Request named documents for Generator Set, Engine Driven

DE&S Secretariat Land Equipment
DESSEC-PolSec LE-JSC-WPNS@mod.uk
Defence Equipment & Support
Maple 0a #2043
MOD Abbey Wood
Bristol BS34 8JH
Via:
26-Sep-17 Our Reference:2017/08151
,
Thank you for your e-mail dated 21st August 2017, requesting the following information:
Can I have AESP’s for Generator Set, Engine Driven (Gasoline), Battery Charging 14/28V 300/500 W (Hopkins)
I would be grateful if you could supply copies of any of the following documents but especially the 201 –
Operating Information.
6115-G-153-101 Purpose and Planning Information
6115-G-153-201 Operating Information
6115-G-153-302 Technical Description (contains wiring diagram)
6115-G-153-512 Failure Diagnosis
6115-G-153-601 Maintenance Schedule
6115-G-153-711 Illustrated Parts Catalogue
6115-G-153-811 Modification Instruction and Index
I am treating your correspondence as a request for information under the Freedom of Information Act 2000 (FOIA).
A search for the information has now been completed within the Ministry of Defence, and I can confirm that information in
scope of your request is held. The information you have requested can be found attached below, but some of the
information falls entirely within the scope of the absolute exemption provided for at Section 40 (2) (Personal Data) of the
FOIA and has been redacted.
Section 40(2) has been applied to some of the information in order to protect personal information as governed by the
Data Protection Act 1998. Section 40 is an absolute exemption and there is therefore no requirement to consider the
public interest in making a decision to withhold the information.
If you have any queries regarding the content of this letter, please contact this office in the first instance.
If you wish to complain about the handling of your request, or the content of this response, you can request an
independent internal review by contacting the Information Rights Compliance team, Ground Floor, MOD Main Building,
Whitehall, SW1A 2HB (e-mail CIO-FOI-IR@mod.uk). Please note that any request for an internal review should be made
within 40 working days of the date of this response.
If you remain dissatisfied following an internal review, you may raise your complaint directly to the Information
Commissioner under the provisions of Section 50 of the Freedom of Information Act. Please note that the Information
Commissioner will not normally investigate your case until the MOD internal review process has been completed. The
Information Commissioner can be contacted at: Information Commissioner’s Office, Wycliffe House, Water Lane,
Wilmslow, Cheshire, SK9 5AF. Further details of the role and powers of the Information Commissioner can be found on
the Commissioner's website at https://ico.org.uk/.
Yours Sincerely
DE&S Secretariat Land Equipment
1
ARMY EQUIPMENT
SUPPORT PUBLICATION
61 15-G-153-1O1
2nd Edition September 1996
(Superseding edition dated Jan 93)
CONDITIONS OF RELEASE
I
2
4
This information may be subject to privately owned rights.
GENERATOR SET, ENGINE DRIVEN
(GASOLINE), BATTERY CHARGING,
14/28 V, 300/500 W (HOPKINS)
PURPOSE AND PLANNING INFORMATION
REPRINTED INCORPORATING AMDTS 1-2
This publication co ntains information coven ng the requirements of
Category 1.0 at information levels 1, 2, 3 and 4
BY COMMAND OF THE DEFENCE COUNCIL
Ministry of Defence
Issued by
ARMY TECHNICAL SUPPORT AGENCY
DIRECTORATE OF TECHNICAL SERVICES
9609\WCP-0401
Page (i)/(ii)
ARMY EQUIPMENT
SUPPORT PUBLICATION
6115-G-153-101
2nd Edition
AMENDMENT RECORD
Amdt
No.
Incorporated
By (Signature)
Date
Amdt
Incorporated
No.
By_(Signature)
I
32
2
33
3
34
Date
35
5
36
6
37
7
38
8
39
9
40
10
41
11
42
12
43
13
44
14
45
15
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48
18
49
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20
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21
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27
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61
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62
9609\WCP-01 04
Sep 96
Page (iii)/(iv)
ARMY EQUIPMENT
SUPPORT PUBLICATION
6115-G-153-1O1
CONTENTS
PRELIMINARY MATERIAL
Front cover (title page)
Amendment record
Contents (this list)
Preface
Introduction
Related and associated publications
Related publications
Associated publications
Hazardous substances
Warnings
Generator - Three-quarter rear view
Generator - Three-quarter front view
Comments on AESP
Page
(1)1(u)
(iii)/(iv)
(v)
(vi)
(vi)
(vi)
(vi)
(vii)
(vii)
(viii)
(x)
(x)
Final leaf
Para
1
2
3
4
5
6
7
8
9
10
PURPOSE AND PLANNING INFORMATION
Equipment identity
Role
Brief description
Physical data
Performance
Fuel requirement
Environmental data
Transportation data
Manning requirements
Electrical data
Table
1
2
Performance data
Electrical data
Jan 03 (Amdt 2)
2
3/4
Page (v)
6115-G-153-101
ARMY EQUIPMENT
SUPPORT PUBLICATION
PREFACE
Sponsor:
DGES(A)
File ref:
Publications Agency:
ATSA Chertsey
Project No: 72111(210)
File ret:
INTRODUCTION
1
Service users should forward any comments on this publication through channels prescribed in AESP
0100-P-01 1-013. An AESP Form 10 is provided at the end of this publication; it should be photocopied and
used for forwarding comments on this AESP.
The subject matter of this publication may be affected by Defence Council Instructions (DCIs), Standing
Operating Procedures (SOPs) or by local regulations. When any such instruction, order or regulation
2
contradicts any portion of this publication, it is to be taken as the overriding authority.
RELATED AND ASSOCIATED PUBLICATIONS
Related publications
The Octad for the subject equipment consists of the publication shown opposite. All references are
prefixed by the first eight digits of this publication. The availability of the publications can be checked by
3
reference to the relevant Group Index (see AESP 0100-A-001-013).
.
.
9609\WCP-0401
Page (vi)
Sep 96
ARMY EQUIPMENT
SUPPORT PUBLICATION
6115-G-153-1O1
Information Level
Category/Sub-category
—
0
1
2
O
1
2
—
1
2
1
2
3
4
1
2
—
1
2
—
Purpose and Planning Information
Equipment Support Policy Directives
Purpose and Planning Information
Medical and Dental
Operating Information
Aide Memoire
Training Aids
1
2
3
4
User!
Operator
Unit
Maintenance
Field
Maintenance
Base
Maintenance
101
101
101
101
*
*
*
*
*
*
201
*
*
*
Technical Description
201
Installation Instructions
Preparation for Special Environments
Failure Diagnosis
Repair Instructions
Inspection Standards
Calibration Procedures
201
302
302
*
*
*
*
*
*
201
512
522
512
*
522
*
*
532
532
*
*
*
*
Maintenance Schedules
601
601
601
601
Illustrated Parts Catalogues
Commercial Parts Lists
Complete Equipment Schedules
Production Edition
Complete Equipment Schedules
Service Edition (Simple Equipment)
Complete Equipment Schedules
Service Edition (Complex Equipment)
Modification Instructions
General Instructions, Special Technical
Instructions and Servicing Instructions
Service Engineered Modification
Instructions (RAF only)
711
711
711
711
*
*
*
*
*
*
*
*
201
*
*
*
* Category/Sub-category not published
Associated publications
4
Reference
ThIe
AESP 2805-B-900-octad
Engine, Gasoline, S/Cyl, OHV Kubota
SEI 14411
Safety Precautions for Electrical Equipment
AESP 6150-A-i 00-201
Earthing and Electrical Protection
AESP 6140-A-i 00-013
Lead Acid Batteries
Hazardous substances
5
Before using any hazardous substance or material, the user must be conversant with the safety
precautions and first aid instructions:
5.1
On the label of the container it was supplied in.
5.2
On the material Safety Data Sheet.
5.3
In local Safety Orders and Regulations.
9609\WCP-040i
Sep 96
Page (vii)
6115-G-153-1O1
ARMY EQUIPMENT
SUPPORT PUBLICATION
WARNINGS
(1) GASOLtNE. GASOLINE FUEL VAPOUR IS EXPLOSIVE WHEN CONTAINED IN A
CONFINED SPACE.
(2)
GASOLINE. GASOLINE FUEL IS FLAMMABLE AND CONSTITUTES A FIRE HAZARD.
DO NOT SMOKE CIGARETTES OR EXPOSE NAKED FLAMES IN THE VICINITY OF THE
GENERATOR SET. SPECIAL CARE MUST BE TAKEN WHEN REFUELLING, SHUTDOWN
OR PERFORMING MAINTENANCE ACTIVITIES
EARTHING. THE EQUIPMENT MUST BE
PROPERLY EARTHED
BEFORE
ATTEMPTING TO OPERATE THE GENERATOR SET. WHEN USED WITH ANCILLARY
EQUIPMENT, IT IS ESSENTIAL THAT THE EARTHING INSTRUCTIONS FOR THAT
(3)
EQUIPMENT BE FOLLOWED.
(4)
ELECTRIC SHOCK. AN EARTH PIN WILL NOT NECESSARILY PROVIDE IMMUNITY
FROM ELECTRIC SHOCK. ADEQUATE UNIT SAFETY INSTRUCTIONS ARE TO BE HELD
AND SAFE WORKING PRACTICES AND PROCEDURES IMPLEMENTED.
(5) PERSONAL INJURY. MANUAL LIFTING OF THE TOTAL EQUIPMENT MUST BE
CARRIED OUT BY TWO PERSONS.
(6) TOXIC FUMES. IF THE GENERATOR IS OPERATED IN A CONFINED SPACE, ENSURE
THAT THE EXHAUST GASES ARE VENTED TO THE OUTSIDE ATMOSPHERE.
(7)
SKIN BURNS. THE ACOUSTIC CANOPY MUST BE FITTED TO THE GENERATOR SET
WHEN IN OPERATION. DURING SCHEDULED MAINTENANCE OR REPAIR ACTIVITIES,
EXERCISE EXTREME CARE WHEN CARRYING OUT TASKS ADJACENT TO THE EXHAUST
SYSTEM, ENGINE OR ALTERNATOR, AS BOTH ITEMS CAN RETAIN HEAT FOR SEVERAL
MINUTES AFTER SHUT DOWN.
(8) INFLAMMABLE GASES. HIGHLY INFLAMMABLE GASES ARE LIBERATED FROM
LEAD-ACID BATTERIES DURING CHARGING AND UP TO ONE HOUR AFTER COMPLETION
OF CHARGE. NAKED LIGHTS MUST NOT BE USED WHEN CHECKING ELECTROLYTE
LEVELS NOR MUST LIVE ELECTRICAL
BE MADE
DURING THESE PERIODS.
(9)
LEAD-ACID BATTERIES. CARE SHOULD BE TAKEN WHEN WORKING ON OR
AROUND HIGH CAPACITY LEAD-ACID BATTERIES AS THE EXTREMELY HIGH CURRENTS
GENERATED BY AN ACCIDENTAL SHORT CIRCUIT MAY CAUSE SEVERE BURNS OR THE
BATTERY TO EXPLODE. THEREFORE WATCHES, RINGS, ETC. SHOULD BE REMOVED
BEFORE COMMENCING BATTERY ASSOCIATED TASKS.
(10) FIRE HAZARD. WHEN THE JERRYCAN ADAPTOR ASSEMBLY IS STOWED IN THE
VALISE, SEEPAGE OF FUEL INTO THE VALISE CAN CONSTITUTE A FIRE HAZARD.
ENSURE THE JERRYCAN ADAPTOR ASSEMBLY IS DRAINED BEFORE STOWAGE.
(11) FIRE HAZARD. THE ACOUSTIC CANOPY MUST BE FITTED TO THE GENERATOR
SET WHEN IN OPERATION TO PREVENT COMBUSTIBLE MATERIALS (IE CAMOUFLAGE
NETTING) COMING INTO CONTACT WITH THE GENERATORS HOT SURFACES.
(12) PERSONAL INJURY. THE ACOUSTIC CANOPY MUST BE FITTED TO THE
GENERATOR SET TO PREVENT THE RISK OF PERSONNEL BEING CUT ON SHARP
UNPROTECTED EDGES.
(13) NOISE HAZARD. EAR DEFENDERS MUST BE WORN BY MAINTENANCE
PERSONNEL DURING SCHEDULED MAINTENANCE OR REPAIR TASKS WHEN THE
GENERATOR SET IS RUNNING WITH THE ACOUSTIC CANOPY REMOVED.
Page (viii)
Jan 03 (Amdt 2)
•
ARMY EQUIPMENT
SUPPORT PUBLICATION
6115-G-153-1O1
(14) FALLING HAZARD. THE ACOUSTIC CANOPY MUST NOT BE USED AS A SEAT OR
STEP DURING MAINTENANCE OPERATIONS. THE ACOUSTIC CANOPY WILL NOT BARE
WEIGHT WHEN REMOVED FROM THE GENERATOR SET.
(15) FIRE HAZARD. CARE MUST BE TAKEN WHEN DEPLOYING THE EXHAUST
EXTENSION MUFFLER TO ENSURE THAT IT IS NOT CLOSE TO OR CAN COME INTO
CONTACT WITH ANY COMBUSTIBLE MATERIAL.
(16) TOXIC FUMES. MATERIAL USED IN THE CONSTRUCTION OF THE GENERATOR SET
GIVE OFF TOXIC AND IRRITANT FUMES WHEN BURNT. DO NOT INHALE SMOKE OR
FUMES IF THE GENERATOR SET IS INVOLVED IN A FIRE.
(17) FIRE HAZARD. BEFORE USING THE GENERATOR SET, OPERATORS MUST BE
FAMILIAR WITH THE LOCATION OF SUITABLE FIRE EXTINGUISHING EQUIPMENT.
(18) TOXIC FUMES. MAINTAINERS OF THE EQUIPMENT MUST ENSURE THAT NO PART
OF THE WIRING LOOM IS ROUTED NEAR ANY POTENTIAL HOT SURFACE. I.E. EXHAUST
SYSTEM, ALTERNATOR OR ENGINE. ENSURE THAT ONLY WIRES WITH SILICON
INSULATION ARE USED IN ANY REPAIRS OR FUTURE MODIFICATIONS.
Jan 03 (Amdt 2)
Page (ix)
ARMY EQUIPMENT
SUPPORT PUBLICATION
611 5-G-1 53-101
Generator - Three-quarter rear view
Generator - Three-quarter front view
Page (x)
Jan 03 (Amdt 2)
ARMY EQUIPMENT
SUPPORT PUBLICATION
61 15-G-153-101
PURPOSE AND PLANNING INFORMATION
EQUIPMENT IDENTITY
1
The equipment identity data is as follows:
1.1
Equipment designations
:
Generator set, gasoline engine, 300/500 W, general purpose,
(battery charger), (Hopkins).
Generator set, gasoline engine, 300/500 W, ADAD only version,
(battery charger), (Hopkins).
1.2
NATO Stock No (NSN)
:
General purpose version — X2/61 15-99-983-9538.
ADAD only version — X2/61 15-99-396-0315.
1.3
Manufacturer
:
E. C. Hopkins Ltd.
ROLE
The 14/28 V, 300-500 W generator is intended to provide a portable d.c. source for charging lead-acid
batteries in the field. It may also be used as a general purpose d.c. source. Once the generator is running,
no action is required by the operator other than monitoring performance and refuelling as necessary.
2
BRIEF DESCRIPTION
The generator set comprises a rigid tubular steel frame which supports a gasoline powered engine, an
alternator and a control box assembly. The top and sides of the complete assembly are shrouded by an
acoustic cover held in place by spring loaded catches. Moulded fibreglass end panels are attached at the
front and rear ends of the assembly. Accessory equipment is stowed in a waterproof, removable bag
attached to the top of the acoustic cover. A recoil (rope) type starting system is incorporated for starting the
generator set engine. Output voltage is automatically regulated and the alternator is protected by a
3
resettable overload protection device.
PHYSICAL DATA
4
The main physical parameters of the assembled equipment are as follows:
4.1
Overall dimensions:
Length
-
470 mm.
Width
-
370 mm.
-
500 mm.
380 mm.
Height:
Full stowage bag
Empty stowage bag
4.2
Weight:
Full stowage bag
Empty stowage bag
4.3
-
-
43 kg.
36 kg.
Engine:
Fuel consumption at full load
Oil sump capacity
Aug 98 (Amdt 1)
-
0.69 kg/hour (approx).
0.55 litres
Page 1
6115-G-153-101
ARMY EQUIPMENT
SUPPORT PUBLICATION
PERFORMANCE
5
The generator set performance data is given in Table 1.
TABLE I PERFORMANCE DATA
Serial
Item
(1)
(2)
Maximum gross continuous output of
1
Performance data
(3)
2.7 kW (3.7 hp) at 3200 rpm.
engine.
Noise level.
2
63 dBA at 6 m.
FUEL REQUIREMENT
6
The fuel requirement for the equipment is as follows:
Either NATOGAS NATO F-57 or4* Gasoline to BS4040 or
ULGAS - NATO F-67 or Unleaded Gasoline to BS7070/EN228.
6.1
NOTE
ULGAS is the preferred fuel.
ENVIRONMENTAL DATA
7
The environmental data for the equipment is as follows:
The generator set is designed for continuous operation in weather conditions ranging from
arctic to tropical.
7.1
7.2 The engine is capable of starting and running in ambient temperatures between -32 and +44
degrees centigrade.
7.3 The operational altitude range is from sea level to 1500 m.
7.4 The storage temperature range for the equipment is between -13 and +55 degrees centigrade.
TRANSPORTATION DATA
8
The generator set is suitable for transportation by land, sea or air.
MANNING REQUIREMENTS
9
The manning requirements for the equipment are as follows:
9.1
One person can start and operate the equipment.
9.2 Two persons are required to lift the equipment safely.
.
9609\WCP-0401a
Page 2
Sep 96
6115-G-153-101
ARMY EQUIPMENT
SUPPORT PUBLICATION
ELECTRICAL DATA
10
Generator set electrical data is given in Table 2.
TABLE 2 ELECTRICAL DATA
Serial
Item
(1)
(2)
Data
(3)
I
Output.
14 V d.c. nominal, 300 W.
28 V d.c. nominal, 500 W.
2
Voltage regulation.
± 1%.
3
RFI suppression.
DEF STAN 59-41 Class A.
4
Circuit breaker rating.
50 A.
9609\WCP-0401 a
Sep 96
Page 3/4
xox-x-xxx-MXX
ARMY EQUIPMENT
SUPPORT PUBLICATION
COMMENT(S) ON AESP
To:
From:
ATSADTS3.2
Ha-Ha Road
Woolwich
LONDON SE18 4QF
Signed:
Telephone
Name
RanklGrade
DateS
ATSA DTS 3.2 USE ONLY
From:
To:
ATSADTS3.2
Ha-Ha Road
Woolwich
LONDON SE18 4QF
Thank you for commenting on AESP
Dated
Your reference
Action is being taken to:
Tick
Tick
Issue a revised/amended AESP
Under investigation
Incorporate comment(s) in future amendments
No action required
Remarks
Telephone No:
Name (Capitals)
AESP Form 10 (Issue 3 dated Oct 97)
RanklGrade
DateS
ARMY EQUIPMENT
SUPPORT PUBLICATION
61 15-G-153-201
February 1993
CONDITIONS OF RELEASE
1
.
.
2
4
This information may be subject to privately owned rights.
.
GENERATOR SET, ENGINE DRIVEN
(GASOLINE), BATTERY CHARGING,
14/28 V, 300/500 W (HOPKINS)
REPRINTED INCORPORATING AMDTS 1-3
OPERATING INFORMATION
This publication contains information covering the requirements of
Categories 2, 3, 4, 5-1 and 5-2 at information level 1.
BY COMMAND OF THE DEFENCE COUNCIL
Ministry of Defence
Issued by
ARMY TECHNICAL SUPPORT AGENCY
DIRECTORATE OF TECHNICAL SERVICES
72111(209)
ATSA Chertsey
9609\WCP-0402
Sep 96 (Amdt 1)
Page (i)/(ii)
ARMY EQUIPMENT
SUPPORT PUBLICATION
61 15-G-153-201
1st Edition
AMENDMENT RECORD
Amdt
No.
Incorporated
By (Signature)
Date
'
2
Amdt
Incorporated
No.
By_(Signature)
Date
32
h5QQ
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
9609\WCP-0402
Sep 96 (Amdt 1)
Page (iii)/(iv)
ARMY EQUIPMENT
SUPPORT PUBLICATION
6115-G-153-201
CONTENTS
PRELIMINARY MATERIAL
Front cover (title page)
Amendment record
Contents (this list)
Preface
Introduction
Related and associated publications
Related publications
Associated publications
Hazardous substances
Warnings and caution
Comment on AESP
Page
(i)I(ii)
(iii)/(iv)
(v)
(vi)
(vi)
(vi)
(vi)
(vii)
(vii)
(viii)
Final leaf
OPERATING INFORMATION
Chapter
I
2
3
4
General description
Operating procedures
Operator maintenance
Destruction of equipment
9609\WCP-0402
Sep 96 (Amdt 1)
Page (v)
6115-G-153-201
ARMY EQUIPMENT
SUPPORT PUBLICATION
PREFACE
Sponsor:
DGES(A)
File ref: DGES(A)/1 73/12/1 0/ES42b(3)
Publication Agency:
ATSA Chertsey
Project No: ES42b(3) 8793(119)
File ref: 11 MAGIO8/8793
INTRODUCTION
I
Service, users should forward any comments on this publication through the channels prescribed in
AESP 01 00-P-01 1-013. An AESP Form 10 is provided at the end of this publication; it should be
photocopied and used for forwarding comments on this AESP.
2
The subject matter of this publication may be affected by Defence Council Instructions (DCls),
Standing Operating Procedures (SOPs) or by local regulations. When any such instruction, order or
regulation contradicts any portion of this publication it is to be taken as the overriding authority.
RELATED AND ASSOCIATED PUBLICATIONS
Related publications
The Octad for the subject equipment consists of the publications shown opposite. All references are
prefixed with the first eight digits of this publication. The availability of the publications can be checked by
reference to the relevant Group Index (see AESP 0100-A-001-013).
3
.
9609\WCP-0402
Page (vi)
.
(Amdt 1) Sep 96
6115-G-153-201
ARMY EQUIPMENT
SUPPORT PUBLICATION
Information Level
Category/Sub-category
—
—p-1
1
2
0
2
1
2
3
4
1
2
1
2
3
4
6
1
2
7
—
1
8
2
—
1
2
3
4
User!
Operator
Unit
Maintenance
Field
Maintenance
Base
Maintenance
Purpose and Planning Information
Equipment Support Policy Directives
Purpose and Planning Information
Medical and Dental
Operating Information
Aide Memoire
Training Aids
101
101
101
101
*
*
*
*
*
*
*
*
*
*
*
*
Technical Description
201
302
Installation Instructions
Preparation for Special Environments
Failure Diagnosis
Repair Instructions
Inspection Standards
Calibration Procedures
201
Maintenance Schedules
201
*
Illustrated Parts Catalogues
Commercial Parts Lists
Complete Equipment Schedules
Production Edition
Complete Equipment Schedules
Service Edition (Simple Equipment)
Complete Equipment Schedules
Service Edition (Complex Equipment)
Modification Instructions
General Instructions, Special Technical
Instructions and Servicing Instructions
Service Engineered Modification
Instructions (RAF only)
302
*
*
*
*
*
*
201
512
512
201
522
522
*
532
532
*
*
*
*
601
601
601
601
711
711
711
711
*
*
*
*
*
*
*
*
*
*
*
*
*
* Category/Sub-category not published
Associated publications
4
Reference
Tftle
AESP 2805-B-900
Engine, Gasoline, S1CyI, OHV Kubota
SEI 14411
Safety Precautions for Electrical Equipment
AESP 6150-A-100-201
Earthing and Electrical Protection
AESP 6140-A-i 00-013
Lead Acid Batteries
Hazardous substances
5
Before using any hazardous substance or material, the user must be conversant with the safety
precautions and first aid instructions:
5.1
On the label of the container it was supplied in.
5.2
On the material Safety Data Sheet.
5.3
In local Safety Orders and Regulations.
9609\WCP-0402
Sep 96 (Amdt 1)
Page (vii)
6115-G-153-201
ARMY EQUIPMENT
SUPPORT PUBLICATION
WARNINGS
(1) GASOLINE. GASOLINE FUEL VAPOUR IS EXPLOSIVE WHEN CONTAINED IN A
CONFINED SPACE.
GASOLINE. GASOLINE FUEL IS FLAMMABLE AND CONSTITUTES A FIRE HAZARD.
DO NOT SMOKE CIGARETTES OR EXPOSE NAKED FLAMES IN THE VICINITY OF THE
GENERATOR SET. SPECIAL CARE MUST BE TAKEN WHEN REFUELLING, SHUTDOWN
(2)
OR PERFORMING MAINTENANCE ACTIVITIES
EARTHING. THE EQUIPMENT MUST BE PROPERLY EARTHED BEFORE
ATTEMPTING TO OPERATE THE GENERATOR SET. WHEN USED WITH ANCILLARY
EQUIPMENT, IT IS ESSENTIAL THAT THE EARTHING INSTRUCTIONS FOR THAT
(3)
EQUIPMENT BE FOLLOWED.
ELECTRIC SHOCK. AN EARTH PIN WILL NOT NECESSARILY PROVIDE IMMUNITY
FROM ELECTRIC SHOCK. ADEQUATE UNIT SAFETY INSTRUCTIONS ARE TO BE HELD
AND SAFE WORKING PRACTICES AND PROCEDURES IMPLEMENTED.
(4)
(5)
PERSONAL INJURY. MANUAL LIFTING OF THE TOTAL EQUIPMENT MUST BE
CARRIED OUT BY TWO PERSONS.
TOXIC FUMES. IF THE GENERATOR IS OPERATED IN A CONFINED SPACE, ENSURE
THAT THE EXHAUST GASES ARE VENTED TO THE OUTSIDE ATMOSPHERE.
(6)
SKIN BURNS. THE ACOUSTIC CANOPY MUST BE FITTED TO THE GENERATOR SET
WHEN IN OPERATION. DURING SCHEDULED MAINTENANCE OR REPAIR ACTIVITIES,
EXERCISE EXTREME CARE WHEN CARRYING OUT TASKS ADJACENT TO THE EXHAUST
SYSTEM, ENGINE OR ALTERNATOR, AS BOTH ITEMS CAN RETAIN HEAT FOR SEVERAL
(7)
MINUTES AFTER SHUT DOWN.
(8)
INFLAMMABLE GASES. HIGHLY INFLAMMABLE GASES ARE LIBERATED FROM
LEAD-ACID BATTERIES DURING CHARGING AND UP TO ONE HOUR AFTER COMPLETION
OF CHARGE. NAKED LIGHTS MUST NOT BE USED WHEN CHECKING ELECTROLYTE
LEVELS NOR MUST LIVE ELECTRICAL CONNECTIONS/DISCONNECTIONS BE MADE
DURING THESE PERIODS.
(9)
LEAD-ACID BATTERIES. CARE SHOULD BE TAKEN WHEN WORKING ON OR
AROUND HIGH CAPACITY LEAD-ACID BATTERIES AS THE EXTREMELY HIGH CURRENTS
GENERATED BY AN ACCIDENTAL SHORT CIRCUIT MAY CAUSE SEVERE BURNS OR THE
BATTERY TO EXPLODE. THEREFORE WATCHES, RINGS, ETC. SHOULD BE REMOVED
BEFORE COMMENCING BATTERY ASSOCIATED TASKS.
(10) FIRE HAZARD. WHEN THE JERRYCAN ADAPTOR ASSEMBLY IS STOWED IN THE
VALISE, SEEPAGE OF FUEL INTO THE VALISE CAN CONSTITUTE A FIRE HAZARD.
ENSURE THE JERRYCAN ADAPTOR ASSEMBLY IS DRAINED BEFORE STOWAGE.
(11) FIRE HAZARD. THE ACOUSTIC CANOPY MUST BE FITTED TO THE GENERATOR
SET WHEN IN OPERATION TO PREVENT COMBUSTIBLE MATERIALS (IE CAMOUFLAGE
NETTING) COMING INTO CONTACT WITH THE GENERATORS HOT SURFACES.
(12) PERSONAL INJURY. THE ACOUSTIC CANOPY MUST BE FITTED TO THE
GENERATOR SET TO PREVENT THE RISK OF PERSONNEL BEING CUT ON SHARP
UNPROTECTED EDGES.
(13) NOISE HAZARD. EAR DEFENDERS MUST BE WORN BY MAINTENANCE
PERSONNEL DURING SCHEDULED MAINTENANCE OR REPAIR TASKS WHEN THE
GENERATOR SET IS RUNNING WITH THE ACOUSTIC CANOPY REMOVED.
Page (Viii)
Jan 03 (Amdt 3)
ARMY EQUIPMENT
SUPPORT PUBLICATION
6115-G-153-201
(14) FALLING HAZARD. THE ACOUSTIC CANOPY MUST NOT BE USED AS A SEAT OR
STEP DURING MAINTENANCE OPERATIONS. THE ACOUSTIC CANOPY WILL NOT BARE
WEIGHT WHEN REMOVED FROM THE GENERATOR SET.
(15) FIRE HAZARD. CARE MUST BE TAKEN WHEN DEPLOYING THE EXHAUST
EXTENSION MUFFLER TO ENSURE THAT IT IS NOT CLOSE TO OR CAN COME INTO
CONTACT WITH ANY COMBUSTIBLE MATERIAL.
(16) TOXIC FUMES. MATERIAL USED IN THE CONSTRUCTION OF THE GENERATOR SET
GIVE OFF TOXIC AND IRRITANT FUMES WHEN BURNT. DO NOT INHALE SMOKE OR
FUMES IF THE GENERATOR SET IS INVOLVED IN A FIRE.
(17) FIRE HAZARD. BEFORE USING THE GENERATOR SET, OPERATORS MUST BE
FAMILIAR WITH THE LOCATION OF SUITABLE FIRE EXTINGUISHING EQUIPMENT.
(18) TOXIC FUMES. MAINTAINERS OF THE EQUIPMENT MUST ENSURE THAT NO PART
OF THE WIRING LOOM IS ROUTED NEAR ANY POTENTIAL HOT SURFACE. I.E. EXHAUST
ENSURE THAT ONLY WIRES WITH SILICON
SYSTEM, ALTERNATOR OR ENGINE.
INSULATION ARE USED IN ANY REPAIRS OR FUTURE MODIFICATIONS.
CAUTION
EQUIPMENT DAMAGE. Ensure the air Iouvres in the acoustic cover are not obstructed.
Jan 03 (Amdt 3)
Page (Ix)I(x)
ARMY EQUIPMENT
SUPPORT PUBLICATION
61 15-G-153-201
This proforma should be retained in this publication. When required for use, reproduce locally.
COMMENT ON AESP
To: ARMY TECHNICAL SUPPORT AGENCY
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Repository Road
Woolwich
London SE18 4QA
From:
Senders Reference:
Tel No
Date:
Title of AESP: Generator Set, Engine Driven (Gasoline), Battery Charging, 14/28 V, 300/500 W (Hopkins)
COMMENT
Signed
To:
From:
ARMY TECHNICAL SUPPORT AGENCY
Directorate of Technical Services
Repository Road
Woolwich
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Thank you for commenting on AESP 61 15-G-153-201
* Action is being taken to:
*
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Signed:
Date
6115-G-153-201
ARMY EQUIPMENT
SUPPORT PUBLICATION
CHAPTER 1
GENERAL DESCRIPTION
CONTENTS
Para
Introduction
1
2
8
11
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
Role
Facilities and general data
Construction
Brief functional description
Engine
Air intake system
Ignition system
Exhaust system
Lubrication system
Fuel system (WARNINGS)
Cooling
Starting system
Alternator
Control box
Front panel
Connectors
Operator controls
Front panel controls
Rear end panel controls
Indicators
Page
Table
1
2
3
4
5
Generator set general data
Connectors
Front panel controls
Rear end panel controls
Front panel indicators
.
.
. .
2
3
4
5
6
7
8
9
10
Feb 93
11
11
13/14
Page
Fig
1
3
10
Generator set - Three-quarter rear view
Generator set - Three-quarter front view
Component locations - Front left-hand side
Component locations - Rear right-hand side
Generator set simplified block diagram
Control box assembly
Connector locations
Front panel control locations
Rear end panel control locations .
Front panel indicator locations
. .
4
4
5
6
7
9
10
12
12
13/14
Chap 1
Page 1
6115-G-153-201
ARMY EQUIPMENT
SUPPORT PUBLICATION
INTRODUCTION
Role
I
The 14/28 V, 300/500 W generator set is intended to provide a portable d.c. source for
charging lead-acid batteries in the field. It may also be used as a general purpose d.c. source.
General views of the generator set are shown in Figs 1 and 2. These diagrams also indicate the
generator set orientation and should be referred to when explanations of component locations are
given.
FACILITIES AND GENERALDATA
The generator set provides two selectable nominal outputs of 14 V d.c. (300 W) and 28 V d.c.
(500 W). A rotary control on the front panel is used to set the voltage level of the selected output.
The output is variable over the ranges 12.3 V - 16 V and 24 V - 32 V.
2
An oil level sensor acts to shut the engine down when the engine oil level becomes too low.
The alternator is protected by a. resettable circuit breaker.
3
The top and sides of the complete assembly are shrouded by a metal cover which provides
acoustic attenuation and weather protection.
4
5
A removable, waterproof accessory equipment bag containing all necessary generator
accessory equipment is attached to the top of the acoustic cover.
6
A recoil (rope) type starting system is incorporated for starting the generator set engine.
7
Fuel is supplied to the engine externally from a jerrycan.
.
.
Chap 1
Page 2
Feb 93
ARMY EQUIPMENT
SUPPORT PUBLICATION
61 15-G-153-201
TABLE 1 GENERATOR SET GENERAL DATA
Serial
Description
Value
(1)
(2)
(3)
1
Overall dimensions:
Length
470 mm
.
Width
Height
2
Weight
-
370 mm
-
with full stowage bag
500 mm
with stowage bag removed
380 mm
with full stowage bag
43 kg
with stowage bag removed/empty
36 kg
3
Operating ambient temperature range
-32° C to 44° C
4
Output
14 V d.c. nominal, 300 W
(12.3 V to 16 V manual
adjustment)
28 V d.c. nominal, 500 W
(24 V to 32 V manual
adjustment)
Feb93
Chap 1
Page 3
61 15-G-153-201
ARMY EQUIPMENT
SUPPORT PUBLICATION
LEFT-HAND
SIDE
.
Fig 1 Generator set - Three-quarter rear view
.
.
Fig 2 Generator set - Three-quarter front view
Chap 1
Page 4
Aug 98 (Amdt 2)
ARMY EQUIPMENT
SUPPORT PUBLICATION
611 5-G-l 53-201
Construction
8
The components of the 14/28 V generator set are mounted on a rigid tubular steel frame. The top and
sides of the complete assembly are shrouded by a metal acoustic cover. Moulded fibreglass panels are
attached at the front and rear ends of the assembly. A removable, waterproof accessory equipment bag is
situated on top of the acoustic cover.
9
The main items of the generator set are a single cylinder gasoline engine, an alternator and a control
box assembly. The engine and alternator are combined to form an assembled unit which is mounted onto
the tubular frame via resilient mountings.
10
Figs 3 and 4 show views of the generator set with the acoustic cover removed and indicate the locations
of the component items associated with the operation and maintenance activities covered in this document.
-4
1 Frame
2 Front panel
3 Earth stud terminal
4 Front end cover
5 Fuel connection point
6 Dipstick/oil filler plug
Fig 3 Component locations - Front left-hand side
Chap 1
Aug 98 (Amdt 2)
Page 5
ARMY EQUIPMENT
SUPPORT PUBLICATION
611 5-G-1 53-201
.
t
.
8
.
1
Carrying handle/shoulder strap lugs
2 Carrying handle/shoulder strap lugs
3 Rear end panel
4 Starter pull-cord
5 Fuel primer control
6 Choke control
7 Air filter system
8 Exhaust silencer unit tail pipe
Fig 4 Component locations - Rear right-hand side
.
Chap 1
Page 6
Aug 98 (Amdt 2)
6115-G-153-201
ARMY EQUIPMENT
SUPPORT PUBLICATION
Brief functional description
11
The main functional areas of the 14/28 V, 300/500 W generator set are shown in Fig 5.
Once the operator has set the output voltage level, engine speed and output voltage are regulated to
suit the load requirements.
12
13
Instrumentation on the front panel displays the output voltage and current continuously when the
generator set is in operation. Lamp indicators on the front panel indicate the selected output voltage range
and the presence of an output overload condition.
In the event of an output over load condition, a resettable overload protection device disconnects output
power from the output terminals.
14
I
I
I
1
OUTPUT
SOCKET
(ADADS
SERVICE
ONLY)
L
Fig 5 Generator set simplified block diagram
Feb 93
Chap 1
Page 7
6115-G-153-201
ARMY EQUIPMENT
SUPPORT PUBLICATION
ENGINE
15 The generator set alternator is driven by a Kubota GH12O, single cylinder, overhead valve, four cycle,
gasoline fuelled, 121 cm3 engine, which is air cooled. There are a number of engine mounted accessories
and support systems used for controlling engine operation.
Air intake system
16
Air intake to the engine carburettor is via an air filter assembly incorporating disposable and re-usable
air filter elements.
Ignition system
17
The ignition system is a transistor/magnet type comprising a transistor/magnet ignition unit and a spark
plug.
Exhaust system
WARNINGS
TOXIC FUMES. IF THE GENERATOR IS OPERATED IN A CONFINED SPACE, ENSURE
THAT THE EXHAUST GASES ARE VENTED TO THE OUTSIDE ATMOSPHERE.
(1)
(2)
FIRE HAZARD. CARE MUST BE TAKEN WHEN DEPLOYING THE EXHAUST
EXTENSION MUFFLER TO ENSURE THAT IT IS NOT CLOSE TO OR CAN COME INTO
CONTACT WITH ANY COMBUSTIBLE MATERIAL.
18
Exhaust gas expelled from the engine is routed through a silencer unit and out to the atmosphere via a
flexible exhaust extension pipe.
Lubrication system
19 An oil splash system is incorporated for lubricating the moving parts of the engine. A low engine oil
level sensing system acts to shut the engine down and disable engine starting until the correct oil level is
restored. An oil drain plug is situated at the bottom left-hand side of the crank case.
Fuel system
(1)
GASOLINE. GASOLINE FUEL VAPOUR IS EXPLOSIVE WHEN CONTAINED IN A
CONFINED SPACE.
(2)
GASOLINE. GASOLINE FUEL IS FLAMMABLE AND CONSTITUTES A FIRE HAZARD.
