may result if personnel fail to

observe the cautions contained in this manual.

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

CHANGE HEADQUARTERS,

DEPARTMENTS OF THE ARMY, NAVY AND AIR FORCE

NO. 18

AND HEADQUARTERS U.S. MARINE CORPS

WASHINGTON, D. C., 12 February 1991

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

NSN

MEP-006A

UTILITY

50/60

6115-00-116-1243

MEP-105A

PRECISE

50/60

6115-00-118-1252

MEP-115A

PRECISE

400

6115-00-118-1253

INCLUDING OPTIONAL KITS

DOD MODEL NOMENCLATURE FSN

MEP006AWF WINTERIZATION KIT, FUEL BURNING

6115-407-8314

MEP006AWE WINTERIZATION KIT, ELECTRIC

6115-455-7693

MEP006ALM LOAD BANK KIT

6115-407-8322

MEP006AWM WHEEL MOUNTING KIT

6115-463-9092

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) a/(b blank)

2–1 and 2–2

2–1 and 2–2

3–3 and 3-4

3–3 and 3–4

3-8.1 /(3-8.2 blank) 3-8.1 /(3-8.2 blank)

3–15 and 3–1 6

3–15 and 3–16

3–19 through 3-22 3–19 through 3–22

3–105 and 3–106 3–105 and 3–106

3–115 and 3–116 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

DEPARTMENT OF THE AIR FORCE TECHNICAL ORDER

DEPARTMENT OF THE NAVY PUBLICATION

MARINE CORPS TECHNICAL MANUAL

OPERATOR AND ORGANIZATIONAL

MAINTENANCE MANUAL

Approved for public falease; distribution is unlimited.

D0D MODELS

MEPO06A

MEP105A

MEP115A

TECHNICAL MANUAL

GENERATOR SET,

SKID MTD., 60 KW, 3

DOD MODELS

MEP006AWF

MEP006AWE

MEP006ALM

MEP006AWM

TM-5-6115-545-12

TO-35C2-3-444-1

NAVFAC P-8-626-12

TM-00038G-12

HEADQUARTERS

DEPARTMENT OF THE ARMY

WASHINGTON, DC.,

DIESEL ENGINE DRIVEN, TACTICAL

PHASE, 4 WIRE, 120/208 AND 240/416 VOLTS

CLASS

HERTZ

UTILITY

50/60

PRECISE

50/60

PRECISE 400

INCLUDING OPTIONAL KITS

NOMENCLATURE

WINTERIZATION KIT,FUEL BURNING

WINTERIZATION KIT, ELECTRIC

LOAD BANK KIT

WHEEL MOUNTING KIT

TABLE OF CONTENTS

FSN

6115-118-1243

6115-118-1252

6115-118-1253

FSN

—

6115-407-8314

6115-455-7693

6115-407-8322

6115-463-9092

i

10 June 1973

TM 5-6115-545-12

TO-35C2-3-444-1

NAVFAC P-8-626-12

TM-00038G-12

Chapter Page

LIST OF ILLUSTRATIONS . . . . . . . . . . . . iii

LIST OF TABLES

iv

1lNTRODUCTION . . . . . . . . . . . . . . . . . . . .

I

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

II

Description and Data . . . .

2

INSTALLATION AND OPERATION

INSTRUCTIONS . . . . . . . . . . . . . .

I

Service Upon Receipt of Material .

II

Movement to New Worksite . . . . .

III Controls and Instruments . . .

IV

Operation Under Usual Conditions . . . .

V

Operation Under Unusual

Conditions . . . . . . . . . . . . . . . .

VI

Operation of Auxiliary Material

Used in Conjunction with the

Equipment . . . . . . . . . . . . . . . .

3

OPERATOR AND ORGANIZATIONAL

I

II

III

IV

V

VI

VII

VIII

IX

X

XI

XII

XIII

XIV

XV

XVI

XVII

XVIII

XIX

xx

XXI

XXII

XXIII

XXIV

MAINTENANCE INSTRUCTIONS . . .

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. . . . . .

(Deleted)

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

Change 15

1-1

1-1

2-1

2-1

2-10

2-10

2-18

2-27

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

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

Chapter

XXV

XXVI

XXVII

XXVIII

XXIX

XXX

XXXI

XXXII

XXXIII

XXXIV

XXXV

XXXVI

XXXVII

XXXVIII

XXXIX

XL

XLI

XLII

XLIII

XLIV

XLV

Cooling Group. . . . . . . . . . .. . . .

Hydraulic Actuator and Sump

and Filter (C1ass 1 Sets

Only Except MEP115A)

Engine Assembly .

Alternator and Related Parts

Speed Switch. . . . .

Oil Level Gage and Filter .

Electric Starter and Adapter

Lube Oil Filters and Sensors.

Secondary Fuel Filter . .

Lube Oil Cooler . . . .

Nozzle Holder Assemblies

andLines........

Diffuser and Turbocharter

Water Pump and Fan . . .

Thermostat and Housing

Crankshaft and Pulley and

Vibration Dampener .

Idler Pulley and Mounting

Bracket . . . . . . . . .

Intake Manifold . .

Exhaust Manifold

Rocker Arm Shaft Assembly.

Base Group and Related

Components. . . .

Accessory Items . . . .

A

AUXILIARY MATERIAL USED IN CONJUNCTION

WITH THE EQUIPMENT . . . .

I

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

II Fuel Burning Winterization Kit.

III Electric Winterization Kit. . .

IV

Wheel Mounting Kit. . .

V

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

APPENDIX

A

REFERENCES . . . . . . . . . . . . . .

B

BASIC ISSUE ITEM LIST AND) ITEMS

TROOP INSTALLED OR

AUTHORIZED. . . . . . . . . . . . . .

I

Introduction . . . . . . . . . . . . . . . .

II Basic Issue Items . . . . . . . . . . . . .

III Items Troop Installed or

Authorized List . . . . . . . . . .

IV

Maintenance and operating

Supplies . . . . . . . . . . . . . . .

C

MAINTENANCE ALLOCATION CHART

(ARMY and USMC only)

I

Introduction . . . . . . . . . . . . . . . . .

II Maintenance Allocation Chart.

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

Page

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

4-1

4-1

4-1

4-11

4-21

4-29

A- 1

B-1

B-1

B-2

B-2

B-3

C-1

C-1

C-2

1-1

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 . . . . . . . . . . .

TM 5-6115-545-12

TO-35C2-3-444-1

NAVFACP-8-626-12

TM-00038G-12

LIST OF ILLUSTRATIONS

Page

1-2

1-3

1-4

1-6

1-7

1-8

1-9

1-10

1-11

1-12

1-13

1-14

1-17

1-19

1-21

1-23

1-25

1-27

1-29

1-31

1-33

1-35

1-37

1-39

1-39

1-41

1-43

1-45

1-47

1-49

2-4

2-4

Number

2-2.

2-3.

2-4.

2-5.

2-6.

2-7.

2-8.

2-9.

2-10.

2-11.

2-12.

2-13.

2-14.

3-1.

3-2.

3-3.

3-4.

3-5.

3-6.

3-7.

3-8.

3-9.

3-10.

3-11.

3-12.

3-13.

3-14.

3-15.

3-16.

3-17.

3-18.

3-19.

3-20.

3-21.

3-22.

3-23.

3-24.

3-24.1

3-24.2

3-25.

3-26.

3-27.

3-28

3-29.

3-30.

3-31.

3-32.

3-33.

Title

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

Page

2-5

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 Title Page

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.

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

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

Number Title

Page

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.

LIST OF TABLES

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

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

iv

Change 13

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 AC-

COMPLISHED ONLY BY THE PERSONNEL OF

THE SERVICE TO WHICH THEY APPLY.

a. Forms and Records used by the Army will

be only those prescribed by DA Pam 738-

750. Those used by the Marine Corps will

be those prescribed by TM 4700-15/1.

Other Service users should refer to ap-

propriate specification/publications

for equipment maintenance forms and

records.

b. Report of errors, omissions, and recom-

mendations 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 Com-

mand, 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.

Section 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 follow-

ing kits: (See chapter 4 for Items 1 thru 4.)

(1)

(2)

(3)

(4)

(5)

Load Bank.

Fuel Burning Winterization.

Electric Winterization.

Wheel Mounting.

Automatic Transfer Panel 50/60 Hz. Pro-

vides 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 techni-

cal manual).

(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 tech-

nical manual).

Change 7

1-2

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

b. Engine. The engine is a liquid-cooled, 6 cylinder, valve-in-

head, 4 stroke cycle, turbo-charged, diesel engine.

c. Generator. The 400 Hz generator is a 60 KW, brushless,

air-cooled rotating field generator.

d. Generator. The 50/60 Hz generator is a 50/60KW,

brushless, air-cooled rotating field generator.

1-4. Identification and Tabulated Data.

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. In-

struction plates for kits are located in figure 1-21, and figures 1-22

through 1-24 illustrate their content.

Change 11 1-3

1.

2.

3.

4.

5.

6.

7.

Fuel System Diagram Instruction Plate

(fig. 1-4)

Lifting Instructions Instruction Plate (fig.

1-5)

AC Troubleshooting Diagram (Mode I) and

Plate (fig. 1-13)

AC Troubleshooting Diagram (Mode II) and

Plate (fig. 1-14)

Operating Instructions Instruction Plate

(fig. 1-6)

Service Instructions and System Capacities

Instruction Plate (fig. 1-7)

Voltage Reconnection Instruction Plate

(fig. 1-8)

Operational Data Information Plate (Mode I)

(fig. 1-9)

Operational Data Information Plate (Mode II)

(fig. 1-10)

8.

9.

10.

11.

12.

13.

Schematic Wiring Diagram Class 1, AC and

Plate (fig. 1-17)

Schematic Wiring Diagram Class 2, AC and

Plate (fig. 1 -19)

Schematic Wiring Diagram Class 1, DC and

Plate (fig. 1-18)

Schematic Wiring Diagram Class 2, DC and

Plate (fig. 1-20)

DC Troubleshooting Diagram (Mode I) and

Plate (fig. 1-15)

DC Troubleshooting Diagram (Mode II) and

Plate (fig. 1-16)

Battery Arrangement and Connections

Instructions Plate (fig. 1-11)

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

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. Weight dry (less kits and optional

(1) Engine generator set (end item). equip.) . . . . . . 4300 lbs (50/60 HZ

DOD drawing no. . . . . . 70-0105 (50/60 Hz precise)

Weight dry (less kits and optional

equip.) . . . . . .

4240 lbs (50/60 H

Z

70-0006 (50/60 Hz utility)

precise set)

utility set)

70-0115 (400h Hz precise) Operating temperature

Models :

range . . . . . . . . . .

125°F to -25°F (-25° to -65°F

with winterization systems)

Model

. . . . . . . . . . . MEP105A (50/60 Hz precise)

Model

Voltage output . . . . 120/208

. . . . . . . . . . . MEP006A (50/60 Hz utility)

Model

. . . . . . . . . . .

MEP115A (400 Hz precise)

Length

. . . . . . . . . . . 87 inches

Power factor

. . . . 0.8

Width

. . . . . . . . . . . 36 inches

Height . . . . . . . . . . . 59 inches

Size . . . . . . . . . . . . . . 60 KW

Weight dry (less kits and optional

equip. )

. . . . . .

4400 lbs (400 Hz set)

volts and 240/416 volts

50 KW at 50 Hz)

1-5

b.

Tabulated Data. (Cont)

Type

(2) Engine.

COD drawing no. . . . . . . . . .

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

Fuel . . . . . . . . . . . . . . . . . . . .

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

Rotation (viewed from

70-1049

fan end) . . . . . . . . . . . . . . . . Clockwise

6 cylinder, turbocharged

Cooling . . . . . . . . . . . . . . . . . . . . Circulating coolant

diesel

Cycle . . . . . . . . . . . . . . . . . . . . . . 4 stroke

Diesel fuel W-F-800

JP-4 or JP-5

Valves . . . . . . . . . . . . . . . . . . . . .

2 per cylinder

Maximum permissible exhaust

restriction . . . . . . . . . . . . . 2 inches of mercury

Brake horsepower

CAUTION

1500 rpm . . . . . . . . . . . . . 100

JP-4 and JP-5 fuel are considered

1800 rpm . . . . . . . . . . . . . 120

emergency fuels only.

2000 rpm . . . . . . . . . . . . . 130

Figure 1-4.Fuel System Diagram Instruction Plate

1-6Change 7

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

volts . . . . . . . . . . . . . . .

Amperes . . . . . . . . . . . .

50/60

120/208 or 240/416

(Adjustable to 197/240

or 395/480, 60 Hz

fig. 1 -9)

208/104 (173/87 at 50 Hz)

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

1-7

Figure 1-6.

b. Tabulated Data. (Cont)

(4) Main generator (400 Hz,

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

tactical precise).

Type . . . . . . . . . . . . .

Rotating field synchronous,

brushless with integral

exciter

KVA (Kilovolt Amperes) . . . 75

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

Hertz . . . . . . . . . . . . . . . . 400

Volts . . . . . . . . . . . . . l20/208 or 240/416

(Adjustable to 197/229 or

395 458 - fig, 1-10)

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

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

Change 3

Power factor . . . . . . . . 0.8

Coating . . . . . . . . . .. Air

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

Lubrication . . . . . . . . . . . .

None required

Drive . . . . . . . . . . . . . . . . Direct

Duty classification . . . . . . . Continuous

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

(5) Fuel level switch (day tank).

DOD drawing no. . . . . . 70-1594

Type . . . . . . . . . . . . . Float

Current . . . . . . . . . . 3.0 amperes at

6 to 32 Vdc

Pressure . . . . . . . . . .

0 to 150 psi

1-8

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

b.

Tabulated Data. (Cont)

Switch contact data

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

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 tank-

Upper switch is closed and lower switch opens.

When fuel level drops below 5.75

±

0.12 inches from top of tank-

Upper and lower switches are closed.

(6) Engine accessories.

(a)

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

b. Tabulated Data. (Cent)

(b) Turbocharger.

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

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

(c) Electric starter.

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

volts . . . . . . . . . . . . .

Rotation at drive end .

Torque . . . . . . . . . . .

Pinion data

Pinion teeth . . . . . . . .

Engagement . . . . . . . .

1-10

. . . 24 dc

. . Clockwise

22 ft-lbs (rein) at 400

amperes, 4.0 volts

12 tooth (on 13 tooth blank)

Positive engagement index-

ing drive with overrunning

clutch

(d) Battery charging alternator.

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

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

Rating

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

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

Operating temperature

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

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

(f) Radiator.

—

DOD drawing no . . . 70-1126

Capacity .

Pressure.

(g)

Type . . .

(h)

1.

—

. . . . . . 15 quarts

. . . . . . 7 psi

Water Pump.

—

. . . . . . Belt driven

Safety devices:

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

Switch Configuration

A

. . . 1 circuit N. O.

B

. . . 1 circuit N. C.

Pressure Range:

500 psi maximum

Pressure Setting

A

. . . A-D circuit trip at 18-22 psi decreasing

(N. O.)

B

. . . B-C circuit trip at 18-22 psi decreasing

(N. C.)

2. Coolant high temperature switch.

DOD drawing no. . . 69-697-3

Rating

volts . . . . . . . . . . .

Current . . . . . . . . .

Trip temperature . . . .

3. Overspeed switch.

DOD drawing no . . . . .

28 dc

10 amperes

222° F ± 3° F

70-1105-1 (400 Hz)

70-1105-2 (50/60 Hz)

Change 1

1-11

Figure 1-10.

b. Tabulated Data. (Cont)

—

Type. . . . . . . . . . Speed sensitive,

Operational Data Information Plate (Mode II)

manual reset

Overspeed trip . . . . 2400 to 2450 rpm, engine speed;

1200 to 1225 rpm, switch speed

Element trip speed . . S9-1 set - 290-310 rpm,

automatic reset 190-210 rpm.

(i)

Type . . . .

(j)

Service part

volts . . .

Connections

. .

(all sets)

S9-2 set -825-850 (400 Hz)

rpm, automatic reset 725-750

rpm. Set -590-610 rpm (50/

60 Hz) automatic reset 490-

510 rpm.

S9-3 set -1200-1225 rpm,

manual reset. (all sets)

Oil filters (2).

. . . . . . Replaceable element

Batteries (2).

type no. .

MS35000-3

. . . . . . 12 dc

. . . . . . series for 24 volts

(k) Ether solenoid.

—

DOD drawing no . . . . 70-1609

Volts . . . . . . . . .24dc

Change 1

(1) Primary fuel filter and strainer

assembly.

DOD drawing no. . . . 70-507

(m) Secondary fuel filter.

.—

Cartridge. . . . . . . . . C-1125PL

(n) Ether tank.

—

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 (ohms) pressure (psi)

0.0 to 1.0 ------ 0

1.5 to 3.0 ------ 10

14.5 to 16.5 ----- 60

28.0 to 31.0 ----- 120

(p) Temperature transmitter.

DOD drawing no. . . . 69-781

Voltage rating . . . . . 24 Vdc

Temperature range . . 120° F to 280° F

1-12

Figure 1-11. Battery Arrangement and Connections Instruction Plate

b. Tabulated Data. (Cont)

Resistance (ohms)

2360 ± 10 percent at 120° F

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

(9) Lubricating system.

Type system . . . . . . . . . . . Full flow, circulating

pressure

Oil pump type Gear, positive

displacement

Oil pressure range,

hot, at rated

speed . . . . . . . . . . . . . . 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

b. Tabulated Data. (Cont)

Intake valve

clearance (cold) . . . . 0.018 inch

Figure 1-12. Set I. D. Plate

(13)

Fan drive

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.

Length108 inches crated

87 inches uncrated

Exhaust manifold screws.25 ft - lbs (12 ft lb

increments)

Engine lube oil filter

assembly mounting screws . . . . . 50 ft - lbs

Intake manifold securing

capscrews . . . . . . . . . . . . . . .33 ft - lbs

LOW oil pressure

switch . . . . . . . . .20 ft - lbs

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

Belt deflections.

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).

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)

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

(crate included)

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

(crate included)

Volume . . . . . . . . . . . . . . . . . ..216 cubic feet

(15) Optional equipment.

(a) Fuel burning winterization kit.

—

DOD drawing no. . . . . . . . . . . . 70-1297

Volts . . . . . . . . . . . . . . . . . . . . .24Vdc

Change 1

1-14

&

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)

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

shut-

off

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.

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)

(17)

Maintenance

and

operating

supplies.

Refer

to

Appendix B

for

a

complete

list

of

maintenance

and

oper-

ating

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).

The

difference

between

precise

and

utility

50/60

Hz

and

400

Hz

generator

sets

are

noted

in

the

appropriate

paragraphs

through-

out

the

manual.

Figures 1-26 and 1-27

show

the

harness

intercon-

nection

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

electro-

hydraulic

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.

<

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)

Figure 1-31.1

TM 5-6115-545-12

Change 11 1-18.1/(1-18.2 blank)

TM 5-6115-545-12

1-22.1 /(1-22.2 blank)

Figure 1-15.1 Troubleshooting Diagram, MEP115A Change 11

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

1-28.1/(1-28.2 blank)Change 14

Figure 1-19. Schematic Wiring Diagram

Class 2, AC and plate

1-29/(1-30 blank)

Change 1

Figure 1-20. Schematic Wiring Diagram

Class 2, DC and Plate

1-31/(1-32 blank)

Change 1

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

1-34

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

Figure 1-22. Fuel Burning Winterization System

Diagram and Heater Control Schematic

Diagram Instruction Plate

1-35/(1-36 blank)

Change 1

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 31-39

Table 1-1. Differences in Performance Characteristics

1. Voltage

(a)

(b)

(c)

(d)

Dip with application of

rated load.

Rise with rejection of

rated load.

Dip or rise with appli-

cation of simulated

motor load.

Adjustment range

2. Frequency

(a) Regulation.

(b) Short term steady state

stability.

(c) Long term steady state

stability.

(d) Undershoot with applica-

tion of rated load.

(e) Recovery after application

of rated load.

(f) Overshoot with rejection

of rated load.

(g) Recovery after rejection

of rated load.

(h) Drift (60° F change).

(i) Adjustment range

MEP006A

20% max.

20% max.

40% max.

50 Hz +2.5%

-10%

60Hz +15%

-5%

2 to 3%

Within

2% bandwidth

Within

3% bandwidth

3% max.

Within

3 seconds

4% max.

Within

3 seconds

1%

45-65 Hz

(Manual)

MEP105A

15% max.

15% max.

30% max.

50 Hz +2.5%

-10%

60Hz +15%

-5%

Within

± 0. 25%

Within

0.5% bandwidth

Within

1% bandwidth

1.5% max.

Within

1 second

1.5% max.

Within

1 second

0.5%

50 Hz

48 to 52 Hz

60 Hz

58 to 62 Hz

MEP115A

12% max.

12% max.

25% max.

400 Hz +10%

-5%

Within

±0.25%

Within

0.5% bandwidth

Within

1% bandwidth

1.5% max.

Within

1 second

1.5% max.

Within

1 second

0.5%

390 to 420 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.

Lowest

expected

ambient

temperature

oF

+20

+10

0

-10

-20

-30

-40

-50

-60

-75

Pints of

inhibited

glycol per

gallons of

coolant

1½

2

2¾

3¼

3½

4

4¼

Arctic

antifreeze

preferred

Compound, antifreeze

Arctic

2

Issued full strength

and ready mixed for

0o to -65oF temperatures

for both initial

installation and

replenishment of

losses.

DO NOT DILUTE

WITH WATER OR

ANY OTHER SUBSTANCE

Ethylene glycol

coolant solution

specific gravity

68

o

F3

1.022

1.036

1.047

1.055

1.062

1.067

1.073

1

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

2

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

o

F or drops below, to as low as -75°F.

3

Use an accurate hydrometer. To test hydrometer, use 1 part ethylene glycol antifreeze to 2 parts water. This should produce a hydrometer

reading of 0

o

F. 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.

The electrolyte level must be rechecked approximately 30

minutes after initial filling as the plates and separators will ab-

sorb 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 8-82 b. for the ambient tem-

perature 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).

Other methods are not author-

(5) Perform the before operation preventive maintenance

ized,as arcing at batteries

services specified in table 3-1.

could occur.

2-4. Installation of Separately Packed Components.

(3) Batteries are shipped in a dry state. Battery electrolyte No separately packed components are shipped with generator

must be requisitioned separately. To activate the battery remove sets.

cell caps and fill battery cells with electrolyte. Make sure vent

holes in cell caps are open, and replace caps.

2-2

Change 12

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 auxi-

liary 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 venti-

lated 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 ex-

haust pipe should include a low point with suitable

means for draining of condensate. Provide metal

shields, 12 inches larger in diameter than the ex-

haust 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.

WARNING

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 opera-

tion at 120/208 Vac or 240/416 Vac are given in

figure 2-4.

b. Conversion instructions for equipment opera-

tion 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

Figure 2-1.

2-4

Figure 2-2. Grounding Procedures (Sheet 1 of 3)

Change 32-5

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 32-7

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 CON-

NECT OR DISCONNECT LOAD LEADS WHILE THE GENERATOR SET IS

OPERATING.

DO NOT ATTEMPT TO CONNECT OR DISCONNECT LOAD

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.

NOTE

ONE OR MORE SINGLE-PHASE LOADS CAN BE SERVED ALONE OR IN

COMBINATION WITH 3-PHASE LOADS, BUT THE LOAD ON ANY ONE

PHASE MUST NOT EXCEED 33 PERCENT OF THE CURRENT RATING OF

THE ENGINE GENERATOR SET (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.

Generator Load Terminal Board Connections

Change 14

2-8

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.

Change 13

2-8.2

Figure 2-4.

Voltage Conversion

Change 7 2-9

Section II. MOVEMENT TO NEW WORKSITE

2-7. Dismantling for Movement.

WARNING

Make certain that engine generator set is

not operating in a standby mode, or con-

nected to a parallel bus.

a. Preparation for Movement.

(1) Disconnect the load cables from the load

terminal board (fig. 2-3) and tag for identifica-

tion.

(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.

(4) Refer to the basic issue item list

(Appendix B) and make sure that all items are

present and properly stowed.

(5) Disconnect the ground lead from the

ground terminal stud (fig. 2-2).

(6) Disconnect any other external hoses,

lines and cables, if used.

(7) Close and secure all doors and panels.

b. Movement.

(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.

(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. Reinstallation after Movement.

Refer to paragraph 2-5 for reinstallation after

movement to a new worksite.

Section III.

CONTROLS AND INSTRUMENTS

2-9. General.

2-10.

Controls and Instruments.

This section describes and illustrates the various The purpose of the generator set controls and

controls and instruments required for generator instruments and the normal and scale readings of

set operation. the instruments are illustrated in figure 2-5.

2-10

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

Change 3

2-11

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

2-12

Figure 2-5. Generator Set Controls and Instruments (Sheet 3 of 6)

Change l

2-13

Figure 2-5.

2-14Change 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 FUNCTION

(Fig. 2-5)

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.

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 stop-

ping the engine generator set, operation of the gener-

ator set and coordinating the basic motions to perform

the specific tasks for which the equipment is de-

signed. Since nearly every job presents a different

problem, the operator may have to vary procedures

to fit the individual job.

2-12. Starting.

a. Preparation for Starting. Instructions to be

followed when preparing to start the engine genera-

tor set are shown in figure 2-6. Preventive main-

tenance procedures to be performed before opera-

tion 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.

2-13. Stopping.

a. Normal Stopping. (See figure 2-8). Preventive

maintenance procedures to be performed after equip-

ment operation are given in table 3-1.

b. Stopping by Safety Devices. The engine gen-

erator 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 protec-

tive relay will automatically open the main ac con-

tactor 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).

a. Single Engine Generator Set Operation.

See-fig. 2-9 for single engine generator set operating

instructions.

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.

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.

NOTE

The BATTLE SHORT switch

may be actuated, as necessary,

any time the engine generator

set is operating.

d.

Load Connections for Parallel Op-

eration.

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

2-18 Change 12

source, or while the generator set is

paralleled to another set which is op-

erating.

WARNING

Do not attempt to connect the paral-

leling 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 rat-

ing of a single set, connect load ter-

minal boards as shown in figure 2-3A.

This arrangement allows for sharing or

transferring of the load between gen-

erator 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 accommo-

date 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 ex-

ceed 100 percent of the current rating

of that phase. Be sure that wire sizes

are correct for load to be carried.

(4) Connect the load to terminals

marked L1, L2, L3 and L0 (figure 2-3).

NOTE

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 paral-

leling 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 genera-

tor sets requires that paralleling ca-

bles be installed and the shorting plug

located on one of the paralleling re-

ceptacles of each generator set be re-

moved.

2-15. Exercise of Engine on Standby Service.

A diesel engine on standby service that is custom-

arily operated under optimum conditions should be

exercised at least every 30 days. However, under

environmental conditions involving extreme tempera-

tures, 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 instruc-

tion shown in figure 2-6. Make complete visual

inspection of unit to be sure it is in operating condi-

tion.

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

O

F) 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 PROCEED-

ING .

STEP 8.

CLOSE MAIN AC CONTACTOR BY MOMENTARILY PLACING CKT BKR SWITCH IN CLOSE PO-

SITION.

MOMENTARILY PLACING CKT BKR SWITCH IN OPEN POSITION WILL OPEN THE AC CON-

TACTOR.

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 RESPECTIVE-

LY .

STEP 2.

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

25° F.

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

2-22 Change 3

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.

STEP 2.

STEP 3.

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

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

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 PAR-

ALLEL 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

TICALLY POSITIONED.

CAUTION

DO NOT PLACE THE CIRCUIT BREAKER SWITCH ON ANY OF THE GEN-

ERATOR SETS IN THE CLOSE POSITION UNTIL SPECIFICALLY DI-

RECTED TO DO SO. CLOSING THE CIRCUIT BREAKER SWITCH AT

ANY OTHER TIME MAY SEVERELY DAMAGE ONE OR MORE OF THE GEN-

ERATOR 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

FORM STEP 8 OF FIGURE 2-7.

ARE IDEN-

NOT PER-

STEP 3.

HOLD THE CKT BRK SWITCH (FIGURE 2-5) OF THE “ON-LINE” SET IN THE CLOSE PO-

SITION 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 FREQUEN-

CY 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 DE-

SCRIBED IN (FIGuRE 2-3.1).

IF THE PROBLEM PERSISTS, RE-

FER TO NEXT HIGHER LEVEL OF MAINTENANCE.

STEP 5.

ADJUST THE FREQUENCY OF THE “ON-COMING” SET A LITTLE HIGHER THAN THE “ON-

LINE” SET.

THEN REDUCE THE FREQUENCY SLOWLY WITH THE FREQUENCY ADJUST RHEOSTAT UN-

TIL 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 OP-

ERATING 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 DE-

CREASE 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 CUR-

RENT ON ANY PHASE BETWEEN THE “ON-LINE” AND “ON-COMING” SETS IS NOT MORE THAN 20

PERCENT. IF

STEP 10. TO

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 RAT-

ED 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.

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 AT-

TACHED AS INDICATED, SHUT DOWN THE “ON-LINE” SET AND FOL-

LOW 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 OPER-

ATION 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.

LOAD AND

STEP 9.

STEP 10.

ADJUST THE VOLTAGE AND FREQUENCY RHEOSTATS OF THE “ON-COMING” SET UNTIL

CURRENT ARE DIVIDED EQUALLY BETWEEN THE TWO GENERATOR SETS.

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

PLACE THE OPERATIONS SWITCH OF THE “ON-COMING” SET TO THE SINGLE UNIT OPER-

ATION POSITION.

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

2-26.2

Change 12

(Sheet 4 of 5)

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

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 2-10A. Parallel Operation of Tactical Utility Generator Sets

(Load Sharing and Load Transfer) (Sheet 1 of 4)

Change 12

2-26.4

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 PAR-

ALLEL 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 RECON-

NECTION 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 SPECIFICAL-

LY 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 PER-

FORM STEP 8 OF FIGURE 2-7.

STEP 3.

HOLD THE CKT BRK SWITCH (FIGURE 2-5) OF THE “ON-LINE” SET IN THE CLOSE PO-

SITION 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 CONNEC-

TION 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-COM-

ING” 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 SYNCHRON-

IZING 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 OP-

ERATING 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 CON-

TROL 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 COUNTER-

CLOCKWISE 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. DE-

CREASE 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 CUR-

RENT 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 BREAK-

ER 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 AT-

TACHED 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 OPER-

ATION 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

LIGHTS FLASH AT 2 TO 3

THE FREQUENCY OF THE “ON-COMING” SET UNTIL THE

SECOND INTERVALS. SYNCHRONIZING

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”

TO THE CLOSE POSITION.

STEP 8.

ADJUST THE VOLTAGE AND FREQUENCY RHEOSTATS OF BOTH SETS UNTIL LOAD AND

RENT ARE DIVIDED EQUALLY BETWEEN THE TWO GENERATOR SETS,AS EXPLAINED IN FIGURE

2-10.1, PARAGRAPH A, STEPS 7 AND 8.

SET

CUR-

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 OPER-

ATION 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

od) during a six-month period, it is

water temperature readings of 160° F minimum,

recommended that the filters and lubri-

taken at a 15-minute interval. Then continue to eating oil be changed (para 3-4). If

operate engine for 30 minutes. Check and correct

any coolant or oil leaks.

the accumulated hours of operation dur-

ing the above exercise periods do not

c.

Stop engine as shown in figure

total 100 hours (recommended fuel filter

2-8.

If the accumulated hours of opera- change period) during a 12-month period,

tion during the above exercise periods it is recommended that the fuel filter

do not total 300 hours (recommended lube element be replaced (para 3-160).

filters and lubricating oil change peri-

Section V. OPERATION UNDER UNUSUAL CONDITIONS

2-16. Operation in Extreme Cold (Below- 25°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 winteriza-

tion system (fig. 2-11). Operate fuel burning winter-

ization system for 55 minutes or until fuel burning

winterization system cycles off. Operate electric win-

terization for 5 hrs.

b. Fuel System. Keep the fuel tank as full as pos-

sible to prevent condensation of moisture. Be sure

the proper grade of fuel is used for existing tempera-

tures. 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).

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 freez-

ing, 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 thor-

oughly 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.

Cooling System. Inspect the level of the coolant

in the radiator. Inspect the cooling system for leaks,

aying particular attention to gaskets and hose con-

nections. Verify that antifreeze mixture is in ac-

cordance with table 2-1.

f. Air Cleaner. Refer to paragraph 3-32 for proper

maintenance of air cleaner.

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

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. Lubricate the engine in accordance with the

instructions in paragraph 3-3 and 3-4.

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 nox-

ious and deadly fumes. Do not

operate generator sets in in-

closed areas unless exhaust dis-

charge is properly vented to

the outside.

e.

Check that the engine generator

—

set is free of air-flow restrictions.

When operating indoors, make provisions

for adequate ventilation and the vent-

ing of exhaust fumes to the outside. T

O

prevent excessive back pressure, it is

recommended that an exhaust extension

of flexible tubing be no longer than 20

feet

f.

g.

allow

2-18.

(maximum).

Keep external surface of engine clean.

The unit should be allowed to run at no load to

the engine to cool prior to shutdown.

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 ON

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 OPERA-

TED SIMULTANEOUSLY.

STEP 1. INSURE THAT A 205-240 VOLT, 50/60 OR 400 HZ, SINGLE PHASE SOURCE OF EXTERNAL POW-

ER 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)

2-30Figure 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 lub-

ricant 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.

2-19. Operation Under Rainy or Humid Conditions.

Keep the fuel tank full to prevent forming of conden-

sation. 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 ex-

posed 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 ser-

vices requirements.

2-21. Operation at High Altitudes.

The engine generator set will operate at elevations

up to 5,000 feet above sea level without special ad-

justment 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 possi-

bility 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.

2-22. Operation in Snow.

Keep the fuel tank full to prevent forming of condensa-

tion. Drain water and sediment from fuel tank (fig.

3-7) more frequently. Check coolant antifreeze pro-

tection (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 lo-

cation for mounting the panel. Disconnect and remove

wiring harness (1, Fig. 3-17) and control cubicle as-

sembly (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 pre-

heat 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. Op-

erating 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 ex-

changer, 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

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 temper-

ature 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 tempera-

ture 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 winter-

ization 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.

2-32

Change 12

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. are required by operator or organizational mainten-

ance personnel for maintenance of the engine gen-

a. Basic Issue (Army). Tools and repair parts erator set.

issued with or authorized for use with the engine

generator set are listed in the basic issue items list, 3-2. Organizational Maintenance Repair Parts (Army).

Appendix B of this manual.

Organizational maintenance repair parts are listed

b. Special Tools. No special tools or equipment 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 dis-

connect 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 lubrica-

tion 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 crank-

case 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 redi-

rected 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 con-

tainers 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.

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.

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.

(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.

Oil Level Gage and Filler

(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.

(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

Disconnect negative lead from battery prior to

servicing oil falter.

(1) Drain oil filter by removing plug (l). Drain oil into

appropriate container.

3-4 Change 18

1. Plug

2. Screw

3. Washer

4. Gasket

5. Screw

6. Washer

7. Filter body 13. Washer

8. Filter element 14. Oil Seal

9. Header 15. Spring

10. Gasket 16. Switch

11. Retaining Ring 17. Nipple

12. Adapter 18. Transmitter

Figure 3-3. Engine Lube Oil Filters

19. Nipple

20. Cap

21. Plug

22. Connector

23. Gasket

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.

(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

(5) Replace plug (1) in filter body (7). (10) are properly installed.

Section III.

PREVENTIVE MAINTENANCE CHECKS AND SERVICES

body (7) and gasket

3-5. General.

To insure that the engine generator set is ready for

operation at all times, it must be inspected systema-

tically so that defects may be discovered and cor-

rected before thay result in serious damage or fail-

ure. The necessary preventive maintenance services

to be performed are listed and described in para-

graphs 3-6 and 3-7. Item numbers indicate the se-

quence 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 defi-

ciency 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 pre-

ventive 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).

Table 3-1 contains a tabulated listing of Pre-

ventive maintenance services which must be per-

formed daily by the operator. The item numbers

are listed consecutively and indicate the sequence of

minimum requirements.

3-7. Monthly and Semi-annual Preventive Mainten-

ance 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.

b. The item numbers are listed con-

secutively and indicate the sequence of

minimum requirements.Refer to table

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 fol-

lows :

CLASS I

Seepage of fluid (as indicat-

ed by wetness or discolora-

tion) 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/in-

spected.

3-6Change 12

Section IV. OPERATOR’S MAINTENANCE

3-8. General. 3-10. Slave Receptacle Inspection.

Instructions in this section are provided to assist the A slave receptacle (17, fig. 3-4) is located in a

operator in maintaining the engine generator set. receptacle box on the forward left side of the housing.

Inspect the slave receptacle for loose mounting,

3-9. Batteries. loose electrical connections, loose covers, corrosion

and other damage.

a. Inspection. See figure 3.4 and remove screws

(9),and washers (10) and studs (8) which attach bat- 3-11. Muffler, Exhaust Pipe and Breather System Inspection

tery tray (11) to base and slide storage batteries and Inspect muffler and exhaust pipes (fig. 3-12) and breather

trays (11) out. Inspect storage batteries for cracks system (Fig. 3-12.1) for crocks, leaks, breaks, loose mounting,

and leaks. Check for loose cables (1, 2 and 3) and

and other damage.

mountings and excessive corrosion. 3-12. Convenience Receptacle Assembly

b. Service. Refer to table 3-1. Fill to 3/8 inch Inspection.

above plates. In freezing weather, run engine a mini-

mum of 1 hour after adding distilled water. Apply Inspect convenience receptacles assembly

grease to cable connectors. and components for loose mounting, loose

corrosion and other damage.

(fig. 3-13)

covers,

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

ITEM

NO.

1

B – BEFORE OPERATION D – DURING OPERATION A – AFTER OPERATION

INTERVAL

B

●

●

●

D

—AITEM TO BE

INSPECTED PROCEDURES

Generator Set

Dead Crank Switch

Do not attempt to service

(make adjustments, connec-

tions, reconnection of wires

or cables) or correct anything

inside the generator set until

the generator set is shut down

and completely de-energized.

●

●

●

Equipment operation is allow-

able with minor leakages

(Class I or II). Of course, you

must consider the fluid capa-

city 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 re-

ported to your supervisor or

organizational maintenance,

Visually inspect unit for fuel, oil,

coolant, and hydraulic leaks. Check

for proper levels.

Visually inspect the generator

for missing,loose or damaged

parts and hardware , and for

unusual wear or deterioration.

Check for proper ground connection.

(Para. 2-5e, fig. 2-2).

Place dead crank switch in the run

position.

EQUIPMENT WILL

BE REPORTED NOT

READY (RED) IF:

Class III oil, coolant,

and hydraulic fluid are

found during inspection

Generator set not

properly grounded.

If switch

malfunctions.

Change 133-7

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

ITEM

NO.

2

INTERVAL

B

●

●

D

●

A

ITEM TO BE

INSPECTED

Batteries

Fuel Selector Valve

Controls and instruments:

a.

b.

c.

d.

e.

f.

g.

Battery charging

ammeter

Coolant temp gage

Voltmeter

Oil pressure gage

A.C. ammeter

Wattmeter

Frequency meter

PROCEDURES

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 instal-

ling. In freezing weather run engine

a minimum of 1 hour after adding

water.

Turn fuel selector valve to the

correct position.

Instruments shall indicate within

specified limits. (Fig. 2-5)

Green portion of scale

180° to 200° F

120/208 - 240/416

30 to 55 psi

Indicates percentage of applied

current. Not to exceed 100%

Indicates applied load. Not to

exceed 100%.

400 Hz - 50/60 Hz

EQUIPMENT WILL

BE REPORTED NOT

READY (RED) IF:

Cable connections

cannot be tightened,

or battery is cracked

or leaking.

Fuel selector valve is

inoperable.

Ammeter does not

indicate charging

current.

Temp exceeds 200° F.

Voltage cannot be

properly adjusted.

Pressure is below

30 psi.

Meter is

nonfunctional.

Meter is

nonfunctional.

Frequency cannot be

properly adjusted.

3-8

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 D -DURING OPERATION A - AFTER OPERATION

ITEM

NO.

3

4

5

6

INTERVAL

B

●

●

•

D

●

A

●

●

●

ITEM TO BE

INSPECTED

PROCEDURES

EQUIPMENT WILL

BE REPORTED NOT

READY (RED) IF

h. Fault indicator

panel

Fuel tank

Oil level

Fuel filters and

strainers

Day Tank

All lights out during operation. Check bulb opera-

tion using test or reset switch on panel.

Fill fuel tank at completion of operation.

para 2-16b, 2-17c, 2-19, and 2-22)

(Fig. 1-2;

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))

Check for leaks. Drain water and sediment.

NOTE

In freezing weather, drain shortly

after operation. Allow to drain

until fuel runs clear.

Drain water and sediment.

NOTE

In freezing weather, drain shortly

after operation. Allow to drain

until fuel runs clear.

Fault light will not extin-

guish when switch is placed

to TEST RESET position,

then released.

Class III leakage is detected.

Change 18

3-8.1 /(3.8-2 blank)

Table 3-1.1. ORGANIZATIONAL PREVENTIVE MAINTENANCE CHECKS AND SERVICES

W-WEEKLY (40 HOURS) S-SEMIANNUAL (500 HOURS)

ITEM

NO.

1

2

3

4

5

6

M

—

INTERVAL

H

M-MONTHLY(1O0

ITEM TO BE

INSPECTED

Fluid level

a. Lubricat-

ing oil

b. Hydraulic

sump

c. Cooling

system

Fuel tank

Fuel fil-

ters and

strainers

Batteries

Day tank

Generator

set

HOURS)

H-HOURS (AS INDICA

PROCEDURES

Check fluid levels.

Check oil and add as required.

(Fig. 3-1; 3-2)

Check and add fluid as required.

(Fig. 3-44)

Check coolant level.

Proper level

is 2 inches below filler neck.

(Para 2-3 c 2).

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.

Drain water and sediment from

filters and strainers.

Note:

In freezing weather, fil-

ters and strainers should be

drained shortly after operation.

Close

clean

(Fig.

Check

(Para

check

prior

drain cocks as soon as

fuel begins to run out.

1-1; para 3-6 and 3-9)

battery electrolyte level.

3-9) Perform a hydrometer

of the battery electrolyte

to adding distilled water.

Recharge or replace battery if

specific gravity reading is low.

(Para 3-82 b)

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)

Inspect entire unit for loose,

damaged, or missing parts; and

unusual wear or deterioration.

TED)

-

EQUIPMENT WILL

BE REPORTED NOT

READY (RED) IF:

Change 6

3-9

Table. 3-1.1. ORGANIZATIONAL PREVENTIVE MAINTENANCE CHECKS AND SERVICES--continued

W-WEEKLY (40 HOURS) S-SEMIANNUAL (500 HOURS)

ITEM

NO.

7

8

9

10

11

12

13

14

15

s

—

●

●

●

H

●

●

M-MONTHLY(1O0

ITEM TO BE

INSPECTED

V-belts

Air filters

Deleted.

Engine oil

Oil filters

Fuel filters

and strainer:

Hydraul

sump

Hydraul

filter

ic

ic

Hydraulic

actuator

HOURS )

H-HOURS (AS INDICI

PROCEDURES

Inspect

for worn, frayed, oil

soaked, or cracked belts. Check

adjustment of V-belts.

Pro-

per adjustment for fan belt is a

deflection of 9/32 inch with ap-

plication 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 pres-

sure midway between alternator

pulley and accessory drive pulley.

(Fig. 3-35)

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 indi-

cated by the light.

Drain engine oil and refill.

(Para 3-4c)

Change lubricating oil every 300

hours or 6 months.

Replace lubricating oil filters.

(Para 3-4d)

Change lubricating oil filters

every 300 hours or 6 months.

Replace primary and secondary fuel

filters, and clean fuel strainers

every 100 hours.

(Para 3-34, 3-36, and 3-165 a)

Drain and refill hydraulic sump.

(Para 3-44)

Replace hydraulic filter.

(Para 3-45)

Clean actuator filter screen.

(Para 3-175)

ED)

EQUIPMENT WILL

BE REPORTED NOT

READY (RED)

IF:

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.

3-15. Paralleling Receptacles Inspection.

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.

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 connec-

tions, 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.

3-17. AC Voltmeter.

a. Inspection. Inspect ac voltmeter (42, fig. 3-18)

for cracks, breaks, corroded and/or loose terminals,

and other damage.

b. Adjustment. With generator off, adjust volt-

meter zero control until the pointer is at zero.

3-18. Kilowatt Meter.

a. Inspection. Inspect kilowatt meter (39, fig.

3-18) for cracks, breaks, corroded and/or loose

terminals, and other damage.

b. Adjustment. With generator off, adjust kilo-

watt meter zero control until pointer is at zero.

Change 1

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.

3-20. Frequency Meter.

Inspect freq meter (7, fig. 3-18) for cracks, breaks,

loose and/or corroded terminals, and other damage.

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.

—

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

breaks, loose mounting.

loose

b.

—

lamp.

(2) Inspect lamp (24, fig. 3-18) for breaks or

mounting.

Test and Replacement.

(1) Close DC circuit breaker.

(2) Set PANEL LIGHT switch to ON position.

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

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

a. Inspection.

—

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

breaks, loose mounting.

3-12

Table 3-2. Fault Indicator Test Points

Fault indicator

LOW OIL PRESSURE

OVER SPEED

COOLANT HIGH TEMP

NO FUEL

SHORT CIRCUIT

UNDER VOLTAGE

REVERSE POWER

OVER LOAD

UNDER FREQ

OVER VOLT

(2) Inspect lamps (31 and 38, fig. 3-18) for

breaks or loose mounting.

b.

Test and Replacement,

(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

(16, fig. 3-18) for damage or loose mounting.

3-28. Door Holders Inspection

lights

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 opera-

tion. Inspect doors, covers, and panels for loose

mounting, dents or other damage (fig. 3 -22).

Pin no.

12-D

12-E

12-K

12-L

12-F

12-G

12-H

12-M

12-N

12-I

3-32. Air Cleaner Assembly.

a. Inspection.

(1) (Deleted)

(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 elec-

trical 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 1. REMOVE WING NUTS AND RETAINER.

STEP 2. CAREFULLY REMOVE DIRTY FILTER ELEMENT.

STEP 3. CLEAN INSIDE OF HOUSING.

STEP 4. 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. INSTALL FILTER ELEMENT.

STEP 6. INSTALL WING NUTS AND RETAINER AND TIGHTEN WING NUTS

FINGER TIGHT.

Figure 3-5. Air Cleaner Service

3-14 Change 7

1. Drain Cock 9. Nut

2. Drain Cock 10. Stud

3. Filter body 11. Nut

4. Header 12. Strainer body

5. Screw 13. Gasket

6. Gasket 14. Retainer

7. Filter cartridge 15. Strainer element

8. Gasket

Figure 3-6. Fuel Filter and Strainer

b.Service.Service the fuel fil-

ter assembly at intervals shown in ta-

ble 3-1.1, item 12, and proceed as fol-

lows :

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

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 re-

move 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 cart-

ridge (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.

(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.

(2) Inspect main fuel tank cap gasket for tears

or deterioration. Check that valve opening in cap IS

clear of obstruction.

(3) Inspect fuel tank filler hose for leaks.

cracks, loose mounting, deterioration or other evi-

dence of damage.

Change 123-15

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 3-40. Shutter and Shutter Thermostat Inspection.

mounting, deterioration or other evidence of damage. Verify that the linkage connecting the shutter control assembly

b. Service. (See fig. 3-7.)

(10, fig. 3-30), which houses the shutter thermostat (6) to the

shutter (2, fig. 3-31 ) is secure and not damaged. Check

(1) Remove main fuel tank cap, gasket, and strainer.

thermostat housing for cracks, leaks or other damage.

(2) Clean all metal parts and dry thoroughly. 3-41. Radiator.

a. Inspection. Inspect the radiator assembly (35, fig. 3-29)

(3) Replace a damaged or defective gasket.

for leaks.

(4) Replace a damaged or defective main fuel tank b. Service.

strainer.

(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.

3-39. Fan Guard Inspection.

Inspect the LH and RH fan guards (25 and 26, fig. 3-29) for

dirt, cracks, dents or other damage.

Change 18

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.

( b ) Refer to Table 2-1 for proper coolant and fill

radiator until coolant level is two inches below filler neck.

( c ) Fasten tag near radiator cap indicating date, type

of coolant and level of protection.

3-16

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 para-

graph 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).

3-42. Hydraulic Cooler (MEP105A Only) Inspection.

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 con-

nections, 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).

(2) Remove tiller cap (3). Add hydraulic oil conforming to

Military Specification MIL-H-5606 to obtain proper level.

(3) To drain tank, place suitable container beneath drain plug

(4) and remove drain plug. Repeat step (2) to refill sump tank.

3-45. Hydraulic Filter (MEP105A Only).

a. Inspection. Inspect hydraulic filter (fig. 3-8) for cracks,

breaks, and other damage.

b. Service. To service the hydraulic filter refer to table 3-1 and

figure 3-8 and proceed as follows:

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

(7). Discard filter element.

(2) Clean filter body with cleaning solvent, Federal Specifica-

tion P-D-680 and dry thoroughly.

(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 pack-

ing (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.

Refer to table 3-1 and service the engine crankcase as follows:

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 lev-

el 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.

Inspect battery charging alternator (fig. 3-36) for cracks, loose

mounting, dents, loose or damaged connector, and other defects.

