Technical Manual MEP-006a
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Description
This copy pagesIS a reprint which 1 includes current 18. from Changes through ARMY TM-5-6115-545-12 AIR FORCE T0-35C2-3-444-1 NAVY NAVFAC P-8-626-12 MARINE CORPS TM-00038G-12 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 MEP006A MEP105A MEP115A CLASS UTILITY PRECISE PRECISE HERTZ 50/60 50/60 400 NSN 6115-00-118-1243 6115-00-118-1252 6115-00-118-1253 Including Optional Kits DOD MODELS N O M E N C L A T U R E WINTERIZATION WINTERIZATION LOAD WHEEL BANK KIT KIT KIT, KIT, FUEL BURNING F S N 6115-407-8314 6115-455-7693 6115-407-8322 6115-463-9092 MEP006AWF MEP006AWE M E P 0 0 6 A L M M E P 0 0 6 A W M ELECTRIC MOUNTING 10 JUNE 1973 Published under authority of t h e Departments of the Air U. Force, S. the Army, Corps) and the Navy (Including Marine TM 5-6115-545-12 TO 35C2-3-444-1 NAVFAC P-8-626-12 TM 00038G-12 DANGEROUS GASES (Cont) 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 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. 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. WARNING 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. 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 NO. 18 HEADQUARTERS, DEPARTMENTS OF THE ARMY, NAVY AND AIR FORCE 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 MEP-006A MEP-105A MEP-115A CLASS UTILITY PRECISE PRECISE HERTZ 50/60 50/60 400 INCLUDING OPTIONAL KITS DOD MODEL MEP006AWF MEP006AWE MEP006ALM MEP006AWM NOMENCLATURE WINTERIZATION KIT, FUEL BURNING WINTERIZATION KIT, ELECTRIC LOAD BANK KIT WHEEL MOUNTING KIT FSN 6115-407-8314 6115-455-7693 6115-407-8322 6115-463-9092 NSN 6115-00-116-1243 6115-00-118-1252 6115-00-118-1253 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 a/(b blank) 2–1 and 2–2 3–3 and 3-4 3-8.1 /(3-8.2 blank) 3–15 and 3–1 6 3–19 through 3-22 3–105 and 3–106 3–115 and 3–116 Insert pages a/(b blank) 2–1 and 2–2 3–3 and 3–4 3-8.1 /(3-8.2 blank) 3–15 and 3–16 3–19 through 3–22 3–105 and 3–106 3–115 through 3–118 2. Retain this sheet in front of manual for reference purposes. TM 5–6115-545-12 TO 35C2-3-444-1 NAVFAC P-8-626-12 TM 00038G-12 C18 By Order of the Secretaries of the Army, Air Force, and Navy (Including the Marine Corps): CARL E. VUONO General, United States Army Chief of Staff Official: THOMAS F. SIKORA Brigadier General, United States Army The Adjutant Genera/ MERRILL A. McPEAK General USAF Chief of Staff Official: CHARLES C. McDONALD General, USAF Commander, Air Force Logistics Command DAVID E. BUTTORFF Rear Admiral, CEC, US Navy Commander Navy Facilities Engineering Command H.E. REESE Executive Director Marine Corps Research, Development and Acquisition Command DISTRIBUTION: To be distributed in accordance with DA Form 12-25E, (qty rqr block no. 0859) . . . . . . . . . . . . . . . . 16 April 1984 . . . . . . . . . . . . . . . . FUEL BURNING WINTERIZATION KIT. 4 WIRE. 10 June 1973 DC. DIESEL ENGINE DRIVEN. GENERATOR SET. ELECTRIC LOAD BANK KIT WHEEL MOUNTING KIT FSN — 6115-407-8314 6115-455-7693 6115-407-8322 6115-463-9092 TABLE OF CONTENTS i . TACTICAL SKID MTD.. MAINTENANCE MANUAL Approved for public falease. 120/208 AND 240/416 VOLTS D0D MODELS MEPO06A MEP105A MEP115A CLASS UTILITY PRECISE PRECISE HERTZ 50/60 50/60 400 FSN 6115-118-1243 6115-118-1252 6115-118-1253 INCLUDING OPTIONAL KITS DOD MODELS MEP006AWF MEP006AWE MEP006ALM MEP006AWM NOMENCLATURE WINTERIZATION KIT. distribution is unlimited. 60 KW..DEPARTMENT OF THE ARMY TECHNICAL MANUAL DEPARTMENT OF THE AIR FORCE TECHNICAL ORDER DEPARTMENT OF THE NAVY PUBLICATION MARINE CORPS TECHNICAL MANUAL TM-5-6115-545-12 TO-35C2-3-444-1 NAVFAC P-8-626-12 TM-00038G-12 HEADQUARTERS TECHNICAL MANUAL OPERATOR AND ORGANIZATIONAL DEPARTMENT OF THE ARMY WASHINGTON. 3 PHASE. . . . . . Load Bank . . . . . . . . . . XLI Intake Manifold . . . . . . . . . . . .. . . . . . . XXXIV Lube Oil Cooler . . . Relay Table Group . . . . . Engine Generator Set-Housing Group . Engine Generator and Chassis Interconnecting Wiring Harnesses . XXV XXVI Page 3-81 LIST OF TABLES 1 lNTRODUCTION . Operator’s Maintenance. . . Hydraulic Actuator and Sump and Filter (C1ass 1 Sets Only Except MEP115A) XXVII Engine Assembly . . . Radio Interference Suppression. . . . . . . . . . . . XXXIII Secondary Fuel Filter . . . . . . XXXI Electric Starter and Adapter XXXII Lube Oil Filters and Sensors. . . . . . . I II III IV V VI Service Upon Receipt of Material Movement to New Worksite . . . . . . . .1 XVIII XIX xx XXI XXII XXIII XXIV Plate and Sleeve Assembly. XXXV Nozzle Holder Assemblies andLines. . . . . . . . . Generator Set Controls . . . Troubleshooting. . . . . Wheel Mounting Kit. . . . . . . . . . . . . . Day Tank and Fuel Filter Assembly. . . . . Kit. . . . . . . . . Preventive Maintenance Checks and Services . . . . . . A. . . 3-77 1-1 ii Change 15 . . . . . . XLIV Base Group and Related Components. . Lifting Frame Assembly. . . . . . . . . .3 3-72 3-74 3-74 I II Introduction . .. Air Cleaner Assembly . . . Muffler. . 3-60 3-60 C 3-72 3-72. . . . . . . . . . Lubrication . . . . . . . . XXXVIII Thermostat and Housing XXXIX Crankshaft and Pulley and Vibration Dampener . . . . Operation Under Unusual Conditions . . . . . . . . . . 3-1 3-1 A 3-6 3-6 3-20 3-27 3-28 3-29 3-29 3-31 3-32 AUXILIARY MATERIAL USED IN CONJUNCTION WITH THE EQUIPMENT . . XXX Oil Level Gage and Filter . . . . . . . . Exhaust and Breather Tubes . . . . Tools and Equipment . . . . . . . . . . . . . . IV Maintenance and operating Supplies . I II III IV V General . . . . . . . 2-1 2-1 2-10 2-10 2-18 2-27 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 . . . . . . . . . . . .. . . Load Connection Group. . . . . . 1-1 1-1 INSTALLATION AND OPERATION INSTRUCTIONS . . 4-1 4-1 4-1 4-11 4-21 4-29 VI VII VIII IX X XI XII XIII XIV XV XVI XVII APPENDIX A B REFERENCES . . . Description and Data . . . . . . . . . . . . . . . XLII Exhaust Manifold XLIII Rocker Arm Shaft Assembly. . . . . . . . . . . . . . . . . . ) B-1 B-1 B-2 B-2 B-3 C-1 C-1 C-2 . Maintenance Allocation Chart. . Controls and Instruments . . . . . . . . . . . . . Items Troop Installed or Authorized List . . . . . . . . . . . . 2-32 3 OPERATOR AND ORGANIZATIONAL MAINTENANCE INSTRUCTIONS . . . . Fuel Burning Winterization Electric Winterization Kit. . . . . . . . . . . . . . Governor Control Unit (MEP115A) . . . . Convenience Receptacle. . . . . . Operation Under Usual Conditions . . . . . . . . . . . . . . 3-35 3-36 3-37 3-60 BASIC ISSUE ITEM LIST AND) ITEMS TROOP INSTALLED OR AUTHORIZED. . . . . . . Start Aid Assembly and Fuel Transfer Pumps . . . . iv Page iii Chapter Cooling Group. . . . . . ... . . . . . . . . . . . . . . I II III Introduction . . . . . (Deleted) 3-1 II III IV V . . . . . . . . . . . . . . . . I II 2 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TM 5-6115-545-12 TO-35C2-3-444-1 NAVFAC P-8-626-12 TM-00038G-12 Chapter LIST OF ILLUSTRATIONS . . . . . . . XL Idler Pulley and Mounting Bracket .. . . . . . . . . . . . . . . . . . .. . . . . Operation of Auxiliary Material Used in Conjunction with the Equipment . . . . . . Batteries and Related Parts . Organizational Maintenance Procedures . . Field Expedient Repairs. . . . . . . Generator Assembly. . . I Operator and organizational Maintenance Repair Parts. . . . MAINTENANCE ALLOCATION CHART ( A R M Y a n d U S M C o n l y . XLV Accessory Items . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INDEX . . . . . . . . . . . . . . . . . . XXVIII Alternator and Related Parts XXIX Speed Switch. . . . . . . Paralleling Receptacles . . . . . Basic Issue Items . XXXVI Diffuser and Turbocharter XXXVII Water Pump and Fan . 3-14. . . . . . . . . . . . . Hydraulic Actuator Servicing . . . Schematic Wiring Diagram Class 1. . . . . . 3-5. . . . . . . . 3-23. . . . . . . . . . . . Schematic Wiring Diagram Class 2. . . 3-31. AC andPlate . . . 3-28 3-29. . 3-22. . . 2-7. . . . . . . . 1-18. . . . 2-3. . . . . . . . . . . . . . . . . . . . Title Grounding Procedures (3 Sheets). . . . . . . . . . . . . .2 3-72. . . . . . 3-6. . . Plate. . . . . . . . . . . . . . . . .3 3-73 3-75 3-79 3-80 3-82 3-83 3-85 3-86 1-23. . . . . . Control Cubicle Schematic Diagram . 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.. . . . . 3-33. . . . 3-18. . . . 1-9. Exhaust and Breather System. . . . . . . .. . . . . . . . . . Operational Data Information Plate (Mode II) . . . . . Control Cubicle Assembly (2 Sheets) . . . . 3-3. . 2-5. Cooling Groups . . . . . . Cooling Group and Related Parts . . . . . . . Battery Arrangement and Connections Instruction Plate . . . . . . . . . . . . 1-24. . . . . . . . . 3-15. . . . . . . .. . . . . . . . . . . . . . . . . Control Cubicle Wiring Diagram (sheets) . . . . . . . . . . . . . . . . . . Kit Data and Instruction Plate Location (2 Sheets) . . . . . . . . . . . . . . Hydraulic Flow Diagram . . . Paralleling Receptacles . . . . . . Schematic Wiring Diagram Class 2. . Fuel Filter and Strainer. . . . 1-14. Wheel Mounting Kit Operation Load Bank Operating Instructions Lubrication Order (2 Sheets) . . Oil Level Gage and Filler . Single Generator Unit. . . . . . . . Fuel System Diagram Instruction Plate . . . . . Hydraulic Sump and Filter . . . . . . . . . . . . . . . . . . Parallel Generator Units Operating Instructions . . Governor Control Unit (MEP-115A) . . 1-28. 1-5. . . . . . . . 2-13. . . DC Troubleshooting Diagram (Mode II) and Plate . . . . . DC and Plate . 1-13. 1-21. . . . . . . . . . . 1-30. . . . . . . . . 2-14. . . 2-8. . . . . . . .. . Terminal Clip Replacement . . Hydraulic Sump and Filter . . . Operational Data Information Plate (Mode I) . . . . . Housing Group (2 Sheets) . . . . . . . . (Deleted) . 50/60 Hz Precise and Utility Interconnecting Diagram . . . 1-6. . . . . . . . . . Shutter Thermostat Replacement . Secondary Fuel Filter . . . . Starting Instructions (2 Sheets) . . AC and Plate . . . . . . . . . . . . . . . . . . . . . . Lifting Instructions Instruction Plate . 2-6. Load Connection Group . Center Support and Related Parts . . . 3-24. .. . . Generator Load Terminal Board Connections. . . . 3-26. . . . . . . . . . . . . 3-32. . . . . . . . . . . Fuel Burning Winterization System Diagram and Heater Control Schematic Diagram Instruction Plate . . Schematic Wiring Diagram Class 1. . . . . . . . . . . . . . 3-9. 2-4. . . . . . . . . . . . . . . . . . . . . . Electric Winterization System Diagram and Electric Heater Control Schematic Diagram Instruction Plate . . . . . . . Generator Set Controls and Instruments (6 Sheets) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400 Hz Precise Interconnecting Diagram. Engine Generator and Chassis Wiring Harness (2 Sheets) . . . 3-10. . . . . . . 2-9. . . . 3-16. . . . . . . . . . . 3-24. 2-12. . DC Troubleshooting Diagram (Mode I) and Plate. . . . . AC Troubleshooting Diagram (Mode I)andPlate. . . Voltage Conversion . . . . . Preparation for Starting (2 Sheets) . . . . . . . . . . . . . . . . . 1-4.. . 1-19. . . . . . 1-8. . . . . . . . . . Convenience Receptacle . .. . . . . . . . . . . . Voltage Reconnection Instruction Plate . . . . . . . . . . . . . .TM 5-6115-545-12 TO-35C2-3-444-1 NAVFACP-8-626-12 TM-00038G-12 LIST OF ILLUSTRATIONS Number 1-1. . . . . Electric Winterization Kit Operating Instructions (2 Sheets). . . . . . . . . . 1-37 1-39 1-39 1-41 1-43 1-45 1-47 1-49 2-4 2-4 3-25. . . . . . . . . . 2-1A. . . . . Stopping Instructions . Change 15 iii . . . . . . . . . 3-1. . Main Fuel Tank . . . .. . . 2-11. . . . . . . . . . . . . . 3-2. 1-15. 3-20. . . . . . . Plate and Sleeve Assembly . . . . . Day Tank and Fuel Filter Assembly . . . . . 3-7. . Precise and Utility . . . Data Instruction Plate Locations (2 Sheets) .. . . . . . . . . . . . Operating Instructions . . . Ammeter-Voltmeter Selector Switch Schematic . . 1-27. . . . . . DC and Plate . . . . . 1-3. . . 3-30. . Load Bank Connection and Operation Instruction Plate . 1-17. . . . Backwire of Fuel Injector Pump for Class 2 0peration . 1-7. 1-26. . . . . . . . . . . . . . . Three Quarter View. . . . . . . . . . Engine Lube Oil Filters . . . . . 2-10. Batteries and Slave Receptacles. . .2 Number 2-2. Title Engine Generator Set. . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . 3-17. . . . 1-2. . .. . . . . Three Quarter View. . . . .1 3-24. . . . . . . . Operating Instructions Instruction Plate . . . . . 3-8. . Shipping Crate . . . . . .. . . . . . . . . . Reconnections Board . 3-13. . . 1-20. . . . . . . . . . . Set I. . . . . 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 3-21. . . . . . .1. . . . . . . . . 3-19. . . . . . . . 3-12. 1-25. . . . . . Interference Suppression Components Removal and Installation . . . . .D. . . Right Front. . . . . . . . . . . .. . . Interconnection Wiring Diagram 50/60 Hz Precise and Utility Interconnection Wiring Diagram 400 Hz. . Generator Set Controls . . . Service Instruction and System Capacities Instruction Plate . . . . Fuel Burning Winterization Kit Operating Instructions (2 Sheets) . . . 3-27. . . 1-12. . . . . Air Cleaner and Related Parts . Air Cleaner Service . . . . AC Troubleshooting Diagram (Mode II)andPlate . . . . . . . . Left Rear. . . . . . . Noise Level Warning . 2. . 1-22. . . Engine Generator Set. 3-11. . . . . . . . . . . . . . . . . . . . . . . . . 1-11. . . . . . 3-4. . . 1-29. Installation Plan . . . . . . . 1-16. . . . 1-10. . . . . . . . . . 3-53. . . 3-115 Accessory Items with Attaching Hardware . . . 4-10 Thermostat Switch Replacement . . . . . . . . . . . . 4-13. . . . . . . . . 3-111 Valve Locations . . . . . . . . . . . . . . . . . 3-89 Alternator and Related Parts . . . . . . . and Specific Gravities of Military Anti-freeze Materials . . 4-37 iv Change 13 . . . . . 4-11. 4-17 Electric Winterization Kit Troubleshooting . . . . 4-25 Load Bank Preventive Maintenance Checks and Services . . . . . . 3-113 Base Group . . . 3-43. . . . . . . . . . . . . . . . 3-95 Lube Oil Cooler . 3-39. . . 3-42. . . . 4-1. . . . 3-90 Speed Switch . . . . . . . . . . . . . . 3-52. . . . . 2-17 Preventive Maintenance Checks and Services . . . . . . . . . 4-41 Load Selector Switch Contact Positions . . . 3-49. . . . . . . . . . . . . . . . . . . . . . . . . . 4-23 Wheel Mounting Kit Troubleshooting . . . . 4-26 Load Bank Schematic Diagram . . . . . . . . . . . 3-38. . . 4-36 Wiring Diagram Load Bank . . . . . . . . . 4-3. . . . . . . . . . . . . . . . . Title Page Number 4-2. . . . . . . . . 4-6. . . . . . . . . . . . . . . . . . . . . 3-50. . . . . . . . . . . . . 4-9. . . . . . . . . . . . . . . 3-109 Rocker Arm Shaft Assembly . . . . . . . . . 3-21 Preventive Maintenance Checks and Services . . . . . . . . . . . . . . . 3-105 Idler Pulley and Mounting Bracket . . . . . 3-97 Nozzle Holder and Line Assemblies. . Composition. . . . . 4-20 Running Gear Assembly . . . . . . . . 3-45. . . . . 3-7 Fault Indicator Test Points. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41. . . . . 4-9 Adjusting Flame Switch . . . . Title Page Drain Hose Removed . 2-2 Fault Indicator Function . . . . . 4-16. . 3-99 Diffuser and Turbocharger . . . . . . . . . . . . . . . . . 4-41 LIST OF TABLES Number 1-1 2-1 2-2 3-1 3-2 3-3 4-1 4-2 4-3 4-4 4-5 4-6 4-7 4-8 Title Page Difference in Performance Characteristics . 4-4. . . . . . . . . . 4-8. . . . . . . . . . . 3-91 Oil Level Gage and Adapter and Filler Elbow and Cap . . . . . 4-7. 3-111 Base Group and Related Components . . 4-10. 3-94 Secondary Fuel Filter Assembly . . . 3-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 Electric Winterization Kit (3 Sheets) . . 3-104 Thermostat and Housing . . . . . . . . . . . . . . . . . . . 1-40 Freezing Points. . . . . 3-109 Exhaust Manifold . . . . . . . . 3-48. . 4-2 Fuel Burning Winterization Kit Troubleshooting . 4-39 Voltage Selector Switch Contact Positions . . . . . . 4-24 Hub and Brake and Front Unit Axle Assemblies (2 Sheets) . . . 3-46. 3-88 Belt Adjustment and Replacement . . . . . . . . . . . . . . . . . . . . . 4-17. . . . . 3-101 Water Pump and Fan . . . . . . . . . . . . 4-31 Load Bank (2 Sheets) . . . 4-18 Electric Winterization Kit Control Box Fuse and Lamp Replacement . . . . . . . . . 3-114 Fuel Quantity Transmitter Set . . . . . . . . 4-18. . . 4-15. . . . . . . . . . . . . . . . . . . . . . . . 4-8 Fuel Regulator Valve Adjustment . . . . . 3-36. . . 3-92 Electrical Starter Removal . . . . . .1. . . . 4-33 Fan and Motor Assembly . . . . .Brush and Connector Replacement . . . . . . . . . . . 4-13 Coolant Pump Motor . . . . . . . . . . 3-51. . . . . . . . . . . 3-13 Troubleshooting . . . . . 3-38. . . . . . . . . . . . . . . 3-47. . . . . . . . 4-10 Electric Winterization Kit Schematic Wiring Diagram . . . . . 3-35. . . . . . . . . . . . . . . 4-7 Electric Winterization Kit Preventive Maintenance Checks and Services . . 4-35 Load Bank Troubleshooting . . 3-116 Fuel Burning Winterization Kit (2 Sheets) . . . . . . 3-40. . . 4-22 Hand Lever and Bracket Assembly . . . . . 4-3 Fuel Burning Winterization Kit Control Box Lamp Replacement . . 4-19 Wheel Mounting Kit Preventive Maintenance Checks and Services . . . . . 4-5. . . . . . 4-12. .TM 5-6115-545-12 TO-35C2-3-444-1 NAVFAC P-8-626-12 TM-00038G-12 LIST OF ILLUSTRATIONS (Cont) Number 3-34. . . 3-107 Intake Manifold . . . . . . . . . . . . . . . 4-14. . . . . . 3-44. . . ATTN: Code LMO. (4) Navy-by letter direct to: Commanding Officer. a. Louis. ) Change 12 1-1 . Description. Report of errors. to extend their capability. Army). St. Other Service users should refer to apSection II DESCRIPTION AND DATA 1-3. THIS TECHNICAL MANUAL IS USED BY THE ARMY. military models MEP105A. Forms and Records. (3) Electric Winterization. These instructions are published for use by personnel to whom the 60 KW Diesel Engine Driven Generator Sets are issued. (2) Army-DA Form 2028 directly to: Commander. S.S. Pa. (2) Fuel Burning Winterization. This manual provides information on the operation and organizational maintenance of the equipment. ATTN: MMST.) (1) Load Bank. 1-2. and recommendations for improvement of this publication by the individual users is encouraged. 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. Marine Corps. Army will be in accordance with TB 740-97-2.NAVMC Form 10772 direct to: Commandant. U... NOTE (Army only) Applicable Army Forms. Shipment and storage for U. excluding Standard Form 46 (United States Government Motor Vehicles Operator’s Identification Card) which is carried by the operator. Forms and Records used by the Army will be only those prescribed by DA Pam 738750. 1-1 and 1-2). D. The generator sets. Reports should be submitted as follows. are portable skid mounted self contained units. (Procedures For Destruction of Equipment to Prevent Enemy Use for U. Sacramento Air Materiel Area. In addition. They are provided with controls. shall be kept in manual compartment mounted on equipment. Army Troop Support Command. b.S. Scope.S. 17055. MEP006A and MEP115A (fig. The generator sets may be mounted on trailers or wheel kits if desired. 20380. S. 95652. in accordance with T0-00-5-1. a. Navy. a. (See Appendix A for technical manual. NAVY AND MARINE CORPS. California. b. U. Those used by the Marine Corps will be those prescribed by TM 4700-15/1. (Mode II) Tactical Precise Sets are used in applications which demand precise frequency control. Provides a means to monitor 60 Hz primary power and automatically start and transfer the load to a standby generator set in the event of abnormal primary power fluctuation. 4300 Good fellow Boulevard. ATTN: Code 783. McClellan Air Force Base. Each set is equipped with engine oil pan heating elements and necessary connections for field installation of winterization kits. The 50/60 Hertz (Mode I) Tactical Utility (Class 2) Set is used in application where exact frequency is not required. propriate specification/publications for equipment maintenance forms and records. Preservation for shipment and storage for U. (3) Marine Corps. omissions. Mechanicsburg. MO 63120-1798. THE USE OF FORMS IN COMPLIANCE WITH DIRECTIVES AS STATED HEREIN WILL BE ACCOMPLISHED ONLY BY THE PERSONNEL OF THE SERVICE TO WHICH THEY APPLY. O.CHAPTER 1 INTRODUCTION Section I. the sets have been designed to accept and operate with the following kits: (See chapter 4 for Items 1 thru 4. ATTN: AMSTR-MCTS. Also included are descriptions of main units and their functions in relationship to other components. 35-1-4. c. (5) Automatic Transfer Panel 50/60 Hz. Washington. Air Force will be in accordance with T. General. (4) Wheel Mounting. C. (Mode I) Tactical Precise (Class 1) and 400 Hertz. Demolition of material to prevent enemy use will be in accordance with the requirement of TM 750-244-3. U. The 50/60 Hertz. Ships Parts Control Center. GENERAL 1-1.S. AIR FORCE. (1) Air Force-AFTO Form 22 direct to: Commander. (See Appendix A for technical manual. Permits starting. to -65°F. Engine Generator Set. 1 . Provides a dependable external source of battery power for starting of generator set in ambient temperatures from -25°F. Right Front. stopping and voltage adjustment of the generator set from a remote location.2 C h a n g e 7 . Provides a dependable external source of battery power for starting of generator set in ambient temperatures from -25°F. ) (9) Auxiliary Electric Winterization.Figure 1-1. to -65°F. (See Appendix A for technical manual). (See Appendix A for technical manual). (8) Auxiliary Fuel Burning Winterization. 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. Change 11 1 . turbo-charged. a. Three Quarter View b. Identification and Tabulated Data. Generator. brushless. and figures 1-22 through 1-24 illustrate their content. Left Rear. Engine. The engine is a liquid-cooled. valve-inhead. c. Figure 1-3 locates these plates. air-cooled rotating field generator. 1-4. Generator.Figure 1-2. and figures 1-4 through 1-20 illustrate their content. air-cooled rotating field generator. Instruction plates for kits are located in figure 1-21. diesel engine. Engine Generator Set. The 50/60 Hz generator is a 50/60KW. The 400 Hz generator is a 60 KW. The generator set has data and instructional plates located throughout the set.3 . 4 stroke cycle. brushless. d. 6 cylinder. Identification. DC and Plate (fig. 1-17) Schematic Wiring Diagram Class 2. 1-6) Service Instructions and System Capacities Instruction Plate (fig. 1-9) Operational Data Information Plate (Mode II) (fig.1. Fuel System Diagram Instruction Plate (fig. 1-4) Lifting Instructions Instruction Plate (fig. 12. 4. 1-5) AC Troubleshooting Diagram (Mode I) and Plate (fig. 6. 3. 1-18) Schematic Wiring Diagram Class 2. 1-8) Operational Data Information Plate (Mode I) (fig. 1-10) 8. 10. 1-16) Battery Arrangement and Connections Instructions Plate (fig. 1-13) AC Troubleshooting Diagram (Mode II) and Plate (fig. AC and Plate (fig. 1-7) Voltage Reconnection Instruction Plate (fig. 1-20) DC Troubleshooting Diagram (Mode I) and Plate (fig. DC and Plate (fig. 2. 13. 1-11) Set I. 5. 11. 1-15) DC Troubleshooting Diagram (Mode II) and Plate (fig. 1-14) Operating Instructions Instruction Plate (fig. 7. Data Instruction Plate Locations (Sheet 1 of 2) 1-4 . Figure 1-3.D. Plate (fig. 1 -12) Fuel Selector Valve Instruction Plate 9. AC and Plate (fig. 1 -19) Schematic Wiring Diagram Class 1. Schematic Wiring Diagram Class 1. MEP006A (50/60 Hz utility) Model . . . . 70-0105 (50/60 Hz precise) 70-0006 (50/60 Hz utility) 70-0115 (400h Hz precise) Models : Model . DOD drawing no. . (1) Engine generator set (end item). . . 36 inches Height .) .) . . . . 120/208 volts and 240/416 volts Power factor . . . MEP115A (400 Hz precise) Length . . . . . . . . . . . . . . . Data Instruction Plate Locations (Sheet 2 of 2) b _. . . . . . . . . . . . . . . . . . . . . . . . . . . 125°F to -25°F (-25° to -65°F with winterization systems) Voltage output . . . . . . . 4300 lbs (50/60 HZ precise set) Weight dry (less kits and optional equip. . . 4240 lbs (50/60 HZ utility set) Operating temperature range . . . . Tabulated Data. . . 59 inches Weight dry (less kits and optional equip. . . . . . . . . . . . . 60 KW 50 KW at 50 Hz) 1-5 . 87 inches Width . . . . MEP105A (50/60 Hz precise) Model . . . . 4400 lbs (400 Hz set) Weight dry (less kits and optional equip. . . . 0. . . .Figure 1-3. . ) . . . . . . . . . . . . . . . . . . . .8 Size . . . . . . . . . . . . 1-5-3-6-2-4 Rotation (viewed from fan end) . . . . .b. . . . . . . . . Fuel System Diagram Instruction Plate 1-6 Change 7 . . . . . . . . . . . . . . . . . . . . 130 Figure 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Circulating coolant Cycle . . . . . . . (Cont) (2) Engine. . . . . . . . . . . . . . . . Firing order . 6 cylinder. . . . . . . . . . . . . . . . . . . . . . 2 per cylinder Maximum permissible exhaust restriction . . . . . 1500 rpm . . 70-1049 T y p e. . . . . . . . . . Tabulated Data. . . . . . 2 inches of mercury Brake horsepower COD drawing no. . . . . . . . . . . . . Clockwise Cooling . 4 stroke Valves . . . Diesel fuel W-F-800 JP-4 or JP-5 CAUTION JP-4 and JP-5 fuel are considered emergency fuels only. . . . . . . . . turbocharged diesel Fuel . 100 1800 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . 120 2000 rpm . . . . 3 power factor . . . . Air Degree of enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1800 rpm for 60 Hz. .8 Hertz . . . . . . . . . 120/208 or 240/416 (Adjustable to 197/240 or 395/480. . . . . . . . . . 70-1900 Type . . . . . . . . . .Figure 1-5. . . Drip-proof Lubrication . 60 Hz fig. . . . . . 5/75 KW . . . brushless with integral exciter KVA (Kilovolt amperes). . . . . Direct Duty classification . . . . 1500 rpm for 50 Hz . . 1 -9) Amperes . . . . . . . . . . . . . . . . . (Cont) (3) Main generator (50/60 Hz tactical utility and tactical precise). . . . Rotating field synchronous. . . . . . . . . . . . . . . . . Continuous Operating speed. . . Tabulated Data. . .62. .. . . 50/60 Cooling . . . 0. . . . . . . DOD drawing no. . . 50/60 volts . . . . . . . . . . . Lifting Instructions Instruction Plate b. . . . . . . . 208/104 (173/87 at 50 Hz) 1-7 Phases . . . . . . None required Drive . 3. . .8 Change 3 Power factor . . . tactical precise). . . . . . l20/208 or 240/416 (Adjustable to 197/229 or 395 458 . . . . . . . . . . . . . . . . . . . . . . Rotating field synchronous. . . 70-1594 Type . . . . . . . . . Air Degree of enclosure . .. . b. 400 Volts . . . . . . . 208/104 Phases . . . . . . . . .0 amperes at 6 to 32 Vdc Pressure . . . . . . . . . . 1-10) Amperes . . . . . . . . . . . . . . .. . . . . Drip-proof Lubrication . . . . . . 0. . . . . None required Drive . . . Direct Duty classification . . . . DOD drawing no. . . . . . . . . . . . . . . . . . . . . . . . . .2000 rpm (5) Fuel level switch (day tank). . . . .fig. (Cont) (4) Main generator (400 Hz. . . . . brushless with integral exciter KVA (Kilovolt Amperes) . . . . . . Continuous Operating speed . . .60 Hertz . . . . Tabulated Data. . 70-1901 Type . . 75 KW . . .Figure 1-6. . . . . . . . . . . . . . . Float Current . . . . . . . . 3 1 . . . . . . . . 0 to 150 psi . . . DOD drawing no.8 Coating . . . . . . . . . . . . . . . .24dc psi(max) . . . .12 inches from top of tankUpper switch is closed and lower switch opens. . . . . Tabulated Data.75 ± 0. . . (a) Switch contact data Normal fuel level is 2. .Figure 1-7. . . . . .75±0. . . . . .18 gallons per hr Change 11 1-9 . . . .12 inches from top of tank. . . Fuel transfer pumps. . . . . Service Instructions and System Capacities Instruction Plate b. . . . . (Cont) When fuel level drops below 5.7 Delivery (max) . .12 inches from top of tankUpper and lower switches are closed. When fuel level drops below 2. . . MS5132-2 Volts . . . Model (MS) . .00±0. . . . Open continuity exists between connector pins A-B (upper switch) and C-D (lower switch). . . (6) Engine accessories. . . . . . . . . . . . . . 12 tooth (on 13 tooth blank) Engagement . . . .35 Operating temperature range . . . . . . . . . . 32 volts. 22 ft-lbs (rein) at 400 amperes. . . . . . . Belt Rating volts . . . . . . 4. . . . . . .. 0 to 15 amperes. . . . . . . . . Voltage Reconnection Instruction Plate b . . . . . . . . . . Clockwise Charge rate . . . . . . . . . . . . Impeller (c) Electric starter. . . . . . .24 Amperes .. Service parts type no. -65° F to + 175° F Torque . . . . . . . . . . .Figure 1-8. . MS53011-1 volts . 1900-4000 rpm at rated temperature ( d ) Battery charging alternator. . . . Drive . . . . . 24 dc Rotation at drive end . . Style AGC40. . . . . . . . . . . . . . .0 volts Pinion data Pinion teeth . . . . . .69-780-2 Type drive . . . . . . Tabulated Data. . . . Engine exhaust Type . . . . . .. . 0 to 2 amperes adjustable with fully charged battery Fuse . . . 40 amperes Current output . . . . (Cent) (b) Turbocharger. . . . . . . . . . Positive engagement indexing drive with overrunning clutch 1-10 . . DOD drawing no. . . 1 circuit N. . 70-1126 Capacity . . . Coolant high temperature switch. O. . . . 69-697-3 Rating volts . . Switch Configuration A . DOD drawing no . 15 quarts P r e s s u r e . 70-1105-1 (400 Hz) 70-1105-2 (50/60 Hz) Change 1 1-11 DOD part no. . Pressure Range: 500 psi maximum Pressure Setting A . 10 amperes 125 volt ac resistive . . . . . 1 circuit N. . 7 psi Water Pump. . 10 amperes 28 volt dc resistive B . . . 222° F ± 3° F 3. . . . Permanent tubular element (f) Radiator. . . 10 amperes Trip temperature . . . B . C. . O. 28 dc Current .) 2 . . DOD drawing no. . . B . (Cent) (e) Oil cooler. . . (g) — Type . Overspeed switch. . . . . . . . C. . Operational Data Information Plate (Mode I) b. . . . . . — Low oil pressure switch. . — Tabulated Data. . 70-1309 Contact Rating A . . . — DOD drawing no . . . . . . . . . .Figure 1-9. . A-D circuit trip at 18-22 psi decreasing (N. . Belt driven (h) Safety devices: 1. . . .) B-C circuit trip at 18-22 psi decreasing (N. . . — Type . . . . . . . . . . . Figure 1-10. Operational Data Information Plate (Mode II) b. — Tabulated Data. (Cont) Type. . . . . . . . . . Speed sensitive, manual reset ( 1 ) Primary fuel filter and strainer assembly. Overspeed trip . . . . 2400 to 2450 rpm, engine speed; DOD drawing no. . . . 70-507 1200 to 1225 rpm, switch speed (m) Secondary fuel filter. .— Element trip speed . . S9-1 set - 290-310 rpm, Cartridge. . . . . . . . . C-1125PL automatic reset 190-210 rpm. . . (all sets) (n) Ether tank. — S9-2 set -825-850 (400 Hz) rpm, automatic reset 725-750 rpm. Set -590-610 rpm (50/ 60 Hz) automatic reset 490510 rpm. S9-3 set -1200-1225 rpm, manual reset. (all sets) (i) Oil filters (2). Type . . . . . . . . . . Replaceable element (j) Batteries (2). Service part type no. . MS35000-3 volts . . . . . . . . . 12 dc Connections . . . . . . series for 24 volts (k) Ether solenoid. — DOD drawing no . . . . 70-1609 Volts . . . . . . . . .24dc 1 - 1 2 Change 1 DOD drawing no. . . . 70-1608 Capacity (fluid ounces, ethyl ether) . . . . . 26.7 (o) Lube oil pressure transmitter. — DOD drawing no. . . . 69-779 Voltage rating . . . . . 24 Vdc Pressure range . . . . 0-120 psi Resistance 0.0 to 1.5 to 14.5 to 28.0 to (ohms) pressure (psi) 1.0 ------ 0 3.0 ------ 10 16.5 ----- 60 31.0 ----- 120 transmitter. ( p ) Temperature DOD drawing no. . . . 69-781 Voltage rating . . . . . 24 Vdc Temperature range . . 120° F to 280° F Figure 1-11. Battery Arrangement and Connections Instruction Plate b. Tabulated Data. (Cont) (9) Lubricating system. Type system . . . . . . . . . . . Full flow, circulating pressure Oil pump type 710 ± 5 percent at 200° F 310 ± 8 percent at 280° F (7) Capacities. Fuel tank . . . . . . . . 55 gallons Usable fuel . . . . . . ..50 gallons Engine crankcase. . . .20 quarts Engine cooling system . . . . . . 33.5 quarts Hydraulic governor system (See fig. 1-28.) . . . . . . . . 5 quarts (8) Cooling system. stabilized coolant temperature (minimum) . . . . . .180° F Water pump type . . . . Centrifugal, belt driven Oil pressure range, hot, at rated speed . . . . . . . . . . . . . . Gear, positive displacement Resistance (ohms) 2360 ± 10 percent at 120° F 30-55 psi Pressure regulation governed by . . . . . . . . . . Regulation valve Nominal oil capacities: Oil change . . . . . . . . . . . . .20 quarts Crankcase and oil filters . . . . . . . . . . .26 quarts Lubricating oil filters . . . . . . . . . . . . . Dual full flow (10) Valve data. Valve lash adjustment. Intake valve clearance (hot) . . 0.015 inch Change 3 1-13 Figure 1-12. Set I. D. Plate b . Tabulated Data. (Cont) (13) Belt deflections. Intake valve clearance (cold) . . . . 0.018 inch Exhaust valve clearance (hot) . . . . 0.015 inch Exhaust valve clearance (cold). . . . 0.018 inch (11) Governor (mechanical). Type . . . .. .. Variable speed, flyball Regulation . . . . . . . 2-3% (12) Torque data. NOTE Torque values with threads lubricated with engine oil. Exhaust manifold screws.25 ft - lbs (12 ft lb increments) Engine lube oil filter assembly mounting screws . . . . . 50 ft - lbs Intake manifold securing capscrews . . . . . . . . . . . . . . .33 ft - lbs L OW 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 1-14 Change 1 Fan drive belt . . . . . . 9/32 inch at 12 to 14 lb force (measured at center point between pulleys) Alternator belt . . . . . 9/64 inch at 3 to 5-1/4 lb force (measured center point between pulleys) (14) Shipping dimensions and weights (fig. 1-25). Length 108 inches crated 87 inches uncrated 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 & 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 shutoff at 1500F +5° on at 130 °F~50 (17) Maintenance and operating supplies. Refer to Appendix B for a complete list of maintenance and operating supplies required for initial operation. 1-5. Difference in Models This manual covers generator sets model MEPO06A, MEP105A, and ME P1 15A. Model ME PO06A is a 50/60 Hz utility set (Class 2 Model MEP105A is a 50/60 Hz precise set (Class I Mode I), and model MEP115A is a 400 Hz precise set (Class I Mode II). The difference between precise and utility 50/60 Hz and 400 Hz generator sets are noted in the appropriate paragraphs throughout the manual. Figures 1-26 and 1-27 show the harness interconnection for these models. These differences are summarized as follows: ~ The generator used on models MEPO06A and MEP105A is a 50/60 Hz generator. That used in Model MEP115A is a 400 Hz generator. ~ The governor used on model MEP105A is an electrohydraulic governor consisting of a governor control unit, load measuring unit and hydraulic sump, filter, pump and actuator (See fig. 1-28). An electric governor is used on model MEP115A. The governor control unit on MEP105A is 50/60 Hz, and 400 Hz on MEP1 15A. The load measuring unit however is used on all models. Frequency is controlled by a rheostat on the control panel on MEP115A and MEP105A unit. The governor used on model MEPO06A is a mechanical governor which is integral with the fuel injection pump. Frequency is adjusted by a manual speed control. g The same special relay box is used on models ME P105A and MEPO06A, but model MEP105A also has a precise relay box. The precise relay box contains a frequency selector switch, under frequency relay, undervoltage relay, permissive paralleling relay, governor feedback capacitor and frequency adjust fixed resistors. The special relay box used on model MEP1 15A contains the same components as that used on models ME PO06A and ME P105A, and also those contained in the precise relay box with the excep tion of the frequency selector switch. < 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. @ 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) Change 11 1-15/(1-16 blank) 2 blank) .1/(1-18.TM 5-6115-545-12 Figure 1-31.1 Change 11 1-18. . . 2 blank) . MEP115A C h a n g e 1 1 1-22.1 Troubleshooting Diagram.TM 5-6115-545-12 Figure 1-15.1 /(1-22. . AC and Plate Change 1 1-25/(1-26 blank) . Schematic Wiring Diagram Class 1.Figure 1-17. 1 /(1-26.1 Schematic Wiring Diagram.2 blank) .TM 5-6115-545-12 Figure 1-17. MEP 115A Change 11 1-26. Figure 1-18. DC and Plate Change 1 1-27/(1-28 blank) . Schematic Wiring Diagram Class 1. 2 blank) . MEP 115A Change 14 1-28.1 Schematic Wiring Diagram.1/(1-28.TM 5-6115-545-12 TO-35C2-3-444-1 NAVFAC P-8-626-12 TM-00038G-12 Figure 1-18. Schematic Wiring Diagram Class 2. AC and plate Change 1 1-29/(1-30 blank) .Figure 1-19. Schematic Wiring Diagram Class 2.Figure 1-20. DC and Plate Change 1 1-31/(1-32 blank) . Kit Data and Instruction Plate Location (Sheet 1 of 2) 1-33 . Electric Winterization System Diagram and Electric Heater Control Schematic Diagram Instruction Plate (fig. Remote Operation Instruction Plate. Load Bank Connection and Operation Instruction Plate (fig.1. Figure 1-21. 1-24). 4. 1-22). 3. 1-23). 2. Fuel Burning Winterization System Diagram and Heater Control Schematic Diagram Instruction Plate (fig. Kit Data and Instruction Plate Location (Sheet 2 of 2) 1-34 .Figure 1-21. Figure 1-22. Fuel Burning Winterization System Diagram and Heater Control Schematic Diagram Instruction Plate Change 1 1-35/(1-36 blank) . Figure 1-23. Electric Winterization System Diagram and Electric Heater Control Schematic Diagram Instruction Plate 1-37/(1-38 blank) . Shipping Crate Change 3 1 .Figure 1-24. Load Bank Connection and Operation Instruction Plate Figure 1-25.3 9 . (f) Overshoot with rejection of rated load. 12% max. Voltage (a) Dip with application of rated load. 2 to 3% Within ± 0. 15% max.5% max.5% 390 to 420 Hz 1-40 . Differences in Performance Characteristics MEP006A 1. (i) Adjustment range Within 2% bandwidth Within 3% bandwidth 3% max.25% Within 0. (h) Drift (60° F change).5% max.5% -10% 60Hz +15% -5% 50 Hz +2. Frequency (a) Regulation. 12% max.5% max. (c) Dip or rise with application of simulated motor load.5% -10% 60Hz +15% -5% 400 Hz +10% -5% 2. (c) Long term steady state stability.5% 50 Hz 48 to 52 Hz (Manual) 60 Hz 58 to 62 Hz Within ±0. 15% max.Table 1-1. 30% max. Within 1 second 0. (g) Recovery after rejection of rated load. Within 3 seconds 4% max.5% bandwidth Within 1% bandwidth 1. Within 1 second 0. 20% max. Within 3 seconds 1% 45-65 Hz Within 0. MEP105A MEP115A 50 Hz +2. (b) Rise with rejection of rated load.5% max. (e) Recovery after application of rated load. Within 1 second 1. (d) Adjustment range 20% max. 25% (b) Short term steady state stability.5% bandwidth Within 1% bandwidth 1. (d) Undershoot with application of rated load. 40% max. Within 1 second 1. 25% max. 50/60 Hz Precise and Utility Interconnecting Diagram Change 1 1-41/(1-42 blank) .Figure 1-26. Figure 1-27. 400 Hz Precise Interconnecting Diagram Change 1 1-43/(1-44 blank) . Hydraulic Flow Diagram (MEP105A) Change 11 1-45/(1-46 blank) .Figure 1-28. . . . If an auxiliary source of fuel is to be used in operating the engine generator set. or other damage (table 3-l). nuts. (5) Inspect the fuel. in accordance with table 2-1. b. Inspection. The dry weight of the engine generator set is 4240 pounds (50/60 Hz utility set). Depreservation of the cooling system includes draining the cooling system (para 3-41) and cleaning the system with low pressure steam or. 3-29) and/or crankcase drain plug (11. Unloading Equipment. Change 18 2 . c. SERVICE UPON RECEIPT OF MATERIEL 2-1. fig. move the engine generator set as near as possible to the location where it will be operated. or damaged or missing parts. with hot water. WARNING Do not use a lifting device with a capacity of less than 6. 3-12) to make certain they are unobstructed by foreign material. In case of emergency. Report all damaged or missing parts on DD Form 6. death and/or damage to equipment may result. 2-2. A crane. 2-5) to SET TANK position to connect main fuel tank to electrical fuel pumps. Inspecting and Servicing the Equipment. 4300 pounds (50/60 Hz precise set) or 4400 pounds (400 Hz set). fork lift or similar lifting device or fabricated skids must be used to unload the equipment. Before unpacking. (2) Inspect all air cleaner connections for tightness and damage. c. d. Check that these drain cocks are closed. and lift set off of skid crate. if steam is not available. b. connect fuel hose to AUXILIARY FUEL CONNECTION and set FUEL SELECTOR VALVE to AUXILIARY position. Severe injury. install them properly. (8) Make a thorough visual inspection of the entire engine generator set for loose or missing mounting hardware. Do not allow the crated generator set to swing while it is suspended. and shipping material from engine generator set. Preparation. washers. For Army users refer to DA Form 2258. 2-1 A. a. fig. (2) Fill radiator with arctic antifreeze solution. 3-5) and exhaust systems (fig. Prepare the engine generator set for inspection and operation as outlined in the following paragraphs. 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. hammers. (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. Disconnect engine generator set from crate skid by removing carriage bolts. a. Remove barrier bag. leaks. Unpacking the Equipment.1 . fig.000 pounds. WARNING Hot refueling of generators while they are operating poses a safety hazard and shall not be attempted. and similar tools while uncrating the unit to avoid damaging the equipment. 3-50) have been removed.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. Servicing. Inspection is to be performed as follows: (1) Inspect radiator for damage and foreign material (table 3-l). Failure to observe this warning may result in serious injury or death to personnel. dessicant bags. 3-27) are closed. 2-3. (7) Check that main fuel tank drain cock (fig. Hot engine surfaces and sparks produced from the engine and generator circuitry are possible sources of ignition. 3-7) and day tank drain cock (36. Remove the top and then the sides of the crate (fig. (3) Check fan belts and alternator drive belt for correct adjustment (table 3-1 ) (4) Check engine intake (fig. (1) Fill fuel tank with appropriate fuel through filler neck and set FUEL SELECTOR VALVE (A. 1-25). water with rust inhibitor can be used. (6) If cooling system shutoff cock (21. CAUTION Exercise care in the use of bars. water and coolant lines for cracks. Depreservation requires that the coolant in the lube oil cooler also be drained and refilled (para 3-199). Check that oil cooler drain plug is installed. The equipment must be kept in the UP position while unloading. the standard coolant for this engine generator set. fig. (4) Check crankcase oil level (para3-3c. If the solution comes in contact with the body. 3-1). Installation of Separately Packed Components. Check hydraulic oil level and add oil as necessary in accordance with the lubrication order (fig.) and add oil as necessary (para 3-4c.062 1. It is used for protection against freezing primarily in Arctic regions where the ambient temperature remains for extended periods close to -40 oF or drops below.022 1. Fasten a tag near the radiator tiler cap indicating the type antifreeze. cinity when servicing batteries. Electrolyte contains sulfuric acid and can cause severe burns. (5) Perform the before operation preventive maintenance services specified in table 3-1. The electrolyte level must be rechecked approximately 30 minutes after initial filling as the plates and separators will absorb the solution. (3) Batteries are shipped in a dry state. 3-l).it should be put on a charger and brought up to the correct specific gravity. Freezing Points. To activate the battery remove cell caps and fill battery cells with electrolyte. a highly explosive gas.Table 2-1. To test hydrometer.036 1. No separately packed components are shipped with generator sets. Handle it with care. eyes or clothing.047 1. Avoid spilling electrolyte on painted surfaces. Other methods are not authorized. nonvolatile antifreeze compound is intended for use in the cooling system of liquid-cooled internal combustion engines. Battery electrolyte must be requisitioned separately. Make sure vent holes in cell caps are open. and Specific Gravities of Military Antifreeze Materials.8 pints of ethylene glycol per gallon of solution. 2-2 Change 12 . to as low as -75°F. rinse immediately with clean water. (MEP105A).073 2 2¾ 3¼ 3½ 4 4¼ Arctic antifreeze preferred 1 Maximum protection is obtained at 60 percent by volume (4. Depreservation requires that the crankcase be drained and refilled (para 3-46). as arcing at batteries could occur. Composition. thus. DO NOT DILUTE WITH WATER OR ANY OTHER SUBSTANCE o o Ethylene glycol coolant solution specific gravity 68oF3 1. If the battery is not used within 12 hours after initial filling. WARNING Do not smoke or use an open flame in the vi. (4a) Class 1 sets only. Slave receptacle is to be used when extra cranking power is required for starting unit. use 1 part ethylene glycol antifreeze to 2 parts water. ) in accordance with the lubrication order (fig. Test batteries as described in paragraph 8-82b. antifreeze Arctic2 Issued full strength and ready mixed for 0 to -65 F temperatures for both initial installation and replenishment of losses.067 1. 3 Use an accurate hydrometer. Batteries generate hydrogen.055 1. 2-4. This should produce a hydrometer reading of 0oF. resulting in a low level.) 2 Military Specification MI L-A-11755 Arctic type. Lowest expected ambient temperature o F +20 +10 0 -10 -20 -30 -40 -50 -60 -75 Pints of inhibited glycol per gallons of coolant 1½ Compound. and replace caps. for the ambient temperature in effect. 2-6. move the engine generator set as close to the worksite as practical. Set up the unit as level as possible and keep it as level as possible during operation. The engine generator set is a portable unit and is designed to operate satisfactorily up to 15° out-of-level. f. b . Noise level warning. Inhalation of exhaust fumes will result in serious illness or death. The site must be within 25 feet of any paralleled generator set. and be buried at a minimum depth of 4 feet. Leveling. Installation and Setting-up Instructions. Loosen the screw and nut which secure the weather cap to the exhaust outlet and re move the weather cap. minimum thickness of 1/4 inch. and with ample ventilation. General. logs. See figure 2-1 for dimensions of the base. or other material for a base in an area where the ground is soft . When preparing for a permanent installation. When preparing a temporary 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.2-5. clear of obstacles. Conversion instructions for remote operation by removal and relocation of the control cubicle are given in paragraph 2-23. d . WARNING Do not operate the engine generator set in an enclosed area unless the exhaust gases are piped to the outside. and driven to a minimum depth of 8 feet. The engine generator set must be grounded prior to operation. Conversion instructions for equipment operation at 120/208 Vac or 240/416 Vac are given in figure 2-4. Use suitable planks. air flow requirements and floor loading requirements. to the outside of the installation. 12 inches larger in diameter than the exhaust pipe where the line passes through flammable walls. The engine generator set should be installed on a level site. this preferred grounding method must be supplemented by an additional driven metal rod ground or a buried metal plate ground. If a free supply of fresh air is not available. provide duct work. The ground lead must be at least No. Outdoor Installation. A driven metal ground rod must have a minimum diameter of 5/8 inch if solid or 3/4 inch if pipe. Provide metal shields. Instructions for making the required generator load connections are designated in figure 2-3. Generator Load Connections. be sure the base is solid enough to support the weight of the unit. Equipment Conversion. a . Refer to figure 2-1 for dimensions. The exhaust pipe should include a low point with suitable means for draining of condensate. 6 AWG (American Wire Gauge) copper wire. c . b . The procedures for making a ground connection are shown in figure 2-2. Install a gas-tight metal pipe exhaust from the exhaust outlet to the outside of the installation. (2) a driven metal rod or (3) a buried metal plate (fig. Select a location where there will be sufficient space on all sides for servicing and operation of the engine generator set. Ground rods are available as optional equipment. Wrap the exhaust pipe with asbestos if there is any danger of anyone touching it. (1) an underground metallic water piping system. 25 feet of any auxiliary fuel supply and 500 feet of any remote control area. Figure 2-1A. so that the engine generator set will receive a maximum supply of air. A buried metal ground plate must have a minimum area of 9 square feet. increase the duct work size by 25 to 50 percent. 2-2). c . in order of preference. Change 2 2-3 . Indoor Installation. Grounding. e. If louvers are used at the air entrance. If the effectively grounded portion of the buried metallic water pipe is less than 10 feet due to insulated sections or joints. Conversion instructions for equipment operation of 50 or 60 Hz are given in figure 2-6. Keep the area well ventilated at all times. The ground can be. with an opening at least as large as the radiator. Use as few bends in the pipe and as short a pipe as possible. a. Figure 2-1. 2-4 . Figure 2-2. Grounding Procedures (Sheet 1 of 3) C h a n g e 3 2-5 . Figure 2-2. Grounding Procedures (Sheet 2 of 3) 2-6 Change 3 . 7 . Grounding Procedures (Sheet 3 of 3) Change 3 2 .TM 5-6115-545-12 TO-35C2-3-444-1 NAVFAC P-8-626-12 TM-00038G-12 Figure 2-2. BUT THE LOAD ON ANY ONE PERCENT OF THE CURRENT RATING OF (PHASE BALANCE IS 5 PERCENT). 2 . 120V OR 240V SINGLE-PHASE LOAD CONNECTIONS. STEP 2. CONNECT THIRD LOAD TO L1 AND L3. NEXT ROUTE THE CABLES OVER THE TERMINAL BOARD. 3-PHASE LOAD CONNECTIONS.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. CONNECT FIRST LOAD TO L1 AND L2. THEN DOWN AND AROUND TO THE PROPER TERMINAL. NOTE LOADS CAN BE SERVED ALONE OR IN LOADS. WHEN MAKING ANY ELECTRICAL CONNECTIONS. 2-5) IS OPEN AND THE NEGATIVE BATTERY TERMINAL IS DISCONNECTED. ROUTE THE POWER CABLE THROUGH THE LEATHER OR CANVAS BOOT. USING WRENCH PROVIDED. AFTER THE END OF THE BLACK INSULATION IS INTO THE BOOT. STEP 3. SECURE THE BOOT AROUND THE CABLE BY PULLING THE DRAW STRING. 208V OR 416V SINGLE-PHASE LOAD CONNECTIONS. CONNECT FIRST LOAD TO L1 AND L0. THE PHASE SEQUENCE OF THE ENGINE GENERATOR SET OUTPUT IS L1-L2-L3 AND INSURE THAT THE EXTERNAL LOAD IS APPROPRIATELY CONNECTED. CONNECT SECOND LOAD TO L2 AND L3. LEADS WITH THE GENERATOR SET SHUTDOWN AND THE LOAD CONNECTED TO ANOTHER POWER SOURCE. CONNECT SECOND LOAD TO L2 and L0. TO PREVENT WATER AND MOISTURE DAMAGE TO CABLE. DO NOT ATTEMPT TO CONNECT OR DISCONNECT LOAD LEADS WHILE THE GENERATOR SET IS DO NOT ATTEMPT TO CONNECT OR DISCONNECT LOAD OPERATING. CONNECT THIRD LOAD TO L3 AND L0. ONE OR MORE SINGLE-PHASE COMBINATION WITH 3-PHASE PHASE MUST NOT EXCEED 33 THE ENGINE GENERATOR SET STEP 1. Figure 2-3. MAKE SURE THE DC CONTROL CIRCUIT BREAKER (FIG.8 Change 14 Generator Load Terminal Board Connections . OR WHILE THE GENERATOR SET IS PARALLELED TO ANOTHER THAT IS OPERATING. 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 Change 13 . 2-8. Parallel Connection.TM 5-6115-545-12 TO-35C2-3-444-1 NAVFAC P-8-626-12 TM-00038G-12 Figure 2-3.2. Figure 2-4. Voltage Conversion Change 7 2-9 . prepare engine generator set for moving as described in paragraph 2-7 a. (7) Close and secure all doors and panels. Reinstallation after Movement. Controls and Instruments. (2) Remove the exhaust pipe extension. a. if used . Refer to paragraph 2-5 for reinstallation after movement to a new worksite. MOVEMENT TO NEW WORKSITE 2-7. (1) If the engine generator set is to be moved only a short distance and the terrain is suitable. b. (3) Drain fuel (fig. General. (5) Disconnect the ground lead from the ground terminal stud (fig. Dismantling for Movement. or if the terrain is unsuitable for towing. 