TM-9-6115-671-14
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 9249A/09246A-14
TECHNICAL MANUAL
OPERATOR, UNIT, DIRECT SUPPORT
HOW TO USE THIS MANUAL
AND GENERAL SUPPORT
PAGE viii
MAINTENANCE MANUAL
EQUIPMENT DESCRIPTION
AND DATA
PAGE 1-4
PRINCIPLES OF OPERATION
PAGE 1-17
CONTROLS AND INDICATORS
PAGE 2-1
OPERATOR PMCS
PAGE 2-14
OPERATOR TROUBLESHOOTING
PAGE 3-1
OPERATOR MAINTENANCE
PAGE 3-18
UNIT TROUBLESHOOTING
PAGE 4-10
UNIT MAINTENANCE
PAGE 4-49
GENERATOR SET,
SKID MOUNTED, TACTICAL QUIET
30 KW, 50/60 AND 400 HZ
MEP-805B (50/60 HZ) (NSN 6115-01-461-9335) EIC: GGU
MEP-815B (400 HZ) (NSN 6115-01-462-0290) EIC: GGV
DIRECT SUPPORT
TROUBLESHOOTING
PAGE 5-2
DIRECT SUPPORT
MAINTENANCE
PAGE 5-14
GENERAL SUPPORT
MAINTENANCE
PAGE 6-1
DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited
DEPARTMENTS OF THE ARMY AND THE AIR FORCE
AND HEADQUARTERS, MARINE CORPS
1 JULY 2000
PCN 182 092491 00
TM 9-6115-671-14
INSERT LATEST CHANGED PAGES, DESTROY SUPERSEDED PAGES
LIST OF EFFECTIVE PAGES
NOTE: The portion of the text affected by the changes is indicated by a vertical line in the
outer margins of the page. Changes to illustrations are indicated by miniature
pointing hands. Changes to wiring diagrams are indicated by shaded areas.
Dates of issue for original and changed pages are:
Original........ 0............1 July 2000
TOTAL NUMBER OF PAGES IS 490, CONSISTING OF THE FOLLOWING:
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A (B blank)
USA
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
WARNING PAGES
__________
WARNING
High voltage is produced when this generator set is in operation. Make sure
unit is completely shut down and free of any power source before
attempting any repair or maintenance on the unit. Failure to comply can
cause injury or death to personnel.
__________
WARNING
High voltage is produced when the generator set is in operation. Never
attempt to start the generator set unless it is properly grounded. Failure to
comply can cause injury or death to personnel.
__________
WARNING
High voltage is produced when the generator set is in operation. Never
attempt to connect or disconnect load cables while the generator set is
running. Failure to comply can cause injury or death to personnel.
__________
WARNING
DC voltages are present at generator set electrical components even with
generator set shut down. Avoid shorting any positive with ground/negative.
Failure to comply can cause injury to personnel and damage to equipment.
__________
WARNING
Metal jewelry can conduct electricity. Remove metal jewelry when working
on electrical system or components. Failure to comply can cause injury or
death to personnel by electrocution.
__________
WARNING
Diesel fuel is flammable and toxic to eyes, skin, and respiratory tract. Skin
and eye protection are required when working in contact with diesel fuel,
and avoid repeated or prolonged contact. Provide adequate ventilation.
Failure to comply can cause injury or death to personnel.
a
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
__________
WARNING
Fuels used in the generator set are flammable. When filling the fuel tank,
maintain metal-to-metal contact between filler nozzle and fuel tank opening
to eliminate static electrical discharge. Failure to comply can result in
flames and possible explosion and can cause injury or death to personnel
and damage to the generator set.
__________
WARNING
Fuels used in the generator set are flammable. Do not smoke or use open
flames when performing maintenance. Failure to comply can result in
flames and possible explosion and can cause injury or death to personnel
and damage to the generator set.
__________
WARNING
CARC paint is a health hazard. Wear protective eyewear, mask and gloves
when sanding CARC painted surfaces. Failure to comply can cause
personal injury.
__________
WARNING
Dry cleaning solvent is flammable and toxic to eyes, skin, and respiratory
tract. Skin and eye protection are required when working in contact with
dry cleaning solvent. Avoid repeated or prolonged contact. Work in
ventilated area only. Failure to comply can cause injury or death to
personnel.
__________
WARNING
Exhaust discharge contains deadly gases including carbon monoxide. Do
not operate generator set in an enclosed area unless exhaust discharge is
properly vented outside. Failure to comply can cause injury or death to
personnel.
__________
WARNING
Batteries give off a flammable gas. Do not smoke or use open flame when
performing maintenance. Failure to comply can cause injury or death to
personnel and equipment damage due to flames and explosion.
b
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
__________
WARNING
Hot engine surfaces and sparks from the engine and generator circuitry are
possible sources of ignition. When hot refueling with DF-1, DF-2, DF-A,
JP5 or JP8, avoid fuel splash and fuel spill. Do not smoke or use open flame
when performing refueling. Failure to comply can result in flames and
possible explosion and can cause injury or death to personnel and damage
to the generator set.
__________
WARNING
Hot exhaust gases can ignite flammable materials. Allow room for safe
discharge of hot gases and sparks. Failure to comply can cause injury or
death to personnel.
__________
WARNING
If necessary to move a generator set which has been operating in parallel
with another generator set, shut down both generator sets prior to
removing load cables or ground. Failure to comply can cause injury or
death to personnel by electrocution.
__________
WARNING
Engine exhaust is hot. When it is required to extend exhaust pipe through
flammable material (i.e., wall), shield the extension pipe to protect
personnel from burns and prevent fire hazard. Failure to comply can cause
injury to personnel, damage to equipment, and fire.
__________
WARNING
Prior to making any connections for parallel operation or moving a
generator set which has been operating in parallel, ensure there is no input
to the load output terminal board and the generator sets are shut down.
Failure to comply can cause injury or death to personnel by electrocution.
c
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
__________
WARNING
Cooling system operates at high temperature and pressure. Contact with
high pressure steam and/or liquids can result in burns and scalding. Shut
down generator set, and allow system to cool before performing checks,
services, and maintenance. Failure to comply can cause injury to personnel.
__________
WARNING
Cooling system operates at high temperatures. Hot coolant is under high
pressure and can spray when cooling system is opened. Shut down
generator set and allow to cool before servicing radiator. Failure to comply
can cause damage to equipment and injury to personnel.
__________
WARNING
In extreme cold weather, skin can stick to metal. Avoid contacting metal
items with bare skin in extreme cold weather. Failure to comply can cause
injury to personnel.
__________
WARNING
Battery acid can cause burns to unprotected skin. Wear protective gloves
and safety goggles. Failure to comply can cause injury to personnel.
__________
WARNING
Cleaning with compressed air can cause flying particles. When using
compressed air, wear protective glasses and use clean, low pressure air, less
than 30 psi (206.8 kPa). Failure to comply can cause eye injury.
__________
WARNING
Exhaust system can get very hot. Allow system to cool before performing
maintenance. Failure to comply can cause severe burns and injury to
personnel.
__________
WARNING
If not wrapped, hot exhaust pipe can cause burns. Wrap exhaust pipe with
protective material. Failure to comply can cause severe injury to personnel.
d
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
_________
WARNING
Lifting batteries from the battery tray can cause back strain. Ensure
proper lifting techniques are used when lifting batteries. Failure to comply
can cause personal injury.
_________
WARNING
Top housing panels can get very hot. Allow panels to cool down before
performing maintenance. Failure to comply can result in severe burns to
personnel.
__________
WARNING
Operating the generator set with any access door open exposes personnel to
a high noise level. Hearing protection must be worn when operating or
working near the generator set with any access door open. Failure to
comply can cause hearing damage to personnel.
__________
WARNING
Breathing ether fumes can cause fainting. Do not manually discharge or
deliberately inhale ether. Failure to comply can cause injury to personnel.
__________
WARNING
Operating the generator set with restricted air flow for cooling can cause
the generator set to overheat. Keep all access door inlet panels clear to
ensure maximum air flow for engine and generator cooling. Failure to
comply can result in poor engine performance and possible overheating and
automatic shutdown.
_________
WARNING
Generator is heavy. Obtain assistance when moving generator with hoist.
Failure to comply can cause injury to personnel.
e
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
__________
WARNING
When disconnecting or removing batteries, disconnect the negative lead
that connects directly to the grounding stud first. Disconnect the negative
end of the interconnection cable next. When installing batteries, reverse the
connection sequence. Failure to comply can cause serious personal injury.
FOR FIRST AID, REFER TO FM 21-11.
f
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/0246A-14
Technical Manual
No. 9-6115-671-14
Technical Order
No. 35C2-3-446-32
Technical Manual
No. 09249A/0246A-14
DEPARTMENTS OF THE ARMY
AND THE AIR FORCE
AND HEADQUARTERS, MARINE CORPS
Washington, DC, 1 July 2000
OPERATOR, UNIT, DIRECT SUPPORT AND GENERAL SUPPORT
MAINTENANCE MANUAL
FOR
GENERATOR, SKID MOUNTED,TACTICAL QUIET,
30 KW, 50/60 AND 400 HZ
MEP-805B (50/60 HZ) (NSN 6115-01-461-9335) (EIC:GGU)
MEP-815B (400 HZ) (NSN 6115-01-462-0290) (EIC:GGV)
Reporting Errors and Recommending Improvements.
You can help improve this manual. If you find any mistakes or if you know of a way to improve the
procedures, please let us know. Mail your letter, DA Form 2028 (Recommended Changes to
Publications and Blank Forms), or DA 2028-2 located in the back of this manual direct to:
Commander, U.S. Army Communications and Electronics Command (CECOM), ATTN: AMSELLC-LEO-D-CS-CFO, Fort Monmouth, New Jersey 07703-5000. You may also submit your
recommended changes by E-mail directly to [email protected] For Air Force, mail AFTO
Form 22 directly to Commander, Sacramento Air Logistics Center, ATTN: TILBA, McClellan AFB,
CA 95652-5990 (AFMC). For Marine Corps, mail NAVMC Form 10772 directly to Commander,
Marine Corps Logistics Bases (CODE 850), Albany, GA 31704-5000. A reply will be furnished to
you.
DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited
i
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
TABLE OF CONTENTS
Page
How To Use This Manual.............................................................................................................................................ix
Chapter 1
Section I
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
1.10
1.11
Section II
1.12
1.13
1.14
Section III
1.15
1.16
1.17
Chapter 2
Section I
2.1
2.2
2.3
2.4
Section II
2.5
2.6
Section III
2.7
2.8
2.9
2.10
2.11
2.12
2.13
2.14
Section IV
2.15
2.16
2.17
2.18
2.19
2.20
2.21
ii
Introduction
General Information.........................................................................................................1-1
Scope ...............................................................................................................................1-1
Limited Applicability.......................................................................................................1-1
Maintenance Forms and Records .....................................................................................1-1
Reporting of Errors ..........................................................................................................1-1
Preparation for Storage or Shipment................................................................................1-3
Quality Assurance ............................................................................................................1-3
Reporting Equipment Improvement Recommendation (EIR) ..........................................1-3
List of Abbreviations .......................................................................................................1-3
Levels of Maintenance .....................................................................................................1-4
Corrosion Prevention and Control ...................................................................................1-4
Destruction of Army Materiel to Prevent Enemy Use......................................................1-4
Equipment Description and Data .....................................................................................1-4
General.............................................................................................................................1-4
Tabulated/Illustrated Data................................................................................................1-4
Differences Between Models .........................................................................................1-15
Principles of Operation ..................................................................................................1-17
Introduction....................................................................................................................1-17
Principles of Operation ..................................................................................................1-17
Location and Description of Major Components...........................................................1-36
Operating Instructions
Description and Use of Operator Controls and Indicators ...............................................2-1
General.............................................................................................................................2-1
DCS Controls and Indicators ...........................................................................................2-1
Computer Interface Module (CIM) Display Screen Controls and Indicators...................2-4
Diagnostic Controls and Indicators..................................................................................2-8
Preventative Maintenance Checks and Services (PMCS) ..............................................2-14
General...........................................................................................................................2-14
PMCS Procedures..........................................................................................................2-14
Operation Under Usual Conditions................................................................................2-21
General...........................................................................................................................2-21
Generator Set Installation ..............................................................................................2-21
Assembly and Preparation for Use.................................................................................2-24
Initial Adjustments, Checks, and Self-Test ....................................................................2-27
Operating Procedure ......................................................................................................2-30
Parallel Unit Operation (Load Sharing) .........................................................................2-33
Remote Operation ..........................................................................................................2-36
Preparation for Movement .............................................................................................2-39
Operation Under Unusual Conditions............................................................................2-41
Operation in Extreme Cold Weather Below -25° F (-31° C) .........................................2-41
Operation in Extreme Heat Above 120° F (48.8° C) .....................................................2-42
Operation in Dusty or Sandy Areas................................................................................2-42
Operation Under Rainy or Humid Conditions ...............................................................2-43
Operation in Salt Water Areas .......................................................................................2-43
Operation at High Altitudes ...........................................................................................2-44
NATO SLAVE RECEPTACLE Start Operation ...........................................................2-44
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/0246A-14
TABLE OF CONTENTS (continued)
2.22
2.23
2.24
2.25
2.26
Chapter 3
Section I
3.1
Section II
3.2
Section III
3.3
Chapter 4
Section I
4.1
Section II
4.2
Section III
4.3
Section IV
4.4
Section V
4.5
Section VI
4.6
4.7
4.8
4.9
4.10
4.11
4.12
4.13
4.14
Section VII
4.15
4.16
Chapter 5
Section I
5.1
Section II
5.2
Section III
5.3
Page
Emergency Stopping ......................................................................................................2-44
Operation Using Battle Short Switch .............................................................................2-44
Nuclear, Biological, and Chemical (NBC) Decontamination Procedures......................2-45
Operation While Contaminated .....................................................................................2-46
Operation in a High Altitude Electromagnetic Pulse (HAEMP) Environment ..............2-46
Operator Maintenance Instructions
Lubrication Procedures ....................................................................................................3-1
Operator Lubrication Instructions....................................................................................3-1
Troubleshooting...............................................................................................................3-1
General.............................................................................................................................3-1
Symptom Index................................................................................................................3-1
Operator Maintenance Procedures.................................................................................3-18
Generator Set Inspection and Service ............................................................................3-18
Unit Maintenance Instructions
Inspecting and Servicing the Equipment..........................................................................4-1
Inspecting and Servicing the Equipment..........................................................................4-1
Repair Parts; Tools; Test, Measurement and Diagnostic
Equipment (TMDE); and Support Equipment .................................................................4-6
Introduction......................................................................................................................4-6
Lubrication Procedures ....................................................................................................4-6
Unit Lubrication Instructions ...........................................................................................4-6
Unit Preventive Maintenance Checks and Services (PMCS) ...........................................4-7
PMCS Procedures............................................................................................................4-7
Troubleshooting.............................................................................................................4-10
General...........................................................................................................................4-10
Symptom Index..............................................................................................................4-10
Unit Maintenance Procedures ........................................................................................4-49
Maintenance of DC Electrical System ...........................................................................4-49
Maintenance of Housing ................................................................................................4-57
Maintenance of DCS Control Box Assembly ................................................................4-77
Maintenance of Air Intake and Exhaust System ..........................................................4-141
Maintenance of Engine Cooling System ......................................................................4-152
Maintenance of Fuel System........................................................................................4-170
Maintenance of Output Box Assembly ........................................................................4-183
Maintenance of Engine Accessories ............................................................................4-194
Maintenance of Lubrication System.............................................................................4-204
Preparation for Shipment and Storage .........................................................................4-207
Preparation for Shipment and Storage .........................................................................4-207
CIM Configuration Switch...........................................................................................4-208
Direct Support Maintenance Instructions
Repair Parts; Tools; Test, Measurement and Diagnostic Equipment (TMDE); and Support
Equipment........................................................................................................................5-1
Introduction......................................................................................................................5-1
Lubrication Procedures ....................................................................................................5-1
Direct Support Lubrication Instructions...........................................................................5-1
Troubleshooting...............................................................................................................5-2
General.............................................................................................................................5-2
iii
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
TABLE OF CONTENTS (continued)
Section IV
5.4
5.5
5.6
5.7
5.8
5.9
5.10
5.11
Page
Symptom Index................................................................................................................5-2
Direct Support Maintenance Procedures........................................................................5-14
Removal and Installation of Major Components ...........................................................5-14
Maintenance of DCS Control Box Assembly ................................................................5-23
Maintenance of Cooling System ....................................................................................5-25
Maintenance of Fuel System..........................................................................................5-25
Maintenance of Output Box Assembly ..........................................................................5-29
Maintenance of Engine Accessories ..............................................................................5-43
Maintenance of Generator Assembly.............................................................................5-46
Maintenance of Skid Base .............................................................................................5-61
Chapter 6
General Support Maintenance Instructions ......................................................................6-1
Appendix A
References.......................................................................................................................A-1
Appendix B
Maintenance Allocation Chart (MAC)
Section I
Section II
Section III
Section IV
Introduction.....................................................................................................................B-1
Maintenance Allocation Chart (MAC)............................................................................B-4
Tools and Test Equipment for MEP-805B and 815B ...................................................B-13
Remarks ........................................................................................................................B-13
Appendix C
Section I
Section II
Section III
Components of End Item (COEI) and Basic Issue Items (BII) List
Introduction.....................................................................................................................C-1
Components of End Item ................................................................................................C-1
Basic Issue Items ............................................................................................................C-1
Appendix D
Section I
Section II
Additional Authorization List (AAL)
Introduction.....................................................................................................................D-1
Additional Authorization List .........................................................................................D-1
Appendix E
Section I
Section II
Expendable and Durable Items List
Introduction..................................................................................................................... E-1
Expendable and Durable Items List ................................................................................ E-1
Appendix F
Operator’s Lubrication Instructions ................................................................................ F-1
Appendix G
Illustrated List of Manufactured Items............................................................................G-1
Appendix H
Section I
Section II
Torque Limits
Introduction.....................................................................................................................H-1
Torque Limits .................................................................................................................H-1
Appendix I
Section I
Section II
Mandatory Replacement Parts
Introduction...................................................................................................................... I-1
Mandatory Replacement Parts ......................................................................................... I-1
Index ....................................................................................................................................................................Index-1
iv
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/0246A-14
TABLE OF CONTENTS (continued)
Page
Fold-outs
Schematic ................................................................................................................................................. FO-1
Wiring Diagram........................................................................................................................................ FO-3
Wire Harness, CIM Interface and Control Box ........................................................................................ FO-7
LIST OF ILLUSTRATIONS
Figure
1-1
1-2
1-3
1-4
1-5
1-6
1-7
1-8
1-9
1-10
1-11
1-12
1-13
1-14
1-15
1-16
1-17
1-18
1-19
1-20
1-21
1-22
1-23
1-24
1-25
1-26
1-27
1-28
1-29
1-30
2-1
2-2
2-3
2-4
2-5
2-6
2-7
2-8
2-9
2-10
2-11
2-12
Page
30 kW Tactical Quiet Generator Set ............................................................................................................1-2
Locations of Data Plates and Access Panels (Front and Right Side) ............................................................1-7
Locations of Data Plates and Access Panels (Rear and Left Side) ...............................................................1-8
Operating Instruction Plate, MEP-805B.......................................................................................................1-9
Operating Instruction Plate, MEP-815B.....................................................................................................1-10
Identification Plate, MEP-805B and MEP-815B .......................................................................................1-11
Set Rating Identification Plate, MEP-805B and MEP-815B ......................................................................1-11
Voltage Connection Caution Plate..............................................................................................................1-12
Grounding Stud Plate .................................................................................................................................1-12
NATO SLAVE RECEPTACLE Plate ........................................................................................................1-12
PARALLELING RECEPTACLE Plate......................................................................................................1-12
CONVENIENCE RECEPTACLE Plate, MEP-805B and MEP-815B.......................................................1-12
EXTERNAL FUEL SUPPLY Plate ...........................................................................................................1-12
Battery Connection Instruction Plate..........................................................................................................1-13
Lifting and Tiedown Diagram Plate ...........................................................................................................1-13
FUEL SYSTEM DIAGRAM Plate ............................................................................................................1-14
Generator Identification Plate (located on generator), MEP-805B and MEP-815B...................................1-14
COMMUNICATION RECEPTACLE Plate ..............................................................................................1-14
Fault System Flow Diagram .......................................................................................................................1-18
Governor Control System Flow Diagram ...................................................................................................1-20
Voltage Regulation System Flow Diagram.................................................................................................1-21
Fuel System Flow Diagram ........................................................................................................................1-22
Generator Set Cooling System Flow Diagram............................................................................................1-24
Engine Cooling System Flow Diagram.......................................................................................................1-26
Lubrication System Flow Diagram.............................................................................................................1-27
Engine Air Intake and Exhaust System Flow Diagram...............................................................................1-28
Output Supply System Flow Diagram ........................................................................................................1-30
Brushless Generator Schematic ..................................................................................................................1-32
Engine Starting System Flow Diagram.......................................................................................................1-34
30 kW Generator Set Components .............................................................................................................1-37
DCS Controls and Indicators........................................................................................................................2-2
CIM Display Screen Controls and Indicators ..............................................................................................2-5
Diagnostic Controls and Indicators ..............................................................................................................2-9
Base Mounting Measurements ...................................................................................................................2-22
Minimum Enclosure Clearance Measurements ..........................................................................................2-23
Grounding Connections..............................................................................................................................2-25
Installation of Load Cables.........................................................................................................................2-27
Generator Set Controls ...............................................................................................................................2-28
CIM Display Screen Controls and Indicators ............................................................................................2-32
Parallel Operation Setup.............................................................................................................................2-34
Remote PC Display Modes.........................................................................................................................2-40
Remote PC Setup........................................................................................................................................2-41
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ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
LIST OF ILLUSTRATIONS (continued)
Figure
2-13
3-1
3-2
3-3
3-4
3-5
3-6
4-1
4-2
4-3
4-4
4-5
4-6
4-7
4-8
4-9
4-10
4-11
4-12
4-13
4-14
4-15
4-16
4-17
4-18
4-19
4-20
4-21
4-22
4-23
4-24
4-25
4-26
4-27
4-28
4-29
4-30
4-31
4-32
5-1
5-2
5-3
5-4
5-5
5-6
5-7
5-8
5-9
5-10
vi
Page
NATO Slave Receptacle.............................................................................................................................2-45
Air Cleaner Element Replacement .............................................................................................................3-21
Crankcase Breather Filter Assembly ..........................................................................................................3-23
Coolant Recovery (Overflow) Bottle..........................................................................................................3-25
Fuel Tank Filler Neck.................................................................................................................................3-27
Fuel Filter/Water Separator ........................................................................................................................3-30
Dipstick and Oil Fill Cap............................................................................................................................3-31
Fuel Drain Valve and Oil Drain ...................................................................................................................4-4
Dipstick and Oil Fill Cap..............................................................................................................................4-6
Batteries and Cables ...................................................................................................................................4-51
NATO SLAVE RECEPTACLE and Cables ..............................................................................................4-52
Generator Set Access Doors.......................................................................................................................4-58
DCS Control Box Top Panel ......................................................................................................................4-61
Top Housing Section ..................................................................................................................................4-64
Front Housing Section................................................................................................................................4-69
Rear Housing Section .................................................................................................................................4-74
DCS Control Box Assembly.......................................................................................................................4-78
DCS Control Panel Lights DS1 Through DS3 and NETWORK FAILURE Light DS5.............................4-81
Time Meter and Switches ...........................................................................................................................4-84
DCS Control Panel Components ................................................................................................................4-91
CIM and Receptacles................................................................................................................................4-100
DCS Control Box Back Panel Components .............................................................................................4-108
DCS Control Box Floor Components.......................................................................................................4-119
Diode Identification..................................................................................................................................4-123
DCS Control Box Panels ..........................................................................................................................4-137
Muffler and Exhaust Pipe .........................................................................................................................4-143
Air Cleaner Assembly...............................................................................................................................4-145
Crankcase Breather Filter Assembly ........................................................................................................4-150
Cooling System ........................................................................................................................................4-153
Fan Guards ..............................................................................................................................................4-157
Fan Belt ....................................................................................................................................................4-165
Coolant Recovery System.........................................................................................................................4-169
Fuel Tank Filler Neck and Low Pressure Fuel System.............................................................................4-171
Ether Start System ....................................................................................................................................4-179
Output Box Assembly ..............................................................................................................................4-185
Load Output Terminal Board Assembly...................................................................................................4-192
Engine Switches and Senders ...................................................................................................................4-195
Battery Current Transducer ......................................................................................................................4-203
Oil Drain Valve ........................................................................................................................................4-206
Engine and Generator Assembly ................................................................................................................5-18
Fuel Tank....................................................................................................................................................5-28
Output Box Assembly ................................................................................................................................5-31
Output Box Components ............................................................................................................................5-37
Testing Current Transformer ......................................................................................................................5-38
Testing Droop Current Transformer...........................................................................................................5-39
Electric Actuator.........................................................................................................................................5-44
Generator Assembly Removal ....................................................................................................................5-48
Generator Assembly ...................................................................................................................................5-50
End Bell Removal ......................................................................................................................................5-51
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LIST OF ILLUSTRATIONS (continued)
Figure
5-11
5-12
5-13
G-1
G-2
G-3
G-4
G-5
G-6
G-7
G-8
G-9
G-10
G-11
G-12
G-13
G-14
G-15
G-16
G-17
G-18
G-19
G-20
G-21
G-22
Page
Rectifier Assembly .....................................................................................................................................5-55
Rotor Assembly Lifting Device (Typical) ..................................................................................................5-60
Skid Base....................................................................................................................................................5-63
Cable Assembly, AC Power (P/Ns 88-22126-1 through 88-22126-7).........................................................G-2
Cable Assembly, Battery (P/N 88-22178) ...................................................................................................G-3
Cable Assembly, Battery (P/N 88-22127) ...................................................................................................G-4
Cable Assembly, Battery (P/N 88-22181) ...................................................................................................G-5
Cable Assembly, Battery (P/N 88-22179) ...................................................................................................G-6
Cable Assembly, Battery (P/N 88-22207) ...................................................................................................G-7
Holder, Control Panel (P/N 88-22120)........................................................................................................G-8
Hose Assembly (P/N 88-20191-6) ..............................................................................................................G-9
Insulation, Panel, Top (P/N 88-22582) .....................................................................................................G-10
Insulation, Baffle (P/N 88-22592) .............................................................................................................G-11
Insulation, Panel, Top (P/N 88-22593) .....................................................................................................G-12
Insulation, Top, Center (P/N 88-22584)....................................................................................................G-13
Insulation, Top, Rear (P/N 88-22585).......................................................................................................G-14
Insulation, Front Housing (P/N 88-22591)................................................................................................G-15
Insulation, Top, Front (P/N 88-22586)......................................................................................................G-16
Insulation, Top, Center (P/N 88-22587)....................................................................................................G-17
Insulation, Top, Center (P/N 88-22588)....................................................................................................G-18
Insulation, Top, Front (P/N 88-22583)......................................................................................................G-19
Pump Assembly, Fuel (P/N 88-22546)......................................................................................................G-20
Solenoid Assembly (P/N 88-22553)..........................................................................................................G-21
Switch Assembly (P/N 88-22548) .............................................................................................................G-22
Wire, Varistor (P/Ns 88-20305-1 through 88-20305-3 and 88-20305-5)..................................................G-23
LIST OF TABLES
Table
1-1
1-2
2-1
2-2
2-3
2-4
2-5
2-6
2-7
3-1
3-2
3-3
3-4
4-1
4-2
4-3
Page
Tabulated Data .............................................................................................................................................1-5
Performance Characteristics .......................................................................................................................1-15
DCS Controls and Indicators........................................................................................................................2-3
CIM Display Screen Controls and Indicators ...............................................................................................2-6
Faults ............................................................................................................................................................2-7
Diagnostic Controls and Indicators ............................................................................................................2-11
Operator Preventive Maintenance Checks and Services (PMCS) ..............................................................2-16
Load Terminal and AC Reconnection Board Selection..............................................................................2-26
Fuel.............................................................................................................................................................2-42
Operator Troubleshooting ............................................................................................................................3-2
Coolant .......................................................................................................................................................3-26
Diesel Fuel..................................................................................................................................................3-28
Quick Reference General Inspection ..........................................................................................................3-32
Coolant .........................................................................................................................................................4-3
Fuel...............................................................................................................................................................4-5
Unit Preventive Maintenance Checks and Services (PMCS) .......................................................................4-8
vii
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LIST OF TABLES (continued)
Table
4-4
5-1
5-2
G-1
H-1
H-2
H-3
viii
Page
Unit Troubleshooting .................................................................................................................................4-12
Direct Support Troubleshooting ...................................................................................................................5-3
Generator Resistance Values at 25° C (77° F)............................................................................................5-56
Metric Conversion.....................................................................................................................................G-24
Torque Limits for Dry Fasteners .................................................................................................................H-1
Effect of Lubrication on Torque..................................................................................................................H-2
Torque Limits for Dry Fasteners (Metric) ...................................................................................................H-3
ARMY TM 9-6115-671-14
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HOW TO USE THIS MANUAL
In this manual (TM 9-6115-671-14) paragraphs are underlined and sections and chapters appear in capital letters.
The location of additional material that must be referenced is clearly marked. Illustrations in this text are located as
close as possible to their references.
Chapter 1 – INTRODUCTION. Contains general information, equipment description and data, and principles of
operation for the generator set.
Chapter 2 – OPERATING INSTRUCTIONS. Contains description and use of operator controls and indicators,
Preventive Maintenance Checks and Services (PMCS), procedures for inspecting and servicing the generator set, and
instructions for operating the generator set under usual and unusual conditions.
Chapter 3 – OPERATOR MAINTENANCE INSTRUCTIONS. Contains troubleshooting procedures used to
recognize and correct operator level generator set malfunctions, and all maintenance procedures authorized to be
performed on the generator set at the operator level.
Chapter 4 – UNIT MAINTENANCE INSTRUCTIONS. Contains troubleshooting procedures used to recognize and
correct generator set malfunctions at the unit level, and all maintenance procedures authorized to be performed on
the generator set at the unit level.
Chapter 5 – DIRECT SUPPORT MAINTENANCE INSTRUCTIONS. Contains direct support level troubleshooting
procedures used to recognize and correct generator set malfunctions at the direct support level, and all maintenance
procedures authorized to be performed on the generator set at the direct support level.
Chapter 6 – GENERAL SUPPORT MAINTENANCE INSTRUCTIONS. There are no general support level
maintenance tasks for the generator set.
APPENDICES.
Appendix A lists publications referenced in this manual and should be used in conjunction with this manual.
Appendix B is the Maintenance Allocation Chart (MAC) which designates all maintenance and repair functions
authorized to be performed at the different maintenance levels.
Appendix C lists the Components of End Item (COEI) and Basic Issue Items (BII).
Appendix D lists items authorized for use with the generator set, but not issued with it or supported by generator set
engineering drawings.
Appendix E is the Expendable/Durable Supplies and Materials List (EDSML) which lists all expendable/durable
supplies and materials required in performing the maintenance procedures presented in this manual.
Appendix F contains lubrication procedures for the generator set at the operator level.
Appendix G lists all parts that require fabrication or assembly for the maintenance of the generator set. Materials
and procedures required are included.
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HOW TO USE THIS MANUAL (continued)
Appendix H provides torque limits for fasteners used in maintenance of the generator set.
Appendix I lists parts that must be replaced when maintenance tasks require their removal.
Index. The index contains key technical manual subjects arranged in alphabetical order. To find information on a
specific subject (i.e., Time Meter), use the index to locate specific paragraph.
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x
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CHAPTER 1
INTRODUCTION
SECTION I. GENERAL INFORMATION
1.1
SCOPE.
1.1.1
Type of Manual.
This manual contains Unit, Direct Support, and General Support maintenance instructions for the Tactical
Quiet (TQ), 30 kW 50/60 and 400 Hz Generator Sets (Figure 1-1), herein referred to as generator sets.
Included are descriptions of major components and their functions in relation to other components.
1.1.2
1.2
Model Numbers and Equipment Names
Model Number
Equipment Name
MEP-805B
Generator Set,
Skid Mounted,
Tactical Quiet
30 kW 50/60 Hz
MEP-815B
Generator Set,
Skid Mounted,
Tactical Quiet
30 kW 400 Hz
LIMITED APPLICABILITY.
Some portions of this publication are not applicable to all services. These portions are prefixed to indicate
the service(s) to which they pertain: (A) for Army, (F) for Air force, and (MC) for Marine Corps. Portions
not prefixed are applicable to all services.
1.3
MAINTENANCE FORMS AND RECORDS.
(A) Maintenance forms and records used by Army Personnel are prescribed by DA PAM 738-750.
(F) Maintenance forms and records used by Air Force personnel are prescribed in AFI 21-101, AFI 37-160
and the applicable TO 00-20 Series Technical Orders.
(MC) Maintenance forms and records used by Marine Corps personnel are prescribed by TM 4700-15/1.
1.4
REPORTING OF ERRORS.
Reporting of errors, omissions, and recommendations for the improvement of this publication by the
individual user is encouraged. Reports should be submitted as follows:
(A) Army – Mail your letter, DA Form 2028 (Recommended Changes to Publications and Blank Forms),
or DA Form 2028-2 located in the back of this manual direct to: Commander, U.S. Army Communications
and Electronics Command (CECOM), Customer Feedback Office, ATTN: AMSEL-LC-LEO-D-CS-CFO,
Fort Monmouth, New Jersey 07703-5008
(F) Air Force – AFTO Form 22 in accordance with TO-00-5-1. Mail directly to Commander, Sacramento
Air Logistics Center, ATTN: TILBA, McClellan AFB, CA 95652-5990 (AFMC).
1-1
ARMY TM 9-6115-671-14
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FIGURE 1-1. 30 kW TACTICAL QUIET GENERATOR SET
1-2
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(MC) Marine Corps – by NAVMC form 10772 directly to Commanding General Marine Corps Logistics
Base (Code 850), Albany, GA 31704-5000.
1.5
PREPARATION FOR STORAGE OR SHIPMENT.
Refer to TB 740-97-2/TO 35-1-4 for procedures to place the generator set into storage. Refer to MIL-G28554 for procedures on preparing the generator set for shipment.
1.6.
QUALITY ASSURANCE (QA).
Where applicable, Quality Assurance (QA) requirements have been incorporated into the technical manual.
When required, each procedure, paragraph or step in this manual requiring quality assurance is highlighted
by the designation "(QA)".
1.7
REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATION (EIR).
If your 30 kW Generator needs improvement, let us know. Send us an EIR. You, the user, are the only one
who can tell us what you don’t like about your equipment. Let us know why you don’t like the design or
performance. Put it on an SF 368 (Product Quality Deficiency Report). Mail it to us at the address below.
We will send you a reply.
Commander
U.S. Army Communications and Electronics Command (CECOM)
Customer Feedback Office
ATTN: AMSEL-LC-LEO-D-CS-CFO
Fort Monmouth, New Jersey 07703-5008
1.7.1
(AF)
USAF Deficiency Reporting and Investigating System, TO 00-35D-54, Appendix A procedures
will be used for electronic submission. Submit mailed forms to:
SMALC/LHCABD
5029 Dudley Boulevard
McClellan AFB, CA 95652-1095
1.7.2
(MC) Quality Deficiency Reports (QDR) shall be submitted on SF 368 in accordance with MCO
4855.10. Submissions may also be made using NAVMC Form 10772. Submit directly to:
Commander
Marine Corps Logistics Bases
(Code 856)
Albany, GA 31704-5000
A reply will be furnished to you.
1.8
LIST OF ABBREVIATIONS.
AOAP
CIM
DCS
DS2
PC
PPE
STB
TQ
Army Oil Analysis Program
Computer Interface Module
Digital Control System
Decontaminating Solution Number 2
Personal Computer
Personal Protection Equipment
Supertropical Bleach
Tactical Quiet
1-3
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1.9
LEVELS OF MAINTENANCE.
1.9.1
(A) Army users shall refer to the Maintenance Allocation Chart (MAC) for tasks and levels of maintenance
to be performed.
1.9.2
(MC) Marine Corps users shall refer to the Source, Maintenance and Recoverability (SMR) Codes for
maintenance to be performed.
1.10
CORROSION PREVENTION AND CONTROL.
Refer to Corrosion and Corrosion Prevention: Metals, MIL-HDBK-729.
1.11
DESTRUCTION OF ARMY MATERIEL TO PREVENT ENEMY USE.
Destruction of the generator set to prevent enemy use shall be in accordance with TM 750-244-3.
SECTION II. EQUIPMENT DESCRIPTION AND DATA
1.12
GENERAL.
The generator set, models MEP-805B and MEP-815B (Figure 1-1) are fully enclosed, self-contained, skidmounted, portable units. They are equipped with controls, instruments, and accessories necessary for
operation as single units or in parallel with another unit of the same class and mode. The generator sets
include a diesel engine, brushless generator, cooling system, excitation system, governing system, fuel
system, 24 VDC starting system, DCS, and fault system.
1.13
TABULATED/ILLUSTRATED DATA.
1.13.1
For a list of Tabulated Data, refer to Table 1-1.
1.13.2
DATA PLATES. There are data plates at various locations on the generator set to provide instructions,
cautions, and identification. Figures 1-2 through 1-18 show the location and contents of each plate on the
generator set. The wiring diagram and schematic diagram data plates are located at the back of this manual
as fold-outs.
1-4
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TABLE 1-1. TABULATED DATA
MEP-805B
1.
2.
Generator Set:
a. National Stock Number
b. Overall Length
c. Overall Width
d. Overall Height
e. Dry Weight (less Basic Issue Items List)
f. Wet Weight
Engine:
a. Manufacturer
b. Model
c. Type
6115-01-461-9335
79.7 in. (202.5 cm)
35.7 in. (90.8 cm)
55 in. (139.7 cm)
2732 lb. (1239.2 kg)
2931 lb. (1329.5 kg)
6115-01-462-0290
79.7 in. (202.5 cm)
35.7 in. (90.8 cm)
55 in. (139.7 cm)
2732 lb. (1239.2 kg)
2931 lb. (1329.5 kg)
John Deere
4045TF151
Four cylinder, four cycle,
Turbocharged diesel
239 cu. in. (3.9 liters)
3.5% per 1000 ft. (305 m)
John Deere
4045TF151
Four cylinder, four cycle,
turbocharged diesel
239 cu. in. (3.9 liters)
3.5% per 1000 ft. (305 m)
1, 3, 4, 2
40°F (4°C) or below
1, 3, 4, 2
40°F (4°C) or below
0.014 in. (0.35 mm)
0.018 in. (0.45 mm)
0.014 in. (0.35 mm)
0.018 in. (0.45 mm)
b.
c.
d.
Pressurized radiator and
Pump
15.5 qts. (14.7 liters)
170-200°F (77-93°C)
24 VDC
Pressurized radiator and
pump
15.5 qts. (14.7 liters)
170-200°F (77-93°C)
24 VDC
e.
f.
Full flow, circulating pressure
Positive displacement gear
25-60 psi (172-414 kPa)
Full flow, spin-on
replacement element
15 qts. (14.2 liters)
24 VDC
Full flow, circulating pressure
Positive displacement gear
25-60 psi (172-414 kPa)
Full flow, spin-on
replacement element
15 qts. (14.2 liters)
24 VDC
DF-1, DF-2, DF-A,
JP5, JP8
23 gal. (87.05 liters)
2.60 gal. (9.8 liters) per
Hour
DF-1, DF-2, DF-A,
JP5, JP8
23 gal. (87.05 liters)
2.75 gal. (10.4 liters) per
hour
24 VDC
5.0-6.5 psi
(34.5-65.5 kPa) (max.)
