TM-5-4940-200-35

DEPARTMENT OF THE ARMY TECHNICAL MANUAL

TM 5-4940-200-35

FIELD AND DEPOT MAINTENANCE MANUAL

SHOP EQUIPMENT, CONTACT MAINTENANCE, TRUCK

MOUNTED, SET NUMBER 3 (SOUTHWEST MODEL SECM)

SERIAL NO. S-3-628 THROUGH S-3-730 AND

(DAVEY MODEL CMU-5) SERIAL NO. 33343

THROUGH 33343-234

FSN 4940-294-9518

HEADQUARTERS, DEPARTMENT OF THE ARMY

SEPTEMBER 1963

TM 5-4940-200-35

SAFETY PRECAUTIONS

Do not connect an external power source or operate the generator-welder until it has been properly grounded. Electrical faults in the generator-welder, load lines, or equipment can cause death by electrocution from contact with an ungrounded system.

When filling the fuel tank, do not smoke or use an open flame in the vicinity. Maintain a metal-to-metal contact between the filling container and the tank to prevent sparks from being generated as fuel flows over the metallic surfaces.

Lifting equipment must have a capacity of at least 5 tons.

Do not overload shop set with additional pe rsonnel, equipment, or parts. Failure to observe this warning will result in an overloaded condition dangerous to personnel and equipment.

The voltage of the shop set is dangerous to persons coming into contact with any part of the electrical system during operation. Severe, possibly fatal, shock may result. This is especially true when the ground is damp. in case of accident, shut off the power immediately. If this is not possible, free the victim from electrical contact, using a nonconductor such as a dry board or dry rope. Avoid contact with the victim. If the victim is unconscious, apply artificial respiration and send for medical assistance.

Do not permit an energized electrode holder or electrode to touch the skin or damp clothing of the operator or nearby personnel When operating in an inclosed area, the exhaust gases must be piped to the outside. The exhaust gases contain carbon monoxide, which is a colorless, odorless, and poisonous gas.

To prevent eye burns, it is necessary that the eyes of the operator or the arc welder, as well as the eyes of personnel nearby, be shielded from the intense light of the electric arc. Ordinary sun glasses or gas welding goggles do NOT provide sufficient protection.

CHAPTER

Section

CHAPTER

Section

CHAPTER

Section

APPENDIX

INDEX

V.

VI.

VII.

VIII.

IX.

X.

I.

II.

III.

IV.

I.

I.

II.

III.

3.

1.

I.

II.

2.

TECHNICAL MANUAL

TM 5-4940-200-35

HEADQUARTERS,

DEPARTMENT OF THE ARMY

WASHINGTON, D. C., 16 September 1963

No. 5-4940-200-35

FIELD AND DEPOT MAINTENANCE EQUIPMENT

SHOP EQUIPMENT, CONTACT MAINTENANCE, TRUCK MOUNTED, SET NUMBER 3

(SOUTHWEST MODEL SECM) SERIAL NO. S-3-628 THROUGH S-3-720 AND

(DAVEY MODEL CMU-5) SERIAL NO. 33343 THROUGH 33343-234

FSN 4940-294-9518

INTRODUCTION..............................................................................

Paragraph

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

Description and data.........................................................................

GENERAL MAINTENANCE INSTRUCTIONS ....................................

1, 2

3, 4

5-7

8-20

21-24

Special tools and equipment .............................................................

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

Removal and installation of major components...................................

SHOP SET MAINTENANCE INSTRUCTIONS ...................................

Engine speed governor and governor adapter drive............................

Engine overspeed relay ....................................................................

Electric brake lock ............................................................................

Declutcher, propeller shaft, and power takeoff universal joint and shaft assembly ...............................................................

Power takeoff and power takeoff controls...........................................

Generator-welder .............................................................................

Controls and instruments ..................................................................

Battery-charging resistors and resistor box.........................................

Receptacle boxes and cables............................................................

Vehicle frame extension and shop set body........................................

25-27

28-30

31, 32

33-36

37-40

41-43

44-47

48, 49

50, 51

52-54

REFERE NCES.................................................................................

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

20

23

27

28

33

40

44

54

54

55

62

64

Page

2

2

2

13

13

13

14

20

________________

* This manual supersedes TM 5-4940-200-35, 19 December 1961.

TAGO 5918A-704415 -SEPTEMBER 1963

1

TM 5-4940-200-35

CHAPTER 1

INTRODUCTION

1. Scope

a.

Section I. GENERAL

These instructions are published for the use of the field and depot maintenance personnel maintaining the Southwest Truck Body Company, Model SECM, and

Davey Compressor Company, Model CMU-5, Truck

Mounted Shop Equipment Set Number 3. They provide information on the maintenance of the equipment which is beyond the scope of the tools, equipment, personnel, or supplies normally available to using organizations.

2628 Recommended Changes to DA Technical Manual

Parts Lists or Supply Manual 7, 8, or 9) will be used for reporting these improvements. This form will be completed in triplicate using pencil, pen, or typewriter.

The original and one copy will be forwarded direct to the

Commanding Officer, U. S. Army Mobility Support

Center, ATTN: SMOMS-MM, P. O. Box 119, Columbus,

Ohio 43216. One information copy will be provided to the individual's immediate supervisor (e.g., officer, noncommissioned officer, supervisor, etc.).

b.

Appendix I contains a list of publications

applicable to this manual. The maintenance allocation chart is located in the operator and organizational maintenance manual TM 54940-200-12. Field and depot maintenance repair parts are listed in

TM 5-4940-200-35P.

c.

Numbers in parentheses on illustrations indicate quantity. Numbers preceding nomenclature callouts on illustrations indicate the preferred maintenance sequence.

d.

The direct reporting by the individual user of errors, omissions, and recommendations for improving this manual is authorized and encouraged. DA Form

e.

Report all equipment improvement recommendations as prescribed by TM 38-750.

2. Record and Report Forms

For record and report forms applicable to field and depot maintenance, refer to TM 38750.

Note

Applicable forms, excluding Standard

Form 46, (United States Government

Motor Vehicle Operator's

Identification Card), which is carried by the operator, will be kept in a canvas bag mounted on the equipment.

3. Description

A general description of the shop set, the location and description of the identification plates, and information on the difference in models are contained in

TM 5-4940-200-12. A more detailed description of the components is contained in TM 5-4940-200-12. The repair and maintenance instructions are described in appropriate sections of this manual.

Section II. DESCRIPTION AND DATA

4. Tabulated Data

a.

Motor-Generator Classification and Rating.

Rating .........................7.5 kw (kilowatt)

Voltage ........................208 v (volts)

Amperes .....................38 amp (amperes)

Phase .........................3

Frequency....................50/60 cycles

Cooling ........................Fan

Lubrication....................Sealed bearings

2

Duty classification ...............Continuous

Degree of inclosure.............Full

Drive ..................................Pulley and 4 V-belts

Type ..................................Synchronous

b.

Exciter Classification and Rating.

Rating ...............................0.99 kw

Voltage...............................110 v, de (volts, direct current)

Amperes ............................9 amp

Rated speed.......................1,450 rpm (revolutions per minute)

Field winding ......................Shunt

Cooling ..............................Fan

Duty classification ..............Continuous

Degree of inclosure ............Full

Mounting............................Integral

c.

Welder Classification and Rating.

Voltage...............................40 v, dc

Amperes ...........................200 amp

Rated speed.......................1,800 rpm

Field winding .....................Shunt

Duty classification ...............60 percent duty cycle

Degree of inclosure.............Full

Mounting............................Integral

d.

Motor-Generator Repair and Replacement

Standards.

Revolving field:

Number of coils.............4

Turns per coil................600

Turns per layer ............Random wound

Wire size .....................No. 18 AWG (American

Wire Gage)

Type of wire..................Copper magnet wire, heavy eze.

Coil connection .............Series

Insulating materials .......Top revolving pole piece insulator (1 rqr). Bottom revolving pole piece insulator (1 rqr). Insulation wrapper 0.015 x 2

1/16 x 25 3/4 in. (inch) (1 rqr).

Dipping compounds ......Varnish, Type AN, Grade

CB, MIL-V-1137A.

Dipping and baking procedures. ..................First, dip 3 min (minutes), drain 10 min, bake 1 1/2 hr (hours). Second, dip 3 min, drain 10 min, bake hr. All baking temperatures 320°F. (Fahrenheit).

TM 5-4940-200-35

Fungus treatment ...Spray with MIL-V-173 varnish.

Stator:

Number of poles ...........4

Number of slots ...........54

Number of coils.............54

Coil span .....................2 1/4 in.

Turns per coil 7.............7

Wire size......................No. 15 AWG

Type of wire..................Copper magnet wire, heavy synthetic resin covered.

Insulating materials .......Slot insulators, slot No. 11 x

4 core (36 rqr). Slot insulation 9 in. x 13 in. x 54 in. No. 38 slot (54 qr).

Core wedge, No. 38 slot,

4 3/16 in, long (54 rqr).

Dipping compounds .....Varnish, Type AN, Grade

CB, MIL-V-1137A.

Dipping and baking procedures. ................First, preheat for 1 hr at

320°F., dip for 10 min, drain 10 min, bake 1 1/2 hr. Second, dip for 3 min, drain 10 min, bake 4 hr, spray with T-613 varnish, and bake 1/2 hr. All baking temperatures

320°F.

Fungus treatment .........Spray with MIL-V-173 varnish.

e.

Exciter Repair and Replacement Standards.

Exciter armature:

Number of coils ............43

Turns per coil -..............6


Number of coils per slot.

Coil pitch......................1 to 11

Commutator pitch .........1 to 43

Number of commutator bars ...........85

Wire size......................No. 17 AWG

Type of wire..................Round, dead, soft, copper magnet wire, heavy synthetic resin covered.

Type of winding.............Wave

Connection ..................Clockwise 11 bars

Exciter shunt field:


Number of turns per ......1,400

coil.

Turns per layer .............Random wound

Wire size......................No. 21 AWG

3

Type of wire..................Round copper magnet wire, plain, enamel covered.

Insulating materials ......Field insulation (2 rqr).

Field insulation, 3 3/4 in.

Ig (long) (2 rqr). Pole piece wrapping (4 rqr).

Procedures...................One dip, drain 10 min. bake

1 1/2 hr at 320

°

F.

Fungus treatment .........Spray with MIL-V-173 varnish after baking.

f.

Generator-Welder Repair and Replacement

Standards.

Armature:


Number of coils

per slot. ....................3


Turns per coil 1.............

Coil pitch .....................1 to 9

Commutator pitch - .......1 to 50

Number of

commutator bars.........99

Type of winding ............Wave

Insulating materials ......Core winding insulating (2 rqr). Core slot wedge, 1/2 in. Ig (43 rqr). Cuffed core insulation (33 rqr).

Fiber disk, 6 in. (2 rqr).

Insulator flange, 4 5/16 in.

(2 rqr.) Insulating tube (1 rqr). Supplementary mica segment (as rqr). Commutator insulator (1 rqr).

Round commutator insulator (2 rqr). Slipspring separator (3 rqr).

Dipping compounds .....Varnish, Type AN, Grads

CB, MIL-V-1137A.

Dipping and baking

procedures. ................First, dip 3 min, drain 10 min, bake 1 1/2 hr.

Second, dip for 3 min, drain 10 min, bake 4 hr.

All baking temperatures

320°F.

Fungus treatment .........Spray with MIL-V-173 varnish after final baking.

Wire size .....................0.050 x 3/8 in.

Type of wire .................Bare, copper magnet wire

Type of winding ............Wave

Coil connection ............Clockwise 12 bars

Insulating material.........Between coils insulation (33 rqr). Mica ring (2 rqr).

Mica segment (99 rqr).

Core wedge, 1 3/4 in. Ig

(99 rqr). Generator disk,

8 in. (2 rqr).

4

TM 5-4940-200-35


CB, MIL-V-1137A.

Dipping and baking

procedures. ................First, dip 3 min, drain 10 min, bake 1 1/2 hr.

Second, dip 3 min, drain

10 min, bake 4 hr. All baking temperatures

320 o

F.

Fungus treatment..........Spray with MIL-V-173 varnish.

Interpoles or commutating poles:


Turns per coil ...............16

Turns per layer .............1

Wire size......................1/6 x Y2 in.

Type of wire .................Bare, soft-drawn strip copper (round edge).

Coil connection ............Series

Insulating materials .......Interpole coil separator (115 rqr), 1/2 in. cotton loom

(15 in. rqr).


CB, MIL-V-1137A.

Dipping and baking

procedures .................Dip in and out, drain 10 min, bake 1 hr at 320°F.

Fungus treatment..........Spray with MIL-V-173 varnish.

Generator-welder compound fields:

Shunt section:

Turns per coil.............1,300

Turns per layer ...........Random wound wire size ...................No. 19 AWG

Type of wire ..............Round, copper magnet wire, plain enamel covered.

Series section:

Compounds No. 1

and No. 2:

Turns per coil........5

Size of wire..........1/16 X 3/8 in.

Type of wire.........Bare, copper strip and double cotton covered.

Compounds No. 3

and No. 4:

Turns per coil.......6

Wire size ............3/32 x 3/8 in.

Type of wire.........Double cotton-covered strip copper.