2-2). CONTROLS AND INSTRUMENTS 2-10. (4) Refer to the basic issue item list (Appendix B) and make sure that all items are present and properly stowed. Preparation for Movement. 2-10 . (1) Disconnect the load cables from the load terminal board (fig. (2) If the engine generator set is to be moved a long distance. attach a suitable towing device to the towing openings of the engine generator set and tow the engine generator set to the new worksite. This section describes and illustrates the various controls and instruments required for generator set operation. (6) Disconnect any other external hoses. or connected to a parallel bus.Section II. if used. 2-3) and tag for identification. The purpose of the generator set controls and instruments and the normal and scale readings of the instruments are illustrated in figure 2-5. 2-9. 3-7) and coolant (para 3-41) if transportation by railroad is anticipated or the distance to be traveled is great. Section III. lines and cables. WARNING Make certain that engine generator set is not operating in a standby mode. Movement. 2-8. Generator Set Controls and Instruments (Sheet l of 6) C h a n g e 3 2-11 .Figure 2-5. Figure 2-5. Generator Set Controls and Instruments (Sheet 2 of 6) 2-12 . G e n e r a t o r Set Controls and Instruments (Sheet 3 of 6) Change l 2-13 .Figure 2-5. Figure 2-5. 2-14 Change 12 . Generator Set Controls and Instruments (Sheet 5 of 6) Change 1 2-15 .Figure 2-5. Figure 2-5. Generator Set Controls and Instruments (Sheet 6 of 6) 2-16 . Table 2-2. 2-5) LOW OIL PRESSURE COOLANT HIGH TEMP FUNCTION Lights if oil pressure drops below 20 ± 2 psi.370 ± 5 Hz for 400 Hz. Lights (Class 1 sets only) instantaneously if output falls below 48 volts. Lights if any phase current exceeds 110% of rated load. OVER VOLT Change 1 2-17 . or 6 ± 2 sec after output reaches 99 ± 4 volts.46 ± 1 Hz for 50 Hz operation. OVERSPEED NO FUEL SHORT CIRCUIT OVER LOAD UNDER VOLT UNDER FREQ REVERSE POWER Lights if power flow into set exceeds 20% of rated value. Fault Indicators Function INDICATOR (Fig. Lights if output voltage rises above 153 ± 3 volts. Lights if output reaches 425 ± 25% of rated current. 55 ± 1 Hz for 60 Hz operation. Lights if engine rpm reaches 2400 to 2450 rpm. Lights if coolant temperature rises above 222 ± 3° F. Mode II . Lights if fuel in day tank falls to level permitting only one minute of engine operation. Lights on (Class 1 sets only) when output freq drops to: Mode I . Do not attempt to connect or disconnect load leads while the generator set is operating. Refer to table 2-2 for the specific criteria for which these safety device electrical circuits operate. any time the engine generator set is operating. To stop the engine generator set in an emergency. operation of the generator set and coordinating the basic motions to perform the specific tasks for which the equipment is designed. General. start the engine generator set as shown in figure 2-7. (3) Lift cover and push BATTLE SHORT switch to ON position. 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. a . 2-5) will light when any of these abnormal conditions occur. Emergency Stopping. b . This section gives instructions on starting and stopping the engine generator set. 2-7). See-fig. On precise class 1 engine generator sets only. NOTE a . the BATTLE SHORT switch (fig. c. b . A specific FAULT INDICATOR (fig. Once the engine generator set has been stopped due to the action of one of these safety devices. (1) high coolant temperature. (2) Hold START-RUN-STOP switch in START POSITION and start engine (fig. Starting. d. NOTE Prior to attempting parallel operation. Normal Stopping. b . The engine generator set is equipped with safety device electrical circuits that will automatically stop the engine and simultaneously open the main ac contactor in case of. the problem must be corrected before the engine generator set is placed back in operation. b . 2-10 for parallel operation instructions for up to 3 engine generator sets of the same class. 2-14. 2-8). Single Engine Generator Set Operation. Stopping. mode and size. or reverse power protective relay will automatically open the main ac contactor but will not stop the engine. as necessary. Stopping by Safety Devices. The operator must know how to perform every operation of which the engine generator set is capable. (5) no fuel. notify organizational maintenance personnel. (3) engine overspeed. Load Connections for Parallel 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). 2-9 for single engine generator set operating instructions. (See figure 2-8). Since nearly every job presents a different problem. Preventive maintenance procedures to be performed before operation are given in table 3-1. (2) low oil pressure. 2-12. (4) Release START switch and push BATTLE SHORT switch to OFF position as soon as possible after emergency has passed. If the engine will not start or if any other abnormality is observed. Operation of Equipment. the operator may have to vary procedures to fit the individual job. OPERATION UNDER USUAL CONDITIONS 2-11. Preventive maintenance procedures to be performed after equipment operation are given in table 3-1. After performing the preparation for starting procedure of paragraph 2-12a. Instructions in this section are provided for information and guidance of personnel responsible for operation of the engine generator set. Instructions to be followed when preparing to start the engine generator set are shown in figure 2-6. a . a. WARNING Lethal voltages are present at the load terminal board of the generator set during operation. c. The BATTLE SHORT switch may be actuated. ensure all generator sets have the same frequency and voltage output. Parallel Operation of Engine Generator Sets. Preparation for Starting. 2-13. under voltage and under frequency relay protective circuits will similarly open the main ac contactor but will also not stop the engine. Emergency Operation.Section IV. 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 . overload. Starting. See-fig. A short circuit. open DC CONTROL CIRCUIT BREAKER (fig. (4) over-voltage or. Exercise period should be long enough to enable the engine to attain normal operating temperature (160°-200°F) while carrying. but the load on any one phase must not exceed 100 percent of the current rating of that phase. A diesel engine on standby service that is customarily operated under optimum conditions should be exercised at least every 30 days. dust. under environmental conditions involving extreme temperatures. humidity.1/(2-18. etc. Exercise of Engine on Standby Service. or while the generator set is paralleled to another set which is operating. L2. To exercise engine. L2. WARNING Do not attempt to connect the paralleling cable while either or both of the sets to be paralleled is operating. However.2 blank) . L3. Be sure that wire sizes are correct for load to be carried. Make sure that there is no input to the load from another source. sand. Perform the preparation for starting instruction shown in figure 2-6. run engine at rated speed with whatever load is available. for NOTE The load terminal boards will accommodate 2-wire single phase and 4-wire three phase loads. etc. tighten binding nuts with plastic/phenolic box end wrench and install safety cover. (3) Insert load leads through plate and sleeve assembly (figure 2-3) located to the left of the generator set air intake. (2) Open the left access door to the set compartment and remove the safety cover from the terminal board (figure 2-3). phase rotation for the phase loads is L1. (5) Connect load leads and paralleling cables as shown in figures 2-3A and 2-3B. CAUTION Precise generator sets equipped with the electric governor system cannot be paralleled with sets that have the electro hydraulic governor system.. 2-15. Start engine as shown in figure 2-7. if possible. One or more single phase loads can be served alone or in combinations with three phase loads. connect load terminal boards as shown in figure 2-3A. b . NOTE Paralleling of tactical precise generator sets requires that paralleling cables be installed and the shorting plug located on one of the paralleling receptacles of each generator set be removed. (1) If the generator sets are to share a load greater than the KW rating of a single set. NOTE Make certain that the load terminal boards of the sets to be paralleled are connected properly. NOTE After load connection. Change 12 2-18. This arrangement allows for sharing or transferring of the load between generator sets. Reading left to right. L3 and L0 (figure 2-3). Make complete visual inspection of unit to be sure it is in operating condition. it maybe found necessary to shorten the interval between exercise periods teas often as weekly.source. at least 50 percent of its normal load. L2 is connected to L2. up to full load. After an acceptable warm-up period. Be sure L1 is connected to L1. Failure to observe this warning may result in death by electrocution. (4) Connect the load to terminals marked L1. proceed as follows: a . . Change 11 2-19 .Figure 2-6. Preparation for Starting (Sheet 2 of 2) 2-20 .Figure 2-6. Starting Instructions (Sheet 1 of 2) Change 12 2-21 .Figure 2-7. PREHEAT ENGINE COOLANT AND LUBRICATING OIL USING EITHER THE FUEL BURNING OR ELECTRIC WINTERIZATION KIT CONTROLS AS SHOWN IN FIGURES 2-11 and 2-12 RESPECTIVELY . THE INDICATED FAULT (TABLE 2-2) MUST BE CORRECTED BEFORE PROCEEDING . IF FAULT INDICATORS.150 OF) WITH NO LOAD APPLIED. TACTOR.Step 6. Starting Instructions (Sheet 2 of 2) 2-22 Change 3 . 25° F. ALLOW ENGINE TO WARM UP TO NORMAL OPERATING TEMPERATURE (100 . STEP 7. RESET FAULT INDICATOR LIGHTS BY PRESSING TEST OR RESET SWITCH. IF ANY FAULT INDICATOR LIGHTS. CAUTION TO PREVENT ENGINE CARBON DEPOSITS DO NOT RUN ENGINE-GENERATOR SETS FOR MORE THAN 5 MINUTES AT GOVERNED SPEED WITHOUT LOAD. STEP 8. ARE EXTINGUISHED AFTER BEING RESET. PERFORM STARTING PROCEDURE OF STEPS 1 THROUGH 8 SPECIFIED FOR ABOVE MINUS Figure 2-7. CLOSE MAIN AC CONTACTOR BY MOMENTARILY PLACING CKT BKR SWITCH IN CLOSE POMOMENTARILY PLACING CKT BKR SWITCH IN OPEN POSITION WILL OPEN THE AC CON- AMBIENT AIR TEMPERATURE BELOW MINUS 25° F STEP 1. STEP 2. SITION. PROCEED WITH STEP (8). Stopping Instructions Change 3 2-23 . OPEN MAIN AC CONTACTOR BY MOMENTARILY PLACING CKT BRK SWITCH IN OPEN POSITION. STEP 2. REMOVE DC CONTROL POWER BY OPENING DC CONTROL CIRCUIT BREAKER. ALLOW 3 MINUTES TO ELAPSE AFTER PERFORMING STEP 1 AND PLACE START-RUN-STOP SWITCH IN STOP POSITION. EMERGENCY PULL DC CONTROL CIRCUIT BREAKER. ME 6115-545-12/2-8 C3 Figure 2-8. AFTER ENGINE STOPS. STEP 3.NORMAL STEP 1. STEP 1. PREPARE ENGINE GENERATOR SET FOR STARTING (FIG. ME 6115-545-12/2-9 Figure 2-9. IF MORE THAN THE 100% PERCENT LOAD IS INDICATED ON THE KILOWATT METER. STEP 2. 2-6). STEP 4. REDUCE THE LOAD. STEP 3. IF MORE THAN 100% RATED CURRENT IS INDICATED IN ANY PHASE POSITION. ROTATE AMPS-VOLTS SELECTOR SWITCH TO EACH PHASE POSITION WHILE OBSERVING AC AMMETER. START ENGINE GENERATOR SET (FIG. Operating Instructions 2-24 . 2-7). Single Generator Unit. REDUCE THE LOAD. 29. 27. 8. 32. Parallel Operation (Load Sharing and Load Transfer) (Sheet 1 of 5 ) Change 12 2-25 . 24. 6. 28. 26. 30. 2. 9. 12. 38. 16. 35. 3. 22. 15. 18.1. 23. 4. 34. 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. 25. 14. 10. 33. 5. 19. 37. 7. 36. 17. 13. 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. 11. 21. 31. IF THE LIGHTS GO ON AND OFF ALTERNATELY. START THE GENERATOR SETS AS DESCRIBED IN FIGURES 2-6 AND 2-7. STOP BOTH SETS AND CORRECT INTERCONNECTION CABLES AS DESCRIBED IN (FIGuRE 2-3.A . PLACE THE OPERATION SWITCH IN THE PARALLEL POSITION. Parallel Operation (Load Sharing and Load Transfer) (Sheet 2 of 5) 2-26 Change 12 . WHEN THE CKT BRK INDICATOR LIGHT ILLUMINATES.2) AT THE LOAD IS OPEN BEFORE ATTEMPTING TO PLACE A GENERATOR SET ON LINE. CAREFULLY OBSERVE THE SYNCHRONIZING LIGHTS OF THE “ON-COMING” SET AND. DO NOT PERFORM STEP 8 OF FIGURE 2-7. CAUTION DO NOT PLACE THE CIRCUIT BREAKER SWITCH ON ANY OF THE GENERATOR SETS IN THE CLOSE POSITION UNTIL SPECIFICALLY DIRECTED TO DO SO. STEP 3. ADJUST THE FREQUENCY OF THE “ON-COMING” SET A LITTLE HIGHER THAN THE “ONLINE” SET. STEP 6. STEP 4. STEP 2.1). Figure 2-10. NOTE OBSERVE THE SYNCHRONIZING LIGHTS OF THE “ON-COMING” SET. THE FIRST SET STARTED SHALL BE DESIGNATED AS “ON-LINE” AND THE SETS IN PARALLEL OPERATION SHALL BE DESIGNATED “ON-COMING. PLACE THE OPERATION SWITCH OF THE “ON-COMING” SET IN THE PARALLEL POSITION. AT THE INSTANT BOTH LIGHTS GO DARK.PARALLEL OPERATION (LOAD SHARING) STEP 1. HOLD THE CKT BRK SWITCH (FIGURE 2-5) OF THE “ON-LINE” SET IN THE CLOSE POSITION UNTIL THE CKT BRK INDICATOR LIGHT ILLUMINATES. ADJUST THE VOLTAGE ON BOTH SETS TO THE REQUIRED VALUE. CLOSING THE CIRCUIT BREAKER SWITCH AT ANY OTHER TIME MAY SEVERELY DAMAGE ONE OR MORE OF THE GENERATOR SETS.” WITH ALL SETS SHUT DOWN INSTALL THE PARALLELING CABLE AND CONNECT THE LOAD TERMINAL BOARDS AS DESCRIBED IN FIGURE 2-3A. CHECK THAT THE VOLTAGE RECONNECTION BOARDS (FIGURE 2-4) OF THE SETS ARE IDENTICALLY POSITIONED. IF THE PROBLEM PERSISTS. SETS ARE OUT OF PHASE. CAUTION CHECK THAT THE MAIN POWER SWITCH (FIGURE 2-3. STEP 5. ADJUST THE FREQUENCY OF THE “ON-LINE” SET TO THE REQUIRED VALUE. THE LIGHTS SHOULD GO ON AND OFF SIMULTANEOUSLY. REFER TO NEXT HIGHER LEVEL OF MAINTENANCE. THE SETS ARE OPERATING IN PARALLEL. THEN REDUCE THE FREQUENCY SLOWLY WITH THE FREQUENCY ADJUST RHEOSTAT UNTIL THE SYNCHRONIZING LIGHTS REMAIN ON OR OFF AT 2 TO 3 SECOND INTERVALS. PLACE THE CKT BRK SWITCH OF THE “ON-COMING” SET TO THE CLOSE POSITION. IF THE READINGS ARE NOT WITHIN 20 PERCENT. CAUTION PRIOR TO REMOVAL OF GENERATOR SETS FROM PARALLEL OPERATION. Parallel Operation (Load Sharing and Load Transfer) (Sheet 3 of 5) Change 12 2-26. THE KILOWATT LOAD SHOULD DIVIDE SO THAT THE LOAD ON EACH SET IS EQUAL.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. APPLY LOAD TO THE SETS. NOTE IF THE REVERSE POWER INDICATOR OF EITHER SET ILLUMINATES AND THE MAIN LOAD CONTACTOR OPENS. PARALLELING PROCEDURES-ARE THE SAME AS THOSE DESCRIBED ABOVE. TO REMOVE A GENERATOR SET FROM PARALLEL OPERATION. STEP 7. NOTE TWO OR MORE GENERATOR SETS CAN BE OPERATED IN PARALLEL. WITH NO EXTERNAL LOAD ON THE PARALLELED SETS. OPEN THE MAIN POWER SWITCH AND REPARALLEL THE GENERATOR SETS. STEP 8. ONE OR MORE OPERATORS MUST REMAIN WITH THE SETS TO MONITOR THE RATED LOAD AND CURRENT METERS. NOTIFY HIGHER LEVEL MAINTENANCE. STOP THE SET AS DESCRIBED IN FIGURE 2-8. CAUTION WHEN GENERATOR SETS ARE BEING OPERATED IN PARALLEL. STEP 9. THE CURRENT SHOULD DIVIDE SO THAT THE OBSERVED DIFFERENCE BETWEEN THE CURRENT ON ANY PHASE BETWEEN THE “ON-LINE” AND “ON-COMING” SETS IS NOT MORE THAN 20 PERCENT. STEP 10. PLACE THE CIRCUIT BREAKER SWITCH OF THE SET IN THE OPEN POSITION. IF THE LOAD AND CURRENT ARE NOT SHARED EQUALLY. ADJUST THE FREQUENCY ADJUST RHEOSTAT OF THE “ON-COMING” SET UNTIL BOTH RATED LOAD METERS (KILOWATT) READ ZERO. TURNING COUNTERCLOCKWISE WILL DECREASE READINGS. B . ONE GENERATOR AT A TIME IS BROUGHT ON LINE. MAKE SURE THE LOAD DOES NOT EXCEED THE FULL LOAD RATING OF GENERATOR SETS(S) REMAINING ON LINE.1 . ADJUST THE VOLTAGE ADJUST RHEOSTAT OF THE “ON-COMING SET UNTIL THE PERCENT OF RATED CURRENT METERS (AMMETERS) ON BOTH SETS READ ZERO. ADJUST THE VOLTAGE AND FREQUENCY RHEOSTATS OF THE “ON-COMING” SET UNTIL LOAD AND CURRENT ARE DIVIDED EQUALLY BETWEEN THE GENERATOR SETS. Figure 2-10.CAUTION THE KILOWATT METER AND AC AMMETER INDICATE PERCENTAGES AND DO NOT INDICATE TRUE KW AND AMPERE READINGS. PLACE THE OPERATIONS SWITCH OF THE “ON-COMING” SET TO THE SINGLE UNIT OPERATION POSITION. STEP 8. NOTE THE VOLTAGE INDICATED ON THE “ON-LINE" SET.” STEP 20 PLACE THE OPERATIONS SWITCH (FIGURE 2-5) ON BOTH SETS IN THE PARALLEL OPERATION POSITION. Parallel Operation (Load Sharing and Load Transfer) (Sheet 4 of 5) 2-26. 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 5. MOVE THE CIRCUIT BREAKER SWITCH OF THE “ON-LINE” SET TO THE OPEN POSITION.NOTE VISUALLY CHECK THAT THE POWER CABLE AND PARALLEL CABLE ARE IN ACCORDANCE WITH FIGURE 2-3B. ADJUST THE VOLTAGE AND FREQUENCY RHEOSTATS OF THE “ON-COMING” SET UNTIL LOAD AND CURRENT ARE DIVIDED EQUALLY BETWEEN THE TWO GENERATOR SETS. STEP 9. SHUT DOWN THE “ON-LINE” SET AND FOLLOW INSTRUCTIONS IN PARAGRAPH 2-14D.2 Change 12 . CAREFULLY WATCH THE SYNCHRONIZING LIGHTS OF THE “ON-COMING” SET. SLOWLY REDUCE THE FREQUENCY OF THE “ON-COMING” SET UNTIL THE SYNCHRONIZING LIGHTS (FIGURE 2-5) FLASH AT 2 TO 3 SECOND INTERVALS. THE SET IN OPERATION SHALL BE DESIGNATED AS “ON-LINE” AND THE SETS PLACED IN PARALLEL OPERATION SHALL BE DESIGNATED “ON-COMING. ADJUST THE FREQUENCY OF THE “ON-COMING” SET TO A HIGHER VALUE THAN THAT OF THE “ON-LINE” SET. AT THE INSTANT BOTH LIGHTS GO DARK. MOVE THE CIRCUIT BREAKER SWITCH OF THE “ON-COMING” SET TO THE CLOSE POSITION. STEP 4. AND START THE “ON-COMING” SET. 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 7. IF THE CABLES ARE NOT ATTACHED AS INDICATED. 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. ADJUST THE VOLTAGE OF THE “ON-COMING" SET TO THE VOLTAGE NOTED ON THE “ON-LINE” SET. STEP 1. REFER TO FIGURE 2-6 AND 2-7 (DO NOT PERFORM STEP 8 OF FIGURE 2-7). Figure 2-10. STEP 3. STEP 6. STEP 10. STEP 11. READJUST VOLTAGE AND FREQUENCY OF THE “ON-COMING” SET AS NECESSARY. STEP 12. Parallel Operation (Load Sharing and Load Transfer) (Sheet 5 of 5) Change 12 2-26. Figure 2-10.3 . REFER TO FIGURE 2-8 AND STOP THE “ON-LINE” SET. Coolant high temperature indicator 10. 36. 30. Overload indicator 14. Under voltage indicator 15. AC ammeter 7. 31. Overspeed indicator 11. 33. Fault location indicator fuse 19. Test or reset switch 20. 29. 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. 35. Under frequency indicator 16.1. Short circuit indicator 13. Over voltage indicator 18. Volts-amps transfer switch 6. 32. Frequency meter 4. 38. 27. 23. 25. Reverse power indicator 17. 24. 22. Kilowatt meter 5.4 Parallel Operation of Tactical Utility Generator Sets (Load Sharing and Load Transfer) (Sheet 1 of 4) Change 12 . Air cleaner condition indicator 3. 37. 28. No fuel indicator 12. AC voltmeter 8. Low oil pressure indicator 9. 21. 2-26. Panel illumination light 2. 26. 34. CAUTION CHECK THAT THE MAIN POWER SWITCH (FIGURE 2-3. SIMULTANEOUSLY. DO NOT PER- STEP 3. CLOSING THE CIRCUIT BREAKER SWITCH AT ANY OTHER TIME MAY SEVERELY DAMAGE ONE OR MORE OF THE GENERATOR SETS. REFER TO NEXT HIGHER LEVEL OF MAINTENANCE. PLACE THE OPERATION SWITCH IN THE PARALLEL POSITION. WHEN THE CKT BRK INDICATOR LIGHT ILLUMINATES. REMAIN ON OR OFF AT 2 TO 3 SECOND INTERVALS. CAUTION DO NOT PLACE THE CIRCUIT BREAKER SWITCH ON ANY OF THE GENERATOR SETS IN THE CLOSE POSITION UNTIL SPECIFICALLY DIRECTED TO DO SO.PARALLEL OPERATION OF TACTICAL UTILITY GENERATOR SETS (LOAD SHARING) STEP 1. SET “VOLT-AMPS TRANSFER SWITCH” IN THE LI-LO POSITION. THE LIGHTS SHOULD GO ON AND OFF SIMULTANEOUSLY IF THE LIGHTS GO ON AND OFF ALTERNATELY. PLACE THE OPERATION SWITCH OF THE “ON-COMING” SET IN THE PARALLEL POSITION. SETS ARE OUT OF PHASE. START THE GENERATOR SETS AS DESCRIBED IN FIGURES 2-6 AND 2-7. STOP BOTH SETS AND CORRECT INTERCONNECT CABLES (FIGURE 2-3. STEP 2. THE SETS ARE OPERATING IN PARALLEL.A . HOLD THE CKT BRK SWITCH (FIGURE 2-5) OF THE “ON-LINE” SET IN THE CLOSE POSITION UNTIL THE CKT BRK INDICATOR LIGHT ILLUMINATES. STEP 5. ADJUST THE MANUAL SPEED CONTROL OF THE “ON-COMING” SET UNTIL THE SYNCHRONIZING LIGHTS. Parallel Operation of Tactical Utility Generator Sets (Load Sharing and Load Transfer) (Sheet 2 of 4) Change 12 2-26.1). STEP 6. NOTE OBSERVE THE SYNCHRONIZING LIGHTS OF THE “ON-COMING” SET. CAREFULLY OBSERVE THE SYNCHRONIZING LIGHTS OF THE “ON-COMING” SET AND. FORM STEP 8 OF FIGURE 2-7. ADJUST THE VOLTAGE ADJUST RHEOSTAT UNTIL THE AC VOLTMETER INDICATES 122 VOLTS FOR THE 120/208 CONNECTION AND 244 VOLTS FOR THE 240/416 CONNECTION.2) AT THE LOAD IS OPEN BEFORE ATTEMPTING TO PLACE A GENERATOR SET ON LINE.” WITH ALL SETS SHUT DOWN CONNECT THE LOAD TERMINAL BOARDS AS DESCRIBED IN FIGURE 2-3. AT THE INSTANT BOTH LIGHTS GO DARK. STEP 4. CHECK THAT THE VOLTAGE RECONNECTION BOARDS (FIGURE 2-4) OF THE SETS ARE IDENTICALLY POSITIONED. PLACE THE CKT BRK SWITCH OF THE “ON-COMING” SET TO THE CLOSE POSITION. THE FIRST SET STARTED SHALL BE DESIGNATED AS “ON-LINE” AND THE SETS IN PARALLEL OPERATION SHALL BE DESIGNATED “ON-COMING. IF PROBLEM PERSISTS. Figure 2-10A. ADJUST MANUAL SPEED CONTROL UNTIL THE FREQUENCY METER INDICATES 61 HERTZ.5 . STEP 7. WITH NO EXTERNAL LOAD ON THE PARALLELED SETS, ADJUST THE MANUAL SPEED CONTROL OF THE “ON-COMING” SET UNTIL BOTH PERCENT POWER METERS (KILOWATT) INDICATE ZERO . ADJUST THE VOLTAGE ADJUST RHEOSTAT OF THE “ON-COMING” SET UNTIL THE PERCENT OF RATED CURRENT METERS (AMMETERS) ON BOTH SETS INDICATE ZERO. TURNING COUNTERCLOCKWISE WILL DECREASE READINGS. STEP 8. APPLY LOAD TO THE SETS. THE KILOWATT LOAD SHOULD DIVIDE SO THAT THE LOAD ON EACH SET IS EQUAL. IF THE LOAD AND CURRENT ARE NOT SHARED EQUALLY, ADJUST THE LOAD BY OBSERVING THE SET WHICH HAS THE HIGHER READING ON THE KILOWATT METER. DECREASE THE ENGINE SPEED OF THIS SET BY ADJUSTING COUNTERCLOCKWISE THE MANUAL SPEED CONTROL IN SMALL INCREMENTS. INCREASE THE ENGINE SPEED OF THE SET WITH THE LOWER KILOWATT READING BY ADJUSTING CLOCKWISE THE MANUAL SPEED CONTROL IN SMALL INCREMENTS. ADJUSTMENTS SHOULD BE MADE BETWEEN BOTH SETS UNTIL THE KILOWATT METERS ARE BALANCED. STEP 9. THE CURRENT SHOULD DIVIDE SO THAT THE OBSERVED DIFFERENCE BETWEEN THE CURRENT ON ANY PHASE BETWEEN THE “ON-LINE” AND “ON-COMING” SETS IS NOT MORE THAN 20 PERCENT. IF THE READINGS ARE NOT WITHIN 20 PERCENT, NOTIFY HIGHER LEVEL MAINTENANCE. CAUTION WHEN GENERATOR SETS ARE BEING OPERATED IN PARALLEL, ONE OR MORE OPERATORS MUST REMAIN WITH THE SETS TO MONITOR THE RATED LOAD AND CURRENT METERS. MAKE FURTHER ADJUSTMENTS AS REQUIRED TO MAINTAIN EQUAL LOAD ON THE PARALLELED SETS. CAUTION PRIOR TO REMOVAL OF GENERATOR SET FROM PARALLEL OPERATION, MAKE SURE THE LOAD DOES NOT EXCEED THE FULL LOAD RATING OF SETS(S) REMAINING ON LINE. STEP 10. TO REMOVE A GENERATOR SET FROM PARALLEL OPERATION, PLACE THE CIRCUIT BREAKER SWITCH OF THAT SET IN THE OPEN POSITION. STOP THE SET AS DESCRIBED IN FIGURE 2-8. B - PARALLEL OPERATION (LOAD TRANSFER) THE FOLLOWING METHOD OF PARALLEL OPERATION IS TO BE USED WHEN IT IS NECESSARY TO TRANSFER THE LOAD FROM ONE SET TO THE OTHER WITHOUT INTERRUPTING POWER. NOTE VISUALLY CHECK THAT THE POWER CABLE AND PARALLEL CABLE ARE IN ACCORDANCE WITH FIGURE 2-3.2. IF THE CABLES ARE NOT ATTACHED AS INDICATED, SHUT DOWN THE “ON-LINE” SET AND FOLLOW INSTRUCTIONS IN PARAGRAPH 2-14D. CAUTION DO NOT ATTEMPT LOAD CONNECTS IN PARAGRAPH 2-14D UNLESS ALL SETS ARE OFF AND NO OTHER EXTERNAL VOLTAGE IS APPLIED TO THE LOAD. Figure 2-l0.l. Parallel Operation of Tactical Utility Generator Sets (Load Sharing and Load Transfer) (Sheet 3 of 4) 2-26.6 Change 12 STEP 1. THE SET IN OPERATION SHALL BE DESIGNATED AS “ON-LINE” AND THE SETS PLACED IN PARALLEL OPERATION SHALL BE DESIGNATED “ON-COMING.” STEP 2. PLACE THE OPERATIONS SWITCH (FIGURE 2-5) ON BOTH SETS IN THE PARALLEL OPERATION POSITION. CAUTION DO NOT CLOSE THE CIRCUIT BREAKER SWITCH AFTER STARTING THE “ON-COMING” SET AS SERIOUS DAMAGE TO ONE OR BOTH GENERATOR SETS MAY RESULT. STEP 3. REFER TO FIGURE 2-6 AND 2-7 (DO NOT PERFORM STEP 8 OF FIGURE 2-7), AND START THE “ON-COMING” SET. STEP 4. NOTE THE VOLTAGE INDICATED ON THE “ON-LINE” SET. ADJUST THE VOLTAGE OF THE “ON-COMING” SET TO THE VOLTAGE NOTED ON THE “ON-LINE” SET. STEP 5. ADJUST THE FREQUENCY OF THE “ON-COMING” SET TO A HIGHER VALUE THAN THAT OF THE “ON-LINE” SET. STEP 6. SLOWLY REDUCE THE FREQUENCY OF THE “ON-COMING” SET UNTIL THE SYNCHRONIZING LIGHTS FLASH AT 2 TO 3 SECOND INTERVALS. CAUTION DO NOT PLACE THE CIRCUIT BREAKER SWITCH OF THE “ON-COMING” SET IN THE CLOSE POSITION WHILE THE SYNCHRONIZING LIGHTS ARE LIT AS DAMAGE TO ONE OR BOTH GENERATOR SETS MAY RESULT. STEP 7. CAREFULLY WATCH THE SYNCHRONIZING LIGHTS OF THE “ON-COMING” SET. AT THE INSTANT BOTH LIGHTS GO DARK, MOVE THE CIRCUIT BREAKER SWITCH OF THE “ON-COMING” SET TO THE CLOSE POSITION. STEP 8. ADJUST THE VOLTAGE AND FREQUENCY RHEOSTATS OF BOTH SETS UNTIL LOAD AND CURRENT ARE DIVIDED EQUALLY BETWEEN THE TWO GENERATOR SETS,AS EXPLAINED IN FIGURE 2-10.1, PARAGRAPH A, STEPS 7 AND 8. STEP 9. MOVE THE CIRCUIT BREAKER SWITCH OF THE “ON-LINE” SET TO THE OPEN POSITION. STEP 10. PLACE THE OPERATIONS SWITCH OF THE “ON-COMING” SET TO THE SINGLE UNIT OPERATION POSITION. STEP 11. READJUST VOLTAGE AND FREQUENCY OF THE “ON-COMING” SET AS NECESSARY. STEP 12. REFER TO FIGURE 2-8 AND STOP THE “ON-LINE” SET. Figure 2-10.1. Parallel Operation of Tactical Utility Generator Sets (Load Sharing and Load Transfer) (Sheet 4 of 4) Change 12 2-26.7/(2-26.8 blank) the period of time required to obtain two consecutive water temperature readings of 160° F minimum, taken at a 15-minute interval. Then continue t o operate engine for 30 minutes. Check and correct any coolant or oil leaks. c. Stop engine as shown in figure 2-8. If the accumulated hours of operation during the above exercise periods do not total 300 hours (recommended lube filters and lubricating oil change peri- od) during a six-month period, it is recommended that the filters and lubrieating oil be changed (para 3-4). If the accumulated hours of operation during the above exercise periods do not total 100 hours (recommended fuel filter change period) during a 12-month period, it is recommended that the fuel filter element be replaced (para 3-160). Section V. OPERATION UNDER UNUSUAL CONDITIONS 2-16. Operation in Extreme Cold (Below- 25°F). a. General. The engine generator set is designed to operate in temperatures down to - 25°F without winterization equipment. To operate successfully at temperatures below -25° F, the engine must be heated by integrally mounted electric winterization heating equipment (fig. 2-12) which receives auxiliary power from an external source or by a fuel burning winterization system (fig. 2-11). Operate fuel burning winterization system for 55 minutes or until fuel burning winterization system cycles off. Operate electric winterization for 5 hrs. b . Fuel System. Keep the fuel tank as full as possible to prevent condensation of moisture. Be sure the proper grade of fuel is used for existing temperatures. Service the fuel filters and strainers (para 3-34b) more frequently than normal. Remove ice, snow, and moisture from the filler cap and filler neck. At end of day’s operation, drain water from fuel tank (fig. 3-7) and from the fuel filters (para 3-56). c . Engine Electrical System. Clean the batteries and cables and inspect for cracked or damaged cases. Be sure the battery terminals are tight, clean, and lightly greased. See that the battery cap vent holes are open. The electrolyte level must be 3/8 inch above the plates. To prevent the batteries from freezing, see that they are kept fully charged. Inspect all electrical wiring for cracks, breaks, and fraying. Tighten loose connections. NOTE 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 noxious and deadly fumes. Do not operate generator sets in inclosed areas unless exhaust discharge 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 venting of exhaust fumes to the outside. TO prevent excessive back pressure, it is recommended that an exhaust extension of flexible tubing be no longer than 20 feet (maximum). f. Keep external surface of engine clean. g. The unit should be allowed to run at no load to allow the engine to cool prior to shutdown. 2-18. Operation in Dusty or Sandy Areas. After adding water to the batteries in freezing temperatures, run the engine for at least an hour to thoroughly mix the water with the electrolyte. d . Lubrication. Lubricate the engine generator set in accordance with instructions in paragraphs 3-3 and 3-4. e . Cooli ng System. Inspect the level of the coolant in the radiator. Inspect the cooling system for leaks, aying particular attention to gaskets and hose connections. Verify that antifreeze mixture is in accordance with table 2-1. f . Air Cleaner. Refer to paragraph 3-32 for proper maintenance of air cleaner. Change 12 2-27 NOTE ELECTRIC AND FUEL BURNING WINTERIZATION KITS CAN NOT BE OPERATED SIMULTANEOUSLY. STARTING STEP 1. CHECK FUEL SUPPLY AND TURN MANUAL HEATER FUEL SHUT-OFF VALVE (A) TO O N STEP 2. OPEN BOTH COOLANT SHUTOFF VALVES LOCATED NEXT TO LUBE OIL COOLER (B) AND THERMOSTAT ASSEMBLY (C). STEP 3. OPEN COOLANT SELECTOR VALVE (D) BY PLACING HANDLE (IN 3-O’CLOCK POSITION) POINTING TOWARDS FUEL BURNING HEATER. Figure 2-11. Fuel Burning Winterization Kit Operating Instructions (Sheet 1 of 2) 2-28 Change 12 E - HEATER CONTROL PANEL STEP 4. PRESS HEATER CIRCUIT BREAKER AND PRESS THE PRESS-TO-TEST INDICATOR, INDICATOR LAMP SHALL LIGHT. STEP 5. SET ON - OFF SWITCH TO ON. INDICATOR LAMP SHALL LIGHT WHEN HEATER GOES INTO RUN CYCLE (APPROXIMATELY THREE MINUTES). OPERATE HEATER FOR 50 MINUTES OR UNTIL CYCLE OPERATION OCCURS AS INDICATED BY EXTINGUISHING OF INDICATOR LAMP. NOTE IF INDICATOR LAMP DOES NOT LIGHT IN APPROXIMATELY FOUR MINUTES, SET ON-OFF SWITCH TO OFF. WAIT THREE MINUTES BEFORE ATTEMPTING TO RESTART HEATER. STOPPING STEP 1. SET ON-OFF SWITCH TO OFF. INDICATOR LAMP SHALL REMAIN ILLUMINATED UNTIL HEATER COMPLETE PURGE CYCLE (APPROXIMATELY 4-1/2 MINUTES). STEP 2. AFTER INDICATOR LAMP EXTINGUISHES, REENERGIZE BREAKER. STEP 3. CLOSE BOTH COOLANT SHUTOFF VALVES (B AND C). STEP 4. TURN MANUAL HEATER FUEL VALVE TO OFF. STEP 5. PLACE COOLANT SELECTOR VALVE (D) HANDLE (IN 9-O'CLOCK POSITION) POINTING DIRECTLY AWAY FROM FUEL BURNING HEATER. ME 6115-545-12/2-11(2) C1 Figure 2-11. Fuel Burning Winterization Kit Operating Instructions (Sheet 2 of 2) Change 1 2-29 Operating Instructions (Sheet 1 of 2) . STEP 2. STEP 3. OPEN BOTH COOLANT SHUTOFF VALVES (C & D) LOCATED NEXT TO LUBE OIL COOLER AND THERMOSTAT ASSEMBLY. STEP 1. PLACE COOLANT SELECTOR VALVE (B) HANDLE (IN 12-0’CLOCK POSITION) POINTING STRAIGHT UP.SHUT OFF VALVE ELECTRIC AND FUEL WINTERIZATION KITS CAN NOT BE OPERATED SIMULTANEOUSLY.RECEPTACLE J49 B -COOLANT SELECTOR VALVE C .SHUTOFF VALVE STARTING NOTE D . SINGLE PHASE SOURCE OF EXTERNAL POWER TO ELECTRIC WINTERIZATION KIT RECEPTACLE 49 (A) HAS BEEN CONNECTED. INSURE THAT A 205-240 VOLT. Electric Winterization Kit. ME 6115-545-12/2-12 (1) 2-30 Figure 2-12.A . 50/60 OR 400 HZ. SET ON-OFF SWITCH TO OFF AND OPEN CIRCUIT BREAKER. POWER ON AND HEATER ON INDICATORS SHOULD BE EXTINGUISHED. STEP 5. STEP 2. Operating Instructions (Sheet 2 of 2) 2-31 . CHECK THAT POWER ON AND HEATER ON INDICATORS LIGHT. Figure 2-12. CLOSE CIRCUIT BREAKER (E) AND SET ON-OFF SWITCH TO ON.E . STOPPING STEP 1. PLACE COOLANT SELECTOR VALVE (A) HANDLE (IN 9-O’CLOCK POSITION) POINTING DIRECTLY AWAY FROM FUEL BURNING HEATER. COOLANT IS NOW BEING HEATED AND PUMP IS OPERATING. Electric Winterization Kit.ELECTRIC HEATER CONTROL BOX STEP 4. If a remote location is desired. 2-12. Drain water and sediment from fuel tank (fig. 60 or 400 Hz single phase. 2-28. General. Insure that drifting snow does not obstruct normal – cooling air flow. respectively. 2-26. Keep the fuel tank full to prevent forming of condensation. The electrical winterization kit consists of a heat exchanger. prepare a suitable location for mounting the panel. 3-7) more frequently. Included are the fuel burning winterization kit. at any ambient temperature from 125° F.a. wash the generator set frequently with clean. 2-27. the kit should be placed in operation a minimum of 55 minutes prior to starting. 2-25. This section contains operating instructions for all kits and auxiliary equipment. Be sure that all lubricant containers are tightly sealed and stored in an area free from dust and sand. b . wheel mounting kit. Load Bank. Since higher altitudes also increase the possibility of freezing. thermostat and accessories. 2-22. Operation in Salt Water Areas. 2-21. The coolant temperature is thermostatically controlled at 130° F. During dry periods when the set is not operating. Drain water and sediment from fuel tank (fig. Operation of the wheel mounting kit is illustrated in figure 2-13. In ambient temperature of -65° F. 2-32 Change 12 . Fig. A reduction in the load may be also be necessary since engines are more likely to overheat at high altitudes. paying special attention to the screens and grilles. Take all necessary precautions to keep dirt and grit out of the fuel tank. Operating instructions for the fuel burning winterization kit are shown in figure 2-11. Clean filters and strainers more frequently than under normal conditions. and load bank. The wheel mounting kit provides a means of mobility for the generator set. The fuel burning winterization kit is utilized to preheat engine coolant and lubricating oil in extreme cold weather. Disconnect and remove wiring harness (1. Operating instructions for the load bank are illustrated in figure 2-14. The fuel burning winterization kit is installed as described in paragraph 4-4. 2-23. Keep the fuel tank full to prevent forming of condensation. Operation at High Altitudes. The kit can also be used to warm the Generator Set for initial starting within 5 hours at any ambient temperature down to -65°F. electric winterization kit. fresh water. 2-19. to enable it to accept 75% of rated load in one step within 20 seconds after starting action is initiated. For electrical winterization kit operating instructions refer to Fig. Power for operation of the kit may be obtained from any power source that supplies 205 to 240 volts at 50. a. Check coolant antifreeze protection (table 2-1) and test the batteries (para 3-82b). Fabricate a new cable of required length using wire compatible with the connectors P1 and P2. the coolant antifreeze protection should be checked (table 2-1) and the batteries should be tested (paragraph 3-82 b). c. The set is designed for operation with the control panel located up to 500 feet from the set. OPERATION OF AUXILIARY MATERIAL USED IN CONJUNCTION WITH THE EQUIPMENT 2-24. Electrical Winterization Kit. Care must be taken to avoid equipment contact with salt water. open the doors and allow the set to dry out. Section VI. The maximum towing speed is 5 mph on paved surfaces. 3-17) and control cubicle assembly (7). Wheel Mounting Kit. Keep the unit as clean as possible. The primary purpose of the kit is to maintain the set in a heated condition. to -65° F. Operation Under Rainy or Humid Conditions. Operation in Snow. Remove rust or other corrosion and paint all damaged preprinted surfaces in accordance with services requirements. The load bank provides up to 50% of the rated load of the generator set to compensate for underrated loads. At 8. coolant pump. the 50/60 kw rating is reduced to 45 54 kw.000 feet above sea level without special adjustment or reduction in load. Control Cubicle Removal for Remote Operation. Fuel Burning Winterization Kit. The engine generator set will operate at elevations up to 5. b . 3-7) more frequently. If contact is made. Where water is available. control box. keep the immediate area wetted down. or if the unit is exposed to salt spray. 2-20. to 150° F. 000 feet above sea level. Salt water causes corrosive action on metal. Operating time may be reduced or increased for warmer or colder temperatures. ENGAGE PARKING BRAKES AND REMOVE TOWBAR AND SAFETY CHAINS FROM THE TOWING VEHICLE.STEP 1. STEP 3. RAISE TOWBAR UNTIL TOWBAR LOCK ENGAGES. ME 6115-545-12/2-13 Figure 2-13. STEP 4. RELEASE TOWBAR LOCK AND CONNECT TOWBAR AND SAFETY CHAIN TO THE TOWING VEHICLE. RELEASE PARKING BRAKE HANDLE AND TOW GENERATOR SET TO DESIRED LOCATION. Wheel Mounting Kit Operation 2-33 . STEP 2. Figure 2-14. 2-34 . 3-4. Inspect engine for evidence of oil leaks and make necessary repairs. dirt or other foreign material to mix with the lubricants. Detailed Lubrication information. To avoid accidental engine cranking or startup. TOOLS. f . Allow no dust. The oil level gage (fig.CHAPTER 3 OPERATOR AND ORGANIZATIONAL MAINTENANCE INSTRUCTIONS Section I. the proper amount of oil is in the crankcase. NOTE When changing oil. check oil level in the crankcase. FULL. (2) Before each period of operation. Basic Issue (Army). General Lubrication Information. fig. For these reasons. the Change 12 3-1 . The engine RUNNING side is stamped ADD. AND EQUIPMENT 3-1. Keep all lubrication equipment clean and ready for use. Each time oil is changed. oil level gauge or cylinder head cover gasket. inspect the seal to make certain it is in good condition. 6. The purpose of the breather tubes 2. 3-2) is the shielded type which allows the operator to check oil level while the engine is either stopped or running. Fumes are redirected into the air intake system and burned in the combustion of the engine. (3) After each operation interval of 100 hours. Reconnect cable at completion of service procedures. If the tubes become clogged. a . Appendix B of this manual. The engine cannot be operated safely when the oil level has dropped to the add mark on the oil level gage. If necessary. and not covered in the lubrication order. When oil level is at the full mark. No special tools or equipment are required by operator or organizational maintenance personnel for maintenance of the engine generator set. Keep oil free of water and abrasives by proper handling and storage. Refer to DA Pam 310-4 (Army) for the current LO. Tools and repair parts issued with or authorized for use with the engine generator set are listed in the basic issue items list. 3-2. & 8. The engine STOPPED side is stamped ADD. 3-12. The lubrication order shown in figure 3-1 is an exact reproduction of the approved lubrication order. Organizational maintenance repair parts are listed and illustrated in the publications listed in Appendix A. (1) Lubricating oil must be in accordance with the requirements of figure 3-1. Keep all lubricants in closed containers and store in a clean. A seal in the oil level gage cap prevents oil from leaking to the outside of the engine and foreign material from entering. and valve compartment . Tools and Equipment. b . and pressure buildup could force oil past crankcase seals. Never fill crankcase above full marks. e. and RUNNING. c. a . drain valve must be open to drain crankcase and closed before refilling. WARNING gage must be kept tight on the level gage adaptor. Special Tools. add oil to bring level to full mark on the oil level gage. OPERATOR AND ORGANIZATIONAL MAINTENANCE REPAIR PARTS. d. CAUTION Use appropriate ADD and FULL marks depending upon whether the engine is stopped or running. set CKT BRK switch (fig. Organizational Maintenance Repair Parts (Army). This paragraph contains a reproduction of the lubrication order and lubrication instructions which are supplemental to. The gage is stamped on both sides to indicate two different oil level locations.1) is to vent the inside of the engine thus preventing pressure buildup and removing harmful vapors from the crankcase . LUBRICATION 3-3. General. vapors are trapped within the engine. oil must be added to raise its level to the full mark. dry place away from external heat. prior to servicing the engine generator set. b . Section II. a. FULL. 2-5) to OPEN position and disconnect cable from battery negative terminal. and STOPPED. gear train. Lubrication Order (Sheet 1 of 2) .TM5-6115-545-12 3-2 Change 12 Figure 3-1. Figure 3-1. Lubrication Order (Sheet 2 of 2) Change 12 3-3 . crankcase.1) from the valve cover. Shut engine off. 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. fig. (7) Stop the engine and allow several minutes for the oil to drain back to the crankcase before checking the oil level. Refer to para 3-4 d. open the engine oil drain valve and remove the oil drain plug from the skid and allow the oil to drain into appropriate container. blow out with compressed air. c. 3-12. Oil Level. (fig. Drain oil into appropriate container. 6 & 8. d. fig. and replace on engine and oil separator. Clean all lubrication points after lubrication to prevent accumulation of foreign matter. CAUTION To prevent overfill of the oil sump. (3) Before draining the oil system. 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. b. then place dead crank switch in on (up) position. wipe all lubrication points free of dirt and grease. 3-4 Change 18 . Cleaning. (8) Using the oil level gage. (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. (1) Crankcase oil level must be checked frequently. operate the engine until a minimum coolant temperature of 160° F is obtained. Oil Level Gage and Filler remove breather tubes (2. Before lubricating equipment. Repair oil leaks before continuing operation. (6) Start and operate the engine for approximately 5 minutes. oil separator and air intake system. (4) Install the drain plug. 3-27) in the off (down) position and crank engine for 15 seconds. Keep all external parts not requiring lubrication clean of lubricants. (1) Drain oil filter by removing plug (l). (9) Observe the engine for oil leakage. Use the side of the oil level gage stamped STOPPED. 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. for oil filter service.TM 5-6115-545-12 TO 35C2-3-444-1 NAVFAC P-8-626-12 TM 00038G-12 Figure 3-2. (5) Place dead crank switch (49. Clean inside of tubes with cleaning solvent. remove oil filler cap when checking oil with set running. Plug Screw Washer Gasket Screw Washer 7. 15. 16. 10. 9. 12. Engine Lube Oil Filters 3-5 . 21. 17. 20. 8. 2.1. 18. 23. 4. 22. Nipple Cap Plug Connector Gasket Figure 3-3. Washer Oil Seal Spring Switch Nipple Transmitter 19. 14. 3. 5. Filter body Filter element Header Gasket Retaining Ring Adapter 13. 6. 11. header (9). Item numbers indicate the sequence of minimum inspection requirements. Remove and discard filter element (8) and gasket (10). 3-7.1 contains a tabulated listing of preventive maintenance checks and service: which must be performed by 3-7.lbs. Daily Preventive Maintenance Checks and Services (Army and Navy). CLASS II Leakage of fluid great enough to form drops but not enough to cause drops to drip from item being checked/inspected.2. a . and surrounding area. To insure that the engine generator set is ready for operation at all times. (6) Tighten screw (5) to a torque of 45 to 50 ft. .(2) Remove screw (5). The necessary preventive maintenance services to be performed are listed and described in paragraphs 3-6 and 3-7. and remove filter body (7) and filter element (8) as an assembly from the header (9). CLASS III Leakage of fluid great enough to form drops that fall from the item being checked/inspected. O. fig. Table 3-1. (5) Replace plug (1) in filter body (7). Leakage definitions for operator/ crew PMCS shall be classified as follows : CLASS I Seepage of fluid (as indicated by wetness or discoloration) not great enough to form drops. You are the assigned operator and have not operated the item since the last weekly inspection. The item numbers are listed consecutively and indicate the sequence of minimum requirements. Perform weekly as well as before PMCS if: a. You are operating the item for the first time. Table 3-1 contains a tabulated listing of Preventive maintenance services which must be performed daily by the operator. (3) Remove filter element (8) from filter body (7). b. 35C2-3-Series for periodic preventive maintenance requirements and table 3-1 for detailed procedures. Stop operation immediately if a deficiency is noticed which would damage the equipment if operation were continued. Then place dead crank switch in on (up) position (9) Observe the engine lube oil filter for oil leakage and be certain that filter body (7) and gasket (10) are properly installed. The item numbers are listed consecutively and indicate the sequence of minimum requirements. to be made as soon as operation has ceased. 3-6. R e f e r t o t a b l e 3-1. it must be inspected systematically so that defects may be discovered and corrected before thay result in serious damage or failure. Section III. 3-5. Defects discovered during operation of the unit shall be noted for future correction. and washer (6). (4) Thoroughly wash and dry interior of filter body (7). (8) Place dead crank switch (49. General. Air Force users shall refer to the applicable inspection manuals and work card sets in T. Install the new filter element (8) and gasket (10) in filter body (7) using reverse procedure of disassembly. (7) Add oil as described in paragraphs 3-4 c (4) through 3-4 c (9). 3-7. PREVENTIVE MAINTENANCE CHECKS AND SERVICES b. 3-27) in off (down) position and crank engine in 15 second cranks followed by 3 minute rests until oil pressure gauge shows pressure. Monthly and Semi-annual Preventive Maintenance Checks and Services (Army and Navy).1. organizational maintenance personnel at monthly and semi-annual intervals.1 for the preventive maintenance services. Marine Corps users should refer to the current issue of TM 11275-15/1. 3-6 Change 1 2 . Inspection. 2 and 3) and mountings and excessive corrosion. and other damage. See figure 3. 3-9. loose covers. Inspect convenience receptacles assembly (fig. General. loose covers. Change 12 3-6.2 blank) . Service. Check for loose cables (1.Section IV. Inspect the slave receptacle for loose mounting. Apply grease to cable connectors. run engine a minimum of 1 hour after adding distilled water.and washers (10) and studs (8) which attach battery tray (11) to base and slide storage batteries and trays (11) out. leaks. a . corrosion and other damage. Convenience Receptacle Assembly Inspection. fig. 3-13) and components for loose mounting. A slave receptacle (17.1) for crocks. Muffler. corrosion and other damage. 3-12) and breather system (Fig.1/(3-6. 3-4) is located in a receptacle box on the forward left side of the housing. loose mounting. Slave Receptacle Inspection. breaks. Instructions in this section are provided to assist the operator in maintaining the engine generator set. Fill to 3/8 inch b. Exhaust Pipe and Breather System Inspection Inspect muffler and exhaust pipes (fig. Batteries. Inspect storage batteries for cracks and leaks. OPERATOR’S MAINTENANCE 3-8. 3-12. 3-12. 3-11. In freezing weather. loose electrical connections. Refer to table 3-1. above plates.4 and remove screws (9). 3-10. . q q Generator set not properly grounded. notify your supervisor. B D — A ITEM TO BE INSPECTED PROCEDURES EQUIPMENT WILL BE REPORTED NOT READY (RED) IF: Do not attempt to service (make adjustments. Of course. OPERATOR/CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES B – BEFORE OPERATION D – DURING OPERATION A – AFTER OPERATION INTERVAL ITEM NO. Change 13 3-7 .TM 5-6115-545-12 TO-35C2-3-444-1 NAVFAC P-8-626-12 TM-00038G-12 Table 3-1. loose or damaged parts and hardware . coolant. coolant. oil. When operating with Class I or Class II leaks. q Equipment operation is allowable with minor leakages (Class I or II). and for unusual wear or deterioration. 2-2). reconnection of wires or cables) or correct anything inside the generator set until the generator set is shut down and completely de-energized. (Para. and hydraulic fluid are found during inspection q q 1 Generator Set Visually inspect unit for fuel. Class III leaks should be reported to your supervisor or organizational maintenance. and hydraulic leaks. continue to check fluid levels as required in your PMCS. Check for proper ground connection. you must consider the fluid capacity in the item/system being checked/inspected. Class III oil. When in doubt. Check for proper levels. If switch malfunctions. 2-5e. connections. q Dead Crank Switch Place dead crank switch in the run position. Visually inspect the generator f o r m i s s i n g . fig. Voltage cannot be properly adjusted. Tighten loose cables and mountings. In freezing weather run engine a minimum of 1 hour after adding water. Not to exceed 100%. 180° to 200° F 120/208 . Temp exceeds 200° F.C. OPERATOR/CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES (Cent) D – DURING OPERATION A – AFTER OPERATION B – BEFORE OPERATION INTERVAL ITEM NO.240/416 30 to 55 psi Indicates percentage of applied current. Inspect for cracks and leaks. Frequency cannot be properly adjusted. 2-5) Green portion of scale EQUIPMENT WILL BE REPORTED NOT READY (RED) IF: Cable connections cannot be tightened. Battery charging ammeter b. Frequency meter Ammeter does not indicate charging current.50/60 Hz 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. Oil pressure gage e. 400 Hz . Wattmeter g. Coolant temp gage c. 2 q a. Fill batteries to 3/8 inch above the plates. Instruments shall indicate within specified limits. q q Fuel Selector Valve Controls and instruments: Fuel selector valve is inoperable. Not to exceed 100% Indicates applied load. Voltmeter d. or battery is cracked or leaking. Clean vent hole in filler cap before installing. B D A ITEM TO BE INSPECTED Batteries PROCEDURES Remove corrosion and apply grease to cable connectors. A. Turn fuel selector valve to the correct position. Pressure is below 30 psi. ammeter f. (Fig. Meter is nonfunctional. Meter is nonfunctional. 3-4b. OPERATOR/CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES B . • q 6 Day Tank Drain water and sediment. (l-9)) 5 q q Fuel filters and strainers Check for leaks. ITEM NO. NOTE In freezing weather. para 2-16b. (Fig.TM 5-6115-545-12 TO 35C2-3-444-1 NAVFAC P-8-626-12 TM 00038G-12 Table 3-1. A ITEM TO BE INSPECTED h. then released. 2-19.8-2 blank) .BEFORE OPERATION INTERVAL B D D -DURING OPERATION A . 2-17c. 3-4c. 3-2. 1-2. and 2-22) 4 q q Oil level Check engine oil and add as required as indicated by oil level gage. Fault indicator panel PROCEDURES All lights out during operation. para 3-4a. NOTE In freezing weather.AFTER OPERATION EQUIPMENT WILL BE REPORTED NOT READY (RED) IF Fault light will not extinguish when switch is placed to TEST RESET position. Drain water and sediment. Allow to drain until fuel runs clear. Check bulb operation using test or reset switch on panel. Class III leakage is detected. 3 q Fuel tank Fill fuel tank at completion of operation. (Fig.1 /(3. Allow to drain until fuel runs clear. drain shortly after operation. Change 18 3-8. drain shortly after operation. . (Para 3-9) Perform a hydrometer check of the battery electrolyte prior to adding distilled water. Hydraulic sump c. Close drain cock as soon as clean fuel begins to run out. (Fig. ORGANIZATIONAL PREVENTIVE MAINTENANCE CHECKS AND SERVICES W-WEEKLY (40 HOURS) M-MONTHLY(1O0 HOURS) ITEM TO BE INSPECTED Fluid level a.Table 3-1. 1 M — H Check fluid levels. Proper level is 2 inches below filler neck. Recharge or replace battery if specific gravity reading is low. Change 6 3-9 2 Fuel tank 3 Fuel filters and strainers 4 Batteries 5 Day tank 6 Generator set . (Para 3-82 b) Drain water and sediment from day tank. (Para 3-33 b) Inspect entire unit for loose. Cooling system S-SEMIANNUAL (500 HOURS) H-HOURS (AS INDICA TED) EQUIPMENT WILL BE REPORTED NOT PROCEDURES READY (RED) IF: INTERVAL ITEM NO. Lubricating oil b. Drain water and sediment from filters and strainers. 1-4. 3-1. Close drain cocks as soon as clean fuel begins to run out. 3-2) Check and add fluid as required. filters and strainers should be drained shortly after operation. (Fig. Note: In freezing weather. (Fig. (Para 2-3 c 2). and unusual wear or deterioration. para 3-6 and 3-9) Check battery electrolyte level. tank should be drained shortly after operation. Drain water and sediment from fuel tank.1. Check oil and add as required. Note: In freezing weather. (Fig. 3-44) Check coolant level. 1-1. damaged. Close drain cocks as soon as clean fuel begins to run out. tank should be drained shortly after operation. or missing parts. para 3-62b2) Note: In freezing weather. oil soaked. 