3-49. Speed Switch Inspection.

Inspect speed switch (fig. 3-37) for loose mounting, loose connec-

tor and other damage.

3-50. Angle Adapter Inspection.

Inspect angle adapter (fig. 3-38) for loose mounting, breaks,

cracks and other damage.

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

spection.

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

and loose mounting.

Change 113-17

1. Hydraulic sump

6. Filter body

2. Sight glass 7. Filter element

3. Filler cap 8. Preformed packing

4. Drain plug 9. Backup rings

5. Lockwire 10. Header

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

3-52. Oil Level Gage and Filler Inspection.

See figure 3-2 and proceed as follows:

a. Inspect oil level gage legibility of marking, loose

fitting and other damage.

b. Inspect oil filler cap for secure fitting.

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

other damage.

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

damage.

3-53. Starter Assembly Inspection.

Inspect starter assembly for cracks, dents, loose, damaged or

missing parts, loose mounting, loose electrical connections, and

other damage.

3-54. Oil Pressure Transmitter Inspection.

Inspect transmitter (18, fig. 3-3) for leaks, cracks, loose mounting,

loose electrical connection and other damage.

3-55. Lube Oil Filter Assemblies Inspection.

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 4. Gasket 7. Filter element

2. Bleed screw 5. Header 8. Bowl

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

parts for damage or stripped threads. filter.

b. Service. To service the fuel filter proceed (3) Open bleed screw (2)

as follows: and remove and discard gasket remove capscrew (3)

(6) and filter element.

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.

(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).

(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.

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.

3-61. 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.

3-62. Main Fuel Tank.

a. Inspection.

(1) Inspect main fuel tank (fig. 3-7) for loose mounting.

(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.

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.

3-20

Change 18

TM 5-6115-545-12

TO 35C2-3-444-1

NAVFAC P-8-626-12

TM 000838G-12

Section V. TROUBLESHOOTING

3-65. General

maintenance. The engine generator set must be completely

Table 3-3 provides information useful in diagnosing and serviced with fuel, coolant, and lubricating oil. Before

troubleshooting, check that all electrical connections are correct

correcting unsatisfactory operation or failure of the engine and operating controls are in the correct positions.

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 NOTE

probable cause. Any trouble beyond the scope of organizational Air Force and Navy users are authorized to perform

maintenance shall be reported to the next higher level of maintenance within the scope of their capability.

Table 3-3 Troubleshooting

MALFUNCTION

1.

Engine

fails to crank

when START-STOP-

RUN switch is moved

to START position.

2. Engine cranks but will

not start.

PROBABLE CAUSE

a.

b.

c.

d.

e.

f.

g.

h.

a.

b.

c.

d.

e.

f.

g.

h.

i.

i.

k.

Improper starting

procedure.

Batteries weak,

Batteries improperly

installed.

Defective, corroded or loose

battery cables.

Defective or loose control

wires.

Defective DC CONTROL

CIRCUIT BREAKER.

Defective START-RUN-STOP

switch

Defective speed switch

Improper starting procedure.

Fuel supply exhausted

Water in fuel supply

Air in fuel system.

Restricted fuel supply line.

Defective day tank float

switch.

Defective fuel solenoid

valve.

Clogged fuel fitter and

strainer elements,

Clogged secondary filter

element.

Defective nozzle holder

assembly.

Clogged air intake system.

CORRECTIVE ACTION

a.

b.

c.

d.

e.

f.

g.

h.

a.

b.

c.

d.

e.

f.

g.

h.

i.

i.

k.

Perform starting procedure as described in

paragraph 2-12.

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.

Connect batteries as indicated in figure 3-4.

Tighten all loose connections and clean corrosion

from all terminals. (Refer to item 16, table 3-1.)

Inspect control wires and repair or tighten

as necessary.

Replace DC CONTROL CIRCUIT BREAKER

(para 3-100).

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

Replace defective speed switch (para 3-186).

Perform starting procedure as described in

paragraph 2-12.

Fill fuel tank or use auxiliary fuel supply

(para 2-3).

Drain fuel system, service with proper grade of

fuel (para l-4b).

Bleed fuel system (para 3-56c).

Clean restriction or replace tine.

Replace float switch (para 3-159).

Replace fuel solenoid valve (para 3-158).

Service filter and strainer (para 3-34).

Service filter (pars 3-197).

Replace nozzle holder assembly (para 3-201).

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

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)

MALFUNCTION

1.

3.

Engine runs when START

-RUN-STOP SWITCH is

held in START position

but stops when switch

is set to RUN.

4.

Engine runs errati-

tally or misfires

5.

Engine exhaust

excessively black

6.

Engine exhaust white

or blue.

PROBABLE CAUSE

Contaminated or improper

m.

n.

o.

a.

b.

c.

d.

e.

a.

b.

c.

d.

e.

f.

a.

b.

c.

d.

e.

a.

b.

c.

d.

e.

grade of fuel.

Speed switch not reset

after overspeed shutdown.

Open or defective dead

crank switch.

Closed fuel shutoff lever

(Class I only).

Switch not held in start

position sufficient amount

of time to enable engine to

exceed 600 rpm.

Defective speed switch.

Defective START-RUN-

STOP switch.

Defective oil pressure switch.

High coolant temperature.

Contaminated or improper

fuel.

Air in fuel system.

Restricted fuel fines.

Defective nozzle holder

assembly.

Dirty air cleaner.

Defective turbocharger.

Improper fuel.

Clogged air intake

Defective turbocharger.

Clogged turbo.

Generator set overloaded.

Improper timing.

Improper fuel.

Engine operating temperature

too low due to faulty thermostat.

Oil level too high.

Defective nozzle holder

assembly.

improperly adjusted valves.

CORRECTIVE ACTION

l.

m.

n.

o.

a.

b.

c.

d.

e.

a.

b.

c.

d.

e.

f.

a.

b.

c.

d.

e.

a.

b.

c.

d.

e.

Drain fuel supply, service with proper grade

of fuel (para l-4b).

Reset speed switch by depressing reset button

on back end of switch.

Close switch (49, fig. 3-27) and test for

continuity. Replace if defective.

Open lever for fuel inlet to injection pump.

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

Replace speed switch (para 3-186).

Replace switch (para 3-119).

Replace oil pressure switch (para 3-194).

Refer to malfunction item 11.

Drain fuel system and fill with proper fuel

(para 1-4).

Bleed fuel lines (pars 3-56).

Clean fuel lines.

Replace nozzle holder assembly (para 3-201).

Service air filters (fig. 3-5).

Replace turbocharger (para 3-203).

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

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

Replace turbocharger (para 3-203).

Reduce load to rated level.

Correct timing.

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

Replace thermostat (para 3-209).

Drain crankcase until proper level is indicated

on oil level gage (para 3-4).

Replace nozzle holder assembly (para 3-201).

Adjust valves (para 3-220).

3-22 Change 18

Table 3-3. Troubleshooting (Cont)

MALFUNCTION

7. LOW oil pressure indi-

cated on oil pressure

gage.

8. Noisy turbocharger.

9. Turbocharger leaks

oil.

10. High oil pressure

indicated on oil

pressure gage.

11. High coolant temper-

ature indicated on

coolant temperature

gage.

PROBABLE CAUSE

a.

—

b.

c.

—

d.

—

e.

—

f.

—

g.

a.

—

b.

—

a.

—

b.

a.

—

b.

—

a.

—

b.

—

c.

—

d.

—

e.

—

f.

—

g.

h.

—

i.

j.

k.

—

Oil level too low.

Defective oil pressure

gage.

Defective oil pressure

transmitter.

Clogged lube oil filters.

Improper viscosity oil

Worn oil pump.

Worn bearings.

Improper turbocharger

lubrication.

Loose turbocharger end

plates.

Loose turbocharger

end plates.

Defective turbocharger

housing.

See b, c and e from

malfunction 7.

Oil pressure regulator.

Coolant level low.

High coolant temperature

due to incorrect coolant.

Lube oil level low.

Defective or improperly

adjusted fan belts.

Insufficient heat transfer

through radiator.

Defective coolant

thermostat.

Defective water pump.

Clogged radiator.

Generator set over-

loaded.

Defective coolant tem-

perature transmitter.

Defective coolant tem-

perature gage.

CORRECTIVE ACTION

a.

b.

c.

d.

—

e.

f.

—

g.

a.

—

b.

a.

—

b.

—

a.

—

b.

—

a.

—

b.

—

c.

—

d.

—

e.

—

f.

g.

h

i.

j.

k.

Add oil until proper level is indicated on oil

level gage (para 3-4).

Replace gage (para 3-121).

Replace transmitter (para 3-193).

Service filters (para 3-4).

Drain crankcase and fill with proper lube oil

(fig. 3-l).

Replace oil pump.

Replace bearings.

Clean turbocharger oil passages (para 3-203).

Tighten end plate screws (para 3 -203).

Tighten turbocharger end plate screws

(para 3-203).

Inspect housing. Replace turbocharger

(para 3-203).

See b. c and e of malfunction 7.

—

—

Replace oil pressure regulator

Add coolant (para 3-41).

Check for proper coolant mixture. Correct

or replace as necessary (para 3-41).

Add lube oil (fig. 3-l).

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

Check that air inlet doors are open.

Check shutter operation (para 3-171).

Insure that there is at least 10.200 CFM or

12,300 CFM cu. ft. air supply (fig. 2-l).

Replace thermostat (para 3-209).

Replace water pump (para 3-206).

Replace radiator (para 3-172).

Check that the generator load does not ex-

ceed the ratings specified on the kilowatt

capacity nameplate 70-1345 (M2), 70-1346

(Ml).

Replace transmitter (para 3-209).

Replace gage (para 3-120).

Change 3

3-23

MALFUNCTION

11.

12.

13.

14.

15.

(Deleted)

Low coolant tempera-

ture indicated on

coolant temperature

gage.

c.

Battery charging

ammeter shows no

charging when bat-

teries are low or

discharged.

c.

Battery charging

ammeter indicates

excessive charging

rate after prolonged

operation.

Ac voltmeter does

not indicate any

set voltage,

PROBABLE CAUSE

Table 3-3. Troubleshooting (Cont)

CORRECTIVE ACTION

l.

a.

—

b.

—

c.

—

d.

—

a.

—

b.

—

c.

—

d.

—

e.

—

f.

—

a.

—

b.

—

c.

—

d.

e.

—

a.

—

b.

—

c.

—

& m. (Deleted)

Defective coolant thermo-

stat.

Defective or improperly

adjusted radiator

shutter and control

assembly.

Defective coolant temp-

erature transmitter.

Defective coolant

temperature gage.

Blown alternator fuse.

Improperly adjusted

alternator.

Defective or improperly

adjusted alternator belt.

Defective alternator.

Defective battery

charging ammeter.

Open wire in charging

circuit.

Improperly adjusted

alternator.

Defective batteries.

Low resistance or short

to ground.

Defective alternator.

Defective battery

charging ammeter.

Defective speed switch.

Defective VOLTS-AMPS

selector switch.

Defective ac voltmeter.

l. & m. (Deleted)

a. replace thermostat (para 3-209).

b.

—

d.

—

a.

—

b.

—

d.

—

e.

—

f.

—

a.

—

b.

—

c.

—

d.

e.

—

a.

b.

—

c.

—

Adjust or replace shutter or control assembly

(para 3-171).

Replace transmitter (para 3-209).

Replace gage (para 3-120).

Replace fuse located at back end of alternator.

Adjust alternator (para 3-184).

Adjust or replace belt (para 3-183).

Replace alternator- (para 3-184).

Replace ammeter (para 3-124).

Find open wire and repair.

Adjust alternator (para 3-184).

Service or replace batteries (para 3-82).

Inspect wiring and repair as necessary.

Replace alternator (para 3-184).

Replace ammeter (para 3-108).

Replace speed switch (para 3-186).

Replace switch (para 3-11 2).

Replace voltmeter (para 3-105).

Change 1

3-24

Table 3-3. Troubleshooting (Cont)

MALFUNCTION

16.

17.

18.

19.

20.

21.

22.

Ac voltage too high

or too low.

Ac voltmeter indi-

cates voltage but

frequency is off

scale to left.

Ac voltage

fluctuates.

Erratic frequency

indicator on fre-

quency meter.

Frequency meter

fails to register.

Kilowatt. meter fails

to register.

Engine generator set

shuts down, NO FUEL

indicator illuminates,

but sufficient fuel re-

mains in main tank

for operation.

PROBABLE CAUSE

a.

b.

a.

b.

c.

d.

a.

b.

c.

d.

a.

b.

a.

b.

c.

d.

e.

—

Defective VOLTAGE

ADJUST rheostat.

Engine speed too low.

Defective meter or

transducer.

Loose electrical

connection.

Defective VOLTS-AMPS

switch.

Defective VOLTAGE

ADJUST rheostat.

Defective ac voltmeter.

Air in fuel.

Defective nozzle holder

assembly.

Improperly adjusted

valves.

Defective frequency

transducer or fre-

quency meter.

Frequency meter

defective.

Frequency transducer

defective.

Kilowatt meter defective,

Defective day tank

float switch.

Defective fuel solenoid

valve.

Clogged fuel filter or

strainer.

Clogged fuel transfer

pump screens.

Defective fuel transfer

pumps.

CORRECTIVE ACTION

a.

b.

a.

b.

c.

d.

a.

b.

c.

d.

a.

b.

a.

b.

c.

d.

e.

Replace rheostat (para 3-110).

Adjust frequency adjust control (precise).

Increase speed manually (utility).

Replace meter and transducer (para 3-111).

Inspect harness and connectors and repair

(para 3-139).

Replace switch (para 3-112).

Replace Rheostat (para 3-110).

Replace meter (para 3-105).

Bleed fuel system (para 3-56).

Replace nozzle holder assembly (para 3-201).

Adjust valves (para 3-220).

Replace transducer and meter (para 3-111).

Replace meter and transducer (para 3-111).

Replace frequency meter and transducer

(para 3-111).

Replace meter (para 3-106).

Replace float switch (para 3-159).

Replace solenoid valve (para 3-158).

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

Service fuel transfer pumps (para 3-165).

Replace pumps (para 3-165).

3-25

MALFUNCTION

23.

24.

25.

26.

27.

28.

Engine generator set

shuts down, HIGH

COOLANT TEMP

indicator illuminates

but coolant tempera-

ture is normal.

Engine generator set

shuts down, low oil

pressure indicator

illuminates, but oil

pressure is normal.

Engine generator set

shuts down, over -

speed indicator il-

luminates, but engine

speed is normal.

All meters read cor-

rectly except volt -

meter reads off scale

high.

Circuit breaker

switch is closed and

indicator does not

light.

Main AC contactor

(CB2) will not close.

Table 3-3. Troubleshooting (Cont)

PROBABLE CAUSE

Defective coolant

temperature switch.

Defective oil pressure

switch.

Defective overspeed

switch.

Defective voltage adjust

rheostat.

a.

b.

Defective load circuit

breaker switch.

Lamp burned out.

Main AC contactor (CB2)

defective.

CORRECTIVE ACTION

Replace switch (para 3-209).

Replace switch (para 3-194).

Replace switch (para 3-186).

Replace rheostat (para 3-110).

a. Replace circuit breaker switch (para 3-117).

b.

Replace lamp (para 3-26).

Measure continuity of coil pins A and B. If no

continuity, replace contactor (para 3-141).

3-26 Change 8

Section VI.FIELD EXPEDIENT REPAIRS

Trouble3-66. General.

Organizational

maintenance

level

troubles

may

oc-

cur

while

the

engine

generator

set

is

operating

in

the

field

where

supplies

and

repair

parts

are

not

available

and

normal

corrective

action

cannot

be

performed.

When

this

condition

exists,

the

follow-

ing

expedient

repairs

may

be

used

in

emergencies

upon

the

decision

of

the

unit

commander. Equip-

ment

so

repaired

must

be

removed

from

operation

as

soon

as

possible

and

properly

repaired

before

being

placed

in

operation

again.

3-67. Fuel is not Strained.

Trouble

Expedient

Remedy

Fuel

tank

strainer

Run

engine

generator

set,

element

defective.

with

defective

strainer

element

installed

until

replacement

is

obtained

(para 3-34).

3-68. Housing Filled With Smoke.

Trouble

Expedient

Remedy

Defective

exhaust

pipe.

Run

engine

generator

set

with

defective

exhaust

pipe

until

replacement

is

ob-

tained

(para 3-86).

3-69. Engine Overheating.

Trouble

Shutter

control

assembly

not

operational.

3-70. Loss of Coolant.

Trouble

Leaking

coolant

hose.

Leaking

radiator.

Expedient

Remedy

If

the

engine

is

running

too

hot,

manually

open

shutter

with

the

lever

to

keep

shutters

open

until

the

engine

is

normally

shut

down

for

n>ainten-

ance

or

other

reason.

Expedient

Remedy

If

necessary

shut

down

engine,

drain

coolant,

tightly

wrap

leaky

area

of

hose

with

plastic

elec

-

tricians

tape.

Keep

moni-

toring

repaired

hose

area

while

engine

is

operating

until

replacement

hose

is

obtained.

Liberally

apply

epoxy,

tar,

putty,

or

other

nonsoluble

substance

to

leaking

area

of

radiator.

Let

dry.

Fill

radiator

and

operate

engine

until

replacement

radiator

is

obtained.

Do

Expedient Remedy

WARNING

not

add

coolant

to

radiator

until

pressure

has

been

relieved.

Water

pump

leaks. Loosen

radiator

cap

so

as

to

relieve

pressure.

Cont-

inue

engine

operation

adding

coolant

to

radiator

as

frequently

as

necessary

to

maintain

water

level

above

top

of

radiator

coil

assembly

until

engine

can

be

conveniently

shut

down

for

water

pump

re-

placement.

3-71. Engine Heat Up.

Trouble

Expedient

Remedy

Badly

worn

fan

belt.

Continue

engine

operation

with

defective

fan

belt

installed

until

replacement

belt

is

obtained,

or

until

engine

can

be

shut

down.

Frequently

observe

fan

belt

(Para 3-183. )

3-72. Engine Cranks But Will Not Start or Starts

and Runs Erratically or Misfires.

Trouble

Clogged

fuel

filter.

Clogged

fuel

transfer

pump

screen.

Defective

fuel

line.

Expedient

Remedy

Shut

down

engine

and

remove

fuel

filter

cartridge

and

strainer

element

(para

3-34b).

Use

compressed

air,

If

available,

or

shake

vigorously,

to

clear

ob

-

struction.

Reassemble

and

continue

operation

until

re-

placement

parts

are

ob

-

tained.

Shut

down

engine

and

remove

pump

screen

(para 3-165).

Use

compressed

air,

if

available,

or

shake

vigor-

OUSIY,

to

clear

obstruction.

Reassemble

and

continue

operation

until

replacement

parts

are

obtained.

Shut

down

engine

and

tightly

wrap

area

of

line

leak

with

plastic

electrician’s

tape.

Keep

monitoring

repaired

line

while

engine

is

until

a

replacement

is

obtained.

operating

fuel

line

3-27

3-72. Engine Cranks But Will Not Start or Starts

and Runs Erratically or Misfires.(Cont)

Trouble

Clogged

air

filter.

Defective

fuel

selector

valve,

3-73.

Expedient

Remedy

If

repaired

fuel

line

leaks,

shut

down

engine.

Shut

down

engine

and

re-

move

filter

element

(fig.

3-5).

Use

compressed

air,

if

available,

or

shake

vigor

ously,

to

clear

obstruction.

Reassemble

and

continue

operation

until

replacement

parts

are

obtained.

Shut

down

engine

and

dis

-

connect

fuel

selector

valve

(para 3-166).

Connect

hose

assembly

(21, fig.

3-28)

directly

to

hose

as-

sembly

(24).

Use

hose

assembly

(15)

connection

and

plastic

electrician’s

tape

as

necessary

to

comp-

lete

connection.

Keep

moni-

toring

reconnected

fuel

line

while

engine

is

operating

until

a

replacement

fuel

selector

valve

is

obtained.

If

reconnected

fuel

line

leaks,

shut

down

engine.

Engine Shuts Down

and

LOW OIL PRESSURE

Indicator Lights.

Trouble

Expedient

Remedy

Defective

oil

line. Tightly

wrap

area

of

oil

line

leak

with

plastic

electrician’s

Trouble

3-74. Battery Charging

Trouble

Battery

charging

alter-

nator

defective.

Expedient

Remedy

tape.

Keep

monitoring

re-

paired

line

while

engine

is

operating

and

a

replacement

oil

line

is

obtained.

Ammeter Shows No Charge.

Expedient

Remedy

Continue

engine

operation

with

defective

battery

charg

-

ing

alternator

installed

until

replacement

is

obtained

or

until

engine

can

be

shut

down

for

battery

charging

alter-

nator

service

or

repair.

3-75. Loss of Frequency Control (Class 1 Sets Only).

Trouble

Expedient

Remedy

Governor

system

fails

Shut

down

the

engine

genera-

to

operate

properly. tor

set

and

disconnect

plugs

J17

and

J21

on

the

electrical

governor

control

(fig. l-l).

Remove

cover

(12, fig. 3-17).

Loosen

screw

(13)

and

move

fuel

pump

lever

all

the

way

forward

and

tighten

screw,

Move

actuator

linkage

to

the

retracted

position.

Operate

set

as

class

2

unit

until

fault

in

governor

system

can

be

corrected.

NOTE

If

actuator

linkage

does

not

re-

main

in

retracted

position

dis

-

connect

actuator

linkage

and

wire

arm

(3, fig, 3-32)

in

the

down

position

(fig. 3-10).

Section VII. RADIO INTERFERENCE SUPPRESSION

3-76. General Methods Used to Attain Proper

Suppression.

Essentially,

suppression

is

attained

by

providing

a

low

resistance

path

to

ground

for

the

stray

currents.

The

methods

used

include

shielding

high

frequency

wires,

grounding

the

frame

with

bonding

straps,

and

using

capacitors, inductors

and

resistors.

3-77. Interference Suppression Components.

a.

Primary

Suppression

Components.

The

pri%ary

suppression

components

are

those

whose

function

is

to

suppress

radio

interference.

The

exciter

regulator

contains

an

Electromagnetic

Interference

(EMI)

suppression

assembly

to

suppress

EMI

from

this

assembly.

The

fuel

pumps,

main

ac

contactor,

day

tank

solenoid

valve,

battery

charg

-

ing

alternator

and

load

bank

(if

installed)

contain

primary

suppression

components.

3-28

b.

Secondary

Suppression

Components.

These

components

have

radio

interference

suppression

functions

which

are

incidental

or

secondary

to

their

primary

function.

No

secondarv

suppression

compo-

nents

are

included

on

this

generator

set,

3-78. Replacement of Suppression Components.

a.

Fuel

Pumps.

Replace

fuel

pumps

with

integral

rad<o

interference

suppression

components

as

des

-

cribed

in

paragraph 3-165.

b.

Battery

Charging

Alternator.

Replace

the

—

alternator

with

integral

RFI

suppression

diodes

as

described

in

paragraph 3-184.

c.

Load

Bank.

RFI

suppression

capacitors

C301

thr~ugh

C306

(fig. 4-14)

are

replaced

in

the

Load

Bank

as

described

in

paragraph 4-38.

TM 5-6115-545-12

TO-35C2-3-444-1

NAVFAC P-8-626-12

TM-00038G-12

3.78 Replacement of Suppression Components, (Cont)

d. Main AC Contactor Three RFI suppression

capacitors C3, C4 and C5 are connected between terminals

A2, B2, and C2 respectively, of the main ac contractor CB2

and ground. Replace suppression capacitors as shown in A

of figure 3–11.

e. Day

Tank Solenoid Valve. Diode suppressors

CR27 are provided at the connector of the day tank solenoid

valve. Replace diode suppressors as shown in B of figure

3-11.

3-79. Testing of Radio Interference Suppression

Components.

Test the capacitors for leaks and shorts using a multimeter or

other capacitor tester. Replace defective capacitors. If test

equipment is not available and interference is indicated,

isolate the cause of interference by the trial and error method

of re- placing each component in turn until the cause of

interference is located and eliminated.

Figure 3-10. Lockwire of Fuel Injector Pump

for Class 2 Operation

Section VIII. ORGANIZATIONAL MAINTENANCE

3-80. General

maintain the engine generator set at the organizational level.

Instructions are provided in sections IX through XLIV for Where essential, sections are arranged in the most logical

the information and guidance of responsible personnel to

order of disassembly of equipment.

Section IX. BATTERIES, AND RELATED PARTS

3-81. General.

This section contains information on the batteries,

battery tray and slave receptacles of the engine generator set.

Two 12-volt 100 ampere, lead acid type batteries are

mounted side by side on a battery tray. The batteries are

electrically connected in series to supply 24 Vdc for starting

the engine generator set. There is a slave receptacle

electrically connected in parallel with the batteries. The

receptacle facilitates external connection with the batteries,

in order to supply or receive an auxiliary source of electrical

power. A source of 24 Vdc electrical power is therefore

available for other development. Normally, the engine

generator set should be operating so as not to run down the

batteries when supplying this source of dc power.

3-82. Batteries.

a. Replacement. To replace one or both batteries, see

figure 3-4 and proceed as follows:

(1) Remove screw (lA), nut (lB) and clamp (lC).

Disconnect battery negative cable (1) positive cable (2) and

jumper cable (3) from storage batteries (4)

(2) Remove two nuts (5) and lockwashers (6),

which secure battery retainer (7) to studs (8), and remove

storage batteries (4).

(3) Install new storage battery in reverse order of

removal.

b.

Battery Testing.

NOTE

Failure to perform this task prior to

adding distilled water will result in an

erroneous reading.

Battery hydrometer readings should be tested on all

cells monthly. Always test a battery for a degree of charge

before adding water. The specific gravity between the cells

should be within .05. A dangerously low point of charge

indicated by a hydrometer reading of 1.150 or less will

permit the battery to freeze at a temperature of 5° F. A

specific gravity of 1.250 will permit the battery to withstand

temperatures as low as -65°F without freezing. An

acceptable hydrometer reading of 1.210-1.220 at 80°F will

be obtained from a fully charged battery (2.0-2.2 volts dc

per cell).

Battery reading of less than 1.200 or cell variance of .05

or greater will be replaced if attempts to restore the battery

fail. Compare specific gravity readings with previous

readings for cell deterioration.

NOTE

The 6TN and 6TL batteries can be mixed or matched.

However, maintenance–free batteries cannot be mixed or

matched with military batteries. The 6TN and or the 6TL

batteries will perform properly in hot weather as long as

electrolyte levels are carefully monitored. If the electrolyte

expands and causes the level to rise, some fluid must be

removed. If the level becomes too low due to evaporation,

distilled water may be used to obtain the proper level. A

good grade of drinking water (excluding mineral waters)

may be used if distilled water is not available.

Electrolyte (NSNs 6810-00-249-9354 and

6810-00-843-1640) have a specific gravity of 1.280 and

should be used in these batteries. Do NOT adjust the

electrolyte in wet batteries to a lower specific gravity.

Change 17

3-29

A. MAIN AC CONTACTOR CAPACITORS

B. DAY TANK SOLENOID VALVE DIODES

Figure 3-11. Interference Suppression Components Removal and Installation

Change 1

3-30

temperatures as low as -65°F. without freezing. An

acceptable hydrometer reading of 1.210 - 1.220 at 80°F will

be obtained from a fully charged battery (2.0-2.2 volts dc

per cell).

c. Battery Preparation

WARNING

Do not smoke or use an open flame in

the vicinity when servicing batteries.

Batteries generate hydrogen during

charging, a highly explosive gas. A

severe

bum will result when

electrolyte is spilled on the skin or

clothing.

Use extreme care in

handling while filling batteries.

(1) Remove cell caps and fill battery cells with

electrolyte to 38 inches above the plates.

(2) Make sure vent holes in cell caps are open and

install caps.

TM 5-6115-545-12

TO-35C2-3-444-l

NAVFAC P-8-626-12

TM-00038G-12

3-83. Battery Tray Replacement

To replace the battery tray, remove batteries as described in

paragraph 3-82a. Remove screws (9, fig. 3-4) and

lockwashers (10) which secures battery tray (11) in

position, and install new battery tray.

3-84. Slave Receptacle Replacement.

To replace the slave receptacle, see figure 3-4 and proceed

as follows:

a. Disconnect battery negative cable (1).

b. Remove six screws (12) which secure receptacle

box (13) to housing and tilt box forward to gain access to

wiring connections.

Disconnect

wiring connections,

clamps, harness ties and tag for ease of Installation.

c.

Remove four screws (IS) and nuts (16) which

secure slave receptacle (I”), and remove receptacle.

d. (Deleted)

e.

install receptacle in reverse order of removal.

Section X. MUFFLER AND EXHAUST PIPES AND BREATHER SYSTEM

3.85. General.

Thin section contains information on the muffler and

exhaust pipes and breather system of the engine generator

set. The muffler and exhaust pipes provide a method for

expelling exhaust gases from the engine generator set. The

exhaust pipe allows the exhaust gases from the engine to he

discharged from an opening above the grille. The discharge

opening is covered by a cap that is opened by exhaust

pressure when the engine generator set is running. The

breather system provides a method for returning oil to the

crankcase and improving the atmosphere around the engine

generator set. Accumulated oil residue and gases in the valve

cover pass through an oil separator which separates the oil

and the gases. The oil is returned to the crankcase and the

gases exhaust into the air cleaner inlet. The breather system

is removed as outlined in paragraph 3-87.

3-86. Muffler and Exhaust Pipe Replacement.

To replace the exhaust pipe, see figure 3-12 and proceed as

follows

cap (3).

WARNING

Allow exhaust pipe to cool if engine has

been running.

Loosen nut (1) from screw (2) and remove weather

b. Loosen nuts (4) which secure 0-bolt (6) and

bracket (7) to nozzle (8) and muffler (9) pipes, and slide

0-bolt (6) and bracket (7) toward muffler.

Remove screws (10) which secure nozzle (8) to

housing. Place 0-bolt (6) on muffler (9) pipe and remove

nozzle (8).

d. Loosen nuts (11) which secure 0-bolt (13) and

bracket (14) to muffler (9) and exhaust pipe (15). Place

0-bolt (13) with bracket (14) on muffler pipe and remove

muffler and both 0-bolt assemblies.

e.

Disconnect exhaust pipe (15) from engine and

remove exhaust pipe.

f. Install new exhaust pipe in reverse order of removal.

3-87. Breather System Replacement.

To replace the breather system. see figure 3-12.1 and

proceed as follows:

Loosen clamps (1) and disconnect hose (2) from oil

separator (4) and elbow (3).

b. Loosen clamps (5) and disconnect hose (6) from oil

separator (4) and valve cover crankcase breather.

c. Loosen clamps (7) and disconnect hose (8) from oil

separator (4) and air cleaner inlet (9).

d. Loosen clamp (10) and slide out oil separator (4)

Remove nuts (1 1). camp and bracket (10), nuts

(12), and screws (13).

f. Install breather system in reverse order of removal.

Change 17 3-31

TM 5-6115-545-12

TO-35C2-344-1

NAVFAC P–8-626-12

TM-00038G-12

1. Nut 5. Washer

9. Muffler 13. u–bolt

22. Document Compartment

2. Screw 6. U-bolt

10. Screw 14. Bracket

3. Weather Cap 7. Bracket

11. Nut 15. Exhaust Pipe

4. Nut 8. Nozzle

12. Washer 16.-21. Deleted

Figure 3-12. Exhaust Pipe

Section XI. CONVENIENCE RECEPTACLE

3-88. General. c. Remove grommet (12) from box (3) and feed

This section contains information on the convenience

electrical wires back through grommet hole. Tag all

receptacle and associated circuit breaker.

electrical connections for positive identification during

installation.

3-89. Convenience

Receptacle

Box

Assembly

d. Install new convenience receptacle box assembly

Replacement. in reverse order of removal.

See figure 3-13 and proceed as follows 3-90. Convenience Receptacle Replacement.

Remove six screws (1) which secure box cover (2) and box

See figure 3-13 and proceed as follows

(3) to frame (4).

a. Remove six screws (1) which secure box cover (2)

b. Tilt box cover (2) and disconnect electrical

and box (3) to frame (4).

connections from receptacle (5) and circuit breaker (9) and

b. Tilt box cover (2) and disconnect electrical

remove box cover and assembly.

connections from receptacle (5).

3-32

Change 7

Figure 3-12.1. Crankcase Breather System

Change 7 3-33

1. Screw 4. Frame 7. Cover 10. Nut

2. Box cover 5. Receptacle 8. Screw 11. Washer

3. Box 6. Screw 9. Circuit breaker 12. Grommet

Figure 3-13. Convenience Receptacle

c. Remove five screws (6) which secure re- Close circuit breaker and test for continuity. If de-

ceptacle cover (7) to box cover (2). fective see figure 3-13 and proceed as follows:

d. Remove two screws (8) which secure re- a. Repeat paragraph 3-89 a and tilt box cover (2)

to disconnect electrical connections from circuit

ceptacle (5) to rear of box cover. breaker (9).

e. Redate receptacle with new one in reverse b. Remove nut (10) and washer (11) which

sequence of removal.

3-91. Circuit Breaker

Change 7

secure circuit breaker to box cover.

c. Replace circuit breaker with new one in

Test and Replacement. reverse sequence of removal.

3-34

1. Screw

2. Cover

3. Screw

4. Plate7. Screw 10. Cloth sleeve

5. Plate and sleeve assy 8. Nut

6. Bushing 9. Retaining plate

Figure 3-15. Plate and Sleeve Assembly.

Section XIII. PLATE AND SLEEVE ASSEMBLY

3-95. General. a. Remove screws (1) which secure cover (2) to

housing. Remove screws (3) which secure plate (4)

This section contains information on the plate and of plate and sleeve assembly (5) to housing.

sleeve assembly. The plate and sleeve assembly

provides an opening for kit installation. and load b. Remove screws (7) and nuts (8) which secure

cable, with a cover to secure the opening.

retaining plate (9) and cloth sleeve (10) to plate.

Remove bushing (6), cloth sleeve (10) and retain-

3-96. Replacement. ing plate (9).

To replace the cover plate and sleeve assembly see c. Install a new plate and sleeve assembly, or

figure 3-15, and proceed as follows: parts thereof, in the reverse order of removal.

Change 9 3-35

Section XIV.PARALLELING RECEPTACLES

3-97. General.

This

section

contains

information

on

the

paral-

leling

receptacles

of

the

engine

generator

set.

The

paralleling

receptacles

provide

a

means

of

inter-

connecting

three

generator

sets

of

the

same

class,

mode

and

size

by

the

use

of

25

foot,

four

conduc-

tor

cables.

The

paralleling

receptacles

include

the

wiring

harness

with

connectors,

protector

caps

for

the

connectors,

and

the

shorting

plug

dummy

connector.

3-98. Replacement.

To

replace

the

paralleling

receptacles,

see

figure

3-16

and

proceed

as

follows:

a.

Disconnect

battery

power

cable

from

battery

neg;tive

terminal.

~.

Remove

plate

and

sleeve

assembly

(para 3-96)

to

gain

access

to

convenience

and

paralleling

wiring

harness.

c.

Remove

cap

and

chain

(4)

and

shorting

plug

(5)

%y

removing

screws

(l),

washers

(2),

and

nuts

(3).

Q.

Remove

screws

(8)

and

nuts

(9)

which

secure

receptacle

in

place.

e.

Using

full

wiring

harness

(10)

slack

avail-

abl~,

discomect

wiring

connections

at

rear

of

recep-

tacles

and

tag

wiring

to

ease

installation.

Each

paralleling

receptacle

may

be

replaced

in

the

reverse

order

of

removal.

&

Disconnect

convenience

receptacle

wiring

harness

by

performing

procedure

of

paragraph 3-89a

through c.

—

—

g.

Unscrew

wiring

harness

connector

from

receptacle

on

special

relay

box.

~.

Remove

two

clamps

(13)

which

secure

wiring

harness

along

relay

table

by

removing

nuts

(12)

and

screws

(11).

i.

Reinstall

new

or

repaired

wiring

harness

in

rev%rse

order

of

removal.

&

Replace

any

damaged

cap

and

chain

(4)

with

new

ones

and

secure

in

place

with

screws

(l),

washers

(2)

and

nuts(3).

k.

Replace

and

plate

and

sleeve

assembly

re

-

moved

in

step

b.

—

1.

Reconnect

battery

power

cable.

—

1.

Screw

7.

Connector

2.

Washer

8.

Screw

3.

Nut

9.

Nut

4.

Cap

and

chain

10.

Wiring

harness

5.

Dummy

connector

11.

Screw

(shorting

plug)

~~.

Nut

~

;A.

Screw

.

Clamp

.

Chain

Figure 3-16.Paralleling Receptacles

Change 1

3-36

SECTION XV. GENERATOR SET CONTROLS

3-99. General.

The

engine

generator set control assembly consists

of

a

wiring harness,

and

an

engine

generator control

panel assembly. The generator control panel

assem-

bly provides

a

means

of controlling

engine

generator

operation.

3-100. DC Control Circuit Breaker.

a. Test.

—

(1)

Depress

circuit

breaker (27, fig. 3-17)

to insure

that

it

is

in

the

reset

position (flush to

panel).

(2)

Remove

screw

and

lockwasher

which

se-

cure leads to

one

terminal of

circuit

breaker.

(3)

With

an

ohmmeter test

circuit

breaker

for

closed

contacts. If meter shows

an

open

circuit,

re-

place

circuit

breaker.

b.

Replacement. Replace defective

DC

CONTROL

CI~CUfT BREAKER

(27)

as

follows:

(1)

Removal.

(a)

Tag leads

and

remove

screws

and

lock-

washers

wlich

secure

leads to

DC

CONTROL

CIRCUIT

BREAKER.

(b)

Remove

DC

CONTROL

CIRCUIT

BREAK-

ER

mount~~ hardware

and

remove

circuit

breaker.

(2)

Installation. Install

DC

CONTROL

CIRCUIT

BREAKER using removal steps

in

reverse

order.

Remove tags.

3-101. Wiring Harness Replacement.

See

figure 3-17

and

remove wiring harnesses

(1

and

2)

as

follows:

a.

Unplug

and

disconnect wiring harnesses

at

terfiinations.

Tag all connectors

and

electrical

leads to assure position identification during

replace-

ment.

b.

See

detail

A

of figure 3-17,

and

remove all

scr;ws

(3),

nuts

(4)

and

clamps

(5)

securing wiring

harnesses

in

position.

c.

Install

new

or repaired wiring harnesses

in

rev<rse

sequence of removal.

3-102. Manual Speed Control.

a. Inspection. Inspect throttle

and

governor

liti-~es

for

loose

mounting,

loose connections,

and

loose linkage.

b. Test. Check

that

the

throttle

and

governor

li&~es

motion is smooth

and

unrestricted.

A

90-degree rotation of

the

manual

speed control

knob

shall provide

a

linear cable movement of

0.036

+

0.005 inch.

—

c. Replacement.

—

(1)

Disconnect negative lead

from

the

battery.

On

Class

1

sets,

remove

screws

(11, fig. 3-17) which

secures

cover

(12)

and

remove

cover.

(2)

See

detail

B

and

remove

manual

control

assembly

(21

)

by loosening screw

(13)

and

removing

nut

(16), washer

(1

7),

nut

(18),

nut

(19)

and

washer

(20).

3-103.

Fault

Indicator.

See

figure 3-17

and

proceed

as

follows

a. Inspection. Inspect FAULT INDICATOR panel

(10~

for

cracks,

Ii

reaks,

and

other damage.

b. Testing. Test

the

fuse as

described

below:

—

(1)

Open

DC

CONTROL

CIRCUIT BREAKER

(27, fig. 3-17).

(2)

Unscrew fuseholder cap (24),

and

remove

fuse (25).

(3)

Using

ohmmeter, check

that

continuity exists

through fuse

and

open

circuit

is

not

in

effect.

(4)

Install existing fuse, or replacement fuse

as

necessary,

and

replace fuse holder cap (24).

(5)

Remove

the

harness plug

from

the

back of

the

fault indicator control box. Apply

24

Vdc to pins

12-A (positive)

and

12-B of

the

fault

indicator

recep-

tacle.

(6)

Sequentially jump pin

C

of

the

fault indicator

receptacle

to

the

pins listed

in

table 3-2 of

the

fault

indicator

receptacle.

The

light

that

corresponds

to

the

particular fault opposite

the

pin numbers should

light

and

stay lit. Reset the lights

with

the

TEST

OR

RESET switch

before

proceeding to

the

next

set of

pins. If

the

correct

light does

not

light

up

or if

an

in-

correct

light lights,

the

fault indicator control box

must be replaced.

Replacement.

See

figure 3-17 to remove

and

ins&H FAULT

INDICATOR

panel (10).

d.

Lamp

and

Fuse. To replace indicator

lamp

and

fus~, see detail C of figure 3-17

and

proceed

as

follows

(1)

Unscrew lens

(22)

and

remove lamp

(23).

Change 1

3-37

1. Wiring harness 8.

2. Wiring harness 9.

3. Screw

10.

4. Nut 11.

5. Clamp 12.

6. Wiring harness 13.

7. Control cubicle

13A.

assembly

14.

Blank panel

Blank panel

Fault indicator panel

Screw

Cover(Class 1 sets)

Screw, stop lever

Throttle lever

assembly

(Deleted)

15. (Deleted)

16. Nut

17. Washer

18. Nut

19. Nut

20. Washer

21. Manual control

assembly

Figure 3-17. Generator Set Controls

(2) Unscrew fuse holder cap (24) and remove

fuse (25). Install new fuse and replace fuse holder

cap (24).

3-104. Control Cubicle Assembly.

See figures 3-18, 19 and 20, and proceed as follows:

a. Inspection. Inspect the generator control

cubicle for defective, broken, cracked, or otherwise

defective components.

b. Testing. Testing of components of the control

cubicle is described under the appropriate heading

in paragraphs 3-105 through 3-130.

c. Repair. Repair by replacement of components

which do not function properly during testing.

Change 1

22. Lens

23. Lamp

24. Fuse holder cap

25. Fuse

26. Test or reset

switch

27. Dc control

circuit breaker

CAUTION

Turn engine off and remove the

battery negative connection be-

fore removing any electrical

leads to avoid possible short

circuit and resulting damage.

d. Replacement. If a component needs replace-

ment, gain access to the rear of the control cubicle

panel (96, fig. 3-18) by loosening the three quarter-

turn fastener and permitting the control cubicle panel

to pivot about its hinges in a forward direction. Re-

place control cubicle panel components which do not

function properly in step b (testing) as indicated in

following paragraphs. Replace control box (123, fig.

3-18) as described in paragraph 3-135 b.

3-38

3-105. AC Voltmeter Replacement.

See (42, fig. 3-18) and replace the ac voltmeter as

follows:

CAUTION

Open DC CONTROL CIRCUIT

BREAKER before testing or

replacing the ac voltmeter.

a. Testing.

(1) Gain access to rear of control cubicle

panel (96).

(2) Connect multimeter with appropriate ac

voltmeter connections across ac voltmeter terminals.

(3) Perform preparation for starting proced-

ure (fig. 2-6) and zero ac voltmeter with front panel

VOLTAGE ADJUST control.

(4) Perform starting procedure (fig. 2-7) steps

1 through 4.

(5) Check that readings on multimeter and ac

voltmeter do not differ by a voltage greater than that

listed below for each setting of the AMPS-VOLTS

selector switch.

(a) 240/416 V operation.

AMPS -VOLTS setting Voltage Difference

L1-L2 . . . . . . . . . . . . . . . ...34 V

L1-L0 . . . . . . . . . . . . . . . ...22 V

(b) 120/208 V operation.

AMPS -VOLTS setting Voltage Difference

L1-L2 . . . . . . . . . . . . . . . ...21 V

L1-L0 . . . . . . . . . . . . . . . ...11 V

(6) If voltage differences, greater than those

specified above are obtained, the ac voltmeter is

faulty and must be replaced. Faulty ac voltmeter

must be forwarded to higher maintenance level for

repair.

(7) Stop engine generator (fig. 2-8).

(8) Disconnect multimeter and secure control

cubicle panel.

b. Removal.

(1) Gain access to rear of control cubicle

panel (96).

(2) Tag and remove ac voltmeter (42) leads.

(3) Remove screws (40) and nuts (41) which

secure ac voltmeter and remove ac voltmeter.

c. Installation. Install replacement ac voltmeter

using removal steps in reverse order. Remove tags.

3-106. Kilowatt Met er Replacement.

See (39, fig. 3-18) and replace the kilowatt meter as

follows:

a. Removal.

—

(1) Gain access to rear of control cubicle

panel (96).

(2) Tag and remove kilowatt meter (39) leads.

(3) Remove three screws and nuts which secure

kilowatt meter and remove kilowatt meter.

b. Installation. Install replacement kilowatt

meter using removal steps in reverse order. Remove

tags.

3-107. Watt meter Converter Inspection and Replace -

ment.

See (102, fig. 3-18) and proceed as follows:

a. Inspection. Gain access to interior of control

cubicle and inspect wattmeter converter for signs of

corrosion, loose mounting, loose electrical connec-

t ions, or evidence of damage.

b. Removal.

—

(1) Gain access to rear of control cubicle

panel (96).

(2) Tag and remove electrical leads.

(3) Remove screws (100) and nuts (101) which

secure wattmeter converter (102) and remove watt-

meter converter.

c. Installation. Install replacement wattmeter

converter (102) using removal steps in reverse

order. Remove tags.

3-108. AC Ammeter Replacement,

See (8, fig. 3-18) and replace the ac ammeter (8) as

follows:

a. Removal.

—

(1) Gain access to rear of control cubicle

panel (96).

(2) Tag and remove ac ammeter leads.

(3) Remove three screws and nuts which secure

ac ammeter (8) and remove ac ammeter.

b. Installation. Install replacement ac am-

meter (8) removal steps in reverse order.

Remove tags.

3-39

3-109. Frequency Adjust Rheostat.

See (57, fig. 3-18) and proceed as follows:

a. Inspection.

(1) Gain access to rear of control

panel (96).

(2) Inspect FREQUENCY ADJUST

for breaks, loose mounting, evidence of

or other damage.

b. Testing.

cubicle

rheostat (57)

corrosion,

(1) Tag leads and remove screws which secure

leads to the FREQUENCY ADJUST rheostat (57).

(2) Connect an ohmmeter probe to each of the

outer terminals on the FREQUENCY ADJUST rheo-

stat (57), The ohmmeter should read 500 ohms ±3%.

(3) To check wiper arm of the FREQUENCY

ADJUST rheostat (57), connect one ohmmeter probe

to either outer terminal and the other probe to the

center terminal (wiper arm). Turn the FREQUENCY

ADJUST rheostat slowly throughout its range, which

should be 0 to 500 ohms. As the shaft is rotated, the

ohmmeter indicator should move at the same rate as

the rotating shaft. If the pointer does not move, or

moves unevenly, the FREQUENCY ADJUST rheostat

is defective and should be replaced.

(4) Reconnect leads as tagged using screws and

washers. Remove tags.

c. Replacement. Replace defective FREQUENCY

ADJUST rheostat (57) as follows:

(1) Removal.

(a) Tag leads and remove three nuts and

lockwashers which secure the three leads to FRE-

QUENCY ADJUST rheostat (57).

(b) Remove knob and hardware which se-

cure rheostat to panel and remove rheostat,

(2) Installation. Install FREQUENCY ADJUST

rheostat (57) using removal steps in reverse order.

Remove tags.

3-110. Voltage Adjust Rheostat.

See (54, fig. 3-18) and proceed as follows:

a. Inspection.

—

(1) Gain access to rear of control cubicle

panel (96).

(2) Inspect VOLTAGE ADJUST rheostat (54)

for breaks, loose mounting, cracks, evidence of

corrosion, and other damage.

b. Testing.

—

(1) Tag and unsolder leads from VOLTAGE

ADJUST rheostat (54) and test rheostat as described

for FREQUENCY ADJUST rheostat (para 3 -109),

3-40

except that the resistance value is 250 ohms ±3%

and the range is 0 - 250 ohms.

(2) Resolder leads to terminals as tagged.

Remove tags.

c. Replacement.

—

(1) Removal.

(a) Tag leads and unsolder leads from

VOLTAGE ADJUST rheostat (54).

(b) Remove knob and hardware which secure

VOLTAGE ADJUST rheostat (54) to panel (96) and

remove rheostat.

(2) Installation. Install VOLT AGE ADJUST

rheostat (54) using removal steps in reverse order.

Solder leads to rheostat. Remove tags.

3-111. Frequency Transducer and Meter. (See

fig. 3-18. )

a. Inspection. Inspect transducer (6) and frequency

meter (7) for loose mounting, loose leads and other

damage.

b. Replacement. The transducer (6) and frequency

meter (7) are a matched set (5) and must be replaced

by another matched set. Replace frequency meter and

transducer as follows:

(1) Removal.

(a) Gain access to rear of control cubicle

panel (96).

(b) Tag and remove frequency meter (7) leads.

(c) Remove screws (3) and nuts (4) which

secure the frequency meter to the panel (96) and re-

move frequency meter (7).

(d) Tag and remove transducer (6) leads.

(e) Remove screws (1) and nuts (2) which

secure transducer (6) to the rear panel and remove

the transducer.

(2) Installation. Install frequency meter (7) and

transducer (6) using removal steps in reverse order.

Remove tags.

3-112. AMPS-VOLTS Selector Switch.

See (48, fig. 3-18) and proceed as follows:

a. Testing.