24 VDC
5.0-6.5 psi
(34.5-65.5 kPa) (max.)
Stanadyne
DB4429-5281
Stanadyne
DB4429-5281
d.
e.
3.
4.
5.
MEP-815B
Displacement
Altitude Degradation,
4000 ft. (1220 m) to
8000 ft. (2440 m)
f. Firing Order
g. Cold Weather Starting Aid System Use
h. Valve Tappet Clearance Adjustment:
Hot or Cold (Intake)
Hot or Cold (Exhaust)
Cooling System:
a. Type
Capacity
Normal Operating Temperature
Temperature Indicating System
Voltage Rating
Lubricating System:
a. Type
b. Oil Pump Type
c. Normal Operating Pressure
d. Oil Filter Type
Capacity
Pressure Indicating System Voltage
Rating
Fuel System:
a. Type of Fuel
b.
c.
Fuel Tank Capacity
Fuel Consumption Rate
d.
Auxiliary Fuel Pump:
(1) Voltage Rating
(2) Delivery Pressure
e.
Injection Fuel Pump
(1) Manufacturer
(2) Model
1-5
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TABLE 1-1. TABULATED DATA (continued)
MEP-805B
5.
6.
Fuel System (continued);
f. Electric Actuator
(1) Manufacturer
(2) Model
Engine Starting System:
a. Batteries
Governors of America
ADC100-24
Governors of America
ADC100-24
Two 12 volt, connected in
series
Two 12 volt, connected in
series
Denso
RE 40595
24 VDC
Gear reduction
Denso
RE 40595
24 VDC
Gear reduction
Bosch
9 120 060 039
42 amps at 24 VDC
30 amps
Bosch
9 120 060 039
42 amps at 24 VDC
30 amps
Marathon Electric
Rotating field, synchronous
30 kW
88-21007
Marathon Electric
Rotating field, synchronous
30 kW
88-21008
60 Hz: 104 amps
50 Hz: 86 amps
60 Hz: 52 amps
50 Hz: 43 amps
0.8
Fan cooled
Direct coupling
Continuous
104 amps
0.8
Fan cooled
Direct coupling
Continuous
Governors of America
LSS100
Governors of America
LSS400
Governors of America
ESD5551
Governors of America
ESD5551
Governors of America
TCM100
Governors of America
TCM400
Governors of America
TCM102
Governors of America
TCM102
Governors of America
AVR100
Governors of America
AVR400
b.
7.
Starter:
(1) Manufacturer
(2) Model
(3) Voltage Rating
(4) Drive Type
c. Battery Charging Alternator:
(1) Manufacturer
(2) Model
(3) Rating
(4) Protective Fuse
AC Generator:
a. Manufacturer
b. Type
c. Load Capacity
d. Model
e. Current Ratings:
(1) 120/208 volt connection
MEP-815B
(2) 240/416 volt connection
8.
1-6
f. Power Factor
g. Cooling
h. Drive Type
i. Duty Classification
Digital Control System:
a. DCS Load Sharing Synchronizer:
(1) Manufacturer
(2) Model
b. DCS Speed Control Unit:
(1) Manufacturer
(2) Model
c. I/O Interface Module
(1) Manufacturer
(2) Model
d. Backplane Module
(1) Manufacturer
(2) Model
e. Automatic Voltage Regulator
(1) Manufacturer
(2) Model
52 amps
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FIGURE 1-2. LOCATIONS OF DATA PLATES AND ACCESS DOORS (FRONT AND RIGHT SIDE)
1-7
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FIGURE 1-3. LOCATIONS OF DATA PLATES AND ACCESS DOORS (REAR AND LEFT SIDE)
1-8
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FIGURE 1-4. OPERATING INSTRUCTION PLATE, MEP-805B
1-9
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FIGURE 1-5. OPERATING INSTRUCTION PLATE, MEP-815B
1-10
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FIGURE 1-6. IDENTIFICATION PLATE, MEP-805B AND MEP-815B
FIGURE 1-7. SET RATING IDENTIFICATION PLATE, MEP-805B AND MEP-815B
1-11
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1-12
FIGURE 1-8. VOLTAGE
CONNECTION CAUTION PLATE
FIGURE 1-9. GROUNDING STUD PLATE
FIGURE 1-10. NATO SLAVE
RECEPTACLE
FIGURE 1-11. PARALLELING
RECEPTACLE PLATE
FIGURE 1-12. CONVENIENCE
RECEPTACLE PLATE,
MEP-805B AND MEP-815B
FIGURE 1-13. EXTERNAL FUEL
SUPPLY PLATE
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FIGURE 1-14. BATTERY CONNECTION INSTRUCTION PLATE
FIGURE 1-15. LIFTING AND TIEDOWN DIAGRAM PLATE
1-13
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FIGURE 1-16. FUEL SYSTEM DIAGRAM PLATE
FIGURE 1-17. GENERATOR IDENTIFICATION PLATE (LOCATED ON GENERATOR),
MEP-805B AND MEP-815B
R EC EP TAC LE
FIGURE 1-18. COMMUNICATION RECEPTACLE PLATE
1-14
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1.14
DIFFERENCES BETWEEN MODELS.
1.14.1
The differences between generator set models covered in this manual are as follows:
1.14.2
a.
Model MEP-805B is equipped with a 50/60 Hz AC generator and three DCS modules which may
not be used on the MEP-815B (see Table 1-1).
b.
Model MEP-815B is equipped with a 400 Hz AC generator and three DCS modules which may
not be used on the MEP-805B (see Table 1-1).
Performance characteristics for the two models are shown in Table 1-2.
TABLE 1-2. PERFORMANCE CHARACTERISTICS
MEP-805B
1.
Voltage:
a. Voltage wave form deviation factor
Singe voltage harmonics
b. Voltage unbalance
c. Phase balance voltage
d. Voltage modulation
e. Voltage regulation
f. Short-term stability (30 seconds)
g. Long-term stability (4 hours)
h. Voltage drift (60°F [16°C] in 8-hour
period)
i. Dip and rise for rated load
Recovery time
j. Dip for low power factor load
Recovery time
k.
2.
Adjustment range VAC
120/208V connection
240/416V connection
120/208V connection
240/416V connection
Frequency:
a. Regulation
b. Short-term steady-state stability
(30 seconds)
c. Long-term steady-state stability
(4 hours)
d. Frequency drift (60°F [16°C] in 8 hour
period)
e. Undershoot with application of load
Recovery time
f. Overshoot with application of load
Recovery time
g. Adjustment range
MEP-815B
5% (max.)
2% (max.)
5% of rated voltage (max.)
1% of rated voltage (max.)
1% (max.)
1% (max.)
1% of rated voltage
2% of rated voltage
±1% (max.)
5% (max.)
2% (max.)
5% of rated voltage (max.)
1% of rated voltage (max.)
1% (max.)
1% (max.)
1% of rated voltage
2% of rated voltage
±1% (max.)
15% of rated voltage (max.)
0.5 seconds
30% of no-load voltage
(max.)
0.7 seconds 95% of no-load
voltage
50 Hz
190-213V
380-426V
60 Hz
197-240V
395-480V
12% of rated voltage (max.)
0.5 seconds
25% of no-load voltage
(max.)
0.7 seconds 95% of no-load
Voltage
400 Hz
195-229V
395-458V
0.25% of rated frequency
0.5% of rated frequency
0.25% of rated frequency
0.5% of rated frequency
1% of rated frequency
1% of rated frequency
0.5% (max.)
0.5% (max.)
4% of rated frequency (max.)
2 seconds
4% of rated frequency (max.)
2 seconds
48-52 Hz, not below 45 Hz
for 50 Hz operation
58-62 Hz, not above 65 Hz
for 60 Hz operation
1.5% of rated frequency (max.)
1 second
1.5% of rated frequency (max.)
1 second
390-420 Hz, not below 370
Hz or above 430 Hz
1-15
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14A
SECTION III. PRINCIPLES OF OPERATION
1.15
INTRODUCTION.
This section contains functional descriptions of the generator set. How the controls and indicators
interact with the system is explained as well as the location and description of major components.
1.16
PRINCIPLES OF OPERATION.
1.16.1
Digital Control System (DCS).
1.16.1.1
The DCS is a closed-loop system providing the operator with real-time system status information and
control. It includes automatic shutdown features if critical components fail to protect the generator set
from damage and to prevent damaging output power and voltage levels. It includes a digital computer
using software to process inputs from the generator set and from the operator. The DCS accepts
operator commands to adjust various generator set parameters such as frequency and voltage. The
DCS also facilitates operating two or more generator sets in parallel. The DCS can be operated at the
generator set or from a remote location using an IBM-compatible personal computer (PC)
1.16.1.2
In the event that the computer operating software is lost or operating incorrectly, the software must be
restored. Procedures are provided for TQG remote software restoration in Paragraph 2.13.2.
1.16.1.3
Eight major components or modules are included in the DCS: The DCS speed control unit, automatic
voltage regulator, load sharing synchronizer, I/O interface module, backplane module, electric actuator,
computer interface module (CIM), and keypad assembly. The DCS provides multiple, integrated
functions as the controller of the fault, governor, and voltage regulation systems, as described below.
1.16.1.4
The CIM is the primary operator interface with the DCS. It is a self-contained IBM compatible
computer with an AMD 486 processor running the Windows CE operating system. An internally lit
Liquid Crystal Display (LCD) screen provides the operator with status displays and control capability.
A cursor symbol on the display is controlled by the keypad assembly, which is a set of four arrow keys
and a SELECT key to enter commands. The load sharing synchronizer is used when paralleling the
generator set to a main bus or to another generator set. This module provides signals to the DCS speed
control unit to adjust engine speed settings to maintain a match between the outputs of the two
generator sets. The I/O interface module controls and interfaces with all the other components in the
DCS. For example, it receives inputs from engine sensors and converts them for use by the CIM. Most
of the DCS signals, including control panel inputs, are routed through this module. The status of the
I/O interface module is indicated by a green HEARTBEAT light emitting diode (LED) which blinks at
a rate of approximately two times per second to indicate the module is operational.
The backplane module is an installation point for three DCS modules and for the main electrical
connectors from the AC generator. It connects the front panel switches and these DCs modules with
the I/O interface module. This module simplifies the wiring inside the DCS control box by placing
many interconnections onto one circuit board assembly. This module also includes diagnostic
indicators for the DCS. The other DCS modules are discussed in paragraphs below.
1.16.2
Fault System.
1.16.2.1
The Fault System (Figure 1-19) protects the generator set and any connected load against the potential
faults described below and provides an indication of any incurred fault. The following summary of the
Fault System will assist in understanding the operation of other generator set systems. Additional
details relating to specific protection devices are provided in the descriptions of the respective systems.
1-16
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
FIGURE 1-19. FAULT SYSTEM FLOW DIAGRAM
1-17
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14A
1.16.2.2
The Fault System consists of the CIM, I/O interface module, fuel level sender, oil pressure sender,
coolant temperature sender, and BATTLE SHORT switch.
1.16.2.3
Inappropriate signals received from the senders by the I/O interface module will cause the CIM to
display the fault, and a message describing the condition causing the fault, on the CIM display screen.
Depending on the nature of the fault, the generator set will shut down or the operator will be warned
that action must be taken to avoid shutdown.
1.16.2.4
Activation of the fault system will cause two events to occur. The AC interrupter relay will open and
CONTACTOR POSITION status indicator on CIM display screen will indicate OPEN.
1.16.2.5
Although it is possible for more than one fault to occur at one time during operation, and for more than
one fault to be displayed on the CIM display screen at a time, only the first fault to occur will cause a
message to appear in the MESSAGES display area of the CIM display screen. Once the condition
addressed in that message has been corrected by the operator, the operator will activate the FAULT
RESET switch, and the next message will be displayed.
1.16.2.6
After the generator set engine has been started, the BATTLE SHORT switch may be used to override
all potential faults except engine overspeed and short circuit.
1.16.3
Governor Control System.
1.16.3.1
The governor control system (Figure 1-20) includes the DCS speed control unit, electric actuator, DCS
load sharing synchronizer, magnetic pickup, fuel injection pump, and FREQUENCY SELECT switch.
1.16.3.2
The electric actuator controls the output of the fuel injection pump in response to the electrical input
from the DCS speed control unit. The DCS provides a signal representing the desired engine
speed/generator frequency to the DCS speed control unit. A signal representative of the actual engine
speed/generator frequency is sent to the DCS speed control unit by the magnetic pickup. Any change
in engine speed from that selected by the operator, as sensed by the magnetic pickup, causes the DCS
speed control unit to increase or decrease fuel injection pump output to maintain the desired speed.
Generator set frequency and power output are indicated on the CIM display screen. The
FREQUENCY SELECT switch is used to set the generator for 50 hertz or 60 hertz operating
frequencies (MEP-805B only).
1.16.3.3
Twenty-four VDC power is supplied to the DCS speed control unit through the governor control power
relay. The governor control power relay is controlled by the fault system. The DCS speed control
units of two generator sets operating in parallel are interconnected by the paralleling cable.
1.16.4
Voltage Regulation System.
The Voltage Regulation System (Figure 1-21) consists of the automatic voltage regulator and power
potential transformer. The automatic voltage regulator senses and controls generator output voltage
which is operator adjustable within the design limits by use of the VOLTAGE ADJUST switch. The
power potential transformer provides operating power to the automatic voltage regulator module.
Generator output voltage is indicated on the CIM display screen.
1.16.5
Fuel System.
1.16.5.1
The Fuel System (Figure 1-22) includes a primary subsystem and an auxiliary subsystem.
1.16.5.2
The primary subsystem consists of fuel lines, fittings, fuel tank, fuel level sender, transfer pump, fuel
filter/water separator, injection pump, DCS speed control unit, and injectors. The injection pump
includes a 24 VDC fuel shutoff valve.
1-18
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
FIGURE 1-20. GOVERNOR CONTROL SYSTEM FLOW DIAGRAM
1-19
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14A
FIGURE 1-21. VOLTAGE REGULATION SYSTEM FLOW DIAGRAM
1-20
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
FIGURE 1-22. FUEL SYSTEM FLOW DIAGRAM
1-21
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14A
1.16.5.3
The injection pump output is controlled by the DCS speed control unit and electric actuator. The DCS
speed control unit is energized whenever the ENGINE CONTROL switch is in the START position or
either of the two RUN positions. With the engine cranking or running, fuel is drawn from the fuel tank
by the transfer pump. After reaching the transfer pump, fuel passes through a fuel filter/water separator
where water and small impurities are removed. The fuel then goes to the injection pump. With the
governor system energized, the fuel is metered, pressurized and pushed through the injectors by the
injection pump. Fuel is sprayed by the injectors into the diesel engine combustion chambers where it is
mixed with air and ignited. Fuel that is not used by the injectors is returned to the fuel tank by an
excess fuel return line. Power is removed from the DCS speed control unit, and the fuel is shut off
whenever the ENGINE CONTROL switch is set to the OFF position. The DCS speed control unit is
also de-energized by the fault system, paragraph 1.14.2. The CIM display screen FUEL LEVEL
indicator displays the fuel level of the fuel tank from E (empty) to F (full) expressed as percent
remaining.
1.16.5.4
The auxiliary subsystem consists of an auxiliary fuel supply, fuel lines, fittings, and an auxiliary fuel
pump.
1.16.5.5
When the ENGINE CONTROL switch is set on PRIME & RUN AUX FUEL, it actuates the auxiliary
fuel pump and transfers fuel from the auxiliary fuel supply to the fuel tank. The CIM shuts off the
auxiliary fuel pump when the fuel tank is full and reactivates the pump as the level drops.
1.16.5.6
The 24 VDC control circuits provide control and power for indicators, fault system, DCS, and auxiliary
fuel pump.
1.16.6
Mechanical System.
1.16.6.1
The mechanical system provides protection from the elements, structural integrity, transportability,
noise suppression, and the cooling system for the generator set. The generator set cooling system is
described separately below.
1.16.6.2
The mechanical system consists of the housing, insulation, air baffles, and skid base.
1.16.6.3
The generator set housing is insulated to provide "tactical quiet" noise suppression which makes
detection of the generator set by it's audio signature more difficult under battle conditions. Air baffles
allow for airflow to cool the generator set with as little impact as possible to the generator set's noise
output.
1.16.6.4
The skid base provides a stable base for the generator set during operation and transport, and allows the
generator set to be moved by forklift or mounted on a trailer.
1.16.7
Generator Set Cooling System.
1.16.7.1
The Generator Set Cooling System (Figure 1-23) includes air intake and exhaust grilles, baffles, and
ducting within the generator set housing and the engine driven radiator cooling fan. The air intake
grilles are located in panels on both sides of the generator set housing. The air exhaust grille is located
in the housing top panel.
1.16.7.2
Air is drawn in through the air intake grilles and forced through the engine coolant radiator and out of
the generator set through the exhaust grille by the radiator cooling fan. Most of the cooling air flows
externally past the generator assembly and engine. Some cooling air is circulated internally through the
generator assembly by a generator fan which is an integral part of the AC generator assembly. Baffles,
ducting, and sound absorbing material are used to control the air flow through the generator set and to
reduce sound transmission through the grilles.
1-22
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
FIGURE 1-23. GENERATOR SET COOLING SYSTEM FLOW DIAGRAM
1-23
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14A
1.16.8
Engine Cooling System.
1.16.8.1
The Engine Cooling System (Figure 1-24) consists of a radiator, hoses, thermostat, coolant temperature
sender, CIM display screen COOLANT TEMP indicator, water pump, oil cooler, cooling fan, and
cooling jackets (part of engine).
1.16.8.2
The water pump forces coolant through passages (cooling jackets) in the engine block and cylinder
head where the coolant absorbs heat from the engine. When the engine reaches normal operating
temperature, the thermostat opens and the heated coolant flows through the upper radiator hose
assembly into the radiator. The cooling fan circulates air through the radiator where the coolant
temperature is reduced.
1.16.8.3
The DCS, in conjunction with the fault system, provides automatic shutdown in the event coolant
temperature exceeds 230 ± 5°F (110 ± 3°C). The CIM display screen COOLANT TEMP indicator
indicates the engine coolant temperature from 100°F to 250°F (38°C to 121°C).
1.16.8.4
The water pump also circulates coolant through the engine oil cooler to cool the engine oil.
1.16.9
Lubrication System.
1.16.9.1
The Engine Lubrication System (Figure 1-25) consists of an oil pan, dipstick, pump, oil cooler, oil
sample valve, oil pressure sender, CIM display screen OIL PRESSURE indicator, oil drain valve, and
filter.
1.16.9.2
The oil pan is a reservoir for engine lubricating oil. The dipstick indicates oil level in the pan. The oil
level can be checked during engine operation. One side of the dipstick is used for checking oil level
while the engine is running and the other side is used while the engine is shut down. The pump draws
oil from the oil pan through a screen which removes large impurities. The oil then passes through tubes
in the oil cooler. Engine coolant from the engine cooling system is circulated around the tubes to cool
the oil. From the cooler, oil passes through a spin-on type filter where small impurities are removed.
From the filter, oil is distributed to the engine and turbocharger moving parts and then returns to the oil
pan. The oil pressure sender located in the engine block senses oil pressure. Oil pressure is displayed
on the CIM display screen OIL PRESSURE indicator. An Army Oil Analysis Program (AOAP)
sample valve located in the block allows oil samples to be taken while the engine is operating. The
DCS automatically shuts off the engine if oil pressure drops below 15 ± 3 psi (103.4 ± 20.7 kPa).
1.16.10
Engine Air Intake and Exhaust System.
1.16.10.1
The Engine Air Intake and Exhaust System (Figure 1-26) consists of an air cleaner assembly, intake
manifold, ether supply tank, ether solenoid valve, ETHER START switch, exhaust manifold,
turbocharger, muffler, and crankcase breather filter. The air cleaner assembly includes a dust collector,
filter element, restriction indicator, and dust evacuator valve.
1.16.10.2
Air is drawn into the dust collector and passes through the filter element. Airborne dirt is removed and
trapped in the dust collector and filter element. Some dust can be removed from the dust collector by
pinching the evacuator valve. The restriction indicator indicates when the filter should be serviced.
Filtered air is drawn out of the filter through air intake tubes into the turbocharger where it is
compressed and forced into the engine.
1-24
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
FIGURE 1-24. ENGINE COOLING SYSTEM FLOW DIAGRAM
1-25
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14A
FIGURE 1-25. LUBRICATION SYSTEM FLOW DIAGRAM
1-26
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
FIGURE 1-26. ENGINE AIR INTAKE AND EXHAUST SYSTEM FLOW DIAGRAM
1-27
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14A
1.16.10.3
Engine exhaust gases are expelled into the exhaust manifold and ported to the turbine of the
turbocharger. The turbine drives the turbocharger compressor which compresses the intake air.
Exhaust gases discharged by the turbocharger are channeled into the muffler that deadens the sound of
the exhaust gases. Gases pass from the muffler through the muffler outlet and are vented upward from
the generator set housing. A cover, which is held open by the pressure of the exhaust gases during
operation, closes over the exhaust port to prevent rain, water, or other foreign matter from entering the
exhaust port when the set is not in use. The cover is easily removed for connection of an exhaust pipe
for indoor operation.
1.16.10.4
Combustion gases, which enter the crankcase, are filtered through the crankcase breather filter to
remove oil droplets and are then recycled through the intake manifold.
1.16.10.5
An ether supply system is provided to improve engine starting when outside ambient air temperature is
below 40°F (4°C). The ether system includes an ether supply tank, ether solenoid valve, ETHER
switch, and piping from the solenoid valve to the intake manifold. The ether system is activated by
turning the ENGINE CONTROL switch to START and momentarily holding the ETHER switch in the
ON position while continuing to crank engine.
1.16.10.6
Air in the engine crankcase is drawn out the right side of the engine through a rubber hose and into the
crankcase breather filter assembly. There the air swirls around, leaving oil particles in the removable
filter, and leaves through a second rubber hose. The air then passes through this output hose into the
engine air cleaner assembly output hose. That is, the filtered air from the crankcase enters the engine
intake air flow downstream of the intake air filter. Engine intake air flow is then compressed with the
turbocharger, enabling filtered crankcase air to be recycled into the engine intake air and used in the
combustion process of the engine.
1.16.11
Output Supply System.
1.16.11.1
The Output Supply System (Figure 1-27) consists of the AC generator, ground fault circuit interrupter,
CONVENIENCE RECEPTACLE, current transformer, voltage reconnection terminal board, AC
circuit interrupter, load output terminals, AC CIRCUIT INTERRUPT switch, load sharing
synchronizer, automatic voltage regulator, CIM display screen FREQ gage, VOLTAGE gage, and
POWER gage.
1.16.11.2
Power created by the generator is supplied through the current transformer, voltage reconnection
terminal board, and AC circuit interrupter to the load output terminals. The voltage reconnection
terminal board allows configuration of the generator set for 120/208 volt connections or 240/416 volt
connections. The AC CIRCUIT INTERRUPT switch closes and opens the AC circuit interrupter. This
enables or interrupts power flow between the voltage reconnection terminal board and load output
terminals. The voltage regulation system (paragraph 1.14.4) senses generator output voltage and
provides a control signal to the generator exciter to maintain the desired generator output voltage.
Generator output frequency is controlled by the governor control system (paragraph 1.14.3) and is read
on the CIM display screen FREQ gage (Hz). The current transformer provides a reduced current signal
to the DCS and CIM display screen GEN CURRENT indicators (amps AC). The CIM display
POWER gage (kW) provides an indication of the power being used by the load. The GEN
AMMETER indicates rated current in amps required by the load. The AC circuit interrupter will open
and disconnect the load whenever any of the following faults occur: reverse power, undervoltage,
overload, overspeed, low oil pressure, high water temperature, or short circuit.
1.16.11.3
The AC generator also provides 120 VAC power to the CONVENIENCE RECEPTACLE through the
GROUND FAULT CIRCUIT INTERRUPTER.
1-28
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
FIGURE 1-27. OUTPUT SUPPLY SYSTEM FLOW DIAGRAM
1-29
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14A
1.16.12
Generator Assembly.
1.16.12.1
General. Revolving field type generators have a DC field revolving within a stationary AC winding
called the stator. See brushless generator schematic, Figure 1-28. AC power is distributed from the
generator through leads connected to the stator windings. There are no sliding contacts between the
AC winding and the load, therefore, great amounts of power may be drawn from this generator.
To energize the field, DC excitation must be applied to the generator field coils. The excitation current
is supplied from a brushless exciter mounted on the generator shaft.
The brushless exciter is actually an AC generator with its output rectified through a full wave bridge
circuit. This type of brushless exciter will provide the necessary excitation current. The generator set
field flash circuit, activated during each engine start, applies voltage to the exciter stator to begin the
voltage build-up process to energize the generator field.
The generator output voltage is controlled by controlling the alternating field current. This is
accomplished by regulating the exciter field coil voltage. The exciter field coil voltage is regulated
with a solid state type automatic voltage regulator.
1.16.12.2
Damper Bars. Damper bars are inserted through the field laminations and welded at the end to a solid
copper plate. The damper windings provide stable parallel operation, reduce damping current losses,
and limit the increase of third harmonic voltage with increase in load.
1.16.12.3
Brushless Exciter. The brushless exciter consists of an armature with a three-phase AC winding and
rotating rectifier assembly within a stationary field.
The stationary exciter field assembly is mounted in the main generator frame. The exciter armature is
press fit and keyed onto the shaft assembly. The rotating rectifier assembly slides over the bearing end
of the generator rotor shaft and is secured with bolts and washers to an adapter hub which is shrunk on
the generator shaft.
1.16.12.4
Rotating Rectifier Bridge. The rotating rectifier bridge consists of rectifying diodes mounted on a
brass heat sink which is in turn mounted on an insulating ring. The entire assembly bolts to the adapter
on the generator shaft. Therefore, the rotating rectifier assembly will rotate with the exciter armature
eliminating the need for any sliding contacts between the exciter output and the alternator field.
1.16.12.5
Exciter Field. The exciter field on the high frequency exciter consists of laminated segments of high
carbon steel which are fitted together to make up the field poles. The field coils are placed into the
slots of the field poles.
1.16.12.6
Exciter Field Coil Voltage Source. Field coil DC voltage is obtained by rectifying the voltage from a
phase to neutral line of the generator output, or other appropriate terminal, to provide the needed
voltage reference.
The rectifier bridge is an integral part of the static regulator. The static regulator senses a change in the
generator output and automatically regulates current flow in the exciter field coil circuit to increase or
decrease the exciter field strength. An external adjust rheostat sized to be compatible with the regulator
is used to provide adjustment to the regulator sensing circuit.
1.16.12.7
1-30
Balance. The rotor assembly is precision balanced to a high degree of static and dynamic balance.
Balance is achieved with the balance lugs on the field pole tips. The balance will remain dynamically
stable at speed in excess of the design frequencies.
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
FIGURE 1-28. BRUSHLESS GENERATOR SCHEMATIC
1-31
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14A
1.16.12.8
Bearing. The generator rotor assembly is suspended on shielded, factory lubricated ball bearings.
They are greased for life and do not require lubrication.
1.16.12.9
Stator Assembly. The stator assembly consists of laminations of steel mounted in a rolled steel frame.
Random wound stator coils are fitted into the insulated slots.
1.16.13
Generator Set Controls.
1.16.13.1
Engine Starting System.
1.16.13.1.1 Engine starting is accomplished primarily with two 12 volt batteries, connected in series to provide 24
VDC power, and a starter (Figure 1-29). The starter includes a cranking motor and a solenoid. To
permit engine starting, the DC CONTROL POWER circuit breaker must be pushed in, the DEAD
CRANK switch must be in the NORMAL position, and the BATTLE SHORT switch must be in the
OFF position. In addition, any ENGINE SHUTDOWN fault previously registered on the CIM display
screen must have been corrected by activating the FAULT RESET switch.
When the ENGINE CONTROL switch is then placed in the START position, the starting circuits
supply 24 VDC power to the starter. As the engine accelerates to approximately 900 RPM, the DCS
speed control unit disconnects power from the starter.
1.16.13.1.2 When the ENGINE CONTROL switch is first moved to the START position, the control modules are
energized. The Engine Starting System includes three control circuits. One starting control circuit
energizes the K2 relay through closed switch contacts of the crank disconnect relay. The second
starting control circuit signals the I/O interface module. With the K2 relay energized, power passes
from the batteries through closed contacts of the K2 relay to energize the starter solenoid. With the
starter solenoid energized, power passes from the starter solenoid to the cranking motor. The cranking
motor then cranks the engine. Engine speed is sensed by the magnetic pickup which sends a signal to
the DCS speed control unit. As the engine accelerates to approximately 900 RPM, the signal from the
magnetic pickup causes the crank disconnect switch to open the crank disconnect relay. The open
contacts break the circuit to the cranking relay and stop engine cranking. The third control circuit
causes the field flash relay to be energized. When the ENGINE CONTROL switch is moved to one of
the two RUN positions, all starting control circuits are de-energized. The other generator set control
and instrument circuits remain energized.
1.16.13.1.3 The engine may be cranked without starting by use of the DEAD CRANK switch. With the DEAD
CRANK switch in the CRANK position, the K2 relay coil is energized to initiate engine cranking
without energizing any other starting or control functions.
1.16.13.1.4 The generator set can be started without batteries by connecting an external 24 VDC power source to
the NATO/SLAVE RECEPTACLE. The generator set can also supply power to another set through
the NATO/SLAVE RECEPTACLE.
1.16.13.1.5 The batteries are charged by the battery charging alternator which is belt driven by the engine. The
CIM display screen BATTERY CHARGE ammeter indicates the charge/discharge rate of the batteries,
from -60 amps to +60 amps. A sensor provides a DC voltage signal, which is directly proportional to
the actual battery current flow, to the BATTERY CHARGE ammeter. Normal operating indication on
the BATTERY CHARGE ammeter depends on the state of the charge in the batteries. A low charge,
which may exist immediately after engine starting, will cause a high reading (indication toward
CHARGE area). When the charge in the batteries has been restored, the indicator moves near zero.
The battery charging system is protected from reverse polarity in the battery connections by a diode.
1-32
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
FIGURE 1-29. ENGINE STARTING SYSTEM FLOW DIAGRAM
1-33
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14A
1.16.13.2
Field Flash. This circuit provides current to the exciter field windings which sets up an electromagnetic
field. The field current is necessary for the set to generate sufficient voltage for the automatic voltage
regulator to begin controlling the output voltage of the generator set. The field flash circuit is
maintained until the ENGINE CONTROL switch is released from the START position.
1.16.13.3
Operation. Placing the ENGINE CONTROL switch in the PRIME & RUN AUX FUEL positions
keeps the DCS speed control unit energized, and fuel will be supplied to the fuel injection pump as
long as no fault condition exists. During operation, the operator should periodically check the CIM
display screen to ensure readings are in normal operating ranges. The VOLTAGE ADJUST and
FREQUENCY ADJUST switches are adjusted as required to maintain desired frequency and voltage
output.
1.16.13.4
Applying the Load. The load is applied by placing the AC CIRCUIT INTERRUPT switch in the
CLOSED position. This is a momentary contact switch that returns to the neutral, or center, position.
The AC circuit interrupter is energized by this momentary contact and a holding circuit keeps it closed,
bringing the load on line.
1.16.13.5
Shutdown.
1.16.13.5.1 The AC circuit interrupter is disengaged by placing the AC CIRCUIT INTERRUPT switch in the
OPEN position. This is a momentary contact switch which will break the AC circuit interrupter
holding circuit and then return to the neutral, or center, position, disconnecting the load from the line.
1.16.13.5.2 The generator set should remain running for five minutes after disconnecting the load. During this five
minute interval, oil circulates through the turbocharger, cooling it enough to be shut down.
1.16.13.5.3 When the ENGINE CONTROL switch is placed in the OFF position, all power is removed from the
governor control circuit and the engine will stop.
1.16.13.5.4 The EMERGENCY STOP switch will remove power from the governor control circuit by deenergizing circuitry in the DCS. This will cause the engine to shut down. The EMERGENCY STOP
switch will not be used as an alternative for routine shutdown procedures. When the generator set is
stopped using the EMERGENCY STOP switch, some circuits remain energized causing a drain on the
batteries until the ENGINE CONTROL switch is placed in the OFF position.
1.16.13.6
Paralleling.
1.16.13.6.1 The generator set is capable of being operated in parallel with one other set of the same model number.
This capability is provided by the PARALLELING RECEPTACLE, paralleling cable, and the load
sharing synchronizer.
1.16.13.6.2 The paralleling cable is used to interconnect the governor and automatic voltage regulator paralleling
circuits of the two sets. Voltage and frequency of the two generator sets are synchronized by the DCS
load sharing synchronizer. The permissive paralleling relay monitors the voltage phase relationship and
prevents the AC circuit interrupter from closing when the units are not properly synchronized.
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1.17
LOCATION AND DESCRIPTION OF MAJOR COMPONENTS.
NOTE
All locations (Figure 1-30) referenced herein are given facing the control box side
(rear) of the generator set.
1.17.1
COMMUNICATION RECEPTACLE (1). The COMMUNICATION RECEPTACLE is used to
connect a remote PC to the DCS control box to facilitate remote operation and monitoring of the
generator set.
1.17.2
PARALLELING RECEPTACLE (2). The PARALLELING RECEPTACLE is used to connect the
paralleling cable between two generator sets of the same size and mode to operate in parallel.
1.17.3
CONVENIENCE RECEPTACLE (3). The CONVENIENCE RECEPTACLE is a 120VAC receptacle
use to operate small plug-in type equipment.
1.17.4
DCS Control Panel Assembly (4). The DCS control panel is located at the rear of the generator set and
contains the CIM, switches, and connectors used to control and monitor generator set operation.
1.17.5
Computer Interface Module (CIM) (5). The CIM is located in the DCS control box and contains
controls and indicators for operating the generator set.
1.17.6
Air Cleaner Assembly (6). The air cleaner assembly is located on the left side behind the AIR
CLEANER ACCESS door. It consists of a dry-type, disposable paper filter and canister. The air
cleaner assembly features a dust collector which traps large dust particles. The air cleaner assembly
has a restriction indicator which will pop up during operation when the air cleaner requires servicing.
1.17.7
AC Generator (7). The AC generator is a single bearing, drip-proof, synchronous, brushless, three
phase, air-cooled generator. The generator is coupled directly to the rear of the diesel engine.
1.17.8
Fuel Drain Valve (8). The fuel drain valve is located on the left side of the skid base. It allows
personnel to drain the fuel tank for maintenance.
1.17.9
Fuel Tank (9). The 23 gallon (87.05 liter) fuel tank is located in the front of the generator set below the
engine and between the skid base members. The fuel tank has sufficient capacity to enable the
generator set to operate for at least 8 hours without refueling.
1.17.10
DEAD CRANK Switch (10). The DEAD CRANK switch is located in the engine compartment on the
left side. The switch allows the engine to be turned over without starting for maintenance purposes.
1.17.11
Muffler (11). The muffler and exhaust tubing are connected to the turbocharger on the engine. The
exhaust exits from the top of the generator set housing. Gases are exhausted upward.
1.17.12
Radiator (12). The radiator is located at the front of the generator set. It acts as a heat exchanger for
engine coolant.
1.17.13
Fan Belt (13). The fan belt is located in the engine compartment on the front of the engine. The belt
drives the fan, water pump, and battery charging alternator.
1.17.14
Oil Drain Valve (14). The oil drain valve is located at the front of the skid base. It allows personnel to
drain engine oil for maintenance.
1-35
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FIGURE 1-30. 30 KW GENERATOR SET COMPONENTS (SHEET 1 OF 2)
1-36
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FIGURE 1-30. 30 KW GENERATOR SET COMPONENTS (SHEET 2 OF 2)
1-37
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1.17.15
Batteries (15). Two batteries are located at the front of the generator set. The batteries are
maintenance free, 12 volt type. After starting, the generator set is capable of operating with batteries
removed. A diode, located behind the control panel, protects the generator set if the batteries are
incorrectly connected.
1.17.16
Skid Base (16). The skid base supports the generator set. It has fork lift access openings and cross
members for short distance movement. The skid base has provisions in the bottom for installation of
the generator set on a trailer.
1.17.17
NATO SLAVE RECEPTACLE (17). The NATO SLAVE RECEPTACLE is located on the right side
(front) of the generator set. It is a NATO receptacle used for remote battery connection.
1.17.18
Water Pump (18). The water pump is located on the front of the engine. The pump circulates engine
coolant through the engine block and the radiator.
1.17.19
Oil Filter (19). The oil filter is located in the engine compartment on the left side. The filter removes
impurities from engine oil.
1.17.20
Engine (20). The generator is powered by a four cylinder, four cycle, fuel injected, turbocharged,
liquid-cooled diesel engine which occupies the front half of the generator set. The engine is also
equipped with a fuel filter/water separator, oil filter, and air cleaner assembly. Protection devices
automatically stop the engine during conditions of high coolant temperature, low oil pressure, no fuel,
overspeed, and overvoltage.
1.17.21
Battery Charging Alternator (21). The battery charging alternator is located on the right side of the
engine. It is capable of maintaining the batteries in a state of full charge in addition to providing the
required 24 VDC control power.
1.17.22
Dipstick (22). The dipstick is located in the engine compartment on the left side. The dipstick shows
the level of oil in the engine drain pan.
1.17.23
Starter (23). The starter is located on the left side of the engine. The electric cranking motor
mechanically engages the engine flywheel in order to start the diesel engine.
1.17.24
Crankcase Breather Filter Assembly (24). The crankcase breather filter assembly is located in the
engine compartment on the right side. The filter element removes oil particles and contaminants from
air as it passes from the crankcase to engine air intake.
1.17.25
Fuel Filter/Water Separator (25). The fuel filter/water separator is located in the engine compartment
on the right side. The element removes impurities and water from the diesel fuel.
1.17.26
Load Output Terminal Board (26). The load output terminal board is located on the right side (rear) of
the generator set. Four AC output terminals are located on the board. The are marked L1, L2, L3, and
L0. A fifth terminal, marked GND, is located next to the output terminals and serves as equipment
ground for the generator set. A removable, solid copper bar is connected between the L0 and GND
terminals.
1.17.27
Voltage Reconnection Terminal Board (27). The voltage reconnection terminal board is located on the
right side (rear) of the generator set. The board allows reconfiguration from 120/208 to 240/416 VAC
output.
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THIS PAGE INTENTIONALLY LEFT BLANK.
1-40
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CHAPTER 2
OPERATING INSTRUCTIONS
CHAPTER INDEX
SECTION I
DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS .......................2-1
SECTION II
PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)...................................2-14
SECTION III
OPERATION UNDER USUAL CONDITIONS .........................................................................2-21
SECTION IV
OPERATION UNDER UNUSUAL CONDITIONS ...................................................................2-41
SECTION I. DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS.
2.1
GENERAL.
This section describes and illustrates generator set controls and indicators to ensure proper operation of
generator set.
2.2
DCS CONTROLS AND INDICATORS.
The Digital Control System (DCS) contains most of the operating controls for the generator set. Figure 2-1
shows the DCS control panel assembly layout. Table 2-1 describes each control and indicator.