Gasoline fuel for powering the engine is supplied externally from a jerrycan, via a 3.7 m long jerrycan
adaptor assembly stowed in the accessory equipment bag. An electrical fuel pump, mounted on the
generator set frame, forces fuel to the carburettor via an in-line, disposable fuel filter. The fuel system is
20
primed using a rubber bubble type priming control mounted on the generator set rear end cover.
Cooling
21
The engine fan draws cooling air in through grills in the engine fan cover and forces it around the
engine.
Starting system
22
A conventional recoil (rope) type starting system is incorporated at the rear end of the engine.
Chap 1
Page 8
Jan 03 (Amdt 3)
.
ARMY EQUIPMENT
SUPPORT PUBLICATION
61 15-G-153201
ALTERNATOR
The alternator assembly Is a separately excited type and Is of brush gear construction. It is
assembled onto the engine drive shaft to form a combined engine/alternator unit. An automatic
23
voltage regulator (AVR) is an integral part of the alternator assembly and forms part of the
excitation system. The AVR provides output sensing and excitation current control functions for
maintaining the alternator output voltage.
CONTROL BOX
The control box assembly (Fig 6) is resiliently mounted at the front end of the generator set
and houses the operation control and indication circuitry.
24
Front panel
The front panel is the control
which carries the majority of operator controls, the
main output terminals and the necessary instrumentation and indicators for monitoring generator
set performance. Other controls, used for engine starting, are situated on the generator set rear
end panel.
25
CIRCUIT DIAGRAM
Fig 6 Control box assembly
Feb 93
Chap 1
Page 9
61 15-G-153-201
ARMY EOUIPMENT
SUPPORT PUBLICATION
CONNECTORS
26
External connectors are provided on the control box front panel and below the front panel on
a bracket attached to the right-hand side of the generator set frame. The connector locations and
identifications are shown in Fig 7 and their functions are described in Table 2.
.
TABLE 2 CONNECTORS
Serial
Connector
Fig Item
Function
Ref.
(1)
(2)
I
2
(3)
+- Output terminal
1
Output terminal.
2
Negative main output load connection
terminal
Earth terminal
3
Earthing point for the metal. earth spike
and the negative output terminal.
4
Six pin output socket connected to the
main output terminals (fitted only to
generator sets supplied for ADADS
.
3
4
(4)
ADADS service output
socket (no ident)
Positive main output. load connection
terminal
.
service use)
1
.
Fig 7 Connector locations
Chap 1
Page 10
Feb 93
ARMY EQUIPMENT
SUPPORT PUBLICATION
61 15-G-153-201
OPERATOR CONTROLS
Operator controls are provided on the control box front panel and on the rear end panel of
the generator set.
27
Front panel controls
28
Front panel mounted controls are shown in Fig 8 and their functions are given in Table 3.
TABLE 3 FRONT PANEL CONTROLS
Control
Serial
Function
Fig Item
Ref.
(1)
1
(2)
Circuit breaker (no
1
ident)
2
ENGINE STOP
ADJUST VOLTS
Pushbutton switch, which shuts the
engine down
3
A rotary control used for adjusting the
generator set output voltage
4
Three position rotary switch for
selecting the generator set output
potentiometer control
4
RANGE SELECTOR
A resettable 50 A magnetic circuit
breaker providing alternator overload
protection
2
pushbutton switch
3
(4)
(3)
switch
mode:
OFF = Alternator output disabled
14
= 14 V output mode selected
28
= 28 V output mode selected
Rear end panel controls
29
Rear end panel controls are shown in Fig 9 and their functions are given in Table 4.
TABLE 4 REAR END PANEL CONTROLS
Serial
Control
(1)
(2)
Fig Item
Function
Ref.
(4)
Carburettor choke
control (no Ident)
I
Carburettor choke starting aid control,
which is pulled outwards before recoil
starter is operated
2
Fuel priming control
2
Rubber bubble type pump used for
priming the fuel system before startIng
the engine
3
Recoil starter pull-cord
grip
3
Pulled to turn engine when starting up
1
Feb 93
(3)
Chap 1
Page 11
ARMY EQUIPMENT
SUPPORT PUBLICATION
61
3
2
1
in
4
.
.
(di
Fig 8 Front panel control locations
3
.
1
.
Fig 9 Rear end panel control locations
Chap 1
Page 12
Feb93
ARMY EQUIPMENT
SUPPORT PUBLICATION
INDICATORS
All indicators (i.e. instrumentation and indicator lamps) are mounted on the control box front
panel. The indicator locations are shown in Fig 10 and their functions are given in Table 5.
30
TABLE 5 FRONT PANEL INDICATORS
Serial
Control
Function
Fig Item
Ref.
(1)
1
2
(2)
(4)
(3)
OFF indicator lamp
Hours run meter (no
ident)
1
2
Red LED lamp which lights when the
magnetic circuit breaker is open
A meter which records the total elapsed
operating time of the generator set
engine
3
Ammeter (no ident)
3
A meter displaying the current drawn by
the output load
4
Voltmeter (no ident)
4
A meter displaying the output voltage
5
14 indicator lamp
5
Yellow LED lamp which lights when the
RANGE SELECTOR switch is in the 14 V
mode position
6
28 indicator lamp
6
Green LED lamp which lights when the
RANGE SELECTOR switch is in the 28 V
mode position
Fig 10 Front panel indicator locations
Chap 1
Feb 93
13/14
ARMY EQUIPMENT
SUPPORT PUBLICATION
6115-G-153-201
CHAPTER 2
OPERATING PROCEDURES
CONTENTS
Para
1
2
5
6
7
8
9
10
11
12
14
15
Introduction
Preparation for use
Siting (WARNING)
Earthing (WARNING)
Fitting the exhaust extension pipe (WARNING)
Connecting the fuel supply (WARNING)
Pre-starting checks (CAUTION)
Lubricating oil level
Leakages
Connecting a load
Starting procedure
Generator set shut down procedure
Draining the jerrycan adaptor assembly before stowage (WARNING)
Page
Fig
1
2
3
4
5
6
7
8
Generator set lifting shoulder straps/handles (ADADS service only)
Earthing spike connections
Fitting the exhaust extension pipe
Connecting the fuel supply
Engine oil levels
Front end controls/indicators/connectors locations
Rear end control locations
Draining the jerrycan adaptor assembly
2
3
4
5
6
8
9
10
Chap 2
Aug 98 (Amdt 2)
Page 1
I
611 5-G-1 53-201
ARMY EQUIPMENT
SUPPORT PUBLICATION
INTRODUCTION
This chapter provides the information necessary to enable personnel to prepare the generator set for
use and to operate it efficiently. It is essential that the operator is fully conversant with the equipment and
the contents of Chapter 1 before attempting to operate the generator set.
1
.
PREPARATION FOR USE
Siting
WARNING
PERSONAL INJURY. TWO PERSONS ARE REQUIRED TO CARRY THE TOTAL EQUIPMENT
SAFELY.
For generator sets supplied for ADADS service use, two shoulder straps and two carrying handles are
provided in the accessory equipment bag for lifting and carrying the generator set. The straps and handles
incorporate snap-action fasteners, which attach to the two carrying lugs at the front and rear ends of the
generator set frame.
2
.
CARRYING
.
Fig 1 Generator set lifting shoulder straps/handles (ADADS service only)
The ground site for operating the generator set should be firm and as level as possible. If no level
ground is available, the generator set may be operated at any angle not exceeding 15 degrees from the
3
horizontal in any plane.
Placing of the generator set must be such that exhaust gas does not pollute personnel working or living
environments.
4
Chap 2
Page 2
Aug 98 (Amdt 2)
S
6115-G-153-201
ARMY EQUIPMENT
SUPPORT PUBLICATION
Earthing
WARNING
EARTHING. BEFORE THE GENERATOR IS STARTED UP, A GOOD EARTH CONNECTION
MUST BE ESTABLISHED USiNG THE GENERATOR SET EARTH TERMINAL.
5
When the equipment is used in the field, the earthing spike and cable stowed in the accessory
equipment bag must be used, as follows:
Select an area of ground which is most easily penetrable by the earthing spike and drive the spike
into the ground.
5.1
NOTE
Wetting dry ground will improve penetration by the spike and will also improve electrical contact.
Connect the earthing cable between the earthing spike and the generator set earth terminal
5.2
(Fig 2).
EARTH
TERMINAL
EARTHING
SPIKE
T701201-O6
Fig 2 Earthing spike connections
Aug 98 (Amdt 2)
Chap 2
Page 3
6115-G-153-201
ARMY EQUIPMENT
SUPPORT PUBLICATION
Fitting the exhaust extension pipe
WARNINGS
.
(1) TOXIC FUMES. EXHAUST GASES ARE TOXIC AND CAN QUICKLY REACH TOXIC
PROPORTIONS IF BASIC PRECAUTIONS ARE NOT FOLLOWED. IF THE GENERATOR IS
TO BE USED IN A CONFINED SPACE, A STANDARD ISSUE EXHAUST EXTENSION MUST
BE FITTED. THE EXHAUST EXTENSION MUST NOT BE FURTHER MUFFLED OR
RESTRICTED IN ANY WAY FROM ITS ORIGINAL DESIGN AS THE RESULTING BACK
PRESSURE COULD CAUSE ADDITIONAL LEAKS TO OCCUR OR DAMAGE THE ENGINE.
EXTREME CARE MUST BE TAKEN TO ENSURE THAT EXHAUST GASES ARE VENTED
SAFELY AWAY FROM ANY PERSONNEL IN THE VICINITY WITH DUE CONSIDERATION
BEING GIVEN TO TOPOGRAPHY AND PREVAILING WIND CONDITIONS. HARMFUL
CONCENTRATIONS CAN BE ODOURLESS AND NOT VISUALLY PERCEPTIBLE.
(2) FIRE HAZARD. CARE MUST BE TAKEN WHEN DEPLOYING THE EXHAUST EXTENSION
MUFFLER TO ENSURE THAT IT IS NOT CLOSE TO OR CAN COME INTO CONTACT WITH
ANY COMBUSTIBLE MATERIAL.
Obtain the exhaust extension pipe from the accessory equipment stowage bag. Apply grease (ROCAL
J166) to the mating surfaces of the exhaust silencer tail pipe and the exhaust extension pipe. Fit the pipe to
the exhaust silencer tail pipe, which is visible below the acoustic cover at the right-hand side of the generator
set (Fig 3).
6
.
.
EXHAUST
EXTENSION
PIPE
.
Fig 3 Fitting the exhaust extension pipe
Chap 2
Page 4
Jan 03 (Amdt 3)
6115-G-153-201
ARMY EQUIPMENT
SUPPORT PUBLICATION
Connecting the fuel supply
WARNING
GASOLINE.
GASOLINE FUEL IS FLAMMABLE AND CONSTITUTES A FIRE HAZARD. DO
NOT SMOKE CIGARETTES OR EXPOSE NAKED FLAMES IN THE VICINITY OF THE
GENERATOR SET. SPECIAL CARE MUST BE TAKEN WHEN REFUELLING, SHUTTING
DOWN OR PERFORMING MAINTENANCE ACTIVITIES.
Obtain the jerrycan adaptor assembly from the accessory equipment bag, insert the dip tube into the
jerrycan and secure the filler neck adaptor to the jerrycan. Connect the fuel pipe to the quick-release type
fuel connection point below the acoustic cover at the front end of the left-hand side of the generator set.
Ensure that a positive snap lock is experienced and the coupling socket sleeve slides forward. Set the fuel
7
tap on fully (tap handle in line with pipe) by turning it in a counter-clockwise direction.
Fig 4 Connecting the fuel supply
Jan 03 (Amdt 3)
Chap 2
Page 5
6115-G-153-201
ARMY EQUIPMENT
SUPPORT PUBLICATION
PRE-STARTING CHECKS
WARNINGS
(1) FIRE HAZARD. THE ACOUSTIC CANOPY MUST BE FITTED TO THE GENERATOR SET
WHEN IN OPERATION TO PREVENT COMBUSTIBLE MATERIALS (IE CAMOUFLAGE
NETTING) COMING INTO CONTACT WITH THE GENERATORS HOT SURFACES.
(2) GASOLINE. GASOLINE FUEL IS FLAMMABLE AND CONSTITUTES A FIRE HAZARD.
DO NOT SMOKE CIGARETTES OR EXPOSE NAKED FLAMES IN THE VICINITY OF THE
GENERATOR SET. SPECIAL CARE MUST BE TAKEN WHEN REFUELLING, SHUTTING
DOWN OR PERFORMING MAINTENANCE ACTIVITIES.
CAUTION
EQUIPMENT DAMAGE.
Ensure that the air Iouvres in the acoustic cover are not
obstructed.
8
Before starting the engine, the checks described in the following paragraphs must be carried out.
Lubricating oil level
9
The dipstick/oil filler plug is located on the left-hand side of the engine crank case. Check the oil level,
as follows:
9.1
Remove the acoustic cover.
9.2 Unscrew and withdraw the dipstick/oil filler plug and clean the dipstick part of it with a lint free
cloth.
9.3
Insert and screw in the dipstick/filler plug fully then unscrew and withdraw it.
Check where the oil level is in relation to the maximum and minimum requirements shown in Fig 5
and, if necessary, top up using the approved oil type (Chap 3, Table 3).
9.4
.
DIPSTICK/OIL
FILLER PLUG
Fig 5 Engine oil levels
Chap 2
Page 6
Jan 03 (Amdt 3)
ARMY EQUIPMENT
SUPPORT PUBLICATION
6115-G-153-201
Leakages
10
Check for evidence of leakage of fuel and oil, as follows:
10.1 Check fuel piping, connections and associated components for signs of leakage.
10.2 Check engine surfaces for signs of oil leakage.
10.3 If a leak is found, identify the source and report the find.
10.4 Replace the acoustic cover.
CONNECTING A LOAD
11
A load can be connected to the generator set at this stage or when it is running.
NOTES
(1) Before connecting/disconnecting a load to/from the generator set when it is running, ensure that the
RANGE SELECTOR switch is set to the OFF position.
(2)
Observe correct polarity when connecting the load.
(3)
The circuit breaker may be used as an output isolation switch.
STARTING PROCEDURE
12
The generator set incorporates a conventional recoil (rope) type starting system.
NOTE
The pre-starting checks (Para 8) must be carried out before attempting to start the generator set
engine.
13
To start the generator set engine, proceed as follows:
13.1 Ensure that the RANGE SELECTOR switch (Fig 6) is in the OFF position.
13.2 Depress and release the fuel primer bubble (Fig 7) repeatedly until resistance is felt.
13.3 At initial start only (engine cold), pull out the choke control (Fig 7).
13.4 Operate the recoil starter by pulling the starter pull cord (Fig 7). Repeat until engine starts.
13.5 Gradually return the choke control when the engine is running.
13.6 Set the circuit breaker to the on" (down) position and check that the OFF indicator is
extinguished.
NOTE
At this stage, if not already connected, the battery/load must be connected to the output terminals.
13.7 Set the RANGE SELECTOR switch (Fig 6) to either 14 or 28, as required, and check that the
associated output indicator is lit.
13.8 Adjust the ADJUST VOLTS control (Fig 6) to set the required output voltage.
13.9 Check that the ammeter is working.
Jan 03 (Amdt 3)
Chap 2
Page 7
ARMY EQUIPMENT
SUPPORT PUBLICATION
611 5-G-1 53-201
.
2
1
.
10
13
11
.
1
2
3
4
5
6
7
Magnetic circuit breaker
Hours run meter
Output ammeter
Output voltmeter
14 V mode indicator
Range selector switch
28 V mode indicator
8
9
10
11
12
13
14
Positive output terminal
Negative output terminal
Earth terminal
ADADS service output socket
Output voltage adjust control
Engine stop switch
Circuit breaker OFF indicator
.
Fig 6 Front end controls/indicators/connectors locations
Chap 2
Page 8
Feb 93
ARMY EQUIPMENT
SUPPORT PUBLICATION
61 15-G-153-201
STARTER
PULL CORD
FUEL
PRIMER
Fig 7 Rear end control locations
Aug 98 (Amdt 2)
Chap 2
Page 9
6115-G-153-201
ARMY EQUIPMENT
SUPPORT PUBLICATION
GENERATOR SET SHUT DOWN PROCEDURE
14
To shut down the generator set, proceed as follows:
14.1
Set the RANGE SELECTOR switch to the OFF position.
14.2
Press and hold in the ENGINE STOP pushbutton and release when the engine is at rest.
14.3
Remove and stow the exhaust extension pipe assembly.
Draining the jerrycan adaptor assembly before stowage
WARNING
FIRE HAZARD. WHEN THE JERRYCAN ADAPTOR ASSEMBLY IS STOWED IN THE VALISE,
SEEPAGE OF FUEL INTO THE VALISE CAN CONSTITUTE A FIRE HAZARD. ENSURE THE
JERRYCAN ADAPTOR ASSEMBLY IS DRAINED BEFORE STOWAGE.
15
To drain the jerrycan adaptor assembly, proceed as follows:
15.1
Refer to Fig 4 and disconnect the jerrycan adaptor assembly from the generator set quick
release self sealing connector.
15.2
Fit the protection cap on the generator set fuel connection point.
15.3 With the dip tube in the jerrycan suspended above the fuel level, hold the fuel pipe above the
jerrycan and insert the nipple of the protection cap (Fig 8) into the quick release connector. This will
allow air into the fuel pipe enabling the retained fuel in the fuel pipe to drain into the jerrycan.
15.4
When the fuel pipe is fully drained, turn the protection cap around and fit the cap to the self
sealing connector on the fuel pipe.
15.5
Turn the fuel tap of the jerrycan adaptor assembly to the 'off" position (i.e. fully clockwise).
15.6
Remove the jerrycan adaptor assembly from the jerrycan and store in the valise.
SELF SEALING
CONNECTOR
Fig 8 Draining the jerrycan adaptor assembly
Chap 2
Page 10
Aug 98 (Amdt 2)
ARMY EQUIPMENT
SUPPORT PUBLICATION
6115-G-153-201
CHAPTER 3
OPERATOR MAINTENANCE
CONTENTS
Para
1
3
4
5
6
7
8
9
10
11
12
13
15
17
19
21
23
25
27
28
29
Introduction
Operator level routine maintenance schedule
Equipment and materials
Special equipment and spares
Materials
Routine maintenance (WARNINGS)
Physical inspection
Acoustic cover
End panels
Frame
Front panel
Cables and pipes
Leakages
Lubricating oil level - check and top-up
Lubricating oil - drain and replace
Foam air filter element - clean
Paper air filter element - replace
Jerrycan adaptor gauze filter
Functional testing (WARNINGS)
Corrective maintenance
Faults and remedies
Painted surface repair
Table
I
2
3
4
Page
Routine maintenance schedule
Special-to-type equipment and service spares
Materials
Faults and remedies
Fig
1
2
3
4
2
3
4
12
Page
Engine oil levels
Draining the engine lubricating oil
Air filtering system
Jerrycan adaptor gauze filter
7
8
10
11
Chap 3
Feb 93
Page 1
ARMY EQUIPMENT
SUPPORT PUBLICATION
61 15-G-153-201
INTRODUCTION
.
This chapter provides the operator level technical information and step-by-step instructions
relating to the procedures, tools and materials required to maintain the 14/28 V, 300/500 W
generator set in an operational condition.
1
All other maintenance tasks and fault remedies which are outside the scope of these
2
procedures must be carried out by suitably qualified personnel in accordance with the relevant
maintenance schedule/repair procedures.
Operator level routine, maintenance scheduleRoutine operator maintenance tasks are restricted to those listed in Table 1 and must be
carried out at the intervals specified or at any time a fault is suspected.
3
NOTE
If, for any reason, it is necessary to alter any- partof the maintenance schedule, revision and
authorisation: must be carried out bythe appropriatepersanneL
TABLE I ROUTINE MAINTENANCE SCHEDULE
Serial
Maintenance task
Period
(1)
(2)
(3)
PHYSICAL INSPECTION
1
Acoustic enclosure condition
)
2
Frame condition
)
3
Controls - mechanical operation
)
4
Serviceability of pipes, cables
)
5
Leakages
)
Weekly
ENGINE LUBRICATING OIL SYSTEM
.
6
Oil level - check and top-up
Prior to use and every 8
.
hours
7
Drain and replace
Initial 20 hours (new engine)
and every 50 hours
AIR FILTER SYSTEM
8
Foam filter element - clean
50 hours
9
Paper filter element - replace
yearly
FUEL SYSTEM
10
Chap 3
Page 2
Jerrycan adaptor assembly gauze filter - clean
200 hours
.
Feb 93
ARMY EQUIPMENT
SUPPORT PUBLICATION
6115-G-153-201
EQUIPMENT AND MATERIALS
Special equipment and spares
The items listed in Table 2 are the special-to-type equipment and service spares required to carry out
the procedures detailed in this chapter.
4
TABLE 2 SPECIAL-TO-TYPE EQUIPMENT AND SERVICE SPARES
Serial
Special-to-type equipment!spares
NATO stock No.
(1)
(2)
(3)
1
Exhaust extension pipe
X2/2990-99-623-9060
2
Jerrycan adaptor assembly
X2/291 0-99-701-5563
3
Earthing spike
X2161 15-99-842-1503
4
Earthing cable
X2/61 15-99-016-8510
5
Carrying handles (ADADS service only)
X2/61 15-99-425-1839
6
Shoulder straps (ADADS service only)
X2/61 15-99-883-5813
7
Paper filter element
X3/2940-99-335-4668
8
Spanner, box, l4mm/l5mm
F1/5120999106277
Spanner operating rod
9
Screwdriver, cross-point
F1/51 20-99-910-5866
10
Screwdriver, flat-point
Fl /5120-99-136-5590
11
Spanner, adjustable, 8 inch
Fl /5120-99-910-5964
12
Pliers, side-cutting
Fl /5120-99-910-5525
Aug 98 (Amdt 2)
Chap 3
Page 3
61 15-G-153-201
ARMY EQUIPMENT
SUPPORT PUBLICATION
Materials
The items listed in
this chapter.
5
arethe materials required to carry out the procedures detailed in
.
TABLE 3 MATERIALS
Sen al
(1)
Materials
Use
(2)
(3)
I
Fuel, general purpose, unleaded
gasoline
For all operating environmental
temperatures-
2
Oil, OMD 80, capacity 0.55 litres
Engine lubricating oil for
temperatures above -15°C
3
Oil, OMD 55, capacity 0.55 litres
:
Engine lubricating oil for
temperatures below -15°C
4
Cleaning solvent (i.e. ARKLONE)
Engine degreasing and cleaning
5
Primer, to DEF STAN 80-41,
Eau-de-nil to BS 381C, Tint 216
Paint, acoustic cover, frame surface
repair
6
Undercoat, to DEF STAN 80-41,
Dark Admiralty Grey, to BS 381 C, Tint
Paint, acoustic cover, frame surface
repair
0
.
632
7
Finish, IRR Matt, to DEF STAN 80-41,
NATO Green to BS 381C, Tint 285
Paint, acoustic cover, frame surface
repair
8
Paper, emery, size 00
Acoustic cover, frame repair
9
Lint free cloth
General cleaning
.
.
Chap 3
Page -4
Feb 93.
ARMY EQUIPMENT
SUPPORT PUBLICATION
6115-G-153-201
ROUTINE MAINTENANCE
WARNINGS
TOXIC FUMES. EXHAUST GASES ARE TOXIC AND CAN QUICKLY REACH TOXIC
PROPORTIONS IF BASIC PRECAUTIONS ARE NOT FOLLOWED. IF THE GENERATOR IS TO BE
USED IN A CONFINED SPACE, A STANDARD ISSUE EXHAUST EXTENSION MUST BE FITTED.
THE EXHAUST EXTENSION MUST NOT BE FURTHER MUFFLED OR RESTRICTED IN ANY WAY
(1)
FROM ITS ORIGINAL DESIGN AS THE RESULTING BACK PRESSURE COULD CAUSE
ADDITION LEAKS TO OCCUR OR DAMAGE THE ENGINE. EXTREME CARE MUST BE TAKEN
TO ENSURE THAT EXHAUST GASES ARE VENTED SAFELY AWAY FROM ANY PERSONNEL IN
THE VICINITY WITH DUE CONSIDERATION BEING GIVEN TO TOPOGRAPHY AND PREVAILING
WIND CONDITIONS. HARMFUL CONCENTRATIONS CAN BE ODOURLESS AND NOT VISUALLY
PERCEPTIBLE.
NOISE HAZARD. EAR DEFENDERS MUST BE WORN BY MAINTENANCE PERSONNEL
DURING SCHEDULED MAINTENANCE OR REPAIR TASKS WHEN THE GENERATOR SET IS
RUNNING WITH THE ACOUSTIC CANOPY REMOVED.
(2)
FALLING HAZARD. THE ACOUSTIC CANOPY MUST NOT BE USED AS A SEAT OR
STEP DURING MAINTENANCE OPERATIONS. THE ACOUSTIC CANOPY WILL NOT BARE
WEIGHT WHEN REMOVED FROM THE GENERATOR SET.
(3)
(4)
FIRE HAZARD. CARE MUST BE TAKEN WHEN DEPLOYING THE EXHAUST
EXTENSION MUFFLER TO ENSURE THAT IT IS NOT CLOSE TO OR CAN COME INTO
CONTACT WITH ANY COMBUSTIBLE MATERIAL.
TOXIC FUMES. MATERIAL USED IN THE CONSTRUCTION OF THE GENERATOR SET
GIVE OFF TOXIC AND IRRITANT FUMES WHEN BURNT. DO NOT INHALE SMOKE OR
(5)
FUMES IF THE GENERATOR SET IS INVOLVED IN A FIRE.
FIRE HAZARD. BEFORE USING THE GENERATOR SET, OPERATORS MUST BE
FAMILIAR WITH THE LOCATION OF SUITABLE FIRE EXTINGUISHING EQUIPMENT.
(6)
TOXIC FUMES. MAINTAINERS OF THE EQUIPMENT MUST ENSURE THAT NO PART
OF THE WIRING LOOM IS ROUTED NEAR ANY POTENTIAL HOT SURFACE. I.E. EXHAUST
SYSTEM, ALTERNATOR OR ENGINE. ENSURE THAT ONLY WIRES WITH SILICON
INSULATION ARE USED IN ANY REPAIRS OR FUTURE MODIFICATIONS.
(7)
SKIN BURNS. THE ACOUSTIC CANOPY MUST BE FITTED TO THE GENERATOR SET
WHEN IN OPERATION. DURING SCHEDULED MAINTENANCE OR REPAIR ACTIVITIES,
EXERCISE EXTREME CARE WHEN CARRYING OUT TASKS ADJACENT TO THE EXHAUST
SYSTEM, ENGINE OR ALTERNATOR, AS BOTH ITEMS CAN RETAIN HEAT FOR SEVERAL
(8)
MINUTES AFTER SHUT DOWN.
GASOLINE. GASOLINE FUEL IS FLAMMABLE AND CONSTITUTES A FIRE HAZARD.
DO NOT SMOKE CIGARETTES OR EXPOSE NAKED FLAMES IN THE VICINITY OF THE
GENERATOR SET. SPECIAL CARE MUST BE TAKEN WHEN REFUELLING, SHUTTING
(9)
DOWN OR PERFORMING MAINTENANCE ACTIVITIES.
6
Routine maintenance tasks to be carried out by the operator are those specified in Table 1.
Jan 03 (Amdt 3)
Chap 3
Page 5
ARMY EQUIPMENT
SUPPORT PUBLICATION
611 5-G-1 53-201
Physical inspection
7
The following inspection procedures should be carried out on initial receipt of the equipment and then at
weekly intervals. The inspection involves a physical scrutiny of the equipment to make sure that there is
no evidence of physical defects, contamination, leakages or the presence of foreign matter which may
render the generator set unfit for use. Where applicable, manual operation of a control component is
required to make sure of its correct mechanical action.
Any defects found shall be reported and
repaired in strict accordance with the appropriate maintenance procedures.
Acoustic cover
8
Inspect the external and internal surfaces of the acoustic enclosure, as follows:
Examine the surfaces of the acoustic enclosure for evidence of physical damage such as dents,
scratches and corrosion.
8.1
8.2
Examine rivets for corrosion and security of fixing.
8.3
Check the operation of the four spring loaded catches and security of fixings.
End panels
9
Inspect the front and rear end panels, as follows:
9.1
Examine the fibreglass end panels for cracks, deformation and security of fixing.
9.2
Check that all label information is clearly legible.
Frame
10
Inspect the frame structure, as follows:
10.1 Examine the frame for evidence of physical damage such as dents, scratches and corrosion.
10.2 Examine welded tugs and bracketry for security and damage.
Front panel
11
Inspect the control box front panel, as follows:
11.1 Examine the panel facia for evidence of physical damage.
11.2 Check that the panel mounted components are securely fixed.
11.3 Manually operate each panel mounted control and check for correct mechanical action.
11.4 Check that all labelling and surface etched information is clearly legible.
Cables and pipes
12
Inspect all cables and pipes, as follows:
12.1 Ensure all cables are clear of potential hot surfaces.
12.2 Examine all fuel piping, cable loom, cable outer coverings and cable connector sleeves for
evidence of overheating, deformation, cuts and chafing.
12.3 Examine each cable connector for physical damage, the presence of foreign matter and
corrosion.
12.4 Check that identification labels are firmly attached and clearly legible.
Chap 3
Page 6
Jan 03 (Amdt 3)
6115-G-153-201
ARMY EQUIPMENT
SUPPORT PUBLICATION
Leakages
13
Examine fuel piping, pipe connections and associated component items for evidence of fuel leakage.
14
Examine engine surfaces for evidence of oil leakage.
Lubricating oil level - check and top-up
15
The engine lubricating oil level should be checked prior to starting the generator set and after
every 8-hour period of operation and, if required, topped up. The dipstick/oil filler plug is located on the lefthand side of the engine crank case.
16
To check and top up the engine lubricating oil, proceed as follows:
16.1 Place the generator set on a level surface.
16.2 Remove the acoustic cover.
16.3 Unscrew and withdraw the dipstick/oil filler plug and clean the dipstick part with a lint free cloth.
16.4 Replace the dipstick/oil filler plug then unscrew and withdraw it.
16.5 Check where the oil level is in relation to the maximum and minimum requirements shown
in Fig 1 and, if necessary, top up using the approved oil type (Table 3).
16.6 On completing the oil level check and top up operations, replace the dipstick/oil filler plug and refit
the acoustic cover.
DIPSTICK/OIL
FILLER PLUG
Fig 1 Engine oil levels
Jan 03 (Amdt 3)
Chap 3
Page 7
ARMY EQUIPMENT
SUPPORT PUBLICATION
611 5-G-1 53-201
Lubricating oil - drain and replace
The engine lubricating oil must be drained and replaced after every 50-hour period of operation. The
engine oil drain plug is located at the bottom left-hand side of the crank case.
17
18
.
To drain and replace the engine lubricating oil, proceed as follows:
18.1 Remove the acoustic cover.
18.2 Remove the dipstick/oil filler plug (Fig 1) and oil drain plug (Fig 2).
18.3 Tilt the generator set and drain the oil into a suitable container.
18.4 Level the generator set and replace the oil drain plug.
18.5 Refill the engine with new oil of the correct type (Table 3) to the correct level (Fig 1) and replace
the dipstick/oil filler plug.
.
18.6 Refit the acoustic cover.
.
PLUG
Fig 2 Draining the engine lubricating oil
Chap 3
Page 8
Feb 93
ARMY EQUIPMENT
SUPPORT PUBLICATION
6115-G-153'-201
Foam air filter element - clean
The foam filter element of the air filter system must be removed and cleaned after every 50hour period of operation.
19
20
To remove and clean the foam air cleaning element (Fig 3), proceed as follows:
20.1 Remove the acoustic cover.
20.2 Unhook (from the bottom) and remove the air filter cover from the air filter casing.
20.3 Remove the foam filter element from the air filter casing and wash it thoroughly in a
mixture of water and detergent.
20.4 When dry, replace the foam filter element in the air filter casing and refit the air filter
cover.
20.5 Refit the acoustic cover.
Paper air filter element - replace
21
The paper filter element of the air filter system must be replaced by a new one on a yearly
basis.
22
To replace the paper air cleaning element (Fig 3), proceed as follows:
22.1 Remove the acoustic cover.
22.2 Unhook (from the bottom) and remove the air filter cover from the air filter casing.
22.3 Remove the foam filter element and paper filter element from the air filter casing.
22.4 Fit a new paper filter element in the air filter casing and refit the foam filter element.
22.5 Refit the air filter cover.
22.6 Refit the acoustic cover.
Feb 93
Chap 3
Page 9
ARMY EQUIPMENT
SUPPORT PUBLICATION
6115-G-153-201
1
2
.
1 Air filter casing
2 Paper filter element
3 Foam filter element
4 Air filter cover
Fig 3 Air filtering system
.
Chap 3
Page 10
Aug 98 (Amdt 2)
6115-G-153-201
ARMY EQUIPMENT
SUPPORT PUBLICATION
Jerrycan adaptor gauze filter
The jerrycan adaptor gauze filter on the end of the dip tube (Fig 4) must be cleaned after
every 200-hour period of operation.
23
24
To clean the filter, immerse it in clean gasoline and agitate it until the filter appears clean.
GAUZE.
FILTER
Fig 4 Jerrycan adaptor gauze filter
FUNCTIONAL TESTING
WARNINGS
(1) ELECTRIC SHOCK. AN EARTH PIN WILL NOT NECESSARILY PROVIDE
IMMUNITY FROM ELECTRIC SHOCK. ENSURE THAT ADEQUATE UNIT SAFETY
INSTRUCTIONS ARE HELD AND SAFE WORKING PRACTICES PROCEDURES
IMPLEMENTED.
(2) EARTHING.
THE EQUIPMENT MUST BE PROPERLY EARTHED BEFORE
ATTEMPTING TO OPERATE THE GENERATOR SET.
25 A generator set functional test must be carried out on a yearly basis to ensure that correct
Functional testing consists primarily of monitoring generator set
operation is maintained.
performance by observing the Instrumentation and Indicators. if any faults are found during the
following functional tests, refer to the failure diagnosis/repair information provided in Table 4.
26
Start up the generator set and make the following assessments:
26.1 Recoil starter system performance.
26.2 Check that engine is running evenly.
26.3 Check that the VOLTS ADJUST control enables the correct voltage swing for each output
mode:
26.4
12.3 V to 16 V.
26.3.1
14 V mode -
26.3.2
28 V mode - 24 V to 32 V.
Check that the hours run meter Is operating by observing movement of the minutes
digits.
26.5 Check the OFF indicator is lit with
extinguished in the on (down) position.
Feb 93
the circuit breaker in the off (up) position and
Chap 3
Page 11
ARMY EQUIPMENT
SUPPORT PUBLICATION
61 15-G-153-201
CORRECTIVE MAINTENANCE
The corrective maintenance procedures cover generator set faults and remedies which may
be carried out by the operator.
27
.
Faults and remedies
The generator set faults listed in Table 4 are at operator level only. If a fault is not rectified
by using the remedy suggested, the fault must be reported to and corrected by suitably qualified
28
personnel.
FAULTS AND REMEDIES;
Serial
Fault
Possible cause
Suggested remedy
Doc. ref.
(1)
(2)
(3)
(4)
(5)
STARTING
1
Enginedoes not
start or is difficult
to start.
Choke
pull ed out far
enough.
Reset choke control and.
Chap 2
try starting again.
Jerrycan
adaptor
assembly fuel tap
turned off.
Check tap position.
Empty jerrycan.
Check jerrycan fuel level
and, if necessary, refill.
Low engine oil.
Check oil level and, if
necessary, top up with
.
Chap 2
Para 15
new oil.
2
Engine will not
run.
Restricted air filter.
Check air filter assembly
filter elements and, if
necessary, clean/replace
elements as
Para 20
and 22
Blocked gauze fuel
filter in Jerrycan
adaptor assembly dip
tube.
Check gauze fuel filter
and, if necessary, clean
Para 24
it.
.
OUTPUT
OVERLOAD
3
OFF indicator lit.
Circuit breaker
tripped due to
excessive load
current.
Circuit breaker
tripped due to
incorrectly connected
battery (i.e. wrong
polarity).
Chap 3
Page 12
Disconnect load cable
and report the fault.
Reconnect battery
observing correct
polarity.
.
Feb 93
ARMY EQUIPMENT
SUPPORT PUBLICATION
611
5-G-153201
Painted surface repair
29
Repair of abrasions to the painted metal surfaces of the acoustic cover and frame must be
carried out as follows:
29.1 Use emery paper (grade 00) to make the abraded area smooth.
29.2 Clean the area to be repaired, using a lint free cloth and a suitable solvent ensuring that
no grease or deposits remain in the cleaned area.
29.3 Apply one coat of primer (Table 3), in accordance with the maker's instructions.
29.4 Apply one coat of undercoat (Table 3), In accordance with the maker's instructions.
29.5 Apply one coat of paint (Table 3), in accordance with the maker's instructions.
29.6 Remove paint from brush(es), using a suitable solvent.
Feb 93
Chap 3
Page 13/14
T.
ARMY EQUIPMENT
SUPPORT PUBLICATION
6115-6-153-201
CHAPTER 4
DESTRUCTION OF EQUIPMENT
CONTENTS
Para
Mandatory directive
Degree of damage
1
3
5
Priorities of destruction
Methods of destruction
6
Mechanical
Burning (WARNING)
Gunfire (WARNING)
8
9
10
Table
Page
Priorities of destruction
1
2
MANDATORY DIRECTIVE
1
Destruction of the equipment when subject to capture by the enemy will be undertaken by the
user arm, ONLY WHEN, in the judgement of the unit commander concerned, such action is
necessary in accordance with orders of, or policy established by the Army or Divisional
Commanders.
2
The reporting of the destruction of equipment is to be done through command channels.
Degree of damage
3
The degree of damage inflicted, to prevent the equipment being used by an enemy, shall be
as follows:
3.1
Methods of destruction should achieve such damage to equipment and essential spare
parts, that it will not be possible to restore the equipment to a usable condition in the combat
zone either by repair or by cannibalisation.
3.2 Classified equipment must be destroyed in such degree as to prevent, whenever possible,
duplication, or determination of operation or function by the enemy.
3.3 Any classified documents, notes, instructions or other written material pertaining to
function, operation, maintenance or employment, including drawings or parts lists, must be
destroyed in a manner to render them useless to the enemy.
4
In general, destruction of essential parts, followed by burning will usually be sufficient to
render the equipment useless. However, selection of the particular method of destruction requires
imagination and resourcefulness in utilisation of the facilities at hand under the existing conditions.
Time is usually critical.