Compound No. 5:

Number of turns ......11

Wire size................3/32 x 1/4 in.

Type of wire............Double cotton-covered strip copper.

TM 5-4940-200-35

D E V I C E L E G E N D

A1 WELDER ARMATURE

A2 EXCITER ARMATURE

BCT BATTERY-CHARGING TERMINALS

C1 CAPACITOR

C2 CAPACITOR

EF EXCITER FIELDS

HE OVERLOAD SNITCH HEAT ELEMENT (45 AMPERE)

IP INTERPOLE WINDING

K1 NO VOLTAGE RELEASE COIL

NT REVERSE CURRENT RELAY

K3 OVERSPEED RELAY SWITCH

OL OVERLOAD RESET SWITCH

M1 AC VOLTMETER

M2 FREQUENCY METER

M3 DC VOLTMETER

M4 DC AMMETER

M5 HOUR METER

M6 BATTERY-CHARGING AMMETER

MS CIRCUIT BREAKER

P1 220-VOLT RECEPTACLE CONNECTOR


PT 220-VOLT RECEPTACLE CONNECTOR


PS 110-VOLT RECEPTACLE CONNECTOR


P7 110-VOLT BODY CUTLET RECEPTACLE CONNECTOR

P8 110-VOLT BODY OUTLET RECEPTACLE CONNECTOR

RI MOTOR OPERATION RHEOSTAT

R2 FIELD DISCHARGE RESISTOR ,300-OHM, 40-WATT

R3 60 CYCLE OPERATION RESISTOR,-OHM, 40-WATT

R4 WELDING RHEOSTAT

RS ENGINE STARTING CONTROL RHEOSTAT

RF

S1

S2

REVOLVING FIELD

WELDING POLARITY CONTROL SWITCH

WELD-OFF-ENGINE START SWITCH

S3 TEN-RANGE SWITCH

S4 REVERSE CURRENT RESET SWITCH

SS BATTERY-CHARGING RATE SELECTOR

56 MOTOR-GENERATOR SWITCH

S7 S0-60 CYCLE SELECTOR SWITCH

SM MOTOR-GENERATOR STATOR

R6 BATTERY-CHARGING RESISTOR, 100 WATT, 10 OHM SHF SHUNT FIELD

R7 BATTERY-CHARGING RESISTOR. 100 WATT, 10 OHM SF WELDER SERIES FIELD

R8 BATTERY-CHARGING BALLAST RESISTOR, 2.38-OHM WO WELDING ELECTRODE TERMINALS

R9 OVERSPEED RESISTOR, 100T-WATT, 2,500-OHM X1 AMMETER SHUNT

Figure 1. Schematic wiring diagram, model SECM.

5

(1)

Compound No. 6:

Number of turns.

Wire size

19

1/16 x 1/4 in.

Type of wire...Double cotton-covered strip copper.

Compounds No. 7 and No. 8:

Number of turns. 21

Series section-Continued

Compounds No. 7 and No. 8-Continued

Wire size 1/16 x 1/4 in.

Type of wire - Double cotton-covered strip copper.

Dipping compounds Varnish, Type AN, Grade

CB, MIL-V-1137A.

Dipping and baking

Number of coils.

Coil

2 assemblies connection. Series

Insulating materials. 150A insulator (2 rqr). BW insulation (2 rqr). BW compound insulation (2 rqr). Pole piece wrapper

(as rqr). 4 1/2 in. pole piece toe insulation (as rqr). Flux ring insulation (as rqr). Class B interpole wrapper (as rqr).

Lower compound lead insulation (1 rqr).

Dipping compound. Varnish, Type AN, Grade

CB, MIL-V-1137A.

Dipping and baking.

Fungus

TM 5-4940-200-35

Dip in and out, drain 10 min, bake 1 1/2 hr at 320 treatment. Spray with MIL-V-173 varnish.

g. Schematic Wiring Diagrams.

(1) Refer to figure 1 for a schematic wiring

diagram for moder SECM shop set.

(2) Refer to figure 2 for a schematic wiring

diagram for model CMU-5 shop set.

Figure 2. Schematic wiring diagram, model CMU-5.

(Located in back of Manual)

°

F.

h. Time Standards. Table I lists the number of

man-hours required under normal conditions for various operations in the maintenance and repair of the generator set. The man-hours listed are not intended to be rigid standards. Under adverse conditions, the operations will take considerably longer; whereas, under ideal conditions with highly skilled mechanics, most of the operations can be accomplished in considerably less time.

Table I. Time Standards

Hours

Lubrication and service.

03 FUEL SYSTEM

0308 Engine Speed Governor

Governor assembly

(change oil) .................................................................................................................. 0.5

17 BODY; CAB; HOOD; HULL

1712 Special Purpose Bodies

Body, assembly, special purpose

(clean) .......................................................................................................................... 1.0

44 WELDING

4406 Ventilating, Cooling System

Filter, air

(clean with air)............................................................................................................... 0.1

6

(1)

(2)

TM 5-4940-200-35

Table I. Time Standards-Continued

Hours

Lubrication and service-Continued.

50 PNEUMATIC EQUIPMENT

5008 Air Intake

Pad, filter

(clean)................................................................................................................................. 0.1

Remove and replace.

03 FUEL SYSTEM

0306 Tanks, Lines, Fittings

Tube, filler ........................................................................................................................... 0.5

0308 Engine Speed Governor.

Governor assembly, engine

(includes adjustment) .-........................................................................................................ 1.1

Rod assembly, throttle -.............................................................................................................. 0.6

Adapter, governor drive ............................................................................................................. 0.5

0308 Engine Speed Governor-Continued

Pulley, adapter drive ............................................................................................................ 0.2

Cable, flexible, governor drive............................................................................................... 0.2

Belt "V" drive

(includes removal and installation of guard, power divider and propeller shafts) includes adjustment) . ......................................................................................... 4.6

0312 Accelerator, Throttle or choke controls

Cable control, hand throttle .................................................................................................. 0.5

Bracket, throttle linkage-. ...................................................................................................... 0.4

Spring, throttle return ........................................................................................................... 0.1

06 ELECTRICAL SYSTEM

0606 Engine Safety Controls

Relay assembly, ove rspeed.................................................................................................. 1.2

0606 Engine Safety Controls-Continued

Harness, wiring, overspeed relay to engine............................................................................ 0.2

Harness, wiring, overspeed relay to generator welder

(includes removal and installation of panel guard and generator welder cover) .................. 1.5

0608 Miscellaneous Items

Switch, brake lock ......................................................................................................... 0.1

Brake lock, electric

(includes bleeding brake system) ................................................................................... 1.0

Wiring harness, brake lock ................................................................................................... 0.6

Control, directional signal light, automotive ............................................................................ 0.5

0609 Lights

Lamp assembly, turn signal ................................................................................................. 0.5

Lamp, incandescent ............................................................................................................ 0.2

Wiring harness, turn signal ................................................................................................... 1.0

0611 Horn

Bracket, horn ....................................................................................................................... 0.1

0613 Hull or Chassis Wiring Harness

Bracket, receptacle, trailer .................................................................................................... 1.0

08 POWER TRANSFER

0802 Clutch and Clutch Controls

Declutcher assembly, transfer case

(includes removal and installation of propeller shaft)

(includes adjustment)............................................................................................... 3.2

7

(2)

TM 5-4940-200-35


Hours

Remove and replace- continued.

0803 Gearshift Controls

Shift lever assembly, declutcher............................................................................................ 0.5

Bracket, shift bar

(includes adjustment) .................................................................................................... 0.6

0803 Gearshift Controls-Continued

Shifter and shoe assembly, declutcher

(includes removal and installation of declutcher shifter bracket assembly).......................... 0.5

09 PROPELLER SHAFT

0900 Propeller Shafts

Universal joint and shaft assembly, slip

(short) (includes removal and installation or companion flange, yoke and brakedrum hub) ........................................................................................ 2.0

Shaft, assembly, drive .......................................................................................................... 1.0

Spider, universal joint

(short shaft removed)..................................................................................................... 1.5

15 FRAME

1501 Frame Assembly

Extension, frame

(includes raising and blocking at body) . .......................................................................... 9.0

Base, Generator

(includes removal and installation or electrical leads and drive belts) ................................ 3.5

Member, frame extension and body support .......................................................................... 5.0

17 BODY; CAB; HOOD; HULL

1708 Straps

Clips, tool (1 ea)- ....................................................................................................................... 0.1

Loop, footmen (1 ea).................................................................................................................. 0.2

Spring, pail `.............................................................................................................................. 0.1

Straps, mounting (1 ea) . ............................................................................................................ 0.1

1712 Special Purpose Bodies

Body assembly

(includes removal and installation of generator, control panel, power divider and throttle controls) ............................................................................... 11.0

Door assembly........................................................................................................................... 1.5

Tailgate assembly...................................................................................................................... 1.5

Latch assembly ......................................................................................................................... 0.5

Receptacle, 110 v ..................................................................................................................... 0.2

Chain ........................................................................................................................................ 0.2

Wiring, body (ea) ...................................................................................................................... 0.5

Panel assembly, roof

(includes removal and installation of top rear door assembly) -................................................ 1.0

Floor assembly

(includes removal and installation of generator, welder belts, short propeller shaft, generator welder and power divider assembly)....................................... 20.0

Compartment assembly, body, right and left side .- .................................................................... 12.0

Shelf, flange (ea) ....................................................................................................................... 1.5

Panel assembly, head

(body removed) (includes removal and installation of front channel) ........................................ 4.6

20 POWER TAKEOFF

2004 Power Takeoff Assembly

Power takeoff assembly ....................................................................................................... 3.0

8

(2)

TM 5-4940-200-35


Hours

Remove and replace-Continued.

2004 Power Takeoff Assembly-Continued

Box assembly, power takeoff support

(power divider removed) ................................................................................................ 6.0

Linkage assembly, lower ...................................................................................................... 1.5

Fort, shifter clutch ............................................................................................................... 3.5

Bracket assembly, clutch operating....................................................................................... 1.6

Linkage assembly, upper ..................................................................................................... 1.0

Shaft, power takeff

(power divider assembly removed) ................................................................................. 2.5

Block, pillow (ea)

(power divider assembly removed) ................................................................................. 0.5

Bearing, ball, annular

(power divider assembly removed).................................................................................. 3.0

Clutch assembly

(power divider assembly removed) (includes adjustment) ................................................. 2.1

Plate, drive


Plate, hub, back


Pulley, power takeoff


22 MISCELLANEOUS BODY, CHASSIS OR HULL, AND ACCESSORY ITEMS

2202 Accessory Items

Reflectors, indicating clearance............................................................................................. 0.1

2210 Data Plates and Instruction Holders

Plates, data and instruction................................................................................................... 0.1

Plates, C.O.E- .......................................................................................................................... 0.1

40 ELECTRIC MOTORS

4000 Motor Assembly

Motor, electric, air compressor drive

(includes removal and installation of compressor) ............................................................ 3.0

Plate, motor base (ea).......................................................................................................... 0.1

Bumper, rubber, motor base (ea) .......................................................................................... 0.1

4006 Starting and Protective Devices

Switch, air compressor ......................................................................................................... 0.2

42 ELECTRICAL EQUIPMENT

4216 Miscellaneous Wiring, Fittings, Formed Cable Assemblies

Cord w/plug, electric motor................................................................................................... 0.5

Receptacle assembly, slave ................................................................................................. 0.5

Cable assembly, slave.......................................................................................................... 0.2

44 WELDING

4400 Are Welders

Generator, welder assembly

(includes removal and installation of guard, power divider, and drive belts) ................................................................................................. 3.0

Eye, lifting ........................................................................................................................... 0.1

9

(2)

TM 5-4940-200-35


Hour


4401 Rotor Assembly

Armature assembly

(generator removed) (includes removal and installation of pulley assembly and housing end) ........................................................................... 3.0

Ring, electrical contact

(armature removed) ....................................................................................................... 4.5

4402 Stator Assembly

Stator, generator

(generator removed) (includes removal and installation of armature and brushes)............................................................................................. 4.5

4403 Brush Holder Assembly

Holder assembly

(armature assembly removed) ........................................................................................ 1.5

Brush, electrical contact

(includes seating brushes).............................................................................................. 1.0

4404 Drive Components

Belts, "V"

(includes adjustment) (includes removal and installation of power divider assembly)....................................................................................... 3.7

Pulley, generator drive includes readjustment of drive belts) ............................................................................... 1.5

4450 Frame Support, Housing, Carrier

Housing, generator (ea)

(generator removed) (includes removal and installation of armature, exciter field coils, brush rings and stator).................................................. 15.0

Cap, bearing........................................................................................................................ 0.5

Wrappers, generator (ea) ..................................................................................................... 0.1


(armature removed) ....................................................................................................... 0.5

Washer, nonmetallic

(cap, bearings removed) ................................................................................................ 0.1

4406 Ventilating, Cooling System

Fan, generator cooling

(armature removed) (includes removal and installation of ac, dc, armature and fields).......................................................................................... 20.0

Guard assembly, fan ............................................................................................................ 0.1

Filter, air, generator.............................................................................................................. 0.1

4407 Control Panels, Housings, Cubicles

Panel assembly, control

(includes removal and installation of guard screen, wiring and leads) ................................ 1.5