—

(1) Gain access to rear of control cubicle

panel (96).

(2) Tag AMPS-VOLTS selector switch (48) leads

and removes crews and lockwashers which secure leads

to AMPS-VOLTS selector switch (48) and test AMPS-

VOLTS selector switch for continuity using ohmmeter

and schematic, figure 3-21. Sequentially select each

position,

starting

with

L1

-L2

(volts),

and

rotate

AMPS-VOLTS

selector

switch

clockwise

a

step

at

a

time.

The

circuit

for

the

L1

-L2

position

is

illus

-

trated

in

figure 3-21.

As

the

selector

switch

is

rotated

clockwise

(CW),

the

contacts

rotate

CW

as

shown.

(3)

Install

leads

as

kwged

and

remove

tags.

b.

Replacement.

Replace

defective

AMPS-VOLTS

sel;ctor

switch

(48)

as

follows:

(1)

Removal.

(a)

Tag

AMPS-VOLTS

selector

switch

(48)

leads

and~emove

screws

and

lockwashers

which

secure

the

leads

to

the

AMPS-VOLTS

switch.

(b)

Remove

knob

(43)

and

hardware

which

secure

AMPS-VOLTS

selector

switch

(48)

to

panel

(96)

and

remove

switch.

(2)

Installation.

Install

AMPS-VOLTS

selector

switch

(48)

using

removal

steps

in

reverse

order

and

remove

3-113.

See

(66,

tags.

Panel Light Switch.

fig. 3-18)

and

proceed

as

follows:

CAUTION

a.

—

panel

Open

DC

CONTROL

CIRCUIT

BREAKER

(27, fig. 3-17)

be-

fore

testing

or

replacing

PANEL

LIGHT

switch.

i

esting.

(1)

Gain

access

to

rear

of

control

cubicle

(96, fig. 3-18).

(2)

Remove

screw

that

secures

one

of

the

leads

to

PANE!.

LIGHT

switch

(66).

(3)

With

an

ohmmeter

test

PANEL

LIGHT

switch

for

continuity

in

ON

position.

(4)

Test

PANEL

LIGHT

switch

for

open

con-

tacts

no

continuity

in

OFF

position.

(5)

Reconnect

lead

to

PANEL

LIGHT

switch.

~.

Replacement. Replace

defective

PANEL

LIGHT

switch

(66)

as

follows:

(1)

Removal.

(~)

Tag

PANEL

LIGHT

switch

leads

and

re-

move

screws

and

lockwashers

which

secure

leads

to

switch.

(Q)

Remove

mounting

hardware

which

sec-

ures

PANEL

LIGHT

switch

to

panel

and

remove

switch.

(2)

Installation. Install

PANEL

LIGHT

switch

(66)

usin~

removal

steps

in

reverse

order

and

remove

tags.

3-114. Voltage Sensing Switch, Local-Remote.

See

(67, fig. 3-18)

and

proceed

as

follows:

CAUTION

Open

DC

CONTROL

CIRCUIT

BREAKER

(27, figure 3-17)

before

testing

or

replaciqq

VOLTAGE

SENSING

switch.

a.

Testing.

.

(1)

Gain

access

to

rear

of

control

cubicle

panel

(96, fig. 3-18).

(2)

Tag

all

VOLTAGE

SENSING

switch

(67)

leads.

(3)

Remove

screws

and

lockwashers

which

secure

tagged

leads

to

VOLTAGE

SENSING

switch.

(4)

Place

VOLTAGE

SENSING

switch

to

RE-

MOTE

position.

With

an

ohmmeter,

test

for

contin-

uity,

(closed

contacts)

from

center

contacts

to

upPer

COIltaC&.

NOT

E

Upper

contacts

are

those

closest

to

panel

hinge.

(5)

Place

VOLTAGE

SENSING

switch

in

LOCAL

position,

Test

for

continuity

(closed

contacts)

from

center

contacts

to

lower

contacts.

(6)

If

the

VOLTAGE

SENSING

switch

does

not

operate

correctly

replace

it.

(7)

Reconnect

leads,

as

tag~ecf,

and

remove

tags.

b.

Replacement. Replace

VOLTAGE

SENSING

swi~ch

(67)

as

follows:

(1]

Removal.

(a)

Tag

VOLTAGE

SENSING

switch

leads

and

remove

screws

and

lockwashers

which

secure

leads

to

the

VOLTAGE

SENSING

switch.

(~)

Remove

mounting

hardware

which

secures

VOLTAGE

SENSING

switch

to

panel

(96)

and

remove

switch.

(2)

Installation. Install

VOLTAGE

SENSING

switch

(67)

using

removal

steps

in

reverse

order.

Remove

tags.

3-41

3-115. Single/Parallel Operation Switch.

See

(68, fig. 3-18)

and

proceed

as

follows:

CAUTION

Open

DC

CONTROL

CIRCUIT

BREAKER

(27, fig. 3-17)

before

testing

or

replacing

OPERATION

switch

(68).

a.

Testing.

(1)

Gain

access

to

rear

of

control

cubicle

panel

(96, fig. 3-18).

(2)

Tag

the

center

leads

of

BATTLE

SHORT

switch

(62).

(3)

Remove

screws

and

lockwashers

which

sec-

ure

tagged

leads

to

BATTLE

SHORT

switch.

g.

Testing.

(4)

Place

BATTLE

SHORT

switch

in

ON

posi-

tion.

With

an

ohmmeter

test

for

continuity

(closed

(1)

Gain

access

to

rear

of

control

cubicle contacts)

from

center

contacts

to

upper

contacts.

panel

(96, fig. 3-18).

NOT

E

(2)

Tag

all

OPERATION

switch

(68)

leads.

(3)

Remove

screws

and

lockwashers

which

secure

tagged

leads

to

the

OPERATION

switch.

(4),

Place

OPERATION

switch

in

PARALLEL

OPERATION

position.

With

an

ohmmeter,

test

for

continuity

(closed

contacts)

from

center

contacts

to

upper

contacts.

NOTE

Upper

contacts

are

those

closest

to

the

panel

hinge,

(5)

Place

OPERATION

switch

in

SINGLE

UNIT

OPERATION

position.

Test

for

continuity

(closed

contacts)

from

center

contacts

to

lower

contacts.

(6)

If

the

OPERATION

switch

does

not

operate

correctly,

replace

it.

(7)

Reconnect

leads,

as

tagged,

and

remove

tags.

Upper

contacts

are

those

closest

to

the

panel

hinge.

(5)

Place

BATTLE

SHORT

switch

in

OFF

posi-

tion.

Test

for

continuity

(closed

contacts)

from

cent

er

contacts

to

lower

contacts.

(6)

If

the

BATTLE

SHORT

switch

does

not

operate

correctly,

replace

it.

b.

Replacement.

Replace

defective

BATTLE

SH~RT

switch

(62)

as

follows

(1)

Removal.

(a)

Tag

BATTLE

SHORT

switch

(62)

leads

and

remov–e

screws

and

lockwashers

which

secure

leads

to

BATTLE

SHORT

switch.

(~)

Remove

BATTLE

SHORT

switch

mount

-

ing

hardware

and

remove

switch.

(g)

Remove

BATTLE

SHORT

switch

cover.

b.

Replacement. Replace

defective

OPERATION

(2)

Installation. Install

BATTLE

SHORT

switch

SWitC

h

138~s-=w

S:

(62)

using

removal

steps

in

reverse

order.

Remove

tags

.

(1)

Removal.

3-117. Circuit Breaker Switch.

(~)

Tag

OPERATION

switch

leads

and

re-

move

screws

and

lockwashers

which

secure

leads

to See

(65, fig. 3-18)

and

proceed

as

follows:

OPERATION

switch.

CAUTION

(~)

Remove

mounting

hardware

which

secures

OPERATION

switch

(68)

to

panel

(96)

and

remove

Open

DC

CONTROL

CIRCUIT

OPERATION

switch.

BREAKER

(27, fig. 3-17)

before

testing

or

replacing

(2)

Installation. Install

OPERATION

switch

CKT

BRK

switch.

(68)

using

removal

steps

in

reverse

order.

Remove

tags.

3-116. Battle Short Switch.

See

(62, fig. 3-18)

and

proceed

as

follows

CAUTION

Open

DC

CONTROL

CIRCUIT

BREAKER

(27, fig. 3-17)

be-

fore

testing

or

replacing

BATTLE

SHORT

switch.

3-42

a,

Testing.

—

(1)

Gain

access

to

rear

of

control

cubicle

panel

(96, fig. 3-18).

(2)

Check

that

spring

return

is

in

its

center

position.

(3)

Tag

and

remove

all

leads

from

CKT

BRK

switch

(65, fig. 3-18).

(4)

With

an

ohmmeter,

test

for

continuity

be-

tween

contact

5

and

contact

6

with

CKT

BRK

switch

(65)

in

the

CLOSE

and

center

position

and

no

contin-

uity

with

the

CKT

BRK

switch

in

the

OPEN

position.

(5)

With

an

ohmmeter,

test

for

no

continuity

between

contact

2

and

contact

3

with

CKT

BRK

switch

(65)

in

CENTER

and

OPEN

position,

and

continuity

with

CKT

BRK

switch

in

CLOSE

position.

(6)

If

the

CKT

BRK

switch

does

not

operate

correctly,

replace

it.

(7)

Reconnect

leads.

b.

Replacement.

Replace

CKT

BRK

switch

(65)

as

rollows:

(1)

Removal.

(~)

Tag

leads

and

remove

screws

and

lock-

washers

which

secure

leads

to

CKT

BRK

switch.

~)

Remove

CKT

BRK

switch

mounting

hardware

and

remove

CKT

BRK

switch.

(2)

Installation.

Install

CKT

BRK

switch

(65)

using

removal

steps

in

reverse

order.

Remove

tags.

3-118. Engine Primer Switch.

See

(63, fig. 3-18)

and

proced

as

follows:

CAUTION

Open

DC

CONTROL

CIRCUIT

BREAKER

(27, fig. 3-17)

before

testing

or

replacing

ENGINE

PRIMER

switch.

a.

Testi

Test

ENGINE

PRIMER

switch

(63,

fig. 3-18

as

follows:

(1)

Gain

access

to

the

rear

of

the

control

cubicle

panel

(96).

(2)

Remove

screw

and

lockwa.sher

which

secure

a

lead

to

the

ENGINE

PRIMER

switch.

(3)

Check

that

ENGINE

PRIMER

switch

is

spring

loaded

to

“OFF”

position.

With

an

ohmmeter,

test

ENGINE

PRIMER

switch

for

open

circuit

with

ENGINE

PRIMER

switch

in

“OFF”

position.

(4)

Test

ENGINE

PRIMER

switch

for

a

closed

circpit

with

ENGINE

PRIMER

switch

held

in

“ON’

posit

ion.

(5)

Reconnect

lead

using

screw

and

lockwasher.

b.

Replacement. Replace

ENGINE

PRIMER

swi~ch

(63)

as

follows:

(1)

Removal.

(~)

Tag

both

leads

and

remove

two

screws

and

lockwashers

which

secure

leads

to

the

ENGINE

PRIMER

switch.

(Q)

Remove

mounting

hardware

which

sec

-

ures

ENGINE

PRIMER

switch

(63)

to

panel

(96)

and

remove

ENGINE

PRIMER

switch.

(2)

Installation. Install

ENGINE

PRIMER

switch

(63)

using

removal

steps

in

reverse

order.

Remove

tags.

3-119. Engine Start-Run-Stop Switch.

See

(64, fig. 3-18)

and

proceed

as

follows:

CAUTION

Open

DC

CONTROL

CIRCUIT

BREAKER

(27, fig. 3-17)

before

testing

or

replacing

START-RUN-STOP switch.

a.

Testing.

Test

the

engine

START-

RUN-STOP

swi~ch

(64, fig. 3-18)

as

follows:

(1)

Gain

access

to

the

rear

of

the

control

cubicle

panel

(96).

(2)

Check

spring

return

from

START

to

RUN

position.

(3)

Tag

and

remove

leads

from

the

engine

START

-RUN-STOP

switch

and

test

the

switch

for

continuity

as

follows:

(~

Place

engine

START

-RUN-STOP

switch

to

START

position

and

with

an

ohmmeter

test

for

con-

tinuity

(closed

contacts)

between

contacts

2

to

3;

contacts

5

to

6;

coutacts

8

to

9:

and

contacts

11

to

12.

(b)

Place

engine

START

-RUN-STOP

switch

to

RUN

position,

test

for

continuity

between

contacts

2

to

3

and

contacts

8

to

9.

(c)

Check

for

open

circuit

between

contacts

5

to

6.

an~between

contacts

11

to

12.

(~)

Place

engine

START

-RUN-STOP

switch

to

STOP

position

and

test

for

open

circuit

between

all

contacts.

(~)

If

engine

START-RUN-STOP

switch

does

not

operate

correctly,

replace

it.

@

Reconnect

leads

as

tagged

and

remove

tags

.

~.

Replacement.

Replace

defective

engine

START-

RUN-STOP

switch

as

follows:

(1)

Removal.

(q)

Tag

and

remove

leads

from

the

engine

START

-RUN-STOP

switch.

(b)

Remove

mounting

hardware

which

se-

cures

eng~ne

START-RUN-STOP

switch

(64)

to

panel

(96)

and

remove

switch.

3-43

(2) Installation. Install engine START-RUN-

STOP (64) switch using removal steps in reverse

order. Remove tags.

3-120. Coolant Temperature Gage.

See (80, fig. 3-18) and proceed as follows:

a. Testing.

—

(1) Gain access to the rear of the control

cubicle panel (96).

CAUTION

Disconnect negative battery terminal prior

to making circuit changes. Reconnect this

terminal prior to checking meters, gages

and indicating lights.

(2) Tag and remove the lead from the SEND

contact of the COOLANT TEMPERATURE gage (80).

(3) The O to 500 ohm FREQUENCY ADJUST

rheostat on the control cubicle panel (96) can be used

to check the COOLANT TEMPERATURE gage. Dis-

connect and tag all leads from the FREQUENCY AD-

JUST rheostat.

(4) Connect a multimeter between the wiper

arm terminal and either other terminal of the FRE-

QUENCY ADJUST rheostat and adjust the rheostat

until the multimeter reads precisely 460 ohms. Dis-

connect the multimeter but do not disturb the rheostat

setting.

(5) Check that START-RUN-STOP switch (fig.

2-5) is set to RUN, BATTLE SHORT switch (fig. 2-5)

to ON, and the DC CONTROL CIRCUIT BREAKER

(27, fig. 3-17) is in closed ON position. Connect the

460 ohm resistance of the FREQUENCY ADJUST

rheostat in series with ground and the SEND terminal

of the coolant temperature gage. Gage should read

approximately 240°F.

(6) Disconnect rheostat from circuit and re-

connect leads removed in paragraph (3) above/

(7) If the COOLANT TEMPERATURE gage

does not operate correctly, replace it.

b. Replacement. Replace the COOLANT TEM-

PERATURE gage as follows:

(1) Removal.

(a) Gain access to the rear of the control

cubicle panel (96).

(b) Tag and remove the leads from

COOLANT-TEMPERATURE gage (80).

(c) Remove the two nuts (81), two washers

(82), and clamp (83) which secure the COOLANT

TEMPERATURE gage (80) and remove gage.

(2) Installation.Install COOLANT TEMPERA-

TURE gage (80) using removal steps in reverse

order, Remove tags.

3-121. Oil Pressure Gage.

See (78, fig. 3-18) and proceed as follows:

a. Testing

(1) Gain access to the rear of the control

cubicle panel (96).

CAUTION

Connect battery negative terminal prior

to checking the OIL PRESSURE gage (78)

readings.Remove this terminal prior

to making circuit changes.

(2) Tag and remove the lead from the SEND

terminal of the OIL PRESSURE gage.

(3) The 0-500 ohm FREQUENCY ADJUST

rheostat can be used to check the OIL PRESSURE

gage. Disconnect and tag all leads from the

FREQUENCY ADJUST rheostat.

(4) Connect a multimeter between the wiper

arm terminal and either terminal of the FREQUENCY

ADJUST rheostaL and adjust FREQUENCY ADJUST-

MENT rheostat until the multimeter reads precisely

30 ohms. Disconnect the multimeter but do not

disturb rheostat setting.

(5) Set START-RUN-STOP switch to RUN,

BATTLE SHORT switch to ON, and DC CONTROL

CIRCUIT BREAKER to the closed ON position.

Connect the 30 ohm resistance of the FREQUENCY

ADJUST rheostat in series with ground to the SEND

terminal of the OIL PRESSURE gage. Gage should

read approximately 120 psi.

(6) Disconnect FREQUENCY ADJUST rheostat

from circuit and reconnect leads removed in

paragraph (3) above.

(7) If the OIL PRESSURE gage does not operate

correctly, replace it.

b. Replacement. Replace the OIL PRESSURE

gage (78) as follows

(1) Removal.

(a) Gain access to the rear of the control

cubicle panel (96).

(b) Tag and remove the leads from the OIL

PRESSURE gage/

(c) Remove the two nuts, two washers, and

clamp which secure the OIL PRESSURE gage and

remove gage.

3-44

(2) Installation. Install OIL PRESSURE gage

(78) using removal steps in reverse order.

3-122. Fuel Level Gage.

See (79, fig. 3-18) and proceed as follows:

a. Testing.

—

(1) Gain access to the rear of the cubicle

control panel (96).

CAUTION

Connect battery negative terminal

prior to checking the gage read-

ings. Remove this terminal prior

to making circuit changes.

(2) Tag and remove the lead from FUEL

LEVEL gage (79). Check that START-RUN-STOP

switch is set to RUN. BATTLE SHORT switch to

ON, and that DC CONTROL CIRCUIT BREAKER

is in closed (on) position. Apply ground (0 ohms)

to SEND terminal of the gage. Gage should read

EMPTY.

(3) The 0-500 ohm FREQUENCY ADJUST

rheostat can be used to check the FUEL LEVEL

gage. Discomect and tag all leads from the

FREQUENCY ADJUST rheostat.

(4) Connect a multimeter between the wiper

arm terminal and either other terminal of the

rheostat and adjust the FREQUENCY ADJUST-

MENT rheostat until the multimeter reads 30

ohms. Disconnect the multimeter but do not

disturb rheostat setting.

(5) Check that START-RUN-STOP switch is

set to RUN, BATTLE SHORT switch to ON, and

that DC CONTROL CIRCUIT BREAKER is in closed

(on) position. Connect the 30 ohm resistance of the

FREQUENCY ADJUST rheostat in series with

ground to the SEND terminal of the FUEL LEVEL

gage. FUEL LEVEL gage should read FULL.

(6) Disconnect FREQUENCY ADJUST

rheostat from circuit and reconnect leads

removed in paragraph (3) above.

(7) If the FUEL LEVEL gage does not operate

correctly, replace it.

b. Replacement. Replace the FUEL LEVEL

gage (79) as follows:

(1) Removal.

(a) Gain access to the rear of the control

cubicle panel (96).

(b) Tag and remove the leads from FUEL

LEVEL gage.

(c) Remove the two nuts, two washers, and

clamp which secure the FUEL LEVEL gage and re-

move gage.

(2) Installation. Install FUEL LEVEL gage

(79) using removal steps in reverse order. Remove

tags.

3-123. Running Time Meter.

See (74, fig. 3-18) and proceed as follows:

a. Testing. Check that START-RUN-STOP switch

is set to RUN, BATTLE SHORT switch to ON, and

that DC CONTROL CIRCUfT BREAKER is in closed

(on) position. RUNNING TIME meter should operate

and change by one-tenth of an hour. Check for 24

Vdc input to meter. If voltage is present and the

meter does not operate, replace it.

b. Replacement. Replace RUNNING TIME

meter

(74)

as follows:

(1) Removal.

(a) Gain access to the rear of the control

cubicle panel (96).

(b) Tag and remove the leads from tne

RUNNING TIME meter.

(c) Remove the three screws (72) and nuts

(73) which secure the RUNNING TIME meter (74)

and remove meter.

(2) Installation. Install RUNNING TIME

meter (74) using removal steps in reverse order.

Remove tags.

3-124. Battery Charging Ammeter.

See (77, fig. 3-18) and proceed as follows:

a. Testing.

—

(1) Gain access to the rear of the control

cubicle panel (96).

CAUTION

Disconnect battery negative terminal prior

to checking the indicator readings or

making circuit changes.

(2) Set VOLTMETER to R Xl scale and connect

across terminals of BATTERY CHG AMMEtER (77).

Reading on voltmeter should be zero and BATTERY

CHG AMMETER should indicate a charge or discharge

reading. If voltmeter does not read zero, replace

BATTERY CHG AMMETER.

b. Replacement. Replace

AMMETER (77) as follows

(1) Removal.

the BATTERY CHG

(a) Gain access to the rear of the control

cubicle panel (96). 3-45

(b) Tag and remove the leads from the

BATTERY CHG AMMETER.

3-128. Panel Light Assembly.

See (9, fig. 3-18) and proceed as follows:

(c) Remove the three screws (75) and nuts

(76) which secure the BATTERY CHG AMMETER

(77) and remove meter.

a. Replacement. Replace panel light assemblies

as follows:

(2) Installation.Install BATTERY CHG

AMMETER (77) using removal steps in reverse

order.Remove tags.

(1) Removal.

(a) Tag leads and remove screws which

secure leads to panel light assembly.

3-125. DC Control Circuit Breaker.

(b) Remove panel light assembly mounting

hardware and remove panel light assembly.

Test and replacement instructions for DC circuit

breaker are contained in paragraph 3-100.b. Installation. Install panel light assembly

using removal steps in reverse order. Remove tags.

3-126. Control Box Relay Assembly.

3-129. Press-to-Test Light Assembly Replacement.

See (99, fig. 3-18) and proceed as follows:

a. Removal. See (25, 32, 124, fig. 3-18) and

proceed as follows

a. Inspection. Visually inspect for damaged

components.

(1) Tag leads and unsolder leads to light

assembly.(b). Replacement.

(1) Removal.(2) Remove light assembly mounting hardware

and remove light assembly.

(a) Gain access to inside of control box

(123). b. Installation. Install light assembly using re-

moval steps in reverse order. Solder leads to light

assembly. Remove tags.(b) Tag and remove the leads from relay

assembly (99).

3-130. Synchronizing Lights.

(c) Remove the relay assembly (99) by

removing the four attaching nuts (98). See (16, fig. 3-18) and proceed as follows:

(2) Installation. Install relay assembly (99)

using removal steps in reverse order. Remove tags.

a. Testing.

—

(1) Gain access to the rear of the control

cubicle panel (96).3-127. Terminal Board Assembly.

See (105, fig. 3-18) and proceed as follows: NOTE

a. Inspection. Visually inspect for broken bar-

riers, loose hardware and other damage.

Make certain DC CONTROL

CIRCUIT BREAKER is open.

(2) Remove screw which secures lead to one

terminal of SYNCHRONIZING LIGHT assembly (16).

b. Replacement.

—

(1) Removal.

(3) With an ohmmeter, test lamp (24) for

continuity.If meter shows an open circuit, replace

lamp.

(a) Gain access to inside of control box

(123).

(b) Tag and remove the leads from the

terminal board (105).

(4) Reconnect lead.

b. Replacement. Replace SYNCHRONIZING LIGHT

assemblies (16) as follows:

(1) Removal.

(c) Remove jumper (107) by removing

screws (106) and note location of jumper.

(d) Remove the four screws (103) and

nuts (104) and remove terminal board (105). (a) Tag leads and remove screws which

secure leads to light assembly.

(b) Remove light assembly mounting hardware

and remove light assembly.

(2) Installation. Install terminal board (105)

assembly using removal steps in reverse order. Re-

move tags. Make certain to replace jumper (107)

across same terminals in removal procedures.

3-46

c. Installation. Install SYNCHRONIZING LIGHT

assembly (16) using removal steps in reverse order.

Remove tags.

3-131. Door Holder.

See (85, fig. 3-18) and proceed as follows:

a. Removal and Installation.

(1) Remove screw (88), nut (87) and washer

(86) which secures one end of door holder (85) to

panel.

(2) Unhook other end of door holder from

bracket in control box (123) and remove door holder

(85).

(3) Install door holder using removal steps

in reverse order.

3-132. Crosspin Assembly.

See (94, fig. 3-18) and proceed as follows:

a. Removal and Installation.

(1) Gain access to rear of control cubicle

panel (96).

(2) Press out crosspin (94) through stud.

(3) Remove stud (93) and grommet (95) from

panel (96).

(4) Install in reverse order of removal.

3-133. Control Cubicle Panel Replacement.

See (96, fig. 3-18) and proceed as follows:

Remove the six screws (89) and nuts (92) which at-

tach the panel (96) to the hinge (90) and remove

panel.Replace panel (96) in reverse order of re-

moval.

3-134. Control Box Wiring Harness.

See (119, fig 3-18) and proceed as follows:

a.

bent,

tion.

b.

Inspection.

(1) Inspect connectors for damaged threads;

loose, or missing pins.

(2) Inspect terminal lug for security and condi-

(3) Inspect wiring for defective insulation.

Repair.

(2) If a wire is broken from a terminal lug, re-

place the lug. If a wire is broken from a connector,

resolder and reassemble.

CAUTION

Under no condition leave the

bare connection exposed.

(3) If a break in the wire is inaccessible within

wiring harness (119), disconnect it at both ends and

tape both ends. Lace a new lead of the same gage and

insulation outside the wiring harness and connect it

to the proper terminals or pins. Properly tag both

ends of all replacement wires.

c.Replacement. If 30% of the harness wires are

defective, the wiring harness must be rebuilt by

intermediate maintenance, and replaced by organi-

zational maintenance.Tag all wires, connectors,

and terminals for positive identification when a

defective wiring harness is removed. To remove

wiring harness, remove four screws and nuts which

attach connector to box. Remove the four clamps

71, 110, 113 and 116 with the associated attaching

hardware and remove wiring harness. Install wiring

harness in reverse order of removal. Remove tags.

3-135. Control Box.

See (123, fig. 3-18) and proceed as follows:

a.Inspection. Visually inspect control box for

damage.

b. Replacement.

—

(1) Removal.

(a) Disconnect all electrical connections at

rear of control box.

(b) Remove control cubicle panel (96)

from hinge (90) by removing six screws (89) and

nuts (92).

(c) Remove 14 screws (97) and attached

washers which secure control box (123) to frame and

remove control box.

(d) Remove six rivets (89A) which secure

the hinge (9O) and spacer (91) to the control box (123).

(2) Installation.Install box in reverse order

of removal.

(1) If a broken wire is accessible; remove

sufficient insulation from each side of the break to

allow a good connection of the bared ends by twisting

them together. Solder the connection and wrap with

electrical tape.

Change 1 3-47

KEY to fig. 3-18:

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

29.

30.

31.

32.

33.

34.

35.

36.

37.

38.

39.

40.

41.

42.

43.

44.

45.

46.

47.

48.

49.

50.

51.

52.

53.

54.

55.

56.

57.

58.

59.

60.

61.

62.

63.

Screw

Nut

Screw

Nut

Freq meter and transducer (Matched Set)

Transducer

Freq meter

AC ammeter

Panel light (3)

Hood

Nut

Washer

Washer

Holder

Lamp

Synchronizing lights (2)

Lens

Washer

Nut

Washer

Washer

Gasket

Holder

Lamp

Air cleaner condition light assembly

Lens

Nut

Washer

Nut

Light Assembly

Lamp

Ckt bkr light assembly

Lens

Nut

Washer

Nut

Holder

Lamp

Kilowatt meter

Screw

Nut

Ac voltmeter

Knob

Nut

Washer

Washer

Nut

Amps-volts selector switch

Knob

Nut

Washer

Washer

Nut

Voltage adjust rheostat

Knob

Nut

Frequency adjust rheostat

Guard

Nut

Washer

Washer

Battle short switch

Engine prlrner switch

64. Start-run-stop switch

65. Ckt bkr switch

66. Panel light switch

67. Voltage sensing switch

68. single/parallel operation switch

69. Screw

70. Nut

71. Clamp

72. Screw

73. Nut

74. Running time meter

75. Screw

76. Nut

77. Battery chg ammeter

78. Oil pressure gage

79. Fuel level gage

80. Coolant temperature gage

81. Nut

82. Washer

83. Clamp

84. Hook

85. Door holder

86. Washer

87. Nut

88. Screw

89. Screw

89A. Rivet

90. Hinge

91. blacer

92. Nut

93. Stud

94. Cross pin

95. Grommet

96. Panel

97. Screw

98. Nut

99. Relay assembly

100. Screw

101. Nut

102. Wattmeter converter

103. Screw

104. Nut

105. Terminal board

106. Screw

107. Jumper

108. Screw

109. Nut

110. Clamp

111. Screw

112. Nut

113. Clamp

113A. Nut

114. Screw

115. Nut

116. ClaInp

1170 Screw

118. Nut

119. Wiring harness

120. Rivet

121. Receptacle

122. (Deleted)

123. Control box

124. Battle short light assembly

Change 1

3-48

Figure 3-18.

Change 1

3-49

Figure 3-18.

Change 1

3-50

Figure 3-19. Control Cubicle Schematic Diagram

(Sheet 1 of 2)

Change 1 3-51/(3-52 blank)

Figure 3-19. Control Cubicle Schematic Diagram

(Sheet 2 of 2)

3-53/(3-54 blank)

Figure 3-20. Control Cubicle Wiring Diagram

(Sheet 1 of 2)

Change 3 3-55/(3-56 blank)

Figure 3-20. Control Cubicle Wiring Diagram

(Sheet 2 of 2)

Change 3 3-57/(3-58 blank)

Figure 3-21. Ammeter-Voltmeter Selector Switch Schematic

Change 13-59

Section XVI. ENGINE GENERATOR SET HOUSING GROUP

3-136. General.3-137. Removal and Replacement.

This

section

contains

information

on

the

housing

See

figure 3-22

and

remove

and

replace

damaged

group

which

encloses

the

engine

generator

set.

The

doors,

covers,

panels,

and

associated

hardware

of

housing

group

is

made

up

of

covers

and

panels

the

housing

group.

Remove

the

load

bank,

if

in-

which

are

bolted

together,

and

hinged

doors

which

stalled,

as

described

in

paragraph 4-49.

provide

access

to

components:

Section XVII. ENGINE GENERATOR AND CHASSIS

INTERCONNECTING WIRING HARNESSES

3-138. General.

This

section

contains

information

on

interconnect-

ing

wiring

harnesses

of

the

engine

generator

and

chassis.

The

wiring

harnesses

provides

electrical

interconnection

between

major

assemblies

of

the

engine

generator

set.

3-139. Inspection, Test, Repair and Replacement.

See

figure 3-23

and

proceed

as

follows:

CAUTION

As

a

precaution

against

short

circuits,

disconnect

the

bat

-

tery

ground

cable

from

the

batteries

before

inspecting,

testing,

or

replacing

any

wiring.

~.

Inspection.

(1)

Inspect

connectors

for

damaged

threads;

bent,

loose,

or

missing

pins.

(2)

Inspect

terminal

lug

for

security

and

condi-

tion.

(3)

Inspect

wiring

for

defective

insulation.

b.

Test.

Perform

continuity

check,

using

multi-

me~er

between

connecting

points

in

the

wiring

harness

using

the

wiring

data

contained

in

figs. 1-13

through 1-16.

Check

for

short

circuits

between

con-

nector

pins

of

the

same

receptacle

or

terminal

board

following

data

shown

in

figs. 1-13 through

1-16.

c.

Repair.

—

(1)

If

a

broken

wire

is

accessible,

remove

sufficient

insulation

from

each

side

of

the

break

to

allow

a

good

connection

of

the

bared

ends

by

twist-

ing

them

together.

Solder

the

connection

and

wrap

with

electrical

tape.

(2)

If

a

wire

is

broken

from

a

terminal

lug,

replace

the

lug. If

a

wire

is

broken

from

a

connec-

t

or,

resolder

and

reassemble.

CAUTION

Under

no

condition

leave

the

bare

connection

exposed.

(3)

If

a

break

in

the

wire

is

inaccessible

with-

in

the

wiring

harness,

disconnect

it

at

ooth

ends

and

tape

both

ends.

Lace

a

new

lead

of

the

same

gage

and

insulation

outside

the

harness

and

connect

it

to

the

proper

terminals

or

pins.

Properly

tag

both

ends

of

all

replacement

wires.

~.

Replacement.

If

30%

of

the

harness

wires

are

defective,

the

harness

must

be

rebuilt

by

inter-

mediate

maintenance,

but

may

be

replaced

by

org

-

anizational

maintenance.

Tag

all

wires,

connectors,

and

terminal

boards

for

positive

identification

when

a

defective

harness

is

removed.

Disconnect

harness

connectors

from

receptacles

by

unscrewing

connec-

tors

in

counterclockwise

direction.

Remove

all

clamps

which

secure

harness

in

position.

Install

new

or

repaired

harness

in

reverse

sequence

of

removal.

Section

XVIII

LOAD

CONNECTION

GROUP

3-140. General.3-141. Main AC Contactor.

The

lend

connection

group

(fig. 3-24)

is

used

to

pro-

See

figure 3-24

and

proceed

as

follows:

vide

the

electrical

connection

between

the

engine

a.

Inspection.

Inspect

mam

ac

contactor

(3),

generator

set

and

the

external

equipment

to

be whi?h

is

located

at

the

right

of

the

reconnection

board

operated.

(15),

for

secure

mounting,

loose

electrical

connec

-

tions,

frayed

cables

or

insulation,

loose

connector

mating

and

other

damage.

3-60

KEY to fig. 3-22.

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

29.

30.

31.

32.

33.

34.

35.

Screw

Nut

Rubber

seal

Paddle

lock

Access

door

Screw

Nut

Access

door

Rivet

Plate,

information,

dc

troubleshooting

Screw

Nut

Access

door

Screw

Nut

Access

door

Rivet

Plate.

information,

dc

schematic

Rivet

Plate,

information,

ac

schematic

Screw

Nut

Access

door

Screw

Nut

Access

door

Screw

Nut

Access

door

Screw

Nut

Access

door

Rivet

Plate,

information

Safety

cover

assembly

36.

Screw

36A.Washer

37.

38.

39.

40.

41,

42,

43.

44.

45,

46.

47.

48.

49.

50.

51.

52.

53.

54.

55.

56.

57.

58.

59.

60.

61.

62.

63.

Cover

Rivet

Plate,

operational

data

Rivet

Plate,

operational

data

Screw

Nut

Access

cover,

radiator

cap

Oval

stud

Retainer

stud

Screw

Nut

Receptacle,

lock

Screw

Compartment,

document

Screw

Lockwasher

Nut

Screw

Nut

Housing,

top,

front

Screw

Nut,

cage

Side

housing,

left

front

Side

housing,

right

front

Screw

Nut

64.

Housing,

top

rear

65.

Screw

66.

Nut,

cage

67.

Screw

68.

Nut

69.

Post,

left

hand,

rear

70.

Screw

71.

Nut

72.

Side

housing,

right

rear

73.

Screw

74.

Nut

75.

Side

housing,

left

rear

76.

Screw

77.

Nut,

cage

78.

Grille

79.

Screw

80.

Screw

81.

Washer

82.

Nut

83.

Door

holder

84.

Screw

85.

Nut

86.

Battery

access

door

87.

Rivet

88.

Battery

connection

instruction

plate

89.

Screw

90.

Nut,

cage

91.

Screw

92.

Nut,

cage

93.

Housing,

lower

front

94.

Screw

95.

Nut

96.

Housing,

upper

front

97.

Screw

98.

Nut

99.

Screw

100.

Nut

101.

Control

and

access

door,

right

102.

Door

hook

103.

Rivet

104.

Instruction

plate,

service

instructions

105.

Screw

106.

Nut

107.

Control

panel,

access

door,

left

108.

Door

hook

109.

Rivet

110.

Instruction

plate,

operating

111.

Screw

112.

Nut

113.

Air

inlet

door,

right

114.

Door

hook

115.

Screw

116.

Nut

117.

Air

inlet

door,

left

118.

Door

hook

119.

Screw

120.

Control

box,

mounting

121.

Screw

122.

Nut

123.

Rear

corner

panel,

left

hand

124.

Screw

125.

Rear

corner

panel,

right

hand

126.

Screw

127.

Screw

128.

Panel,

air

intake

Change 1 3-61

KEY to fig. 3-22. (Cont)

129.

130.

131.

132.

133.

134.

135.

136.

13’7.

138.

139.

140.

141.

142.

143.

144.

145.

146.

147.

148.

149.

150.

151.

Screw

Nut

Rivet

Plate,

designator,

paralleling

receptacles

Screw

Screw

Panel,

fuel

tank

access

Screw

Nut,

cage

Housing

corner

post,

left

hand

Housing

corner

post,

right

hand

Screw

Screw

Rear

corner

panel,

left

hand

Rivet

Plate,

lifting

instructions

Rivet

Plate,

fuel

system

instructions

Screw

Screw

Rear

corner

panel,

right

hand

Rivet

Plate,

identification

3-62

Figure 3-22. Housing Group, Top and Side

(Sheet 1 of 2)

3-63/(3-64 blank)

Change 1

Figure 3-22. Housing Group, Front and Rear

(Sheet 2 of 2)

3-65/(3-66 blank)

KEY to fig. 3-23.

1.

2.

3.

4.

::

7.

8.

8.

9.

+::

12.

13.

14.

;::

17.

18.

Precise

relay

boxwiring

harness

to

governor

control

unit

(Mode

1

Class

1

only)

Precise

relay

box

wiring

harness

to

special

relay

box

(Mode

1

Class

1

only)

Screw

Clamp

Excitation

group

wiring

harness

LMU

assembly

wiring

harness

Tactical

relay

box

wiring

harness

Governor

control

unit

to

precise

relay

wiring

harness

(Mode

1

Class

1

only)

Governor

control

unit

wiring

harness

(Mode

11

Class

1

only)

Screw

Nut

Clamp

(Class

1

only)

Bracket

Dead

Crank

Switch

Screw

Nut

Clamp

(Class

1

only)

Screw

Nut

Clamp

(Class

1

only)

19:

19A.

Screw

19B.

Nut

19C.

Clamp

20.

21.

22.

23.

24.

25.

26.

27.

28.

Screw

Nut

Clamp

(Deleted)

(Deleted)

(Deleted)

(Deleted)

(Deleted)

(Deleted)

29.

Screw

30.

Nut

31.

Bracket

32.

Governor

control

to

actuator

wiring

harness

(Class

1

only)

33.

Governor

control

to

actuator

wiring

harness

(Class

1

only)

34.

Screw

35.

Nut

36. Clamp

36A.

Screw

36B.

Nut

36C.

Clamp

37. Screw

38.

Nut

39.

Clamp

40.

(Deleted)

41. (Deleted)

42. (Deleted)

43. (Deleted)

44.

(Deleted)

45. (Deleted)

46. Screw

47.

Nut

48. Clamp

49. Screw

50. Nut

51.

Clamp

52.

Screw

Nut

:::

Clamp

(Class

1

only)

55.

Screw

56.

Clamp

57.

Screw

58. Nut

59.

Screw

60.

Nut

61.

Bracket

Bracket

:::

(Deleted)

64. Clamp

65.

Screw

66.

Nut

67.

Clamp

68.

Screw

69.

Washer

70.

Bracket

71.

Engine

accessories

wiring

harness

72.

AC

power

control

wiring

harness

73.

Screw

74.

Diode

Suppressor

75.

Bracket

76.

Screw

77. Nut

78.

Clamp

79.

Screw

80.

Nut

81. Clamp

82.

Screw

83.

Nut

84.

Clamp

84A.

Screw

84B.

Nut

84C.

Clamp

84D.

Screw

84E.

Nut

84F,

Clamp

84G.

Screw

84H.

Nut

84J.

Clamp

85.

Nut

86.

Screw

ground

stud

87.

Ground

strap

88.

RFI

capacitors

wiring

harness

Change 13-67

Figure 3-23. Engine Generator and Chassis Wiring Harness (Sheet 1 of 2)

Change 1

3-68

Figure 3-23. Engine Generator and Chassis Wiring Harness (Sheet 2 of 2)

Change 1 3-69

Figure 3-24.

3-70Change 1

TM 5-6115-545-12

TO-35C2-3-444-1

NAVFAC P-8-626-12

TM-00038G-12

b.

?estirw,

—

(~ply

24

Vdc

at

pins

A

and

B

of

main

ac

contactor

(3)

connector.

When

main

ac

contactor

operates,

it

should

create

a

distinctive

noise.

(2)

With

an

ohmmeter,

check

for

continuity

between

terminal

Al

to

A2,

B1

to

B2,

and

Cl

to

C2

on

top

of

the

main

ac

contactor.

(3)

At

the

connector,

check

for

continuity

b~tween

pins

C

to

D,

E

to

F,

G

to

H,

J

to

K,

and

R

to

T.

(4)

At

the

connector,

check

for

an

open

cir-

cuit

between

pins

L

to

M,

N

to

P,

and

R

to

S.

(5)

Remove

the

24

Vdc

and

check

for

the

oppo-

site

of

the

conditions

(continuity

or

open

circuit)

listed

in

steps

(2),

(3),

and

(4).

c.

Replacement.

See

figure 3-24

and

replace

the—main

ac

contactor

(3)

as

follows:

(1)

Removal.

(a)

Remove

four

screws

( 1 )

which

secure

covers

(2)

on

top

of

main

ac

contactor

(3).

(b)

Tag

and

remove

electrical

connections

to

main

ac

contactor

by

removing

six

nuts

and

washers

(

5

and

6).

(c)

Remove

four

screws

(4)

which

secure

main

ac

contactor

to

mounting

bracket

(7).

(2)

Installation.

See

figure 3-24

and

install

the

main

ac

contactor

(3)

in

reverse

order

of

removal.

3-142. Repair of Load Terminal Board.

a.

Inspection.

See

figure 3-24

and

inspect

the

loa~terminal

board

(8)

for

cracks,

breaks,

loose

terminals

and

other

damage.

Inspect

all

electrical

leads

for

broken

or

frayed

insulation

and

other

darnage.

~

Replacement

of

Load

Terminal

Board.

See

figure

3-24

and

replace

the

load

terminal

board

(8)

as

follows:

(

1

)

Removal.

(a)

Tag

and

remove

electrical

connections

to

load

terminal

board

(8).

(b)

Remove

the

two

screws

(9),

four

washers

(10

and

11),

and

two

nuts

(12)

at

the

top

and

the

two

screws

(

13)

and

nuts

(14)

at

the

bottom

and

remove

the

load

terminal

board

(8).

(C)

Disassemble

load

terminal

board

(8)

as

shown

in

detail

A.

(d)

Inspect

load

terminal

board

(8)

for

dam-

aged

threads

on

studs,

and

signs

of

physical

damage.

(e)

Reassemble

in

the

reverse

order

of

disassembly.

(2)

Installation.

See

figure 3-24

and

install

load

terminal

board

in

reverse

order

of

removal.

c.

Replacement

of

Lost

or

Broken

Terminal

Clip

(R~ainer,

Safety

Clip).

The

terminal

clip

is

a

compo-

nent

of

both

the

load

terminal

and

the

ground

terminal.

If

the

terminal

clip

is

lost

or

broken,

fabricate

as

follows:

(1)

Requisition

bulk

wire

NSN

9505-00-804-3814

(0.042

inch

diameter)

for

the

ground

terminal

(ground

stud).

Requisition

bulk

wire

NSN

9505-01-049-0144

(0.050

inch

diameter)

for

the

load

terminal.

(2)

Cut

off

about

3

inches

of

the

wire;

short

enough

to

keep

the

clips

from

touching

another

terminal

or

the

generator

frame

in

the

open

or

closed

position.

(3)

Slip

the

wire

through

the

hole

in

the

terminrd.

(4)

Hold

the

terminal

as

shown

(Detail

A,

figure

3-24.1)

and

bend

both

ends

of

the

wire

straight

up

keep-

ing

the

wire

in

as

straight

a

line

as

you

can

with

the

terminal

body.

(5)

Bend

the

wire

into

back-to-back

90°

angles

(Detail

B,

figure 3-24.1)

so

that

the

legs

of

both

angles

are

about

one-half

inch

long.

(6)

Bend

the

ends

of

each

90°

angle

down

and

around

into

a

U-shape

(Detail

C,

figure 3-24.1)

so

that

if

done

properly,

the

clip

will

hold

the

nut

when

it

is

un-

screwed

to

install

the

cable

(Detail

D,

figure 3-24.1).

d.

Repair.

Repair

damaged

threads

with

a

die

or

by

fili~

w~ne

mill

triangular

file,

3-143. Current Transformer Assembly.

See

figure 3-24

and

inspect

the

current

transformer

assembly

(18

)

for

cracks,

breaks,

loose

mounting,

loose

connections,

corrosion

and

other

damage.

3-144. Reconnection Board.

See

figure 3-25

and

proceed

as

follows:

a.

Inspection.

Inspect

reconnection

board

(

15,

fig. 3-24)

for

cracks,

breaks,

loose

mounting

nuts,

and

other

damage.

&

Testing.

Test

reconnection

board

for

continuity

as

follows:

(1)

Remove

12

nuts

(1, fig. 3-25)

holding

insula-

tor

(20)

and

remove

insulator

(2o).

(2)

Inspect

bus

bars

(19)

on

rear

of

insulator

(20)

and

replace

bus

bars

if

damaged

or

missing,

(3)

See

figure 2-4

and

check

for

continuity

be-

tween

studs

1

and

4;2

and

5;3

and

6;7

and

10;8

and

11;

and

9

and

12.

If

no

continuity,

check

respective

studs

for

continuity

on

insulator

(24, fig. 3-25),

If

continuity

is

not

obtained,

generator

is

at

fault.

If

check

indicates

continuity,

replace

reconnection

panel.

c.

Replacement.

Replace

reconnection

board

(15,

fig. 3-24)

as

follows:

(1)

Removal.

(a)

Remove

four

screws

(

16)

which

secure

the

reconnection

board

(15)

to

the

brackets

(17).

(b)

Tag

and

disconnect

wires

at

back

of

recon-

nection

board.

(c)

Remove

reconnection

board

(15

).

(2)

Installation.

Install

reconnection

board

(15

)

using

removal

steps

in

reverse

order.

Q.

Repair.

Repair

reconnection

board

(see

fig. 3-25)

by

replacement

of

damaged

components.

Change 133-71

TM 5-6115-545-12

TO-35C2-3-444-1

NAVFAC P-8-626-12

TM-00038G-12

DETAIL

A

DETAIL

B

DETAILC

DETAIL

D

Figure

3-24.1

Terminal

Clip

Replacement

SECTION XIX. GOVERNOR CONTROL UNIT (CLASS 1 ONLY)

3-145. General.

The

governor

control

unit

is

the

control

position

of

the

governing

system

on

precise

generator

sets.

This

section

contains

information

on

organizational

maintenance

inspection

requirements

for

the

governor

control

unit.

3-146. Governor Control Unit Inspection.

Inspect

the

governor

control

unit

(fig. 1-1)

for

cracks,

breaks,

loose

mounting,

damage

or

loose

connectors,

and

other

damage.

3-72Change 13

TM 5-6115-545-12

TO-35C2-3-444-1

NAVFAC P-8-626-12

TM-00038G-12

3-146.1 Electric Governor Control Box Frequency

Adjust Rheostat (MEP115A).

g.

The

frequency

adjust

rheostat

(1, Fig 3-24.2)

will

adjust

the

oscillator

frequency

of

the

control

box

(2).

The

control

box

compares

the

oscillator

frequency

with

the

signal

frequency

sent

from

the

magnetic

pick

up

speed

sensor

(3).

This

sends

the

proper

voltage

to

the

electric

governor

actuator

(4)

which

controls

the

speed

of

the

engine.

NOTE

Normally

this

rheostat

is

only

adjusted

when

the

control

box

is

changed

or

when

there

is

a

requirement

to

change

the

frequency

of

the

governor

set.

~.

If

the

frequency

of

the

generator

fluctuates

or

is

incorrect

and

cannot

be

adjusted

by

the

Frequency

Adjust

(29, Fig 2-10)

control

located

on

the

generator

set

control

panel,

do

not

adjust

the

rheostat

on

the

Electric

Governor

Control

Box

until

the

following

checks

are

made:

(1)

Frequency

Adjust

(29, Fig 2-10)

on

generator

set

control

panel

is

in

mid-position.

(2)

The

magnetic

pickup

speed

sensor

is

checked

by

removing

its

connector

plug

and

sensor

(3, Fig 3-24.2).

Ensure

there

is

no

dirt

or

magnetic

particles

on

the

sensor’s

end.

To

install

the

sensor,

turn

slightly

by

hand

until

the

tip

contacts

the

top

of

the

Ring

Gear

Tooth

(5).

Then

back

out

three-

quarters

of

a

turn

and

secure

with

jam

nut

(6).

Reconnect

wiring

on

the

magnetic

pickup

speed

sensor

(3).

WARNING

Ensure

DC

power

source

is

disconnected

before

the

following

step

is

accomplished.

Serious

injury

could

result

if

this

procedure

is

not

followed.

(3)

Remove

connector

plug

(P22)

from

J-22

(7)

and

using

a

multimeter

the

following

checks

should

be

made:

on

P22;

pin

“G”

to

ground

should

be

O

ohms;

pin

“B”

to

“D”

8

ohms;

pins

“T”

to

“S”

should

read

between

50

to

500

ohms;

pins

“F”

to

“R

500

ohms;

pins

“R”

to

“K”

2,000

ohms

and

pins

“J”

to

“H”

should

read

85,000

ohms.