2-1
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FIGURE 2-1. DCS CONTROLS AND INDICATORS
2-2
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TABLE 2-1. DCS CONTROLS AND INDICATORS
KEY
1
2
3
CONTROL OR INDICATOR
ELAPSED TIME Meter
Panel Lights
EMERGENCY STOP Switch
4
5
PANEL LIGHTS Switch
NETWORK FAILURE Indicator
6
BATTLE SHORT Switch
7
ETHER START Switch
8
ENGINE CONTROL Switch
9
FREQUENCY ADJUST Switch
10
AC CIRCUIT INTERRUPT Switch
11
VOLTAGE ADJUST Switch
12
FAULT RESET Switch
13
MASTER CONTROL Switch
14
16
GROUND FAULT CIRCUIT
INTERRUPTER TEST Switch
GROUND FAULT CIRCUIT
INTERRUPTER RESET Switch
Keypad Up Arrow Pushbutton
↑
17
18
Keypad Right Arrow Pushbutton →
Keypad SELECT Pushbutton
19
Keypad Down Arrow Pushbutton ↓
15
FUNCTION
Indicates total engine operating hours.
Illuminate DCS control panel.
Shuts down generator set when activated. Removes electrical
power to governor controller and stops engine from operating.
Activates and deactivates panel lights.
When illuminated indicates a failure between Computer
Interface Module and Input/Output Module. Generator set will
not continue to operate, and capability to monitor its operation
and to make adjustments will be degraded or lost.
Bypasses protective devices on generator set. Set will continue
to operate until overvoltage occurs or fuel is exhausted.
When held in ON position momentarily during engine cranking,
activates ether cold weather starting system for starting engine
at temperatures below 40°F (4°C).
Four position switch:
OFF – de-energizes all circuits except panel lights and power to
CIM.
PRIME & RUN AUX FUEL – energizes generator set run
circuits with auxiliary fuel pump operating.
PRIME & RUN – energizes generator set run circuits with
auxiliary fuel pump de-energized.
START – energizes engine starter and flashes generator field.
Momentary-action toggle switch. Adjusts frequency output of
generator set for each activation of the switch. Works in both
directions to increase and decrease output frequency.
Opens and closes AC Circuit Interrupt Relay. Used during
parallel operation.
Momentary-action toggle switch. Adjusts voltage output of
generator set. Works in both directions to increase and
decrease output voltage.
Resets (turns off) fault indicators displayed on Computer
Interface Module display screen. Will re-energize governor
power.
When placed in ON position, provides battery power to DCS.
Should be first switch activated on panel. Generator set cannot
be started unless switch is activated.
Tests GROUND FAULT CIRCUIT INTERRUPTER.
Resets GROUND FAULT CIRCUIT INTERRUPTER.
Moves cursor on CIM display screen in upward direction until
released.
Moves cursor on CIM display screen to the right until released.
When pressed, selects item on CIM display screen indicated by
cursor.
Moves cursor on CIM display screen in downward direction
until released.
2-3
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TABLE 2-1. DCS CONTROLS AND INDICATORS (continued)
KEY
20
21
22
23
24
2.3
CONTROL OR INDICATOR
Keypad Left Arrow Pushbutton ←
DC CONTROL POWER Fuse
FREQUENCY SELECT Switch
(MEP-806B only)
REACTIVE CURRENT ADJUST
rheostat
VOLTAGE SCALE Switch
FUNCTION
Moves cursor on CIM display screen to the left until released.
Provides overcurrent protection for DC circuits.
Allows selection of 50 Hz or 60 Hz.
Adjusts voltage droop when two generator sets are operated in
parallel.
Reports configuration of output voltage connection selected on
voltage reconnection terminal board.
COMPUTER INTERFACE MODULE (CIM) DISPLAY SCREEN CONTROLS AND INDICATORS.
The Computer Interface Module (CIM) Display Screen displays most of the indicators for the generator set.
Figure 2-2 shows the CIM display screen layout. Table 2-2 describes each control and indicator. Table 2-3
describes faults that may be displayed in the FAULT INDICATOR section of the CIM display screen and
related operator messages that may be displayed in the MESSAGES section.
2-4
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FIGURE 2-2. CIM DISPLAY SCREEN CONTROLS AND INDICATORS
2-5
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TABLE 2-2. CIM DISPLAY SCREEN CONTROLS AND INDICATORS
KEY
1
2
3
GEN CURRENT indicators
4
FAULT INDICATOR display
5
DELTA VAC gage
6
MESSAGES display
7
8
WATER TEMP virtual meter
BATTLE SHORT CIRCUIT status
indicator
CONTACTOR POSITION status
indicator
DISPLAY MODE FULL/MAIN
switch
9
10
2-6
CONTROL OR INDICATOR
GEN VOLTAGE indicators
BATTERY VDC indicator
11
SHUTDOWN COMPUTER
EXIT button
12
13
14
BATTERY AMPS virtual meter
OIL PRESSURE virtual meter
BUS VOLTAGE indicators
15
16
17
18
VOLTAGE gage
FREQ gage
POWER gage
FUEL LEVEL gage
FUNCTION
Indicates generator output voltage for each of the three phases.
Indicates charge status of both generator set DC batteries
(VDC).
Indicates generator output current (amps) for each of the three
phases.
Displays fault indications as they occur. Specific warnings and
instructions related to a fault are displayed simultaneously in
the MESSAGES display. See Table 2-3 for the list of possible
faults.
Indicates generator set output voltage versus bus voltage. Used
prior to operating in parallel with another unit. Used to monitor
system prior to parallel operation to ensure generator and bus
voltage are balanced within 5 volts before closing contactor to
bus.
Displays warnings and instructions in the form of operator
messages related to faults displayed in FAULT INDICATOR
display.
Indicates generator set cooling system water temperature (°F).
Indicates whether generator set is in battle short mode or not.
ON indication means battle short circuit is energized.
Indicates whether contactor is open or closed.
When FULL/MAIN button is selected with the keypad, CIM
display screen toggles between FULL and MAIN modes and
button changes to show name of mode currently displayed.
When EXIT button is selected with the keypad, the DCS
software shuts down so the CIM can be safely deactivated.
This will also shut down the generator set if it is running.
Indicates input current of generator set DC batteries (amps).
Indicates engine oil pressure (psi).
Indicate voltage on output bus. The GEN VOLTAGE and BUS
VOLTAGE indicators must match within five volts, each phase,
to perform paralleling operation.
Indicates generator set voltage output (VAC).
Indicates generator set frequency output (Hz).
Indicates generator set power output (kW).
Indicates amount of fuel in fuel tank (percent remaining).
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TABLE 2-3. FAULTS
NOTE: Maintainers can only check faults at their level.
FAULT
MESSAGE #
MESSAGE
CIRCUIT FAILURE 01
The fuel level signal is lower than the operating range.
FUEL LEVEL
Check fuel level. Check fuel sensor and circuit. (Para. 4.11.5)
SHUTDOWN - LOW FUEL
02
Fuel level is abnormally low.
Check fuel level. Verify fuel system lineup.
WARNING - LOW FUEL
03
Fuel level is abnormally low.
Check fuel level. Verify fuel system lineup.
CIRCUIT FAILURE 04
The fuel level signal is higher than the operating range.
FUEL LEVEL
Check fuel level. Check fuel sensor and circuit. (Para. 4.11.5)
CIRCUIT FAILURE COOLANT TEMP
05
06
WARNING - COOLANT
TEMP
SHUTDOWN - COOLANT
TEMP
07
CIRCUIT FAILURE - OIL
PRESSURE
09
08
10
WARNING - LOW OIL
11
SHUTDOWN - LOW OIL
12
WARNING OVERVOLTAGE
SHUTDOWN OVERVOLTAGE
13
WARNING - OVERSPEED
15
SHUTDOWN OVERSPEED
16
WARNING UNDERVOLTAGE
CONTACTOR TRIP UNDERVOLTAGE
17
WARNING - OVERLOAD
19
14
18
The coolant temperature signal is lower than the operating range.
Check coolant level. Check coolant temperature sensor and circuit.
(Para. 4.13.2)
The coolant temperature is higher than the operating range.
Check coolant level. Check coolant temperature sensor and circuit.
(Para. 4.13.2)
Coolant temperature is abnormally high.
Check coolant level. Verify coolant system lineup. (Para. 3.3.5)
Coolant temperature is abnormally high.
Check coolant level. Verify coolant system lineup. (Para. 3.3.5)
The oil pressure signal is lower than the operating range.
Check oil pressure. Check oil pressure sensor and circuit.(Para.
4.13.1)
The oil pressure signal is higher than the operating range.
Check oil pressure. check oil pressure sensor and circuit.(Para.
4.13.1)
Oil pressure is abnormally low.
Check oil. Verify lubricating system lineup. (Para. 3.3.8)
Oil pressure is abnormally low.
Check oil. Verify lubricating system lineup. (Para. 3.3.8)
Generator voltage is abnormally high.
Adjust VOLTAGE ADJUST switch. (Para. 2.11.1 j)
Generator voltage is abnormally high.
Adjust VOLTAGE ADJUST switch. (Para. 2.11.1 j)
Generator frequency is abnormally high.
Adjust FREQUENCY ADJUST switch. (Para. 2.11.1 j)
Generator frequency is abnormally high.
Adjust FREQUENCY ADJUST switch. (Para. 2.11.1 j)
Generator voltage is abnormally low.
Adjust VOLTAGE ADJUST switch. (Para. 2.11.1 j)
Generator voltage is abnormally low.
Adjust VOLTAGE ADJUST switch. (Para. 2.11.1 j)
System load is abnormally high.
Reduce load to within generator set ratings. (Para. 2.11.1 n and o)
2-7
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TABLE 2-3. FAULTS (continued)
FAULT
CONTACTOR TRIP OVERLOAD
MESSAGE #
20
CONTACTOR TRIP REVERSE POWER
21
Load share device sensed reverse power conditions.
Verify load share device setpoints are correct.
CONTACTOR TRIP SHORT CIRCUIT
22
System load was abnormally high.
Reduce load to within generator set ratings.
2.4
MESSAGE
System load is abnormally high.
Reduce load to within generator set ratings. (Para. 2.12)
DIAGNOSTIC CONTROLS AND INDICATORS.
The DCS load sharing synchronizer, DCS speed control unit, automatic voltage regulator, backplane
module, and I/O interface module are equipped with indicators used as diagnostic tools in troubleshooting.
Some of the DCS modules also include controls that are set at installation and may need to be adjusted
during troubleshooting. Figure 2-3 shows the locations of the controls and indicators on the DCS modules.
Table 2-4 describes each control and indicator.
2-8
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FIGURE 2-3. DIAGNOSTIC CONTROLS AND INDICATORS (SHEET 1 OF 2)
2-9
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FIGURE 2-3. DIAGNOSTIC CONTROLS AND INDICATORS (SHEET 2 OF 2)
2-10
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TABLE 2-4. DIAGNOSTIC CONTROLS AND INDICATORS
KEY
CONTROL OR INDICATOR
DCS LOAD SHARING SYNCHRONIZER
1
L1 indicator (green LED)
2
L2 indicator (green LED)
3
REVERSE POWER (red LED)
4
GEN indicator (green LED)
5
BUS indicator (green LED)
6
SYNCH ENABLED indicator
(green LED)
7
PARALLEL ENABLE indicator
(green LED)
8
SYNCHRONIZED indicator
(green LED)
9
DC POWER indicator (green
LED)
FUNCTION
This indicator is lit when the load sharing control is making
transition from zero power output up to a power output in a
load sharing (paralleling) condition. Normally, this LED is lit
only during the load sharing (paralleling) period.
This indicator is lit only when zero power from the generator
set is reached before the breaker is opened. It indicates when
the I/O interface module is calling for the generator to go to
zero power output before the generator breaker is opened
automatically by the I/O interface module.
This indicator is lit when a reverse power situation exists. The
I/O interface module has been notified to remove the generator
set from service (open the breaker).
This indicator is normally lit when the generator set is operating
(engine is running). When lit, the LED indicates the module is
receiving AC power from the generator.
This indicator is normally lit only when the generator set is
running and the main breaker is closed. It is also lit when
another generator set is connected to the main breaker and its
breaker is closed. When lit, the LED indicates AC power is
being received from the bus (the output of the generator set
main breaker) into the module. The indicator is not lit if the
bus has failed, and when this module is not being used.
This indicator is lit only when the I/O interface module requests
synchronizing the output power of the generator set with a
second generator set and the paralleling cable has been
connected between the two sets. In addition, the AC CIRCUIT
INTERRUPT switch on the primary set has been previously
moved to the CLOSED position. This indicator is lit only
during the synchronizing period.
This indicator will be lit when the I/O interface module has
closed the main breaker. That is, the I/O interface module has
commanded the DCS load sharing synchronizer to close the
connection with the paralleling cable and begin parallel
operation of the two generator sets.
This indicator will be lit when the generator is in synch with the
bus. When this LED is lit, the DCS load sharing synchronizer
has signaled the I/O interface module that paralleling may
occur.
This indicator is normally lit only when the generator set is
operating (engine is running). It is off at all other times. When
lit, the LED indicates the internal DC supply of the module is
operating (i.e., the module is receiving DC power from the
generator set, and the module is properly converting the power
into its own operating voltage(s).
2-11
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TABLE 2-4. DIAGNOSTIC CONTROLS AND INDICATORS (continued)
KEY
CONTROL OR INDICATOR
SPEED CONTROL UNIT
10
OVERSPEED indicator (red LED)
11
ACTUATOR indicator (green
LED)
12
SPEED SENSOR indicator (green
LED)
13
OVERSPEED RESET pushbutton
14
OVERSPEED TEST pushbutton
15
DC POWER indicator (green
LED)
CRANK TERMINATION (green
LED)
16
BACKPLANE MODULE
17
LED 16 (red) indicator
18
LED 15 (red) indicator
19
LED 14 (red) indicator
2-12
FUNCTION
This indicator is normally off, even when the generator set is
operating. When the LED is lit, an engine overspeed condition
has occurred (the flywheel RPM sensor has sent the speed
control unit a value which is defined as out-of-tolerance). The
indicator will remain lit until either of two events has occurred:
(1) The OVERSPEED RESET pushbutton has been manually
activated, or (2) the generator set (engine) has been stopped and
the DC power is reset.
This indicator is normally lit when the electric actuator (on the
injection fuel pump) has power applied to it. The LED will be
lit when the engine is operating or when the engine is being
cranked (started). If the indicator is off while the engine is
operating, it can mean: (1) the electric actuator has failed, (2)
the connection between the actuator and the module has failed,
or (3) the module has malfunctioned or failed.
This indicator is normally lit when the engine is operating. The
indicator lit/off function is directly related to the signal from the
speed sensor connected to the flywheel. If the indicator is off,
but the engine is operating, this indicates the engine RPM
signal is not being received. This can be caused by sensor
failure or by a failure in the connection to the sensor.
If the OVERSPEED indicator is lit and the engine has stopped,
this switch may be used to attempt to reset the overspeed
protection system. If the OVERSPEED indicator turns off
when the switch is activated, the protection system is reset, and
the engine may be restarted. (The conclusion is that no
problem exists with engine speed.) If after restarting the
OVERSPEED indicator comes on again and the engine stops,
there is a problem with engine speed control.
This switch is used to test one of the protective systems of the
generator set: engine overspeed protection. Pressing this
switch while the engine is running at rated speed will activate
the overspeed protection system, thereby stopping the engine.
This indicator is normally lit when the engine is operating. It
indicates the internal DC power in the module is operating.
This indicator is normally lit when the engine is operating.
When the engine is being started, the indicator will remain off
until engine speed exceeds 400 RPM and the cranking relay
returns to its normal (non-energized) state. If the indicator
remains off and the engine starter continues operation, this is an
indication of a failure in the starter assembly or of the cranking
relay.
(not assigned)
(not assigned)
Fault indication. If indicator is lit, indicates a fault has
occurred. If off, indicates normal running condition.
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TABLE 2-4. DIAGNOSTIC CONTROLS AND INDICATORS (continued)
KEY
CONTROL OR INDICATOR
BACKPLANE MODULE (continued)
20
LED 13 (red) indicator
21
22
LED 12 (green)
LED 11 (green)
23
LED 10 (green)
24
LED 9 (green)
25
26
LED 8 (red)
LED 7 (red)
27
LED 6 (red)
28
LED 5 (red)
29
30
LED 4 (green)
LED 3 (green)
31
32
LED 2 (green)
LED 1 (green)
FUNCTION
Short circuit indication. If indicator is lit, indicates a short
circuit condition affecting generator set output has been
detected.
(not assigned)
Remote display connection. Indicator blinks on and off when
remote display is properly connected. If not lit, indicates no
remote display connection has been made.
Data validity from remote display. Indicator blinks on and off
to indicate remote data is being received properly. If not lit,
remote data is not being received properly. If not lit, can also
indicate no remote display function has been connected.
Status of the main generator power bus. If indicator is lit, the
bus is energized (voltage is present), and voltage is available
for paralleling operation. If not lit, indicates the generator set is
operating in a stand-alone mode.
(not assigned)
Network failure. If indicator is lit, indicates the CIM is not
communicating with the I/O interface module. If not lit,
indicates the CIM is communicating properly.
Emergency stop. If indicator is lit, indicates the
EMERGENCY STOP switch has been activated. If not lit,
indicates normal running condition.
CMOS voltage. If indicator is lit, indicates voltage necessary
for CMOS device operation is too low. If not lit, CMOS device
voltage source is sufficient.
(not assigned)
Heartbeat. If indicator is blinking on and off, indicates proper
operation of this module. If not lit, indicates module has no
power applied or has failed.
(not assigned)
If indicator is lit, fuel pump is operating. If not lit, fuel pump is
not operating.
AUTOMATIC VOLTAGE REGULATOR
33
AC SENSING (green LED)
34
DC SUPPLY indicator (green
LED)
35
FIELD VOLTAGE (green LED)
This indicator is normally lit, indicating the AC sensor is
sending the proper signal to this module.
This indicator is normally lit, indicating that the module's
internal DC supply is operating. The source for input power to
this module is the AC output of the generator set. Therefore,
the indicator will not be lit until the generator set is providing
power output to a load.
This indicator is normally lit. It indicates field voltage is
present, which means the generator is developing AC power.
2-13
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TABLE 2-4. DIAGNOSTIC CONTROLS AND INDICATORS (continued)
KEY
CONTROL OR INDICATOR
I/O INTERFACE MODULE
36
HEARTBEAT (green LED)
37
DIP Switch Assembly (8 positions)
FUNCTION
This indicator is normally blinking on and off when DC power
has been applied to the module. It is also normally blinking
when the generator set is operating (engine running) and the
module is functioning properly. If the indicator is either steadystate lit or steady-state off, but the CIM has been turned on and
the engine is operating, this is an indication that there is a
problem in the I/O interface module.
These switches define the configuration of the generator set for
the CIM. The generator set configuration is defined in two
ways: its output power (kW) rating and its frequency rating.
These switches must be set to a specified configuration prior to
the module's use in the generator set. Unless these switches are
properly set (and remain so), the generator set can experience a
malfunction. For the MEP-806B, all switches are set to OFF.
For the MEP-816B, Switch 5 is set to ON and all the other
switches to OFF. (Ref Figure 4-31)
SECTION II. PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
2.5
GENERAL.
To ensure the generator set is ready for operation at all times, it must be inspected so that defects can be
discovered and corrected before they result in serious damage or failure.
2.5.1
Before Operation. Always keep in mind the CAUTIONS and WARNINGS. Perform Before (B) PMCS.
2.5.2
During Operation. Always keep in mind the CAUTIONS and WARNINGS. Perform During (D) PMCS.
2.5.3
After Operation. Perform After (A) PMCS.
2.5.4
If the Equipment Fails. If the equipment does not perform as required, refer to Chapter 3, Section II under
Troubleshooting for possible problems. The Symptom Index is provided as a guide for troubleshooting
procedures. Report any malfunctions or failures on DA Form 2404 (refer to DA PAM 738-750).
2.6
PMCS Procedures.
NOTE
For general location of items to be inspected in Table 2-5, refer to Figures 1-30
and 2-1.
2.6.1
Purpose of PMCS Table. PMCS, Table 2-5, lists inspections and care of equipment required to keep the
generator set in good operating condition.
2.6.2
Purpose of Service Intervals. The interval column of the PMCS table indicates when to perform a certain
check or service.
Special Instructions. The following guidelines are provided to help classify leaks observed while
performing PMCS.
2.6.3
Class I.
2-14
Seepage of fluid (as indicated by wetness or discoloration) not great enough to form drops.
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Class II.
Leakage of fluid great enough to form drops, but not enough to cause drops to drip from item
being checked/inspected.
Class III.
Leakage of fluid great enough to form drops that fall from the item being checked/inspected.
CAUTION
Equipment operation is allowable with minor oil and coolant leakage (Class
I or II). When operating with Class I or II leaks, continue to check fluid
levels as required in PMCS. All leaks should be reported to the next higher
level of maintenance. Failure to comply can cause damage to equipment.
2.6.4
Procedures Column. The procedures column of the PMCS table tells how to perform required checks and
services. If required tools are not available, or if a procedure indicates, complete DA Form 2404 and
submit it to the next higher level of maintenance.
NOTE
The terms "ready/available" and "mission capable" refer to the same status. The
generator set is on hand and able to perform combat missions. Refer to DA
PAM 738-750.
2.6.5
"Equipment is not ready/available if" Column. This column tells when and why the generator set cannot be
used.
2.6.6
Reporting and Correcting Deficiencies. If the generator set does not perform as required, refer to Chapter
3, Operator Troubleshooting, to diagnose the problem.
2.6.7
Removal of Assemblies/Equipment to Perform PMCS. There is no requirement to remove
assemblies/equipment prior to performing PMCS.
NOTE
If generator set must be kept in continuous operation, check and service only those
items which can be checked and serviced without disturbing operation. Perform
complete checks and services when the generator set can be shut down.
NOTE
The generator set can be operated continuously at any load from no load up to and
including rated load. However, at light loads an oily residue (unburned fuel oil)
may occasionally be noticed in the exhaust system outlet and around connection
joints in the exhaust system. This residue is caused by the inability of the fuel
injection system to consistently meter the small amount of fuel required to operate
at these low load levels and is not a defect in the fuel system. The oily residue
could affect engine performance and create a cosmetic problem on and around the
generator set. Operation at rated load will burn off this oily residue. The length of
time required at rated load depends on the amount of residue. This oily residue can
be prevented by increasing the electrical load on the set.
2-15
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TABLE 2-5. OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
CAUTION
Engine oil and filter must be changed at a hardtime - 100 hours on initial
break-in. Failure to change oil and filter may void warranty.
B-BEFORE
D-DURING
Interval
Item
No.
B
D
A
Item to
be inspected
A-AFTER
Procedures
Check for and have
repaired or adjusted
as necessary
Equipment is
not ready/
available if:
GENERATOR SET
1
•
2
•
3
•
4
•
•
•
Housing
Check door, panels, hinges, and latches
for damaged, loose or corroded items.
Inspect air intake and exhaust grilles for
debris.
Identification Plates
Check to ensure identification plates are
secure.
•
Skid Base
Inspect skid base for cracks or corrosion.
•
Insulating/Materials
Ensure that insulating materials are free
of damage, not missing, and not touching
moving or exhaust system parts.
Cannot secure doors.
Cannot clear debris.
Skid base is cracked
or shows signs of
structural damage.
__________
WARNING
Operating the generator set with any
access door open exposes personnel to
high noise level. Hearing protection
must be worn when operating or
working near the generator set with
any access door open. Failure to
comply can cause hearing damage to
personnel.
__________
WARNING
Fuels in the generator set are
flammable. Do not smoke or use open
flame when performing maintenance
Failure to comply can result in flames
and possible explosion and can cause
injury or death to personnel and
damage to the generator set.
TABLE 2-5. OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
(continued)
2-16
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B-BEFORE
D-DURING
Interval
Item
No.
B
D
A
Item to
be inspected
A-AFTER
Procedures
Check for and have
repaired or adjusted
as necessary
Equipment is
not ready/
available if:
ENGINE
COMPARTMENT
5
•
•
•
Engine Assembly
Check for loose, damaged, or missing
hardware and wires.
Any loose, damaged
or missing hardware
or wires.
6
•
•
•
Fuel System
Inspect fuel system for leaks and
damaged, loose, or missing parts. Check
fuel lines fuel injection pump and fuel
injectors for cracks, leaks or evidence of
damage. See TM 9-2815-259-24.
Any fuel leaks or
damaged, loose, or
missing parts.
7
•
•
Fuel Filter/Water
Separator
Inspect fuel filter/water separator for
leaks, proper mounting, cracks, damage,
and missing parts (Refer to Figure 1-30,
sheet 2).
Any fuel leaks.
Drain water from fuel filter/water
separator (Refer to paragraph 3.3.7).
Fuel filter/water
separator not drained.
CAUTION
Catch in suitable container.
8
•
9
•
•
•
Ether Start System
Check for deteriorated, loose, or missing
parts; loose tubing; and missing or
damaged bottle gasket (Refer to Figure
4-26).
Any deteriorated,
loose, or missing
parts; loose tubing;
and missing or
damaged bottle
gasket.
Lubrication System
Inspect lubrication system for leaks and
damaged, loose, or missing parts.
Oil leaks at Class III.
Damaged, loose, or
missing parts.
Check engine oil level.
Oil level is low, and
dipstick reads add.
Check engine oil for contamination (oil
color is milky, bubbles, foreign material
in oil, etc.).
Engine oil shows
signs of
contamination.
2-17
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TABLE 2-5. OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
(continued)
B-BEFORE
Item
No.
Item to
be inspected
Interval
B
D
D-DURING
A
Procedures
Check for and have
repaired or adjusted
as necessary
__________
WARNING
A-AFTER
Equipment is
not ready/
available if:
Cooling system operates at high
temperature and pressure. Contact
with high pressure steam and/or
liquids can result in burns and
scalding. Shut down generator set,
and allow system to cool before
performing checks, services, and
maintenance. Failure to comply can
cause injury to personnel.
COOLING
SYSTEM
10
•
•
Radiator
Check radiator for leaks, damage, or
missing parts.
Class III leaks.
Radiator cap is
missing.
11
•
•
Hoses
Check hose for leaks or cracks.
Class III leaks.
12
•
Cooling Fan
Check fan for damage or looseness.
Cooling fan is
damaged or loose.
•
13
•
14
•
•
•
Check for unusual noise being emitted
from fan area.
•
Fan Belts
Inspect belts for cracks, fraying, or
looseness.
Broken belt(s).
•
Overflow Bottle
Check overflow bottle for leaks and
missing parts.
Class III leaks.
Check overflow bottle coolant level.
Coolant level is
below COLD line.
Check muffler for leaks and exhaust
system for corrosion and damaged or
missing parts.
Muffler or exhaust
system damaged or
leaking excessively.
•
EXHAUST/
INTAKE SYSTEM
15
2-18
•
Exhaust System
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TABLE 2-5. OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
(continued)
B-BEFORE
D-DURING
Interval
Item
No.
16
B
•
D
A
Item to
be inspected
Air Cleaner
Assembly
A-AFTER
Procedures
Check for and have
repaired or adjusted
as necessary
Inspect air cleaner assembly and piping
for loose or damaged connections.
Check restriction indicator for indication
of clogged air cleaner element (Refer to
Figure 3-1).
Equipment is
not ready/
available if:
Piping connections
are loose.
Clogged element is
indicated.
ELECTRICAL
SYSTEM
__________
WARNING
DC voltages are present at generator
set electrical components even with
generator set shut down. Avoid
shorting any positive terminal with
ground/negative. Failure to comply
can cause injury to personnel and
damage to equipment..
__________
WARNING
Batteries give off a flammable gas. Do
not smoke or use open flame when
performing maintenance. Failure to
comply can cause injury or death to
personnel and equipment damage due
to flames and explosion.
__________
WARNING
Battery acid can cause burns to
unprotected skin. Avoid contact with
battery acid. Failure to comply can
cause injury to personnel.
17
•
Batteries
Inspect electrolyte level (wet cell
batteries only).
Electrolyte level is
below battery plates.
18
•
Battery Cables
Inspect cables and connectors for
corrosion and loose, damaged, or
missing parts.
Battery cables are
loose, damaged, or
missing.
2-19
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TABLE 2-5. OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
(continued)
B-BEFORE
D-DURING
Interval
Item
No.
B
D
A
Item to
be inspected
A-AFTER
Procedures
Check for and have
Repaired or adjusted
as necessary
__________
WARNING
Equipment is
not ready/
available if:
High voltage is produced when this
generator set is in operation. Make
sure unit is completely shut down and
free of any power source before
attempting any repair or maintenance
on the unit. Failure to comply can
cause injury or death to personnel.
19
•
Output Box
Assembly
Check for loose or damaged wiring or
cables (Figure 1-2).
Loose or damaged
wiring or cables.
20
•
Load Output
Terminal Board
Check output terminals for damaged or
missing hardware (26, Figure 1-30 sheet
2)
Damaged or missing
hardware.
Check all controls and indicators for
damaged or missing parts. Ensure relays
are securely plugged in.
Controls or indicators
with damaged or
missing parts.
Ensure all indicators are operating
properly.
CIM inoperative.
Loose or damaged
wires.
DCS CONTROL
BOX ASSEMBLY
21
•
•
Controls and
Indicators
•
22
•
Control Box Wiring
Harness
Check for loose or damaged wiring.
23
•
Parallel Operation
Cable
If required for generator set operation,
inspect parallel operation cable for
damage.
2-20
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TABLE 2-5. OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
(continued)
B-BEFORE
D-DURING
Interval
Item
No.
B
D
Procedures
Check for and have
repaired or adjusted
as necessary
__________
WARNING
Item to
be inspected
A
A-AFTER
Equipment is
not ready/
available if:
High voltage is produced when the
generator set is in operation. Never
attempt to start the generator set
unless it is properly grounded.
Failure to comply can cause injury or
death to personnel.
•
24
Ground Rod Cable
and Connection
•
Inspect ground rod and cable for loose
connections, breaks, damage, and
corrosion.
Visual inspection only.
Cable is missing or
damaged.
SECTION III. OPERATION UNDER USUAL CONDITIONS
2.7
GENERAL.
This section provides information and guidance for generator set operation under normal conditions. Refer
to FM 20-31.
2.8
GENERATOR SET INSTALLATION.
2.8.1
General.
__________
WARNING
Exhaust discharge contains deadly gases including carbon monoxide. Do
not operate generator set in an enclosed area unless exhaust discharge is
properly vented outside. Failure to comply can cause injury or death to
personnel.
2.8.2
a.
Ensure that installation site is as level as possible.
b.
Provide adequate ventilation to prevent recirculation of hot air exhausted from generator set.
c.
Refer to Figure 2-4 for base mounting measurements.
Outdoor Installation.
a.
Make use of natural protective barriers.
FIGURE 2-4. BASE MOUNTING MEASUREMENTS
2-21
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2.8.3
b.
Allow space on all sides for service and maintenance. Refer to Figure 2-5 for minimum clearance
measurements.
c.
Ensure soil is firm and well drained.
d.
Use planks or other material for support in areas where soil will not support the generator set.
Indoor Installation.
__________
WARNING
Exhaust discharge contains deadly gases including carbon monoxide. Do
not operate generator set in an enclosed area unless exhaust discharge is
properly vented outside. Failure to comply can cause injury or death to
personnel.
CAUTION
Never position generator set with air inlets near a wall or other object that
interferes with cooling air circulation. Failure to comply can cause damage
to equipment.
2-22
a.
Provide ducts and vents to outside of building if good supply of cooling air is not available.
b.
Make air intake and outlet openings in building same size or larger than those on the generator set.
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FIGURE 2-5. MINIMUM ENCLOSURE CLEARANCE MEASUREMENTS
2-23
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NOTE
Make exhaust pipe extension as short and straight as possible, with only one 90
degree bend if needed.
NOTE
Ensure that inside diameter of exhaust pipe extension is as large or larger than
generator exhaust pipe.
c.
Install a gas-tight metal pipe from exhaust pipe of generator set to outside of building.
__________
WARNING
Hot exhaust gases can ignite flammable materials. Allow room for safe
discharge of hot gases and sparks. Failure to comply can cause injury or
death to personnel.
d.
Provide for harmless discharge of hot gases and sparks. Do not direct exhaust into area containing
flammable materials.
_________
WARNING
Engine exhaust is hot. When it is required to extend exhaust pipe through
flammable material (i.e., wall), shield the extension pipe to protect
personnel from burns and prevent fire hazard. Failure to comply can cause
injury to personnel, damage to equipment, and fire.
2.9
e.
Shield exhaust pipe with fireproof material at point where it passes through a flammable wall.
f.
Wrap exhaust pipe in heat insulating material.
g.
Allow space on all sides of generator set for service and maintenance. Refer to Figure 2-5 for
minimum clearance measurements.
ASSEMBLY AND PREPARATION FOR USE.
__________
WARNING
High voltage is produced when the generator set is in operation. Never
attempt to start the generator set unless it is properly grounded. Failure to
comply can cause injury or death to personnel.
2.9.1
2-24
Installation of Grounding Rod.
a.
Open Load Terminal access door (Figure 1-2).
b.
Insert ground cable (2, Figure 2-6) through load terminal access boot and into GND terminal (5) on
load output terminal board. Tighten terminal nut.
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FIGURE 2-6. GROUNDING CONNECTIONS
2-25
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2.9.2
c.
Remove grounding rod from inside generator set by removing top left bolts from left side of generator
(Figure 1-3). Replace bolt after removing ground rod.
d.
Connect coupling (6) to pointed ground rod section (1), and install driving stud (4) in coupling. Make
sure driving stud seats on ground rod section.
e.
Drive ground rod section (1) into ground until coupling is just above surface.
f.
Remove driving stud (4) from coupling (6), and install another ground rod section (1) in coupling.
g.
Install another coupling (6) on ground rod section (1). Install driving stud (4) in coupling, and drive
ground rod down until new coupling is just above surface.
h.
Repeat steps f and g until ground rod has been driven eight feet or deeper, providing an effective
ground.
i.
Connect clamp (3) and ground cable (2) to ground rod. Tighten clamp screw.
Installation of Load Cables.
__________
WARNING
High voltage is produced when the generator set is in operation. Never
attempt to connect or disconnect load cables while the generator set is
running. Failure to comply can cause injury or death to personnel.
a.
Shut down generator set, paragraph 2.11.2.
CAUTION
When using single phase connections, balance loads between terminals. Do
not connect all loads between one terminal and L0. Failure to observe this
caution can result in damage to equipment.
b.
Select required output terminals from Table 2-6.
TABLE 2-6. LOAD TERMINAL AND AC RECONNECTION BOARD SELECTION
RECONNECTION
BOARD
POSITION
120/208
240/416
2-26
TERMINALS
L1, L2, L3, N
3 Phase
(Single phase loads can be served
using any terminal to N)
L1, L2, L3, N
3 Phase
(Single phase loads can be served
using any terminal to N)
VOLTAGE READING
L1-N 120 volts
L2-N 120 volts
L3-N120 volts
L1-L2 208 volts
L2-L3 208 volts
L3-L1 208 volts
L1-N 240 volts
L2-N 240 volts
L3-N 240 volts
L1-L2 416 volts
L2-L3 416 volts
L3-L1 416 volts
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c.
Open Load Terminal access door (Figure 1-2).
d.
Using insulated wrench (1, Figure 2-7), loosen terminal nuts (2) on terminals selected in step b.
e.
Insert load cables through load terminal access boot and into terminal studs (3). Tighten terminal nuts
(2).
f.
Secure insulated wrench (1) in bracket beside output load terminal board, and close terminal board
access door.
2.10
INITIAL ADJUSTMENTS, CHECKS, AND SELF-TEST.
2.10.1
Preparation. Perform all BEFORE (B) PMCS. Refer to Table 2-5.
2.10.2
Initial Adjustments and Checks.
a.
Open left side engine compartment doors (Figure 1-3).
b.
Place DEAD CRANK switch (1, Figure 2-8) in NORMAL position.
FIGURE 2-7. INSTALLATION OF LOAD CABLES
2-27
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c.
2-28
FIGURE 2-8. GENERATOR SET CONTROLS
Close engine compartment doors.
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d.
Release DCS control panel by turning two fasteners, and lower DCS control panel slowly.
e.
Ensure FREQUENCY SELECT switch (10) is in required position.
f.
Ensure VOLTAGE SELECTION switch (9) is set to match voltage requirements.
g.
Raise and secure DCS control panel with two fasteners.
NOTE
If software fails to boot properly, notify next higher level of maintenance.
h.
Place MASTER CONTROL switch (12) in ON position. While DCS software is loading and running
its diagnostics on CIM, perform steps i through m.
i.
Open output box access door (Figure 1-2).
j.
Ensure voltage reconnection terminal board (27, Figure 1-30) is positioned to match voltage
requirements. If voltage reconnection board must be changed, notify next higher level of maintenance.
k.
Close output box access door.
l.
Ensure EMERGENCY STOP switch (2, Figure 2-8) is pulled out.
m. Ensure BATTLE SHORT switch (4) is in OFF position.
n.
2.10.3
Ensure NETWORK FAILURE indicator (3) on DCS control panel goes out when DCS software has
finished loading and is displayed on CIM display screen as shown in Figure 2-2. If NETWORK
FAILURE indicator is still illuminated, use keypad to exit software, place MASTER CONTROL
switch (12) in OFF position and panel light switch (16) is in off position, and notify next higher level of
maintenance.
Self Test.
a.
Place ENGINE CONTROL switch (6) in PRIME & RUN position.
b.
Hold FAULT RESET switch (14) in ON position for two seconds. Release switch. FAULT
INDICATOR and MESSAGES portions of CIM display screen should be blank unless a fault condition
still exists.
c.
Use arrow buttons on keypad to move cursor to DISPLAY MODE portion of CIM display screen. Use
SELECT button to alternately click MAIN / FULL button to ensure MAIN screen and FULL screen
display properly.
d.
Push PRESS TO TEST pushbutton on NETWORK FAILURE INDICATOR (3). Ensure indicator
light illuminates. When pushbutton is released, indicator light should go out.
2-29
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2.11
OPERATING PROCEDURE.
__________
WARNING
Exhaust discharge contains deadly gases including carbon monoxide. Do
not operate generator set in an enclosed area unless exhaust discharge is
properly vented outside. Failure to comply can cause injury or death to
personnel.
NOTE
If generator set is to be operated in parallel with another unit, refer to paragraph
2.12.
2.11.1
Start Generator Set.
__________
WARNING
High voltage is produced when the generator set is in operation. Never
attempt to start the generator set unless it is properly grounded. Failure to
comply can cause injury or death to personnel.
__________
WARNING
Operating the generator set with any access door open exposes personnel to
high noise level and can cause hearing damage. Hearing protection must be
worn when operating or working near the generator set with any access
door open. Failure to comply can cause hearing damage to personnel.
a.
Perform initial adjustments, checks, and self test, paragraph 2.10.
b.
Ensure CIM display screen is in MAIN mode (Figure 2-9). If necessary, use keypad arrow buttons to
move cursor to DISPLAY MODE. Use SELECT button to click FULL/MAIN button to access MAIN
mode screen.
c.
Hold FAULT RESET switch (14, Figure 2-8) in ON position for two seconds. Release switch.
CAUTION
Do not crank engine in excess of 15 seconds at a time. Allow starter to cool
at least 15 seconds between attempted starts. Failure to comply can cause
damage to equipment.
NOTE
If engine is not started within 25 seconds after FAULT RESET switch is
operated, reset condition will time out and have to be reset again before starting
the engine.