Meters (ea)

(panel removed) -........................................................................................................... 0.5

4407 Control Panels, Housings, Cubicles-Continued

Wiring harness

(control panel removed).................................................................................................. 9.0

4408 Connecting Devices

Connector, receptacle, electrical ........................................................................................... 0.1

Board, terminal .................................................................................................................... 0.5

Block, terminal..................................................................................................................... 0.5

4409 Protective Devices, Electrical

Fuse, cartridge..................................................................................................................... 0.1

10

(2)

TM 5-4940-200-35


Hours


4410 Switching, Timing and Speed Control

Switch, rotary


Relay assembly


4410 Switching, Timing and Speed Control-Continued

Switch, toggle


4411 Resistor Components

Resistors, fixed and adjustable

(includes removal and installation of screen guard) .......................................................... 0.5

Resistors, variable

(includes removal and installation of screen guard) .......................................................... 1.0

4414 Radio Interference Suppression

Capacitor

(includes removal and installation of guard screen, air filter and wrapper) ............................................................................................... 0.3

Strap, ground ...................................................................................................................... 0.3

47 Gages (Nonelectrical) : Weighing and Measuring Devices

4703 Time Meter

Meter, time totalizing


50 PNEUMATIC EQUIPMENT

5000 Air Compressor Assembly

Compressor, reciprocating, power drive................................................................................. 3.0

5001 Crankcase, Block, Cylinder Head

Head, compressor

(includes removal and installation of inlet valve, valve plate assembly and gasket) .............................................................................................. 1.0

Housing, compressor

(includes removal and installation of head, piston, eccentric bearing cover, bearing and motor)............................................................................. 2.5

Handle, compressor lifting .................................................................................................... 0.1

5002 Crankshaft

Eccentric, piston, driving

(includes removal and installation of head, housing, piston, bearing, outboard bearing and bearing cover)............................................................ 2.5


5004 Pistons, Connecting Rods, and Rotors

Piston, compressor

(includes removal and installation of head, housing, eccentric, outboard bearing and cover bearing)......................................................................... 2.5

Seal, plain

(includes removal and installation of cylinder head).......................................................... 0.5

Bearing, sleeve, piston to eccentric

(includes removal and installation of head, housing, piston, eccentric, crankshaft, outboard bearing and cover bearing) ........................................ 2.5

5006 Valves, Camshaft and Timing Mechanism

Plate assembly, valve

(includes removal and installation of head and air seal).................................................... 1.0

11

(2)

TM 5-4940-200-35


Hours


5005 Valves, Camshaft and Timing Mechanism-Continued

Valve, inlet

(head removed) ............................................................................................................. 0.1

6008 Air Intake

Pad, filter ............................................................................................................................ 0.1

76 FIRE FIGHTING EQUIPMENT

7603 Fire Extinguisher

Extinguisher, fire .................................................................................................................. 0.1

12

TM 5-4940-200-35

CHAPTER 2

GENERAL MAINTENANCE INSTRUCTIONS

5. Special Tools and Equipment

Section I. SPECIAL TOOLS AND EQUIPMENT

illustrated in TM 5-4940-200-35P.

No special tools or equipment are required for the maintenance of this shop set.

6. Field and Depot Maintenance Repair

7. Specially Designed Tools and Equipment

No specially designed tools or equipment are required for the maintenance of this shop set.

Field and depot maintenance repair parts are listed and

Section II. TROUBLESHOOTING

8. General

This section provides information useful in diagnosing and correcting unsatisfactory operation or failure of the shop set and its components. Each trouble symptom stated is followed by a list of probable causes of the trouble. The possible remedy recommended is described opposite the probable cause.

9. Engine Speed Fluctuates

Probable cause

Governor defective .............Repair or replace the gover-

Governor adapter drive........Repair or replace the govdefective

Possible remedy

nor (par. 26).

ernor adapter drive

(par. 27).

10. Generator-Welder Will Not Start or Come Up To

Speed

Probable cause

Power takeoff damaged

Possible remedy

Repair or replace the power

takeoff (par. 38).

11. Generator-Welder Does Not Deliver Output

Probable cause

switch defective

Possible remedy

Cycle selector switch...........Replace cycle selector

(par. 45).

Field rheostat defective .......Replace a defective rheo-

stat (par. 46).

Ten-range switch defective.

Repair or replace the ten-

range switch (par. 46).

Field circuit open.................Inspect the field rheostat and connections to rheostat. Repair or replace a defective rheostat

(par. 46).

Generator-welder defective.

Test and repair generator-

welder (pars. 42 and 43).

Circuit breaker defective-.....Repair or replace a defective circuit breaker

(par. 47).

Welding polarity control switch defective

Replace a defective welding polarity control switch

(par. 45).

13

12. Circuit Breaker Lacks Current When On

t

Probable cause Possible remedy

Circuit breaker defective.........Repair or replace a defecive circuit breaker

(par. 47).

13. Circuit Breaker Will Not Stay Closed

Probable cause

Overload trip assembly defective.

Possible remedy

Replace overload trip as-

sembly (par. 47).

Circuit breaker defective..........Replace circuit breaker

(par. 47).

14. Polarity Fails To Reverse

Probable cause

Polarity control switch jumper defective.

Possible remedy

Replace jumper wires as

necessary (par. 45).

Polarity control switch defective.

Fails To Register

Probable cause

Direct current ammeter or voltmeter defective.

Replace polarity control

switch (par. 45).

15. Direct Current Ammeter or Voltmeter

Possible remedy

Replace direct current meter or voltmeter

(par. 45).

Ammeter shunt defective-.......Replace ammeter shunt

(par. 45). Repair or

replace electrical lead.

TM 5-4940-200-35

16. Alternating Current Voltmeter Fails To Register

Probable cause

Alternating current voltmeter defective.

17. Battery-Charging Ammeter Fails To Register

Probable cause

Battery-charging resistor defective.

Battery-charging ammeter defective.

Possible remedy

Replace alternating current voltmeter

(par. 45).

Possible remedy

Inspect the batteryresistors. Replace defective resistors

(par. 49).

Replace battery-charging

ammeter (par. 45).

18. Frequency Meter Fails To Register

Probable cause Possible remedy

Frequency meter defective Replace the frequency

meter (par. 45).

19. Welding Arc Breaks Down and Cannot

Be Maintained

Probable cause

Commutator rough or worn.

Possible remedy

Reface the commutator

(par. 43).

20. Power Takeoff Noisy

Probable case

Bearings defective

Possible remedy

Replace the bearings

(par. 38).

21. Power Takeoff

a.

Removal.

One or more gears chipped Replace defective gears or broken.

(par. 38).

Section III. REMOVAL AND INSTALLATION OF MAJOR COMPONENTS

(1) Refer to TM 5-4940-200-12 and remove the power takeoff guard.

(2) Refer to TM 5-4940-200-12 and adjust the generator-welder drive belts to full loose.

Remove the belts from the generatorwelder pulley.

(3) Refer to TM 5-4940-200-12 and remove the governor adapter drive V-belt from the governor adapter drive pulley.

(4) Refer to TM 5-4940-200-12 and disconnect the lower linkage from the clutch linkage bracket assembly.

(5) Refer to paragraph 36 and remove the

power takeoff universal joint and shaft assembly.

(6) Refer to figure 3 and remove the power

takeoff.

14

TM 5-4940-200-35

b.

Installation.

(1) Refer to figure 3 and install the power

takeoff.

Figure 3. Power takeoff, removal and installation.

(6) Refer to TM 5-4940-200-12 and install the power takeoff guard.

22. Generator-Welder and Generator Welder Base

Note

Support the power takeoff with a suitable jack and be sure to reinstall the clutch operating linkage bracket assembly before installing the mounting hardware.

(2) Refer to paragraph 36 and install the


(3) Refer to TX 5-4940-200-12 and connect the lower linkage to the clutch operating linkage bracket assembly.

(4) Refer to TM 5-4940-200-12 and install the governor adapter drive V-belt on the governor adapter drive pulley.

(5) Install the generator-welder drive belts on the generator-welder pulley. Refer to TM

5-4940-200-12 and adjust the generatorwelder drive belts.

a.

b.

Removal

(1) Refer to TM 5-4940-200-12 and remove the lifting eye and generator welder top cover. On model CMU-5 shop sets, remove the engine overspeed relay resistor and switches from the generatorwelder.

(2) Refer to figure 4 and remove the model

SECM generator-welder and generatorwelder base. Remove model CMU-5 generator-welder and generator welder base in a similar manner.

Installation.

(1) Refer to figure 4 and install the model

SECM generator-welder and genera

15

16

Figure 4. Generator-welder and generator-welder base, model SECM, removal and installation.

TM 5-4940-200-35

tor-welder base. Install model CMU-5 generator-welder and generator-welder base in a similar manner.

(2) Refer to TM 5-4940-200-12 and install the lifting eye and the generator welder to cover. On model CMU-5 shop sets, install the engine overspeed relay resistor and switches to the generator-welder.

23. Control Panel

a.

Removal.

(1) Refer to TM 5-4940-200-12 and remove the control panel screen.

(2) Refer to figure 5 and remove the control

panel, model SECM.

(3) Refer to figure 5 and remove the control

panel, model CMU-5, in a similar manner.

Note

Remove the two screws that secure the reverse current relay mounting bracket to the control panel and hold the reverse current relay while removing the panel.

b.

Installation.

(1) Refer to figure 5 and install the control

panel, model SECM.

(2) Refer to figure 5 and install the control,

model CMU-5, in a similar manner.

(3) Refer to TM 5-4940-200-12 and install the control panel screen.

Figure 5. Control panel, model SECM, removal and installation.

17

18

References A through C

Figure 6. Shop set body, removal and installation.

TM 5-4940-200-35

24. Shop Set Body

a.

Removal.

(1) Remove all tools and accessories from the compartments. Store the various components in containers marked to identify the locations in order to facilitate replacement in the proper compartments.



(3) Refer to TM 5-4940-200-12 and disconnect the governor drive cable at the governor adapter drive.

(4) Refer to TM 5-4940-200-12 and disconnect the overspeed relay wiring harness from the engine ignition switch and free the relay wiring harness from the truck.

(5) Refer to figure 6 and remove the shop set

body from the carrier.

Caution

Be sure to provide suitable support for the shop set body after removal from the carrier; otherwise, damage to the power takeoff guard or power takeoff may result.

b.

Installation.

(1) Refer to figure 6 and install the shop set

body.

(2) Refer to TM 5-4940-200-12 and re connect the overspeed relay wiring harness to the engine ignition switch.

TM 5-4940-200-35

(3) Refer to TM 5-4940-200-12 and reconnect the governor drive cable.



(5) Install all tools and accessories in the compartment from which they were removed. (Refer to TM 5-4940-200-12 for location.)

Reference D

Figure 6-Continued.

19

TM 5-4940-200-35

CHAPTER 3

SHOP SET MAINTENANCE INSTRUCTIONS

Section I. ENGINE SPEED GOVERNOR AND GOVERNOR ADAPTER DRIVE

25. General

The centrifugal flyweight-type governor is bracketmounted on the cylinder head of the truck engine. The governor is driven by the generator-welder power takeoff by means of a V-belt, governor adapter drive, and flexible cable. The governor maintains constant engine speed under varying load conditions and prevents the engine from exceeding the revolutions per minute rate for which it is adjusted. When the engine speed decreases as a heavy load is applied, the governor spring overcomes the centrifugal force of the flyweights and moves the throttle lever to open the butterfly valve in the carburetor to increase the engine speed. The limiting action of the governor returns with increased engine speed.

26. Engine Speed Governor

d.

(4) Inspect the bearings for rusted balls or races, fractured races, and galled or scored surfaces. Replace a defective bearing.

(5) Inspect all the components for cracks, breaks, or other defects. Replace all defective parts.

Reassembly. Refer to figure 7 and reassemble

the engine speed governor.

e.

Installation and Adjustment. Refer to

TM 5-4940-200-12 and install and adjust the engine speed governor.

27. Governor Adapter Drive

a.

Removal. Refer to TM 5-4940-200-12 and remove the engine speed governor.

a.

Removal. Refer to TM 5-4940-200-12 and remove the governor adapter drive and drive pulley.

b.

c.

Disassembly. Refer to figure 7 and disassemble

the engine speed governor.

Cleaning, Inspection, and Repair.

(1) Clean all metal parts, except ball bearings, in an approved cleaning solvent and dry thoroughly.

(2) Place the ball bearings in an approved cleaning solvent until all grease and sludge is loosened. After cleaning, allow bearing to drain dry.

(3) Dip the bearings in clean light oil, rotate a few times, and drain excess oil.

b.

Disassembly. Refer to figure 8 and disassemble

the governor adapter drive.

c.

Cleaning, Inspection, and Repair.

(1) Clean all metal parts, except ball bearings, in an approved cleaning solvent and dry thoroughly.

(2) Clean and inspect the ball bearings as

instructed in paragraph 26.

(3) Inspect the governor drive bracket for cracks and breaks.

(4) Inspect the drive shaft for excessive wear, burs, and nicks. File smooth all minor burs and nicks.