Reconnect

the

battery,

DC

Control

Circuit

Breaker

(20, Fig 2-10)

pushed

in

and

the

Start,

Run,

Stop

Switch

(32, Fig 2-10)

placed

in

the

Run

position.

Connect

the

Multimeter

between

pin

“C”

and

ground.

A

reading

of

24

VDC

should

be

obtained.

Disconnect

DC

power

source

and

connect

plug

(P22)

to

J22

(7, Fig 3-24.2);

(4)

Check

for

loose

and/or

binding

electric

governor

actuator

linkage.

CAUTION

The

Frequency

Adjust

Rheostat

(1, Fig 3-24.2)

is

a

multi

turn

rheostat

and

will

not

handle

excessive

twisting

and

turning,

otherwise

damage

to

the

rheostat

will

result.

Adjust

with

care.

(5)

If

the

generator

frequency

is

either

high

of

low

with

the

Frequency

Adjust

(29, Fig 2-10)

control

located

on

the

generator

set

control

panel

in

mid

position,

adjust

the

Frequency

Adjust

rheostat

(1, Fig 3-24.2)

in

small

increments.

Check

the

Frequency

Meter

(3, Fig 2-10)

on

the

generator

control

panel

after

each

increment.

Adjust

until

the

proper

frequency

is

attained.

(6)

If

you

cannot

get

the

correct

frequency

after

completing

all

of

the

above

checks,

notify

higher

level

of

maintenance

for

troubleshooting

and

repair.

Change 153-72.1

Figure 3-24.2.

TM 5-6115-545-12

TO-35C2-3-444-1

NAVFAC P-8-626-12

TM-00038G-12

3-72.2Change 15

TM 5-6115-545-12

TO-35C2-3-444-1

NAVFAC P-8-626-12

TM-00038G-12

Figure 3-25. Reconnection Board

SECTION XX. AIR CLEANER ASSEMBLY

3-147. Air Cleaner Assembly.

~.

Replacement.

See

figure

3-26

and

remove

air

cleaner

assembly

in

accordance

with

the

sequence

of

index

numbers.

See

paragraph

3-87

for

removal

and

replacement

a.

Removal.

The

air

cleaner

assembly

filters

incoming

of

hose

connecting

air

cleaner

inlet

to

oil

separator,

Install

combustion

air

to

the

engine. air

cleaner

assembly

in

reverse

order

of

removal.

Removal

and

replacement

of

filter

element

is

shown

in

figure

3-5.

SECTION XXI. RELAY TABLE GROUP

3-148. General.

to

control

the

generator

set

during

paralleling

and

to

provide

monitoring

of

voltages

and

frequencies.

a.

This

section

contains

information

on

the

relay

table

~:

On

Class

1,

Mode

I

generator

sets

there

is

a

grofip.

The

relay

table

boxes

are

located

behind

the

control

precw.e

relay

assembly

that

provides

under

frequency,

cubicle

on

a

relay

table

(19, Fig 3-24)

above

the

generator. under

voltage

and

permissive

paralleling

monitors

The

relay

boxes

contain

protective

relays

and

devices

used

of

the

generator

set

for

more

complex

ap-

Change 153-72.3 /(3-72.4 blank)

Figure 3-26.Air Cleaner and Related Parts

plicat

ions.

These

monitors

are

included

in

the c.

Inspect

wiril~

for

fraying,

corrosion

and

Mcxie

II,

Class

1

sets

within

the

set

special

box.

oth;r

damage.

3-149. Tactical Relay Assembly Inspection.

a.

Remove

nine

screws

which

secure

cover

find

rell=ove

cover.

b.

Inspect

tern]

lnill

I>tr.irds

for

loose

nluuntin:,

IooEe

terminal

connecllt)ns.

corrosion.

and

other

damage.

f.

Reassemble

the

assembly

by

replacing

cover

a]ld-nine

screws.

3-150. Precise Relay Assembly Class 1 (50 60 Hz

Sets) Inspection.

1

Inspect

[he

two

connectors

for

bent

or

broken

. .

pin;

and

other

ciaml:e.

c. Inspect connectors for bent or broken pins

and other damage.

b.

Inspect

{he

50

60

Hz

switch

for

loose

mcmnting.

cor;’osion

and

other

damage.

3-151. Special Relay Assembly (50 60 Hz) Inspection.

d. Inspect relays for loose mounting, loose

wiring corrosion and other damage.

Change 73-73

a,

Loosen

the

two

top

screws

which

secure

the

cov;r

to

the

front

panel.

b.

Remove

the

bottom

two

screws

and

let

the

frofit

panel

slide

down,

then

remove.

c.

Inspect

the

cross

current

adjust

control

for

loo;e

mounting,

loose

wiring,

corrosion,

and

other

damage.

~.

Inspect

the

terminal

boards

for

loose

mount-

ing,

loose

terminal

connections,

and

other

damage.

e.

Inspect

transformer

for

loose

mounting,

Ioo;e

connections,

corrosion,

and

other

damage.

&

Inspect

wiring

for

fraying,

corrosion,

and

other

damage.

~.

Inspect

the

special

relay

assembly

for

dents,

loose

mounting,

loose

connectors,

and

other

damage.

~.

Replace

by

sliding

front

panel

under

the

top

two

screws

and

securing

it

to

special

relay

assembly

with

bottom

two

screws.

i.

Tighten

top

two

screws.

3-152. Special Relay Assembly (400 Hz) Inspection.

a.

Loosen

the

two

top

screws

which

secure

the

cov;r

to

the

front

panel.

b.

Remove

the

bottom

two

screws

and

let

the

frofit

panel

slide

down

then

remove.

c.

Inspect

the

load

sharing

adjust

and

cross

cur-

ren~

adjust

controls

for

loose

mounting,

loose

wiring,

corrosion,

and

other

damage.

d.

Inspect

the

terminal

boards

for

loose

mount-

ing~

loose

terminal

connections,

for

corrosion,

and

other

damage.

~.

Inspect

transformer

for

loose

mounting,

loose

connections,

corrosion,

and

other

damage.

f.

Inspect

the

relays

for

loose

mounting,

loose

cofiections,

corrosion,

and

other

damage.

~.

Inspect

wiring

for

fraying,

corrosion,

and

other

damage.

h.

Inspect

the

special

relay

assembly

for

dents,

loo;e

mounting,

loose

connectors,

and

other

damage.

i.

Replace

front

panel

by

sliding

the

panel

under

the~op

two

screws

and

securing

it

to

special

relay

assembly

with

bottom

two

screws.

~

Tighten

top

two

screws.

3-153. Load Measuring Unit Inspection.

Inspect

the

load

measuring

unit

for

dents,

breaks,

loose

mounting,

loose

connector,

and

other

damage.

Section XXII. GENERATOR ASSEMBLY

3-154. General.

The

generator

assembly

is

used

to

generate

elec-

trical

power.

Maintenance

at

the

organizational

level

consists

of

the

following

inspections.

3-155. Generator Inspection.

a.

Inspect

ac

generator

(fig. 1-1)

for

excessive

hea~

by

placing

an

open

hand

on

the

generator

end

bell.

If

the

hand

cannot

be

maintained

in

this

posi

-

tion

for

one

minute,

due

to

overheat,

refer

to

next

higher

maintenance

level.

b.

Inspect

ac

generator

frame

for

cracks,

and

oth~r

damage.

c.

Listen

for

unusual

nowes

while

in

operation.

—

3-156. Generator Bearing Inspection.

Inspect

ac

generator

bearing

by

removing

inspec-

tion

cover

plate.

Examine

bearing

for

signs

of

wear,

or

discoloration

due

to

overheating.

Section XXIII. DAY TANK AND FUEL FILTER ASSEMBLY

3-157. General.

primary

fuel

filter

prevent

foreign

particles

from

entering

the

day

tank.

A

solenoid

valve

on

the

main

This

section

contains

information

on

day

tank

and

tank

is

used

to

control

the

flow

of

fuel

to

the

day

tank.

fuel

filter

assembly.

The

day

tank

is

used

to

gravity

The

solenoid

valve

is

controlled

by

the

float

level

feed

fuel

to

the

fuel

injector

pump.

The

fuel

supplied switch

which

is

actuated

by

the

level

of

the

fuel

in

to

the

day

tank

from

the

main

tank

passes

through

the the

day

tank.

strainer

and

primary

fuel

filter.

The

strainer

and

3-74

1.

Hose

assy

14.

2. Elbow

15.

3.

Reducer

16.

4. Hose

assy

17.

5.

Connector

18.

6.

Reducer

19.

7.

Screw

20.

8.

Washer

21.

8A.

Screw

22.

8B.

Washer

23.

9.

Fuel

filter

assy

24.

10.

Connector

25.

11”

Screw

26.

12.

Nut 27.

13. Clamp

28.

Hose

assy

Hose

assy

Clamp

Screw

Nut

Clamp

Screw

Nut

Clamp

Bracket

Hose

assy

Screw

Bracket

Screw

Nut

28A.

Washer

41.

Elbow

42. Day

tank

:

~;;jed)

43.

Screw

Elbow

44.

Nut

32:

Plug*

45.

Washer

*Note:

Heater

fuel

shutoff

valve

if

46. Screw

fuel

winterization

kit

installed

46A.

Nut

33. Tee 47.

Screw

34. Solenoid

valve 48.

Washer

35. Nipple

49.

Dead

crank

switch

36.

Drain

cock

50.

Bracket

37.

Reducer

51.

Bracket

38.

Float

switch

39.

Elbow

40.

Elbow

Figure 3-27.Day Tank and Fuel Filter Assembly

3-158. Solenoid Valve.

b.

Testing.

Test

solenoid

valve

(34)

as

follows:

—

See

figure 3-27

and

proceed

as

follows:

(1)

Disconnect

electrical

connector

on

solenoid

valve

(34).

a.

Inspection.

Inspect

solenoid

valve

(34)

for

loo;e

mounting,

dents,

breaks,

stripped

threads

or

(2)

Intermittently

apply

24

volts

to

the

other

damage.

terminals

on

the

solenoid

valve

connector

and

Change 13-75

listen

for

evidence

of

solenoid

actuation.

If

no

sole-

(5)

Install

float

switch

(38)

using

above

re-

-

noid

action

is

heard,

replace

the

solenoid

valve

(34).

moval

steps

in

reverse

order.

(3)

Reconnect

the

electrical

connector.

c.

Removal

and

Replacement.

Replace

the

day

tati–

(42)

as

follows:

c.

Removal

and

Replacement.

To

repltice

the

sol=noid

valve

(34)

proceed

as

follows:

(1)

Removal.

(1)

Open

drain

cock(36)

on

bottom

of

day

tank

(~)

Open

drain

cock

(36)

on

bottom

of

day

(42)

and

drain

talk

coutents

ir,to

a

suitable

contain-

tank

(42)

and

drain

tank

contents

into

a

suitable

er.

container.

(2)

Disconnect

and

tag

electrical

connectors

(b)

Tag

and

disconnect

the

electrical

con-

from

the

float

switch

(38)

and

the

solenoid

valve

nectors

frfim

float

switch

(38)

and

solenoid

valve

.,

(34). (34).

(3)

Disconnect

fuel

lines

from

day

tank.

(~)

Unscrew

the

float

switch

(38)

from

the

day

tank

(42)

and

lift

the

float

switch

assembly

(4)

Disconnect

fuel

line

attached

to

elbow

(31)

from

the

tank.

and

remove

elbow

from

tee

(33).

(d)

Discomect

fuel

lines

from

day

tank

NOT

E

(42)

and

s~lenoid

valve

(34)

If

fuel

winterizat

ion

kit

is

installed,

(~)

Remove

the

four

screws

(25)

and

wash-

disconnect

heater

fuel

shutoff

valve

(32)

from

tee

(33).

ers

(28A)

which

secure

day

tank

(42)

to

bracket

(51)

and

remove

day

tank.

(5)

Remove

the

four

screws

(25)

and

washers

(2)

Replacement.

Install

day

tank

(42)

by

(28A)

which

secure

day

tank

(42)

to

bracket

(51)

and

using

the

removal

steps

in

reverse

order.

remove

day

tank.

(6)

Remove

tee

(33)

from

solenoid

valve

(34).

3-160. Fuel Filter Assembly Removal and Replace-

ment.

(7)

Unscrew

and

remove

solenoid

valve

(34)

from

day

tank

(42).

To

replace

the

fuel

filter

assembly,

see

figure

3-27

and

proceed

as

follows:

(8)

Install

new

solenoid

valve

(34)

in

reverse

sequence

of

removal

procedures.

NOT

E

3-159. Day Tank and Float Switch

Refer

to

paragraph 3-34

for

prc

-

cedure’s

to

replace

filter

element

See

figure 3-27

and

proceed

as

follows:

of

fuel

filter

assembly.

a.

Inspection.

Inspect

the

float

switch

(38)

which

is

iiiounted

on

the

day

tank

(42)

for

loose

connector

(10),

loose

mounting,

and

other

damage.

~.

Testing.

‘Test

the

float

switch

(38)

as

follows:

(1)

Remove

connector

(10)

from

float

switch

(38).

(2)

Remove

float

switch

(38)

from

day

tank

(42).

(3)

Connect

an

ohmmeter

between

pina

C

and

D

of

the

connector

(10)

and

verify

continuity

when

the

bottom

float

is

placed

at

its

bottom

position

and

verify

open

circuit

when

float

is

placed

at

its

top

position.

(4)

Connect

an

ohmmeter

between

pins

A

and

B

of

the

connector

(10)

and

verify

continuity

when

the

top

float

is

placed

at

its

bottom

position

and

verify

open

circuit

when

float

is

placed

at

its

top

posi-

t

ion.

a.

Removal.

—

(1)

Open

drain

cocks

on

fuel

filter

assembly

(9)

and

drain

into

suitable

container.

(2)

Clean

dirt

from

filter

head,

filter

body

and

surrounding

area.

(3)

Disconnect

hose

assemblies

(1

and

4)

and

remove

fuel

filter

assembly

(9)

by

removing

the

four

screws

(7)

and

washers(8).

b.

Installation.

(1)

See

figure 3-27

and

replace

fuel

filter

assembly

(9)

in

the

reverse

order

of

removal.

(2)

Close

drain

cocks

on

fuel

filter

assem-

blv

(9).

.

.

.

3-76 Change 9

Section XXIV. LIFTING FRAME ASSEMBLY, START AID ASSEMBLY

AND FUEL TRANSFER PUMPS

3-161. General.

The

center

support

is

located

at

the

center

of

the

housing

and

provides

a

means

of

lifting

the

genera-

tor

set

by

use

of

a

clevis

located

on

each

side

of

the

top

of

the

center

support.

The

start

aid

as-

sembly

mounted

on

the

center

support,

is

used

as

an

aid

in

starting

the

engine

at

temperatures

below

40°

F.

This

system

is

controlled

by

the

ENGINE

PRIMER

switch

on

the

control

cubicle

panel

when

the

engine

is

being

cranked

aml

the

START-RUN-

STOP

switch

is

in

the

START

position.

Each

time

the

ENGINE

PRIMER

switch

is

momentarily

actu-

ated,

under

these

conditions,

one

metered

shot

of

ether

is

injected

into

the

engine

air

intake

system.

This

section

also

contains

information

for

main-

tenance

of

the

electric

fuel

transfer

pumps

which

are

utilized

to

transfer

fuel

from

the

main

fuel

tank

to

the

day

tank.

3-162. Start Aid Assembly.

a. Inspection. Inspect

ether

tank

(8, fig. 3-28)

sol=nold

valve

(4)

and

bracket

(7)

for

loose

mount-

ing,

dents,

loose

fittings,

and

other

damage.

~.

Testi

w

and

Replacement.

(1)

Disconnect

tube

(1, fig. 3-28)

from

adap-

ter

(3)

on

solenoid

valve

(4),

WARNING

Be

careful

n~t

to

inhale

ether

gas

as

drowsiness

and

unconsciousness

may

result.

(2)

Crank

the

engine

and

momentarily

actuate

and

release

the

ENGINE

PRIMER

switch,

while

an

ob-

server

watches

the

solenoid

valve

(4)

opening.

If

no

spray

of

ether

is

observed,

perform

step

(3).

(3)

Listen

for

audible

evidence

of

solenoid

valve

(4)

operation

while

the

ENGINE

PRIMER

switch

is

repeatedly

actuated.

(4)

If

solenoid

valve

(4),

operation

is

veri-

fied

in

step

(3),

replace

ether

tank

(8)

as

follows:

(~)

Open

bracket

(7).

@)

Unscrew

ether

tank

(8)

from

solenoid

valve

(4)

and

remove

ether

tank.

(c)

Install

new

ether

tank

(8)

using

above

procedure–in

reverse.

WARNING

Be

careful

not

to

inhale

ether

gas

as

drowsiness

and

unconsciousness

may

result.

(Q)

Check

operation

of

ether

outlined

in

step

(2)

above.

tank

(8)

as

(s)

Connect

tube

(1)

to

adapter

(3)

on

solenoid

valve

(4).

(5)

If

solenoid

valve

(4)

operation

was

not

verified

in

step

(3),

disconnect

solenoid

connector

and

check

for

24

volts

dc

at

the

pins

of

its

mating

connector

each

time

the

ENGINE

PRIMER

switch

is

actuated

with

the

engine

cranked.

(6)

If

24

volts

dc

is

measured

in

step

(5),

re-

place

the

solenoid

valve

(4)

as

follows:

(~)

Remove

two

screws

(9)

and

nuts

(10)

which

secure

the

solenoid

valve

(4)

to

the

frame-

work.

~)

while

holding

ether

tank

(8)

securely,

open

bracket

(7)

and

remove

the

tank

and

attached

solenoid

valve

as

an

assembly.

(c)

Remove

adapter

(3)

and

install

in

a

new

solen~id

valve.

(~)

Install

the

new

solenoid

valve

(4)

with

adapter

using

two

screws

(9)

and

nuts

(10).

Do

not

tighten

screws

(9)

securely.

(g)

Connect

tube

(1)

to

adapter

(3)

on

solenoid

valve

(4)

and

tighten

the

solenoid

valve

mounting

screws

(9)

securely.

(f)

Screw

a

new

ether

tank

(8)

into

the

solenoid

~itlve

(4).

(g)

Close

bracket

(7)

to

secure

ether

tank

(8).

(7)

If

24

volts

dc

was

not

measured

in

step

(5),

test

the

ENGINE

PRIMER

switch

and

replace

if

defective. (Refer

to

paragraph 3-118a.)

3-163. Lifting Frame.

a.

Inspection.

See

figure 3-28

and

inspect

lift~W

irame

(8 1)

for

breaks,

cracks,

loose

mount-

ing,

corrosion

and

rust.

b.

Re

lacement.

Replace

clevis

(80)

in

accord-

-

+8.

ante

with

figure

3-164. Filler Cap, Gasket, Strainer, and Hose

Replacement.

See

figure 3-28

(items

39

thru

59

and

proceed

as

follows:

a.

Remove

item

(39).

Items

(40)

and

(42)

will

co~e

out

together.

3-77

b.

see

paragraph 3-87

and

remove

oil

separator

(85).

c.

Remove

nuts

(82),

clamp

and

bracket

(84),

nuts

(83),

and

screws

(W.

d.

Remove

screws

(49),

washers

(51)

and

nuts

(50T

Loosen

clamps

and

remove

hoses

(47

and48).

e.

Remove

clamp

(44)

and

remove

filler

neck

(43L

f.

Remove

remainder

of

items

in

sequential

ordir.

~.

InSt._dl

in

reverse

sequence

of

removal.

3-165. Fuel Transfer Pumps.

See

figure 3-28

and

proceed

as

follows:

a.

Servicing.

(1)

Twist

and

remove

cover

and

gasket

from

body

of

fuel

pump

(3’7

and

38).

(2)

Carefully

remove

filter

from

fuel

pump

body.

(3)

Wash

filter

with

cleaning

solvent

Federal

Specification

P-D-680

and

dry

thoroughly.

(4)

Inspect

filter

and

gasket

for

tears.

Re-

place

defective

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

bottom

(outlet)

of

fuel

pump

to

a

clean

empty

container.

(4)

Connect

a

24-Vdc

power

supply

to

male

receptacle

and

ground,

observing

ground

polarity

requirements

(+

or

-)

as

stamped

on

fuel

pump

bracket.

Fuel

pump

should

deliver

18

gallons

per

hour

of

fuel

with

zero

pressure.

If

fuel

pump

is

inoperative,

there

may

be

an

open

circuit

in

the

wire

lead

assembly.

If

fuel

pump

does

not

operate

after

rechecking

electrical

test

connection,

re-

place

the

fuel

pump.

(5)

At

completion

of

test,

reconnect

fuel

hose

assemblies

to

fuel

pump

(37

and

38).

c.

Replacement.

See

figure 3-28

(detail

A)

and-proceed

as

follows:

(1)

Disconnect

connectors

on

fuel

pumps

(37

and

38).

(2)

Disconnect

hose

assemblies

(24).

3-78Change 9

(3)

Disconnect

tube

assembly

(30)

from

both

fuel

pumps

(37

and

38).

(4)

Remove

four

screws

(34)

and

nuts

(35)

which

secure

fuel

pumps.

(5)

To

reassemble,

reverse

the

disassembly

sequence.

3-166. Fuel Selector Valve and Lines Replacement.

See

figure 3-28

and

remove

and

replace

item

num-

bers

(24),

(25),

(15),

(17),

(16),

(18),

(20),

(19),

(21),

(23),

(22),

(27),

(28)

and

(29),

as

required.

KEY to fig. 3-28:

1. Tube

2.

Atomizer

3.

Adapter

4. Solenoid

valve

5.

Screw

6.

Nut

6A.

Nut

7.

Bracket

7A.

Strap

8.

Ether

tank

9. Screw

10.

Nut

lOA.

Nut

11. Screw

12.

Nut

13. Cap

and

chain

14. Adapter

15.

Hose

assembly

16.

Elbow

17.

Elbow

18.

Hose

assembly

19.

Elbow

20.

Elbow

21.

Hose

assembly

22. Elbow

23.

Elbow

24.

Hose

assembly

25.

Connector

26.

Elbow

27.

Screw

28.

Nut

29.

Fuel

selector

valve

30. Tube

assembly

31.

Elbow

32.

Elbow

33.

Elbow

34.

Screw

35.

Nut

36.

(Deletefi)

37.

Fuel

pump

38.

Fuel

pump

39. Fuel

cap

40. Fuel

cap

gasket

41.

Hook

42.

Strainer

43.

Filler

neck

44.

Clamp

45.

Fillerneck

hose

46.

Clamp

47.

48.

49.

50.

51,

52.

53.

54.

55.

56.

57.

58.

59.

60.

Hose

Hose

Screw

Nut

Washer

Hose

Tee

Hose

Tee

Hose

Hose

Tee

Hose

Screw

61.

Nut

62.

Washer

63.

Load

bank

support

bracket

64. Screw

65.

Nut

66.

Washer

67.

Bracket

68.

Screw

69.

Nut

70.

Washer

71.

Tail

pipe

bracket

72.

Rivet

73.

Fuel

selector

valve

instruction

plate

74.

Screw

75. Nut

76.

Cap

and

chain

77.

Cotter

pin

78. Nut

79.

Bolt

80.

Clevis

80A.

Nut

80B.

Washer

80C.

Screw

80D.

Nut

80E.

Washer,

flat

80F.

Washer,

bevel

80G.

Screw

81.

Lifting

frame

82.

Nut

83.

Nut

84.

Clamp

and

bracket

85.

Oil

separator

86.

Screw

Figure 3-28. Center Support and Related Parts

Change 7

3-79

Figure 3-29.

3-80 Change 9

3-167. General.

Section XXV.COOLING GROUP

CAUTION

The

cooling

system

consists

of

a

radiator,

shutter

and

shutter

controls,

and

the

necessary

lines,

fit-

tings,

and

linkage

to

connect

these

components.

The

shutter

is

controlled

by

the

shutter

control

thermostat,

which

can

also

be

operated

manually.

See

figure 3-29

to

remove

hoses

and

other

related

parts.

3-168. Grille.

~.

Replacemerit.

Replace

grille

(78, fig. 3-22)

as

follows:

(1)

Removal.

(~)

Remove

screws

(76, fig. 3-22)

and

cage

nuts

(77)

which

secure

grille

(78)

at

top

and

bottom.

(Q)

Remove

2

screws

(79)

which

secure

grille

at

each

side

and

remove

grille

(78).

(2)

Installation.

Install

grille

in

reverse

order

of

removal.

~.

Repair.

Repair

grille

(78)

by

straightening

cross

members

and

corners.

Remove

rust

or

other

corrosion

and

repaint

prepainted

surfaces

in

accord-

ance

with

services

requirements.

3-169. Fan Guard.

a.

Replacement.

—

(1)

Remove

the

2

screws

(15 and 17, fig. 3-29)

which

secure

the

two

clamps

(16

and

18)

on

the

hy-

draulic

cooler

lines

to

the

fan

guards

(25

and

26).

(2

Remove

7

screws

(24)

which

secure

fan

[

guards

25

and

26)

to

radiator

shroud

(36)

and

re-

move

both

fan

guards.

(3)

Re-install

in

reverse

order

of

removal.

b.

Repair.

Repair

fan

guard

(25

and

26)

by

strZig

htemng

cross

members.

Remove

rust

or

other

corrosion

and

repaint

preprinted

surfaces

in

accord-

ance

with

service

requirements.

3-170. Shutter Thermostat.

a.

Testing.

—

(1)

To

test

shutter

thermostat

(fig. 3-30)

opera

-

tion,

verify

that

the

shutters

on

the

shutter

assembly

change

from

a

closed

position

when

the

engine

is

cold,

and

to

an

open

position

when

the

engine

is

at

operating

temperature.

(2)

Remove

the

thermostat

(6, fig. 3-30).

(Refer

to

paragraph b below).

(3) Suspend

thermostat

(6)

in

a

container

of

clean water. Thermostat

must

be

completely

im-

mersed

but

not

touching

bottom

of

container.

(4)

Heat

water

gradually

and

stir

so

heat

is

evenly

distributed.

Check

temperature

of

water

with

a

re-

liable

thermometer.

DO

not

overheat.

(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.

(6)

Thermostat

(6)

is

not

adjustable.

If

it

does

not

operate

within

the

above

limits

it

must

be

replaced,

b.

Replacement.

Replace

the

thermostat

(6)

as

follmws:

(1)

Removal.

(a)

Drain

radiator

assembly

(35, fig. 3-29)

by

removfig

the

radiator

cap

and

opening

shutoff

cock

(21).

(b)

Loosen

hose

clamp

(4)

which

secures

lower

hosF

(6)

to

the

shutter

control

assembly.

(c)

Remove

nuts

1, fig. 3-30)

which

secure

\

shutter

assembly

to

contro

assembly

(10)

and

re-

move

the

rod

(2)

from

control

assembly

(10).

(~)

Remove

the

two

screws

(3, fig. 3-31)

and

washers

(4)

which

secure

shutter

control

assem-

bly

(5)

to

the

bottom

of

radiator

(17)

and

remove

shutter

control

assembly

(5)

with

attached

coupling

fitti~-,

elbow,

drain

valve,

and

drain

hose.

(e)

Remove

two

nuts

(3, fig. 3-30)

and

studs

(4)

w“hich

secure

the

control

assembly

to

the

coupling

fitting

and

remove

thermostat

(6).

(2)

Installation.

Install

the

thermostat

(6,

fig. 3-30)

in

reverse

order

of

removal

steps.

3-171. Shutter Assembly.

a.

Testing. Test

shutter

(2, fig. 3-31)

as

follows:

—

(1)

Verify

that

shutter

(2)

changes

from

a

closed

position,

when

the

engine

is

cold,

to

an

open

position

when

the

engine

is

at

operating

temp-

eratures.

(2)

Verify

shutter

(2)

opens

and

closes

freely

when

operated

manually.

b.

Adjustment.

With

the

engine

cold

and

the

ma~ual

shutter

control

in

the

closed

position

ad-

just

the

nuts

on

the

shutter

assembly

threaded

link

shaft

to

assure

that

the

shutters

are

fully

closed.

Check

that

with

manual

shutter

control

in

open

posi-

tion,

the

shutters

are

opened

fully.

c.

Replacement. Replace

the

shutter(2)

as

foll;ws:

(1)

Removal.

(~)

Remove

~rille

as

described

in

paragraph

3-168a.

—

Change 13-81

1.

Nut 4.

stud

7.

Packing

W

10.

Control

assy

2.

Rod

5.

Gasket

8.

Nut

3.

Nut 6.

Thermostat

9.

Piston

Figure 3-30. Shutter Thermostat Replacement

(~)

Remove

nuts

(1, fig. 3-30)

which

secure

shutter

assembly

threaded

rod

(2)

to

control

assem-

bly

(10).

(~)

Remove

the

8

screws

and

washers

(1, 1A, fig. 3-31)

w~ch

secure

shutter

(2)

to

the

radiator

(17),

and

remove

the

shutter

(2).

(2)

Installation.

Install

shutter

(2)

in

the

re-

verse

order

of

removal.

3-172. Radiator.

a.

Replacement.

To

replace

the

radiator

(17,

fig. 3-31)

proceed

as

follows:

(~)

Perform

steps

(s)

through

@)

of

para-

graph 3-170b

(1).

(c)

Loosen

hose

clamp

(1, fig. 3-29)

and

remove

up–per

hose

(3)

from

radiator.

(y)

Remove

shutter

as

described

in

paragraph

3-171.

(s)

Remove

six

screws

(84, fig. 3-22)

and

nuts

(85)

which

secure

the

battery

access

door

(86)

to

the

lower

front

housing

(93)

and

remove

battery

access

door

(86).

~)

Perform

steps

~

through

~

of

paragraph

3-87.

(1)

Removal.

(g)

Remove

10

screws

(55)

and

nuts

(56)

(~)

Position

suitable

container

to

collect

which

secure

the

housing

top

front

(57)

in

the

front

radiator

coolant.

and

rear.

Change 9

3-82

1. Screw

fA.

Washer

2.

Shutter

3. Screw

4. Washer

5.

Shutter

control

assy

9.

Screw

14.

LH

radiator

support

6. Gasket

10.

Washer

15.

Cap

7.

Screw

11.

(Delete) 16.

Drain

hose

7A.

Washer

12.

Shroud

17.

Radiator

8.

(Delete)

13.

RH

radiator

support

Figure 3-31. Cooling Group

(Q)

Remove

12

screws

(58)

and

cage

nuts

(j)

Remove

7

screws

(24)

which

secure

(59)

which

secure

the

housing

top

front

(57)

on

the

fan

guards

(25

and

26)

to

radiator

shroud

(36)

and

sides,

and

remove

the

cover. remove

both

fan

guards.

(i)

Remove

the

2

screws

(15 and 17, fig.

(k)

Disconnect

wiring

connections

(14,

3-29)

whi~h

secure

the

two

clamps

(16

and

18)

on

fig. 3-4)

Z

the

battery

slave

receptacles.

the

hydraulic

cooler

lines

to

the

fan

guards

(25

and

26).

Change 93-83

(!)

Remove

4

screws

(89 and 91, fig. 3-22)

and

cage

nuts

(90

and

92)

which

secure

the

lower

front

housing

(93)

to

the

left

and

right

hand

housing

corner

posts

(138

and

139).

(@

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).

(g)

Perform

steps

~

through

~

of

paragraph 3-86.

(g)

Remove

10

screws

(141

and

148)

which

secure

the

front

left

and

right

hand

housing

corner

posts

(138

and

139)

to

the

radi-

ator

support.

(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)

Remove

6

screws

(31, fig. 3-29), 12

bevel

washers

(32),

washer

(33)

and

nuts

(34)

which

secure

the

RH

and

LH

radiator

supports

(37

and

38)

at

the

top

of

the

skid

base

(39).

(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).

(~)

Remove

radiator

assembly

(35),

RH

and

LH

radiator

supports

(37

and

38)

and

radiator

shroud

(36)

from

skid

base

(39).

(~)

Remove

8

screws

and

washers

(7, 7A, fig. 3-31)

and

nuts

(8)

which

secure

radiator

(17)

and

shroud

(12)

to

RH

and

LH

radiator

supports

(13

and

14)

and

remove

supports.

(y)

Remove

screws

(9)

and

washers

(10)

which

secure

radiator

17)

to

shroud

(12)

and

remove

the

shroud

and

radiator.

(2)

Installation.

Install

radiator

assembly

component

using

the

removal

steps

as

applicable

in

reverse

order.

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

3-173. Hydraulic Cooler.

The

hydraulic

cooler

is

used

on

Class

1

sets

only.

a.

Service.

To

service

the

hydraulic

cooler

(19, fig. 3-29)

.—

proceed

as

follows:

(1)

Check

that

the

mounting

screws

(1.5

and

17)

are

secure.

(2)

Clean

dirt

off

fins.

~

Replacement.

To

replace

the

hydraulic

cooler

(19, fig. 3-29)

proceed

as

follows:

(1)

Removal.

(q)

Position

suitable

container

to

receive

hydraulic

oil

drained

from

hoses

and

tubing

when

disconnected.

@)

Disconnect

hose

(7)

from

elbow

(8)

(g)

Remove

elbow

(8)

from

connector

(9)

and

remove

connector

from

flare

nut

(10).

(~)

Disconnect

hose

(11)

from

connector

(12)

and

remove

connector

from

adapter

(13).

(s)

Disconnect

adapter

(13)

from

return

line

(14).

(~

Remove

screw

(15)

and

clamp

(16)

which

secure

return

line

to

RH

fan

guard

(26).

@

Remove

screw

(17)

and

clamp

(18)

which

secure

input

line

to

LH

fian

guard

(25),

and

remove

hydraulic

cooler

(19).

(2)

Installation.

Install

hydraulic

cooler

(19)

in

reverse

order

of

removal,

Replenish

hydraulic

sump

with

hydraulic

oil.

Section XXVI. HYDRAULIC ACTUATOR AND SUMP AND FILTER

(MEP105A ONLY)

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

reservoir

for

the

hydraulic

oil

pump,

used

to

supply

hydraulic

power

to

the

hydraulic

actuator.

c.

The

hydrmdic

oil

filter

is

mounted

on

the

sump

and

provides

pr%ection

against

contaminant

in

the

hydraulic

oil

pressure

system.

3-175. Hydraulic Actuator Service.

a.

Disconnect

hose

(6, fig. 3-32)

from

elbow

(7)

and

remove

el~ow

(7)

and

packing

(8).

Q,

Disconnect

reducer

expander

(9)

w-ith

packing

(10)

from

filter

plug

(11).

c.

Remove

filter

plug

(11)

and

packing

(12)

from

hydraulic

actuator.

~,

Clean

filter

plug

(11)

with

cleaning

solvent,

Federal

Specification

P-D-680,

and

dry

thoroughly.

e.

Inspect

filter

screen

for

tears,

holes,

irregularity

of

mesh,

or

—

other

damage,

$

Replace

cleaned

filter

plug

(1 1),

if

serviceable,

or

install

a

new

plug

and

reassemble

in

the

reverse

order

of

removal.

3-84Change 11

3-176. Removal, of Sump and Filter.

Figure 3-32. Hydraulic Actuator Servicing (MEP105A)

1. Throttle linkage

2. Nut self-locking

3. Lever arm

4. Return Adapter

5. Connector J25

6. Hose

7. Elbow assembly bulkhead

8. Packing

9. Reducer expander

10. Packing

11. Filter plug

12. Packing

13. Connector J24

14. Piston

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. a. Cleaning.

—

c. Remove hose assembly (3) from elbow assembly (7) and from (1) Flush sump tank (21) thoroughly with hot water or steam

elbow assembly (3A). under pressure.

Change 113-85

Figure 3-33.

3-86Change 11

(2)

Clean

sumv

tank

and

filter

thorou~hlv

with

[3)

Ins~ect

filter

for

damze.

cleani~

solvent,

Fe~eral

Specification

P-D--680.

b.

Inspection.

—

(1)

Inspect

threaded

areas

for

damage.

(2)

Inspect

sump

tank

(21)

for

cracks

or

distort

ion.

Section XXVII.

3-179. General.

The

engine

assembly

and

components

generate

the

mechanical

power

to

drive

the

generator.

3-180. Engine Assembly Testing.

a.

Testing.

To

test

the

engine

assembly

proceed

as

Follows:

(1)

With

engine

running,

test

for

overheating

by

observing

COOLANT

TEMPERATURE

indicator

(fig. 2-5).

(2)

With

engine

running

test

for

proper

oil

pressure

by

observing

OIL

PRESSURE

indicator

(fig. 2-5).

(3)

With

engine

running

test

by

listening

for

engine

knocks,

excessive

noise

and

visually

observe

for

vibrations.

(4)

With

engine

ruining

observe

exhaust

for

excessive

black,

gray,

or

blue

emissions.

.,.

<.

3-178. Installation.

a.

See

figure 3-33

and

install

sump

tank

(21)

and

filt=r

in

reverse

order

of

removal.

~.

Connect

hydraulic

lines.

c.

Fill

sump

with

hydraulic

oil,

MIL-H-5606.

—

ENGINE ASSEMBLY

(5)

With

engine

running

observe

BATTERY

CHG

AMMETER

(fig. 2-5)

for

proper

charging

indication.

3-181. Drain Hoses.

To

remove

and

install

the

oil

pan

drain

hose

assem-

bly

and

the

water

block

drain

hcse

assembly.

See

figure 3-34

and

proceed

as

follows:

a.

Remove

oil

drain

hose

(3)

by

removing

clamps

(1

;nd

2).

b.

Unscrew

and

remove

nipple

(4)

shutoff

cock

(5)

=nd

connector

(6).

c.

Disconnect

water

drain

hose

(7)

from

nipple

(8)

and–remove

water

drain

hose

(7).

d.

Unscrew

and

remove

nipple

(8

val;e

(9).

e.

Install

oil

drain

hose

and

wate:

rev<rse

sequence

of

removal.

Section XXVIII. ALTERNATOR AND RELATED PARTS

3-182. General.

CAUTION

The

alternator

is

a

24

volt,

continuous

output,

diode

rectified

unit,

designed

and

constructed

to

provide

extra

long

periods

of

reliable

service

with

minimum

maintenance.

The

rotor

is

mounted

on

bearings.

Both

front

and

rear

bearings

are

sealed

and

lubri

-

cated

for

life.

The

alternator

is

driven

by

the

crank-

shaft

pulley

with

a

single

belt.

The

idler,

the

water

pump

and

the

fan

mounted

on

the

water

pump

pulley

are

driven

simultaneously

by

the

crankshaft

pulley

with

an

identical

matched

pair

of

belts.

3-183. Drive Belts.

See

figure 3-35.

and

proceed

as

follows:

and

needle

drain

hose

in

When

adjusting

alternator

belt

tension,

apply

force

against

stator

laminations

between

alter-

nator

and

frames,

not

against

the

end

frames.

(3)

Retighten

the

alternator

adjusting

brace

capscrew

(5).

(4)

To

obtain

proper

fan

belt

(9)

ten-

sion

loosen

the

idler

pulley

adjusting

bracket

capscrew

(6)

and

move

idler

pulley

(4)

as

required.

(5)

Tighten

idler

pulley

adjusting

bracket

capscrew

(6).

~.

Adjustment.

b.

Replacement.

(1)

Adiust

belts

for

tension

which

conforms

with

–

table 3-1.

(1)

Replace

fan

follows:

(2)

To

obtain

proper

altermtor

belt

(7, fig.

3-35)

tension,

loosen

the

alternator

adjusting

brace

caPscrew

(5)

and

move

alternator

in

or

out

as

re-

quired.

belts

as

required.

Proceed

as

3-87

Figure 3-34.

3-88Change 1

Figure 3-35.

(~)

Remove

fan

guard

by

removing

the

seven

fan

guard

mounting

screws

(24, fig. 3-29),

which

sec-

ure

the

left

and

right

hand

fan

guards

(26,

25)

to

the

radiator

shroud

(36).

(~)

Remove

alternator

belt

(7, fig. 3-35)

as

follows:

~.

Loosen

the

alternator

mounting

bolt

(8).

2.

Loosen

the

alternator

adjusting

brace

capscrew

(5L

and

remove

the

alternator

belt

from

its

pulleys.

@

3.

Remove

the

alternator

belt

(7)

by

care-

fully

manipu~ating

it

over

the

fan

blades,

Manually

rotate

the

fan,

as

required,

to

facilitate

belt

removal.

CAUTION

—

Do

not

force

a

belt

over

sharp

metal

surfaces.

(~)

Remove

the

fan

belts

as

follows:

1.

Manually

position

the

fan

blades

to

gain

access~o

the

idler

pulley

adjusling

bracket

cap-

screw

(6).

2.

Loosen

idler

pulley

adjusting

bracket

capscrew

(6~and

remove

the

front

belt

from

its

pul-

leys.

3.

Remove

the

fan

belts,

one

at

a

time,

by

ca~efully

manipulating

them

over

the

fan

blades.

Manually

rotate

the

fan,

as

required,

to

faci-

litate

belt

removal.

CAUTION

Do

not

force

a

belt

over

sharp

metal

surfaces.

(2)

Installation.

Install

the

alternator

and

fan

belts

using

appropriate

removal

steps

in

reverse

order

and

adjust

the

belts

as

described

in

paragraph

3-183 a (1) and (2).

NOTE

Replace

fan

belts

in

sets.

3-184. Battery Charging Alternator.

a.

Testing.

Testing

of

the

battery

charging

alter-

nat;r

(14, fig. 3-36)

at

the

organizational

maintenance

level

is

accomplished

by

performing

an

operational

verification

as

instructed

in

step

c

below.

If

the

alter-

nator

output

cannot

be

varied

in

a~cordance

with

the

recommended

voltage

settings

in

step

~,

shut

down

generator

set

and

proceed

as

follows:

(1)

Measure

and

adjust

alternator

belt

tension,

(para 3-183 a (1) and (2).

(2)

Check

that

fuse

(21, fig. 3-36)

is

not

burned

out

,

(~)

Cut

lockwires

(1)

attached

to

connector

(2)

and

receptacle

mounting

screw

(3)

and

remove

con-

nector

and

lockwire.

(3)

Check

battery

connections

for

security.

(4)

If

alternator

(14)

output

is

not

correct

after

belt

tension

has

been

adjusted,

replace

the

alternator

(14).

b.

Replacement. Replace

the

alternator

(14),

ad-

jus~able

brace

(10),

or

mounting

bracket

(20)

as

fol-

lows:

(1)

Removal.

(a)

Remove

screw

(4)

and

washers

(5

and

6)

from

alte~nator

(1

4).

(b)

Remove

belt

tension

and

remove

belt

(7)

from

altei+nator

pulley.

(c)

Remove

screw

(8)

and

washer

(9)

secur-

ing

adjust~ble

brace

(10)

to

alternator

mounting

bracket

(20)

and

remove

adjustable

brace

(10).

(d)

Remove

screw

(11)

washer

(1

2),

spacer

(13)

and

afiernator

(14)

from

the

mounting

bracket

(20).

Change 33-89

1.

Lockwire

7.

Belt

2,

Connector

8.

Screw

3.

Receptacle

mounting

9.

Washer

screw

10.

Adjustable

brace

4.

Screw

11.

Screw

5.

Washer

12.

Washer

6.

Washer

13.

Spacer

14,

Alternator 21.

Fuse

15.

Screw

22.

Adjusting

Screw

16.

Washer

17.

Support

bracket

18.

Screw

19.

Washer

20.

Mounting

bracket

Figure 3-36. Alternator and Related Parts

(Q)

Remove

two

screws

(15)

and

washers

(16)

securing

support

bracket

(17)

to

the

mounting

bracket

(20),

and

remove

the

support

bracket.

(j)

Remove

screw

(18)

and

washer

(19)

sec-

uring

mounting

bracket

(20)

to

the

front

cover

and

re-

move

mounting

bracket.

2.

Installation.

Install

the

battery

charging

alternator

(14),

adjustable

brace

(10)

and

mounting

bracket

(20)

using

removal

steps

in

reverse

order

as

required.

Wind

lockwire

(1)

one

turn

around

threads

at

rcct-ptacle

mounting

screw

(3)

before

tightening

screw

and

attach:ng

iockwlre

to

Installed

comector

(2).

c. Adjustment.

With

the

engine

generator

set

run;ing,

adjust

the

alternator

as

follows:

(1)

Discomect

negative

terminal

from

battery.

(2)

Comect

a

voltmeter

across

terminals

of

either

slave

receptacle

ad

adjust

alternator

output

by

rotating

adjusting

screw

(22)

located

on

the

rear

housing.

(3)

To

increase

alternator

output,

rotate

output

adjusting

screw

(22)

clockwise.

To

decrease

alter-

nator

output,

rotate

adjusting

screw

(22)

countercIock

-

wise.

3-90 Change 12

Figure 3-37.

(4)

follows:

Recommended

Above

100°

F

. . . .

voltage

settings

are

as

.

.

26.2

Vdc

O°Fto

1000

F.....

28.

OVdc

Section XXIX.

3-185. General.

The

speed

switch

is

driven

by

the

camshaft

through

a

drive

assembly

and

an

angle

adapter.

The

speed

switch

provides

sequenced

control

of

circuits

during

engine

startup

and

protection

against

engine

over-

speed

during’

operation.

3-186. Testing and Replacement.

a.

Testing.

A

complete

test

of

the

speed

switch

can–only

be

performed

at

a

higher

maintenance

level.

Organizational

level

testing

is

accomplished

as

fol-

lows

(see fig. 3-37).

(1)

Remove

connector

(3)

from

the

speed

switch

(5)

and

perform

the

continuity

measurements

as

indi-

cated

in

steps

(2)

and

(3)

with

the

engine

off.

If

any

continuity

measurement

is

not

verified,

replace

the

speed

switch.

0°Fto-650F

. . . . . .

..30.

OVdc

(5)

At

completion

of

adjustment,

discon-

nect

voltmeter

and

reconnect

battery

negative

terminal.

SPEED SWITCH

(2)

Short

circuit

between

speed

switch

connec-

tor

pins

A

and

B;

G

and

H.

(3)

open

circuit

between

speed

switch

connec-

tor

pins

F

and

J,

A

and

C,

D

and

E.

(4)

Reconnect

connector

(3)

to

the

speed

switch

(5).

Q.

Replacement.

Replace

speed

switch

(5, fig.

3-37)

as

follows:

(1)

Removal.

(~)

Remove

cable

connector

(3).

(Q)

Loosen

nut

from

adapter

(2)

and

remove

speed

switch

(5)

from

adapter

(2).

(2)

Installation.

Install

speed

switch

(5)

using

removal

steps

in

reverse

order.

Change 3 3-91

Figure 3-38.

Section XXX. OIL LEVEL GAGE AND FILLER

3-187. General.

The

oil

level

gage

is

used

to

check

the

engine

oil

level.

The

filler

cap

provides

means

of

adding

oil

as

required.

3-188. Replacement.

See

figure 3-38

and

proceed

as

follows:

a.

Replace

oil

level

gage

(1, fig. 3-38)

by

re-

moving

and

installing

new

gage.

b.

Replace

oil

level

gage

adapter

(2)

by

unscrew-

ing-and

installing

new

adapter.

c.

Replace

oil

filler

cap

(3)

by

unscrewing

cap

han~le

and

removing

cap.

Install

new

cap

and

screw

handle

tight.

d.

Replace

oil

filler

elbow

(7)

by

removing

screw

(4),-lock

washer

(5)

and

flat

washer

(6),

and

gas

-

ket

(8).

Install

elbow

(7)

in

reverse

order

of

removal.

3-92

TM 5-6115-545-12

TO-35C2-3-444-1

NAVFAC P-8-626-12

TM-00038G-12

Section XXXI. ELECTRIC STARTER AND ADAPTER

3-189. General.

The

starting

motor

is

a

heavy

duty,

24

volt

overrunning

clutch

type

unit.

A

solenoid

switch,

which

is

an

integral

part

of

the

starting

motor

is

connected

by

linkage

and

a

shift

lever

to

a

clutch

in

the

starting

motor

nose

housing.

The

solenoid

shifts

the

starter

pinion

gear

into

mesh

with

the

engine

flywheel

ring

gear

and

holds

it

in

mesh

during

engine

cranking.

CAUTION

Do

not

operate

starting

motor

for

more

than

15

seconds

at

a

time.

Allow

at

least

3

minutes

before

op-

erating

again.

Failure

to

observe

this

rule

can

result

in

over

heating

and

failure

of

the

motor.

3-190. Starter Assembly.

~.

Testing. Testing

starter

is

an

operational

test.

Perform

test

as

follows:

(1)

Verify

that

the

battery

is

fully

charged

(2)

Verify

that

battery

connector/terminal

contact

surfaces

are

not

corroded.

(3)

Tighten

battery

connectors

securely.

(4)

Verify

that

all

leads

to

the

starter

and

the

starter

solenoid

are

tightened

securely.

(5)

Verify

that

the

three

starter

mounting

bolts

are

tightened

securely.

(6)

Refer

to

paragraph 2-12 b

and

perform

the

starting

procedure

while

a

qualified

observer

observes

starter

motor

operation.

(7)

If

the

starter

solenoid

emits

an

audible

noise

each

time

the

START-RUN-STOP

switch

is

cycled

into

the

START

position,

and

the

engine

does

not

turn

over,

the

starter

assembly

must

be

replaced.

b.

Starter

Replacement.

—

(1)

Removal.