Chap 4
Feb 93
Page 1
61 15-G-153-201
ARMY EQUIPMENT
SUPPORT PUBLICATION
PRIORITIES OF DESTRUCTION
5
The priorities of destruction should be considered, as follows:
Priority must be given to the destruction of classified equipment and associated
5.1
documents.
5.2 When lack of time and/or means prevents complete destruction of equipment, priority
must be given to the destruction of essential parts. The same parts are to be destroyed on
all like equipment and in spare parts storage areas.
5.3 A guide to priorities of destruction, of:
shown in Table 1.
TABLE I PRIORITIES OF DESTRUCTION
Serial
Item
Priority
(1)
(2)
(3)
I
Fuel pump and carburettor
2
Engine block
2nd
3
Alternator, control boxes and control panel
3rd
.
1st
METHODS OF DESTRUCTION
6
If destruction is ordered, due consideration should be given to:
6.1
Selection of a point of destruction that will cause greatest obstruction to enemy
movement and also prevent hazard to friendly troops.
6.2 Observance of appropriate safety precautions.
The following information Is for guidance only. Of the possible methods of destruction, those
most generally applicable are mechanical, burning and gunfire.
7
Mechanical.
This method requires the use of an axe, pick, crowbar or similar implement. The equipment
should be destroyed in accordance with the priorities given on Table 1.
8
.
Burning
WARNING
DUE CONSIDERATION SHOULD BE GIVEN TO THE HIGHLY FLAMMABLE NATURE OF
GASOLINE. CARELESSNESS IN ITS USE MAY RESULT IN SERIOUS BURNS.
This method requires the use of gasoline, oil or other flammables. To destroy the equipment
by burning, proceed as follows:
9
9.1
Remove and empty the portable fire extinguishers.
9.2
If quantities of combustibles are limited, smash all vital elements such as switches,
instruments and control levers.
9.3 Place ammunition and charges in and about the equipment so that the greatest damage
will result from the explosion.
Chap 4
Page 2
Feb 93
..
ARMY EQUIPMENT
SUPPORT PUBLICATION
6115-G-153-201
9.4 Pour gasoline and oil liberally over the equipment.
9.5 Ignite the equipment, using one of the following methods and exercise all necessary
personal safety precautions:
9.5.1
An incendiary grenade.
9.5.2 A burst from a flame thrower.
9.5.3 A combustible train of suitable length.
9.5.4 Or any other appropriate means.
Gunfire
WARNING
FIRING ARTILLERY AT RANGES OF 500 YARDS OR LESS, AND FIRING RIFLE
GRENADES OR ANTI-TANK ROCKETS SHOULD BE FROM COVER.
10 When destroying the equipment by gunfire, proceed as follows:
10.1
Remove and empty the portable fire extinguishers.
10.2 Smash all vital elements, such as switches, instruments and control levers.
10.3
Destroy the equipment by gunfire, using any of the following methods:
10.3.1
Tank guns.
10.3.2
Self-propelled guns.
10.3.3 Artillery.
10.3.4 Rifle grenades.
10.3.5 Anti-tank rockets from launchers.
Chap 4
Feb 93
Page 3/4
ARMY EQUIPMENT
SUPPORT PUBLICATION
6115-(3-153-302
February 1993
CONDITIONS OF RELEASE
I
2
4
This information may be subject to privately owned rights.
GENERATOR SET, ENGINE DRIVEN
(GASOLINE), BATTERY CHARGING,
14/28 V, 300/500 W (HOPKINS)
TECHNICAL DESCRIPTION
REPRINTED INCORPORATING AMDTS 1-3
This publication contains information covering the requirements of
Category 3 at information levels 2 and 3
BY COMMAND OF THE DEFENCE COUNCIL
Ministry of Defence
Issued by
ARMY TECHNICAL SUPPORT AGENCY
DIRECTORATE OF TECHNICAL SERVICES
72111(208)
ATSA Chertsey
9609\WCP-0502
Sep 96 (Amdt 1)
Page (i)I(ii)
61 15-G-153-302
1st Edition
ARMY EQUIPMENT
SUPPORT PUBLICATION
AMENDMENT RECORD
Amdt
No.
Incorporated
By (Signature)
Date
Amdt
Incorporated
No.
By_(Signature)
I
32
2
33
Date
34
35
.4
36
6
37
7
38
8
39
9
40
10
41
11
42
12
.
43
13
44
14
45
15
46
16
47
17
48
18
49
19
50
20
51
21
52
22
53
23
54
24
55
25
56
26
57
27
58
28
59
29
60
30
61
31
62
9609\WCP-0502
Sep 96 (Amdt 1)
Page (iii)I(iv)
ARMY EQUIPMENT
SUPPORT PUBLICATION
6115-G-153-302
CONTENTS
PRELIMINARY MATERIAL
Front cover (title page)
Amendment record
Contents (this list)
Preface
Introduction
Related and associated publications
Related publications
Associated publications
Hazardous substances
Warnings and caution
Comment on AESP
Page
(1)1(11)
(iii)/(iv)
(v)
(vi)
(vi)
(vi)
(vi)
(vii)
(vii)
(viii)
Final leaf
TECHNICAL DESCRIPTION
Chapter
I
2
3
General information
Power unit
Detailed electrical description
9609\WCP-0502
Sep 96 (Amdt I)
Page (v)
ARMY EQUIPMENT
SUPPORT PUBLICATION
6115-G-153-302
PREFACE
DGES(A)
File ret
Publication Agency:
ATSA Chertsey
Project No: 72111(208)
File ret
INTRODUCTION
I
Service UsCrsshôuldforard any comments on this publication through the channels prescribed in
AESP 0100-P-Oil -013. An AESP Form 10 is provided at the end of this publication; it should be
photocopied and used for forwarding comments on this AESP.
The subject matter of this publication may be affected by Defence Council Instructions (DCIs),
Standing Operating Procedures (SOPs) or by local regulations. When any such instruction, order or
regulation contradicts any portion of this publication it is to be taken as the overriding
2
RELATED AND ASSOCIATED PUBLICATIONS
Related publications
The Octad for the subject equipment consists of the publications shown opposite. All references are
prefixed with the first eight digits of this publication. The availability of the publications can be checked by
reference to the relevant Group Index (see AESP O100-A-001-013).
3
9609\WCP-0502
Page (vi)
(Amdt 1) Sep 96
ARMY EQUIPMENT
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6115-G-153-302
Category/Sub-category
Information Level
——
1
1
2
0
2
1
2
Technical Description
3
1
2
1
2
3
4
6
1
2
7
1
8
Purpose and Planning Information
Equipment Support Policy Directives
Purpose and Planning Information
Medical and Dental
Operating Information
Aide Memoire
Training Aids
2
1
2
3
4
User!
Operator
Unit
Maintenance
Field
Maintenance
Base
Maintenance
101
101
101
101
*
*
*
*
*
*
201
*
*
*
*
*
*
*
*
*
*
*
201
302
302
*
*
Installation Instructions
Preparation for Special Environments
Failure Diagnosis
Repair Instructions
Inspection Standards
Calibration Procedures
201
*
*
*
*
*
*
201
512
522
532
512
522
*
532
*
*
*
*
*
Maintenance Schedules
601
601
601
601
Illustrated Parts Catalogues
Commercial Parts Lists
Complete Equipment Schedules
Production Edition
Complete Equipment Schedules
Service Edition (Simple Equipment)
Complete Equipment Schedules
Service Edition (Complex Equipment)
Modification Instructions
General Instructions, Special Technical
Instructions and Servicing Instructions
Service Engineered Modification
Instructions (RAF only)
711
711
711
711
*
*
*
*
*
*
*
*
201
*
*
*
*
*
* Category/Sub-category not published
Associated publications
4
Reference
Tftle
AESP 2805-B-900
Engine, Gasoline, S/Cyl, OHV Kubota
SEI 14411
Safety Precautions for Electrical Equipment
AESP 6150-A-i00-201
Earthing and Electrical Protection
AESP 6140-A-i 00-013
Lead Acid Batteries
Hazardous substances
5
Before using any hazardous substance or material, the user must be conversant with the safety
precautions and first aid instructions:
5.1
On the label of the container it was supplied in.
5.2
On the material Safety Data Sheet.
5.3
In local Safety Orders and Regulations.
9609\WCP-0502
Sep 96 (Amdt 1)
Page (vii)
6115-G-153-302
ARMY EQUIPMENT
SUPPORT PUBLICATION
WARNINGS
(1)
GASOLINE. GASOLINE FUEL VAPOUR IS EXPLOSIVE WHEN CONTAINED IN A
CONFINED SPACE.
GASOLINE. GASOLINE FUEL IS FLAMMABLE AND CONSTITUTES A FIRE HAZARD.
DO NOT SMOKE CIGARETTES OR EXPOSE NAKED FLAMES IN THE VICINITY OF THE
GENERATOR SET. SPECIAL CARE MUST BE TAKEN WHEN REFUELLING, SHUTDOWN
(2)
OR PERFORMING MAINTENANCE ACTIVITIES
EARTHING. THE EQUIPMENT MUST BE PROPERLY EARTHED BEFORE
ATTEMPTING TO OPERATE THE GENERATOR SET. WHEN USED WITH ANCILLARY
(3)
EQUIPMENT, IT IS ESSENTIAL THAT THE EARTHING INSTRUCTIONS FOR THAT
EQUIPMENT BE FOLLOWED.
ELECTRIC SHOCK. AN EARTH PIN WILL NOT NECESSARILY PROVIDE IMMUNITY
FROM ELECTRIC SHOCK. ADEQUATE UNIT SAFETY INSTRUCTIONS ARE TO BE HELD
AND SAFE WORKING PRACTICES AND PROCEDURES IMPLEMENTED.
(4)
(5)
PERSONAL INJURY. MANUAL LIFTING OF THE TOTAL EQUIPMENT MUST BE
CARRIED OUT BY TWO PERSONS.
(6)
TOXIC FUMES. EXHAUST GASES ARE TOXIC AND CAN QUICKLY REACH TOXIC
PROPORTIONS IF BASIC PRECAUTIONS ARE NOT FOLLOWED. IF THE GENERATOR IS TO
BE USED IN A CONFINED SPACE, A STANDARD ISSUE EXHAUST EXTENSION MUST BE
FITTED. THE EXHAUST EXTENSION MUST NOT BE FURTHER MUFFLED OR RESTRICTED IN
ANY WAY FROM ITS ORIGINAL DESIGN AS THE RESULTING BACK PRESSURE COULD
CAUSE ADDITION LEAKS TO OCCUR OR DAMAGE THE ENGINE. EXTREME CARE MUST BE
TAKEN TO ENSURE THAT EXHAUST GASES ARE VENTED SAFELY AWAY FROM ANY
PERSONNEL IN THE VICINITY WITH DUE CONSIDERATION BEING GIVEN TO TOPOGRAPHY
AND PREVAILING WIND CONDITIONS. HARMFUL CONCENTRATIONS CAN BE ODOURLESS
AND NOT VISUALLY PERCEPTIBLE.
SKIN BURNS. THE ACOUSTIC CANOPY MUST BE FITTED TO THE GENERATOR SET
WHEN IN OPERATION. DURING SCHEDULED MAINTENANCE OR REPAIR ACTIVITIES,
EXERCISE EXTREME CARE WHEN CARRYING OUT TASKS ADJACENT TO THE EXHAUST
SYSTEM, ENGINE OR ALTERNATOR, AS BOTH ITEMS CAN RETAIN HEAT FOR SEVERAL
(7)
MINUTES AFTER SHUT DOWN.
(8)
INFLAMMABLE GASES. HIGHLY INFLAMMABLE GASES ARE LIBERATED FROM
LEAD-ACID BATTERIES DURING CHARGING AND UP TO ONE HOUR AFTER COMPLETION
OF CHARGE. NAKED LIGHTS MUST NOT BE USED WHEN CHECKING ELECTROLYTE
LEVELS NOR MUST LIVE ELECTRICAL CONNECTIONS/DISCONNECTIONS BE MADE
DURING THESE PERIODS.
(9)
LEAD ACID BATTERIES. CARE SHOULD BE TAKEN WHEN WORKING ON OR
AROUND HIGH CAPACITY LEAD-ACID BATTERIES AS THE EXTREMELY HIGH CURRENTS
GENERATED BY AN ACCIDENTAL SHORT CIRCUIT MAY CAUSE SEVERE BURNS OR THE
BATTERY TO EXPLODE. THEREFORE WATCHES, RINGS, ETC. SHOULD BE REMOVED
BEFORE COMMENCING BATTERY ASSOCIATED TASKS.
(10) FIRE HAZARD. WHEN THE JERRYCAN ADAPTOR ASSEMBLY IS STOWED IN THE
VALISE, SEEPAGE OF FUEL INTO THE VALISE CAN CONSTITUTE A FIRE HAZARD.
ENSURE THE JERRYCAN ADAPTOR ASSEMBLY IS DRAINED BEFORE STOWAGE.
(11) FIRE HAZARD. THE ACOUSTIC CANOPY MUST BE FITTED TO THE GENERATOR
SET WHEN IN OPERATION TO PREVENT COMBUSTIBLE MATERIALS (IE CAMOUFLAGE
NETTING) COMING INTO CONTACT WITH THE GENERATORS HOT SURFACES.
Page (viii)
Jan 03 (Amdt 3)
6115-G-153-302
ARMY EQUIPMENT
SUPPORT PUBLICATION
(12) PERSONAL INJURY. THE ACOUSTIC CANOPY MUST BE
FITTED TO THE
GENERATOR SET TO PREVENT THE RISK OF PERSONNEL BEING CUT ON SHARP
UNPROTECTED EDGES.
(13) NOISE HAZARD. EAR DEFENDERS MUST BE WORN BY MAINTENANCE
PERSONNEL DURING SCHEDULED MAINTENANCE OR REPAIR TASKS WHEN THE
GENERATOR SET IS RUNNING WITH THE ACOUSTIC CANOPY REMOVED.
(14) FALLING HAZARD. THE ACOUSTIC CANOPY MUST NOT BE USED AS A SEAT OR
STEP DURING MAINTENANCE OPERATIONS. THE ACOUSTIC CANOPY WILL NOT BARE
WEIGHT WHEN REMOVED FROM THE GENERATOR SET.
(15) FIRE HAZARD. CARE MUST BE TAKEN WHEN DEPLOYING THE EXHAUST
EXTENSION MUFFLER TO ENSURE THAT IT IS NOT CLOSE TO OR CAN COME INTO
CONTACT WITH ANY COMBUSTIBLE MATERIAL.
(16) TOXIC FUMES. MATERIAL USED IN THE CONSTRUCTION OF THE GENERATOR
SET GIVE OFF TOXIC AND IRRITANT FUMES WHEN BURNT. DO NOT INHALE SMOKE OR
FUMES IF THE GENERATOR SET IS INVOLVED IN A FIRE.
(17) FIRE HAZARD. BEFORE USING THE GENERATOR SET, OPERATORS MUST BE
FAMILIAR WITH THE LOCATION OF SUITABLE FIRE EXTINGUISHING EQUIPMENT.
(18) TOXIC FUMES. MAINTAINERS OF THE EQUIPMENT MUST ENSURE THAT NO PART
OF THE WIRING LOOM IS ROUTED NEAR ANY POTENTIAL HOT SURFACE. I.E. EXHAUST
SYSTEM, ALTERNATOR OR ENGINE. ENSURE THAT ONLY WIRES WITH SILICON
INSULATION ARE USED IN ANY REPAIRS OR FUTURE MODIFICATIONS.
CAUTION
EQUIPMENT DAMAGE. Ensure the air Iouvres in the acoustic cover are not obstructed.
Jan 03 (Amdt 3)
Page (ix)/(x)
XXXX-X-XXX-XXX
ARMY EQUIPMENT
SUPPORT PUBLICATION
COMMENT(S) ON AESP
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ARMY EQUIPMENT
SUPPORT PUBLICATION
6115-G-153-302
CHAPTER 1
GENERAL INFORMATION
CONTENTS
Para
1
8
11
18
22
24
25
27
Introduction
Purpose and facilities
Construction
Engine
Alternator
Control box
Frame
Acoustic cover (CAUTION)
Brief functional description
Fig
1
2
3
4
5
6
7
8
9
10
11
Jan 93
Page
Generator set - Three-quarter rear view
Generator set - Three-quarter front view
Component locations - Plan view .'
Component locations - Right-hand side
Component locations - Left-hand side
Component locations - End views
Alternator assembly
Control box assembly
Generator set frame assembly
Acoustic cover and accessory equipment
Generator set simplified block diagram
3
3
4
5
6
7
9
10
11
13
14
Chap 1
Page 1
6115-G-153-302
ARMY EQUIPMENT
SUPPORT PUBLICATION
INTRODUCTION
Purpose and facilities
1
The 14/28 V, 300/500 W generator set is intended to provide a portable d.c. source for
charging lead-acid batteries In the field. It may also be used as a general purpose d.c. source.
General views of the generator set are shown in Figs 1 and 2. These diagrams also indicate the
generator set orientation and should be referred to when explanations of component locations are
given.
The generator set provides two selectable nominal outputs of 14 V d.c. (300 W) and 28 V d.c.
(500 W). A rotary control on the front panel is used to set the voltage level of the selected output.
The output Is variable overthe ranges 12.3 V - 16 V and 24 V - 32 V.
2
3
An oil level sensor acts to shut the engine down when the engine oil level becomes too low.
The alternator Is protected by a resettable circuit breaker.
The top and sides of the complete assembly are shrouded by a metal cover which provides
acoustic attenuation and weather protection.
4
A removable, waterproof accessory equipment bag containing all necessary generator
accessory equipment is attached to the top of the acoustic cover.
5
6
A recoil (rope) type starting system is incorporated for starting the generator set engine.
7
Fuel is supplied to the engine externally from a jerrycan.
Chap 1
Page 2
Jan 93
61 15-G-153-302
ARMY EQUIPMENT
SUPPORT PUBLICATION
LEFT-HAND
SIDE
Fig 1 Generator set - Three-quarter rear view
Fig 2 Generator set - Three-quarter front
98/42b/01 1(730)
Chap 1
Aug 98 (Amdt 2)
Page 3
611 5-G-1 53-302
ARMY EQUIPMENT
SUPPORT PUBLICATION
Construction
8
I
The components of the 14/28 V generator set are mounted on a rigid tubular steel frame. The top and
sides of the complete assembly are shrouded by a metal acoustic cover. Moulded fibreglass panels are
attached at the front and rear ends of the assembly. A removable, waterproof accessory equipment bag is
situated on top of the acoustic cover.
.
The main items of the generator set are a single cylinder gasoline engine, an alternator and a control
box assembly. The engine and alternator are combined to form an assembled unit which is mounted onto
the tubular frame via resilient mountings.
9
10
Figs 3 to 6 show the locations of the main items and auxiliary items that make up the generator set.
S
S
1
2
3
4
5
Control box assembly
Cooling air hose
Ignition lead
Magnet/transistor ignition unit
Electronic switch module
6
7
8
9
10
Engine fan cover
Carburettor
Air filter assembly
Choke control
Exhaust silencer
S
Fig 3 Component locations - Plan view
Chap 1
Page 4
Aug 98 (Amdt 2)
6115-G-153-302
ARMY EQUIPMENT
SUPPORT PUBLICATION
Control box assembly
Exhaust silencer
Air filter assembly
4 Canopy retaining lug
5 Fuel pump
6 Governing system
7 Exhaust outlet
8 Fuel filter
1
2
3
Fig 4 Component locations - Right-hand side
Chap 1
Aug 98 (Amdt 2)
Page 5
ARMY EQUIPMENT
61 15-G-153-302
SUPPORT PUBLICATION
I
2
.
3
.
.
1
Electronic switch module
2 Ignition lead
3 Cooling air hose
4 Control box assembly
5 Cover retaining lug
6 Alternator
7 Fuel connection point
8 Oil level dipstick/filler plug
9 Oil drain plug
10 Engine fan cover
.
Fig 5 Component locations - Left-hand side
Chap 1
Page 6
Jan 93
ARMY EQUIPMENT
SUPPORT PUBLICATION
611 5-G-1 53-302
REAR END VIEW
Carrying handle/shoulder strap lugs
2 Control panel
3 Earth stud
4 Output socket (ADADS only)
5 End cover
1
6 End cover
7 Recoil starter case
8 Starter pull-grip
9 Choke control
10 Fuel primer control
Fig 6 Component locations - End views
Jan 93
Chap 1
Page 7
6115-G-153-302
ARMY EQUIPMENT
SUPPORT PUBLICATION
ENGINE
The generator set alternator is driven by a Kubota GH12O, single cylinder; overhead valve,
four cycle, air cooled, gasoline fuelled, 121 cm3 engine, which incorporates some minor external
modifications to suit the application.
11
A recoil starting system is situated at the non-drive end of the engine. Starting is aided by
an automatic decompression system.
12
13 An electronic, magnet type ignition system is used to fire the engine. This type of system
does not use switching contacts for ignition control.
14 The engine is lubricated using an oil splash system.
Engine speed is regulated by a mechanical governing system, which adjusts the engine
throttle control to maintain constant engine speed under varying load conditions.
15
The engine Is combined with the alternator to form a unit assembly, which is mounted to the
generator frame via resilient mounts.
16
Cooling air is forced around the engine by a fan attached to the engine shaft at the non-drive
end of the engine.
17
ALTERNATOR
The alternator assembly (Fig 7) is a separately excited type of brush gear construction. It is
rated to provide nominal outputs of 14/28 V d.c. at 300/500 W and is capable of sustaining a 150%
overload condition.
18
A 3-phase rectifier unit, an automatic voltage regulator (AVR) module and a brush guide
housing are mounted on the rear (non-drive end) section casting of the alternator. The 3-phase
rectifier unit converts the alternator 3-phase output to a d.c. output. The AVR module forms part
of the excitation system and provides output sensing and excitation voltage control functions for
maintaining the alternator output voltage. The brush guide housing, which forms part of the AVR
module, situates the two brushes above and in contact with the two slip rings mounted on the end
of the alternator rotor shaft.
19
The alternator is fitted to the engine by assembling the alternator component parts, in stages,
to the engine drive shaft. The engine/alternator assembly is mounted to the generator frame via
resilient mounts.
20
Cooling air is forced into the alternator through a hose on top of the middle casing section
and is expelled through holes in the middle and rear casing sections.
21
Chap 1
Page 8
Jan 93
611 5-G-1 53-302
ARMY EQUIPMENT
SUPPORT PUBLICATION
6
3-phase rectifier unit
Brush guides
Cooling air hose
Alternator casing
5 Automatic voltage regulator module
6 Slip rings
1
2
3
4
Fig 7 Alternator assembly
Chap 1
Aug 98 (Amdt 2)
Page 9
ARMY EQUIPMENT
SUPPORT PUBLICATION
611 5-G-1 53-302
CONTROL BOX
The control box assembly (Fig 8) is resiliently mounted at the front end of the generator set
and houses the operation control and indication circuitry. The assembly consists of a mild steel
fabricated box, an afluminium alloy front panel and an alluminium alloy rear panel. The front and
rear panels and two mild steel brackets are bolted together to form a component chassis on which
all control and indication circuitry components are mounted.
22
23
.
The front panel Is the control consoje, which carries the operator controls1 the main output
terminals and the necessary instrumentation and indicators for monitoring generator set
performance.
2
.
I
.
Control box
2 Generator circuit diagram
3 Rear panel
4 Bracket (2)
5 Front panel
1
.
Fig 8 Control box assembly
Chap 1
Page 10
Jan 93
6115-G-153-302
ARMY EQUIPMENT
SUPPORT PUBLICATION
FRAME
The generator set frame (Fig 9) is constructed of 19 mm (outside diameter) steel tube and has
various welded lugs and bracketing for supporting the generator set components.
24
Carrying handle/shoulder strap lug
1
2 Rear end panel fixing point
3 Frame assembly
4 Support feet mounting point
5 Control box resilient mount bracket
6 Output socket mounting bracket
7 Acoustic cover retaining lug
8 Front end panel fixing point
9 Fuel filter mounting bracket
10 Engine resilient mount bracket
11 Alternator resilient mount bracket
12 Fuel input connector bracket
Fig 9 Generator set frame assembly
Chap I
Jan 93
Page 11
611 5-G-1 53-302
ARMY EQUIPMENT
SUPPORT PUBLICATION
ACOUSTIC COVER
CAUTION
EQUIPMENT DAMAGE. Ensure that the air louvres in the side of the acoustic cover are not
obstructed.
The top and sides of the generator set are shrouded by an acoustic cover (Fig 10) which provides
environmental protection and noise attenuation. The cover is constructed from aluminium and the inner,
upper surface is lined with acoustic insulation material. Rubber edging strip is installed around the front and
rear edges of the cover to prevent noise caused by vibration transmission through the cover. Four spring
loaded over-centre toggle catches (two each side) are used to secure the cover to the generator set frame.
25
Louvres in the right-hand side of the cover enable respiratory air to be drawn directly into the engine air intake
system and to allow cool air to circulate around the engine exhaust silencer area.
A removable, waterproof accessory equipment bag is situated on top of the cover. The bag contains
the equipment necessary for generator set operation, carrying the generator set and for performing general
maintenance operations. The accessory equipment items are shown and listed in Fig 10.
26
.
.
.
Chap 1
Page 12
Aug 98 (Amdt 2)
Accessory equipment stowage bag
Acoustic lining
Air louvres
Fig 10
Aug 98 (Amdt 2)
19
Boxspannerrod
Adjustable spanner
20 Screwdriver, flat blade
18
15 Side cutting pliers
16 Box spanner
17 Screwdriver, cross-point
7
8
9
Earthing spike
Fuel connector cap
Earth cable
10 Carrying handles (ADADS service only)
11 Shoulder straps (ADADS service only)
12 Fuel connection point
13 Acoustic cover retaining lugs (4)
14 Cover retaining catch (4)
5
Exhaust extension pipe
6 Jerrycan adaptor assembly
4 Rubber edging strip
2
3
1
ARMY EQUIPMENT
SUPPORT PUBLICATION
Acoustic cover and accessory equipment
1
2'
10
11
13-
14
16
9
2
1
6
7
5
Page 13
Fig 10
Chap 1
611 5-G-1 53-302
61 15-G-153-302
BRIEF FUNCTIONAL DESCRIPTION
ARMY EQUIPMENT
SUPPORT PUBLICATION
27 The main functional areas of the 14/28 V1 300/500 W generator set are shown in Fig 11, which
Indicates the functional locations of these areas within the generating system in a simplified block
schematic form.
28 Once the operator has set the output voltage level, engine speed and output voltage are
regulated to suit the load requirements.
Generator set simplified block diagram
I
—
I
I
(ADADS
ONLY)
SERVICE
I
-I
I
I
Jan 93
L_ — __-i
p
OUTPUT
SOCKET
in the event of an output over load condition, a resettable overload protection device
29 Instrumentation on the front panel displays the output voltage and current when the generator
set is in operation. Lamp Indicators on the front panel indicate the selected output voltage range
and the presence of an output overload condition.
30
Fig 11
disconnects output power from the output terminals.
Chap 1
Page 14
.
-J
6115-G-153-302
ARMY EQUIPMENT
SUPPORT PUBLICATION
CHAPTER 2
POWER UNIT
CONTENTS
Para
I
2
3
4
8
9
10
11
12
13
14
15
16
19
20
Introduction
Air filtering
Exhaust system (WARNINGS)
Lubrication system (CAUTION)
Fuel system (WARNINGS)
Fuel supply equipment
Fuel filter
Fuel pump
Carburettor
Fuel priming system
Speed governing
Ignition system
Ignition system operation
Starting system
Engine cooling
Page
Fig
1
2
3
4
5
6
7
8
9
Air filtering system
Exhaust system
Lubrication system
Fuel system
Governing system
Ignition system component locations
Ignition system schematic and circuit diagram
Recoil starter assembly
Cooling air flow - Plan view
2
3
6
8
10
11/12
Chap 2
Jan 93
Page 1
ARMY EQUIPMENT
SUPPORT PUBLICATION
61 15-G-153-302
INTRODUCTION
The power unit consists of an engine, engine mounted accessories and engine support systems.
Equipment location is shown in Chapter 1, Figs 3 to 6. The engine is a Kubota GH1 20, single cylinder,
121 cm3, gasoline fuelled engine and is supplied with some special options and minor modifications to suit
1
the application.
AIR FILTERING
2
Air drawn in from the atmosphere passes through a dry type air cleaning system (Fig 1), which
incorporates a re-usable foam filter element and a disposable paper filter element. The foam filter element
collects larger airborne particles before they reach the paper element.
1
.
7
8
.
1
2
Breather pipe
Carburettor
3 Gasket
4
Air filter casing
5
Plate
6 Paper filter element
7 Foam filter element
8
Air filter cover
Fig 1 Air filtering system
Chap 2
Page 2
Aug 98 (Amdt 2)
61 15-G-153-302
ARMY EQUIPMENT
SUPPORT PUBLICATION
EXHAUST SYSTEM
WARNINGS
TOXIC FUMES. EXHAUST GASES ARE TOXIC AND CAN QUICKLY REACH TOXIC
PROPORTIONS IF BASIC PRECAUTIONS ARE NOT FOLLOWED. IF THE GENERATOR IS TO BE
USED IN A CONFINED SPACE, A STANDARD ISSUE EXHAUST EXTENSION MUST BE FITTED.
THE EXHAUST EXTENSION MUST NOT BE FURTHER MUFFLED OR RESTRICTED IN ANY WAY
(1)
FROM ITS ORIGINAL DESIGN AS THE RESULTING BACK PRESSURE COULD CAUSE
ADDITIONAL LEAKS TO OCCUR OR DAMAGE THE ENGINE. EXTREME CARE MUST BE TAKEN
TO ENSURE THAT EXHAUST GASES ARE VENTED SAFELY AWAY FROM ANY PERSONNEL IN
THE VICINITY WITH DUE CONSIDERATION BEING GIVEN TO TOPOGRAPHY AND PREVAILING
WIND CONDITIONS. HARMFUL CONCENTRATIONS CAN BE ODOURLESS AND NOT VISUALLY
PERCEPTIBLE.
SKIN BURNS. THE EXHAUST FITTINGS BECOME EXTREMELY HOT AND APPROPRIATE
SAFETY PRECAUTIONS ARE TO BE OBSERVED.
(2)
FIRE HAZARD. THE ACOUSTIC CANOPY MUST BE FITTED TO THE GENERATOR SET
WHEN IN OPERATION TO PREVENT COMBUSTIBLE MATERIALS (IE CAMOUFLAGE NETTING)
COMING INTO CONTACT WITH THE GENERATORS HOT SURFACES.
(3)
FIRE HAZARD. CARE MUST BE TAKEN WHEN DEPLOYING THE EXHAUST EXTENSION
MUFFLER TO ENSURE THAT IT IS NOT CLOSE TO OR CAN COME INTO CONTACT WITH ANY
COMBUSTIBLE MATERIAL.
(4)
Exhaust gas expelled from the engine (Fig 2) passes directly into an exhaust silencing unit located at
the right-hand side of the generator set. The exhaust silencer unit connection pipe and inside the rear of the
exhaust silencer unit is covered with a special compound to improve exhaust silencing. A tail pipe at the
bottom of the silencer unit directs exhaust gas under the bottom edge of the acoustic cover and out to the
atmosphere. Exhaust gas can be routed away from the generator set by attaching the exhaust extension
pipe assembly to the silencer unit tail pipe.
3
1
2
3
Cover
Exhaust silencer unit
Exhaust extension pipe
Fig 2 Exhaust system
Jan 03 (Amdt 3)
Chap 2
Page 3
ARMY EQUIPMENT
SUPPORT PUBLICATION
611 5-G-1 53-302
LUBRICATION SYSTEM
4
The Kubota GH12O engine incorporates an oil splash system for lubricating the moving parts of the
engine.
CAUTION
EQUIPMENT DAMAGE. Engine oil OMD 80 may be used in ambient temperatures down to
-15°C, but MUST NOT be used in temperatures below -15°C.
5
The lubrication oils specified for use in the 14/28 V generator set are as follows:
5.1
Engine oil OMD 80 for ambient temperatures above -15°C.
5.2
Engine oil OMD 55 for ambient temperatures below -15°C.
The oil level dipstick (Fig 3) is combined with the oil filler plug situated in a threaded orifice at the rear,
left-hand side of the engine. An oil drain plug is situated at the bottom, left-hand side of the engine crank
6
case.
For a low oil level condition, a low oil level sensing system acts to shut the engine down and disable
engine starting until the correct oil level is restored. The low oil level sensing system consists of a float
operated oil level sensor module, situated in the crank case at the drive shaft end of the engine, and an
electronic switch module mounted on the engine fan cover. When the oil falls below a predetermined level,
7
S
the float in the oil level sensor module activates an integral reed switch, which in turn operates the electronic
switch module to shut the engine down. The electronic switch module performs in the same way as the
engine stop switch by connecting the ignition coil (Para 16) primary current to chassis (earth) potential.
ELECTRONIC
SWITCH MODULE
.
OIL DRAIN
PLUG
OIL LEVEL
SENSOR MODULE
DIPSTICK/OIL
FILLER PLUG
.
Fig 3 Lubrication system
Chap 2
Page 4
Jan 93
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6115-G-153-302
FUEL SYSTEM
WARNINGS
(1)
GASOLINE. GASOLINE FUEL VAPOUR IS EXPLOSIVE WHEN CONTAINED IN A
CONFINED SPACE.
(2)
GASOLINE. GASOLINE FUEL IS FLAMMABLE AND CONSTITUTES A FIRE HAZARD. DO
NOT SMOKE CIGARETTES OR EXPOSE NAKED FLAMES IN THE VICINITY OF THE
GENERATOR SET. SPECIAL CARE MUST BE TAKEN WHEN REFUELLING, SHUTTING DOWN
OR PERFORMING MAINTENANCE ACTIVITIES.
8
The generator set fuel system arrangement is illustrated in Fig 4.
Fuel supply equipment
Fuel is supplied from a jerrycan via the jerrycan adaptor assembly stowed in the accessory equipment
bag on the acoustic cover. The jerrycan adaptor assembly comprises a 3.7 m long fuel pipe, a tap, a
jerrycan filler neck adaptor, and a dip tube assembly. A fine gauze fuel filter is fitted to the lower end of the
dip tube assembly. A quick-release connector at the free end of the fuel pipe connects to the mating
connector on the generator set. The tap prevents fuel spillage from the fuel pipe when the jerrycan adaptor
9
is removed from the jerrycan.
Fuel filter
10 Fuel initially passes through a filter situated at the right-hand side, towards the front of the generator set
frame. This filter is a disposable type and is replaced in accordance with the maintenance schedule.
Fuel pump
An electrically driven fuel pump is situated at the front, right-hand side of the generator set frame. The
pump provides an unrestricted outlet flow of 500 cc/mm. Fuel is pumped by means of an electrically
operated solenoid, which operates a spring loaded piston. An integral, transistorised oscillator circuit
provides pulsed d.c. power to the solenoid, which operates the piston to provide the pumping action at a
frequency of 18 ±3 Hz. Pumping action is obtained by the piston being drawn (magnetically) by the solenoid
during the on
of the driving signal and then pulled back by the return spring during the off time of the
11
driving signal. A unidirectional valve enables the piston to return without forcing fuel in the opposite direction.
Carburettor
12
The air/fuel mixture for combustion is produced by a carburettor attached to the engine inlet manifold.
The carburettor is a conventional side-draft type comprising mainly a float chamber, a pilot air jet, a main air
jet, a throttle flap valve, a choke flap valve and various adjustment facilities. The choke flap valve is operated
by the choke control situated on the generator set rear end panel, next to the fuel primer control. To prevent
the carburettor from flooding when the jerrycan is sited at the same height as or above the carburettor, a
spring has been added inside the carburettor to suppress excess movement of the needle valve due to
increased fuel pump pressure.
Fuel priming system
13 A fuel priming control is mounted on the generator set rear end cover for priming the carburettor before
starting the engine. The priming control comprises a flexible, transparent, rubber bubble which, when
repeatedly pressed and released, pumps fuel from the jerrycan to the carburettor. The pumping action is
enabled by two unidirectional valves strategically placed in a priming module connected in the fuel input pipe
line.
Jan 03 (Amdt 3)
Chap 2
Page 5
ARMY EQUIPMENT
SUPPORT PUBLICATION
611 5-G-1 53-302
2
.
.
.
1
Jerrycan filler neck adaptor
2 Fueltap
3
4
5
6
7
Fuel pipe
Fuel primer control
Unidirectional valve
Priming module
Carburettor
8 Fuelpump
9
10
11
Fuel filter
Fuel connection point
Fuel connector cap
12 Jerrycan
13 Gauze filter
14 Dip tube assembly
.
Fig 4 Fuel system
Chap 2
Page 6
Aug 98 (Amdt 2)
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61 15-G-153-302
SPEED GOVERNING
14 Engine speed is initially set by the speed adjustment screw (Fig 5) and when engine speed
changes occur due to load variations, the speed governing system restores the set engine speed
by adjusting the carburettor throttle flap valve. The governing system (Fig 5) Is a mechanical type
and is situated on the right-hand side of the engine. It Is designed to set a balance between the
centrifugal force produced by the governor weights inside the engine and the external governor
tension spring. When the engine load increases, the engine speed and hence the governor
weights spinning rate decreases. The reduced centrifugal force produced by the governor weights
causes the governor tension spring to pull the governor lever in direction (A) (Fig 5), which adjusts
the throttle flap valve to increase the engine speed. When the engine load decreases, the
centrifugal force produced by the governor weights increases and the governor lever is moved in
direction (B) (Fig 5) to adjust the throttle flap valve and decrease the engine speed.
2
1
4
5
9
8
1
Governor lever
2 Throttle control rod spring
3 Throttle control rod
4 Carburettor
5 Speed adustment screw
6 Speed adjustment plate
7 Governor lever shaft
8 Governor weights
9 Clamping screw
10 Governor tension spring
Fig 5 Governing system
Jan 93
Chap 2
Page 7
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6115-G-153-302
IGNITION SYSTEM
(Fig 6) Is a transistor/magnet type comprising a transistor/magnet
The ignition
ignition unit and a spark plug. A magnet attached to the engine flywheel Induces the energy
necessary for powering the system and controlling the ignition timing. The transistor/magnet
ignition unit is mounted on the rear end of the engine, above the engine flywheel. The ignition
lead is attached to the transistor/magnet ignition unit and is electrically screened along its entire
length. An earth lead is attached to the screening braid at the spark plug cap end of the ignition
lead. A cable is provided for connection to the ENGINE STOP switch on the control box front
panel and to the electronic switch module of the oil level sensing system (Para 7).