20

TM 5-4940-200-35

3

4

5

1

2

Lubricating oilcup

Governor flange

Gasket

Oil seal

Ball bearing

6

7

8

Hairpin clip (4 rqr)

Headless grooved pin (2 rqr)

Governor control weight assembly

(2 rqr)

9 Shaft and spider

10 Governor housing

11 Packing retainer

12 Oil seal

13 Retaining ring (2 rqr)

14 Ball bearing (2 rqr)

15 Rocker arm shaft

16

17

18 Bolt, machine, hex-hd, No. 10-32

19

20 Washer, thrust, 1/2 in. id, 2/32 in.

21

22

23 Thrust sleeve

24

25

26

27

Rocker shaft yoke

Washer, lock, No. 10 ( rqr) x 7/16 in. (2 rqr)

Retaining ring od, 3/32 in. thk (2 rqr)

Thrust bearing

Washer, thrust, 1/2 in. id, 21/32, in.

od, 1/32 in. thk

Screw, machine, No. 10-24 x

3/4 in. (4 rqr)

Expansion plug

Spacer (spec) (2 rqr)

Bushing

Figure 7. Engine speed governor, disassembly and reassembly.

21

(5) Inspect the drive cover for breaks and cracks.

(6) Inspect all hardware for worn or damaged threads.

(7) Replace all defective parts.

TM 5-4940-200-35

d.

Reassembly. Refer to figure 8 and reassemble

the governor adapter drive.

e.

Installation. Refer to TM 5-4940-200-12 and install the governor adapter and drive pulley.

22

1

2

3

4

5

Shaft collar, 5/8 id, 1 3/8 od,

1/4 in. thk

Plain encased oil seal

Screw, machine, No. 10-24 x

5/8 in. (4 rqr)

Washer, lock, No. 10 (4 rqr)

Governor drive bracket

6

7

8

9

10

11

Ball bearing

Drive cover

Sleeve bushing

Gasket

Drive shaft

Pin, headless, 1/8 x

1 1/4 in.

Figure 8. Governor adapter drive, disassembly and reassembly.

TM 5-4940-200-35

28. General

Section II. ENGINE OVERSPEED RELAY

The engine overspeed relay is a safety device that is controlled by the speed of the generator welder armature. The exciter voltage is increased as the speed of the armature is increased. On model SECM shop sets the relay solenoid is adjusted so that excessive exciter voltage will cause it to actuate. The solenoid plunger trips a microswitch that is connected in series with the engine ignition switch. When the microswitch is tripped, the engine ignition circuit is interrupted, causing the engine to stop. On model CMU-5 shop sets overspeed is sensed by the resistor which trips the relay switches, causing the engine to stop.

29. Engine Overspeed Relay, Model SECM

a.

Removal. Components of the overspeed relay can be removed while the box is in place; however, for convenience in component removal, refer to

TM 5-4940-200-12 to remove the engine overspeed relay from the shop set body.

Figure 9. Engine overspeed relay resistor, microswitch, solenoid, and terminal block, model SECM, removal and installation.

23

b.

Removal of Components. Refer to figure 9 and

remove the engine overspeed relay resistor, microswitch, solenoid, and terminal block.

c.

Cleaning, Inspection, and Testing.

(1) Wash nonelectrical metal parts in an approved cleaning solvent and dry thoroughly.

(2) Inspect the microswitch for cracks and faulty operation. Test the continuity of the switch by placing the leads of a multimeter at the switch terminal C and terminal NC.

When the reset button is depressed, continuity should not be indicated. When the circuit is open, continuity should not be indicated. Replace a defective microswitch.

(3) Inspect the insulation plate, located between the microswitch and switch bracket, for cracks or breaks.

(4) Inspect the resistor for cracked or broken insulation. Test the resistor with a multimeter. Resistance should be 2,500 ohms ± 10 percent. Replace a defective resistor.

(5) Inspect the solenoid for visible damage or defects. Connect the solenoid, momentarily, to a 40-volt direct current power source. Solenoid should operate.

Replace a defective solenoid.

(6) Inspect the terminal blocks for cracks or breaks, loose or damaged terminal plates, and damaged terminal screws.

(7) Inspect all electrical leads for damaged terminal lugs and cracked or damaged insulation.

(8) Inspect the microswitch bracket for cracks or breaks.


(10) Inspect the overspeed relay box for breaks, cracks, or other damage.

d.

Installation of Components. Refer to figure 9

and install the engine overspeed relay resistor, microswitch, solenoid, and terminal block.

TM 5-4940-200-35

e.

Installation. If the engine overspeed relay is removed from the shop set body, refer to

TM 5-4940-200-12 and install it.

f.

Adjustment. Refer to figure 10 and adjust the

engine overspeed relay.

30. Engine Overspeed Relay, Model CMU-5

a.

Removal. Refer to TM 5-4940-200-12 and remove the engine overspeed relay resistor and switches.

b.

Cleaning, Inspection, and Testing.

(1) Wash nonelectrical metal parts in an approved cleaning solvent and dry thoroughly.

(2) Inspect the resistor for cracked and broken insulation. Test the resistor with a multimeter. Resistance should be 10,000 ohms +10 percent. Replace a defective resistor.

(3) Inspect the auxiliary relay switch for cracks, breaks, or other damage. Test the switch coil with a multimeter.

Resistance should be 500 ohms ± 10 per cent. Replace a defective auxiliary relay switch.

(4) Inspect the overspeed relay switch for cracks, breaks, or other damage. Test the switch coil with a multimeter. Resistance should be 6,000 ohms ± 10 percent.

Replace a defective overspeed relay switch.

(5) Inspect all electrical leads for damaged terminal lugs and cracked or damaged insulation. Replace all defective parts.

c.

Installation. Refer to TM 5-4940-200-12 and install the engine overspeed relay resistor and switches.

d.

Adjustment. Refer to figure 11 and adjust the

engine overspeed relay.

24

TM 5-4940-200-35

Figure 10. Engine overspeed relay, model SECM, adjustment.

25

26

Figure 11. Engine overspeed relay, model CMU-5, adjustment.

TM 5-4940-200-35

TM 5-4940-200-35

32. Electric Brake Lock

a.

Removal. Refer to figure 12 and remove the

electric brake lock.

b.

Cleaning and Inspection.

Section III. ELECTRIC BRAKE LOCK

31. General

The electric brake lock is installed in the hydraulic brake system to lock the rear wheels of the truck. It is mounted on the inside of the right frame member near the center body bracket and is actuated by an electrical switch located on the dash of the truck. The brake lock maintains enough pressure on the hydraulic brake system of the rear wheels to prevent the truck from moving while the generator-welder is in operation.

may result.

Note

Be careful not to allow foreign matter to enter the brake lock. Damage to the brake lock or hydraulic system

(2) Inspect the brake lock for breaks, cracks, or other damage and defects.

(3) Inspect the clamp loop and mounting screw for damage and defects.

(4) Replace a defective brake lock, mounting screw, or clamp loop.

c.

Installation.

(1) Refer to figure 12 and install the electric

brake lock.

(1) Clean the brake lock with a stiff brush to remove any heavy dirt; then wipe with a cloth dampened with an approved cleaning solvent. Dry with a stream of clean, dry, compressed air.

Figure 12. Electric brake lock, removal and installation.

27

Note

Be sure the electric brake lock is installed in such a manner that the output side is toward the rear.

TM 5-4940-200-35

(2) Refer to TM 5-4940-200-12 and set the brake lock. Inspect lines for leaking connections. Tighten leaking connections.

If the brakes fail to hold the truck in position, the electric brake lock is defective and must be replaced.

33. General

a.

Section IV. DECLUTCHER, PROPELLER SHAFT, AND POWER TAKEOFF

UNIVERSAL JOINT AND SHAFT ASSEMBLY

transfer case and the propeller shaft. It provides a means of disconnecting the power from the transfer case to the rear wheels in order that the truck transmission may be placed in gear to provide power takeoff for driving the generator-welder.

b.

The declutcher is located between the truck

The propeller shaft of the truck has been shortened to provide space for introduction of the declutcher into the power train; otherwise it remains in its normal position.

c.

The power takeoff universal joint and shaft assembly is mounted to the emergency brakedrum by means of a yoke; it provides driving power to the power takeoff.

34. Declutcher and Coupling Flange

a.

Removal. Refer to figure 13 and remove the

declutcher and coupling flange.

28

Figure 13. Declatchcr and coupling flange, removal and installation.

Note

Match mark the propeller shaft and the declutcher bearing housing, and the declutcher drive gear and the coupling flange before removal so that identical positions are maintained on installation.

b.

Disassembly. Refer to figure 14 and

disassemble the declutcher.

c.


TM 5-4940-200-35

(1) Clean all metal parts, except bearings, in an approved cleaning solvent and dry thoroughly.

(2) Clean the bearings as described in

paragraph 26.

(3) Inspect the drive gear, bearing housing, and sliding gear splines for excessive wear, burs, scores, nicks, or other damage.

(4) Inspect the bearings for wear rust, or rough spots.

(5) Inspect all metal parts for cracks and nicks.

1 Bearing housing

2 Steel locking ball, 1/4 in. dia.

3 Helical compression spring


5 Lubrication fitting

6 Slide gear

7 Drive gear

8

9

11

Ball bearing (2 rqr)

Bearing spacer

10 Washer, flat, 13/32 in. id,

1 1/4 in. od, 3/32 in. thk

Screw, cap, hex-hd, 3/8-24 x

3/4 in.

Figure 14. Declutcher, disassembly and reassembly.

29

TM 5-4940-200-35

(6) File minor burs and nicks smooth.

(7) Replace all damaged parts and hardware.

d.

Reassembly. Refer to figure 14 and reassemble

the declutcher.

e.

Inspection. Inspect the coupling flange (Fig. 13)

for cracks or breaks. Replace a defective coupling flange.

f.

Installation. Refer to figure 13 and install the

coupling flange and declutcher.

35.

Propeller Shaft

a.

Removal.

(1) Refer to paragraph 34 and disconnect the

propeller shaft flange from the declutcher.

(2) Refer to figure 15 and remove the

propeller shaft.

b.


disassemble the propeller shaft.

c.


(1) Clean all metal parts with an approved cleaning solvent and dry thoroughly.

(2) Inspect the propeller shaft splines for excessive wear, burs, scores, nicks, or other damage.

(3) File off all burs and smooth nicks with a file.

(4) Inspect the hub yoke for burred, nicked, or scored splines and for cracks, damaged threads, and other defects.

(5) File burs and nicks from the splines.

Replace a damaged hub yoke.

(6) Inspect the shaft assembly for cracks or breaks. Replace a cracked or broken shaft assembly.

(7) Clean the bearings as described in

paragraph 26.

Figure 15. Propeller shaft, removal and installation.

(8) Inspect the bearings for wear, rust, galls, or rough spots.

(9) Replace a defective bearing by replacing the universal joint cross.

d.


the propeller shaft.

e.

Installation.

(1) Refer to figure 15 and install the propeller

shaft.

(2) Refer to paragraph 34 and reconnect the

propeller shaft flange to the declutcher.

36.

Power Takeoff Universal Joint and Shaft

Assembly

a.

Removal. Refer to figure 17 and remove the


30

b.


disassemble the power takeoff universal joint and shaft.

c.

Cleaning, Inspection, and Repair. Clean, inspect, and repair the power takeoff universal joint and

shaft as described in paragraph 35.

TM 5-4940-200-35

d.


the power takeoff universal joint and shaft.

e.

Installation. Refer to figure 17 and install the


1 Flange yoke (2 rqr)


3 Needle roller bearing (8 rqr)

4 Cork seal (8 rqr)

5 Bearing seal retainer (8 rqr)

6 Universal joint cross (2 rqr)

7 Propeller shaft

8 Lubrication fittings, 67 1/2°,

1/8-27 in. (2 rqr)

9 Splined sleeve yoke

10 Seal washer (2 rqr)

11 Felt seal

12 Seal retainer

13 Straight lubrication fitting

1/8-27 in.

Figure 16. Propeller shaft, disassembly and reassembly.

31

32

Figure 17. Power takeoff universal joint and shaft assembly, removal and installation.

TM 5-4940-200-35

TM 5-4940-200-35

1 Companion flange


3 Needle roller bearing (8 rqr)

4 Cork seal (8 rqr)

5 Retainer seal (8 rqr)

6 Universal joint cross (2 rqr)

7 Male yoke

8

11

12

Straight lubrication fitting,

1/8-27 in.

9 Female yoke

10 Lubricating fitting 67°, 1/8-27 in. (2 rqr)

Universal joint spider (2 rqr)

Hub yoke

Figure 18. Power takeoff universal joint and shaft, disassembly and reassembly.

Section V. POWER TAKEOFF AND POWER TAKEOFF CONTROLS

38.

Power Takeoff 37.

General

The power takeoff, located at the front of the body below the floor, is mounted on crossmembers through pillow blocks. Power is transmitted from the truck engine to the power takeoff and from the power takeoff through drive belts to the generator-welder. The power takeoff has a clutch which, through a linkage system, can be disengaged to shut off power to the generator-welder. It is protected from road dirt and water by a shield.

a.

b.

Removal. Refer to paragraph 21 and remove

the power takeoff.

Disassembly.

(1) Refer to figure 19 and disassemble the

Model SECM power takeoff.