NOTE
At temperatures below 40°F (4°C) it may be necessary to use the cold weather
starting aid (See step d).
2-30
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d.
In cold weather conditions, while performing step e, momentarily hold ETHER START switch (5) to
ON position and release. Repeat as necessary until engine accelerates to governed speed.
e.
Hold ENGINE CONTROL switch (6) in START position (for 2 seconds) and observe
CIM display screen until oil pressure reaches at least 25 psi (172 kPa), voltage has
increased to its approximate rated value, and engine has reached stable operating speed.
f.
Release ENGINE CONTROL switch (6) to PRIME & RUN position.
g.
If operating with an auxiliary fuel source, rotate ENGINE CONTROL switch (6) to PRIME & RUN
AUX FUEL position.
h.
Check WATER TEMP (170-200°F [11-93°C]) and OIL PRESSURE (25-60 psi [172-414 kPa]) meters
on CIM display screen for normal readings.
i.
Use keypad arrow buttons to move cursor to DISPLAY MODE on CIM display screen. Use SELECT
button to click FULL / MAIN button to toggle between full and main mode screens. Access FULL
mode screen.
NOTE
Warm up engine without load for five minutes. (If necessary, load can be
applied immediately.)
j.
Use VOLTAGE ADJUST switch (8) and FREQUENCY ADJUST switch (7) to adjust values for
voltage and frequency until required values are displayed on VOLTAGE and FREQUENCY gages on
CIM display screen. If required reading cannot be obtained, shut down generator set (paragraph
2.11.2), and notify next higher level of maintenance.
k.
Press TEST pushbutton on GROUND FAULT CIRCUIT INTERRUPTER (13). Ensure RESET
pushbutton is in in position.
l.
Hold AC CIRCUIT INTERRUPT switch (15) in CLOSED position until CONTACTOR POSITION
on CIM display screen reads CLOSED.
m. With CIM display in Main Display Mode, ensure VOLTAGE (15) and FREQUENCY (16) gages
(Figure 2-9) still indicate rated values. Adjust if necessary.
2.11.2
n.
With CIM display in Full mode screen, if more than rated load is indicated on GEN CURRENT
indicator (3) (Figure 2-9) for any phase, reduce load.
o.
With CIM Display in Main Mode, observe POWER gage (17) (Figure 2-9) on CIM display screen. If
indication is more than 30KW, reduce load.
p.
Perform all DURING (D) PMCS requirements in accordance with Table 2-5.
Shut Down Generator Set.
a.
Hold AC CIRCUIT INTERRUPT switch (15, Figure 2-8) in OPEN position until CONTACTOR
POSITION on CIM display screen reads OPEN.
b.
c.
Allow generator set to operate five minutes with no load applied.
Place ENGINE CONTROL switch (6) in OFF position.
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NOTE
REFER TO PAGE 2-6 FOR LEGEND
FIGURE 2-9. CIM DISPLAY SCREEN CONTROLS AND INDICATORS
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d.
Perform all AFTER (A) PMCS requirements in accordance with Table 2-5.
NOTE
If software fails to boot properly, notify next higher level of maintenance.
2.12
e.
Use keypad arrow buttons to move cursor to SHUTDOWN COMPUTER on CIM display screen. Use
SELECT button to click on EXIT button to exit the DCS software.
f.
When CIM display screen displays message that it is safe to turn off the computer, place MASTER
CONTROL switch (12) in OFF position. Turn off panel lights.
g.
Place DEAD CRANK switch (1) in OFF position.
PARALLEL UNIT OPERATION (LOAD SHARING).
CAUTION
Ensure generator sets are the same size and mode before attempting
parallel operation.
2.12.1
General. The following method of parallel operation is used to share the load between two generator sets.
Refer to Figures 2-1 and 2-2 for location of operator controls and indicators mentioned below and Figure 210 for proper paralleling configuration.
2.12.2
Pre-Operation.
__________
WARNING
Prior to making any connections for parallel operation or moving a
generator set which has been operating in parallel, ensure there is no input
to the load output terminal board and the generator sets are shut down.
Failure to comply can cause injury or death to personnel by electrocution.
a.
Ensure load requirement is equal or below the combined rated capacity of the two generator sets.
__________
WARNING
High voltage is produced when the generator set is in operation. Never
attempt to start the generator set unless it is properly grounded. Failure to
comply can cause injury or death to personnel.
b.
Determine voltage requirements of load and position voltage reconnection terminal boards of the two
generator sets to the required voltage connection. Ensure FREQUENCY SELECT switches (10, Figure
2-8) on both generators are positioned for the same frequency requirements (50 Hz or 60 Hz).
c.
Identify one generator set as No. 1 and the other as No. 2.
d.
Open BATTERY ACCESS door (Figure 1-2).
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FIGURE 2-10. PARALLEL OPERATION SETUP
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e.
Remove paralleling cable from storage box, and close BATTERY ACCESS door (Figure 1-2).
f.
Connect paralleling cable between the two generators sets. Connect the generator sets to the load
observing proper phase sequence. Check connections with phase rotation meter (Appendix B).
CAUTION
Do not close the AC CIRCUIT INTERRUPT switch on either of the
generator sets, nor close the load contactor at load, until specifically
directed to do so. Closing any of these devices at any other time may
severely damage one or both of the generator sets.
2.12.3
Operation.
a.
Start each generator set. Refer to paragraph 2.11.1.
b.
Use keypad arrow buttons to move cursor to DISPLAY MODE on CIM display screen. If necessary,
use SELECT button to access FULL mode screen.
c.
Use VOLTAGE ADJUST switch (8, Figure 2-8) to obtain the same voltage indication on each set.
d.
Use FREQUENCY ADJUST switch (7) to obtain approximately the same frequency indication on both
sets. Observe CONTACTOR POSITION on CIM display screen to ensure load contactor at load is
open.
e.
Momentarily hold AC CIRCUIT INTERRUPT switch (15) on generator set No. 1 in CLOSED position
until CONTACTOR POSITION reads CLOSED.
CAUTION
Check CONTACTOR POSITION indication on CIM display screen to
ensure load contactor at load is OPEN before attempting to place
generators on the line. Failure to comply can cause damage to generator
sets.
f.
Momentarily hold AC CIRCUIT INTERRUPT switch (15) on generator set No. 2 in CLOSED position
until CONTACTOR POSITION on CIM display screen reads CLOSED.
NOTE
The generator sets are now operating in parallel with no load.
g.
Check that POWER gage on CIM display screen indicates approximately zero.
h.
Close the load contactor at the load.
i.
Check that GEN CURRENT indicators (Figure 2-11) on CIM display screens of both generator sets
display approximately the same amperage. If not, adjust VOLTAGE ADJUST switch (8, Figure 2-8)
up or down to achieve proper reading.
j.
Compare POWER Meter readings from CIM display screens on both generator sets. If readings are not
within 10 percent, remove from parallel operation at once (paragraph 2.12.4) and notify next higher
level of maintenance.
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2.12.4
Remove from Parallel Operation.
__________
WARNING
If necessary to move a generator set which has been operating in parallel
with another generator set, shut down remaining generator set connected to
the load prior to removing load cables or ground. Failure to comply can
cause injury or death to personnel by electrocution.
CAUTION
Prior to removal of one generator set from parallel operation, make sure
load does not exceed full load rating of generator set remaining on the line.
Failure to comply can cause damage to generator set still on line.
a.
Momentarily hold AC CIRCUIT INTERRUPT switch (15, Figure 2-8) in OPEN position until
CONTACTOR POSITION on CIM display screen reads OPEN.
b.
Shut down generator set, paragraph 2.11.2.
2.13
REMOTE OPERATION.
2.13.1
Description and Operating Instructions.
2-36
a.
The DCS provides the ability to control and monitor the generator set from a remote location using an
IBM-compatible personal computer (PC). Minimum requirements for that computer are: a 486
processor, RS485 serial card, 3.5" Floppy Drive and /or CD ROM drive, Windows 95 operating
system, and a mouse. (Note: Multiple RS 485 serial cards are available to use. Recommend an
internally installed RS 485 card be used for desktop PCs and a PCMCIA card be used for laptop
computers).
b.
Remote instrument monitoring allows the operator to observe metering and protective device status. To
start and run the generator set the operator must follow the operating procedures described in paragraph
2.11. When connected, the remote display functions are independent of the onboard CIM display.
That is, the remote display includes the same controls and indicators as the CIM display (Figure 2-2),
but with added controls as indicated in step c below. Switching modes on the remote display screen
does not affect the screen mode displayed on the CIM.
c.
Additional switching controls on the remote screen allow the operator to control four functions of the
remote PC and generator set from the remote location. The SHUTDOWN COMPUTER EXIT button
(1, Figure 2-11) is used to shut down the remote operation shutdown and return control of the generator
set to the DCS onboard controls. The DISPLAY MODE FULL/MAIN button (2, Figure 2-11) allows
the operator to toggle between display modes on the remote computer like the same button does on the
CIM display screen. The BATTLESHORT SEL. SW. ON/OFF button (3, Figure.2-11) allows the
remote operator to remotely activate and deactivate the generator set's battle short function. The
ENGINE CONTROL RUN/STOP button (4, Figure 2-11) allows the operator to stop the generator set
engine from the remote PC.
d.
A cable links the remote PC to the generator set via the COMMUNICATION RECEPTACLE (J3) (1,
Figure 1-30). COMMUNICATION RECEPTACLE (J3) internally connects to (J21) (Figure 2-3), of
the I/O interface module via generator set wiring. COMMUNICATION RECEPTACLE (J3) is a nine
pin environmentally sealed connector. One end of the remote cable hooks to COMMUNICATION
RECEPTACLE (J3), the other end terminates at the RS485 serial card installed in the remote PC.
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User needs to follow the specific installation instructions for the 485 serial card that is being used.
Refer to Figure 2-12 for information concerning the remote PC setup and pin configurations.
e.
2.13.2
Special-purpose software (included in the CD called "30/60kW Tactical Quiet Generator CIM
Software") is provided with the generator set for use at the remote site to process digital signals
between the remote PC and the DCS. This software must be installed on an IBM-compatible PC as
described in step a above. Setup of the software is described in paragraph 2.13.2.
TQG Remote Software Installation.
a.
Set up computer in accordance with your computer's instruction manual.
b.
Turn on computer. Refer to computer's instruction manual. Wait for computer to boot into Windows
95.
c.
The generator set comes with a CD labeled "30/60kW Tactical Quiet Generator CIM Software". If the
computer has a CD ROM drive then use procedures d (1) through d (7) below. If the computer only
has a 3.5 inch floppy drive then floppy disks need to be prepared using instructions provided in
paragraphs e (1) through e (11) below followed by the procedures in paragraphs f (1) through f (7).
below.
d.
CD ROM Procedures - Insert the CD in the CD ROM drive of computer, refer to computer instruction
manual.
(1). Left click mouse on Windows 95 START button in the lower left corner of the screen. The
START menu will pop up on the screen.
(2). Left click mouse on RUN from the START menu. The RUN window will appear.
(3). Type the following: d:\remop\setup (Note: 'd:' represents the drive letter of the CD ROM drive.
This may not be the same drive letter for all computers. Refer to computer instruction manual to
identify the correct drive letter and use that letter in place of 'd')
(4). Left click on OK button. At this point the setup wizard will guide you through the installation.
(5). To start remote data display software left click mouse on START button in the lower left corner of
the screen. The START menu will pop up on the screen.
(6). Select PROGRAMS, then left click the "Remote Data Display" icon. (Note: If the message
"Error: Communication Failed" comes up on the screen, click OK. This error may come up because
the PC is not connected to the CIM).
(7). To exit out of this screen, move cursor to EXIT button and left click the mouse.
e.
Floppy disk preparation. (Note: Any computer that meets the minimum requirements in para. 2.13.1.a
above (except for the RS485 serial card which is not required), and has both a 3.5" floppy drive and
CD ROM drive can be used for these procedures).
(1). Set up computer in accordance with your computer's instruction manual.
(2). Turn on computer. Refer to computer's instruction manual. Wait for computer to boot.
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(3). Insert the CD labeled " 30/60kW Tactical Quiet Generator CIM Software" in the CD ROM drive
of computer, refer to computer instruction manual.
(4). Insert a blank, formatted 3.5" floppy disk in the 3.5" floppy drive of computer, refer to computer
instruction manual.
(5). Left click mouse on START button in the lower left corner of the screen. The START menu will
pop up on the screen.
(6). Select PROGRAMS, then left click the "MS-DOS Command Prompt" icon.
(7). Type in d: (Note: 'd:' represents the drive letter of the CD ROM drive. This may not be the same
drive letter for all computers. Refer to computer instruction manual to identify the correct drive letter
and use that letter in place of 'd'). Press [ENTER].
(8). After 'D:>\' comes up on screen type in cd batch. Press [ENTER]. (Note: There are three (3)
possible ways to make floppy disks. The following paragraphs describe the 3 options).
(a) To make only one disk type in the command create[SPACE]# where # represents the number
of the disk to be made – i.e. "create 2" makes a copy of disk #2.
(b) If more than one disk needs to be made type in the command
create[SPACE]#[SPACE]#[SPACE]# where # represents the number of the disk that is to be made, ie.
To make disks 1, 3, &5 type in "create 1 3 5".
(c) To make all eight (8) disks at one time simply type in the command makeall.
(9). At next prompt (D:\BATCH>) type in the command from (8) above that is applicable to the
number of disks that are to be made, i.e. "create 1", "create 3 4 5…" or "makeall". The names of the
eight (8) disks are as follows:
Disk 1 - Generator Software Remote Operator. Disk 1 of 2
Disk 2 - Generator Software Remote Operator. Disk 2 of 2
Disk 3 - Generator Software Operator Log. Disk 1 of 2
Disk 4 - Generator Software Operator Log. Disk 2 of 2
Disk 5 - Generator Software CIM Network Link. Disk 1 of 1
Disk 6 - Generator Software Windows CE. Disk 1 of 2
Disk 7 - Generator Software Windows CE. Disk 2 of 2
Disk 8 - Generator Software Digital Controls. Disk 1 of 1
(10). Press [ENTER] key. When the copy is complete the screen will prompt you to insert a blank
floppy disk. Label each disk as shown above -i.e. "Generator Software Remote Operator. Disk 2 of 2".
(11). When copying of the required disks is complete, press [ENTER] and type in exit to return to
Windows screen. Remove floppy disk and CD.
f.
Floppy Disk procedures. Insert 3.5" floppy disk labeled "Generator Software Remote Operator. Disk 1
of 2", in 3.5" floppy drive of computer, refer to computer instruction manual.
(1). Left click mouse on Windows 95 START button in the lower left corner of the screen. The
START menu will pop up on the screen.
(2). Left click mouse on RUN from the START menu. The RUN window will appear.
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(3). Type the following: a:\setup
(4). Left click on OK button. At this point the setup wizard will guide you through the installation.
When prompted hit "Next" and complete requested information. Keep hitting "Next" until prompted to
insert Disk 2. Insert 3.5" floppy disk labeled "Generator Software Remote Operator. Disk 2 of 2", in
3.5" floppy drive of computer.
(5). To start remote data display software, left click mouse on Windows 95 START button in the lower
left corner of the screen. The START menu will pop up on the screen.
(6). Select Programs, then left click the "Remote Data Display" icon. (Note: If the message "Error:
Communication Failed" comes up on the screen, click OK. This error may come up because the PC is
not connected to the CIM).
(7). To exit out of this screen, move cursor to EXIT button and left click the mouse.
2.14
PREPARATION FOR MOVEMENT.
a.
Shut down generator set, paragraph 2.11.2. If generator set is operating in parallel, refer to paragraph
2.12.4.
b.
Disconnect load cables (Figure 2-7).
c.
Disconnect paralleling cable, if used, and store in storage box inside BATTERY ACCESS door (Figure
1-2).
d.
When using auxiliary fuel line, disconnect line, drain excess fuel from line, and store line in storage
box inside BATTERY ACCESS door (Figure 1-2).
e.
Disconnect ground cable, and remove ground rods. Store ground rods in holding brackets located
inside generator set housing, below engine compartment access doors. Store ground cable, couplings,
clamp, and driving stud in storage box inside BATTERY ACCESS door.
f.
Secure all generator set access doors and panels.
g.
For assembly and preparation for use, refer to paragraph 2.9.
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FIGURE 2-11. REMOTE PC DISPLAY MODES
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FIGURE 2-12. REMOTE PC SETUP
SECTION IV. OPERATION UNDER UNUSUAL CONDITIONS
2.15
OPERATION IN EXTREME COLD WEATHER BELOW -25° F (-31° C).
The generator set operates in ambient temperatures as low as -25°F (-31°C) without special winterization
equipment. To ensure satisfactory operation under extreme cold weather the following steps must be taken:
__________
WARNING
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In extreme cold weather, skin can stick to metal. Avoid contacting metal
items with bare skin in extreme cold weather. Failure to comply can cause
injury to personnel.
a.
Keep generator set and surrounding area as free of ice and snow as practical.
b.
Keep fuel tank full to protect against moisture, condensation, and accumulation of water.
c.
Ensure proper grade diesel fuel is used. Refer to Table 2-7.
TABLE 2-7. FUEL
AMBIENT TEMPERATURE
+20°F TO 120°F
(-6°C TO +49°C)
0°F TO +20°F
(-17°C TO -6°C)
-25°F TO 0°F
(-32°C TO -17°C)
-25°F TO 0°F
(-32°C TO -17°C)
2.16
2.17
2-42
DIESEL FUEL
VV-F-800 GRADE DF-2, JP5, OR JP8
VV-F-800 GRADE DF-1, JP5, OR JP8
VV-F-800
GRADE DF-1
VV-F-800
GRADE DF-A
d.
Keep batteries free from corrosion and in a well charged condition.
e.
Ensure proper oil is used. See Appendix F.
OPERATION IN EXTREME HEAT ABOVE 120° F (48.8° C).
a.
Check vents and radiator air passages frequently for obstructions.
b.
Check coolant temperature indicator frequently for any indication of overheating.
c.
Allow sufficient space for fuel expansion when filling fuel tank.
d.
Keep generator clean and free of dirt. Clean obstructions from generator intake and outlet screens.
e.
Clean external surface of engine when generator set is not operating.
OPERATION IN DUSTY OR SANDY AREAS.
a.
If possible, provide a shelter for generator set. Use available natural barriers to shield generator set
from blowing dust and sand.
b.
Wet down dusty and sandy surfaces areas around generator set frequently if water is available.
c.
Keep all access doors closed as much as possible to prevent entry of dust and sand into housing
assembly.
d.
Wipe dust and sand frequently from the generator set external surface and components. Wash exterior
surfaces frequently with clean water when generator set is not operating.
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2.18
e.
Service engine air cleaner assembly frequently to compensate for intake of additional dust or sand.
f.
Drain sediment frequently from fuel filter/water separator. When servicing fuel tank, be careful to
prevent dust or sand from entering fuel tank.
g.
Change engine oil and oil filter frequently.
h.
Store oil and fuel in dust-free containers.
i.
Ensure generator set ground connections are free of dust and sand, and connections are tight before
starting the unit.
OPERATION UNDER RAINY OR HUMID CONDITIONS.
CAUTION
Failure to remove waterproof material before operating generator set could
result in damage to equipment.
a.
If possible, provide a shelter for generator set. Cover generator set with canvas or other waterproof
material when it is not being operated.
b.
Provide adequate drainage to prevent water from accumulating on operation site.
c.
Keep all generator set access doors closed, as much as possible, to prevent entry of water into housing
assembly.
d.
Drain water frequently from fuel filter/water separator.
__________
WARNING
DC voltages are present at generator set electrical components even with
generator set shut down. Avoid shorting any positive terminal with
ground/negative. Failure to comply can cause injury to personnel and
damage to equipment.
2.19
e.
Remove moisture from generator set components before and after each operating period.
f.
Keep fuel tank full to protect against moisture, condensation, and accumulation of water.
OPERATION IN SALT WATER AREAS.
CAUTION
Failure to remove waterproof material before operating generator set could
result in damage to equipment.
a.
If possible, provide a shelter for the generator set. Locate generator set so radiator faces into prevailing
winds. Use natural barriers or, if possible, construct a barrier to protect generator set from salt water.
Cover generator set with canvas or other waterproof material when it is not being operated.
b.
Keep all generator set access doors closed, as much as possible, to prevent entry of salt water into
housing assembly.
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2.20
c.
Wash exterior surfaces frequently with clean water when generator set is not operating.
d.
Check wiring connections for corrosion and wire insulation for signs of deterioration.
OPERATION AT HIGH ALTITUDES.
The generator set will operate at elevations up to 4000 feet (1219.1 meters) above sea level without special
adjustment or reduction in load. At elevations greater than 4000 feet, the kilowatt rating is reduced
approximately 3.5 percent for each additional 1000 feet (304.8 meters).
2.21
NATO SLAVE RECEPTACLE START OPERATION.
2.21.1
General. The NATO SLAVE RECEPTACLE (Figure 2-13) can be used to start the generator set when
batteries are discharged.
2.21.2
NATO/Slave Emergency Starting Procedure.
a.
Connect one end of NATO/SLAVE RECEPTACLE cable to fully charged 24 VDC system and other
end to discharged generator set's NATO/SLAVE RECEPTACLE (Figure 2-13).
b.
Start discharged generator set, paragraph 2.11.1.
c.
Remove NATO/SLAVE RECEPTACLE cable after generator set starts.
NOTE
The generator set cannot be restarted without resetting the EMERGENCY STOP
pushbutton and turning ENGINE CONTROL switch to OFF position.
2.22
EMERGENCY STOPPING. Depressing the EMERGENCY STOP pushbutton (2, Figure 2-8) will stop the
generator set.
2.23
OPERATION USING BATTLE SHORT SWITCH.
CAUTION
Continued operation using the BATTLE SHORT switch can result in
damage to the generator set.
NOTE
If any emergency situation requires continued operation of the generator set, the
BATTLE SHORT switch is used to override all protection devices except the
overspeed, short circuit devices, and EMERGENCY STOP function.
NOTE
BATTLE SHORT switch must be in OFF position to start generator set.
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FIGURE 2-13. NATO SLAVE RECEPTACLE
2.24
a.
Start generator set, paragraph 2.11.1.
b.
Lift cover on BATTLE SHORT switch (4, Figure 2-8), and place switch in ON position to operate
generator set under these emergency conditions.
NUCLEAR, BIOLOGICAL, AND CHEMICAL (NBC) DECONTAMINATION PROCEDURES. Refer to
FM 3-5, NBC Decontamination, for information on decontamination procedures. Specific procedures for
the generator set are as follows:
a.
Control panel indicator sealing gaskets, rubber sleeves, rope draw cords at output terminal access ports,
control panel door gaskets, access door gaskets, rubber tubing and belts within the engine
compartment, coverings for electrical conduits, external water drain tubing, and retaining cords for
NATO SLAVE RECEPTACLE covers will absorb and retain chemical agents. Replacement of these
items is the recommended method of decontamination.
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b.
Lubricants, fuel, coolant, and battery fluid may be present on external surfaces of the generator set or
its components due to leaks or normal operation. These fluids will absorb NBC agents. The preferred
method of decontamination is removal of these fluids using conventional decontamination methods in
accordance with FM 3-5.
c.
Continued decontamination of external generator set surfaces with supertropical bleach
(STB)/decontaminating solution number 2 (DS2) will degrade clear plastic indicator coverings to a
point where reading indicators will become impossible. This problem will become more evident for
soldiers wearing protective masks. Therefore, the use of STB or DS2 decontaminates in these areas
should be minimized. Indicators and the CIM display screen should be decontaminated with warm
soapy water.
d.
External surfaces of the control panel assembly that are marked with painted or stamped lettering will
not withstand repeated decontamination with STB or DS2 without degradation of this lettering. The
recommended method of decontamination for these areas is warm soapy water.
e.
Areas that will entrap contaminants, making efficient decontamination extremely difficult, include the
following: space behind knobs and switches on the control panel, exposed heads of screws, areas
adjacent to and behind exposed wiring conduits, hinged areas of access doors, spaces behind externally
mounted equipment specification data plates, areas around external oil drain valve, retaining chains for
external receptacle covers, areas behind external receptacle covers, access door locking mechanisms,
recessed walls for access door handles, fuel caps, load output terminal board access door, NATO
SLAVE RECEPTACLE, frequency adjustment controls, areas around tie-down/lifting rings, crevices
around access doors, external screens covering ventilation areas, and areas adjacent to the external fuel
drain valve. Replacement of these items, if available, is the preferred method of decontamination.
Conventional decontamination methods should be used on these areas, while stressing the importance
of thoroughness and the probability of some degree of continuing contact and vapor hazard.
f.
In an NBC contaminated environment, the generator set should be operated with all access doors
closed to reduce the effects of contamination.
g.
The use of overhead shelters or chemical protective covers is recommended as an additional means of
protection against contamination in accordance with FM 3-5. When using covers, care should be taken
to provide adequate space for air flow and exhaust.
h.
For additional NBC information, refer to FM 3-3 and FM 3-4.
2.25
OPERATION WHILE CONTAMINATED. The generator will operate in a normal manner when exposed
to nuclear, biological, or chemical (NBC) contamination. It is capable of being operated by personnel
wearing NBC clothing without special tools or support equipment. Refer to FM 3-3, FM 3-4, and FM 3-5.
2.26
OPERATION IN A HIGH ALTITUDE ELECTROMAGNETIC PULSE (HAEMP) ENVIRONMENT.
2-46
a.
Hold AC CIRCUIT INTERRUPTER switch (15, Figure 2-8) in open position until CONTACTOR
POSITION on CIM display screen reads OPEN.
b.
Place ENGINE CONTROL SWITCH (6) in OFF position.
c.
Place MASTER SWITCH (12) in OFF position and wait approximately 10 seconds.
d.
Restart and operate generator set in accordance with applicable normal procedures (refer to para 2.11).
ARMY TM 9-6115-671-14
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CHAPTER 2
OPERATING INSTRUCTIONS
CHAPTER INDEX
SECTION I
DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS .......................2-1
SECTION II
PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)...................................2-14
SECTION III
OPERATION UNDER USUAL CONDITIONS .........................................................................2-21
SECTION IV
OPERATION UNDER UNUSUAL CONDITIONS ...................................................................2-41
SECTION I. DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS.
2.1
GENERAL.
This section describes and illustrates generator set controls and indicators to ensure proper operation of
generator set.
2.2
DCS CONTROLS AND INDICATORS.
The Digital Control System (DCS) contains most of the operating controls for the generator set. Figure 2-1
shows the DCS control panel assembly layout. Table 2-1 describes each control and indicator.
2-1
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FIGURE 2-1. DCS CONTROLS AND INDICATORS
2-2
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TABLE 2-1. DCS CONTROLS AND INDICATORS
KEY
1
2
3
CONTROL OR INDICATOR
ELAPSED TIME Meter
Panel Lights
EMERGENCY STOP Switch
4
5
PANEL LIGHTS Switch
NETWORK FAILURE Indicator
6
BATTLE SHORT Switch
7
ETHER START Switch
8
ENGINE CONTROL Switch
9
FREQUENCY ADJUST Switch
10
AC CIRCUIT INTERRUPT Switch
11
VOLTAGE ADJUST Switch
12
FAULT RESET Switch
13
MASTER CONTROL Switch
14
16
GROUND FAULT CIRCUIT
INTERRUPTER TEST Switch
GROUND FAULT CIRCUIT
INTERRUPTER RESET Switch
Keypad Up Arrow Pushbutton
↑
17
18
Keypad Right Arrow Pushbutton →
Keypad SELECT Pushbutton
19
Keypad Down Arrow Pushbutton ↓
15
FUNCTION
Indicates total engine operating hours.
Illuminate DCS control panel.
Shuts down generator set when activated. Removes electrical
power to governor controller and stops engine from operating.
Activates and deactivates panel lights.
When illuminated indicates a failure between Computer
Interface Module and Input/Output Module. Generator set will
not continue to operate, and capability to monitor its operation
and to make adjustments will be degraded or lost.
Bypasses protective devices on generator set. Set will continue
to operate until overvoltage occurs or fuel is exhausted.
When held in ON position momentarily during engine cranking,
activates ether cold weather starting system for starting engine
at temperatures below 40°F (4°C).
Four position switch:
OFF – de-energizes all circuits except panel lights and power to
CIM.
PRIME & RUN AUX FUEL – energizes generator set run
circuits with auxiliary fuel pump operating.
PRIME & RUN – energizes generator set run circuits with
auxiliary fuel pump de-energized.
START – energizes engine starter and flashes generator field.
Momentary-action toggle switch. Adjusts frequency output of
generator set for each activation of the switch. Works in both
directions to increase and decrease output frequency.
Opens and closes AC Circuit Interrupt Relay. Used during
parallel operation.
Momentary-action toggle switch. Adjusts voltage output of
generator set. Works in both directions to increase and
decrease output voltage.
Resets (turns off) fault indicators displayed on Computer
Interface Module display screen. Will re-energize governor
power.
When placed in ON position, provides battery power to DCS.
Should be first switch activated on panel. Generator set cannot
be started unless switch is activated.
Tests GROUND FAULT CIRCUIT INTERRUPTER.
Resets GROUND FAULT CIRCUIT INTERRUPTER.
Moves cursor on CIM display screen in upward direction until
released.
Moves cursor on CIM display screen to the right until released.
When pressed, selects item on CIM display screen indicated by
cursor.
Moves cursor on CIM display screen in downward direction
until released.
2-3
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TABLE 2-1. DCS CONTROLS AND INDICATORS (continued)
KEY
20
21
22
23
24
2.3
CONTROL OR INDICATOR
Keypad Left Arrow Pushbutton ←
DC CONTROL POWER Fuse
FREQUENCY SELECT Switch
(MEP-806B only)
REACTIVE CURRENT ADJUST
rheostat
VOLTAGE SCALE Switch
FUNCTION
Moves cursor on CIM display screen to the left until released.
Provides overcurrent protection for DC circuits.
Allows selection of 50 Hz or 60 Hz.
Adjusts voltage droop when two generator sets are operated in
parallel.
Reports configuration of output voltage connection selected on
voltage reconnection terminal board.
COMPUTER INTERFACE MODULE (CIM) DISPLAY SCREEN CONTROLS AND INDICATORS.
The Computer Interface Module (CIM) Display Screen displays most of the indicators for the generator set.
Figure 2-2 shows the CIM display screen layout. Table 2-2 describes each control and indicator. Table 2-3
describes faults that may be displayed in the FAULT INDICATOR section of the CIM display screen and
related operator messages that may be displayed in the MESSAGES section.
2-4
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FIGURE 2-2. CIM DISPLAY SCREEN CONTROLS AND INDICATORS
2-5
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TABLE 2-2. CIM DISPLAY SCREEN CONTROLS AND INDICATORS
KEY
1
2
3
GEN CURRENT indicators
4
FAULT INDICATOR display
5
DELTA VAC gage
6
MESSAGES display
7
8
WATER TEMP virtual meter
BATTLE SHORT CIRCUIT status
indicator
CONTACTOR POSITION status
indicator
DISPLAY MODE FULL/MAIN
switch
9
10
2-6
CONTROL OR INDICATOR
GEN VOLTAGE indicators
BATTERY VDC indicator
11
SHUTDOWN COMPUTER
EXIT button
12
13
14
BATTERY AMPS virtual meter
OIL PRESSURE virtual meter
BUS VOLTAGE indicators
15
16
17
18
VOLTAGE gage
FREQ gage
POWER gage
FUEL LEVEL gage
FUNCTION
Indicates generator output voltage for each of the three phases.
Indicates charge status of both generator set DC batteries
(VDC).
Indicates generator output current (amps) for each of the three
phases.
Displays fault indications as they occur. Specific warnings and
instructions related to a fault are displayed simultaneously in
the MESSAGES display. See Table 2-3 for the list of possible
faults.
Indicates generator set output voltage versus bus voltage. Used
prior to operating in parallel with another unit. Used to monitor
system prior to parallel operation to ensure generator and bus
voltage are balanced within 5 volts before closing contactor to
bus.
Displays warnings and instructions in the form of operator
messages related to faults displayed in FAULT INDICATOR
display.
Indicates generator set cooling system water temperature (°F).
Indicates whether generator set is in battle short mode or not.
ON indication means battle short circuit is energized.
Indicates whether contactor is open or closed.
When FULL/MAIN button is selected with the keypad, CIM
display screen toggles between FULL and MAIN modes and
button changes to show name of mode currently displayed.
When EXIT button is selected with the keypad, the DCS
software shuts down so the CIM can be safely deactivated.
This will also shut down the generator set if it is running.
Indicates input current of generator set DC batteries (amps).
Indicates engine oil pressure (psi).
Indicate voltage on output bus. The GEN VOLTAGE and BUS
VOLTAGE indicators must match within five volts, each phase,
to perform paralleling operation.
Indicates generator set voltage output (VAC).
Indicates generator set frequency output (Hz).
Indicates generator set power output (kW).
Indicates amount of fuel in fuel tank (percent remaining).
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TABLE 2-3. FAULTS
NOTE: Maintainers can only check faults at their level.
FAULT
MESSAGE #
MESSAGE
CIRCUIT FAILURE 01
The fuel level signal is lower than the operating range.
FUEL LEVEL
Check fuel level. Check fuel sensor and circuit. (Para. 4.11.5)
SHUTDOWN - LOW FUEL
02
Fuel level is abnormally low.
Check fuel level. Verify fuel system lineup.
WARNING - LOW FUEL
03
Fuel level is abnormally low.
Check fuel level. Verify fuel system lineup.
CIRCUIT FAILURE 04
The fuel level signal is higher than the operating range.
FUEL LEVEL
Check fuel level. Check fuel sensor and circuit. (Para. 4.11.5)
CIRCUIT FAILURE COOLANT TEMP
05
06
WARNING - COOLANT
TEMP
SHUTDOWN - COOLANT
TEMP
07
CIRCUIT FAILURE - OIL
PRESSURE
09
08
10
WARNING - LOW OIL
11
SHUTDOWN - LOW OIL
12
WARNING OVERVOLTAGE
SHUTDOWN OVERVOLTAGE
13
WARNING - OVERSPEED
15
SHUTDOWN OVERSPEED
16
WARNING UNDERVOLTAGE
CONTACTOR TRIP UNDERVOLTAGE
17
WARNING - OVERLOAD
19
14
18
The coolant temperature signal is lower than the operating range.
Check coolant level. Check coolant temperature sensor and circuit.
(Para. 4.13.2)
The coolant temperature is higher than the operating range.
Check coolant level. Check coolant temperature sensor and circuit.
(Para. 4.13.2)
Coolant temperature is abnormally high.
Check coolant level. Verify coolant system lineup. (Para. 3.3.5)
Coolant temperature is abnormally high.
Check coolant level. Verify coolant system lineup. (Para. 3.3.5)
The oil pressure signal is lower than the operating range.
Check oil pressure. Check oil pressure sensor and circuit.(Para.
4.13.1)
The oil pressure signal is higher than the operating range.
Check oil pressure. check oil pressure sensor and circuit.(Para.
4.13.1)
Oil pressure is abnormally low.
Check oil. Verify lubricating system lineup. (Para. 3.3.8)
Oil pressure is abnormally low.
Check oil. Verify lubricating system lineup. (Para. 3.3.8)
Generator voltage is abnormally high.
Adjust VOLTAGE ADJUST switch. (Para. 2.11.1 j)
Generator voltage is abnormally high.
Adjust VOLTAGE ADJUST switch. (Para. 2.11.1 j)
Generator frequency is abnormally high.
Adjust FREQUENCY ADJUST switch. (Para. 2.11.1 j)
Generator frequency is abnormally high.
Adjust FREQUENCY ADJUST switch. (Para. 2.11.1 j)
Generator voltage is abnormally low.
Adjust VOLTAGE ADJUST switch. (Para. 2.11.1 j)
Generator voltage is abnormally low.
Adjust VOLTAGE ADJUST switch. (Para. 2.11.1 j)
System load is abnormally high.
Reduce load to within generator set ratings. (Para. 2.11.1 n and o)
2-7
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TABLE 2-3. FAULTS (continued)
FAULT
CONTACTOR TRIP OVERLOAD
MESSAGE #
20
CONTACTOR TRIP REVERSE POWER
21
Load share device sensed reverse power conditions.
Verify load share device setpoints are correct.
CONTACTOR TRIP SHORT CIRCUIT
22
System load was abnormally high.
Reduce load to within generator set ratings.
2.4
MESSAGE
System load is abnormally high.
Reduce load to within generator set ratings. (Para. 2.12)
DIAGNOSTIC CONTROLS AND INDICATORS.
The DCS load sharing synchronizer, DCS speed control unit, automatic voltage regulator, backplane
module, and I/O interface module are equipped with indicators used as diagnostic tools in troubleshooting.
Some of the DCS modules also include controls that are set at installation and may need to be adjusted
during troubleshooting. Figure 2-3 shows the locations of the controls and indicators on the DCS modules.
Table 2-4 describes each control and indicator.
2-8
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FIGURE 2-3. DIAGNOSTIC CONTROLS AND INDICATORS (SHEET 1 OF 2)
2-9
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FIGURE 2-3. DIAGNOSTIC CONTROLS AND INDICATORS (SHEET 2 OF 2)
2-10
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TABLE 2-4. DIAGNOSTIC CONTROLS AND INDICATORS
KEY
CONTROL OR INDICATOR
DCS LOAD SHARING SYNCHRONIZER
1
L1 indicator (green LED)
2
L2 indicator (green LED)
3
REVERSE POWER (red LED)
4
GEN indicator (green LED)
5
BUS indicator (green LED)
6
SYNCH ENABLED indicator
(green LED)
7
PARALLEL ENABLE indicator
(green LED)
8
SYNCHRONIZED indicator
(green LED)
9
DC POWER indicator (green
LED)
FUNCTION
This indicator is lit when the load sharing control is making
transition from zero power output up to a power output in a
load sharing (paralleling) condition. Normally, this LED is lit
only during the load sharing (paralleling) period.
This indicator is lit only when zero power from the generator
set is reached before the breaker is opened. It indicates when
the I/O interface module is calling for the generator to go to
zero power output before the generator breaker is opened
automatically by the I/O interface module.
This indicator is lit when a reverse power situation exists. The
I/O interface module has been notified to remove the generator
set from service (open the breaker).
This indicator is normally lit when the generator set is operating
(engine is running). When lit, the LED indicates the module is
receiving AC power from the generator.
This indicator is normally lit only when the generator set is
running and the main breaker is closed. It is also lit when
another generator set is connected to the main breaker and its
breaker is closed. When lit, the LED indicates AC power is
being received from the bus (the output of the generator set
main breaker) into the module. The indicator is not lit if the
bus has failed, and when this module is not being used.
This indicator is lit only when the I/O interface module requests
synchronizing the output power of the generator set with a
second generator set and the paralleling cable has been
connected between the two sets. In addition, the AC CIRCUIT
INTERRUPT switch on the primary set has been previously
moved to the CLOSED position. This indicator is lit only
during the synchronizing period.
This indicator will be lit when the I/O interface module has
closed the main breaker. That is, the I/O interface module has
commanded the DCS load sharing synchronizer to close the
connection with the paralleling cable and begin parallel
operation of the two generator sets.
This indicator will be lit when the generator is in synch with the
bus. When this LED is lit, the DCS load sharing synchronizer
has signaled the I/O interface module that paralleling may
occur.