15
3
\
4
2
1
TO ENGINE STOP SWITCH
6
Transistor/magnet ignition unit
2 Spark plug
3 Earth lead
1
TO ELECTRONIC
SWITCH MODULE
(OIL LEVEL
SENSING SYSTEM)
4 Ignition lead
5 Magnet
6 Engine flywheel
Fig 6 Ignition system component locations
Ignition system operation
The transistor/magnet ignition unit (Fig 7) comprises an ignition coil to generate a high
secondary winding voltage from current generated in the primary winding and an ignition timing
circuit for generating the ignition coil primary current.
16
During the period where the engine flywheel magnet passes the transistor/magnet ignition
unit, a voltage is induced in the primary winding of the ignition coil. The induced voltage provides
power to the electronic circuitry causing current to flow in the base of transistor TR1 and the
ignition timing control circuit to be activated. Transistor TR1 turns on and initiates a current flow
between the primary winding of the ignition coil and TR1. At the appropriate time, a signal from
the ignition timing control circuit turns transistor TR2 on and TR1 off. At this instant, the ignition
coil primary winding current is cut off sharply, causing a high output voltage to be induced in the
secondary winding, a spark to be generated at the spark plug and the engine to start.
17
18 The engine is stopped by pressing the ENGINE STOP switch, which connects the primary
winding current to ground.
Chap 2
Page 8
Jan 93
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6
th77
I>1<
z
LI,
L__
'7)77
1
Engine flywheel
2 Magnet
3 Transistor/magnet ignition unit
4 Screened ignition lead
5 Engine stop switch
6 Electronic switch module
7 Spark plug
Fig 7 Ignition system schematic and circuit diagram
Jan 93
Chap 2
Page 9
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611 5-G-1 53-302
STARTING SYSTEM
19
A conventional recoil (rope) type starting system is incorporated at therear end of the engine
with the start pulley and turn
rewind
the rope onto the rope
the engine. On releasing the starting rope, the spiral spring acts to
(Fig 8). When the starting rope is pulled, the ratchet dogs engage
reel.
5
6
1
Engine fan cover
2 Start pulley
3 Centre screw
4 Ratchet dog retainer
5 Ratchet dog
6 Brake spring
7 Ratchet dog spring
8 Rope reel
9 Spiral spring
10 Recoil starter case
11 Pull grip
12 Rope
Fig 8 Recoil starter assembly
Chap 2
Page 10
Jan 93
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ENGINE COOLING
A forced air flow is maintained around the engine and through the alternator by a fan attached
to the engine flywheel. Air is drawn in via the grills in the recoil starter case (Para 19) and flows
around the engine and into the alternator via a short hose. Air is expelled from the alternator via
holes in the castings and then passes under the generator set cover to the atmosphere. The
cooling air flow through the generator set is shown in Fig 9.
20
7
1
Engine fan
2 Engine
3 Alternator
4 Acoustic cover
5 Cooling air hose
6 Engine fan cover and cowling
7 Recoil starter case
Fig 9 Cooling air flow - Plan view
Chap 2
Jan 93
Page 11/12
6115-G-153-302
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CHAPTER 3
DETAILED ELECTRICAL DESCRIPTION
CONTENTS
Para
1
2
3
4
5
7
10
11
12
18
20
Introduction
Electrical system functional overview (WARNINGS)
Engine
Alternator output voltage control
Output voltage distribution
Alternator assembly
General
Automatic voltage regulator module
AVR functional description
AVR enable/disable
Excitation control at switch-on
Alternator excitation/output voltage control
3-phase rectifier unit
Control box assembly
General
Voltage regulator module
22
23
25
26
27
28
29
30
General
Circuit description
Terminal board
General
Functional description
13.5 V d.c. distribution
Alternator excitation control
Exciter stator voltage test points
Generator set overall circuit information
Table
1
Page
Automatic voltage regulator specification
.
.
7
.
Fig
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Page
Electrical system - functional block digaram
Alternator assembly
Alternator construction and control system schematic
Alternator AVR module
Alternator excitation control
3-phase rectifier unit
AVR module and 3-phase rectifier unit functional locations
Control box - General view
Control box - Internal view
Front panel - Component locations
Voltage regulator module
Terminal board
Generator set circuit/interconnection diagram Applicable to Equipment Serial Nos 001 to 102
Generator set circuit/interconnection diagram .
Applicable to Equipment Serial Nos from 103
.
3
5
7
9
10
11
12
13
13
14
15
17/18
19/20
Chap 3
Jan 93
Page 1
6115-G-153-302
ARMY EQUIPMENT
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INTRODUCTION
This chapter provides detailed descriptions of the electrical system assemblies and sub1
assemblies that make up the 14/28 V, 300/500 W generator set. The main items of the electrical
system are the alternator assembly and control box assembly. A functional block diagram for the
generator set electrical system functions and how they interact is shown in Fig 1.
Electrical system functional overview
WARNINGS
ELECTRIC SHOCK. AN EARTH PIN WILL NOT NECESSARILY PROVIDE
IMMUNITY FROM ELECTRIC SHOCK. ENSURE THAT ADEQUATE UNIT SAFETY
INSTRUCTIONS ARE HELD AND SAFE WORKING PRACTICES AND PROCEDURES
(1)
IMPLEMENTED.
EARTHING. THE EQUIPMENT MUST BE PROPERLY EARTHED BEFORE
ATTEMPTING TO OPERATE THE GENERATOR SET.
(2)
Engine
The engine ignition system is a transistor/magnet type incorporating an ignition coil to
produce a high output voltage for generating a spark at the spark plug. Once the engine is
2
started, the mechanical engine speed governing system maintains engine speed by compensating
for load variations. When pressed, the ENGINE STOP pushbutton stops the engine by disabling
the ignition system. An oil level sensing system detects a low engine oil level condition and
disables the ignition system until the correct oil level is restored.
Alternator output voltage control
3
Alternator output voltage is controlled by an excitation voltage control circuit and an
automatic voltage regulator (AVR) inside the alternator. Once the operator has set the output
voltage level by setting the RANGE SELECTOR switch and ADJUST VOLTS control, the AVR
automatically maintains the set level by responding to output load variations. The selected output
voltage mode is indicated on the front panel.
Output voltage distribution
The d.c. output from the alternator is smoothed and passed to the output terminals via output
voltage/current instrumentation and a magnetic circuit breaker. An indicator on the front panel
lights when the circuit breaker is open.
4
Chap 3
Page 2
Jan 93
*
Fig 1
Jan 93
ARMY EQUIPMENT
SUPPORT PUBLICATION
OUTPUT
RANGE
SELECTOR
SWITCH
I
J
I
I
I
I
I
14Y MODE SELECTED
® 28V MODE SELECTED
Electrical system - Functional block diagram
1
1(FRONT PANEL)1
I
I
L.ALTERNAT OR]
1
(FRONT PANEL)1
CONTROL
OUTPUT
CONTROL
VOLTS ADJUST1
L_
r
T
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
r
Ii
——--K
C
OUTPUT
SOCKET
(AD ADS
SERVICE
ONLY)
I
Chap 3
Page 3
Fig 1
611 5-G-1 53-302
7
611 5-G-1 53-302
ALTERNATOR ASSEMBLY
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Aug 98 (Amdt 2)
The alternator assembly comprises mainly a separately excited, brush type alternator, an automatic
General
5
1.
6
3-phase rectifier unit
Cooling air hose
Fig 2 Alternator assembly
6 Slip rings
4 Alternator casing
5 Automatic voltage regulator module
3
2' Brush guides
1
voltage regulator module and a 3-phase rectifier unit (Fig 2).
Chap 3
Page 4
.
.
.
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6115-G-153-302
The alternator is a two-stage machine comprising a six-pole permanant magnet rotor rotating
inside a stationary exciter stator and a brush connected 12-pole main rotor winding rotating inside
a stationary 3-phase main stator (Fig 3). The a.c. voltage produced by the exciter stator winding
6
is passed to the excitation voltage control circuit in the control box, where it is processed to
produce a stable d.c. excitation voltage. An ADJUST VOLTS control and RANGE SELECTOR
switch on the control box front panel are used to set the excitation control voltage level at the
alternator AVR module (Para 7), which controls the main rotor winding current and hence, the
alternator output voltage. Alternator output voltage variations are sensed by the AVR, which
restores the set voltage by increasing or decreasing the main stator field current. The main stator
windings are connected in delta configuration and the 3-phase output produced is converted to
d.c. by the 3-phase rectifier unit.
Fig 3 Alternator construction and control system schematic
Jan 93
Chap 3
Page 5
.
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Automatic voitageregulator. module
The automatic voltage regulator (AVR) (Fig 4) is mounted on the rear end casting section of
the alternator. Its purpose is to maintain the alternator output voltage under varying load
conditions in accordance with a preset level. The AVR module comprises an integrated circuit set
In a plastic housing, which also Incorporates the brush guides. Maintenance is restricted to
replacement of the two brushes. Functionally, the AVR module interlinks with the main stator
winding and main rotor winding to provide closed loop control of the alternator output voltage.
The 13.5 V d.c. voltage regulator module in the control box provides the operating power for the
alternator AVR module.
7
The AVR moduleprovides a number of operating features and the main functions used In this
application are:
8
An excitation enable/disable function, which allows the field excitation to be switched
off while the excitation input to the AVR is still applied.
8.1
8.2
Controlled field excitation at initial switch-on.
8.3
Controlled excitation current switching frequency for controlling the alternator output
voltage.
9
Signal connections to the AVR module (Figs 4 and 7) are as follows:
W - + 13.5 V AVR power/excitation voltage input from the voltage regulator module in
the control box.
9.1
9.2
S
-
excitation control voltage input from the terminal board in the control box.
field excitation enable/disable input from the terminal board in the control box.
(13.5 V d.c. = Enable, 0 V = Disable.)
9.3
D
9.4
Phase (unmarked)
9.5
Negative (unmarked) - AVR module negative supply connection.
-
-
sensing input from one phase of the main stator.
Suppression (unmarked)
side of 3-phase rectifier unit.
9.6
9.7
Chap 3
Page 6
-
integral suppression capacitor connection to the positive
Brush (unmarked) - brush connection points.
Jan 93
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BRUSH
S
D
NEGATIVE
SUPPRESSION
BRUSH
GUIDES
Fig 4 Alternator AVR module
TABLE 1 AUTOMATIC VOLTAGE REGULATOR SPECIFICATION
Serial
Parameter
Value
(1)
(2)
(3)
Jan 93
I
Standby current
2.5 mA max. (at 25°C)
2
Regulation voltage (Vreg) setting
accuracy
Vreg ± 0.1 V
3
Load regulation (5% to 95% load
change)
0.3 V max.
4
Switching frequency
50 Hz to 1200 Hz
5
Temperature compensation (Tc)
(regulator temperature)
0 mV/°C
6
Output saturation voltage (at 3.25 A
and 25°C)
1.2 V max. (between field and ground
terminal)
7
Field current excitation at switch-on
(no machine rotation; battery voltage
less than Vreg)
0.4 A to 1.0 A average field current;
frequency range 1.0 kHz to 4.5 kHz
Chap 3
Page 7
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AVR functional description
AVR enable/disable
When the RANGE SELECTOR switch is set in the 14 V or 28 V output mode position, 13.5 V
d.c. Es connected to the "D" input of the AVR to enable operation of the AVR functions. In the OFF
position, the "D" input is disconnected (open circuit) to disable excitation of the alternator.
10
Excitation control at switch-on
During slow rotation of the alternator rotor assembly at initial start-up, an oscillator circuit in
the AVR acts to switch the main: rotor current off and on at a frequency of 1 kHz (25% on-time,
75% off-time). This limits the alternator output until the alternator is rotating fast enough to
achieve the 4.5 V, half-wave, minimum ripple voltage level required at the "Phase" input to turn the
AVR on fully.
11
Alternator excitation/output voltage control
The ADJUST VOLTS control RV3, RANGE SELECTOR switch SW2 and control box terminal
board resistors RV1, RV2, Ri and R2 form part of the alternator excitation control circuit. Variable
resistors RV1 and RV2 are set during manufacture to obtain the required output voltage swing
between the maximum and minimum positions of front panel control RV3 for the 14 V and 28 V
output modes. Fig 5 shows the arrangement of the resistor components and how the arrangement
changes when the generator set output mode is switched from 14 V to 28 V.
12
The purpose of this resistance circuit is to maintain 12.3 V d.c at the "5" input of the AVR
module by operating ADJUST VOLTS control RV3.
13
The AVR module generates excitation current when 12.3 V d.c. is applied to the "5" terminal
and switches the excitation current off when this voltage exceeds 12.3 V d.c. An internal potential
divider circuit converts the 12.3 V input to 3.26 V, which is fed to an internal comparitor circuit to
switch the excitation current on.
14
In the 14 V mode, variable resistor RV2 and fixed resistors Ri and R2 are switched out. When
VOLTS ADJUST control RV3 is set at zero, there is no resistance between the generator positive
output and the AVR US" input, and the voltage present at the US" input AVR is greater than 12.3 V.
This causes the excitation current to be switched off until the generatoroutput voltage falls to 12.3
V. This means that the minimum possible generator operating voltage is 12.3 V. As the resistance
of RV3 is increased, a higher generator output voltage is required to maintain 12.3 V at the "5"
input. When RV3 is set to maximum resistance, the generator output voltage must be at 16 V to
obtain 12.3 V at the "S" input. Therefore, for this resistor configuration, the output voltage range
is 12.3 V to 16 V.
15
For the 28 V mode, RV3 provides a voltage swing of 8 V, which is double the 14 V mode
voltage swing. To achieve this, a precise resistance, made up by resistors Ri and R2, is switched
in between the "5" input and generator negative, and variable resistor RV2 is switched in between
the positive generator output and RV1. For this configuration, more alternator output voltage is
required to achieve 12.3 V at the "5" input, resulting in an output voltage range of 24 V to 32 V.
16
Once the required output voltage is set, any subsequent changes in output voltage due to
load variations is sensed at the US" input and the excitation is increased/decreased accordingly.
17
Chap 3
Page 8
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GENERATOR +VE
OUTPUT
SELECTOR
SW2B
—
I
BOARD (PART)
0
L___1
28V
ADJUST
VOLTS
(FRONT PANEL)
OUTPUT
SELECTOR
SW2C
OFF
12.3V
14 V0
AVR
MODULE
T
L
-J
GENERATOR —yE
Fig 5 Alternator excitation control
Jan 93
Chap 3
Page 9
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6115-G-153-302
3-phase rectifier
unit.
-
18
The 3-phase rectifier unit (Figs 6 and 7) Is mounted on the rear casting section of the
19
Connections to the 3-phase rectifier unit are as follows:
alternator, next to the AVR module, and is used to convert the main stator 3-phase output to d.c.
The unit comprises two diode sub-assemblies and a moulded plastic termination sub-assembly.
Each diode sub-assemblycofltaiflS three diodes mounted on a metal baseplate. One diode subassembly provides the positive half of the rectifer and the other, the negative half. The free ends
of the diodes are soldered at six locations on the termination sub-assembly. If a diode fails, the
complete 3-phase rectifier unit is replaced.
19.1
-
19.2 e -
alternator positive d.c. output connection to the control box.
alternator negative d.c. output connection to the control box.
Main stator winding (unmarked) - six crimp-and-solder terminals for connecting the six
main stator winding leads.
19.3
MAIN STATOR
CONNECTION POINT
(6)
POINT
0
NOT USED
/
3-PHASE
RECTIFIER UNIT
Fig 6 3-phase rectifier unit
Chap 3
Page 10
Jan 93
-J
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E
I
RECTIFIER UNIT
FROM
EXCITATION VOLTAGE
CONTROL CIRCUIT
(CONTROL BOX)
Fig 7 AVR module and 3-phase rectifier unit functional locations
Jan 93
Chap 3
Page 11
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611 5-G-1 53-302
CONTROL BOXASSEMBLY:
General
20 The control box assembly (Fig 8), located at the front of the generator set, houses the
alternator excitation voltage control, output smoothing and output connection circuitry component
Items (Fig 9). All generator set controls (apart from engine start controls) and indicators are
mounted on the control box front panel (Fig 10).
21
Two electronic sub-assemblies are contained Inside the control box:
21.1 Voltage Regulator Module - provides a stabilised d.c. supply.
t.
21.2 Terminal Board - Incorporates various fixed and variable resistors used in the excitation
control circuit (Para 12) and distributes the d.c. power provided by the voltage regulator
module.
CIRCUIT DIAGRAM
Fig 8 Control box - General view
Chap 3
Page 12
Jan 93
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Voltage regulator module
2 Rectifier bridge (MR1)
3 Ammeter shunt resistor
1
4 Smoothing capacitor (C3)
5 Ballast resistor (R7)
6 Terminal board
Fig 9 Control box - Internal view
1
Magnetic circuit breaker (SW1)
2 Hours run meter (Ml)
3 Output ammeter (M2)
4 Output volts meter(M3)
5 14 V indicator (yellow)
6 Range selector switch (SW2)
7 28 V indicator (green)
8 Negative output terminal
9 Positive output terminal
10 Adjust volts control (RV3)
11 Engine stop switch (SW3)
12 Magnetic circuit breaker OFF indicator (red)
Fig 10 Front panel - Component locations
Jan 93
Chap 3
Page 13
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61 15-G-153-302
Voltage
General
The voltage regulator module is mounted on the inside of the control box rear panel and
comprises a printed circuit board attached to a metal alloy heatsink, on which the voltage
22
regulator device is mounted. The output produced by the voltage regulator module is 13.5 V d.c.
and is connected to the terminal board (Para 25), from where it Is distributed to power the
alternator excitation control functions, the fuel pump, the LED indicators and the hours run meter.
Fig 11 shows the physical layout of the voltage regulator components and connection terminals.
LT1038
VOLTAGE
PRINTED
CIRCUIT
BOARD
SUPPORT
TERMINAL
BLOCK
PILLAR (4)
Fig. ii Voltage regulator module
Circuit description
When reading this description, it is necessary to refer to the generator set circuit diagram
shown in Fig 13.
23
The a.c. voltage produced by the alternator exciter stator winding is full-wave rectified and
smoothed by capacitor C2 of the voltage regulator module to provide 30-32 V d.c. at the input of
the Lii 038 type voltage regulator device. A regulated d.c. output of 13.5 V is generated by the
maximum current of 10 A. The output
voltage regulator device, which is capable of
voltage level is set by the regulator control voltage derived by resistors R5 and R6. Capacitor Cl
smoothes out any ripple content in the regulated output.
24
Chap 3
Page 14
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Terminal board
General
The terminal board is mounted on the right-hand bracket Inside the control box. It comprises
a printed circuit board on which two rows of screw terminals, two variable resistors and various
fixed resistors are mounted. The terminal board can be accessed by removing a metal plate on
the right-hand side of the control box. Fig 12 shows the physical layout of the terminal board
components.
25
23456789©
A
R
V
34
URR
QR1
2
R
V______
TERMINAL
BLOCKS
QR2
B
23
4
S
a
1
8
Fig 12 Terminal board
Functional description
26 When reading this description, it is necessary to refer to the generator set circuit diagram
shown in Fig 13.
13.5 V d.c. distribution
The 13.5 V d.c. output from the voltage regulator module is connected to terminals 1, 2, and
3 of terminal row B. From these terminals it is distributed to the:
27
27.1 Excitation input (terminal "W') of the alternator AVR module.
27.2 AVR module enable/disable input (terminal NDN), via front panel RANGE SELECTOR
switch SW2A and current limit resistor R4 on the terminal board.
27.3 Fuel pump.
27.4 Control panel LED indicators, via current limit resistor R3 on the terminal board.
27.5 Hours run meter (Ml).
Jan 93
Chap 3
Page 15
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Alternator excitation control
Terminal board variable resistors RV1, RV2 and fixed resistors Ri and R2 form part of the
alternator excitation control circuit. For details of their function, refer to Para 12.
28
Exciter stator voltage test points
A test point facility is provided by the terminal board for measuring the rectified exciter stator
voltage input to the voltage regulator module In the control box. The terminals used are:
29
29.1 Positive - terminal 8 of terminal row NAN and "B".
29.2 Negative - terminal 9 of terminal row "A" and B"
GENERATOR SET OVERALL CIRCUIT INFORMATION
The
circuit/interconnection information is given in Fig 13 and Fig 14.
the
cable
circuit/interconnection information is the same for both diagrams, but Fig 13 reflects
number configuration for generator sets with Equipment Serial Nos from 001 to 102, and Fig 14
30
Overall
reflects the cable number configuration for generator set with Equipment Serial Nos starting from
103.
Chap 3
Page 16
Jan 93
Fig 13
Jan 93
ARMY EQUIPMENT
SUPPORT PUBLICATION
I
___________
SWITCH
STATE
SOLID
I
I
Generator set circuit/interconnection diagram - Applicable to Equipment Serial Nos 001 to 102
OIL LEVEL
ENGINE OIL-WATCH SYSTEM
___________
Fig 13
Chap 3
_J
I,.
Page 17/18
————
—
6115-G-153-302
Fig 14
Jan 93
ARMY EQUIPMENT
SUPPORT PUBLICATION
I
I
--—n
SWITCH
STATE
SOLID
Generator set circuit/interconnection diagram
ENGINE OIL-WATCH SYSTEM
—
I
Applicable to Equipment Serial Nos from 103
Fig 14
Chap 3
Page 19/20
-J
I
6115-G-153-302
ARMY EQUIPMENT
SUPPORT PUBLICATION
61 15-G-153-512
April 1993
CONDITIONS OF RELEASE
I
.
.
2
4
This information may be subject to privately owned rights.
GENERATOR SET, ENGINE DRIVEN
(GASOLINE), BATTERY CHARGING,
14/28 V, 300/500 W (HOPKINS)
FAILURE DIAGNOSIS
REPRINTED INCORPORATING AMDTS 1-4
This publication contains information covering the requirements of
Category 5.1 at information levels 2 and 3
BY COMMAND OF THE DEFENCE COUNCIL
Ministry of Defence
Issued by
ARMY TECHNICAL SUPPORT AGENCY
DIRECTORATE OF TECHNICAL SERVICES
72111(206)
ATSA Chertsey
9609\WCP-0904
Sep 96 (Amdt 2)
Page (1)1(11)
61 15-G-153-512
1st Edition
ARMY EQUIPMENT
SUPPORT PUBLICATION
AMENDMENT RECORD
Amdt
No.
Incorporated
By (Signature)
I
2
Amdt
Date
No.
Sep 96
32
Incorporated
By (Signature)
Date
33
34
35
:
36
6
37
7
38
8
39
9
40
10
41
11
42
12
43
13
44
14
45
15
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16
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61
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9609\WCP-0904
Sep 96 (Amdt 2)
Page (iii)I(iv)
I
6115-G-153-512
ARMY EQUIPMENT
SUPPORT PUBLICATION
CONTENTS
PRELIMINARY MATERIAL
Front cover (title page)
Amendment record
Contents (this list)
Preface
Introduction
Related and associated publications
Related publications
Associated publications
Hazardous substances
Warnings
Comment on AESP
Page
(1)1(u)
(iii)/(iv)
(v)
(vi)
(vi)
(vi)
(vi)
(vii)
(vii)
(viii)
Final leaf
Frame Para
I
3
4
5
6
7
8
9
10
11
FAILURE DIAGNOSIS
Introduction
General
Failure diagnosis procedure format
Tools and test equipment
300/500 W generator set circuit/interconnection diagram
Failure diagnosis procedures
Engine fails to start - failure diagnosis
Engine runs unevenly - failure diagnosis
No output voltage indicated - failure diagnosis
Output voltage incorrect - failure diagnosis
No output current indicated - failure diagnosis
Page
Table
I
2
3
4
5
6
Tools and test equipment
Engine fails to start - failure diagnosis
Engine runs unevenly - failure diagnosis
No output voltage indicated - failure diagnosis
Output voltage incorrect-failure diagnosis
No output current indicated - failure diagnosis
I
6
8
9
12
16
Fig
I
2
3
Generator set circuit/interconnection diagram equipment serial Nos 001 to 102
Generator set circuit/interconnection diagram equipment serial Nos from 103
Generator set power-up algorithm
9609\WCP-0904
Sep 96 (Amdt 2)
3
4
5
Page (v)
ARMY EQUIPMENT
SUPPORT PUBLICATION
6115-G-153-512
PREFACE
Sponsor:
DGES(A)
File ref: DIDGESII73/12110
Publication Agency:
ATSA Chertsey
Project No: 2542b(3)8793(64)
File ref:
INTRODUCTION
I
Service users should forward any comments on this publication through the channels prescribed in
AESP 01 00-P-01 1-013. An AESP Form 10 is provided at the end of this publication; it should be
photocopied and used for forwarding comments on this AESP.
The subject matter of this publication may be affected by Defence Council Instructions (DCI5),
Standing Operating Procedures (SOPs) or by local regulations. When any such instruction, order or
regulation contradicts any portion of this publication it is to be taken as the overriding authority.
2
RELATED AND ASSOCIATED PUBLICATIONS
Related publications
The Octad for the subject equipment consists of the publications shown opposite. All references are
prefixed with the first eight digits of this publication. The availability of the publications can be checked by
reference to the relevant Group Index (see AESP 0100-A-001-013).
3
.
.
Page (vi)
(Amdt 2) Sep 96
61 15-G-153-512
ARMY EQUIPMENT
SUPPORT PUBLICATION
Information Level
Category/Sub-category
0
1
2
O
1
2
1
2
1
2
3
4
1
2
—
1
2
—
1
2
3
4
User!
Operator
Unit
Maintenance
Field
Maintenance
Base
Maintenance
Purpose and Planning Information
Equipment Support Policy Directives
Purpose and Planning Information
Medical and Dental
Operating Information
Aide Memoire
Training Aids
101
101
101
101
*
*
*
*
*
*
*
*
Technical Description
201
302
Installation Instructions
Preparation for Special Environments
Failure Diagnosis
Repair Instructions
Inspection Standards
Calibration Procedures
201
201
*
302
*
*
*
*
*
*
201
512
512
201
522
532
522
532
*
*
*
*
Maintenance Schedules
601
601
601
601
Illustrated Parts Catalogues
Commercial Parts Lists
Complete Equipment Schedules
Production Edition
Complete Equipment Schedules
Service Edition (Simple Equipment)
Complete Equipment Schedules
Service Edition (Complex Equipment)
Modification Instructions
General Instructions, Special Technical
Instructions and Servicing Instructions
Service Engineered Modification
Instructions (RAF only)
711
711
711
711
*
*
*
*
*
*
*
*
*
*
* Category/Sub-category not published
Associated publications
4
Reference
Title
AESP 2085-B-900-octad
Engine, Gasoline, S/CyI, OHV Kubota
AESP 6115-G-153-octad
Generator Set, Engine Driven (Gasoline), Battery Charging,
14/28 V, 300/500 W, (Hopkins)
AESP 6150-A-i 00-201
Earthing and Electrical Protection
SEI 14411
Safety Precautions for Electrical Equipment
Hazardous substances
5
Before using any hazardous substance or material, the user must be conversant with the safety
precautions and first aid instructions:
5.1
On the label of the container it was supplied in.
5.2
On the material Safety Data Sheet.
5.3
In local Safety Orders and Regulations.
9609\WCP-0904
Sep 96 (Amdt 2)
Page (vii)
6115-G-153-512
ARMY EQUIPMENT
SUPPORT PUBLICATION
WARNINGS
(1)
GASOLINE. GASOLINE FUEL VAPOUR IS EXPLOSIVE WHEN CONTAINED IN A
CONFINED SPACE.
(2)
GASOLINE. GASOLINE FUEL IS FLAMMABLE AND CONSTITUTES A FIRE HAZARD.
DO NOT SMOKE CIGARETTES OR EXPOSE NAKED FLAMES IN THE VICINITY OF THE
GENERATOR SET. SPECIAL CARE MUST BE TAKEN WHEN REFUELLING, SHUTDOWN
OR PERFORMING MAINTENANCE ACTIVITIES
(3) EARTHING. THE
EQUIPMENT MUST
PROPERLY EARTHED
BE
BEFORE
ATTEMPTING TO OPERATE THE GENERATOR SET. WHEN USED WITH ANCILLARY
EQUIPMENT, IT IS ESSENTIAL THAT THE EARTHING INSTRUCTIONS FOR THAT
EQUIPMENT BE FOLLOWED.
ELECTRIC SHOCK. AN EARTH PIN WILL NOT NECESSARILY PROVIDE IMMUNITY
FROM ELECTRIC SHOCK. ADEQUATE UNIT SAFETY INSTRUCTIONS ARE TO BE HELD
AND SAFE WORKING PRACTICES AND PROCEDURES IMPLEMENTED.
(4)
(5)
PERSONAL INJURY. MANUAL LIFTING OF THE TOTAL EQUIPMENT MUST BE
CARRIED OUT BY TWO PERSONS.
(6)
TOXIC FUMES. EXHAUST GASES ARE TOXIC AND CAN QUICKLY REACH TOXIC
PROPORTIONS IF BASIC PRECAUTIONS ARE NOT FOLLOWED. IF THE GENERATOR IS TO
BE USED IN A CONFINED SPACE, A STANDARD ISSUE EXHAUST EXTENSION MUST BE
FITTED. THE EXHAUST EXTENSION MUST NOT BE FURTHER MUFFLED OR RESTRICTED IN
ANY WAY FROM ITS ORIGINAL DESIGN AS THE RESULTING BACK PRESSURE COULD
CAUSE ADDITION LEAKS TO OCCUR OR DAMAGE THE ENGINE. EXTREME CARE MUST BE
TAKEN TO ENSURE THAT EXHAUST GASES ARE VENTED SAFELY AWAY FROM ANY
PERSONNEL IN THE VICINITY WITH DUE CONSIDERATION BEING GIVEN TO TOPOGRAPHY
AND PREVAILING WIND CONDITIONS. HARMFUL CONCENTRATIONS CAN BE ODOURLESS
AND NOT VISUALLY PERCEPTIBLE.
(7)
SKIN BURNS. THE ACOUSTIC CANOPY MUST BE FITTED TO THE GENERATOR SET
WHEN IN OPERATION. DURING SCHEDULED MAINTENANCE OR REPAIR ACTIVITIES,
EXERCISE EXTREME CARE WHEN CARRYING OUT TASKS ADJACENT TO THE EXHAUST
SYSTEM, ENGINE OR ALTERNATOR, AS BOTH ITEMS CAN RETAIN HEAT FOR SEVERAL
MINUTES AFTER SHUT DOWN.
(8)
INFLAMMABLE GASES. HIGHLY INFLAMMABLE GASES ARE LIBERATED FROM
LEAD-ACID BATTERIES DURING CHARGING AND UP TO ONE HOUR AFTER COMPLETION
OF CHARGE. NAKED LIGHTS MUST NOT BE USED WHEN CHECKING ELECTROLYTE
LEVELS NOR MUST LIVE ELECTRICAL CONNECTIONS/DISCONNECTIONS BE MADE
DURING THESE PERIODS.
(9)
LEAD ACID BATTERIES. CARE SHOULD BE TAKEN WHEN WORKING ON OR
AROUND HIGH CAPACITY LEAD-ACID BATTERIES AS THE EXTREMELY HIGH CURRENTS
GENERATED BY AN ACCIDENTAL SHORT CIRCUIT MAY CAUSE SEVERE BURNS OR THE
BATTERY TO EXPLODE. THEREFORE WATCHES, RINGS, ETC. SHOULD BE REMOVED
BEFORE COMMENCING BATTERY ASSOCIATED TASKS.
(10) FIRE HAZARD. WHEN THE JERRYCAN ADAPTOR ASSEMBLY IS STOWED IN THE
VALISE, SEEPAGE OF FUEL INTO THE VALISE CAN CONSTITUTE A FIRE HAZARD.
ENSURE THE JERRYCAN ADAPTOR ASSEMBLY IS DRAINED BEFORE STOWAGE.
(11) FIRE HAZARD. THE ACOUSTIC CANOPY MUST BE FITTED TO THE GENERATOR
SET WHEN IN OPERATION TO PREVENT COMBUSTIBLE MATERIALS (IE CAMOUFLAGE
NETTING) COMING INTO CONTACT WITH THE GENERATORS HOT SURFACES.
Page (viii)
Jan 03 (Amdt 4)
•
ARMY EQUIPMENT
SUPPORT PUBLICATION
6115-G-153-512
(12) PERSONAL INJURY. THE ACOUSTIC CANOPY MUST BE FITTED TO THE
GENERATOR SET TO PREVENT THE RISK OF PERSONNEL BEING CUT ON SHARP
UNPROTECTED EDGES.
(13) NOISE HAZARD. EAR DEFENDERS MUST BE WORN BY MAINTENANCE
PERSONNEL DURING SCHEDULED MAINTENANCE OR REPAIR TASKS WHEN THE
GENERATOR SET IS RUNNING WITH THE ACOUSTIC CANOPY REMOVED.
(14) FALLING HAZARD. THE ACOUSTIC CANOPY MUST NOT BE USED AS A SEAT OR
STEP DURING MAINTENANCE OPERATIONS. THE ACOUSTIC CANOPY WILL NOT BARE
WEIGHT WHEN REMOVED FROM THE GENERATOR SET.
(15) FIRE HAZARD. CARE MUST BE TAKEN WHEN DEPLOYING THE EXHAUST
EXTENSION MUFFLER TO ENSURE THAT IT IS NOT CLOSE TO OR CAN COME INTO
CONTACT WITH ANY COMBUSTIBLE MATERIAL.
(16) TOXIC FUMES. MATERIAL USED IN THE CONSTRUCTION OF THE GENERATOR
SET GIVE OFF TOXIC AND IRRITANT FUMES WHEN BURNT. DO NOT INHALE SMOKE OR
FUMES IF THE GENERATOR SET IS INVOLVED IN A FIRE.
(17) FIRE HAZARD. BEFORE USING THE GENERATOR SET, OPERATORS MUST BE
FAMILIAR WITH THE LOCATION OF SUITABLE FIRE EXTINGUISHING EQUIPMENT.
(18) TOXIC FUMES. MAINTAINERS OF THE EQUIPMENT MUST ENSURE THAT NO PART
OF THE WIRING LOOM IS ROUTED NEAR ANY POTENTIAL HOT SURFACE. I.E. EXHAUST
SYSTEM, ALTERNATOR OR ENGINE. ENSURE THAT ONLY WIRES WITH SILICON
INSULATION ARE USED IN ANY REPAIRS OR FUTURE MODIFICATIONS.
Jan 03 (Amdt 4)
Page (ix)/(x)
xxxx-x-xxx-xxx
ARMY EQUIPMENT
SUPPORT PUBLICATION
COMMENT(S) ON AESP
To:
From:
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Woolwich
LONDON 5E18 4QF
Date
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Thank you for commenting on AESP
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DateS
ARMY EQUIPMENT
SUPPORT PUBLICATION
6115-G-153-512
INTRODUCTION
General
It
1
Is assumed for the purpose of this AESP category that the generator set start-up
procedures, as described in AESP 61 15-G-153-201, have been carried out correctly up to the point
of failure.
2
Failure diagnosis by the operator is restricted to checking that routine maintenance operations
have been carried out. When faults occur, action must initially be taken at Unit level (level 2),
although Field or Base involvement may subsequently be required.
Failure diagnosis procedure format
The failure diagnosis procedures are presented in the form of tables providing columned
step-by-step information on testing, results, possible cause of failure and the action to be taken.
Each procedure must be carried out in the order given.
3
Tools and test equipment
4
The tools and test equipment required for carrying out the following inspection standards are
listed in Table 1.
TABLE 1 TOOLS AND TEST EQUIPMENT
Item
Nato Stock No.
(1)
Designation
(2)
(3)
Use
(4)
1
Z4/6625-99-545-1 446
Insulation resistance
tester - Type Megohmeter
set, 4 voltages, J4 Mk 2.
Insulation resistance
measurements.
2
Z4/6625-gg-252..3605
Multimeter, Fluke 25.
General electrical testing.
Resistance bridge.
Low resistance
measurements.
3
Apr 93
NYK
Page 1
I
611 5-G-153-51 2
ARMY EQUIPMENT
SUPPORT PUBLICATION
W generator set circuit/interconnection diagram
In cases where a failure diagnosis procedure states circuit or cable number references, it Is
necessary to refer to the generator set circuit/interconnection diagram shown in Fig 1 or Fig 2,
as appropriate. The circuit arrangement is the same for both diagrams, but the cable numbering
5
is different, depending on the Equipment Serial No.
Fig
1 shows the cable numbering for
Equipement Serial Nos from 001 to 102, whereas Fig 2 shows the cable numbering for Equipment
Serial Nos from 103, Inclusive.
Page 2
Apr 93
F—
I
I
Apr 93
L__J
I
I
I
(PART)
ALTERNATOR
r——1
FUEL PUMP
1+
ARMY
SUPPORT PUBLICATION
ENGINE
STOP
SW3
STATE
SWITCH
SOLID
C
Fig 1
____—
(8)
R5
'MODULE5
:V
(9)
(131
(10)
I
I
I
—
(19)
I'
IV
IV V
r
(9)
'3
V
V
V
V
V
T
V
V
L__J
V
V
VS
I
M3
-
M2
+
0'
V
A
/4,
+
—
L_ _f — — — —I —
I
S
40Vd.c.
V
g3
'5
I
A
—
(10)
(10)
(10)
5_V J
——
Generator set circuit/interconnection diagram - Equipment serial Nos 001 to 102
——
OIL LEVEL
V5
I
——
——
CONTROL BOX
— — S — _a_
ENGINE OIL-WATCH SYSTEM
÷
(10)
(17)
——
__________
L ———
H
L
I
___________
(4)
J1)
(S)
(6)
SW2B
RANGE
SELECTOR
-
r
14V
Ur
(13)
°28V
—
NC
I
10
-
14V
28V
I
(RED)
14V
(GREEN)
(20)
SW2C,pZ8V V
SW2D
OUTPUT TERMINALS
/
(10)
ADJUST
RV3
SW1A
Ci
RANGE
SELECTOR
14V
(22)
(10)
(10)
(13)
-j
Fig 1
Page 3
1701
I
I
I
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I
I
I
I
I
I
I
1
-I
611 5-G-1 53-512
I
I
L
J
®
I
I
I
—1
——
RECTU9ER
UNIT
ALTERNATOR
6115-G-153-512
I
I
L
Fig 2
Page 4
I
I
i
I
I
I
I
L
i
+
I
1
—
(38)
—
ENGINE OIL-WATCH SYSTEM
L ——
I
I
(13)
(9)
I
(19)
Ri
t
—
—
50
&GARD
A
+
————
+L(
(28L('' I
40Vd.c.