Model CMU-5 power takeoff.

33

34

1 Clutch cover

2 Clutch cone ring

3 Cone sleeve

4 Snapring

5 Flat washer (spec)

6 Ball bearing

7 Snapring

8 Cone collar

9 Pillow block (2 rqr)

10 Adjusting yoke

11 Shifter clutch lever (6 rqr)

12 Lever roller spring (3 rqr)

13 Lever roller (6 rqr)

14 Power takeoff shaft

15 Key, machine, 7/32 x 1/4 x

2 3/4 in.

16 Key, machine, 5/16 x 5/16 x 2 in.

17 Key, machine, 1/4 x ¼ x 1¼ in.

18 Bolt, machine, 5A6-18 x

1¼ in. (6 rqr)

19 Washer, lock, 5/16 in. (6 rqr)

20 Interval gear

26

27

28

29

30

31

32

33

34

35

36

37

21

22

23

24

25

Pulley

Ball bearing (2 rqr)

Spacer, 13/8 in. id x 1 3/4 in.

od x 1.108 in. thk

Setscrew, socket-hd, 5/16-24 x 1/2 in. (2 rqr)

Lubrication fitting, 1/8-27 in.

(3 rqr)

Screw, machine, rd-hd, 1/4-20 x 1/2 in. (3 rqr)

Setscrew, socket-hd, half dog point, 3/8-16 x 7/16, in.

Roller clutch disk

Pin (spec) (3 rqr)

Pin, roll, 1/8 in. x 5/6 in.

(3 rqr)

Pin spring

Clutch lockpin

Floating clutch plate

Pin, roll, 5/32 in. x 13/16 in.

(4 rqr)

Drive plate (3 section)

Clutch release spring (4 rqr)

Hub back plate

Figure 19. Power takeoff, Model SECM, disassembly and reassembly.

TM 5-4940-200-35

TM 5-4940-200-35

1 Pillow block

2 Spacer

3 Retaining ring

4 Bearing baffle


6 Spacer

7 Oil seal

8 Pulley

9 Spacer

10 Interval gear

11 Snapring

12 Bolt, machine, 5/16-18 x 1 1/2 in. (6 rqr)

13 Washer, lock, 0.319 in. id, 0.519

in. od, 0.078 in. thk (6 rqr)

14 Shim (2 rqr)

15 Split cone collar

16 Screw, cap, hex-hd, 3/8-24 x

2 1/4 in. (2 rqr)

17 Nut, plain, hex, 3/8-24

(2 rqr)

18 Lubrication fitting, 45 degrees,

1/4-28 (2 rqr)

19 Shaft

20 Key

37

38

39

40

41

32

33

34

35

36

25

26

27

28

29

30

31

21

22

23

24

Square key

Hub and back plate

Setscrew, 3/8-16 x 78 in. lg.

Driving plate (2 rqr)

Floating clutch plate

Roller disk

Lever (6 rqr)

Roller (6 rqr)

Lever spring (3 rqr)

Lever pin (3 rqr)

Pin, roll, 0.125 in. dia. 0.625

in. Ig, 0.028 in. thk. (3 rqr)

Cover

Cone ring

Cone sleeve

Lubrication fitting, 1/8-27

Screw, machine, 1/4-20 x 1/2 in. (3 rqr)

Adjusting yoke

Lock pin

Pin spring

Release spring (4 rqr)

Pin, spring, release, 5/32 in. dia, 13/16 in. lg,

0.032 in. thk (4 rqr)

Figure 20. Power takeoff, Model CMU-5, disassembly and reassembly.

35

36

c.


(1) Clean all metal parts, except bearings, in an approved cleaning solvent and dry thoroughly.

(2) Clean and inspect the bearings as

described in paragraph 26.

(3) Inspect all metal parts for cracks or breaks.

(4) Inspect the pulley for nicks, wear, burs, or cracks. Smooth all burs and minor nicks with a file. Replace a defective pulley.

(5) Inspect the hub and back plate, floating plate, and roller disk for cracks, breaks, galled bearing surfaces, rough bearing surfaces, and excessive wear. Replace a defective hub and back plate, floating plate, or roller disk.

(6) Inspect all gears for excessive wear, nicks, and cracks. Replace a damaged gear.

(7) Inspect the adjusting yoke, lever pin, lever, roller, and lever spring for cracks, breaks, excessive wear, or other damage.

Replace if defective.

(8) Inspect the clutch cover for cracks, breaks, or dents.

(9) Hammer out dents in the clutch cover.

Discard a cracked or broken clutch cover.

(10) Inspect the cone sleeve for burs, nicks, galls, and excessive wear. Replace a damaged cone ring or cone sleeve.

(11) Inspect the cone collar for excessive wear, cracks, or breaks. Replace a defective cone collar.

(12) Inspect the pillow blocks for excessive wear, cracks, or breaks. Replace a defective pillow block.

(13) Inspect all V-belts for wear, cracks, and fraying. Replace defective V-belts.

TM 5-4940-200-35

d.

Reassembly.

(1) Refer to figure 19 and reassemble the

model SECM power takeoff.


model CMU-5 power takeoff.

e.

Installation. Refer to paragraph 21 and install

the power takeoff.

f.

Adjustment. Refer to TM 5-4940-200-12 and adjust the power takeoff clutch.

39.

Clutch Operating Linkage Bracket Assembly

a.


the clutch operating linkage bracket assembly.

b.


disassemble the clutch operating linkage bracket assembly.

c.


(1) Clean all parts in an approved cleaning solvent and dry thoroughly.

(2) Inspect all parts for cracks, breaks, or excessive wear.

(3) Replace all worn or defective parts.

d.



e.

Installation. Refer to paragraph 21 and install


40.

Power Takeoff Upper Linkage

a.

Removal. Refer to TM 5-4940-200-12 and remove the model SECM or model CMU-5 power takeoff upper linkage.

b.

Disassembly.


power takeoff upper linkage, model

SECM.

TM 5-4940-200-35

1 Lower linkage bracket

2 Takeoff arm shaft

3 Pin, cotter, 1/8 x 2 in. (2 rqr)

4 Operating arm

5 Setscrew, socket-hd, 1/4-20 x

1/4 in.

6 Key, machine, 1/4 x 1/4 x

3/4 in.

7

8

9

10

11

12

Key, machine, 1/4 x 1/4 x 1 in.

Screw, cap, hex-hd, 3/8-16 x 1 1/2 in. (2 rqr)

Washer, lock, IT, 3/8 in.

(2 rqr)

Lower bushing

Clutch shifter fork

Upper bushing

Figure 21. Clutch operating linkage bracket assembly, disassembly and reassembly.

37



CMU-5.

c.


(1) Clean the upper linkage in an approved cleaning solvent.

(2) Inspect all parts for cracks, breaks and other damage.

(3) Weld cracks and minor breaks.


TM 5-4940-200-35

d.

Reassembly.



SECM.


power takeoff upper linkage, model CMU-

5.

e.

Installation. Refer to TM 5-4940-200-12 and install the model SECM or model CMU-5 power takeoff upper linkage.

38

1 Knob

2 Stud (spec)

3

4

Operating lever

Lever shaft

5

6

7

8

Washer, flat, 1 3/16 in. id, 2 in.

od, 0.177 in. thk (2 rqr)

Sleeve bearing (2 rqr)

Upper linkage bracket

Operating link

Figure 22. Power takeoff upper linkage, model SECM, disassembly and reassembly.

TM 5-4940-200-35

1

2

3

5

Knob

Shift rod

Nut, plain, hex, 3/8-24

(3 rqr)

4 Pin, cotter, 1/8 in. dia,

1 in. Ig (3 rqr)

Clevis (3 rqr)

6

7

8

9

10

11

Clevis pin, 3/8 in. dia,

1 in. Ig (3 rqr)

Bellcrank

Clutch rod

Washer, plain, flat, 1/2 in. id,

1 3/8 in. od, 1/8 in. thk

Nut, shoulder, hex (spec)

Bracket

Figure 23. Power takeoff upper linkage, model CMU-5, disassembly and reassembly.

39

TM 5-4940-200-35

Section VI. GENERATOR-WELDER

41.

General

The generator-welder is a multi-purpose machine capable of generating direct current for welding, battery charging, or furnishing power to start equipment with low or defective batteries. It will generate 120-volt, singlephase, or 200-volt, 3-phase current and has an integrated 220-volt, 3-phase electric motor which can be used to drive the direct current generator portion when an outside electrical power source is available. The truck engine is the basic source of power for operation of the machine. Power from the truck engine is delivered through flange and brakedrum, universal joint and shaft assembly, power takeoff pulleys, and belts to the armature shaft.

42.

On-Equipment Testing

a.

b.

Exciter Armature. Refer to TM 5-764 for armature testing procedures.

Revolving Field.

(2) Refer to TM 5-4940-200-12 and lift the brushes from the sliprings and from the exciter commutator.

(3) Refer to TM 5-4940-200-12 and remove the capacitor from the positive brush group.

(4) Using a multimeter, test between leads. A reading of more than 63 ohms or less than

57 ohms indicates a faulty field coil or interconnections; the stator assembly must be removed for additional testing.

(5) Test between the field and one of the exciter leads marked EXF or EX + as described in TM 5-764. A reading of less than 0.5 megohm indicates faulty insulation; the stator assembly must be removed for additional testing.

f.

Shunt Field. Refer to TM 5-764 for shunt field testing procedures. A reading of less than 0.5 megohm indicates faulty insulation; the field frame must be removed for additional testing.

(1) Refer to TM 5-4940-200-12 and lift the brushes from the electrical contact rings.

(2) Using a multimeter, test between the two electrical contact rings. A reading of more than 19.95 ohms or less than 18.05 ohms indicates defective wiring or electrical contact rings; the armature must be removed for further testing.

(3) Refer to TM 5-764 for procedures to be used in testing between the armature shaft and the electrical contact rings.

c.

Generator-welder Armature. Refer to TM 5-764 for armature testing procedures.

d.

Motor Stator. Refer to TM 5-764 for motor stator testing procedures.

TM 5-764 for series field group testing

TM 5-764 for interpole group testing procedures.

43.

g.

h.

a.

b.

c.

Welding Generator Series Field Group. Refer to

Welding Generator Interpole Group. Refer to

Generator-Welder


the generator-welder.

Testing During or After Disassembly. Refer to

TM 5-764 and test each component of the generatorwelder at the appropriate time during disassembly.

Disassembly.

e.

Exciter Field Group.

(1) Disconnect the exciter leads marked EXF and EX + at the terminal board on the

generator-welder. Refer to figure 1 or 2.

(1) Refer to TM 5-4940-200-12 and remove the air filters, and wrappers, rear shaft guard, and end cover.


generator-welder.

40

TM 5-4940-200-35

1 Welder stator assembly

2 Nut, hex, 1 9/16-14 ( 2 rqr)


4 Armature assembly

5 Key, machine, 3/8 x 2 1/2 in.

6 Bolt, machine, hex-hd, 5/16-18 x 2 in. (6 rqr)


8 Pulley

9 Pulley hub

10

11

12

13

14

15

16

17

18

End cover

Felt washer (2 rqr)

Bearing cap (2 rqr)

Bearing shim

Gasket

Exciter stator assembly

Electrical contact ring assembly

Bolt, machine, hex-hd, 5/16-18 x 3/4 in. (3 rqr)

Setscrew, socket-hd, 1/4-20 x 3/8 in.

Figure 24. Generator-welder, disassembly and reassembly.