This indicator is normally lit only when the generator set is
operating (engine is running). It is off at all other times. When
lit, the LED indicates the internal DC supply of the module is
operating (i.e., the module is receiving DC power from the
generator set, and the module is properly converting the power
into its own operating voltage(s).
2-11
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TABLE 2-4. DIAGNOSTIC CONTROLS AND INDICATORS (continued)
KEY
CONTROL OR INDICATOR
SPEED CONTROL UNIT
10
OVERSPEED indicator (red LED)
11
ACTUATOR indicator (green
LED)
12
SPEED SENSOR indicator (green
LED)
13
OVERSPEED RESET pushbutton
14
OVERSPEED TEST pushbutton
15
DC POWER indicator (green
LED)
CRANK TERMINATION (green
LED)
16
BACKPLANE MODULE
17
LED 16 (red) indicator
18
LED 15 (red) indicator
19
LED 14 (red) indicator
2-12
FUNCTION
This indicator is normally off, even when the generator set is
operating. When the LED is lit, an engine overspeed condition
has occurred (the flywheel RPM sensor has sent the speed
control unit a value which is defined as out-of-tolerance). The
indicator will remain lit until either of two events has occurred:
(1) The OVERSPEED RESET pushbutton has been manually
activated, or (2) the generator set (engine) has been stopped and
the DC power is reset.
This indicator is normally lit when the electric actuator (on the
injection fuel pump) has power applied to it. The LED will be
lit when the engine is operating or when the engine is being
cranked (started). If the indicator is off while the engine is
operating, it can mean: (1) the electric actuator has failed, (2)
the connection between the actuator and the module has failed,
or (3) the module has malfunctioned or failed.
This indicator is normally lit when the engine is operating. The
indicator lit/off function is directly related to the signal from the
speed sensor connected to the flywheel. If the indicator is off,
but the engine is operating, this indicates the engine RPM
signal is not being received. This can be caused by sensor
failure or by a failure in the connection to the sensor.
If the OVERSPEED indicator is lit and the engine has stopped,
this switch may be used to attempt to reset the overspeed
protection system. If the OVERSPEED indicator turns off
when the switch is activated, the protection system is reset, and
the engine may be restarted. (The conclusion is that no
problem exists with engine speed.) If after restarting the
OVERSPEED indicator comes on again and the engine stops,
there is a problem with engine speed control.
This switch is used to test one of the protective systems of the
generator set: engine overspeed protection. Pressing this
switch while the engine is running at rated speed will activate
the overspeed protection system, thereby stopping the engine.
This indicator is normally lit when the engine is operating. It
indicates the internal DC power in the module is operating.
This indicator is normally lit when the engine is operating.
When the engine is being started, the indicator will remain off
until engine speed exceeds 400 RPM and the cranking relay
returns to its normal (non-energized) state. If the indicator
remains off and the engine starter continues operation, this is an
indication of a failure in the starter assembly or of the cranking
relay.
(not assigned)
(not assigned)
Fault indication. If indicator is lit, indicates a fault has
occurred. If off, indicates normal running condition.
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TABLE 2-4. DIAGNOSTIC CONTROLS AND INDICATORS (continued)
KEY
CONTROL OR INDICATOR
BACKPLANE MODULE (continued)
20
LED 13 (red) indicator
21
22
LED 12 (green)
LED 11 (green)
23
LED 10 (green)
24
LED 9 (green)
25
26
LED 8 (red)
LED 7 (red)
27
LED 6 (red)
28
LED 5 (red)
29
30
LED 4 (green)
LED 3 (green)
31
32
LED 2 (green)
LED 1 (green)
FUNCTION
Short circuit indication. If indicator is lit, indicates a short
circuit condition affecting generator set output has been
detected.
(not assigned)
Remote display connection. Indicator blinks on and off when
remote display is properly connected. If not lit, indicates no
remote display connection has been made.
Data validity from remote display. Indicator blinks on and off
to indicate remote data is being received properly. If not lit,
remote data is not being received properly. If not lit, can also
indicate no remote display function has been connected.
Status of the main generator power bus. If indicator is lit, the
bus is energized (voltage is present), and voltage is available
for paralleling operation. If not lit, indicates the generator set is
operating in a stand-alone mode.
(not assigned)
Network failure. If indicator is lit, indicates the CIM is not
communicating with the I/O interface module. If not lit,
indicates the CIM is communicating properly.
Emergency stop. If indicator is lit, indicates the
EMERGENCY STOP switch has been activated. If not lit,
indicates normal running condition.
CMOS voltage. If indicator is lit, indicates voltage necessary
for CMOS device operation is too low. If not lit, CMOS device
voltage source is sufficient.
(not assigned)
Heartbeat. If indicator is blinking on and off, indicates proper
operation of this module. If not lit, indicates module has no
power applied or has failed.
(not assigned)
If indicator is lit, fuel pump is operating. If not lit, fuel pump is
not operating.
AUTOMATIC VOLTAGE REGULATOR
33
AC SENSING (green LED)
34
DC SUPPLY indicator (green
LED)
35
FIELD VOLTAGE (green LED)
This indicator is normally lit, indicating the AC sensor is
sending the proper signal to this module.
This indicator is normally lit, indicating that the module's
internal DC supply is operating. The source for input power to
this module is the AC output of the generator set. Therefore,
the indicator will not be lit until the generator set is providing
power output to a load.
This indicator is normally lit. It indicates field voltage is
present, which means the generator is developing AC power.
2-13
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TABLE 2-4. DIAGNOSTIC CONTROLS AND INDICATORS (continued)
KEY
CONTROL OR INDICATOR
I/O INTERFACE MODULE
36
HEARTBEAT (green LED)
37
DIP Switch Assembly (8 positions)
FUNCTION
This indicator is normally blinking on and off when DC power
has been applied to the module. It is also normally blinking
when the generator set is operating (engine running) and the
module is functioning properly. If the indicator is either steadystate lit or steady-state off, but the CIM has been turned on and
the engine is operating, this is an indication that there is a
problem in the I/O interface module.
These switches define the configuration of the generator set for
the CIM. The generator set configuration is defined in two
ways: its output power (kW) rating and its frequency rating.
These switches must be set to a specified configuration prior to
the module's use in the generator set. Unless these switches are
properly set (and remain so), the generator set can experience a
malfunction. For the MEP-806B, all switches are set to OFF.
For the MEP-816B, Switch 5 is set to ON and all the other
switches to OFF. (Ref Figure 4-31)
SECTION II. PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
2.5
GENERAL.
To ensure the generator set is ready for operation at all times, it must be inspected so that defects can be
discovered and corrected before they result in serious damage or failure.
2.5.1
Before Operation. Always keep in mind the CAUTIONS and WARNINGS. Perform Before (B) PMCS.
2.5.2
During Operation. Always keep in mind the CAUTIONS and WARNINGS. Perform During (D) PMCS.
2.5.3
After Operation. Perform After (A) PMCS.
2.5.4
If the Equipment Fails. If the equipment does not perform as required, refer to Chapter 3, Section II under
Troubleshooting for possible problems. The Symptom Index is provided as a guide for troubleshooting
procedures. Report any malfunctions or failures on DA Form 2404 (refer to DA PAM 738-750).
2.6
PMCS Procedures.
NOTE
For general location of items to be inspected in Table 2-5, refer to Figures 1-30
and 2-1.
2.6.1
Purpose of PMCS Table. PMCS, Table 2-5, lists inspections and care of equipment required to keep the
generator set in good operating condition.
2.6.2
Purpose of Service Intervals. The interval column of the PMCS table indicates when to perform a certain
check or service.
Special Instructions. The following guidelines are provided to help classify leaks observed while
performing PMCS.
2.6.3
Class I.
2-14
Seepage of fluid (as indicated by wetness or discoloration) not great enough to form drops.
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Class II.
Leakage of fluid great enough to form drops, but not enough to cause drops to drip from item
being checked/inspected.
Class III.
Leakage of fluid great enough to form drops that fall from the item being checked/inspected.
CAUTION
Equipment operation is allowable with minor oil and coolant leakage (Class
I or II). When operating with Class I or II leaks, continue to check fluid
levels as required in PMCS. All leaks should be reported to the next higher
level of maintenance. Failure to comply can cause damage to equipment.
2.6.4
Procedures Column. The procedures column of the PMCS table tells how to perform required checks and
services. If required tools are not available, or if a procedure indicates, complete DA Form 2404 and
submit it to the next higher level of maintenance.
NOTE
The terms "ready/available" and "mission capable" refer to the same status. The
generator set is on hand and able to perform combat missions. Refer to DA
PAM 738-750.
2.6.5
"Equipment is not ready/available if" Column. This column tells when and why the generator set cannot be
used.
2.6.6
Reporting and Correcting Deficiencies. If the generator set does not perform as required, refer to Chapter
3, Operator Troubleshooting, to diagnose the problem.
2.6.7
Removal of Assemblies/Equipment to Perform PMCS. There is no requirement to remove
assemblies/equipment prior to performing PMCS.
NOTE
If generator set must be kept in continuous operation, check and service only those
items which can be checked and serviced without disturbing operation. Perform
complete checks and services when the generator set can be shut down.
NOTE
The generator set can be operated continuously at any load from no load up to and
including rated load. However, at light loads an oily residue (unburned fuel oil)
may occasionally be noticed in the exhaust system outlet and around connection
joints in the exhaust system. This residue is caused by the inability of the fuel
injection system to consistently meter the small amount of fuel required to operate
at these low load levels and is not a defect in the fuel system. The oily residue
could affect engine performance and create a cosmetic problem on and around the
generator set. Operation at rated load will burn off this oily residue. The length of
time required at rated load depends on the amount of residue. This oily residue can
be prevented by increasing the electrical load on the set.
2-15
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TABLE 2-5. OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
CAUTION
Engine oil and filter must be changed at a hardtime - 100 hours on initial
break-in. Failure to change oil and filter may void warranty.
B-BEFORE
D-DURING
Interval
Item
No.
B
D
A
Item to
be inspected
A-AFTER
Procedures
Check for and have
repaired or adjusted
as necessary
Equipment is
not ready/
available if:
GENERATOR SET
1
•
2
•
3
•
4
•
•
•
Housing
Check door, panels, hinges, and latches
for damaged, loose or corroded items.
Inspect air intake and exhaust grilles for
debris.
Identification Plates
Check to ensure identification plates are
secure.
•
Skid Base
Inspect skid base for cracks or corrosion.
•
Insulating/Materials
Ensure that insulating materials are free
of damage, not missing, and not touching
moving or exhaust system parts.
Cannot secure doors.
Cannot clear debris.
Skid base is cracked
or shows signs of
structural damage.
__________
WARNING
Operating the generator set with any
access door open exposes personnel to
high noise level. Hearing protection
must be worn when operating or
working near the generator set with
any access door open. Failure to
comply can cause hearing damage to
personnel.
__________
WARNING
Fuels in the generator set are
flammable. Do not smoke or use open
flame when performing maintenance
Failure to comply can result in flames
and possible explosion and can cause
injury or death to personnel and
damage to the generator set.
TABLE 2-5. OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
(continued)
2-16
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B-BEFORE
D-DURING
Interval
Item
No.
B
D
A
Item to
be inspected
A-AFTER
Procedures
Check for and have
repaired or adjusted
as necessary
Equipment is
not ready/
available if:
ENGINE
COMPARTMENT
5
•
•
•
Engine Assembly
Check for loose, damaged, or missing
hardware and wires.
Any loose, damaged
or missing hardware
or wires.
6
•
•
•
Fuel System
Inspect fuel system for leaks and
damaged, loose, or missing parts. Check
fuel lines fuel injection pump and fuel
injectors for cracks, leaks or evidence of
damage. See TM 9-2815-259-24.
Any fuel leaks or
damaged, loose, or
missing parts.
7
•
•
Fuel Filter/Water
Separator
Inspect fuel filter/water separator for
leaks, proper mounting, cracks, damage,
and missing parts (Refer to Figure 1-30,
sheet 2).
Any fuel leaks.
Drain water from fuel filter/water
separator (Refer to paragraph 3.3.7).
Fuel filter/water
separator not drained.
CAUTION
Catch in suitable container.
8
•
9
•
•
•
Ether Start System
Check for deteriorated, loose, or missing
parts; loose tubing; and missing or
damaged bottle gasket (Refer to Figure
4-26).
Any deteriorated,
loose, or missing
parts; loose tubing;
and missing or
damaged bottle
gasket.
Lubrication System
Inspect lubrication system for leaks and
damaged, loose, or missing parts.
Oil leaks at Class III.
Damaged, loose, or
missing parts.
Check engine oil level.
Oil level is low, and
dipstick reads add.
Check engine oil for contamination (oil
color is milky, bubbles, foreign material
in oil, etc.).
Engine oil shows
signs of
contamination.
2-17
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TABLE 2-5. OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
(continued)
B-BEFORE
Item
No.
Item to
be inspected
Interval
B
D
D-DURING
A
Procedures
Check for and have
repaired or adjusted
as necessary
__________
WARNING
A-AFTER
Equipment is
not ready/
available if:
Cooling system operates at high
temperature and pressure. Contact
with high pressure steam and/or
liquids can result in burns and
scalding. Shut down generator set,
and allow system to cool before
performing checks, services, and
maintenance. Failure to comply can
cause injury to personnel.
COOLING
SYSTEM
10
•
•
Radiator
Check radiator for leaks, damage, or
missing parts.
Class III leaks.
Radiator cap is
missing.
11
•
•
Hoses
Check hose for leaks or cracks.
Class III leaks.
12
•
Cooling Fan
Check fan for damage or looseness.
Cooling fan is
damaged or loose.
•
13
•
14
•
•
•
Check for unusual noise being emitted
from fan area.
•
Fan Belts
Inspect belts for cracks, fraying, or
looseness.
Broken belt(s).
•
Overflow Bottle
Check overflow bottle for leaks and
missing parts.
Class III leaks.
Check overflow bottle coolant level.
Coolant level is
below COLD line.
Check muffler for leaks and exhaust
system for corrosion and damaged or
missing parts.
Muffler or exhaust
system damaged or
leaking excessively.
•
EXHAUST/
INTAKE SYSTEM
15
2-18
•
Exhaust System
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TABLE 2-5. OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
(continued)
B-BEFORE
D-DURING
Interval
Item
No.
16
B
•
D
A
Item to
be inspected
Air Cleaner
Assembly
A-AFTER
Procedures
Check for and have
repaired or adjusted
as necessary
Inspect air cleaner assembly and piping
for loose or damaged connections.
Check restriction indicator for indication
of clogged air cleaner element (Refer to
Figure 3-1).
Equipment is
not ready/
available if:
Piping connections
are loose.
Clogged element is
indicated.
ELECTRICAL
SYSTEM
__________
WARNING
DC voltages are present at generator
set electrical components even with
generator set shut down. Avoid
shorting any positive terminal with
ground/negative. Failure to comply
can cause injury to personnel and
damage to equipment..
__________
WARNING
Batteries give off a flammable gas. Do
not smoke or use open flame when
performing maintenance. Failure to
comply can cause injury or death to
personnel and equipment damage due
to flames and explosion.
__________
WARNING
Battery acid can cause burns to
unprotected skin. Avoid contact with
battery acid. Failure to comply can
cause injury to personnel.
17
•
Batteries
Inspect electrolyte level (wet cell
batteries only).
Electrolyte level is
below battery plates.
18
•
Battery Cables
Inspect cables and connectors for
corrosion and loose, damaged, or
missing parts.
Battery cables are
loose, damaged, or
missing.
2-19
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TABLE 2-5. OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
(continued)
B-BEFORE
D-DURING
Interval
Item
No.
B
D
A
Item to
be inspected
A-AFTER
Procedures
Check for and have
Repaired or adjusted
as necessary
__________
WARNING
Equipment is
not ready/
available if:
High voltage is produced when this
generator set is in operation. Make
sure unit is completely shut down and
free of any power source before
attempting any repair or maintenance
on the unit. Failure to comply can
cause injury or death to personnel.
19
•
Output Box
Assembly
Check for loose or damaged wiring or
cables (Figure 1-2).
Loose or damaged
wiring or cables.
20
•
Load Output
Terminal Board
Check output terminals for damaged or
missing hardware (26, Figure 1-30 sheet
2)
Damaged or missing
hardware.
Check all controls and indicators for
damaged or missing parts. Ensure relays
are securely plugged in.
Controls or indicators
with damaged or
missing parts.
Ensure all indicators are operating
properly.
CIM inoperative.
Loose or damaged
wires.
DCS CONTROL
BOX ASSEMBLY
21
•
•
Controls and
Indicators
•
22
•
Control Box Wiring
Harness
Check for loose or damaged wiring.
23
•
Parallel Operation
Cable
If required for generator set operation,
inspect parallel operation cable for
damage.
2-20
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TABLE 2-5. OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
(continued)
B-BEFORE
D-DURING
Interval
Item
No.
B
D
Procedures
Check for and have
repaired or adjusted
as necessary
__________
WARNING
Item to
be inspected
A
A-AFTER
Equipment is
not ready/
available if:
High voltage is produced when the
generator set is in operation. Never
attempt to start the generator set
unless it is properly grounded.
Failure to comply can cause injury or
death to personnel.
•
24
Ground Rod Cable
and Connection
•
Inspect ground rod and cable for loose
connections, breaks, damage, and
corrosion.
Visual inspection only.
Cable is missing or
damaged.
SECTION III. OPERATION UNDER USUAL CONDITIONS
2.7
GENERAL.
This section provides information and guidance for generator set operation under normal conditions. Refer
to FM 20-31.
2.8
GENERATOR SET INSTALLATION.
2.8.1
General.
__________
WARNING
Exhaust discharge contains deadly gases including carbon monoxide. Do
not operate generator set in an enclosed area unless exhaust discharge is
properly vented outside. Failure to comply can cause injury or death to
personnel.
2.8.2
a.
Ensure that installation site is as level as possible.
b.
Provide adequate ventilation to prevent recirculation of hot air exhausted from generator set.
c.
Refer to Figure 2-4 for base mounting measurements.
Outdoor Installation.
a.
Make use of natural protective barriers.
FIGURE 2-4. BASE MOUNTING MEASUREMENTS
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2.8.3
b.
Allow space on all sides for service and maintenance. Refer to Figure 2-5 for minimum clearance
measurements.
c.
Ensure soil is firm and well drained.
d.
Use planks or other material for support in areas where soil will not support the generator set.
Indoor Installation.
__________
WARNING
Exhaust discharge contains deadly gases including carbon monoxide. Do
not operate generator set in an enclosed area unless exhaust discharge is
properly vented outside. Failure to comply can cause injury or death to
personnel.
CAUTION
Never position generator set with air inlets near a wall or other object that
interferes with cooling air circulation. Failure to comply can cause damage
to equipment.
2-22
a.
Provide ducts and vents to outside of building if good supply of cooling air is not available.
b.
Make air intake and outlet openings in building same size or larger than those on the generator set.
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FIGURE 2-5. MINIMUM ENCLOSURE CLEARANCE MEASUREMENTS
2-23
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NOTE
Make exhaust pipe extension as short and straight as possible, with only one 90
degree bend if needed.
NOTE
Ensure that inside diameter of exhaust pipe extension is as large or larger than
generator exhaust pipe.
c.
Install a gas-tight metal pipe from exhaust pipe of generator set to outside of building.
__________
WARNING
Hot exhaust gases can ignite flammable materials. Allow room for safe
discharge of hot gases and sparks. Failure to comply can cause injury or
death to personnel.
d.
Provide for harmless discharge of hot gases and sparks. Do not direct exhaust into area containing
flammable materials.
_________
WARNING
Engine exhaust is hot. When it is required to extend exhaust pipe through
flammable material (i.e., wall), shield the extension pipe to protect
personnel from burns and prevent fire hazard. Failure to comply can cause
injury to personnel, damage to equipment, and fire.
2.9
e.
Shield exhaust pipe with fireproof material at point where it passes through a flammable wall.
f.
Wrap exhaust pipe in heat insulating material.
g.
Allow space on all sides of generator set for service and maintenance. Refer to Figure 2-5 for
minimum clearance measurements.
ASSEMBLY AND PREPARATION FOR USE.
__________
WARNING
High voltage is produced when the generator set is in operation. Never
attempt to start the generator set unless it is properly grounded. Failure to
comply can cause injury or death to personnel.
2.9.1
2-24
Installation of Grounding Rod.
a.
Open Load Terminal access door (Figure 1-2).
b.
Insert ground cable (2, Figure 2-6) through load terminal access boot and into GND terminal (5) on
load output terminal board. Tighten terminal nut.
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FIGURE 2-6. GROUNDING CONNECTIONS
2-25
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2.9.2
c.
Remove grounding rod from inside generator set by removing top left bolts from left side of generator
(Figure 1-3). Replace bolt after removing ground rod.
d.
Connect coupling (6) to pointed ground rod section (1), and install driving stud (4) in coupling. Make
sure driving stud seats on ground rod section.
e.
Drive ground rod section (1) into ground until coupling is just above surface.
f.
Remove driving stud (4) from coupling (6), and install another ground rod section (1) in coupling.
g.
Install another coupling (6) on ground rod section (1). Install driving stud (4) in coupling, and drive
ground rod down until new coupling is just above surface.
h.
Repeat steps f and g until ground rod has been driven eight feet or deeper, providing an effective
ground.
i.
Connect clamp (3) and ground cable (2) to ground rod. Tighten clamp screw.
Installation of Load Cables.
__________
WARNING
High voltage is produced when the generator set is in operation. Never
attempt to connect or disconnect load cables while the generator set is
running. Failure to comply can cause injury or death to personnel.
a.
Shut down generator set, paragraph 2.11.2.
CAUTION
When using single phase connections, balance loads between terminals. Do
not connect all loads between one terminal and L0. Failure to observe this
caution can result in damage to equipment.
b.
Select required output terminals from Table 2-6.
TABLE 2-6. LOAD TERMINAL AND AC RECONNECTION BOARD SELECTION
RECONNECTION
BOARD
POSITION
120/208
240/416
2-26
TERMINALS
L1, L2, L3, N
3 Phase
(Single phase loads can be served
using any terminal to N)
L1, L2, L3, N
3 Phase
(Single phase loads can be served
using any terminal to N)
VOLTAGE READING
L1-N 120 volts
L2-N 120 volts
L3-N120 volts
L1-L2 208 volts
L2-L3 208 volts
L3-L1 208 volts
L1-N 240 volts
L2-N 240 volts
L3-N 240 volts
L1-L2 416 volts
L2-L3 416 volts
L3-L1 416 volts
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c.
Open Load Terminal access door (Figure 1-2).
d.
Using insulated wrench (1, Figure 2-7), loosen terminal nuts (2) on terminals selected in step b.
e.
Insert load cables through load terminal access boot and into terminal studs (3). Tighten terminal nuts
(2).
f.
Secure insulated wrench (1) in bracket beside output load terminal board, and close terminal board
access door.
2.10
INITIAL ADJUSTMENTS, CHECKS, AND SELF-TEST.
2.10.1
Preparation. Perform all BEFORE (B) PMCS. Refer to Table 2-5.
2.10.2
Initial Adjustments and Checks.
a.
Open left side engine compartment doors (Figure 1-3).
b.
Place DEAD CRANK switch (1, Figure 2-8) in NORMAL position.
FIGURE 2-7. INSTALLATION OF LOAD CABLES
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c.
2-28
FIGURE 2-8. GENERATOR SET CONTROLS
Close engine compartment doors.
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d.
Release DCS control panel by turning two fasteners, and lower DCS control panel slowly.
e.
Ensure FREQUENCY SELECT switch (10) is in required position.
f.
Ensure VOLTAGE SELECTION switch (9) is set to match voltage requirements.
g.
Raise and secure DCS control panel with two fasteners.
NOTE
If software fails to boot properly, notify next higher level of maintenance.
h.
Place MASTER CONTROL switch (12) in ON position. While DCS software is loading and running
its diagnostics on CIM, perform steps i through m.
i.
Open output box access door (Figure 1-2).
j.
Ensure voltage reconnection terminal board (27, Figure 1-30) is positioned to match voltage
requirements. If voltage reconnection board must be changed, notify next higher level of maintenance.
k.
Close output box access door.
l.
Ensure EMERGENCY STOP switch (2, Figure 2-8) is pulled out.
m. Ensure BATTLE SHORT switch (4) is in OFF position.
n.
2.10.3
Ensure NETWORK FAILURE indicator (3) on DCS control panel goes out when DCS software has
finished loading and is displayed on CIM display screen as shown in Figure 2-2. If NETWORK
FAILURE indicator is still illuminated, use keypad to exit software, place MASTER CONTROL
switch (12) in OFF position and panel light switch (16) is in off position, and notify next higher level of
maintenance.
Self Test.
a.
Place ENGINE CONTROL switch (6) in PRIME & RUN position.
b.
Hold FAULT RESET switch (14) in ON position for two seconds. Release switch. FAULT
INDICATOR and MESSAGES portions of CIM display screen should be blank unless a fault condition
still exists.
c.
Use arrow buttons on keypad to move cursor to DISPLAY MODE portion of CIM display screen. Use
SELECT button to alternately click MAIN / FULL button to ensure MAIN screen and FULL screen
display properly.
d.
Push PRESS TO TEST pushbutton on NETWORK FAILURE INDICATOR (3). Ensure indicator
light illuminates. When pushbutton is released, indicator light should go out.
2-29
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2.11
OPERATING PROCEDURE.
__________
WARNING
Exhaust discharge contains deadly gases including carbon monoxide. Do
not operate generator set in an enclosed area unless exhaust discharge is
properly vented outside. Failure to comply can cause injury or death to
personnel.
NOTE
If generator set is to be operated in parallel with another unit, refer to paragraph
2.12.
2.11.1
Start Generator Set.
__________
WARNING
High voltage is produced when the generator set is in operation. Never
attempt to start the generator set unless it is properly grounded. Failure to
comply can cause injury or death to personnel.
__________
WARNING
Operating the generator set with any access door open exposes personnel to
high noise level and can cause hearing damage. Hearing protection must be
worn when operating or working near the generator set with any access
door open. Failure to comply can cause hearing damage to personnel.
a.
Perform initial adjustments, checks, and self test, paragraph 2.10.
b.
Ensure CIM display screen is in MAIN mode (Figure 2-9). If necessary, use keypad arrow buttons to
move cursor to DISPLAY MODE. Use SELECT button to click FULL/MAIN button to access MAIN
mode screen.
c.
Hold FAULT RESET switch (14, Figure 2-8) in ON position for two seconds. Release switch.
CAUTION
Do not crank engine in excess of 15 seconds at a time. Allow starter to cool
at least 15 seconds between attempted starts. Failure to comply can cause
damage to equipment.
NOTE
If engine is not started within 25 seconds after FAULT RESET switch is
operated, reset condition will time out and have to be reset again before starting
the engine.
NOTE
At temperatures below 40°F (4°C) it may be necessary to use the cold weather
starting aid (See step d).
2-30
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d.
In cold weather conditions, while performing step e, momentarily hold ETHER START switch (5) to
ON position and release. Repeat as necessary until engine accelerates to governed speed.
e.
Hold ENGINE CONTROL switch (6) in START position (for 2 seconds) and observe
CIM display screen until oil pressure reaches at least 25 psi (172 kPa), voltage has
increased to its approximate rated value, and engine has reached stable operating speed.
f.
Release ENGINE CONTROL switch (6) to PRIME & RUN position.
g.
If operating with an auxiliary fuel source, rotate ENGINE CONTROL switch (6) to PRIME & RUN
AUX FUEL position.
h.
Check WATER TEMP (170-200°F [11-93°C]) and OIL PRESSURE (25-60 psi [172-414 kPa]) meters
on CIM display screen for normal readings.
i.
Use keypad arrow buttons to move cursor to DISPLAY MODE on CIM display screen. Use SELECT
button to click FULL / MAIN button to toggle between full and main mode screens. Access FULL
mode screen.
NOTE
Warm up engine without load for five minutes. (If necessary, load can be
applied immediately.)
j.
Use VOLTAGE ADJUST switch (8) and FREQUENCY ADJUST switch (7) to adjust values for
voltage and frequency until required values are displayed on VOLTAGE and FREQUENCY gages on
CIM display screen. If required reading cannot be obtained, shut down generator set (paragraph
2.11.2), and notify next higher level of maintenance.
k.
Press TEST pushbutton on GROUND FAULT CIRCUIT INTERRUPTER (13). Ensure RESET
pushbutton is in in position.
l.
Hold AC CIRCUIT INTERRUPT switch (15) in CLOSED position until CONTACTOR POSITION
on CIM display screen reads CLOSED.
m. With CIM display in Main Display Mode, ensure VOLTAGE (15) and FREQUENCY (16) gages
(Figure 2-9) still indicate rated values. Adjust if necessary.
2.11.2
n.
With CIM display in Full mode screen, if more than rated load is indicated on GEN CURRENT
indicator (3) (Figure 2-9) for any phase, reduce load.
o.
With CIM Display in Main Mode, observe POWER gage (17) (Figure 2-9) on CIM display screen. If
indication is more than 30KW, reduce load.
p.
Perform all DURING (D) PMCS requirements in accordance with Table 2-5.
Shut Down Generator Set.
a.
Hold AC CIRCUIT INTERRUPT switch (15, Figure 2-8) in OPEN position until CONTACTOR
POSITION on CIM display screen reads OPEN.
b.
c.
Allow generator set to operate five minutes with no load applied.
Place ENGINE CONTROL switch (6) in OFF position.
2-31
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NOTE
REFER TO PAGE 2-6 FOR LEGEND
FIGURE 2-9. CIM DISPLAY SCREEN CONTROLS AND INDICATORS
2-32
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d.
Perform all AFTER (A) PMCS requirements in accordance with Table 2-5.
NOTE
If software fails to boot properly, notify next higher level of maintenance.
2.12
e.
Use keypad arrow buttons to move cursor to SHUTDOWN COMPUTER on CIM display screen. Use
SELECT button to click on EXIT button to exit the DCS software.
f.
When CIM display screen displays message that it is safe to turn off the computer, place MASTER
CONTROL switch (12) in OFF position. Turn off panel lights.
g.
Place DEAD CRANK switch (1) in OFF position.
PARALLEL UNIT OPERATION (LOAD SHARING).
CAUTION
Ensure generator sets are the same size and mode before attempting
parallel operation.
2.12.1
General. The following method of parallel operation is used to share the load between two generator sets.
Refer to Figures 2-1 and 2-2 for location of operator controls and indicators mentioned below and Figure 210 for proper paralleling configuration.
2.12.2
Pre-Operation.
__________
WARNING
Prior to making any connections for parallel operation or moving a
generator set which has been operating in parallel, ensure there is no input
to the load output terminal board and the generator sets are shut down.
Failure to comply can cause injury or death to personnel by electrocution.
a.
Ensure load requirement is equal or below the combined rated capacity of the two generator sets.
__________
WARNING
High voltage is produced when the generator set is in operation. Never
attempt to start the generator set unless it is properly grounded. Failure to
comply can cause injury or death to personnel.
b.
Determine voltage requirements of load and position voltage reconnection terminal boards of the two
generator sets to the required voltage connection. Ensure FREQUENCY SELECT switches (10, Figure
2-8) on both generators are positioned for the same frequency requirements (50 Hz or 60 Hz).
c.
Identify one generator set as No. 1 and the other as No. 2.
d.
Open BATTERY ACCESS door (Figure 1-2).
2-33
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FIGURE 2-10. PARALLEL OPERATION SETUP
2-34
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e.
Remove paralleling cable from storage box, and close BATTERY ACCESS door (Figure 1-2).
f.
Connect paralleling cable between the two generators sets. Connect the generator sets to the load
observing proper phase sequence. Check connections with phase rotation meter (Appendix B).
CAUTION
Do not close the AC CIRCUIT INTERRUPT switch on either of the
generator sets, nor close the load contactor at load, until specifically
directed to do so. Closing any of these devices at any other time may
severely damage one or both of the generator sets.
2.12.3
Operation.
a.
Start each generator set. Refer to paragraph 2.11.1.
b.
Use keypad arrow buttons to move cursor to DISPLAY MODE on CIM display screen. If necessary,
use SELECT button to access FULL mode screen.
c.
Use VOLTAGE ADJUST switch (8, Figure 2-8) to obtain the same voltage indication on each set.
d.
Use FREQUENCY ADJUST switch (7) to obtain approximately the same frequency indication on both
sets. Observe CONTACTOR POSITION on CIM display screen to ensure load contactor at load is
open.
e.
Momentarily hold AC CIRCUIT INTERRUPT switch (15) on generator set No. 1 in CLOSED position
until CONTACTOR POSITION reads CLOSED.
CAUTION
Check CONTACTOR POSITION indication on CIM display screen to
ensure load contactor at load is OPEN before attempting to place
generators on the line. Failure to comply can cause damage to generator
sets.
f.
Momentarily hold AC CIRCUIT INTERRUPT switch (15) on generator set No. 2 in CLOSED position
until CONTACTOR POSITION on CIM display screen reads CLOSED.
NOTE
The generator sets are now operating in parallel with no load.
g.
Check that POWER gage on CIM display screen indicates approximately zero.
h.
Close the load contactor at the load.
i.
Check that GEN CURRENT indicators (Figure 2-11) on CIM display screens of both generator sets
display approximately the same amperage. If not, adjust VOLTAGE ADJUST switch (8, Figure 2-8)
up or down to achieve proper reading.
j.
Compare POWER Meter readings from CIM display screens on both generator sets. If readings are not
within 10 percent, remove from parallel operation at once (paragraph 2.12.4) and notify next higher
level of maintenance.
2-35
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2.12.4
Remove from Parallel Operation.
__________
WARNING
If necessary to move a generator set which has been operating in parallel
with another generator set, shut down remaining generator set connected to
the load prior to removing load cables or ground. Failure to comply can
cause injury or death to personnel by electrocution.
CAUTION
Prior to removal of one generator set from parallel operation, make sure
load does not exceed full load rating of generator set remaining on the line.
Failure to comply can cause damage to generator set still on line.
a.
Momentarily hold AC CIRCUIT INTERRUPT switch (15, Figure 2-8) in OPEN position until
CONTACTOR POSITION on CIM display screen reads OPEN.
b.
Shut down generator set, paragraph 2.11.2.
2.13
REMOTE OPERATION.
2.13.1
Description and Operating Instructions.
2-36
a.
The DCS provides the ability to control and monitor the generator set from a remote location using an
IBM-compatible personal computer (PC). Minimum requirements for that computer are: a 486
processor, RS485 serial card, 3.5" Floppy Drive and /or CD ROM drive, Windows 95 operating
system, and a mouse. (Note: Multiple RS 485 serial cards are available to use. Recommend an
internally installed RS 485 card be used for desktop PCs and a PCMCIA card be used for laptop
computers).
b.
Remote instrument monitoring allows the operator to observe metering and protective device status. To
start and run the generator set the operator must follow the operating procedures described in paragraph
2.11. When connected, the remote display functions are independent of the onboard CIM display.
That is, the remote display includes the same controls and indicators as the CIM display (Figure 2-2),
but with added controls as indicated in step c below. Switching modes on the remote display screen
does not affect the screen mode displayed on the CIM.
c.
Additional switching controls on the remote screen allow the operator to control four functions of the
remote PC and generator set from the remote location. The SHUTDOWN COMPUTER EXIT button
(1, Figure 2-11) is used to shut down the remote operation shutdown and return control of the generator
set to the DCS onboard controls. The DISPLAY MODE FULL/MAIN button (2, Figure 2-11) allows
the operator to toggle between display modes on the remote computer like the same button does on the
CIM display screen. The BATTLESHORT SEL. SW. ON/OFF button (3, Figure.2-11) allows the
remote operator to remotely activate and deactivate the generator set's battle short function. The
ENGINE CONTROL RUN/STOP button (4, Figure 2-11) allows the operator to stop the generator set
engine from the remote PC.
d.
A cable links the remote PC to the generator set via the COMMUNICATION RECEPTACLE (J3) (1,
Figure 1-30). COMMUNICATION RECEPTACLE (J3) internally connects to (J21) (Figure 2-3), of
the I/O interface module via generator set wiring. COMMUNICATION RECEPTACLE (J3) is a nine
pin environmentally sealed connector. One end of the remote cable hooks to COMMUNICATION
RECEPTACLE (J3), the other end terminates at the RS485 serial card installed in the remote PC.
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User needs to follow the specific installation instructions for the 485 serial card that is being used.
Refer to Figure 2-12 for information concerning the remote PC setup and pin configurations.
e.
2.13.2
Special-purpose software (included in the CD called "30/60kW Tactical Quiet Generator CIM
Software") is provided with the generator set for use at the remote site to process digital signals
between the remote PC and the DCS. This software must be installed on an IBM-compatible PC as
described in step a above. Setup of the software is described in paragraph 2.13.2.
TQG Remote Software Installation.
a.
Set up computer in accordance with your computer's instruction manual.
b.
Turn on computer. Refer to computer's instruction manual. Wait for computer to boot into Windows
95.
c.
The generator set comes with a CD labeled "30/60kW Tactical Quiet Generator CIM Software". If the
computer has a CD ROM drive then use procedures d (1) through d (7) below. If the computer only
has a 3.5 inch floppy drive then floppy disks need to be prepared using instructions provided in
paragraphs e (1) through e (11) below followed by the procedures in paragraphs f (1) through f (7).
below.
d.
CD ROM Procedures - Insert the CD in the CD ROM drive of computer, refer to computer instruction
manual.
(1). Left click mouse on Windows 95 START button in the lower left corner of the screen. The
START menu will pop up on the screen.
(2). Left click mouse on RUN from the START menu. The RUN window will appear.
(3). Type the following: d:\remop\setup (Note: 'd:' represents the drive letter of the CD ROM drive.
This may not be the same drive letter for all computers. Refer to computer instruction manual to
identify the correct drive letter and use that letter in place of 'd')
(4). Left click on OK button. At this point the setup wizard will guide you through the installation.
(5). To start remote data display software left click mouse on START button in the lower left corner of
the screen. The START menu will pop up on the screen.
(6). Select PROGRAMS, then left click the "Remote Data Display" icon. (Note: If the message
"Error: Communication Failed" comes up on the screen, click OK. This error may come up because
the PC is not connected to the CIM).
(7). To exit out of this screen, move cursor to EXIT button and left click the mouse.
e.
Floppy disk preparation. (Note: Any computer that meets the minimum requirements in para. 2.13.1.a
above (except for the RS485 serial card which is not required), and has both a 3.5" floppy drive and
CD ROM drive can be used for these procedures).
(1). Set up computer in accordance with your computer's instruction manual.
(2). Turn on computer. Refer to computer's instruction manual. Wait for computer to boot.
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(3). Insert the CD labeled " 30/60kW Tactical Quiet Generator CIM Software" in the CD ROM drive
of computer, refer to computer instruction manual.
(4). Insert a blank, formatted 3.5" floppy disk in the 3.5" floppy drive of computer, refer to computer
instruction manual.
(5). Left click mouse on START button in the lower left corner of the screen. The START menu will
pop up on the screen.
(6). Select PROGRAMS, then left click the "MS-DOS Command Prompt" icon.
(7). Type in d: (Note: 'd:' represents the drive letter of the CD ROM drive. This may not be the same
drive letter for all computers. Refer to computer instruction manual to identify the correct drive letter
and use that letter in place of 'd'). Press [ENTER].
(8). After 'D:>\' comes up on screen type in cd batch. Press [ENTER]. (Note: There are three (3)
possible ways to make floppy disks. The following paragraphs describe the 3 options).