3-36. 3-35) 8 q Air filters This unit is equipped with an air filter condition indicating light that will indicate when the filter elements need cleaning. or cracked belts. 10 q Engine oil Drain engine oil and refill. 3-1. (Para 3-4d) Change lubricating oil filters every 300 hours or 6 months. and clean fuel strainers every 100 hours. and 3-165 a) Drain and refill hydraulic sump. (Para 3-45) Clean actuator filter screen. Replace lubricating oil filters. For alternator drive belt. Replace primary and secondary fuel filters.1. frayed. Proper adjustment for fan belt is a deflection of 9/32 inch with application of 12-14 lb pressure midway between accessory drive pulley. s — H ITEM TO BE INSPECTED V-belts 7 Inspect for worn. Check adjustment of V-belts. (Fig. (Para 3-175) 11 Oil filters 12 Fuel filters and strainer: 13 14 15 q q q Hydraul ic sump Hydraul ic filter Hydraulic actuator 3-10 Change 7 . ORGANIZATIONAL PREVENTIVE MAINTENANCE CHECKS AND SERVICES--continued W-WEEKLY (40 HOURS) M-MONTHLY(1O0 HOURS ) S-SEMIANNUAL (500 HOURS) H-HOURS (AS INDICI ED) EQUIPMENT WILL BE REPORTED NOT PROCEDURES READY (RED) IF: ITEM NO. (Para 3-4c) Change lubricating oil every 300 hours or 6 months.Table. a deflection of 9/64 inch with application of 3-5 lb pressure midway between alternator pulley and accessory drive pulley. 9 Deleted. (Para 3-44) Replace hydraulic filter. (Para 3-34. Clean elements when necessary as indicated by the light. Batteries and Slave Receptacles Change 12 3-11 .Figure 3-4. . Plate and Sleeve Assembly Inspection. 3-18) for cracks. 2-5). breaks. and other damage. Inspect gages on the control cubicle panel (96. fig. loose mounting. Control Cubicle Panel Gages Inspection. and other damage. and other damage. corrosion. Inspect switches on the control cubicle panel (96. loose mounting. 3-17. fig. Set and hold fault indicator TEST OR RESET switch to test and check that all fault indicators light. Panel Light Assemblies. Inspect the connector leads for broken or frayed insulation and other damage. c. Running Time Meter Inspection. Inspection. (2) Set PANEL LIGHT switch to ON position. Inspection. 3-18). Inspect plate and sleeve assembly (fig. adjust ac ammeter zero control until pointer is at zero. Control Cubicle Panel Switches Inspection. breaks. a. 3-16) for loose electrical connection. corroded terminals. — (1) Inspect lens (26 and 33. 3-23. fig. loose mounting. loose mounting. b . bent pins. 3-18) for breaks or loose mounting. 3-16. a. Inspect BATTERY CHG AMMETER (77. fig. fig. Inspection. breaks. and other damage. AC Ammeter. breaks. Set and hold fault indicator TEST OR RESET switch to test and check that all fault indicators light. loose and/or corroded terminals. 3-20. and other damage. fig. Kilowatt Meter. breaks. — (1) Close DC circuit breaker. Inspect freq meter (7. loose electrical connections. Set START-RUN-STOP switch to RUN. and other damage. 3-18) for cracks. 3-18) on the control cubicle panel for cracks. (3) If any panel lamps do not light. Battery Charge Ammeter Inspection. b . 3-15) for tears. With generator off. (1) Inspect lens (17. loose electrical connections. adjust voltmeter zero control until the pointer is at zero. cracks.1 2 Change 1 3-26. fig. b. loose electrical connections. and other damage. Test and Replacement. fig. 3-18) for cracks. Inspection. loose electrical connections. AC Voltmeter. for cracks. for cracks. b. Adjustment. breaks. 3-22. b. Inspect RUNNING TIME meter on the control cubicle panel (96. Adjustment. corroded and/or loose terminals. — Inspection. a. corroded and/or loose terminals. corroded terminals. breaks. or damage and check lamp operation as follows: a. corroded and/or loose terminals. fig. fig. Frequency Meter. Paralleling Receptacles Inspection. Inspect DC CONTROL CIRCUIT BREAKER (27. 3-18). With generator off. loose mounting. corroded terminals. Inspect the paralleling receptacles (fig. loose electrical connection. 3-24. c. breaks. breaks. 3-17) for loose mounting. (2) Inspect lamp (24. dents and other damage. 3-21.3-13. replace lamp. fig. Inspect ac voltmeter (42. 3-15. Set START-RUN-STOP switch to RUN. Adjustment. loose mounting. fig. 3-18) for cracks. breaks. 3-18) for cracks. DC Circuit Breaker Inspection and Fault Indicator Lamp Test. Inspect ac ammeter (8. b. 3-18) for cracks. and other damage. Inspect kilowatt meter (39. for cracks. adjust kilowatt meter zero control until pointer is at zero. 3-19. 3-18. corroded terminals. Close DC CONTROL CIRCUIT BREAKER (fig. loose mounting. a. and other damage. breaks. 3 . 3-18). With generator off. a. 3-25. Press-to-Test Light Assemblies. (Deleted) 3-14. Test and Replacement. 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 Pin no. 3-33. Open door to gain access to rear of control cubicle panel and examine crosspin (94. breaks. dents and other damage. Door Holders Inspection Open door and inspect door holder (85. Inspection. (2) (Deleted) (3) Inspect air cleaner condition switch for loose mounting. Inspect fuel filter and strainer assembly (fig. Inspect the day tank assembly (fig. 3-28. Change 12 3-13 (2) Inspect lamps (31 and 38. dents or other damage (fig. and panels for loose mounting. and other damage. Inspection. 3-34. 3-6) for leaks. and other damage.Table 3-2. a . 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. 3-27. fig. (4) Inspect air cleaner filter element for signs of blockage. loose connector wires. (1) (Deleted) (1) Close DC circuit breaker. Inspect doors. cracks. a . 12-D 12-E 12-K 12-L 12-F 12-G 12-H 12-M 12-N 12-I 3-32. Service. Day Tank Assembly. 3-29. b Service. Crosspin Assembly Inspection. Inspect engine generator set doors for proper operation. . covers. (3) If lamp doesn’t light. unscrew lens and replace lamp. holes. 3-30. loose electrical connector and other damage. fig. Service the air cleaner as described and illustrated in figure 3-5. 3-18) for damage. Synchronizing Light Assembly Inspection. holes. Control Cubicle Door Inspection. then close the drain cock. assembly at intervals shown in table 3-1. 3-18) for damage. fig. Fuel Filter and Strainer Assembly. a .1. 3-18) for breaks or loose mounting. Housing Group Inspection. breaks. Inspection. (2) Press press-to-test light assemblies. 3-27) for cracks. Service the day tank —. (4) Re-install lens. Air Cleaner Assembly. 3 -22). 3-18) for damage or loose mounting. Remove lens and inspect lamp (of synchronizing lights (16. b. Open door and inspect both sides for damage. fig. 3-31. b . COMPRESSED AIR DIRECT COMPRESSED AIR (100 PSI MAX. RINSE UNTIL CLEAN. METHOD A. STEP 6. REMOVE WING NUTS AND RETAINER. Figure 3-5. 4. WASHING WITH WATER SOAK 15 MINUTES IN WATER AND MILD DETERGENT. INSTALL FILTER ELEMENT. CAUTION DO NOT CLEAN IN GASOLINE OR OTHER PETROLEUM SOLVENT. CLEAN FILTER ELEMENT BY EITHER METHOD A OR B DESCRIBED BELOW. INSTALL WING NUTS AND RETAINER AND TIGHTEN WING NUTS FINGER TIGHT. 2.) THROUGH PANEL OPPOSITE DIRECTION OF ARROWS ON ELEMENT DECAL OR OPPOSITE AIRFLOW DIRECTION. STEP 5. 3. METHOD B. 3-14 C h a n g e 7 Air Cleaner Service .STEP STEP STEP STEP 1. AIR DRY DO NOT USE COMPRESSED AIR. CLEAN INSIDE OF HOUSING. CAREFULLY REMOVE DIRTY FILTER ELEMENT. loose mounting. and proceed as follows : (2) Inspect main fuel tank cap gasket for tears or deterioration. If no spray is observed. Filler Cap. (3) Remove and discard filter cartridge (7) and gasket (8). (7) See figure 3-6 and install new filter cartridge (7) and gasket (8) and replace fuel filter and strainer in reverse order of removal. 12. notify Organizational Maintenance personnel.1.bottom of filter and strainer and allow to drain into suitable container. 6. Filter body Header Screw Gasket Filter cartridge Gasket 9. 11. cracks. 13. Service. 3-28). fig. 15. 3-6) at Change 12 3-15 . Drain Cock 2. 1. 7. 5. loose fittings. fig. (4) Remove retainer (14) and strainer element (15). 8. Nut Stud Nut Strainer body Gasket Retainer Strainer element (3) Clean atomizer and tube with a source of compressed air. Inspect ether tank (8. Inspection. a . item 12. (6) Dry with compressed air or lint free cloth. Inspection. 4. Either tank must be replaced by Organizational Maintenance personnel when empty (tank weighs 2 lbs. when empty). 10. (2) Remove filter body (3) from header (4) by removing screw (5) and gasket (6). Fuel Filter and Strainer b. Unscrew nut (9) from stud (10) and remove strainer body (12) and gasket (13). (1) Open the drain cocks (1 and 2. deterioration or other evidence of damage. (3) Inspect fuel tank filler hose for leaks. b . and other damage. Gasket and Strainer. S e r v i c e t h e f u e l f i l ter assembly at intervals shown in table 3-1.. fig. dents. cracks. 3-7) (1) Inspect main fuel tank cap and strainer for breaks. 14. 1 lb. 3-28) and tube (1) from intake manifold and solenoid valve adapter (3). 4 oz. 3-35. (5) Clean the strainer element (15) and all parts including interior of strainer body (12) with cleaning solvent Federal Specification P-D-680. (See fig. and tank bracket for loose mounting. Check that valve opening in cap I S clear of obstruction. Servicing. Drain Cock 3. Service the starting aid assembly as follows: WARNING Be careful not to inhale ether gas as drowsiness and unconsciousness may result. (2) Crank engine and momentarily actuate ENGINE PRIMER switch while an observer watches adapter opening. holes or other evidence of damage. 3-36. Start Aid Assembly. a . when full. solenoid valve. Figure 3-6. (1) Disconnect atomizer (2. leaks or other damage. loose correctors. fig. Inspection. type of coolant and level of protection. Verify that the linkage connecting the shutter control assembly (10. Main Fuel Tank (4) Inspect main fuel tank vent hoses for cracks. (4) Replace a damaged or defective main fuel tank strainer. fig. (2) Clean all metal parts and dry thoroughly.) (1) Remove main fuel tank cap. Fuel Transfer Pump. 3-29) for leaks. Inspect the radiator assembly (35. 3-31) for dirt. Radiator Grille. b. which houses the shutter thermostat (6) to the shutter (2. 3-38. dents. dents. cracks and other damages. fig. gasket. ( b ) Refer to Table 2-1 for proper coolant and fill radiator until coolant level is two inches below filler neck. fig. dents or other damage. loose mounting. ( c ) Fasten tag near radiator cap indicating date. 3-39. cracks. 3-16 Change 18 . foreign matter. and strainer. 3-7. (1) Service the radiator as follows: 3-40. 3-30). Scalding can result from steam in the coolant system escaping when the radiator cap is removed. WARNING Inspect fuel transfer pumps (37 and 38. fig. (See fig. Shutter and Shutter Thermostat Inspection. Service. b. 3-29) for dirt. (3) Replace a damaged or defective gasket. Radiator.TM 5-6115-545-12 TO 35C2-3-444-1 NAVFAC P-8-626-12 TM 00038G-12 Figure 3-7. 3-37. Check thermostat housing for cracks. Service. a. cracks. 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. Fan Guard Inspection. 3-41. 3-31 ) is secure and not damaged. and other damage. leaks. Inspect radiator grille (fig. 3-28) for leaks. deterioration or other evidence of damage. Inspect the LH and RH fan guards (25 and 26. To drain the crankcase. 3-38) for loose mounting. damage or oil soaking. Inspection. 3-42. fig. fig. Hydraulic Cooler (MEP105A Only) Inspection. Fan Belts Inspection Inspect drive belts (fig. loose linkage. 3-37) for loose mounting. place suitable container beneath drain plug (4) and remove drain plug.NOTE At the time the cooling system is required to be drained. (5) Apply a light coat of hydraulic oil to the preformed packing (8). To service the hydraulic filter refer to table 3-1 and figure 3-8 and proceed as follows: (1) Cut lockwire (5). Remove engine lubricating oil filler cap and add oil as required to obtain full level on oil level gage. 3-8) for cracks. 3-45. Hydraulic Filter (MEP105A Only). and other damage. (2) Clean filter body with cleaning solvent. the coolant in the lube oil cooler should also be drained as described in paragraph 3-199 b. 3-29) for cracks. 3-47. 3-8). Inspect angle adapter (fig. 3-46. Engine Assembly Service. Needle valve (9. 3-43. Inspect seal on tiller cap (3) for excessive wear and other damage. remove plug and place suitable container at drain hose. loose hose connections. Open engine lubricating shutoff cock valve and drain oil into container. a. Inspect speed switch (fig. 3-49. fig. c. loose mounting. Change 11 3-17 . dents. fig. Inspect hydraulic sump for cracks. level should be up to sight glass (2. breaks and other damage. Inspect hydraulic sump (1. Close shutoff cock and replace plug. Inspect filler cap (3) for secure fitting. b. 3-34) should be also opened to drain the engine block. (3) Soak new filter element in clean hydraulic oil conforming to Military Specification MIL-H-5606 to remove air trapped in filter material. and other damage. a. 3-35) for signs of wear. 1-2) for leaks and loose mounting. d. and other defects. breaks. remove the oil filler cap and add oil until crankcase is full. 3-44. 3-2). and other damage. Inspect hydraulic pump and drive assembly (fig. loose connector and other damage. loose or damaged connector. loose mounting and other damage. e. Inspect battery charging alternator (fig. breaks. To refill the crankcase. Remove filter body (6) and filter element (7). dents. (6) Install new element in filter body (6) and fill bowl with clean hydraulic fluid. Install filter body (6) in header (10) and tighten. Inspect hydraulic actuator (fig. leaks and other damage. header (10). 3-8) refer to table 3-1 and proceeds as follows: (1) Check oil level. Hydraulic Sump (MEP105A Only) Inspection. b. 3-36) for cracks. (f) Close shutoff cock (21. (e) Open radiator shutoff cock (21) and drain radiator coolant into container. Add hydraulic oil conforming to Military Specification MIL-H-5606 to obtain proper level. Check crankcase lubricating oil level using oil level gage (fig. leaks. Battery Charging Alternator Inspection. 3-34). cracks and other damage. To service hydraulic sump (1. leaks. b. 3-51. Inspection. 3-32) for loose mounting. fig. Service. loose connectors. Refer to table 3-1 and service the engine crankcase as follows: Inspect fins and lines of hydraulic cooler (19. 3-29) and close needle valve (9. a. (2) Remove tiller cap (3). Remove radiator cap. breaks. Hydraulic Sump (MEP105A Only). fig. Service. Angle Adapter Inspection. Inspect hydraulic sump sight glass (2) for legibility of marking. Discard filter element. Lockwire header to filter body on the threads of the filter body. and the threads of the filter body (6). (3) To drain tank. (4) Install new preformed packing (8) and backup rings (9). f. loose mounting. loose fitting. (d) To drain the radiator place suitable container to collect coolant. Federal Specification P-D-680 and dry thoroughly. Repeat step (2) to refill sump tank. 3-50. verify crankcase is full by checking oil level gage. 3-8) for cracks. and backup rings (9). Speed Switch Inspection. Hydraulic Pump and Drive Assembly (MEP105A Only) Inspection. fig. 3-48. See figure 3-1 for proper lubricating oil. Inspect hydraulic filter (fig. Oil Level Gage and Filler Inspection. loose electrical connection and other damage. Hydraulic sump 2. Inspect oil filler for cracks. loose mounting. 3-53. Lube Oil Filter Assemblies Inspection. and other damage. 3-55. See figure 3-2 and proceed as follows: a. d. Inspect seal on oil filler cap for excessive wear. Header Figure 3-8. and other damage. 3-3) for leaks. dents. loose electrical connections. dents and other damage. Drain plug 5. Inspect oil level gage legibility of marking. Filter element 8. fig. and other damage. Oil Pressure Transmitter Inspection. loose. 3-54. Lockwire 6. Inspect transmitter (18. breaks. 3-18 Change 11 . c. Starter Assembly Inspection. cracks. Backup rings 10. 3-3) for leaks. loose fitting and other damage. damaged or missing parts. Filler cap 4. cracks. Inspect lube oil filters (fig.1. b. loose mounting. Hydraulic Sump and Filter (MEP105A) 3-52. loose mounting. Sight glass 3. Preformed packing 9. Inspect starter assembly for cracks. Filter body 7. Inspect oil filler cap for secure fitting. (3) Open bleed screw (2) remove capscrew (3) and remove and discard gasket (6) and filter element. Capscrew 4. Drain cock 2. Secondary Fuel Filter. Gasket 5.TM 5-6115-545-12 TO 35C2-3-444-1 NAVFAC P-8-626-12 TM 00038G-12 1. b . 3-9) for breaks or cracks. Filter element 8. and raise line above day tank level. Bowl Figure 3-9. (2) Open drain cock (1. Inspect threaded parts for damage or stripped threads. Header 6. a. Secondary Fuel Filter 3-56. Bleed screw 3. Gasket 7. Inspection. fig. Service. To service the fuel filter proceed as follows: (1) Uncouple line from day tank at filter. 3-19 . Inspect secondary fuel filter (fig. 3-9) and drain filter. (3) Inspect fuel quantity transmitter gasket and electrical connection. 3-61. fig. Inspect coolant temperature transmitter (10. (6) Close drain cock (l). cracks. (2) Inspect main fuel tank for leaks. Fuel System Bleeding Procedure. loose mounting. (2) Connect auxiliary fuel line (fig. a. With engine running check that excessive noise is not heard from water pump. cracks. tighten bleed screw (2). loose line connections. gasket and strainer inspection procedure. located at the engine end of the fuel tank. gasket and strainer servicing procedure. and other damage. breaks. cracks. (1) Inspect main fuel tank (fig. Inspect fuel injection pump (fig. leaky connections and other damage. Dry with compressed air or lint free cloth. a. 1-1 ) for loose connections. Temperature Transmitter Inspection. and other damage. valve. Inspect drain fitting. loose mounting. 3-44) for leaks. Inspect the parallel cable (fig. damaged cable. and bleed fuel filter and recouple fuel line to fuel filter. 3-64. c. c. Oil Pan Assembly Inspection. 1-1) to hose connector at end of fuel tank drain valve (fig. Service. (5) Install new filter element (7) and new gasket (6) in the reverse order of removal. tears and other damage. Inspect the auxiliary fuel line (fig. breaks and other damage. Inspect oil heater coolant line connections for leaks around fittings. (3) Add fuel as required. fig. leaks. Main Fuel Tank. cracks. (6) Place the start-run-stop switch to stop position (32. 3-60. Inspect hose for deterioration. 2-10A). fig. 3-62. 1-1 ) for dents.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. loose electrical connections and other damage. damaged connectors/pins. 3-43) for leaks. (7) Open the DC Circuit Breaker (20. 2-10A). (2) Depress the DC Circuit Breaker (20. breaks. leaks and other damage. (3) Place the battle short switch to the ON position (22. (4) Place the start-run-stop switch to the run position (32. 2-10A). dents. Paralleling Cable Inspection. 3-20 Change 18 . a. 2-10A). 3-58. b. Inspect oil pan for cracks. breaks. 3-63. Close drain cock when clean fuel runs out. Drain into suitable container. fig. (8) Place the battle short switch to the OFF position (22. cracks. loose mounting and other damage. Auxiliary Fuel Line Inspection. hose connections and plug for leaks. 2-10A). (4) Refer to paragraph 3-36 a for fuel tank cap. (5) Observe fuel coming from top of secondary filter. b. Inspect fan for cracks. fig. Water Pump Inspection. 2-10A). Inspection. fig. Fuel Injection Pump Inspection. 3-7). 3-57. (1) Open bleed screw (2) on secondary filter. 3-7) for loose mounting. Open drain cock and allow water and sediment to completely drain off. and other damage. fig. 3-59. and other damage. (1) Refer to paragraph 3-36 b for fuel tank cap. Inspect water pump (18. When air free fuel is flowing. fig. breaks. loose mounting. loose mounting and other damage. cracks. b. Fan Inspection. 1-1) for loose connections. cracks. TM 5-6115-545-12 TO 35C2-3-444-1 NAVFAC P-8-626-12 TM 000838G-12 Section V. The engine generator set must be completely serviced with fuel. Defective fuel solenoid valve. d. c. NOTE Air Force and Navy users are authorized to perform maintenance within the scope of their capability. c. f. Clogged air intake system. Batteries weak. i. Defective or loose wires. 2-5c and page 2-21. Fill fuel tank or use auxiliary fuel supply (para 2-3). Replace DC CONTROL CIRCUIT BREAKER (para 3-100). Defective nozzle holder a. h. g. Replace START-RUN-STOP switch (para 3-119). Replace defective speed switch (para 3-186). Replace fuel solenoid valve (para 3-158). 2. Replace float switch (para 3-159). check that all electrical connections are correct and operating controls are in the correct positions. e. step 1. k. Defective DC CONTROL CIRCUIT BREAKER. Any trouble beyond the scope of organizational maintenance shall be reported to the next higher level of maintenance. prior to replacing batteries. e. Clogged secondary filter element. Before troubleshooting. TROUBLESHOOTING 3-65. (Refer to item 16. k. Connect batteries as indicated in figure 3-4. Tighten all loose connections and clean corrosion from all terminals. PROBABLE CAUSE a. e. h. i. g. and lubricating oil. b. i. Replace nozzle holder assembly (para 3-201). g. g. Defective. h. f. Defective START-RUN-STOP switch Defective speed switch Improper starting procedure. c. d. a. Service filter and strainer (para 3-34). Service air filter assembly (fig. Clean restriction or replace tine. Perform starting procedure as described in paragraph 2-12. a. h. d. CORRECTIVE ACTION Perform starting procedure as described in paragraph 2-12. Change 18 3-21 . b. corroded or loose battery cables. c. General Table 3-3 provides information useful in diagnosing and correcting unsatisfactory operation or failure of the engine generator set and its components. 3-5). table 3-1. Service filter (pars 3-197).) Inspect control wires and repair or tighten as necessary. Engine cranks but will not start. Clogged fuel fitter and strainer elements. Batteries improperly installed. Bleed fuel system (para 3-56c). coolant. Recharge or replace batteries (para 3-82). i. Fuel supply exhausted Water in fuel supply Air in fuel system. Restricted fuel supply line. b. Drain fuel system. Refer to page 2-14. Table 3-3 Troubleshooting MALFUNCTION 1. fig. f. The corrective action recommended is described opposite the probable cause. control e. service with proper grade of fuel (para l-4b). f. Engine fails to crank when START-STOPRUN switch is moved to START position. b. d. Defective day tank float switch. assembly. Improper starting procedure. Each malfunction stated is followed by a list of the probable causes of the trouble. Defective turbocharger. e. Engine operating temperature too low due to faulty thermostat.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. Defective nozzle holder assembly. Generator set overloaded. m. Close switch (49. Engine exhaust white or blue. Clogged turbo. Engine runs erratitally or misfires a. Reduce load to rated level. Air in fuel system. e. Clogged air intake Defective turbocharger. d. Replace speed switch (para 3-186). Replace oil pressure switch (para 3-194). Oil level too high. Engine runs when START -RUN-STOP SWITCH is held in START position but stops when switch is set to RUN. e. b. e. e. Replace if defective. Drain fuel system and fill with proper fuel (para 1-4). f. High coolant temperature. o. Drain fuel system and fill with proper fuel (para 1-4). Open or defective dead crank switch. 3-27) and test for continuity. Improper fuel. d. Drain fuel system and fill with proper fuel (para 1-4). Service sir filter assembly (fig. b. o. Defective oil pressure switch. c. a. c. Closed fuel shutoff lever (Class I only). Improper timing. d. Clean fuel lines. b. d. c. Adjust valves (para 3-220). service with proper grade of fuel (para l-4b). n. Replace switch (para 3-119). c. 6. a. Open lever for fuel inlet to injection pump. Replace nozzle holder assembly (para 3-201). Improper fuel. Service air filters (fig. m. b. 5. Replace thermostat (para 3-209). c. PROBABLE CAUSE Contaminated or improper grade of fuel. a. Replace turbocharger (para 3-203). a. Bleed fuel lines (pars 3-56). Restricted fuel fines. c. Speed switch not reset after overspeed shutdown. l. Drain crankcase until proper level is indicated on oil level gage (para 3-4). d. b. CORRECTIVE ACTION Drain fuel supply. 3-5). f. 3-5). Defective speed switch. d. Correct timing. e. n. a. Replace nozzle holder assembly (para 3-201). b. a. Replace turbocharger (para 3-203). Dirty air cleaner. Defective START-RUNSTOP switch. improperly adjusted valves. fig. c. Contaminated or improper fuel. c. Reset speed switch by depressing reset button on back end of switch. Refer to malfunction item 11. Defective nozzle holder assembly. 3. 4. 3-22 Change 18 . b. Switch not held in start position sufficient amount of time to enable engine to exceed 600 rpm. Engine exhaust excessively black a. d. Hold in start for a longer period (para 2-12). d. e. b. e. that there is at least 10. LOW PROBABLE CAUSE a. — d. a. e — Replace oil pressure regulator Add coolant (para 3-41). Generator set overloaded. Insufficient heat transfer through radiator. Replace oil pump. — g. a. Tighten turbocharger end plate screws (para 3-203). c and — of malfunction 7. f. Tighten end plate screws (para 3 -203). — g. Inspect housing. Add lube oil (fig. c. Replace thermostat (para 3-209). Drain crankcase and fill with proper lube oil (fig. 10. Service filters (para 3-4). Improper turbocharger lubrication. Oil level too low.200 CFM or CFM cu. Replace water pump (para 3-206).300 that air inlet doors are open. — b. ft. 3-l). 8. — c. Clogged lube oil filters. a. C h a n g e 3 3-23 . — f. Check that the generator load does not exceed the ratings specified on the kilowatt capacity nameplate 70-1345 (M2). 11. Defective oil pressure gage. Check Check Insure 12. g. — b. Replace transmitter (para 3-209). j. High coolant temperature due to incorrect coolant. b. — b. a. — Defective coolant temperature transmitter. See b. — i. — e. See b. — a. High coolant temperature indicated on coolant temperature gage. — b. Coolant level low. — e. — e. Defective water pump. d. leaks a —. Check for proper coolant mixture. shutter operation (para 3-171). a. 70-1346 (Ml). — c. Defective oil pressure transmitter. air supply (fig. — a. Correct or replace as necessary (para 3-41). f. c. k. Defective or improperly adjusted fan belts. Improper viscosity oil Worn oil pump. Defective turbocharger housing. Clean turbocharger oil passages (para 3-203). Worn bearings. High oil pressure indicated on oil pressure gage. — d. c and e from malfunction 7. — e. Turbocharger oil. Oil pressure regulator. 3-l). Loose turbocharger end plates. Defective coolant temperature gage. Replace radiator (para 3-172). Clogged radiator. Noisy turbocharger. 2-l). Adjust or replace fan belts (para 3-183). Replace gage (para 3-120). Replace gage (para 3-121). — b. — b. Troubleshooting (Cont) MALFUNCTION 7. k. h. Lube oil level low. — d. b. — a. Loose turbocharger end plates. j. Defective coolant thermostat. oil pressure indicated on oil pressure gage. — b. — 9. — b.Table 3-3. — f. — g. — CORRECTIVE ACTION Add oil until proper level is indicated on oil level gage (para 3-4). Replace bearings. Replace turbocharger (para 3-203). h i. Replace transmitter (para 3-193). — 15. — e. Adjust alternator (para 3-184). — d. Ac voltmeter does not indicate any set voltage. Replace gage (para 3-120). Improperly adjusted alternator. — a. — d. b. Defective coolant temperature transmitter. — a. CORRECTIVE ACTION l . a —. b. — d. Open wire in charging circuit. Replace ammeter (para 3-124). — 13. b. Troubleshooting (Cont) MALFUNCTION 1 1 .2 4 Change 1 . b. — c. Replace switch (para 3-11 2). Find open wire and repair. Low coolant temperature indicated on coolant temperature gage. b. & m . a —.Table 3-3. — c. Defective batteries. — c. Replace ammeter (para 3-108). Adjust or replace belt (para 3-183). Defective speed switch. a —. d. Defective or improperly adjusted alternator belt. Low resistance or short to ground. — 14. Defective coolant temperature gage. Defective alternator. — f. Defective battery charging ammeter. Replace speed switch (para 3-186). 3 . PROBABLE CAUSE l.(para 3-184). (Deleted) a. e. Battery charging ammeter indicates excessive charging rate after prolonged operation. Blown alternator fuse. b. — c. b. Replace transmitter (para 3-209). Defective alternator. d. — f. Service or replace batteries (para 3-82). replace thermostat (para 3-209). Replace alternator (para 3-184). — c. Defective ac voltmeter. Improperly adjusted alternator. e. — Adjust or replace shutter or control assembly (para 3-171). Replace fuse located at back end of alternator. Defective coolant thermo— stat. — c. & m. Replace voltmeter (para 3-105). — c. — e. Defective battery charging ammeter. Replace alternator . — a —. Adjust alternator (para 3-184). — Defective or improperly adjusted radiator shutter and control assembly. Inspect wiring and repair as necessary. — b. (Deleted) a. c. (Deleted) 12. — d. Battery charging ammeter shows no charging when batteries are low or discharged. — Defective VOLTS-AMPS selector switch. c. 22. 18. Defective fuel transfer pumps. d. c. c. b. a. a. Clogged fuel transfer pump screens. b. (para 3-34). Frequency transducer defective. b. 20. 3-25 . a. 19. Kilowatt meter defective. b. d. a. Replace meter and transducer (para 3-111). Replace meter and transducer (para 3-111). d. Defective nozzle holder assembly. a. b. Defective fuel solenoid valve. c. b. Defective frequency transducer or frequency meter. Erratic frequency indicator on frequency meter. Improperly adjusted valves. Defective ac voltmeter. Replace Rheostat (para 3-110). 17. 21. a. Replace float switch (para 3-159). b. a. b. a. Replace pumps (para 3-165). PROBABLE CAUSE Defective VOLTAGE ADJUST rheostat. Replace solenoid valve (para 3-158). Adjust valves (para 3-220). Replace switch (para 3-112). Loose electrical connection. Clogged fuel filter or strainer. Air in fuel. but sufficient fuel remains in main tank for operation. d. Replace meter (para 3-106). c. Kilowatt.Table 3-3. a. Service fuel transfer pumps (para 3-165). Bleed fuel system (para 3-56). b. meter fails to register. Increase speed manually (utility). Replace meter (para 3-105). Defective VOLTAGE ADJUST rheostat. Service filter and strainer. — Defective day tank float switch. CORRECTIVE ACTION Replace rheostat (para 3-110). Replace nozzle holder assembly (para 3-201). Engine speed too low. Inspect harness and connectors and repair (para 3-139). e. Replace frequency meter and transducer (para 3-111). Frequency meter defective. Defective VOLTS-AMPS switch. Adjust frequency adjust control (precise). Frequency meter fails to register. Replace transducer and meter (para 3-111). Defective meter or transducer. e. Ac voltage too high or too low. Ac voltage fluctuates. a. Troubleshooting (Cont) MALFUNCTION 16. d. b. NO FUEL indicator illuminates. Engine generator set shuts down. d. Ac voltmeter indicates voltage but frequency is off scale to left. c. b. Measure continuity of coil pins A and B. Main AC contactor (CB2) defective. Engine generator set shuts down. b. All meters read correctly except volt meter reads off scale high. 28. Defective overspeed switch. Engine generator set shuts down. Defective voltage adjust rheostat. Lamp burned out. 26. 24. Defective oil pressure switch. Troubleshooting (Cont) MALFUNCTION 23. but engine speed is normal. Replace switch (para 3-186). Replace circuit breaker switch (para 3-117). but oil pressure is normal. replace contactor (para 3-141). Replace switch (para 3-194). 3-26 Change 8 . Replace rheostat (para 3-110). 25. low oil pressure indicator illuminates. CORRECTIVE ACTION Replace switch (para 3-209). PROBABLE CAUSE Defective coolant temperature switch. Engine generator set shuts down. a. over speed indicator illuminates. Main AC contactor (CB2) will not close. If no continuity. Circuit breaker switch is closed and indicator does not light. 27. Defective load circuit breaker switch. HIGH COOLANT TEMP indicator illuminates but coolant temperature is normal. a.Table 3-3. Replace lamp (para 3-26). Shut down engine pump screen available. down for water pump re- with defective element strainer until 3-71. performed. Run engine generator set. Leaking radiator. be conveniently placement.Section VI. apply epoxy. installed replacement (para 3-34). Liberally putty. assembly If the engine is running open Trouble Expedient Remedy too hot. vigorplacement Reassemble parts are ob and operation until re- (para of hose with plastic elec tricians toring while tape. until a replacement . is operating hose is and continue until replacement obtained. Engine and Cranks But Will Expedient Remedy Runs Erratically Misfires. F I E L D E X P E D I E N T R E P A I R S 3 . ing expedient repairs may be used in emergencies EquipWater pump leaks. Let dry. belt installed until replacement is obtained. Start or ) Starts 3-69. 3 . Engine Heat Up. G e n e r a l . wrap leaky area Clogged fuel transfer pump screen. Shut down engine and tightly wrap area of line leak with plastic electrician’s tape. Keep moni- Use compressed air. shut down for n>aintenance or other reason. to clear Reassemble obstruction. Leaking coolant hose. Fuel is not Strained. If available. Frequently belt (Para Not or observe fan 3-183.2 7 repaired is operating fuel line or other substance to leaking of radiator. 3-72. Expedient Remedy Continue engine operation fan belt or until with defective Defective exhaust pipe. 3-67.3 4 b ) . Loss of Coolant. manually shutter with the lever to keep shutters open until the engine is normally Clogged fuel filter. Run engine until tained generator set with defective (para exhaust pipe is ob3-86). Fill radiator and operate engine until replacement radiator is obtained. Keep monitoring line while engine is obtained. tightly drain coolant. to clear ob 3-70. Shut down engine fuel filter and remove cartridge and ( p a r a strainer element 3 . is obtained Trouble 3-68. vigorously. tar. replacement engine can be shut down. Expedient Remedy Badly worn fan belt. ment so repaired must be removed from operation as soon as possible and properly being placed in operation again. Engine Overheating. if or shake repaired engine hose area OUSIY. the follow- Do not add coolant to radiator until pressure has been relieved. and remove 3-165).6 6 . Loosen radiator cap so as to relieve pressure. T r o u b l e Expedient Remedy Organizational maintenance level troubles may ocset is operating in WARNING cur while the engine available generator the field where supplies and repair parts are not and normal corrective When this condition action cannot be exists. continue Trouble tained. Housing Trouble Filled With Smoke. Use compressed or shake air. nonsoluble area Defective fuel line. If necessary shut down engine. Trouble Shutter control not operational. repaired before inue engine adding coolant as frequently to maintain water level Trouble Expedient Remedy above top of radiator coil assembly until engine shut can Fuel tank strainer element defective. operation until replacement parts are obtained. Expedient Remedy struction. operation to radiator as necessary Cont- upon the decision of the unit commander. shut down engine. Essentially. inductors and resistors. Fuel Pumps. battery and load bank (if installed) charg - thr~ugh C306 4 . (fig. wire arm down position Section VII.1 4 ) are replaced in the Load paragraph 4-38. 3 . fuel line leaks. Engine and Cranks But Will or Not Start or Starts (Cont) Trouble Expedient Remedy Runs Erratically Misfires.5 ) . nents are included on this generator 3-78. Trouble Expedient Remedy Keep monitoring re- paired line while engine is operating and a replacement If repaired fuel line leaks. Trouble Expedient Remedy main in retracted position dis actuator (3. Operate set as class 2 unit until fault in governor system can be corrected. or secondary to their suppression set. toring reconnected fuel line (12. 3-17). to compKeep moni- to operate properly. Defective valve. move filter element if available. fig. main described in Interference EMI from contactor. Clogged air filter. The b. a. shut down engine. a. fuel selector Shut down engine and dis connect ( p a r a fuel selector 3 . Loss of Frequency Connect fig. Tightly wrap area of oil line leak with plastic electrician’s connect linkage does not re- Indicator Lights. Battery Charging p a r a g r a p h Alternator. fig. and using capacitors.7 3 . c. (21. The methods used include wires. and re(fig. regulator this contains The — alternator with integral RFI suppression diodes as an Electromagnetic assembly to suppress ac The fuel pumps. 3 . Load Bank. General Methods Used to Attain Proper b. Move actuator retracted linkage to the until a replacement selector valve If reconnected is obtained. Use hose Trouble Expedient Remedy assembly (15) connection Governor system fails Shut down the engine generator set and disconnect plugs and plastic electrician’s tape as necessary lete connection. linkage and 3 . to clear Reassemble operation with defective battery charg ing alternator replacement for battery installed is obtained until or and continue until replacement parts are obtained. Secondary Suppression Components. compo- No secondarv low resistance path to ground for the stray currents. Battery charging nator defective. NOTE If actuator Defective oil line. Replace the pri%ary function exciter suppression components are those whose is to suppress radio interference. Use compressed or shake vigor obstruction. These Suppression. valve 3-75. alterContinue engine operation Trouble Expedient Remedy Battery Charging Ammeter Shows No Charge. 3 .3 2 ) in the 3-10). shielding high frequency grounding the frame with bonding straps. (fig. Replacement of Suppression Components. ing alternator contain Bank as described in primary suppression components.1 8 4 . hose assembly 3 . Engine Shuts D o w n and LOW OIL PRESSURE position.2 8 . RADIO INTERFERENCE SUPPRESSION 3-76. until engine can be shut down charging alternator service or repair. Interference Suppression Components.3-72. (EMI) suppression assembly. Control (Class 1 Sets Only). Shut down engine 3 . tape. l-l). Primary Suppression Components. 3-77. J17 and J21 on the electrical governor control Remove cover (fig. while engine is operating fuel Loosen screw (13) and move fuel pump lever all the way forward and tighten screw. Replace fuel pumps with integral components as des - rad<o interference cribed in paragraph suppression 3-165. suppression is attained by providing a components have radio interference suppression functions which are incidental primary function.2 8 ) sembly directly to hose as(24).1 6 6 ) . air. 3-74. oil line is obtained. RFI suppression capacitors C301 day tank solenoid valve. ously. BATTERIES. The specific gravity between the cells battery tray and slave receptacles of the engine generator set. The temperatures as low as -65°F without freezing. 3-79. cells monthly. Section IX. Day Tank Solenoid Valve. There is a slave receptacle electrically connected in parallel with the batteries.TM 5-6115-545-12 TO-35C2-3-444-1 NAVFAC P-8-626-12 TM-00038G-12 3. (3) Install new storage battery in reverse order of distilled water may be used to obtain the proper level.78 Replacement of Suppression Components.250 will permit the battery to withstand the engine generator set. Normally. ORGANIZATIONAL MAINTENANCE maintain the engine generator set at the organizational level. Batteries. 3-80. A dangerously low point of charge Two 12-volt 100 ampere. A electrically connected in series to supply 24 Vdc for starting specific gravity of 1. a.150 or less will mounted side by side on a battery tray. The batteries are permit the battery to freeze at a temperature of 5° F. readings for cell deterioration. e. b. C4 and C5 are connected between terminals A2. Test the capacitors for leaks and shorts using a multimeter or other capacitor tester. should be within . Testing of Radio Interference Suppression Components.220 at 80°F will in order to supply or receive an auxiliary source of electrical be obtained from a fully charged battery (2. (Cont) d. The 6TN and 6TL batteries can be mixed or matched. before adding water.05 generator set should be operating so as not to run down the or greater will be replaced if attempts to restore the battery batteries when supplying this source of dc power. electrolyte in wet batteries to a lower specific gravity. General. fail. Disconnect battery negative cable (1) positive cable (2) and However. lead acid type batteries are indicated by a hydrometer reading of 1. If the level becomes too low due to evaporation. acceptable hydrometer reading of 1.05. Replace diode suppressors as shown in B of figure 3-11.210-1. maintenance–free batteries cannot be mixed or jumper cable (3) from storage batteries (4) matched with military batteries.280 and adding distilled water will result in an should be used in these batteries. Diode suppressors CR27 are provided at the connector of the day tank solenoid valve. General Where essential. AND RELATED PARTS Battery hydrometer readings should be tested on all 3-81. Replace suppression capacitors as shown in A of figure 3–11. electrolyte levels are carefully monitored. B2. see NOTE figure 3-4 and proceed as follows: (1) Remove screw (lA). Lockwire of Fuel Injector Pump for Class 2 Operation Section VIII.200 or cell variance of . of the main ac contractor CB2 and ground. Always test a battery for a degree of charge This section contains information on the batteries. A removal. Figure 3-10. Change 17 3-29 . If the electrolyte which secure battery retainer (7) to studs (8). NOTE Electrolyte (NSNs 6810-00-249-9354 and Failure to perform this task prior to 6810-00-843-1640) have a specific gravity of 1. A source of 24 Vdc electrical power is therefore per cell). may be used if distilled water is not available. good grade of drinking water (excluding mineral waters) Battery Testing. If test equipment is not available and interference is indicated. An receptacle facilitates external connection with the batteries. and C2 respectively. Compare specific gravity readings with previous 3-82. The 6TN and or the 6TL batteries will perform properly in hot weather as long as (2) Remove two nuts (5) and lockwashers (6).placing each component in turn until the cause of interference is located and eliminated. To replace one or both batteries. available for other development. the engine Battery reading of less than 1. Main AC Contac tor Three RFI suppression capacitors C3. some fluid must be storage batteries (4). removed. Replacement. Do NOT adjust the erroneous reading. Replace defective capacitors.0-2. and remove expands and causes the level to rise. sections are arranged in the most logical Instructions are provided in sections IX through XLIV for the information and guidance of responsible personnel to order of disassembly of equipment. isolate the cause of interference by the trial and error method of re.2 volts dc power. nut (lB) and clamp (lC). A. DAY TANK SOLENOID VALVE DIODES Figure 3-11. Interference Suppression Components Removal and Installation 3-30 Change 1 . MAIN AC CONTACTOR CAPACITORS B. 1 and gases exhaust into the air cleaner inlet. Slave Receptacle Replacement.1. cover pass through an oil separator which separates the oil 3-87. Loosen clamps (5) and disconnect hose (6) from oil separator (4) and valve cover crankcase breather. To replace the exhaust pipe. 3-84. Loosen clamp (10) and slide out oil separator (4) Allow exhaust pipe to cool if engine has been running. as follows: Batteries generate hydrogen during a.85.2 volts dc per cell). d. Place 0-bolt (6) on muffler (9) pipe and remove expelling exhaust gases from the engine generator set. An acceptable hydrometer reading of 1. and remove receptacle. see figure 3-12. Loosen nuts (4) which secure 0-bolt (6) and 3. d. and screws (13). charging. harness ties and tag for ease of Installation. bracket (7) to nozzle (8) and muffler (9) pipes. Change 17 3-31 .210 . electrolyte to 38 inches above the plates. clothing. and slide Thin section contains information on the muffler and 0-bolt (6) and bracket (7) toward muffler. Disconnect exhaust pipe (15) from engine and crankcase and improving the atmosphere around the engine remove exhaust pipe. Loosen clamps (7) and disconnect hose (8) from oil WARNING separator (4) and air cleaner inlet (9). The discharge bracket (14) to muffler (9) and exhaust pipe (15). The muffler and both 0-bolt assemblies. Disconnect wiring connections. install receptacle in reverse order of removal. Install new exhaust pipe in reverse order of removal. Install breather system in reverse order of removal. Remove screws (9. exhaust pipe allows the exhaust gases from the engine to he d. A b.temperatures as low as -65°F. cap (3). fig. Use extreme care in clamps. exhaust pipes and breather system of the engine generator Remove screws (10) which secure nozzle (8) to set. General. breather system provides a method for returning oil to the e. follows c. and the gases. Loosen nut (1) from screw (2) and remove weather f. and install new battery tray. camp and bracket (10). Remove six screws (12) which secure receptacle severe bum will result when box (13) to housing and tilt box forward to gain access to electrolyte is spilled on the skin or wiring connections. Muffler and Exhaust Pipe Replacement. handling while filling batteries. c. MUFFLER AND EXHAUST PIPES AND BREATHER SYSTEM b. Breather System Replacement. Battery Preparation TM 5-6115-545-12 TO-35C2-3-444-l NAVFAC P-8-626-12 TM-00038G-12 3-83. Section X. c. see figure 3-4 and proceed the vicinity when servicing batteries. nuts (12). Loosen nuts (11) which secure 0-bolt (13) and discharged from an opening above the grille. The nozzle (8). a highly explosive gas. Place opening is covered by a cap that is opened by exhaust 0-bolt (13) with bracket (14) on muffler pipe and remove pressure when the engine generator set is running. 3-4) and lockwashers (10) which secures battery tray (11) in position. Disconnect battery negative cable (1). WARNING Do not smoke or use an open flame in To replace the slave receptacle. install caps. The muffler and exhaust pipes provide a method for housing. The oil is returned to the crankcase and the To replace the breather system. Accumulated oil residue and gases in the valve f.220 at 80°F will be obtained from a fully charged battery (2. Battery Tray Replacement To replace the battery tray. remove batteries as described in paragraph 3-82a. The breather system proceed as follows: is removed as outlined in paragraph 3-87. without freezing. see figure 3-12 and proceed as b. Remove four screws (IS) and nuts (16) which (1) Remove cell caps and fill battery cells with secure slave receptacle (I”). Remove nuts (1 1). Loosen clamps (1) and disconnect hose (2) from oil 3-86. separator (4) and elbow (3).0-2. (Deleted) (2) Make sure vent holes in cell caps are open and e. generator set. General. Remove grommet (12) from box (3) and feed electrical wires back through grommet hole. in reverse order of removal. Tilt box cover (2) and disconnect electrical remove box cover and assembly. 7. 3-89. 3-90. installation. Nut 2. 6. Tag all This section contains information on the convenience electrical connections for positive identification during receptacle and associated circuit breaker. Convenience Receptacle Replacement. 8. b. Washer U-bolt Bracket Nozzle 9. Nut 5. connections from receptacle (5). Deleted 22. Exhaust Pipe Section XI. Bracket 15. Exhaust Pipe 16. Tilt box cover (2) and disconnect electrical connections from receptacle (5) and circuit breaker (9) and b. Nut 12. Convenience Receptacle Box Assembly d. Washer 13. Screw 3. 3-32 Change 7 . Weather Cap 4. Document Compartment Figure 3-12. u–bolt 14. Install new convenience receptacle box assembly Replacement. See figure 3-13 and proceed as follows See figure 3-13 and proceed as follows Remove six screws (1) which secure box cover (2) and box (3) to frame (4).-21. Muffler 10. a.TM 5-6115-545-12 TO-35C2-344-1 NAVFAC P–8-626-12 TM-00038G-12 1. Remove six screws (1) which secure box cover (2) and box (3) to frame (4). c. Screw 11. CONVENIENCE RECEPTACLE 3-88. Figure 3-12. Crankcase Breather System Change 7 3-33 .1. Screw 9. Convenience Receptacle c. Grommet Figure 3-13. Screw 2. b. 3 .1. Circuit breaker 10.3 4 Change 7 Close circuit breaker and test for continuity. Cover 8. d . Remove two screws (8) which secure receptacle (5) to rear of box cover. Nut 11. Circuit Breaker Test and Replacement. Redate receptacle with new one in reverse sequence of removal. c. 7. Replace circuit breaker with new one in reverse sequence of removal. Repeat paragraph 3-89 a and tilt box cover (2) to disconnect electrical connections from circuit breaker (9). If defective see figure 3-13 and proceed as follows: a. Receptacle 6. Screw 4. Remove five screws (6) which secure receptacle cover (7) to box cover (2). Washer 12. Box Frame 5. Remove nut (10) and washer (11) which secure circuit breaker to box cover. Box cover 3. e . 3-91. . 3-96. Cover 3. or parts thereof. b . and load cable. Screw 2. Install a new plate and sleeve assembly. This section contains information on the plate and sleeve assembly. Screw 8. Plate and sleeve assy 6. Retaining plate 10. 7. in the reverse order of removal. PLATE AND SLEEVE ASSEMBLY 3-95. Bushing Figure 3-15.1. cloth sleeve (10) and retaining plate (9). a. Plate 5. To replace the cover plate and sleeve assembly see figure 3-15. Change 9 3-35 . Remove screws (7) and nuts (8) which secure retaining plate (9) and cloth sleeve (10) to plate. Remove screws (1) which secure cover (2) to housing. Nut 9. General. with a cover to secure the opening. Screw 4. Remove screws (3) which secure plate (4) of plate and sleeve assembly (5) to housing. Cloth sleeve Plate and Sleeve Assembly. The plate and sleeve assembly provides an opening for kit installation. Replacement. and proceed as follows: c. Section XIII. Remove bushing (6). 3 6 Change 1 . 9. Remove cap and chain (4) and shorting screws (l). 3 . 2. for the connectors. by removing nuts (12) and Paralleling Receptacles 3 . The & Replace any damaged cap and chain (4) with of the engine paralleling connecting receptacles provide a means of inter- new ones and secure in place washers (2) and nuts(3). see f i g u r e and proceed as follows: a. the wiring The paralleling receptacles include k. harness along relay screws (11). Q. three generator sets of the same class.A. To replace 3 . connector. tacles Using full wiring harness (10) slack availdiscomect wiring connections at rear of recepEach and tag wiring receptacle to ease installation. 11. — 1. & Disconnect convenience receptacle wiring 3 . mode and size by the use of 25 foot. 4. and plug (5) %y removing nuts (3).9 6 ) wiring and paralleling c. and the shorting protector caps plug dummy moved in step b.1 6 the paralleling receptacles.Section XIV. P A R A L L E L I N G R E C E P T A C L E S 3 . ~. 8. Reconnect — battery power cable. paralleling may be replaced in the reverse order of removal. washers (2). Reinstall new or repaired wiring harness in rev%rse order of removal. ~~. 10. G e n e r a l . receptacle on special relay box. Connector Screw Nut Wiring harness Screw Nut Clamp harness by performing procedure of through c. 3. Remove receptacle screws (8) and nuts (9) which secure in place. abl~. 5. Remove plate and sleeve assembly to gain access to convenience harness. ( p a r a 3 . four conductor cables. i. Remove two clamps table (13) which secure wiring ~ . with screws (l). — p a r a g r a p h Unscrew wiring harness connector g.9 8 . . Dummy (shorting ~. from Screw Washer Nut Cap and chain connector plug) 7. Chain Figure 3-16. e. R e p l a c e m e n t .9 7 . This section contains leling receptacles information on the paralgenerator set.8 9 a — 1. Replace and plate and sleeve assembly re - harness with connectors.tive battery power cable from battery terminal. Disconnect neg. Screw . 