41

TM 5-4940-200-35

19 Terminal board, rh

20 Terminal board, lh

21 Washer, lock, No. 10

(20 rqr)

22 Nut, plain, hex, No.

(10 rqr)

23 Clamp shim, copper, 11/16 x 3/4 x 1/8 in. (20 rqr)

24 Setscrew, 3/8-16 x 3/8 in.

(10 rqr)

25 Washer, lock, 5/16 in.

(10 rqr)

26 Screw, cap, hex-hd, 5/16-18 x 1/2 in. (10 rqr)

27 Screw, machine, rd-hd, No.

10-24 x 1 in. (8 rqr)

28 Terminal lug (10 rqr)

29 Insulating strip, 1 1/2 x

18 in. (3 rqr)

42


31 Screw, machine, rd-hd, 1/4-20 x 3/4 in. (10 rqr)

32 Brush holder ring clamp (2 rqr)

33 Screw, cap, hex-hd 1/4-20 x

1 1/4 in. (2 rqr)


1 3/4 in. (12 rqr)

35 Brush holder bushing (4 rqr)

36 Nut, hex, 1/4-20 (24 rqr)

37 Brush holder (4 rqr)

38 Setscrew, 3/8-20 x 1/2 in.

(2 rqr)

39 Interpole winding (4 rqr)

40 Shunt field winding (2 rqr)

41 Magnet insulator (2 rqr)

42 Insulator strip (2 rqr)

43 Pole piece magnet (2 rqr)

44 Winding wrapper (4 rqr)


45 Pole piece (2 rqr)

46 Terminal (4 rqr)

47 Electrical lead (4 rqr)

48 Brush holder mounting ring

49 Fiber bushing (2 rqr)

50 Screw, machine, rd-hd, No. 10-

24 x 1 in. (10 rqr)

51 Brush holder spacer (4 rqr)

52 Screw, cap, hex-hd, type Z,

1/4-20 x 3/8 in. (4 rqr)

53 Spring adjusting washer

(10 rqr)

54 Brush spring (4 rqr)

55 Brush tension arm (4 rqr)

56 Brush tension arm bushing

(4 rqr)

57 Screw, machine, rd-hd, 1/4-

20 x 2 in. (12 rqr)

TM 5-4940-200-35

58 Washer, flat, 1/4 in. (12 rqr)

59 Terminal board

60 Washer, lock, IT, 1/4 IN.

(14 rqr)

61 Screw, machine, rd-hd,

1/4-20 x 1 1/4 in. (6 rqr)

62 Rubber bushing

63 Motor end stator

64 Screw, cap, hex-hd, 3/8-16 x 2½ in. (4 rqr)


(4 rqr)

66 Washer, flat, 3/8 in.

(13 rqr)

67 Washer, nonmetallic, 33/64 in.

id, 1 1/8 in. od (14 rqr)


69 Brush holder (4 rqr)

70 Exciter commutator inner brush ring

71 Exciter commutator outer brush ring

72 Brush holder stud insulator (4 rqr)

13 Brush holder ring (2 rqr)

74 Brush ring sleeve bearing

75 Brush holder mounting ring




(2 rqr)

79 Insulator bushing


81 Brush arm (2 rqr)

82 Brush spring bushing (6 rqr)



84 Shunt winding (4 rqr)

85 Winding wrapper (4 rqr)

86 Pole piece (4 rqr)

87 Washer, flat, 7/32 in. id, 1/2 in.

od, 0.049 in. thk -(12 rqr)

88 Washer, lock, IT, No. 10

(6 rqr)


1 3/8 in. (4 rqr)


1 1/4 in. (4 rqr)

91 Brush arm (4 rqr)


93 Setscrew, 3/8-16 x 7/8 in.

(4 rqr)

43

d.


(1) Clean all metal parts with an approved cleaning solvent and dry thoroughly.

(2) Inspect the brush holders, brush holder rings, plates, and brush spring assemblies for breaks, cracks, or other damage.

Replace all parts found to be defective.

(3) Clean a slightly dirty or discolored commutator with No. 00 sandpaper. Blow sand, dust, and dirt from the armature with clean, dry, compressed air.

Caution

Do not use emery paper or emery cloth on any commutator.

(4) Inspect the armature shaft bearing surface for wear or damage. Examine the bearing for wear, galling, roughness, or other damage. Replace a damaged bearing.

(5) Inspect the electrical contact ring assembly for roughness, wear, and roundness. If defects cannot be corrected, replace the electrical contact ring assembly.

(6) Inspect the welder commutator and the generator commutator for roughness, wear, or eccentricity. Measure the commutator runout with a dial indicator.

Place the armature assembly in a lathe and turn a commutator that is 0.003 inch or more out-of-round. Make light cuts until the commutator is cleaned.

(7) Undercut the mica separators in the commutator to a depth of one thirty e.

f.

Reassembly.


generator-welder.

(2) Refer to TM 5-4940-200-12 and install the end cover, rear shaft guard, end wrappers, and air filters.


the generator-welder.

TM 5-4940-200-35

second inch below the commutator bars, either by hand or by machine.

(8) Inspect all stator assemblies and field coils for defective insulation, broken leads, or other defects. Replace defective windings, leads, or insulation.

(9) Inspect the terminal boards for cracks, breaks, defective terminals or terminal components. Replace a defective terminal board or components.

(10) Inspect each frame member for cracks or breaks. Weld minor cracks and replace a damaged frame.

(11) Inspect each panel of the generator box for cracks, dents, and defective mounting hardware. Straighten dents, weld cracks, and replace defective mounting hardware.

Replace a badly; damaged panel.

(12) Inspect the conduit assembly for cracks' and breaks. Replace a damaged conduit assembly.

(13) Inspect the generator-welder base for cracks, breaks, and damaged mounting hardware. Weld cracks and minor breaks.

Replace damaged mounting hardware.

44.

General

Section VII. CONTROLS AND INSTRUMENTS

generator, and as a source of direct current for engine starting.

The control panel for the generator-welder is located in the front compartment of the left side of the shop set body. It contains all the instruments necessary to operate the generator-welder as an arc welder, a battery-charging generator, an alternating current

45.

Controls and Instruments

a.

Removal.


control panel.

44

TM 5-4940-200-35

1 Real view

b.

Figure 25. Controls and instruments, model SECM, removal and installation.

(2) Refer to figure 25 and remove the controls

and instruments, model SECM.

(3) Refer to figure 25 and remove the controls

and instruments, model CMU-5, in a similar manner.


(1) Clean metal components with a bristle brush. Remove dust with clean, dry, compressed air.

(2) Inspect all electrical leads for defective insulation, broken lugs, frayed wires, or other defects. Repair or replace all defective electrical leads.

(3) Refer to TM 5-4940-200-12 and inspect and test the capacitors. Replace a defective capacitor (TM 5-4940-200-12).

(4) Inspect each meter for cracked glass, defective terminals, cracked or broken cases, incorrect readings, and inaccuracy.

Replace a defective meter.

(5) Inspect each switch for cracks, breaks, defective action, defective or damaged terminals, or other damage. Replace a defective or damaged switch.

(6) Inspect the 110-volt and 220-volt receptacles for defective terminals, defective contacts, and cracked or broken

45

46

2 Detail of rear view.


TM 5-4940-200-35

insulation. Replace a defective receptacle.

(7) Inspect each terminal stud for damaged threads, insulation, or wingnuts. Replace a damaged terminal.

(8) Inspect each rheostat for broken or worn contacts, cracked or broken insulators, defective resistor wire, damaged or defective terminals, and damaged mounting hardware. Use a multimeter to test the resistor for continuity and resistance. Repair or replace a damaged or defective rheostat.

46.

c.

Installation.

(1) Refer to figure 25 and install the controls

and instruments, model SECM.

(2) Refer to figure 25 and install the controls

and instruments, model CMU-5, in a similar manner.


control panel.

Ten-Range Switch and Field Rheostat

a.

Removal and Disassembly.

(1) Remove the ten-range switch and field

rheostat (par. 45).

Note

Match mark inside housing, control contact ring, front disk, and dial plate before disassembly to insure identical location on reassembly.

(2) Remove the field rheostat from the tenrange switch.

(3) Remove the setscrew (24, fig. 26) that

secures the handwheel (23) to the variable resistor (31) and remove the handwheel.

(4) Remove the four screws (25) that secure the case (27) to the springs (30) and remove the case. Remove dial (26) from the case.

(5) Remove the two screws (28) and washers

(29) and remove the springs (30) from the variable resistor (31).

TM 5-4940-200-35

(6) Remove the six screws (16), lockwashers

(15), and three brackets (14) and handwheel (19) from the front disk (12).

(7) Remove the three screws (13) and separate the handwheel from the brackets

(14).

(8) Remove the four screws (32), lockwashers (33) and inside housing (4) from the control contact ring (11). Place control contact ring (and assembled part) aside for later disassembly.

(9) Remove the two screws (1), lockwashers

(2) and bracket (3) from the inside housing

(4).

(10) Remove the screw (5), washers (6 and 7), and clip (8) from the inside housing (4).

(11) Remove screw (38), nut (36) and resistance element (37) from the contact control ring (11).

(12) Remove the front disk (12), and attached parts from the contact control ring (11).

(13) Remove two screws (20), washers (21), insulators (40), four washers (22), and insulator block (39) from the front disk

(12).

(14) Remove the five drive screws (18) and dial plate (17) from the front disk.

(15) Remove the two insulation plates (10) from the contact rings (9).

(16) Remove the four spring clips (35) from the control contact ring (11) and the two contact rings (9). Remove the contact rings (9) and electrical contacts (34) from the control contact ring.

b.


(1) Remove dirt and grease from all nonmetallic parts with a clean, dry, lint-free cloth. Clean metal parts in approved cleaning solvent and dry thoroughly.

47

TM 5-4940-200-35

NOTE: MATCH MARK THE SWITCH INSIDE HOUSING, CONTROL

CONTACT RING, FRONT DISK, AND DIAL PLATE BEFORE

DISASSEMBLY TO INSURE IDENTICAL LOCATION ON

REASSEMBLY.

48

Figure 26. Ten-range switch and field rheostat, disassembly and reassembly.

17

18

19

20

14

15

16

1

2

3

4

5

8

9

10

11

12

13

6

7

Screw, machine, 1/4-20 x 3/8 in. (2 rqr)

Washer, lock, IET, 1/4 x in. (2 rqr)

Plug mounting bracket

Switch inside housing

Screw, machine, No. 10-24 x 3/8

Washer, lock, IET, No. 10

Washer, flat, brass. No. 10

Field rheostat catch

Contact ring (2 rqr)

Insulation plate (2 rqr)

Control contact ring

Front disk

Screw, self-threading, No. 8-15 x 3/8 in. (3 rqr)

Handwheel mounting bracket

(3 rqr)

Washer, lock, No. 10 (6 rqr)

Screw, machine, No. 10-24 x 3/8 in. (6 rqr)

Dial plate

Screw, drive, No. 6 x 1/4 in. (5 rqr)

Handwheel

Screw, machine, 1/4-20 x

1 1/2 in. (2 rqr)


21 Washer, flat, 1/4 in. id, 5/8 in. od, 1/16 in. thk (2 rqr)

22 Washer, nonmetallic, 25/64 in.

id, 5/8 in. od, 1/8 in.

thk (4 rqr)

23 Rheostat handwheel

24 Setscrew, 1/4-20 x 3/8 in.

25 Screw, machine, No. 8-32 x 3/8 in. (4 rqr)

26 Field rheostat dial

27 Field rheostat case

28 Screw, machine, No. 10-32 x 1/4 in. (2 rqr)

29 Washer, lock, No. 10 (2 rqr)

30 Rheostat mounting spring (2 rqr)

31 Variable resistor

32 Screw, machine, 1/4-20 x

3/8 in. (4 rqr)


34 Movable contact

35 Clip spring (4 rqr)

36 Nut, plain, hex, 3/8-16

37 Resistance element

38 Screw, cap, hex-hd, 3/8-16 x 1/2 in.

39 Electrical contact

40 Contact bushing (2 rqr)

TM 5-4940-200-35

49

50

Figure 27. Circuit breaker, disassembly and reassembly.

TM 5-4940-200-35

51

1 Screw, hex-hd, brass, 5/16-18 x 1 3/4 in. (2 rqr)


3 Bus bar, left hand

4 Screw, machine, rd-hd, 14-20 x 1 1/4 in. (3 rqr)


6 Washer, flat, 1/4 in. (14 rqr)

7 Electrical lead

8 Nut, hex, No. 10-24 (6 rqr)


10 Washer, flat, brass, No. 10

(7 rqr)

11 Nut plain, hex, 1/4-20

(15 rqr)

12 Nut, 1/4-20 (spec)

13 Arc shield holder, rh

14 Screw, machine, hex-hd,

1/4-20 x 5/8 in.

15 Arc shield holder, lh

16 Overload trip assembly

17 Trip assembly block


No. 6-32 x 1 3/4 in.

19 Nut, lock No. 10-32

20 Overload reset button

21 Screw, machine, hex-rd,

5/16-18 x 3/4 in. (2 rqr)

22 Heat element (2 rqr)


24 Nut, lock, No. 6-32

25 Screw, machine, rd-hd, No. 6-32 x 3/4 in. (2 rqr)


27 Armature support

28 Arc shield

29 Armature shaft assembly

30 Movable yoke

31 Screw, machine, hex-hd,

No. 10-24 x 2 in.

32 Screw, cap, hex-hd, 1/4-20 x 1/2 in. (2 rqr)

33 Coil holddown bracket (2 rqr)

34 Switch mounting bracket

35 Spacer, 1/4 in. id, 13/32 in.

od, 3/4 in. lg (4 rqr)

36 Screw, machine, rd-hd, 1/4-20 x 1 3/4 in. (4 rqr)

37 Resistor, 30-ohm

38 Nut, hex, No. 6-32 (2 rqr)


40 Screw, machine, rd-hd, No. 6-32 x 1/2 in. (2 rqr)

41 Screw, pan-hd, No. 8-32 x

1/4 in. (4 rqr)

42 Resistor, 300-ohm

43 Electrical lead

44 Screw, machine, rd-hd, 1/4-20 x 1 3/4 in. (3 rqr)

45 Screw, machine, hex-hd, 1/4-20 x 1 in. (3 rqr)

46 Bus bar, short link

47 Bus bar, center

48 Contact assembly screw (2 rqr)

49 Screw, self-tapping, No. 8-32 x 1/2 in. (4 rqr)

50 Fixed contact (3 rqr)

51 Arc shield baffle (2 rqr)

52 Screw, machine, rd-hd, No. 10-24 x 1 1/2 in. (3 rqr)

53 Contact mount (3 rqr)

54 Movable contact (3 rqr)


No. 6-32 x 1/4 in. (4 rqr)

56 Electrical lead

57 Strap electrical connector

58 Relay coil

59 Fixed yoke


61 Mounting panel

62 Screw, thread-forming, No. 8-18 x 3/4 in.


TM 5-4940-200-35

52

(2) Inspect parts for cracks, breaks, chips, bends, or other damage. Repair or replace all defective parts.

c.