— ——____________
I
LL
I
CONTROL BOX
I
I
—
—0—
—
J
I
(24)
Fig 2 Generator set circuit/interconnection diagram - Equipment serial Nos from
—
1
SW1A
I
NC
(40)
(22)
14V
ARMY EQUIPMENT
(GREEN)
(20)
I
1
I
I
I
-I
SUPPORT PUBLICATION
10
28V
I
I
I
I
I
I
(10)
r— ———-n
I
I
I
I
1
I
L
(401
OUTPUT TERMINALS
Apr93
ARMY EQUIPMENT
SUPPORT PUBLICATION
6115-G-153-512
FAILURE DIAGNOSIS PROCEDURES
The failure diagnosis procedures are intended for use in conjunction with the generator set
power-up algorithm shown in Fig 3. The algorithm shows the points in the sequence at which fault
conditions would be indicated and refers to the relevant fault diagnosis procedure for corrective
action. It also assumes that a suitable load is connected to the generator set.
6
Fig 3 Generator set power-up algorithm
Apr 93
Page 5
6115-G-153-512
ARMY EQUIPMENT
SUPPORT PUBLICATION
Engine fails to start - Failure diagnosis
Engine fails to start when using the recoil. starter system.
7
TABLE 2 ENGINE FAILS TO START - FAILURE DIAGNOSIS
Serial
Procedure
Result
Possible Cause
Action
(1)
(2)
(3)
(4)
(5)
Yes
-
Go to Serial 2.
No
-
Pull choke control
out fully and
operate recoil
starter.
Yes
-
Go to Serial 3.
Is choke control pulled
out fully ?
2
Is fuel primer control
operating?
No
3
Does the spark plug
(with ignition lead
attached) spark when
held against the engine
and the recoil starter
operated?
Yes
-
No
Rubber bubble split.
Replace fuel
primer.
Fuel piping
damaged, split.
Replace fuel piping.
Defective fuel
primer,
Check fuel primer
operation and
replace, if
necessary.
Jerrycan adaptor
assembly dip-tube
filter blocked,
Clean foreign
matter from diptube filter.
Clogged air filter.
Clean/replace air
filter element.
Defective fuel pump.
Check fuel pump
operation and
replace, if
necessary.
Defective
carburettor.
Check
serviceability of
carburettor and
replace, if
necessary.
Engine fault.
Replace engine
unit, if necessary.
Spark plug not
serviceable,
Clean spark plug
and set spark gap.
If fault persists, go
to Serial 4.
(continued)
71911(98)
Veh & Wpns Br
Page 6
Apr 94 (Amdt 1)
ARMY EQUIPMENT
SUPPORT PUBLICATION
61 15-G-153-512
TABLE 2 ENGINE FAILS TO START - FAILURE DIAGNOSIS (CONTINUED)
Serial
Procedure
Result
Possible Cause
(1)
Action
(2)
(3)
(4)
(5)
4
Does short circuit condition
exist between oil level
sensor cable and frame?
No
5
6
7
Does a short circuit
condition exist between
cable 14 and frame?
Yes
No
Yes
Measure the resistance of
Approx
the ignition coil primary
1.2 ohms.
winding - between cable 14
and frame.
Significantly
greater or less
than 1.2 ohms.
Measure the resistance of
Approx 11.7 k
the ignition coil secondary
ohms.
winding - between cable 14
and ignition lead.
Significantly
greater or less
than 11.7 k
ohms.
Go to Serial 5.
Oil level low.
Top up oil level.
Defective oil level
sensor.
Replace oil level
sensor.
-
Go to Serial 6.
Defective ENGINE
STOP switch SW3.
Check operation of
SW3 and replace, if
necessary.
Defective solid state
switch.
Check operation of
solid state switch and
replace, if necessary.
-
Defective ignition coil.
-
Defective ignition coil.
Go to Serial 7.
Replace
transistor/magnet
ignition unit.
No action.
Replace
transistor/magnet
ignition unit.
98/42b/O1 1(731)
Aug 98 (Amdt 3)
Page 7
6115-G-153-512
ARMY EQUIPMENT
SUPPORT PUBLICATION
Engine runs unevenly - Failure diagnosis
8.
Engine does not run smoothly once started.
TABLE 3 ENGINE RUNS UNEVENLY - FAILURE DIAGNOSIS
Serial
Procedure
Result
(1)
Possible Cause
(2)
Action
(3)
(4)
(5)
No
-
Is choke control
returned to normal
operation position?
control fully.
Yes
2
With spark plug
(attached to IgnitIon
lead) held against
engine, does sparking
appear erratic when
recoil starter Is
Return choke
Yes
Go
-
Spark plug not
servIceable,
to Serial 2.
Clean spark plug
and reset electrode
gap.
If fault persists, go
to Serial 3.
operated?
No
Engine overheating.
Check engine
cooling aIr Inlet
grills In starter
casing for
blockage.
Clogged air filter.
Clean/replace air
filter element(s), as
appropriate.
Defective fuel pump.
Check fuel pump
serviceabIlity and
renew, if
necessary.
Clogged fuel filter.
Check fuel filter
and renew, If
necessary.
Defective
Clean/adjust/
carburettor,
renew carburettor,
as approprIate.
Governor system out
of adjustment or
loose parts.
Secure any loose
parts.and set up
governor system.
Engine head gasket
leaklng.
Renew head
gasket.
Engine fault.
Renew engine unit.
(contInued)
Page 8
..
.
Apr 94 (Amdt 1)
ARMY EQUIPMENT
SUPPORT PUBLICATION
61 15-G-153-512
TABLE 3 ENGINE RUNS UNEVENLY - FAILURE DIAGNOSIS (ôontinued)
Serial
Procedure
Result
Possible Cause
Action
(1)
(2)
(3)
(4)
(5
Measure the resistance
of the ignition coil
primary winding between cable 14 and
frame.
Approx
1.2 ohms.
-
Measure the resistance
of the ignition coil
secondary winding between cable 14 and
ignition lead.
Approx
3
4
Significantly
greater or
less than
1.2 ohms.
Defective ignition
coil.
-
Go to Serial 4.
Replace
transistor/magnet
ignition unit.
No action.
11.7 k
ohms.
Significantly
greater or
less than
11.7 k
Defective ignition
coil.
Replace
transistor/magnet
ignition unit.
ohms.
No output voltage indicated - Failure diagnosis
9
No output voltage indicated on the front panel voltmeter for both 14 V and 28 V output modes.
TABLE 4 NO OUTPUT VOLTAGE INDICATED - FAILURE DIAGNOSIS
Serial
Procedure
Result
Possible Cause
Action
(1)
(2)
(3)
(4)
(5)
Is the associated output
voltage mode LED on?
Yes
Go to Serial 2.
No
Go to Serial 4.
No
Go to Serial 3.
1
2
Are d.c. volts present at
output terminals?
Yes
Defective wiring.
Check
cables/connections
between voltmeter,
shunt resistance
and negative
output terminal.
3
Is 13.5 V d.c. nom.
present between
Terminal Board/B4 and
the negative output
terminal ?
Yes
Defective voltmeter.
Renew voltmeter.
Loose connection to
O terminal of
alternator AVR
Tighten D terminal
connection.
Module.
(continued)
Apr 94 (Amdt 1)
Page 9
ARMY EQUIPMENT
SUPPORT PUBLICATION
6115-G-153-512
TABLE 4 NO OUTPUT VOLTAGE INDICATED - FAILURE DIAGNOSIS
Serial
Procedure
Result
Possible Cause
Action
(1)
(2)
(3)
(4)
(5)
3
cant...
Worn or damaged
alternator brushes.
Check
Defective AVR
Module.
Renew AVR
Module.
Catastrophic failure
of alternator 3-Phase
Rectifier Unit.
Measure continuity
Defective main rotor
winding,
serviceability of
brushes and renew,
if necessary.
(1 V
re)
across W and
terminals of
3-Phase Rectifier
Unit with cable 9
disconnected Open circuit in one
direction and
conduction in the
other. Renew
3-Phase Rectifier
Unit, if necessary.
Measure main rotor
winding resistance
across slip rings
with brushes
removed (2.5 ohms
approx). If
necessary, renew
main rotor.
Measure main rotor
insulation
resistance between
one slip ring and
rotor shaft
(1 M ohm mm.). If
necessary, renew
main rotor.
Defective main stator
winding,
Unsolder and
remove the main
stator winding
leads from the
3-Phase Rectifier
Unit and measure
the resistance of
each winding (0.7
to 0.9 ohms). If
necessary, renew
main stator.
(continued)
Page 10
Apr 94 (Amdt 1)
P
ARMY EQUIPMENT
SUPPORT PUBLICATION
61 15-G-153-512
TABLE 4 NO OUTPUT VOLTAGE INDICATED - FAILURE DIAGNOSIS (continued)
Serial
Procedure
Result
Possible Cause
Action
(1)
(2)
(3)
(4)
(5)
Measure main
stator insulation
resistance between
windings and
casing (1 M ohm
3
cant...
mm.).
No
Defective wiring.
Check cables!
connections
between Terminal
Board/B4, Terminal
Board/A3, RANGE
SELECTOR switch
SW2A and Terminal
Board/A2.
4
5
Is 20 - 25 V average a.c.
(measured with moving
coil meter) present
between exciter stator
flying leads (cables 52 &
53) ?
Yes
Is 30 V d.c. nom.
present between
terminals 1 (-ye) and 3
(+ve) of the Voltage
Regulator Module?
Yes
No
No
Defective RANGE
SELECTOR switch
segment SW2A.
Check operation of
SW2A and renew
SW2, if necessary.
Defective Terminal
Board.
Renew Terminal
Board.
-
Defective exciter
stator winding.
-
Defective wiring.
Go to Serial 5.
Measure exciter
stator winding
resistance
(0.05 ohms
approx.).
Go to Serial 6.
Check
cables/connections
between exciter
stator leads,
rectifier module
MR1 and Voltage
Regulator Module.
Defective rectifier
module MR1.
Renew MR1.
(continued)
Apr94 (Amdt 1)
Page 11
6115-G-153-512
ARMY EQUIPMENT
SUPPORT PUBLICATION
TABLE 4 NO OUTPUT VOLTAGE INDICATED - FAILURE DIAGNOSIS (continued)
Serial
Procedure
Result
Possible Cause
Action
(2)
(3)
(4)
(5)
Is 13.5 V d.c. nom.
present between
terminals I (-ye) and 2
(+ve) of Voltage
Regulator Module ?
Yes
-
No
Defective Voltage
Regulator Module.
Renew Voltage
Regulator Module.
Is 13.5 V d.c. nom.
present between
negative output terminal
and Terminal Board/B2
Yes
Defective Terminal
Board.
Renew Terminal
Board.
Defective wiring.
Check
-
(1)
6
7
No
Go to Serial 7.
cables/connections
between Voltage
?
Regulator
Module/2 and
Terminal Board/B2.
Output voltage incorrect - Failure diagnosis
10
Output voltage or voltage range not obtainable.
TABLE 5 OUTPUT VOLTAGE INCORRECT - FAILURE DIAGNOSIS
Serial
Procedure
Result
Possible Cause
Action
(1)
(2)
(3)
(4)
(5)
Does ADJUST VOLTS
No
control vary the output
voltage ?
ADJUST VOLTS
Check
control associated
wiring fault.
serviceability of
associated wiring.
Defective ADJUST
VOLTS control RV3.
Check operation of
RV3 control
If fault persists, go
to Serial 2.
Yes, but
volts
range not
correct.
RANGE SELECTOR
Check
switch associated
wiring fault.
serviceability of
SW2 associated
wiring.
Defective RANGE
SELECTOR switch
Check operation of
SW2.
SW2B and SW2C
switch segments.
If fault persists, go
to Serial 2.
(continued)
Page 12
Apr 94 (Amdt 1)
6115-G-153-512
ARMY EQUIPMENT
SUPPORT PUBLICATION
TABLE 5 OUTPUT VOLTAGE INCORRECT - FAILURE DIAGNOSIS
Serial
Procedure
Result
Possible Cause
Action
(1)
(2)
(3)
(4)
(5)
2
Low no-load output
Go to Serial 3.
No
voltage?
Yes
Defective AVR
Module.
Renew AVR
Module.
Defective main rotor
winding,
Measure main rotor
winding resistance
across slip rings
with brushes
removed (2.5 ohms
approx). If
necessary, renew
main rotor.
Measure main rotor
insulation
resistance between
one slip ring and
rotor shaft
(1 M ohm mm.). If
necessary, renew
main rotor.
Defective main stator
winding,
Unsolder and
remove the main
stator winding
leads from the
3-Phase Rectifier
Unit and measure
the resistance of
each winding (0.7
to 0.9 ohms). If
necessary, renew
main stator.
Measure main
stator insulation
resistance between
windings and
casing (1 M ohm
mm.). If necessary,
renew main stator.
(continued)
Apr 94 (Amdt 1)
Page 13
ARMY EQUIPMENT
SUPPORT PUBLICATION
6115-G-153-512
TABLE 5 OUTPUT VOLTAGE INCORRECT - FAILURE DIAGNOSIS (continued)
Serial
Procedure
Result
Possible Cause
Action
(1)
(2)
(3)
(4)
(5)
Defective 3-Phase
Rectifier Unit
diode(s)
2
cont...
With the main
stator leads
disconnected from
the 3-Phase
Rectifier Unit,
check each diode
with a continuity
testerS (1 V mini
pressure) - Open
circuit in one
direction,
conduction in the
other. If a diode
has failed, renew
the complete
rectifier unit.
3
High no-load output
voltage?
No
Yes
-
Defective wiring.
Go to Serial 4.
Check
cables/connections
between AVR
Module terminal S
and Terminal
Board /B5.
Check
cables/connections
between shunt
resistance and
Terminal Board/A4.
4
Low on-load output
volts?
No
Yes
Defective Terminal
Board.
Renew Terminal
Board.
Defective AVR
Module.
Renew AVR
Module.
-
No 13.5 V d.c.nom.
present at AVR
Module terminal W.
Go to Serial 5.
Check for 13.5 V
d.c. and
cable/connections
between AVR
Module terminal W
and Terminal
B oard/B3.
(continued)
Page 14
Apr 94 (Amdt 1)
611 5:G..1 53-512
ARMY EQUIPMENT
SUPPORT PUBLICATION
TABLE 5 OUTPUT
INCORRECT - FAILURE DIAGNOSIS (continued)
Serial
Procedure
Result
Possible Cause
Action
(1)
(2)
(3)
(4)
(5)
4
cont...
5
High on-load output
voltage?
Open circuit AVR
Module PHASE link
connection.
Check PHASE link
connection.
Defective AVR
Module.
Renew AVR
Module.
No
Yes
-
Open circuit AVR
Module S
connection.
Go to Serial 5.
Check
cable/connections
between AVR
Module terminal S
and Terminal
Board/B5.
6
Output voltage
unstable?
Defective AVR
Module.
Renew AVR
Module.
Defective Terminal
Board.
Renew Terminal
Board.
No
Yes
-
Worn or damaged
brushes causing
intermittent contact.
No action.
Check
serviceability of
brushes and renew
brushes, if
necessary.
Loose AVR Module
connections.
Check security of
AVR Module
Co fl nections.
Loose connections
to 3-Phase Rectifier
Unit.
Apr 94 (Amdt 1)
Check security of
3-Phase Rectifier
Unit connections.
Page 15
ARMY EQUIPMENT
SUPPORT PUBLICATION
611 5-G-l 53-512
No output current indicated - Failure diagnosis
current-
11
TABLE 6 NO OUTPUT CURRENT INDICATED - FAILURE DIAGNOSIS
Serial
P rocedure
Result
Possible Cause
Action
(1)
(2)
(3)
(4)
(5)
1
Has the MCB tripped
out
Yes
Excessive load.
Reduce load.
Load incorrectly
Check load
connections,.
?
-
polarity).
No
Defective MCB
(oversensitive).
Renew MCB.
Loose connections.
Check security of
cable connections
between load and
generator set
output terminals.
Check security of
cable connections
between output
terminals and
alternator.
Page 16
Ammeter associated
wiring fault.
Check
Defective ammeter.
Renew ammeter.
serviceability of
ammeter
associated cables/
connections.
Apr 94 (Amdt 1)
4
This information may be subject to privately owned rights.
GENERATOR SET, ENGINE DRIVEN
(GASOLINE) BATTERY CHARGING
14/28 V, 300/500 W (HOPKINS)
MAINTENANCE SCHEDULE
REPRINTED INCORPORATING AMDTS 1-5
This publication contains information covering the requirements of
Category 6 at information levels 1.2.3 and 4
BY COMMAND OF THE DEFENCE COUNCIL
Ministry of Defence
Issued by
ARMY TECHNICAL SUPPORT AGENCY
DIRECTORATE OF TECHNiCAL SERVICES
9609/ILM1 002
Page (i)/(ii)
ARMY EQUIPMENT
SUPPORT PUBLICATION
611 5—G—1 53—601
2nd Edition
AMENDMENT RECORD
Amdt
No.
1
2
Incorporated
By (Signature)
Date
Amdt
No.
Sep 96
Incorporated
By (Signature)
Date
32
33
34
4
35
36
:
37
38
39
9
40
10
41
11
42
12
43
13
44
14
45
15
46
16
47
17
48
18
49
19
50
20
51
21
52
22
53
23
54
24
55
25
56
26
57
27
58
28
59
29
60
30
61
31
62
9609/ILM1 002
Nov 96
Page (iii)/(iv)
P
-
6115-G-153-601
ARMY EQUIPMENT
SUPPORT PUBLICATION
CONTENTS
PRELIMINARY MATERIAL
Front cover (title page)
Amendment record
Contents (this list)
Preface
Introduction
Related and associated publications
Related publications
Associated publications
Warnings
Cautions
Comments on AESP
Page
(i)/(ii)
(iii)I(iv)
(v)
(vi)
(vi)
(vi)
(vi)
(vii)
(vii)
(viii)
Final leaf
Para
1
2
5
7
8
9
MAINTENANCE SCHEDULE
Introduction
Authority
Responsibilities
Inspection and examinations
Records
Serial numbers
Abbreviations
Table
1
2
3
4
5
6
7
Equipment applicability
Fuels, lubricants and associated products
Equipment data
Action on receipt
Daily operator checks
Generator periodic maintenance
Out of use maintenance
Jan 03 (Amdt 3)
2
2
3
4
5
6
7/8
Page (v)
6115-G-153-601
ARMY EQUIPMENT
SUPPORT PUBLICATION
PREFACE
.
Sponsor:
DGES(A)
File ret:
Publication Agency:
ATSA Chertsey
Project No: 72111(204)
File ret: EEPI721 ii
INTRODUCTION
Service users should forward any comments on this publication through channels prescribed in
1
AESP 0100-P-Oil -013. An AESP Form 10 is provided at the end of this publication; it should be
photocopied and used for forwarding comments on this AESP.
RELATED AND ASSOCIATED PUBLICATIONS
Related publications
.
The Octad for the subject equipment consists of the publications shown below. All references
are prefixed by the first eight digits of this publication. The availability of the publications can be checked
by reference to the relevant Group Index (see AESP Ol0O-A-O01-013).
2
Information Level
Category/Sub-category
1
User!
Operator
1
0
2
1
2
3
T
2
1
2
3
4
6
1
7
2
3
4
5
1
2
8
—
3
Purpose and Planning Information
Equipment Support Policy Directives
Operating Information
Aide Memoire
Training Aids
Technical Description
2
3
4
Unit
Field
Base
Maintenance Maintenance Maintenance
101
101
101
*
*
*
101
*
*
*
*
*
*
*
*
*
*
*
201
302
302
*
*
*
*
201
Installation Instructions
Preparation for Special Environments
Failure Diagnosis
Repair Instructions
Inspection Standards
Calibration Procedures
Maintenance Schedules
201
Illustrated Parts Catalogues
Commercial Parts Lists
Complete Equipment Schedule, Production
Complete Equipment Schedule,
Service Edition (Simple Equipment)
Complete Equipment Schedule,
Service Edition (Complex Equipment)
Modification Instructions
General Instruction, Special Technical
Instructions and Servicing Instructions
Service Engineered Modification Instructions
(RAE only)
*
*
*
201
201
512
512
532
512
512
532
*
*
*
*
601
601
601
601
711
711
711
711
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
* Category/Sub-category not published
9609/I LM1 002
Page (vi)
.
Nov 96
.
ARMY EQUIPMENT
SUPPORT PUBLICATION
61 15-G-153-601
Associated publications
Reference
Title
AESP 2805-G-900 Octad
Engine, Gasoline, S/CYL, OHV, KUBOTA
AESP 61 15-G-153 Octad
Generator Set, Engine Drive (Gasoline), Battery Charging,
14/28 V, 300/500 W, (HOPKINS)
AESP 6150-A-I 00-201
Earthing and Electrical Protection
SEI 14411
Safety Precautions for Electrical Equipment
3
WARNINGS
(1)
GASOLINE. GASOLINE FUEL IS FLAMMABLE AND CONSTITUTES A FIRE HAZARD.
DO NOT SMOKE CIGARETTES OR EXPOSE NAKED FLAMES IN THE VICINITY OF THE
GENERATOR SET. SPECIAL CARE MUST BE TAKEN WHEN REFUELLING, SHUTTING DOWN
OR PERFORMING MAINTENANCE ACTIVITIES.
(2)
LETHAL VOLTAGE. THE EQUIPMENT MUST BE PROPERLY EARTHED BEFORE
ATTEMPTING TO OPERATE THE GENERATOR.
(3)
TOXIC FUMES. EXHAUST GASES ARE TOXIC AND CAN QUICKLY REACH TOXIC
PROPORTIONS IF BASIC PRECAUTIONS ARE NOT FOLLOWED. IF THE GENERATOR IS TO
BE USED IN A CONFINED SPACE, A STANDARD ISSUE EXHAUST EXTENSION MUST BE
FITTED. THE EXHAUST EXTENSION MUST NOT BE FURTHER MUFFLED OR RESTRICTED IN
ANY WAY FROM ITS ORIGINAL DESIGN AS THE RESULTING BACK PRESSURE COULD
CAUSE ADDITIONAL LEAKS TO OCCUR OR DAMAGE THE ENGINE. EXTREME CARE MUST
BE TAKEN TO ENSURE THAT EXHAUST GASES ARE VENTED SAFELY AWAY FROM ANY
PERSONNEL IN THE VICINITY WITH DUE CONSIDERATION BEING GIVEN TO TOPOGRAPHY
AND PREVAILING WIND CONDITIONS. HARMFUL CONCENTRATIONS CAN BE ODOURLESS
AND NOT VISUALLY PERCEPTIBLE.
(4)
LIFTING. MANUAL LIFTING OF THE TOTAL EQUIPMENT MUST BE CARRIED OUT BY
TWO PERSONS.
(5)
SKIN BURNS. THE ACOUSTIC CANOPY MUST BE FITTED TO THE GENERATOR SET
WHEN IN OPERATION. DURING SCHEDULED MAINTENANCE OR REPAIR ACTMTIES,
EXERCISE EXTREME CARE WHEN CARRYING OUT TASKS ADJACENT TO THE EXHAUST
SYSTEM, ENGINE OR ALTERNATOR, AS THESE ITEMS CAN RETAIN HEAT FOR SEVERAL
MINUTES AFTER SHUT DOWN.
(6)
PERSONAL INJURY. WHEN THE ACOUSTIC CANOPY IS REMOVED FROM THE
GENERATOR SET DURING MAINTENANCE ACTIVITIES, CARE MUST BE TAKEN TO AVOID
THE RISK TO PERSONNEL BEING CUT ON SHARP UNPROTECTED EDGES.
(7)
NOISE HAZARD. EAR DEFENDERS MUST BE WORN BY MAINTENANCE PERSONNEL
DURING SCHEDULED MAINTENANCE OR REPAIR TASKS WHEN THE GENERATOR SET IS
RUNNING WITH THE ACOUSTIC CANOPY REMOVED.
(8)
FALLING HAZARD. THE ACOUSTIC CANOPY MUST NOT BE USED AS A SEAT OR
STEP DURING MAINTENANCE OPERATIONS. THE ACOUSTIC CANOPY WILL NOT BEAR
WEIGHT WHEN REMOVED FROM THE GENERATOR SET.
(9)
FIRE HAZARD. CARE MUST BE TAKEN WHEN DEPLOYING THE EXHAUST
EXTENSION MUFFLER TO ENSURE THAT IT IS NOT CLOSE TO OR CAN COME INTO
CONTACT WITH ANY COMBUSTIBLE MATERIAL.
Sep 03 (Amdt 5)
Page (vii)
6115-G-153-601
ARMY EQUIPMENT
SUPPORT PUBLICATION
(10)
TOXIC FUMES. MATERIAL USED IN THE CONSTRUCTION OF THE GENERATOR SET
GIVE OFF TOXIC AND IRRITANT FUMES WHEN BURNT. DO NOT INHALE SMOKE OR FUMES
IF THE GENERATOR SET IS INVOLVED IN A FIRE.
(11)
FIRE HAZARD. BEFORE USING THE GENERATOR SET, OPERATORS MUST BE
FAMILIAR WITH THE LOCATION OF SUITABLE FIRE EXTINGUISHING EQUIPMENT.
(12)
TOXIC FUMES. MAINTAINERS OF THE EQUIPMENT MUST ENSURE THAT NO PART
OF THE WIRING LOOM IS ROUTED NEAR ANY POTENTIAL HOT SURFACE. I.E. EXHAUST
SYSTEM, ALTERNATOR OR ENGINE. ENSURE THAT ONLY WIRES WITH SILICON
INSULATION ARE USED IN ANY REPAIRS OR FUTURE MODIFICATIONS.
CAUTIONS
(1)
EARTHING REQUIREMENT. When used with certain equipments the normal earthing
method should not be used. Consult earthing instructions for ancillary equipment.
(2)
AIR SUPPLY PRECAUTION. Do not obstruct air filter louvres in acoustic cover.
(3)
OPERATING PRECAUTION. Do not connect or disconnect equipment with the
generator running and the power switched 'ON'.
.
.
Page (viii)
Sep 03 (Amdt 5)
ARMY EQUIPMENT
SUPPORT PUBLICATION
61 1 5-G—1 53-601
MAINTENANCE SCHEDULE
INTRODUCTION
Authority
1
This Maintenance Schedule is the authority for carrying out all maintenance tasks on the subject
equipment.
Responsibilities
The Unit Commander is responsible for ensuring that the operations detailed in this Maintenance
Schedule are properly carried out. He may order any operation to be carried out more frequently than is
specified if the conditions under which the equipment operates render it necessary. He should consult
his REME advisor before ordering such changes.
2
The unit commander may adjust the specified maintenance intervals by plus or minus 10 per cent
to suit local circumstances.
3
The operator/driver is responsible for ensuring the equipment is fit for task. If the mechanical
fitness is in doubt, the equipment is not to be used until advice has been sought.
4
Inspection and examinations
The unit commander is advised to arrange inspections to be carried out on receipt of the equipment
and thereafter in accordance with JSP 341 Chap 16 Para 16.454.
5
6
Examination is carried out by REME in accordance with AGAI Vol 4 Para 142.031 — 142.036.
Records
7
Maintenance and inspections are to be recorded in the equipment documents.
Serial numbers
8
Serial numbers left blank may be taken up by amendment action at a later date.
Abbreviations
9
9.1
Li — Level 1 (User Unit Maintenance).
9.2
L2 — Level 2 (REME Unit Maintenance).
9.3
L3 — Level 3 (REME Field Repair).
9.4
L4 — Level 4 (Base Repair, including contract repair and Manufacturer's Repair).
9609/ILM1 002
Nov 96
Page 1
ARMY EQUIPMENT
SUPPORT PUBLICATION
611 5—G—1 53—601
TABLE 1
EQUIPMENT APPLICABILITY
Serial
Equipment
Asset Code
Designation
(1)
(2)
(3)
.
Generator, Gasoline Engine 300/500 W (Battery Charger)
Hopkins.
1
TABLE 2
FUELS, LUBRICANTS AND ASSOCIATED PRODUCTS
NOTES
(1)
Only the products listed below are to be used on this equipment.
(2)
The local REME advisor may authorize the use of OMD 30 where the ambient temperature
is persistently below—is deg C and the oil temperature is likely to reach —15 deg C for a
significant period of time.
Serial
Assembly
(1)
1
2
(2)
Engine oil.
Product
Above
Below
—l5degC —l5degC
Capacity
Litres
Pints
(3)
(4)
(5)
(6)
OMD 80
OMD 30
0.55
0.97
Fuel, general purpose, uses either:
NATOGAS — NATO F—57 or 4 star gasoline
to BS4040, or ULGAS — NATO F—67 or
Unleaded Gasoline to BS7070/EN228. For
all operating environmental temperatures.
Direct
from
jerrycan
NOTE
ULGAS is the preferred fuel.
3
Exhaust extension face.
ROCAL
J166
ROCAL
Ji66
S
9609/ILM1002
Page 2
S
(Amdt 2) Jun 97
ARMY EQUIPMENT
SUPPORT PUBLICATION
611 5—G—1 53—601
TABLE 3
Serial
EQUIPMENT DATA
Detail
(3)
Item
(2)
(1)
ENGINE
1
Valve clearance (engine cold);
1.1
2
Inlet and exhaust.
0.05 to 0.10 mm
(0.0020 to 0.0039 in.)
Torque settings:
2.1
Spark plug.
9.8 to 24.5 Nm
(7.2 to 18.1 ft Ib)
2.2
Cylinder head screws.
24.5 to 32.4 Nm
(18.1 to23.9ftlb)
2.3
Crankcase screws.
9.8 to 14.7 Nm
(7.2 to 10.8 ft Ib)
2.4
Connecting rod screws.
13.7 to 19.6 Nm
(10.1 to 14.5 ft Ib)
2.5
Rocker arm lock nut.
7.8 to 12.7 Nm
(5.8 to 9.4 ft Ib)
2.6
Governor lever screw.
6.9 to 11.8 Nm
(5.1 to 8.7 ft Ib)
3
Spark plug gap.
0.6 to 0.7 mm
(0.0236 to 0.0276 in.)
4
Compression pressure.
196 to 245 kPa
(28 to 36 Ibf/1n2)
5
Ignition timing:
0.44 rad (25 degrees) BTDC
6
Engine oil capacity.
0.55 litres
9609/JLM 1002
Nov 96
Page 3
611 5—G---1 53—601
ARMY EQUIPMENT
SUPPORT PUBLICATION
TABLE 4
ACTION ON RECEIPT
Serial
Action
(1)
.
(2)
Check
1
Equipment for damage.
2
Tools and equipment against CES.
Remove
3
Preservation, sealing and packaging where applicable.
Refit
4
Any components removed to aid tran sit.
Clean
5
Equipment, tools and attachments.
.
Read
6
Operator/User Handbook and learn position, and function of all controls.
Report
7
Any defect or damage.
Maintenance
8
Carry out column (5) tasks of Table 6.
.
.
9609/ILM.1 002
Page 4
Nov 96
ARMY EQU IPMENT
SUPPORT PUBLICATION
611 5-G-l 53-601
TABLE 5 DAILY OPERATOR CHECKS
NOTES
(1)
This maintenance is to be carried out on those days when the equipment is to be used.
(2)
All faults are to be reported as soon as possible to L2.
Serial
(1)
Task
Product
(2)
(3)
WARNING
HEALTH PRECAUTIONS. BEFORE CARRYING OUT ANY
MAINTENANCE, READ AND ABIDE BY THE WARNINGS ON
PAGES (vii) AND (viii).
Bet ore starting the engine:
1
Check/top up engine oil.
OMO 80
2
Connect exhaust extension if required, grease connecting face.
ROCAL J 166
3
Earth the machine to earth stud wing nut, using earth spike and lead provided.
4
Connect fuel supply pipe between machine and jerrycan adaptor.
5
Connect jerrycan adaptor to jerrycan, ensuring sufficient fuel is available.
6
Ensure output control switch is set to 'ON'.
7
Set voltage selector switch to the central 'OFF' position
Unleaded
petrol
After starting the engine:
8
Check for oil, fuel and exhaust leaks.
9
Check for correct operation of all gauges and warning lights.
10
Check for unusual running noises.
After use:
11
Close down.
12
Check for damage/faults.
13
Ensure equipment is ready for future use.
14
Ensure relevant entries are made in equipment documents.
Jan 03 (Amdt 3)
Page 5
611 5-G-i 53-601
ARMY EQUIPMENT
SUPPORT PUBLICATION
TABLE 6 GENERATOR PERIODIC MAINTENANCE
NOTE
Column 5 tasks are to be carried out after a new or reconditioned engine has been fitted.
Serial
Task
(1)
(2)
Lubri
Support
—cant
level
First 20
hours
Every
Every
50
200
500
hours
run
hours
run
hours
run
(7)
(8)
(3)
(4)
(5)
(6)
OMD
80
Li
X
X
Every
WARNING
HEALTH PRECAUTION. BEFORE
CARRYING OUT ANY
MAINTENANCE TASKS, READ AND
ABIDE BY THE WARNINGS ON
PAGES (vii) AND (viii).
Renew
1
Engine oil.
2
Fuel filter (external)
Li
X
X
Check
3
Spark plug clearance.
L2
4
Inlet/exhaust valve seats (relap if necessary)
L2
X
Tighten/adjust
5
Valve clearance
L2
X
6
All nuts, bolts, screws, connections, hose
clips etc.
Li
X
X
X
X
X
Clean
7
Spark plug
L2
8
Air cleaner element
Li
9
Cylinder head (remove carbon deposits).
L2
X
10
Carburettor.
ii
L2
X
Fuel filter element and pot (carburettor).
L2
X
X
X
X
X
.
Page 6
Jan 03 (Amdt 3)
ARMY EQUIPMENT
SUPPORT PUBLICATION
TABLE 7 OUT OF USE MAINTENANCE
NOTES
(1)
This servicing inspection is to be carried out when the equipment is taken out of use for
periods exceeding one month.
(2)
An equipment taken out of use for periods exceeding four months is to be put into
preservation in accordance with EMER Wh Veh A 019 Miscellaneous Instruction No. 9.
(3)
The equipment is to be cleaned, dried and stored under cover where possible.
Serial
Operation
(1)
(2)
1
Prior to storage, the equipment is to be fully inspected at L2 and all necessary repairs
completed.
2
Unit fire orders should be displayed and cover any fire risk created by the choice of location
for stored equipment.
3
The equipment should be visually inspected monthly, or more frequently if considered
necessary, for signs of deterioration.
4
Every two months during storage carry out Table 5 — Daily Operator Checks and ensure that
the engine reaches the correct working temperature.
5
When an equipment is brought back into service carry out Table 5 — Daily Operator Checks.
9609/ILM1 002
Nov 96
Page 7/8
ARMY EQUIPMENT
SUPPORT PUBLICATION
611 5—G—i 53—601
This proforma should be retained in this publication. When required for use, reproduce locally.
COMMENT ON AESP
ARMY TECHNICAL SUPPORT AGENCY
Directorate of Technical Services
Repository Road
To:
From:
Woo Iwich
London SE18 4QA
Sender's Reference:
Tel No
Date:
Title of AESP: Generator Set, Engine Driven (Gasoline) Battery Charging, 14/28 V, 300/500 W
(Hopkins)
COMMENT
Signed
From:
To:
ARMY TECHNICAL SUPPORT AGENCY
Directorate of Technical Services
Repository Road
Woo Iwich
London SE18 4QA
Thank you for commenting on AESP 611 5—G—1 53—601
* Action is being taken to:
*
(i)
*
(ii) Amend the AESP
Revise the AESP
* No action is considered necessary for the following reasons:
*
Delete as necessary
AESP Form 10
9609/I LM1 002
Nov 96
Signed
Date:
611 5-G-1 53-71 1
ARMY EQUIPMENT
SUPPORT PUBLICATON
January 1995
1
4
This information may be subject to privately owned rights.
GENERATOR SET,
ENGINE DRIVEN (GASOLINE),
BATTERY CHARGING,
14/28V, 300/500 W
(HOPKINS)
REPRINTED INCORPORATING AMDTS 1-2
ILLUSTRATED PARTS CATALOGUE
THIS DOCUMENT IS THE PROPERTY OF HER BRITANNIC MAJESTY'S GOVERNMENT, and is
issued for the information of such persons only as need to know its contents in the course of
their official duties. Any person finding this document should hand it in to a British forces unit or
to a police station for its safe return to the MINISTRY OF DEFENCE, D MOD Sy, LONDON SW1A
2HB, with particulars of how and where found. THE UNAUTHORIZED RETENTION OR
DESTRUCTION OF THE DOCUMENT IS AN OFFENCE UNDER THE OFFICIAL SECRETS ACTS OF
1911 - 1 989. (When released to persons outside Government service, this document is issued on
a personal basis and the recipient to whom it is entrusted in confidence, within the provisions of
the Official Secrets Acts 1 911 - 1989, is personally responsible for its safe custody and for
seeing that its contents are disclosed only to authorized persons.)
BY COMMAND OF THE DEFENCE COUNCIL
Ministry of Defence
PUBLICATIONS SPONSOR
LSOR8
PUBLICATIONS AUTHORITY
Army Scaling and Cataloguing Authority
Ha Ha Road
Woolwich SE18 4QF
Page (i)I(ii)
6115-G-153-71 1
ARMY EQUIPMENT
SUPPORT PUBLICATION
AMENDMENT RECORD
Amdt
No.
1
Incorporated
By (Signature)
Date
Incorporated
By (Signature)
Amdt
No.
Date
32
33
•
,.
•
.
:
34
4
35
5
36
6
37
7
38
39
-
40
41
11
42
12
43
13
44
14
45
15
46
16
47
17
48
18
49
19
50
20
51
21
52
22
53
23
54
24
55
25
56
26
57
27
58
28
59
29
60
30
61
31
62
Jan 95
Page (iii)/Qv)
ARMY EQUIPMENT
SUPPORT PUBLICATION
6115-G-153-711
CONTENTS
PreUminary material
Title Page
Amendment Record
Contents (this list)
Preface
Abbreviations and Symbols
Page
(1)1(11)
(iii)/(iv)
(v)
(vi)
(viii)
Chapters
1
Index of Assemblies and Sub-assemblies
2-0
Parts list - Generator set, gasoline engine
300/500W (Battery charger) (Hopkins)
2-1
Parts list - Main Assemblies
2-2
Parts list - Frame Assembly
2-2-1
Parts list - Engine Gasoline ECH/BC/930055 (Z3 2805-99-499-9679)
2-2-2
Parts list - Alternator Assembly 14/28V 300/500W
2-2-3
Parts list - Control Box Assembly
2-2-3-1
Parts list - Chassis Assembly
2-3
Parts list - Cover Assembly
3
Index of NATO Stock Numbers
4
Index of Part Numbers/Drawing Numbers
Jan 95
Page (v)
6115-G-153-711
ARMY EQUIPMENT
SUPPORT PUBLICATION
PREFACE
Introduction
1. This Illustrated Parts Catalogue (IPC) is designed as an aid to the identification of component parts
or assemblies of parts of the equipment, and to provide information necessary for the demanding of
spares.