(a)

Disconnect

the

negative

cable

from

the

battery.

(b)

Tag

and

disconnect

battery

cables

and

electrical

wires

from

starter

(3, fig. 3-38.1).

(c)

Remove

tool

box

to

gain

access

to

starter

screws

(l).

(d)

Remove

three

12-point

screws

(1)

and

three

washers

(2).

Remove

starter

(3)

and

starter

adapter

(4).

NOTE

Check

ring

gear

to

assure

that

teeth

are

not

damaged.

(2)

Installation.

Install

the

starter

(3, fig. 3-38.1)

on

the

flywheel

housing

in

reverse

order

of

removal.

3-191. Starter Solenoid.

To

test

the

starter

solenoid

proceed

as

follows:

If

the

starter

solenoid

does

not

operate

with

an

audible

click

each

time

the

START-RUN-STOP

switch

is

cycled

into

the

START

position,

check

for

24

Vdc

across

sole-

noid

and

ground.

If

voltage

is

present,

the

starter

assembly

must

be

replaced.

Section XXXII. LUBE OIL FILTERS AND SENSORS

3-192. General.

The

engine

lubricating

oil

filters

are

of

the

full-flow

type

and

contain

replaceable

elements.

A

drain

plug

in

each

filter

permits

draining

of

the

filters

before

replacing

the

filter

elements.

The

sensors

provide

a

means

of

monitoring

the

engine

lubricating

system.

3-193. Oil Pressure Transmitter.

See

figure 3-3

and

proceed

as

follows:

a.

Testing.

(1)

Remove

nut,

lockwasher,

flat

washer,

and

electrical

lead

from

transmitter

(18, fig. 3-3)

threaded

terminal.

(2)

Using

multimeter,

measure

resistance

between

transmitter

screw

terminal

and

ground.

If

measured

resistance

on

the

R

x

1

scale

is

greater

than

60

ohms,

replace

the

transmitter

(18).

If

re-

sistance

is

approximately

zero

ohms,

crank

engine

to

determine

that

resistance

increases.

If

resist-

ance

does

not

increase,

replace

transmitter

(18).

b.

Replacement.

(1)

Removal.

(~)

Remove

nut,

lockwasher,

flat

washer

and

lead

from

transmitter

(18, fig. 3-3)

threaded

terminal.

(~)

Unscrew

transmitter

(18)

from

nipple

(19).

(2)

Installation.

(a)

Screw

transmitter

(18, fig. 3-3)

into

threaded

fipple

(19).

Change 133-93

Figure 3-38.1

TM 5-6115-545-12

TO-35C2-3-444-1

NAVFAC P-8-626-12

TM-00038G-12

3-94Change 13

(~)

Reconnect

electrical

lead

using

nut,

lock-

waaher,

and

flat

washer.

3-194. Low Oil Pressure Shutdown Switch.

See

figure 3-3

and

proceed

as

follows:

a.

Inspection.

Inspect

the

switch

(16, fig. 3-3)

for

loo~e

mounting,

loose

connector,

dents,

and

other

damage.

Q.

Testing.

To

test

the

switch

(16, fig. 3-3),

discon-

nect

the

connector

and

connect

a

multimeter

between

pins

B

and

C

of

the

switch

and

verify

continuity.

Then

connect

multimeter

between

pins

A

and

D

and

verify

open

circuit.

If

switch

does

not

check

out

properly,

replace

switch.

c.

Replacement.

Replace

switch

(16, fig. 3-3)

as

folbws

:

(1)

Removal.

(Q)

Disconnect

connector

from

switch

(

16),

(Q)

Unscrew

switch

(

16)

from

nipple

(

17).

(2)

Installation.

Screw

switch

(16, fig. 3-3)

into

nipple

(17

)

and

tighten

to

20

foot-pounds.

Reconnect

connector

to

switch.

3-196. General.

TM 5-6115-545-12

TO-35C2-3-444-1

NAVFAC P-8-626-12

TM-00038G-12

3-195. Oil Filter Assembly.

~.

Replacement.

To

replace

the

oil

filter

assembly,

see

figure 3-3

and

remove

and

install

as

illustrated,

while

observing

the

following:

(1)

Drain

oil

system

as

described

in

paragraph

3-4c (3)

and

drain

filter

by

removing

plug

(1, fig. 3-3)

and

draining

into

a

suitable

container.

(2)

Remove

screw

(5)

and

washer

(6)

and

remove

both

filter

bodies

(7)

and

filter

elements

(8)

as

assem-

blies

from

header

(9).

(3)

Disconnect

and

tag

oil

line

and

electrical

connections

and

remove

screws

(2)

and

washers

(3)

which

secure

header

(9)

to

engine

block.

Remove

straight

connector

(22)

and

gasket

(4).

(4)

Install

using

a

new

gasket

(4)

and

mount

onto

engine

block

with

screws

(2)

and

washers

(3).

Tighten

center

screw

(

5

)

to

a

torque

of

45

to

50

foot-pounds.

Replace

straight

connector

and

reconnect

oil

line

and

electrical

connections

(22

).

Q.

Check

the

engine

lube

oil

filter

for

oil

leakage

and

be

certain

that

filter

body

(

7

)

and

gasket

(

10)

are

properly

installed.

Section XXXIII. SECONDARY FUEL FILTER

The

secondary

fuel

filter

is

the

final

filtration

device

in

the

fuel

system.

It

removes

contaminated

particles

of

five

micron

and

larger

from

the

fuel.

3-197. Replacement.

To

replace

the

secondary

fuel

filter,

see

figure 3-39

and

proceed

as

follows:

~

Open

drain

cock

(1).

~.

Drain

fuel

into

suitable

container.

(1)

Removal.

(~)

Remove

fuel

lines

to

filter

and

remove

elbows

(2

and

3)

from

filter

assembly

(6).

(Q)

Remove

four

screws

(4)

and

lockwashers

(5)

holding

filter

assembly

(6)

to

bracket

(9)

and

remove

filter

assembly

(6).

(g)

Remove

two

screws

(7)

lockwashers

(8)

and

washer

(8A)

and

remove

bracket

(9)

from

engine,

(2)

Installation.

(~)

Close

drain

cock

(1).

(Q)

Install

bracket

(9)

and

filter

assembly

(6)

in

the

reverse

order

of

removal.

Change 93-94.1/(3-94.2 blank)

Figure 3-39.

Change 93-95

Section XXXIV.

LUBE OIL COOLER

3-198. General.

The

engine

lube

(JI1

c{mh’r,

of

the

cncine. consists of

a

localeci

on

the

right

side

corrosion

resistant

,,

cooling c[)re

and

tank.

The

water

pump

circulates

coolant

t

hrtw~h

the

coolir~

core

tubes,

and

the

e~~-

ine

oil

pr-ussurp

pump

circulates oil

through

the

tank

and

around

(he

outside of

the

tubes

of

the

cool-

ing

core.

thereby controlling oil temperature.

3-199. Inspection and Replacement.

See

figure 3-40

,ind

proceed

as

follows:

~.

hw])f:clif)n.

lIISIJW1

(jIl

cw}lir

for

internal

l~~ll~s,

”;’;;

(;ii.

--li;,,se

Ill[JUlltlllg,

:ii)cf

other

damage.

b.

Fk!pl;l(’rment

Replace

the

engine

oil

cooler

——.

—

.

.

..

———

-

.“

as

fi)llows:

(1)

Renl(w:li.

(~)

[t(hfer

[

o

paragraph 3-41 md

cfrwn

cu(dir~ system.

Also

drain coolant frotn

lube

oil

cooler

by

rclll,)vll~

rfr:lll]

Illug

(1, fig. 3-40) or

]f

winter

izati~m

kit

is

mstallqci

by

opening shutoff

cock

(45, fig. 4-1) after removing

hose

(34) from

elbow

(46).

(~)

Drain secondary

fuel

fllt

er

in(o

a

two

~allon

container. Refer

to

paragraph 3-197

and

re-

move secnndarv

fuel

filter.

(g)

Remove

fuel

fr

It

er

head

with

filter

element intact.

(Q)

Refer

to

paragraph 3-203

and

remove

turbocharger oil drain

tube

assembly

between

turbocharger

ancl

cylinder block.

(~)

Renlovef]v

screws (2 and 5, fig. 3-40)

and

lockwashers

(3)

and

(6)

and

securing

lube

oil

cooler

(7)

to

cylinder block.

Fifth

screw

(2)

and

lockwasher

(3)

secures

manualc

ontrolb

racket

(4)

to

lube

oil

cooler

(7). Remove

Iube

oil

cooler

(7)

by

pulling

t[]WArdS

the

rear of

engine.

~~)

Remove preformed

packing

(8)

from

lube

oil

cooler

(7).

(g)

Remove

coo!er

tube

(9)

with

preformed

packing

(10)

from

the

lube

oil

cooler

(7)

volute.

(h)

Remove winterization

kit

nipple,

shutoff

cock,

and

elbow from

lube

oil

cooler

(7)

drain

plug

(1)

receptacle.

(2)

Installation.

NOT

E

If winterization

kit

1s

installed,

install

kit,

nipple,

shutoff cock,

and

elbow

in

lube

oil

cooler

(7,

fig. 3-40) drain

plug

(1)

receptacle.

(~)

Assemble

new

preformed packing (10,

fig. 3-40)

on

cooler

tube

(9)

and

install

one

end

of cooler

tube

(9)

into

lube

oil

cooler

(7)

volute.

Irustall

new

preformed

packing

(8)

in

the

back of

the

lube

oil

cooler

(7).

Hold

packing

in

place

with

a

light

coating of

grease.

(~)

Inslall

lube

oil

cooler

(7)

by positioning

header over

lhe

rear

end

of

cooler

tube

(9)

and

pushing

forward.

(~)

Install

five

screws

(2)

and

(5),

five

lockwashers

(3)

and

(6)

and

manual

control bracket

(4). Secure

lube

oil

cooler

(7)

to cvlinder block

tightening

screws

(2)

and

(5)

secur”ely.

(d)

Install

lube

oil

cooler

drain

plug

(1)

or

connect hose (34, fig. 4-1)

to

elbow

(46)

and

open

shutoff cock

(45).

(~)

Refer

to

paragraph 3-203

and

install

turbocharger oil drain

tube

assembly

between

turbo

charger

and

cylinder block.

(f)

Refer

to

paragraph 3-197

and

install

secondary–filter.

(g)

Refer to paragraph 3-41

and

fill cooling

system.

(~)

Operate

engine

and

check for

oil

and

water

leaks

at

oil

cooler

(7, fig. 3-40) connections.

Correct

any

leaks

found.

Stop

engine.

Refer to

paragraph 3-46

and

check

mcrankcase

moil

level

in

oil

pan

adding

oil as necessary to raise oil level

to

the

full

mark

on

the

oil level gage. Refer

to

para-

graph 3-41

and

check coolant level

in

the

radiator

adding

coolant

as

necessary.

Section XXXV.

NOZZLE HOLDER ASSEMBLIES AND LINES

3-200. General. 3-201. Inspection, Testing, and Replacement.

There

is

a

nozzle bolder assembly for each cylinder

See

figure 3-41

and

proceed

as

follows:

consisting of

a

fuel

injection nozzle holder. The

nozzle holder assemblies are used to position

the

a. Inspection.

injection nozzles

in

the

cylinder

head.

The

lines

provide

a

means

of delivering

the

fuel from

the (1)

Check

for

a

sufficient

fuel

level for

fuel

injection

pump

to

the

nozzle. operation.

3-96

Figure 3-40.Lube Oil Cooler

3-97

(2)

Examine

all

fuel

lines

(3, 8, and 23 through

28, fig. 3-41)

and

nozzle

holder

assemblies

(32)

for

signs

of

leakage.

b.

Testing.

.-

——

(1)

With

engine

running,

one

by

one

loosen

the

fuel

input

connection

to

each

injector

while

ob-

serving

the

engine

action

and

listening

to

the

sound.

Fuel

should

flow

out

when

the

connection

is

loosened.

When

the

input

to

a

faulty

injector

is

loosened,

there

should

be

little

or

no

change

in

engine

sound

or

ac-

tion.

The

engine

action

(or

symptom)

should

be-

come

worse

when

the

input

to

a

good

injector

is

loosened.

(2)

To

verify

a

low

compression

condition

as

opposed

to

an

injector

malfunction,

proceed

as

follows:

(a)

With

the

engine

stopped

and

the

DEAD

CRANK

swit~h

in

down

position,

remove

the

injector

assembly

from

number

one

cylinder

(or

the

cylinder

which

has

a

suspected

failure).

(b)

Insert

a

compression

gage

into

the

in-

j

ector

openini.

(~)

Turn

the

START-STOP-RUN

switch

the

START

position

for

a

period

of

5

to

15

seconds

to

obtain

a

compression

reading

while

the

engine

is

cranking.

Return

the

switch

to

the

STOP

position.

CAUTION

—..———

Do

not

crank

more

than

15

seconds

at

a

time.

A11ow

at

least

15

seconds

before

operating

again.

(d)

A

compression

gage

reading

of

400

psi

(at

sea

level)

is

normal

for

a

new

engine.

If

a

difference

in

compression

readings

in

excess

of

50

lbs

between

high

and

low

cylinders

exists

refer

to

next

higher

maintenance

level.

c.

Replacement.

To

replace

the

nozzle

holder

.-—

..—

—

assZmbIf6s

and

lines,

see

figure 3-41

and

proceed

as

follows

(1)

Removal.

(a)

Thoroughly

clean

nozzle

holders

(32

fig. 3-41),

Ii=es

(3),

(8),

and

(23)

through

(28),

con-

nections

and

surrounding

area.

Gain

access

to

noz-

zle

holder

assemblies

(32)

from

right

side

reaching

over

the

engine

valve

cover.

CAUTION

——.———

Cleanliness

is

extremely

impor-

tant

when

working

with

fuel

in-

j

ectors.

Injection

nozzle

service

troubles

are,

in

most

instances,

caused

by

dirt.

Use

clean

paper

on

the

work

bench

and

place

com-

ponents

in

a

container

of

clean

diesel

fuel

as

they

are

removed.

3-98 Change 9

to

(:)

‘e.qnve

fuel

return

line

(8)

by

dis-

connecting

connectors

(ti)

;.C

th~

fll~l

iniection

pump

(detail

A)

and

tee

(4).

(c)

Disconnect

fuel

injection

lines

(23)

through

(28),–nuts

(9)

at

the

nozzle

holder

assem-

blies

(32)

and

screws

(11

)

at

the

fuel

injection

pump

(detail

A).

NOTE

Gain

access

to

screws

(11)

and

washers

(12)

Which

secure

fuel

lines

(23

through

28)

to

fuel

injection

pump

by

removing

self-locking

nut

(see

fig. 3-32)

and

swing-

ing

lever

arm

of

hydraulic

actuator. Temporarily

stow

self-

locking

nut

back

in

place.

Remove

coupling

nuts

(1, fig. 3-41)

and

washers

(12)

from

fuel

in-

jection

pump,

remove

lines

from

pump,

and

temporarily

stow

screws

and

washers

on

pump.

LNOT

E

Clamps

(16,

21

and

29)

must

be

unclamped

(detail

B

and

C)

before

removing

lines

(23

through

28).

(d)

Remove

manifold

drip

line

(3)

by

disconnecting

coupling

nut

(1)

from

tee

(4)

and

nozzle-holder

assemblies

(32).

CAUTION

Do

not

bend

lines

when

disconnecting.

Cover

all

openings

immediately

to

prevent

entrance

of

dirt.

(e)

Remove

two

capscrews

(30)

and

two

Iockwashers

731)

securing

nozzle-holder

assemblies

(32)

to

cylinder

head.

(f)

Remove

~,ozzle-holder

assemblies

(32)

from

c

ylinde~

head

by

using

two

small

pry

bars,

or

by

using

a

slide

hammer

with

an

adapter.

Mark

each

inject

or

nozzle

with

the

number

of

the

cylinder

from

which

it

was

removed.

Insure

that

nozzle

gasket

(34)

is

removed.

CAUTION

Use

care

when

removing

an

injector

nozzle

to

tmevent

striking

nozzle

tip

again~

a

hard

object

&hich

could

result

in

damage

to

the

tip.

Figure 3-41.

3-99

(2)

Installation.

.——

—..

(a)

Thoroughly

clean

nozzle-holder

assem-

blies

(32, fig. 3-41)

bores

in

cylinder

head.

When

cleaning

bores,

ensure

old

nozzle

holder

gaskets

are

removed

because

new

gaskets

must

be

used

when

in-

stalling

the

nozzle

holders.

Ensure

no

small

parti-

cles

of

carbon

are

in

nozzle

holder

bores

that

could

prevent

nozzle

holder

gaskets

from

seating

properly,

thereby

permitting

“blow-by”

from

the

cylinders.

(b)

Install

new

nozzle

gasket

(34),

con-

cave

face

dew-n,

in

position

on

nozzle-holder

assem-

blies

(32).

Carefully

position

nozzle-holder

assem-

blies

in

nozzle

bore

of

cylinder

head.

(~)

Install

two

nozzle

holder

Iockwashers

(31)

and

two

capscrews

(30)

for

each

nozzle

holder

assembly

but

do

not

tighten

at

this

time.

Place

fuel

injection

lines

(

23

through

28)

in

position

in

nozzle

holders

(32)

and

fuel

injection

pump

(detail

A).

Start

injection

line

nuts

(9)

and

screws

(11

)

but

do

not

tighten

at

this

time.

Install

fuel

return

line

(8)

by

connecting

connectors

(6)

to

tee

(4)

and

fuel

injection

pump

(detail

A).

NOTE

Always

install

new

washers

(12)

when-connecting

injector

lines

to

injector

pump.

(d)

Install

manifold

drip

line

(3)

by

con-

necting

coupling

nut

(1)

to

tee

(4)

and

nozzle-holder

assembly

(32).

e.

Tighten

nozzle-holder

capscrews

(30)

alter-

natd

y.

Tighten

capscrew

on

one

side

to

3

to

6

foot-

pounds

torque.

Tighten

capscrew

on

opposite

side

to

full

torque

of

11

to

13

foot-pounds.

Then

tighten

first

capscrew

to

full

torque.

Tighten

injection

lines

fuel

return

line,

and

manifold

drip

line

nut

(9)

and

screws

(11),

connectors

(6),

and

coupling

nuts

(1).

NOTE

Secure

clamps

(16,

(21

)

and

(29)

after

lines

(23

through

28)

have

been

installed.

f.

Start

engine

and

observe

fuel

injection

line,

fuel

return

line,

and

manifold

drip

line

connections

for

fuel

leakage.

Correct

any

leaks

found.

Section XXXVI.DIFFUSER AND TURBOCHARGER

3-202. General.

This

section

contains

information

on

the

inspection

and

replacement

of

the

turbocharger

and

diffuser.

The

turbocharger

provides

greater

engine

power

out-

put.

It

is

driven

by

engine

exhaust

gases.

The

tur-

bocharger

draws

in

ambient

air

through

the

input

dif-

fuser,

compresses

the

air

and

directs

the

compressed

air

into

the

engine

intake

manifold.

3-203. Turbocharger.

See

figure 3-42

and

proceed

as

follows:

a.

Inspection.

Operate

engine

at

approximate

rat~d

o~listen

for

unusual

turbocharger

noise.

Do

not

mistake

whine

heard

during

rundown

for

one

that

indicates

impeller

shaft

bearing

failure

during

operation.

Other

unusual

noises

can

result

from

im-

proper

clearance

between

turbine

impeller

and

tur-

bine

housing. If

such

noises

are

heard,

the

turbo-

charger

must

be

removed,

disassembled,

and

in-

spected.

Inspect

for

an

accumulation

of

dirt

on

the

compressor

impeller

vanes

and

in

the

compressor

housing.

Proceed

as

follows:

(1)

Clean

the

turbocharger

(28, fig. 3-42)

and

surrounding

area

with

cleaning

solvent

Federal

Spec-

ification

P-D-680.

(2)

Loosen

setscrew

(17)

which

secures

the

exhaust

pipe

to

the

diffuser

(24).

(3)

Ref

to

paragraph 3-86

and

remove

nozzle,

muffler

and

exhaust

pipe.

(4)

Inspect

the

turbine

wheel

and

shaft

assembly

in

the

exhaust

end

of

turbocharger

(28)

for

signs

of

damage.

(5)

Loosen

the

clamps

(13)

which

secure

air

hose

(15)

to

the

turbocharger

(28)

and

remove

the

hose

from

the

turbocharger.

Remove

air

hose

from

air

cleaner

outlet

to

turbocharger

inlet.

(6)

Inspect

the

turbocharger

compressor

wheel

and

compressor

housing

for

dirt.

If

the

coating

of

dirt

is

light

and

even,

cleaning

the

compressor

wheel

is

not

necessary.

An

uneven

buildup

of

dirt

will

disturb

the

balance

of

the

rotating

parts

and

lead

to

failure

of

the

turbocharger

(28).

If

the

coating

of

dirt

is

uneven,

excessive,

or

approaching

the

appearance

of

a

layer

which

might

flake-off,

cleaning

is

neces-

sary.

If

this

cannot

be

cleaned

satisfactorily,

replace

turbocharger.

Should

an

excessive

build-up

of

dirt

occur

in

the

diffuser

(24)

a

loss

of

efficiency

in

the

turbocharger

will

result.

This

loss

of

turbocharger

efficiency

is

recognized

by

excessive

exhaust

smoke.

if

this

cannot

be

cleaned

satisfactorily,

replace

dif-

fuser.

If

replacement

is

not

required,

reconnect

the

exhaust

pipe

and

air

hoses

which

were

dis-

connected

above.

‘

b.

Replacement.

See

figure 3-42

and

proceed

as

Tollows:

(1)

Removal.

Remove

turbocharger

(28)

and

diffuser

(24)

as

follows:

3-100

Figure 3-42.

Change 9 3-101

(a)

Disconnect

and

remove

the

oil

inlet

line

(2).

-

(b)

Disconnect

and

remove

the

oil

return

line

(10).

-

(~)

Loosen

hose

(15)

clamp

(13).

(d)

Remove

the

four

nuts

(26)

which

attach

turbocharger-(28)

to

the

exhaust

manifold.

(e)

Remove

four

screws

(19)

and

washers

(20)

which

atiach

diffuser

ring

(21)

to

the

exhaust

manifold

and

remove

diffuser

(24)

turbocharger

(28).

Refer

to

paragraph 3-204

to

remove

diffuser

(24)

from

turbocharger

(28).

(2)

CAUTION

While

diffuser

(24)

turbocharger

(28)

is

off

the

engine,

keep

all

intake

and

exhaust

manifold

openings

cov-

ered.

This

will

prevent

foreign

ob-

jects

from

accidentally

getting

into

the

manifolds

and

damaging

the

turbocharger

or

engine

when

the

engine

is

again

put

into

operation.

Installation.

(a)

Before

installing

the

turbocharger:

(28, fig. 3-42):

1.

Refer

to

paragraph 3-32

and

ser-

vice

the

air

cleaiier.

2.

Refer

to

paragraph 3-195

and

re-

place

the

lubricating

oil

filter

elements.

3.

Refer

to

paragraph 3-46

and

change

engine

lube

oil.

–

4.

Ensure

that

the

oil

inlet

line

and

oil

return

line

a~e

clean

before

they

are

connected.

Remove

the

lines

and

inspect

for

cleanliness

and

re-

strictions.

5.

Check

exhaust

manifold

for

cracks,

foreign

matter,

iind

proper

mounting.

Check

condition

of

gaskets,

tightness

of

mounting

nuts,

and

flatness

of

the

turbocharger

mounting

surfaces.

6.

Check

intake

manifold

and

air

inlet

elbow

and

hoses

for

cracks,

foreign

matter,

and

gen-

eral

condition.

Check

condition

of

manifold

mounting

nuts

and

tightness

of

28-33

foot-pounds

torque.

7.

Replace

any

air

or

oil

line

hose

connections

(15 and 8, fig. 3-42)

found

to

be

deterior-

ated.

8.

Ensure

all

air

and

oil

line

hose

clamps

(13

and

7)

are

tight.

9.

Ensure

the

gaskets

29)

do

not

extend-into

the

port

openings

3-102 Change 1

(9,16,25,

and

of

the

exhaust

manifold,

turbocharger

mounting

adaptor,

and

mounting

pads.

10.

Just

prior

to

mounting

the

unit,

prime

the

lubr~ation

system.

Pour

clean

oil

into

the

oil

in-

let

of

the

center

housing.

Turn

the

rotating

assembly

by

hand

to

coat

the

bearings

and

thrust

collar

with

oil.

(b)

Refer

to

paragraph 3-204

to

install

diffuser

(24)

o~

turbocharger

(28).

(c)

Install

a

new

gasket

(29)

and

mount

the

turbocharger

(28)

and

diffuser

ring

(21

)

on

the

ex-

haust

manifold.

Lubricate

the

four

nuts

(26)

with

anti-

seize

compound

Military

Specification

MI

L-A-1

3881

R,

and

secure

the

turbocharger

(28)

to

the

exhaust

mani-

fold

tightening

nuts

(26)

to

18-21

foot-pounds

torque,

and

tightening

screws

(19).

(d)

Connect

the

oil

inlet

line

(2)

to

the

lubricating

oil–supply.

CAUTION

Do

not

connect

the

oil

inlet

or

return

lines

(2

and

10)

to

the

turbocharger

(28)

until

it

is

certain

that

there

is

a

free

flow

of

oil

to

the

turbocharger

and

through

it.

CAUTION

Do

not

crank

start

motor

more

than

15

seconds

at

a

time.

Al-

low

at

least

3

minutes

to

elap-

se

between

crankings.

(e)

Place

dead

crank

switch

in

open

position

(49, fig. 3-27).

Hold

ENGINE

START-RUN-

STOP

switch

to

START

position.

Continue

cranking

engine

until

there

is

a

free

flow

of

oil

from

the

upper

end

of

the

oil

inlet

line,

then

connect

the

line

to

the

oil

inlet

of

the

turbocharger

center

housing.

Crank

the

engine

until

oil

runs

from

the

oil

outlet

of

the

cen-

ter

housing.

Return

switch

to

STOP

position.

Place

dead

crank

switch

in

on

position.

(f)

Connect

the

oil

return

line

(1

O)

to

the

turbocharger

(28)

and

to

the

side

of

the

cylinder

block.

(g)

Connect

the

air

cleaner

hose

assem-

bly

using

inspection

instructions

(a

above)

in

reverse

—

order.

(~)

Install

the

exhaust

pipe,

muffler

and

nozzle.

(i)

Upon

completion

of

the

installation,

run

engine,

an–d

check

turbocharger

operation.

3-204. Exhaust Diffuser.

a.

Inspection.

Inspect

diffuser

(24)

for

cracks,

loos=

mounting,

and

other

damage.

b.

Replacement.

as

~ollows:

(1)

Removal.

follows:

See

figure 3-42

and

proceed

(b)

Remove

four

screws

(19)

which

secure

diffuser

r~~

(21)

to

the

exhaust

manifold.

Remove

the

diffuser

(24)

as

(~)

Remove

the

four

bolts

(22)

and

nuts

(23)

which

secure

diffuser

(24)

to

the

turbocharger

(28)

and

remove

diffuser

(24)

and

gasket

(25).

(a)

Remove

exhaust

components

from

diffuser

ring;

(2)

Installation.

Install

diffuser

(24)

using

the

removal

steps

in

reverse

order.

Section XXXVII. WATER PUMP AND FAN

3-205. General.

The

water

pump

is

a

centrifugal

type

pump

that

circulates

coolant

through

the

engine

and

radiator.

The

pump

is

mounted

on

the

front

of

the

cylinder

block

and

is

belt

driven

from

the

crankshaft

pulley.

3-206. Replacement.

See

figure 3-43

and

proceed

as

follows:

a.

Removal.

Drain

engine

coolant

(para 3-41).

——.

Remove

fan

guards

(25 and 26, fig. 3-39).

Re-

move

drive

belts

(para 3-183),

and

remove

fan

(3)

spacer

(4)

and

pulley

(5, fig. 3-43)

coolant

hoses,

and

water

pump

(18)

as

illustrated

in

figure 3-43.

(b.

Installation.

Install

water

pump

(18, fig.

3-43),

coolant

hoses,

and

fan

(3)

as

illustrated

in

figure 3-43.

Install

and

adjust

drive

belts

(para

3-183)

and

install

fan

guard

(25

and

26,

fig.

3-29).

Refill

engine

cooling

system

in

accordance

with

table 2-1.

NOTE

Apply

a

small

amount

of

grease

to

packing

groove

in

water

pump

volute

(25, fig. 3-43).

Install

new

packing

(24)

in

groove

and

install

new

gasket

(19).

Torque

screws

(20,

22,

12,

14,

and

16)

to

28-33

foot-pounds.

Torque

screws

(1)

to

30-35

foot-pounds.

Section XXXVIII. THERMOSTAT AND HOUSING

3-207. General.

a.

The

temperature

sensitive

components

nafiely

the

thermostat,

temperature

transmitter

and

temperature

switch

are

located

in

the

housing.

The

thermostat

is

positioned

in

the

system

so

that

when

closed,

coolant

flow

from

the

engine

to

the

radiator

is

shut-off.

When

coolant

temperature

reaches

180°

F

the

thermostat

starts

to

open

allow-

ing

coolant

to

pass

to

the

radiator.

b.

The

temperature

transmitter

senses

the

tem–perature

of

the

engine

coolant

to

operate

the

unit

temperature

indicator

on

the

control

cubicle

panel.

c. The

temperature

switch

which

also

senses

the~emperature

of

the

engine

coolant

and

has

two

sets

of

contacts,

one

normally

closed

and

the

other

normally

open.

When

the

engine

coolant

reaches

a

temperature

over

222°

F

*

3°

F

the

normally

closed

contacts

open

and

the

normally

open

con-

tacts

close.

This

action

results

in

automatic

shutdown

of

engine

operation

at

engine

coolant

temperatures

in

excess

of

222°

F

~

3°

F.

3-208. Inspection and Operational Check.

a.

Thermostat.

Replacement

of

the*thermo-

sta~

(8, fig. 3-44)

is

necessary

when

the

thermo-

stat

sticks

in

the

open

or

closed

position.

If

the

engine

overheats

or

does

not

reach

a

minimum

temperature

of

180°

F,

the

thermostat

should

be

removed

and

tested

as

a

possible

cause

of

trouble

(refer

to

para 3-209).

b.

Temperature

Transmitter.

The

transmitter

(10, fig. 3-44)

is

not

repairable

and

replacement

is

necessary

when

it

fails

to

operate.

If

the

opera-

tion

of

the

COOLANT

TEMPERATURE

indicator

in

the

control

cubicle

is

erratic

or

inoperative,

the

trans

-

mitter

(1

O)

should

be

removed

and

tested

as

a

pos

-

sible

cause

of

trouble.

c.

Temperature

Switch.

Inspect

switch

(12,

fig. 3-44)

for

corrosion

and

to

assure

that

the

electrical

connector

to

the

unit

is

secure.

The

switch

is

not

repairable

and

replacement

is

neces

-

sary

when

it

fails

to

operate.

If

the

engine

is

not

overheating

and

the

unit

shuts

down

as

though

it

were,

or

if

the

engine

continues

to

operate

when

obviously

running

hot,

switch

(12)

should

be

re-

moved

and

tested

as

a

possible

cause

of

trouble

(refer

to

para 3-209).

3-209. Removal, Testing and Installation.

a.

Removal.

Drain

the

cooling

system

(para

3-41)

and

remove

thermostat

(8, fig. 3-44),

trans

-

mitt

er

(1

O),

and

switch

(12)

as

illustrated

in

figure

3-44).

Change 13-103

Figure 3-43.

Change 9

3-104

Figure 3-44.

TM 5-6115-545-12

TO 35C2-3-444-1

NAVFAC P-8-626-12

TM00038G-12

3-105

TM 5-6115-545-12

TO 35C2-3-444-1

NAVFAC P-8-826-12

TM 00038G-12

~.

Thermostat

Testing.

To

test

thermostat

(8),

proceed

as

follows:

(1)

Suspend

thermostat

(8)

in

a

container

of

Clean

water.

Thermostat

must

be

completely

inlnler

-

sed

but

not

touching

bottom

of

contmner.

(2)

Heat

water

gradually

and

stir so

heat

is

evenly

distributed.

(3)

Check

temperature

of

water

with

reliable thermometer.

DO

not

overheat,

Observe

thermostat

(8)

as

temperature

increases.

If

the

thermostat

is

functioning

pro~erly

it

should

begin

to

open

between

175°F

to

182

F

and

be

fully

open

at

205°F.

(4)

The

thermostat

(8)

M

not

adjustable.

If

it

does

not

operate

within

the

above

lit-nits,

it

should

be

replaced.

$.

Temperature Transmitter

Testing.

To

test

the

transmitter

(10),

proceed

as

follows:

of clean

(la)ektspend

transmitter

(1

O)

in

a

container

.

Transmitter

should

be

inserted

so

that

sensing

element

is

completely’

imn)ersed

but

connector

end

M

out

of

water.

(2)

Connect

ohmmeter

between

single

con-

ductor

and

case.

Heat

water

gradually

and

stir so

heat

is

evenly

distributed,

(3)

Check

temperature

of

water

with

relia-

ble thermometer.

Do

not

overheat.

Observe

ohm-

meter as

temperature

increases.

If

the

transmitter

(10)

is

functioning

pro erly,

the

resistanc~

should

read

between

2100 and 2600

ohms

at

1200

F

and

be-

tween

680

and

745

ohms

at

2000

F.

Section XXXIX. CRANKSHAFT PULLEY

3-210. General.

a.

The

crankshaft

pulley

is

moumed

on

the

front

eflof

the

crankshaft

and

M

used

to

transfer drive

power

from

the

crankshaft

to

belt

dr]ven

accessor-

ies

such

as

the

water

pump,

fan

and

alternator.

p.

Vibration

dampenihg

is

accomplished

by

bond-

ing

a

neoprene

compound

between

the

crankshaft

pulley

and

the

crankshaft

hub.

(4)

The

transmitter

(10)

is

not

repamable.

If

it

does

not

indicate

a

resistance

within

the

above

range,

it

should

be

replaced.

~.

T~.

To

test

the

switch

(12).

proceed

as

follows:

(1)

Suspend

switch

(12)

in

a

container

of

anti

freeze

compound.

Switch

should

be

inserted

so

that

sensing

element

is completely immersed

but

con-

nector

end

is

out

of

compound.

(2)

Heat

compound

gradual]

y

and

stir

so

heat

is

evenly

distributed.

(3)

Check

temperature

of

compound

with

reliable thermometer.

Do

not

overheat.

(4)

Use

ohmmeter

and

check

continuity

between

pins

A

and

D

and

also

between

pins

B

and

C.

Under

217°F

S3°F.

contacts

A

and

D

should

indicate

a

closed circuit

and

contacts

B

and

C

an

open

circuit.

(5)

The

switch

(12)

is

not

repairable.

If

it

does

not

operate

within

the

above

limits

it

should

be

replaced.

g.

Installation. See

figure 3-44

and

install

thermostat

(8),

transmitter

(]0),

and

suitch

(12).

Fill

radiator

with

coolant

in

accordance

with

table 2-1.

AND VIBRATION DAMPENER

3-211. Inspection.

a.

Inspect

pulley

belt

grooves for

step

wear

aloiii

sides

and

bottom

of

groove.

indicating

ex.

cessive

wear,

b.

Inspect

pulley

belt

grooves

around

total

circumference of

pulley

for cracks or

distortion.

~.

Inspect

hub

area for cracks.

Section XL. IDLER PULLEY AND MOUNTING BRACKET

3-212. General. bracket,

the

bracket

itself

is

moveable

and

can

be

positioned

to increase or decrease

tension

of

the

a.

The

idler

pulley

provides

capability

to

adjust engine

drive belts.

ten%ion

of

the

engine

drive

belts

for

the

fan

and

the

water

pump.

3-213.

~.

The

idler

pulley

is

mounted

on

it

bracket,

with

an

adjustment

slot,

located

on

the

front

of

the

engine.

While

the

idler

pulley

is

mounted

m

place

on

the

See

3-106

Change 18

Inspection, Removal and Installation.

figure 3-45

and

proceed

as

follows:

Figure 3-45.

Change 33-107

a. Inspection. Inspect the idler pulley to assure

freedom of rotation and that there is no evidence of

cracking or signs of excessive wear.

b. Removal. To remove and disassemble the

idler pulley, proceed as follows:

(1) Refer to paragraph 3-183 and remove

engine drive belts from around idler pulley (1 O,

fig. 3-45).

(2) See figure 3-45 and remove bracket (15)

with pulley (1 O) still in place on the bracket (15).

(3) Remove pulley (10) and related hardware

from bracket (15).

c. Installation.

(1) Install pulley (10) and related hardware on

mounting bracket (15).

(2) Install bracket (15) onto engine.

(3) Torque nut (5) to 140 lb-ft (lubricated).

(4) Pack areas between bearing (9) and two seals

(4) and (7) 2/3 - full of BR grease.

NOTE

Do not repack bearing

(5) Refer to paragraph 3-183 and install engine

drive belts onto pulley (10). Position bracket (15)

for proper belt tension.

d. Repair. Repair of the idler pulley and mount-

ing-bracket is accomplished by replacement of defec -

tive components.

Section XLI. INTAKE MANIFOLD

3-214. General.

a. The air intake system consists of components

which convey filtered air to the engine cylinders.

The intake system includes the air cleaner, com-

pressor side of the turbocharger, and the intake

manifold.

b. The intake manifold is sealed to the cylinder

head with a one piece gasket and secured in place with

screws and washers.

3-215. Removal and Replacement.

See figure 3-46 and proceed as follows

a. Removal.

(1) Disconnect atomizer (1, fig. 3-46) and

tube (1A) from intake manifold (6).

(2) Remove screws (11, fig. 3-42) and washers

(12) securing turbocharger air outlet elbow (14) to

top of intake manifold (6, fig. 3-46). Loosen clamp

(13, fig. 3-42) and remove air outlet elbow (14) and

gasket (16).

(3) Remove screws (2, fig. 3-46) washers (3),

securing intake manifold (6) to cylinder head; remove

brackets (5), intake manifold (6), and gasket (7).

b. Inspection. Proceed as follows:

(1) Wash and clean intake manifold with

cleaning solvent, Federal Specification P-D-680.

(2) Check manifold for foreign deposits. Clear

and remove obstructions found within the manifold.

(3) If manifold is cracked, it must be replaced.

(4) If the mounting surface of the intake

manifold is warped enough so that it will not seal,

the manifold must be replaced.

(5) Inspect and clean the mounting surface on

the cylinder head to make certain it is free of gasket

particles or foreign matter.

c. Installation. Proceed as follows

(1) Install the intake manifold (6, fig. 3-46)

to the engine in reverse order of removal.

(2) Always use a new gasket (7) when in-

stalling the intake manifold (6).

(3) Torque the intake manifold securing screws

(2) to 28-33 foot -pounds.

(3A) Install atomizer and tighten atomizer so

that locating dots on hex are located as shown in view

A of figure 3-46.

(4) After the engine is run and the water

temperature reaches approximately 170°F, again

torque screws (2) to 28-33 foot-pounds.

3-108 Change 8

Figure 3-47.

Figure 3-46.

Change 93-109

Section XLII. EXHAUST

3-216. General.

The

exhaust

manifold

provides

for

the

routing

of

the

engine

exhaust

gases.

At

the

same

time

the

exhaust

gases

work

to

drive

the

turbocharger.

3-217. Inspection and Replacement.

a.

Inspection.

Inspect

the

exhaust

manifold

for

loo=e

mounting,

cracks,

breaks

and

other

damage.

b.

Replacement.

See

figure 3-47

and

proceed

as

Follows:

(1)

Removal.

(~)

Refer

to

paragraph 3-203

and

remove

turbocharger.

&)

Disconnect

and

plug

fuel

and

oil

lines

as

needed

to

facilitate

removal.

MANIFOLD

(g)

tank.

(d)

Use

suitable

container

and

drain

day

Use

suitable

container

and

drain

primary

fiiel

filter

and

strainer.

(e)

Remove

day

tank

and

fuel

filter

assembly.–

(f)

Remove

injection

lines.

—

(g)

See

figure 3-47

and

remove

exhaust

manifold

in

sequential

order.

(2)

Installation. Install

exhaust

manifold

(4, 9, and 13, fig. 3-47)

using

the

removal

steps

in

reverse

order.

Use

new

gaskets

(5)

(10),

and

14)

when

the

exhaust

manifold

is

re-

placed.

Torque

the

exhaust

manifold

screws

(2,

7

and

11),

25

foot-pounds

in

12

foot-pounds

incre-

ments.

Section XLIII. ROCKER ARM SHAFT ASSEMBLY

3-218. General.

This

section

contains

information

for

the

rocker

arm

assembly

inspection

and

the

valve

tappet

inspection

and

adjustment.

The

rocker

arm

assembly

is

mechanically

synchronized

through

drive

gear

lo-

cated

at

the

front

of

the

engine

to

the

crankshaft.

3-219. Rocker Arm Shaft Assembly Inspection.

&

Remove

cylinder

head

cover

and

gasket.

~.

See

figure 3-48

and

inspect

adjusting

screw

(1)

end

of

rocker

arm

(2)

and

shaft

(3)

for

evidence

of

physical

damage.

Refer

to

next

higher

maintenance

level

for

replacement

of

any

damaged

items.

NOTE

Adjusting

screw

must

be

replaced

when

less

than

36

in-lb

driving

torque

is

required

to

turn

screw.

3-220. Valve Tappet Clearance Adjustment.

Correct

clearance

(valve

lash)

between

end

of

intake

valve

stem,

exhaust

valve

stem,

and

related

rocker

arms,

is

very

important

in

diesel

engine

performance

because

of

high

compression

developed

within

the

cylinders.

Insufficient

valve

lash

will

cause

10SS

of

compression,

misfiring,

and

eventually

lead

to

burn-

ing

of

valves

and

valve

seats.

Excessive

valve

lash

will

result

in

faulty

engine

operation,

valve

lifter

noise,

and

cause

rapid

wear

on

the

valve

operating

mechanism.

With

engine

at

normal

operating

tem-

perature

or

160°F

minimum,

valve

lash

for

both

intake

and

exhaust

valves

is

O.

015”.

After

any

mechanical

work

has

been

done

that

may

have

disturbed

the

valve

lash

adjust

ment,

set

valves

“cold”

at

0.018”

clearance

so

engine

can

be

run

and

allowed

to

warm

to

normal

operating

temper-

ature.

After

engine

has

warmed

up

to

normal

operating

temperature,

check

valve

lash

again

for

proper

clearance.

CAUTION

After

any

mechanical

work

has

been

done

that

may

have

disturbed

the

valve

lash

adjustment,

ensure

the

rocker

arm

adjusting

screws

are

turned

upward

(counterclockwise)

high

enough

to

prevent

rocker

arms

and

push

rcxds

from

opening

too

far.

If

rocker

arms

and

push

rods

open

too

far,

the

pistons

will

strike

the

valves

when

the

engine

is

barred

over.

Valve

lash

must

be

adjusted

when

the

piston

is

near

top

dead

center

on

its

compression

stroke

and

intake

and

exhaust

valves

are

closed.

Number

1

and

Num-

ber

6

pistons

move

up

and

down

in

their

respective

cylinders

simultaneously.

When

one

piston

is

on

its

compression

stroke,

the

other

is

on

its

exhaust

stroke,

and

vice

versa.

Observe

valves

for

Num-

ber

6

cylinder;

when

the

exhaust

valve

is

almost

closed

and

the

intake

valve

starts

to

open,

Number

6

piston

is

near

top

dead

center

on

its

exhaust

stroke

and

Number

1

piston

is

in

the

same

position

on

its

compression

stroke.

At

this

point,

both

valves

for

Number

1

cylinder

are

closed

and

valve

lash

can

be

adjusted.

Engine

firing

order

is

1-5-3-6-2-4,

3-110 Change 1

Figure 3-48.

Figure 3-49.

3-111

and

if

this

sequence

is

followed,

the

lash

for

all

valves

can

be

checked

and

adjusted

in

2

complete

revolutions

of

the

crankshaft.

Check

valve

clear-

ance

periodically.

See

figures 3-48 and 3-49

and

proceed

as

follows

to

obtain

specified

clearance

#

Run.

engine

until

operating

temperature

of

160

F

mmlmum

is

reached.

Stop

the

engine.

-Q.

Thoroughly

clean

cylinder

head

cover

and

surrounding

area.

c

Remove

breather

tube,

capscrews,

washers,

and–;ylinder

head

cover.

Q.

Using

1-1/2

inch

socket

wrench

on

crank-

shaft

pulley

nut,

bar

over

engine

until

exhaust

valve

for

number

6

cylinder

(fig. 3-49)

is

almost

closed

and

intake

valve

starts

to

open,

then

check

and

adjust

intake

and

exhaust

valve

lash

for

number

1

cylinder.

e.

Using

a

O.

015

inch

feeler

gauge

(4, fig. 3-48)

ch;ck

clearance

between

valve

stems

and

rocker

arms

(2).

Gauge

should

pass

between

rocker

arm

and

corresponding

valve

stem

with

a

slight

drag

when

valve

lash

is

properly

adjusted.

NOT

E

Cold

clearance

between

valve

stems

and

rocker

arms

(2)

is

O.

018

inch

and

hot

clearance

is

O.

015

inch

as

described

in

paragraph 3-220

above.

J.

Adjust

each

valve

by

turning

adjusting

screw

(1)

clockwise

to

decrease

clearance

or

counterclockwise

to

increase

clearance

as

necessary.

E.

Using

1-1/2

inch

socket

wrench

on

crankshaft

pulley

nut,

bar

over

engine

until

number

2

cylinder

exhaust

valve

(fig. 3-49)

is

almost

closed

and

intake

valve

starts

to

open,

then

adjust

lash

for

intake

and

exhaust

valves

for

number

5

cylinder,

following

procedure

in

paragraphs

e

and

~

above.

—

~.

Using

1

-1,/2

inch

socket

wrench

on

crankshaft

pulley

nut,

bar

over

engine

until

number

4

cylinder

exhaust

valve

is

almost

closed

and

intake

valve

starts

to

open,

then

adjust

lash

for

intake

and

exhaust

valves

for

number

3

cylinder,

following

procedure

in

e

and

f

above.

.

~.

Using

1-1/2

inch

socket

wrench

on

crankshaft

pulley

nut,

bar

over

engine

until

number

1

cylinder

exhaust

valve

is

almost

closed

and

intake

valve

starts

to

open,

then

adjust

lash

for

intake

and

exhaust

valves

for

number

6

cylinder,

following

procedure

in

e

and

f

above.

—

&

Using

1-1/2

inch

socket

wrench

on

crankshaft

pulley

nut,

bar

over

engine

until

number

5

cylinder

exhaust

valve

is

almost

closed

and

intake

valve

starts

to

open,

then

adjust

lash

for

intake

and

exhaust

valves

for

number

2

cylinder,

following

procedure

in

e

and

a

above.

— —

~.

Using

1-1/2

inch

socket

wrench

on

crankshaft

pulley

nut,

bar

over

engine

until

number

3

cylinder

exhaust

valve

is

almost

closed

and

intake

valve

starts

to

open,

then

adjust

lash

for

intake

and

exhaust

valves

for

number

4

cylinder,

following

procedure

in

e

and

f

above.

——

l_.

Replace

cylinder

head

cover

using

associated

capscrews

and

washers.

N.

Replace

breather

tube.

Section XLIV. BASE GROUP AND RELATED COMPONENTS

3-221. General.

The

base

group

consists

of

a

rigid

frame

skid

base,

fuel

tank,

and

related

components.

The

fuel

tank

is

recess

mounted

in

the

skid

base.

The

engine

and

generator

are

mounted

upon

the

skid

base

assembly.

Procedures

in

this

section

include

inspection

of

the

skid-base,

testing

and

replacement

of

the

fuel

quantity

transmitter,

and

replacement

of

the

fuel

tank

and

replacement

of

related

compon

-

ents

illustrated

in

figures 3-50 and 3-51.

3-222. Skid Base Inspection.

See

figure 3-50

and

proceed

as

follows:

a.

Inspec

&

the

skid

base

assembly

for

rust,

cor~osion,

breaks,

loose

hardware,

and

other

damage.

~.

Verify

that

the

oil

drain

plug

(10)

and

hose

between

skid

base

and

engine

is

not

leaking.

3-223. Fuel Quantity Transmitter Removal, Test-

ing and Replacement.

a.

Removal.

Disconnect

electrical

connector

and–see

figure 3-50

to

remove

the

transmitter

(3).

~.

Testing. Proceed

as

follows:

(1)

Connect

multimeter

between

case

of

trans

-

mitter

(3)

and

the

transmitter

connector

pin

as

shown

in

3-52.

With

sensing

arm

of

transmitter

in

lowered

position

(A),

multimeter

shall

read

between

O.

00

and

O.

90

ohms

and

with

sensing

arm

of

trans

-

mitt

er

in

raised

position

(B),

multimet

er

shall

read

between

29.8

and

31.3

ohms.

Disconnect

multimeter.

(2)

Submerge

transmitter

(3, figure 3-50)

in

about

12

inches

of

water

heated

to

not

less

than

200°F.

Float

tank

of

transmitter

must

withstand

air

pressure

of

6

PSI

without

leaking.

Bubbles

of

air

will

be

observed

if

float

tank

leaks.

Replace

fuel

quantity

transmitter

if

it

fails

test

(see

fig. 3-52).