Reassembly and Installation.

(1) Position the dial plate (17, fig. 26) on the

front disk (12) and secure by installing the five drive screws (18).

(2) Install the two insulators (40), insulator block (39), four washers (22), two washers

(21) and screws (20) on the front disk

(12). Set this subassembly aside.

Note

Lubricate electrical contacts upon reassembly to assure proper operation. Use approved lubricant.

(3) Position the electrical contacts (34) and contact rings (9) in the control contact ring

(11) and secure by installing the four spring clips (35).

(4) Install the insulation plates (10) on the contact rings (9).

(5) Position the resistance element (37) on the contact ring (11) and secure with screw (38) and nut (36).

(6) Install the front disk (12), with attached parts, in the control contact ring (11). Set this subassembly aside.

(7) Position the clip (8) in the inside housing

(4) and secure with screw (5) and washers

(6 and 7).

(8) Secure the bracket (3) to the inside housing (4) with the two screws (1) and washers (2).

(9) Secure the three brackets (14) to the handwheel (19) with the three screws

(13).

(10) Insert the inside housing, with attached parts, in the control contact ring subassembly and secure with four screws

(32) and washers (33).

(11) Secure the three handwheel mounting brackets (14) to the front disk (12) with the six screws (16) and washers (15).

TM 5-4940-200-35

(12) Secure the two springs (30) to the variable resistor (31) with the two screws (28) and washers (29).

(13) Position the dial (26) on the case (27) and secure dial and case to the springs (30) with the four screws (25).

(14) Place the handwheel (23) on the variable resistor (31) and secure with the setscrew

(24).

(15) Install the field rheostat in the tenrange switch.

(16) Install the ten-range switch and field

rheostat on the control panel (par. 45).

(Refer to wiring diagram, fig. 1 or fig. 2).

Circuit Breaker 47.

a.


the circuit breaker and bracket.

b.


disassemble the circuit breaker.

Caution

Be very careful when handling the arc shield. It is extremely fragile.

c.


(1) Clean with a stiff brush and blow clean with dry, compressed air.

(2) Inspect the arc shield for cracks; breaks, or chips. Replace a defective arc shield.

(3) Inspect the armature shaft assembly for defective insulation or evidence of shorting of electrical current. Replace a defective armature shaft.

(4) Inspect the fixed and movable contacts for excessive wear, pits, or corrosion.

Remove corrosion with No. 00 sandpaper.

Replace a badly pitted contact.

(5) Inspect the yokes for wear or damage.

Repair or replace a worn or damaged yoke.

TM 5-4940-200-35

Figure 28. Battery-charging resistor box and resistors, removal and installation.

53

48.

a.

TM 5-4940-200-35

(6) Inspect the overlaid trip assembly for cracked or broken block, damaged bimetal thermal bracket, pitted contact points or maladjustment. Repair or replace a defective overload trip assembly.

(7) Inspect the mounting panel for cracks or breaks. Replace a defective mounting panel.

d.


the circuit breaker.

e.


the circuit breaker and bracket.

Section VIII. BATTERY-CHARGING RESISTORS AND RESISTOR BOX

General

The battery-charging resistors are used to control the rate of charge during any battery-charging operation.

A 2.38-ohm resistor is used during both high-and lowrate charging; the 10-ohm resistors, used during low-rate charging only, are connected in series with the 2.38-ohm resistor. The resistors are placed in the circuit by means of the battery-charging rate selector switch.

49.

Battery-Charging Resistor Box and Resistors

Removal.

(1) Refer to figure 5 and tag and disconnect

the battery-charging resistor electrical leads from the ammeter and batterycharging rate selector switch.

(2) Refer to figure 28 and remove the battery-

charging resistor box and resistors.

(2) Visually inspect the resistors for breaks, damage, and loose or broken terminals.

Replace a damaged or defective resistor.

(3) Use a multimeter and test the resistance of each resistor. Replace any resistor that does not have the rated resistance.

(4) Inspect the resistor box and all mounting hardware for damage or defects. Repair or replace the resistor box and replace all defective mounting hardware.

c.

Installation.

(1) Refer to figure 28 and install the battery-

charging resistors and resistor box.

(2) Refer to figure 5 and connect the battery-

charging resistor electrical leads to the ammeter and battery-charging rate selector switch.

b.


(1) Blow accumulated dust and dirt from the resistors with a stream of clean, dry, compressed air at low pressure.

Section IX. RECEPTACLE BOXES AND CABLES

51.

Receptacle Boxes and Cables 50.

General

Two 110-volt electrical receptacles are provided on the shop set body. These receptacles provide a convenient source of power at the front and rear of the body for the operation of electrical tools and equipment.

Power is transmitted through an armored cable connected at the rear of the 110-volt load terminals on the control panel.

a.

Removal.

(1) Refer to TM 5-4940-200-12 and remove the cover and receptacle.

(2) Refer to paragraph 23 and disconnect the

receptacle box cable leads at the control panel.

54

TM 5-4940-200-35

b.

Figure 29. Receptacle boxes and cables, removal and installation.

(3) Refer to figure 29 and remove the

receptacle box and cable.

c.

Installation.


(1) Clean the receptacle box with an approved cleaning solvent. Clean the armored cable with a stiff brush.

(2) Inspect the receptacle box for cracks or breaks. Replace a damaged receptacle box.

(3) Inspect the armored cable for cracks or breaks or other damage. Replace a damaged or defective cable.

(1) Refer to figure 29 and install the

receptacle box and cable.

(2) Refer to paragraph 23 and reconnect the

receptacle box cable leads at the control panel.

(3) Refer to TM 5-4940-200-12 and install the receptacle and cover.

52.

General

Section X. VEHICLE FRAME EXTENSION AND SHOP SET BODY

The shop set body is mounted on a 3/4-ton 4 by 4, modified truck frame. The body is constructed of aluminum with riveted joints. It has weathertight compartments on each side for storing tools and equipment. The compartments are designed to accommodate specific items so that the load is balanced. A generator-welder is mounted inside the body and can be operated by an integrated power takeoff or an outside electrical power source.

53.

Frame Assembly

a.

General. The frame assembly is a rear extension welded to the truck frame to provide support to the shop set body that is longer than the standard 3/,-ton truck body.

55

b.

Removal.


shop set body.

(2) Refer to TM 5-4940-200-12 and remove the taillights and taillight brackets.

(3) Refer to TM 9-8030 and remove the bumpers, lifting eyes, and pintle.

(4) Refer to figure 30 and remove the frame

assembly.

c.


(1) Clean with a steam cleaner.

(2) Inspect the frame for cracks and breaks or other damage. Repair cracks and breaks by welding. Replace a bent or sprung frame.

(3) If it becomes necessary to remove a component of the frame, replace it with a new part.

TM 5-4940-200-35

d.

Installation.

(1) Refer to figure 30 and install the frame

assembly.

Note

Aline and clamp each component in place before welding.

(2) Refer to TM 5-4940-200-12 and install the taillight brackets, and taillights.

(3) Refer to TM 9-8030 and install the bumpers, lifting eyes, and pintle.

(4) Refer to paragraph 24 and install the shop

set body.

54.

Shop Set Body

a.


the shop set body.

b.

Disassembly.

(1) Refer to TM 5-4940-200-12 and remove the doors, brackets, tailgate, tailgate chain, tailgate latch, access plates, door guides, cable hanger

56

Figure 30. Frame assembly, removal and installation.

TM 5-4940-200-35

5

6

7

8

9

3

4

1

2

Front panel assembly

Top panel

Top splash shield

Rivet, solid aluminum, 3/16 in. x 7/16 in. (488 rqr)

Left wheelhousing panel

Wheelhouse panel brace

Bottom splash shield

Splash shield hinge

Front body channel

Figure 31. Shop set body, model SECM, disassembly and reassembly.

57

TM 5-4940-200-35

10 Floor

11 Wheelwell (2 rqr)

12 Short floor support

13 Rear intermediate crossmember (2 rqr)

14 Rivet, solid, aluminum, 1/4 in. x 7/8 in. (97 rqr)

15 Power takeoff box left rail

16 Power takeoff box rear crossmember

17 Power takeoff box right rail

18 Power takeoff box front crossmember

19 Front crossmember

Figure 31--Continued.

58

20 Front intermediate crossmember

21 Wheelhouse crossmember

22 Long floor support

TM 5-4940-200-35

59

23 Right side compartment assembly

24 Drip ledge (2 rqr)

25 Rivet, aluminum, 1/8 IN. x 5/16 in. (56 rqr)

26 Shelf (6 rqr)

27 Shelf support (18 rqr)

28 Tank retainer

29 Shelf divider (2 rqr)

30 Lower shelf, right rear compartment

31 Right wheelhousing panel

32 Short drip ledge (2 rqr)

33 Rear body crossmember


brackets, cylinder rack assembly, striker plates, door moulding and seal, gage compartment door, hose bracket, control panel screen, cylinder guide, and hinged roof panel.


control panel.


power takeoff.


generator-welder.


battery-charging resistor box and resistors.


electrical receptacle boxes and cables.


engine overspeed relay (model SECM).


model SECM shop set body.

Disassemble the model CMU-5 shop set body in a similar manner.

c.


(1) Clean the shop set body with a steam cleaner to remove all dirt, oil, and dust.

(2) Inspect each compartment for loose rivets, dents, cracks, holes, or other damage.

(3) Repeen or replace all loose rivets, straighten dents, weld cracks or breaks, and patch and weld holes.

TM 5-4940-200-35

34 Conduit capnut

35 Conduit nut

36 Left side compartment assembly

60

37 Box connector

38 Shelf (short)

39 Bottom shelf (left rear compartment)

49 Shelf support (short)

41 Shelf (narrow) (2 rqr)

42 Gage compartment side


43 Gage compartment shelf

(2 rqr)

44 Tailgate channel (2 rqr)

(4) Inspect the floor, head panel, and top panel for dents, cracks, holes, or other damage.

(5) Straighten dents, weld cracks and breaks, and patch holes. Replace a badly damaged floor, head panel, or top panel.

d.

Reassembly.


model SECM shop set body. Reassemble the model CMU-5 shop set body in a similar manner.


engine overspeed relay (model SECM).


receptacle boxes and cables.


battery-charging resistor box and resistors.

TM 5-4940-200-35


generator-welder.


power takeoff.


control panel.

(8) Refer to TM 5-4940-200-12 and install the doors, brackets, tailgate, tailgate chain, tailgate latch, access plates, door guides, cable hanger brackets, cylinder rack assembly, striker plates, door moulding and seal, gage compartment door, hose bracket, control panel screen, cylinder guide, and hinged roof panel.

e.


the shop set body.

61

TM 5-4940-200-35

APPENDIX I

REFERENCES

1.

Dictionaries of Terms and Abbreviations

AR 320-5 Dictionary of United States Army Terms.

AR 320-50 Authorized Abbreviations and Brevity Codes.

2.

Field Maintenance

TM 5-764 Electric Motor and Generator Repair.

3.

Fire Protection

TM 5-687 Repairs and Utilities: Fire Protection Equipment and Appliances; Inspections, Operations, and Preventive Maintenance.

Ordnance Maintenance: Fire Extinguishers.

TM 9-1799

4.

Lubrication

LO 5-4940-200-12 Shop Equipment, Contact Maintenance, Truck Mounted: Set No. 3 (Southwest Truck

Body Co. Model SECM).

5.

Operator and Organizational Maintenance

TM 5-4940-200-12 Operator and Organizational Maintenance Manual, Shop Equipment, Contact

Maintenance, Truck Mounted, Set No. 3 (Southwest Model SECM) Serial No. S-3-628 through S-3-720 and (Davey Model CMU-5) Serial No. 33343 through 33343-234 FSN

4940-294-9518.

TM 9-8030 Operation and Organizational Maintenance, 3/4-Ton 4 x 4 Cargo Truck M37, 3/4-Ton 4 x

4 Command Truck M42, 3/4-Ton 4 x 4 Ambulance Truck M43, and 3/4-Ton 4 x 4

Telephone Installation Light Maintenance and Cable Splicing Truck V-41/GT.

6.

Painting and Preservation

TB ENG 60 Preservation and Painting of Serviceable Corps of Engineer Equipment.

62

TM 5-4940-200-35

7.

Preventive Maintenance

AR 750-5

TB 9-1870-1/1

TM 9-1870-1

Organization, Policies, and Responsibilities for Maintenance Operations.

Care and Maintenance of Pneumatic Tires; New Type Valve Assemblies for Inner Tubes.

Care and Maintenance of Pneumatic Tires.

TM 5-505

TM 9-2852

TM 9-6140-200-15

Maintenance of Engineer Equipment.

Welding, Theory and Application.

Storage Batteries: Lead-Acid Type.

TM 38-750

8.

Publication Indexes

The Army Equipment Record System and Procedures.

DA Pam 108-1 Index of Army Motion Pictures, Film Strips, Slides and Phono-Recordings.

DA Pam 310-1

DA Pam 310-2

DA Pam 310-3

DA Pam 310-4

Index of Administrative Publications.