2. This IPC may list some or all of the parts comprising the equipment concerned, but only those parts
assigned a NATO Stock Number, Service Catalogue or Reference Number will normally be available as
spares. Should there be a requirement for an item not assigned a number, demands may be submitted
quoting the AESP, Item Number, Figure Reference and Item Name. Where a manufacturer's reference
is. known, this. should also be quoted.
Quantity
3. The figure in the 'Number off column specifies the quantity for the unit, (or assembly, subassembly
etc); it does not indicate the quantity to be demanded.
Demands
4. When demanding Spare Parts, the following particulars must be quoted:a.
Management Code (Man Code).
b.
NATO Stock Number.
c.
Item name.
d.
Name of Equipment for which part is required.
e.
Manufacturers reference, if known.
Alternatives quoted apply only to the Equipment covered by this IPC.
Modification State
When appropriate, a list at the front of each chapter or sub-chapter will indicate the modification
numbers which have been incorporated in the IPC by amendment action, subsequent to initial issue.
5.
Annotations
6. a.
AR When appearing in the 'Number off column indicates that the quantity is 'as required'.
b.
NI
(Not Illustrated) when appearing with a number in the 'Fig Item' column indicates that the item
is not illustrated
c.
*
(Obsolescent stock) - an asterisk in the 'Part Number' column indicates an obsolescent item,
no further purchase of which will be made but stocks are to be used until exhausted.
d.
NP (Non-provisioned) - when appearing in the 'NATO Stock Number' column indicates that the
item may be illustrated, but not available from stock as a replacement item.
e.
LM Indicates local manufacture, ie a part that is to be manufactured by service units from local
resources.
f.
Ref In the 'Number off column indicates that the item is listed for reference purposes only.
Page (vi)
Jan 95
ARMY EQUIPMENT
SUPPORT PUBLICATION
611 5-G-1 53-711
PREFACE - Coritd
Abbreviations
7.
Abbreviations and symbols used in this IPC have been approved and are listed separately.
Amendments
Amendments to the catalogue will be published as and when necessary. They will be numbered
8.
consecutively, and the Amendment Record Sheet is to be completed for each Amendment List embodied.
New or amended material will be highlighted by side lining to show the extent of the amendment.
9.
Indentations
10. Items are listed in a logical assembly/disassembly order and are indented by the 'Dot System' in which
each 'dot' depicts the relationship of the item to the main assembly.
MAIN ASSEMBLY
Attaching parts for main assembly
•
•
FIRST LEVEL OF BREAKDOWN (Subassembly or
detail part of main assembly)
Attaching parts for first level
SECOND LEVEL OF BREAKDOWN (Sub-assembly)
or detail part of Subassembly)
Attaching parts for second level
•
.
.
THIRD LEVEL OF BREAKDOWN (Sub-sub-subassembly
or detail part of Sub-subassembly)
Attaching parts for third level
Note:
a.
Attaching parts for the Main Assembly are listed at the end of the text of the Main Assembly.
b.
Catalogue numbers quoted in this catalogue will supersede any number that may have been
allocated previously.
Publication Information
11. Should any comment on the contents of the AESP be necessary, a locally produced copy of Form 10
(which can be found at the last page of this publication) should be completed and forwarded to the
Publication Approving Authority at the address shown on the form, in accordance with 0100-P-011-013.
Jan 95
Page (vii)
6115-G-153-711
ARMY EQUIPMENT
SUPPORT PUBLICATION
Abbreviations and symbols
Al
...... Aluminium
amp
AR
AWG
BA
Be Cu
blk
BSP
BSP.F
cap
Amplifier
As required
American Wire Gauge
British Association Screw Thread
Beryllium Copper
Blackened (black)
British Standard Pipe Thread
British Standard Pipe, Fastening Thread
c/w
Capstan Head
Cadmium
Cheese
Corrosion Resistant Steel
Cathode Ray Tube
Countersunk
Copper
Complete with
dia
Diameter
F
Farad
h
Height (high)
hd
HIS
Head
Hexagon
High Tensile Steel
Id
in.
Inside Diameter
Inch
JIC
Joint industries conference
k
kg
Kilogramme
Cd
ch
cres
CAT
csk
Cu
hex
LED
Ig
Ih)
Light emitting diode
Length (long)
Left Hand
LH)
mm
Metre
Maximum
Machine(d)
Millimetre
n
Nano
ND
neg
No.
Not Drawn (No manufacturer's drawing)
Negative
Number
0/a
Over-all
od
Outside Diameter
Over size
M
max
M/C
o/s
Page (viii)
S
Jan 95
ARMY EQUIPMENT
SUPPORT PUBLICATION
p
Pico
PEC
Panel Electronic Circuit
p1
Plated
Positive
Pair
pos
pr
rh)
RH)
Right Hand
s/d
Sodium Dichromate
Section
Socket
Square
Standard Wire Gauge
sect
skt
sq
SWG
thd
thk
Thread (ed)
6UN
UNC
UNF
Unified 6-Thread Series
Unified Coarse Thread
Unified Fine Thread
V
Volt
W
w
Watt
Width
Zn
Zinc
u
Micro
Jan 95
6115-G-153-711
Thickness
Page (ix)/(x)
6115-G-153-711
ARMY EQUIPMENT
SUPPORT PUBLICATION
Chapter 1
INDEX OF ASSEMBLIES AND SUB-ASSEMBLIES
Chap 1
Jan 95
Page 1/2
ARMY EQUIPMENT
SUPPORT PUBLICATION
6115-G-153-711
GENERATOR SET
GASOLINE ENGINE
300/500W
(BATTERY CHARGER)
(HOPKINS)
Chap 2-0
MAIN
ASSEMBLIES
Chap 2-1
ENGINE
ASSEMBLY
ECH/BC1930055
Chap 2-2-1
FRAME
ASSEMBLY
Chap_2-2
ALTERNATOR
ASSEMBLY
P391 007
Chap 2-2-2
COVER
ASSEMBLY
P391098
Chap 2-3
CONTROL
BOX
ASSEMBLY
P391100
Chap 2-2-3
CHASSIS
ASSEMBLY
P391100/i
Chap 2-2-3-i
Chap 1
Jan 95
Page 3/4
ARMY EQUIPMENT
SUPPORT PUBLICATION
6115-G-153-711
Chapter
2-0
PARTS LIST
GENERATOR SET,
GASOLINE ENGINE
300/500W 14/28V
(BA1TERY CHARGER)
(HOPKINS)
Jan 95
Chap 2-0
Page 1/2
ARMY EQUIPMENT
SUPPORT PUBLICATION
61 15-G-153-71 1
RECORD OF MODIFICATIONS
INCCRPORATED IN THIS CHAPTER
MOD No.
Amdt.
No.
Jan 95
MOD No.
Amdt.
No.
MOD No.
Amdt.
No.
Chap 2-0
Page 3
61 15-G-153-71 1
ARMY EQUIPMENT
SUPPORT PUBLICATION
.
.
.
Fig.1 Generator set, gasolene engine 300/500W (Battery Charger) (Hopkins)
Chap 2-0
Page 4
98/42b/01 1(734)
Aug 98 (Amdt 1)
.
ARMY EQUIPMENT
SUPPORT PUBLICATION
ARMY
MAN
6115-G-153-711
NATO STOCK
NUMBER
ITEM NAME AND DESCRIPTION
PART NO.
DRAWING
GENERATOR SET GASOLENE
ENGINE 300/500W 14/28V
1-Nil
ANNOTATIONS
NO.
REF
X2
6116-99-983-9538 . GENERATOR SET, gasolene
engine 300/500W, general
purpose, (battery charger) c/w
spares pack and operating
instructions
Complete REF
Equipment
Schedule
40652
2
X2
6115-99-463-2357
.
. GENERATOR SET, gasolene
engine 300/500W, general
purpose, (battery charger)
P391354
N13
X2
6115-99-396-0315
.
GENERATOR SET, gasolene
engine 300/500W, ADAD only
version, (battery charger) clw
spares pack and operating
instructions
Complete
REF )
Equipment
)SEE
Schedule
)NOTE
40696
)
. GENERATOR SET, gasolene
engine 300/500W, ADAD only
version, (battery charger)
ECH/BC/
930060
4
X2
6115-99-593-8403
.
REF
)
REF )
)SEE
)NOTE
Note:- ADAD Versions (items 3 &
4) is as general purpose
machine (items 1 & 2) apart from
the following:Additional,
5
X2
6115-99-425-1839
.
HANDLE CARRYING
ECH/BC/
2
940001
6
X2
6115-99-883-5813
.
STRAP SHOULDER
ECH/BC/
940002
2
7
NP
. HARNESS ASSY (SOCKET)
PUW1297
1
8
NP
. COVER PLATE
P391114
1
Aug 98 (Amdt 1)
Chap 2-0
Page 5/6
6115-G-153-711
ARMY EQUIPMENT
SUPPORT PUBLICATION
Chapter 2-1
PARTS LIST
MAIN ASSEMBLIES
Chap 2-1
Jan 95
Page 1/2
61 15-G-153-71 1
ARMY EQUIPMENT
SUPPORT PUBUCATION
RECORD OF MODIFICATIONS.
INCORPORATED IN THIS CHAPTER
Jan 95
Chap 2-1
Page 3
ARMY EQUIPMENT
SUPPORT PUBLICATION
6115-G-153-711
.
2
.
1
.
.
Fig. 1 Main assemblies
Chap 2-1
Page 4
(Amdt 1) Oct 97
6115-G-153-711
ARMY EQUIPMENT
SUPPORT PUBLJCATION
FIG
ITEM
ARMY
NATO STOCK
NUMBER
MAN
ITEM NAME AND DESCRIPTION
PART NO.
DRAWING
ANNOTATIONS
NO.
REF
MAIN ASSEMBLIES
1-1
NP
. FRAME ASSEMBLY
2
NP
.
COVER ASSEMBLY
REF Chap 2-2
P391098
3
X2
6115-99-396-1448 . VALISE ASSEMBLY, containing ECH/BC/
950032
accessories
4
Gi
5305-99-135-0438
5
Gi
5310-99-139-8995 . WASHER, RE-ENFORCING,
.
SCREW, PAN HD, M6 X
10 mm Ig
1
Chap 2-3
1
6
6
M6
EXHAUST EXTENSION
ASSEMBLY
ECH/BC
950003
JERRY CAN ADAPTOR AND
EXTENSION HOSE
ECH/BC/
930000
6
X2
4720-99-623-9060
.
7
X2
2910-99-701-5563
.
8
X2
6115-99-842-1503 . EARTH SPIKE ASSEMBLY
NI9
Gi
5305-99-941-3498
. .
Gi
5310-99-941-3188
.
NIh
Gi
5310-99-941-3223
.
NI12
Gi
5305-99-941-1341
.
NI13
Gi
5310-99-941-3188
. .
ECH/BC/
930006
1
1
Chap 2-1
Fig 2
1
SCREW, MACHINE, HEX
FILLISTER HD 1/2 in
UNF x 1 1/2 in Ig
brass
BS1 981
1
. NUT, PLAIN, HEX 1/2 UNF
tin p1. brass
BS1768
1
. NUT,PLAIN, WING HS or DC
No 7 1/2 in UNF tin p1
brass
BS8561969
. SCREW, MACHINE, HEX hd
1/4 in UNF x 1 in Ig brass
BS1768
1
NUT, PLAIN, HEX 1/4 in UNF BS1768
1
1
tin p1 brass
N114
Gi
5310-99-137-6970
.
15
X2
6115-99-016-8510
.
Aug 98 (Amdt 1)
. NUT, PLAIN, WING HS or DC BS8561969
No 3 1/4 in UNF tin p1 brass
CABLE ASSEMBLY, EARTH,
12 feet Ig
ECH/BC/
930024
1
1
Chap 2-1
Fig 3
Chap 2-1
Page 5
6115-G-153-711
ARMY EQUIPMENT
SUPPORT PUBLICATION
Fl
ITEM
ARMY
MAN
NATO STOCK
NUMBER
ITEM NAME AND DESCRIPTION
PART NO.
DRAWING
ANNOTATIONS
NO.
MAIN ASSEMBLIES
(continued)
16
Fl
5120-99-910-6277
NP
17
.
.
. SPANNER, BOX 14mm
.ROD, BOX SPANNER
. SCREWDRIVER CROSS
POINT
18
Fl
5120-99-910-5866
19
Fl
5120-99-136-5590
.
20
Fl
5120-99-910-5964
.
21
Fl
5120-99-910-5525
.
22
X2
6115-99-883-5813 . STRAP SHOULDER
.
124019121-0
1
KUBOTA
1
KUBOTA
1
. SCREWDRIVER FLAT
BLADE
1
. SPANNER, ADJUSTABLE,
8 in
1
. PLIERS, SIDE CUTTING
1
ECHIBCI
940002
2
)ADADS
)SERVICE
)ON LY
23
X2
6115-99-425-1839 . HANDLE CARRYING
ECH/BC/
940001
24
X2
9905-99-370-9643 . PLATE, INSTRUCTION
ECH/BC/
2
)ADADS
)SERVICE
)ONLY
1
930021
25
NP
. RIVET, TUBULAR 3.2 mm
x 8 mm Ig
4
26
NP
. WASHER, PLAIN M3
4
27
NP
. PLATE IDENTIFICATION
ECH/BC/
930022
. PLATE MOD RECORD
ECHIBC/
930019
. LABEL EARTH SYMBOL
ECH/BC/
930020
28
Yl
29
Aug 98 (Amdt 1)
NP
1
1
1
Chap 2-1
Page 7
ARMY EQUIPMENT
SUPPORT PUBLICATION
611 5-G-1 53-711
.
13
12
11
.
.
.7
Fig.2 Jerry Can Adaptor
Chap 2-1
Page 8
Aug 98 (Amdt 1)
.
6115-G-153-711
ARMY EQUIPMENT
SUPPORT PUBLICATION
FIG.
ITEM
ARMY
MAN.
CODE
NATO STOCK
NUMBER
ITEM NAME AND DESCRIPTION
X2
2910-99-701-5563
JERRY CAN ADAPTOR
NP
2-1
PART NO.
DRAWING
NO.
FILLER CAP
ECH/BC/
930000
ECH/BC/
—
ANNOTATION
REF
1
930001
NI 2
3
NP
G1
5310-99-710-2851
NP
4
NIPPLE FUEL SYSTEM
ECH/BC/
930004
NUT, PLAIN, HEX 1/8 in BSP
brass
D/94182
1
ELBOW, female/female 1/8 BSP
1/8DD/
1
1
LISTER
44B
HOSE, POLYVINYL CHLORIDE
dip tube
HN 45
FILTER ASSEMBLY
FV4/
2045203
CLAMP, HOSE, worm drive
stainless 1/2 in - 5/8 in size 16
DEF STAN
47-13
SEATING RING
FV4/
2045197
2910-99-398-0610
FUEL TAP 1/8 BSP Male x Male
ECH/BC
950037
10
NP
WASHER, PLAIN, COPPER 1/8
BSP
11
NP
FITTING 1/8 in BSP
female x 7/16 in JIC
12
NP
FITTING 7/16 in JIC x 1/4 in bore XO7JFO4
hose, reusable
5
6MT6 4720-99-947-0962
NP
6
7
6MT1 4730-99-352-3452
NP
8
9
X2
GRIFLEX
1
1
4
1
1
1
4/64X-S
1
LISTER
NORTON
HYDRAULICS
13
X2
4720-99-730-4876
HOSE, RUBBER SILICON
1/4 in id petrol oil resistant
Fuel supply
BSAU1O8/ 1.5m NORTON
HYDRAULICS
2-L4/C4/R
14
X2
2910-99-968-2523
COUPLING, self sealing, female
c/w 1/4 in hose tail
21KBTFO6
MPX
15
X2
2910-99-352-7060
CAP, PROTECTIVE, socket
ECH/BC/
1
1
950031
NI 16
Jan 03 (Amdt 2)
NP
ADHESIVE
648
NR LOCTITE
Chap 2-1
Page 9
$
6115-G-153-711
ARMY EQUIPMENT
SUPPORT PUBLICATION
.
.
4\
.
6
.
Fig. 3 Cables, earth
Chap 2-1
Page 10
Jan 95
6115-G-153-711
ARMY EQUIPMENT
SUPPORT PUBLICATION
ITEM
ARMY
MAN
NATO STOCK
NUMBER
ITEM NAME AND DESCRIPTION
PART NO.
DRAWING
CABLES, EARTH
NP
3-1
ANNOTATIONS
NO.
. CABLE, ELECTRICAL,
NEGATIVE EARTH LINK
REF
ECH/BC/
930009
1
2
Y3
6145-99-620-5179 . CABLE, ELECTRICAL, PVC
6 mm sq cross sect area
BS6231
AR
3
Z37
5940-99-104-6232 . TERMINAL, LUG, insulated
crimp OBA yellow
A4665G
2
NP
4
. CABLE, ELECTRICAL
ECH/BC/
930024
5
Y3
6145-99-620-5179 . CABLE, ELECTRICAL, PVC
6 mm sq cross sect area
BS6231
6
Z37
5940-99-104-6232 . TERMINAL, LUG, insulated
crimp OBA yellow
A4665G
Aug 98 (Amdt 1)
ELPRESS
12ft
2
ELPRESS
Chap 2-1
Page 11/12
6115-G-153-711
ARMY EQUIPMENT
SUPPORT PUBLICATION
Chapter 2-2
PARTS LIST
FRAME ASSEMBLY
Jan 95
Chap 2-2
Page 1/2
ARMY EQUIPMENT
SUPPORT PUBLICATION
611 5-G-1 53-711
RECORD OF MODIFICATIONS
INCORPORATED IN THIS CHAPTER
MOD No.
Jan 95
Amdt.
No.
MOD No.
Amdt.
No.
MOD No.
Amdt.
No.
Chap 2-2
Page 3
611 5-G-1 53-711
ARMY EQUIPMENT
SUPPORT PUBLICATION
28
.
Fig.1 Frame Assembly
Chap 2-2
Page 4
Jan 95
6115-G-153-711
ARMY EQUIPMENT
SUPPORT PUBLICATION
FIG.
ITEM
ARMY
MAN
CODE
NATO STOCK
NUMBER
PART NO.
ANNOTATIONS
ITEM NAME AND DESCRIPTION
NO.
REF
FRAME ASSEMBLY
1-1
X2
2
3
GI
6115-99-257-7741
FRAME ASSEMBLY, welded
P391 099
1
KEPAS
NP
CONTROL BOX ASSEMBLY
P391100
1
KEPAS
5305-99-122-5362
SCREW, MACHINE, M6 x 25
BS 3.692
3
mmlg
NP
4
WASHER, LOCK, single coil
3
M6
BS4320
5
GI
5310-99-122-6474
WASHER, FLAT, M6 Zn p1
6
X2
5340-99-314-5831
BMSFM/3/
MOUNT, RESILIENT, control
box (rubber) 50 shore hardness C
7
NP
RIVET, TUBULAR, 4 mm x
8 mm Ig
8
NP
CABLE, EARTH
ISO9002
3
3
12
REF Chap 2-1
Fig 3
BS 3692
9
GI
5305-99-122-5362
SCREW, MACHINE, HEX hd
M6 x 25 mm Ig
10
Gi
5310-99-122-6482
WASHER, FLAT, BRASS M6
11
X2
5340-99-617-3459
POST, ELECTRICALMECHANICAL EQUIPMENT,
earth contact
P391029
1
12
G1
5310-99-135-0757
NUT, PLAIN, HEX M6 Zn p1
BS 3692
1
NP
LEAD, ELECTRICAL, EARTH
LINK negative
ECH/BC/
930009
5310-99-941-6432
NUT, PLAIN, WING, brass M6
BS8561939
13
14
Gi
NP
15
1
3
CABLE ASSEMBLY, SPECIAL PUW 1297
1
17
18
Jan 95
NP
Gi
Gi
5305-99-122-5223
531 0-99-647-6504
1
COVER PLATE
P391114
1
SCREW, MACHINE, PAN hd
BS4183-
4
M3xlOmmIg
1967
WASHER, LOCK, shakeproof
M3 internal tooth Zn p1
KEPAS
HOPKINS
Chap 2-1
Fig 3
1
PURPOSE, ELECTRICAL,
BRANCHED, (SOCKET)
[ADADS SERVICE]
16
R&B
ASSOCIATES
PYLE
NATIONAL LTD
KEPAS
4
—
Chap 2-2
Page 5
01
(0
CD
N.)
-Uc)
.
CD
3
-n
(p
.
S
C,)
•
oz
Z-4
—m
Clii
0>
-tJ
C
(I)
C.)
01
4)
01
0)
6115-G-153-711
ARMY EQUIPMENT
SUPPORT PUBLICATION
FIG.
ITEM
ARMY
MAN
CODE
PART NO.
NATO STOCK
NUMBER
ITEM NAME AND DESCRIPTION
NO.
NP
19
ANNOTATIONS
DRAWNG
FRAME ASSEMBLY
(continued)
REF
NUT, PLAIN, BUSH RIVET M3
4
20
X2
6115-99-996-0211
COVER, GENERATOR SET,
alternator end moulding
P391095
1
KEPAS
21
X2
6115-99-701-6719
COVER, GENERATOR SET
engine end moulding
P391087
1
KEPAS
22
X2
5330-99-020-7083
SEAL, NON METALIC
CHANNEL, edge strip
ECH/BC/
930014
23
GI
5305-99-122-5356
SCREW, MACHINE, HEX hd
M5 X 16 mm Ig
8
24
Gi
5310-99-756-9561
WASHER, M5 heavy duty
8
25
Gi
5310-99-636-2987
WASHER, LOCK, shakeproof
internal tooth M5
8
26
Gi
5310-99-122-5294
NUT, PLAIN, M5
8
27
X3
2990-99-588-0603
CONTROL WIRE, CHOKE
c/w stop
ECH/BC/
AR
1
HOPKINS
1
Chap 2-2-1
930011
28
X3
2805-99-499-9679
ENGiNE, GASOLENE
ECH/BC/
930055
29
X2
6115-99-549-3455
ALTERNATOR, 14/28V
300/500W
P391 007
1
NP
HOSE, AIR COOLING
P391128
1
30
SCREW, MACHINE, HEX hd
M8 x 15 mm Ig
2
5305-99-135-8984
SCREW, MACHINE, HEX hd
M8 x 25 mm Ig
2
GI
5310-99-122-3034
WASHER, FLAT, M8
2
Gi
5310-99-135-9293
WASHER, LOCK, single coil
2
31
G1
5305-99-122-3020
32
GI
33
34
.
KEPAS
Chap 2-2-2
KING
INDUSTRIAL
PRODUCTS
KUBOTA
M8
35
G1
5310-99-139-0313
NUT, PLAIN, M8
36
GI
5305-99-122-5362
SCREW, MACHINE, HEX hd
M6 x 25 mm Ig
Jan 95
2
BS 3692
2
Chap 2-2
Page 7
Ui
CO
0)
CD
UC)
S
Cl)
CD
-n
m
•
.
.
—rn
oz
Z-i
Do
Cm
0>
C
CI)
01
4)
01
a,
6115-G-153-711
ARMY EQUIPMENT
SUPPORT PUBLICATION
ARMY
IrEM
CODE
•
NATO STOCK
NUMBER
ITEM NAME AND DESCRIPTION
PART NO.
DRA\MNG
FRAME ASSEMBLY
(continued)
37
GI
5310-99-137-9232
ANNOTATIONS
NO.
REF
WASHER, LOCK, single Coil
•
3
M6
GI
5310-99-122-6474
•
39
NP
•
40
NP
•
38
41
G1
5306-99-122-5363
•
42
G1
5310-99-135-0757
•
43
X2
5340-99-921 -7092
NP
44
WASHER, FLAT M6 Zn p1
BS 4320
5
MOUNTING BRACKET,
ENGINE (upper)
P391012
1
CLAMP, CABLE, P clip
PCL1P1O
1
SCREW, MACHINE, HEX hd
M6 x 30 mm Ig
•
•
KEPAS
1
NUT, PLAIN, HEX M6 Zn p1
BS 3692
2
MOUNT, RESILIENT, engine
upper/alternator lower
(rubber)60 shore hardness
BMSFM/3/
2
RIVET, TUBULAR 4 mm x 8
1S09002
8
MOUNTING BRACKET
ENGINE (lower)
P391014
1
MOUNT, RESILIENT, engine
lower, neoprene 70 shore
hardness
BMSFM/3/
NEO5
FOOT, mounting
BM3520/
R&B
ASSOCIATES
E
mmlg
NP
45
46
47-
X2
X2
5340-99-577-6081
6115-99-304-1612
•
•
•
1
KEPAS
R&B
ASSOC IATES
4
R&B
ASSOC IATES
OEO/3
48
GI
5310-99-122-5303
•
NUT, PLAIN, HEX, M10
4
49
Gi
5310-99-138-9228
•
WASHER, LOCK, single coil
4
MI 0
Jan 95
Chap 2-2
Page 9
61 15-G-153-71 1
ARMY EQUIPMENT
SUPPORT PUBLICATION
.
.
.
Fig.2 Fuel System
Chap 2-2
Page 10
Aug 98 (Amdt 1)
.
6115-G-153-711
ARMY EQUIPMENT
SUPPORT PUBLICATION
FIG.
ITEM
ARMY
MAN
CODE
NATO STOCK
NUMBER
ITEM NAME AND DESCRIPTION
X2
2
Gi
2910-99-905-5099 . COUPLING, self sealing, male,
clw 5/16 in hose tail
NP
ANNOTATIONS
NO
FUEL SYSTEM
2-1
PART NO.
DRAWING
ECH/BC
930016
21SBTSO8
MPX
REF
1
REF Part of
.. LOCK NUT, 7/16 in JIC Zn
Item 1
p1
3
4
5
X2
2910-99-126-5372 . CAP PROTECTIVE, Plug
6MT1 4730-99-352-3452 . CLAMP, hose size No. 15
X2
4720-99-500-3127 . HOSE, RUBBER SILICON 5/16
in id oil/petrol resistant
NP
6
. BRACKET, FUEL FILTER
ECH/BC/
950030
1
DEF
STAN
10
BSAU1O8/
2-L4/C4/R
AR
P391086
1
7
G1
5305-99-122-5355 . SCREW, MACHINE, HEX hd
M5 x 10 mm Ig
2
8
Gi
5310-99-122-3032 . WASHER, PLAIN M5
2
9
Gi
5310-99-636-2987 . WASHER, LOCK, shakeproof,
internal tooth M5
2
10
Gi
5310-99-122-5294 . NUT, PLAIN, HEX M5
2
NP
11
. GROMMET, 31 mm id 36 mm
dia hole
MR122
1
12
X2
2910-99-430-6709 . FILTER PETROL
25120151
1VW
13
X2
2910-99-168-8199 . PUMP PETROL, ELECTRIC
ECH/BC/
930016/9
14
Gi
5305-99-122-3020 . SCREW, MACHINE,
M8 x 16 mm Ig
1
15
Gi
5310-99-122-3034 . WASHER, FLAT, M8
2
16
Gi
5310-99-135-9293 . WASHER, LOCK single coil M8
1
17
Gi
5310-99-139-0313 . NUT, PLAIN, M8
1
18
Gi
5305-99-122-5359 . SCREW, MACHINE,
M6 x 12 mm Ig
1
19
Gi
5310-99-122-6474 . WASHER, FLAT, M6
2
1
MOUNTFORD
RUBBER
U.R.O.
AUTOMOTIVE
1
Chap 2-2
Aug 98 (Amdt 1)
Page 11
ARMY EQUIPMENT
SUPPORT PUBLICATION
6115-G-153-711
.
.
.
Fig.2 Fuel System
Chap 2-2
Page 12
Aug 98 (Amdt 1)
.
6115-G-153-711
ARMY EQUIPMENT
SUPPORT PUBLICATION
FIG.
ITEM
ARMY
NATO STOCK
NUMBER
MAN
CODE
ITEM NAME AND DESCRIPTION
FUEL SYSTEM
(continued)
20
Gi
PART NO.
DRAWING
NO.
ECH/BC
930016
5310-99-137-9232 . WASHER, LOCK, single coil
ANNOTATIONS
REF
1
M6
21
Gi
5310-99-135-0757 . NUT, PLAIN, HEX, M6
22
X3
4720-99-795-0335 . SPRING, REINFORCING,
HOSE
14.2 Id 5 mm pitch, 1.6 mm dia
wire x 3 in Ig
651422
23
Gi
2910-99-496-1153 . PRIMER FUEL clw 7/64 in id
hoses
ECH/BC
930016/16
24
X3
2910-99-840-3478 . PRIMING MODULE
ECH/BC/
950028
25
X3
2910-99-149-2398
Aug 98 (Amdt 1)
.
. CHECK VALVE, non return
1
363-589
1
BY
1
1
2
TILLOTSON
Chap 2-2
Page 13/14
6115-G-153-711
ARMY EQUIPMENT
SUPPORT PUBLICATION
Chapter 2-2-1
PARTS LIST
ENGINE, GASOLENE
ECH/BC/930055
(X3 2805-99-499-9679)
Jan 95
Chap 2-2-1
Page 1
ARMY EQUIPMENT
SUPPORT PUBLICATION
611 5-G-1 53-711
3
4
6
61'
.
.
7
15
16
2
Fig.1
Chap 2-2-1
Page 2
Engine, Gasolene
Aug 98 (Amdt 1)
.
.
6115-G-153-711
ARMY EQUIPMENT
SUPPORT PUBLICATION
ARMY
NATO STOCK
NUMBER
ITEM NAME AND DESCRIPTION
PART NO.
DRAWING
ANNOTATIONS
NO
ENGINE, GASOLENE
ECHIBCI
930055
REF
KUBOTA
NIl
X3
2805-99-499-9679 . ENGINE, GASOLENE
GHI2O-Q4-W-UK2
2
X3
2910-99-051-9621 . CARBURETTOR ASSEMBLY
ECH/BC
950002
3
X3
2910-99-256-5269 . GASKET, CARBURETTOR
139014611-0
1
4
X3
2910-99-701-5599 . FILTER ASSIMBLY, FUEL
12643-
1
1
1
4301 -0
5
X3
2910-99-341-3860 . RING SEALING, TOROIDAL
126439675-0
1
6
X3
2910-99-770-9885 . SCREW ASSEMBLY
0302450512
2
7
X3
2910-99-327-7725 . ELEMENT, FILTER, FUEL
124544316-0
8
X3
2990-99-591-2681
. LEVER ASSEMBLY, governor
9
X3
2990-99-757-0911
.
. ROD, governor
126535635-0
10
X3
2910-99-884-6145
.
. SPRING, ROD
126535639-0
11
X3
2910-99-974-5999
.
. SPRING, governor
126415641-0
12
X3
2910-99-305-3400
.
. SPRING, governor
126415642-0
13
X3
2910-99-795-0039 . SPEED CONTROL PLATE
ASSEMBLY
. SCREW, MACHINE, sump plug
126435602-0
12647-
1
1
1
1
1
1
5701 -0
P391119
14
X3
5305-99-831-5531
15
X3
2805-99-027-2853 . PLUG, oil
139013375-0
16
X3
2805-99-031-7260 . GASKET
0472400120
17
X3
2805-99-730-3483 . PLUG ASSEMBLY, oil filler
139013308-2
Aug 98 (Amdt 1)
1
1
KEPAS
1
2
1
Chap 2-2-1
Page 3
6115-G-153-711
ARMY EQUIPMENT
SUPPORT PUBLICATION
3
.
.
4
7
15
16
.
Fig.1
Chap 2-2-1
Page 4
Engine, Gasolene
Aug 98 (Amdt 1)
.
6115-G-153-711
ARMY EQUIPMENT
SUPPORT PUBLICATION
FIG.
IEM
ARMY
MAN
CODE
NATO STOCK
NUMBER
ITEM NAME AND DESCRIPTION
PART NO.
DRAWING
ANNOTATIONS
NO.
REF
ENGINE, GASOLENE
(continued)
0481100160
18
X3
2805-99-244-6170 .. RING, SEALING TOROIDAL
19
X3
2805-99-016-8530
.
TUBE, BREATHER
126410551-0
20
X3
2805-99-660-6108
.
GASKET, HEAD COVER
126431452-0
N121
X3
2805-99-147-1019 . KIT, GASKET SET
22
X3
2910-99-244-5995
.
GASKET, FILTER BOWL
079162936-0
12866-
1
1
1
1
1
431 4-0
Aug 98 (Amdt 1)
Chap 2-2-1
Page 5
ARMY EQUIPMENT
SUPPORT PUBLICATION
6115-G-153-711
.
.
3
2
1
.
.
Fig.2 AIr Cleaner
Chap 2-2-1
Page 6
Jan 95
6115-G-153-711
ARMY EQUIPMENT
SUPPORT PUBUCATION
AG.
ARMY
CODE
NATO STOCK
NUMBER
ITEM NAME AND DESCRIPTION
NO.
AIR CLEANER
2-1
X3
2940-99-822-0593
.
2
X3
2940-99-335-4668
. .
.
NO.
DRAWING NO. OFF.
ANNOTATIONS
REF
COVER, AIR CLEANER
123011116-0
1
ELEMENT
1281 2-
1
1121-0
3
Jan 95
X3
2940-99-980-8432
.
BOLT
0102350675
2
Chap 2-2-1
Page 7
6115-G-153-711
ARMY EQUIPMENT
SUPPORT PUBLICATION
.
2
.
.
Fig.3 Silencer Assembly
Chap 2-2-1
Page 8
Aug 98 (Amdt 1)
.
ARMY EQUIPMENT
SUPPORT PUBLICATION
ARMY
6115-G-153-711
NATO STOCK
NUMBER
MAN
ITEM NAME AND DESCRIPTION
PART NO.
DRAWING
ANNOTATIONS
NO
SILENCER ASSEMBLY
3-1
X3
2990-99-083-2777
2
X3
2990-99-151-2002 . GASKET, SILENCER
3
X3
5307-99-757-0925
.
SILENCER, modified
STUD
REF
ECH/BC/
950004
126431223-0
12101-
1
1
2
91 52-0
4
X2
2910-99-225-5161 . NUT
13901-
2
9201 -0
5
Gi
5305-99-135-1385
..
BOLT, cap, sk hd
M8 x 40 mm Ig
6
Gi
5310-99-130-2196
..
WASHER, lock, s/coil
M8 heavy duty
7
X3
2990-99-300-7881
.
8
X2
2990-99-842-0334 . SCREW, ciw washer
Aug 98 (Amdt 1)
COVER, SILENCER FLANGE
BS4168
2
2
126411272-3
126419321-0
1
2
Chap 2-2-1
Page 9
ARMY EQUIPMENT
SUPPORT PUBLICATION
61 15-G-153-71 1
.
.
1
3
.
2
FIg.4 Recoil Starter Assembly
Chap 2-2-1
Page 10
95
.
61 15-G-153-71 1
ARMY EQUIPMENT
SUPPORT PUBLICATION
ITEM NAME AND DESCRIPTION
NO.
PART NO.
DRAWING NO. OFF.
REF
RECOIL STARTER ASSEMBLY
2990-99-523-9299
STARTER ASSEMBLY,
RECOIL SUB ASSEMBLY
•
2
2990-99-660-6109
•
3
2990-99-147-0815
•
Jan 95
ROPE ASSEMBLY, STARTER
PULLEY, START
ANNOTATIONS
123546108-0
123546109-0
128156174-0
1
1
1
Chap 2-2-1
Page 11
p
(71
(0
0)
C-
—hr')
(D
.
3
CD
(I,
>
'I,
0
Qo
a
0)
01
.
.
.
oz
z-.I
cm
wo
0>
-t,
C
Cl)
01
(31
0)
ARMY EQUIPMENT
SUPPORT PUBUCATION
FiG.
ARMY
CODE
61 15-G-153-71 I
NATO STOCK
NUMBER
ITEM NAME AND DESCRIPTION
PART NO.
DRAWING NO.
MAGNETO & IGNITION
ASSEMBLY
5-1
2
Jan 95
X3
X3
2920-99-835-9596
2920-99-215-4125
.
.
IGNITION MODULE, EMC
SUPPRESSED
SPARK PLUG
NO.
ANNOTATIONS
REE-
ECH/BC/
1
930010
BPR6H5
NGK
1
Chap 2-2-1
Page 13
ARMY EQUIPMENT
SUPPORT PUBLICATION
61 15-G-153-71 1
.
6
.
.
Fig.6 Oil Watch Unit
Chap 2-2-1
Page 14
Aug 98 (Amdt 1)
.
6115-G-153-711
ARMY EQUIPMENT
SUPPORT PUBLICATION
FIG.
ARMY
MAN
CODE
NATO STOCK
NUMBER
ITEM NAME AND DESCRIPTION
PART NO.
DRAWING
REF
OIL WATCH SYSTEM
6-1
X3
2920-99-701-5600
2
X2
2920-99-314-1049
ANNOTATIONS
NO.
.
SENSOR, OIL WATCH UNIT
126473951-0
.
BOLT
13901-
1
1
91 04-0
RETAINER, CORD
3
X3
2920-99-660-6758
4
X3
2805-99-731-5634 . BOLT
5
X3
2920-99-352-6806
6
X2
5306-99-932-6824
Aug 98 (Amdt 1)
.
126473955-0
139219104-0
.
SWITCH, OIL WATCH UNIT
126526715-0
.
BOLT
0120250620
1
1
1
1
Chap 2-2-1
Page 15/16
6115-G-153-711
ARMY EQUIPMENT
SUPPORT PUBLICATION
Chapter 2-2-2
PARTS LIST
ALTERNATOR ASSEMBLY
14/28V 300/500W
Chap 2-2-2
Jan 95
Page 1
6115-G-153-711
ARMY EQUIPMENT
SUPPORT PUBLICATION
ARMY
ITEM
CODE
X2
NATO STOCK
NUMBER
6115-99-549-3455
NP
1-1
ITEM NAME AND DESCRIPTION
PART NO.
DRA\MNG
NO.
NO.
OFF.