3-17) to insure that it is in the reset position (flush to panel). Replacement. fig. The engine generator set control assembly consists of a wiring harness. See figure 3-17 to remove and ins&H FAULT INDICATOR panel (10). (b) Remove DC CONTROL CIRCUIT BREAKER mount~~ hardware and remove circuit breaker. — Testing. nut (19) and washer (20). Replacement. On Class 1 sets. the fault indicator control box must be replaced. If the correct light does not light up or if an incorrect light lights. General. Remove tags. and remove fuse (25). — Test. Lamp and Fuse. To replace indicator lamp and fus~. (5) Remove the harness plug from the back of the fault indicator control box. or replacement fuse as necessary. The light that corresponds to the particular fault opposite the pin numbers should light and stay lit. and remove all scr. b. a. See figure 3-17 and proceed as follows a. Install new or repaired wiring harnesses in rev<rse sequence of removal. 3-101. washer (1 7). (3) With an ohmmeter test circuit breaker for closed contacts. 3-100. Iireaks. 3-17). fig. Test. A 90-degree rotation of the manual speed control knob shall provide a linear cable movement of 0. and other damage. Test the fuse as described below: (1) Depress circuit breaker (27. (2) Unscrew fuseholder cap (24). b. and replace fuse holder cap (24). (a) Tag leads and remove screws and lockwashers wlich secure leads to DC CONTROL CIRCUIT BREAKER. DC Control Circuit Breaker. GENERATOR SET CONTROLS 3-99. 3-103. see detail C of figure 3-17 and proceed as follows (1) Unscrew lens (22) and remove lamp (23). Inspection.036 + 0. 3-102.SECTION XV. c. Reset the lights with the TEST OR RESET switch before proceeding to the next set of pins. (2) Remove screw and lockwasher which secure leads to one terminal of circuit breaker.005 inch. (1) Disconnect negative lead from the battery. remove screws (11. b. 3-17) which secures cover (12) and remove cover. loose connections.ws (3). Install DC CONTROL CIRCUIT BREAKER using removal steps in reverse order. If meter shows an open circuit. — Replacement. Change 1 3-37 . (2) Installation. (6) Sequentially jump pin C of the fault indicator receptacle to the pins listed in table 3-2 of the fault indicator receptacle. See figure 3-17 and remove wiring harnesses (1 and 2) as follows: a. Tag all connectors and electrical leads to assure position identification during replacement. nuts (4) and clamps (5) securing wiring harnesses in position. Inspection. The generator control panel assembly provides a means of controlling engine generator operation. replace circuit breaker. nut (18). Inspect throttle and governor liti-~es for loose mounting. Check that the throttle and governor li&~es motion is smooth and unrestricted. Fault Indicator. See detail A of figure 3-17. a. Inspect FAULT INDICATOR panel (10~ for cracks. d. c. Wiring Harness Replacement. fig. Manual Speed Control. (2) See detail B and remove manual control assembly (21 ) by loosening screw (13) and removing nut (16). Unplug and disconnect wiring harnesses at terfiinations. Replace defective DC CONTROL CI~CUfT BREAKER (27) as follows: (1) Removal. (3) Using ohmmeter. check that continuity exists through fuse and open circuit is not in effect. and loose linkage. and an engine generator control panel assembly. b. — (1) Open DC CONTROL CIRCUIT BREAKER (27. (4) Install existing fuse. Apply 24 Vdc to pins 12-A (positive) and 12-B of the fault indicator receptacle. broken. 4. 3-104. 13A. 3 . 10. Inspection. Install new fuse and replace fuse holder cap (24). (Deleted) Nut Washer Nut Nut Washer Manual control assembly Lens Lamp Fuse holder cap Fuse Test or reset switch 27. Dc control circuit breaker 22. or otherwise defective components. See figures 3-18. 13. cracked. 16. 2. Testing. 17.3 8Change 1 CAUTION Turn engine off and remove the battery negative connection before removing any electrical leads to avoid possible short circuit and resulting damage. 7. d . 5.1. 20. Replace control box (123. Figure 3-17. Replace control cubicle panel components which do not function properly in step b (testing) as indicated in following paragraphs. 24. Blank panel Blank panel Fault indicator panel Screw Cover(Class 1 sets) Screw. 3-18) as described in paragraph 3-135 b. 14. 26. Repair. 3-18) by loosening the three quarterturn fastener and permitting the control cubicle panel to pivot about its hinges in a forward direction. 21. 18. stop lever Throttle lever assembly (Deleted) 15. b . 6. Generator Set Controls (2) Unscrew fuse holder cap (24) and remove fuse (25). 23. 19 and 20. Inspect the generator control cubicle for defective. and proceed as follows: a . gain access to the rear of the control cubicle panel (96. 11. 12. Repair by replacement of components which do not function properly during testing. c. 19. 3. 25. 9. If a component needs replacement. Control Cubicle Assembly. fig. Wiring harness Wiring harness Screw Nut Clamp Wiring harness Control cubicle assembly 8. Replacement. Testing of components of the control cubicle is described under the appropriate heading in paragraphs 3-105 through 3-130. . fig. L1-L2 . 2-6) and zero ac voltmeter with front panel VOLTAGE ADJUST control. .. 3-107. b. . (4) Perform starting procedure (fig. 3-18) and proceed as follows: a. . (2) Tag and remove electrical leads. loose mounting. (1) Gain access to rear of control cubicle panel (96). . (3) Remove three screws and nuts which secure kilowatt meter and remove kilowatt meter. . . (1) Gain access to rear of control cubicle panel (96). . Installation. fig. Installation. (2) Connect multimeter with appropriate ac voltmeter connections across ac voltmeter terminals. . . loose electrical connect ions. . Install replacement wattmeter converter (102) using removal steps in reverse order. . . . . . (2) Tag and remove ac ammeter leads. — Removal. b. Remove tags. . . . . . . Removal..3-105. AC Ammeter Replacement. . (8) Disconnect multimeter and secure control cubicle panel. . . .21 V L1-L0 . L1-L2 . Watt meter Converter Inspection and Replace ment. Inspection. 3-39 . . . . fig. See (102. fig. c. Install replacement kilowatt meter using removal steps in reverse order. Testing. the ac voltmeter is faulty and must be replaced.. 3-18) and replace the ac voltmeter as follows: CAUTION Open DC CONTROL CIRCUIT BREAKER before testing or replacing the ac voltmeter.. . See (42.. See (8. .22 V (b) 120/208 V operation. AMPS -VOLTS setting Voltage Difference c. Remove tags. . . . (2) Tag and remove kilowatt meter (39) leads. (3) Remove three screws and nuts which secure ac ammeter (8) and remove ac ammeter. . b. greater than those specified above are obtained. Installation. . (1) Gain access to rear of control cubicle panel (96). . 2-8). (3) Perform preparation for starting procedure (fig. . (2) Tag and remove ac voltmeter (42) leads. Install replacement ac voltmeter using removal steps in reverse order. Remove tags. (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. b . . . . . See (39. . (7) Stop engine generator (fig. 3-18) and replace the ac ammeter (8) as follows: a. . . (3) Remove screws (40) and nuts (41) which secure ac voltmeter and remove ac voltmeter. 3-18) and replace the kilowatt meter as follows: a. — (1) Gain access to rear of control cubicle panel (96). — (1) Gain access to rear of control cubicle panel (96). . fig. AMPS -VOLTS setting Voltage Difference (3) Remove screws (100) and nuts (101) which secure wattmeter converter (102) and remove wattmeter converter. Gain access to interior of control cubicle and inspect wattmeter converter for signs of corrosion. . or evidence of damage.11 V (6) If voltage differences. . . a . Removal. .. 2-7) steps 1 through 4. 3-108. 3-106. AC Voltmeter Replacement. . .34 V L1-L0 . Kilowatt Met er Replacement. . . . ... Installation. (a) 240/416 V operation. . . Removal. Install replacement ac ammeter (8) removal steps in reverse order. . Remove tags. . Faulty ac voltmeter must be forwarded to higher maintenance level for repair. . which should be 0 to 500 ohms. The ohmmeter should read 500 ohms ±3%. The transducer (6) and frequency meter (7) are a matched set (5) and must be replaced by another matched set. cracks. If the pointer does not move. Remove tags. Frequency Transducer and Meter. 3-18) and proceed as follows: a. 3-18. 3-111. See (48. Sequentially select each . b. Inspection. (b) Remove knob and hardware which secure VOLTAGE ADJUST rheostat (54) to panel (96) and remove rheostat. — (1) Tag and unsolder leads from VOLTAGE ADJUST rheostat (54) and test rheostat as described for FREQUENCY ADJUST rheostat (para 3 -109). (c) Remove screws (3) and nuts (4) which secure the frequency meter to the panel (96) and remove frequency meter (7). fig. loose leads and other damage. (2) Connect an ohmmeter probe to each of the outer terminals on the FREQUENCY ADJUST rheostat (57). (1) Tag leads and remove screws which secure leads to the FREQUENCY ADJUST rheostat (57). connect one ohmmeter probe to either outer terminal and the other probe to the center terminal (wiper arm). Remove tags. See (57. Inspection. Replacement. (1) Gain access to rear of control cubicle panel (96). ) a. (a) Gain access to rear of control cubicle panel (96). (2) Inspect VOLTAGE ADJUST rheostat (54) for breaks. loose mounting. or other damage.3-109. evidence of corrosion. and other damage. 3-112. — Replacement. Replace frequency meter and transducer as follows: (1) Removal. c. or moves unevenly. c. Remove tags. AMPS-VOLTS Selector Switch. (2) Resolder leads to terminals as tagged. the FREQUENCY ADJUST rheostat is defective and should be replaced. As the shaft is rotated. (2) Installation. (3) To check wiper arm of the FREQUENCY ADJUST rheostat (57). Inspect transducer (6) and frequency meter (7) for loose mounting. evidence of corrosion. (a) Tag leads and remove three nuts and lockwashers which secure the three leads to FREQUENCY ADJUST rheostat (57). figure 3-21.250 ohms. Remove tags. Install frequency meter (7) and transducer (6) using removal steps in reverse order. b . loose mounting. Replacement. (2) Tag AMPS-VOLTS selector switch (48) leads and removes crews and lockwashers which secure leads to AMPS-VOLTS selector switch (48) and test AMPSVOLTS selector switch for continuity using ohmmeter and schematic. (d) Tag and remove transducer (6) leads. (b) Tag and remove frequency meter (7) leads. 3-18) and proceed as follows: a . (2) Inspect FREQUENCY ADJUST rheostat (57) for breaks. Inspection. Install FREQUENCY ADJUST rheostat (57) using removal steps in reverse order. Frequency Adjust Rheostat. — (1) Gain access to rear of control cubicle panel (96). See (54. fig. Install VOLT AGE ADJUST rheostat (54) using removal steps in reverse order. (1) Removal. — Testing. (e) Remove screws (1) and nuts (2) which secure transducer (6) to the rear panel and remove the transducer. (See fig. (a) Tag leads and unsolder leads from VOLTAGE ADJUST rheostat (54). Voltage Adjust Rheostat. (4) Reconnect leads as tagged using screws and washers. 3-18) and proceed as follows: a. (1) Gain access to rear of control cubicle panel (96). Solder leads to rheostat. Testing. the ohmmeter indicator should move at the same rate as the rotating shaft. (2) Installation. 3-110. fig. 3-40 except that the resistance value is 250 ohms ±3% and the range is 0 . Replace defective FREQUENCY ADJUST rheostat (57) as follows: (1) Removal. Testing. (2) Installation. Turn the FREQUENCY ADJUST rheostat slowly throughout its range. b . (b) Remove knob and hardware which secure rheostat to panel and remove rheostat. Remove tags. center (1) Gain access to rear of control panel (96. tacts no continuity in OFF position. Install switch (48) using removal remove tags. screw that secures one of the leads (7) tags. and remove cubicle (6) If the VOLTAGE operate (2) Remove correctly replace SENSING switch it. LIGHT switch to panel and remove 3 . Testing. fig. are those closest fore testing or replacing PANEL LIGHT switch. trated in rotated shown.4 1 . leads and~emove screws and lockwashers secure the leads to the AMPS-VOLTS switch. (5) Place a. CIRCUIT 3-17) figure sel. as tag~ecf. As the selector switch is the contacts rotate CW as 3-114. Replace VOLTAGE SENSING swi~ch (67) as follows: (4) Test PANEL LIGHT switch for open con(1] Removal. 3-18) and proceed as follows: CAUTION Replacement. switch (48) to panel (2) Tag leads. leads as kwged and remove tags. Replacement. starting with L1 -L2 (volts). hardware which secures SENSING switch to panel (96) and remove screws and lockwashers which secure leads to switch. fig. switch (67) using removal steps in reverse Remove (Q) Remove ures PANEL switch. (3) With an ohmmeter test PANEL LIGHT b. (~) Tag PANEL move LIGHT switch leads and re(2) Installation. to rear of control cubicle (b) Remove secure AMPS-VOLTS (96) and remove knob (43) and hardware selector which panel (96. selector switch clockwise steps in reverse order The circuit figure for the L1 -L2 position 3-21. to RE- 3-113. 3 . . (a) Tag remove ~. VOLTAGE switch. — i esting. does not VOLTAGE SENSING switch in LOCAL from Test for continuity (closed contacts) contacts to lower contacts. (67. VOLTAGE With SENSING switch.1 7 ) beUpper contacts to panel hinge. Replace defective PANEL screws VOLTAGE SENSING switch which leads and to Reconnect leads. 3-18). (2) (66) usin~ Installation. (a) Tag AMPS-VOLTS selector switch which (48) a. (2) Installation. Install VOLTAGE SENSING order. mounting hardware which sectags. (1) Gain access 3-18). fig. from center for continto upPer See ( 6 6 . and lockwashers SENSING switch. (closed contacts) COIltaC&. and rotate a step at is illus tags. AMPS-VOLTS selector (3) Remove screws and lockwashers which all VOLTAGE SENSING switch (67) switch. Panel Light Switch. SENSING switch test an ohmmeter. Replace defective AMPS-VOLTS Open DC CONTROL BREAKER (1) Removal. steps in reverse order and secure tagged leads to VOLTAGE (4) Place MOTE position. Local-Remote. 3-18) and proceed as follows: uity. clockwise See (3) Install b. LIGHT switch (66). (CW). fig. switch for continuity in ON position. to PANE!. Voltage Sensing Switch. removal Install PANEL LIGHT switch and remove AMPS-VOLTS a time.ctor switch (48) as follows: before testing or replaciqq VOLTAGE SENSING switch. position.position. (27. fig. contacts CAUTION NOT E Open DC CONTROL CIRCUIT BREAKER (27. Replacement. (5) Reconnect lead to PANEL LIGHT switch. mounting secure leads the VOLTAGE LIGHT switch (66) as follows: (~) Remove (1) Removal. Remove (1) Removal. a. Place OPERATION OPERATION continuity position. steps Testing. (6) If the BATTLE operate correctly. (~) Tag OPERATION switch leads and reSee (65. as tagged. b. and proceed as follows: (1) Gain access (96. (a) Tag BATTLE SHORT switch (62) leads (5) Place OPERATION OPERATION contacts) position.4 2 SHORT switch. fig. Testing. With (closed contacts) switch in PARALLEL test for to an ohmmeter. Install OPERATION in reverse order. — before testing or replacing Installation. 3 . NOTE b. (2) Installation. With an ohmmeter SHORT switch in ON positest for continuity (closed (1) Gain access to rear of control panel (96. (4) Place BATTLE tion. removal CKT BRK switch.1 1 7 . replace Reconnect it. fig. (5) Place BATTLE SHORT switch (closed in OFF posifrom tion. (7) tags. Removal. SHORT switch it. NOT E (2) Tag all OPERATION switch (68) leads. (68. to rear of control cubicle panel See (62. CAUTION Open DC CONTROL CIRCUIT BREAKER (27. switch Remove a. 3-18). Test for continuity contacts) (4). 3-18) Operation Switch. leads to BATTLE SHORT switch. Testing. fig. fig. fig. cent er contacts to lower contacts. all leads from CKT BRK fig. Test switch in SINGLE UNIT (closed and remov–e screws and lockwashers which secure leads to BATTLE SHORT switch. Upper (3) Remove secure tagged screws and lockwashers which contacts are those closest to the panel hinge. which secure leads to CAUTION (~) Remove OPERATION OPERATION (2) (68) using tags. fig.3-115.1 7 ) beswitch fore testing or replacing BATTLE 3 . Battle Short Switch. CIRCUIT 3-17) (3) Remove ure tagged screws and lockwashers which secswitch (62). See Single/Parallel fig. (96. Install BATTLE SHORT switch SWitC h 138~s-=w S: (62) using removal steps in reverse order. 3-18) and proceed as follows (2) Check that spring return is in its center position. and remove 3-18). Replacement. (1) Gain access fig. g. fig. leads. 3 . and remove (g) Remove BATTLE SHORT switch cover. for continuity from center contacts to lower contacts. (6) If the OPERATION correctly. mounting hardware which secures Open DC CONTROL BREAKER (27. Replace defective OPERATION tags . (3) Tag (65. CIRCUIT 3-17) switch (68) to panel (96) and remove switch. to rear of control cubicle panel CAUTION (2) Tag Open DC CONTROL BREAKER (27. . 3-18). Replace defective BATTLE SH~RT switch (1) (62) as follows to the panel hinge. switch does not operate (~) Remove BATTLE SHORT switch mount ing hardware and remove switch. move screws and lockwashers OPERATION switch. 3-18) and proceed as follows: C i r c u i t B r e a k e r S w i t c h . Upper contacts are those closest replace Replacement. does not from center contacts upper contacts. 3-116. leads to the OPERATION switch. 3-18). cubicle contacts) from center contacts to upper contacts. the center leads of BATTLE SHORT before testing or replacing OPERATION switch (68). tags . and test for open circuit between a lead to the ENGINE PRIMER (3) Check spring loaded that ENGINE PRIMER With switch is (~) If engine not operate correctly. in reverse order. switch (63) using removal steps in reverse Remove tags. to the rear of the control 5 to 6. 5 to 6. fig. 3-119. CIRCUIT 3-17) contacts 12. START-RUN-STOP replace it. position. 3 . f i g . 3-18) and proced as follows: (~ Place engine START -RUN-STOP switch to START position tinuity (closed and with an ohmmeter between test for con2 to 3. switch as follows: (5) Reconnect lead using screw and lockwasher. b. an~between 11 to 12. (2) Check spring return from START to RUN mounting cubicle panel (96). using removal steps Install CKT BRK switch (65) tags. which secure STOP position all contacts. (1) Removal.sher switch. an ohmmeter.1 8 ) as follows: which secure leads to CKT BRK switch. (~) Place engine START -RUN-STOP switch to (2) Remove screw and lockwa. replace it. coutacts 8 to 9: and contacts before testing or replacing ENGINE PRIMER switch. 11 to CAUTION contacts) contacts Open DC CONTROL BREAKER (27. fig. Replace CKT BRK switch (65) BREAKER (27. switch does to “OFF” PRIMER position. test for continuity be- (Q) Remove ures ENGINE mounting hardware which sec - 5 and contact 6 with CKT BRK switch and no contin- PRIMER switch (63) to panel (96) and switch. between contacts 2 to 3 and contacts as follows: (c) Check for open circuit contacts between contacts (1) Gain access cubicle panel (96). STARTRUN-STOP engine fig. Reconnect leads. Engine Start-Run-Stop Switch. switch (64) to panel (96) and remove and lockwashers PRIMER switch. which secure leads to the ENGINE 3 .1 8 Test ENGINE PRIMER switch ( 6 3 . test for no continuity Installation. (b) Place engine START -RUN-STOP switch to RUN position. with test ENGINE switch for open circuit ENGINE PRIMER switch in “OFF” position. test for continuity 8 to 9. Remove (3) Tag 3-118. contact 2 and contact 3 with CKT BRK switch and continuity (65) in CENTER and OPEN position. Replacement. fig. Testing. (65) in the CLOSE and center position remove ENGINE PRIMER uity with the CKT BRK switch in the OPEN position. (6) If the CKT BRK switch does not operate correctly. fig. START-RUN-STOP a. 3-18) and proceed as follows: CAUTION (7) b. (4) Test ENGINE circpit PRIMER switch for a closed @ Reconnect leads as tagged and remove with ENGINE PRIMER switch held in “ON’ ~. RUN-STOP Replace defective engine START- posit ion. and remove leads from the engine START -RUN-STOP switch and test the switch for continuity as follows: See (63. See (64. Install ENGINE PRIMER order. (~) Tag washers leads and remove screws and lockswi~ch (64. Test the switch. with CKT BRK switch in CLOSE position. (2) (5) between With an ohmmeter. Open DC CONTROL CIRCUIT Replacement. 3-17) before testing or replacing as rollows: (1) Removal. a.4 3 . (1) Gain access ~) Remove CKT BRK switch CKT BRK switch. Replacement. Testi 3 . PRIMER (1) Removal. cures (~) Tag both leads and remove two screws (b) eng~ne Remove mounting hardware which se- START-RUN-STOP switch. Engine Primer Switch.(4) With tween contact an ohmmeter. Replace ENGINE (q) Tag and remove leads from the engine swi~ch (63) as follows: START -RUN-STOP switch. to the rear of the control hardware and remove (2) Installation. ( c ) Remove the two nuts (81). Disconnect and tag all leads from the FREQUENCY ADJUST rheostat. ( a ) Gain access to the rear of the control cubicle panel (96). two washers. 2-5) is set to RUN. Gage should read approximately 120 psi. fig. 3-17) is in closed ON position. Coolant Temperature Gage. 3-18) and proceed as follows: a —. (3) The 0-500 ohm FREQUENCY ADJUST rheostat can be used to check the OIL PRESSURE gage. 3-120. and clamp (83) which secure the COOLANT TEMPERATURE gage (80) and remove gage. replace it. 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. Replace the OIL PRESSURE gage (78) as follows (1) Removal. fig. 3-18) and proceed as follows: a . Replace the COOLANT TEMPERATURE gage as follows: (1) Removal. fig. ( a ) Gain access to the rear of the control cubicle panel (96). (3) The O to 500 ohm FREQUENCY ADJUST rheostat on the control cubicle panel (96) can be used to check the COOLANT TEMPERATURE gage. Disconnect and tag all leads from the FREQUENCY ADJUST rheostat. Remove tags.Testing (1) Gain access to the rear of the control cubicle panel (96). CAUTION Disconnect negative battery terminal prior to making circuit changes. Remove this terminal prior to making circuit changes. See (80. Replacement. Connect the 460 ohm resistance of the FREQUENCY ADJUST rheostat in series with ground and the SEND terminal of the coolant temperature gage. Install engine START-RUNSTOP (64) switch using removal steps in reverse order. Disconnect the multimeter but do not disturb the rheostat setting. gages and indicating lights. Gage should read approximately 240°F. (6) Disconnect FREQUENCY ADJUST rheostat from circuit and reconnect leads removed in paragraph (3) above. 3-121. ( b ) Tag and remove the leads from C O O L A N T -T E M P E R A T U R E g a g e ( 8 0 ) . (5) Check that START-RUN-STOP switch (fig. and clamp which secure the OIL PRESSURE gage and remove gage. CAUTION Connect battery negative terminal prior to checking the OIL PRESSURE gage (78) readings. See (78. Oil Pressure Gage. (6) Disconnect rheostat from circuit and reconnect leads removed in paragraph (3) above/ (7) If the COOLANT TEMPERATURE gage does not operate correctly. Disconnect the multimeter but do not disturb rheostat setting. BATTLE SHORT switch (fig. (2) Tag and remove the lead from the SEND contact of the COOLANT TEMPERATURE gage (80). two washers (82). b . Reconnect this terminal prior to checking meters.(2) Installation. (4) Connect a multimeter between the wiper arm terminal and either other terminal of the FREQUENCY ADJUST rheostat and adjust the rheostat until the multimeter reads precisely 460 ohms. (b) Tag and remove the leads from the OIL PRESSURE gage/ (c) Remove the two nuts. BATTLE SHORT switch to ON. (7) If the OIL PRESSURE gage does not operate correctly. Install COOLANT TEMPERATURE gage (80) using removal steps in reverse order. b . (2) Installation. replace it. Testing. 2-5) to ON. (5) Set START-RUN-STOP switch to RUN. Replacement. Remove tags. (1) Gain access to the rear of the control cubicle panel (96). 3-44 . and the DC CONTROL CIRCUIT BREAKER (27. (2) Tag and remove the lead from the SEND terminal of the OIL PRESSURE gage. (4) Connect a multimeter between the wiper arm terminal and either terminal of the FREQUENCY ADJUST rheostaL and adjust FREQUENCY ADJUSTMENT rheostat until the multimeter reads precisely 30 ohms. BATTLE SHORT switch to ON. Install FUEL LEVEL gage (79) using removal steps in reverse order. fig. Replace the FUEL LEVEL gage (79) as follows: (1) Removal. Testing. 3-18) and proceed as follows: See (74. (3) The 0-500 ohm FREQUENCY ADJUST rheostat can be used to check the FUEL LEVEL gage. replace it. (2) Installation. (7) If the FUEL LEVEL gage does not operate correctly. 3-18) and proceed as follows: a. and that DC CONTROL CIRCUIT BREAKER is in closed (on) position. (c) Remove the two nuts. 3-18) and proceed as follows: a. See (77. Check that START-RUN-STOP switch is set to RUN. — Testing. (4) Connect a multimeter between the wiper arm terminal and either other terminal of the rheostat and adjust the FREQUENCY ADJUSTMENT rheostat until the multimeter reads 30 ohms. (2) Set VOLTMETER to R Xl scale and connect across terminals of BATTERY CHG AMMEtER (77). Install RUNNING TIME meter (74) using removal steps in reverse order. Connect the 30 ohm resistance of the FREQUENCY ADJUST rheostat in series with ground to the SEND terminal of the FUEL LEVEL gage. (5) Check that START-RUN-STOP switch is set to RUN. (c) Remove the three screws (72) and nuts (73) which secure the RUNNING TIME meter (74) and remove meter. See (79. (a) Gain access to the rear of the control cubicle panel (96). fig. Gage should read EMPTY. Battery Charging Ammeter. — (1) Gain access to the rear of the control cubicle panel (96). Replace RUNNING TIME meter (74) as follows: (1) Removal. If voltmeter does not read zero. Fuel Level Gage. (b) Tag and remove the leads from FUEL LEVEL gage. Remove this terminal prior to making circuit changes. Reading on voltmeter should be zero and BATTERY CHG AMMETER should indicate a charge or discharge reading. Running Time Meter. b . (a) Gain access to the rear of the control cubicle panel (96). Replacement. (2) Tag and remove the lead from FUEL LEVEL gage (79). b . BATTLE SHORT switch to ON. Replace the BATTERY CHG AMMETER (77) as follows (1) Removal. and clamp which secure the FUEL LEVEL gage and remove gage. Apply ground (0 ohms) to SEND terminal of the gage. two washers. If voltage is present and the meter does not operate. RUNNING TIME meter should operate and change by one-tenth of an hour.(2) Installation. Replacement. (1) Gain access to the rear of the cubicle control panel (96). Install OIL PRESSURE gage (78) using removal steps in reverse order. Discomect and tag all leads from the FREQUENCY ADJUST rheostat. CAUTION Connect battery negative terminal prior to checking the gage readings. 3-122. b . replace it. Check that START-RUN-STOP switch is set to RUN. 3-124. (2) Installation. (6) Disconnect FREQUENCY ADJUST rheostat from circuit and reconnect leads removed in paragraph (3) above. Testing. and that DC CONTROL CIRCUIT BREAKER is in closed (on) position. replace BATTERY CHG AMMETER. Disconnect the multimeter but do not disturb rheostat setting. FUEL LEVEL gage should read FULL. CAUTION Disconnect battery negative terminal prior to checking the indicator readings or making circuit changes. Replacement. fig. (b) Tag and remove the leads from tne RUNNING TIME meter. Remove tags. (a) Gain access to the rear of the control cubicle panel (96). and that DC CONTROL CIRCUfT BREAKER is in closed (on) position. Remove tags. 3-45 . a . Check for 24 Vdc input to meter. BATTLE SHORT switch to ON. 3-123. fig. Replacement. 3-18) and proceed as follows: a —. (1) Gain access to the rear of the control cubicle panel (96). 3-125. 3-18) and proceed as follows: a . Panel Light Assembly. 32.( b ) Tag and remove the leads from the BATTERY CHG AMMETER. Replacement. (2) Remove light assembly mounting hardware and remove light assembly. Installation. Visually inspect for damaged components. 124. ( a ) Gain access to inside of control box (123). . Remove tags. Installation. Install terminal board (105) assembly using removal steps in reverse order. (4) Reconnect lead. See (99. Make certain to replace jumper (107) across same terminals in removal procedures. NOTE Make certain DC CONTROL CIRCUIT BREAKER is open. fig. 3-18) and proceed as follows (1) Tag leads and unsolder leads to light assembly. Terminal Board Assembly. fig. 3-129. ( b ) Tag and remove the leads from relay assembly (99). 3-126. Inspection. Remove tags. Remove tags. T e s t i n g . Remove tags. Remove tags. Control Box Relay Assembly. ( c ) Remove the relay assembly (99) by removing the four attaching nuts (98). ( b ) Tag and remove the leads from the terminal board (105). — (1) Removal. 3-18) and proceed as follows: a . loose hardware and other damage. test lamp (24) for c o n t i n u i t y . ( b ) Remove light assembly mounting hardware and remove light assembly. Press-to-Test Light Assembly Replacement. ( a ) Tag leads and remove screws which secure leads to light assembly. fig. ( c ) Remove jumper (107) by removing screws (106) and note location of jumper. If meter shows an open circuit. ( d ) Remove the four screws (103) and nuts (104) and remove terminal board (105). See (105. b . Inspection. Removal. Solder leads to light assembly. Synchronizing Lights. fig. See (16. 3-46 (3) With an ohmmeter. (2) Installation. 3-130. (2) Remove screw which secures lead to one terminal of SYNCHRONIZING LIGHT assembly (16). (2) Installation. See (25. (2) Installation. See (9. Visually inspect for broken barriers. DC Control Circuit Breaker. ( a ) Tag leads and remove screws which secure leads to panel light assembly. Test and replacement instructions for DC circuit breaker are contained in paragraph 3-100. Replace panel light assemblies as follows: (1) Removal. a . b . Replace SYNCHRONIZING LIGHT assemblies (16) as follows: (1) Removal. 3-127. Install BATTERY CHG AMMETER (77) using removal steps in reverse o r d e r . (1) Removal. ( b ) Remove panel light assembly mounting hardware and remove panel light assembly. 3-128. Install relay assembly (99) using removal steps in reverse order. ( c ) Remove the three screws (75) and nuts (76) which secure the BATTERY CHG AMMETER (77) and remove meter. 3-18) and proceed as follows: a . ( a ) Gain access to inside of control box (123). (b). Install panel light assembly using removal steps in reverse order. b . b. Install light assembly using removal steps in reverse order. Replacement. Replacement. replace lamp. 3-135. 3-131. If 30% of the harness wires are defective. (4) Install in reverse order of removal. (2) Unhook other end of door holder from bracket in control box (123) and remove door holder (85). fig. 3-18) and proceed as follows: a . fig. or missing pins. Tag all wires. (3) Inspect wiring for defective insulation. Visually inspect control box for damage. Door Holder. b. Change 1 3-47 . Removal and Installation. sufficient insulation from each side of the allow a good connection of the bared ends them together. ( d ) Remove six rivets (89A) which secure the hinge (9O) and spacer (91) to the control box (123). ( c ) Remove 14 screws (97) and attached washers which secure control box (123) to frame and remove control box. Remove tags. Remove the four clamps 71. loose. Inspection. 3-18) and proceed as follows: a . Replacement.c. — 3-133. remove four screws and nuts which attach connector to box. (1) Gain access to rear of control cubicle panel (96). (1) Remove screw (88). Replacement. Properly tag both ends of all replacement wires. ( a ) Disconnect all electrical connections at rear of control box. connectors. 3-134. I n s t a l l S Y N C H R O N I Z I N G L I G H T assembly (16) using removal steps in reverse order. fig. and terminals for positive identification when a defective wiring harness is removed. (3) Install door holder using removal steps in reverse order. (2) Press out crosspin (94) through stud. CAUTION Under no condition leave the bare connection exposed. a . 3-18) and proceed as follows: Remove the six screws (89) and nuts (92) which attach the panel (96) to the hinge (90) and remove panel. Control Box. Install box in reverse order (1) If a broken wire is accessible. Lace a new lead of the same gage and insulation outside the wiring harness and connect it to the proper terminals or pins. See (96. Removal and Installation. Replace panel (96) in reverse order of removal. Control Cubicle Panel Replacement. nut (87) and washer (86) which secures one end of door holder (85) to panel. ( b ) Remove control cubicle panel (96) from hinge (90) by removing six screws (89) and nuts (92). bent. Inspection. 3-18) and proceed as follows: (3) Remove stud (93) and grommet (95) from panel (96). (2) If a wire is broken from a terminal l u g . remove break to by twisting wrap with (2) Installation. (2) Inspect terminal lug for security and condition. Install wiring harness in reverse order of removal. 110. Crosspin Assembly. (1) Removal. (1) Inspect connectors for damaged threads. To remove wiring harness. (3) If a break in the wire is inaccessible within wiring harness (119). See (119. See (85. replace the lug. See (123. Repair. the wiring harness must be rebuilt by intermediate maintenance. and replaced by organizational maintenance. I n s t a l l a t i o n . 3-132. disconnect it at both ends and tape both ends. Remove tags. If a wire is broken from a connector. fig. 113 and 116 with the associated attaching hardware and remove wiring harness. fig 3-18) and proceed as follows: a. See (94. Solder the connection and electrical tape. Control Box Wiring Harness. c . of removal. b. resolder and reassemble. 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 1 1 70 S c r e w 118. Nut 119. Wiring harness 120. Rivet 121. Receptacle 122. (Deleted) 123. Control box 124. Battle short light assembly 3-48 Change 1 Figure 3-18. Change 1 3-49 Figure 3-18. 3-50 Change 1 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 1 3-59 . ENGINE GENERATOR SET HOUSING GROUP 3 . wiring.1 4 0 . connectors for damaged threads. Inspection. 3-137. loose. me~er between connecting points in the wiring f i g s . G e n e r a l . Test. The wiring set. disconnect bare connection exposed. and associated p a r a g r a p h hardware of doors.Section XVI. covers. See figure 3 . if in4 . G e n e r a l . — information on interconnectgenerator and Repair.2 2 and remove and replace damaged panels. This section contains group which encloses information the engine on the housing generator set. sequence between conthrough nector pins of the same receptacle board following data shown in f i g s . tors in clamps 1 . 3 . housing group is made up of covers and panels which are bolted together. connectors. harness in position. identification Disconnect connectors from receptacles Perform continuity check. ~. board - connection between the engine equipment to be a. cables connec connector mating and other damage. If a wire is broken from a connec- See figure 3 . and terminal (3) Inspect b. Inspection. interconnection engine generator between major assemblies 3-139. This section contains (1) If a broken wire is accessible. the proper terminals of all replacement (1) Inspect bent. Check for short circuits 1-13 new or repaired harness in reverse removal. The lend connection group vide the electrical generator operated. Replacement. (15). G e n e r a l . terminal mediate harness maintenance. harnesses from each side of the break to Solder the connection and wrap provides electrical of the allow a good connection of the bared ends by twistwith electrical tape. 1-16. CAUTION As a precaution against short the bat - CAUTION Under no condition leave the circuits. Properly tag both ends ~. as described in Section XVII. (fig. Removal and Replacement. and hinged doors which provide access to components: the housing group. Install of harness using the wiring data contained in through 1-16.1 3 counterclockwise which secure by unscrewing connecRemove all direction. but may be replaced by org Tag all wires. or terminal Section XVIII LOAD CONNECTION GROUP 3 . frayed at the right of the reconnection loose electrical loose or insulation. wiring for defective insulation.2 4 and proceed as follows: Inspect mam ac contactor (3). for secure mounting. when harness anizational maintenance.1 3 8 . lug for security and condi- defective. remove ing wiring harnesses of the engine chassis. resolder and reassemble. any (3) If a break in the wire is inaccessible within the wiring harness. tery ground cable from the batteries testing. Inspection. the wires. 3-141. ENGINE GENERATOR AND CHASSIS INTERCONNECTING WIRING HARNESSES 3 . Lace a new lead of the same gage and insulation outside the harness and connect it to or pins. Remove the load bank.4 9 . (2) If a wire is broken from a terminal replace the lug. Repair and Replacement. 3 . set and the external whi?h is located tions. before inspecting. disconnect it at ooth ends and or replacing tape both ends. If 30% of the harness wires are must be rebuilt by inter- or missing pins.2 3 and proceed as follows: t or. The See figure 3 . stalled.1 3 6 . c. (2) Inspect tion. sufficient ing them insulation together. using multia defective boards for positive harness is removed.6 0 .2 4 ) is used to pro- Main AC Contactor. Test. lug. 60. 40. 21. Screw Compartment. mounting Side housing. 95. 58. 120. 32. 30. 62. information. 14. right rear left hand. 73. Screw Nut. Screw 36A. top rear 128. 31. 71. document 115. 16. 65. left Door hook Screw Control Screw Nut Rear corner panel. 111. Rivet 39. right hook Instruction Screw Nut Control Door Rivet Instruction Screw Nut Air inlet plate. cage 1. door 96. 34. 7. right hand Screw Screw Panel. 49. Screw Lockwasher Nut Screw Nut Housing. Screw Nut Access door Screw Nut Access door Rivet Plate. cage Grille Screw Screw Washer Nut Door Screw Nut Battery Rivet Battery Screw Nut. 88. 125. 105. 67. top. left hook Oval stud Retainer Screw Nut Receptacle. 86. 8. dc troubleshooting 74. Plate. 92. 27. 15. 90. 94. 100. 81. 53. rear Access door Screw Nut Access door Rivet Plate. 9. cage connection instruction plate access door holder Screw Nut. 83. 85. 61. data data 104. 24. 46. 56. stud 110.Washer Cover 37. 112. 33. 103. 3. 19. 76. 75. 22. Screw Nut Access operational operational and access door. 5. 29. 26. 79. 119. 44. 51. 12. 35. 28. 93. 126. 91. 3-22. 89.KEY to fig. 114. 48. 42. 78. 116. lock 113. Safety Screw Nut Side housing. 66. 107. 69. Screw Nut Rubber seal Paddle lock Screw Nut Post. 45. 109. 25. left hand box. air intake Change 1 3-61 . 38. 41. cage lower front Housing. 47. information. 117. Screw Nut Screw Nut Control Door Rivet upper front 36. 63. 80. 87. 101. service instructions panel. 102. 77. 55. information. 106. left front front 124. Screw Nut. 54. Screw Nut Access door Screw Nut Access door Screw Nut Access door Screw Nut Access Rivet Plate. 18. 50. 64. 123. cage right plate. 68. radiator cap 108. Screw Nut Housing. 99. 23. 118. ac schematic 84. access door. right Door Screw Nut Air hook inlet door. 122. 10. 13. 11. 59. operating door. information cover assembly 98. Side housing. 6. 2. 57. Screw Nut Side housing. 52. 17. front 121. 127. 72. left rear Screw Nut. 43. cover. Rivet Plate. 70. 20. Screw Nut Housing. Screw Rear corner panel. 4. 97. Rivet Plate. dc schematic 82. Screw Nut Rivet Plate. 144. (Cont) 129. 151. 3-22. Screw Screw Panel. right hand designator. 141. 130. 140. 147. 149. Screw Screw Rear corner panel. Rivet Plate. 150. cage corner post.KEY to fig. identification hand fuel system instructions lifting instructions 3 . right Rivet Plate. fuel tank access Screw Nut. paralleling receptacles Housing Housing Screw Screw Rear corner panel. 138. 131. 139. 142. 148. 13’7. left hand corner post. 135.6 2 . 136. 143. left hand Rivet Plate. 146. 134. 133. 145. 132. Top and Side (Sheet 1 of 2) Change 1 3-63/(3-64 blank) . Housing Group.Figure 3-22. Figure 3-22. Housing Group, Front and Rear (Sheet 2 of 2) 3-65/(3-66 blank) KEY to fig. 3-23. 46. 47. 48. 49. 50. 51. group wiring harness 52. Screw Nut Clamp Screw Nut Clamp Screw Nut ::: 55. 56. 57. 58. 59. 60. 1 only) 61. Clamp (Class 1 only) Screw Clamp Screw Nut Screw Nut Bracket Bracket ::: 64. 65. 66. 67. 68. (Class 1 only) 69. 70. 71. 72. 73. 74. 75. 76. 77. 78. 79. 80. 81. 82. 83. 84. wiring 84A. 84B. wiring 84C. 84D. 84E. 84F, 84G. 84H. 84J. 85. 86. 87. 88. (Deleted) Clamp Screw Nut Clamp Screw Washer Bracket Engine accessories wiring harness AC power control wiring harness Screw Diode Suppressor 1. Precise relay boxwiring harness to governor control unit (Mode 1 Class 1 only) 2. Precise relay box wiring harness to special relay box (Mode 1 Class 1 only) 3. 4. Screw Clamp Excitation :: 7. 8. LMU assembly wiring harness Tactical relay box wiring harness Governor control unit to precise relay wiring harness (Mode 1 Class 1 only) 8. Governor control unit wiring harness (Mode 11 Class 1 only) 9. Screw Nut +:: 12. 13. 14. Clamp (Class Bracket Dead Crank Switch Screw Nut ;:: 17. 18. 19: 19A. 19B. 19C. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. Clamp (Class 1 only) Screw Nut Clamp Screw Nut Clamp Screw Nut Clamp (Deleted) (Deleted) (Deleted) (Deleted) (Deleted) (Deleted) Screw Nut Bracket Governor control to actuator harness (Class 1 only) Bracket Screw Nut Clamp Screw Nut Clamp Screw Nut Clamp Screw Nut Clamp Screw Nut Clamp Screw Nut Clamp Nut Screw ground stud Ground strap RFI capacitors wiring harness 33. Governor control to actuator harness (Class 1 only) 34. 35. 36. 36A. 36B. 36C. 37. 38. 39. 40. 41. 42. 43. 44. 45. Screw Nut Clamp Screw Nut Clamp Screw Nut Clamp (Deleted) (Deleted) (Deleted) (Deleted) (Deleted) (Deleted) C h a n g e 1 3-67 Figure 3-23. Engine Generator and Chassis Wiring Harness (Sheet 1 of 2) 3-68 Change 1 Figure 3-23. Engine Generator and Chassis Wiring Harness (Sheet 2 of 2) Change 1 3-69 Figure 3-24. 3 - 7 0 Change 1 TM 5-6115-545-12 P-8-626-12 TO-35C2-3-444-1 NAVFAC TM-00038G-12 b. — ?estirw, (~ply 24 Vdc at pins A and B of main ac c. Replacement of Lost or Broken Terminal The terminal Clip (R~ainer, Safety Clip). (3) connector. When main ac contactor it should create a distinctive noise. clip is a compo- nent of both the load terminal If the terminal follows: (1) Requisition and the ground terminal. as contactor operates, clip is lost or broken, fabricate (2) With an ohmmeter, between terminal check for continuity bulk wire NSN 9505-00-804-3814 (ground Al to A2, B1 to B2, and Cl to (0.042 inch diameter) for the ground terminal C2 on top of the main ac contactor. (3) At the connector, check for continuity 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. 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- (3) Slip the wire through the hole in the terminrd. (4) Hold the terminal as shown (Detail A, 3-24.1) f i g u r e cuit between pins L to M, N to P, and R to S. (5) Remove the 24 Vdc and check for the opposite of the conditions (continuity listed in steps (2), (3), and (4). c. Replacement. See figure 3-24 and replace or open circuit) 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. 90° angles (5) Bend the wire into back-to-back (Detail B, figure 3 - 2 4 . 1 ) so that the legs of both angles the—main ac contactor (1) Removal. (3) as follows: are about one-half inch long. (6) Bend the ends of each 90° angle down and around into a U-shape (Detail C, f i g u r e 3 - 2 4 . 1 ) so that if done properly, the clip will hold the nut when it is unscrewed to install the cable (Detail D, f i g u r e d. Repair. Repair 3-24.1). (a) Remove four screws ( 1 ) which secure covers (2) on top of main ac contactor (b) Tag and remove electrical to main ac contactor washers ( 5 and 6). (c) Remove four screws (4) which secure main ac contactor to mounting bracket (7). figure 3-24 and install (3). connections damaged threads with a die or by file, by removing six nuts and fili~ w~ne mill triangular 3-143. See Current Transformer Assembly. figure 3 - 2 4 and inspect the current transformer assembly (18 ) for cracks, breaks, loose mounting, loose connections, corrosion and other damage. 3-144. Reconnection Board. (2) Installation. See the main ac contactor 3-142. Repair of (3) in reverse order of removal. Terminal Board. Load See f i g u r e 3 - 2 5 and proceed as follows: board ( 1 5 , a. Inspection. See loa~terminal terminals figure 3 - 2 4 and inspect the a. Inspection. Inspect reconnection fig. other damage. & Testing. as follows: (1) Remove 12 nuts ( 1 , fig. Test reconnection board (8) for cracks, breaks, loose 3 - 2 4 ) for cracks, breaks, loose mounting nuts, and and other damage. Inspect all electrical leads for broken or frayed insulation and other darnage. board for continuity 3 - 2 5 ) holding insula- tor (20) and remove insulator (2o). ~ Replacement of Load Terminal 3 - 2 4 Board. See f i g u r e (2) Inspect bus bars (19) on rear of insulator (20) and replace bus bars if damaged or missing, (3) See f i g u r e connections to 2 - 4 and check for continuity beand replace the load terminal board (8) as follows: ( 1 ) Removal. (a) Tag and remove electrical load terminal board (8). tween studs 1 and 4;2 and 5;3 and 6;7 and 10;8 and 11; and 9 and 12. If no continuity, studs for continuity on insulator continuity indicates check respective fig. 3 - 2 5 ) , If (24, (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). load terminal board (8) as is not obtained, generator is at fault. If check replace reconnection panel. board ( 1 5 , continuity, c. Replacement. fig. Replace reconnection 3 - 2 4 ) as follows: (1) Removal. (a) Remove four screws ( 16) which secure the board (15) to the brackets (17). wires at back of recon- (C) Disassemble shown in detail A. reconnection (d) Inspect load terminal board (8) for damaged threads on studs, and signs of physical damage. (e) Reassemble disassembly. (2) Installation. terminal See figure 3 - 2 4 and install load in the reverse order of (b) Tag and disconnect nection board. (c) Remove (2) Installation. reconnection Install board (15 ). board (15 ) reconnection using removal steps in reverse order. Q. Repair. Repair reconnection board (see by replacement of damaged components. f i g . 3 - 2 5 ) board in reverse order of removal. Change 13 3-71 damage or loose connectors. breaks. loose mounting. GOVERNOR CONTROL UNIT (CLASS 1 ONLY) 3-145. Inspect the governor control unit ( f i g . 1 . General. 3-146.TM 5-6115-545-12 P-8-626-12 TO-35C2-3-444-1 NAVFAC TM-00038G-12 DETAIL A DETAIL B DETAILC DETAIL D Figure 3-24. This section contains information on organizational maintenance inspection requirements for the governor control unit.1 ) for cracks. 3-72 Change 13 . Governor Control Unit Inspection. The governor control unit is the control position of the governing system on precise generator sets.1 Terminal Clip Replacement SECTION XIX. and other damage. and ground. pins “F” to “R 500 ohms.000 ohms and 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. CAUTION The Frequency Adjust Rheostat (1.1 0 ) pushed Fig 2 . Run. Check the Frequency Meter ( 3 .2). F i g 3 .2 4 . pins “R” to “K” 2. F i g 3 . DC Control Circuit Breaker ( 2 0 . The control box compares the oscillator frequency with the signal frequency sent from the magnetic pick up speed sensor (3). Reconnect wiring on the magnetic pickup speed sensor (3). F i g 2 . this procedure Serious is not g. (3) Remove connector plug (P22) from J-22 (7) and using a multimeter the following checks should be made: on P22. Connect the Multimeter between pin “C” A reading of 24 VDC should be obtained. F i g 3 . 2 ) . adjust the Frequency Adjust rheostat ( 1 .quarters of a turn and secure with jam nut (6). Fig 3-24. The frequency adjust rheostat ( 1 . 1 . Reconnect the battery.2 4 .1 0 ) on generator pins “J” to “H” should read 85.000 ohms. in and the Start.1 0 ) control located on the generator set control panel. Adjust with care. Fig 2 . Disconnect DC power source and connect plug (P22) to J22 ( 7 . will adjust the oscillator frequency of the control box (2). Adjust until the proper frequency is attained. pin “B” to “D” 8 ohms.1 0 ) placed in the Run position. NOTE injury followed.1 0 ) control located on the generator set control panel in mid position.2) is (2) The magnetic pickup speed sensor is checked by removing its connector plug and sensor ( 3 . 2 ) the following could step result is if accomplished. (5) If the generator frequency is either high of low with the Frequency Adjust ( 2 9 . If the frequency of the generator fluctuates or is incorrect and cannot be adjusted by the Frequency Adjust (29.1 0 ) on the generator control panel after each increment.TM 5-6115-545-12 TO-35C2-3-444-1 NAVFAC P-8-626-12 TM-00038G-12 3-146. a multi turn rheostat and and will not handle excessive twisting turning. (6) If you cannot get the correct frequency after completing all of the above checks. Fig 2 . do not adjust the rheostat on the Electric Governor Control Box until the following checks are made: (1) Frequency Adjust ( 2 9 . pin “G” to ground should be O ohms. otherwise damage to the rheostat will result.1 Electric Adjust Governor Rheostat Control Box Frequency WARNING Ensure DC power source is disconnected before (MEP115A). Fig 2 . Ensure there is no dirt or magnetic particles on the sensor’s end. To install the sensor. set control panel is in mid-position. Then back out three. ~. (4) Check for loose and/or binding electric governor actuator linkage. C h a n g e 1 5 3 . 2 ) in small increments. Stop Switch ( 3 2 . pins “T” to “S” should read between 50 to 500 ohms.2 4 . Fig 3-24.7 2 . F i g 2 . This sends the proper voltage to the electric governor actuator (4) which controls the speed of the engine. notify higher level of maintenance for troubleshooting and repair. turn slightly by hand until the tip contacts the top of the Ring Gear Tooth (5). 2 Change 15 .2. 3-72.TM 5-6115-545-12 TO-35C2-3-444-1 NAVFAC P-8-626-12 TM-00038G-12 Figure 3-24. 2 4 ) above the generator. to control the generator set during paralleling and to provide monitoring of voltages and frequencies. The air cleaner assembly filters incoming combustion air to the engine. 4 b l a n k ) . of hose connecting air cleaner inlet to oil separator. 3 / ( 3 . Install air cleaner assembly in reverse order of removal. Removal and replacement of filter element is shown in figure 3-5.7 2 . AIR CLEANER ASSEMBLY 3-147. Removal. Mode I generator sets there is a precw.7 2 . SECTION XXI. This section contains information on the relay table grofip. F i g 3 . under voltage and permissive paralleling monitors of the generator set for more complex ap- C h a n g e 1 5 3 . a. Reconnection Board SECTION XX. See paragraph 3-87 for removal and replacement a. General. The relay table boxes are located behind the control cubicle on a relay table ( 1 9 . RELAY TABLE GROUP 3-148.e relay assembly that provides under frequency. ~. Replacement. The relay boxes contain protective relays and devices used ~: On Class 1. See figure 3-26 and remove air cleaner assembly in accordance with the sequence of index numbers. Air Cleaner Assembly.TM 5-6115-545-12 TO-35C2-3-444-1 NAVFAC P-8-626-12 TM-00038G-12 Figure 3-25. . Inspect [he two connectors for bent or broken IooEe terminal damage. Mcxie These monitors are included 1 sets within in the box.r damage.’osion and other damage. w i r i n g c o r r o s i o n d a m a g e . c. I n s p e c t c o n n e c t o r s f o r b e n t o r b r o k e n p i n s b. f. nluuntin:. and other pin. Reassemble a]ld-nine screws. Sets) Precise the assembly by replacing cover a. a n d o t h e r d a m a g e . I n s p e c t r e l a y s f o r l o o s e a n d m o u n t i n g . nine screws which secure cover Relay Assembly Class 1 (50 60 Hz Inspection. find 3-150. Tactical Relay Assembly Inspection.7 3 . Inspect tern] lnill I>tr. b.Figure 3-26. c . C h a n g e 7 3 . 