(a) To make only one disk type in the command create[SPACE]# where # represents the number
of the disk to be made – i.e. "create 2" makes a copy of disk #2.
(b) If more than one disk needs to be made type in the command
create[SPACE]#[SPACE]#[SPACE]# where # represents the number of the disk that is to be made, ie.
To make disks 1, 3, &5 type in "create 1 3 5".
(c) To make all eight (8) disks at one time simply type in the command makeall.
(9). At next prompt (D:\BATCH>) type in the command from (8) above that is applicable to the
number of disks that are to be made, i.e. "create 1", "create 3 4 5…" or "makeall". The names of the
eight (8) disks are as follows:
Disk 1 - Generator Software Remote Operator. Disk 1 of 2
Disk 2 - Generator Software Remote Operator. Disk 2 of 2
Disk 3 - Generator Software Operator Log. Disk 1 of 2
Disk 4 - Generator Software Operator Log. Disk 2 of 2
Disk 5 - Generator Software CIM Network Link. Disk 1 of 1
Disk 6 - Generator Software Windows CE. Disk 1 of 2
Disk 7 - Generator Software Windows CE. Disk 2 of 2
Disk 8 - Generator Software Digital Controls. Disk 1 of 1
(10). Press [ENTER] key. When the copy is complete the screen will prompt you to insert a blank
floppy disk. Label each disk as shown above -i.e. "Generator Software Remote Operator. Disk 2 of 2".
(11). When copying of the required disks is complete, press [ENTER] and type in exit to return to
Windows screen. Remove floppy disk and CD.
f.
Floppy Disk procedures. Insert 3.5" floppy disk labeled "Generator Software Remote Operator. Disk 1
of 2", in 3.5" floppy drive of computer, refer to computer instruction manual.
(1). Left click mouse on Windows 95 START button in the lower left corner of the screen. The
START menu will pop up on the screen.
(2). Left click mouse on RUN from the START menu. The RUN window will appear.
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(3). Type the following: a:\setup
(4). Left click on OK button. At this point the setup wizard will guide you through the installation.
When prompted hit "Next" and complete requested information. Keep hitting "Next" until prompted to
insert Disk 2. Insert 3.5" floppy disk labeled "Generator Software Remote Operator. Disk 2 of 2", in
3.5" floppy drive of computer.
(5). To start remote data display software, left click mouse on Windows 95 START button in the lower
left corner of the screen. The START menu will pop up on the screen.
(6). Select Programs, then left click the "Remote Data Display" icon. (Note: If the message "Error:
Communication Failed" comes up on the screen, click OK. This error may come up because the PC is
not connected to the CIM).
(7). To exit out of this screen, move cursor to EXIT button and left click the mouse.
2.14
PREPARATION FOR MOVEMENT.
a.
Shut down generator set, paragraph 2.11.2. If generator set is operating in parallel, refer to paragraph
2.12.4.
b.
Disconnect load cables (Figure 2-7).
c.
Disconnect paralleling cable, if used, and store in storage box inside BATTERY ACCESS door (Figure
1-2).
d.
When using auxiliary fuel line, disconnect line, drain excess fuel from line, and store line in storage
box inside BATTERY ACCESS door (Figure 1-2).
e.
Disconnect ground cable, and remove ground rods. Store ground rods in holding brackets located
inside generator set housing, below engine compartment access doors. Store ground cable, couplings,
clamp, and driving stud in storage box inside BATTERY ACCESS door.
f.
Secure all generator set access doors and panels.
g.
For assembly and preparation for use, refer to paragraph 2.9.
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FIGURE 2-11. REMOTE PC DISPLAY MODES
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FIGURE 2-12. REMOTE PC SETUP
SECTION IV. OPERATION UNDER UNUSUAL CONDITIONS
2.15
OPERATION IN EXTREME COLD WEATHER BELOW -25° F (-31° C).
The generator set operates in ambient temperatures as low as -25°F (-31°C) without special winterization
equipment. To ensure satisfactory operation under extreme cold weather the following steps must be taken:
__________
WARNING
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In extreme cold weather, skin can stick to metal. Avoid contacting metal
items with bare skin in extreme cold weather. Failure to comply can cause
injury to personnel.
a.
Keep generator set and surrounding area as free of ice and snow as practical.
b.
Keep fuel tank full to protect against moisture, condensation, and accumulation of water.
c.
Ensure proper grade diesel fuel is used. Refer to Table 2-7.
TABLE 2-7. FUEL
AMBIENT TEMPERATURE
+20°F TO 120°F
(-6°C TO +49°C)
0°F TO +20°F
(-17°C TO -6°C)
-25°F TO 0°F
(-32°C TO -17°C)
-25°F TO 0°F
(-32°C TO -17°C)
2.16
2.17
2-42
DIESEL FUEL
VV-F-800 GRADE DF-2, JP5, OR JP8
VV-F-800 GRADE DF-1, JP5, OR JP8
VV-F-800
GRADE DF-1
VV-F-800
GRADE DF-A
d.
Keep batteries free from corrosion and in a well charged condition.
e.
Ensure proper oil is used. See Appendix F.
OPERATION IN EXTREME HEAT ABOVE 120° F (48.8° C).
a.
Check vents and radiator air passages frequently for obstructions.
b.
Check coolant temperature indicator frequently for any indication of overheating.
c.
Allow sufficient space for fuel expansion when filling fuel tank.
d.
Keep generator clean and free of dirt. Clean obstructions from generator intake and outlet screens.
e.
Clean external surface of engine when generator set is not operating.
OPERATION IN DUSTY OR SANDY AREAS.
a.
If possible, provide a shelter for generator set. Use available natural barriers to shield generator set
from blowing dust and sand.
b.
Wet down dusty and sandy surfaces areas around generator set frequently if water is available.
c.
Keep all access doors closed as much as possible to prevent entry of dust and sand into housing
assembly.
d.
Wipe dust and sand frequently from the generator set external surface and components. Wash exterior
surfaces frequently with clean water when generator set is not operating.
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2.18
e.
Service engine air cleaner assembly frequently to compensate for intake of additional dust or sand.
f.
Drain sediment frequently from fuel filter/water separator. When servicing fuel tank, be careful to
prevent dust or sand from entering fuel tank.
g.
Change engine oil and oil filter frequently.
h.
Store oil and fuel in dust-free containers.
i.
Ensure generator set ground connections are free of dust and sand, and connections are tight before
starting the unit.
OPERATION UNDER RAINY OR HUMID CONDITIONS.
CAUTION
Failure to remove waterproof material before operating generator set could
result in damage to equipment.
a.
If possible, provide a shelter for generator set. Cover generator set with canvas or other waterproof
material when it is not being operated.
b.
Provide adequate drainage to prevent water from accumulating on operation site.
c.
Keep all generator set access doors closed, as much as possible, to prevent entry of water into housing
assembly.
d.
Drain water frequently from fuel filter/water separator.
__________
WARNING
DC voltages are present at generator set electrical components even with
generator set shut down. Avoid shorting any positive terminal with
ground/negative. Failure to comply can cause injury to personnel and
damage to equipment.
2.19
e.
Remove moisture from generator set components before and after each operating period.
f.
Keep fuel tank full to protect against moisture, condensation, and accumulation of water.
OPERATION IN SALT WATER AREAS.
CAUTION
Failure to remove waterproof material before operating generator set could
result in damage to equipment.
a.
If possible, provide a shelter for the generator set. Locate generator set so radiator faces into prevailing
winds. Use natural barriers or, if possible, construct a barrier to protect generator set from salt water.
Cover generator set with canvas or other waterproof material when it is not being operated.
b.
Keep all generator set access doors closed, as much as possible, to prevent entry of salt water into
housing assembly.
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2.20
c.
Wash exterior surfaces frequently with clean water when generator set is not operating.
d.
Check wiring connections for corrosion and wire insulation for signs of deterioration.
OPERATION AT HIGH ALTITUDES.
The generator set will operate at elevations up to 4000 feet (1219.1 meters) above sea level without special
adjustment or reduction in load. At elevations greater than 4000 feet, the kilowatt rating is reduced
approximately 3.5 percent for each additional 1000 feet (304.8 meters).
2.21
NATO SLAVE RECEPTACLE START OPERATION.
2.21.1
General. The NATO SLAVE RECEPTACLE (Figure 2-13) can be used to start the generator set when
batteries are discharged.
2.21.2
NATO/Slave Emergency Starting Procedure.
a.
Connect one end of NATO/SLAVE RECEPTACLE cable to fully charged 24 VDC system and other
end to discharged generator set's NATO/SLAVE RECEPTACLE (Figure 2-13).
b.
Start discharged generator set, paragraph 2.11.1.
c.
Remove NATO/SLAVE RECEPTACLE cable after generator set starts.
NOTE
The generator set cannot be restarted without resetting the EMERGENCY STOP
pushbutton and turning ENGINE CONTROL switch to OFF position.
2.22
EMERGENCY STOPPING. Depressing the EMERGENCY STOP pushbutton (2, Figure 2-8) will stop the
generator set.
2.23
OPERATION USING BATTLE SHORT SWITCH.
CAUTION
Continued operation using the BATTLE SHORT switch can result in
damage to the generator set.
NOTE
If any emergency situation requires continued operation of the generator set, the
BATTLE SHORT switch is used to override all protection devices except the
overspeed, short circuit devices, and EMERGENCY STOP function.
NOTE
BATTLE SHORT switch must be in OFF position to start generator set.
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FIGURE 2-13. NATO SLAVE RECEPTACLE
2.24
a.
Start generator set, paragraph 2.11.1.
b.
Lift cover on BATTLE SHORT switch (4, Figure 2-8), and place switch in ON position to operate
generator set under these emergency conditions.
NUCLEAR, BIOLOGICAL, AND CHEMICAL (NBC) DECONTAMINATION PROCEDURES. Refer to
FM 3-5, NBC Decontamination, for information on decontamination procedures. Specific procedures for
the generator set are as follows:
a.
Control panel indicator sealing gaskets, rubber sleeves, rope draw cords at output terminal access ports,
control panel door gaskets, access door gaskets, rubber tubing and belts within the engine
compartment, coverings for electrical conduits, external water drain tubing, and retaining cords for
NATO SLAVE RECEPTACLE covers will absorb and retain chemical agents. Replacement of these
items is the recommended method of decontamination.
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b.
Lubricants, fuel, coolant, and battery fluid may be present on external surfaces of the generator set or
its components due to leaks or normal operation. These fluids will absorb NBC agents. The preferred
method of decontamination is removal of these fluids using conventional decontamination methods in
accordance with FM 3-5.
c.
Continued decontamination of external generator set surfaces with supertropical bleach
(STB)/decontaminating solution number 2 (DS2) will degrade clear plastic indicator coverings to a
point where reading indicators will become impossible. This problem will become more evident for
soldiers wearing protective masks. Therefore, the use of STB or DS2 decontaminates in these areas
should be minimized. Indicators and the CIM display screen should be decontaminated with warm
soapy water.
d.
External surfaces of the control panel assembly that are marked with painted or stamped lettering will
not withstand repeated decontamination with STB or DS2 without degradation of this lettering. The
recommended method of decontamination for these areas is warm soapy water.
e.
Areas that will entrap contaminants, making efficient decontamination extremely difficult, include the
following: space behind knobs and switches on the control panel, exposed heads of screws, areas
adjacent to and behind exposed wiring conduits, hinged areas of access doors, spaces behind externally
mounted equipment specification data plates, areas around external oil drain valve, retaining chains for
external receptacle covers, areas behind external receptacle covers, access door locking mechanisms,
recessed walls for access door handles, fuel caps, load output terminal board access door, NATO
SLAVE RECEPTACLE, frequency adjustment controls, areas around tie-down/lifting rings, crevices
around access doors, external screens covering ventilation areas, and areas adjacent to the external fuel
drain valve. Replacement of these items, if available, is the preferred method of decontamination.
Conventional decontamination methods should be used on these areas, while stressing the importance
of thoroughness and the probability of some degree of continuing contact and vapor hazard.
f.
In an NBC contaminated environment, the generator set should be operated with all access doors
closed to reduce the effects of contamination.
g.
The use of overhead shelters or chemical protective covers is recommended as an additional means of
protection against contamination in accordance with FM 3-5. When using covers, care should be taken
to provide adequate space for air flow and exhaust.
h.
For additional NBC information, refer to FM 3-3 and FM 3-4.
2.25
OPERATION WHILE CONTAMINATED. The generator will operate in a normal manner when exposed
to nuclear, biological, or chemical (NBC) contamination. It is capable of being operated by personnel
wearing NBC clothing without special tools or support equipment. Refer to FM 3-3, FM 3-4, and FM 3-5.
2.26
OPERATION IN A HIGH ALTITUDE ELECTROMAGNETIC PULSE (HAEMP) ENVIRONMENT.
2-46
a.
Hold AC CIRCUIT INTERRUPTER switch (15, Figure 2-8) in open position until CONTACTOR
POSITION on CIM display screen reads OPEN.
b.
Place ENGINE CONTROL SWITCH (6) in OFF position.
c.
Place MASTER SWITCH (12) in OFF position and wait approximately 10 seconds.
d.
Restart and operate generator set in accordance with applicable normal procedures (refer to para 2.11).
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CHAPTER 3
OPERATOR MAINTENANCE INSTRUCTIONS
CHAPTER INDEX
SECTION I
LUBRICATION PROCEDURES..................................................................................................3-1
SECTION II
TROUBLESHOOTING.................................................................................................................3-1
SECTION III
OPERATOR MAINTENANCE PROCEDURES........................................................................3-18
SECTION I. LUBRICATION PROCEDURES
3.1
OPERATOR LUBRICATION INSTRUCTIONS. Refer to Appendix F.
SECTION II. TROUBLESHOOTING
3.2
GENERAL.
This section contains troubleshooting information for locating and correcting operating troubles which may
develop in the generator set. Each malfunction for an individual component unit or system is followed by a
list of tests or inspections which will help to determine probable causes and corrective actions to take.
Perform the tests/inspections in the order listed.
Table 3-1 is provided for operator troubleshooting. A symptom index is provided for quick identification
and location of possible trouble. Table 3-1 cannot list all malfunctions that may occur, nor all tests or
inspections and corrective actions. If a malfunction is not listed, or is not corrected by listed corrective
actions, notify your supervisor.
SYMPTOM INDEX
Page
Engine Fails to Crank .................................................................................................................................................3-2
Engine Cranks, But Fails To Start ..............................................................................................................................3-3
Engine Starts, But Stops When Engine Control Switch Is Released From Start.........................................................3-4
Engine Stops Suddenly ...............................................................................................................................................3-5
Engine Runs Erratically or Stalls Frequently..............................................................................................................3-5
Engine Knocks............................................................................................................................................................3-6
Engine Does Not Develop Full Power........................................................................................................................3-7
Engine Exhaust Smokes..............................................................................................................................................3-8
Engine Oil Pressure Low ............................................................................................................................................3-9
Engine Overheating ..................................................................................................................................................3-10
Generator Set Fails to Parallel Correctly ..................................................................................................................3-11
CIM Display Screen Does Not Display and Backlight Does Not Light....................................................................3-13
CIM Display Screen BATTERY VDC Indicator Shows Excessive Charging After Prolonged Operation ..............3-14
CIM Display Screen VOLTAGE Gage Fluctuates ...................................................................................................3-15
CIM Display Screen FREQ Gage Fluctuates............................................................................................................3-16
CIM Display Screen does not respond to keypad input test......................................................................................3-17
3-1
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TABLE 3-1. OPERATOR TROUBLESHOOTING
ENGINE FAILS TO CRANK
Engine fails to crank.
Notify next higher level of
maintenance.
3-2
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TABLE 3-1. OPERATOR TROUBLESHOOTING (CONTINUED)
ENGINE CRANKS BUT FAILS TO START
Engine cranks but fails to start.
Check FAULT INDICATOR
on CIM display screen. Is a
fault displayed? (Fig 2-2)
Yes
No
Activate FAULT RESET Switch
(12, Fig 2-1) on DCS control
panel. Does fault clear?
No
No
Yes
Go to troubleshooting
section corresponding to
fault displayed. See
Symptom Index, page 3-1.
Is speed control unit
DC POWER LED (15,
Fig 2-3) lit?
Is EMERGENCY
STOP switch (3, Fig
2-1) pushed in?
No
Pull EMERGENCY
STOP switch to out
(deactivated) position.
Activate FAULT RESET Switch
(12, Fig 2-1) on DCS control
panel. Does fault clear?
Yes
Is ambient temperature above
40°F(4°C)?
No
Not OK
Service air cleaner
assembly (see para.
3.3.3).
Inspect air cleaner
assembly (see para. 3.3.3).
Not OK
Notify next higher
level of maintenance.
Yes
No
No
Notify next higher
level of maintenance.
Use ETHER START switch (7,
Fig 2-1) to assist in starting
engine in cold weather, below
40°F (4°C). Does Engine start ?
OK
Inspect/service fuel filter/water
separator (see para. 3.3.7).
OK
Notify next higher
level of maintenance.
3-3
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TABLE 3-1. OPERATOR TROUBLESHOOTING (CONTINUED)
ENGINE STARTS BUT STOPS WHEN ENGINE CONTROL
SWITCH IS RELEASED FROM START
Engine starts but stops when
ENGINE CONTROL switch is
released from START position.
Check for proper starting procedure. Hold ENGINE
CONTROL switch (8, fig 2-1) in START position
until 25 psi (172 kPa) oil pressure is reached, then
release switch to PRIME & RUN position.
Yes
Check FAULT INDICATOR on CIM display
screen. Is a fault displayed? (fig.2-2)
Go to troubleshooting
section corresponding to
fault displayed. See
Symptom Index, page
3-1.
OK
OK
Notify next higher
level of
maintenance.
3-4
Inspect/service
fuel filter/water
seperator
(see para.3.3.7).
No
Inspect air cleaner
Not OK
assembly
(see para.3.3.3).
Not OK
Notify next higher
level of
maintenance.
Service air
cleaner assembly
(see para.3.3.3).
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TABLE 3-1. OPERATOR TROUBLESHOOTING (CONTINUED)
ENGINE STOPS SUDDENLY
Engine stops
suddenly.
Yes
Check FAULT INDICATOR on
CIM display screen. Is a fault
displayed? (fig.2-2)
No
Notify next higher
level of maintenance.
Go to troubleshooting section
corresponding to fault displayed. See
Symptom Index, page 3-1.
ENGINE RUNS ERRATICALLY OR STALLS
FREQUENTLY
Engine runs erratically
or stalls frequently.
Yes
Check FAULT INDICATOR on
CIM display screen. Is a fault
displayed? (fig.2-2)
Go to troubleshooting section
corresponding to fault displayed.
See Symptom Index, page 3-1.
OK
Notify next higher level
of maintenance.
OK
Inspect/service fuel
filter/water separator
(see para.3.3.7).
No
Inspect air cleaner assembly
(see para.3.3.3).
Not OK
Not OK
Service air cleaner
assembly
(see para.3.3.3).
Notify next higher level
of maintenance.
3-5
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TABLE 3-1. OPERATOR TROUBLESHOOTING (CONTINUED)
ENGINE KNOCKS
Engine knocks
Yes
Check FAULT INDICATOR on
CIM display screen. Is a fault
displayed? (fig.2-2)
Go to troubleshooting section
corresponding to fault displayed. See
Symptom Index, page 3-1.
Not OK
Not OK
Inspect lubrication
system (see para.3.3.8).
Check for loose parts or foreign
objects in the engine compartment.
Remove foreign objects
from compartment.
3-6
OK
No
OK
Service lubrication system
(see para.3.3.8).
Notify next higher level of
maintenance.
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
TABLE 3-1. OPERATOR TROUBLESHOOTING (CONTINUED)
ENGINE DOES NOT DEVELOP FULL POWER
Engine does not
develop full power.
Yes
Check FAULT INDICATOR on
CIM display screen. Is a fault
displayed? (fig.2-2)
OK
Go to troubleshooting section
corresponding to fault displayed.
See Symptom Index, page 3-1.
Not OK
Inspect/service fuel filter/water
separator (see para.3.3.7).
Notify next higher level of
maintenance.
Not OK
Remove obstruction
from exhaust opening.
No
Inspect air cleaner
assembly
(see para.3.3.3).
OK
Not OK
Service air cleaner
assembly (see para.3.3.3).
Check to see if exhaust opening
is free from obstructions.
OK
Notify next higher level
of maintenance.
3-7
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
TABLE 3-1. OPERATOR TROUBLESHOOTING (CONTINUED)
ENGINE EXHAUST SMOKES
Exhaust smokes.
Yes
Check FAULT INDICATOR on
CIM display screen. Is a fault
displayed? (fig.2-2)
Go to troubleshooting section
corresponding to fault displayed.
See Symptom Index, page 3-1.
No
No
Is exhaust smoke
black or gray?
Not OK
Yes
Smoke is white and goes
away after a few
minutes.
No
White smoke
during startup is
normal.
Check for improper
type of fuel
(see Table 3-3).
Notify next
higher level of
maintenance.
3-8
Service air
cleaner assembly
(see para.3.3.3).
Yes
Inspect air cleaner
assembly
(see para.3.3.3).
OK
Notify next higher
level of
maintenance.
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
TABLE 3-1. OPERATOR TROUBLESHOOTING (CONTINUED)
ENGINE OIL PRESSURE LOW
Engine has low oil
pressure.
Not OK
Service lubrication
system (see para.3.3.8).
Not OK
Inspect lubrication system
(see para.3.3.8).
No
OK
Check WATER TEMP
on CIM display screen. Is
temperature over 200°F?
Inspect engine cooling
system (see para.3.3.5).
Yes
Notify next higher level
of maintenance.
OK
Service engine
cooling system
(see para.3.3.5)
Inspect air cleaner
assembly
(see para.3.3.3).
Not OK
OK
Service air
cleaner assembly
(see para.3.3.3).
Notify next
higher level of
maintenance.
3-9
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
TABLE 3-1. OPERATOR TROUBLESHOOTING (CONTINUED)
ENGINE OVERHEATING
Engine
overheating.
Yes
Check FAULT INDICATOR on
CIM display screen. Is a fault
displayed? (fig.2-2)
Go to troubleshooting
section corresponding to
fault displayed. See
Symptom Index, page
3-1.
No
OK
No
Check WATER TEMP on
CIM display screen. Is
temperature over 220°F?
(fig.2-2)
Inspect engine cooling
system (see para.3.3.5).
Not OK
Service engine
cooling system
(see para.3.3.5).
OK
Notify next
higher level of
maintenance.
3-10
Inspect air cleaner
assembly
(see para.3.3.3).
Not OK
Service air
cleaner assembly
(see para.3.3.3).
Yes
Notify next higher
level of
maintenance.
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
TABLE 3-1. OPERATOR TROUBLESHOOTING (CONTINUED)
GENERATOR SET FAILS TO PARALLEL CORRECTLY
Generator set fails to parallel correctly.
Check FAULT INDICATOR
on CIM display screen. Is a
fault displayed? (Fig 2-2)
Yes
Go to troubleshooting section
corresponding to fault displayed.
See Symptom Index, page 3-1.
OK
Not OK
Check that load cables
are installed properly
(see para. 2.9.2).
No
Install load cables
properly (see para.
2.9.2).
OK
Not OK
Not OK
Connect parallel
cable properly (see
para. 2.12.2).
Momentarily hold AC CIRCUIT
INTERRUPTER switch (10, Fig 2-1) on
generator set(s) in CLOSED position
until STATUS/CONTACT POSITION
indicator reads CLOSED. (Fig 2-2)
OK
Is generator set a
50/60 Hz unit? (Fig.
1-3)
Check that FREQ gage on
CIM display screen
indicates proper Hz setting.
(Fig. 2-2)
Use FREQUENCY
ADJUST switch (9, Fig. 2-1) to
obtain proper Hz setting.
Check that parallel cable
is connected properly (see
para. 2.12.2).
Check that STATUS/CONTACT
POSITION indicator on both
generator sets reads CLOSED.
(Fig 2-2)
OK
Not OK
No
Yes
Check that FREQUENCY
SELECT switch (22, Fig 2-1)
is in the same position on both
units.
OK
Not OK
Set FREQUENCY
SELECT switch on
both generators to the
same position.
Continued on next page.
3-11
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
TABLE 3-1. OPERATOR TROUBLESHOOTING (CONTINUED)
GENERATOR SET FAILS TO PARALLEL CORRECTLY (CONTINUED)
Continued from
previous page.
OK
No
Are both generators
adjusted to the same
voltage?
Adjust generator sets to rated
voltage using VOLTAGE
ADJUST switch . (11, Fig 2-1)
3-12
Check that both generator
voltage reconnect boards
are set to the same voltage
(Fig. 1-30)
Yes
Notify next higher level of
maintenance.
Not OK
Notify next higher level of
maintenance.
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
TABLE 3-1. OPERATOR TROUBLESHOOTING (CONTINUED)
CIM DISPLAY SCREEN DOES NOT DISPLAY AND BACKLIGHT
DOES NOT LIGHT
CIM display screen does not display and
backlight does not light.
Not OK
Is MASTER CONTROL switch
ON?
(13, fig.2-1)
Place MASTER
CONTROL switch to ON
position.
Not OK
OK
Confirm that
Control Panel is lit.
OK
Not OK
Inspect engine cooling
system (see para.3.3.5).
OK
Attempt
dead crank.
OK
Not OK
Replace fuse. Confirm
that back light
illuminates. If fuse blows
again, notify next higher
level of maintenance.
Notify next higher
level of
maintenance.
OK
Connect slave unit.
Refer to para.2.21.
Check battery
connections.
Not OK
Replace battery
connections
(see para.4.6.2).
Not OK
Notify next higher
level of
maintenance.
3-13
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
TABLE 3-1. OPERATOR TROUBLESHOOTING (CONTINUED)
CIM DISPLAY SCREEN BATTERY VDC INDICATOR SHOWS
EXCESSIVE CHARGING AFTER PROLONGED OPERATION
CIM display screen BATTERY VDC indicator
shows excessive charging after prolonged
operation. (fig.2-2)
No
Inspect batteries
(see para.3.3.2).
Are batteries maintenance
free type?
OK
Not OK
Service batteries
(see para.3.3.2).
3-14
Notify next higher
level of
maintenance.
Yes
Notify next higher
level of maintenance.
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
TABLE 3-1. OPERATOR TROUBLESHOOTING (CONTINUED)
CIM DISPLAY SCREEN VOLTAGE GAGE FLUCTUATES
CIM display screen VOLTAGE gage fluctuates.
No
Is engine running erratically?
Notify next higher
level of maintenance.
Yes
Got to troubleshooting
section corresponding to
fault displayed. See
Symptom Index, page 3-1.
Not OK
Notify next higher
level of maintenance.
Yes
Check FAULT INDICATOR
on CIM display screen. Is a
fault displayed? (fig. 2-2)
OK
Inspect/service fuel
filter/water separator
(see para.3.3.7).
No
Inspect air cleaner
assembly (see
para.3.3.3).
OK
Not OK
Service air
cleaner assembly
(see para.3.3.3).
Notify next higher
level of maintenance.
3-15
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
TABLE 3-1. OPERATOR TROUBLESHOOTING (CONTINUED)
CIM DISPLAY SCREEN FREQ GAGE FLUCTUATES
CIM display screen FREQ gage fluctuates.
(fig.2-2)
No
Is engine running erratically?
Yes
Notify next higher
level of maintenance.
Got to troubleshooting
section corresponding to
fault displayed. See
Symptom Index, page 3-1.
Not OK
Notify next higher
level of maintenance.
3-16
Yes
Check FAULT INDICATOR
on CIM display screen. Is a
fault displayed? (fig. 2-2)
OK
Inspect/service fuel
filter/water separator
(see para.3.3.7).
No
Inspect air cleaner
assembly (see
para.3.3.3).
OK
Not OK
Service air
cleaner assembly
(see para.3.3.3).
Notify next higher
level of maintenance.
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
TABLE 3-1. OPERATOR TROUBLESHOOTING (CONTINUED)
CIM DISPLAY SCREEN DOES NOT RESPOND TO KEYPAD
INPUT TEST
CIM display screen works, but backlight does not light or
only partially lights.
Yes
Toggle FAULT RESET switch (12, fig.2-1) to
No
the ON position. Release Fault switch. Does CIM
display screen respond to keypad input?
Start and operate
generator set normally.
Refer to para.2.11.1.
Yes
Verify DEAD CRANK switch
(10, fig.1-30) is set to
NORMAL position.
Notify next higher
level of
maintenance.
No
Set DEAD CRANK
switch in NORMAL
position.
Toggle FAULT RESET switch (12,
fig.2-1) to the ON position. Release
FAULT switch. Does CIM display
screen respond to keypad input?
Reboot
Toggle FAULT RESET switch
(12, fig.2-1) to the ON position.
Release FAULT switch. Does
CIM display screen respond to
keypad input?
No
Notify next higher
level of
maintenance.
No
Yes
Start and operate
generator set normally.
Refer to para.2.11.1.
Yes
Start and operate
generator set normally.
Refer to para.2.11.1.
3-17
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
SECTION III. OPERATOR MAINTENANCE PROCEDURES
__________
WARNING
Batteries give off a flammable gas. Do not smoke or use open flame when
performing maintenance. Failure to comply can cause injury or death to
personnel and equipment damage due to flames and explosion.
__________
WARNING
Battery acid can cause burns to unprotected skin. Wear protective gloves
and safety goggles. Failure to comply can cause personal injury.
3.3
GENERATOR SET INSPECTION AND SERVICE.
3.3.1
Introduction.
3.3.2
a.
This section contains operator maintenance procedures. Deficiencies noted during inspection which
are beyond the scope of operator level maintenance shall be reported to the next higher level of
maintenance.
b.
Refer to Table 3-4 for Quick Reference General Inspection.
Batteries BT1 and BT2.
__________
WARNING
DC voltage is present at generator set electrical components even with
generator set shut down. Avoid grounding yourself when in contact with
any electrical components. Failure to comply can cause injury or death to
personnel.
a.
Inspection.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door at front of generator set (Figure 1-2).
(3)
Inspect for damaged battery case, corrosion, or damaged and loose connections on terminal
cable.
__________
WARNING
Batteries give off a flammable gas. Do not smoke or use open flame when
performing maintenance. Failure to comply can cause injury or death to
personnel and equipment damage due to flames and explosion.
NOTE
Batteries used in the generator sets may be the maintenance-free type or the type
that contains electrolyte. If the batteries in your generator set are maintenance
free, skip steps (4) through (7), and go to step (8).
3-18
ARMY TM 9-6115-671-14
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MARINE CORPS TM 09249A/09246A-14
(4)
Remove battery caps. (located on top of electrolyte type batteries).
CAUTION
Electrolyte level must cover battery plates in all cells. Failure to comply
can cause damage to battery.
NOTE
Electrolyte level should be at bottom of each cap cylinder.
b.
(5)
Inspect electrolyte level.
(6)
Perform service procedure, step b below, if required.
(7)
Install battery caps.
(8)
Close BATTERY ACCESS door (Figure 1-2).
Service.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2).
__________
WARNING
Batteries give off a flammable gas. Do not smoke or use open flame when
performing maintenance. Failure to comply can cause injury or death to
personnel and equipment damage due to flames and explosion.
NOTE
Batteries used in the generator sets may be the maintenance-free type or the type
that contains electrolyte. If the batteries in your generator set are maintenance
free, skip steps (3) through (5), and go to step (6).
NOTE
Batteries used in the generator sets may be the maintenance-free type or the type
that contains electrolyte. If the batteries in your generator set are maintenance
free, skip steps (3) through (5) and go to step (6).
(3)
Remove battery caps .(located on top of electrolyte type batteries).
3-19
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
CAUTION
Electrolyte level must cover battery plates in all cells. Failure to comply can
cause damage to battery.
NOTE
Electrolyte level should be at bottom of each cap cylinder.
3.3.3
(4)
Add distilled water to each battery cell as required.
(5)
Replace battery caps.
(6)
Close BATTERY ACCESS door (Figure 1-2).
(7)
If necessary, contact next higher level of maintenance to clean or replace batteries or battery
terminals.
Air Cleaner Assembly.
a.
Inspection.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open AIR CLEANER ACCESS door (9, Figure 3-1) at rear of generator set.
(3)
Inspect air cleaner housing (1) for dents, corrosion, missing hardware, and other damage.
(4)
Close AIR CLEANER ACCESS door (9, Figure 3-1).
(5)
Open left side engine compartment access doors (Figure 1-3).
NOTE
Restriction indicator will pop out displaying a red band when flow through the
air cleaner is restricted and requires service.
NOTE
Restriction indicator is located halfway between the left side engine access door
and the rear of the generator set. It may be necessary to use a flashlight to see
the indicator.
b.
3-20
(6)
Inspect restriction indicator assembly (2) for indication of restricted air flow through the air
cleaner.
(7)
Close engine compartment access doors.
Service.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open AIR CLEANER ACCESS door (9, Figure 3-1) at rear of generator set.
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
FIGURE 3-1. AIR CLEANER ELEMENT REPLACEMENT
(3)
Loosen wing nut (3, Figure 3-1), and remove end cap assembly (4) from rod (5) in air cleaner
housing (1).
(4)
Remove wing nut (6) and filter element (7) from rod (5). If dirty or worn, replace filter element.
(5)
Inspect inside of air cleaner housing (1) for debris and grime. Wipe housing interior with clean,
lint-free cloth (Item 8, Appendix E).
(6)
Install filter element (7) and wing nut (6) on rod (5).
(7)
Install end cap assembly (4) on rod (5), and tighten wing nut (3) fingertight.
(8)
Close AIR CLEANER ACCESS door (9).
(9)
Open left side engine compartment access doors (Figure 1-3).
3-21
ARMY TM 9-6115-671-14
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MARINE CORPS TM 09249A/09246A-14
NOTE
Restriction indicator will pop out displaying a red band when flow through the
air cleaner is restricted and requires service.
NOTE
Restriction indicator is located halfway between the left side engine access door
and the rear of the generator set. It may be necessary to use a flashlight to see
the indicator.
3.3.4
(10)
Inspect restriction indicator (2). If the red indicator is visible, reset by pressing the reset button
(8).
(11)
Close left side engine compartment access doors.
Crankcase Breather Filter Assembly.
a.
Inspection.
(1)
Shut down generator set, paragraph 2.11.2.
__________
WARNING
Exhaust system can get very hot. Allow system to cool before performing
maintenance. Failure to comply can cause severe burns and injury to
personnel.
b.
(2)
Open right side engine compartment access door (Figure 1-2).
(3)
Inspect sight glass (1, Figure 3-2). If fluid is visible, service crankcase breather filter assembly
(3), step b below.
(4)
Inspect hoses (2) for cracks, holes, dry rot, and damaged or missing hose clamps.
(5)
Inspect crankcase breather filter assembly (3) for cracks, excessive corrosion, and other damage.
(6)
Close engine compartment access doors.
Service.
(1)
Shut down generator set, paragraph 2.11.2.
__________
WARNING
Exhaust system can get very hot. Allow system to cool before performing
maintenance. Failure to comply can cause severe burns and injury to
personnel.
(2)
3-22
Open right side engine compartment access doors (Figure 1-2).
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
FIGURE 3-2
CRANKCASE BREATHER FILTER ASSEMBLY
(3)
Position suitable container under crankcase breather filter assembly (3, Figure 3-2), loosen drain
valve (4), and drain fluid into a suitable container. Tighten drain valve (4).
(4)
Close engine compartment access doors.
3-23
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MARINE CORPS TM 09249A/09246A-14
3.3.5
Engine Cooling System.
a.
Inspection.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open both right and left sets of engine compartment access doors (Figures 1-2 and 1-3).
__________
WARNING
Cooling system operates at high temperature and pressure. Contact with
high pressure steam and/or liquids can result in burns and scalding. Shut
down generator set, and allow system to cool before performing checks,
services, and maintenance. Failure to use caution can cause injury or death
to personnel.
b.
(3)
Check radiator for dirt, leaves, insects and other blockage inhibiting air flow.
(4)
Check radiator and hoses for leaks, loose connections, loose mountings, corrosion, chafing, and
missing parts.
(5)
Check coolant level on coolant recovery (overflow) bottle (1, Figure 3-3).
(6)
Close engine access doors.
Service.
__________
WARNING
Cooling system operates at high temperature and pressure. Contact with
high pressure steam and/or liquids can result in burns and scalding. Shut
down generator set, and allow system to cool before performing checks,
services, and maintenance. Failure to use caution can cause injury or death
to personnel.
3-24
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open right side engine compartment access doors (Figure 1-2).
(3)
Remove cap (2, Figure 3-3) from coolant recovery (overflow) bottle (1).
(4)
Fill coolant recovery (overflow) bottle (1) to HOT line if engine is hot, COLD if engine is
cooled down, with proper coolant/antifreeze in accordance with Table 3-2.
(5)
Install cap (2) on coolant recover (overflow) bottle (1).
(6)
Close engine compartment access doors.
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
FIGURE 3-3. COOLANT RECOVERY (OVERFLOW) BOTTLE
3-25
ARMY TM 9-6115-671-14
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MARINE CORPS TM 09249A/09246A-14
TABLE 3-2. COOLANT
AMBIENT TEMPERATURE
+40° F to +120° F
(+4° C to 49° C)
-25° F to +120° F
(-32° C to 49° C)
-25° F to +120° F
(-32° C to 49° C)
3.3.6
RADIATOR COOLANT
Water: MIL-A-53009
Inhibitor,
Corrosion
ANTIFREEZE, MULTI ENGINE TYPE
Commercial Item Description (CID) A-A-52624
Type IP, Ethylene Glycol Base
MIL-A-11755
Antifreeze
RATIO
35:1
N/A
Not Applicable
Use Full Strength
Fuel Tank.
a.
Inspection.
(1)
Start up generator set, paragraph 2.11.1.
(2)
Place ENGINE CONTROL switch (8, Figure 2-1) on control panel in PRIME & RUN or
PRIME & RUN AUX FUEL position.
(3)
If CIM display screen is not in MAIN mode (Figure 2-2), use keypad arrow buttons to move
cursor to DISPLAY MODE (10, Figure 2-2). Press SELECT button (18, Figure 2-1) to click
MAIN button to access MAIN mode screen.
(4)
Check FUEL LEVEL gage (18, Figure 2-2) on CIM display screen for level of fuel in the fuel
tank.
(5)
Shut down generator set, paragraph 2.11.2.
__________
WARNING
Fuels used in the generator set are flammable. Do not smoke or use open
flames when performing maintenance. Failure to comply can result in
flames and explosion and can cause injury or death to personnel and damage
to the generator set.
3-26
(6)
Remove fuel cap (1, Figure 3-4) from filler neck (2) on left side of generator set housing.
(7)
Check fuel strainer in filler tube (3) for dirt and other foreign material.
(8)
Install fuel cap (1) on filler neck (2).
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
FIGURE 3-4. FUEL TANK FILLER NECK
3-27
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MARINE CORPS TM 09249A/09246A-14
b.
Service.
NOTE
If mission characteristics do not allow shutting down the generator set, it can
safely be “Hot Refueled,” but it is safer to shut down the generator set before
refueling.
(1)
Shut down generator set, paragraph 2.11.2.
__________
WARNING
Fuels used in the generator set are highly flammable. Do not smoke or use
open flames when performing maintenance. Failure to comply can result in
flames and explosion and can cause injury or death to personnel and
damage to the generator set.