3-112

Figure 3-50.

Change 93-113

Figure 3-51.

3-114 Change 9

ReDla

mm.

See

figure 3-50

and

replace

transmitter

(3)Qk

reverse’&ptence

of

removal.

3-224. Related Components Replacement.

~.

See

figure 3-50

to

remove

and

replace

related

components

as

required.

~.

Replace

lost

or

broken

terminal

clip

(Retainer,

Safety

Clip).

For

fabrication

procedure,

see

Chapter 3, Section XVIII,

Organizational Maintenance of the Generator Electrical System,

paragraph 3-142.

1

Load

Terminaf

Board

Assembly.

3-225. Metal Fuel Tank Removal, Cleaning and Inspection,

and Installation.

~.

~emoval.

See

figures 3-7, 3-50, and 3-51

and

pro–

teed

as

follows:

(1)

Remove

cap

(21, fig. 3-50)

and

connect

auxiliary

fuel

hose

to

cormector

(24)

at

end

of

valve

(25).

(2)

Operr

valve

(25)

and

allow

water

and

sediment

to

completely

drain

off

into

a

suitable

container.

Close

valve

(25)

when

clean

diesel

fuel

runs

out.

Drain

clean

fuel

into

suitable

container.

Discorutect

auxiliary

fuel

hose.

(3)

Refer

to

paragraph 3-223

and

remove

fuel

quantity

transmitter

(3, fig. 3-50).

(4)

Disconnect

four

vent

hoses

and

two

fuel

lines

from

tank

(14, fig. 3-51),

tagging

each

hose

and

line.

(5)

Disconnect

main

metal

fuel

tank

filler

hose

from

tank

(14).

(6)

See

figure 3-51,

and

remove

metal

tank

(14)

from

base

(15)

using

sequential

order

of

indexes.

b.

~lefin~

~d

~soect

iou.

(1)

Flush

inside

of

metal

fuel

tank

with

steam

under

pressure.

Rinse

with

hot

water

and

detergent

to

insure

that

rust

flakes

and

other

foreign

material

are

removed.

(2)

Insptxt

metal

fuel

tank

for

cracks

and

distortion.

(3)

Inspect

tapped

holes

for

darnaged

threads.

s.

bsd

latio~.

(1)

See

figure 3-51,

and

install

metal

tank

(14)

into

base

(15)

in

reverse

order

of

removal

procedure.

(2)

Connect

main

fuel

tank

filler

hose

to

plastic

tank

(14).

(3)

Connect

four

vent

hoses

and

two

fuel

lines

to

tank

(14)

as

tagged.

TM 5-6115-545-12

TO 35C2-3-444-1

NAVFAC P-8-626-12

TM 00038G-12

(4)

Refer

to

paragraph 3-223

and

instafl

transmitter

(3, fig. 3-50).

(5)

Close

valve

(25),

replace

cap

(21

)

on

connector

(24),

and

add

diesel

fuel

as

required.

3-225A. Plastic Fuel Tank Removal, Cleaning and Inspection,

and Installation.

a.

&tDQ@

See

figures 3-7 and 3-51A

~d

proceed

~

follows:

(1)

Remove

cap

(17, fig. 3-51A)

from

connector

(18)

and

comect

auxiliary

fuel

hose

to

valve

(19).

(2)

Open

vafve

(19)

and

allow

water

and

sediment

to

completely

drain

off

into

a

suitable

container.

Close

valve

(19)

when

clean

diesel

fuel

runs

out.

Drain

clean

fuel

into

suitable

container.

Disconnect

auxiliary

fuel

hose.

(3)

Refer

to

paragraph 3-323

and

remove

fuel

quantity

transmitter

(3, fig. 3-50).

(4)

Disconnect

vent

hoses

(13A, fig. 3-51A),

fuel

lines

and

ground

terminal

from

tank

(14),

tagging

each

hose

and

line.

(5)

fuel

tank

(

(6)

from

base

Discomect

main

fuel

tank

filler

hose

from

plastic

4).

See

figure 3-51A

and

remove

p]aslic

tank

(14)

15)

using

sequential

order

of

indexes.

~.

Cleaning

and

Inspection.

(1)

Rinse

inside

of

plastic

fuel

tank

(14)

with

hot

water

and

detergent

to

insure

foreign

material

is

removed.

(2)

Inspect

plastic

fuel

tank

(14)

for

cracks

and

distortion.

(3)

Inspect

tapped

holes

for

damaged

threads.

G.

Ins

tall

at

ion.

(1)

See

figure 3-51A

and

install

plastic

tank

(14)

into

base

(15)

in

reverse

order

of

removal

procedure.

(2)

Connect

main

fuel

tank

filler

hose

to

plastic

tank

(14).

(3)

Connect

vent

hoses

(13A),

fuel

Iincs

and

ground

terminal

to

tank

(14)

as

tagged.

(4)

Refer

to

paragraph 3-223

and

install

transmiucr

(3, fig. 3-50).

(5)

Close

valve

(19, fig. 3-51A),

rcplacc

cap

(17)

on

connector

(18),

and

add

diesel

fuel

as

required.

Change 18 3-115

Figure 3-51A.

TM 5-6115-545-12

TO 35C2-3-444-1

NAVFAC P-8-626-12

TM 00038G-12

Change 18

3-116

Figure 3-52.

TO 35C2-3-444-1

TM 5-6115-545-12

NAVFAC P-8-626-12

TM 00038G-12

Change 18 3-117

Figure 3-53.

TM 5-6115-545-12

TO 35C2-3-444-1

NAVFAC P-8-626-12

TM 00038G-12

Section XLV. ACCESSORY ITEMS

3-226. General.

~.

The

engine

generator

set

is

provided

with

a

paralleling

cable

assembly

(class

1

only)

and

an

auxiliary

fuel

line.

(Refer

to

fig. 3-53.)

~.

The

paralleling

cable

assembly

is

a

25

foot,

four

conductor,

flexible,

heat

and

oil

resistant

cable,

which

is

utilized

with

the

paralleling

receptacle

to

interconnect

two

precise

generator

sets.

Q.

The

auxiliary

fuel

line

hose

assembly

is

a

25

foo~

flexible,

heat

and

oil

resistant

hose

which

is

utilized

to

intercmmect

the

engine

generator

set

to

supply

or

receive

fuel.

3-227. Paralleling Cable Assembly

Q.

-.

Test

each

parallel

wire

for

continuity,

ensuring

wire

is

not

shorted

to

connectors

or

adjacent

wires.

Wire

routing

is

common

between

like

pins

of

connectors:

A

to

A,

B

to

B,

etc.

b.

~.

No

special

instructions

are

required

to

install

or

replace

a

paralleling

cable

(1, fig. 3-53).

When

not

installed,

coil

paralleling

cable

into

a

loop

and

install

with

chain

provided

in

housing

on

right

side

of

relay

table.

(See

fig. 1-1.).

3-228. Auxiliary Fuel Line Hose Assembly.

a.

Installation and Replacement. No

special

instructions

we

required

to

install

or

replace

the

auxiliary

fuel

line

hose

(2,

fig. 3-53).

When

not

installed

coil

auxiliary

fuel

line

hcse

into

a

loop,

with

ends

connected

and

install

on

chain

provided

in

housing

beneath

the

governor

control

unit.

(See

figure l-l.)

b.

&p&.

Replace

defective

hose

(6, fig. 3-53)

fittings.

3-229. Storage Space.

Storage

space

for

ground

rods

is

provided

on

left

side

of

skid

base

charmel

facing

battery

tray.

Connectors

and

ground

wire

should

be

stowed

in

tool

box

(fig. 1-1)

under

governor

actuator

assembly.

3-118

Change 18

CHAPTER 4

AUXILIARY MATERIAL USED IN CONJUNCTION WITH THE EQUIPMENT

4-1. Scope.

Section I. GENERAL

This

chapter

contains

maintenance

instructions

within

the

scope

of

the

operator

and

organizational

mainte-

nance

level

for

material

used

in

conjunction

with

the

generator

set,

as

allocated

by

the

maintenance

alloca-

tion

chart

provided

in

Appendix C.

4-2. Service upon Receipt of Material.

Upon

receipt

of

material,

components

shall

be

re-

moved

from

shipping

containers,

placed

in

a

clean

work

area,

and

the

following

performed:

a.

Check

to

see

that

all

components

are

present.

—

b.

Remove

corrosion

preventive

compounds

usi;g

cleaning

solvent,

Federal

Specification

P-D-680,

as

applicable.

c.

Perform

a

visual

inspection

of

components

for

obvious

deficiencies,

such

as

loose

or

missing

bolts,

nuts,

and

pins

and

for

bent,

cracked,

or

broken

parts.

d.

Inspect

wires

and

terminals

for

damage

and

loo;e

connections.

Section II.FUEL BURNING WINTERIZATION KIT

4-3. General.

Winterization

equipment

for

starting

the

engine

when

temperatures

are

between

-25°F.

and

-65°F.

consists

of

a

heater,

coolant

hoses,

fuel

lines,

electrical

con-

trols,

wiring

harness,

and

mounting

hardware

to

be

installed

in

the

generator

set

for

preheating

the

engine

oil

pan

and

cooling

system.

The

heater

can

be

operated

on

the

fuel

available

from

the

engine

fuel

system.

For

fuel

burning

winterization

kit

operating

instructions,

refer

to

paragraph 2-24.

4-4. Installation.

For

wiring

information,

see

figures 1-15 or 1-16.

To

perform

initial

installation

of

fuel

burning

win-

terization

kit,

see

figure 1-22, 1-26 or 1-27 and

4-1

and

proceed

as

follows:

NOTE

F~r

installation

with

electrical

winteriza-

tion

kit,

refer

to

paragraph 4-18.

a.

Disconnect

plate

to

the

right

of

control

cubicle

(fig. 1-2)

below

Fault

indicator

panel

by

removing

two

screws

and

washers.

Retain

screws

and

washers

for

installing

kit

control

box

(14, fig. 4-l).

b.

Remove

protective

cover

from

receptacle

J7

on

spe~ial

relay

box

(fig. 1-2).

~.

Refer

to

paragraph 3-41

and

drain

radiator.

~.

Remove

plugs

from

engine

thermostat

housing

and

oil

cooler

bonnet.

Retain

plugs.

e.

Remove

plugs

from

engine

oil

pan

heat

ex-

cha~ger. Retain

plugs.

f.

Disconnect

exhaust

plate

by

removing

two

scr=ws.

g.

Install

kit

as

described

and

illustrated

in

figure 1-22

using

installation

sequence 74 through

1

of

figure 4-1.

h.

Insure

that

valves

(41,

45)

are

open,

fill

radi-

ato~

with

proper

coolant

in

accordance

with

table 2-1

and

check

for

leaks.

4-5. Removal.

To

remove

the

fuel

burning

winterization

kit,

see

figures 1-22 and 4-1

and

proceed

as

follows:

NOTE

For

removal

with

electrical

winteri

-

zation

kit,

refer

to

paragraph 4-19.

a.

Refer

to

paragraph 3-41

and

drain

radiator.

—

b.

Remove

kit

by

proceeding

in

reverse

order

of

ins~allation

pkocedure

using

figure 1-22

and

removal

sequence 1 through 74

of

figure 4-1.

c.

Refer

to

paragraph 4-4

and

replace

plugs,

pla~es,

and

covers

removed

during

installation.

d.

Fill

radiator

with

proper

coolant

in

accordance

witfi

table 2-1

and

check

for

leaks.

4-6. Preventive Maintenance.

To

insure

that

the

fuel

burning

winterization

kit

is

ready

for

operation

at

all

times,

when

installed

on

4-1

the

generator

set,

it

must

be

inspected

systematically

4-8. Control Box Inspection, Testing, and Replacement.

so

that

defects

may

be

discovered

and

corrected

be-

fore

they

result

in

serious

damage

or

failure.

Defects

a.

Inspect.

Inspect

indicator

light,

circuit

breaker,

discovered

during

operation

of

the

kit

shall

be

noted

swi~ch

and

control

box

for

cracks,

loose

connections,

for

future

correction,

to

be

made

as

soon

as

operation

breaks

and

other

damage.

has

ceased.

Stop

operation

immediately

if

a

deficiency

is

noted

during

operation

which

would

damage

the

kit

or

the

end

item

generator

to

which

it

is

attached.

All

deficiencies

and

shortcomings

SHALL

be

recorded

together

with

the

corrective

action

on

the

applicable

form

at

the

earliest

possible

opportunity.

Air

Force

users

shall

refer

to

the

applicable

inspection

manuals

and

work

card

sets

in

the

T. O. 35C2-3-

Series

for

periodic

preventive

maintenance

requirements

and

table 4-1

for

detailed

procedures.

4-7. Troubleshooting.

Table 4-2

provides

information

useful

in

diagnosing

and

correcting

unsatisfactory

operation

or

failure

of

the

fuel

burning

winterization

kit.

(See

figure 1-22, 1-15 or 1-16.)

ITEM

NO.

1

2

3

4

5

6

7

8

9

10

11

12

INTERVA

3PERATOR

DAILY

—

B

—

x

x

x

x

x

—

D

—

x

—

A

—

x

x

(

i

b.

Test.

—

(1)

Test

the

lamp

and

light

assembly

for

continuity.

(2)

Energize

circuit

breaker

and

press

press

to

test

indicator.

Indicator

should

illuminate

when

pressed.

c.

Removal.

—

(1)

R-eplace

control

box

(14, fig. 4-1)

lamp

as

il-

lustrated

in

figure 4-2.

(2)

Remove

electrical

connectors

and

attaching

hardware

from

control

box

and

remove

control

box.

d.

Installation. Install

control

box

and

connectors

in

~eve=d=of

removal.

Table 4-1.Preventive Maintenance Checks and Services

:(

i

B

-

Before

Operation

A

-

After

Operation

M

-

Monthly

(100

hrs)

D

-

During

Operat

ITEM

TO

BE

INSPECTED

Heater

fuel

shut-

off

and

coolant

valves.

Heater

exhaust.

Generator

set

radiator.

Generator

set

doors.

Generator

set

fuel

tank.

Fuel

lines

and

coolant

hoses.

Heater

exhaust.

Heater

fuel

shut-

off

valve.

Coolant

hoses

and

fuel

lines.

Attaching

hardwart

Wiring

harness.

Thermostat

switch.

n

W

-

Weekly

(40

hrs)

S.-s

PROCEDURE

Open

valves.

Move

exhaust

cover

plate

away

from

exhaust

opening

Check

for

proper

coolant

level,

Close

all

doors.

Check

that

fuel

level

is

adequate

for

operating

time

required.

Check

for

leakage.

Cover

exhaust

opening

with

exhaust

plate.

C:ose

valve.

Tighten

hoses

and

lines

and

check

condition.

Tighten

hardware.

Inspect

for

frayed

or

defective

insulation. Inspect

connectors

for

damaged

threads,

bent,

loose

or

missing

pins.

Test

switch

for

proper

operation.

mi

Annual

(500

hrs)

REFERENCE

(fig. 2-11)

(para 4-9)

(para 2-3 and 3-41

(fig. 1-1 and 1-2)

(para 2-3)

(para 4-16)

(para 4-9)

(fig. 2-11)

(para 4-16)

(para 4-16)

(para 3-139)

(para 4-15)

4-2Change 1

Figure 4-1. Fuel Burning Winterization Kit

(Sheet 1 of 2)

Change 14-3(4-4 blank)

Figure 4-1. Fuel Burning Winterization Kit

(Sheet 2 of 2)

4-5/(4 -6 blank)

Change 1

Table 4-2.Fuel Burning Winterization Kit Troubleshooting

MALFUNCTION

I

PR013AI+I,

E

CAUSE

1.

Press

to

test

light

a.

does

not

illuminate

‘-

when

pressed.

b.

—

t

c.

,..-

2.

Switch

positioned

to

a.

ON

and

nothing

happens.

1-

]

h.

3.

Heater

pump

operates

but

will

not

ignite.

4.

Heater

does

not

ignite

(fuel

present).

Heater overheat switch

tripped

Defective heater.

4-13.)

5.

Heater

will

not

shutoff

when

switch

is

positioned

to

OFF

(after

purge

cycle!.

Circuit

breaker

open.

Defective

lamp.

Defective

control

box.

Circuit

breaker

open.

Deacl

generator

set

batter]

es.

c.

.

.

d.

—

a,

b.

—

c.

.-

C1.

-.

a.

-.

b

.

.

“

c.

Lf

-“

e,

.

a.

.

.

Defective

controi

bt)x.

Open

thermostat

switrh.

Heater

t’uel

shut-off

valve

not

opel],

Generator

set

i!]cl

supply

mhau

st

ed.

Restri(tiutl

in

t’ucl

supply.

Df:fcwtive

generator

set

fuel

transfer

pure,].

D?iective

ttl(’I’ll”l

OSi&t

switch.

Low

ot

e]

~aLI[:

voltage

tu

hf’ater,

1)(.ltct:l

[’

(!olltrul

Iwx,

CORRECTNE

ACTION

a.

—

b.

—

c,

—

a.

.-

b.

c.

.

c1

a.

—

b.

—

(’

—

d.

—

a.

t).

c

.

—

d.

.

.

(!,

-.

a.

Reset

circuit

breaker.

(Refer

to

paragraph

4-8.)

Replace

lamp.

(Reier

to

paragraph 4-8.)

Replace

if

defective.

(Refer

to

paragraph

4-8.)

Reset

circuit

breaker.

(Refer

to

paragraph

4-8.)

Charge

or

replace

batl

cries,

(Refer

to

paragraphs 2-3 and 3-82.)

Replace

if

defective.

(Refer

to

paragraph

4-8.)

Test

and

replace

if

defective.

(Refer

to

paragraph 4-15.)

Ol)en

[alve.

(Rei’cr

to

paragraph 2-24.)

Adcl

f[!cl

as

rwuireci.

(

Refer

to

paragraph 2-3.)

Remwe

restriction.

Replace

if

defective.

(Refer

to

paragraph

3-165.)

Pern]it

heutcr

to

cool

and

restart.

I?eplace

heater,

(Next

higher

lwel

of

maintenan~

c.

)

‘rest

and

I’ephce

if

deiwtive,

(Refe~

to

paragraph 4-15.)

C[)l,rC4~[

i’dLISC

L)]

lltI[)rOf)er

VOltEige.

Replace if defective. (Refer

to

paragraph

Replace if defective. (Refer to paragraph

4-8.)

4-7

Figure 4-2.

b. Test.

4-9.Heater Assembly Inspect, Test, Service, and

Adjust.

a.

Inspect.

Remove

protective

cover

(75, fig.

4-1)

and

proceed

as

follows:

(1)

Inspect

for

cracks,

breaks

and

other

damage.

(2)

Inspect

terminal

block

and

limit

switch

for

cracks,

damage,

loose

terminals

or

stripped

threads.

(3)

Inspect

receptacle

assembly

for

cracks,

burned

or

damaged

insulation,

loose

connections,

and

bent

or

broken

terminals.

Check

for

continuity

between

wires

and

terminal

pins

with

ohmmeter.

(4)

Inspect

igniter

for

broken

coil

or

shorts.

Check

resistance.

Resistance

must

be

one

ohm

with

igniter

cold.

(5)

Inspect

wiring

harness

(refer

to

para-

graph 3-139).

(6)

Inspect

thermostat

switch

for

loose

connections

and

bent

or

broken

terminals.

(7)

Inspect

hoses,

lines,

and

fittings

for

cracks,

fraying,

damaged

ends

or

stripped

threads.

(8)

Replace

protective

cover

(75, fig. 4-l).

To

test

heater

assembly

(61, fig. 4-l),

set

switch

to

ON

position

and

ascertain

that

24

volts

DC

are

connected

to

the

heater

igniter.

If

ambient

temperature

is

above

50°F

attach

jumper

across

terminals

of

thermostat

switch.

(para 4-5)

(1)

If

indicator

light

on

heater

control

panel

(fig. 4-2)

does

not

illuminate

in

approximately

three

minutes,

position

switch

to

OFF,

wait

three

minutes

and

attempt

to

restart

heater.

If

heater

indicator

does

not

light,

and

no

jumper

is

connected

across

terminals

of

thermostat

switch,

connect

a

jumper.

Jf

heater

indicator

lights,

remove

jumper

and

replace

thermostat

switch

(39, fig. 4-1).

(2)

If

heater

indicator

does

not

light

with

thermostat

switch

jumpered,

replace

heater

assembly

(61, fig. 4-l).

c.

Service.

Service

heater

assembly

in

accordance

with

procedures

in

table 4-1.

4-10. Fuel Regulator Valve Adjustment (fig. 4-3).

a.

Remove

protective

cover

(75, fig. 4-1)

and

disconnect

fuel

tube

assembly

at

orifice

assembly.

b.

With

fuel

tube

assembly

disconnected

from

ign~ter

(fig. 4-3)

apply

24

volts

to

solenoid.

Time

fuel

flow

into

a

quart

container.

Flow

should

measure

one

quart

in

40

to

45

minutes.

Turn

adjusting

screw

clockwise

to

increase

flow

rate

or

counterclockwise

to

decrease

flow

rate.

4-11. Flame Micro-switch Adjustment (fig. 4-4).

a.

Rem.we

protective

cover

(75, fig. 4-l).

To

adj~st

micro-switch

in

starter

condition,

back

off

adjusting

screw

clockwise

slowly

until

a

click

is

heard.

Note

the

exact

spot

(screw

slot)

that

this

happens.

Then

give

an

additional

1/2

(180°)

turn

clockwise.

b.

Remove

protective

cover

(75, fig. 4-l).

To

—

adjtist

micro-switch

in

dynamic

condition,

turn

adjusting

screw

counterclockwise

until

motor

starts,

then

turn

adjusting

screw

clockwise

until

motor

stops.

Give

adjusting

screw

an

additional

1/2

(180°)

turn

clockwise.

4-8Change 1

Figure 4-3.

4-9

Figure 4-4. Figure 4-5.

4-12. Receptacle Assembly Replacement.

a.

Removal.

(1)

Remove

protective

cover

(75, fig. 4-1).

b.

Fill

a

suitable

container

with

antifreeze

soliition

and

place

thermometer

in

container.

Place

temperature

sensing

end

of

switch

in

Solutiom

(2)

Remove

screws

(76)

and

remove

receptacle

assembly

(77)

terminals

from

terminal

board.

(3)

Remove

screws

(76)

and

remove

recep-

tacle

assembly

(77)

from

br~ket.

Q.

Installation.

Install

receptacle

assembly

(77, fig. 4-1)

using

removal

steps

of

a,

above

in

reverse

order.

4-13. Igniter Assembly Replacement.

To

replace

igniter

assembly,

remove

protective

cover

(75, fig. 4-1)

and

proceed

as

follows:

~.

Disconnect

power

lead

to

igniter.

~.

Remove

igniter

from

heater

using

a

7/8

inch

socket

or

spark

plug

wrench.

c.

Install

igniter

and

reconnect

power

lead

to

ign~ter,

4-14. Wiring Harness Replacement.

See

figure 4-1

and

proceed

as

follows:

a.

Removal,

Tag

and

disconnect

all

electrical

le~s

and

connectors

from

wiring

harness

(4 or 11,

fig. 4-1)

to

be

removed.

Remove

all

harness

clamps

and

remove

wiring

harness,

If

30%

of

the

harness

wires

are

defective,

the

harness

must

be

rebuilt

at

next

higher

level

of

maintenance.

b.

Installation.

Place

wiring

harness

in

position,

ins~all

all

harness

clamps,

and

reconnect

electrical

leads

and

connectors.

Remove

tags.

4-15. Thermostat Switch Testing and Replacement.

“a.

Disconnect

and

tag

electrical

connections

and

refiove

switch

as

illustrated

in

figure 4-5.

Plug

engine

opening.

c.

Vary

the

temperature

of

the

solution

to

det~rmine

that

switch

opens

at

155°

*

3°F.

and

closes

at

35

*

5°F.

d.

Replace

defective

switch.

e.

To

install

switch,

see

figure 4-5.

Connect

ele~trical

connections

removed

in

step

a.

above.

4-16. Hoses, Lines, and Fittings Replacement.

See

figure

4-1

and

proceed

as

follows:

~.

Removal.

(1)

Remove

hose

or

line

being

replaced

after

closing

cock

(41,

45).

(2)

If

fitting

is

to

be

replaced,

remove

fitting

and

plug

opening

until

part

is

replaced.

b.

Installation.

Install

hose

assembly

using

reriioval

steps

m

reverse

order.

4-10 Change 3

Section III. ELECTRIC WINTERIZATION KIT

4-17. General.

The

electrical

winterization

kit

consists

of

a

heat

ex-

changer,

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

temperature

from

125°F.

to

-65°F.

to

enable

it

to

accept

75%

of

rated

load

in

one

step

within

20

seconds

fter

starting

action

is

initiated.

The

coolant

temp-

erature

is

thermostatically

controlled

at

130°

F.

to

150°F.

The

kit

can

also

be

used

to

warm

the

Genera-

tor

Set

for

initial

starting

within

5

hours

at

any

ambi-

ent

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. 2-11.

4-18. Installation.

For

wiring

information,

see

figure 4-6.

To

perform

initial

installation

of

the

electric

winterization

kit,

see

figures 1-23, 1-26 or 1-27, and 4-7

and

proceed

as

follows:

a.

Remove

plate

from

redr

housing,

adj

scent

to

con~rol

cubicle

(figure 1-2)

adj

scent

to

Fault

indica-

tor

panel,

and

retain

attaching

hardware

for

instal-

lation

of

the

electric

winterization

control

box

(45,

fig. 4-7).

~.

Refer

to

paragraph 3-41

and

drain

cooling

system.

c. Remove

two

plugs

from

engine

oil

pan

heat

exc%anger.

Retain

plugs.

~.

Remove

plugs

from

engine

thermostat

housing

and

engine

oil

cooler.

Retain

plugs.

e.

Install

kit

as

described

and

illustrated

in

figure 1-23

using

installation

sequence

68

through

1

of

figure 4-7

except

as

noted

in

(1)

through

(3)

below

when

fuel

burning

winterization

kit

and

electric

win-

terization

kit

are

used

together.

(See

sheet

2

of

figure 4-7.)

(1)

Remove

plug

(64, fig. 4-1)

from

three

way

valve

(67)

and

install

nipple

(69, fig. 4-7)

into

three

way

valve

(67, fig. 4-1).

Connect

hose

(70, fig. 4-7)

between

elbow

(13)

and

nipple

(69).

(2)

Remove

plug

(49, fig. 4-1)

and

install

nipple

(18, fig. 4-7).

Connect

hose

(41)

between

nipple

(18)

and

nipple

(3

I).

(3)

Remove

plug

(19, fig. 4-7)

and

install

elbow

(43, fig. 4-l).

Connect

hose

(47)

between

lbow

(43)

and

elbow

(50).

~.

Refer

to

paragraph 2-3

and

close

coolant

shut-

off

cocks

and

service

radiator.

g.

Set

electric

heater

control

box

POWER

switch

to

OFF

position.

h.

Connect

50/60

or

400

Hz

single

phase

power

cab~e

from

an

external

208

to

240

volts

power

source

to

J49

of

kit

(figures 1-26 or 1-27).

Perform

all

daily

checks

before

operation

preven-

tiv;

maintenance

checks

and

services

listed

in

table

4-3.

Refer

to

paragraph 4-20.

~.

Refer

to

paragraph 2-24

and

energize

the

electric

winterization

kit

and

check

kit

operation

as

follows:

(1)

Audibly

check

that

kit

coolant

~,

‘T.

P

is

operative.

(2)

Check

complete

kit

installation

to

assure

there

are

no

coolant

leaks.

(3)

Allow

five

minutes

for

warmup

and

then

place

hand

near

the

heat

exchanger.

Determine

that

the

heat

exchanger

is

heating.

WARNING

Do

not

attempt

to

hold

the

hand

in

contact

with

the

heat

exchanger.

NOTE

To

determine

that

each

heating

element

is

functioning,

disconnect

electrical

lead

from

one

element

and

check

as

in

step

(3)

above.

Reconnect

element

and

disconnect

remaining

element

and

check

as

ir,

step

(3)

above.

(4)

Slightly

100S,W

the

hose

coupling

on

the

outp~t

end

of

the

heat

exchanger

(left

side,

facing

the

engine

radiator).

Coolant,

under

pressure

should

flow

from

the

union.

(5)

Tighten

the

coupling

when

the

test

is

complete.

4-19. Removal.

To

remove

the

electric

winterization

kit,

see

figure 4-7

and

proceecl

as

follows:

a.

Refer

to

paragraph 3-41

and

drain

cooling

sys~em.

b.

Set

electric

control

box

POWER

switch

to

OFF

position

and

remove

power

cable

from

J49.

c. Remove

kit

by

proceeding

in

reverse

order

of

ins~allatiori

procedure

using

figure 1-24

and

removal

sequence

of

1

through

69

of

figure 4-7

except

as

4-11

Figure 4-6.

4-12Change 1

TM 5-6115-545-12

Change 111-26.1/(1-26.2blank)Figure 4-7. Electric Winterization Kit (Sheet 1 of 3)

4-13/(4-14 blank)

Figure 4-7.

4-15

Figure 4-7.

4-16

Table 4-3. Electric Winterization Kit Preventive Maintenance Checks and Services

ITEM

NO.

1

2

3

4

5

6

7

8

9

10

11

12

13

DAILY

B

-

Before

Operation

A

-

After

Operation

M

-

Monthly

(100

hrs)

D

-

During

Operation

W

-

Weekly-(40

hrs)

S

-

Semi

A-nnual

(500

hrs)

l’TEM TO BE

INSPECTED

Power

cable.

Coolant

shutoff

cocks.

;enerator

set

radiator.

Senerator

set

doors.

Coolant

hoses

Coolant

shutoff

cocks.

Power

cable.

Coolant

lines.

Attaching

hardwart

Wiring

harness.

Coolant

pump.

Thermostat.

Heating

elements.

PROCEDURE

:onnect

cable

to

power

supply.

)pen

shutoff

cocks.

:heck

for

proper

coolant

level.

;lose

all

doors.

;heck

for

leakage.

;lose

shutoff

cocks.

temove

from

power

source.

?ighten

lines

and

check

~ndition.

~ighten

hardware.

nspect

for

frayed

insulation

and

security

of

terminal

lugs

and

damaged

threads,

bent,

loose,

or

missing

pins

of

connectors.

rest

for

proper

operation.

rest

for

proper

operation.

pest

heating

elements.

REFERENCE

(para 2-25 and 4-18)

(para 2-25)

(para 3-41)

(fig. 1-1 and 1-2)

(para 4-22)

(para 2-25)

(para 2-25 and 4-19)

(para 4-22)

(para 4-22)

(para 4-26)

(para 4-22)

(para 4-23)

(para 4-24)

Change 1 4-17

Figure 4-8.

noted

below

when

fuel

burning

winterization

kit

and

electric

winterization

kit

are

used

together.

(See

sheet

2

of

figure 4-7.)

(1)

Disconnect

hose

(70)

from

elbow

(13)

and

elbow

(69).

Remove

nipple

(69)

from

three

way

valve

(67, fig. 4-1)

and

install

plug

(64)

into

three

way

valve

(67).

(2)

Disconnect

hose

(42, fig. 4-7)

from

nipple

(18)

and

elbow

(31).

Remove

adapter

(18)

and

replace

plug

(49, fig. 4-l).

(3)

Disconnect

hose

(47, fig. 4-1)

from

elbow

(43)

and

elbow

(50).

Remove

elbow

(43)

and

replace

plug

(19, fig. 4-7).

~.

Refer

to

paragraph 4-18

and

replace

plugs

and

plates

removed

during

installation.

e.

FiLl

radiator

with

proper

coolant

in

accordance

witii

table 2-1

and

check

for

leaks.

4-20. Preventive Maintenance.

To

insure

that

the

electric

winterization

kit

is

ready

for

operation

at

all

times,

when

installed

on

the

generator

set,

”

it

must

be

inspected

systematically

so

that

defects

may

be

discovered

and

corrected

before

they

result

in

serious

damage

or

failure.

Defects

discovered

during

operation

of

the

kit

shall

be

noted

for

future

correction,

to

be

made

as

soon

as

opera-

tion

has

ceased.

Stop

operation

immediately

if

a

deficiency

is

noted

during

operation

which

would

damage

the

kit

or

the

end

item

generator

to

which

it

is

attached.

All

deficiencies

and

shortcomings

SHALL

be

recorded

together

with

the

corrective

action

on

the

applicable

form

at

the

earliest

possible

opportunity.

Air

Force

users

shall

refer

to

the

ap-

plicable

inspection

manuals

and

work

card

sets

in

the

T. O. 35C2-3-

Series

for

periodic

preventive

maintenance

requirements

and

table 4-3

for

detailed

procedure.

4-21. Troubleshooting.

Table 4-4

provides

information

useful

in

diagnosing,

isolating,

and

correcting

unsatisfactory

operation

or

failure

of

the

electric

winterization

kit.

(See

figures

1-23, 1-26 or 1-27, and 4-6.)

4-22. Coolant Pump and Motor Assembly Inspection,

Testing, and Replacement.

a.

Inspection.

Proceed

as

follows:

(1)

See

figure 4-7

and

inspect

motor

assembly

for

overheating

and

inspect

coolant

pump

for

leaks,

loose

connections

and

loose

mounting.

(2)

See

figure 4-8,

remove

brushcap

(1)

and

check

motor

brush

and

spring

(2)

for

damage

or

excessive

wear.

Brushes

should

be

at

least

1/4

inch

Long.

(3)

See

figure 4-8

and

check

connector

(4)

for

bent

pins

or

damaged

threads.

Change 1

b.

Testing.

Coolant

pump

and

motor

assembly

(40, fig. 4-7) testing

consists

of

an

operational

verification

and

is

performed

as

follows:

(1)

Set

heat

control

switch

to

OFF

position.

(2)

Crack

the

fitting

on

the

output

of

the

coolant

pump

until

a

very

slow

leak

is

observed.

(3)

Set

heater

control

switch

to

ON

position

and

observe

the

leak

just

created

in

step

(2)

above.

If

the

leakage

rate

does

not

increase,

the

pump

is

defective

and

must

be

replaced.

(4)

Tighten

the

fitting

loosened

in

step

(2)

above.

~.

Replacement.

Proceed

as

follows:

(1)

See

figure 4-8

to

remove

and

replace

worn

or

damaged

brushes

(2)

and

connector

(4).

(2)

See

figure 4-7

to

remove

and

replace

coolant

pump

assembly

(40).

4-23. Thermostat Switch Inspection, Testing and

Replacement.

a.

Inspection.

fnspect

the

thermostat

switch

(9,

4-18

fig. 4-7)

for

loose

connection,

frayed

wires,

cor-

rosion,

and

loose

mounting.

~.

Testing.

(1)

Remove

thermostat

switch

(9, fig. 4-7)

and

plug

heat

exchanger

opening.

(2)

Fill

a

container

with

clean

water

and

place

thermometer

in

water.

tWspend

temperature

sens-

ing

end

of

switch

in

water.

(3)

Heat

water

and

check

switch

for

continuity.

Observe

water

temperature.

Switch

continuity

should

be

indicated

between

terminals

up

to

150°

+5°F

and

open

thereafter.

(4)

Permit

water

to

cool

and

observe

that

con-

tinuity

is

again

indicated

at

130°

+50F.

(5)

If

switch

fails

to

meet

above

tests,

it

should

be

replaced.

illustrated (9, fig. 4-7).

c. Replacement.

Replace

thermostat

switch

as

4-24. Heating Elements Inspection, Testing and

Replacement.

See

figure 4-7

and

proceed

as

follows:

&

Inspection.

(1)

Check

that

heating

elements

(6, fig. 4-7)

are

screwed

securely

into

both

ends

of

electric

win-

terisation

pipe

(10).

(2)

Check

that

electrical

connections

to

both

heater

elements

are

secure

and

protective

sleeving

is

installed.

b.

Testing.

To

test

heating

element,

proceed

as

~ollows:

(1)

Remove

electrical

lead

from

one

terminal

of

heating

element

(6, fig. 4-7).

(2)

Use

a

multimeter

and

check

resistance

between

heating

element

case

and

terminal.

Reading

should

indicate

an

open

circuit.

(3)

Check

resistance

between

heating

element

terminals.

Resistance

should

be

between

27

and

33

ohms.

(4)

If

heater

element

resistance

check

does

not

satisfy

above

requirements,

heating

element

is

defective

and

must

be

replaced.

c. Replacement. Remove and replace heating

elements (6) as illustrated in figure 4-7.

4-25. Hoses and Fittings Inspection, Repair and

Replacement.

See

figure 4-7

and

proceed

as

follows:

a.

Inspection.

(1)

Check

all

hoses

for

cracks

and

coolant

leaks.

(2)

Check

hoses

and

pipe

fittings

for

MALFUNCTK)N

1.

2.

3.

4.

control

box

POWER

ON

switch

ON,

and

nothing

-s.

Heaters

inoperative.

coolant

pump

iqoperattve.

HEATER

ON

indica-

tor

inoperative.

Table 4-4. Electric Winterization Kit Troubleshooting

PROBABLE

CAUSE

a.

b.

c.

d.

a.

b.

c.

a.

b.

a.

Power

cable

not

con-

nected

to

power

supply.

Blown

fuse.

Circuit

breaker

open.

Defective

control

box.

Thermostat

switch.

Defective

heater

elements.

Defective

wiring.

Defective

pump.

Defective

motor.

Defective

lamp.

CORRECTIVE

ACTION

a.

b

-“

c.

d

—“

a.

b

—’

c.

a.

—

b.

a.

Connect

power

cable.

Replace

fuse

(para 4-28).

Reset

circuit

breaker

(para 4-27).

Replace

if

defective

(para 4-27).

Replace

switch

(para 4-23).

Replace

elements

(para 4-24).

Replace

wiring

(para 4-26).

Replace

pump

and

motor

assembly

(para 4-22).

Replace

brushes

and/or

connector

(para 4-22).

Replace

lamp

(para 4-28).

4-19

Figure 4-9.

4-26. Wiring Harnesses Inspection, Repair, and

Replacement.

See

figure 4-7

and

proceed

as

follows:

a.

Inspection.

(1)

Inspect

wiring

harness

(59, fig. 4-7)

for

frayed

insulation.

cracked

or

loose

ty-wraps,

loose

har-ness

clamping,

and

loose

connection

to

‘co’mpo-

nents

and

plugs.

(2)

Inspect

wiring

harness

connectors

for

loose,

bent

or

missing

pins.

b.

Repair.

Tape

frayed

insulation,

replace

cra?ked

or

loose

ty-wraps.

tighten

wiring

harness

mounting

clamps

and

tighten

all

electrical

connections.

c.

Replacem

mt.

(1)

Removal. Tag

and

disconnect

all

electri-

cal

leads

and

connectors

from

wiring

harness

(59,

fig. 4-7)

to

be

removed.

Remove

all

harness

clamps

and

remove

wiring

harness.

If

30%

of

the

harness

wires

are

defective,

the

harness

must

be

rebuilt

by

direct

maintenance

level.

(2)

Installation. Place

wiring

harness

(59,

fig. 4-7)

in

position,

install

all

harness

clamps.

Install

red

sleeving

over

each

wire

terminating

at

heating

element

(6, fig. 4-7),

adjacent

to

the

manual

shutter

control.

Reconnect

electrical

leads

and

connectors.

Remove

tags.

4-27. Control Box Inspection, Testing, and

Replacement.

See

figure 4-7

and

proceed

as

follows:

a.

Inspection.

Proceed

as

follows:

(1)

See

figure 4-7

and

inspect

control

box

(45)

for

loose

mounting,

loose

connections,

and

other

evidence

of

damage.

looeeness,

damage,

and

coolant

leaks.

(2)

See

figure 4-9,

and

inspect

fuseholder

assembly,

fuse,

indicator

light

assemblies,

cir-

cuit

breaker,

and

power

switch

for

loose

mounting

and

other

damage.

b.

Repair.

Hoses

and

fittings

are

to

be

replaced,

not-rep=

c.

Replacement.

Replace

a

hose

assembly

or

fitt~ng

as

follows:

b.

Testing.

Test

control

box

as

follows:

(1)

Removal:

(1)

Set

circuit

breaker

to

close

position.

(a)

Close

heater

system

shutoff

cocks.

(2)

Set

switch

to

ON

position.

(3)

Using

multimeter,

check

resistance

across

pins

J49-A

and

J49-B.

Resistance

should

be

approx-

(b)

Remove

hose

aseembly

being

replaced,

(c)

If

fitting

is

to

be

replaced,

remove

the

fitting

and

plug

opening

until

part

is

replaced.

imately

7

ohms.

Removal

of

fuse,

opening

of

circuit

breaker,

or

setting

switch

to

OFF

position

should

remove

continuity

.-

If

continuity

is-not

removed,

repair

control

box

at

next

higher

level

of

maintenance.

(2)

Installation.

Install

hose

assembly

using

removal

steps

in

reverse

order,

4-20

c.

Replacement.

See

figures 4-8 and 4-9

and

4-28. Control Box Fuse and Lamp Testing and

pro~eed

as

follows:

Replacement.

See

figure 4-9

to

remove

and

install

control

box

(1)

Removal.

Disconnect

two

wiring

harness

lamps

and

fuse.

connectors

(59, fig. 4-7)

from

rear

of

control

box.

Unscrew

four

capscrews

(44)

which

secure

box

to a.

Fuse.

See

figure 4-9

and

remove

fuse.

Using

mumimeter,

check

fuse

for

continuity.

If

continuity

panel

and

remove

control

box

(45).

is

not

obtained,

replace

fuse.

b.

Lamps.

Press

to

test

each

indicator.

If

an

(2)

Installation.

Secure

control

box

(45, fig.

ind~cat~s

not

illuminate,

see

figure 4-9

and

4-7)

to

panel

with

four

capscrews

(44).

Screw

two

~

wiring

harness

(59)

connectors

to

receptacles

at

replace

lamp.

Press

to

test

indicator

again.

E

lamp

does

not

illuminate,

replace

indicator

light

rear

of

control

box

(45).

assembly

at

next

higher

level

of

maintenance.

Section IV. WHEEL MOUNTING KIT

4-29. General.

a.

The

wheel

mounting

kit

is

provided

to

enable

the-engine

generator

set

to

become

mobile.

The

wheel

mounting

kit

consists

of

two

detachable

wheel-

axle

assemblies,

parking

brake,

safety

chains,

pintle,

and

towbar.

The

front

axle

wheels

are

free

to

pivot

up

to

40

degrees

for

steering.

The

mechan-

ical

parking

brake

locks

rear

wheels

against

rotation

and

is

actuated

by

a

hand

lever

located

at

the

right

rear

of

the

kit.

b.

When

the

wheel

mounting

kit

is

installed

on

the

gen%rator

set,

the

set

may

be

towed

a

maximum

of

5

mph

on

paved

highways.

The

kit

has

a

ground

clearance

of

8

inches

and

front

wheels

turn

for

steering.

For

wheel

mounting

kit

operating

instruc-

tions,

refer

to

paragraph 2-26.

4-30. Preventive Maintenance.

To

insure

that

the

wheel

mounting

kit

is

ready

for

operation

at

all

times,

when

installed

on

the

genera-

tor

set,

it

must

be

inspected

systematically

so

that

defects

may

be

discovered

and

corrected

before

they

result

@

serious

damage

or

failure.

Defects

dis-

covered

during

operation

of

the

kit

shall

be

noted

for

future

correction,

to

be

made

as

soon

as

operation

has

ceased.

Stop

operation

immediately

if

a

defici-

ency

is

noted

during

operation

which

would

damage

the

kit

or

the

end

item

generator

to

which

it

is

at-

tached.

ml

deficiencies

and

shortcomings

SHALL

be

record&

together

with

the

corrective

action

on

the

applicable

form

at

the

earliest

possible

opportu-

nity.

Air

Force

users

shall

refer

to

the

applicable

inspection

manuals

and

work

card

sets

in

the

T. O. 35C2-3-

Series

for

periodic

preventive

main-

tenance

requirements

and

table 4-5

for

detailed

procedure.

4-31. Troubleshooting.

Table 4-6

contains

information

useful

in

diagnosing

and

correcting

unsatisfactory

operation

of

the

wheel

mounting

kit.

4-32. Kit Maintenmce Procedures.

Inspection,

test,

service,

and

repair

of

the

wheel

mounting

kit

(figures 4-10, 4-11 and 4-12)

consists

of

preventive

and

corrective

maintenance

of

the

various

components

of

the

kit

as

described

in

table 4-5 and

paragraphs 4-33 through 4-35.

4-33. Wheels and Tires.

See

figure 4-10

and

proceed

as

follows:

a.

Inspection,

Test

and

Service.

(1)

Visually

inspect

tires

(5, fig. 4-10)

to

assure

there

are

no

cuts

on

the

sidewalls

and

that

each

tire

has

good

tread.

Check

that

wheels

(3)

are

securely

mounted.

(2)

Check

tires

for

proper

air

pressure

using

a

standard

tire

pressure

gage.

Tire

pressure

should

be

60

psi. Service

with

compressed

air

as

required,

KEY to fig. 4-10.

1.

Nut

2.

Washer

3.

Wheel

4.

Tube

5.

Tire

6.

Nut

7.

Washer

8.

Bolt

9.

Cotter

pin

10.

Pin

11.

Tow

12.

Cotter

pin

13.

Pin

14.

Cotter

pin

15.

Pin

16.

Nut

17.

Clevis

18.

Clevis

19.

Brake

rod

20.

Lube

fitting

21.

Pin

22.

Lever

23.

Bearing

24.

Shaft

25.

Tie

rod

26.

Nut

27.

Cotter

pin

28.

Nut

29.

Tie

rod

end

30.

Spindle

and

knuckle

31.

Grease

fitting

Change 14-21

Figure 4-10.

4-22

Table 4-5. Wheel Mounting Kit Preventive Maintenance Checks and Services

ITEM

NO.

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

INTERVA

)PERATOR

DAILY

B

x

x

x

x

x

x

—

D

—

—

A

—

B

-

Before

Operation

A

-

After

Operation

M

-

Monthly

(100

hrs)

D

-

During

Operat

ITEM

TO

BE

INSPECTED

Tires.

Tires.

Safety

chain.

Steering

linkages

and

pivot

points.

Wheel

bearings.

Attaching

hard-

ware.

Kit

to

generator

skid

base

at-

taching

hard-

ware.

Wheel

brakes.

Handbrake.

Wheels.

Wheel

alignment.

Front

wheel

toe-in.

Tow

bar

assembly.

King

pins.

Tie

rod

ends.

mW

-

Weekly

(40

hrs)

S

-

PROCEDURE

Note:

Perform

Item No. 10

for

ex-

cessive

tire

wear

or

uneven

wear.

Perform

Item No. 11

for

uneven

tire

wear

or

if

trailer

wanders

while

being

towed.

hspect

tires

for

cuts,

breaks

and

blisters

and

evidence

of

deflation,

excessive

deterioration,

or

wear.

Service

tires.

hspect

safety

chain

for

condition

and

proper

connection.

Lubricate

steering

linkage

and

pivot

points.

:lean,

inspect,

and

lubricate.

I’ighten

hardware.

Zheck

for

security

and

tighten

hardware

as

required.

fnspect

linings

for

wear

and

adjust

brakes.

Check

for

proper

operation.

Inspect

security

of

wheels.

Check

wheel

alignment.

Check

front

wheel

toe-in.

inspect

for

evidence

of

damage,

mis-

alignment,

and

freedom

of

movement.

tnspect

for

wear.

Lnspect

for

wear.

mi

Annual

(5OO

hrs)

REFERENCE

(para 4-33)

(para 4-33)

(para 2-26)

(para 3-3 and 3-4)

(para 4-34)

(para 4-42)

(para 4-35)

(para 2-26)

(para 4-33)

(para 4-36)

(para 4-37)

(para 2-26)

(fig. 4-12)

(fig. 4-12)

Change 14-23

Figure 4-11.

b.

Removal,

—

(1)

Remove

wheels

(3)

and

tires

(5)

as

illus-

trated

in

figure 4-10,

observing

the

instructions

in

steps

(2)

and

(3)

below.

WARNING

If

parking

brakes

must

be

released

to

per-

form

maintenance

when

generator

set

is

jacked,

release

brakes

prior

to

jacking.

Do

not

perform

maintenance

on

a

jacked

gener-

ator

set

unless

it

is

properly

blocked.

suitable

blocks

under

skid

base

and

lower

skid

base

on

blocks.

~.

Repair

and

Replacement.

(1)

Refer

to

Appendix

A

for

listing

of

appli-

cable

service

manual

for

repair

of

pneumatic

tires.

(2)

Install

wheels

(3)

and

tires

(5)

as

illus-

trated

in

figure 4-10.

(3)

Remove

support

blocks,

lower

generator

set

and

remove

jack.

(2)

Block

wheel

to

prevent

movement

when

4-34. Wheel Bearings.

generator

set

is

jacked.

Jack

generator

set

and

remove

wheel

(3, fig. 4-10)

(3)

Place

suitable

jack

under

skid

base

of

as

described

in

paragraph 4-33

and

proceed

as

generator

set

and

jack

wheels

off

ground.

Place

follows:

4-24

Table 4-6. Wheel Mounting Kit Troubleshooting

MALFUNCTION

1.

2.

3.

4.

Abnormal

tire

wear.

Wheel

wobbles.

Kit

pulls

to

one

side.

Kit

tends

to

wander.