3-149. 3-151. and other ciaml:e.irds for loose connecllt)ns. o t h e r l o o s e Special Relay Assembly (50 60 Hz) Inspection. Inspect {he 50 60 Hz switch for loose mcmnting. . Air Cleaner and Related Parts plicat ions. d . 1 . Remove rell=ove cover. cor. corrosion. Inspect wiril~ for fraying. corrosion and II. Class the set special oth. mounting. mounting. Replace by sliding front panel under the top i. higher maintenance due to overheat. corrosion. loose relay assembly for dents. The solenoid valve is controlled by the float level switch which is actuated by the level of the fuel in the day tank. under mounting. and other damage. loose e. wiring fraying. damage. and ing.e connections. Remove the bottom two screws and let the slide down. bearing Examine bearing for signs of hea~ by placing an open hand on the generator end bell.r to the front panel.r to the front panel. 3-152. corrosion. for and other corrosion. & Inspect corrosion. Generator Inspection. ~. and other damage. Inspect the special loo. for unusual nowes while in operation. then remove. Inspect loose the special relay assembly for dents. Special Relay Assembly (400 Hz) Inspection.e c. Inspect the terminal ing~ loose terminal boards for loose mountfor corrosion. damage. Replace front panel relay assembly the~op two screws and securing it to special relay two screws and securing it to special with bottom two screws. The fuel supplied to the day tank from the main tank passes through the strainer and primary fuel filter. loose unit for dents. Inspect ac generator ( f i g . Loosen the two top screws which secure the a. corrosion. Inspect loo. Inspect the load measuring loose mounting. Remove frofit panel the bottom two screws and let the cov. damage. General.1 ) for excessive Inspect ac generator tion cover plate. wiring for fraying.1 5 7 . Loosen the two top screws which secure the cov. connections. and other other damage. and ~. GENERATOR ASSEMBLY 3-154. Inspect transformer loose connections. c. assembly is used to generate Maintenance elecb. Measuring Unit Inspection. and other damage.7 4 . The day tank is used to gravity pump. Generator Bearing Inspection. Tighten top two screws. ~. feed fuel to the fuel injector on day tank and tank is used to control the flow of fuel to the day tank. breaks. c. the cross loose current wiring. by removing inspec- a. and Ioo. and other Section XXII. connector. i. adjust control for frofit panel slide down then remove. Section XXIII. relays for loose mounting. h. damage. Inspect oth~r damage. If the hand cannot be maintained in this posi - wear. ~ Tighten 3-153. connectors. ~. and at the organizational level consists of the following inspections. f. level. tion for one minute. 1 . DAY TANK AND FUEL FILTER ASSEMBLY 3 .e mounting. and other controls for loose and other damage. primary entering fuel filter prevent the day tank. corrosion. by sliding and other the panel ~. frame refer to next The generator trical power. Inspect the for loose mounting. sharing adjust and cross curloose wiring. Inspect the terminal boards for loose mount- d. Load top two screws. Inspect transformer for loose mounting. loose connectors. b. G e n e r a l . ac generator for cracks. damage. Inspect cofiections.a. other damage. other damage. Listen — 3-156. assembly with bottom two screws. Inspect the load ren~ adjust corrosion. b. The strainer and 3 . 3-155. or discoloration due to overheating. foreign particles from A solenoid valve on the main This section contains information fuel filter assembly. loose terminal connections. 39. 15. valve 48. Solenoid Valve. 45.e Inspection. 16. 27. 21. 32: fuel Plug* shutoff valve fuel winterization 33. 4 6 A . 8B. — Testing. 4. 42. Elbow Day tank Screw Nut Washer Screw Nut Screw Washer Dead crank switch Bracket Bracket : ~. 44. 37. Hose assy Elbow Reducer Hose assy Connector Reducer Screw Washer Screw Washer Fuel filter assy 14. 18. stripped threads other damage. 19. solenoid valve (34) for or (2) terminals Intermittently on the apply 24 volts to the and breaks. 10. 51. Tee kit installed Solenoid Nipple Drain cock Reducer Float Elbow Elbow switch Connector Screw Nut Clamp Figure 3-27. 13. loo. 17. Hose assy Hose assy Clamp Screw Nut Clamp Screw Nut Clamp Bracket Hose assy Screw Bracket Screw Nut *Note: Heater 2 8 A .. 8. if 46. 5. 50. 7. Washer 41. 25. 8A. electrical connector on a. solenoid valve connector C h a n g e 1 3 . Inspect dents. 35. 49. b. 47.jed) Elbow 43. 26. 6. Test solenoid valve (34) as follows: See figure 3-27 and proceed as follows: (1) Disconnect solenoid valve (34). 40. 2. 20. mounting. Day Tank and Fuel Filter Assembly 3-158. 23. 11” 12. 36. 38. 34.1.7 5 . 28. 3. 22. 9. 24. (10) and verify continuity when the top float is placed at its bottom position when float is placed at its top posi- 3 . Install day tank (42) by (32) from tee (33). . sol=noid (34) proceed as follows: (1) Open drain cock(36) on bottom of day tank (~) Open drain cock (36) on bottom of day (42) and drain talk coutents er. (2) Remove (42). is iiiounted (10). (5) Remove remove day tank. (3) Connect an ohmmeter between pina C and Installation. (2) blv (9). (2) Disconnect and tag electrical connectors nectors (34). replace the solenoid steps in reverse order. (1) Open drain cocks on fuel filter assembly (9) and drain into suitable container. c. filter body and surrounding area.. . a. Removal and Replacement.to a suitable contain- tank (42) and drain tank contents into a suitable container. Day Tank and Float Switch Refer to p a r a g r a p h cedure’s to replace 3 . .listen for evidence of solenoid actuation. (b) Tag and disconnect the electrical con- from the float switch (38) and the solenoid valve . see 3 .3 4 for prc filter element See figure 3 . and other damage. D of the connector (10) and verify continuity when the bottom float is placed at its bottom position and verify open circuit position. To repltice the (1) Removal. (34). — of fuel filter assembly. Replace the day tati– (42) as follows: c. If no solevalve (34). Close drain cocks on fuel filter assem- and B of the connector verify open circuit t ion. (3) Reconnect the electrical connector. 3-160. Inspection. (6) Remove (7) Unscrew the four screws (25) and washers (28A) which secure day tank (42) to bracket (51) and using the removal steps in reverse order. connector (10) from float (3) Disconnect remove fuel filter hose assemblies (1 and 4) and assembly (9) by removing the float switch (38) from day tank four screws (7) and washers(8).noid action is heard. ~. elbow from tee (33). moval (5) Install float switch (38) using above re- . (d) Discomect NOT E (42) and s~lenoid fuel lines from day tank valve (34) If fuel winterizat ion kit is installed. Testing. b. ir. valve (34) To replace the fuel filter assembly. (2) Replacement. (4) Connect an ohmmeter between pins A and when float is placed at its top (1) See assembly f i g u r e 3 . loose Inspect the float switch (38) which Removal. tee (33) from solenoid and remove solenoid valve (34). ‘Test the float switch (38) as (2) Clean dirt from filter head. 3-159.2 7 (8) Install sequence new solenoid valve (34) in reverse NOT E and proceed as follows: f i g u r e from day tank (42). on the day tank (42) for loose connector mounting. disconnect heater fuel shutoff valve (~) Remove the four screws (25) and wash- ers (28A) which secure day tank (42) to bracket (51) and remove day tank. Removal valve and Replacement.7 6 C h a n g e 9 . Fuel Filter Assembly Removal and Replace- m e n t . follows: (1) Remove switch (38). frfim float switch (38) and solenoid valve (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 and remove fuel line attached to elbow (31) from the tank. of removal procedures.2 7 and replace fuel filter (9) in the reverse order of removal.2 7 and proceed as follows: a. valve switch. ~. @) Unscrew valve (4) and remove ether tank ether tank. information for maintwo screws fuel transfer pumps which which secure the solenoid valve (4) to the framework. (~) Open bracket (7). Strainer. This system PRIMER switch on the control cubicle in step (3). is used as below is controlled by the ENGINE panel when (5) If solenoid valve verified (4) operation was not an aid in starting the engine at temperatures 40° F. a. Filler Cap. G e n e r a l . 3-28) (c) Remove new solen~id valve. a .2 8 and inspect loose mount- (8 1) for breaks. adapter (1) Disconnect tube (1. and release the ENGINE PRIMER server watches the solenoid spray of ether is observed. loose fittings. fig. 3-164. Re f i g u r e 3 . dents. (g) Connect WARNING Be careful n~t to inhale ether gas as drowsiness and unconsciousness result. (7) to secure ether tank may (f) Screw a new ether tank (8) into the solenoid ~itlve (4). The center support is located at the center of the (s) Connect solenoid valve (4).) (8). test the ENGINE PRIMER if defective. tube (1) to adapter (3) on solenoid valve (4) and tighten the solenoid valve mounting screws (9) securely.7 7 and unconsciousness item (39). (3) Listen for audible evidence of solenoid 3-163. re- these conditions. disconnect solenoid connector and check for 24 volts dc at the pins of its mating connector actuated each time the ENGINE PRIMER switch is the engine is being cranked aml the START-RUNSTOP switch ated. the ENGINE PRIMER switch is momentarily one metered (6) If 24 volts dc is measured place the solenoid valve (~) Remove in step (5). valve (4) with using two screws (9) and nuts (10). See (4) If solenoid valve (4). I n s p e c t ether tank (8. Testi w and Replacement. perform valve (4) operation switch is repeatedly while the ENGINE PRIMER actuated. This section also contains tenance of the electric are utilized to transfer fuel from the main fuel tank to the day tank. 3 . (g) Close bracket (2) Crank the engine and momentarily actuate an obIf no (7) If 24 volts dc was not measured (5). adapter (3) and install in a open bracket (7) and remove the tank and attached solenoid valve as an assembly. clevis (80) in accord- ante with figure . START AID ASSEMBLY A N D F U E L T R A N S F E R P U M P S 3 .1 6 1 . ~) while holding ether tank (8) securely. replace ether tank (8) as follows: ing. fig. valve sol=nold ( 4 ) and bracket (7) for loose mountand other damage. (Refer to paragraph in step switch and replace 3-118a. Inspection. (8) from solenoid lacement. LIFTING FRAME ASSEMBLY. outlined (Q) Check operation of ether tank (8) as in step (2) above. Replace cracks. shot of (4) as follows: (9) and nuts (10) ether is injected into the engine air intake system. WARNING a. The start aid assembly mounted on the center support. step (3). while (4) opening. Start Aid Assembly.Section XXIV. operation is verilift~W irame fied in step (3). under is in the START position. Items (40) and (42) will See figure 3-28 (items 39 thru 59 and proceed as follows: co~e out together. and Hose Replacement. corrosion b. 3-162. Each time actu- with the engine cranked. (c) Install new ether tank (8) using above procedure–in reverse. ing. Gasket. Do not ter (3) on solenoid valve (4). tube (1) to adapter (3) on on each side of housing and provides a means of lifting the generator set by use of a clevis located the top of the center support. Remove Be careful not to inhale drowsiness ether gas as may result. and rust. 3-28) from adap- (~) Install the new solenoid tighten screws (9) securely. Lifting Frame. I n s p e c t i o n .+8. . Testing. Test each fuel pump (37 and 38) 16. 33. clamp (44) and remove filler neck (5) To sequence. from body of fuel pump (3’7 and 38). 2. (3) Disconnect tube assembly (30) from both c. Washer. 14. 53. 42. 76. 80E. (2) Connect top (inlet) of fuel pump to a fuel source. and (18). 55. requirements bracket. reassemble. Remove nuts (82). (17).2 8 and remove and replace (25). 1. 70. 23. 45. See F u e l T r a n s f e r 3-28 P u m p s . after place rechecking does not operate re- electrical test connection. 34. 37. body and secure with cover. ~. 66. 21.1 6 5 . and screws (W. Lifting frame Nut Nut Clamp and bracket Oil separator Screw and-proceed as follows: (1) Disconnect (37 and 38). 29. and gasket in fuel pump 13. fuel hose assemblies from 19. See ~. 50. 60. 84. 72. 40. 31. remove filter from fuel pump 6. . 8. 80F. empty container. Screw c. 26. 6A. the fuel pump. (5) Position filter. hose assemblies to fuel pump (37 and 38). 54. 39. one at a time as follows: (1) Disconnect fuel pumps. 20. Screw Nut Washer Bracket Screw Nut Washer Tail pipe bracket Rivet Fuel selector valve instruction 74. 24. 80C. 27. connectors on fuel pumps 44. 46. washers (51) and nuts fuel pumps (37 and 38). 22. 3-28: 47. (15). KEY to f i g u r e (24). 71. 18. 82. (3) Connect a clean bottom (outlet) of fuel pump to 25. d. 3 . 52. 69.b. 11. 3 . 35. filter and gasket. 7. (23). 32. 30. 67. required. (2) Disconnect 3 . 80B. 81. 80G.8 7 and remove oil separator (85). 5. 17. figure and proceed as follows: fig. 58. P-D-680 and dry thoroughly. see p a r a g r a p h 3 . 48. 62. (4) Inspect place defective filter and gasket for tears. 56. lOA. 51. and ground. e.7 8 Change 9 hose assemblies (24). 77. (20). InSt. (4) Remove four screws (34) and nuts (35) and remove hoses (47 and48). 80. clamp and bracket (84). 85. which secure fuel pumps. 61. Remove (43L f. (3) Wash Specification filter with cleaning solvent Federal 7A. 9._dl in reverse sequence of removal. as item num(19). (5) At completion of test. 49. 57. (29). If fuel pump there may be an open circuit If fuel pump in the wire lead assembly. flat bevel plate a. (2) Carefully body. 12. 36. bers (21). 86. See figure 3-28 (detail A) 41. inoperative. Screw Nut Cap and chain Cotter pin Nut Bolt Clevis Nut Washer Screw Nut Washer. reconnect fuel 38. (+ or -) as stamped should Fuel pump deliver hour of fuel with zero pressure. Hose Hose Screw Nut Washer Hose Tee Hose Tee Hose Hose Tee Hose Screw Nut Washer Load bank support bracket 64. (28) (16). 68. (27). (22). 59. 43. 63. 79. Re- 10. Remove ordir. 65. reverse the disassembly remainder of items in sequential 3-166. Remove (50T Loosen screws clamps (49). 4. Replacement. 73. 15. 80A. Fuel Selector Valve and Lines Replacement. Servicing. 83. Tube Atomizer Adapter Solenoid valve Screw Nut Nut Bracket Strap Ether tank Screw Nut Nut Screw Nut Cap and chain Adapter Hose assembly Elbow Elbow Hose assembly Elbow Elbow Hose assembly Elbow Elbow Hose assembly Connector Elbow Screw Nut Fuel selector valve Tube assembly Elbow Elbow Elbow Screw Nut (Deletefi) Fuel pump Fuel pump Fuel cap Fuel cap gasket Hook Strainer Filler neck Clamp Fillerneck hose Clamp (1) Twist and remove cover and gasket 3. 78. 75. nuts (83). 80D. (4) Connect receptacle a 24-Vdc power supply to male observing ground polarity on fuel pump 18 gallons per is 28. Figure 3-28. Center Support and Related Parts Change 7 3-79 . Figure 3-29. 3-80 Change 9 . (2 Remove guards 3-171. fit- to connect components. 3 . ~. DO not overheat. as follows: Replace grille ( 7 8 . verify that the shutters ( f i g . G e n e r a l . fig. 25 and 26) to radiator [ move both fan guards. just the nuts on the shutter assembly shaft to assure that the shutters Check are fully closed. (b) Loosen hose clamp (4) which secures lower hosF (6) to the shutter control assembly. tion. G r i l l e . gradually distributed. 3-170. open position when the engine is at operating eratures. drain (5) with attached and drain requirements. 3 . C O O L I N G G R O U P CAUTION 3 . Removal. prepainted surfaces in accord- shutter control assembly fitti~-. (c) Remove nuts 1 .2 9 to remove hoses and other related parts. and linkage and the of a radiator. 3-29) studs (4) w“hich secure the control assembly to the coupling fitting and remove thermostat (6). (1) (a) Drain radiator assembly ( 3 5 . to an temp- b. f i g . f i g .Section XXV. which secure draulic the two clamps (16 and 18) on the hy- cooler lines to the fan guards (25 and 26). (2) Installation. b. (1) Verify that shutter (2) changes from a closed position. 3 . hose. 3-30) and Replacement. fig. Repair fan guard (25 and 26) by Remove rust or other strZig htemng cross members.3 1 ) and washers (4) which secure shutter control assem(17) and remove coupling grille (78) by straightening rust or other cross members corners. corrosion and repaint preprinted surfaces in accordance with service requirements. Replacemerit. T h e r m o s t a t must be completely imbottom of container. 3 . it should begin to open at 160° F and be fully open at 202° F. Replacement. Check temperature of water with a reliable thermometer. 3-168a.2 9 ) by removfig the radiator cap and opening shutoff (76. With the engine cold and the position adthreaded link on the shutter assembly shutter control in the closed change from a closed position when the engine is cold. (1) To test shutter thermostat tion. a. elbow. — F a n G u a r d .3 0 ) opera Thermostat. 3 . necessary these shutter lines. f i g . fig. f i g .3 0 ) Install the thermostat ( 6 . 3-22) and cage cock (21). of removal. tings.1 6 9 . (6) Thermostat (6) is not adjustable. 3 . Test shutter (2. f i g . 3-31) as follows: in reverse order of removal. Replace the shutter(2) as foll.3 0 ) . (5) Observe thermostat (6) as temperature of the water increases. Repair. that with manual shutter control in open posifully.2 2 ) follmws: (1) Removal. and to an open position when the engine is at operating temperature. 3 . Repair and Install grille in reverse order (~) Remove the two screws ( 3 . — Testing. (1) Remove the 2 screws (15 and 17. S u s p e n d thermostat (6) in a container of w a t e r .1 6 7 . ~. The shutter is controlled by the shutter control thermostat. 3 . ma~ual Adjustment. Repair. If the thermostat (6) is func tioning properly. If it does not operate within the above limits it must be replaced. — (~) Remove ~rille as described in p a r a g r a p h C h a n g e 1 3-81 . (2) Installation.1 6 8 . when the engine is cold. See f i g u r e which can also be operated manually. the shutters are opened c. fig. b. valve. (2) Verify shutter (2) opens and closes freely when operated manually. 3 .ws: mersed but not touching (4) Heat evenly water (1) Removal. (3) Re-install shroud (36) and rea. ( 6 . Shutter Assembly. Replace the thermostat (6) as The cooling system consists and shutter controls. and stir so heat is Replacement. Remove bly (5) to the bottom of radiator corrosion and repaint ance with services 3 . (e) Remove two nuts (3. — Shutter Testing. a. f i g . 7 screws (24) which secure fan in reverse order of removal steps. (~) Remove screws nuts (77) which secure grille (78) at top and bottom.3 0 ) which secure shutter assembly to contro\ assembly (10) and remove the rod (2) from control assembly (10). (2) Remove the thermostat (Refer to ( 3 ) c l e a n paragraph b below). (Q) Remove 2 screws (79) which secure grille at each side and remove grille (78). 3 . a. 5. Control assy Figure 3-30. Install shutter (2) in the re(s) Remove six screws ( 8 4 . fig. and remove (2) Installation. 1A .8 7 . Nut Rod Nut 4.1. 8. 6. To replace the radiator ( 1 7 .8 2 Change 9 . 2. shutter assembly bly (10). radiator coolant. Shutter Thermostat Replacement (~) Remove nuts ( 1 . Packing Nut Piston W 10. p a r a g r a p h 3 . ~) Perform steps ~ through ~ of 3 . (y) Remove shutter as described in p a r a g r a p h radiator (17). 3 . 3-30) which secure graph (~) Perform steps (s) through @) of 3 . f i g . R a d i a t o r . the 8 screws and washers remove (1. 3 . p a r a - rod (2) to control assem- (c) Loosen hose clamp (~) Remove ( 1 .1 7 1 . 3 . 3-29) and up–per hose (3) from radiator. fig.1 7 2 . fig.2 2 ) and nuts (85) which secure the battery access door verse order of removal. (g) Remove (~) Position suitable container to collect 10 screws (55) and nuts (56) which secure the housing top front (57) in the front and rear.3 1 ) proceed as follows: (1) Removal. stud Gasket Thermostat 7.3 1 ) w~ch secure shutter (2) to the the shutter (2). (86) to the lower front housing (93) and remove battery access door (86). 3 . Replacement. threaded fig. 3.1 7 0 b (1). 9. 1. 3. 10. Screw Washer (Delete) Shroud RH radiator support 14. 7. 12. fig. 6. Screw Washer Shutter Screw Washer 5. Shutter Gasket Screw Washer control assy 9. 11. Cooling Group (Q) Remove 12 screws (58) and cage nuts (j) Remove fan guards 7 screws (24) which secure (59) which secure the housing top front (57) on the sides. LH Cap radiator support Drain hose Radiator (Delete) Figure 3-31. 2. fig. 8. (25 and 26) to radiator shroud (36) and remove both fan guards. 3-4) (k) Disconnect wiring connections ( 1 4 . whi~h secure the two clamps (16 and 18) on Z the battery slave receptacles. fA.2 9 ) (15 and 17. and remove the cover. 17. 7A. C h a n g e 9 3-83 . 15. the hydraulic cooler lines to the fan guards (25 and 26). 4. 13. 16. (i) Remove the 2 screws 3 . Q. Hydraulic Cooler. Install radiator assembly component using the removal steps as applicable in reverse order.2 9 ) .3 2 ) from elbow (7) and remove el~ow (7) and packing (8). 1-28. or — other damage. Disconnect reducer expander (9) w-ith packing (10) from filter plug (11). To replace the hydraulic cooler ( 1 9 . 3 . f i g . The hydrmdic oil filter is mounted on the sump and provides pr%ection against contaminant system. f i g . and remove corner posts. if serviceable. The hydraulic cooler is used on Class 1 sets only. f i g . The actuator regulates the engine fuel injection system in order to maintain rated speed for all load conditions. Inspect filter screen for tears. Disconnect hose ( 6 . @ Remove screw (17) and clamp (18) which secure input (y) Remove screws (9) and washers (10) which secure radiator 17) to shroud (12) and remove the shroud and radiator. (g) Remove 10 screws (141 and 148) which secure the front left and right hand housing corner posts (138 and 139) to the radiator support. 3 . Service. Replenish hydraulic sump with hydraulic oil. The sump acts as a reservoir for the hydraulic oil pump.emtor sets. (q) Position suitable container to receive hydraulic oil drained from hoses and tubing when disconnected. The hydrwdic actuator is utilized on precise engine ge. Remove filter plug (11) and packing (12) from hydraulic actuator. General (See fig.8 4 C h a n g e 1 1 . or install a 3-175. Clean filter plug (11) with cleaning solvent. ~. connector from flare nut (10). and remove hydraulic cooler (19). 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). (g) Remove elbow (8) from connector (9) and remove (1) Remove 8 screws (27).(!) Remove 4 screws ( 8 9 a n d 9 1 . (2) Installation. (~) Disconnect hose (11) from connector (12) and remove connector from adapter (13). (1) Removal. 3 . 3-173. 3 . e.—To service the hydraulic cooler ( 1 9 . ~ Replacement. (~ Remove screw (15) and clamp (16) which secure return line to RH fan guard (26). in the hydraulic oil pressure c. Federal Specification P-D-680. washer (33) and nuts (34) which secure the RH and LH radiator supports (37 and 38) at the top of the skid base (39). Hydraulic Actuator Service. Install hydraulic cooler (19) in reverse order of removal. HYDRAULIC ACTUATOR AND SUMP AND FILTER (MEP105A ONLY) a. b. 3 . a. 3 . (q) Remove 6 screws ( 3 1 . c. Section XXVI. 3-174. (s) Disconnect adapter (13) from return line (14). used to supply hydraulic power to the hydraulic actuator. f i g . The hydraulic sump is mounted on the left side of the engine.3 1 ) and nuts (8) which secure radiator (17) and shroud (12) to RH and LH radiator supports (13 and 14) and remove supports.2 9 ) proceed as follows: (1) Check that the mounting screws (1. irregularity of mesh. and dry thoroughly. (g) Perform steps ~ through ~ of p a r a g r a p h 3-86. . line to LH fian guard (25). (2) Clean dirt off fins. 7 A .2 2 ) 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). (2) Installation. $ Replace cleaned filter plug (1 1). (~) Remove radiator assembly (35). holes. RH and LH radiator supports (37 and 38) and radiator shroud (36) from skid base (39).5 and 17) are secure. f i g . on Class 1 precise generator sets. f i g .) a. new plug and reassemble in the reverse order of removal.2 9 ) proceed as follows: (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. 12 bevel washers (32). @) Disconnect hose (7) from elbow (8) (~) Remove 8 screws and washers ( 7 . (@ 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). 3 . 3-33) on sump tank (21). 2. Drain sump and discard oil. 6. b. of Sump and Filter. Remove hose assembly (2) from elbow assembly (7).1. See figure 3-33 and remove sump and filter as illustrated. Remove hose assembly (3) from elbow assembly (7) and from elbow assembly (3A). 4. 12. Throttle linkage Nut self-locking Lever arm Return Adapter Connector J25 Hose Elbow assembly bulkhead Packing Reducer expander Packing Filter plug Packing Connector J24 Piston Figure 3-32. a. 9. Remove two loop clamps and associated hardware front of engine. 7. Hydraulic Actuator Servicing (MEP105A) 3-176. 10. (1) Flush sump tank (21) thoroughly with hot water or steam under pressure. Remove plug (1. 13. 3. 3-177. d. — Cleaning. 5. Change 11 3-85 . Removal. a. 11. 14. fig. c. Cleaning and Inspection of Sump and Filter. 8. 3-86 Change 11 .Figure 3-33. . 3-180. t a b l e 3 . for vibrations. figure 3-34 and proceed as follows: See (1) With engine running. G e n e r a l . (1) Adiust belts for tension which conforms with – (1) follows: (2) To obtain proper altermtor belt (7. engine running test for proper oil and remove (6). G e n e r a l . Testing. Unscrew val.nd 2). To remove and install the oil pan drain hose assem- a.1 8 2 . designed to provide extra long periods of reliable maintenance..3 5 ) quired. oil drain hose (3) by removing clamps by observing COOLANT (fig. the alternator adjusting brace pump and the fan mounted on the water pump pulley are driven simultaneously by the crankshaft pulley with an identical matched pair of belts. (4) To obtain proper fan belt (9) tenbracket capscrew sion loosen the idler pulley adjusting 3-183. (3) Retighten capscrew (5). filt=r ~. Fe~eral Specification P-D--680. (6) and move idler pulley (4) as required. filter for damze. e. TEMPERATURE b. or blue emissions.1 . Fill sump with hydraulic Section XXVII. drain hose in and remove nipple (8 and needle (4) With engine ruining excessive black. loosen the alternator adjusting caPscrew (5) and move alternator in or out as re- 3 . ALTERNATOR AND RELATED PARTS 3 . b. [3) Ins~ect . Engine Assembly Testing. — Inspection. 3-181. See (1) Inspect threaded areas for damage. Drive Belts. (2) Inspect sump tank (21) for cracks or c. as Follows: To test the engine assembly proceed bly and the water block drain hcse assembly. 3-178. — in reverse order of removal. (3) With engine running test by listening for engine knocks. <. running observe 2-5) BATTERY CHG AMMETER The engine assembly mechanical and components generate the indication. Installation. Disconnect pressure by observing OIL PRESSURE indicator water drain hose (7) from nipple (8) and–remove water drain hose (7). rev<rse sequence Section XXVIII. Connect hydraulic lines. 3 . The rotor is mounted not against the Both front and rear bearings are sealed and lubri cated for life. (5) Tighten capscrew (6). service with minimum on bearings.3 3 and install sump tank (21) and a. Remove (1 .(2) Clean sumv tank and filter thorou~hlv with cleani~ solvent. f i g u r e 3 . Proceed as Replacement. Unscrew (2) With (fig. 2-5). Drain Hoses. for proper charging power to drive the generator. stator laminations nator and frames. 2-5). excessive noise and visually observe d. and proceed as follows: ~. CAUTION The alternator rectified is a 24 volt.e (9). end frames. observe exhaust for gray. E N G I N E A S S E M B L Y 3 . The alternator is driven by the crankThe idler. brace Replace fan belts as required. nipple (4) shutoff cock (5) =nd connector c. MIL-H-5606. distort ion. (5) With engine (fig. continuous output. Install oil drain hose and wate: of removal.8 7 .1 7 9 . and constructed diode When adjusting tension. b. tension. the water shaft pulley with a single belt. idler pulley adjusting bracket See figure 3-35. fig. test for overheating indicator a. Adjustment. apply alternator belt force against between alter- unit. oil. 8 8 Change 1 . 3 .Figure 3-34. nat. the alternator adjusting brace Replacement. fig. f i g . CAUTION — Do not force a belt over sharp metal surfaces. 2. 3-184. Testing. NOTE Replace fan belts in sets.8 9 Change . gain access~o the idler pulley adjusling screw (6). fig. (b) Remove from altei+nator belt tension and remove belt (7) pulley. brace Replace Loosen the alternator mounting bolt (14).r (14. (14) from the mounting bracket 3 3 . by ca~efully manipulating blades. (8). 3-29). Loosen capscrew leys. as required.2. ~. (3) Check (~) Remove alternator belt as follows: (7. shut down set and proceed as follows: (1) Measure (para Figure 3-35. 3-183 a (1) and adjust alternator and (2). ad- jus~able lows: (10). one at a time. (4) If alternator (14) output is not correct replace after belt tension has been adjusted. out . (2) and receptacle screw (3) and remove hand fan guards (26. screw (4) and washers (5 the fan. (c) Remove ing adjust~ble brace and screw (8) and washer (9) secur- (10) to alternator mounting adjustable brace (10). or mounting (20) as fol- (5L and remove @ the alternator belt from its (1) 3. as required. a. nator output cannot recommended generator be varied in a~cordance settings voltage in step ~. screw (11) washer (1 2). 3 . Remove the fan belts. CAUTION Do not force a belt over sharp metal (2) Installation. b. (2) Check that fuse ( 2 1 . fig. and 6) it over fan blades. surfaces. the alternator the alternator bracket (14). 25) to the nector and lockwire. (a) Remove from alte~nator (1 4). 3-35) battery connections for security. spacer (~) Remove the fan belts as follows: bracket (20) remove 1. to facilitate belt removal. Testing 3-36) of the battery charging alter- at the organizational maintenance by performing an operational If the alterwith the level is accomplished verification as instructed in step c below. belt tension. Manually position the fan blades bracket to cap- (d) Remove (13) and afiernator (20). Manually rotate them over the fan the fan. Remove fully rotate manipu~ating the alternator the belt (7) by careManually Removal.3 6 ) is not burned (~) Remove fan guard by removing (24. the seven which sec- (~) Cut lockwires mounting (1) attached to connector con- fan guard mounting screws ure the left and right radiator shroud (36). Battery Charging Alternator. idler pulley adjusting bracket (6~and remove the front belt from its pul- 3. Loosen capscrew pulleys. to faci- litate belt removal. Install the alternator and removal steps in reverse p a r a g r a p h fan belts using appropriate order and adjust the belts as described in 3-183 a (1) and (2). Install the battery charging housing. Screw Washer Washer 10. threads lockwire (1) one turn around screw (3) before to Installed screw (22) clockwise. 16. rotate wise. bracket bracket. adjusting To decrease alter- at rcct-ptacle mounting nator output. Screw Washer bracket 20. Installation. 9. 15. Adjusting 3. Support bracket 18. rotate output (20) using removal Wind as required. the alternator as follows: (1) Discomect (j) Remove uring mounting move mounting screw (18) and washer (19) sec(2) Comect either negative terminal from battery. Mounting Figure 3-36. c. 8. (20) to the front cover and re- a voltmeter across terminals of slave receptacle ad adjust alternator output by rotating adjusting 2. Alternator and Related Parts (Q) Remove two screws (15) and washers (16) securing support bracket (17) to the mounting bracket (20).ing. screw (22) located on the rear alternator bracket adjustable brace steps (10) and mounting in reverse order (3) To adjusting increase alternator output. 19. 5. Fuse Screw 22. Screw Washer Spacer 17. iockwlre 3 .9 0 C h a n g e 1 2 . 13. 6. and remove the support bracket. Lockwire Connector mounting 7. (14). 2. Adjustment. screw (22) countercIock tightening comector screw and attach:ng (2). Adjustable 11. Receptacle screw 4. adjust With the engine generator set run.1. Belt Screw Washer brace 14. 12. Alternator Screw Washer 21. . . . Testing and Replacement. G and H. over(4) Reconnect (5). steps in reverse order. (~) Remove cable connector (3).. . OVdc Above 100° F . A and C. Q. Replace speed switch ( 5 . .1 8 5 . a. testing is accomplished as fol- (1) Remove connector (3) from the speed switch (Q) Loosen nut from adapter (2). S P E E D S W I T C H 3 . connector (3) to the speed switch 3-186. . . (2) Short circuit between speed switch connec- tor pins A and B. 26. Install speed switch (5) using continuity measurement speed switch. Figure 3-37. battery disconnegative voltmeter reconnect O°Fto 1000 F. 28.. . at a higher maintenance Organizational lows (see fig. . can–only A complete test of the speed switch level. . Change 3 3-91 . If any replace the (2) removal Installation. f i g .3 7 ) as follows: (1) Removal.(4) follows: Recommended voltage settings are as 0°Fto-650F . through speed during (3) open circuit between speed switch connec- The provides sequenced control of circuits against engine tor pins F and J.. OVdc terminal. (2) and remove (5) and perform the continuity cated in steps measurements as indi- speed switch (5) from adapter (2) and (3) with the engine is not verified.2 Vdc nect (5) At completion and of adjustment. Section XXIX.. G e n e r a l .. be performed level 3-37). The speed switch is driven by the camshaft a drive switch assembly and an angle adapter. Testing. Replacement. engine startup and protection speed during’ operation. D and E.30. off. 3 . . See R e p l a c e m e n t . The filler cap provides means oil c.9 2 . 3 .Section XXX. 3-38) by re- handle tight. Replace (4).-lock oil filler elbow elbow (7) by removing flat (7) washer in (6). figure d. 3 . Figure 3-38. Install new cap and screw of adding oil as required. 3-38 and proceed as follows: (1. Replace han~le oil filler cap (3) by unscrewing cap and removing cap.1 8 7 . G e n e r a l . moving and installing new gage. Replace oil level gage adapter (2) by unscrew- ing-and installing new adapter. OIL LEVEL GAGE AND FILLER 3 . b.1 8 8 . The oil level gage is used to check the engine level. fig. Replace oil level gage ket (8). removal. and reverse order screw gas of - washer Install (5) and a. Remove starter (3) and starter adapter (4). (d) Remove three 12-point screws (1) and three washers (2). (18). fig. The sensors provide system. Check ring gear to assure that teeth are not damaged. and (19). (a) Disconnect the negative cable from the battery. (6) Refer to paragraph 2-12 b and perform the mounting bolts click each time the START-RUN-STOP switch is cycled into the START position. 3-191. part of the starting motor is connected by linkage and a shift lever to a clutch in the starting motor nose housing. the starter assembly must be replaced. (4) Verify that all leads to the starter starter solenoid are tightened securely. 3-3 and proceed as follows: Remove nut. replaceable does not increase. fig. Assembly. flat washer. (~) Unscrew (1) Remove nut. Install the starter (3. (~) See figure a. ELECTRIC STARTER AND ADAPTER 3-189.1). starting procedure while a qualified observer observes starter motor operation. 3-3) (2) Installation. G e n e r a l . (1) 3 . is fully charged contact (2) Installation. Allow at least 3 minutes before operating again. replace the transmitter zero ohms. than 60 ohms. fig. Starter Testing. If recrank engine sistance The engine lubricating type and contain oil filters are of the full-flow elements. (18. fig. and the engine does not turn over. — Starter (1) Replacement. Testing starter is an operational test. (18. Testing. If voltage is present. A solenoid switch. 3-38. Section XXXII. rule can result in over heating and failure of the motor. The solenoid shifts the starter pinion gear into mesh with the engine flywheel ring gear and holds it in mesh during engine cranking. 24 volt overrunning clutch type unit. the starter assembly must be replaced. a means of monitoring the engine lubricating electrical lead from transmitter threaded terminal. O i l P r e s s u r e T r a n s m i t t e r . check for 24 Vdc across solenoid and ground. If resist(18). b. (2) between Using multimeter. transmitter (18) from nipple 3-3) threaded Removal. 3-3) into transmitter resistance measured on the R x 1 scale is greater Change 13 3-93 . ~. General. (3) Tighten battery connectors securely. b. flat washer and lead from transmitter terminal. A drain plug is approximately that to determine ance resistance increases. lockwasher. LUBE OIL FILTERS AND SENSORS 3 . Do not operate starting motor for more than 15 seconds at a time. and the To test the starter solenoid proceed as follows: Starter Solenoid. Failure to observe this (c) Remove tool box to gain access to starter screws (l). (b) Tag and disconnect electrical wires from starter battery cables and (3. lockwasher. (18. NOTE 3-190. fig.1 9 3 . Replacement.1) Perform test as follows: (1) Verify (2) Verify that the battery that battery connector/terminal on the flywheel housing in reverse order of removal. 3-38.1 9 2 .TM 5-6115-545-12 P-8-626-12 TO-35C2-3-444-1 NAVFAC TM-00038G-12 Section XXXI. CAUTION Removal. replace transmitter in each filter permits draining of the filters before replacing the filter elements. If threaded (a) Screw transmitter fipple (19). screw measure terminal resistance and ground. If the starter solenoid does not operate with an audible (5) Verify that the three starter are tightened securely. which is an integral the START position. surfaces are not corroded. (7) If the starter solenoid emits an audible noise switch is cycled into each time the START-RUN-STOP The starting motor is a heavy duty. 1 3 .TM TO-35C2-3-444-1 NAVFAC TM-00038G-12 P-8-626-12 5-6115-545-12 Figure 3-38.9 4 Change 13 . If switch does not check out properly. Testing. Replacement. General. center screw ( 5 ) to a torque of 45 to 50 foot-pounds. 3 . (1) Removal. SECONDARY FUEL FILTER 3-196. nect the connector and connect a multimeter between pins B and C of the switch and verify continuity. Tighten (Q) Disconnect connector from switch ( 16). and draining into a suitable container.3 ) . fig. see f i g u r e proceed as follows: (2) ~ Open drain cock (1). loose connector. fig. (Q) Install bracket (9) and filter assembly (6) in the reverse order of removal. Drain fuel into suitable container. 3 .3 9 and (g) Remove two screws (7) lockwashers (8) and washer (8A) and remove bracket (9) from engine.1/(3-94. 3-3) 3-195. Inspect the switch ( 1 6 .3 and proceed as follows: a. C h a n g e 9 3-94. To replace the oil filter assembly. (Q) Remove four screws (4) and lockwashers (5) holding filter assembly (6) to bracket (9) and remove filter assembly (6). It removes contaminated particles of five micron and larger from the fuel. lockwaaher. 3-194. 3-197. Then connect multimeter between pins A and D and verify open circuit. while observing the following: See f i g u r e 3 . and other damage.3 ) as which secure header (9) to engine block. Replace switch ( 1 6 . see f i g u r e 3 . Reconnect connector to switch. Remove straight connector (22) and gasket (4). electrical connections (22 ). discon- ( 3 ) and drain filter by removing plug ( 1 . Section XXXIII.2 blank) . Screw switch ( 1 6 . 3 . (2) Installation. (1) Removal. (~) Remove fuel lines to filter and remove elbows (2 and 3) from filter assembly (6). ~. and flat washer. dents.TM 5-6115-545-12 P-8-626-12 TO-35C2-3-444-1 NAVFAC TM-00038G-12 (~) Reconnect electrical lead using nut. To test the switch ( 1 6 .3 and remove and install as illustrated. folbws : fig. ~. Replacement. fig.3 ) into Q. Q. replace switch. 3 . loo~e mounting.3 ) for 3-4c (1) Drain oil system as described in paragraph fig. Low Oil Pressure Shutdown Switch. (2) Remove screw (5) and washer (6) and remove both filter bodies (7) and filter elements (8) as assemblies from header (9). (4) Install using a new gasket (4) and mount onto engine block with screws (2) and washers (3). Check the engine lube oil filter for oil leakage and be certain that filter body ( 7 ) and gasket ( 10) are properly installed. Installation. Replacement. Inspection. The secondary fuel filter is the final filtration device in the fuel system. To replace the secondary fuel filter. 3 . Oil Filter Assembly. nipple (17 ) and tighten to 20 foot-pounds. (3) Disconnect and tag oil line and electrical connections and remove screws (2) and washers (3) c. Replace straight connector and reconnect oil line and (Q) Unscrew switch ( 16) from nipple ( 17). (~) Close drain cock (1). . Figure 3-39. C h a n g e 9 3-95 . . (g) Refer to paragraph 3-41 and fill cooling system. 3-96 Replace the engine oil cooler LUBE OIL COOLER (h) Remove winterization kit nipple. install kit. (~) [t(hfer [ o paragraph 3-41 md cfrwn cu(dir~ system. See figure 3-41 and proceed as follows: a.ii. The engine lube (JI1 c{mh’r. 3-40) and lockwashers (3) and (6) and securing lube oil cooler (7) to cylinder block. Hold packing in place with a light coating of grease. Refer to p a r a graph 3-41 and check coolant level in the radiator adding coolant as necessary. . 3-198. Fifth screw (2) and lockwasher (3) secures manualc ontrolb racket (4) to lube oil cooler (7). The nozzle holder assemblies are used to position the injection nozzles in the cylinder head. Irustall new preformed packing (8) in the back of the lube oil cooler (7). and elbow from lube oil cooler (7) drain plug (1) receptacle. 3-199. — . 3-40) or ]f winter izati~m kit is mstallqci by opening shutoff cock (45. ”. Inspection. Stop engine. 3-40) on cooler tube (9) and install one end of cooler tube (9) into lube oil cooler (7) volute. See figure 3-40 .)vll~ rfr:lll] Illug (1. localeci on the right side of the cncine.. Secure lube oil cooler (7) to cvlinder block tightening screws (2) and (5) secur”ely. thereby controlling oil temperature. (~) Assemble new preformed packing ( 1 0 . five lockwashers (3) and (6) and manual control bracket (4). (~) Inslall lube oil cooler (7) by positioning header over lhe rear end of cooler tube (9) and pushing forward. fig. There is a nozzle bolder assembly for each cylinder consisting of a fuel injection nozzle holder.ind proceed as follows: ~. and Replacement.l(’rment . 4-1) to elbow (46) and open shutoff cock (45). (~) Install five screws (2) and (5). (1) Check for a sufficient fuel level for operation. shutoff cock.“ ——. Testing. (~) Refer to paragraph 3-203 and install turbocharger oil drain tube assembly between turbo charger and cylinder block. shutoff cock.. 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.. 3-40) drain plug (1) receptacle. Fk!pl. fig. (Q) Refer to paragraph 3-203 and remove turbocharger oil drain tube assembly between turbocharger ancl cylinder block. Correct any leaks found. Section XXXV. Also drain coolant frotn lube oil cooler by rclll. Inspection and Replacement.. ——— as fi)llows: (1) Renl(w:li. 3-200. 3-40) connections. b. (d) Install lube oil cooler drain plug (1) or connect hose (34.Section XXXIV. . (g) Remove fuel fr It er head with filter element intact. fig. hw])f:clif)n. Remove Iube oil cooler (7) by pulling t[]WArdS the rear of engine. (g) Remove coo!er tube (9) with preformed packing (10) from the lube oil cooler (7) volute. (. Refer to paragraph 3-197 and remove secnndarv fuel filter. fig. consists of a corrosion resistant . cooling c[)re and tank. General. :ii)cf other damage. and elbow in lube oil cooler (7. The lines provide a means of delivering the fuel from the fuel injection pump to the nozzle. fig. lIISIJW1 (jIl cw}lir for internal l~~ll~s. General. (~) Operate engine and check for oil and water leaks at oil cooler (7. (~) Renlovef]v screws (2 and 5. fig. . (~) Drain secondary fuel fllt er in(o a two ~allon container. (2) Installation. fig.’. and the e~~ine oil pr-ussurp pump circulates oil through the tank and around (he outside of the tubes of the cooling core. (f) Refer to paragraph 3-197 and install secondary–filter. NOZZLE HOLDER ASSEMBLIES AND LINES 3-201. Inspection. nipple. 4-1) after removing hose (34) from elbow (46). NOT E If winterization kit 1s installed.se Ill[JUlltlllg. The water pump circulates coolant t hrtw~h the coolir~ core tubes. --li. ~~) Remove preformed packing (8) from lube oil cooler (7). 9 7 . Lube Oil Cooler 3 .Figure 3-40. Fuel should flow out when the connection When the input to a faulty injector is loosened.3 2 ) and swing- as opposed to an injector follows: proceed ing lever arm of hydraulic actuator. conarea. CAUTION ——. or by using a slide hammer with an adapter. Use clean on the work bench and place components in a container of clean diesel fuel as they are removed. CAUTION tant when working with fuel inj ectors. (detail A) and tee (4). is removed.4 1 ) and washers (12) from fuel inpump. A11ow at least 15 seconds lines (23 through 28). in compression readings in excess of 50 exists refer to lbs between high and low cylinders next higher c. there Gain access to screws (11) and washers (12) Which secure fuel lines (23 through 28) to fuel injection removing (2) To verify a low compression malfunction. pump by nut NOTE is loosened. condition as (see fig.C th~ fll~l iniection signs of leakage. 3 . Mark each nections and surrounding assemblies zle holder (32) from right side reaching inject or nozzle with the number of the cylinder from which it was removed.–nuts (9) at the nozzle holder assemblies (32) and screws (11 ) at the fuel injection pump (detail A). nuts ( 1 . before operating again. fig. and temporarily (b) Insert a compression j ector openini. one by one loosen while ob- (c) Disconnect fuel injection lines (23) through (28). self-locking 3 . Do not bend lines when disconnecting. (~) Turn the START-STOP-RUN to obtain a compression switch LNOT E the START position for a period of 5 to 15 seconds reading while the engine is to the STOP position. Gain access to noz- from c ylinde~ head by using two small pry bars. jection 3 . paper by dirt.. Cover all to openings immediately prevent entrance To replace the nozzle holder Replacement. and (23) through (28). should be little or no change in engine sound or action. the fuel input connection to each injector serving the engine action and listening to the sound. remove lines from pump.- Testing.4 1 and proceed as follows Iockwashers (1) Removal... of dirt. 21 and 29) (detail cranking. see f i g u r e 3 .(2) Examine all fuel lines 28. Temporarily stow self. to gage into the instow screws and washers on pump. remove the injector assembly from number one cylinder (or the cylinder which has a suspected failure). Remove fig. (a) Thoroughly clean nozzle holders f i g .qnve fuel return line (8) by dispump and nozzle holder assemblies (32) for connectors (ti) . Injection nozzle service troubles are.ozzle-holder assemblies (32) Ii=es (3). (d) Remove disconnecting nozzle-holder manifold drip line (3) by coupling nut (1) from tee (4) and assemblies (32). ( 3 2 (f) Remove ~. (d) A compression psi (at sea level) difference is normal gage reading of 400 If a CAUTION for a new engine. 3 . . coupling CRANK swit~h in down position. (8). —— (1) With engine running. Return the switch must be unclamped B and C) before removing CAUTION —. Insure that nozzle gasket (34) over the engine valve cover.-— . 8. and 23 through connecting (:) ‘e.— — assZmbIf6s and lines. (e) Remove two capscrews (30) and two assemblies 731) securing nozzle-holder (32) to cylinder head.4 1 ) . b. The engine action (or symptom) should beis come worse when the input to a good injector loosened. . 3-41) (3.9 8 C h a n g e 9 . Clamps (16.——— Cleanliness is extremely imporUse care when removing an injector nozzle to tmevent striking nozzle tip again~ a hard object &hich could result in damage to the tip. maintenance level. in most caused instances.locking nut back (a) With the engine stopped and the DEAD in place.——— Do not crank more than 15 seconds at a time. Figure 3-41. 3 - 9 9 . capscrew to full torque. Inspect for an accumulation compressor impeller housing.8 6 and remove nozzle. (28). natd y. return line. e. fig. Carefully position nozzle-holder full torque of 11 to 13 foot-pounds. Start f. Remove turbocharger (28) exhaust pipe to the diffuser (24).. the turbobe removed. build-up replace in the Other unusual noises can result from between turbine impeller Should an excessive of dirt proper clearance bine housing. It is driven bocharger of the turbocharger provides by engine greater engine power outexhaust gases. in position on nozzle-holder blies (32). Section 3 . An uneven See figure 3 .4 2 and proceed as follows: disturb the balance of the rotating parts and lead to a. Proceed as follows: vanes and in the compressor If replacement above. connecting connectors (6) to tee (4) and fuel injection pump (detail A). T u r b o c h a r g e r . XXXVI. Start engine and observe fuel injection line. (2) Loosen setscrew (17) which secures the (1) Removal.(2) Installation. 3-41) bores in cylinder head. charger must and tur- occur in the diffuser (24) a loss of efficiency turbocharger efficiency if this cannot fuser. muffler and exhaust pipe. Place fuel lines (23 through but do not tighten injection lines ( 23 through 28) in position in nozzle holders injection tighten (32) and fuel injection pump (detail A). and diffuser (24) as follows: (3) Ref to p a r a g r a p h 3 . been installed. ensure old nozzle holder gaskets are nut (1) to tee (4) and nozzle-holder because new gaskets must be used when inholders. in the exhaust end of turbocharger (28) for signs of damage. If the coating of dirt is light and even. or approaching Do not mistake whine heard during rundown for one during im- of a layer which might flake-off. impeller for unusual turbocharger shaft bearing failure is uneven. . disassembled. line nuts (9) and screws (11 ) but do not fuel return line (8) by at this time. air cleaner (13) which secure the air and replacement The turbocharger put.1 0 0 . manifold drip line (3) by coninjector lines blies (32. pump. If this cannot turbocharger.4 2 and proceed surrounding area with cleaning solvent Federal Specification P-D-680. outlet to turbocharger inlet. cave face dew-n. (5) Loosen the clamps hose (15) to the turbocharger hose from the turbocharger. Operate engine at approximate noise. Install fuel return line. If the coating of dirt the appearance rat~d o~listen that indicates operation. Replacement. and manifold drip line nut (9) and screws (11).2 0 3 . G e n e r a l . cleaning is necessary. Tighten nozzle-holder capscrews (30) alter- Tighten capscrew on one side to 3 to 6 footTighten capscrew on opposite side to Then tighten first pounds torque. spected. conassemassemassembly stalling the nozzle cles of carbon are in nozzle holder bores that could prevent nozzle holder gaskets from seating thereby permitting “blow-by” from the cylinders. as Tollows: See f i g u r e 3 . 3-42) and b. is recognized be cleaned If such noises are heard.