REF KEPAS
ALTERNATOR ASSEMBLY
14/28V 300/500W
BRACKET DRIVE END
P391007
P391 008
1
2
Gi
5305-99-122-5325
SCREW, skt hd, csk
M8 x 25 mm Ig
BS4168
4
3
X2
5365-99-870-6525
SPACER, SLEEVE, crankshaft
P391 035
1
4
X2
6115-99-340-2300
ROTOR GENERATOR
MAGNET, permanent
RM2I
1
5
X2
3120-99-244-6293
BUSHING, SLEEVE, coupling
P391017
1
6
X2
5315-99-950-2533
KEY, MACHINE, crankshaft
P391 037
1
7
X2
5310-99-452-6263
WASHER, FLAT, retainer
P391036
1
8
G1
5305-99-122-5346
SCREW, skt hd M8 x 20 mm Ig
BS4168
1
NP
ADHESIVE, SCREW THREAD
290
RM21KX1
N19
10
X2
2920-99-300-8554
STATOR, engine generator
permanent magnet
11
Gi
5306-99-122-5245
BOLT, MACHINE HEX hd M6 x BS3692
12
13
Gi
X2
5310-99-122-6474
5307-99-330-1592
NP
14
LAP
AR LOCTITE
LAP
1
3
3OmmIgZnpl
ZP
WASHER, FLAT M6 class 2
3
ZnpI
BS4320
ZP
STUD, PLAIN
P391034
3
BODY ALTERNATOR
P391 024
1
1
15
X2
6115-99-373-9593
STATOR, GENERATOR
ASSEMBLY
54208534
16
Gi
5305-99-122-8526
SCREW, GRUB, DOG POINT
skt lid M4
BS4168
PT4
17
X2
6115-99-547-8302
ROTOR, GENERATOR
P391016
1
18
Gi
5305-99-122-0725
BS2470
6
19
X2
3110-99-701-5643
SCREW, skt hd 10/32 UNF
2-1/2 in Ig
BEARING, BALL
NSK6003
dw
I
BEARING ADHESIVE
641
BRACKET, SLIP RING, rear
P391 006
NP
N120
21
X2
6115-99-305-3431
ANNOTATIONS
MAGNETI
MARELLI
3
NSK
AR LOCTITE
1
casing
Jan 95
Chap 2-2-2
Page 3
6115-G-153-711
ARMY EQUIPMENT
SUPPORT PUBLICATION
FIG
ITEM
ARMY
CODE
NATO STOCK
NUMBER
ITEM NAME AND DESCRIPTION
NO.
PART NO.
DRAWING NO. OFF.
ALTERNATOR ASSEMBLY
REI-
ANNOTATIONS
14/28V 300/500W
(continued)
X2
SPACER,SLEEVE, insulator,
rectifier
P391051
2
•
BOLT, SPECIAL M5 x 30 mm Ig
54207677
4
•
BOLT, SPECIAL M4 x 15 mm Ig
54208517
1
5365-99-179-9444
•
23
NP
24
NP
22
MAGNETI
MARELLI
MAGNETI
MARELLI
25
Gi
5310-99-135-0757
26
X2
5305-99-801-3303
BS3692
3
BS4168
3
GASKET, INSULATION
54208819
1
BOLT, SPECIAL M6,
54208517
1
1
• NUT, PLAIN HEX shouldered
M6
SCREW, skt hd M4 x 35 mm Ig
•
cd p1
27
28
X2
NP
•
6115-99-149-8147
•
connection
MAGNETI
MARELLI
MAGNETI
MARELLI
MAGNETI
MARELLI
5961-99-972-1820
•
RECTIFIER ASSEMBLY
54208687
N130
NP
•
COMPOUND HEAT TRANSFER
340
31
NP
•
NUT, PLAIN, HEX, captive
washer, M5
54134729
6
MAGNETI
MARELLI
32
NP
•
NUT, PLAIN, HEX, captive
washer M4
54208123
2
MAGNETI
MARELLI
SPACER, STEPPED, pos
connection
P391106
1
29
X2
AR DOW CORNING
33
X2
5365-99-056-3432
•
34
G1
5310-99-135-0757
•
NUT, PLAIN HEX M6 Zn p1
BS3692 ZP
3
35
X2
6110-99-325-2318
•
VOLTAGE REGULATOR
54208776
1
MAGNETI
MARELLI
36
X2
5977-99-832-0608
37
X2
5977-99-300-7196
38
Gi
5305-99-137-7590
Jan 95
•
•
BRUSH ASSEMBLY, POSITIVE 54208048
1
MAGNETI
BRUSH ASSEMBLY,NEGATIVE 54208049
1
MARELLI
MAGNETI
MAR ELLI
SCREW, MACHINE, HEX M4 x
30 mm Ig Zn p1
BS3692 ZP
3
Chap 2-2-2
Page 5
ARMY EQUIPMENT
SUPPORT PUBLICATION
FIG.
ARMY
MAN
CODE
611 5-G-1 53-711
NATO STOCK
NUMBER
ITEM NAME AND DESCRIPTION
PART NO.
NO.DRAWING NO. OFF.
ANNOTATIONS
REF
ALTERNATOR ASSEMBLY
1 4/28V 300/500W
(continued)
39
X2
6115-99-990-8616
COVER, SLIP RING
54208280
1
40
X2
5975-99-051-7243
BOOT, DUST & MOISTURE
SEAL SLIP RING
P391107
1
N141
NP
ADHESIVE, CONTACT
42
NP
END COVER, ALTERNATOR
P391 009
N143
NP
INSULATION MATERIAL 3 mm
ESG
10797 IMF
MAGNETI
MERELLI
BAJOFELT
AR
1
AR SISTOFLEX
44
Gi
5310-99-135-0757
NUT, PLAIN HEX M6 Zn p1
BS3692 ZP
3
45
GI
5310-99-122-6474
WASHER, FLAT M6 class 2 Zn
BS4320 ZP
3
p1
N146
Jan 95
NP
SOLDER MULTICORE 60/40
BS441
AR
Chap 2-2-2
Page 7/8
ARMY EQUIPMENT
SUPPORT PUBUCATION
6115-G-153-711
Chapter 2-2-3
PARTS UST
CONTROL BOX
ASSEMBLY
Jan 95
Chap 2-2-3
Page 1
6115-G-153-711
ARMY EQUIPMENT
SUPPORT PUBLICATION
.
1
.
3.
.
Fig.1 Control Box Assembly
Chap 2-2-3
Page 2
Aug 98 (Amdt 1)
.
ARMY EQUIPMENT
SUPPORT PUBLICATION
61 15-G-153-71 1
ITEM NAME AND DESCRIPTION
PART NO.
DRAWING
ANNOTATIONS
NO.
CONTROL BOX ASSEMBLY
NP
• CASE, CONTROL BOX
9905-99-311-3444 • LABEL, SELF ADHESIVE,
CIRCUIT DIAGRAM
2
3
NP
P391100
REF
P391004
1
ECH/BC/
950029
• GASKET, rubber strip 9 mm x
4 mm self adhesive Tessmol,
black
TMS/4772/
• CHASSIS ASSEMBLY,
CONTROL BOX
P391100/i
4
NP
5
NP
•
6
NP
• PLATE, cover
7
NP
•
8
NP
• WASHER, PLAIN M3
1
1
009
SCREW, MACHINE, csk hd M3
x 10 mm Ig
SCREW, MACHINE, cap hd M3
x 10 mm Ig
•
1
THAMES
RUBBER
See Chap
2-2-3
10
P391045
1
BS4168
4
BS4320
4
zP
9
Yl
9905-99-942-9495 . PLATE, MOD RECORD
NIlO
NP
. SEALANT
ECH/BC/
930019
1
AR HYLOMAR
BLUE
Aug 98 (Amdt 1)
Chap 2-2-3
Page 3/4
6115-G-153-711
ARMY EQUIPMENT
SUPPORT PUBLICATION
Chapter 2-2-3-1
PARTS LIST
CHASSIS ASSEMBLY
Jan 95
Chap 2-2-3-1
Page 1
ARMY EQUIPMENT
SUPPORT PUBLICATION
6115-G-153-711
32
.
Figi Chassis Assembly - Control Box
Chap 2-2-3-1
Page 2
Jan 95
611 5-G-1 53-711
ARMY EQUIPMENT
SUPPORT PUBLICATION
FIG.
ARMY
MAN
CODE
NATO STOCK
NUMBER
ITEM NAME AND DESCRIPTION
CHASSIS ASSEMBLY CONTROL BOX
NP
1-1
NI 2
X2
6115-99-859-1490
PART NO
DRAWING
NO.
ANNOTATION
P391100/i REF
PANEL, CONTROL
P391 083
1
PLATE INSTRUCTION, silk
screen (front panel)
P391083/i
1
3
NP
PANEL, REAR
P391 080
1
4
NP
BRACKET, CHASSIS, terminal
end
P391081
1
5
NP
BRACKET, CHASSIS, 2
P391082
1
BS4183
(1967) ZP
6
Gi
5305-99-122-5277
SCREW, MACHINE csk hd M4 x
10mm Ig Zn p1
7
X2
5925-99-811-5220
CIRCUIT BREAKER, MAGNETIC APGN6-1
REC 4-51503
8
X2
5930-99-396-0496
SWITCH, ENGINE STOP
BUTTON
1213C
RED
9
Z22
6625-99-758-9339
SHUNT 75mV 50A
A2181
10
Gi
5305-99-122-5280
SCREW, csk hd M4 x 20 mm Ig
BS4183
(1967) ZP
2
Zn p1
8
1
HIGHLAND
1
HIGHLAND
1
BPL HEALEY
11
Gi
531 0-99-122-3031
WASHER, FLAT M4 Zn p1
B54320 ZP
4
12
G1
5310-99-135-0755
NUT, PLAIN HEX M4 Zn p1
BS3692 ZP
1
13
X2
5905-99-610-4093
SWITCH, POTENTIOMETER,
voltage control
534-50K
1
FARNELL
14
X2
5355-99-147-2219
KNOB, rotary switch c/w grub
screw
P391117
1
KEPAS
15
X2
5930-99-127-3845
SWITCH, rotary 3 position
ECH/BC/
950036
16
X2
5355-99-500-3126
KNOB, rotary switch c/w grub
screw
P391118
1
KEPAS
17
X2
6625-99-831-2826
HOURS RUN COUNTER
CL 4608
1
PBL HEALEY
18
X2
6625-99-061-4034
AMMETER 0-50A scale
CL 4607
1
PBL HEALEY
19
X2
6625-99-994-9430
VOLTMETER 0-40V scale
CL 4606
1
PBL HEALEY
Jan 03 (Amdt 2)
1
Chap 2-2-3-1
Page 3
ARMY EQUIPMENT
SUPPORT PUBLICATION
6115-G-153-711
.
.
.
Fig.1 Chassis Assembly - Control Box
Chap 2-2-3-1
Page 4
Jan 95
6115-G-153-711
ARMY EQUIPMENT
SUPPORT PUBLICATION
FIG.
ARMY
MAN
CODE
NATO STOCK
NUMBER
ITEM NAME AND DESCRIPTION
21
Z37
5940-99-214-1373
6MT4 5940-99-541-9920
ANNOTATION
NO.
CHASSIS ASSEMBLY CONTROL BOX
(continued)
20
PART NO
DRAWING
P391100/i REF
TERMINAL POST, positive
L309/1
RED
TERMINAL POST, negative
L309/i
1
BELLING LEE
1
BELLING LEE
BLACK
22
X2
6115-99-798-1768
TERMINAL INSULATION
P391 044
1
23
X2
6115-99-420-4959
INSULATOR PANEL
P391049
2
24
NP
REF SUPPLIED
WITH ITEM 20
PANEL FITTING
AND 21
1N6053A
HUNTER
ELECTRON ICS
25
X2
5961-99-125-8536
DIODE, transorb
26
Z42
5961-99-661-2285
LIGHT EMITTING DIODE, yellow CMD5353
1
FARNELL
27
X2
5980-99-758-8959
LIGHT EMITTING DIODE, green CMD64520
1
FARNELL
28
X2
5980-99-257-1587
LIGHT EMITTING DIODE, red
CMD5753
1
FARNELL
29
X2
6115-99-349-5353
MOUNT, LIGHT EMITTING
DIODE
232312
3
30
X2
6110-99-979-0495
VOLTAGE REGULATOR
P391056/i
1
1
ARCOLECTRIC
Chap 2-2-3-i
Fig 2
P391058
31
X2
6115-99-836-0050
INSULATOR, REGULATOR
32
Gi
5305-99-135-1347
SCREW, skt hd, csk M3 x 10 mm BS4168 ZP
4
6
Ig Zn p1
33
X2
5961-99-957-9049
BRIDGE, RECTIFIER
BR1O8
34
Gi
5305-99-122-5272
SCREW, MACHINE csk hd
BS4183
(1967) ZP
3
M3 x 10 mm Ig Zn p1
1
35
Gi
5310-99-122-6455
NUT, PLAIN HEX M3 Zn p1
BS3692 ZP
2
36
Z31
5910-99-862-3086
CAPACITOR 3300pf 40V (C3)
ALS 21A
1
AEROVOX
333 MFO4O
37
Jan 03 (Amdt 2)
NP
BRACKET, CAPACITOR
MOUNTING
P391 038
1
Chap 2-2-3-1
Page 5
ARMY EQUIPMENT
SUPPORT PUBLICATION
61 15-G-153-71 1
.
.
.
Fig.1 Chassis Assembly - Control Box
Chap 2-2-3-1
Page 6
Jan 95
6115-G-153-711
ARMY EQUIPMENT
SUPPORT PUBLICATION
FIG.
ITEM
ARMY
MAN
CODE
NATO STOCK
NUMBER
ITEM NAME AND DESCRIPTION
CHASSIS ASSEMBLY CONTROL BOX
(continued)
STEADY, capacitor
NP
38
PART NO.
DRAWING NO.
NO.
OFF.
P391100/i
REF
P391039
SCREW, MACHINE csk hd M4 x BS4183(19
67) ZP
10 mm Ig Zn p1
39
G1
5305-99-122-5277
40
X2
5905-99-796-9943
41
Gi
5305-99-122-5272
42
G1
5310-99-122-6455
.
43
Gi
5310-99-122-3030
.
44
Gi
5305-99-137-9237
45
Gi
5310-99-122-3031
46
Gi
.
RESISTOR, FIXED WIRE
WOUND,ballast (R9)
WH50-50R
1
8
FARNELL
1
SCREW, MACHINE csk hd M3 x BS4183(19
67) ZP
10 mm Ig Zn p1
3
NUT, PLAIN HEX M3 Zn p1
BS3692 ZP
2
WASHER, FLAT M3 Zn p1
BS4320 ZP
6
SCREW, MACHINE hex hd
M4 x 16 mm Ig steel Zn p1
BS3692 ZP
1
.
WASHER, FLAT M4 Zn p1
BS4320 ZP
4
5310-99-135-0755
.
NUT, PLAIN HEX M4 Zn p1
BS3692 ZP
1
47
NP
.
CLIP LOOM
DSNO95
1
48
NP
.
CLIP WIRE
DSNO98
1
SCREW, skt hd, csk M3 x
10 mm Ig Zn p1
BS4168 ZP
6
WASHER, FLAT M3 Zn p1
BS4320 ZP
6
GROMMET RUBBER (6.5 mm
dia hole)
DEF STAN
53-13
GROMMET RUBBER (12.7 mm
dia hole)
DEF STAN
53-13
GROMMET RUBBER (9.5 mm
dia hole)
DEF STAN
53-13
TERMINAL PRINTED CIRCUIT
BOARD
P391054
1
SCREW, skt hd, csk M3 x
10 mm Ig Zn p1
BS4168 ZP
6
WASHER, FLAT M3 Zn p1
BS4320 ZP
6
.
.
49
Gi
5305-99-135-1347
.
50
G1
5310-99-122-3030
.
51
H9
5325-99-942-3407
.
52
H9
5325-99-942-3431
.
53
H9
5325-99-942-3423
.
54
X2
5998-99-192-8069
.
55
Gi
5305-99-135-1347
.
56
Gi
5310-99-122-3030
.
Jan 95
ANNOTATIONS
1
1
2
Chap 2-2-3-1
Fig 3
Chap 2-2-3-1
Page 7
ARMY EQUIPMENT
SUPPORT PUBLICATION
6115-G-153-711
.
.
Fig.1 Chassis Assembly - Control
Chap 2-2-3-1
Page 8
Jan 95
ARMY EQUIPMENT
SUPPORT PUBLICATION
61 15-G-1 53-711
ITEM NAME AND DESCRIPTION
CHASSIS ASSEMBLY CONTROL BOX
(continued)
NP
Jan 95
GROMMET RUBBER (15.5 mm
dia hole)
NO.
PART NO.
DRAWING NO. OFF.
P391100/i
ANNOTATIONS
REF
2
Chap 2-2-3-1
Page 9
ARMY EQUIPMENT
SUPPORT PUBLICATION
611 5-G-1 53-711
2
4
1112
10
.
/
9
10
13
.
Fig.2 Voltage Regulator. Assembly
Chap 2-2-3-1
Page
Jan 95
ARMY EQUIPMENT
SUPPORT PUBLICATION
FIG.
ITEM
ARMY
MAN
CODE
6115-G-153-711
PART NO.
NATO STOCK
NUMBER
ITEM NAME AND DESCRIPTION
DRAWNG
ANNOTATIONS
NO.
VOLTAGE REGULATOR
ASSEMBLY
P391 056
2-1
X2
6110-99-998-8992
VOLTAGE REGULATOR PCB
2
Z31
5910-99-015-8905
CAPACITOR Tantllum imf (Cl) 198976M
3
X2
5910-99-030-9057
.
4
Z30
5905-99-798-4509
.
5
Z30
6
X2
P391056/i
CAPACITOR, FIXED
ELECTROLYTIC l000mf 63V
021 181 02
RESISTOR FIXED FILM
1200fl (R5)
MRS 25
CECC
SPEC
40101-019
5905-99-595-6188
RESISTOR 120fl (R6)
MRS 25
CECC
SPEC
40101-019
6115-99-513-6962
TERMINAL, BLOCK
MKDSFW
REF KEPAS
1
1
ESD HARLOW
1
PHILLIPS
1
PHILLIPS
1
PHILLIPS
1
PHEONIX
1.5/3
NP
7
8
Z42
9
5962-99-354-7305
NP
.
10
Gi
5305-99-122-5228
.
ii
Gi
5305-99-122-5229
.
BASE, VOLTAGE
REGULATOR
P391 057
1
VOLTAGE REGULATOR
LT1O38CK
1
SPACER, VOLTAGE
REGULATOR
P391 059
4
SCREW, MACHINE skt hd M4
x 6 mm Ig
BS4183
4
SCREW, cap hd M4 x 10 mm
BS4183
4
LINEAR
Ig
12
Gi
5310-99-122-3031
.
WASHER, FLAT M4 Zn p1
BS4320 ZP
4
13
X2
6115-99-883-8611
.
GASKET, INSULATING
P391 124
1
Jan 95
Chap 2-2-3-1
Page 11
ARMY EQUIPMENT
SUPPORT PUBLICATION
611 5-G-153-711
© /77
©
6N
ii
NI
3'
2
4
A
A
5
A
9
6
7
A
AA
A
it
B
B
N
8
./
12
A
B
B_B/lB
BJ1
B
J
I
Fig.3 Terminal Board
Chap 2-2-3-1
Page 12
\
.
©
2
S
Assembly
Jan 95
ARMY EQUIPMENT
SUPPORT PUBLICATION
FIG.
ITEM
3-1
ARMY
MAN
CODE
NATO STOCK
NUMBER
X2
5998-99-192-8069
X2
6115-99-096-3355
6115-G-153-711
ITEM NAME AND DESCRIPTION
PART NO.
DRAWING
ANNOTATIONS
NO
TERMINAL BOARD PCB
ASSEMBLY
BLOCK, TERMINAL PCB
P391054
MKDSL 5/3
REF
2
PHEONIX
2
FARNELL
1
PHILLIPS
1
PHILLIPS
1
PHILLIPS
1
PHILLIPS
5.08
POTENTIOMETER 50K
(RV1, RV2)
3296W
50K
6115-99-037-0279
RESISTOR 62K fl.6W (Ri)
MRS 25
CECC
SPEC
40101-019
Z30
5905-99-450-4277
RESISTOR, FIXED FILM
510 116W (R2)
MRS 25
CECC
SPEC
40101-019
Z30
5905-99-179-9185
RESISTOR, FIXED FILM
470 Q.6W (R3)
MRS 25
CECC
SPEC
2
Z30
5905-99-767-6059
3
X2
4
5
.
401 01-019
6
Jan 95
Z30
5905-99-360-3986
.
RESISTOR, FIXED FILM
220 fl PRO1-1W (R4)
MRS 25
CECC
SPEC
40101-004
Chap 2-2-3-1
Page 13/14
611 5-G-1 53-711
ARMY EQUIPMENT
SUPPORT PUBLICATION
Chapter 2-3
PARTS LIST
COVER ASSEMBLY
Chap 2-3
Jan 95
Page 1/2
ARMY EQUIPMENT
SUPPORT PUBLICATION
6115-G-153-71 1
RECORD OF MODIFICATIONS
INCORPORATED IN THIS CHAPTER
MOD No.
Amdt.
No.
Jan 95
MOD No.
Amdt.
No.
MOD No.
Amdt.
No.
Chap 2-3
Page 3
ARMY EQUIPMENT
SUPPORT PUBLICATION
611 5-G-1 53-71 1
.
5
.
Fig.1 COVER ASSEMBLY
Chap 2-3
Page 4
Jan 95
ARMY EQUIPMENT
SUPPORT PUBLICATION
FIG,
ITEM
ARMY
MAN
CODE
NATO STOCK
NUMBER
6115-G-153-711
ITEM NAME AND DESCRIPTION
NP
ANNOTATIONS
NO.
COVER ASSEMBLY
1-Nil
PART NO.
DRA\MNG
COVER SUB ASSEMBLY
P391098
REF
P391098/i
2
NP
COVER
P391011
1
3
NP
CATCH POCKET 90
P391011/i
2
4
NP
CATCH POCKET 80
P391011/2
2
5
NP
RIVET, TUBULAR, Al
4 mm x 8 mm Ig
1S09002
16
N16
NP
NUT, PLAIN, BLIND RIVET
6
M6
NP
7
8
9
X2
6115-99-701-5564
NP
ACCOUSTIC LINER
AM9/5A
CATCH, spring
RIVET, TUBULAR, 4 mm x
1
BAJOFELT
271836
MSZN
4
PROTEX
IS09002
8
8mmlg
10
Jan 95
NP
EDGESTRIP
BRS49
AR
KOPAKWALKER
Chap 2-3
Page 5/6
ARMY EQUIPMENT
SUPPORT PUBLICATION
6115-G-153-711
Chapter 3
INDEX OF NATO STOCK NUMBERS
Jan 95
Chap 3
Page 1/2
6115-G-153-711
ARMY EQUIPMENT
SUPPORT PUBLICATION
NATO Stock No.
5910-99-015-8905
6115-99-016-8510
2805-99-016-8530
5330-99-020-7083
2805-99-027-2853
5910-99-030-9057
2805-99-031-7260
6115-99-037-0279
5975-99-051-7243
2910-99-051-9621
5365-99-056-3432
6625-99-061-4034
2990-99-083-2777
6115-99-096-3355
5940-99-104-6232
5940-99-104-6232
5305-99-122-0725
5305-99-122-3020
5305-99-122-3020
5310-99-122-3030
5310-99-122-3030
5310-99-122-3030
5310-99-122-3031
5310-99-122-3031
5310-99-122-3031
5310-99-122-3032
5310-99-122-3034
5310-99-122-3034
5305-99-122-5223
5305-99-122-5228
5305-99-122-5229
5306-99-122-5245
5305-99-122-5272
5305-99-122-5272
5305-99-122-5277
5305-99-122-5277
5305-99-122-5280
5310-99-122-5294
5310-99-122-5294
5310-99-122-5303
5305-99-122-5325
5305-99-122-5346
5305-99-122-5355
5305-99-122-5356
5305-99-122-5359
5305-99-122-5362
5305-99-122-5362
5305-99-122-5362
5306-99-122-5363
5310-99-122-6455
5310-99-122-6455
5310-99-122-6474
5310-99-122-6474
Chapter, Page
and
Item No.
2-2-3-1.11-2
2-1.5-15
2-2-1.5-19
2-2.7-22
2-2-1.3-15
2-2-3-1.11-3
2-2-1.3-16
2-2-3-1 .13/14-3
2-2-2.7-40
2-2-1.3-2
2-2-2.5-33
2-2-3-1.3-18
2-2-1.9-1
2-2-3-1.13/14-1
2-1.11/12-3
2-1.11/12-6
2-2-2.3-18
2-2.7-31
2-2.11-14
2-2-3-1.7-43
2-2-3-1.7-50
2-2-3-1.7-56
2-2-3-1.11-12
2-2-3-1.3-11
2-2-3-1.7-45
2-2.11-8
2-2.7-33
2-2.11-15
2-2.5-17
2-2-3-1.11-10
2-2-3-1.11-11
2-2-2.3-11
2-2-3-1.5-34
2-2-3-1.7-41
2-2-3-1.3-6
2-2-3-1.7-39
2-2-3-1.3-10
2-2.7-26
2-2.1 1-10
2-2.9-48
2-2-2.3-2
2-2-2.3-8
2-2.11-7
2-2.7-23
2-2.11-18
2-2.5-3
2-2.5-9
2-2.7-36
2-2.9-41
2-2-3-1.5-35
2-2-3-1.7-42
2-2.5-5
2-2.11-19
NATO Stock No.
5310-99-122-6474
5310-99-122-6474
5310-99-122-6474
5310-99-122-6474
5310-99-122-6482
5305-99-122-8526
5961-99-125-8536
2910-99-126-5372
5930-99-127-3845
5310-99-130-2196
5305-99-135-0438
5310-99-135-0755
5310-99-135-0755
5310-99-135-0757
5310-99-135-0757
5310-99-135-0757
5310-99-135-0757
5310-99-135-0757
5310-99-135-0757
5305-99-135-1347
5305-99-135-1347
5305-99-135-1347
5305-99-135-1385
5305-99-135-8984
5310-99-135-9293
5310-99-135-9293
5120-99-136-5590
5310-99-137-6970
5305-99-137-7590
5310-99-137-9232
5310-99-137-9232
5305-99-137-9237
5310-99-138-9228
5310-99-139-0313
5310-99-139-0313
5310-99-139-8995
2990-99-147-0815
2805-99-147-1019
5355-99-147-2219
2910-99-149-2398
6115-99-149-8147
2990-99-151-2002
2910-99-168-8199
5905-99-179-9185
5365-99-179-9444
5998-99-192-8069
5998-99-1 92-806 9
5940-99-214-1373
2920-99-215-4125
2910-99-225-5161
2910-99-244-5995
2805-99-244-6170
3120-99-244-6293
Chapter, Page
and
Item No.
2-2-2.3-12
2-2-2.7-45
2-2.5-10
2-2.7-38
2-2.5-10
2-2-2.3-16
2-2-3-1.5-25
2-2.11-3
2-2-3-1.3-15
2-2-1.9-6
2-1.5-4
2-2-3-1.3-12
2-2-3-1.7-46
2-2-2.5-25
2-2-2.5-34
2-2-2.7-44
2-2.5-12
2-2.9-42
2-2.13/14-21
2-2-3-1.5-32
2-2-3-1.7-49
2-2-3-1.7-55
2-2-1.9-5
2-2.7-32
2-2.7-34
2-2.11-16
2-1.7-19
2-1.5-14
2-2-2.5-38
2-2.7-37
2-2.13/14-20
2-2-3-1.7-44
2-2.9-49
2-2.7-35
2-2.1 1-17
2-1.5-5
2-2-1.11-3
2-2-1.5-21
2-2-3-1.3-14
2-2.13/14-25
2-2-2.5-28
2-2-1.9-2
2-2.11-13
2-2-3-1 .13/14-5
2-2-2.5-22
2-2-3-1.13/14
2-2-3-1.7-54
2-2-3-1.5-20
2-2-1.13-2
2-2-1.9-4
2-2-1.5-22
2-2-1.5-18
2-2-2.3-5
Chap 3
Jan 03 (Amdt 2)
3
6115-G-153-711
NATO Stock No.
2910-99-256-5269
5980-99-257-1587
6115-99-257-7741
5977-99-300-7196
2990-99-300-7881
2920-99-300-8554
6115-99-304-1612
2910-99-305-3400
6115-99-305-3431
9905-99-311-3444
2920-99-314-1049
5340-99-3 1 4-583 1
6110-99-325-2318
2910-99-327-7725
5307-99-330-1592
2940-99-335-4668
6115-99-340-2300
2910-99-341-3860
6115-99-349-5353
4730-99-352-3452
4730-99-352-3452
2920-99-352-6806
2910-99-352-7060
5962-99-354-7305
5970-99-356-7354
5905-99-360-3986
9905-99-370-9643
6115-99-373-9593
6115-99-396-0315
5930-99-396-0496
6115-99-396-1448
2910-99-398-0610
6115-99-420-4959
6115-99-425-1839
6115-99-425-1839
2910-99-430-6709
5905-99-450-4277
5310-99-452-6263
6115-99-463-2357
2910-99-496-1153
2805-99-499-9679
2805-99-499-9679
4720-99-500-3126
4720-99-500-3127
6115-99-513-6962
2990-99-523-9299
5940-99-541-9920
6115-99-547-8302
6115-99-549-3455
6115-99-549-3455
5340-99-577-6081
2990-99-588-0603
2990-99-59 1 -2681
Chap 3
Page 4
ARMY EQUIPMENT
SUPPORT PUBLICATION
Chapter, Page
and
Item No.
2-2-1.3-3
2-2-3-1.5-28
2-2.5-1
2-2-2.5-37
2-2-1.9-7
2-2-2.3-10
2-2.9-47
2-2-1.3-12
2-2-2.3-21
2-2-3.3/4-2
2-2-1.15/16-2
2-2.5-6
2-2-2.5-35
2-2-1.3-7
2-2-2.3-13
2-2-1.7-2
2-2-2.3-4
2-2-1.3-5
2-2-3-1.5-29
2-1.9-7
2-2.11-4
2-2-1.15/16-5
2-1.9-15
2-2-3-1.11-8
2-2-3-1.3-14
2-2-3-1 .13/14-6
2-1.7-24
2-2-2.3-15
2-0.5/6-3
2-2-3-1.3-8
2-1.5-3
2-1.9-9
2-2-3-1.5-23
2-0.5/6-5
2-1.7-23
2-2.1 1-12
2-2-3-1.13/14-4
2-2-2.3-7
2-0.5/6-2
2-2.13/14-23
2-2-1.3-1
2-2.7-28
2-2-3-1.3-16
2-2.11-5
2-2-3-1.11-6
2-2-1.11-1
2-2-3-1.5-21
2-2-2.3-17
2-2-2.3
2-2.7-29
2-2.9-46
2-2.7-27
2-2-1.3-8
NATO Stock No.
6115-99-593-8403
5905-99-595-6188
5905-99-610-4093
5340-99-617-3459
6145-99-620-5179
6145-99-620-5179
4720-99-623-9060
5310-99-636-2987
5310-99-636-2987
2805-99-660-6108
2920-99-660-6758
5340-99-660-7324
5310-99-647-6504
2990-99-660-6109
2920-99-660-6758
5961-99-661-2285
2910-99-701-5563
2910-99-701-5563
6115-99-701-5564
2910-99-701-5599
2920-99-701-5600
3110-99-701-5643
6115-99-701-6719
5310-99-710-2851
2805-99-730-3483
4720-99-730-4876
2805-99-731-5634
5310-99-756-9561
2990-99-757-0911
5307-99-757-0925
5980-99-758-8959
6625-99-758-9339
5905-99-767-6059
2910-99-770-9885
2910-99-795-0039
4720-99-795-0335
5905-99-796-9943
6115-99-798-1768
5905-99-798-4509
5305-99-801-3303
5925-99-811-5220
2940-99-822-0593
6625-99-831-2826
5305-99-831-5531
5977-99-832-0608
2920-99-835-9596
6115-99-836-0050
2910-99-840-3478
2990-99-842-0334
6115-99-842-1503
6115-99-859-1490
5910-99-862-3086
5365-99-870-6525
Chapter, Page
and
Item No.
2-0.5/6-4
2-2-3-1.11-5
2-2-3-1.3-13
2-2.5-11
2-1.11/12-2
2-1.11/12-5
2-1.5-6
2-2.7-25
2-2.11-9
2-2-1.5-20
2-2-1.15/16-3
2-2.13/14-26
2-2.5-18
2-2-1.11-2
2-2-1.15/16-3
2-2-3-1.5-26
2-1.5-7
2-1.9
2-3.5/6-8
2-2-1.3-4
2-2-1.15/16-1
2-2-2.3-19
.
I
.
2-2.7-21
2-1.9-3
2-2-1.3-17
2-1.9-13
2-2-1.15/16-4
2-2.7-24
2-2-1.3-9
2-2-1.9-3
2-2-3-1.5-27
2-2-3-1.3-9
2-2-3-1.13/14-2
2-2-1.3-6
2-2-1.3-13
2-2.13/14-22
2-2-3-1.7-40
2-2-3-1.5-22
2-2-3-1.11-4
2-2-2.5-26
2-2-3-1.3-7
2-2-1.7-1
2-2-3-1.3-17
2-2-1.3-14
2-2-2.5-36
2-2-1.13-1
2-2-3-1.5-31
2-2.13/14-24
2-2-1.9-8
2-1.5-8
2-2-3-1.3-2
2-2-3-1.7-36
2-2-2.3-3
Jan 03 (Amdt 2)
.
.
6115-G-153-711
ARMY EQUIPMENT
SUPPORT PUBLICATION
NATO Stock No.
6115-99-883-5813
6115-99-883-5813
6115-99-883-8611
2910-99-884-6145
2910-99-905-5099
5120-99-910-5525
5120-99-910-5866
5120-99-910-5964
5120-99-910-6277
5340-99-921-7092
5306-99-932-6824
5305-99-941-1341
5310-99-941-3188
5310-99-941 -3188
5310-99-941-3223
5305-99-941-3498
5310-99-941-6432
5325-99-942-3407
5325-99-942-3423
5325-99-942-3431
9905-99-942-9495
9905-99-942-9495
4720-99-947-0962
5315-99-950-2533
5961-99-957-9049
2910-99-968-2523
5961-99-972-1820
2910-99-974-5999
6110-99-979-0495
2940-99-980-8432
6115-99-983-9538
6115-99-990-8616
6625-99-994-9430
6115-99-996-0211
6110-99-998-8992
Jan 03 (Amdt 2)
Chapter, Page
and
Item No.
NATO Stock No.
Chapter, Page
and
Item No.
2-0.5/6-6
2-1.7-22
2-2-3-1.11-13
2-2-1.3-10
2-2.11-1
2-1.7-21
2-1.7-18
2-1.7-20
2-1.7-16
2-2.9-43
2-2-1.15/16-6
2-1.5-12
2-1.5-10
2-1.5-13
2-1.5-11
2-1.5-9
2-2.5-14
2-2-3-1 .7-5 1
2-2-3-1.7-53
2-2-3-1.7-52
2-1.7-28
2-2-3.3/4-9
2-1.9-5
2-2-2.3-6
2-2-3-1.5-33
2-1.9-14
2-2-2.5-29
2-2-1.3-11
2-2-3-1.5-30
2-2-1.7-3
2-0.5/6-1
2-2-2.7/8-39
2-2-3-1.3-19
2-2.7-20
2-2-3-1.11-1
Chap 3
Page 5/6
6115-G-153-711
ARMY EQUtPMENT
SUPPORT PUBLICATION
Chapter 4
INDEX OF PART NUMBERS/DRAWING NUMBERS
Jan 95
Chap 4
Page 1/2
ARMY EQUIPMENT
SUPPORT PUBLICATION
Part No.
Drawing No.
ALS 21A 333 MFO4O
AM9/5A
APGN6-1 REC 4-51 -503
A21 81
A4665G
A4665G
BM3520/OEO/3
BMSFM/3/C
BMSFM/3/NEO5
BMSFM/3/E
BPR6H5NGK
BRS49
BR1O8
BSAU 1 08/2-L4/C4/R
BSAU1 08/2-L4/C4/R
BS1768
BS1 768
BS1768
BS1 981
BS2470
BS3692
BS3692
BS3692
BS3692
BS3692
BS3692
BS3692 ZP
BS3692 ZP
BS3692 ZP
BS3692 ZP
B53692 ZP
BS3692 ZP
BS3692 ZP
BS3692 ZP
BS3692 ZP
BS4168
BS4168
BS4168
BS4168
BS4168
BS4168 PT4
BS4168 ZP
BS4168 ZP
B54168 ZP
BS4183
BS4183
BS41 83-1967
BS41 83(1 967) ZP
B541 83(1967) ZP
BS41 83(1 967) ZP
BS41 83(1967) ZP
B541 83(1 967) ZP
BS4320
Jan 03 (Amdt 2)
611 5-G-1 53-711
Chapter, Page
and
flem No.
2-2-3-1.5-36
2-3.5/6-7
2-2-3-1.3-7
2-2-3-1.3-9
2-1.11/12-6
2-1.11/12-3
2-2.9-47
2-2.5-6
2-2.9-46
2-2.9-43
2-2-1.13-2
2-3.5/6-10
2-2-3-1.5-33
2-1.9-13
2-2.11-5
2-1.5-10
2-1.5-12
2-1.5-13
2-1.5-9
2-2-2.3-18
2-2.5-3
2-2.5-12
2-2.5-9
2-2.7-36
2-2.9-42
2-2-2.5-25
2-2-3-1.7-44
2-2-3-1.7-42
2-2-2.5-38
2-2-3-1.7-46
2-2-2.5-34
2-2-2.3-11
2-2-3-1.5-35
2-2-3-1.3-12
2-2-2.7/8-44
2-2-1.9-5
2-2-3.3/4-7
2-2-2.5-26
2-2-2.3-2
2-2-2.3-8
2-2-2.3-16
2-2-3-1.5-32
2-2-3-1.7-49
2-2-3-1.7-55
2-2-3-1.11-11
2-2-3-1.11-10
2-2.5-17
2-2-3-1.7-41
2-2-3-1.7-39
2-2-3-1.3-6
2-2-3-1.3-10
2-2-3-1.5-34
2-2.5-5
Part No.
Drawing No.