PROBABLE

CAUSE

a.

b

—“

c.

—

a.

b

-“

c.

a.

b

—“

a.

b.

Improper

tire

pressure.

Axle

assemblies

mounting

hardware

loose,

Alignment.

Lug

nuts

loose.

Defective

or

improperly

adjusted

wheel

bearings.

Bent

wheel.

Improper

tire

pressure.

Wheel

brake

dragging.

Improper

tire

pressure.

Axle

assemblies

mount-

ing

hardware

loose.

a.

Removal.

Remove

wheel

bearings

(5)

and

(11)

as

illustrated

in

figure 4-12.

Do

not

remove

bearing

cups

(13)

and

(12)

unless

they

are

found

to

be

defective

at

ti~e

of

inspection.

Tap

cups

(13)

and

(12)

from

drum

(14)

using

drift

and

hammer.

/

~.

Inspection,

Service,

and

Repair.

(1)

Clean

parts

with

a

cleaning

solvent,

Fede-

ral

Specification

P-D-680,

and

dry

thoroughly.

(2)

Inspect

for

cracks,

breaks,

and

other

damage.

(3)

Inspect

bearings

(5 and 11, fig. 4-12)

for

smoothness

of

rotation

and

cups

(13)

and

(12)

for

pitting.

(4)

Repair

by

replacing

defective

parts.

Bear-

ings

and

cups

are

matched

sets.

(5)

Pack

bearings

with

grease

conforming

to

Federal

~ecification

W-G-632,

type

A,

grade

2.

Apply

light

film

of

grease

to

running

surfaces

of

bearing

cups,

outside

and

inside

diameter

of

grease

seal

(10)

and

axle.

c.

Installation.

Jnstall

wheel

bearings

(5)

and

(11)

as

Illustrated

in

figure 4-12

observing

the

following:

CORRECTIVE

ACTION

a.

Correct

tire

pressure.

(Refer

to

paragraph

4-33.)

b

Tighten

hardware.

—.

c.

a.

b

—.

c.

a.

b

—.

a.

b

—.

Correct

wheel

alignment.

(Refer

to

para-

graph 4-36.)

Tighten

lug

nuts.

Adjust

or

replace

wheel

bearings.

(Refer

to

paragraph 4-34.)

Replace

wheel.

(Refer

to

paragraph 4-33.)

Correct

tire

pressure.

(Refer

to

paragraph

4-33.)

Adjust

brakes.

(Refer

to

paragraph 4-35.)

Correct

tire

pressure.

(Refer

to

paragraph

4-33.)

Tighten

hardware.

(1)

Ensure

brake

shoe

linings

(17 and 18,

figure 4-12)

and

drums

(14)

are

free

of

grease

prior

to

installation.

(2)

Install

bearing

cups

(13)

and

(12)

and

grease

seal

(10)

using

sleeves

the

same

diameter

as

cups

and

seal.

(3)

Replace

washer

(4)

and

nut

(3)

and

adjust

wheel

bearings

(5)

and

(11)

as

specified

in

paragraph

4-34 d.

prior

to

installing

cotter

pin

(2)

and

grease

cap

(0.

d.

Adjustment.

See

figure 4-12

and

adjust

wheel

bea;ings

(5)

and

(!11)

as

follows:

(1)

Tighten

nut

(3, fig. 4-12)

until

it

is

snug.

Back

off

nut

until

next

cutout

in

nut

is

aligned

with

cotter

pin

(2)

hole

in

axle.

(2)

Spin

wheel

to

ensure

it

is

free

to

rotate

and

bearings

(5)

and

(11)

are

not

binding.

(3)

Install

new

cotter

pin

(2)

and

grease

cap

(l).

e.

Install

wheel

on

axle,

remove

support

blocks,

low%

generator

set

and

remove

jack.

4-25

Figure 4-12.

4-26

Figure 4-12.

4-27

4-35. Wheel Brakes and Hand Lever and Bracket

Assembly.

Jack

generator

set

as

described

in

paragraph 4-33.

Proceed

as

follows:

a.

Removal,

Remove

components

of

wheel

brakes

and-hand

lever

and

bracket

assembly

as

illustrated

in

figures 4-10, 4-11 and 4-12

observing

the

following:

(1)

As

necessary,

remove

components

of

wheel

brakes

as

illustrated

in

figures 4-10 and 4-12.

NOTE

Pry

spring

clip

(15, fig. 4-12)

off

stud

plate

(29)

before

attempting

to

remove

brake

adjustment

bolt

(22).

(2)

As

necessary,

remove

components

of

hand

lever

and

bracket

assembly

as

illustrated

in

figure

4-11.

b.

Cleaning

and

Inspection.

(1)

Clean

parts,

except

brake

shoes,

with

cleaning

solvent,

Federal

Specification

P-D-680,

and

dry

thoroughly.

Clean

shoes

with

clean

lint-free

cloth.

(2)

Inspect

for

cracks,

breaks,

and

other

damage,

(3)

Inspect

linings

for

wear,

if

brake

lining

thickness

is

1/16

of

an

inch

or

less,

brake

s“hoes

shall

be

replaced.

(4)

Replace

defective

parts.

c.

Lubrication.

(1)

Apply

thin

film

of

grease,

conforming

to

Military

Specification

MIL-G-

10924

to

stud

plate

(29,

fig. 4-12)

brake

shoe

contact

areas.

(2)

Apply

film

of

lubricating

oil,

conforming

to

Military

Specification

MIL-L-

15016

to

threads

of

brake

adjustment

bolts

(22)

and

side

slots

in

wedge

(20).

d.

Installation. Install

components

of

wheel

brfies

and

hand

lever

and

bracket

assembly

as

illus-

trated

in

figures 4-10, 4-11 and 4-12

observing

the

following:

(1)

When

installing

spring

clip

(15, fig. 4-12),

use

hollow

punch

to

tap

spring

clip

onto

plate

stud

(29).

(2)

Ensure

brake

shoes

(17)

and

(18)

and

drums

(14)

are

free

of

grease

prior

to

installation.

(3)

Install

assembled

wheel

and

drum

assembly

as

illustrated

in

figures 4-10 and 4-12.

(4)

As

necessary,

install

components

of

hand

lever

and

bracket

assembly

as

illustrated

in

figure

4-11.

(5)

Adjust

wheel

bearings,

refer

to

paragraph

4-34.

(6)

Adjust

wheel

brakes,

refer

to

paragraph

e.

below.

e.

Adjustment.

Adjust

wheel

brakes

as

follows:

(1)

Jack

generator

set

as

specified

in

para-

graph 4-33.

(2)

Remove

dust

covers

(23, fig. 4-12)

from

stud

plate

(29).

Adjust

each

wheel

brake

using

a

brake

adjusting

tool.

NOTE

Each

brake

shoe

(17)

and

(18)

must

be

adjusted

individually.

(3)

Rotate

brake

adjustment

bolt

(22)

counter-

clockwise

until

shoe

is

snug

against

drum

(14).

Back-off

adjustment

bolt

six

ratchet

clicks,

clock-

wise.

This

will

provide

approximately

0.010

of

an

inch

running

clearance

between

shoe

and

drum.

(4)

Apply

and

release

brakes.

Rotate

wheels

to

ensure

they

turn

freely.

(5).

Lower

generator

set

and

remove

jack.

4-36. Wheel Alignment.

See

figure 4-10

and

check

the

alignment

of

the

front

wheels

to

the

rear

wheels

proceeding

as

follows:

a.

Place

the

trailer

on

a

hard,

flat,

and

level

sur~ace,

with

the

front

wheels

placed

in

the

straight-

ahead

position.

b.

Use

a

straightedge

position

across

the

sides

of

tiie

front

and

rear

wheels

to

check

that

the

front

wheels

align

with

the

rear

wheels

except

for

a

small

amount

of

toe-in.

(Refer

to

paragraph 4-37.)

c.

If

the

front

and

rear

wheels

are

not

aligned,

refiove

the

cotter

pin

(27, fig. 4-10)

and

nut

(28)

that

secure

each

tie

rod

end

(29)

to

the

spindles

and

knuckles

(30).

Disengage

the

tie

rod

end

ball

studs

(29)

and

tie

rods

(25).

d.

Using

the

straightedge,

align

the

front

and

rea~

wheels

so

that

they

are

in

line

on

each

side

of

the

vehicle,

except

for

a

slight

toe-in

of

the

front

wheels.

e.

Loosen

the

nuts

(26)

that

lock

the

tie

rod

ends

(29Tto

the

tie

rods

(25).

Turn

the

tie

rod

ends

in

or

out

on

the

tie

rods

(25)

until

the

tie

rod

ends

(29)

are

aligned

with

the

holes

in

the

spindles

and

knuckles

(30).

4-28

f.

Insert

the

tie

rod

end

ball

studs

(29)

into

the

spiiidles

and

steering

knuckles

(30).

Secure

with

the

slotted

hex

nuts

(28).

Recheck

the

wheel

alignment

as

directed

above

and%heck

the

toe-in

as

directed

in

paragraph 4-37.

If

both

are

correct,

tighten

the

nuts

(26)

between

tie

rods

(25)

and

tie

rod

ends

(29)

and

install

the

cotter

pins

(27)

that

secure

the

ball

stud

nuts

(28).

4-37. Front Wheel Toe-In Adjustment.

See

figure 4-10

and

check

and

adjust

the

front

wheel

toe-in

as

follows:

a.

Position

the

vehicle

on

a

flat,

hard,

even

sur~ace,

with

the

wheels

positioned

in

the

straight-

ahead

position.

Check

wheel

alignment

(paragraph

4-36).

b.

Using

yellow

crayon,

mark

the

front

center

of

the~ire

tread

at

each

front

wheel.

Carefully

measure

the

distance

between

the

marks.

Section V.

4-38. General.

a.

(See

figure 4-13).

The

load

bank

is

a

balanced

thr~e

phase,

four

wire

resistive

type

load

which

is

used

to

maintain

the

generator

set

load

at

approxi-

mately

half-load

at

120/208

volts

and

240/416

volts,

at

50/60

HZ

and

400

Hz.

The

generator

set

is

pro-

tected

against

overloads

by

the

load

bank

reject

con-

trol

system.

b.

The

load

bank

special

purpose

cable

connects

the-automatic

load

bank

reject

control

system

into

the

load

measuring

system.

The

load

bank

is

con-

nected

to

the

generator

set

load

terminal

board

via

the

load

bank

four

wire

power

cable.

A

load

bank

power

on

indicator

lamp

indicates

when

ac

power

is

applied

to

load

bank

heating

elements.

c.

The

load

bank

rotary

selector

switches

permit

ch@es

in

load

from

O

to

50

percent

of

the

generator

set

KW

ra$ing

(60

KW)

in

four

7.5

KW

increments

of

2!

percent

of

the

load

capacity

(30KW)

and

permit

operation

at

either

120/208

or

240/416

volts.

~.

A

load

reject

toggle

switch

provides

for

selection

of

automatic

load

reject

or

manual

mode

reject

mode

of

operation.

During

automatic

mode,

the

load

measuring

unit

senses

the

generator

set

out-

put

(utility

load

plus

load

bank).

If

the

combined

load

exceeds

509+

of

the

generator

set

capacity

of

60”

KW,

the

load

measuring

unit

applied

to

the

load

reject

relay

via

the

tactical

relay

box

trips

the

load

reject

relay

which

trips

the

over

temperature

reset

switch

trip

coil

(3

phase

magnetic

circuit

breaker)

removing

the

selected

load

from

the

generator

set.

(The

load

reject

relay

trips

when

the

total

current

in

any

phase

of

the

generator

set

rises

to

and

remains

at

125

per-

cent

plus

or

minus

five

percent

of

the

maximum

load

c.

Push

the

vehicle

backwards

in

a

straight

line

unt~l

the

marks

are

positioned

at

the

back

of

the

wheel.

Again

measure

the

distance

between

marks.

The

measured

distance

between

marks

when

at

the

rear

must

exceed

the

distance

between

the

marks

when

at

the

front

of

the

wheel

by

1/4

inch.

d.

If

the

toe-in

is

not

correct,

remove

the

cotter

pin_(27, fig. 4-10)

and

nut

(28)

that

secure

each

tie

rod

end

ball

stud

(29)

to

the

spindles

and

knuckles

(30).

Disengage

the

tie

rod

end

ball

studs

(29)

and

tie

rods

(25).

e.

Using

a

straightedge

along

the

sides

of

the

fro

fit

and

rear

wheels,

position

the

front

wheels

so

they

are

correctly

aligned

with

just

sufficient

toe-in

(refer

to

step c.

above).

f.

Adjust

the

tie

rod

ends

(29)

on

the

tie

rods

(25)

as

directed

in

paragraph 4-36

above

and

reconnect

the

tie

rods.

LOAD BANK

.

bank

capacity.

)

Thus,

the

utility

load

continues

to

be

supplied

without

risk

of

generator

set

overload.

When

the

generator

set

load

diminishes

the

load

bank

is

reconnected

by

manually

resetting

the

over

tem-

perature

reset

switch.

During

the

manual

mode

protection

of

the

generator

set

against

overloads

is

the

responsibility

of

the

operator

by

monitoring

the

generator

set

control

panel

KW

meter.

If

sets

rated

load

capacity

is

exceeded,

the

operator

reduces

or

removes

the

load

bank

load

with

the

‘%

load

selector

rotary

switch.

e.

A

fan

and

motor

assembly

provides

for

cooling

the~oad

bank

resistive

load

(heater

elements).

f.

The

thermostatic

switch

operates

the

trip

coil

of

t~e

over

temperature

reset

switch

removing

the

selected

load

from

the

generator

set

when

tempera-

ture

within

load

bank

reaches

450°

F

+-

15°

F.

The

switch

closes

with

temperature

at

450m

F

+-

15°

F

and

opens

with

temperature

at

3510F

+

15~F.

g.

The

purpose

of

the

resistive

load

(heater

ele-

mefits)

is

to

provide

a

partial

load

for

the

generator

set

if

the

normal

utility

load

is

too

low

to

keep

set

operating

without

carbonization

of

the

engine.

h.

For

load

bank

operating

instructions,

refer

to

paragraph 2-27.

4-39. Installation.

See

figures 1-1, 1-2, 1-21, 1-26 or 1-27, and 4-13

and

proceed

as

follows:

~.

Stop

generator

set.

b

Set

%

LOAD

SELECTOR

switch

to

OFF.

—“

Change 14-29

c.

See

figure 1-21

and,

position

and

secure

the

load

bank

to

the

housing

using

six

screws,

12

lock

washers,

and

six

nuts

provided

on

set.

d.

Remove

the

rear

top

left

side

screw

and

nut

loc<ted

on

the

generator

set

housing

and,

loosely

mount

the

load

bank

loop

clamps

to

the

housing

with

screw

provided,

e,

Ensure

special

purpose

cable

70-5098

plug

p81

(6, fig. 4-14)

is

connected

to

load

bank

harness

re-

ceptacle

J81

(7)

and

cable

is

clamped

(5)

to

load

bank

housing

(95).

~.

Ensure

four

wire

power

cable

(13)

is

clamped

(12)

to

load

bank

housing

(95),

~.

Run

the

load

bank

four-wire

power

cable

(13)

and

special

purpose

cable

(6)

through

the

loop

clamps

(step d.

above)

and

tighten

the

screw

and

nut

securely,

~.

Run

both

cables

(13)

and

(6)

through

the

plate

and

sleeve

assembly

hole

(fig. 3-15)

into

the

engine

generator

set.

i,

Connect

the

four-wire

power

cable

wires

(13,

fig.-4-14)

to

the

load

terminal

board

terminals

(figure

3-24)

as

follows:

Wire

color

Load

terminal

Green

LO

Black

L1

White

L2

Red

L3

j.

Disconnect

cable

70-1212

plug

p51

from

tactical

relay

box

receptacle

J51.

~.

Connect

special

purpose

cable

plug

P50

to

cable

70-1212

plug

J51

discon-

nected

in

step j.

above.

~.

Connect

special

purpose

cable

plug

P51

(6, fig. 4-14)

to

tactical

relay

box

receptacle

J51.

m.

Select

voltage

corresponding

to

generator

set

re~onnection

panel

120/208

or

240/416

(fig, 2-4)

with

theload

bank

voltage

selector

switch

(fig. 2-9).

e

n.

Perform

test

procedures

asoutlinedin

para-

graph 4-42 b.

4-40. Preventive Maintenance.

To

insure

that

theload

bank

kit

is

ready

for

operation

at

all

times,

when

installed

on

the

generator

set,

it

must

be

inspected

systematically

so

that

defects

may

rediscovered

andcorrected

before

they

result

in

serious

damage

or

failure.

Defects

discovered

ciur-

ing

operation

of

the

kit

shall

be

noted

for

future

cor-

rection,

to

be

made

as

soon

as

o?eration

has

ceased.

Stop

operation

immediately

if

a

deficiency

is

noted

during

operation

which

would

damaget

hekit

or

the

end

item

generator

to

which

it

is

attached.

All

de-

ficiencies

and

shortcomings

SHALL

be

recorded

to-

gether

with

thecorrective

action

on

the

applicable

form

at

the

earliest

possible

opportunity.

Air

Force

users

shall

refer

to

the

applicable

inspection

manuals

and

work

carcl

sets

in

the

T. O. 35C2-3-

Series

for

periodic

preventive

maintenance

requirements

and

table 4-7

for

detailed

procedure.

4-41. Troubleshooting.

Table 4-8

anti

figure 4-13

provide

information

useful

in

diagnosing.

isolating,

and

correcting

unsatisfac-

tory

operation

or

failure

uf

the

load

bank.

4-42. Kit Maintenance Procedures.

See

figures 4-13 through 4-14 and 4-16

and

proceed

as

follows:

WARNING

Unless

otherwise

specified.

ensure

generator

set

is

stopped

prior

to

performing

load

bank

maintenance

procedures.

a.

Inspection. Inspect

the

load

bank

as

follows:

(1)

Inspect

thespecial

purpose

cable

(6, fig.

4-14

and

four-wire

power

cable

(13)

from

the

load

bank

for

cracks,

breaks,

fraying,

and

other

damage.

(2)

fnspect

special

purpose

cable

(6)

and

fou~

wire

power

cable

(13)

clamps

(5)

and

(12)

for

looseness.

(3)

Inspect

the

cable

clamps

which

secure

special

purpose

cable

(6)

and

four-wire

power

cable

(13)

at

the

top

left

of

the

housing

for

looseness.

(4)

Inspect

special

purpose

cable

(6)

and

four-wire

power

cable

(13)

for

excessive

wear

in

the

vicinity

of

clamps

(5)

and

(12).

(5)

Jnspect

the

terminals

of

the

load

terminal

board

(fig. 3-24)

for

loose

wire

connections

and

for

damage.

(6).

Inspect

the

special

purpose

cable

(6, fig.

4-14)

plugs

P50

and

p51

for

proper

mating

with

receptacles.

(7)

fnspect

six

screws,

12

lockwashers,

and

six

nuts

securing

load

bank

to

housing

for

looseness.

~.

Testing.

See

figure 2-9

and

proceed

as

follows:

(1)

Set

the

load

bank

LOAD

REJECT

switch

to

MANUAL.

(2)

Select

voltage

corresponding

to

the

gene-

.

rator

set

reconnection

panel

120/208

or

240/416

(fig. 2-4

with

the

VOLTAGE

SELECTC)R

switch.

(3)

Set

the

‘?

LOAD

SELECTOR

switch

to

OFF,

(4)

Refer

to

paragraph 2-12

and

start

genera-

tor

set

with

no

external

load

connected.

—

4-30Change 12

Figure 4-13.

4-31

Figure 4-14.

Change 44-33

Figure 4-14.

1.

Rivet

2,

Instruction

plate

3.

Screw

4.

Nut

5.

Harness

clamp

6.

Special

purpose

cable

7.

Wiring

harness

(J81)

8.

Screw

9,

Cover

10.

Screw

11.

Nut

12.

Harness

clamp

13,

Four

wire

power

cable

14,

Grommet

15.

Screw

16.

Cover

17.

Setscrew

18.

Knob

19.

Packing

20.

Escutcheon

plate

21.

Screw

22.

Plate

23.

Load

selector

switch

24.

Setscrew

25.

Knob

26.

Packing

27.

Escutcheon

plate

28.

Screw

29,

Plate

30.

Screw

31.

Nut

32.

Screw

33.

Nut

34.

Washer

35.

Bracket

36.

Voltage

selector

switch

37.

Nut

38.

Washer

39.

Nut

40.

Load

reject

switch

41.

Nut

42.

Screw

43.

Fan

guard

‘

44.

Nut

45.

Screw

46.

Fan

motor

47.

Screw

48.

Circuit

breaker

49.

Lens

50.

Bulb

51.

Nut

52.

Washer

l

53.

Nut

54.

Base

55.

Screw

55A.

Adjustable

resistor

56.

Panel

5’7.

Nut

58.

Screw

59.

Washer

60.

Spacer

61.

Terminal

nut

62.

Nut

63. Screw

64.

Terminal

board

65.

Nut

66.

Screw

67. LockWasher

68.

Washer

69.

Capacitor

70.

LockWasher

71. Nut

72.

Washer

73.

Screw

7’4.

LockWasher

’75.

Washer

76.

Capacitor

77.

Lockwasher

77A.

Screw

77B.

Nut

77C.

Terminal

board

78. Nut

79.

Washer

80.

Nut

81.

Screw

82.

Screw

83.

Nut

84.

Thermostat

switch

84A.

Screw

84B.

Nut

85.

Bracket

86.

Nut

87.

Screw

88.

Heating

element

89.

Screw

90.

Nut

91. Screw

92.

Harness

clamp

93.

Harness

clamp

94.

Wiring

harness

94A.

Screw

94B.

Rectifier

bridge

95.

Load

bank

housing

4-34Change 4

Table 4-7. Load Bank Preventive Maintenance Checks and Services

ITEM

NO.

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

INTERV,

DPERATOI

DAILY

B

x

x

—

D

—

—

A

.

;(

i

B

-

Before

Operation

A

-

After

Operation

M

-

Monthly

(100

hrs)

D

-

During

Operation

W

-

Weeklv

(40

hrs)

s-

:mi

Annual

(500

hrs)

lTEM

TO

BE

INSPECTED PROCEDURE

Kit

attaching

hard.

ware

and

cables,

Wiring

harness.

Control

panel

assembly.

Rotary

switch.

Load

reject

toggle

switch.

Fan

guard.

Air

outlet

and

fan.

Fan

motor

brushes.

Over

temperature

reset

switch

circuit

breaker,

Fan

mounting

grommets.

Indicating

light

and

lamp.

Load

reject

re!ay.

Terminal

board.

Thermostat.

Heater

elements.

Fan

motor

assembly

Tighten

hardware

and

inspect

cables

for

wear

and

security.

Inspect

for

frayed

insulation

and

security

of

termj.nal

lugs

and

damaget

threads,

bent,

loose,

or

missing

pins

of

connectors.

Inspect

for

loose

mounting

hardware

and

tight

en

as

necessary.

Inspect

switches

for

positive

action

between

positions,

wiring

connections

and

damage.

Test

for

proper

operation.

Inspect

switch

for

positive

action

between

positions,

wiring

connections

and

damage.

Test

for

proper

operation.

Inspect

for

foreign

material.

Inspect

for

foreign

material

and

damage

to

fan.

hspect

for

wear

and

refer

to

next

highe

maintenance

level

for

replacement

Inspect

circuit

breaker

for

positive

action

between

positions,

wiring

connections,

and

darnage.

Test

for

proper

operation.

Inspect

for

deterioration

and

looseness.

Inspect

lens

and

lamp

for

looseness

and

damage.

Inspect

wiring

connections

for

looseness. Test

for

proper

operation.

Inspect

for

security

of

mounting

damage,

and

loose

wiring

connections,

hspect

for

loose

mounting

hardware

and

tighten

as

necessary.

kspect

for

loose

mounting

and

wiring

connections.

Test

for

proper

operation.

hspect

for

loose

attaching

hardware,

damage,

and

wiring

connections.

Test

for

proper

operation.

:nspect

for

security

of

mounting

and

physical

damage

REFERENCE

(para 4-42)

(para 4-43)

(para 4-44)

(para 4-44)

(para 4-44)

(para 4-44)

(para 4-44)

(para 4-44)

(para 4-44)

para 4-44)

(para 4-44)

(para 4-45)

(para 4-46)

(para 4-47)

(para 4-48)

(para 4-44)

4-35

Figure 4-15.

4-36

Table 4-8. Load Bank Troubleshooting

MALFUNCTION

1.

2.

3.

4.

5.

6.

Load

bank

does

not

apply

load

to

genera-

tor

set.

Over

temperature

reset

switch

does

not

remain

engaged

in

ON

position

while

in

manual

load

reject

mode.

Over

temperature

reset

switch

does

not

remain

engaged

in

ON

position

while

in

automatic

load

reject

mode.

Load

bank

does

not

disconnect

from

generator

set

with

rated

kilowatt

meter

above

30

W

while

in

automatic

load

reject

mode.

Fan

and

motor

ae-

sembly

not

operating

properly.

Indicator

does

not

illuminate

when

load

back

is

in

operation.

PROBABLE

CAUSE

a.

b

-“

c.

a.

b.

c.

d

-“

a.

b.

a.

b.

a.

—

b

-“

c.

a.

b

-“

c.

Refer

to

malfunction

2

and

3

below.

Defective

load

selector

switch.

Defective

wiring

harness.

Defective

fan

and

motor

assembly.

Defective

thermostat

switch.

Defective

over

tempera-

ture

reset

switch.

Defective

wiring.

me

as

2

above.

If

rated

kilowatt

meter

within

load

limits

of

30

W,

defective

load

reject

relay.

Defective

load

reject

switch.

Defective

wiring

harness.

Defective

fan

end

motor

assembly.

Defective

diode

bridge.

Defective

wiring

harness.

Defective

lamp.

Defective

light.

Defective

wiring

harness.

Corrective

ACTION

a.

b

-“

c.

a.

b

-“

c.

d.

a.

b.

a.

b

-“

a.

b

-“

c.

a.

b

-“

c.

Refer

to

malfunction

2

and

3

below,

Test

and

replace

switch

if

defective.

(Refer

to

paragraph 4-44.)

Repsir

or

replace

wiring

harness.

(Refer

to

paragraph 4-43.)

Check

fan

and

motor

assembly

for

proper

operation

as

in

5

below.

Test

switch

and

replace

if

defective.

(Refer

to

paragraph 4-47.)

Test

switch

and

replace

if

defective,

(Refer

to

paragraph 4-44.)

Repair

or

replace

wiring.

(Refer

to

paragraph

4-43.)

Same

as

2

above.

Test

relay

and

replace

if

defective

(higher

level

of

maintenance

required).

Test

switch

and

replace

if

defective.

(Refer

to

paragraph 4-44.)

Repair

or

replace

wiring

harness.

(Refer

to

paragraph 4-43.)

Test

assembly

and

refer

to

next

higher

level

of

maintenance,

if

defective,

Test

bridge

and

replace

diode(s)

if

defective.

(Higher

level

of

maintenance

required.

)

Repair

or

replace

wiring

harness.

(Refer

to

paragraph 4-43.)

Test

lamp

snd

replace

if

defective.

(Refer

to

paragraph 4-44.)

Test

light

and

replace

if

defective.

(Refer

to

paragraph 4-44.)

Repair

or

replace

wiring

harness.

(Refer

to

paragraph 4-43.)

4-37

MALFUNCTION

7.

8,

9.

Excessive

load

on

generator

set

in

man-

ual

load

reject

mode.

Incorrect

load

bank

output

monitored

on

kilowatt

meter

as

%

LOAD SELECTOR

is

sequentially

rotated.

Over

temperature

switch

does

not

disengage

when

temperature

exceeds

450°

F

+

15°F.

Table 4-8. Load Bank Troubleshooting (Cont)

CORRECTIVE ACTION

PROBABLE CAUSE

a.

Prime

load

has

exceeded

—

30

Kw.

b

Defective

wiring

harness.

-“

a. Defective

heater

element(s).

b

Defective

wiring

harness.

-“

a.

Defective

thermostat

switch.

b.

Defective

over

tempera-

ture

reset

switch.

c.

Defective

diode

bridge.

d,

Defective

wiring

harness.

(5)

Set

the

load

bank

OVER

TEMPERATURE

switch

to ON.

(6) Set

%

LOAD SELECTOR

switch

to

12.5

percent

rated

load.

The

load

bank

fan

shall

operate,

the

load

bank

power

indicator

shall

light,

and

the

generator

set

kilowatt

meter

shall

read

approximately

12.5

percent.

(7)

Sequentially

select

25,

37.5,

and

50

percent

load.

Generator

set

kilowatt

meter

shall

read

ap-

proximately

25,

37.5,

and

50

percent

load.

Return

%

LOAD SELECTOR

switch

to

OFF.

(8)

Refer

to

paragraph 2-13 and

stop

genera-

tor

set.

Connect

an

external

load

to

generator

set

equal

to

25

±

5

percent

of

maximum

Ioad

bank

load.

(9)

Refer

to

paragraph 2-12 and

start

genera-

tor

set

with

external

load

connected.

(10) Set

load

bank

LOAD

REJECT

switch

to

AUTOMATIC.

(11)

Monitor

generator

set

kilowatt

meter

and

sequentially

position

%

LOAD SELECTOR

switch

from

OFF.

Load

bank

shall

be

immediately

removed

when

combined

external

load

and

selected

load

bank

loads

exceed

approximately

30

KW.

4-38

a.

—

b

-“

a.

b

-“

a.

b.

c.

d.

Position

‘%

LOAD SELECTOR

switch

to

a

lower

%

load.

Repair

or

replace

wiring

harness.

(Refer

to

paragraph 4-43.)

Test

heater

element(s)

and

replace

if

de-

fective. (Refer

to

paragraph 4-48.)

Repair

or

replace

wiring

harness.

(Refer

to

paragraph 4-43.)

Test

switch

and

replace

if

defective.

(Refer

to

paragraph 4-47.)

Test

switch

and

replace

if

defective.

(Refer

to

paragraph 4-44 d.)

Test

bridge

and

replace

diode(s)

if

defective.

(Higher

level

of

maintenance

required.

)

Repair

or

replace

wiring

harness.

(Refer

to paragraph 4-43.)

CAUTION

If

load

bank

is

not

removed

immediately

when

loads

exceed

30

KW,

reduce

load

bank

load

with

‘%

LOAD SELECTOR

switch.

(12)

Refer

to

paragraph 2-13 and

stop

genera-

tor

set.

4-43. Wiring Harness. (Figure 4-16)

a.

Inspect

harness

for

frayed

insulation,

cracked

or

loose

ty-wraps,

loose

harness

clamps

and

loose

connections

to

components.

b.

Repair.

Tape

frayed

insulation,

replace

cra%ke=oose

t

y-wraps,

tighten

harness

clamps

and

tighten

all

electrical

connections.

If

a

wire

is

broken

from

a

terminal

lug,

replace

lug.

Repair

harnesses

in

accordance

with

para 3-139.

C.

Replacement.

See figure 4-14

and

proceed

as

Tolloww.

(1)

Removal.

Tag

and

disconnect

all

electri-

cal

leads

and

connectors

from

the

wiring

harness

(7

or 94, fig. 4-14)

to

be

removed.

The%

remove

all

harness

clamps

(5), (12), (92)

and

(93)

and

the

wiring

harness.

Figure 4-16. Wiring Diagram, Load Bank

Change 44-39/(4-40 blank)

Figure 4-17.

Figure 4-18.

(2)

Installation.

Place

wiring

harness

(7)

or

(94)

in

position,

install

all

harness

clamps

(5),

(12),

(92),

and

(93),

and

reconnect

electrical

leads

to

com-

ponents.

Remove

tags.

4-44. Load Bank Control Panel Assembly.

a.

R~tary

Switches.

(1)

Inspection.

Remove

cover

(9, fig. 4-14)

and

insr)ect

switches

(23)

and

(36)

for

freedom

of

.,

movement

between

positions.

minals

for

loose

connections.

switches

for

cracks,

breaks,

damage,

‘

Check

all

contact

ter-

Check

body

of

corrosion,

and

other

(2)

Testing.

To

test

the

rotary

selector

switches

use

a

multimeter

and

proceed

as

follows:

(a)

Remove

switch

knobs

(18 and 25, fig.

4-14)

and

switch

mounting

screws

(21),

(30),

and

(32),

and

remove

switches

(23)

and

(36)

from

panel

(56).

(b)

Test

for

continuity

between

the

termi-

nals

illustrated

in

figure 4-17

for

the

voltage

selec-

tor

switch

(36, fig. 4-14)

and

figure 4-18

for

the

load

selector

switch

(23, fig. 4-14).

Sequentially

select

each

position

and

refer

to

the

particular

figure

for

the

contacts

that

are

closed.

All

closed

circuits

shall

read

zero

ohms.

All

open

circuits

shall

read

5

ohms

to

infinity.

Change 44-41

(3)

Replacement,

See

figure 4-14

and

replace

the

selector

switch

(23)

or

(36)

as

follows:

@)

Removal.

1.

Remove

the

switch

knob

(18 or 25, fig.

4-14)

and

escutcheon

plate

(20)

or

(27).

2.

Remove

the

screws

(21)

or

(28)

which

secure

selector

switch

(23)

or

(36)

to

panel

(56).

3.

On

voltage

selector

switch

(36)

also

remove

screw

(30)

and

nut

(31)

which

secure

rear

of

voltage

selector

switch

[36)

to

the

switch

bracket

(35).

4.

Tag

all

leads

to

switch

and

remove

leads

from

selector

switc!l

(23)

or

(36).

5.

Remove

selector

switch

(23)

or

(36).

(b)

installation.

1.

Reconnect

wires

as

tagged,

and

re-

move

tags.

2.

Remount

selector

switches

(23 and

36, fig. 4-14)

escutcheo,l.

plate

(20)

or

(2’7),

and

knob

(18)

or

(25)

using

removal

steps

in

reverse

order.

b.

Load

Reject

Switch.

-—

(1)

Inspection.

Remove

cover

(9, fig. 4-14)

and

inspect

load

reject

switch

(40)

for

positive

action

between

positions.

Check

for

loose

connections.

Check

bodv

of

switch

for

cracks,

breaks,

corrosion,

and

other

damage.

(2)

Testing.

To

test

the

load

reject

switch

(40, fig. 4-14),

use

a

multimeter

and

make

continuity

check

of

switch

positions,

closed

in

automatic

(zero

ohms)

and

open

in

manual

(imrinity)

positions.

(3)

Replacement.

To

replace

load

reject

switch

(40, fig. 4-14),

remove

nut

(37),

washer

(38),

and

nut

(39)

tagging

leads

before

removing

lead

reje@

switch.

Install

in

reverse

order

of

removal.

c. Fan

and

Motor

Assembly.

—

(1)

Inspection.

Remove

cover

(9, fig. 4-14)

and

inspec-t-rnciuntin~

grommets

(5, fig. 4-14)

ior

de-

terioration

and

looseness,

wiring

leads

for

fraying,

and

check

fan

brushes

for

wear.

Inspect

fan

blade

(2)

fan

guard

(43, fig. 4-14),

and

air

outlet

for

foreign

material,

and

fan

blade

for

damage

and

looseness.

Inspect

motor

assembly

for

unusual

noises,

signs

of

overheating

and

other

damage.

(2)

Testing.

During’

load

bank

testing

(para

4-42b.)

o%-scrvti-fhrough

fan

ward

that

fan

blade

rotates

clockwise

with

air

flow

as

shown

on

figure

4-15.

(3)

Replacement.

To

replace

fan

blade

(2,

fig. 4-15),

remove

tan

guard

(43, fig. 4-14)

by

re-

moving

nut

(41)

and

screw

(42).

Loo.?en

setscrews

(1, fig. 4-15)

securing

fan

blade

(2)

and

remcwe

blade

from

motor

shaft.

To

replace

grommets

(5,

fig. 4-15),

renlove

fan

and

motor

assembly

(46, fig.

4-42

4-14)

by

removing

nut

(44)

and

screw

(45)

and

then

remove

screw

(3, fig. 4-15)

and

washer

(4, fig. 4-15).

fnstall

in

reverse

order

of

removal.

d.

Circuit

Breaker

(Over

Temperature

Reset

Swi?ch.

(1)

Inspection.

Remove

cover

(9, fig. 4-14)

and

inspect

the

circuit

breaker

(48)

for

positive

action

between

positions,

loose

mounting,

loose

electrical

connections,

and

other

damage,

(2)

Testing. Test

the

circuit

breakers

as

follows:

bre&er

(~)

Tag

leads

and

remove

from

circuit

(b)

Using

multimeter,

verify

continuity

(closed

co=tacts)

of

circuit

breaker

in

the

ON

position.

(c)

Place

circuit

breaker

in

OFF

position

and

verify

no

~ontinuity

(open

contacts).

(cJ)

R?connect

leads

and

remove

tags.

(3)

Replacement.

To

replace

the

circuit

breaker

(48, fig. 4-14),

remove

screws

(47)

and

tag

leads

before

removing

circuit

breaker.

fnstall

in

reverse

order

of

removal.

e.

Indicating

Light.

(1)

Inspection.

Remove

cover

(9, fig. 4-14)

and

inspect

indicating

light

for

100SC

m~unting,

loose

connections,

corrosion

and

dam>~e.

Inspect

lens

and

lamp

for

looseness

and

damage.

(2)

Testing.

During

load

bank

testing

(para

4-42b.),

observe

that

indicating

light

lights.

(3)

Replacement.

To

replace

indicating

light

(49 through 54, fig. 4-14),

remove

lens

(49),

bulb(50),

nut

(51),

washer

(52),

and

nut

(53),

tagging

leads

be-

fore

removing

base

(54).

Install

in

reverse

order

of

removal.

4-45. Load Reject Relay.

a.

Inspection.

Remove

cover

(9, fig. 4-14),

and

ins~ect

load

reject

relay

for

loose

mounting,

damage,

and

wiring

connections

for

looseness.

b.

Testing.

Higher

level

of

maintenance

is

req~ired.

c.

Replacement. Higher

level

of

maintenance

is

req~ired.

4-46. Terminal Board.

a.

Impection.

fnspect

the

terminal

board

(64,

fig. 4-14) for

loose

nl&nting,

loose

electrical

con-

nectioiis,

cracks,

breaks,

and

other

damage.

b.

Replace,

[]cmt.

To

repIace

the

terminal

board

(64 fig. 4-14), remove

nut

(57),

screw

(58),

washer

(59)

and

spacer

(60)

tagging

leads

before

removing

terminal

board

(64),

Remove

terminal

nut

(61),

nut

(62),

and

screw

(63).

Install

in

reverse

order

of

re-

moval.

Diodes

are

tested

and

replaced

at

a

higher

level

of

maintenance.

4-47. Thermostat Switch.

a.

Inspection.

Remove

cover

(16, fig. 4-14)

and

ins~ect

thermostat

switch

(85)

for

loose

mounting

and

wiring

connections.

Test

for

proper

operation.

b.

Testing.

(1)

See

figures 4-13, 4-14, and 4-16

and

re-

move

switch

in

accordance

with

paragraph c.

below.

(2)

Fill

suitable

container

with

clean

oil

having

a

flash

point

above

600°F.

(3)

Suspend

thermostat

switch

in

container

of

oil.

Aiso,

suspend

a

thermometer

in

container

of

oil.

(4)

Connect

multimeter

between

switch

terminals.

WARNING

Ensure

oil

in

container

has

a

flash

point

exceeding

600°

F,

oil

is

heated

gradually,

and

necessary

fire

precautions

are

taken.

(5)

Heat

container

of

oil

gradually,

and

stir

so

heat

is

evenly

distributed.

(6)

Observe

multimeter

and

thermometer

for

indication

of

infinity

(open

switch)

below

4500F

+

150F.

At

4500F

+

150F,

multimeter

shall

indicate

continuity

(switch

closed).

(7)

Permit

oil

to

cool,

multimeter

shall

indi-

cate

infinity

{switch

open)

at

351°F

*

15°F.

Replace

if

defective.

c.

Replacement.

To

replace

thermostat

switch

(85, fig. 4-14)

remove

nut

(82),

washer

(83),

and

screw

(84)

tag~ing

leads

before

removing

switch.

Install

switch

in

reverse

order

of

removal.

4-48. Heater Elements.

w

ARNING

Ensure

heater

elements

are

cold

and

load

bank

is

disconnected

from

generator

set.

a.

Inspection.

Remove

cover

(16, fig. 4-14)

and

insfiect

heater

elements

(88)

for

loose

mounting.

loose

electrical

connections,

cracks,

breaks,

cor-

rosion,

and

other

damage.

b.

Testing,

(1)

Remove

one

end

of

heating

elem,3nt.

nut

which

secures

harness

lead

to

element

and

remove

lead

from

(2)

Test

heating

element

for

continuity.

If

open,

replace

heating

element.

(3)

Measure

resistance

between

terminals.

Re.

sistance

should

be

approximately

10

ohms,

(4)

Reconnect

lead.

Replacement.

To

replace

the

heating

elements

(88,fig.4-14),

remove

nut

(86)

and

screw

(87)

tag-

ging

leads

before

removing

elements.

Install

in

re-

verse

order

of

removal.

4-49. Removal.

See

figures 1-1, 1-2, 1-21, 1-26 or 1-27, and 4-13,

and

proceed

as

follows:

~.

Refer

to

paragraph 2-13

and

stop

generator

set.

b.

Set

%

LOAD

SELECTOR

SWITCH

to

OFF.

c.

Disconnect

special

purpose

cable

plug

P50

(6, fig. 4-14)

from

tactical

relay

box

receptacle

J50.

d.

Disconnect

special

purpose

cable

plug

P51

froti

cable

70-1212

plug

P51.

e.

Connect

cable

70-1212

plug

P51

to

tactical

rel~y

box

receptacle

J51.

f.

Disconnect

load

bank

four-wire

power

cable

(13Tfrom

load

terminal

board

terminals

(fig. 3-24).

~.

Remove

load

bank

four-wire

power

cable

(13,

fig. 4-14)

and

special

purpose

cable

(6)

from

the

gene-

rator

set

through

the

plate

and

sleeve

assembly

hole

(fig. 3-15).

h.

Remove

load

bank

four-wire

power

cable

(13,

fig. 4-14)

and

special

purpose

cable

(6)

from

loop

clamps

at

rear

top

left

side

of

housing.

Replace

screws

in

housing

after

removal

of

cables

and

clamps.

i.

Remove

six

screws,

12

lockwashers,

and

six

nut~

securing

load

bank

to

set

housing

and

remove

load

bank

from

housing.

4-43/(4-44 blank)

APPENDIX A

REFERENCES

A-1.Fire Protection.

TB 5-4200-200-10

A-2.Lubrication.

C9100-IL

LO 5-6115-545-12

A-3.Painting.

T.O. 35-1-3

TM 9-213

A-4.Radio Suppression.

MIL-STD-461

TM 11-483

A-5.Maintenance.

T.O. 00-25-225

T.O. 00-25-234

T.O. 1-1-1

T.O. 1-1-2

T.O. 1-1A-14

T.O. 31-1-75

T.O. 35-1-11

T.O. 35-1-12

T.O. 35-1-26

T.O. 35-1-524

TM 9-1870-1

TM 9-2610-200-20

Hand Portable Fire Extinguisher Approved for Army

Users.

Identification List for Fuels, Lubricants, Oils and

Waxes.

Lubrication Order.

Painting and Marking of USAF Aerospace Ground

Equipment.

Painting Instructions for Field Use.

Radio Interference Suppression.

Radio Interference Suppression.

Repair of External Power Cables, Aerospace Ground

Equipment.

General Shop Practice Requirements for the Repair,

Maintenance and Test of Electric Equipment.

Cleaning of Aerospace Equipment.

Corrosion Control and Treatment for Aerospace

Equipment.

Installation Practices for Aircraft Electric and Elec-

tronic Wiring.

General Maintenance Practices.

Organization, Intermediate and Depot Level Maintenance

for FSC 6115 Non-Airborne Equipment.

Components and Procedures for Cleaning Aerospace

Ground Equipment.

Repair/Replacement Criteria for FSC 6115 Aerospace

Ground Equipment.

USAF Equipment Registration Number System Appli-

cable to FSC 6115 Equipment.

Care and Maintenance of Pneumatic Tires.

Organizational Care, Maintenance and Repair of

Pneumatic Tires and Inner Tubes.

A-1

TM 9-2610-200-34

T.O. 36Y32-1-142

TB 750-651

DA Pam 738-750

TM 5-6115-545-12

T.O.35C2-3-444-1

NAVFAC P-8-626-12

TM00038G-12

TM 5-6115-545-34

T.O. 35C2-3-444-2

NAVFAC P-8-626-34

TM 00038G-35

TM 5-6115-545-24P

T.O. 35C2-3-444-4

NAVFAC P-8-626-25P

SL-4-00038G

TM 9-6140-200-15

TM 5-6115-588-14

T.O. 35CA-1-111

NAFAC P-8-601

TM-6115-15/4

A-6.Shipment and storage.

T.O. 35-1-4

T.O. 38-1-5

TB 740-97-2

TM 740-90-1

A-7.Destruction of Material.

TM 750-244-3

A-8.Radioactive Material

TB 750-248

Direct Support and G. S. Maintenance Manual (Including

Depot Rebuild) Pneumatic Tires and Inner Tubes.

Care and Maintenance of Pneumatic Tires.

Use of Antifreeze Solutions and Cleaning Compounds

in Engine Cooling Systems.

The Army Maintenance Management Systems.

Operator and Organizational Maintenance Manual.

Intermediate (Field) (Direct and General Support) and

Depot Maintenance Manual.

Organizational, Intermediate (Field), Direct and General

Support, and Depot Maintenance Repair Parts and

Special Tools List.

Operation and Organizational, Field. and Depot

Maintenance Storage Batteries, Lead Acid Type.

Operator, Organizational, Intermediate (Field) (Direct

and General Support) and Depot Maintenance Manual

Including Repair Parts and Special Tools List for

Auxiliary Equipment 15 Through 200 KW, DOD

Family Generator Sets.

Processing and Inspection of Aerospace Ground

Equipment for Storage and Shipment.

Processing and Inspection of Non-Mounted, Non-Air-

craft Gasoline and Diesel Engines for Storage and

Shipment.

Preservation of USAMEC Mechanical Equipment for

Shipment and Storage.

Administrative Storage of Equipment.

Procedures for Destruction of Equipment to Prevent

Enemy Use.

Instructions for Safe Handling, Maintenance, Storage,

and Disposal of Radioactive Commodities Managed

by U.S. Army Mobility Equipment Command.

A-2Change 12

APPENDIX B

BASIC ISSUE ITEM LIST AND ITEMS

TROOP INSTALLED OR AUTHORIZED

(SECTIONS I, II, AND III NOT Applicable TO USAF)

Section I. INTRODUCTION

B-1. Scope.

This appendix lists basic issue items, items troop

installed or authorized which accompany the diesel

driven generator set, and required by the crew/oper-

ator for operation. installation, or operator’s main-

tenance.

B-2. General.

This basic issue items, items troop installed or

authorized list and maintenance and operating sup-

plies is divided into the following sections

a. Basic Issue Items List - Section II. A list, in

alphabetical sequence, of items which are furnished

with and which must be turned in with the end item.

b. Items Troop Installed or Authorized List -

Section III. A list, in alphabetical sequence of Items

which atthe discretion of the unit commander may

accompany the end item, but are NOT subject to be

turned in with the end item.

c. Maintenance and Operating Supplies - Sec -

tion IV.Alisting of maintenance and operating sup-

plies required for initial operation.

B-3. Explanation of Columns.

The following provides an explanation of columns in

the tabular list of Basic Issue Items List, Section

II, and Items Troop Installed or Authorized List,

Section III.

a. Source, Maintenance, and Recoverability

Code(s) (SMR):

(1) Source code, indicates the source for the

listed item. Source codes are

CodeExplanation

PRepair parts, special tools and test

equipment supplied from GSA/DSA or

Army supply system and authorized

for use at indicated maintenance

levels.

P2Repair parts, special tools and test

equipment which are procured and

stocked for insurance purposes be-

cause the combat or military essen-

tiality of the end item dictates that a

minimum quantity be available in

the supply system.

(2) Maintenance code, indicates the lowest

level of maintenance authorized to install the listed

item. The maintenance level code is:

CodeExplanation

CCrew/Operator

(3) Recoverability code, indicates whether un-

serviceable items should be returned for recovery

or salvage.Items not coded are non-recoverable.

Recoverability y codes are:

CodeExplanation

RApplied to repair parts (assemblies and

components), special tools and test equip-

ment which are considered economically

reparable at direct and general support

maintenance levels.

SRepair parts, special tools, test equip-

ment and assemblies which are econom-

ically reparable at DSU and GSU activ-

ities and which normally are furnished

by supply on an exchange basis.

b. Federal Stock Number. This column indicates

the-Federal stock number assigned to the item and

will be used for requisitioning purposes.

c. Description. This column indicates the Fed-

eral item name and any additional description of the

item required.

d. Unit of Measure (U/M). A 2 character alpha-

betic abbreviation indicating the amount or quantity

of the item upon which the allowances are based,

e.g. , ft, ea, pr, etc.

e. Quantity Furnished With Equipment (BIIL

Only).This column indicates the quantity of an item

furnished with the equipment.

f. Quantity Authorized (Items Troop Installed or

Authorized Only).This column indicates the quan-

tity of the item authorized to be used with the equip-

ment.

g. Illustration (Basic Issue Items List Only).