—— —. required. and manifold drip line connections for fuel leakage. (a) Thoroughly clean nozzle-holder assem- NOTE Always install new washers (12) when-connecting to injector (d) Install necting coupling (32). be cleaned satisfactorily. Ensure no small partiproperly.2 0 2 . the turbocharger compressor wheel and compressor housing for dirt. The tur- (28) and remove Remove draws in ambient air through the input dif- air hose from fuser. (6) Inspect 3 . fig. Inspection. ‘ is not reconnect the exhaust pipe and air hoses which were disconnected (1) Clean the turbocharger (28. connectors (6). and coupling NOTE Secure after clamps (16. (~) Install (31) and two capscrews assembly two nozzle holder Iockwashers (30) for each nozzle holder at this time. and inof dirt on the This loss of turbocharger satisfactorily. cleaning the compressor buildup of dirt will wheel is not necessary. (21 ) and (29) 28) have nuts (1). Tighten injection lines fuel blies in nozzle bore of cylinder head. failure of the turbocharger excessive. D I F F U S E R A N D T U R B O C H A R G E R (4) Inspect the turbine wheel and shaft assembly This section contains information on the inspection and diffuser. will result. Correct any leaks found. 3 . (b) Install new nozzle gasket (34). replace dif- by excessive exhaust smoke. compresses the air and directs the compressed air into the engine intake manifold. When cleaning removed bores. C h a n g e 9 3 .1 0 1 .Figure 3-42. 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 nuts (26) to 18-21 foot-pounds screws (19).1 9 5 and reposition (49. 3-204. Inspect Exhaust Diffuser. (b) Refer to p a r a g r a p h (28). then connect the line to the oil inlet of the turbocharger 4. system. (f) Connect 5. and mounting pads. 3 . Ensure that the oil inlet line and oil return line a~e clean before they are connected. of gaskets. switch in open 2. 8. diffuser (24) for cracks. 9. (~) Install (a above) in reverse — the exhaust pipe. Refer to place the lubricating p a r a g r a p h 3 .25. loos= mounting.1 0 2 C h a n g e 1 . Remove the lines and inspect for cleanliness strictions. Refer to vice the air cleaiier. muffler nuts and tightness of 28-33 foot-pounds torque. and Inspection. Refer to engine lube oil. – p a r a g r a p h 3 . and other damage. Check foreign matter. and flatness of the turbocharger mounting surfaces.4 6 and change engine until there is a free flow of oil from the upper end of the oil inlet line. (13 and 7) are tight. exhaust manifold for cracks. Place dead crank switch in on position. turbocharger mounting adaptor. 3 . turbocharger operation. fig. the gaskets (9. (b) Disconnect line (10). Check intake manifold order. Just prior to mounting the lubr~ation hose (15) clamp (13). elbow and hoses for cracks. prime Pour clean oil into the oil inassembly let of the center housing. fig. Check the oil return line (1 O) to the and recenter housing. Ensure clamps all air and oil line hose a. (2) Installation. the oil inlet line (2) to the manifold openings covforeign obgetting into when the This will prevent jects from accidentally turbocharger or engine the manifolds and damaging the engine is again put into operation. Hold ENGINE START-RUN- STOP switch to START position. foreign matter.2 0 4 to remove diffuser (24) from (28) and diffuser Lubricate the four nuts (26) with antiMI L-A-1 3881 R. 3-42): installing the turbocharger: CAUTION Do not crank start motor more 1. mani- seize compound Military Specification turbocharger and secure the turbocharger (28) to the exhaust fold tightening CAUTION and tightening (28) (d) Connect lubricating oil–supply. condition iind proper mounting. Crank the engine until oil runs from the oil outlet of the center housing. tightness of mounting nuts. and remove the oil return 10. (e) Place dead crank fig. Continue cranking 3. 3-27).2 0 4 to install to the exhaust diffuser (24) o~ turbocharger (e) Remove four screws (19) and washers (c) Install the turbocharger haust manifold. (15 and 8. Ensure 29) do not extend-into the port openings of the exhaust 3 . and general condition. p a r a g r a p h (28). (a) Before (28.(a) Disconnect line (2). any air or oil line hose 3 .16. of oil to the turbocharger and through it. (d) Remove turbocharger-(28) the four nuts (26) which attach manifold. turbocharger (28) and to the side of the cylinder block. oil filter elements. Return switch to STOP position. torque. While diffuser (24) turbocharger keep all intake is off the engine. (~) Loosen and remove the oil inlet manifold. (g) Connect and air inlet the air cleaner hose assem- bly using inspection instructions 6. Replace connections ated. (i) Upon completion 7. an–d check of the installation. Check condition of manifold mounting and nozzle. Allow at least 3 minutes to elapse between crankings. and exhaust ered.3 2 and ser- than 15 seconds at a time. p a r a g r a p h 3 . a new gasket (29) and mount ring (21 ) on the ex- (20) which atiach diffuser ring (21) to the exhaust manifold Refer to and remove diffuser (24) turbocharger (28).4 2 ) found to be deteriorrun engine. Turn the rotating by hand to coat the bearings and thrust collar with oil. the unit. 3 .4 2 and proceed (b) Remove four screws (19) which secure as ~ollows: diffuser r~~ (21) to the exhaust manifold.4 3 . and spacer (4) and pulley 3-43) 28-33 foot-pounds.4 1 ) . fig. Apply a small amount of grease See figure 3-43 and proceed as follows: ( p a r a 3-39). or if the engine obviously continues to operate when open. See figure 3 . and replacement The is neces - electrical c. R e p l a c e m e n t . 3 . with The pump is mounted on the front of the cylinder block and is belt driven from the crankshaft pulley. 3 .1 8 3 ) Refill table through the engine and radiator. THERMOSTAT AND HOUSING 3 . sta~ Thermostat. Remove fan guards ( 2 5 a n d 2 6 . 3-208.4 4 ) . move drive belts (para (5. Reto packing groove in water pump volute a. The nafiely temperature sensitive components transmitter in the housing. The temperature transmitter senses the sible cause of trouble. When the engine coolant temperature over 222° F * 3° F the normally running hot. f i g . type pump that Install water pump ( 1 8 .4 4 ) is necessary when the thermo- stat sticks in the open or closed position. removed and tested (refer to para as a possible cause of trouble the thermostat.4 4 ) Switch. (1) follows: Removal. ( p a r a and remove thermostat 3 . The transmitter is not repairable and replacement to operate. If the engine is not overheating and the unit shuts down as though it were. Install new packing install screws to new (24) in groove and gasket (19). Install and adjust drive belts ( p a r a The water pump is a centrifugal circulates coolant f i g u r e 3 . (10. Inspection and Operational Check.4 3 ) .4 1 ) Removal. G e n e r a l . Removal. engine cooling system in accordance 2-1. figure 3-43. and install fan guard (25 and 26. 3-43). If the Change 1 3 . Installation. 3 . Remove the diffuser (24) as (~) Remove which secure diffuser and remove diffuser the four bolts (22) and nuts (23) (24) to the turbocharger (28) (24) and gasket (25). Replacement of the*thermo- mitt er (1 O).2 0 6 . Testing and Installation. Removal. fig. coolant radiator is shut-off. for corrosion and to assure that the connector to the unit is secure. trans f i g u r e a. removal Install diffuser (24) using the steps in reverse order. switch (12) should be re- closed contacts open and the normally open contacts close.1 0 3 . G e n e r a l . 3-44) Transmitter. Temperature fig. and tested as a pos - tem–perature of the engine coolant to operate the indicator on the control cubicle c. and temperature switch are located The thermostat is positioned in the system so that when closed. unit temperature panel. fig. Drain the cooling system (8. the thermostat a. engine overheats temperature or does not reach a minimum should be of 180° F.2 0 5 . (a) Remove diffuser ring. tion of the COOLANT TEMPERATURE indicator in the control cubicle is erratic or inoperative. fig. (8. f i g . If the opera- is necessary when it fails reaches 180° F the thermostat starts to open allowing coolant to pass to the radiator. 3-29). the trans - mitter (1 O) should be removed b. coolant hoses.2 0 7 . (b. Section XXXVII. exhaust components from (2) Installation. 14. 22.b. Temperature f i g . normally of the engine one normally to operate. Torque and water pump (18) as illustrated in screws (1) to 30-35 foot-pounds. 3-183). temperature 3-209). NOTE 3 . Inspect switch ( 1 2 . WATER PUMP AND FAN 3 . 12. Torque 16) and remove fan (3) coolant hoses. in excess of 222° F ~ 3° F. Replacement. flow from the engine to the When coolant temperature b. and fan (3) as illustrated in 3 . This action results in automatic moved and tested as a possible cause of trouble (refer to p a r a 3-209). 3 . fig. shutdown of engine operation temperatures at engine coolant 3-209. Section XXXVIII. (20. (25. and switch (12) as illustrated in 3-44). a. The temperature switch which also senses coolant and has two closed and the other reaches a switch is not repairable sary when it fails the~emperature sets of contacts. Drain engine coolant ——. 3 .Figure 3-43.1 0 4 C h a n g e 9 . TM TO 5-6115-545-12 35C2-3-444-1 P-8-626-12 NAVFAC T M 0 0 0 3 8 G . 3-105 .1 2 Figure 3-44. General. (4) The thermostat (8) M not adjustable. (2) Heat compound gradual] y and stir so heat is evenly distributed. and suitch (12). Inspection. Inspect pulley belt grooves for step wear aloiii sides and bottom of groove. indicating ex. Thermostat Testing. If the transmitter (10) is functioning pro erly. To test thermostat (8). See figure 3-44 and install thermostat (8). ~. Fill radiator with coolant in accordance with table 2-1. CRANKSHAFT PULLEY AND VIBRATION DAMPENER 3-210. T~. Installation. Do not overheat. Inspection. transmitter (]0). cessive wear. (4) The transmitter (10) is not repamable. DO not overheat. If it does not operate within the above lit-nits. ~. Heat water gradually and stir so heat is evenly distributed. proceed as follows: of clean (la)ektspend transmitter (1 O) in a container . Under 217°F S3°F. 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 accessories such as the water pump. If it does not operate within the above limits it should be replaced. (3) Check temperature of compound with reliable thermometer. Thermostat must be completely inlnler sed but not touching bottom of contmner. To test the transmitter (10). 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. Inspect hub area for cracks. The idler pulley is mounted on it bracket. See figure 3-45 and proceed as follows: . (4) Use ohmmeter and check between pins A and D and also between C. Vibration dampenihg is accomplished by bonding a neoprene compound between the crankshaft pulley and the crankshaft hub. a. IDLER PULLEY AND MOUNTING BRACKET 3-212. it should be replaced. To test the switch (12). a. proceed as follows: (1) Suspend thermostat (8) in a container of Clean water. (3) Check temperature of water with reliable thermometer. the resistanc~ should read between 2100 and 2600 ohms at 1200 F and between 680 and 745 ohms at 2000 F. a. Temperature Transmitter Testing. Switch should be inserted so that sensing element is completely immersed but connector end is out of compound. Removal and Installation. it should be replaced. located on the front of the engine. $. with an adjustment slot. 3-211. If it does not indicate a resistance within the above range. General. Section XL. While the idler pulley is mounted m place on the 3-106 Change 18 bracket. Observe thermostat (8) as temperature increases. b. continuity pins B and D should B and C (5) The switch (12) is not repairable. (2) Heat water gradually and stir so heat is evenly distributed. Inspect pulley belt grooves around total circumference of pulley for cracks or distortion. the bracket itself is moveable and can be positioned to increase or decrease tension of the engine drive belts. contacts A and indicate a closed circuit and contacts an open circuit. (2) Connect ohmmeter between single conductor and case. p. (3) Check temperature of water with reliable thermometer. 3-213. Do not overheat. proceed as follows: (1) Suspend switch (12) in a container of anti freeze compound. Section XXXIX. g.TM 5-6115-545-12 TO 35C2-3-444-1 NAVFAC P-8-826-12 TM 00038G-12 ~. ~. Observe ohmmeter as temperature increases. The idler pulley provides capability to adjust ten%ion of the engine drive belts for the fan and the water pump. Transmitter should be inserted so that sensing element is completely’ imn)ersed but connector end M out of water. fan and alternator. Figure 3-45. C h a n g e 3 3-107 . fig. 3-42) and remove air outlet elbow (14) and gasket (16). again torque screws (2) to 28-33 foot-pounds. d. compressor side of the turbocharger. (3) Remove pulley (10) and related hardware from bracket (15). The air intake system consists of components which convey filtered air to the engine cylinders. The intake system includes the air cleaner. 3-46) and tube (1A) from intake manifold (6). fig. (3A) Install atomizer and tighten atomizer so that locating dots on hex are located as shown in view A of figure 3-46. Inspection. 3-42) and washers (12) securing turbocharger air outlet elbow (14) to top of intake manifold (6. fig. Federal Specification P-D-680. General. Loosen clamp (13. To remove and disassemble the idler pulley. Installation. b . a. it must be replaced. 3-46) to the engine in reverse order of removal.a. Position bracket (15) for proper belt tension. Inspection. Proceed as follows (1) Install the intake manifold (6. c. (3) If manifold is cracked. (5) Inspect and clean the mounting surface on the cylinder head to make certain it is free of gasket particles or foreign matter. 3-46) washers (3). proceed as follows: (1) Refer to paragraph 3-183 and remove engine drive belts from around idler pulley (1 O. (3) Remove screws (2. (4) If the mounting surface of the intake manifold is warped enough so that it will not seal. fig. remove brackets (5). Inspect the idler pulley to assure freedom of rotation and that there is no evidence of cracking or signs of excessive wear. 3-45). Repair. fig. Repair of the idler pulley and mounting-bracket is accomplished by replacement of defec tive components. b . (2) Check manifold for foreign deposits. and the intake manifold. (1) Install pulley (10) and related hardware on mounting bracket (15). fig. (2) See figure 3-45 and remove bracket (15) with pulley (1 O) still in place on the bracket (15). (2) Always use a new gasket (7) when installing the intake manifold (6). Removal. b. Removal. Installation. NOTE Do not repack bearing (5) Refer to paragraph 3-183 and install engine drive belts onto pulley (10). the manifold must be replaced. Proceed as follows: (1) Wash and clean intake manifold with cleaning solvent. 3-46). Clear and remove obstructions found within the manifold. The intake manifold is sealed to the cylinder head with a one piece gasket and secured in place with screws and washers. intake manifold (6). INTAKE MANIFOLD 3-214. 3-215. Removal and Replacement. (2) Install bracket (15) onto engine. securing intake manifold (6) to cylinder head. (4) After the engine is run and the water temperature reaches approximately 170°F. c. Section XLI. (4) Pack areas between bearing (9) and two seals (4) and (7) 2/3 . and gasket (7). fig. See figure 3-46 and proceed as follows a . (1) Disconnect atomizer (1.full of BR grease. (3) Torque nut (5) to 140 lb-ft (lubricated). (3) Torque the intake manifold securing screws (2) to 28-33 foot -pounds. 3-108 Change 8 . (2) Remove screws (11. Figure 3-46.1 0 9 . C h a n g e 9 3 . Figure 3-47. exhaust valve and related arms. 015”. Installation.4 8 head cover and gasket. when the piston is near stroke and intake 1 and Numopening too far. mounting. Observe valves for Num- because of high compression cylinders. G e n e r a l . valves Number ber 6 pistons move up and down in their respective cylinders simultaneously. and vice stroke. After work has been done that may have This section assembly contains information for the rocker arm inspection is disturbed the valve lash adjust ment. Number on its exhaust stroke ing of valves and valve seats. and 14) when the exhaust placed. (e) Remove day tank and fuel filter assembly. At this point. as Follows: See f i g u r e 3 .018” clearance ature.4 7 order. Torque the exhaust is re(2. 3-219. and remove exhaust manifold in sequential (1) Removal. After any mechanical work has been the valve screw done that may have disturbed lash adjustment.4 7 ) using the removal Use new gaskets manifold (5) steps in reverse order. (g) Use suitable container and drain day The exhaust manifold provides for the routing of the (d) Use suitable container and drain primary fiiel filter and strainer. (4. for both intake any mechanical and exhaust valves is O. proper clearance. When one piston is on stem. Inspection and Replacement. CAUTION & Remove ~. tank. the pistons will strike the valves when the engine is barred over. (~) Refer to p a r a g r a p h 3 . Rocker Arm Shaft Assembly Inspection. turbocharger. If rocker arms and push rods open too far. misfiring. ensure the rocker arm screws are turned upward high enough to level for replacement (counterclockwise) prevent rocker arms and push rcxds from NOTE Adjusting screw must be replaced when less than 36 in-lb driving torque is required to turn screw. Inspect cracks. Insufficient valve developed within the lash will cause 10SS of ber 6 cylinder. After engine and adjustment. b. 3 . 7 and 11). At the same time the exhaust gases work to drive the turbocharger. loo=e Inspection. ROCKER ARM SHAFT ASSEMBLY 3 . both valves noise.Section XLII. 25 foot-pounds in 12 foot-pounds increments. the exhaust manifold for (f) Remove — (g) See injection lines. Section XLIII. the other is on its exhaust versa. or 160°F minimum.4 7 and proceed f i g u r e 3 . and cause rapid wear on the valve mechanism.– a. operating temperature. Refer to next higher maintenance of any damaged items.1 1 0 C h a n g e 1 . is very important in diesel engine performance its compression stroke. Engine firing order is 1-5-3-6-2-4. See cylinder 3 . breaks and other damage. Replacement. G e n e r a l .2 1 8 . on its compression are closed. mechanically The rocker arm assembly and allowed to warm to normal operating temperhas warmed up to normal check valve lash again for through drive gear lo- cated at the front of the engine to the crankshaft. 6 piston is near top dead center valve lifter operating and Number 1 piston is in the same position on its compression stroke. and eventually lead to burnvalve lash and the intake valve starts to open. set valves so engine can be run inspection and the valve tappet synchronized “cold” at 0. fig. engine exhaust gases. EXHAUST M A N I F O L D 3 . closed when the exhaust valve is almost compression. manifold screws &) Disconnect as needed to facilitate and plug fuel and oil lines removal. and 13. Install exhaust manifold 3 . Correct valve Valve Tappet Clearance Adjustment. perature With engine at normal operating temvalve lash for Number 1 cylinder are closed and valve lash can be adjusted. adjusting f i g u r e and inspect adjusting (1) end of rocker arm (2) and shaft (3) for evidence of physical damage. (10).2 1 6 . Excessive will result in faulty engine operation. 3-220.2 0 3 and remove (2) 9. 3-217. end of intake rocker Valve lash must be adjusted top dead center and exhaust clearance (valve lash) between stem. Figure 3-49.Figure 3-48. 3-111 . testing and replacement and replacement of related and 3-51. Using socket wrench on crankshaft Q. Gauge should pass between to open. figure and–see to remove the transmitter (3). multimeter shall read between 3-222.ylinder head cover. then adjust lash for intake and exhaust valves e — and for number f above. 3-223. as necessary. — — cylinder head cover using associated l_. of e and ~ above. 018 inch and hot clearance O. compon - of the fuel quantity transmitter. 3 . breaks.8 and 31. washers. 90 ohms and with sensing arm of trans mitt er in raised position (B). loose hardware. must withstand Bubbles f i g .4 8 ) pulley 1-1/2 inch socket wrench on crankshaft 5 cylinder valve starts nut. Inspec & the skid base assembly for rust. following as follows to obtain specified clearance exhaust procedure in paragraphs # Run. Replace J. then adjust lash for intake and valves for number 5 cylinder. Fuel Quantity Transmitter Removal. and other (2) Submerge transmitter Float tank of transmitter of 6 PSI without leaking. 6 cylinder. Proceed as follows: Procedures in this section include of the skid-base. for number 4 cylinder. in e and f above. damage. Replace breather tube. 00 and O.2 2 1 . of the fuel tank and replacement ents illustrated in figures 3-50 (1) Connect mitter multimeter between case of trans pin as in (3) and the transmitter 3 . Skid Base Inspection.and if this sequence valves is followed. figure 3 . — — ~. in e and a above. Testing. Verify that the oil drain plug (10) and hose observed if float tank leaks. bar over engine until number 1 cylinder exhaust valve is almost closed and intake valve valve for number 6 cylinder closed starts to open. & Using e. Check is almost closed and intake ance periodically. clockwise to decrease clearance to increase clearance or counterclockwise N. bar over engine exhaust valve valve (fig. inspection in the skid base. 1-1/2 inch and–. Test- Replacement. following procedure in and intake valve starts to open. fuel tank. Adjust each valve by turning adjusting screw (1) capscrews and washers. multimet er shall read multimeter. Using 1-1/2 inch socket wrench on crankshaft 2 cylinder can be checked and adjusted figures 3-48 pulley nut. BASE GROUP AND RELATED COMPONENTS 3 . Using 1 -1. G e n e r a l . Using 1-1/2 inch socket wrench on crankshaft NOT E pulley nut.ck clearance arms ( 4 . then adjust exhaust valves for number procedure in e and f above. See proceed starts to open. following procedure and corresponding valve stem with a slight drag when valve lash is properly adjusted. ing and a.1 1 2 . . until exhaust 3-49) is almost pulley nut. 3-49) until number revolutions of the crankshaft. c Remove breather tube. Using 1-1/2 inch socket wrench on crankshaft pulley nut. if it fails test (see Replace fuel quantity between skid base and engine is not leaking. transmitter 3 . then adjust exhaust valves procedure lash for intake and following O. The The fuel tank Removal. then check lash for number and adjust intake and exhaust valve 1 cylinder. Disconnect a. then adjust lash for intake and exhaust valves for number 2 cylinder. Using a O. starts to open. bar over engine (fig. (3. capscrews. O. connector shown in lowered With sensing arm of transmitter position (A). ~. following surrounding area. engine are mounted upon the skid base ~. cor~osion./2 inch socket pulley nut. is recess mounted and generator assembly. bar over engine until number 4 cylinder -Q. air pressure be of air will 3 . See figure 3 .5 2 ) .5 0 and proceed as follows: between 29.2 2 0 above. f i g . engine 160 F mmlmum until operating is reached. Thoroughly clean cylinder head cover and exhaust valve is almost closed and intake valve lash for intake and 3 cylinder.5 2 .3 ohms. and related components. 015 inch as described paragraph 3 . — wrench on crankshaft ~. Section XLIV. 015 inch feeler gauge ch. Stop temperature the engine. ~.5 0 ) in about 12 inches of water heated to not less than 200°F. Disconnect 3-50 electrical connector The base group consists of a rigid frame skid base. the lash for all in 2 complete valve and clearand 3-49 E. bar over engine valve is almost until number and intake between valve stems and rocker rocker arm exhaust closed (2). bar over engine Cold clearance stems between valve (2) is is in exhaust valve is almost until number 3 cylinder and intake valve closed and rocker arms starts to open. Figure 3-50. C h a n g e 9 3-113 . 1 1 4 C h a n g e 9 .Figure 3-51. 3 . 3 .5 0 ) and connect auxiliary (3) Refer to p a r a g r a p h transmitter (3. distortion. Cleaning and Inspection. For fabrication procedure. and 3 . 3 .5 0 and replace transmitter (3. System. (3) Inspect tapped holes for darnaged threads. and Installation.TM TO 5-6115-545-12 35C2-3-444-1 NAVFAC P-8-626-12 TM 00038G-12 ReDla mm. main fuel tank filler hose to plastic tank (1) See figure 3-51. (2) Connect s. See f i g u r e s teed as follows: 3-7. 3 . ~lefin~ ~d ~soect iou. 3 . Safety Clip). from tank (14). Cleaning and Inspection. to (4) Disconnect vent hoses and ground terminal (13A. Close valve (25) when clean diesel fuel runs out.5 1 and pro– to (17.5 0 to remove and replace related 3-225A. fig. fig. main metal fuel tank filler hose from 3 . fig. fig.3 2 3 and remove fuel quantity fuel hose to cormector (24) at end of valve (25). &tDQ@ See f i g u r e s follows: 3-7 and 3-51A ~d proceed ~ Electrical p a r a g r a p h 3 . (2) Connect (14). see Organizational Maintenance of the Chapter Generator 3. and install metal tank (14) into (3) Connect terminal vent hoses (13A). and remove metal tank (14) from (2) Inspect b. Discorutect auxiliary fuel hose. (5) (3) Refer to p a r a g r a p h transmitter (3. tagging each hose and line. Replace lost or broken terminal clip (Retainer. tagging each hose and line.2 2 3 and install transmiucr (3) Connect (14) as tagged. (2) Open vafve (19) and allow water and sediment ~. (2) Insptxt metal fuel tank for cracks and distortion. 3-50). f i g . ~. plastic fuel tank (14) for cracks and base (15) using sequential order of indexes. a. Section XVIII.5 1 A ) . Close valve (19) when clean diesel fuel runs out. (1) Flush inside of metal fuel tank with steam under pressure. 1 Load Terminaf Board Assembly. Rinse with hot water and detergent to insure that rust flakes and other foreign material are removed. 3-50). and add diesel fuel as required.2 2 3 and remove fuel quantity Discomect main fuel tank filler hose from plastic fuel tank ( 4). See f i g u r e 3 . fig. (2) Operr valve (25) and allow water and sediment completely drain off into a suitable container.5 1 A ) .5 1 ) .1 4 2 . Drain clean fuel into suitable container. Ins tall at ion. 3 . ~. (3) Inspect tapped holes for damaged threads. to tank (14) as tagged. (5) Disconnect tank (14). fig. Cleaning and Inspection. main fuel tank filler hose to plastic tank (4) Refer to p a r a g r a p h (3. See f i g u r e 3 .5 1 A and remove p]aslic tank (14) 15) using sequential order of indexes. Plastic Fuel Tank Removal. (14). fuel lines 3 . 3-50. G. See f i g u r e 3 . (1) Rinse inside of plastic fuel tank (14) with hot water and detergent to insure foreign material is removed. fig. Related Components Replacement. 3 . 3-224. (1) Remove cap ( 2 1 . Metal Fuel Tank Removal. Disconnect auxiliary fuel hose.5 1 A ) from connector (18) and comect auxiliary fuel hose to valve (19). 3-50). fuel Iincs and ground base (15) in reverse order of removal procedure. completely drain off into a suitable container. components as required. bsd latio~. ~. Change 18 3-115 . and add diesel fuel as required. 3-50). (1) See figure 3-51A and install plastic tank (14) into base (15) in reverse order of removal procedure. and Installation. (1) Remove cap 3-225. Drain clean fuel into suitable container. (4) Refer to p a r a g r a p h fig. 3 . ~emoval. replace cap (21 ) on connector (24). (5) Close valve (25). four vent hoses and two fuel lines to tank (5) Close valve (19.2 2 3 and instafl transmitter (3)Qk reverse’&ptence of removal. rcplacc cap (17) on connector (18). (6) See figure 3-51. (6) (4) Disconnect four vent hoses and two fuel lines from from base tank ( 1 4 . TM T O 5-6115-545-12 3 5 C 2 . 3-116 Change 18 .1 2 Figure 3-51A.4 4 4 .3 .1 P-8-626-12 NAVFAC T M 0 0 0 3 8 G . Change 18 3-117 .TM TO 5-6115-545-12 35C2-3-444-1 NAVFAC P-8-626-12 TM 00038G-12 Figure 3-52. a.) b. ~. Storage space for ground rods is provided on left side of skid base charmel facing battery tray. Test each parallel wire for continuity.). No special instructions are required to install or replace a paralleling cable (1. etc. Storage Space. General. 3-118 Change 18 . fig. 1-1. (Refer to fig. Q. No special instructions we required to install or replace the auxiliary fuel line hose (2. Paralleling Cable Assembly Q. 3-53) fittings. The engine generator set is provided with a paralleling cable assembly (class 1 only) and an auxiliary fuel line. Connectors and ground wire should be stowed in tool box (fig.) ~. with ends connected and install on chain provided in housing beneath the governor control unit. 3-229. ACCESSORY ITEMS 3-226. (See fig. (See figure l-l. The auxiliary fuel line hose assembly is a 25 foo~ flexible. &p&. Figure 3-53. ~. b. 3-228. 3-53). 3-227. coil paralleling cable into a loop and install with chain provided in housing on right side of relay table. which is utilized with the paralleling receptacle to interconnect two precise generator sets.TM 5-6115-545-12 TO 35C2-3-444-1 NAVFAC P-8-626-12 TM 00038G-12 Section XLV. -. Wire routing is common between like pins of connectors: A to A. The paralleling cable assembly is a 25 foot. 1-1) under governor actuator assembly. ensuring wire is not shorted to connectors or adjacent wires. When not installed. 3-53). heat and oil resistant hose which is utilized to intercmmect the engine generator set to supply or receive fuel. 3-53. Replace defective hose (6. When not installed coil auxiliary fuel line hcse into a loop. Installation and Replacement. four conductor. heat and oil resistant cable. fig. fig. flexible. B to B. Auxiliary Fuel Line Hose Assembly. alloca- set. obvious deficiencies.4 1 and drain radiator. Remove plugs from engine oil pan heat ex- cha~ger. and covers removed during spe~ial relay box 1-2). 4 . Service upon Receipt of Material.1 8 .2 2 using installation 4-1. of fuel burning win1-26 or 1-27 and 1-22 and proceed as follows: and proceed as follows: NOTE NOTE For removal winterizaa. installation. g. see installation figure 1-22. The heater can be operated For instructions. cracked. 4-6.1 9 . b. Retain plugs. p a r a g r a p h 3 .2 ) below Fault indicator panel by removing Retain (14. S c o p e . plate to the right of control kit by proceeding in reverse order of 1 . This chapter contains Remove corrosion solvent. Disconnect ( f i g . Installation. d. Refer to p a r a g r a p h 3 . and pins and for bent. when installed 4 . table 4-4. and the following performed: loo. G e n e r a l . Refer to — cubicle b.1 . screws and washers fig. electrical harness. the scope of the operator nance level for material generator and organizational mainte- usi. refer to with electrical p a r a g r a p h p a r a g r a p h 4 . through oil pan and cooling on the fuel available system. FUEL BURNING WINTERIZATION KIT 4 . Specification used in conjunction with the by the maintenance C.2 2 and removal two screws and washers. hardware consists conto be Retain plugs. Refer to paragraph 4-4 and replace plugs.4 1 and drain radiator. Perform a visual inspection of components for 4-2. trols. a. Section II. R e m o v a l . to see that all components are present. ins~allation pkocedure using sequence 1 through figure 1 . nuts. 45) are open.1 and check for leaks. fill radi2-1 ato~ with proper coolant in accordance with and check for leaks. Preventive Maintenance. Disconnect scr=ws. e.1 kit. Inspect wires and terminals for damage and work area.5 .e connections. Insure that valves (41. Check — maintenance instructions within b. Remove protective (fig. and -65°F. Fill witfi table radiator with proper coolant in accordance 2 . Upon receipt moved of material. To perform initial terization 4 . GENERAL 4 . exhaust plate by removing two are between f. Remove with electrical winteri 4 . cover from receptacle J7 on pla~es. Winterization temperatures of a heater. such as loose or missing bolts. h. kit control box c. Install figure hoses. kit is on bonnet. or broken parts. fuel lines. as allocated tion chart provided in Appendix c. To remove figures the fuel burning winterization and 4-1 kit.3 . 4-l). placed in a clean d. see see f i g u r e s 1-15 or 1-16. 1 of f i g u r e from the engine fuel system. ~. preventive Federal compounds P-D-680.g cleaning as applicable. kit operating fuel burning winterization refer to paragraph 2-24.1 . wiring installed equipment coolant for starting the engine when -25°F. refer to F~r installation tion kit. For wiring information. and Remove oil cooler plugs from engine thermostat housing To insure that the fuel burning winterization ready for operation at all times.C H A P T E R 4 AUXILIARY MATERIAL USED IN CONJUNCTION WITH THE EQUIPMENT Section I. ~. components shall be re- from shipping containers. zation kit. a. for installing 7 4 of f i g u r e 4-1. and mounting kit as described and illustrated sequence 74 in in the generator set for preheating the engine 1 . breaks and other damage. Inspect indicator circuit swi~ch and control box for cracks. T a b l e preventive T. pins.Before Operation n A .1 6 ) 3-139) 11 Wiring harness. b. Test switch for proper operation. Air Force Indicator illuminate at the possible users shall refer to the applicable and work card sets in the periodic table 4-7. set fuel Check that fuel level is adequate operating time required. 5 x Generator tank. fuel lines.1 ) lamp as illamp and light assembly for continuity. Defects Inspect. — indicator.2 Change 1 . loose connections.1 6 ) Coolant hoses and Tighten hoses and lines and check condition. has ceased. Troubleshooting. in serious damage discovered during operation of the kit shall be noted to be made as soon as operation if a deficiency the kit All for future correction. (para 4-15) 4 . it must be inspected systematically 4-8. O. light. for (para 2-3) 6 x Fuel lines and Check for leakage. set Close all doors. Inspect for frayed or defective insulation. lustrated (2) hardware in figure 4-2. 4 x (fig. so that defects may be discovered fore they result and corrected beor failure.2 provides information useful in diagnosing and or failure 1-22. 12 Thermostat switch. 9 ( p a r a 4 . with the corrective earliest action on the applicable opportunity.Weekly (40 hrs) D . 2-11) off valve.Monthly (100 hrs) S. (para 2-3 and 3-41 Generator doors. opening with exhaust ( p a r a 4 . ( p a r a (para for or 4 .9 ) 8 x Heater fuel shut- C:ose valve. Removal. and Replacement.1 for detailed procedures. Testing. 2-11) off and coolant valves. 2 x Heater exhaust. breaker. (1) R-eplace control box ( 1 4 . correcting unsatisfactory operation figure 4-1. 4 . (See Table INTERVA 3PERATOR ITEM NO. Control Box Inspection. (fig.After Operation W . and shortcomings SHALL be recorded circuit breaker should and press press to when pressed.1 6 ) coolant hoses. Move exhaust cover plate away from ( p a r a 4 . 4 . ( p a r a 4 .) Remove from control box and remove control d.9 ) exhaust opening Generator radiator. f i g .During Operat M .-s mi Annual (500 hrs) ITEM TO BE INSPECTED PROCEDURE REFERENCE 1 Heater fuel shut- Open valves. Cover exhaust plate. Stop operation immediately is noted during operation which would damage or the end item deficiencies together form generator to which it is attached. in ~eve=d=of burning winterization kit. damaged missing Inspect threads. — Test. Install control box and connectors removal. connectors loose bent. 7 x Heater exhaust. 1-1 and 1-2) set 3 x Check for proper coolant level.the generator set. inspection manuals Series for and 35C2-3- maintenance requirements 4 . electrical connectors and attaching box. a. 10 Attaching hardwart Tighten hardware. (fig. DAILY — — B — x D — — A — ( i :( i 1-15 Preventive Maintenance Checks and Services B . Installation. of the fuel or 1-16. (1) Test the (2) Energize test c. Fuel (Sheet Burning 1 of 2) Winterization Kit C h a n g e 1 4-3(4-4 blank) .Figure 4-1. Figure 4-1. Fuel (Sheet Burning 2 of 2) Winterization Kit Change 1 4-5/(4 -6 blank) . ltct:l [’ (!olltrul Iwx. I?eplace heater. Circuit breaker open.8 ...8 .) if defective. ) if defective. (Refer to p a r a g r a p h 2. 1] h.8 . Pern]it heutcr to cool and restart. .- Circuit breaker open. a. voltage C[)l. -. ) if defective.8 . paragraphs bt)x. (Rei’cr to paragraph 2-24. Lf -“ Low ot e] ~aLI[: tu hf’ater. — Replace lamp. — ‘rest and I’ephce 4-15. -. Df:fcwtive generator pure. -. ) if defective. — box. b.) to batter] es.. (Refe~ to paragraph d. not ignite. a.. (Refer to p a r a g r a p h d. ) Defective control Replace 4 . t r i p p e d b . c. Defective controi c.) if deiwtive. Heater t’uel shut-off a.“ D e f e c t i v e h e a t e r . Heater will not a.1 6 5 . Switch positioned to a. in t’ucl (’ — Remwe restriction.8 . 4 .]. ‘b. E CAUSE CORRECTNE ACTION 1.- Reset circuit breaker. a. Heater does not a. .) operates valve not opel]. Fuel Burning Winterization Kit Troubleshooting MALFUNCTION I PR013AI+I. . (Refer to p a r a g r a p h fuel transfer 4.. . paragraph c. Replace 4 .rC4~[ i’dLISC L)] lltI[)rOf)er VOltEige. Replace 4 . — Open thermostat switrh. (!. c.8 . c .7 . ) (Next higher lwel of maintenan~ c. C1. D?iective ttl(’I’ll”l OSi&t switch. (Refer to 3. (Reier to p a r a g r a p h 4 . 1)(. — Replace 3 .1 3 . (Refer 3-82. (Refer to paragraph shutoff when switch is positioned (after to OFF purge cycle!. . Deacl generator set b. set d. . c. (Refer to 4 . a. ) (Refer to p a r a g r a p h Defective lamp. — Reset circuit breaker. ignite (fuel present). — Generator set i!]cl b. 4 . (Refer to p a r a g r a p h 5.) ( Refer to supply mhau st ed. e. Heater overheat switch a. ) if defective. c1 Test and replace paragraph 4-15. . Heater pump but will a. t).Table 4-2. — Ol)en [alve. Replace 4 . ) if defective. . — t c. Charge or replace 2-3 and batl cries. 2-3. — Adcl f[!cl as rwuireci. b.- Restri(tiutl supply. Press to test light does not illuminate when pressed. ) p a r a g r a p h ON and nothing happens.. Flow should Turn flow into a quart measure adjusting protective cover ( 7 5 . Remove protective cover (75. assembly (61. Test. — b. Remove 4 . one quart in 40 to 45 minutes. loose connections. 4-l). screw clockwise to increase flow rate a.9 . threads.l ) . 4-l). and proceed as follows: (1) Inspect damage. lines. b. (7) Inspect cracks. between wires and terminal pins with ohmmeter. replace thermostat switch (2) If heater indicator thermostat switch jumpered. fig. 4 . 4-10. igniter for broken coil or shorts. Service. To in starter condition. Resistance must be one ohm screw counterclockwise until motor starts. Heater Assembly Inspect.(5) Inspect graph 3-139). does not light with replace heater c. Service heater procedures in table assembly in accordance with 4-1. 4 . adjusting (4) Inspect Check resistance. 4 .l ) .1 ) or counterclockwise to decrease flow rate. and to restart heater. 4-2) light on heater control panel does not illuminate switch in approximately three minutes. f i g . fig. Service. Give screw clockwise screw adjusting an additional with igniter (180°) turn clockwise. position and attempt to OFF.3 ) apply 24 volts to solenoid. fuel tube assembly disconnected from ( f i g . f i g . 4 . fig. and fuel Adjust. breaks and other 4-11. Check for continuity and bent or broken terminals. 4-4).we protective (2) Inspect cracks. Time container. Inspect. a. T e s t . burned or damaged insulation. damaged ends or stripped (8) Replace protective cover (75. clockwise. 4-3).8 C h a n g e 1 . until motor 1/2 then turn adjusting stops. does not light. and fittings for threads. remove jumper (39. a. and no jumper is connected terminals of thermostat switch. Figure 4-2. fig. back off adjusting heard. set To test heater assembly switch to ON position DC are connected temperature and ascertain that 24 volts igniter. connect Jf heater indicator lights. terminal block and limit switch for adj~st micro-switch loose terminals or stripped cover ( 7 5 . Remove adjtist protective cover ( 7 5 . Fuel Regulator Valve Adjustment (fig. Flame Micro-switch Adjustment (fig. for cracks. cold.l ) . wiring harness (refer to p a r a - (6) Inspect connections thermostat switch for loose and bent or broken terminals. 4 . screw clockwise slowly until a click is Note the exact spot (screw slot) that this Then give an additional 1/2 (180°) turn (3) Inspect receptacle assembly for cracks. With ign~ter 4 . wait three minutes If heater indicator across a jumper. (1) If indicator (fig. turn To micro-switch in dynamic condition. fig. fraying. damage. hoses. f i g . Rem. 4-1) and disconnect fuel tube assembly at orifice assembly. (61. jumper (para If ambient across 4-5) to the heater is above 50°F attach terminals of thermostat switch. b . happens. 4-1). 4-9 .Figure 4-3. Removal. 4 . igniter fig. closes at 35 * 5°F. soliition and place thermometer a. Receptacle Assembly Replacement. remove fitting (2) If fitting is to be replaced. Vary the temperature of the solution to (1) Remove protective (2) Remove assembly screws (76) and remove receptacle det~rmine that switch opens at 155° * 3°F. (41. Fill a suitable container with antifreeze in container. Installation. Lines. leads 4-15. wires are defective. Removal. and reconnect tags. Place temperature sensing end of switch in Solutiom cover (75. above. (3) Remove screws (76) and remove recep- d. To install ele~trical switch. Q. 4 . tacle assembly (77) from br~ket. 45).1) Install receptacle assembly e. Removal. the harness must be rebuilt next higher level of maintenance. see f i g u r e 4 .1 ) and proceed as follows: ~. c. b.1 0 C h a n g e 3 . and (77) terminals from terminal board. Replace defective switch. assembly. 4-1). 4 . (1) Remove closing cock ~. “a. le~s and connectors from wiring harness f i g . Remove all harness clamps If 30% of the harness at and remove wiring harness. b. and plug opening until part is replaced. 4-13. 4 . a. Remove igniter from heater using a 7/8 inch hose or line being replaced after Hoses. Disconnect and tag electrical connections 4 . Install ign~ter. Connect using removal steps of a. f i g u r e Plug Figure 4-4. See figure 4-1 and proceed as follows: To replace cover (75.1 ) to be removed. Install hose assembly using reriioval steps m reverse order.5 . ins~all all harness clamps. c. Place wiring harness in position. Installation.4-12. remove protective ~. Installation. (77. Figure 4-5. reverse order.5 . above in connections removed in step a. Wiring Harness Replacement. Disconnect power lead to igniter. See figure 4-1 and proceed as follows: Tag and disconnect all electrical (4 or 11. fig. and refiove switch as illustrated in engine opening. and electrical Remove Thermostat Switch Testing Replacement. Igniter Assembly Replacement. 4-16. and connectors. igniter and reconnect power lead to b. socket or spark plug wrench. 4-14. fig. and Fittings Replacement. at any ambient it to from 125°F. G e n e r a l . (See sheet 2 of (5) Tighten complete. Remove con~rol cubicle plate from redr housing. Install f i g u r e of 1 . p a r a g r a p h 3 . to Refer to p a r a g r a p h 150°F. ~. thermostat and g. (4) Slightly 100S.) (1) Remove plug ( 6 4 . from three way 4 . fig. procedure using figure sequence of 1 through 69 of f i g u r e 4 . kit operating (1) Audibly check operative. The coolant temp- Perform all daily checks before operation preven- fter starting action erature tiv.Section III. plugs from engine cooler.3 and close coolant shut- Remove kit by proceeding ins~allatiori off cocks and service radiator. For wiring information. fig. To perform kit. and remove power cable from J49. 4-1) fig. and proceecl as follows: (2) Remove plug nipple (18.4 1 and drain cooling Connect hose (41) between nipple (18) and nipple (3 I). fig. Connect to J49 of kit 50/60 or 400 Hz single 1-26 or 1-27). 4-l). see initial installation 1-23. winterization kit consists of a heat expump. and retain lation of the electric fig.2 4 and energize the winterization kit and check kit operation of the kit may be obtained from any power source that supplies 205 to 240 volts at 50. to enable cab~e from an external (figures 208 to 240 volts power source the set in a heated 75% of rated load in one step within 20 seconds is initiated. c. 2-11. 60 or 400 HZ single phase. control box. Determine is heating. The kit can also be used to warm the Generator Set for initial starting within 5 hours at any ambient temperature down to -65°F.1 1 . (19. For electrical refer to winterization fig. 4 . 4-7) and install Connect hose (47) between OFF position c. Set electric control box POWER switch to p a r a g r a p h 3 . 4-20.W the hose coupling on the plugs.1 9 . disconnect and check as in element and Reconnect remaining element and check ~. P is instructions 4-18. place complete kit installation to assure there are no coolant leaks. with the heat exchanger. e.2 3 kit as described and illustrated in outp~t end of the heat exchanger the engine radiator). 4-7). the coupling when the test is 4-7. Refer to system. facing pressure using installation sequence 68 through 1 except as noted in (1) through (3) below kit and electric win- under figure 4-7 when fuel burning winterization terization figure kit are used together. fig. that kit coolant ~. in reverse order of 1 . R e m o v a l . 4-7) valve (67) and install nipple way valve (67. should flow from the union. maintenance checks and services listed in table 4-3. Coolant.4 1 and drain cooling To determine is functioning. (49. (2) Check f i g u r e 4 . a. step (3) above. ‘T. Remove and engine oil as ir. Retain thermostat housing that each heating disconnect element electrical lead from one element step (3) above. to -65°F. (3) Remove plug elbow (43. fig. ELECTRIC WINTERIZATION KIT 4 . (left side. Retain plugs. maintain accept temperature The primary purpose of the kit is to condition. see 4 . (69. Installation. heater control box POWER switch The electrical changer.1 7 . Refer to p a r a g r a p h 2 . NOTE ~. coolant h. fig. Refer to sys~em.6 . Connect hose To remove figure 4-7 between elbow (13) and nipple (69). fig. is thermostatically controlled at 130° F. b.1 ) . the electric winterization kit. Set electric to OFF position. 4-1) and install a.2 ) adj scent to Fault indicaDo not attempt to hold the hand in contact tor panel. Refer to electric as follows: p a r a g r a p h 2 . attaching hardware adj scent to for instal- WARNING (figure 1 . Remove two plugs from engine oil pan heat exc%anger.7 ) into three (70. phase power accessories. 4-7). of the electric 1-26 or 1-27. Power for operation ~. winterization control box ( 4 5 .7 except as lbow (43) and elbow (50).2 4 and removal 4 . winterization and 4-7 (3) Allow five minutes hand near the heat the heat exchanger for warmup and then that see f i g u r e s as follows: and proceed exchanger. 4 .Figure 4-6.1 2 C h a n g e 1 . 2 6 . Electric Winterization Kit (Sheet 1 of 3) 4-13/(4-14 blank) .2 6 . 1 / ( 1 . 2 b l a n k ) Figure 4-7.TM 5-6115-545-12 C h a n g e 1 1 1 . Figure 4-7. 4 - 1 5 . Figure 4-7. 4 - 1 6 . loose. Coolant shutoff cocks. Attaching hardwart Wiring harness. Power cable. 1 2 DAILY l’TEM TO BE INSPECTED Power cable. or missing pins of connectors. ?ighten lines and check ~ndition. nspect for frayed insulation and security of terminal lugs and damaged threads. ~ighten hardware. rest for proper operation.After Operation M .Weekly-(40 hrs) S . 5 6 .Before Operation D . A .Semi A-nnual (500 hrs) PROCEDURE :onnect cable to power supply. Electric Winterization Kit Preventive Maintenance Checks and Services B . 7 8 9 10 temove from power source.During Operation ITEM NO. )pen shutoff cocks. (para 4-22) (para 4-23) (para 4-24) Change 1 4-17 .lose all doors. (para 2-25 and 4-19) (para 4-22) (para 4-22) (para 4-26) 11 12 13 Coolant pump. . Heating elements.Table 4-3. Thermostat.heck for leakage.lose shutoff cocks. Senerator set doors.enerator set radiator. Coolant hoses Coolant shutoff cocks. 4 . pest heating elements. Coolant lines.Monthly (100 hrs) W . 1-1 and 1-2) (para 4-22) (para 2-25) 3 :heck for proper coolant level. bent. REFERENCE (para 2-25 and 4-18) (para 2-25) (para 3-41) (fig. . rest for proper operation. a. hose adapter (18) and replace (3) Disconnect (43) and elbow plug (19. kit and (See sheet 2 of (1) Disconnect elbow (69). (2) See coolant f i g u r e 4 . 35C2-3Series for periodic preventive table 4-3 for detailed verification and is performed maintenance procedure. (40.1 and check for leaks. (See f i g u r e s the leak just created If the leakage defective rate does not increase. in accordance Preventive To insure that the electric winterization for operation at all times. 4-l).8 . SHALL be recorded together with the corrective action on the applicable opportunity. elbow (43) and replace ~. 4-1) hose (70) from elbow (13) and nipple (69) from three way valve and install plug (64) into three way valve (67). FiLl radiator with proper coolant table 2 .) kit. ” it must be inspected systematically that defects may be discovered they result in serious discovered damage and corrected or failure. when installed kit is ready on the so generator set. fig. Brushes should be at least pump assembly (40). tion has ceased. deficiency damage Stop operation is noted during operation which would the kit or the end item generator to which it All deficiencies and shortcomings is attached. 4-22. Inspection. 1-26 or 1-27. (3) See f i g u r e 4 . (47. Remove plug (49.7 and inspect motor assembly pump for leaks. Remove (67. the fitting loosened in step (2) Testing. and correcting unsatisfactory operation or (3) Set heater control and observe switch to ON position in step (2) above. (2) Disconnect hose (42. brushes (2) and connector (4). bent pins or damaged 4 . witii 4-20.8 and check connector (4) for a. Refer to p a r a g r a p h 4 . Replacement. and 4-6. 4-1) from elbow (50). the pump is isolating. before Defects during operation of the kit shall be noted to be made as soon as operaimmediately if a Figure 4-8. requirements and (1) Set heat control switch to OFF position.1 8 C h a n g e threads. for future correction.) kit are used together. fig. Maintenance. plicable the T. T a b l e 4 . fig. (2) Crack the fitting coolant on the output of the pump until a very slow leak is observed. fig. Coolant and Pump and Motor Assembly Inspection. Troubleshooting. form at the earliest possible b. remove brushcap (1) and or 1/4 4-23.8 to remove and replace worn for overheating and inspect coolant loose connections and loose mounting. 4-21. e. wear. fig. 4-7) Coolant testing pump and motor assembly consists of an operational as follows: Air Force users shall refer to the ap- inspection manuals and work card sets in O. Proceed as follows: ~.4 provides information useful in diagnosing. (1) See or damaged f i g u r e 4 . (2) See f i g u r e 4 . fig. Inspection. Replacement.7 to remove and replace check motor brush and spring (2) for damage excessive inch Long. Proceed as follows: (1) See f i g u r e 4 . 4-7) from nipple (18) and elbow (31).1 8 and replace plugs and plates removed during installation. and must be replaced. (4) Tighten above. fnspect the thermostat switch (9.noted below when fuel burning winterization electric winterization figure 4-7. Testing and Replacement. Remove 4-7). failure of the electric winterization 1-23. Thermostat Switch Inspection. 1 . Testing. 2. fig. Blown fuse. Power cable not connected to power supply. Replace thermostat switch as (9. (2) Check hoses and pipe fittings for all hoses for cracks and coolant Inspection. heating and must be replaced. (9. should be indicated between terminals up to 150° ohms. frayed wires. a. figure 4-7 and proceed as follows: into both ends of electric win- terisation pipe (10). Testing. a. tWspend ing end of switch in water.1 9 . c . Defective heater elements. proceed as ~ollows: (1) Remove (2) Fill a container thermometer in water. Electric Winterization Kit Troubleshooting MALFUNCTK)N PROBABLE CAUSE CORRECTIVE ACTION 1. c. R e p l a c e m e n t . coolant pump iqoperattve. R e p l a c e m e n t . (1) Check (1) Check that heating elements are screwed securely (6. a. a. & Inspec tion. Replace switch (para 4-23). Reset circuit breaker (para 4-27). — Replace pump and motor assembly (para 4-22). b. d. Reading case (3) Heat water and check switch for continuity. See See figure 4 .7 and proceed as follows: a. d —“ a. fig. with clean water and place temperature sensof heating element electrical (6. Defective control box. Heaters inoperative. Defective lamp. c. Connect power cable. ~. Defective pump. resistance between heating element +5°F and open thereafter. (4) If heater not satisfy above (5) If switch be replaced. 