__________
WARNING
Fuels used in the generator set are flammable. When filling the fuel tank,
maintain metal-to-metal contact between filler nozzle and fuel tank opening
to eliminate static electrical discharge. Failure to comply can result in
flames and explosion and can cause injury or death to personnel and
damage to the generator set.
(2)
Remove fuel cap (1, Figure 3-4) from filler neck (2) on left side of generator set housing.
(3)
Remove filler tube (3) from filler neck (2), clean strainer as necessary, and reinstall filler tube.
CAUTION
Using the wrong grade of fuel can damage the generator set engine. Add only
specified diesel fuel to the fuel tank. Failure to comply can cause damage to
equipment.
NOTE
Fuel tank holds 23 gallons (87.05 liters) of fuel.
(4)
Add diesel fuel (see Table 3-3 ) to fuel tank.
TABLE 3-3. DIESEL FUEL
AMBIENT TEMPERATURE
DIESEL FUEL
+20° F to +120° F
VV-F-800 Grade DF-2
(-7° C to +49° C)
JP5, JP8
0° F to +20° F
VV-F-800 Grade DF-1
(-17° C to +7° C)
JP5, JP8
-25° F to 0° F
VV-F-800 Grade DF-1
(-32° C to -17° C)
-25° F to 0° F
VV-F-800 Grade DF-A
(-32° C to -17° C)
3.3.7
3-28
(5)
Install fuel cap (1) on filler neck (2).
Fuel Filter/Water Separator.
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
a.
b.
3.3.8
Inspection.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open right side engine compartment access doors (Figure 1-2).
(3)
Inspect fuel filter/water separator assembly for proper mounting, cracks, dents, leaks, loose fuel
lines, and missing parts.
(4)
Close engine compartment access doors.
Service.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open right side engine compartment access doors (Figure 1-2).
(3)
Open drain cock (2, Figure 3-5) and air vent (1) on fuel filter/water separator. Allow water and
sediment to drain into a suitable container.
(4)
Close drain cock (2) and air vent (1).
(5)
Close engine compartment access doors.
Lubrication.
a.
Inspection.
(1)
Start up generator set, paragraph 2.11.1. Allow engine to warm up.
(2)
Check for a LOW OIL or OIL PRESSURE fault displayed in the FAULT INDICATOR portion
of the CIM display panel.
(3)
Shut down generator set, paragraph 2.11.2.
(4)
Open both right and left sets of engine compartment access doors (Figures 1-2 and 1-3).
(5)
Inspect engine for oil leaks, damage, and missing parts.
3-29
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
FIGURE 3-5. FUEL FILTER/WATER SEPARATOR
3-30
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
CAUTION
Oil dipstick is marked ENGINE OFF on one side and ENGINE ON on the
other so crankcase oil can be checked with the engine in either condition.
Ensure the appropriate side of the dipstick is used when checking oil level.
Failure to comply can cause damage to equipment.
b.
(6)
Using ENGINE OFF side of dipstick (2, Figure 3-6), check engine crankcase oil level. Refer to
Appendix F.
(7)
Close engine compartment access doors.
Service.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open left side engine compartment access doors (Figure 1-2).
(3)
Remove oil filler cap (1, Figure 3-6) from oil filler neck.
(4)
Add oil to engine crankcase. Refer to Appendix F.
(5)
Install oil filler cap (1) on oil filler neck.
(6)
Close engine compartment doors.
FIGURE 3-6. DIPSTICK AND OIL FILL CAP
3-31
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
TABLE 3-4. QUICK REFERENCE GENERAL INSPECTION
COMPONENT/ASSEMBLY
INSPECTION TASK
DC ELECTRICAL SYSTEM
BATTERY AND SLAVE RECEPTACLE CABLES (9, Figure 4-3)
NATO SLAVE RECEPTACLE (17, Figure 1-30)
Inspect for signs of physical
damage. Inspect for loose or
frayed cables.
HOUSING
ACCESS DOORS (6, Figure 4-5)
DCS CONTROL BOX TOP PANEL (4, Figure 1-30)
TOP HOUSING SECTION (Figure 4-7)
FRONT HOUSING SECTION (Figure 4-8)
REAR HOUSING SECTION (Figure 4-9)
HOUSING DATA PLATES (Refer to paragraph 2.16)
Inspect for signs of physical
damage such as dents, cracks,
loose paint and corrosion.
Ensure all housing data plates are
present and legible.
DCS CONTROL BOX ASSEMBLY
PANEL LIGHTS (1, Figure 4-11)
TIME METER (3, Figure 4-12)
SWITCHES (8, Figure 4-8)
GROUND FAULT CIRCUIT INTERRUPTER (32, Figure 4-13)
KEYPAD ASSEMBLY KP (7, Figure 4-14)
CONVENIENCE RECEPTACLE (3, Figure 1-30)
AUXILIARY CONTROL BRACKET (17, Figure 4-16)
DCS CONTROL BOX WIRING HARNESS (43, Figure 4-16)
CIM WIRING HARNESS (44, Figure 4-16)
DCS CONTROL PANEL FRAME AND PANELS (14, 26, 27 Figure 4-18)
DCS DATA PLATES (Refer to paragraph 2.16)
Inspect for signs of physical
damage including cracked or
broken components. Ensure all
DCS data plates are present and
legible.
AIR INTAKE AND EXHAUST SYSTEM
MUFFLER AND EXHAUST PIPE (11, Figure 1-30)
Inspect for signs of physical
damage such as cracks and
excessive corrosion.
ENGINE COOLING SYSTEM
HOSES (12, 14 Figure 4-22)
RADIATOR (12, Figure 1-30)
FAN GUARDS (22, Figure 4-23)
FAN (40, Figure 4-22)
FAN BELT (13, Figure 1-30)
Inspect for signs of physical
damage including cracked or
broken components. Visually
check hoses for bulges, cracks,
and signs of dry rot.
FUEL SYSTEM
LOW PRESSURE FUEL LINES AND FITTINGS (10, 11 Figure 4-25)
ETHER CYLINDER ASSEMBLY (Figure 4-26)
Inspect for signs of physical
damage. Visually check lines for
signs of leakage.
OUTPUT BOX ASSEMBLY
TRANSFORMERS (10, 11 Figure 4-27)
OUTPUT BOX PANELS (6, Figure 5-3)
Inspect for signs of physical
damage.
ENGINE ACCESSORIES
SENDERS (Figure 4-29)
DEAD CRANK SWITCH (10, Figure 1-30)
OIL DRAIN VALVE (14, Figure 1-30)
Inspect for signs of physical
damage. Ensure oil drain valve
shows no signs of leakage.
GENERATOR ASSEMBLY (Figure 5-1)
Inspect for signs of physical
damage.
ENGINE ASSEMBLY (Figure 5-1)
Inspect for signs of physical
damage.
SKID BASE (16, Figure 1-30)
Inspect for signs of physical
damage such as dents, cracks,
loose paint and corrosion.
3-32
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
CHAPTER 4
UNIT MAINTENANCE INSTRUCTIONS
CHAPTER INDEX
SECTION I
INSPECTING AND SERVICING THE EQUIPMENT................................................................4-1
SECTION II
REPAIR PARTS; TOOLS; TEST, MEASUREMENT AND DIAGNOSTIC
EQUIPMENT (TMDE); AND SUPPORT EQUIPMENT ............................................................4-6
SECTION III
LUBRICATION PROCEDURES..................................................................................................4-6
SECTION IV
UNIT PREVENTIVE MAINTENANCE CHECKS AND SERVICES.........................................4-7
SECTION V
TROUBLESHOOTING...............................................................................................................4-10
SECTION VI
UNIT MAINTENANCE PROCEDURES ...................................................................................4-49
SECTION VII
PREPARATION FOR SHIPMENT AND STORAGE..............................................................4-207
SECTION I. INSPECTING AND SERVICING THE EQUIPMENT
4.1
INSPECTING AND SERVICING THE EQUIPMENT.
4.1.1
Inspection.
a.
Unpack and inventory all end item components for serviceability.
b.
Check that all packing materials have been removed.
c.
Check generator set identification plate for proper identification.
d.
Inspect generator set exterior for shipping damage.
e.
Open BATTERY ACCESS (Figure 1-2), and inspect batteries for damage.
f.
Check battery cables for proper polarity connects, damage, and loose connections.
4-1
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
NOTE
Batteries used in the generator set may be the maintenance-free type or the type that contains
electrolyte. If the batteries in your generator set are maintenance-free, skip steps g and h, and
go to step i.
g.
If applicable, remove battery caps.
h.
Check battery electrolyte level, and install battery caps.
i.
Loosen fasteners, lower control panel, and check electrical components for damage or loose connections.
j.
Raise control panel, and secure fasteners.
k.
Check air cleaner assembly for external damage and exhaust opening for obstruction.
l.
Open engine compartment access doors (Figures 1-2 and 1-3).
m. Check fan belt for looseness, and ensure it is not frayed or cracked.
n.
Inspect generator set for loose or missing mounting hardware or damaged or missing parts.
NOTE
Dipstick is marked indicating oil level may be checked and oil added when engine is
running or stopped. Make sure the correct side of the dipstick is checked.
4.1.2
o.
Check oil level. As required, drain preservative from engine and fill with proper lubricating oil, paragraph
4.1.2.
p.
Unpack grounding rod from inside left engine access door (Figure 1-3) and parallel cable and auxiliary fuel
hose from storage box. Inspect each item for damage and accountability.
q.
Stow grounding rod, parallel cable, and auxiliary fuel hose in storage box, and close engine compartment
and BATTERY ACCESS doors .
Service.
a.
Batteries BT1 and BT2. The batteries shipped with new generator sets are maintenance free. If the
batteries have been replaced with batteries that require service, refer to paragraph 3.3.2 for instructions.
b.
Radiator.
_________
WARNING
Cooling system operates at high temperature. Hot coolant is under high
pressure and can spray when cooling system is opened. Shut down generator
set and allow to cool before servicing radiator. Failure to comply can cause
damage to equipment and injury to personnel.
4-2
(1)
Remove radiator cap.
(2)
Check that radiator drain valve is closed.
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
(3)
Fill radiator with proper coolant/antifreeze in accordance with Table 4-1. Fill radiator to a level two
inches below fill opening.
TABLE 4-1. COOLANT
AMBIENT
TEMPERATURE
+40°F TO +120°F
(4°C TO 49°C)
-25°F TO +120°F
(-32°C TO +49°C)
-25°F TO +120°F
(-32°C TO +49°C)
c.
RADIATOR
COOLANT
WATER: MIL-A-53009
INHIBITOR, CORROSION
ANTIFREEZE, MULTI ENGINE TYPE
Commercial Item Description (CID) A-A-52624
Type IP, Ethylene Glycol Base
MIL-A-11755
ANTIFREEZE
RATIO
35:1
N/A
N/A
(4)
Remove cap from overflow bottle.
(5)
Fill overflow bottle to COLD level mark.
(6)
Install caps on overflow bottle and radiator.
(7)
After 30 minutes of operation, check coolant/antifreeze level at overflow bottle. Add
coolant/antifreeze to overflow bottle as required.
Fuel Tank.
__________
WARNING
Fuels used in the generator set are flammable. Do not smoke or use open
flames when performing maintenance. Failure to comply can result in flames
and possible explosion and can cause injury or death to personnel and damage
to the generator set.
(1)
Check that fuel drain valve (1, Figure 4-1) is closed.
__________
WARNING
Hot engine surfaces and sparks from the engine and generator circuitry are
possible sources of ignition. When hot refueling with DF-1, DF-2, DF-A, JP5
or JP8, avoid fuel splash and fuel spill. Do not smoke or use open flame when
performing refueling. Failure to comply can result in flames and possible
explosion and can cause injury or death to personnel and damage to the
generator set.
(2)
Remove fuel tank filler cap (located on the left side of the generator set housing).
4-3
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
FIGURE 4-1. FUEL DRAIN VALVE AND OIL DRAIN
4-4
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
__________
WARNING
Fuels used in the generator set are flammable. When filling the fuel tank,
maintain metal-to-metal contact between filler nozzle and fuel tank opening to
eliminate static electrical discharge. Failure to comply can result in flames and
possible explosion and can cause injury or death to personnel and damage to
the generator set.
(3)
Fill fuel tank with fuel type in accordance with Table 4-2. Fuel tank capacity is 43 gallons (162.75
liters).
TABLE 4-2. FUEL
AMBIENT TEMPERATURE
+20°F TO 120°F
(-6°C TO +49°C)
0°F TO +20°F
(-17°C TO -6°C)
-25°F TO 0°F
(-32°C TO -17°C)
-25°F TO 0°F
(-32°C TO -17°C)
(4)
d.
DIESEL FUEL
VV-F-800 GRADE DF-2, JP5, OR JP8
VV-F-800 GRADE DF-1, JP5, OR JP8
VV-F-800
GRADE DF-1
VV-F-800
GRADE DF-A
Install fuel tank filler cap.
Lubrication.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Place suitable container under OIL DRAIN (2, Figure 4-1), and remove plug.
(3)
Open BATTERY ACCESS door (Figure 1-2), and open oil drain valve. Drain oil.
(4)
Close oil drain valve, and close BATTERY ACCESS door. Install plug in OIL DRAIN (2).
(5)
Remove oil fill cap (1, Figure.4-2).
NOTE
Dipstick is marked indicating oil level may be checked and oil added when engine is
running or stopped. Make sure the correct side of the dipstick is checked.
(6)
Fill engine with proper engine lubricating oil to FULL mark on dipstick (2). Refer to Appendix F.
Lubrication system capacity is 18 quarts (17.03 liters).
(7)
Install oil fill cap (1).
4-5
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
FIGURE 4-2. DIPSTICK AND OIL FILL CAP
SECTION II. REPAIR PARTS; TOOLS; TEST, MEASUREMENT
AND DIAGNOSTIC EQUIPMENT (TMDE); AND SUPPORT EQUIPMENT
4.2
INTRODUCTION.
4.2.1
Tools and Equipment. There are no special tools or support equipment required to perform unit level of
maintenance on the generator set. A list of recommended tools and support equipment required to maintain the
generator set is contained in Appendix B, Section III.
4.2.2
Maintenance Repair Parts. Repair parts and equipment are listed and illustrated in the Repair Parts and Special
Tools List (RPSTL) manual TM 9-6115-672-24P, and TM 9-2815-259-24.
SECTION III. LUBRICATION PROCEDURES
4.3
4-6
UNIT LUBRICATION INSTRUCTIONS. Refer to Table 4-3, Preventive Maintenance Checks and Services
(PMCS) for unit level lubrication instructions.
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
SECTION IV. UNIT PREVENTIVE MAINTENANCE CHECKS AND SERVICES
4.4
PMCS PROCEDURES.
4.4.1
General. To ensure the generator set is ready for operation at all times, it must be inspected so defects can be
identified and corrected before they result in serious damage or equipment failure.
4.4.2
Purpose of PMCS Table. The PMCS table lists inspections and care required to keep the generator set in good
operating condition.
4.4.3
Purpose of Service Intervals. The interval column of the PMCS tells when to perform a certain check or
service.
4.4.4
Procedures Column. The procedures column of the PMCS tells how to perform required checks and services.
NOTE
The terms "ready/available" and "mission capable" refer to the same status. The
generator set is on hand and able to perform combat missions. Refer to DA Pam
738-750.
4.4.5
"Equipment is not ready/available if" Column. This column specifies when and why the generator set cannot
be used.
4.4.6
Reporting and Correcting Deficiencies. If the generator set does not perform as required, refer to
Troubleshooting section to diagnose problems. Report any malfunctions or failures. Mail it to us at the address below.
We will send you a reply.
a.
(A)
Use DA Form 2404 , or refer to DA Pam 738-750. Submit mailed forms to:
Commander
U.S. Army Communications and Electronics Command (CECOM)
Customer Feedback Office
ATTN: AMSEL-LC-LEO-D-CS-CFO
Fort Monmouth, New Jersey 07703-5008
b.
(AF) USAF Deficiency Reporting and Investigating System, TO 00-35D-54, Appendix A
procedures will be used for electronic submission. Submit mailed forms to:
SMALC/LHCABD
5029 Dudley Boulevard
McClellan AFB, CA 95652-1095
c.
(MC) Quality Deficiency Reports (QDR) shall be submitted on SF 368 in accordance with MCO
4855.10. Submission may also be made using NAVMC Form 10772. Submit directly to:
Commander
Marine Corps Logistics Bases
(Code 856)
Albany, GA 31704-5000
4-7
ARMY TM 9-6115-671-14
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MARINE CORPS TM 09249A/09246A-14
TABLE 4-3. UNIT PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
M - Monthly
Item
No.
M
Q
Q - Quarterly
Interval
S
A
B
H
S - Semi-annually
A - Annually
Item to be
inspected
B - Biannually
Procedures
Check for and have repaired or
adjusted as necessary
H - Hours
Equipment is
not ready/
available if:
CAUTION
Engine oil and filter must be changed at a hardtime of 100 hours on initial
break-in. Failure to change oil and filter may void warranty.
1
2
•
100
First oil
change at 100
hours
NOTE: Oil filter should be
changed with lube oil change.
Refer to TM 9-2815-259-24.
300
Engine lube oil
Drain engine lube oil. Add
proper lube oil per Appendix F.
Fuel filter/
water separator
Change fuel filter/water
separator. Refer to TM 9-2815259-24.
300
Cooling
system
Drain coolant, and flush cooling
system. Add proper coolant.
Refer to paragraph 4.10.1.
1500
Radiator cap
Inspect radiator cap for
corrosion, torn or deteriorated
seal, and obvious damage.
Radiator cap
or seal is
damaged.
Batteries
Remove batteries. Refer to
paragraph 4.6.3. Clean batteries,
cable terminals, and battery
posts. Test batteries for state of
charge.
Batteries will
not hold
charge.
•
•
3
4
•
5
•
6
•
1500
Air cleaner
assembly
Inspect air cleaner assembly and
mounting bracket for cracks,
dents, and other damage. Inspect
element for clogs and damage.
Clean or replace as necessary.
Clean housing with clean cloth.
Refer to paragraph 4.9.2.
7
•
750
Air cleaner
tubing and
breather
Remove, clean, and inspect
tubing and breather hose. Refer
to paragraph 4.9.5.
4-8
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
TABLE 4-3. UNIT PREVENTIVE MAINTENANCE CHECKS AND
SERVICES (PMCS) (continued)
M - Monthly Q - Quarterly S - Semi-annually A - Annually B - Biannually H - Hours
Item
No.
M
Q
Interval
S
A
8
B
H
300
Item to be
inspected
Procedures
Check for and have repaired or
adjusted as necessary
Crankcase
Breather Filter
Assembly
Inspect and service. Refer to
paragraph 4.9.6.
Equipment is
not ready/
available if:
9
•
Hardware and
sound
insulation
Inspect for loose, damaged, or
missing hardware and sound
insulation. tighten loose
hardware. Repair or replace
damaged or missing hardware or
insulation. Refer to paragraph
4.7.
10
•
Radiator and
interior of
generator set
Clean radiator exterior surfaces.
Refer to paragraph 4.10.7.
11
•
Wiring
harnesses
Check wiring harnesses for
breaks and loose connections.
Repair and tighten wiring
harnesses as necessary.
Wiring
harnesses are
damaged or
connections
are loose.
12
•
Muffler
Check muffler for leaks,
restriction, and accumulation of
carbon. Replace or clean as
required. Refer to paragraph
4.9.1.
Muffler leaks,
is restricted, or
has excessive
carbon
accumulation.
Loose,
missing, or
damaged
hardware or
insulation.
NOTE
If the auxiliary fuel system is used as the primary fuel source, the auxiliary fuel
filter must be replaced semi-annually.
13
•
500
Auxiliary fuel
filter
Check for proper operation using
the auxiliary system as primary
source. Refer to paragraph
4.11.2.
NOTE
Refer to TM9-2815-259-24 for engine preventive maintenance checks and services.
4-9
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
SECTION V. TROUBLESHOOTING
4.5
GENERAL.
This section contains troubleshooting information for locating and correcting operating troubles which may
develop in the generator set. Each malfunction for an individual component unit or system is followed by a list
of tests or inspections which will help to determine probable causes and corrective actions to take. Perform the
tests/inspections in the order listed.
Table 4-1 provides unit troubleshooting. This table cannot list all malfunctions that may occur, nor all tests or
inspections and corrective actions. If a malfunction is not listed, or is not corrected by listed corrective actions,
notify your supervisor.
NOTE
Before using this table, PMCS and operator level troubleshooting must have been
performed.
NOTE
Refer to paragraph 2.4 for diagnostic controls and indicators.
SYMPTOM INDEX
Page
Engine Fails to Crank ...............................................................................................................................................4-12
Engine Cranks, But Fails To Start ............................................................................................................................4-15
Engine Fails To Start In Cold Weather.....................................................................................................................4-17
Engine Stops Suddenly .............................................................................................................................................4-18
Engine Runs Erratically or Stalls Frequently............................................................................................................4-19
Engine Does Not Develop Full Power......................................................................................................................4-20
Abnormal Engine Noise............................................................................................................................................4-21
Black or Gray Exhaust Smoke ..................................................................................................................................4-22
Blue or White Exhaust Smoke..................................................................................................................................4-23
CIM Display Screen Does Not Display and Backlight Does Not Light....................................................................4-24
CIM Display Screen Works, But Backlight Does Not Light or Only Partially Lights..............................................4-25
CIM Display Screen BATTERY VDC Indicator Shows Low or No charge ............................................................4-26
CIM Does Not Respond To Keypad Commands or Update Display........................................................................4-27
CIM Display Screen BATTERY VDC Indicator Shows No Charge When Batteries Are Low or Discharged ........4-28
CIM Display Screen BATTERY VDC Indicator Shows Excessive Charging After Prolonged Operation ..............4-29
CIM Display Screen VOLTAGE Gage Fluctuates ...................................................................................................4-30
CIM Display Screen FREQ Gage Fluctuates............................................................................................................4-31
High Oil Consumption..............................................................................................................................................4-33
Engine Misfiring .......................................................................................................................................................4-34
CIM Display Screen Indicates WATER TEMP Meter Indicates Coolant Temperature Too Low ...........................4-35
Excessive Fuel Consumption ....................................................................................................................................4-36
Coolant In Crankcase or Oil In Coolant....................................................................................................................4-37
Engine Vibrating.......................................................................................................................................................4-37
CIM Display Screen VOLTAGE Gage Does Not Indicate Voltage .........................................................................4-38
CIM Display Screen VOLTAGE Gage Indicates Voltage, But FREQ Gage Is Off Scale........................................4-39
FAULT INDICATOR Displays CIRCUIT FAILURE - FUEL LEVEL..................................................................4-40
FAULT INDICATOR Displays CIRCUIT FAILURE - OIL PRESSURE (low) or OIL PRESSURE (high) .........4-41
FAULT INDICATOR Displays CIRCUIT FAILURE - COOLANT TEMP ..........................................................4-42
SYMPTOM INDEX Continued
4-10
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
FAULT INDICATOR Displays WARNING - OVERVOLTAGE or SHUTDOWN -OVERVOLTAGE ..............4-43
CIRCUIT INTERRUPTER will not close................................................................................................................4-44
CIRCUIT INTERRUPTER will not open ................................................................................................................4-46
CIM Display Screen does not respond to keypad input ............................................................................................4-48
4-11
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
TABLE 4-4. UNIT TROUBLESHOOTING
ENGINE FAILS TO CRANK
Engine fails to
crank.
No
Check FAULT INDICATOR on
CIM display screen. Is a fault
displayed?
Check for loose or
corroded battery cable
terminals or battery posts.
OK
Inspect batteries
(see para.4.6.3).
Go to troubleshooting section
corresponding to fault
displayed. See Symptom
Index, page 4-10.
Not OK
Clean and tighten
battery cable terminals
and battery posts.
OK
Not OK
Replace batteries
(see para.4.6.3).
4-12
Yes
Continued on
next page.
ARMY TM 9-6115-671-14
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MARINE CORPS TM 09249A/09246A-14
TABLE 4-4. UNIT TROUBLESHOOTING (CONTINUED)
ENGINE FAILS TO CRANK (CONTINUED)
Continued from previous page.
No
Test for battery voltage at input of
Yes
ENGINE CONTROL switch
(see para.4.8.5). Is voltage present?
Check wires from TB4 to
S1-3. Refer to Wiring
Diagram FO-3.
OK
Not OK
Test diode CR1
(see para.4.8.29).
Repair or replace
defective wires or
connections.
OK
Not OK
Replace diode CR1
(see para.4.8.29).
Not OK
Replace start relay
(see para.4.8.34).
Test ENGINE CONTROL
switch output voltage in
START position. (see
para.4.8.5). Is battery
voltage present between
output terminal No. 7 and
ground?
No
Yes
Replace ENGINE
CONTROL switch
(see para.4.8.5).
Test start relay OK
(see para.4.8.34).
Continued on
next page.
4-13
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
TABLE 4-4. UNIT TROUBLESHOOTING (CONTINUED)
ENGINE FAILS TO CRANK (CONTINUED)
Continued from previous page.
OK
Test cranking relay
(see para. 4.12.7).
Not OK
Replace cranking relay
(see para. 4.12.7).
OK
Not OK
Check starting circuit
Not OK
for breaks or loose
connections. Refer to
Schematic, FO-1.
Test starter solenoid.
Refer to
TM 9-2815-259-24.
Replace starter
solenoid, Refer to
TM 9-2815-259-24.
OK
OK
Test starting motor.
Refer to
TM 9-2815-259-24.
Notify next higher level
of maintenance.
4-14
Repair or replace
defective wires or
connections.
Not OK
Replace starting motor.
Refer to TM 9-2815-259-24.
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
TABLE 4-4. UNIT TROUBLESHOOTING (CONTINUED)
ENGINE CRANKS, BUT FAILS TO START
Engine cranks, but fails to start.
No
Repeat Starting procedure
(Para 2.11.1).
Check FAULT
INDICATOR on
CIM display screen.
Is a fault displayed?
Go to troubleshooting
section corresponding to
fault displayed. See
Symptom Index, page 4-10.
Yes
OK
Check Speed Control Unit DC
POWER LED.(15 Fig 2-3) Is it lit?
Yes
Does SPEED SENSOR
LED (12, Fig 2-3) on Speed
Control Unit illuminate
during cranking?
Yes
No
Continued on next page
No
Check EMERGENCY
STOP switch.(3, Fig
2-1) Is it pressed in?
Yes
No
Check I/O interface module
(Fig 2-3) for 24VDC at
connector P25 pin 9. See
Wiring Diagram, FO-3.
Pull EMERGENCY
STOP switch out.
Repair or replace wires.
See Wiring Diagram,
FO-3.
OK
Check the I/O interface
module (Fig 2-3) for
Not OK
24VDC at connector P25
pin 8. Refer to Wiring
Diagram, FO-3.
No
Replace magnetic
pickup (see para.
4.13.3).
Replace I/O interface
module (see para.
4.8.25).
OK
Check Speed Control
Not OK
Unit connections. See
Wiring Diagram, FO-3.
Not OK
Repair broken
wires and
connections as
necessary.
Inspect magnetic pickup
(see para. 4.13.3). Are
there broken wires or
loose connections?
OK
Not OK
Check EMERGENCY
STOP switch circuit for
broken wires or connections.
See Schematic, FO-1.
Yes
Test Emergency
Stop Switch
(3, fig 2-1)
Ref Para 4.8.14.
OK
Notify next higher level
of maintenance.
Replace DCS speed
control unit (see para.
4.8.22).
OK
Not OK
Replace backplane
module (see para.
4.8.24).
Replace Emergency
Stop Switch (3, fig
2-1) Ref Para
4.8.14.
Notify next higher level of
maintenance.
4-15
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
TABLE 4-4. UNIT TROUBLESHOOTING (CONTINUED)
ENGINE CRANKS, BUT FAILS TO START (CONTINUED)
Continued from previous page.
Push RESET BUTTON
on overspeed module
(13, Fig.2-3). Repeat
starting procedure.
Yes
No
Is Overspeed LED
(10,Fig.2-3) lit ?
Check Actuator LED (11, Fig 2-3). Is
it lit during cranking ?
No
Yes
Replace Speed Control
Module
(see Para 4.8.22).
OK
Check for clogged or
defective fuel filter/water
separator. Refer to
TM 9-2815-259-24.
Replace fuel filter/
water separator.
Refer to TM
9-2815-259-24.
Not OK
Check for contaminated fuel. (see
para.3.3.6) or incorrect grade of
fuel (Table 3-3).
Not OK
OK
Using fuel drain valve, (figure 4-1), drain fuel into
suitable container. Replace fuel filter and fuel/water
separator. Refer to TM 9-2815-259-24. Service fuel
tank (see para. 3.3.6). Bleed fuel lines. Refer to TM
9-2815-259-24.
Not OK
OK
Notify next higher
level of maintenance.
4-16
Check for evidence of air
bubbles or fuel line blockage.
Not OK
OK
Check for defective
fuel supply pump.
Refer to TM
9-2815-259-24.
OK
Not OK
Replace fuel supply
pump. Refer to
TM 9-2815-259-24.
Check for
blocked exhaust
pipe or muffler
(see para.4.9.1).
Not OK
Unblock exhaust
pipe or replace
muffler (see
para.4.9.1).
Unblock or replace fuel
lines as necessary (see
para.4.11.1). Ensure fuel
lines are tight. Bleed fuel
lines. Refer to TM
9-2815-259-24.
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
TABLE 4-4. UNIT TROUBLESHOOTING (CONTINUED)
ENGINE FAILS TO START IN COLD WEATHER
Perform cold weather starting
No
procedure. Ref Para 2.11.1.
Does Engine Start ?
Engine fails to start in
cold weather.
Check FAULT INDICATOR Yes
on CIM display screen. Is a
fault displayed?
No
Not OK
Check CIM display screen
BATTERY VDC indicator for
low or no battery charge.
OK
Inspect batteries (see para.
4.6.3). Service or replace
batteries as necessary.
Not OK
Go to troubleshooting section
corresponding to fault displayed.
See Symptom Index, page 4-10.
OK
Check for proper lube oil
type (Appendix F).
Check for proper grade of
fuel (Table 3-3).
Yes
OK
Is ether cylinder
installed?
Inspect ether cylinder
(see para. 4.11.7).
Inspect ether
Not OK
solenoid valve
(see para 4.11.8).
Replace ether
solenoid valve
(see para 4.11.8).
Test ETHER
START switch
(see para. 4.8.6).
Replace ETHER
START switch
(see para. 4.8.6).
Not OK
Drain oil, and replace oil filter.
Refill with proper oil type.
Refer to para. 4.1.2.
Refer to Appendix F.
OK
Using fuel drain valve (Figure 4-1),
drain fuel into suitable container.
Service fuel tank (see para. 3.3.6).
Bleed fuel lines. Refer to TM
9-2815-259-24.
Not OK
Not OK
No
Install ether
cylinder
(see para. 4.11.7).
Replace ether cylinder
(see para. 4.11.7).
OK
Test Ether Solenoid
Relay (16, Fig 4-26)
Ref Para 4.11.9
Not OK
Replace Ether Solenoid
Relay (16, Fig 4-26).
Ref Para 4.11.9
Notify next higher
level of
maintenance.
OK
4-17
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
TABLE 4-4. UNIT TROUBLESHOOTING (CONTINUED)
ENGINE STOPS SUDDENLY
Engine stops suddenly.
Yes
Check FAULT
INDICATOR on CIM
display screen. Is a fault
displayed? (Fig 2-2)
No
Change fuel filter/
water separator
(para. 4.11.10).
Does Engine Start?
No
Go to troubleshooting section
corresponding to fault displayed.
See Symptom Index, page 4-10.
No
OK
Check for defective fuel
supply pump. Refer to
TM 9-2815-259-24.
Notify next higher
level of maintenance.
4-18
Bleed fuel lines. Refer to TM
9-2815-259-24. Is there
evidence of air bubbles or fuel
line blockage?
Yes
Not OK
Replace fuel supply
pump. Refer to TM
9-2815-259-24.
Unblock or replace fuel lines as
necessary (see para. 4.11.1).
Bleed and tighten fuel lines.
Refer to TM 9-2815-259-24.
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
TABLE 4-4. UNIT TROUBLESHOOTING (CONTINUED)
ENGINE RUNS ERRATICALLY OR STALLS FREQUENTLY
Engine runs erratically or
stalls frequently.
Yes
Check FAULT
INDICATOR on
CIM display screen.
Is a fault displayed?
(Fig 2-2)
Go to troubleshooting section
corresponding to fault displayed.
See Symptom Index, page 4-10.
No
No
Not OK
Inspect exhaust
pipe and muffler
(see para. 4.9.1).
Check for contaminated
fuel (see para. 3.3.6) or OK
incorrect grade of fuel
(Table 3-3).
Replace fuel filter/ water separator.
Refer to TM 9-2815-259-24.
Drain fuel into suitable container.
Service fuel tank (see para. 3.3.6).
Bleed fuel lines. Refer to TM
9-2815-259-24.
Bleed fuel lines. Refer to
TM 9-2815-259-24. Is
there evidence of air
bubbles or fuel line
blockage?
Yes
OK
Unblock exhaust pipe or
replace muffler (see
para. 4.9.1).
Not OK
Change fuel filter/ water separator
(para. 4.11.10).
Does Engine Start?
No
Unblock or replace fuel lines as
necessary (see para. 4.11.1). Bleed
and tighten fuel lines.
Refer to TM 9-2815-259-24.
Notify next higher
level of maintenance.
4-19
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
TABLE 4-4. UNIT TROUBLESHOOTING (CONTINUED)
ENGINE DOES NOT DEVELOP FULL POWER
Engine does not develop full power.
Yes
Go to troubleshooting section
corresponding to fault
displayed. See Symptom
Index, page 4-10.
Not OK
Using fuel drain valve (figure
4-1), drain fuel into suitable
container. Service fuel tank (see
para. 3.3.6.). Bleed fuel lines.
Refer to TM 9-2815-259-24.
Not OK
Unblock exhaust pipe
or replace muffler
(see para. 4.9.1).
4-20
Check FAULT INDICATOR
No
on CIM display screen. Is a
fault displayed? (Fig. 2-2)
Inspect fuel filter/
water separator (see
para. 3.3.7).
OK
Check for contaminated fuel
(see para. 3.3.6) or incorrect
grade of fuel (Table 3-3).
No
Inspect muffler and
exhaust pipe
(see para. 4.9.1.).
OK
Not OK
Replace fuel filter/
water separator. Refer
to TM 9-2815-259-24.
Bleed fuel lines. Refer to
TM 9-2815-259-24. Is there
evidence of air bubbles or
fuel line obstruction?
OK
Notify next
higher level of
maintenance.
Yes
Unblock or replace fuel lines as
necessary (see para. 4.11.1).
Bleed and tighten fuel lines.
Refer to TM 9-2815-259-24.
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
TABLE 4-4. UNIT TROUBLESHOOTING (CONTINUED)
ABNORMAL ENGINE NOISE
Abnormal engine noise.
Yes
Check FAULT INDICATOR
on CIM display screen. Is a
fault displayed? (Fig 2-2)
Go to troubleshooting
section corresponding to
fault displayed. See
Symptom Index, page 4-10.
Not OK
No
Check for contaminated
fuel (see para.3.3.6) or
incorrect grade of fuel
(Table 3-3).
Replace fuel filter/water
separator. Refer to TM
9-2815-259-24. Drain fuel into
suitable container. Service fuel
tank (see para.3.3.6). Bleed fuel
lines. Refer to TM
9-2815-259-24.
OK
Notify next higher
level of maintenance.
4-21
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
TABLE 4-4. UNIT TROUBLESHOOTING (CONTINUED)
BLACK OR GRAY EXHAUST SMOKE
Black or gray exhaust
smoke.
No
OK
Check for contaminated
fuel (see para.3.3.6) or
incorrect grade of fuel
(Table 3-3).
Notify next higher
level of maintenance.
4-22
Check FAULT INDICATOR
on CIM display screen. Is a
fault displayed? (Fig 2-2)
Not OK
Yes
Go to troubleshooting
section corresponding to
fault displayed. See
Symptom Index, page 4-10.
Replace fuel filter/water
separator. Refer to TM
9-2815-259-24. Drain fuel
into suitable container.
Service fuel tank (see
para.3.3.6). Bleed fuel lines.
Refer to TM 9-2815-259-24.
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
TABLE 4-4. UNIT TROUBLESHOOTING (CONTINUED)
BLUE OR WHITE EXHAUST SMOKE
Blue or white exhaust smoke.
No
Not OK
Check FAULT INDICATOR
on CIM display screen. Is a
fault displayed? (Fig. 2-2)
Check for excessive
engine oil level.
OK
Check air filter
(see para. 3.3.3).
Not OK
Not OK
OK
Check for defective
thermostat(s). Refer
to TM 9-2815-259-24.
Replace defective
thermostat(s). Refer to TM
9-2815-259-24.
Go to troubleshooting section
corresponding to fault displayed.
See Symptom Index, page 4-10.
OK
Check for contaminated
fuel (see para. 3.3.6) or
incorrect grade of fuel
(Table 3-3)
Drain oil into suitable container to
obtain proper level. Refer to Figure
4-1 for location of oil drain valve.
Not OK
Yes
OK
Replace air
filter (see para
4.9.4).
Replace fuel filter/water separator.
Refer to TM 9-2815-259-24. Drain fuel
into suitable container. Service fuel tank
(see para. 3.3.6). Bleed fuel lines. Refer
to TM 9-2815-259-24.
Notify next higher
level of maintenance.
TABLE 4-4. UNIT TROUBLESHOOTING (CONTINUED)
4-23
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
CIM DISPLAY SCREEN DOES NOT DISPLAY
AND BACKLIGHT DOES NOT LIGHT
CIM display screen does not display and
backlight does not light.
OK
Not OK
Check for loose or
Not OK
corroded battery cable
terminals or battery posts.
Check that batteries are
installed correctly
(see para.4.6.3).
Install batteries
correctly
(see para.4.6.3).
Not OK
OK
Test diode CR1
(see para.4.8.29).
Replace diode CR1
(see para.4.8.29).
Not OK
Replace MASTER
CONTROL switch
(see para.4.8.9).
OK
Clean and tighten battery
cable terminals and battery
posts (see para.4.6.3).
Test DC CONTROL
POWER fuse (see
para.4.8.26).
Not OK
Replace DC
CONTROL POWER
fuse (see para.4.8.26).
OK
Test MASTER
CONTROL switch
(see para.4.8.9).
Not OK
OK
Check CIM wiring harness
for breaks or loose
connections
(see para.4.8.38).
Replace CIM wiring
harness
(see para.4.8.38).
Replace CIM
(see para.4.8.16).
TABLE 4-4. UNIT TROUBLESHOOTING (CONTINUED)
4-24
OK
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
CIM DISPLAY SCREEN WORKS, BUT BACKLIGHT
DOES NOT LIGHT OR ONLY PARTIALLY LIGHTS
CIM display screen works, but backlight
does not light or only partially lights.
Not OK
Test PANEL LIGHTS switch
(see para. 4.8.12).
Not OK
Replace PANEL
LIGHTS switch
(see para. 4.8.12).
Replace CIM wiring harness
(see para. 4.8.38).
OK
Inspect CIM wiring
harness
(see para. 4.8.38).
OK
OK
Check for voltage at wiring
harness.
Not OK
Replace CIM
(see para.
4.8.16).
Repair/replace CIM
wiring harness.
(see para. 4.8.38).