Index of Blank Forms.

Index of Training Publications.

TM 5-4940-200-35P

Index of Technical Manuals, Technical Bulletins, Lubrication Orders, and Modification

Work Orders.

Index of Graphic Training Aids and Devices.

DA Pam 310-5

DA Pam 310-25

9.

Supply Publications

Index of Supply Manuals-Corps of Engineers.

TM 5-4940-200-20P Organizational Maintenance Repair Parts and Special Tool Lists. Shop Equipment,

Contact Maintenance, Truck Mounted: Set No. 3 (Southwest Model SECM) Serial No.

S-3-628 through S-3-720 and (Davey Model CMU-5) Serial No. 33343 through 33343-

234 FSN 4940-294-9518.

Field and Depot Maintenance Repair Parts and Special Tool Lists. Shop Equipment,

Contact Maintenance, Truck Mounted: Set No. 3 (Southwest Model SECM) Serial No.

S-3-628 through S-3-720 and (Davey Model CMU-5) Serial No. 33343 through 33343-

234 FSN 4940-294-9518.

63

TM 5-4940-200-35

Paragraph Page

Adapter drive, governor ----------------------

Adjustment:

Engine overspeed relay, model CMU-5 - -----------------------

Engine overspeed relay, model SECM -----------------------------

Engine speed governor -------------

Power takeoff. -------------------------

Alternating current voltmeter fails to register---------------------------------------

Ammeter fails to register:

Alternating current ---------------------

Battery-charging -----------------------

Direct current ----------------------------

Armature:

Exciter -------------------------------------

Generator-welder ----------------------

27

30d

29f

26e

38f

16

Battery-charging ammeter fails to register -----------------------------------------

17

Battery-charging resistor box and resistors-----------------------------------------

49

Body, shop set------------------------------------ 24, 54

Brake lock, electric------------------------------

Breaker, circuit ----------------------------------

32

47

Cables, receptacles boxes-------------------

Circuit breaker -----------------------------------

51

47

Lacks current ----------------------------

12

Will not stay closed -------------------

13

Clutch operating linkage bracket assembly --------------------------------------

39

Controls and instruments --------------------

Control panel -------------------------------------

Coupling flange, and declutcher ----------

Data. (see Tabulated data.)

Declutcher and coupling flange -----------

45

23

34

34

Description-----------------------------------------

Direct current ammeter or voltmeter fails to register -------------------------------

Electric brake lock ------------------------------

42a

42c

3

15

32

16

17

15

20

24

14

40

40

14

54

18, 56

27

52

54

52

14

14

14

27

24

20

36

14

14

14

36

44

17

28

28

2

INDEX

Engine speed fluctuates ----------------------

Engine speed governor -----------------------

9

26

Adjustment -------------------------------

26e

Engine overspeed relay, model CMU-5

30

Adjustment --------------------------------

30d

Engine overspeed relay, model SECM -

29

Adjustment -------------------------------

29f

Exciter armature- --------------------------------

42a

On-equipment testing-----------------

42

Exciter field group- ------------------------------

42e

On-equipment testing ----------------

42

Field and depot maintenance repair parts----------------------------------------------

Field rheostat -------------------------------------

Forms, record and report --------------------

Frame assembly --------------------------------

Frequency meter fails to register ---------

Generator-welder-------------------------------- 22, 43

Armature-----------------------------------

42c

On-equipment testing -------

42

6

46

2

53

18

Base- ----------------------------------------

22

Does not deliver rated output ------

11

General -------------------------------------

41

Testing during or after disassembly 43b

Will not start or come up to speed

10

Governor adapter drive------------------------

27

Governor, engine speed ---------------------

26

45

Instruments and controls --------------------

Linkage bracket assembly, clutch operating --------------------------------------

39

Maintenance repair parts, field and depot

6

Motor stator ----------------------------------------

42d


42


42

Exciter armature --------------

42a

Exciter field group-------------

42e

Generator-welder armature

42c

Motor stator ----------------------

42d

Revolving field------------------

42b

Paragraph Page

13

20

24

40

40

40

40

20

24

24

23

40

40

40

40

36

13

40

40

40

40

13

47

2

55

14

15, 40

40

40

15

13

40

40

13

20

20

44

64

Paragraph Page

Revolving field (continued)

Shunt field ---------------------------------

42f

Welding generator interpole group -------------------------------------

42h

Welding generator series field group -------------------------------------

42g

40

40

40

Overspeed relay, engine, model CMU-5

Overspeed relay, engine, model SECM

Panel, control ------------------------------------

30

29

23

24

23

17

Polarity fails to reverse------------------------

14 14

Power takeoff ------------------------------------- 21, 38 14, 33

Adjustment ------------------------------------

Noisy --------------------------------------------

38f

20

36

14

Universal joint and shaft assembly---

Upper linkage --------------------------------

Propeller shaft -----------------------------------

Receptacle boxes and cables --------------

Record and report forms----------------------

36

40

35

51

2

30

36

30

54

2

Repair parts, field and depot maintenance

6

Resistors, battery-charging resistor box and -----------------------------------------

49

13

Revolving field -----------------------------------

42b


Shaft assembly, power takeoff universal joint --------------------------------

42

36

54

40

40

30

Shaft, propeller ----------------------------------

35 30

Shop set body ----------------------------------- 24, 54

18, 56

Shunt field -----------------------------------------

42f 40


Specially designed tools and equipment

42

7

40

13

Special tools and equipment ---------------

Switch, field rheostat and ten-range ----

Tabulated data------------------------------------

5

46

4

4b

Exciter classification and rating --

Exciter repair and replacement standards ------------------------------

Generator-welder repair and replacement standards -----------

Motor-generator classification and rating ------------------------------

4e

4f

4a

13

47

2

3

3

4

2

TM 5-4940-200-35

Time standards -----------------------------

Welder classification End rating-------

Paragraph Page

Tabulated data (continued)

Motor-generator repair and replacement standards --------------

Schematic wiring diagrams ------------

4d

4g

4h

4c

3

6

6

3

47

Ten-range switch and field rheostat -----

Tools

Special -----------------------------------------

46

Specially designed -------------------------

Troubleshooting:

Alternating current ammeter or voltmeter fails to register ------------

Battery-charging ammeter fails to register--------------------------------------

Circuit breaker lacks current when on -----------------------------------

Circuit breaker will not stay closed---

Direct current ammeter or voltmeter fails to register ------------

Engine speed fluctuates -----------------

16

17

12

13

Frequency meter fails to register -----

General------------------------------------------

Generator-welder does not deliver rated output -------------------------------

Generator-welder will not start or come up to speed - ----------------

Polarity fails to reverse -------------------

Power takeoff noisy -----------------------

Welding are breaks down and cannot be maintained ----------------

Universal joint and shaft assembly, power takeoff --------------------------------

11

19

Upper linkage, power takeoff --------------

Voltmeter fails to register:

Alternating current ---------------------

Direct current ----------------------------

Welding are breaks down and cannot be maintained . ------------------------------

36

40

16

15

19

Welding generator interpole group ------

42h


42

Welding generator series field group ---

42g

On-equipment testing --------------------

42

10

14

20

15

9

18

8

5

7

13

13

14

14

14

14

13

13

14

14

14

30

36

14

14

14

13

14

13

14

40

40

40

40

65

DEVICE LEGEND:

A1 WELDER ARMATURE

A2

BCT

BR1

EXCITER ARMATURE

BATTERY-CHARGING TERMINALS

BATTERY-CHARGING BALLAST RESISTOR, 2.38-OHM

BR2

BR3

C1

C2

EF

F1, F2, F3

F4, F5, F6

HE

IP

K1

K2

K3

K3A

BATTERY-CHARGING RESISTOR, 100 WATT, 10 OHM

BATTERY-CHARGING RESISTOR, 100 WATT, 10 OHM

CAPACITOR (0.25 UF.500V/AC/DC)

CAPACITOR (0.10 UF.500V/AC/DC)

EXCITER FIELDS

FUSES, 10 AMPERE

FUSES, 30 AMPERE

OVERLOAD SWITCH HEAT ELEMENT (45 AMPERE)

INTERPOLE WINDING

NO VOLTAGE RELEASE COIL

REVERSE CURRENT RELAY

OVERSPEED RELAY SWITCH

AUXILIARY OVERSPEED RELAY SWITCH

M1

M2

M3

M4

M5

R4

R5

R6

R7

R8

RE1

RE2

M6

MS

OL

R1

R2

R3

AC VOLTMETER

FREQUENCY METER

DC VOLTMETER

DC AMMETER

HOUR METER

BATTERY-CHARGING AMMETER

CIRCUIT BREAKER

OVERLOAD RESET SWITCH

220-VOLT RECEPTACLE CONNECTOR






110-VOLT BODY OUTLET RECEPTACLE CONNECTOR (FRONT)

110-VOLT BODY OUTLET RECEPTACLE CONNECTOR (REAR)

60 CYCLE OPERATION RESISTOR. 30 OHM. 40 WATT

FIELD DISCHARGE RESISTOR. 300 OHM. 100 WATT

Figure 2. Schematic wiring diagram, model CMU-5.

RE3

RF

RH1

RH2

RH3

S1

S2

S3

S4

S5

S6

S7

SF

SHF

SM

WO

X1

OVERSPEED RESISTOR. 10.000 OHM. 50 WATT

REVOLVING FIELD

MOTOR OPERATION RHEOSTAT

ENGINE STARTING CONTROL RHEOSTAT

WELDING RHEOSTAT

WELDING POLARITY CONTROL SWITCH

WELD-OFF-ENGINE START SWITCH

TEN-RANGE SWITCH

REVERSE CURRENT RESET SWITCH

BATTERY-CHARGING RATE SELECTOR

MOTOR-GENERATOR SWITCH

50-60 CYCLE SELECTOR SWITCH

WELDER SERIES FIELD

SHUNT FIELD

ROTOR-GENERATOR STATOR

WELDING ELECTRODE TERMINALS

AMMETER SHUNT

TM 5-4940-200-35

By Order of the Secretary of the Army:

Official:

J. C. LAMBERT,

Major General, United States Army,

The Adjutant General.

EARLE G. WHEELER,

General United States Army,

Chief of Staff.

Distribution:

To be distributed in accordance with DA Form 12-32, Section III (Unclas) requirements for Nike-Ajax, Nike-

Hercules, Corporal, Redstone and Pershing-TM-Vehicles.

67

U. S. GOVERNMENT PRINTING OFFICE: 1963

TM 5-4940-200-35

PIN: 005973-000

This fine document...

Was brought to you by me:

Liberated Manuals -- free army and government manuals

Why do I do it? I am tired of sleazy CD-ROM sellers, who take publicly available information, slap “watermarks” and other junk on it, and sell it.

Those masters of search engine manipulation make sure that their sites that sell free information, come up first in search engines. They did not create it...

They did not even scan it... Why should they get your money? Why are not letting you give those free manuals to your friends?

I am setting this document FREE. This document was made by the US

Government and is NOT protected by Copyright. Feel free to share, republish, sell and so on.

I am not asking you for donations, fees or handouts. If you can, please provide a link to liberatedmanuals.com, so that free manuals come up first in search engines:

<A HREF= http://www.liberatedmanuals.com/ >Free Military and Government Manuals</A>

–

Sincerely

–

Igor Chudov

http://igor.chudov.com/

Chicago Machinery Movers

TM-5-4940-200-35

DEPARTMENT OF THE ARMY TECHNICAL MANUAL

TM 5-4940-200-35

FIELD AND DEPOT MAINTENANCE MANUAL

SHOP EQUIPMENT, CONTACT MAINTENANCE, TRUCK

MOUNTED, SET NUMBER 3 (SOUTHWEST MODEL SECM)

SERIAL NO. S-3-628 THROUGH S-3-730 AND

(DAVEY MODEL CMU-5) SERIAL NO. 33343

THROUGH 33343-234

FSN 4940-294-9518

HEADQUARTERS, DEPARTMENT OF THE ARMY

SEPTEMBER 1963

By Order of the Secretary of the Army:

Official:

J. C. LAMBERT,

Major General, United States Army,

The Adjutant General.

EARLE G. WHEELER,

General United States Army,

Chief of Staff.

Distribution:

To be distributed in accordance with DA Form 12-32, Section III (Unclas) requirements for Nike-Ajax, Nike-

Hercules, Corporal, Redstone and Pershing-TM-Vehicles.

This fine document...

Was brought to you by me:

Liberated Manuals -- free army and government manuals

Why do I do it? I am tired of sleazy CD-ROM sellers, who take publicly available information, slap “watermarks” and other junk on it, and sell it.

Those masters of search engine manipulation make sure that their sites that sell free information, come up first in search engines. They did not create it...

They did not even scan it... Why should they get your money? Why are not letting you give those free manuals to your friends?

I am setting this document FREE. This document was made by the US

Government and is NOT protected by Copyright. Feel free to share, republish, sell and so on.

I am not asking you for donations, fees or handouts. If you can, please provide a link to liberatedmanuals.com, so that free manuals come up first in search engines:

<A HREF= http://www.liberatedmanuals.com/ >Free Military and Government Manuals</A>

–

Sincerely

–

Igor Chudov

http://igor.chudov.com/

Chicago Machinery Movers

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