4-24.7 . Observe water temperature. fig. 4 . and nothing -s. e l e m e n t s ( 6 ) a s R e m o v e a n d r e p l a c e i n h e a t i n g 4 . c. 4-7) leaks. Replace fuse (para 4-28). Thermostat switch.7 ) for loose connection. control box POWER ON switch ON. elements are secure and protective is installed. Replace wiring (para 4-26). HEATER ON indicator inoperative. b -“ c. Heating Elements Inspection. 4-7). it should defective element resistance check does element is requirements. b. Switch continuity should indicate an open circuit. Defective motor. (2) Use a multimeter between heating element and check resistance and terminal. a. Table 4-4.f i g . 3. b. a. Repair and Replacement. Resistance should be between 27 and 33 (4) Permit water to cool and observe that continuity is again indicated at 130° +50F. b —’ Replace elements (para 4-24). 4-7) and Testing. and loose mounting. Replace if defective (para 4-27). b. fails to meet above tests. b. To test heating element. Defective wiring. c . 4-25. corheater (2) Check that electrical connections to both sleeving rosion. Testing and Hoses and Fittings Inspection. Replace brushes and/or connector (para 4-22). 4. 4 . Replace lamp (para 4-28). lead from one terminal 4-7). fig. i l l u s t r a t e d f i g u r e illustrated Replacement. (3) Check terminals. a. (1) Remove thermostat switch plug heat exchanger opening. Circuit breaker open. Repair. in position. heating element shutter control. by and remove wires are defective. Control Box Inspection. multimeter. replace harness cra?ked mounting or loose ty-wraps. Install hose assembly using repair control box at next higher level of maintenance. evidence of damage. and Replacement. tighten wiring clamps and tighten all electrical connections. Test control box as follows: fitt~ng as follows: (1) Removal: (a) Close heater system shutoff cocks. See figure 4 .. 4-7) for or loose ty-wraps. direct maintenance (2) f i g . (1) Removal. c. Place wiring harness (59.If continuity is-not removed. loose and loose connection to ‘co’mpo- (2) Inspect loose. remove the should be approx- of fuse. opening of circuit should fitting and plug opening until part is replaced. nents and plugs. Inspection. 4-7).9 . Testing. Repair. (2) Installation. f i g u r e 4 .7 ) to be removed. wiring harness connectors for bent or missing pins. breaker to close position. and power switch for loose mounting c. at Install red sleeving (6. Proceed as follows: (1) See for loose looeeness. b. Resistance (c) If fitting is to be replaced. cracked (59. If 30% of the harness the harness must be rebuilt level. Removal pins J49-A and J49-B. over each wire terminating fig. Testing. cir- b. damage. (1) Set circuit (2) Set switch (3) imately Using 7 ohms. (2) See assembly. Remove tags. fig. indicator cuit breaker. Replacem mt. removal steps in reverse order. replaced. Tape frayed insulation. Repair. 4 .7 ) Installation. and inspect fuseholder light assemblies.7 and proceed as follows: Inspection. f i g u r e 4 . 4-27. breaker. b. Replace a hose assembly or and other damage. not-rep= Hoses and fittings are to be fuse. 4 . install all harness clamps. check resistance across (b) Remove hose aseembly being replaced. Replacement. 4 . Wiring Harnesses Inspection. See f i g u r e Figure 4-9. 4 . har-ness clamping. loose connections. (1) Inspect wiring harness frayed insulation. adjacent to the manual leads and Reconnect electrical connectors.4-26. to ON position. cal leads and connectors from wiring harness f i g .7 and inspect control box (45) and other mounting. or setting switch to OFF position remove continuity . Tag and disconnect all electri( 5 9 . and Replacement. and coolant leaks.7 and proceed as follows: a. a. Remove all harness clamps wiring harness.2 0 . The wheel the-engine mounting kit is provided to enable set to become mobile. 7. a. 19. 4. Preventive Maintenance. 24. Clevis Clevis Brake Lube Pin Lever Bearing Shaft Tie Nut Cotter Nut Tie rod end and knuckle pin rod rod fitting be record& with the corrective action on the applicable form at the earliest possible opportunity. Grease and correcting unsatisfactory mounting kit.8 a n d 4 . 4-35. parking brake. Air Force users inspection T . Replacement. 25. For wheel mounting kit operating instruc- that wheels (3) are securely mounted. The mechanWheels and ical parking brake locks rear wheels against rotation and is actuated by a hand lever located rear of the kit. 29. 30. see Press to test f i g u r e (2) Installation. a. 4-31. Stop operation ency is noted during operation which would damage the kit or the end item generator to which it is attached. See figure 4-9 to remove and install control box (1) Removal. at the right See figure a.2 9 . not illuminate. and corrective maintenance in of the various 4-5 and of the kit as described 4-33 through Tires. service. safety chains. See mumimeter. Disconnect 4-7) two wiring harness lamps and fuse. Fuse. four capscrews (44) which secure box to check panel and remove control box (45).Series for periodic preventive maintable 4-5 for detailed tenance requirements and procedure. 4 . 13. 12. WHEEL MOUNTING KIT 4 .2 6 . 10. before they Defects dis- covered during operation of the kit shall be noted for to be made as soon as operation immediately if a deficiKEY to fig. replace fuse. When the wheel mounting kit is installed gen%rator on the of (1) Visually inspect tires (5. 8. 4-32. Screw two harness (59) connectors to receptacles at indicator does not illuminate. b. 18.9 and again. The Inspection. O . (figures 4-10. 6.3 . 4 . 4-10) to set. Lamps. ml deficiencies together and shortcomings SHALL 1. Using continuity. 4-10. Nut Washer Wheel Tube Tire Nut Washer Bolt Cotter Pin Tow Cotter Pin Cotter Pin Nut C h a n g e 1 4 . Control Box Fuse and Lamp Testing and Replacement. shall refer to the applicable manuals and work card sets in the 3 5 C 2 . 15. systematically and corrected or failure. and repair 4-11 and of the wheel 4-12) consists of generator mounting kit preventive components paragraphs 4-33. G e n e r a l . 2. 27. Service with compressed air as tor set. assure there are no cuts on the sidewalls each tire has good tread. wheel mounting kit consists of two detachable wheelaxle assemblies. 21.7 ) ~ wiring Secure control box ( 4 5 . Section IV. it must be inspected defects may be discovered result @ serious damage future correction.6 contains information useful in diagnosing operation of the wheel 14. 11. tions.9 for and remove fuse. test. Inspection. pro~eed as follows: See f i g u r e s 4 . Check and that clearance of 8 inches and front wheels turn for steering. refer to p a r a g r a p h 2 .2 1 pin pin pin 17. and towbar. 3. (2) Check tires for proper air pressure pressure gage. fig. is not obtained. has ceased. The front axle wheels are free to pivot up to 40 degrees for steering. lamp 4 . 26.c. table pintle. ind~cat~s replace lamp. 16. Troubleshooting. If an Press to test each indicator. 9. 22. assembly at next higher level of maintenance. T a b l e 4 . 20. replace indicator light rear of control box (45). f i g . If continuity connectors Unscrew fig.9 and 4-28. Spindle 31. from rear of control box. fitting . 28. Tire pressure using 4-30. (59.1 0 and proceed as follows: Test and Service. E to panel with four capscrews (44). 5. a standard tire should be 60 psi. 23. f i g u r e fuse 4 . To insure that the wheel mounting kit is ready for operation at all times. Kit Maintenmce Procedures. the set may be towed a maximum The kit has a ground 5 mph on paved highways. b. when installed on the generaso that required. Figure 4-10. 4 .2 2 . Lubricate points. inspect for evidence alignment. or wear. 11 for uneven tire while wear or if trailer wanders being towed. Check for proper operation. (fig. (para 2-26) x Wheels. (fig. 4-12) 14 King pins. (para 4-37) 13 x Tow bar assembly. steering linkage and pivot (para 3-3 and 3-4) 5 Wheel bearings.Table INTERVA )PERATOR ITEM NO. 7 x Kit to generator skid base attaching ware. and (para 2-26) 4 Steering linkages and pivot points. tnspect for wear. fnspect linings for wear and adjust (para 4-35) brakes. hspect tires for cuts. Lnspect for wear.During Operat m A . (para 4-33) 11 Wheel alignment. (para 4-34) 6 Attaching ware. 2 Tires. 1 0 for ex- (para 4-33) cessive tire wear or uneven wear. Check front wheel toe-in. Inspect security of wheels. (para 4-33) 3 x Safety chain.After Operation W Weekly (40 hrs) M . breaks and blisters and evidence of deflation. inspect. 4-12) C h a n g e 1 4 . hspect safety chain for condition proper connection. Perform Item No. B DAILY — D — — A — 4-5. hard- I’ighten hardware.Monthly S - (100 hrs) mi Annual (5OO hrs) ITEM TO BE INSPECTED PROCEDURE REFERENCE 1 x Tires. Check wheel alignment. :lean. (para 4-36) 12 Front wheel toe-in. excessive deterioration.2 3 . 9 10 x Handbrake. 15 Tie rod ends. mis- (para 2-26) and freedom of movement. hard- Zheck for security and tighten as required. Note: Perform I t e m N o . Wheel Mounting Kit Preventive Maintenance Checks and Services B . and lubricate. hardware (para 4-42) 8 Wheel brakes. of damage. Service tires.Before Operation D . when Jack generator (3) Place suitable generator 4 . fig. 4-34. cable service manual for repair of pneumatic (2) Install wheels trated in Do (3) Remove support blocks. (1) Refer to Appendix W A R N I N G A for listing of applitires. Wheel Bearings. observing the instructions steps (2) and (3) below. (3) and tires (5) as illusin ~. 4-10) and proceed as . (2) Block wheel to prevent movement generator set is jacked. lower generator set and remove jack. (1) Remove trated in f i g u r e wheels 4-10. figure 4-10. (3) and tires If parking brakes must be released to perform maintenance jacked. b. suitable blocks under skid base and lower skid base on blocks. Place as described follows: in set and remove wheel paragraph 4-33 (3. — Removal.Figure 4-11.2 4 set and jack jack under skid base of wheels off ground. release when generator prior set is (5) as illus- brakes to jacking. Repair and Replacement. not perform maintenance on a jacked gener- ator set unless it is properly blocked. Wheel wobbles. a. (Refer to p a r a g r a p h 4 . conforming to 2. (5) and (11) are not binding.3 5 .3 3 . pin (2) and grease cap bearings it is free to rotate and ings and cups are matched sets. fig. Install c. Tighten hardware. and Repair. Service. ) Improper tire pressure. Tighten hardware. loose. cups and seal. smoothness of rotation and cups (13) and (12) for pitting. e. 3. Correct tire pressure.1 2 observing the following: 4 . See f i g u r e 4 .3 4 (3) Replace d .1 2 ) ( 1 7 a n d 1 8 . and other cap (0. for cracks. Adjustment. outside and inside diameter of grease seal (10) and axle. hardware b —. Remove f i g u r e wheel 4 . a. (4) Repair by replacing defective parts. fig. c. Improper tire pressure. (2) Install bearing cups (13) and (12) and the same diameter as drum (14) using drift and hammer. Abnormal tire wear. Wheel Mounting Kit Troubleshooting MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION 1. Correct tire pressure. Tighten lug nuts.2 5 . Kit tends to wander. remove support blocks. (1) Clean parts with ral Specification a cleaning solvent. as illustrated in Do not remove bearing and drums (14) are free of grease prior cups (13) and (12) unless they are found to be defective at ti~e of inspection. a. b —. (Refer to 4 .3 3 .Table 4-6. Defective adjusted or improperly wheel bearings. Correct wheel alignment. Installation. — Alignment. b -“ Lug nuts loose.) wheel bearings.1 2 . Bent wheel. as Illustrated in f i g u r e 4 . ) p a r a g r a p h b —“ Axle assemblies mounting loose.3 3 . Inspection. b —. Bearcotter Back off nut until next cutout in nut is aligned with pin (2) hole in axle. washer (4) and nut (3) and adjust p a r a g r a p h P-D-680. a. a. (Refer to paragraph c. type A. 4-12) until it is snug. ) p a r a g r a p h b.ings (5) and (!11) as follows: (1) Tighten nut (3. Removal. grease seal (10) using sleeves ~. d. Correct tire pressure. a. (3) Install new cotter (l). Tap cups (13) and (12) from / to installation. (Refer to 4 .3 3 . Fede4 .1 2 ) for bea. graph 4-36. (2) Spin wheel to ensure (5) Pack bearings with grease Federal bearing ~ecification W-G-632. Kit pulls to one side. Jnstall wheel bearings (5) and (11) wheel on axle. ) Improper tire pressure. Wheel brake dragging. a. and dry thoroughly. ) p a r a g r a p h b —“ 4. a. (Refer to 4 . Adjust or replace 4-34. breaks. (Refer to p a r a g r a p h 4 . wheel bearings (5) and (11) as specified in prior to installing cotter pin (2) and grease (2) Inspect damage. Axle assemblies ing hardware mount- b —.1 2 and adjust wheel (3) Inspect bearings (5 and 11. c. a. 4 . c. Adjust brakes. low% generator set and remove jack. Replace wheel. grade Apply light film of grease to running surfaces of cups.) (Refer to p a r a - 2. bearings (5) and (11) f i g u r e (1) Ensure brake shoe linings 4 . 4 .Figure 4-12.2 6 . 4 .Figure 4-12.2 7 . is 1/16 of an inch or less. fig. a. 4-10. p a r a g r a p h a. film of lubricating oil. generator set and remove jack. 4-12) from wheel brake using a plate (29) before attempting brake adjustment bolt (22). below. bolt six ratchet clicks. Place the trailer on a hard. fig. (5) Adjust wheel bearings. 4-10 4 . p a r a g r a p h and-hand lever and bracket in f i g u r e s following: and assembly as illustrated 4 . Federal Specification P-D-680. wise. (2) Ensure brake shoes (17) and (18) and drums e. Specification MIL-L. conforming to ( 2 9 . (3) Rotate brake clockwise adjustment bolt (22) counter- until shoe is snug against drum (14).1 2 ) brake shoe contact areas. Lubrication. fig. (4) Apply (2) Inspect damage. except brake shoes.1 2 observing the e.010 of an approximately (1) Clean cleaning parts. Military Specification MIL-G. Using the straightedge.1 1 . 4 . 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 use hollow punch to tap spring clip onto plate stud (29). cloth. See f i g u r e (4) Replace defective parts. are not aligned.10924 to stud plate fig. 4 . breaks. brake s“hoes shall Alignment. and level sur~ace. fig. NOTE (2) As necessary. Rotate wheels to ensure they turn freely. flat. Cleaning and Inspection. (5). 4-12). Adjust wheel brakes as follows: 4-12. d. Installation. (Refer to paragraph 4-37. set as specified in p a r a - NOTE (2) Remove dust covers Pry spring clip (15. Wheel for cracks. 4-12) off stud stud plate (29). brakes as illustrated in remove figures components 4-10 and of wheel Adjustment.) ahead position. Clean shoes with clean lint-free between shoe and drum. if brake lining 4-36. If the front and rear wheels refiove the cotter pin ( 2 7 . (3) Install assembled as illustrated in f i g u r e s wheel and drum assembly and 4-12. 4-11 and assembly as illusobserving the 4-12 (29) and tie rods (25). (1) As necessary. remove components of hand f i g u r e Each brake shoe (17) and (18) must be adjusted individually. 4 .2 8 . Removal. Install components of wheel that secure each tie rod end (29) to the spindles and knuckles (30). Wheel Brakes and Hand Lever and Bracket 4-11. out on the tie rods (25) until the tie rod ends (29) are aligned with the holes in the spindles and knuckles (30). install components of hand f i g u r e A s s e m b l y . This will provide inch running clearance dry thoroughly.3 3 . refer to e . (4) As necessary. (23. Loosen the nuts (26) that lock the tie rod ends (29Tto the tie rods (25). be replaced.3 4 . Use a straightedge position across the sides of tiie front and rear wheels to check that the front (2) Apply Military (20). with and Back-off adjustment solvent. clock0. wheels. to remove brake adjusting lever and bracket assembly as illustrated in b. with the front wheels placed in the straight(1) Apply thin film of grease. refer to 4 . Remove 4-11 components of wheel brakes (6) Adjust wheel brakes. (1) When installing spring clip (15. Disengage the tie rod end ball studs brfies and hand lever and bracket trated in following: figures 4-10.4-35. Lower (3) Inspect thickness linings for wear. and other and release brakes. b.15016 to threads brake adjustment bolts (22) and side slots in wedge c. Adjust each tool. Turn the tie rod ends in or (14) are free of grease prior to installation.1 0 and check the alignment of the front as follows: wheels to the rear wheels proceeding c. lever and bracket assembly as illustrated in Jack generator set as described in Proceed as follows: p a r a g r a p h 4 . graph (1) Jack generator 4-33. conforming of to wheels align with the rear wheels except for a small amount of toe-in. and nut (28) 4-10) d. the operator reduces the load bank load with the ‘% load selector b. For load paragraph 4-39.5 KW increments 2! percent operation of the load capacity (30KW) and permit switch closes with temperature at 450m F +. mark the front center of f. 1-26 or 1-27. ture within load ch@es in load from O to 50 percent of the generator of set KW ra$ing (60 KW) in four 7. ~. above). The load bank is a balanced When the generator set load diminishes is reconnected perature protection reset by manually switch. tie the distance between The measured marks when at the the marks rear must exceed the distance between when at the front of the wheel by 1/4 inch. at either 120/208 or 240/416 volts. a. If sets by the load bank reject con- set control rated load capacity or removes is exceeded. Position sur~ace. set rises to and remains at 125 perof the maximum load b Set —“ % LOAD SELECTOR switch to OFF.3 7 . Disengage the tie rod end ball studs (29) and figure and check and adjust the front wheel tie rods (25). The thermostatic switch operates the trip coil the applied to load bank heating elements. bank operating instructions. power on indicator lamp indicates when ac power is f. ) Thus. The load bank rotary selector switches permit . Secure with the c. fig. load bank reject control system into system. The generator tected against overloads trol system. the load measuring nected to the generator set load terminal board via A load bank the load bank four wire power cable. even a. A fan and motor assembly provides for cooling the~oad bank resistive load (heater elements). pin_(27. tighten in as directed above p a r a g r a p h 4 . 1 4-29 cent plus or minus five percent C h a n g e . The mefits) purpose of the resistive load (heater ele- is to provide a partial load for the generator utility load is too low to keep set of the engine. g. remove the cotter 4 . Using a straightedge along the sides of the the vehicle on a flat. 4-37. If the combined exceeds 509+ of the generator set capacity the load measuring unit applied 2-27. b.15° F. hard. the load bank thr~e phase. of t~e over temperature selected reset switch removing load from the generator set when temperabank reaches 450° F +. unt~l the marks are positioned wheel. 1-2. fro fit and rear wheels. (The load the generator reject relay trips when the total current of the generator in any phase ~.3 6 above and reconnect the~ire tread at each front wheel. Stop generator set. refer to put (utility load plus load bank). bank capacity. Using yellow crayon. Again measure distance slotted hex nuts (28). the utility load continues to be supplied without risk of generator set overload. Carefully measure the distance between the marks. position the front wheels so they are correctly aligned with just sufficient toe-in with the wheels positioned in the straight( p a r a g r a p h ahead position. toe-in as follows: e. of 60” KW. The load bank is cone. The load bank the-automatic special purpose cable connects rotary switch. Check wheel alignment 4-36). L O A D B A N K 4 . to the load reject relay via the tactical relay box trips the load reject reset switch See figures 1-1. set if the normal of automatic load reject or manual During automatic operating without carbonization mode of operation. set is pro- resetting the over temthe manual mode is During of the generator set against overloads at 50/60 HZ and 400 Hz. Adjust the tie rod ends (29) on the tie rods (25) as directed in p a r a g r a p h the tie rods. the load measuring unit senses the generator set outload h. (refer to s t e p c . Push the vehicle backwards in a straight line at the back of the between marks. Recheck the wheel alignment and%heck the toe-in as directed If both are correct. A load selection reject reject toggle switch provides for mode mode. and 4-13 and proceed as follows: relay which trips the over temperature trip coil (3 phase magnetic the selected load from circuit breaker) removing set. the responsibility generator of the operator by monitoring the panel KW meter. four wire resistive type load which is used to maintain the generator set load at approximately half-load at 120/208 volts and 240/416 volts. 4 .1 3 ) . 1-21. See Front Wheel 4-10 Toe-In Adjustment.3 8 . Section V. (See f i g u r e 4 .f. Insert the tie rod end ball studs (29) into the spiiidles and steering knuckles (30). G e n e r a l . Installation. the nuts (26) between rods (25) and tie rod ends (29) and install the cotter pins (27) that secure the ball stud nuts (28). d. If the toe-in is not correct. The c.1 0 ) and nut (28) that secure each tie rod end ball stud (29) to the spindles and knuckles (30).15° F and opens with temperature at 3510F + 15~F. ceptacle housing J81 (7) and cable is clamped (5) to load bank (95). 4 . inspection and work carcl sets in the d. Remove loc<ted the rear top left side screw and nut and. to be made Stop operation immediately during operation end item ficiencies which would damaget hekit to which it is attached. and shortcomings SHALL be recorded 4 . it (2) Select must be inspected rediscovered systematically so that defects may to MANUAL.1 4 ) purpose to tactical damage. 3 . Unless otherwise ~. and six nuts provided on set. Ensure four wire power cable (12) to load bank housing (95).3 0 C h a n g e 1 2 .8 anti f i g u r e 4 .4 . 4-42 b . with the VOLTAGE SELECTC)R switch. generator load connected.3 - Series for and maintenance requirements on the generator set housing 4 . i. See f i g u r e 1 . special purpose cable (6) and fou~ (13) clamps (5) and (12) for the cable clamps which secure special purpose cable (6) and four-wire power cable j. ( 6 . and four-wire power cable (13) from the load fraying. 2 .c. e. to the load terminal board terminals as follows: Wire color Load terminal (2) fnspect Green Black White Red LO L1 L2 L3 cable 70-1212 plug p51 from tactical (3) Inspect wire power cable looseness. 12 lock washers. cable relay plug box of the load terminal 3 . p a r a ~. special 4 . mount the load bank loop clamps screw provided. before they result in Defects discovered ciur- . fig. Run both cables generator set. 12 lockwashers. six nuts securing load bank to housing for looseness. 4-42.1 6 and proceed ~. and re~onnection panel 120/208 or 240/416 theload bank voltage selector switch e n.2 4 ) for loose wire connections and for ~. and sleeve assembly hole Inspection. bank LOAD REJECT switch voltage corresponding to the gene- andcorrected or failure.7 for detailed procedure. loosely periodic table preventive 3 5 C 2 . P50 to Connect cable in J51. asoutlinedin (1) Set the load To insure that theload bank kit is ready for operation at all times.1 4 ) 3-24) - specified. ~. 2-4 panel 120/208 or 240/416 serious damage ing operation rection. Air Force manuals load bank to the housing using six screws. plugs P50 and p51 for proper mating with receptacles. special purpose cable 70-5098 plug p81 Table 4 . Ensure (6. Inspect the special purpose cable ( 6 . to the housing with 4-41. f i g . ensure generator load bank (13) and (6) through the plate (fig. Select J51. position and secure the gether with thecorrective form at the earliest refer action on the applicable opportunity. (4) Inspect special purpose cable (6) and wear in the purpose plug J51 cable plug four-wire power cable (13) for excessive vicinity of clamps (5) and (12). board (5) Jnspect the terminals (fig. (7) fnspect six screws. purpose cable ( 6 . O .1 4 (1) Inspect thespecial bank for cracks. Preventive Maintenance. Run the load bank four-wire power cable (13) WARNING and special purpose cable (6) through the loop clamps ( s t e p d . is noted or the All deto(4) Refer to p a r a g r a p h tor set with no external 2 .9 and proceed as (fig.1 5 ) into the engine set is stopped prior to performing maintenance procedures. Perform test procedures graph 4-40. above) and tighten the screw and nut securely.1 2 and start genera— (3) Set the ‘? LOAD SELECTOR switch to OFF. Inspect the load bank as follows: ( 1 3 .4 ) with 2-9).1 3 provide information useful and correcting unsatisfac- 4-14) is connected to load bank harness re- in diagnosing. See f i g u r e s as follows: 4-13 through 4-14 and 4 . See follows: f i g u r e 2 .1 4 ) voltage corresponding to generator (fig. set (6). or failure uf the load bank. tory operation isolating. P51 Connect f i g . ( f i g u r e 4 . a. and other damage. possible users shall to the applicable T . Troubleshooting. Connect the four-wire power cable wires f i g . when installed on the generator set. breaks. rator set reconnection (fig. discon- nected s t e p above. Testing. of the kit shall be noted for future coras soon as o?eration if a deficiency has ceased. Disconnect (13) at the top left of the housing for looseness. special 70-1212 j . (13) is clamped Kit Maintenance Procedures. receptacle m.2 1 and. f i g . relay box receptacle ~. 4-31 Figure 4-13. . Figure 4-14. Change 4 4 .3 3 . 45. 56. 30. 22. plate 48. 31. 10. 66. 94. 18.Figure 4-14. 4. 67. 24. Rivet Instruction Screw Nut Harness Special cable Wiring (J81) Screw Cover Screw Nut Harness cable clamp power harness clamp purpose plate 26. 5’7. 47. 77C. 90. 84. 77B. 77. 62. 94B. 3. 59. 85. 43. 35. 21. 79. 49. 86. 32. 15. 52. 63. 44. 5. 29. 9. 42. Screw Adjustable Panel Nut Screw Washer Spacer Terminal Nut Screw Terminal board Nut Screw LockWasher Washer Capacitor LockWasher Nut Washer Screw LockWasher Washer Capacitor Lockwasher Screw Nut Terminal Nut Washer board nut resistor 80. 60. 92. 34.3 4 Change 4 . 40. 17. 87. 91. 53. 7. 68. 50. 64. 20. 55A. 77A. 58. 25. 61. Packing Escutcheon Screw Plate Screw Nut Screw Nut Washer Bracket Voltage Nut Washer Nut Load Nut Screw Fan Nut Screw Fan motor breaker Screw Circuit Lens Bulb Nut Washer Nut Base l guard ‘ reject switch selector switch plate 55. 38. 27. 2. 23. 70. 33. 12. 65. Nut Screw Screw Nut Thermostat switch Screw Nut Bracket Nut Screw Heating element Screw Nut Screw Harness clamp Harness clamp Wiring harness Screw Rectifier bridge Load bank housing 13. 89. 81. Four wire 14. 84B. 54. 8. 94A. Grommet Screw Cover Setscrew Knob Packing Escutcheon Screw Plate Load switch Setscrew Knob 4 . 69. 11. 28. 37. 46. 19. 6. 76. 88. 78. 95. 82. 39. ’75. 83. 16. 41. 84A. 71. 73. 36. selector 51. 72. 93. 7’4. 1. Weeklv (40 hrs) M . (para and (para 4-44) 4-44) 7 x Air outlet and fan.( i 4-7. Inspect for security damage. hspect for wear and refer to next highe maintenance level for replacement (para 4-44) (para 4-44) 9 Inspect circuit breaker for positive action between connections. Tighten hardware and inspect cables (para 4-42) ware and cables. Wiring harness. 4 and tight en as necessary. for proper operation. wiring connections Test for proper (para 4-44) between and damage. Test (para 4-48) and wiring connections. 11 Inspect for deterioration and para 4-44) looseness. hardware (para 4-46) 14 Thermostat. positions. 2 for wear and security. 16 Fan motor assembly :nspect for security physical damage of mounting and (para 4-44) 4 . Inspect for foreign material.3 5 . operation. 12 Test for proper Load reject re!ay. hardware. Indicating light and lamp. wiring darnage. (para 4-45) 13 Terminal board. lugs and damaget loose. 8 Fan motor brushes.During Operation lTEM TO BE INSPECTED PROCEDURE REFERENCE 1 Kit attaching hard. and loose of mounting wiring connections. Test for and proper operation. . Rotary switch. and (para pins 4-43) security threads. Inspect switches for positive action positions. operation. hspect for loose mounting and tighten as necessary.Monthly (100 hrs) s:mi Annual (500 hrs) D . Inspect for foreign material damage to fan. Test for and wiring (para 4-47) proper 15 Heater elements. Over temperature reset switch circuit breaker. Inspect switch for positive action positions. 6 x Fan guard. operation. 10 Fan mounting grommets. B DAILY — D — — A . kspect for loose mounting connections.Table INTERV. 5 Load reject toggle switch. 3 Control panel Inspect for loose mounting hardware (para 4-44) assembly. DPERATOI ITEM NO. Load Bank Preventive Maintenance Checks and Services B . Inspect for frayed insulation of termj. Inspect wiring connections (para 4-44) for looseness.nal bent.Before Operation A . Inspect lens and lamp for looseness and damage. hspect for loose attaching damage. operation. wiring connections Test for proper (para 4-44) between and damage.After Operation W . or missing of connectors. 4 - 3 6 .Figure 4-15. b. b. Defective switch. a. a. a. c. Defective assembly. a. (Refer paragraph 4-43. b -“ Repair or replace to paragraph wiring harness.) 4 . Fan and motor aesembly not operating properly.) if defective. 4-44. required. Test switch paragraph and replace 4-44. wiring harness.Table 4-8. Defective load reject a. Repsir to or replace wiring harness. Load bank does not disconnect from generator set with rated kilowatt meter above 30 W while in automatic mode. — Defective assembly. of maintenance. a. a. Repair or replace to paragraph wiring harness. c.3 7 . c. Defective load selector b -“ Test to and replace switch if defective. 4.) if defective. (Refer to paragraph b -“ Defective light. Over temperature reset switch does not remain engaged in ON position while in automatic mode. (Refer to paragraph Defective wiring harness. (Refer paragraph 4-44. Over temperature reset switch does not remain engaged in ON position while in manual load reject mode. (Refer to ture reset switch. fan and motor a. fan end motor a. Repair or replace 4 .) 6. d. wiring harness. thermostat b -“ Test switch paragraph and replace 4-47. b -“ Test light and replace 4-44. Test assembly level and refer to next higher if defective. Load Bank Troubleshooting MALFUNCTION PROBABLE CAUSE Corrective ACTION 1. ) (Higher level of maintenance Repair or replace to paragraph c. defective reject relay.) 2. Test switch and replace if defective. Defective over tempera- c. load required). (Refer to c. load reject a. me as 2 above. load reject a. Load bank does not apply load to generator set.) c. Test lamp snd replace 4-44. Check fan and motor assembly for proper operation as in 5 below. (Refer to p a r a g r a p h 3. Indicator does not illuminate when load back is in operation. ) wiring.) if defective. Defective lamp.) if defective. (Refer 4-43. Refer to malfunction 2 and 3 below. (Refer 4-43. Test relay and replace of maintenance if defective (higher level within load limits of 30 W. Defective wiring harness. If rated kilowatt meter b.) b. Same as 2 above. Refer to malfunction and 3 below. b -“ Defective switch. Defective switch. (Refer to paragraph wiring harness. 2 a.) 5. b -“ Defective diode bridge. d -“ Defective wiring. b -“ Test bridge and replace diode(s) if defective. (Refer 4-43.4 3 . c. Over temperature switch does not disengage when temperature exceeds 450° F + 15°F.1 4 and proceed as Tolloww. replace cra%ke=oose t y-wraps. (Higher level of maintenance required. (1) Removal. 9. See f i g u r e 4 . ) Test bridge and replace diode(s) if defective. Defective wiring harness. Repair or replace wiring harness.5 percent. CAUTION If load bank is not removed immediately when loads exceed 30 KW.) Defective heater element(s). The load bank fan shall operate. — b -“ 8. Repair harnesses in accordance with para 3-139. c. (9) Refer to p a r a g r a p h 2 .Table 4-8. (92) and (93) and the wiring harness. Inspect harness for frayed insulation. a. (Refer to paragraph 4-44 d . (12). replace lug. (Refer to paragraph 4-43. b -“ CORRECTIVE ACTION Position ‘% LOAD SELECTOR switch to a lower % load. b. Tape frayed insulation.) Test switch and replace if defective.1 6 ) a.5. Load Bank Troubleshooting (Cont) MALFUNCTION 7. Repair. Return % LOAD SELECTOR switch to OFF. Defective thermostat switch. Defective wiring harness. 4-38 . and 50 percent load. (11) Monitor generator set kilowatt meter and sequentially position % LOAD SELECTOR switch from OFF.) Test heater element(s) and replace if defective. b -“ PROBABLE CAUSE Prime load has exceeded 30 Kw. (12) Refer to p a r a g r a p h 2 . d. a. b. 4 . (8) Refer to p a r a g r a p h 2 .) Test switch and replace if defective. C. reduce load bank load with ‘% LOAD SELECTOR switch. tighten harness clamps and tighten all electrical connections.) Repair or replace wiring harness. 4-43. and the generator set kilowatt meter shall read approximately 12. loose harness clamps and loose connections to components. the load bank power indicator shall light. The% remove all harness clamps (5). Load bank shall be immediately removed when combined external load and selected load bank loads exceed approximately 30 KW. Incorrect load bank output monitored on kilowatt meter as % LOAD SELECTOR is sequentially rotated.1 3 and stop generator set. Defective wiring harness. c. ( F i g u r e 4 . f i g . (Refer to paragraph 4-43. and 50 percent load. Replacement. Defective diode bridge. b. Generator set kilowatt meter shall read approximately 25. ) Repair or replace wiring harness. (7) Sequentially select 25.1 4 ) to be removed. Tag and disconnect all electrical leads and connectors from the wiring harness ( 7 o r 9 4 . — b -“ a. a. 37. Connect an external load to generator set equal to 25 ± 5 percent of maximum Ioad bank load. If a wire is broken from a terminal lug. (Refer to paragraph 4-47.5. Wiring Harness. a. d. (5) Set the load bank OVER TEMPERATURE switch to ON. a.1 3 and stop generator set. (6) Set % LOAD SELECTOR switch to 12. (10) Set load bank LOAD REJECT switch to AUTOMATIC. 37. cracked or loose ty-wraps. (Refer to paragraph 4-48. Defective over temperature reset switch. Excessive load on generator set in manual load reject mode. (Refer to paragraph 4-43.5 percent rated load.1 2 and start generator set with external load connected. W i r i n g D i a g r a m . L o a d B a n k Change 4 4-39/(4-40 blank) .F i g u r e 4 .1 6 . ‘ Check all contact terminals for loose connections. Remove tags. and (93). and other selector switch the contacts to infinity. 4-44. R~tary Switches. tor switch (36. fig. and reconnect ponents. (23. To test the rotary selector (94) in position.. Load Bank Control and remove switches (23) and (36) from panel (56). Place wiring harness (7) or (2) Testing. f i g . 4 .1 4 ) 4 . (30). between the termi- a. install all harness clamps (5). 4 . breaks. (92).1 7 for the voltage selec4 . damage. Check body of corrosion. and (32).Figure 4-17.1 4 ) and f i g u r e and insr)ect switches (23) and (36) for freedom of . electrical leads to com- switches use a multimeter and proceed as follows: (a) Remove switch knobs 4 . (12). (18 and 25.1 8 for the load figure for shall 4-14). fig. All open circuits that are closed.1 4 ) and switch mounting Panel Assembly. All closed circuits shall read 5 ohms Change 4 4-41 . each position and refer to the particular read zero ohms. movement between positions. Sequentially select (1) Inspection. screws (21). (2) Installation. Remove cover ( 9 . (b) Test for continuity nals illustrated in figure fig. Figure 4-18. switches for cracks. @) Removal. To replace fig. fnstall in plate (20) or (2’7).l. fig. Inspection. 4-14) (18 or 25.?en nectioiis. Remove cover (9. — Install in reverse order of removal. Reconnect wires as tagged. before removing circuit breaker.4 2 4-15). (zero (2) 4 . and other damage. move tags. fan blade fig. fig. remove screws (47) and tag leads b. and recircuit breaker in OFF position and verify no ~ontinuity (open contacts). fore removing removal. breaks. bodv of switch for cracks. c. bulb(50). 4-14). Tag leads from selector all leads to switch and remove bre&er (~) Tag leads and remove from circuit switc!l (23) or (36). fig. During load bank testing light lights. corrosion. Load Reject Relay. fig. Higher level of maintenance is req~ired. fig.1 4 and replace 4 . and inspec-t-rnciuntin~ terioration grommets 4-14) and looseness. Terminal Board. damage. (2) fan guard material. (2) Testing. ( p a r a check of switch positions.1 5 . d. 4 . nut (44) and screw (45) and then 4-15) and washer (4. On remove voltage voltage selector switch (36) also (2) follows: and other damage. breaker ( 4 8 . f i g . nut (41) and To replace (43. To test the load reject switch corrosion and dam>~e. (43. assembly for unusual noises. Inspect fan blade and check fan brushes for wear. Remove the switch knob 4 . (c) Place 1. fig. Replace. renlove fan and motor assembly (46. indicating tagging light be- (40. 4 . Impection. ( 6 4 . and knob steps in reverse order.1 4 ) by removing (3. ins~ect Inspection.4 2 b . and inspect the circuit breaker between positions. verify continuity co=tacts) of circuit breaker in the ON position. Inspection. switch (23) or (36). ( p a r a f i g u r e 4-46. R?connect leads and remove tags. 4-14).1 4 ) by resetscrews f o r loose nl&nting. 4 . fig. fnstall in reverse order of removal.1 4 ) . f i g . loose electrical con- Loo. Testing. a. Testing. loose Inspect lens and between positions.1 4 ) escutcheo. 4 . (1) 2. Remount selector switches 3 6 .4 2 b . load reject (49 lead reje@ (3) nut (51). 54. Circuit Breaker (Over Temperature Reset Swi?ch. 3. m~unting. washer . ( 2 3 a n d To replace the circuit (3) Replacement. base (54). r e m o v e nut (57). and air outlet for foreign and wiring connections for looseness. through 4. Replacement. screw (30) and nut (31) which secure rear of selector switch [36) to the switch bracket (35). Indicating (1) Light. (closed 5. and fan blade for damage and looseness. Testing. (18) or (25) using removal reverse order of removal. and To replace remove nut (53).1 4 ) fnspect the terminal board breaks. (40. (2) Testing. ) o%-scrvti-fhrough rotates clockwise with air flow as shown on 4 . 4 . 4-15). []cmt. 4-14). load reject Remove cover (9.(3) Replacement. (cJ) 2. 1.1 5 ) securing fan blade (2) and remcwe grommets ( 5 . Higher level of maintenance is fan ward that fan blade req~ired. fig. and inspect indicating connections. fig. washer (52). f i g . load reject Remove cover relay for loose (9. wiring leads for fraying. f i g . Remove cover light for 100SC (9. fig. To repIace the terminal board blade from motor shaft. 4-14). connections. and mounting. Remove cover (5.1 4 ) and escutcheon plate (20) or (27). 4-14) e. 4 . screw (58). remove nut (37). f i g . and damage. signs of b. 4-45. ) . During’ load bank testing 4 . f i g . washer (38). b. c. ohms) and open in manual (3) switch Replacement. and other damage. Load Reject -— (1) Switch. Install in reverse order of Fan and Motor Assembly. remove tan guard screw 4 . observe that indicating (imrinity) To replace Replacement.1 4 ) . 4 . Remove selector (b) Using multimeter. Inspect motor overheating and other damage. Check Check for loose connections. fig.1 4 ) ior dea. Remove secure selector switch the screws (21) or (28) which (56).1 4 ) . leads and nut (39) tagging leads before removing switch. 4-14) and inspect switch (40) for positive action Inspection. the selector switch (23) or (36) as follows: remove screw fig. lamp for looseness use a multimeter closed and make continuity in automatic positions. fig. Test the circuit breakers as 4. loose (48) for positive action loose electrical (23) or (36) to panel mounting. (1) Inspection. ( 2 . (3) Replacement. ( 6 4 cracks. lens (49). ( 9 . See f i g u r e 4 . (42). (b) installation. 4-15). moving ( 1 . fig. (59) and spacer terminal (60) tagging leads before removing terminal nut (61). (2) Test open. Disconnect special purpose cable plug P51 indication of infinity (open switch) below 4500F + 150F. 1-21. 3-24). Refer to p a r a g r a p h 2 . (4) Reconnect lead. J50.1 4 ) . Inspection. Set % LOAD SELECTOR SWITCH to OFF. Remove f i g . 4-47. load bank four-wire power cable ( 1 3 . board terminals screw (84) tag~ing leads before removing ~. plug P51 to tactical rel~y box receptacle {switch at 351°F * 15°F. washer (83). multimeter shall indicate continuity (switch closed). (7) Permit cate infinity oil to cool. board (64). a thermometer in container of oil. Replacement. ( 8 8 . before To replace the heating elements move switch in accordance paragraph remove nut (86) and screw (87) tagremoving elements. f i g . Replace screws Ensure heater elements are cold and load set. Install in re- ging leads (2) Fill suitable container with clean oil having a flash point above 600°F. h.1 4 ) and and (3) Measure resistance between terminals. Testing. with and 4-16 and rec.1 3 and stop generator set. cor- nut~ securing load bank to set housing and remove load bank from housing. Re. (85. 1-2. 3-15). ( 1 6 . (13Tfrom load terminal c. breaks. 4 . if defective.3nt. nut b. (6) Observe multimeter and thermometer for d. f i g . and stir so ( 6 . Remove cover insfiect heater loose electrical elements connections. and switch. and six a. and 4-13.1 4 ) and special purpose cable (6) from the gene- rator set through the plate and sleeve assembly hole (fig. switch (85) for loose mounting Test for proper operation. froti cable 70-1212 plug P51. f i g . Heater Elements. If a.1 4 ) special purpose cable plug P50 from tactical relay box receptacle heat is evenly distributed. and other damage. 4 . WARNING ~.1 4 ) and special purpose cable (6) from loop at rear top left side of housing. 4 . 4-14) remove nut (82). f i g . 4 . 12 lockwashers. Inspection. Disconnect To replace thermostat switch load bank four-wire power cable (fig. level of maintenance. 4-14. f. and i. open) multimeter shall indiReplace Connect cable 70-1212 J51. and screw (63). Testing. c. wARNING 4 . (1) See f i g u r e s 4-13. cracks. verse order of removal. sistance should be approximately 10 ohms. fig.1 4 ) (88) for loose mounting. Install in reverse moval. Diodes are tested and replaced order of reat a higher (1) Remove nut which secures harness lead to element and remove lead from one end of heating elem. Remove load bank four-wire power cable fig. Aiso. 4-43/(4-44 blank) . and necessary fire precautions are taken. Install switch in reverse order of removal. Disconnect (5) Heat container of oil gradually. below. clamps bank is disconnected from generator in housing after removal of cables and clamps. rosion. At 4500F + 150F.4 9 . Remove six screws. replace heating heating element element. and proceed as follows: (4) Connect multimeter between switch terminals. Replacement. for continuity. 4-48. See f i g u r e s 1-1. ( 1 3 . Remove (62). ( 1 6 . suspend switch in container of R e m o v a l . 4 . 4 . Ensure oil in container has a flash point exceeding 600° F. b. oil is heated gradually. Thermostat Switch. e. b. (3) Suspend thermostat oil. Remove cover ins~ect wiring thermostat connections. 1-26 or 1-27. . 2 Corrosion Control and Treatment for Aerospace Equipment. O .1 Cleaning of Aerospace Equipment.1 . 1 . T . T M 9 . 1 .1 2 Components Ground and Procedures for Cleaning Aerospace Equipment. Lubricants. for FSC Intermediate and Depot Level Maintenance 6115 Non-Airborne Equipment. T .1 . O . T . A . Radio Interference Suppression.1 . A .I L LO 5-6115-545-12 Lubrication Order. T .5 . 3 5 . Tires Maintenance and Inner and Repair of Tubes. A . Identification W a x e s . 3 5 . Painting and Marking of USAF Aerospace Ground T . O . O .4 6 1 TM 11-483 Radio Interference Suppression. T . M I L . Painting.1 .2 1 3 Painting Instructions for Field Use. T . O . TM 9-1870-1 Care and Maintenance of Pneumatic Tires.1 .1 .4 .1 . 3 1 . List for Fuels.2 6 Repair/Replacement Ground Criteria for FSC 6115 Aerospace Equipment.O.2 . 3 5 . Hand Portable Fire Extinguisher Approved for Army TB 5-4200-200-10 U s e r s .S T D . T .2 5 .3 .5 2 4 USAF Equipment to FSC Registration 6115 Number System Appli- cable Equipment.1 A . Fire Protection. O . 1 .1 .1 1 Organization. 3 5 . O . TM 9-2610-200-20 Organizational Pneumatic Care. O . A . T .7 5 General Maintenance Practices.1 . O . Aerospace Ground T . Lubrication. Oils and C 9 1 0 0 .1 .A P P E N D I X A R E F E R E N C E S A . O . 3 5 .3 Equipment. A .2 2 5 Equipment. Radio Suppression. T. Maintenance Test Equipment. 00-25-234 General Shop Practice and Requirements of Electric for the Repair. Maintenance.1 4 Installation tronic Practices for Aircraft Electric and Elec- Wiring. 0 0 . Repair of External Power Cables. 6 0 1 Batteries.6 2 6 .6 1 4 0 .3 . (Field).9 7 .2 Preservation Shipment of and USAMEC Storage.1 .0 0 0 3 8 G T M 9 . Support) Parts 15 Intermediate and and Depot (Field) (Direct Manual for General Maintenance Tools KW. Support.1 2 TM00038G-12 TM T .8 . O .5 Processing craft and Inspection and of Non-Mounted. 3 5 . 5-6115-588-14 3 5 C A . Direct Repair and Parts General and Maintenance N A V F A C S L .1 .6 .1 4 2 Care and Maintenance of Pneumatic Tires.6 1 1 5 . Storage Field.2 4 P 3 5 C 2 . Destruction of Equipment to Prevent T M 7 5 0 . T .2 5 P Organizational.1 N A V F A C P .5 4 5 .4 Processing and Inspection Storage of and Aerospace Shipment.7 5 0 The Army Maintenance Management Systems. O .4 4 4 . O .4 4 4 . Procedures E n e m y for U s e .8 . Maintenance. Mechanical Equipment for TM 740-90-1 Administrative Storage of Equipment.1 5 Operation and Organizational.S. O .7 . List N A F A C Including Auxiliary Family Repair Special T M . Managed Disposal U. 3 6 Y 3 2 . Shipment and storage. T . A . O . Commodities Storage. N A V F A C T M 0 0 0 3 8 G . and Depot Acid Type.2 0 0 . Ground Equipment for T .1 . A . 3 8 .4 P .4 4 4 .8 .1 5 / 4 Equipment Through 200 DOD Generator Sets. T B 7 4 0 .1 . Destruction of Material. Maintenance TM T .6 1 1 5 .8 . T M 5 . S. and Organizational. Depot Rebuild) Pneumatic and T .1 1 1 P . 3 5 C 2 . Engines for Non-Airand Gasoline Diesel Storage Shipment.4 . Special and Tools Intermediate Depot List. O .8 .TM 9-2610-200-34 Direct Support and G. O . D A P a m 7 3 8 .3 .1 2 Operator and Organizational Maintenance Manual.5 4 5 .6 2 6 . Maintenance Tires Manual Inner (Including Tubes. TB 750-651 Use in of Antifreeze Solutions and Cleaning Compounds Engine Cooling Systems.3 .6 1 1 5 .3 4 Intermediate Depot (Field) (Direct and General Support) and Maintenance Manual.3 5 T M T .2 P . Lead Operator. Army Radioactive Mobility Equipment Command. A . Radioactive Material TB 750-248 Instructions and by for Safe of Handling.6 2 6 .2 C h a n g e 1 2 .2 4 4 . 5-6115-545-34 3 5 C 2 . 5 .3 A . upon pr. Quantity Authorized th e item Authorized T his authorized Only). must be items in furnished end item. S c o p e . in Recoverability codes sequence. Illustration This column (Basic as Issue Items List Only). end commander subject considered and economically support accompany turned in NOT reparable direct levels. Source codes abbreviation item ft. ment which at special are tools discretion item. Federal t h eF e d e r a l will be used - Stock Number. indicates are the source for the item. the the amount quantity based. INTRODUCTION B . indicating which etc. a . C o d e B .g. A li s t i n g for and of Operating maintenance Supplies and - Sec sup- S Repair ment ically ities parts. and test or e . in b . Source. of Maintenance maintenance code. parts. (Items to be Troop indicates used with Installed t he the or use indicated maintenance f . be indicates for whether unC r e w / O p e r a t o r Explanation authorized plies is and into maintenance the divided following serviceable or salvage. A 2 character or are alpha- (1) listed Source code. which and are test are GSU equipeconomactiv- operating assemblies at required initial operation. furnished indicates supply at equipment. Unit of Measure (U/M). Items Section which III. ea. This column to the indicates and Basic List. Description.A P P E N D I X B BASIC ISSUE ITEM LIST AND ITEMS T R O O P I N S T A L L E D O R A U T H O R I Z E D (SECTIONS I. for of the special are insurance or item end tools and test and be- equipment which procured purposes military dictates tity of m e n t . at the Troop A the list. installation. items troop and installed operating sections or sup(3) Recoverability items Items y should not code. AND III NOT Applicable TO USAF) Section I. are the A list. items the troop diesel (2) level item. by supply basis. Explanation of Columns. II. general with item. column quanequip- levels. returned are recovery coded are: non-recoverable. item name and This any column indicates the Fedof the additional description required. minimum the quantity system.2 . s to c k for number assigned item Items III. G e n e r a l . Section c . following tabular and list provides of an explanation Issue Items or of columns Section List. and Recoverability eral item d . Maintenance tion plies IV. end the Installed in Authorized sequence List of repair parts (assemblies and test and equip- a l p h a be t i c a l of the unit but are components). which and accompany by generator required or the crew/opermain- for operation. betic of C o d e P Repair Explanation the . allowances e.1 . maintenance c . Code(s) (SMR): Maintenance. operator’s The maintenance code tenance. Troop Installed Authorized requisitioning purposes. Basic alphabetical with and Issue Items List of - Section which with II. and special tools. is divided folIows: B . the combat essenthat a g . special tools Quantity This with Furnished column the With Equipment th e quantity (BIIL of an item equipment Army for supplied system from and GSA/DSA authorized Only). Items may to be C o d e R Applied to Explanation which turned or b . indicates to the lowest the listed authorized level install is: installed driven ator authorized set. be available in supply This appendix or lists basic issue items. P 2 Repair stocked cause tiality parts. a .1 . reparable and which on an DSU normally exchange furnished B-3. The the II. C This basic issue list items. Special Information. 1 -1/4 lb head. Quantity Required for Initial Operation. This column indicates informative notes keyed t o data appearing in a preceding column. Column 4. 1/8 in NPTF. This colimn identifies the component application of each maintenance or operating supply item. 10 to 160 lbs range. This column indicates the quantity of each maintenance or operating supply item required for inttial operation of the equipment.(1) Figure Number. Quantity Required for 8 Hours Operation. This column indicates the Federal stock number assigned to the item and will be used for requisitioning purposes. Indicates the callout number used to reference the item in the illustration. (Not applicable). I-LAW machinist ball pean. HAMMER. ea ea ea 1 1 1 ea B-2 Change 12 . I NO. hydraulic coupling one end. Abbreviations. b . This column indicates the estimated quantities required for an average 8 hours of operation. lever operated. c. HOSE ASSEMBLY grease gun. Column 3. Federal Stock Number. Explanation of Columns in the Tabular List of Maintenance and Operating Supplies . a. B-5. Column 2.Section IV. Component Application. 3/16 in ID hose. Abbreviation: hv. (See parts manual) GREASE GUN hand. ITEMS TROOP INSTALLED OR AUTHORIZED LIST (1) SMR CODE 1 PAC PAC PAC PAC 4910-273-3663 4930-360-2801 5120-224-4045 4930-141-8311 (2) FEDERAL STOCK NUMBER (3) DESCRIPTION REF NO. e. other end male connection. I I SMR I FEDERAL STOCK NUMBER CODE I REF NO. d . f . Column 6. Notes. 