BS4320
BS4320
BS4320 ZP
BS4320 ZP
BS4320 ZP
BS4320 ZP
BS4320 ZP
BS4320 ZP
BS4320 ZP
BS4320 ZP
BS4320 ZP
BS441
BS6231
BS6231
BS856-1 939
BS856-1 969
BS856-1 969
CL 4606
CL 4607
CL 4608
CMD5353
CM D5753
CMD64520
D/94/82
DEF STAN
DEF STAN 47-13
DEF STAN 53-13
DEF STAN 53-13
DEF STAN 53-13
DSNO95
DSNO98
ECH/BC/930000
ECH/BC/930001
ECH/BC/930004
ECH/BC/930006
ECH/BC/930009
ECH/BC/930009
ECH/BC/93001 0
ECH/BC/93001 1
ECH/BC/93001 4
ECH/BC/93001 6
ECI-11BC193001 6
ECH/BC/93001 6/9
ECH/BC/93001 6/16
ECH/BC/93001 9
ECH/BC/93001 9
ECH/BC/930020
ECH/BC/930021
ECH/BC/930022
ECH/BC/930024
ECH/BC/930024
ECH/BC/930060
ECHIBCI930055
Chapter, Page
and
Item No.
2-2.5-10
2-2.7-38
2-2-3-1.7-50
2-2-3-1.7-56
2-2-3-1.7-45
2-2-3.3/4-8
2-2-2.3-12
2-2-2.7/8-45
2-2-3-1.11-12
2-2-3-1.7-43
2-2-3-1.3-11
2-2-2.7/8-46
2-1.11/12-2
2-1.11/12-5
2-2.5-14
2-1.5-11
2-1.5-14
2-2-3-1.3-19
2-2-3-1.3-18
2-2-3-1.3-17
2-2-3-1.5-26
2-2-3-1.5-28
2-2-3-1.5-27
2-1.9-3
2-2.11-4
2-1.9-7
2-2-3-1 .7-5 1
2-2-3-1.7-52
2-2-3-1.7-53
2-2-3-1.7-47
2-2-3-1.7-48
2-1.5-7
2-1.9-1
2-1.9-2
2-1.5-8
2-1.11-1
2-2.5-13
2-2-1.13-1
2-2.7-27
2-2.7-22
2-2.11
2-2.13/14
2-2.11-13
2-2.13/14-23
2-2-3.3/4-9
2-1.7-28
2-1.7-29
2-1.7-24
2-1.7-27
2-1.5-15
2-1.11-4
2-0.5/6-4
2-2.7-28
Chap 4
Page 3
6i15-G-153-7i1
Part No.
Drawing No.
ECH/BC/930055
ECH/BC1930060
ECH/BC/930000
ECHIBC/930009
ECH/BC/930024
ECH/BC/940001
ECH/BC/940001
ECH/BC/940002
ECH/BC/940002
ECH/BC/950002
ECH/BC/950003
ECH/BC/950004
ECH/BC/950028
ECH/BC/950029
ECH/BC/950030
ECH/BC/950031
ECH/BC/950032
ECH/BC/950036
ECH/BC/950037
ESG 10797 IMF
FV4/20451 97
FV4/2045203
GH1 20-Q-4-W-UK2
HN 45
1N6053A
1S09002
1S09002
1S09002
1S09002
LT1 038CK
L309/1 BLACK
L309/1 RED
MKDSFW1 .5/3
MKDSL 5/3 5.08
MRS 25 CECC SPEC
40101 -019
ARMY EQUIPMENT
SUPPORT PUBLICATION
Chapter, Page
and
Item No.
2-2-1.3
2-0.5/6-4
2-1.9
2-1.11/12-1
2-1.11/12-4
2-0.5/6-5
2-1.7-23
2-0.5/6-6
2-1.7-22
2-2-1.3-2
2-1.5-6
2-2-1.9-1
2-2.13/14-24
2-2-3.3/4-2
2-2.11-3
2-1.9-15
2-1.5-3
2-2-3-1.3-15
2-1.9-9
2-2-2.7/8-43
2-1.9-8
2-1.9-6
2-2-1.3-1
2-1.9-5
2-2-3-1.5-25
2-2.5-7
2-2.9-44
2-3.5/6-5
2-3.5/6-9
2-2-3-1.11-8
2-2-3-1.5-21
2-2-3-1.5-20
2-2-3-1.11-6
2-2-3-1.13/14-1
2-2-3-1.11-4
MRS 25 CECC SPEC
40101 -019
2-2-3-1.11-5
MRS 25 CECC SPEC
40101-019
MRS 25 CECC SPEC
2-2-3-1.13/14-4
40101 -019
2-2-3-1.13/14-5
MRS 25 CECC SPEC
40101-019
MRS 25 CECC SPEC
40101-004
MR1 22
NSK6003dw
P391004
P391006
P391007
P391007
P391008
Chap 4
Page 4
2-2-3-1.13/14-3
2-2-3-1.13/14-6
2-2.11-11
2-2-2.3-19
2-2-3.3/4-1
2-2-2.3-21
2-2-2.3
2-2.7-29
Part No.
Drawing No.
Chapter, Page
and
Item No.
P391011/i
2-2-2.7/8-42
2-3.5/6-2
2-3.5/6-3
P391011/2
2-3.5/6-4
P391 012
2-2.9-39
2-2.9-45
P391009
P391011
P391014
P391016
P391 017
P391024
P391029
P391034
P391035
P391 036
P391 037
P391038
P391039
P391044
P391045
P391049
P391051
P391054
P391 054
P391056
2-2-2.3-17
2-2-2.3-5
2-2-2.3-i
4
2-2.5-il
2-2-2.3-13
2-2-2.3-3
2-2-2.3-7
2-2-2.3-6
2-2-3-1.5-37
2-2-3-1.7-38
2-2-3-i .5-22
2-2-3.3/4-6
2-2-3-1.5-23
2-2-3-1.7-54
2-2-3-1.13/14
2-2-3-1.11
2-2-3-1.5-30
P391058
P391 059
2-2-3-1 .5-3 1
P391080
2-2-3-i
P391081
2-2-3-i .3-4
2-2-3-1.3-5
2-2-3-i .3-1
2-2-3-1.3-2
P391083
P391083/i
2-2-3-1.11-1
2-2-3-1.11-7
2-2-3-1.11-9
.3-3
P391086
P391087
P391095
P391098
P391098
2-2.11-6
P391098/i
2-3.5/6-i
P391099
P391100
P391100
2-2.5-1
P391100/i
P391100/i
P391100/i
P391100/i
P391100/i
2-2-3.3/4-4
P391106
P391107
P391114
P391114
P391117
.
2-2-2.5-22
P391056/i
P391056/i
P391057
P391 082
.
2-2.7-21
2-2.7-20
2-1.5-2
2-3.5/6
2-2-3.3/4
2-2.5-2
2-2-3-1.3
2-2-3-1.5
2-2-3-i .7
2-2-3-1.9
2-2-2.5-33
2-2-2.7/8-40
2-0.5/6-8
2-2.5-16
2-2-3.3-14
2-2-2.3-1
Jan 03 (Amdt 2)
.
6115-0-153-711
ARMY EQUIPMENT
SUPPORT PUBLICATION
Part No.
Drawing No.
P391118
P391119
P391124
P391128
P391354
PCL1 PlO
PUW 1297
PUW1 297
TMS/4772/009
WH5O-50R
2-2-3.3-16
2-2-1.3-14
2-2-3-1.11-13
2-2.7-30
2-0.5/6-2
2-2.9-40
2-2.5-15
2-0.5/6-7
2-2-2.3-4
2-2-2.3-10
2-2-3.3/4-3
2-2-3-1.7-40
XO7J F04
2-1 .9-12
01023-50675
01202-50620
021 181 02
03024-50512
04724-00120
04811-001 60
07916-2936-0
2-2-1.7-3
2-2-1.15/16-6
2-2-3-1.11-3
2-2-1.3-6
2-2-1.3-16
2-2-1.5-18
2-2-1.5-21
2-1.9-4
2-2-1.9-3
2-2-3-1.3-8
2-2-1.7-1
2-2-1.11-1
2-2-1.11-2
2-1.7-16
2-2-1.3-7
2-2-1.5-19
2-2-1.9-7
2-2-1.3-11
2-2-1.3-12
2-2-1.9-8
2-2-1.9-2
2-2-1.5-20
2-2-1.3-4
2-2-1.3-8
2-2-1.3-5
2-2-1.15/16-1
2-2-1 .15/16-3
2-2-1.3-13
2-2-1.15/16-5
2-2-1.3-9
2-2-1.3-10
2-2-1.7-2
2-2-1.11-3
2-2-1.5-22
2-2-1.3-17
2-2-1.3-15
2-2-1.3-3
2-2-1 .15/16-2
2-2-1.9-4
2-2-1.15/16-4
RM21
RM21 KX1
1 /8DD/44B
12101-9152-0
1213C RED
12301 -1116-0
12354-6108-0
12354-6109-0
12401-9121-0
12454-4316-0
12641-0551-0
12641-1272-3
12641-5641-0
12641-5642-0
12641-9321-0
12643-1223-0
12643-1452-0
12643-4301-0
12643-5602-0
12643-9675-0
12647-3951-0
12647-3955-0
12647-5701-0
12652-6715-0
12653-5635-0
12653-5639-0
12812-1121 -0
12815-6174-0
12866-4314-0
13901-3308-2
13901-3375-0
13901 -461 1-0
13901-9104-0
13901-9201-0
13921-9104-0
Jan 03 (Amdt 2)
Part No.
Chapter, Page
and
Item No.
Drawing No.
1 98976M
21 KBTFO6MPX
21 SBTSO8MPX
232312
25120151 1VW
271 836MSZN
290
3296W 50K
340
363-589
4/64X-S
534-50K
54134729
54207677
54208048
54208049
54208123
54208280
54208517
54208517
54208534
54208687
54208776
54208819
641
648
651422
Chapter, Page
and
Item No.
2-2-3-1.1 1-2
2-1.9-14
2-2.11-1
2-2-3-1.5-29
2-2.11-12
2-3.5/6-8
2-2-2.3-9
2-2-3-1.13/14-2
2-2-2.5-30
2-2.13/14-25
2-1.9-11
2-2-3-1.3-13
2-2-2.5-31
2-2-2.5-23
2-2-2.5-36
2-2-2.5-37
2-2-2.5-32
2-2-2.7/8-39
2-2-2.5-28
2-2-2.5-24
2-2-2.3-15
2-2-2.5-29
2-2-2.5-35
2-2-2.5-27
2-2-2.3-20
2-1.9-16
2-2.13/14-22
Chap 4
Page 5/6
61 15-G-153-71 I
ARMY EQUIPMENT
SUPPORT PUBLICATION
This proforma should be retained in this publication.
reproduce locally.
When required for use,
COMMENT ON AESP
TO:
ARMY SCALING & CATALOGUING AUTHORITY
HA HA ROAD
FROM: (Senders name & address)
WOOL WICH
LONDON SE18 4QF
Tel No
Sender's Reference
Date
Title of AESP
COMMENT
Signed:
FROM:
T0
ASCA
HA ROAD
LONDON SE18 4QF
Thank you for commenting on AESP.
*Action is being taken to:
*(j)
Revise the AESP
*(ii) Amend the AESP
* No action is considered necessary for the following reasons:
'Delete as necessary
SignedDateAESP Form 10
ARMY EQUIPMENT
SUPPORT PUBLICATION
6115-G-153-811
January 1996
CONDITIONS OF RELEASE
1
4
This information may be subject to privately owned rights.
GENERATOR SET, GASOLINE ENGINE DRIVEN,
BATTERY CHARGING, 14128V, 3001500W, (HOPKINS)
MODIFICATION INSTRUCTION AND INDEX
BY COMMAND OF THE DEFENCE COUNCIL
Ministry of Defence
Issued by
LAND SYSTEMS TECHNICAL PUBLICATIONS AUTHORITY
Repository Road, Woolwich, London SE18 4QA
9512/RP1306
Jan 96
Page (i)I(ii)
ARMY EQUIPMENT
SUPPORT PUBLICATION
611 5-G-1 53-811
1st Editbn
AMENDMENT RECORD
Amdt
No.
Incorporated
By_(Signature)
Date
Amdt
No.
I
32
2
33
3
34
4
35
5
36
6
37
7
38
8
39
9
40
10
41
11
42
12
43
13
44
14
45
15
46
16
47
17
48
18
49
19
50
20
51
21
52
22
53
23
54
24
55
25
56
26
57
27
58
28
59
29
60
30
61
31
62
9512/RP1306
Jan 96
Incorporated
By_(Signature)
Date
Page (iii)/(iv)
ARMY EQUIPMENT
SUPPORT PUBLICATION
6115-G-153-811
PREFACE
Sponsor:
DGES(A)
Publication Agency:
ATSA Chertsey
Project No: 72012 (314)
File ref: KBCH
INTRODUCTION
The Publication Agency is the authority for allocation of instruction numbers.
1
2
All modification instructions as issued are to be recorded in manuscript by the recipient on the
Numerical Modification Instruction Index provided. Amendments to individual instructions are to be
recorded on the instruction Amendment Record. All extant instructions and amendments can be found
listed in the main AESP index.
3
Service users should forward any comments on this publication through the channels prescribed in
AESP 0100-P-011-013. An AESP Form 10 is provided after the preliminary pages of this publication; it
should be photocopied and used for forwarding comments on this AESP.
MODIFICATION INSTRUCTION INDEX
This index is to be kept up to date by the User entering modification instructions as and when they are
published.
Priority (Pty) is shown as:
Immediate:
I
Routine: R
Mod
Pty
Subject
No.
(1)
Approval No.!
Remarks
(2)
(3)
(4)
1
I
Carburettor modification
2
I
Fitting of new clamp to old style (Mk 1) exhaust extension.
4
5
6
7
8
9
95121RP1 306
Jan 96
Page (v/(vi)
X)OO(-X-XXX-XXX
ARMY EQUIPMENT
SUPPORT PUBLICATION
COMMENT(S) ON AESP
To:
From:
ATSADTS3.2
Ha-Ha Road
Woolwich
LONDON SEI8 4QF
Date
BIN Number
Senders Reference
AESP Title:
Page(s)IParagraph(s)
Chapter(s)Ilnstruction
If you require more space please use the reverse of this form or a separate piece of paper.
Comment(s):
Telephone No.
Name (Capitals):
Date
Rank/Grade:
C—.
ATSA DTS 3.2 USE ONLY
From:
To:
ATSADTS3.2
Ha-Ha Road
Woolwich
LONDON SE18 4QF
Thank you for commenting on AESP
Dated
Your reference
Action is being taken to:
Tick
Tick
Issue a revised/amended AESP
Under investigation
Incorporate comment(s) in future amendments
No action required
Remarks
Signed
Telephone No:
Name (Capitals)
Rank/Grade
AESP Form 10 (Issue 3 dated Oct 97)
DateS
ARMY EQUIPMENT
SUPPORT PUBLICATION
61 15-G-153-811
GENERATOR SET, GASOLINE ENGINE DRIVEN,
BATTERY CHARGING, 14/28 V, 300/500 W (HOPKINS)
MODIFICATION INSTRUCTION No. I
Sponsor:
DGES(A)
Publication Agency:
ATSA Chertsey
Project No: 72012(31 5)
File ref: KBCH
AMENDMENT RECORD
Amdt
Incorporated
By (Signature)
No.
Date
Amdt
No.
1
4
2
5
3
6
Incorporated
By (Signature)
Date
SUBJECT: Carburettor modification
INTRODUCTION
The generator specification required the equipment to operate with the jerry can 1 m below the
operated at the same height, the fuel pump pressure floods the carburettor causing
a fire hazard. The aim of this modification is to fit a spring to the needle valve in order to prevent this
1
carburettor.
hazard.
1.1
Limitations on use of equipment. Nil
APPLICABILITY
Generator Set, 300/500 W, General Purpose, Battery Charger. (Hopkins), X2/61 15-99-983-9538
and Generator Set, 300/500 W, ADAD only, battery charger, (Hopkins), X216115-99-396-0315.
2
2.1
Fitted to subject equipment held by user units.
2.2
Unmodified stock, held at all levels of technical storage.
REASON FOR MODIFICATION
3
Code 1
-
to improve safety
PRIORITY
4
ARMY:
Immediate
ESTIMATED TIME REQUIRED
5
5.1
Embodiment:
9512\MP1402
Feb 96
0.8 man-hours
Mod lnstr No. 1
Page 1
ARMY EQUIPMENT
SUPPORT PUBLICATION
6115-G-153-811
5.2
Testing; 0.3 man-hours
MODIFICATION IMPLEMENTATION PLAN
6
This modification is to be implemented by Units authorized to carry out levels 2, 3 or 4
maintenance and with the authority of ES42b(3).
6.1
6.2
Associated modification instructions.
Nil
Modification plate strike action; After carrying out this modification, locate plate on side of
control panel and strike out mod. '1',
6.3
Action required by
7
7.1
Units and establishments holding equipment.
7.1.1
Examine documents to see if modification is applicable.
Examine equipment or modfication record plate to see if modification is embodied and
where necessary Units with 1st Line REME Support demand the stores required.
7.1.2
7.2
7.1.3
ARMY - On receipt of stores, request REME to modify equipment.
7.1.4
ARMY - Record the modification subject and AESP number in equipment documents.
Army units authorized to carry out levels 2. 3 or 4 maintenance.
'jMien requested by users or during overhaul of equipments on charge
ARMY
without REME 1st Line Support, obtain the items listed in Para 8 and carry out this
7.2.1
modification.
7.2.2
Erase mod '1' from modification record plate.
Record completion details of modification againstappropriate entry in vehicle
7.2.3
documents.
7.3
All recipients of this instruction. Add particulars to AESP 611 5-G-1 53-811 Mod lristr Index.
Stores, tools and equipment
8
8.1
Stores to be demanded.
8.1.1
and
The following item is to be demanded quoting this instruction as authority for demand,
8.1.2
Serial number of equipment held by user units.
Serial number of equipment for unmodified stock held at all levels of technical
8.1.3
storage.
Mod lnstr No.1
Page 2
9512\MP1402
Feb 96
..,
6115-G-153-811
ARMY EQUIPMENT
SUPPORT PUBLICATION
item
DMC
NSN/Part No.
Designation
5360-99-234-4237
Spring helical, compression,
carburettor, ECH/BC/950001
Qty
per eqpt
No.
X3
1
8.2
Item to be modified.
X3
2
2910-99-256-5269
Carburettor assembly
Sequence of operations
NOTE
The item numbers of Para 8 are used as references throughout this instruction.
9
Carry out the modification as follows:
Ensure that the generator is not running and that the engine is cold. Disconnect the jerry
can adaptor hose at the generator connection.
9.1
9.2
Remove the acoustic cover.
9.3
Remove and retain the air filter cover, filter element and support plate.
9.4
Loosen the choke control trunnion grubscrew, withdraw the rod and remove the trunnion.
9.5
Disconnect and remove the breather hose between the cylinder head and air filter body.
9.6
Disconnect the fuel supply pipe at the carburettor.
Remove the air filter body by loosening and withdrawing the two bolts and associated
washers located inside. On withdrawal, take care not to damage or loosen any of the four
9.7
gaskets.
Wthdraw the carburettor from the engine by unhooking the governor linkage arm and
retaining spring.
9.8
Remove the carburettor float chamber and drain the fuel into a suitable container. Place the
carburettor on a clean, well-lit workbench.
9.9
9.10 Remove the float arm pin, float needle valve and wire retainer Clip. Note that the float arm
pin has been flattened at one end to aid withdrawal from that end.
Invert the needle valve and place the modification spring (item 1) on the top. Refit the wire
retainer clip passing through the first coil of the springin accordance with Fig 1. The other end of
the spring should be inside the wire retainer. Refit the float by passing the tab between the wire
retainer and the spring.
9.11
Invert the carburettor and refit the float/needle assembly. Refit the float arm pir, pushed
from the flattened end. Refit the float chamber, ensuring that the r. bber seal is in place. Refer to
Fig 2 for complete assembly details.
9.12
9.13
Refit the carburettor in the reverse order to Sub-Para 9.1 to 9.8.
9512\MP1402
Feb 96
Mod lnstr No. 1
Page 3
ARMY EQUIPMENT
SUPPORT PUBLICATION
61 15-G-153-81 1
Testing after embothment
10
Run the engine with the acoustic cover removed and check for fuel leaks.
EFFECT ON WEIGHT
11
Negligible.
PUBLICA11ON AMENDMENTS
NOTE
Necessary
12
Nil.
will be issued
)
S.
V13168/1
Fig 1 Wre retainer clip and modification spring mounting on needle valve
Mod lnstr No
Page
4
1
9512\MP1402
Feb 96
6115-G-153-811
ARMY EQUIPMENT
SUPPORT PUBLICATION
VITON TIPPED
NEEDLE VALVE
FUEL BOWL
WIRE RETAINER
CLIP
CARBURETTOR CASTING
SUPPRESSION SPRING
(MODIFICATION)
FLOAT TAB
FLOAT FUEL
Vi 3168/2
2 Carburettor complete assembly
9512\MP1402
Dec 95
Mod lnstr No. 1
Page 5/6
6115-G-153-811
ARMY EQUIPMENT
SUPPORT PUBLICATION
GENERATOR SET, GASOLINE ENGINE DRIVEN,
BATTERY CHARGING, I 4128V, 300/500W (HOPKINS)
MODIFICATION INSTRUCTION No. 2
Publication Agency:
ATSA Chertsey
Sponsor:
DGES(A)
Project No: 72012(314)
File ref: KBCH
AMENDMENT RECORD
Amdt
Incorporated
By (Signature)
No.
Date
Amdt
No.
I
4
2
5
3
6
Incorporated
By (Signature)
Date
SUBJECT: Fitting of new clamp to old style (Mk 1) exhaust extension.
INTRODUCTION
The existing cladding material clamp fitted to the Mk 1 exhaust extension has not proven to be
1
robust enough for in-service handling. The aim of this modification is to fit a more durable and wider
clamp to improve the life of the extension. Users should note that future issues of the exhaust
extension may be to a Mk 2 standard which will not require the implementation of this instruction.
1.1
Limitations on use of equipment. Nil
APPLICABILITY
Exhaust extension assembly, X2/2990-99-517-1 764, as fitted to Generator Set, 300/500W, General
Purpose, Battery Charger (Hopkins), X2/6115-99-983-9538 and Generator Set, 300/500W, ADAD only,
Battery Charger (Hopkins), X2/6 115-99-396-0315.
2
2.1
Fitted to subject equipment held by user units.
2.2
Unmodified stock, held at all levels of technical storage.
REASON FOR MODIFICATION
3
Code 4 - to improve maintainability.
PRIORITY
4
ARMY: Immediate.
951 2IRP1 306.1
Jan 96
Mod lnstr No. 2
Page 1
ARMY EQUIPMENT
SUPPORT PUBLICATION
6115-G-153-811
ESTIMATED TIME REQUIRED
5
Embodiment: 0.3 man-hours.
MODIFICATION IMPLEMENTATION PLAN
6
6.1
This modification is to be implemented by:
6.1.1
ARMY - Units authorized to carry out levels 2, 3 or 4 maintenance.
6.2
Associated modification instructions. Nil
6.3
Modification plate strike action: After carrying out this modification, strike out Mod 2'.
Action required by:
7
7.1
Units and establishments holding equipment.
7.1.1
Examine documents to see if modification is applicable.
Examine equipment or modification record plate to see if modification is embodied and
where necessary Units with 1st Line REME Support demand the stores required.
7.1.2
7.1.3 ARMY - On receipt of stores, request REME to modify equipment.
7.1.4 ARMY - Record the modification subject and AESP number in equipment
documents.
7.2
Army units authorized to carry out levels 2, 3 or 4 maintenance.
7.2.1
ARMY - Wien requested by users or during overhaul of equipments on charge
without REME 1st Line Support, obtain the items listed in Para 8 and carry out this
modification.
7.2.2
Erase Mod 2 from modification record plate.
Record completion details of modification against appropriate entry in vehicle
7.2.3
documents.
7.3
All recipients of this instruction. Add particulars to AESP 611 5-G-1 53-811 Mod Instr Index.
Stores, tools and equipment
8
8.1
Stores to be demanded.
8.1.1
and
The following item is to be demanded quoting this instruction as authority for demand,
8.1.2
Serial number of equipment held by user units.
Serial number of equipment for unmodified stock held at all levels of technical
8.1.3
storage.
Mod lnstr No. 2
Page 2
9512/RP1306.1
Jan 96
6115-G-153-811
ARMY EQUIPMENT
SUPPORT PUBLICATION
Item
DMC
NSN/Part No.
Designation
X2
4730-99-588-2202
Clamp, exhaust MIKALOR
No.
1
8.2
047,0-706R
1
Clip, OETIKER
2
Items to be modified.
X2
3
per eqpt
Stores to be removed and reduced to scrap.
2
8.3
QtY
2990-99-517-1764
Exhaust extension assembly
1
Sequence of operations
NOTE
The item numbers of Para 8 are used as references throughout this instruction.
9
Carry out the modification as follows:
Remove the exhaust extension (item 3) from the generator, ensuring that the item is cold
before handling.
9.1
Locate the two adjacent Oetiker clips (item 2) close to the exhaust input coupling. Remove
both clips, taking care not to damage the cladding material.
9.2
9.3
Fit and tighten the new Mikalor clamp (item 1) in place of the existing items.
Testing after embodiment
10
Nil.
EFFECT ON WEIGHT
11
Nil.
PUBLICATION AMENDMENTS
NOTE
Necessary amendments will be issued separately.
12
Nil
9512/RP1306.1
Jan 96
Mod Instr No. 2
Page 3/4
6115-G-153-81 1
ARMY EQUIPMENT
SUPPORT PUBLICATION
GENERATOR SET, ENGINE DRIVEN (GASOLINE),
BATTERY CHARGING, 14128V, 3001500W (HOPKINS)
MODIFICATION INSTRUCTION NO. 3
Publication Agency:
ATSA Chertsey
Project No: 72212(99)
File ref: FERG/1/2/2
Sponsor:
DGES(A)
AMENDMENT RECORD
Amdt
Incorporated
No.
By (Signature)
Date
Incorporated
By (Signature)
Amdt
No.
I
4
2
5
3
6
Date
SUBJECT: Fuel pipe to generator set quick release connector
INTRODUCTION
NOTE
This modification is serial number sensitive. Refer to the relevant section as detailed in the following
table.
Generator Set Serial No.
Section Reference
P391355 to P391405 (mcI.)
0001 to 0658 (mcI.)
0659 to 1349 (md.)
Part A
Part A
Part B
Two build standards exist for the subject generator sets identified under Parts A and B of the above
1
table. The generators falling under Part A have a screw on type fuel connection between the generator
set and the fuel supply pipe of the Jerrycan Adaptor Assembly (JAA), requiring a spanner to complete.
The modification at Part A details the fitting of a Quick Release Coupling (QRC) system together with a
procedure for evacuating fuel trapped in the supply line of the JAA on disconnection.
The generators falling under Part B were manufactured with the QRC incorporated. However a
safely problem has been identified because fuel is trapped in the supply pipe when the QRC is
disconnected. To overcome this problem the modification instruction detailed under Part B introduces a
revised cap protector to allow for a procedure to evacuate the trapped fuel upon disconnection.
2
2.1
Limitations on use of equipment. Nil.
APPLICABILITY
3
.
Generator Set, 300/500W, General Purpose Battery Charger (Hopkins), NSN X216155-99-983-9538.
Generator Set, 300/500W, Battery Charger (Hopkins), ADAD Version, NSN X2161 15-99-396-0315.
3.1
Held by user units.
3.2
Unmodified stock, held at all levels of technical storage.
9802\NTCP-0903
Feb 98
Mod Instr No. 3
Page 1
ARMY EQUIPMENT
SUPPORT PUBLICATION
611 5-G-153-81 1
REASON FOR MODIFICATION
4
Code I - to improve safety.
PRIORITY
5
ARMY: Immediate.
ESTIMATED TIME REQUIRED
6
Part A 1.5 man-hours
Part B 0.5 man-hours
Embodiment:
MODIFICATION IMPLEMENTATION PLAN
7
7.1
This modification is to be implemented by:
7.1.1
7.2
Units authorized to carry out levels 2, 3 or4 maintenance.
Modification plate strike action: Part A - mod strike 3 on control box mod plate. Part B - no
action reqd.
Action required by
8
8.1
8.2
Units and establishments holding equipment:
8.1.1
Examine equipment documents to see if modification is applicable.
8.1.2
Examine equipment and modification record plate to ensure modification is embodied.
8.1.3
Record the AESP and instruction number in equipment documents.
8.1.4
Obtain the items listed in Para 9 Part A or Part B as applicable.
Units authorized to carry out levels 2, 3 or 4 maintenance:
8.2.1
When requested by users carry out this instruction.
8.2.2
Erase mod 3 from control box modification record plate for Part A only.
8.2.3
Record completion details of modification against appropriate entry in equipment
documents.
8.3
All recipients of this instruction. Add particulars to AESP 6115-G-153-811 Mod lnstr Index.
Stores, tools and equipment
9
9.1
Stores to be demanded:
9.1 .1
The following modification set is to be demanded quoting this instruction as authority.
9.1.2
Serial number of equipment held by user units.
Mod lnstr No. 3
Page 2
9802\NTCP-0903
Feb 98
6115.-G-153-811
ARMY EQUIPMENT
SUPPORT PUBLICATION
Qty
per eqpt
NSN!Part No.
Designation
X2
6115-99-852-8835
Mod set: Fuel quick release connection
comprising of:
1
X2
2910-99-905-5099
Fuel quick release coupling, plug
bulkhead fitting x 5/16 in. hose tail
c/w lock nut
(1)
2
X2
2910-99-968-2523
Fuel quick release coupling, socketx
1/4 in. hose tail
(1)
3
X2
2910-99-126-5372
Cap protector - plug
(1)
4
X2
2910-99-352-7060
Cap protector - socket (Iss 2)
(1)
5
9GWR
4720-99-736-5247
Fuel hose - coupling to filter 190 mm
(1)
6
6MT1
4730-99-352-3452
Worm drive clip size No. 15
(2)
2910-99-352-7060
Cap protector - socket (Iss 2)
DMC
Item
No.
Part A only
1
Part B only
X2
7
9.2
1
Stores to be removed and reduced to scrap:
Part A only
8
X07J04
Fitting 7/16 in. JIC x 1/4 in. bore hose,
reusable
9
XO7JFO5
Fitting, reusable swivel, 7/16 in. JIC x
female for 5/16 in. id hose
1
1
10
X2
4720-99-500-3127
Hose, rubber, silicon, 5/16 in. id
oil/petrol resistant
11
X2
5340-99-660-7324
Cap protective, dust and moisture
seal, c/w cord
12
X2
2910-99-730-4019
Nipple, pipe, bulkhead fitting, 7/16 in.
JIC male/male brass
13
Cl
2910-99-420-4923
Lock nut, 7/16 in. JIC Zn p1
1
14
6MT1
4730-99-352-3452
Clamp hose 9/16 in. stainless
2
2910-99-352-7060
Cap protector - socket (lss 1)
1
Connector bracket
1
1
1
1
Part B only
X2
15
9.3
Items to be modified:
Part A only
16
9802\NTCP-0903
Feb 98
NP
Mod lnstr No. 3
Page 3
611 5-G-1 53-811
ARMY EQUIPMENT
SUPPORT PUBLICATION
Sequence of operations
10
Carry out this instruction as follows:
NOTE
The item numbers of Para 9 are used as reference throughout this instruction.
WARNINGS
FIRE HAZARD. EXERCISE EXTREME CARE WHEN IN PROXIMITY TO OR HANDLING
GASOLINE FUEL, AS IT IS HIGHLY FLAMMABLE.
Part A Serial Nos P391 355 to P391405 mcI. and 0001 to 0658 mcI.
Ensure that the generator is not running and that the engine is cold. If connected,
disconnect the Jerrycan Adaptor Assembly (JAA) at both ends and drain any fuel into a suitable
container.
10.1
Release the worm drive clip securing the 7/16 in. x 1/4 in. bore hose fitting (8) attached to the
end of the fuel supply line of the JAA. Pull the fitting (8) from the hose and discard. Retain the worm
drive clip.
10.2
Place the hose tail of the fuel quick release coupling - socket (2) through the retaining ring of
the cap protector - socket (4) and fit on to the fuel hose of the JAA. Position the original worm drive
clip on to the hose tail of the coupling and secure.
10.3
10.4
Remove the acoustic cover from the generator set.
10.5
Locate the fuel hose (1) between the frame mounted fuel connector and the fuel filter.
Release the worm drive clip (14) at the fuel filter and disconnect the fuel hose (10). Drain any
excess fuel into a suitable container. Release the fitting (9) attached to the rear of the fuel connector
with a 14 mm spanner, disconnect, and discard the fuel hose assembly (9, 10 and 14).
10.6
Using two 17 mm spanners release the lock nut (13) at the rear of the frame mounted fuel
connector (12) and remove. Pull the connector (12) out of the bracket and, together with the lock nut
(13) and cap protective (11), discard.
10.7
reqd.
Open out the connector bracket hole to 12.5 mm dia. Remove burrs and patch paint as
10.8
Remove the lock nut from the fuel quick release coupling - plug (1) and pass the hose tail
through the frame connector bracket. Fit the lock nut to the coupling (1) and secure to the frame
using two 17 mm spanners.
10.9
Place the retaining ring of the cap protector - plug (3) over the hose tail of the coupling (1)
and position on the remainder of the threads.
10.10
Place the worm drive clips (6) at both ends of the fuel hose (5) and connect the fuel hose
(5) between the frame mounted coupling and the fuel filter. Secure the worm drive clips (6) at each
end of the fuel pipe (5).
Part B Serial Nos 0659 to 1349 mcI.
Ensure that the generator is not running and that the engine is cold. If connected
disconnect the JAA at both ends.
10.11
Mod lnstr No. 3
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9802\NTCP-0903
Feb 98
.
ARMY EQUIPMENT
SUPPORT PUBLICATION
6115-G-153-811
NOTE
Any fuel trapped in the line will be released when the following operation, Sub-Para 10.12 is
carried out.
Suspend the jerrycan end of the JAA over a suitable container. Release the worm drive clip
securing the fuel quick release coupling socket (2) to the generator end of the JAA and remove the
coupling together with the cap protector - socket (Iss 1) (15). Retain worm drive clip. Discard cap
protector - socket (Iss 1) (15).
10.12
Place the retaining ring of the cap protector - socket (Iss 2) (7) over the hose tail of the fuel
quick release coupling - socket (2) and refit to the fuel hose of the JAA. Position worm drive clip and
secure.
10.13
TESTING AFTER EMBODIMENT
WARNINGS
TOXIC FUMES. EXHAUST GASES ARE TOXIC AND CAN QUICKLY REACH TOXIC
PROPORTIONS IF BASIC PRECAUTIONS ARE NOT FOLLOWED. IF THE GENERATOR IS TO
BE USED IN A CONFINED SPACE, A STANDARD ISSUE EXHAUST EXTENSION MUST BE
FITTED. THE EXHAUST EXTENSION MUST NOT BE ADDITIONALLY MUFFLED OR
RESTRICTED IN ANY WAY FROM ITS ORIGINAL DESIGN, AS THE RESULTING BACK
PRESSURE COULD CAUSE SPURIOUS LEAKS TO OCCUR OR DAMAGE THE ENGINE.
EXTREME CARE MUST BE TAKEN TO ENSURE THAT EXHAUST GASES ARE VENTED
SAFELY AWAY FROM ANY PERSONNEL IN THE VICINITY WITH DUE CONSIDERATION
BEING GIVEN TO TOPOGRAPHY AND PREVAILING WIND CONDITIONS. HARMFUL
CONCENTRATIONS CAN BE ODOURLESS AND NOT VISUALLY PERCEPTIBLE.
(1)
EARTHING. BEFORE THE GENERATOR IS STARTED UP, A GOOD EARTH
CONNECTION MUST BE ESTABLISHED VIA THE GENERATOR SET EARTH TERMINAL.
(2)
11
PartAandB.
NOTE
If at any time fuel leakage is evident, stop the generator immediately and rectify the fault before
proceeding with testing.
11 .1
Inspect all fuel connections.
11.2
Prepare the generator for use in accordance with AESP 611 5-G-1 53-201.
NOTE
With the new quick release coupling fitted a positive snap-lock should be experienced upon
connection, with the sleeve of the coupling socket sliding forwards.
11.3
Check the fuel connection for security.
11.4
Carry out pre-starting checks in accordance with AESP 6115-G-153-201 Para 8 to 10.3.
Start the generator in accordance with AESP 611 5-G-1 53-201 Para 12 to 13.5. Check all
11.5
fuel connections for leaks.
CAUTION
The magnetic circuit breaker must remain in the off position as no load is connected.
9802\NTCP-0903
Feb 98
Mod lnstr No. 3
Page 5
ARMY EQUIPMENT
SUPPORT PUBLICATION
6115-G-153-811
Run the generator for 10 to 15 minutes and monitor for fuel leaks.
11.6
Shut down the generator in accordance with AESP 611 5-G-1 53-201 Sub-Para 14.2 to 14.3.
Check for fuel leaks.
11.7
Disconnect the fuel quick release coupling from the generator by pulling back the sleeve of
11.8
the coupling. On disconnection no more than three or four drops of fuel should spill from the
couplings.
Fit the cap protector to the generator fuel coupling.
11.9
With the JAA still connected to the jerrycan and its fuel tap still in the on position, drain the
remaining fuel as follows:
11.10
Hold the end of the fuel supply line above the jerrycan and open the valve of the
11.10.1
connector by inserting the nipple located on the rear of the cap protector. The sleeve of the
connector will positively spring forward to confirm the valve is open.
Hold the fuel supply line above the jerrycan for approximately five seconds to drain
11.10.2
the majority of the fuel content.
11.10.3
to drain.
Disconnect the JAA and slowly withdraw from the jerrycan to allow the remaining fuel
11.10.4
When drained, fit the cap protector to the coupling that will automatically push back
the sleeve, closing the valve.
NOTE
The Jerrycan Adaptor Assembly must not be stowed until the fuel content is fully drained.
EFFECT ON WEIGHT
12
Negligible.
PUBLICATION AMENDMENTS
NOTE
Necessary amendments will be issued separately.
13
Nil.
.
Mod lnstr No. 3
Page 6
9802\NTCP-0903
Feb 98
ARMY EQUIPMENT
SUPPORT PUBLICATION
61 15-G-153-81 1
Tubutar Frame
FueL Connector Bracket
(Drill Mtg Hole
to
Filter
•Locknut
V13919/1
Fig 1 Generator modified fuel system
9802\NTCP-0903
Feb 98
Mod Instr No. 3
Page 7
ARMY EQUIPMENT
SUPPORT PUBLICATION
6115-C-i 53-811
Fuel Line
Supply Hose
Connected to
Gasoline Can
Adaptor
.
Worm Drive Clip
Vi 3919/2
Fig 2 Modified gasoline can adapter hose
Mod lnstr No. 3
Page 8
9802\NTCP-0903
Feb 98
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