This column isdivided as folIows:

B-1

(1) Figure Number. Indicates the figure num-

ber of the illustration in which the items is shown.

(2) Item Number. Indicates the callout number

used to reference the item in the illustration.

B-4. Explanation of Columns in the Tabular List of

Maintenance and Operating Supplies - Section IV.

a. Component Application, Column 1. This

colimn identifies the component application of each

maintenance or operating supply item.

b. Federal Stock Number, Column 2. This

column indicates the Federal stock number assigned

to the item and will be used for requisitioning pur-

poses.

c. Description, Column 3. This column indica-

tes the item name and b

rief de

scription.

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

quantities required for an average 8 hours of oper-

ation.

f. Notes, Column 6. This column indicates in-

formative notes keyed to data appearing in a pre-

ceding column.

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

B-6. Abbreviations.

Abbreviation: Explanation:

hv- duty

heavy-duty

deg degree

ea each

hd

head

ID

inside diameter

in inch

lb(s) pound(s)

max maximum

nom

nominal

oz ounce

sgl single

w/with

Section II. BASIC ISSUE

(1)

I

(2)

I

(3)

SMR

I

FEDERAL

STOCK

DESCRIPTION

CODE

NUMBER

I

REF

NO.

&

MFR

USABLE

CODE ON

CODE

PAC

7520-559-9618

Case,

Maintenance and Opera-

tional Manual

PAC

5935-00-322-8959

Adapter

Connector

ITEMS

(4)

UNIT

OF

MEAS

ea

ea

(5)

QTY

INC

IN

UNIT

(6)

QTY

FURN

WITH

EQUIP

1

1

Section III. ITEMS TROOP INSTALLED OR AUTHORIZED LIST

(1) (2)

SMR

FEDERAL

STOCK

CODE

NUMBER

1

PAC

4910-273-3663

PAC

4930-360-2801

PAC

5120-224-4045

PAC

4930-141-8311

(3)

DESCRIPTION

REF

NO.

&

MFR

USABLE

CODE ON

CODE

GAGE:

tire

pressure,

10

to

160

lbs

range.

(See

parts

manual)

GREASE

GUN

hand,

lever

operated,

16

oz.

HAMMER,

I-LAW

machinist

ball

pean,

1

-1/4

lb head,

HOSE

ASSEMBLY

grease

gun,

hydraulic

coupling

one

end, other end

male

connec-

tion, 1/8 in NPTF, 3/16 in

ID

hose,

19-1

1/32 in

overall

length.

(7)

ILLUSTRATION

(A)

(B)

FIG

I

ITEM

NO. NO.

(4)

UNf

T

OF

MEAS

ea

ea

ea

ea

(5)

QTY

AUTH

1

1

1

B-2

Change 12

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

(1) (2) (3) (4) (5)

DESCRIPTION

SMR

FEDERAL

STOCK UNIT

QTY

AUTH

CODE

NUMBER

REF

NO.

&

MFR

USABLE

OF

CODE ON

CODE MEAS

PAC

4930-262-8868 OILER,

HAND

Pump,

force

fed

16

oz.

capacity,

flexible

spout. ea

1

PAC

5120-223-7396 PLIERS,

SLIPJOINT

straight

nose,

comb

w/cutter,

6

in

long. ea

1

PAC

5975-878-3791

ROD,

GROUND,

ASSEMBLED

ea

1

PAC

5120-293-3176

SCREWDRIVER,

FLAT

TIP

tip

1/4

in

wide,

blade

4

in

long.

ea

1

PAC

5120-240-5328

WRENCH

OPEN

END,

ADJUSTABLE:

sgl-

hd,

22-112

deg

angle,

hv-

duty,

8

in

nom,

19

overall,

O.947

in

max

jaw

opening.

Section IV. MAINTENANCE AND OPERATING SUPPLIES

(1) (2) (3) (4) (5) (6)

QUANTITY

QUAN~TY

COMPONENT FEDERAL DESCRIPTION REQUfRED REQUIRED NOTES

APPLICATION

STOCK

NUMBER

F/INITIAL

F/8

HRS

OPERATION OPERATION

FUEL

TANK

FUEL

OIL

-

DIESEL

9140-286-5294(1)

Regular

Grade

DF

2

55

(4) 50

gal

(1)

See

C-91

OO-IL

9140-286-5286(1) Winter

Grade

DF

1

55

(4)

for

additional

req-

9140-286-5283(1)

Artic

Grade

DF

A

55

(4)

uisitioning

data.

2910-209-4997(1)

Ether

Bottle

1

f!

AL?TION

(2)

See

C-6800-IL

/

JP-4

&

JP=5

-fuel

are

for

additional

req-

ctmsiclertd

~fi

memencv

ui

sitioning

data.

fuel

onlv

91

30-256-8613(1)

JP4-MIL-T-5b24

55

(4)

JP5-MIL-T-5624

(3)

See

current

LO

CRANKCASE

OIL

LUBRICATING

for

grade

appli-

9150-188-9858(1)

OE/HDO

30

(3)

5

Gal

Pail

20

(6)

cation.

9150-189-6727(1)

OE/HDO

10

(3)

1

Qt

Can

20

(6)

91

50-242-7603(1)

OES

(3)

5

Gal

Pail

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)

91

50-242-7604(1)

OES

(3)

55

Gal

Drum

20

(6)

GOVERNOR

OIL,

HYDRAULIC

(5)

Cooling

system

9150-223-4134(1)

OHA,

MIL-H-5606

1

Gal

Can

5

qts

capacity.

(in

quarts)

RADIATOR

ANTIFREEZE

6850-181-792

Antifreeze,

inhibited

34

(5) (6)

Requires

26

6ww-174-1806(2)

Antifreeze,

Artic

34

(5)

quarts

to

fill

crankcase,

lines

and

filters.

BATTERY

6810-249-9354(2) ELECTROLYTE

4

(7) (7)

Requires

4

gal-

lons

to

fill

batter-

ies.

Change 3B-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 implementa-

tion 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 refer-

enced 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 assem-

bly in a top down breakdown sequence. The appli-

cable assembly groups are listed on the MAC in dis-

assembly sequence beginning with the first assem-

bly removed in a top down disassembly sequence.

b. Group Title. Column 2. This column contains

a brief description of the components of each assem-

bly 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)

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.

B - Test. To verify serviceability and to de-

tect 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 ele-

ments 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 in-

strument 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 cate-

gory of maintenance.

J - Overhaul. Normally, the highest degree of

maintenance performed by the Army in order to min-

imize time work in process is consistent with quality

and economy of operation. It consists of that main-

tenance 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 condi-

tion.

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 consid-

erations 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,

has

been

in

use.

d.

Tools

and

Equipment.

Column4.

This

column

is

Crovided

for

referencing

by

code

t

he

tools

and

test

eq;ipment,

(Section III)

requi-red

to

perform

the

main-

tenance

functions

(Section II).

e.

Remarks.

Column

5.

This

column

is

provided

for–referencing

by

code

t

he

remarks

(Section

IV)

pert-

inent

to

the

maintenance

functions.

C-3. Explanation of Columns in Section III.

a.

Reference

Code.

This

column

consists

of

a

num%er

and

a

letter

separated

by

a

dash.

The

num-

ber

references

the

T

&

TE

requirements

column

on

the

MAC.

The

letter

represents

the

specific

main-

tenance

function

the

item

is

to

be

used

with.

The

letter

is

representative

of

columns

A

through

K

on

the

MAC.

b.

—

R

(1)

G

O

U

P

O.

N

01

02

03

04

05

06

07

C-2

Maintenance

Category. This

column

shows

the

lowest

level

of

maintenance

authorized

to

use

the

tool

or

test

equipment.

c. Nomenclature.

This

column

lists

the

name

or

ideiitificatlon

of

th

e

tool

or

test

equipment.

d.

Tool

Number.

This

column

lists

the

manu-

fac~urer’s

code

and

part

number,

or

Federal

Stock

Number

of

tools

and-test

equipment.

C-4. Explanation of Columns in Section IV.

a.

Reference

Code.

This

column

consists

of

two

letl%rs

separafed

b

y

a

dash,

both

of

which

are

ref-

erences

to

Section II.

The

first

letter

references

column

5

and

the

second

letter

references

a

main-

tenance

function,

column

3,

A

through

K.

b.

Remarks.

This

column

lists

information

per-

tini%t

to

th

e

maintenance

function

being

performed,

as

indicated

on

the

MAC,

Section II.

Section II. MAINTENANCE ALLOCATION CHART

ARMY and USMC only

For DOD Generator Set Family 60 KW, Tactical, Precise and Utility, 50/60 and 400 Hz

(2)

GROUP

TITLE

Batteries

and

Related

Items

Nave

Receptacle

Muffler,

Exhaust,

and

Breather

Pipes

Muffler

Exhaust

Breather

Pipes

Convenience

Receptacle

Circuit

Breaker

(Deleted)

Plate

&

Sleeve

Assembly

Paralleling

Receptacles

Generator

Set

Controls

Circuit

Breaker

DC

Change 1

(3)

MAINTENANCE

FUNCTIONS

—

1

.

4

rY

d

•1

—

D

o

D

—

(4)

TOOLS

AND

IQUIPMENT

1-B

(5)

REMARKS

A-

A,

B-B

A-A

A-A

A-A

A-A

A-A

G-B

A-A

A-A

G-B

(1)

G

O

P

N

O.

R

(2)

GROUP

TITLE

U

07

(Cont)

Manual

Speed

C-d

Fhult

IncMcatcw

Lamp8

lnlee

‘kxdml

Box

Aesembly

Voltmeter

AC

Wattmeter

AC

Wattmeter

Cowerter

Ammeter

AC

Rheoetats/potenuometer

Frequency

Meter

FYequency

lkanechcer

switches

Gauges

Hourmeter

Ammeter

DC

Relay

Assembly

Terminal

Beard

panel

LigM

Assembly

Lamp

Air

Cleaner

LigM

Battle

Short

1A*

Clrcult

Breaker

LigM

mc

LlgMs

A

*

u

w

g

~

G

o

0

c

c

o

c

o

c

o

c

c

c

c

o

0

c

c

c

c

c

(3)

MAINTENANCE

FUNCTIONS

3

~

*

i

o

c

o

0

0

F

F

F

o

F

F

o

0

0

0

F

c

c

c

c

c

c

c

c

0

H

:

<

z

E

a

i

o

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

(4)

TOOLS

AND

EQUIPMENT

2-B

2-B

2-B

(5)

REMARKS

A-A

A-

A,

D-B,

E-

I

D-B

F-D

D-

B,

F-D

D-B

D-

B,

F-D

G-B

D-B

G-B

G-B

D-B

D-B

D-B

c-3

(1)

G

R

U

P

N

o.

(cont)

08

09

10

11

12

13

C-4

(2)

O

GROUP

TITLE

07

Control

Box

Assembly

Lamp

Door

Holder

Cross

Pin

Door

Harness

Housing

Group

Doors

Covers

Panels

Engine,

Generator

and

Chassis

Interconnecting

Wiring

Harnesses

Load

Connection

Group

Main

Load

Contactor

Load

Term

Bd

Assembly

Current

Xfmr

Assembly

Reconnection

Board

Governor

Control

Unit

Electro-Hydraulic

Electric

Control

Actuator

Magnetic

Pick

Up

Air

Cleaner

Ass’y

Element

Relay

Table

Group

Tactical

Relay

Assembly

Precise

Relay

Assembly

Special

Relay

Assembly

Excitation

Assembly

Exciter

Change 15

x

—

6

E

g

—

c

c

c

o

c

c

c

o

0

0

0

0

0

0

0

0

c

c

o

0

0

i’

z

—

$

cd

H

—

o

0

0

F

o

F

F

F

F

F

F

~

(3)

MAINTENANCE

FUNCTIONS

E

—

5

~

a

z

—

0

0

0

0

0

0

0

0

0

0

0

F

0

F

0

F

F

:

F

F

F

F

-i

—

&l

~

&

W

Z

—

0

F

F

F

0

F

0

F

D

F

F

F

H

i’

(4)

TOOLS

AND

3QUIPMEW

3-1

3-1

3-1

2-B,4-X

2-B

2-B,D,I

2-B

2-B

2-B

2-B

(5)

REMARKS

A-A,J-K

1-1

1-1

1-1

A-A,G-B,

J-K

A-A,D-B

A-A

A-A,K-B

L-B,C-l

A-A

A-A

K-B

K-B

K-B

2-B

TM 5-6115-545-12

TO-35C2-3-444-1

NAVFAC P-8-626-12

TM-00038G-12

(1)

G

R

o

u

P

N

o.

13

(Cont)

14

15

16

17

(2)

GROUP

TITLE

Relay

Table

Group

Voltage

Regulator

Load

Measuring

Unit

Generator

Assembly

Bearing

Rectifier

Rotating

Fan

Generator

Rotor

Assembly

Stator

Exciter

Assembly

Stator

Generator

Assembly

Day

Tank

and

Fuel

Filter

Assembly

Solenoid

Valve

Day

Tank

Float

Switch

Fuel

Filter

Assembly

Lifting

Frame

Assembly

Start

Aid

Assembly

Filler

Cap,

Gasket

and

Strainer

Hoses

Lifting

Frame

Fuel

Transfer

Pump

Cooling

Group

Grill

Fan

Guard

A

—

&

c1

5

~

—

F

o

0

0

F

F

F

F

F

o

c

o

c

c

c

c

o

c

c

c

(3)

MAINTENANCE

FUNCTIONS

F

F

F

F

o

0

0

c

c

c

c

o

H

M

~

A

a

F

F

F

F

F

F

F

F

F

o

0

0

0

0

0

0

F

o

0

0

(4)

TOOLS

AND

EQUIPMENT

2–B,

5–I,

J

6,7–H,

8–B

9–I,

J

10–

H

2–B,

11–1

2–B

2-B

2–B

2–B

(5)

REMARKS

D–B

E–I

D–B

N–A

G–B

O–B,

P–K

O–B,

P–K

O–B,

P–K

G–B

Q–C

Q–C

Change 13C-5

TM 5-6115-545-12

TO-35C2-3-444-1

NAVFAC P-8-626-12

TM-00038G-12

(1)

G

R

O

U

P

N

O.

(Cont)

18

19

20

C-6

(2)

GROUP

TITLE

17

Shutter

Thermostat

Shutters

Assembly

Radiator

Hydraulic

Cooler

Hydraulic

Actuator

Hydraulic

Sump

and

Filter

Sump

Filter

Engine

Assembly

Belts,

Fan

Alternator/Battery

Charging

Diodes

Brush

ASSY

Rotor

Field

Assembly

Voltage

Regulator

(DC)

Hydraulic

Pump

&

Drive

Assembly

Speed

Switch

and

Drive

Speed

Switch

Adapter

Tach

Drive

Oil

Level

Gage

and

Filler

Electric

Starter

and

Adapter

Starter

Assembly

Brushes

Change 13

:

L1

b

*

b

n

q

c

c

c

c

c

c

c

c

c

F

F

F

F

F

c

c

c

F

c

c

E

(3)

MAINTENANCE

FUNCTIONS

F

—

w

c)

-j

a

a!

—

o

0

0

0

F

o

0

F

o

0

F

F

F

F

F

F

o

F

F

o

0

F

(4)

TOOLS

AND

EQUIPMENT

12–B

14–B–D

6–H,7–

H

15–D

2–B,

16–

B,D

2–B,

ll–

H

2–B

2–B

2–B,16–

B

17–B

2

–

B,

18,

19–D

2–B

(5)

REMARKS

R–B

D–B

D–B,

T–D

u–c

D–B

V–D

D–B,

V–E

G–B

G–B

G–B

D–B

W–B,

X–D

G–B,

Y–D

D–B

AA–A

(1)

(Cont)

(2)

GROUP

T~LE

20

Solenoid

Starter

Armature

Starter

Drive

Starter

Field

Assembly

Oil

Filter

and

Sensors

Xmtr,

Pressure

Switch,

Pressure

Filter

Assembly,

Oil

Secondary

Fuel

Filter

Lube

Oil

Cooler

Relief

Valve

Nozzle

Holder

Assemblies

and

Lines

Nozzle

Holders

Lines

Pump,

Fuel

Injection

Diffuser

and

Turbocharger

Diffuser

Turbocharger

Water

Pump

and

F%n

Pump

Fan

Thermostat

and

Housing

Thermostat

Xmtr,

Temperature

Switch,

Temperature

(3)

MAINTENANCE FUNCTIONS

(4)

TOOLS

2QUIPME~

2-B

22-B

2-B

2-B

23-

B,

D-

I

12-B

2-B

2-B

(5)

REMARKS

D-B

AB-B

G-B

G-B

AC-C

AC-C

AE-D

L-

B,QI

D

R-B

G-B

G-B

Change 8 C-7

(1)

G

R

O

U

P

N

O.

20

(Cont)

Timing Gear and Cover

C-8

(2)

GROUP

TITLE

Dampener,

Vibration

and

Crankshaft

Pulley

Idler

Pulley

Assembly

Intake

Manifold

EXhSUSt

Manifold

Engine

FYcmt

Support

Oil

Pan

Assembly

011

pump

Flywheel

end

Housing

Flywheel

Assembly

Eungcear

Flywheel

Housiw

Cylinder

Head

and

Vslve

Operating

Mechanism

Rocker

Arm

Shaft

Assem.

bly

Rocker

Arm

Assembly

Pushrod

Cylinder

Head

Assembly

Valves

Intake

and

Exkuet

qx’ings

Valvw

Seats

Intake

and

Exhaust

valves

Guides

Valve

Head,

Cylinder

Lifters,

Valve

camshaft

Change 8

(3)

MMNTENANCE

FUNCTIONS

—

H

5

j

A

w

&

—

F

o

0

0

F

F

H

H

H

H

H

F

F

F

F

F

F

H

H

H

H

H

(4)

‘TOOLS

ZQUIPMENI

21-D

24-1,25-

26-1

27-H

28-H

29-H

(5)

REMARUS

V-D

AF-1

D-B

AG-B

(1)

G

O

U

P

O.

—

(Cont)

21

22

23

(2)

GROUP

TITLE

R

N

20

Piston

snd

I@s

Pietun

P&

Camecting

Rod

Rod

Beu’tng

Plstal

Rtngs

Plstal

Crankshaft

snd

mock

Cylinder

Sleeves

Main Bearings

Craukshatt

Brg,

camshaft

Cylinder

Block

2sss

Graup

sensor,

Fuel

‘Iknk,

Fuel

Skid

Base

Jccessory

Items

Psralleltng

Cable

Fuel

Line,

Auxilisry

Farts

Kits

Garket

Set,

Vslve

Grindlw

Gasket

Set,

Intermediate

Hit,

Starter

Kit,

Starter

Relsy

mt,

Brush,

Electric

(3)

MAINTENANCE

FUNCTIONS

c

9

5

m

ha

a

)

)

F

(4)

TOOLS

lQUIPMEIW

30-A

31-

A,

32-H

33-A

34-

A,

35-H

36-H

33,

37-A,

38-H

33-

A,

37-A

39-A

33,

30-

A

2-B

(5)

REMARKS

I

AH-K

D-B

I-

I

A-

A,

J-K

Change 8C-9

(1)

G

O

u

P

O.

—

(Cont)

24

25

(2)

R

REMARKS

GROUP

TITLE

N

23

Kit,

Starter

Solenoid

Ktt,

Gasket

Set,

Fuel

Pump

Kit,

Water

Pump

Gasket

Set,

Oil

Pan

Kit,

Cylinder

Sleeve

Jot

Used

Vinterization

Kit

Fuel

Burning

Control

Box

Assembly

Light

Assembly

Lamp

Circuit

Breaker

Power

Switch

Heater

Assembly

Valve

Assembly,

Regulator

Terminal

Board

Switch,

Limit

Receptacle

Assembly

Igniter

Assembly

Switch,

Flame

Wiring

Harnesses

Coolant

Pump

and

Motor

Ass

Pump

Relief

Valve

Motor

Assembly

Fan

M&M

4

c-

LI

w

tJ

g

c

0

0

0

c

F

0

0

0

0

F

0

F

F

F

F

F

(3)

MAINTENANCE

FUNCTIONS

i

w

u

~

A

w

a

o

0

F

o

F

F

F

F

F

F

o

0

F

o

F

F

F

F

F

F

I

~

w

a

F

F

F

c

F

F

F

(4)

TOOLS

EQUIPMENT

2-B

2-B

2-B

2-B

2-B

8-B

2-B

8-B

(5)

D-B

D-B

D-B

G-B

G-B

D-B

G-B

G-B

G-

B,

V-D

A-

A,

J-K

C-10

(1)

G

O

U

P

O.

R

N

(Cont)

26

(2)

GROUP

TITLE

25

Thermostat

Switch

Burner

Chamber

Heat

Exchanger

Hoses,

Lines

and

Fittings

Ieater

Kit,

Winterization

Electric

Coolant

Pump

&

Motor

Assy

Pump

Relief

Valve

Motor

Heating

Elements

Thermostat

Switch

Hoses

and

Fifflngs

Wiring

Harness

Electric

Winterization

Control

Box

Wiring

Hmmess

‘iYansformers

Relay

Semi

Conductors

Circuit

Breaker

Power

Switch

Fuse

Holder

Fuse

Light

Assembly

Indicating

lamps

(3)

MAINTENANCE

FUNCTIONS

o

0

c

c

o

F

F

F

o

0

0

0

0

0

0

0

F

F

F

F

F

o

0

c

—

H

—

M

u

4

d

&

w

E

—

0

F

F

0

0

0

F

F

F

0

0

0

0

0

F

F

F

F

F

F

F

0

F

0

(4)

TOOLS

AND

EQUIPMENr

2-B

8-B

2-B

2-B

2-B

2-B

2-B

2-B

2-B

2-B

(5)

REMARKS

D-B

D-B

D-B

E-

I

D-B

D-B

A-

A,

J-K

J-K

G-B

G-B

G-B

G-B

D-B

D-B

C-11

(1)

G

O

U

P

N

o.

27

28

(2)

R

GROUP

TITLE

Kit-Wheel

Mounting

Wheels

and

Tires

Bearings

Wheel

Brakes

Load

Bank

Wiring

Harnesses

Control

Panel

Assembly

Switches,

Rotary

Switch,

Load

Reject

Fan

and

Motor

Assembly

Brushes

Fan

Blade

and

Guard

Grommets,

Mounting

Circuit

Breaker

Indicating

Light

Lamp

Load

Reject

Relay

Terminal

Board

Diodes

Thermostat

Heater

Elements

A

H

u

w

&

~

c

c

o

0

0

0

0

0

0

0

0

0

0

0

0

0

0

(3)

MAINTENANCE

FUNCTIONS

—

B

g

H

c

c

o

0

0

0

0

0

0

0

F

F

o

0

H

:

4

E

E

E

F

0

0

a

c1

o

(1

o

F

F

o

0

0

0

0

F

o

F

o

0

I

5

a

G

o

0

0

F

F

(4)

TOOLS

EQUIPMENT

40-B

2-B

2-B

2-B

2-B

2-B

2-B

(5)

REMARKS

Al-B

D-B

A-

A,

J-K

G-B

G-B

E-

I

G-B

K-B

G-B

G-B

C-12

REFERENCE

CODE

1-B

2-B

3-I

4-K

5-D-I-J

6-H

7-H.

8-B

9-I-J

1O-H

11-1

12-B

13

14-B-D

15-D

16-B-D

17-B

18-D

Section III. MAINTENANCE ALLOCATION CHART

ARMY and USMC only

For DOD Generator Sets, 60 KW, 50/60 and 400 Hz

TOOL AND TEST EQUIPMENT REQUIREMENTS

MAINTENANCE

CATEGORY

o

0

F

o

F

F

F

F

F

F

F

o

F

o

0

F

F

NOMENCLATURE

Tester,

Battery

Elect-

Rolyte

Solution

(Component

of

Tool

Set

L/x

Tl

31

52)

Multimeter

Torch

Outfit,

Cutting

and

Welding

(Tool

Set

L/I

W67706)

Tool

Kt,

Electrical

Connector

Repair

Oscilloscope

Hoist,

Chain,

3

Ton

Trestle,

Hoist,

Portable,

5

Ton

Multimeter,

Split

Core

Ohmmeter

Puller

Attachment

(Component

of

Puller

Kit

5180-701

-8046)

Soldering

Outfit,

Electric

Thermometer,

Self-Indicating

50-400

Degree

F.

Range

Deleted

Test

Stand,

Actuator

(Class

1

only)

Scale,

Dial

Indicating,

O-50

lb

Test

Set,

Generator

and

Voltage

Regulator

Test

Gage

and

Hose

Ay

Tachometer,

Stroboscopic

-.

TOOL

NUMBER

6630-171-5126

or

Equal

6625-581-2036

or

Equal

3433-357-6311

or

Equal

5180-876-9336

or

Equal

6625-643-1740

or

Equal

3950-292-9879

or

Equal

3950-449-7005

or

Equal

6625-892-1497

or

Equal

6625-581-2466

or

Equal

5180-711-6753

or

Equal

3439-853-8760

or

Equal

6685-527-7867

or

Equal

4940-152-2107

or

~qWd~

6670-254-4634

or

Equal

4~10-270.37~0

or

Eqval

4910-774-9343

f.

r

~ql]a]

6630-892-1510

w

Yjual

Change 3C-13

REFERENCE

CODE

19-D

20-I

21-D

22-B

23-B-~1

24-I

25-H

26-I

27-H

28-H

29-H

30-A

31

-A

32-H

33-A

34-A

35-H

36-H

37-A

38-H

39-A

40-B

MAINTENANCE

CATEGORY

F

o

F

F

F

F

F

F

F

H

H

H

H

H

H

H

H

H

H

H

H

c

NOMENCLATURE TOOL

NUMBER

Test

Stand,

Ignition

Magneto

Tester

Spring

Resiliency

Gage,

Thickness

Test

Set,

Armature

Tool

Kit,

Diesel

Injector

Repair

Grinding

Kt,

Valve

Seat

Wrench,

Torque

Grinding

Machine,

Valve

Face

Lifter,

Valve

Spring

Remover

and

Replacer,

Insert

Valve

Seat

Remover

and

Replacer,

Valve

Guide

Caliper

Micrometer,

Outside

1

“

thru

2“

Indicator,

Connecting

Rod

Alignment

Wrench,

Torque

Gage

Set,

Telescoping

Gage,

~

Thickness

Compressor,

Piston

Ring

Expander,

Piston

Ring

Caliper,

Micrometer

Puller,

Mechanical,

Cylinder,

Sleeve

Caliper,

Micrometer

Gage,

Tire

Pressure

4910-912-3960

or

Equal

I

6635-449-3750

or

Equal

5120-221-1999

or

Equal

6625-233-1459

or

Equal

4910-317-8265

or

Equal

4910-473-6437

or

Equal

5120-542-5577

or

Equal

4910-540-4679

or

Equal

5120-239-8686

or

Equal

5120-473-7393

or

Equal

5120-219-8404

or

Equal

5210-243-2933

or

Equal

4910-733-2487

or

Equal

5120-640-6364

or

Equal

5120-473-9350

or

Equal

5210-517-8097

or

Equal

5120-894-0753

or

Equal

5120-393-0549

or

Equal

5120-255-7564

or

Equal

5120

-417

-’2952

or

Equal

5210-221-1934

or

Equal

4910-204-3170

or

Equal

C-14

REFERENCE

CODE

A-A

B-B

C-I

D-B

E-I

F-D

GB

H-C

I-I

J-K

K-B

L-B,

D&I

M-D

N-A

O-B

P-K

Q-C

R-B

S-B

T-D

u-c

V-D

W-B

X-D

Y-D

Z-D

M-A

A&B

Section IV. MAINTENANCE ALLOCATION CHART

ARMY and USMC only

REMARKS

Visual

Inspection

Hydrometer

Test

Cover

Components

Only

Operational

Test

Repair

by

Replacement

of

Components

Zero

Adjust

Continuity

Test

Deleted

Weld

and

Straighten

Fabricate

New

Harness

Test

for

Known

Voltage

at

Terminals

In

Accordance

with

Procedures

in

Applicable

TM

Deleted

Visual,

Audible

and

Physical

Heat

Detection

Insulation

Breakdown

and

Continuity

Tests

Rewind

Drain

Condensation

Thermometer

Test

Deleted

Adjust

after

Replacement

or

Repair

Check

Fluid

Level

Adjust

to

Specifications

in

Applicable

TM

Test

Pressure

Output

Adjust

Pressure

Output

Overspeed

Only

Deleted

Inspect

for

Minimum

Length

Growler

Test

C-15

REFERENCE

CODE

AC-C

AD-D

AE-D

AF-I

AG

B

AH-

K

AI-B

REMARKS

Replace

Element

Deleted

Adjust

Injector

Pressure

Setting

Includes

Replacing

Valves

and

Springs

Spring

Tension

and

Length

Include

Replacement

of

Sleeves

Pressure

Test

C-16

ALPHABETICAL INDEX

Subject

Paragraph,

Figure, Table,

Number

A

Abbreviations . . . .

Accessory Items

Accessory Items

General. . . . .

Hose Assembly .

Paralleling Cable Assembly.

Storage Space . . . . . .- .

Adjusting Flame Switch . . . .

Adjustment

Flame Micro-Switch . . . .

Fuel Regulator . . . . . .

Fuel Regulator Valve . . .

Valve Tappet Clearance . .

Air Cleaner Service . . . . . .

Alternator and Related Parts

Assembly . . . . . . . . .

Battery Charging Alternator

.

Belt Adjustment and Replacement

Drive Belts . . . . . . . . . .

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

B

Base Group and Related Components

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

Base Group . . . . . . . . . . . . . . . . . . . . . . .

Fuel Tank Removal, Cleaning and Inspection and Installation .

Fuel Quantity Transmitter Removal, Testing and Replacement

Fuel Quantity Transmitter Test . .

General, . . . . . . . . . . . .

Related Components . . . . . . .

Skid Base Inspection . . . . . . .

Basic Issue Items List, Section II . . .

Batteries and Related Parts

Batteries . . . . . . .

General . . . . . . . . .

Batteries and Slave Receptacles .

C

Controls and Instruments

Controls and Instruments . ,

General, . . . . . . . . .

Convenience Receptacle

Convenience Receptacle . . .

Box Assembly Replacement ,

Circuit Breaker Test Replacement. .

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

Replacement . . . . . . . . . . .

(Deleted)

(Deleted)

(Deleted)

(Deleted)

(Deleted)

Coolant PumpMotor -Brush and Connector Replacement.

.

B-6

F3-53

3-226

3-228

3-227

3-229

F4-4

4-11

4-10

F4-3

3-220

F3-5

F3-36

3-184

F3-35

3-183

3-182

F3-50

F3-51

3-225

3-223

F3-52

3-221

3-224

3-222

B-2

3-82

3-81

F3-4

2-10, F2-5

2-9

F3-13

3-89

3-91

3-88

3-90

F3-14

3-94

3-92

3-93

F4-8

Change 1I-1

ALPHABETICAL INDEX (Cont)

Cooling Group

Cooling Group, . . . . . . . . . . . . . . . .

Cooling Group and Related Parts . . . . . . . .

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

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

Grille . . . . . . . . . . . . . . . . . . . .

Hydraulic Cooler . . . . . . . . . . . . . . .

Radiator . . . . . . . . . . . . . . . . . . .

Shutter Assembly . . . . . . . . . . . . . . .

Shutter Thermostat . . . . . . . . . . . . .

Shutter Thermostat Replacement . . . . . . . .

Crankshaft Pulley and Vibration Dampener

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

Inspection . . . . . . . . . . . . . . . . . .

D

Data Instruction Plate Locations. . . . . . . . . . . .

Day Tank Fuel Assembly

Day Tank and Float Switch . . . . . . . . . . . .

Day Tank and Fuel Filter Assembly . . . . . . . .

Fuel Filter Assembly Removal and Replacement . .

Solenoid Valve, . . . . . . . . . . .

Description and Data

Description . . . . . . . . . . . . .

Difference in Models . . . . . . . . .

Identification and Tabulated Data . . .

Destruction of Material . . . . . . . . .

Differences in Performance Characteristics

Diffusers and Turbocharger

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

Exhaust Diffuser . . . . . . . . . .

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

Turbocharger, . . . . . . . . . . .

E

Electric Starter and Adapter

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

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

Starter Solenoid . . . . . . . . . . . .

Electric Winterization Kit

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

Control Box Fuse and Lamp Replacement

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

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

Operation . . . . . . . . . . . . . . .

Preventive Maintenance . . . . . . . .

Preventive Maintenance Checks and Services . . . . . .

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

schematic Wiring . . . . . . . . . . . . . . . . . .

Troubleshooting . . . . . . . . . . . . . . . . . . .

Engine Assembly

Drain Hoses . . . . . . . . . . . .

Engine Assembly Testing. . . . . . . . . . . . . . .

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

Engine Generator and Chassis Interconnecting Wiring Harnesses

Engine Generator and Chassis Wiring Harnesses . . . . .

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

Inspection, Test, Repair and Replacement . . . . . . . .

Engine Generator Set

Left Rear, Three Quarter View . . . . . . . . . . . . .

Right Front, Three Quarter View . . . . . . . . . . . .

I-2

F3-31

F3-29

3-169

3-167

3-168

3-173

3-172

3-171

3-170

F3-30

3-210

3-211

F1-3

3-159

F3-27

3-160

3-158

1-3

1-5

1-4

A-7

T1-1

F3-42

3-204

3-202

3-203

3-189

3-190

3-191

F4-7

F4-9

4-17

4-18

2-26

4-20

T4-3

4-19

F4-6

4-21, T4-4

3-181

3-180

3-179

F3-23

3-138

3-139

F1-2

F1-1

ALPHABETICAL INDEX (Cont)

Engine Generator Set Housing Group

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

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

Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Equipment

Inspecting and servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Unloading. . . . , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Unpacking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Equipment Conversion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exhaust and Breather Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exhaust Manifold Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Inspection and Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Explanation of Columns . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Explanation of Columns in Section II. . . . . . . . . . . . . . . . . . . . . . . . . .

Explanation of Columns in Section III . . . . . . . . . . . . . . . . . . . . . . . . .

Explanation of Columns in Section IV . . . . . . . . . . . . . . . . . . . . . . . . .

Explanation of Columns in the Tabular List of Maintenance

and Operating Supplies - Section IV. . . . . . .

Fan and Motor Assembly. . . . . . . . . . . .

Fault Indicator Test Points . . . . . . . . . . .

Fault Indicators Function . . . . . . . . . . . .

Field Expedient Repairs

Battery Charging Ammeter Shows No Charge .

Engine Cranks But Will Not Start or Starts and

Engine Heat Up . . . . . . . . . . . . . .

Engine Overheating . . . . . . . . . . . .

F

Runs Erratically or Misfires . . . . . .

Engine Shuts Down-and Low Oil Pressure Indicator Lights . . . . . . . . . . .

Fuel is Not Strained . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Housing Filled with Smoke... . . . . . . . . . . . . . . . . . . . ..

Loss of Frequency Control (Class 1 sets Only) . . . . . . . . . . . . . . . .

Fire Protection, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Forms and Records . . . . . . . . . . . . . . . . . . . . . . . . .

Freezing Points, Composition, and Specific Gravities of Military Antifreeze Materials

Fuel Burning Winterization Kit

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

Control Box and Lamp Replacement . . . . . . . . . . . . . . . . . . . . .

General, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G

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

Generator Assembly

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

Generator Bearing Inspection.. . . . . . . . . . . . . . . . . . . . . . . . . .

Generator Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Generator Load Terminal Board Connections . . . . . . . . . . . . . . . . . . . . . .

Generator Set Controls

AC Ammeter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . .

AC Voltmeter Replacement . . . . . . . . . . . . . . . . . . . . . . . . .

Ammeter-Voltmeter Selector Switch Schematic . . . . . . . . . . . . . . . . . . .

AMPS-VOLTS Selector Switch, . . . . . . . . . . . . . . . . . . . . . . . . .

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

Battery Charging Ammeter . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-136

F3-22

3-137

2-3

2-1

2-2

2-6

F3-12

F3-47

3-216

3-217

B-3

C-2

C-3

C-4

B-4

F4-15

T3-2

T2-2

3-74

3-72

3-71

3-69

3-73

3-67

3-66

3-68

3-75

A-1

1-2

T2-1

F4-1

F4-2

4-3

4-4

2-25

4-6

4-5

4-7, T4-2

B-2, C-1

3-154

3-156

3-155

F2-3

3-108

3-105

F3-21

3-112

F3-17

3-124

I-3

Generator Set Controls (Cont)

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

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

Control Box. . , , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Control Box Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Cubicle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Cubicle Panel Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

Coolant Temperature Gage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

DC Control Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

Fault Indicator, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Governor Control Unit

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

Air Cleaner Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Governor Control Unit Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Governor Control Box Frequency Adjust Rheostat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Grounding Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Heater Elements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Hydraulic Actuator and Sump and Filter (MEP105AOnly)

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

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

Hydraulic Actuator Servicing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Hydraulic Sump and Filter (MEP105A Only Except MEP115A)

Cleaning and Inspection of Sump and Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drain Hose Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

Idler Pulley and Mounting Bracket

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

I

3-116

3-117

3-135

3-126

3-134

3-104, F3-18

3-133

F3-19

F3-20

3-120

3-132

3-100, 3-125

3-131

3-118

3-119

3-103

3-109

3-111

3-122

3-99

3-106

3-102

3-121

3-115

3-128

3-113

3-129

3-123

3-130

3-127

3-110

3-114

3-107

3-101

F3-26

3-147

3-145

3-146

3-146.1

F2-2

F4-11

4-48

F4-12

3-174

3-175

F3-32

F3-8

3-177

F3-34

F3-33

3-178

3-176

F3-45

I-4Change15

ALPHABETICAL INDEX (Cont)

Idler Pulley and Mounting Bracket (Cont)

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

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

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

Inspection

Auxiliary Fuel Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Water Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..

Inspection, Repair and Replacement

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

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

Inspection, Testing, and Replacement

Control Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

Installation

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

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

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

Of Separately Packed Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Instruction Plate

Battery Arrangement and Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

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

3-212

3-213

4-9

3-64

3-50

3-24

3-48

3-30

3-22

3-21

3-12

3-13

3-211

3-29

3-16

3-28

3-59

3-47

3-39

3-57

3-31

3-43

3-42

3-51

3-55

3-11

3-52

3-61

3-54

3-63

3-15

3-14,F3-15

3-219

3-222

3-10

3-53

3-49

3-27

3-60

3-58

4-25

4-26

4-8,4-27

4-22

4-24

F3-41

4-23

2-5

3-178

4-39

2-4

F2-1

F1-11

F1-23

F1-22

F1-4

F1-5

F1-24

Change 11I-5

ALPHABETICAL INDEX (Cont)

Instruction Plate (Cont)

Operating Instructions . . . . . . . . . . .

Service Instructions and System Capacities . . . . .

Voltage Reconnection . . . . . . . .

Intake Manifold

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

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

Removal and Replacement . . . . . . . .

Interconnecting Diagram

50/60 HZ Precise and Utility . . . . .

400 Hz Precise . . . . . . . . . . .

Interference Suppression Components

Replacement . . . . . . . . . . . .

Items Troop Installed or Authorized List, Section III . .

K

Kit Data and Instruction Plate Location. . . . . . . .

L

Lifting Frame Start Aid Assembly and Fuel Transfer Pumps Assembly

Center Support and Related Parts . . . . . . . .

Filler Cap, Gasket, Strainer, and Hose Replacement . . .

Fuel Selector Valve and Lines Replacement .

Fuel Transfer Pumps . . . . .

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

Lifting Frame . , . . . . .

Start Aid Assembly . . . . .

Load Bank

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

Control Panel Assembly . . . .

General . . . . . . . . . .

Installation . . . . . . . .

Kit Maintenance Procedures . .

Operation . . . . . . . . .

Preventive Maintenance . . . .

Preventive Maintenance Checks and Services .

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

Schematic Diagram . . . . . . . . .

Troubleshooting . . . . . . . . .

Wiring Diagram . . . . . . .

Wiring Harness . . . . . . . . . . . .

Load Connection Group

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

Current Transformer Assembly . . . .

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

Main AC Contactor . . . .

Load Terminal Board . . . . . .

Reconnection Board . . . . . .

Reconnection Board . . . . . . . .

Load Reject Relay . . . . . . . . .

Load Selector Switch Contact Positions

Lockwire of Fuel Injector Pump for Class 2 Operation .

Lube Oil Cooler

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

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

Inspection and Replacement . . . .

Lube Oil Filters and Sensors

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

Low Oil Pressure Shutdown Switch.

Oil Filter Assembly . . . . .

Oil Pressure Transmitter . . . . . .

I-6

F1-6

F1-7

F1-8

F3-46

3-214

3-215

F1-26

F1-27

3-78

B-2

F1-21

F3-28

3-164

3-166

3-165

3-161

3-163

3-162

F4-14

4-44

4-38

4-39

4-42

2-28

4-40

T4-7

4-49

F4-13

4-41, T4-8

F4-16

4-43

F3-24

3-143

3-140

3-141

3-142

3-144

F3-25

4-45

F4-18

F3-10

F3-40

3-198

3-199

3-192

3-194

3-195

3-193

ALPHABETICAL INDEX (Cont)

Lubrication

Detailed Lubrication Information . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Lube Oil Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Lubrication Information . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubrication Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

M

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance and Operating Supplies, Section IV . . . . . . . . . . . . . . . . . . . .

Material, Service upon Receipt of . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Movement

Dismantling for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Reinstallation after . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Muffler, Exhaust and Breather Pipes - General . . . . . . . . . . . . . . . . .

N

Nozzle Holder Assemblies and Lines

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

Inspection, Testing, and Replacement . . . . . . . . . . . . . . . . . . .

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

0

Oil Level Gage and Filler

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

Oil Level Gage and Adapter and Filler Elbow and Cap . . . . . . . . . . . . . . . . . . .

Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation Instructions

Electric Winterization Kit . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Burning Winterization Kit . . . . . . . . . . . . . . . . . . . . . . . . .

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

Parallel Generator Units . . . . . . . . . . . . . . . . . . . . . . . . . .

Single Generator Unit . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation of Auxiliary Material used in Conjunction with the Equipment

Electric Winterization Kit . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Burning Winterization Kit . . . . . . . . . . . . . . . . . . . . . . . . . . .

General

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

Wheel Mounting Bit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation Under Unusual Conditions

Control Cubicle Removal for Remote Operation . . . . . . . . . . . . . . . . . . . .

Operation at High Altitudes . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation in Dusty or Sandy Areas

Operation in Extreme Cold (Below -25oF) . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation in Extreme Heat (Up to +125oF) . . . . . . . . . . . . . . . . . . . . .

Operation in Silt Water Areas . . . . . . . . . . . . . . . . . . . . . . . . .

Operation in Snow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation Under Rainy or Humid Conditions . . . . . . . . . . . . . . . . . . . .

Operation Under Usual Conditions

Exercise of Engine on Standby Service . . . . . . . . . . . . . . . . . . . . . . . .

General

Operation of Equipment

Preparation for Starting

Starting . . . . . . .

Starting Instructions . .

Sopping . . . . . . .

Stopping Instructions

Operational Data Information

(Mode I) . . . . . . . . .

(Mode II) . . . . . . . . . .

Plate

3-4

F3-3

3-3

A-2

F3-1

F3-2

A-5

B-2

4-2

2-7

2-8

3-85

3-200

3-201

F3-41

3-187

F3-38

3-188

F2-12

F2-11

F2-14

F2-10

F2-9

2-26

2-25

2-24

2-28

2-27

2-23

2-18

2-16

2-17

2-20

2-22

2-19

2-15

2-11

2-14

F2-6

2-12

F2-7

2-13

F2-8

F1-9

F1-10

I-7

2-21

ALPHABETICAL INDEX (Cont)

Operator’s Maintenance

AC Ammeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AC Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air Cleaner Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Day Tank Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Assembly Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Filler Cap, Gasket and Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Frequency Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Filter and Strainer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Transfer Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Hydraulic Sump (MEP105A Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Filter (MEP105A Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Kilowatt Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Panel Light Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Press-To-Test Light Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Preventive Maintenance Checks and Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Radiator Grille . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Start Air Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Secondary Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Organization Maintenance-General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Organizational Maintenance Repair Parts (Army) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

P

Painting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Paralleling Receptacles

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

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

Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Plate and Sleeve Assembly

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

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

Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Preventive Maintenance Checks and Services

Daily (Army and Navy) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Buring Winterization Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Monthly and Semi-Annual (Army and Navy) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

R

Radio Interference Suppression

General Methods Used to Attain Proper Suppression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Interference Suppression Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacement and Suppression Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Radio Suppression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Radioactive Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Relay Table Group

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

Load Measuring Unit Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Precise Relay Assembly Class l (50/60 Hz) Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Special Relay Assembly (50/60 Hz) Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Special Relay Assembly (400 Hz) Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tactical Relay Assembly Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacement

AC Ammeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AC Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-19

3-17

3-32

3-9

3-33

3-46

3-36

3-20

3-34,F3-6

3-37

3-8

3-44

3-45

3-18

3-62,F3-7

3-25

3-26

T3-1

3-41

3-38

3-35

3-56,F3-9

3-80

3-2

A-3

F3-16

3-97

3-98

F3-15

3-95

3-96

3-6

T4-1

3-5

3-7

T3-1

3-76

3-77

F3-11

3-78

A-4

A-8

3-148

3-153

3-150

3-151

3-152

3-149

3-108

3-105

I-8Change 11

ALPHABETICAL INDEX (Cont)

Replacement (Cont)

Base Group and

Batteries . .

Battery Tray .

Breather Pipe .

Control Cubicle

Exhaust Pipe .

Related Components . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

Hose, Lines, and Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Igniter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Kilowatt Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gil Level Gage and Filler . . . . . . . . . . . . . . . . . . . . . . . . . .

Press-To-Test Light Assembly . . . . . . . . . . . . . . . . . . . . . . . . .

Receptacle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Secondary Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shutter Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Slave Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Thermostat Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Water Pump and Fan . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rocker Arm Shaft Assembly

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

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

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Valve Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Valve Tappet Clearance Adjustment . . . . . . . . . . . . . . . . . . . . . . . . .

Running Gear Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

S

Schematic Wiring Diagram

AC, Class l, and Plate . . .

AC, Class 2, and Plate . . .

DC, Class l, and Plate . . .

DC, Class 2, and Plate . . .

Scope . . . . . . . . . . . .

Secondary Fuel Filter

Assembly. . . . . . . . . .

General . . . . . . . . .

Replacement . . . . . . . .

Set I.D. Plate. . . . . . . . . .

Shipment and Storage . . . . . .

Shipping Crate . . . . . . . . .

Special Information (Not Applicable)

Speed Switch

Assembly . . . . . . . . .

General. . . . . . .

Testing and Replacement . . .

T

Terminal Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Testing and Replacement

Control Box Fuse and Lamp . . . . . . . . . . . . . . . . . . . . . . . . .

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

Thermostat Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Thermostat and Housing

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

General, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspection and Operational Check . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal, Testing and Installation . . . . . . . . . . . . . . . . . . . . . . . . . .

Thermostat Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tools and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-224

3-82

3-83

3-87

3-133

3-86

4-16

4-13

3-106

3-188

3-129

4-12

3-197

F3-30

3-84

F4-5

3-206

3-101,4-14

F3-48

3-218

3-219

F3-49

3-220

F4-10

F1-17

F1-19

F1-18

F1-20

1-1, 4-l, B-1

F3-39

3-196

3-197

F1-12

A-6

F1-25

B-5

F3-37

3-185

3-186

4-46

4-28

3-186

4-15

F3-44

3-207

3-208

3-209

4-47

3-1

1-9

ALPHABETICAL INDEX (Cont)

Troubleshooting

General . . . . . . .

Troubleshooting . . . .

Troubleshooting Diagram

AC, (Mode I) and Plate

AC, (Mode II) and Plate

DC, (Mode I) and Plate

DC, (Mode II) and Plate

Voltage Selector Switch Contact Positions . . . . .

Voltage Conversion . . . . . . . . . . . . . . .

Water Pump and Fan

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

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

Replacement . . . . . . . . . . . . . . . .

Wheel Alignment . . . . . . . . . . . . . . .

Wheel Bearings . . . . . . . . . . . . . . . .

V

. .

. .

W

. .

. .

. .

. .

. .

Wheel Brakes and Hand Lever and Bracket Assembly .

Wheel Mounting Kit

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

Kit Maintenance Procedures . . . . . . . . . . .

Operation . . . . . . . . . . . . . . . . . . .

Preventive Maintenance . . . . . . . . . . . . .

Preventive Maintenance Checks and Services . . .

Troubleshooting . . . . . . . . . . . . . . . .

Wheels and Tires . . . . . . . . . . . . . . . . . .

3-65

T3-3

F1-13

F1-14

F1-15

F1-16

F4-17

F2-4

F3-43

3-205

3-206

4-36

4-34

4-35

4-29

4-32

F2-13

4-30

T4-5

4-31, T4-6

4-33

I-10

By Order of the Secretaries of the Army, the Navy, and the Air Force:

Official:

VERNE L. BOWERS

Major General, United States Army

The Adjutant General

Official:

DWIGHT W. COVELL, Colonel,

USAF

Director of Administration

CREIGHTON W. ABRAMS

General, United States Army

Chief of Staff

A. R. MARSCHALL

Rear Admiral, CEC, USN

Commander, Naval Facilities

Engineering Command

JOHN D. RYAN, General,

USAF

Chief of Staff

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