19-1 1/32 in overall length. Column 5.duty deg ea hd ID in lb(s) max nom oz sgl w/ Explanation: heavy-duty degree each head inside diameter inch pound(s) maximum nominal ounce single with Section II. This column indicates the item name and brief description. Indicates the figure number of the illustration in which the items is shown. BASIC ISSUE ITEMS (1) (2) (3) DESCRIPTION USABLE ON CODE (4) UNIT OF MEAS (5) QTY INC IN UNIT (6) QTY FURN WITH EQUIP 1 1 (7) ILLUSTRATION (A) (B) ITEM FIG NO. Column 1. 16 oz. Maintenance and Operational Manual Adapter Connector ea ea Section III. (2) Item Number. B-4. & MFR CODE PAC PAC 7520-559-9618 5935-00-322-8959 Case. & MFR CODE USABLE ON CODE (4) UNf T OF MEAS (5) QTY AUTH GAGE: tire pressure. B-6. Description. / 6ww-174-1806(2) Antifreeze. (2) ITEMS TROOP INSTALLED OR (3) AUTHORIZED LIST (cont) (4) (5) DESCRIPTION SMR CODE FEDERAL STOCK NUMBER REF NO. 22-112 deg angle. 8 in nom. blade 4 in long. ea ea 1 1 1 UNIT OF MEAS QTY AUTH flexible spout. fuel onlv JP4-MIL-T-5b24 JP5-MIL-T-5624 OIL LUBRICATING (3) See current for grade appliPail Can 20 (6) 20 (6) 20 (6) 20 (6) 20 (6) 20 (6) (4) Fuel capacity. PAC PAC 5975-878-3791 5120-293-3176 ROD. & MFR CODE PAC 4930-262-8868 OILER. MAINTENANCE (3) AND OPERATING (4) SUPPLIES (5) QUAN~TY REQUIRED F/8 HRS OPERATION NOTES (6) QUANTITY COMPONENT APPLICATION FEDERAL STOCK NUMBER DESCRIPTION REQUfRED F/INITIAL OPERATION FUEL TANK 9140-286-5294(1) 9140-286-5286(1) 9140-286-5283(1) 2910-209-4997(1) FUEL OIL . and filters.DIESEL Regular Grade DF 2 Winter Grade DF 1 Artic Grade DF A Ether Bottle f! AL?TION JP-4 & JP=5 ~fi -fuel are 55 (4) 55 (4) 55 (4) 1 50 gal (1) See C-91 OO-IL for additional req- uisitioning data. capacity. HAND Pump. O. straight SLIPJOINT comb w/cutter. hv. ea nose. quarts) (in RADIATOR 6850-181-792 ANTIFREEZE Antifreeze. force fed USABLE ON CODE 16 oz. LO CRANKCASE 9150-188-9858(1) 9150-189-6727(1) 91 50-242-7603(1) OE/HDO OE/HDO OES OE/HDO OE/HDO OES 30 (3) 5 Gal 10 (3) 1 Qt (3) 5 Gal Pail 30 (3) 55 Gal 10 (3) 55 Gal Drum Drum 9150-265-9436(1) 915!3-191-2772(1) 91 50-242-7604(1) (3) 55 Gal Drum (5) Cooling system GOVERNOR 9150-223-4134(1) OIL. lines 26 BATTERY 6810-249-9354(2) ELECTROLYTE 4 (7) (7) Requires 4 gal- lons to fill batteries.Section (1) III. C h a n g e 3 B-3/B-4 blank) . (2) See C-6800-IL for additional req- ctmsiclertd 91 30-256-8613(1) memencv 55 (4) ui sitioning data.duty. Section (1) (2) IV. END. wide. HYDRAULIC MIL-H-5606 1 Gal Can 5 qts capacity.947 in max jaw opening. gallons) system (in cation. 6 in long. PAC 5120-223-7396 PLIERS. inhibited Artic 34 (5) 34 (5) (6) Requires quarts to fill crankcase. ASSEMBLED FLAT TIP tip 1/4 in SCREWDRIVER. GROUND. 19 overall. ADJUSTABLE: sgl- ea 1 PAC 5120-240-5328 WRENCH OPEN hd. OHA. . Calibrate.Install. Section IV contains supplemental instructions.Adjust. .Align. The implementation of the maintenance functions upon the end item or component will be consistent with the assigned maintenance functions. c . b . site.Overhaul. The symbol designations for the various maintenance categories are as follows C . zero mileage. H . E . lubricants. F . Rebuild reduces to zero the hours or miles the equipment. a.Repair. K . The assembly group is a numerical group assigned to each assembly in a top down breakdown sequence. c.Service. Maintenance Functions. b . to charge. Section II designates overall responsibility for the performance of maintenance functions on the identified end item or component. cooling agents. General. This column contains a brief description of the components of each assembly group. To adjust specified variable elements of an item to bring to optimum performance. Column 1.Inspect. C-2. Repair may be accomplished at each category of maintenance. To determine serviceability of an item by comparing its physical. Group Number. Overhaul normally does not return an item to like new.Direct support maintenance (DS) H . Rebuild is performed only when required by operational considerations or other paramount factors and then only at the depot maintenance category. or zero hour condition. to preserve. Section III lists the tools and test equipment required for each maintenance function as referenced from Section II. explanatory notes and/or illustrations required for a particular maintenance function. To verify serviceability and to detect electrical or mechanical failure by use of test equipment. one of which is a certified standard of known accuracy. Those maintenance operations necessary to restore an item to serviceable condition through correction of material damage or a specific failure. Column 2. It consists of that maintenance necessary to restore an item to completely serviceable condition as prescribed by maintenance standards in technical publications for each item of equipment. To determine the corrections to be made in the readings of instruments or test equipment used in precise measurement. d. or vehicle. be defined separately. and to add fuel. such as painting and lubricating.Rebuild.Test. Column 3. G . or component C-1 B . To replace unserviceable items with serviceable like items. INTRODUCTION ARMY and USMC only C-1. The highest degree of material maintenance consists of restoring equipment as nearly as possible to new condition in accordance with original manufacturing standards. and air. J . and electrical characteristics with established standards.Organizational maintenance F . C . the highest degree of maintenance performed by the Army in order to minimize time work in process is consistent with quality and economy of operation. Explanation of Columns in Section II.Replace.General support maintenance (GS) D . To rectify to the extent necessary to bring into proper operating range. D . The applicable assembly groups are listed on the MAC in disassembly sequence beginning with the first assembly removed in a top down disassembly sequence.Depot maintenance The maintenance functions are defined as follows A . If it is desired that elements. a. This column lists the various maintenance functions (A through K) and indicates the lowest maintenance category authorized to perform these functions. Normally.APPENDIX C MAINTENANCE ALLOCATION CHART Section I.Operator or crew O . I . Group Title. This section provides a general explanation of all maintenance and repair functions authorized at various maintenance levels. mechanical. To set up for use in an operational environment as an emplacement. Consists of the comparison of two instruments. they may be so listed. to detect and adjust any discrepancy in the accuracy of the instrument being compared with the certified standard. To clean. and Breather A-A A-A A-A A-A Exhaust Breather 0 3 Convenience Pipes Receptacle A-A Circuit 0 4 Breaker o G-B (Deleted) 0 5 0 6 0 7 Plate & Sleeve Assembly Paralleling Receptacles Generator Circuit Set Controls Breaker DC 1 D A-A A-A G-B C-2 Change . Precise Utility. is Crovided for referencing by code t he tools and test eq. This column c. Section II. num%er and a letter separated by a dash. Remarks. The A through K on b. lowest level of maintenance tool or test equipment. MAINTENANCE ARMY and ALLOCATION only and CHART USMC For DOD Generator Set Family 60 KW. B-B 0 1 Nave Receptacle 0 2 Muffler. Explanation of Columns in Section III. This column lists information pertini%t to th e maintenance as indicated on the MAC. — Maintenance Category. This column consists of a Code. has been in use. Explanation of Columns in Section IV. This column lists the manuStock code and part number. both of which are references to S e c t i o n tenance function. ( S e c t i o n IV) pert- Number of tools and-test equipment. letter is representative the MAC. of columns b. This column shows the Section II. Column4.ipment. Reference Code.thereof. authorized to use the d. II. The the T & TE requirements letter represents column on main- column 5 and the second letter references column the specific tenance function the item is to be used with. FUNCTIONS — (4) (5) G R O U P N O . This column is provided fac~urer’s Number. 50/60 and 400 Hz (1) (2) (3) MAINTENANCE — 1 . Pipes Muffler Exhaust. or Federal for–referencing by code t he remarks functions. (Section III) requi-red to perform the mainII). Tool e. a. This column lists the name or ideiitificatlon of th e tool or test equipment. Reference a. Remarks. The first letter references a main3. Tactical. Tools and Equipment. This column consists of two letl%rs separafed by a dash. A through K. C-3. Nomenclature. tenance functions ( S e c t i o n d. GROUP TITLE TOOLS REMARKS AND IQUIPMENT 4 rY d •1 — Batteries and Related Items D 1-B AA. inent to the maintenance C-4. function being performed. The number references the MAC. Column 5. 0 7 Manual Speed C-d G A-A (Cont) Fhult IncMcatcw o o o A. F-D o F 0 D-B Ammeter AC c F 0 D2-B B. F-D Rheoetats/potenuometer o o 0 G-B Frequency Meter c F 0 D-B 2-B FYequency lkanechcer o F 0 G-B switches c o 0 2-B G-B Gauges c 0 0 D-B Hourmeter c 0 0 D-B Ammeter DC c 0 0 D-B Relay Assembly o F 0 Terminal Beard 0 0 c panel LigM Assembly c 0 Lamp c LigM 0 Air Cleaner c c 0 c Battle Short 1A* 0 c c 0 c Clrcult Breaker LigM 0 c c 0 c mc LlgMs 0 c 0 0 c .(1) (2) (3) MAINTENANCE FUNCTIONS (4) (5) G R O U P GROUP TITLE A 3 H TOOLS AND * u w g ~ : < ~ * i z E a i REMARKS EQUIPMENT N O .I Lamp8 c 0 lnlee ‘kxdml Box Aesembly o 0 0 0 0 D-B Voltmeter AC c 0 0 F-D Wattmeter Wattmeter AC Cowerter c F 0 D- B.3 .A. D-B. E. C-l Electric Control 0 F 0 Actuator 0 F F Magnetic Pick Up 12 Air Cleaner Ass’y Element 1 3 0 F c c : A-A A-A Relay Table Group Tactical Relay Assembly o F F F 2-B 2-B K-B Precise Relay Assembly 0 F F F K-B Special Relay Assembly 0 F F H 2-B K-B Excitation Assembly Exciter i’ ~ F i’ 2-B 2-B C . J-K Main Load Contactor 0 0 0 F A-A.D.(1) G R O U P (2) (3) MAINTENANCE x — z — FUNCTIONS (4) (5) E — -i — TOOLS GROUP TITLE 6 E $ cd H — a z — 5 ~ &l ~ & W Z — AND REMARKS 3QUIPMEW N o .K-B Reconnection Board 11 Governor Control Unit 0 o 0 D Electro-Hydraulic 0 F F F 2-B.G-B.4-X 1-1 A-A.J-K 0 8 Housing Group Doors Covers Panels 0 9 Engine. Generator and Chassis Interconnecting Harnesses 1 0 Load Connection Group Wiring c c 0 0 F F 3-1 3-1 1-1 1-1 c o 0 0 0 F 0 3-1 2-B.4 C h a n g e 1 5 .I L-B. 07 (cont) Lamp Control Box Assembly g — o 0 Door Holder c 0 Cross Pin c 0 Door c 0 0 Harness o 0 A-A.D-B Load Term Bd Assembly 0 0 F 0 A-A 2-B Current Xfmr Assembly 0 F F A-A. P–K Stator Generator Assembly F F 2–B O–B.TM 5-6115-545-12 P-8-626-12 TO-35C2-3-444-1 NAVFAC TM-00038G-12 ( 1 ) (2) (3) MAINTENANCE FUNCTIONS (4) (5) G R o u P GROUP TITLE & c1 5 ~ — 1 3 (Cont) Voltage Regulator F F 2–B. J D–B Bearing 0 F F 10– H N–A Rectifier Rotating F F 2–B. Load Measuring Unit o F E–I 1 4 Generator Assembly 0 F 6. 8–B 9–I. Gasket and Strainer c c 0 Hoses c 0 Lifting Frame Fuel Transfer Pump o 0 o F c o 1 7 Cooling Group Grill c c 0 0 Fan Guard Change 13 C-5 . P–K Stator Exciter Assembly F F F F 2-B O–B. 11–1 G–B Fan Generator F F F Rotor Assembly F F 2–B O–B. J D–B Relay Table Group M ~ A a EQUIPMENT AND REMARKS A — H TOOLS N o .7–H. 5–I. P–K 1 5 Day Tank and Fuel Filter Assembly o o o G–B Solenoid Valve 2–B Day Tank c c 0 Q–C Float Switch o 0 0 Fuel Filter Assembly c c 0 Q–C 1 6 Lifting Frame Assembly c c 0 Start Aid Assembly Filler Cap. 16– B. Radiator c 0 Hydraulic Cooler c 0 1 8 Hydraulic Actuator c F 14–B–D D–B.7– H Belts.D D–B. 19–D G–B. V–E Diodes F F 2–B. Fan o 15–D V–D Alternator/Battery Charging c 0 2–B. Y–D Speed Switch Adapter c F Tach Drive F F Oil Level Gage and Filler c o Electric Starter and Adapter c 0 2–B D–B Starter Assembly Brushes E F AA–A C-6 Change 13 .16– B F Hydraulic Pump & Drive Assembly c F 17–B W–B. ll– H G–B Brush ASSY F F G–B G–B D–B Rotor Field Assembly Voltage Regulator (DC) F F F F F 2–B 2–B 2–B. 18. T–D 1 9 Hydraulic Sump Sump and Filter c o u–c Filter c 0 D–B 2 0 Engine Assembly c F 6–H. X–D Speed Switch and Drive c o 2 – B.TM 5-6115-545-12 P-8-626-12 TO-35C2-3-444-1 NAVFAC TM-00038G-12 (3) MAINTENANCE G R O U P GROUP TITLE L1 b * b n q w c) -j a a! — 1 7 (Cont) Shutters Assembly c 0 D–B Shutter Thermostat c o 12–B R–B : F — TOOLS FUNCTIONS (4) (5) (1) (2) AND REMARKS EQUIPMENT N O . Fuel Injection Diffuser and Turbocharger Diffuser Turbocharger Water Pump and F%n Pump Fan Thermostat and Housing Thermostat Xmtr. D. Temperature Switch. Pressure Filter Assembly. Pressure Switch.QI D .(1) (2) (3) MAINTENANCE FUNCTIONS (4) (5) TOOLS GROUP T~LE 2QUIPME~ REMARKS 20 (Cont) Solenoid Starter Armature Starter Drive Starter Field Assembly Oil Filter and Sensors Xmtr.I AC-C AE-D Lines Pump. Oil 2-B 22-B D-B AB-B 2-B 2-B G-B G-B AC-C Secondary Fuel Filter Lube Oil Cooler Relief Valve Nozzle Holder Assemblies and Lines Nozzle Holders 23.B.B. Temperature 12-B 2-B 2-B R-B G-B G-B Change 8 C-7 L. Valve H camshaft C . 2 0 ( C o n t ) Crankshaft Idler Pulley Assembly o Intake Manifold 0 EXhSUSt Manifold 0 Engine FYcmt Support F Oil Pan Assembly F 011 pump Flywheel end Housing H Flywheel Assembly Eungcear H Flywheel H Housiw H H Timing Gear and Cover Cylinder Head and Vslve Operating Mechanism Rocker Arm Shaft Assem.( 1 ) G R O U P (2) (3) MMNTENANCE FUNCTIONS — H (4) (5) ‘TOOLS GROUP TITLE 5 j A w & — Dampener. Cylinder H Lifters.25- AF-1 D-B Valves Intake and Exkuet F 26-1 qx’ings Valvw F 27-H AG-B Seats Intake and Exhaust valves H 28-H Guides Valve H 29-H Head.8 Change 8 H . bly F Rocker Arm Assembly F 21-D V-D Pushrod F Cylinder Head Assembly F 24-1. Vibration and Pulley F ZQUIPMENI REMARUS N O . 35-H Plstal 36-H Crankshaft snd mock Cylinder Sleeves 33. 37-A. Intermediate Hit. Electric C h a n g e 8 C . Fuel ‘Iknk.A. Fuel I. Brush. 38-H M a i n B e a r i n g s 33.9 .I Skid Base 2 2 Jccessory Items F A. 32-H Rod Beu’tng 33-A Plstal Rtngs 34. J-K Psralleltng Cable Fuel Line. 37-A Craukshatt ) 39-A I Brg.(1) (2) (3) MAINTENANCE FUNCTIONS (4) (5) G R O U P GROUP TITLE c TOOLS REMARKS 9 N O . Starter Kit. camshaft 33.A.A.A Cylinder Block ) AH-K 2 1 2sss Graup 2-B D-B sensor. Starter Relsy mt. 30. Vslve Grindlw Gasket Set. Auxilisry 2 3 Farts Kits Garket Set.A. — 2 0 Piston snd I@s (Cont) Pietun P& 5 m ha a lQUIPMEIW 30-A Camecting Rod 31. (1) (2) (3) MAINTENANCE FUNCTIONS (4) (5) G R O u P 4 i I TOOLS R E M A R K S GROUP TITLE cLI w tJ g w u ~ ~ A w a w a EQUIPMENT N O . Starter Solenoid Kit. Flame F F 2-B G. Gasket Set. Regulator F F Terminal Board 0 F 2-B Switch. Fuel Pump Kit. J-K Coolant Pump and Motor Ass F F F 8-B Pump F F F Relief Valve F Motor Assembly F F F Fan F F M&M F F C . Limit 0 F G-B Receptacle Assembly 0 o 2-B G-B Igniter Assembly 0 0 8-B Switch. Water Pump Gasket Set.1 0 . V-D Wiring Harnesses 0 o c A. — 2 3 (Cont) Ktt. Cylinder Sleeve 2 4 Jot Used 2 5 Vinterization Burning Kit Fuel c o F Control Box Assembly 0 0 F 2-B D-B Light Assembly Lamp 0 F D-B o D-B Circuit Breaker 0 F 2-B G-B Power Switch F 2-B G-B Heater Assembly c F F D-B Valve Assembly.A.B. Oil Pan Kit. Winterization Electric 0 D-B Coolant Pump & Motor Assy 0 8-B Pump F D-B Relief Valve F Motor F E. Lines and Fittings 0 2 6 Ieater Kit.1 1 . GROUP TITLE TOOLS AND M u 4 d & w E — REMARKS EQUIPMENr 2 5 (Cont) Thermostat Switch 0 2-B D-B Burner Chamber F Heat Exchanger F Hoses.(1) (2) (3) MAINTENANCE FUNCTIONS — H — (4) (5) G R O U P N O .I Heating Elements o 0 0 D-B Thermostat Switch 0 0 0 2-B D-B Hoses and Fifflngs c 0 Wiring Harness c 0 0 A. J-K Electric Winterization Control Box o 0 0 F 2-B Wiring Hmmess F J-K 2-B ‘iYansformers F F F Relay F F F 2-B G-B Semi Conductors F F 2-B Circuit Breaker o F F 2-B G-B Power Switch 0 F F 2-B G-B Fuse Holder 0 F Fuse Light Assembly o 0 2-B G-B 0 0 F D-B Indicating lamps c 0 D-B C .A. (1) G R O U P (2) (3) MAINTENANCE — A B FUNCTIONS (4) (5) H I TOOLS GROUP TITLE H u w & ~ : 4 5 g H c E E E F a G o 40-B EQUIPMENT REMARKS N o .1 2 .A. Load Reject 0 0 o 2-B G-B Fan and Motor Assembly 0 0 F F E. J-K Control Panel Assembly Switches. Rotary 0 0 (1 2-B G-B Switch.I Brushes 0 F Fan Blade and Guard 0 o Grommets. 2 7 Kit-Wheel Mounting c Wheels and Tires c c 0 0 Al-B Bearings Wheel o 0 Brakes 0 a 0 2 8 Load Bank 0 o c1 F D-B Wiring Harnesses 0 0 o A. Mounting 0 0 Circuit Breaker 0 0 0 2-B G-B Indicating Light Lamp 0 0 0 0 0 Load Reject Relay 0 F F 2-B K-B Terminal Diodes Board 0 F o F 2-B G-B Thermostat o o Heater Elements 0 0 0 2-B G-B C . REFERENCE CODE MAINTENANCE CATEGORY Tester. Chain. Electric 3439-853-8760 or Equal 12-B o Thermometer. 60 KW. MAINTENANCE ALLOCATION CHART ARMY and USMC only For DOD Generator Sets. Dial Indicating. r ~ql]a] 16-B-D 0 Test Set. Stroboscopic 6630-892-1510 w Yjual Change 3 C .37~0 or Eqval 4910-774-9343 f. F Trestle.Rolyte Solution of Tool Set L/x Tl 31 52) 6630-171-5126 or Equal (Component Multimeter 2-B 0 6625-581-2036 or Equal 3-I F Torch Outfit. Actuator (Class 1 only) 15-D o Scale.Section III. Generator Regulator and Voltage 17-B F Test Gage and Hose Ay 18-D F Tachometer. Portable. Range 6685-527-7867 or Equal 50-400 Degree 13 F Deleted 4940-152-2107 or ~qWd~ 14-B-D Test Stand. O-50 lb 6670-254-4634 or Equal 4~10-270. Hoist. 3 Ton 3950-292-9879 or Equal 7-H. Cutting and Welding (Tool Set L/I W67706) 3433-357-6311 or Equal 5180-876-9336 or Equal 4-K o Tool Kt.1 3 . Self-Indicating F. Split Core 6625-892-1497 or Equal 9-I-J F Ohmmeter 6625-581-2466 or Equal 1O-H F Puller Attachment (Component of 5180-711-6753 or Equal Puller Kit 5180-701 -8046) 11-1 F Soldering Outfit. Electrical Connector Repair 5-D-I-J F Oscilloscope 6625-643-1740 or Equal 6-H F Hoist. NOMENCLATURE TOOL NUMBER 1-B o Battery Elect. 50/60 and 400 Hz T O O L A N D T E S T E Q U I P M E N T R E Q U I R E M E N T S -. 5 Ton 3950-449-7005 or Equal 8-B F Multimeter. Cylinder. Valve Guide 5120-219-8404 or Equal 30-A H Caliper Micrometer. Connecting Rod Alignment 32-H H Wrench. 5120 -417 -’2952 or Equal 5210-221-1934 or Equal Sleeve 39-A H Caliper. Valve Face 27-H F Lifter.1 4 . Insert Valve 5120-473-7393 or Equal 29-H H Remover and Replacer. Outside 5210-243-2933 or Equal 4910-733-2487 or Equal 1 “ thru 2“ 31 -A H Indicator. Piston Ring 5120-393-0549 or Equal 37-A H Caliper. Armature 6625-233-1459 or Equal 23-B-~1 F Tool Kit. Valve Spring 28-H H Remover Seat and Replacer. Telescoping 5120-473-9350 or Equal 34-A H Gage. ~ Thickness 5210-517-8097 or Equal 35-H H Compressor. Diesel Injector Repair 4910-317-8265 or Equal 24-I F Grinding Kt. Valve Seat 4910-473-6437 or Equal 25-H F Wrench. Torque 5120-542-5577 or Equal 4910-540-4679 or Equal 5120-239-8686 or Equal 26-I F Grinding Machine. Mechanical. Ignition Magneto 4910-912-3960 or Equal I 20-I o Tester Spring Resiliency 6635-449-3750 or Equal 5120-221-1999 or Equal 21-D F Gage. Torque 5120-640-6364 or Equal 33-A H Gage Set. Thickness 22-B F Test Set.REFERENCE CODE 19-D MAINTENANCE CATEGORY F NOMENCLATURE TOOL NUMBER Test Stand. Micrometer 40-B c Gage. Micrometer 5120-255-7564 or Equal 38-H H Puller. Piston Ring 5120-894-0753 or Equal 36-H H Expander. Tire Pressure 4910-204-3170 or Equal C . Audible and Physical Heat Detection O-B Insulation Breakdown and Continuity Tests P-K Rewind Q-C Drain Condensation R-B Thermometer Test S-B Deleted T-D Adjust after Replacement or Repair u-c Check Fluid Level V-D W-B Adjust to Specifications in Applicable TM Test Pressure Output Output X-D Adjust Pressure Y-D Z-D Overspeed Only Deleted M-A A&B Inspect for Minimum Growler Test Length C . MAINTENANCE ALLOCATION CHART ARMY and USMC only REFERENCE CODE A-A REMARKS Visual Inspection Hydrometer Test B-B C-I D-B Cover Components Only Operational Test E-I Repair by Replacement of Components F-D Zero Adjust GB Continuity Test H-C Deleted I-I Weld and Straighten J-K Fabricate New Harness K-B Test for Known Voltage at Terminals L-B. D&I In Accordance with Procedures in Applicable TM M-D Deleted N-A Visual.1 5 .Section IV. K Include Replacement Pressure Test of Sleeves AI-B C .REFERENCE CODE AC-C Replace Element REMARKS AD-D Deleted AE-D Adjust Injector Pressure Setting AF-I Includes Replacing Valves and Springs AG B Spring Tension and Length AH.1 6 . A L P H A B E T I C A L I N D E X P a r a g r a p h . and . 2-10. . . .2 2 0 F 3 . .1 3 3 . .. . and . .8 9 3 . . .1 1 4 . . . .6 Abbreviations A c c e s s o r y .3 6 3 . . . . .3 5 3 . . . . .2 2 5 3 . . .8 8 3 . . . . Replacement Components Base Inspection List.4 Receptacles C Controls and Instruments and . . . . Adjustment Belts . . .2 2 6 3 . . . .2 2 1 3 . . . . . Replacement (Deleted) Breaker . . . . . . F 3 . . . . C l e a r a n c e . . . .2 2 4 3 . H o s e . . .2 2 2 B . . . . . . Transmitter Transmitter . . B Base Group Assembly Base Fuel Fuel Fuel General. .8 1 F 3 .1 8 3 3 . . . Figure. . . . . Alternator Assembly Related . .9 F2-5 Controls General. . . . .9 1 3 . I t e m s I t e m s . . . . . . . . . . . Replacement. S w i t c h M i c r o . . Components . . .9 3 F 4 . . .4 A c c e s s o r y General. . . . . .2 Group Tank Removal. .8 C h a n g e 1 I-1 . Replacement . F 3 . Convenience Receptacle Receptacle . .2 2 3 F 3 . . II . F 3 . . . . .1 4 3 . .5 Regulator R e g u l a t o r T a p p e t Service and . .. . . Instruments . Subject N u m b e r A B .5 3 3 . . . Assembly. Basic Issue Items Section Parts Batteries and Related .Brush and Connector Replacement. . . .9 4 3 . . .5 0 F 3 . . .1 0 F 4 . Cleaning Inspection Testing and and Installation Quantity Quantity .S w i t c h . . . . . . . . . .5 1 3 . . . . . . . Test . . . . . . . V a l v e . . 4 . Related Skid . . . . . . Circuit General . . . . F 3 . .2 2 7 3 . F 3 . . . . Removal. . . .1 8 2 Battery Belt Drive General Charging Alternator and .9 0 Convenience Box Assembly Replacement Test . 2 . Related .2 2 8 3 . Table. .1 8 4 F 3 . A s s e m b l y Paralleling Storage A d j u s t i n g A d j u s t m e n t F l a m e Fuel F u e l V a l v e Air Cleaner Space F l a m e Cable . . . . . 3 . .8 2 3 . . .5 2 3 . . Slave . . . . . .3 3 . Parts . . . . . .2 2 9 F 4 . . . (Deleted) (Deleted) (Deleted) (Deleted) Coolant Pump M o t o r . . . . . .9 2 3 . . . . . B a t t e r i e s General Batteries . . and . . . . . . . and . . . . Vibration . Data . . . . . . . .1 8 0 3 . . . . . . . F 3 . . . . . . . . . . . . Lamp . . . . . . . and . . Replacement . . and . . . . . . . . R e p l a c e m e n t Pulley . . . . . . . . . . . . . . . . . Hydraulic Radiator Shutter . . F 3 . .1 . . . . . .2 6 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 0 Related . . . .ALPHABETICAL INDEX (Cont) Cooling Cooling Cooling Fan General Grille Group Group. . . . . . . . .2 0 2 3 . .2 F 1 . .1 8 1 3 . Services . Parts . . . . . . . . . . . . . . .1 3 8 3 . . . . . .2 0 3 Diffuser . . . . . . . . . .5 1 .1 8 9 3 . . . . . .9 . . . . . Generator . . . . . . Replacement . . . 3 . . .3 1 . . . . . . . .1 9 F 4 . . . 1 .4 2 3 . . . Engine Left Right I . . . . . . . . . Assembly . . . 3 . . . . F 1 . .4 A . . Characteristics and . . . . . . . . . Test. Dampener . . .1 3 9 Engine General . . . . Maintenance . . . . . . . . . . .1 5 9 F 3 . . .7 F 4 . Group . . .3 Data Day Instruction Tank Day Day Fuel Solenoid Plate Locations. . . . . . . . . . . . . . . . . . F 4 . . . . . . . . . . . Fuse . . . . Adapter . . . . .1 7 1 3 . Front.1 6 0 3 . . . . Troubleshooting Assembly Hoses Assembly . . . . . . . . . . .1 6 9 3 . .6 4-21. . .2 Generator Rear. . . 4 . . Differences Diffusers Assembly Exhaust General . Harnesses . . Maintenance Preventive Removal schematic Engine Drain Engine General Engine .2 0 T 4 . . . . . . . . . . . . . . . . . and . and . . . . 3 . and . .1 8 2 . .2 1 1 D F 1 . Assembly S h u t t e r S h u t t e r Crankshaft General Inspection . . . . . . . . Performance Turbocharger . . . Chassis . Checks . . .2 9 3 . . . . . . . . . . . . T h e r m o s t a t T h e r m o s t a t and . . . Cooler . . . . . . Kit . . . . . . . . .7 T 1 . . . . . . . . . .1 Identification Destruction of Material in Tabulated . . . . . . . Fuel and Assembly Float Fuel Switch Filter . . . . Description Description Difference Data . Filter Valve. . . . .2 1 0 3 . . . .3 4 . . Testing. . .1 6 7 3 . . . . . . . . . . . . . . . . . . . .1 7 9 Generator Chassis and . . . . . . F 3 . .1 7 3 3 . . . . .2 3 3 . Inspection. . . . . . . . . . . . . . . . . Box . . . . . . . . .2 0 4 3 . . . . Assembly Control General Installation Operation Preventive . . . . .1 7 2 3 . . . . . . . . . Guard . . . . . . . . . . . . Set Repair and Replacement Three Three Quarter Quarter View View . . . . . . E Electric General Starter Starter Electric Starter .1 5 8 Tank Tank and Assembly Removal . . . . . . . . .1 9 0 3 . .1 6 8 3 . . . T4-4 . . . in . . Turbocharger. 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wiring . and . . . . . . . . . . . . . . . . . . . . . . . Wiring Harnesses . . . . . . . . . . . . .1 9 1 Assembly Solenoid Winterization . . . .1 7 4 . . . . . .3 1 F 3 . . . .1 7 0 F 3 .2 7 3 . . . . . . . . . . . . . . Interconnecting Wiring . . . . Models and . and Breather Manifold . sets . E x p l a n a t i o n Explanation Explanation Explanation of of of C o l u m n s in in in Section Section Section in - Columns Columns Columns of . . . . . . . Pressure . . . . . . . . . . . . . . . Installation Operation Preventive Removal . . Winterization . Group . . . . . . . Ammeter Voltmeter Ammeter-Voltmeter AMPS-VOLTS Assembly Battery . . . . . . . Shows Start . . . . Oil . . . . . . . . . . . . . . . . . . . . . Box . . . . . . . . . . . .1 1-2 T2-1 Battery Engine Engine Engine Engine Fuel General is . . . . . . . . . . . . .6 F 3 . . . of . . . . . . . . . . . . . . . . . . . . . . . . Not . . . . . . . . B . . . . . . .2 2 3 . . III IV the . . T4-2 Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . and . F4-1 F4-2 4-3 4-4 2-25 4 . . . . . . . . .6 4-5 4-7. . . . . . . . . . Charging Ammeter . . Selector . . . . . 3-154 3-156 3-155 F2-3 3-108 3-105 F3-21 3-112 F3-17 3-124 I-3 Bearing Inspection Terminal Set Inspection. . . . . . . . . . II. . . . . Kit .1 3 7 General Housing R e m o v a l Equipment Inspecting Unloading. . . . . . . 3-74 3-72 3-71 3-69 Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 . . . . . . . . . . . . . . . . . Protection. . . . . . . . . . . . . G B-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 7 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust General Inspection Assembly. . . . . . . . . . . .2 C . . . . . . . . . . Strained . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting . . . Replacement . . . . . . . . . . . . .3 2 . . . . . . . . . . . . . . . . . Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 . . . . . . . . . . . . . . . . . . .4 Operating Section F F4-15 T3-2 T2-2 Fan Fault Fault and Motor Assembly. . . . . . . . . . . . Erratically or Misfires .1 2 . .1 3 6 F 3 .2 2 . . . . . . . . . and Records Points. . . . . . . . . . . . . Maintenance . . . . . . . . 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Conversion. . . . . . Frequency . Switch . 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . Set . . . . . . . . . . . . . Unpacking. . Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Housing . . . . . . . . . . . . . . . . . . . . . . a n d R e p l a c e m e n t servicing . . . . . . . . . . . . . . . . . . . . . . . . . . Equipment Exhaust and . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-73 3-67 3-66 3-68 3-75 A . . . . . . . . . . . . . . . . . . . . . . . . . . . .ALPHABETICAL INDEX (Cont) Engine Generator . . . . . . . . . . . . .2 1 7 B . . . Pipe . . . . . . . . . . . of . . . . . . . H o u s i n g Loss Fire Forms of . . . . . . . . . . . . . . Charge Starts . . Down-and . . . . Test Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Class . Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Indicator Indicators Function Field Expedient Repairs Ammeter Will . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . List . . . . . . . . F i l l e d w i t h S m o k e . . .1 2 F 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Freezing Fuel Composition. . . . . . . . . . . . . . . . . . . . . . Connections Generator AC AC Controls Replacement Replacement Selector . . . . . . . . . . . . . . . . . . .2 1 6 3 . . . . . . . . . . . . . . Only) . . . . . Assembly . . . . . . . No or . Control . . Switch. Indicator . . Specific Gravities Military Antifreeze Materials Burning Assembly Control General.. . . . . . . . . . . . . . Heat Up Overheating Shuts Not . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1 G e n e r a l Generator General Generator Generator Generator Load . . . . and . . . . . . . . . . . Maintenance . . . . . . . . and o f . . . . . Charging Cranks But . . . . . . . . .3 C . and Runs . . . . . . . . . . . . . . . . . . . . . . . Group . Explanation and Columns Supplies Tabular IV. . . . . . . . . . . . Schematic . . . . . . . . . . C . . . . . . . . . . . . Frequency Transducer and Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I . . . DC Control Circuit Breaker . . . Terminal Board Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Panel Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Running Time Meter . . . . . . . . . . . . . . . . . . . . . Manual Speed Control . . . Control Box Relay Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Actuator and Sump and Filter (MEP105AOnly) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wattmeter Conversion Inspection and Replacement . . . . . . . . . Local-Remote . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning Drain and Inspection 3-177 F3-34 F3-33 3-178 3-176 Hose Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heater Elements . . . . . . . . . . . . . . . . Voltage Adjust Rheostat . Fuel Level Gage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Box Wiring Harness . . . . . . . . . . . . F4-11 4-48 F4-12 3-174 3-175 F3-32 F3-8 . . . . . . . . . . . . Hydraulic Sump and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Box . . . Air General Cleaner . Door Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Start-Run-StopSwitch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-18 Battle Short Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Panel Light Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Hydraulic Sump Actuator and Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kilowatt Meter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Synchronizing Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Voltage Sensing Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Actuator Service . . . . . . . . . . . . . . . . Fault Indicator. . . Control Cubicle Schematic Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal of Sump and Filter . . . . . . . . . . . . . . . . . . . . Engine Primer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Frequency Adjust Rheostat . . . . . . . . . . . . General . . . . . . . . . . . . . . . . . . . . . . . .Generator Set Controls (Cont) 3-116 3-117 3-135 3-126 3-134 3-104. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 C h a n g e 1 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crosspin Assembly . . . . . . . . . . . . . Governor Control Unit Air Cleaner and Related Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Press-to-Test Light Assembly Replacement . . . . . . . . . . . . . . . . . . . . . .1 F2-2 Governor Governor Grounding Control Control Unit Box Procedures Hand Lever and Bracket Assembly-. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Circuit Breaker Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coolant Temperature Gage . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-133 F3-19 F3-20 3-120 3-132 3-100. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . I Idler Pulley and Mounting Bracket F3-45 Assembly. . . . . 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 Frequency Adjust Rheostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Filter Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-26 3-147 3-145 3-146 3-146. . . . . . . . . . . . . . . . . . . . . . . (MEP105A of Sump Only and Except MEP115A) Hydraulic Sump and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hub and Brake and Front Unit Axle Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Cubicle Panel Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Cubicle Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pressure Gage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wiring Harness Replacement . . . . . . . . . . . . . . . . . . Single/Parallel Operation Switch . . Control Cubicle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Level Gage and Filler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal and Installation. . . . . . . . 2-5 3-178 4-39 2-4 F2-1 Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DC Circuit Breaker and Fault Indicator Lamp Test . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-27 4-22 4-24 F3-41 4-23 Coolant Pump and Motor Assembly . . . . . . . . . Fan Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thermostat Stitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lube Oil Filters Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Actuator Sump and Filter (MEP105A Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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. . . . . . . . . . . . . . . . . . . . . . . . . . Control Cubicle Panel Gages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rocker Arm Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . and Adjust Heater Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lead Bank Connection and Operation . . . . . . . . . . . . . . . . . . . Nozzle Holder and Line Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Pump and Drive Assembly (MEP105A Only) . . . . . . . . . . . . . . . . . . Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Deleted) . . . . . . . . . . . . . P u m p . . . . . . Inspection. . . . . . Battery Charge Ammeter . . . . . . . . . . . . . . . . . Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft Pulley Vibration Dampener . . . . . . . . F1-11 F1-23 F1-22 F1-4 F1-5 F1-24 C h a n g e 1 1 I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . Fuel System Diagram . . . . Synchronizing Light Assembly . . . Skid Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Cubicle Panel Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . and Replacement Repair Hoses and Fittings . . . . . . . . . Oil Pressure Transmitter . . . . . . . .ALPHABETICAL INDEX (Cont) Idler Pulley and Mounting Bracket (Cont) General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fan . . . . . .. . . . . . . . . Lifting Instructions . . Housing Group . . . . . . . . Inspection. . . . . . . . . . . . . . . . . Temperature Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . .F3-15 3-219 3-222 3-10 3-53 3-49 3-27 3-60 3-58 3-212 3-213 4-9 Angle Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wiring Harnesses . . . . . . . . . . . . . . . . . . Muffler Exhaust and Breather Pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspect. . . . . . . . . . . . . . . . . . . Hydraulic Actuator (MEP105A Only) . . . . . . . . . . . . . . . . . . . Slave Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Paralleling Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . and Replacement 4-25 4-26 Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Coler (MEP105A Only) . . . . . . . . Inspection Auxiliary Fuel Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fan Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Speed Switch . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Of Separately Packed Components . . . . . . . Paralleling Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pan . . . . . . . Installation And Setting -up Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Cubicle Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Door Holders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery Charging Alternator . . . . . . . Plate and Sleeve Assembly. . . . . . . . . . . . . Testing. . . . . . . . . . . . . . . . . . . . Starter Assembly. Electric Winterization System Diagram and Electric Heater Control Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Instruction Plate Battery Arrangement and Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Convenience Receptacle Assembly. . . . . . . .. . . . . . . . . . Load Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crosspin Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heating Elements . . . . . . . . Fuel Burning Winterization System Diagram and Heater Control Schematic Diagram . . . . . . . . . . . . . . Assembly . Interconnecting 5 0 / 6 0 400 Hz HZ and . . Selector T r a n s f e r .6 and Replacement Sensors . . . and . . . . . . . . . A s s e m b l y .1 4 3 3 . . . Capacities . . . F 3 . . .7 F 1 . . . . . .2 Installed Authorized List. . . . . . . . . . . M a i n t e n a n c e Maintenance . .1 3 4-41. .1 4 1 3 . . . . . . . . . . . . . . . .1 6 4 .2 8 4 . .3 9 4 .1 9 2 3 . . . . . . . . . . . K Kit Data and Instruction Plate Location. Oil Filter . . . . . . . . . and Fuel . . . . . . F 1 . . . F 3 . . P a n e l .1 4 0 3 . . . . . . . .3 8 Support Cap. .1 4 4 F 3 . . . .4 2 2 . . . . . . . . . . . . . . .1 6 5 3 . . . . . Group . . . . . . . . . . . . . . Switch. .1 6 2 F 4 . . . . . . . . . . .1 6 6 3 . Components .1 4 2 3 . Section III .2 1 5 Assembly .2 5 4 . . . 3 . . . . Transfer . . . .4 9 F 4 .4 5 F 4 . .1 9 8 3 . Pressure Transmitter . . . Replacement Diagram Precise . . . . . 3 . .2 4 3 . . . . or . and . . and . Utility . . . . . F 1 . . . . . .1 9 4 3 . . . . F 3 . . . . . . . . . . .2 1 4 3 . . . . . . . . . . . .ALPHABETICAL Instruction Operating Service Voltage Intake Plate (Cont) . 4 . . . . . .1 6 3 3 . Filters .2 7 Precise Interference Replacement Items Troop Suppression . General Removal . F 4 . Diagram Harness . . .1 9 5 3 .1 9 9 Inspection Lube Oil General Low Oil Oil I .8 Instructions Reconnection . Hose .1 6 4 3 . . . . . . . . and . . .4 0 .2 8 3 . . Reconnection Load Load Reject Relay Selector of Switch Contact Positions for Class Lockwire Lube Oil Assembly General Fuel Injector Pump Cooler . . . . . . . System .4 0 3 . . . . . . . . . . . . . Bank C o n t r o l G e n e r a l Installation Kit . . . . Filler Fuel F u e l General Lifting Start Load Assembly Gasket.4 6 3 . . .1 8 2 Operation . . . .1 9 3 Pressure Assembly Shutdown . . . F 3 . . .4 3 T4-8 Maintenance . . Connection Assembly Current . F1-6 F 1 . . Replacement . .2 1 L Lifting Center Frame Start and Aid Assembly Related Parts and . . Lines . . . . . Manifold F 3 . . . . . . Services . . . Valve Strainer. . . . . . . . Frame Aid . .1 0 Transformer . . . . . .1 4 4 . . . . . . Assembly .2 6 F 1 . . . G e n e r a l Main Load AC Contactor Board Terminal Reconnection Board Board . . . .7 8 B . . P u m p s . . . . Procedures . . Assembly . .7 4 . and . .1 6 1 3 . . . . . . . .4 4 4 . . . . . . . Operation P r e v e n t i v e Preventive Removal . . INDEX (Cont) Instructions . . . . Pumps . . . . Replacement . . . . . Checks . . . T 4 . Schematic Troubleshooting Wiring Wiring Load Diagram . . . . . . . . . . . . . .1 8 8 G e n e r a l Oil Level Gage . . . . . . . . . . . . . . . . and . . . . . . . . . . . . . . . . . . . . . . .1 2 F 2 . Supplies. . . . . Information P l a t e . . . . for . . . . . . . . . . . .2 0 0 3 . . Filler . . . . . . . . . . . . . . . . . . . . . . . Exhaust . . . . . .8 Starting Sopping . . .1 9 Humid Conditions . . . . . . . . . . and . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kit . . .9 F 1 . . . . . . . . . .3 8 3 . . . . . . . . . . . . . . . in . . . . . . . . . . . . . . . . . . . . . .1 0 I . . . . . . . . F 1 . . . . . . . . . . . . . . M A . . . . . . . . . . . . . . . . . . . . . . . . Filler . . . . . 3 . . . . . . . . . . . .2 0 Winterization Burning Winterization G e n e r a l Load Bank Wheel Operation . . . . . . . . . . . . . . . Areas . . . . . . and . . . . . . . . . . . .2 2 2 .7 2 .1 4 F 2 . . . . . . . . . . . . . . . . . . of . . . . . . C o l d Heat . . . . . .1 3 F 2 . . . . . . and . . . (Up to +125 o F) . . . . . . . . . . . Conditions Standby Service 2 . . Kit . . . . . . . .1 F 3 . . . . . . . . . . . . . . . . . . . . . .2 Lubrication . . . . . . . . . . . . . . . . with . . . . . . .2 Maintenance Maintenance Material.1 1 Engine G e n e r a l Operation Preparation Starting .2 0 1 F 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nozzle Testing. . . . . . . . . . . . . .2 F 3 . . . . Service Receipt . . .9 Winterization . . . . . . . . . . . . . Replacement Operation Electric Fuel Load Parallel Single Operation Electric Fuel Instructions Winterization Burning Bank .2 7 2 . . . . . . . . . .1 6 . . . . . .6 2 . . . . . . . . . . . . . ..1 0 F 2 . . . . . . . . . . . . . . . . . . . . . . . . . .2 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 . .8 3 . . . . . . . . . . . . . . . . . . . . . . . . . of Equipment Starting . . o Mounting Under Control Cubicle Removal for Remote Operation Operation at High Altitudes . . . . . . . . .2 3 2 2 2 2 2 . . . . . . . . . . . . . . . . . . . . . . .2 5 F) . . . . . . .1 5 2 . . .2 6 2 . .8 5 Breather Pipes General N Nozzle Holder . . .4 F 3 . . .. . Oil Level Gage and Filler . . . Instructions Data . . . . . M o v e m e n t Dismantling Reinstallation Muffler. . . . . . .7 (Mode II) . the . . . . . Cap . . . . . . . . . 2 . . . . . . . . . .2 5 2 . . . . . . . . . . . . . . . . . 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . and Line . . .1 2 F 2 . . . . . 3 . . . . . . . . . . F 2 . . . . . . . . . Elbow .2 4 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kit . . . . . Rainy Usual on E x t r e m e Extreme Water . Order Information . . . . . . . . . . . . . . . . . . . . . . . . . . . Holder and Replacement Assemblies 0 Oil Level Gage and . . .2 8 .1 4 F 2 . . . . . . . . . . . . . . . . . . Operation in Dusty or Sandy Areas O p e r a t i o n i n Operation in Operation Operation Operation Operation Exercise in in Under Under of Silt Snow . . Unusual Conditions . . . . . . Bit . . . . . . . . . . . Section . . Lines . . . .1 8 7 F 3 .4 1 General Inspection. . ( B e l o w . . .7 2 . Operating upon for after and . ... . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator Generator of Units Unit Auxiliary Material used Conjunction Equipment 2 . . . . .5 B . . . . . . . 2 . . . . Kit . . . . . . . . . . . . . . Assemblies . . . . .3 3 . . . . . . . . . . . . . IV . 2 . . . . . or . . Adapter . . . . . .. . . . . . . . . Stopping Operational (Mode I) Instructions . . . . . . . . . . . .1 8 . . . . . . . . . . . and . . . .3 A .1 1 F 2 . . . . . . . . . . .2 4 . . . . . . . . . . . . . .ALPHABETICAL INDEX (Cont) Lubrication Detailed Engine General Lubrication Lubrication Lubrication Lube Oil Information Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AC Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement Preventive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Radiator Grille . . . . . . . . . . . . . . . . . . . . . . . . . Removal and Installation . Relay Table Group General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General . . . . . . . . . General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ALPHABETICAL INDEX (Cont) Operator’s Maintenance 3-19 3-17 3-32 3-9 3-33 3-46 3-36 3-20 3-34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Special Relay Assembly (400 Hz) Inspection . . . . . . . . Hydraulic Sump (MEP105A Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AC Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement Plate and Sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Assembly Service . . . . . . . . Main Fuel Tank . . . . Fuel Filter and Strainer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Radio Suppression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Secondary Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Radioactive Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Special Relay Assembly (50/60 Hz) Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Panel Light Assemblies . . . . . . . . . . . . Precise Relay Assembly Class l (50/60 Hz) Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tactical Relay Assembly Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Interference Suppression Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checks and Services Maintenance Daily (Army and Navy) . . . . . . . . . . . . . . . . . . . . . . Monthly and Semi-Annual (Army and Navy) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F3-9 3-80 3-2 AC Ammeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-15 3-95 3-96 Assembly General . . . . Kilowatt Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-16 3-97 3-98 Assembly . . . . . . . . . . . . . . . . . . . . . Paralleling Receptacles Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preventive Maintenance Checks and Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-108 3-105 I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement AC Ammeter . . . . . . . . . . . . . . . . . . . . . . Day Tank Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Start Air Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Frequency Meter . . . General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gasket and Strainer . . . . 3-6 T4-1 3-5 3-7 T3-1 R Radio Interference Suppression 3-76 3-77 F3-11 3-78 A-4 A-8 3-148 3-153 3-150 3-151 3-152 3-149 General Methods Used to Attain Proper Suppression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Organization Maintenance-General . . . .8 C h a n g e 1 1 . . . . . . . . . . . . . . . . . . Replacement and Suppression Components . . . . . . . . . . . . . . . . . . . . . .F3-7 3-25 3-26 T3-1 3-41 3-38 3-35 3-56. . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F3-6 3-37 3-8 3-44 3-45 3-18 3-62. . . . . . . . . . . . . . . . . . . . . Organizational Maintenance Repair Parts (Army) . . . . . . . . . . . . . . . . . . Filler Cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Filter (MEP105A Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Radiator . Press-To-Test Light Assemblies . . . . . . . Fuel Buring Winterization Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Cleaner Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Transfer Pump . . . . . . . . . . . . . . . . . . . . . . . . . P A-3 Painting . . . . . . . . . . . . . . . . Load Measuring Unit Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 7 3 . . . . . . . . . . . Tappet Clearance . . . . . Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . P l a t e Plate P l a t e Plate . . . . . . . .4 8 3 . . . T r a y Pipe Pipe and . . .1 5 Control Speed Thermostat Thermostat Assembly General. . . . . . . . . . . . . . . . . . . . . .2 1 9 F 3 .2 1 8 3 . . . . . . . . . . . . . . . . . . 3 . . . . . . . . Igniter Kilowatt Gil Lines. . . . . . .8 4 F 4 . . Inspection Removal. . . . . . . . . . . . . . . . . . . . . . . . F 3 . . . . . . Assembly Meter Level Gage Light Assembly Fuel and Filler Press-To-Test Receptacle Secondary Shutter Slave Water Wiring Rocker Thermostat Assembly . . . .1 3 3 3 . . . Diagram a n d and a n d and . . . . . . . . . . . . . . (Not . . . . . . . . . . . . . . . . . . . . . . . . Wiring C l a s s Class C l a s s Class . . . Filter . . . . . . . .5 3 . . . . . . . . . . . . . . . . . . . . . . . Filter . . . . . . . Assembly . . . .2 2 4 3 . F 3 . . . . . . . . . .1 8 6 4 . . . . . . . . . . .2 0 6 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l . . . . . . . DC. . . . . . . . . . . . . . . . . l . . . .3 7 3 . Check . . . . . . . . . . . . . . . . . . . .1 Operational and . . . . F 3 . . . . . . . . . . . .4 4 3 . . . . . . .1 0 1 . . . . AC. . . . . . . . . . . . . . . . . . . . Plate. . . . . . . . . . . . Information Switch . . . . . . . . . . . . . . . . and Testing . . . . . . . . . . . . . . . . . . . . . . . .6 F 1 . . . . . . . . . . . . . . . . . . . . . . . 4 . . . . . . . . . . . .2 0 7 3 . . . .1 8 5 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 9 7 F 3 . . . . . . . . . . . . . . . . . . .1 7 F 1 .1 2 3 . . . . . . . .4 7 3 . . .1 0 6 3 . . . . . . . . Applicable) Assembly G e n e r a l Testing . . . . . . . . . . . .8 6 4 . . . . (Cont) a n d Related .3 9 3 . . . . . . . and . . . Fittings . .1 8 8 3 . . . . . . . . . . . . . . .ALPHABETICAL INDEX (Cont) Replacement Base Batteries B a t t e r y Breather Control Exhaust Hose. . Adjustment . . . . . . . . . . .2 2 0 F 4 .1 9 6 3 . Thermostat Receptacle Switch Pump Harness Arm . . F 3 . . . . Scope . . . . . . . . . . .1 2 A . . . . . . .9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . . . . . . . .1 3 3 . .4 9 3 . . . . . . . . . .1 8 F 1 . . . . . . . . .2 5 B . . . . . . . . . . . . Lamp . . . . Installation Switch Equipment 1 . . . . . . . . . . . 2. . . D C . . Replacement Fuse . . . . . . . . . . . . . . .D.4 6 Terminal Testing Board and . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fan . . . . . . . . . . . . . . . . . .1 2 9 4 . . . . . . . Assembly S Schematic A C . .5 Replacement Set I. Thermostat Tools and Box Switch Switch and . . . . . . . . . . . . . . F 1 . . . . . . . . . and . . . . . . . . . . . . . . . . .2 0 8 3 . . . . . . . . . . . . . . . . . . . . . . . . . and . . . . . . B-1 Secondary Assembly. . . . . . . . . . . . . . . . . . . 4-l. . . . . . . . . . . . .1 0 Assembly General Inspection Valve Valve Running Gear Locations. . . . .8 2 3 . . . . Shaft .1 9 F 1 . . . .8 3 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 9 7 F 1 . . . . . . . . . . . . . . . . . . . . .3 0 3 . . . . . . . . . . Components . . . . . . . .2 0 1-1. . . . . . . . . . .1 6 4 . . . . . Cubicle . . . . . . . . . . . . . . . . . . . . . . . . .2 0 9 4 . . . . . . . . . . . . . . . . . .1 4 Group . . . . 2. . .2 8 3 . . . . and Crate Shipment Shipping Special Speed Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 8 6 Replacement T 4 . . . . . . . . . . . . . . . . .1 6 V F 4 . . . . . . . .1 7 F 2 . . . . . . .3 4 4 .1 0 . . Operation Preventive Maintenance . . . DC. . . . DC. . . and . . . . .6 5 T 3 . . . . . . .4 Voltage Voltage Selector .3 6 4 . . . . . and . . . . . and . . . . . . . . . . . . . . . . .5 4-31. . . . . . . . . . . . . . . . . . . . . Tires . . .1 3 4 .1 3 F 1 . . . . . . . . . . . . . AC. . .1 5 F 1 . . . . . . . . . . . . .1 4 F 1 . . 4 . . . .3 Troubleshooting Troubleshooting AC. . . . . . . . . .3 2 F 2 . . . . . . . .3 0 T 4 . .2 9 4 . . . . F 3 .ALPHABETICAL Troubleshooting G e n e r a l .4 3 3 . . . . . . . Conversion W Water Pump . Contact . . . . . . . . . . . . . Switch . . . .2 0 6 4 . . . . . . . . . . . . . . . and . . . . . . . . . . Kit . . . . . . . 4 . . . . . .2 0 5 3 . Positions . . . . . . . . INDEX (Cont) 3 . Preventive Troubleshooting Wheels and Maintenance Checks Services I . . . . . . . . . . . .3 3 T4-6 General Kit Maintenance . Fan . Procedures . . . . . . . . . .3 5 Assembly General Wheel Wheel Wheel Wheel Replacement Alignment Bearings Brakes Hand Lever Bracket Assembly Mounting . . (Mode (Mode (Mode (Mode I) II) I) II) Diagram and and and and Plate Plate Plate Plate F 1 . . Utility. United States Army Chief of Staff The Adjutant General A. Precise Power. R. the Navy. COVELL. 60 HZ. 60 HZ. 60 KW. and the Air Force: CREIGHTON W. MARSCHALL Rear Admiral. USAF Official: DWIGHT W. USAF Chief of Staff Director of Administration Distribution: Army: To be distributed in accordance with DA Form 12-25D. BOWERS Major General.By Order of the Secretaries of the Army. MARCORPS CODE: AGC . operator maintenance requirements for Generator Sets: 60 KW. USN Commander. Colonel. General. RYAN. 60 KW. ABRAMS Official: VERNE L. 400 HZ Precise Power. Naval Facilities Engineering Command JOHN D. United States Army General. CEC. . . PIN: 013548-000 . 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