4-25
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
TABLE 4-4. UNIT TROUBLESHOOTING (CONTINUED)
CIM DISPLAY SCREEN BATTERY VDC INDICATOR
SHOWS LOW OR NO VOLTS
CIM display screen BATTERY VDC
indicator shows low or no volts.
OK
Check for loose or
broken wires. Refer to
Schematic, FO-1.
Inspect fan belt
(see para. 4.10.9).
Not OK
OK
Adjust or replace fan
belt (para. 4.10.9).
Not OK
Repair or replace loose
or broken wires. Refer
to Schematic, FO-1.
Check Battery Charging
Alternator.
Refer to TM
9-2815-259-24.
Not OK
Replace Battery
Charging Alternator.
4-26
OK
Notify next higher
level of maintenance.
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
TABLE 4-4. UNIT TROUBLESHOOTING (CONTINUED)
CIM DOES NOT RESPOND TO KEYPAD COMMANDS OR
UPDATE DISPLAY
CIM does not respond to keypad
commands or update display.
No
Not OK
Is NETWORK FAILURE
light lit?
Inspect keypad
assembly
(see para.4.8.17).
Replace keypad assembly
(see para.4.8.17).
OK
Not OK
Yes
Inspect and test CIM
wiring harness
(see para.4.8.38).
OK
Replace CIM .
(see para.4.8.16).
Replace CIM
wiring harness
(see para.4.8.38).
Check CIM wiring harness
connections at CIM and keypad
for proper connection. Refer to
Wiring Diagram, FO-1.
4-27
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
TABLE 4-4. UNIT TROUBLESHOOTING (CONTINUED)
CIM DISPLAY SCREEN BATTERY AMPS INDICATOR SHOWS
NO CHARGE WHEN BATTERIES ARE LOW OR DISCHARGED
CIM display screen BATTERY AMPS
indicator shows no charge when batteries
are low or discharged.
OK
Not OK
Inspect fan belt
(see para. 4.10.9).
Test Battery Current
Transducer (see para. 4.13.5).
Replace Battery
Current Transducer
(see para. 4.13.5).
Yes
Notify next
higher level of
maintenance.
4-28
Adjust or replace fan
belt (see para. 4.10.9).
OK
OK Test alternator.
Refer to TM
9-2815-259-24.
Check for breaks or loose
Not OK connections or corroded
terminals in charging
circuit. Refer to
Schematic, FO-1
Repair charging
circuit. Refer to
Schematic, FO-1.
Not OK
Not OK
OK
Is HEARTBEAT LED
on I/O interface module
blinking? See para.
4.8.25.
Replace alternator.
Refer to TM
9-2815-259-24.
No
Replace I/O
interface module
(see para. 4.8.25).
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
TABLE 4-4. UNIT TROUBLESHOOTING (CONTINUED)
CIM DISPLAY SCREEN BATTERY AMPS INDICATOR SHOWS
EXCESSIVE CHARGING AFTER PROLONGED OPERATION
CIM display screen BATTERY AMPS indicator
shows excessive charging after prolonged operation.
OK
Inspect/service batteries BT1
and BT2 (see para. 4.6.3).
Not OK
Replace batteries
(see para. 4.6.3).
OK
Not OK
Repair charging
circuit. Refer to
Schematic, FO-1.
Test alternator. Refer
to TM 9-2815-259-24.
Check for short in
charging circuit. Refer
to Schematic, FO-1.
No
Replace I/O interface
module
(see para. 4.8.25).
Not OK
OK
Replace alternator. Refer
to TM 9-2815-259-24.
Is HEARTBEAT indicator on I/O
interface module blinking?
(see para. 4.8.25)
OK
Notify next higher level of
maintenance.
Yes
Test Battery Current Transducer
(see para. 4.13.5).
Not OK
Replace Battery Current Transducer
(refer to para. 4.13.5).
4-29
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
TABLE 4-4. UNIT TROUBLESHOOTING (CONTINUED)
CIM DISPLAY SCREEN GENERATOR VOLTAGE GAGE FLUCTUATES
CIM display screen GENERATOR VOLTAGE gage fluctuates.
No
Yes
Check FAULT INDICATOR on CIM
display screen. Is a fault displayed?
(Fig. 2-2)
Check voltage at AC circuit
interrupter. Is voltage fluctuating?
Refer to para.4.12.6.
Yes
Check automatic voltage
regulator. Are any or all LEDs
pulsing with voltage fluctuations?
Yes
Go to troubleshooting section
corresponding to fault displayed.
See symptom Index, page 4-10.
No
Replace automatic voltage
regulator
(see para. 4.8.23).
No
Not OK
Check for loose electrical
connections. Refer to
Schematic, FO-1.
OK
Replace backplane
module (see para. 4.8.24).
No
Tighten electrical
connections.
Not OK Test VOLTAGE ADJUST
switch (see para. 4.8.10).
Replace VOLTAGE
ADJUST switch
(see para. 4.8.10).
Is HEARTBEAT LED on
I/O interface module
blinking?
OK
4-30
Notify next higher
level of maintenance.
Notify next higher
level of maintenance.
TABLE 4-4. UNIT TROUBLESHOOTING (CONTINUED)
Yes
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
CIM DISPLAY SCREEN FREQ GAGE FLUCTUATES
CIM display screen FREQ gage
fluctuates.
Yes
Check FAULT INDICATOR on
CIM display screen. Is a fault
displayed? (4, Figure 2-9)
Go to troubleshooting section
corresponding to fault
displayed. See Symptom
Index, page 4-10.
No
No
Is Engine speed
fluctuating?
Yes
No
Is HEARTBEAT LED on I/O
interface module blinking?
Replace I/O interface
module (see para. 4.8.25).
Yes
Check speed control
unit LED indicators.
Yes
Are the SPEED
SENSOR,
ACTUATOR, and
DC POWER LEDs
fluctuating?
No
Replace CIM. (see para.
4.8.16).
Continued on next page
Continued on next page
Yes
Check Speed control unit. Is DC
POWER LED lit and steady, and
ACTUATOR and SPEED
SENSOR LEDs fluctuating?
No
Replace speed control
unit.
Not OK
Notify next higher
level of maintenance.
4-31
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
TABLE 4-4. UNIT TROUBLESHOOTING (CONTINUED)
CIM DISPLAY SCREEN FREQ GAGE FLUCTUATES (CONTINUED)
Continued from previous page.
Not OK
Using fuel drain valve, (Figure
4-1), drain fuel into suitable
container. Replace fuel filter and
fuel filter/water separator. Refer
to TM 9-2815-259-24. Service
fuel tank (see para. 3.3.6). Bleed
fuel lines. Refer to TM
9-2815-259-24.
Not OK
Check for contaminated
fuel (see para. 3.3.5) or
incorrect grade of fuel
(Table 3-3).
OK
OK
Check for evidence of air
bubbles or fuel line blockage.
Check for blocked exhaust
pipe or muffler
(see para. 4.9.1).
OK
Unblock or replace fuel
lines as necessary (see
para. 4.11.1). Ensure fuel
lines are tight. Bleed fuel
lines. Refer to TM
9-2815-259-24.
Replace DCS speed control
unit (see para. 4.8.22).
Unblock exhaust pipe or
replace muffler
(see para. 4.9.1).
Not OK
Notify next higher level of
maintenance.
4-32
Not OK
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
TABLE 4-4. UNIT TROUBLESHOOTING (CONTINUED)
HIGH OIL CONSUMPTION
High oil consumption.
Not OK
Unblock or replace air
cleaner assembly
components as required
(see para. 4.9.2).
OK
Inspect air cleaner assembly
(see para. 4.9.2).
OK
Check for improper
lube oil. Refer to
Appendix F.
Not OK
Drain oil and replace oil filter. Refer to
TM 9-2815-259-24. Refill with proper
lube oil type. Refer to Appendix F.
Not OK
Not OK
Check for engine
oil leaks.
Inspect/service
crankcase breather
assembly (refer to
para. 4.9.6).
OK
Notify next higher
maintenance level.
Notify next higher
maintenance level.
4-33
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
TABLE 4-4. UNIT TROUBLESHOOTING (CONTINUED)
ENGINE MISFIRING
Engine misfiring.
Check FAULT INDICATOR
on CIM display screen. Is a
fault displayed?
No
Check for contaminated fuel
(see para. 3.3.6) or incorrect
grade of fuel (Table 3-3).
Yes
OK
Go to troubleshooting section
corresponding to fault displayed. See
Symptom Index, page 4-10.
Not OK
Using fuel drain valve (Fig. 4-1),
drain fuel into suitable container.
Replace fuel filter and fuel
filter/water separator.
Refer to TM 9-2815-259-24.
Service fuel tank (see para.
3.3.6). Bleed fuel lines.
Refer to TM 9-2815-259-24.
Check for air blockage in
fuel lines.
Not OK
OK
Check for blocked
exhaust or muffler.
(see para. 4.9.1).
OK
Unclog/Bleed fuel
lines.
Not OK
OK
Unblock or
replace muffler
(see para. 4.9.1).
Inspect air cleaner assembly
(see para. 4.9.4).
Not OK
Unblock air
cleaner assembly
(see para. 4.9.4).
4-34
Notify next
higher level of
maintenance.
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
TABLE 4-4. UNIT TROUBLESHOOTING (CONTINUED)
CIM DISPLAY SCREEN WATER TEMP METER
INDICATES COOLANT TEMPERATURE TOO LOW
CIM display screen WATER TEMP meter
indicates coolant temperature too low.
OK
Inspect thermostat.
Refer to TM
9-2815-259-24.
Test coolant
temperature sender
(see para. 4.13.2).
Not OK
Replace coolant
temperature sender
(see para. 4.13.2).
OK
Not OK
Replace thermostat.
Refer to TM
9-2815-259-24.
Notify next
higher level of
maintenance.
TABLE 4-4. UNIT TROUBLESHOOTING (CONTINUED)
4-35
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
EXCESSIVE FUEL CONSUMPTION
Excessive fuel consumption.
No
OK
Inspect air cleaner
assembly
(see para.4.9.2).
Unblock or replace air
cleaner assembly components
as required (see para.4.9.2).
Not OK
OK
Check for leaks in fuel
system
(see para.4.11.1).
OK
Yes
Go to troubleshooting section
corresponding to fault
displayed. See Symptom
Index, page 4-10.
Not OK
Check for contaminated
oil. Refer to TM
9-2815-259-24.
Drain oil and replace oil filter.
Refer to TM 9-2815-259-24.
Refill with proper lube oil
type. Refer to Appendix F.
4-36
Check FAULT INDICATOR on
CIM display screen. Is a fault
displayed?
Not OK
Repair low pressure fuel
lines and fittings as
required (see para.4.11.1).
Notify next higher
level of maintenance.
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
TABLE 4-4. UNIT TROUBLESHOOTING (CONTINUED)
COOLANT IN CRANKCASE OR OIL IN COOLANT
Coolant in crankcase or oil in coolant.
OK
Check for defective oil cooler.
Refer to TM 9-2815-259-24.
Not OK
Replace oil cooler.
Refer to TM
9-2815-259-24.
Notify next higher
level of maintenance.
ENGINE VIBRATING
Engine vibrating.
OK
Notify next higher
level of maintenance.
Inspect fan
(see para.4.10.8).
Not OK
Replace fan
(see para.4.10.8)
4-37
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
TABLE 4-4 UNIT TROUBLESHOOTING (CONTINUED)
CIM DISPLAY SCREEN VOLTAGE GAGE
DOES NOT INDICATE VOLTAGE
CIM display screen VOLTAGE
gage does not indicate voltage.
Check voltage regulator
Yes LEDs with generator set No
running. Are they all lit?
Not OK
Check for output voltage OK
at AC circuit interrupter.
Is it set for rated voltage?
Repair or replace broken
wires or loose connections.
Refer to Wiring Diagram,
FO-3.
Troubleshoot voltage regulator
circuit for broken wires or loose
connections. Refer to schematic
FO-1.
Replace Field flash relay
K23. (Ref Para. 4.8.34)
No
Are any phases on the CIM display
screen indicating voltage ?
Troubleshoot circuit from P5 to K1
(refer to schematic FO-1).
OK
OK
Repair or replace wires
as needed. (See
schematic F01)
Not OK
Check Field Flash circuit
wires. (see schematic
F01)
Not OK Inspect and test Field
flash relay K23. (Ref
Para. 4.8.34)
OK
Refer to Symptom
Index " CIM does not
respond to key pad or
update display".
OK
Inspect and test
Resistor R6 (see Para
4.8.36).
Not OK
Not OK
Replace I/O module
(see Para. 4.8.25).
Not OK
OK
OK
Yes Is CIM screen being
updated?
No
Troubleshoot voltage
regulator circuit for broken
wires or loose connections.
Refer to Schematic, FO-1.
Not OK
Check ribbon cables
between I/O and
Backplane.
Is HEARTBEAT indicator on
I/O interface module blinking?
(see para. 4.8.25).
Test Backplane
(see Para 4.8.24).
Inspect and Test
Diodes CR7 & CR8
(see Para 4.8.29).
Replace ribbon cables
between I/O and
Backplane.
Test Auto. Voltage
Regulator(see Para
4.8.23).
Yes
Replace Resistor R6
(see Para 4.8.36).
Not OK
OK
Not OK
OK
Replace Diodes CR7
& CR8 (see Para
4.8.29).
Not OK
OK
Replace Backplane
(see para. 4.8.24).
4-38
Notify next higher
level maintanance.
Replace Voltage
Regulator(see Para 4.8.23).
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
TABLE 4-4. UNIT TROUBLESHOOTING (CONTINUED)
CIM DISPLAY SCREEN VOLTAGE GAGE INDICATES
VOLTAGE, BUT FREQ GAGE IS OFF SCALE
CIM display screen VOLTAGE gage indicates voltage,
but FREQ gage is off scale.
Adjust FREQUENCY ADJUST to
lower frequency. Does the FREQ
gage respond?
Yes
Adjust FREQUENCY
ADJUST switch to
desired value.
No
Replace I/O interface
module
(see para.4.8.25).
OK
Is HEARTBEAT LED
on I/O interface
module blinking?
No
Check for breaks or loose
connections in AC circuit.
Refer to Schematic, FO-1.
Yes
Not OK
Repair charging
circuit. Refer to
Schematic, FO-1.
Notify next higher
level of maintenance.
4-39
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
TABLE 4-4. UNIT TROUBLESHOOTING (CONTINUED)
FAULT INDICATOR DISPLAYS CIRCUIT
FAILURE - FUEL LEVEL
FAULT INDICATOR displays CIRCUIT
FAILURE - FUEL LEVEL.
Not OK
Test fuel level system electrical circuit
for breaks or loose connections. Refer
to Schematic, FO-1.
Repair or replace defective wires or
connections. Refer to Wiring Diagram,
FO-1. Hold FAULT RESET switch in
ON position for two seconds to clear
fault.
No
OK
Yes
Replace defective
fuel level sender
(see para.4.11.5).
Check for breaks or loose
Not OK connections in DC electrical
circuit. Refer to Schematic,
FO-1.
Repair charging circuit.
Refer to Schematic,
FO-1.
4-40
Not OK
Test fuel level sender
(see para.4.11.5).
Is HEARTBEAT LED
on I/O interface module
blinking?
Replace I/O interface
module (see para.4.8.25).
OK
OK
Notify next higher level
of maintenance.
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
TABLE 4-4. UNIT TROUBLESHOOTING (CONTINUED)
FAULT INDICATOR DISPLAYS CIRCUIT FAILURE - OIL
PRESSURE (LOW) OR OIL PRESSURE (HIGH)
FAULT INDICATOR displays CIRCUIT
FAILURE - OIL PRESSURE (Low) or OIL
PRESSURE (High).
Not OK Check for improper lube oil
type. Refer to Appendix F.
Drain oil and replace oil filter.
Refer to TM 9-2815-259-24.
Refill with proper lube oil type.
Refer to Appendix F.
OK
Repair or replace defective wires
or connectors. Refer to wiring
Diagram, FO-3.
Test oil pressure sensor
circuit for breaks or loose
connections. Refer to
Schematic, FO-1.
OK
Test oil pressure sender
(see para. 4.13.1).
Not OK Test oil pressure electrical circuit
for breaks or loose connections.
Refer to Schematic, FO-1.
No
OK
Not OK
Not OK
Repair or replace defective
wires or connectors. Refer
to Wiring Diagram, FO-3.
Replace oil pressure sender
(see para. 4.13.1).
Is HEARTBEAT LED on I/O
interface module blinking?
Replace I/O interface
module (see para.4.8.25).
Yes
Notify next higher level of
maintenance.
4-41
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
TABLE 4-4. UNIT TROUBLESHOOTING (CONTINUED)
FAULT INDICATOR DISPLAYS CIRCUIT
FAILURE - COOLANT TEMP
FAULT INDICATOR displays
CIRCUIT FAILURE - COOLANT
TEMP.
Not OK
Test coolant temperature
electrical circuit for breaks
or loose connectors.
Schematic, FO-1.
OK
OK
Repair or replace wires or
connectors. Refer to Wiring
Diagram, FO-3. Hold FAULT
RESET switch in ON position for
2 seconds to clear fault.
Did Fault clear?
OK
Test coolant
temperature sender
(see para. 4.13.2).
Not OK
Not OK
Check Ribbon
cables for breaks
or damage.
Check for breaks or loose
connections in Fault Reset
switch circuit. Refer to
Schematic, FO-1.
Not OK
Replace coolant
temperature sender
(see para. 4.13.2).
OK
OK
Not OK
Test Fault Reset
switch (12, Fig 2-1)
Ref Para. 4.8.8.
OK
Is HEARTBEAT
LED on I/O
interface module
(see para. 4.8.25)
blinking?
Not OK
Not OK
Replace Fault Reset
switch (12, Fig 2-1)
Ref Para. 4.8.8.
Replace I/O
interface module
(see para. 4.8.25).
Replace damaged or
defective ribbon cable.
OK
Test Backplane.
Ref Para.
4.8.24.
Not OK
Replace Backplane
Ref Para. 4.8.24.
4-42
OK
Notify next higher
level of
maintenance.
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
TABLE 4-4. UNIT TROUBLESHOOTING (CONTINUED)
FAULT INDICATOR DISPLAYS WARNING OVERVOLTAGE OR SHUTDOWN - OVERVOLTAGE
FAULT INDICATOR displays WARNING OVERVOLTAGE or SHUTDOWN - OVERVOLTAGE.
Not OK
Repair or replace defective
or loose connections. Refer to
Wiring Diagram, FO-3.
OK
Check for defective or loose
connections on voltage adjust
switch. Refer to Wiring
Diagram, FO-3.
OK
Test VOLTAGE ADJUST
switch (see para. 4.8.10).
Troubleshoot voltage regulator
circuit for breaks or loose
connections. Refer to
Schematic, FO-1.
Replace automatic voltage
regulator (see para. 4.8.23).
Is fault cleared?
OK
Not OK
Replace VOLTAGE
ADJUST switch
(see para. 4.8.10).
Not OK
Repair or replace defective or
loose connections. Refer to
Wiring Diagram, FO-3.
Is fault cleared?
No
No
Notify next higher level of
maintenance.
4-43
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
TABLE 4-4. UNIT TROUBLESHOOTING (CONTINUED)
CIRCUIT INTERRUPTER WILL NOT CLOSE
Circuit interrupter will not close.
No
Check Fault Indicator on CIM.
Is a fault indicated?
Check for 24 VDC at term.1
of Circuit Interrupter
switch, (10, fig 2-1).
Not OK
Go to troubleshooting section
corresponding to fault displayed.
See Symptom Index Page 4-10.
Yes
Check for 24 VDC at OK
term.2 of Battle Short
switch, (6, Fig 2-1).
Check wire 181D16 for
continuity, loose
connections or damage.
OK
OK
Not OK
Not OK
Hold circuit Interrupter
switch (10, Fig 2-1) in the
closed position and check
for 24VDC at term.2.
OK
Check for 24VDC at
TB4-1.
Not OK
OK
Not OK
OK
Remove top cover of
control box. See Para.
4.7.2. Hold Circuit
Interrupter switch (10, Fig
2-1) in the closed position
and check for 24VDC on
J25 pin 10 of I/O interface
module (Ref Fig 2-3).
Replace Circuit
Interrupter
switch (10, Fig
2-1). See Para.
4.8.7
Not OK
Refer to
Schematic,
FO-1.
Check wire number 199A16
for continuity, loose
connections or damage.
Repair
wire.
Check wire 181C16
for continuity, loose
connections or
damage.
Not OK
Repair
wire.
Not OK
Repair wire.
OK
OK
Hold Circuit
Interrupter switch (10,
Fig 2-1) in the closed
position and check for
24VDC on J25 pin 6 of
I/O interface module
(Ref Fig 2-3).
Not OK
Retest Circuit
Interrupter switch (10,
Fig 2-1) See above.
OK
Hold Circuit Interrupter switch
(10, Fig 2-1) in closed position
and check for 24VDC at
terminal A of K17,
(K1 aux relay) 28, Fig 4-16.
OK
OK
Not OK
Replace I/O interface
module, see Para. 4.8.25.
4-44
Check wire number
185A16 for continuity,
loose connections or
damage.
See next page.
Not OK
Repair wire.
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
TABLE 4-4. UNIT TROUBLESHOOTING (CONTINUED)
CIRCUIT INTERRUPTER WILL NOT CLOSE Continued
Continued from previous page.
Check for 24 VDC
at term. 7 of K17.
Yes
Is the K1 Aux Relay K17
actuating?
Not OK
Replace Diode
CR-3 (see Para
4.8.29).
No
Not OK
Check for 24
Not OK
VDC at term.7
of K19.
Check wire
231B16 from
K19-7 to TB4-2
for continuity.
OK
OK
OK
Hold Circuit
Interrupter switch
(10, Fig 2-1) in the
closed position and
check for 24VDC at
J24 pin 9 of the
Not OK
backplane module.
OK
Check for 24VDC at
Relay K1terminal X. Not OK
Not OK
Check wire
231C16 from
K19-7 to K17-7
for continuity.
Not OK
Check for
continuity between
K1-Y and ground.
Test K1Aux relay
K17 Coil(see
para 4.8.25).
Not OK
Not OK
Repair wire.
Replace K1Aux
relay K17 (see
para 4.8.34).
Replace K17 Aux relay.
see Para 4.8.34.
Check wire number
Not OK
224A16 for contiuity, loose
connections or damage.
Release Circuit Interrupter
OK
switch and Check for
continuity between Backplane
connector P6-N and K1-X.
OK
OK
OK
OK
Hold Circuit Interrupter
switch (10, Fig 2-1) in the
closed position and check
for 24VDC at K17-4.
Test Diode CR-3
(see Para 4.8.29).
Repair wire.
Check wire
number 185L16
for contiuity,
loose connections
or damage.
Not OK
Repair
wire.
OK
Check wire 100K16
between K1-Y and
TB7-6 for
continuity.
OK
Not OK
Not OK
Repair wire.
OK
Notify next higher level
of maintenance.
Check for continuity between Not OK
Backplane connector J6-N
and J24-9.
Not OK Replace Backplane
module see Para. 4.8.24.
4-45
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
TABLE 4-4. UNIT TROUBLESHOOTING (CONTINUED)
CIRCUIT INTERRUPTER WILL NOT OPEN
Circuit interrupter will
not open.
No
Hold Circuit Interrupter
switch, (10, Fig 2-1)in the
open position and Check
for 24 VDC at term. 3.
Check for 24
VDC at term. 2
of Battle Short
switch, (6, Fig
2-1).
Not OK
Remove top cover of control
box. See Para 4.7.2.
Hold Circuit Interrupter switch
Not OK
(10, Fig 2-1) in the open
position and check for 24VDC
on J25 pin 11of I/O interface
module (Ref Fig 2-3).
OK
Check for
24VDC at
TB4-1.
Not OK
OK
OK
Not OK
Refer to Schematic,
FO-1.
Test K17,(K1 aux relay)
(28, Fig 4-16) see Para
4.8.34.
Not OK
Replace K17,(K1
aux relay) (28, Fig
4-16) see Para
4.8.34.
Check wire 181C16 for
Not OK
continuity, loose
connections or damage.
Repair wire.
Repair wire.
OK
OK
Continued on
next page.
4-46
Check wire 181D16 for
continuity, loose
connections or damage.
Repair wire.
OK
Check wire number 130A16 Not OK
for contiuity, loose connections
or damage.
Hold Circuit Interrupter
switch (10, Fig 2-1) in the
open position and check Not OK
for 24VDC on J25 pin 6 of
I/O interface module (Ref
Fig 2-3).
Replace I/O
interface module,
see Para 4.8.25.
OK
Not OK
OK
OK
Go to troubleshooting section
corresponding to fault displayed.
See symptom index Page 4-10.
Check Fault Indicator on
Yes
CIM. Is a fault
indicated?
Test wiring in
K17,(K1 aux
relay) (28, Fig
Not OK
4-16) for
contiuity, loose
connections or
damage. see
schematic FO1.
Replace or
repair wiring
as needed.
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
TABLE 4-4. UNIT TROUBLESHOOTING (CONTINUED)
CIRCUIT INTERRUPTER WILL NOT OPEN Continued
Continued from
previous page.
Test Circuit Interrupter
Relay K1 Terminal X for
24VDC.
Not OK
Test Circuit
Interrupter K1 see
Para 4.12.6
Not OK
OK
Check wire between
Backplane connector P6-N
and K1-X for continuity,
loose connections or
damage.
OK
OK
Test wiring in K1
aux relay Aux
Contacts for
continuity, loose
connections or
damage. see
schematic FO1
Replace Circuit
Interrupter K1
see Para 4.12.6
OK
Not OK
Replace wire 185L16
Replace
Backplane
Module see Para
4.8.24
Not OK
Not OK
Repair wire
Notify next higher
level of maintenance.
Notify next higher level
of maintenance.
4-47
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
TABLE 4-4. UNIT TROUBLESHOOTING (CONTINUED)
CIM DISPLAY SCREEN DOES NOT RESPOND TO KEYPAD INPUT
CIM dispaly screen does not
respond to keypad input.
Not OK
Check keyboard power supply (PS-1) OK
for 24VDC. Refer to para. 4.6.5.
Check for 24VDC at TB4. Refer
to Schematic, FO-1.
Check PS-1 for 5VDC Not OK
output.
Not OK
OK
OK
Replace keypad.
Check wiring between TB4 and
PS-1. Refer to Schematic, FO-1.
Not OK
Repair wiring.
4-48
Check for approx
24VDC at J24-6.
Not OK
Trace wiring back to Dead
Crank switch. Refer to
Schematic, FO-1.
OK
Check wiring to
J24-6 at TB4.
Not OK
Replace PS-1.
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
SECTION VI. UNIT MAINTENANCE PROCEDURES
4.6
MAINTENANCE OF DC ELECTRICAL SYSTEM.
__________
WARNING
When disconnecting or removing batteries, disconnect the negative lead that
connects directly to the grounding stud first. Disconnect the negative end of
the interconnection cable next. When installing batteries, reverse the
connection sequence. Failure to comply can cause serious personal injury.
4.6.1
Introduction. This section contains unit maintenance procedures for the DC electrical system. Deficiencies
noted during inspection or repair which are beyond the scope of unit maintenance shall be reported to the next
higher level of maintenance.
4.6.2
Battery and SLAVE RECEPTACLE Cables.
__________
WARNING
Batteries give off a flammable gas. Do not smoke or use open flame when
performing maintenance. Failure to comply can cause injury or death to
personnel and equipment damage due to flames and explosion.
__________
WARNING
Battery acid can cause burns to unprotected skin. Wear protective gloves and
safety goggles. Failure to comply can cause personal injury.
__________
WARNING
DC voltages are present at generator set electrical components even with
generator shut down. Avoid shorting any positive terminal with
ground/negative. Failure to comply can cause injury to personnel and damage
to equipment.
__________
WARNING
Metal jewelry can conduct electricity. Remove metal jewelry when working on
electrical system or components. Failure to comply can cause injury or death
to personnel by electrocution.
NOTE
This procedure is typical for the positive, negative, and interconnect battery cables,
and the positive and negative NATO SLAVE RECEPTACLE cables.
a.
Inspection.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door and right side engine compartment access doors .
4-49
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
b.
c.
d.
(3)
Inspect battery and SLAVE RECEPTACLE cable assemblies for security, cracked insulation,
broken, burned, or corroded terminals, missing parts, and other damage. Refer to Figures 4-3 and 44.
(4)
Close BATTERY ACCESS and engine compartment access doors.
Removal.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door and right side engine compartment access doors .
(3)
Disconnect negative battery cable from battery (1, Figure 4-3).
(4)
Tag and remove applicable cable assembly as shown in Figure 4-3 or 4-4.
Service.
(1)
Remove terminal covers (2, Figure 4-3) from battery posts as required.
(2)
Clean terminals (3, Figure 4-3 or 4-4), battery posts, and terminal lugs (4, 5, 6, and 7, Figure
4-3).
(3)
Install terminal covers (2), if removed.
Repair.
NOTE
If cable cannot be repaired, refer to Appendix G to fabricate a replacement.
e.
4-50
(1)
Remove nuts (8, Figure 4-3) and terminal lugs (4, 5, 6, or 7) from terminals (3) as required.
(2)
Cut heat shrink tubing, and remove broken or damaged terminal (3, Figure 4-3 or 4-4) from cable
assembly.
(3)
Slide new heat shrink tubing over cable end.
(4)
Install terminal (3) on cable end as described in Appendix G.
(5)
Position heat shrink tubing over terminal (3) and cable end, and shrink tubing with heat gun.
(6)
Install terminal lugs (4, 5, 6, or 7, Figure 4-3) and nuts (8).
Installation.
(1)
Install applicable cable assembly as shown in Figure 4-3.
(2)
Connect negative battery cable to battery (1, Figure 4-3).
(3)
Close BATTERY ACCESS and engine compartment access doors.
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
FIGURE 4-3. BATTERIES AND CABLES
4-51
ARMY TM 9-6115-671-14
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MARINE CORPS TM 09249A/09246A-14
FIGURE 4-4. NATO SLAVE RECEPTACLE AND CABLES
4-52
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
4.6.3
Batteries BT1 and BT2.
a.
Testing. The batteries installed in this generator set are maintenance free. There is no electrolyte testing
required. If you have old batteries, see Appendix A.
b.
Removal.
__________
WARNING
When disconnecting or removing batteries, disconnect the negative lead that
connects directly to the grounding stud first. Disconnect the negative end of
the interconnection cable next. When installing batteries, reverse the
connection sequence. Failure to comply can cause serious personal injury.
__________
WARNING
Battery acid can cause burns to unprotected skin. Wear protective gloves and
safety goggles. Failure to comply can cause personal injury.
__________
WARNING
Metal jewelry can conduct electricity. Remove metal jewelry when working on
electrical system or components. Failure to comply can cause injury or death
to personnel by electrocution.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2).
(3)
Disconnect negative battery cable terminal lug (4, figure 4-3) from battery (9).
(4)
Disconnect interconnect battery cable terminal lug (6) first, then lug (5) from batteries (1 and 9).
(5)
Disconnect positive cable battery lug (7) from battery (1).
(6)
Remove nuts (10), washers (11), battery holddown assembly (12), and battery holddown rods (13)
securing batteries (1 and 9) to battery tray (14).
_________
WARNING
Lifting batteries from the battery tray can cause back strain. Ensure proper
lifting techniques are used when lifting batteries. Failure to comply can cause
personal injury.
(7)
Using care, remove batteries (1 and 9) from battery tray (14).
(8)
Place Battery and Adapter (15) on a flat surface.
(9)
Using flat tipped screwdriver, push down on adapter (15) locking tab, and remove battery by sliding
horizontally from the adapter.
4-53
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
c.
d.
e.
Inspection.
(1)
Remove batteries, step b.
(2)
Inspect batteries (1 and 9, Figure 4-3) for cracked cases; broken, burned, or corroded posts; missing
parts; and other damage.
(3)
Install batteries, step e.
Service.
(1)
Remove terminal covers (2, Figure 4-3) from batteries (1 and 9).
(2)
Clean terminal lugs (4, 5, 6, and 7) and battery posts.
(3)
Install terminal covers (2) on batteries (1 and 9).
Installation.
(1)
Slide battery horizontally into battery adapter (15) with negative battery post first, until adapter lock
snaps into the lock position.
(2)
Position batteries (1 and 9, Figure 4-3) in battery tray (14) with positive post toward the generator
set. Ensure batteries are serviced and fully charged.
(3)
Apply general purpose grease (Item 10, Appendix E) to battery posts and terminal lugs (4, 5, 6, and
7).
(4)
Secure batteries (1and 9) to battery tray with battery holddown rods (13), battery holddown
assembly (12), washers (11), and nuts (10).
CAUTION
Interconnect battery cable terminals are marked with positive and negative.
Ensure the cable is installed properly. Failure to comply can cause damage to
equipment.
4.6.4
Connect positive battery cable terminal lug (7) to battery (9).
(6)
Connect interconnect battery cable terminal lug (5) first, then leg (6) to batteries (1 and 9).
(7)
Connect negative battery cable terminal lug (4) to battery (9).
(8)
Close BATTERY ACCESS door.
NATO SLAVE RECEPTACLE.
a.
4-54
(5)
Inspection.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2).
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
b.
c.
4.6.5
(3)
Inspect NATO SLAVE RECEPTACLE (7, Figure 4-4) for loose connections, corrosion, missing
hardware, and other damage.
(4)
Close BATTERY ACCESS door.
Removal.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable .
(3)
Tag battery and NATO SLAVE RECEPTACLE cables. Remove bolts (1, Figure 4-4), lockwashers
(2), wire (18) and terminals (3) from NATO SLAVE RECEPTACLE (7).
(4)
Remove cover (4) from NATO SLAVE RECEPTACLE (7).
(5)
Remove nuts (5), bolts (6), NATO SLAVE RECEPTACLE (7) and gasket (17) from generator set.
(6)
Remove nut (8), bolt (9), and cover (4) from generator set.
Installation.
(1)
Install cap (4, Figure 4-4), with bolt (9), and nut (8) on NATO SLAVE RECEPTACLE (7).
(2)
Position NATO SLAVE RECEPTACLE (7) and gasket (17) in generator set with negative terminal
up.
(3)
Install NATO SLAVE RECEPTACLE (7) and gasket (17), with bolts (6), and nuts (5) on generator
set.
(4)
Install cap (4) on NATO SLAVE RECEPTACLE (7).
(5)
Install terminals (3), wire (18), lockwashers (2), and bolts (1) on NATO SLAVE RECEPTACLE
(7).
(6)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
Keypad Power Supply PS1.
a.
Inspection.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Remove CIM (see paragraph 4.8.16) from the DCS control box assembly.
(3)
Inspect keypad power supply (44, Figure 4-18) mounting surfaces and terminal screws for damage.
Ensure screws are secure.
(4)
Check for evidence of burned or damaged components on surface of keypad power supply.
(5)
Install CIM (see paragraph 4.8.16).
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MARINE CORPS TM 09249A/09246A-14
b.
c.
4-56
Testing.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Remove CIM (see paragraph 4.8.16) from the DCS control box assembly.
(3)
Connect negative battery cable to battery and close battery access door.
(4)
Switch master control switch (12, Figure 2-8) to ON.
(5)
Set multimeter to volts DC and place positive lead of multimeter on terminal 1 and the negative lead
on terminal 2. On PS1 multimeter should read between 12VDC and 24VDC.
(6)
If indications are other than between 12VDC and 24 VDC, replace master control switch, paragraph
4.8.9.
(7)
Place positive lead of multimeter on terminal 3 and negative lead on terminal 4. Multimeter should
read 5VDC.
(8)
If indications are less than 5VDC, replace keypad power supply (44, Figure 4-18).
(9)
Close battery access door and disconnect negative battery cable.
(10)
Install CIM (refer to paragraph 4.8.16).
Replacement.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Remove CIM (see paragraph 4.8.16) from the DCS control box assembly.
(3)
Tag and disconnect keypad power supply (44, Figure 4-18) electrical leads.
(4)
Remove mounting screws (46), standoffs (45), and key pad power supply (44) from air baffle (30).
(5)
Align new key pad power supply (44) to standoffs (45) and install screws (46).
(6)
Connect electrical leads to key pad power supply (44) and remove tags.
(7)
Install the CIM (see paragraph 4.8.16).
(8)
Connect negative battery lead and close battery compartment door.
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
4.7
MAINTENANCE OF HOUSING
__________
WARNING
When disconnecting or removing batteries, disconnect the negative lead that
connects directly to the grounding stud first. Disconnect the negative end of
the interconnection cable next. When installing batteries, reverse the
connection sequence. Failure to comply can cause serious personal injury.
4.7.1
Access Doors.
NOTE
This procedure is written for the left rear engine access door, but is typical for all
access doors, hinges, latches, storage boxes, and data plates.
NOTE
When removing and installation BATTERY ACCESS door, note position of spacers
for door hold open mechanism.
a.
Removal.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open left side engine compartment access doors (Figure 1-3).
(3)
Remove nuts (1, Figure 4-5), lockwashers (2), washers (3), bolts (4), and hinges (5), with door (6)
attached, from generator set housing.
(4)
Remove nuts (7), lockwashers (8), washers (9), bolts (10), and hinges (5) from door (6).
(5)
Remove locknuts (11), bolts (12), and document box (13) from door (6).
(6)
Drill out rivets (14), and remove fuel system diagram data plate (15) from document box (13).
(7)
Remove locknuts (16), bolts (17), and bracket (18) with holding rod (19) from door (6).
(8)
Remove locknuts (20), bolts (21), and bracket (22) from door (6).
NOTE
Note position of latches before removal for reference during installation.
(9)
Remove locknuts (23), screws (24), and latches (25) from door (6).
4-57
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
.
FIGURE 4-5. GENERATOR SET ACCESS DOORS
4-58
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
b.
c.
Inspection.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Inspect access doors, hinges, latches, baffles, and storage boxes for loose and missing hardware,
cracks, dents, and loose paint, or corrosion.
(3)
Inspect data plates for readability and loose or missing rivets.
Repair.
__________
WARNING
CARC paint is a health hazard. Wear protective eyewear, mask and gloves
when sanding CARC painted surfaces. Failure to comply can cause personal
injury.
(1)
Repair all dents and cracks, and remove loose paint.
(2)
Remove light corrosion with fine grit abrasive paper (Item 16, Appendix E).
(3)
Repaint surfaces in accordance with TM 43-0139.
NOTE
Step (4) applies to all access doors except the load terminal access door.
NOTE
Sealant is applied to all four corners of the output box access door.
d.
(4)
Apply industrial sealant (Item 18, Appendix E) to top two corners of access door.
(5)
Replace damaged or unreadable data plates.
(6)
Replace loose or missing rivets.
Installation.
(1)
Position latches (25, Figure 4-5) on door (6) as noted during removal. Secure latches to door with
screws (24), and locknuts (23).
(2)
Install bracket (22), bolts (21), and locknuts (20) on door (6).
(3)
Install bracket (18), holding rod (19), bolts (17), and locknuts (16) on door (6).
(4)
Install fuel system diagram data plate (15) on document box (13) with rivets (14).
(5)
Install document box (13), bolts (12), and locknuts (11) on door (6).
(6)
Install hinges (5), bolts (10), washers (9), lockwashers (8), and nuts (7) on door (6).
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MARINE CORPS TM 09249A/09246A-14
4.7.2
(7)
Position door (6) on generator set housing, and install hinges (5), bolts (4), washers (3), lockwashers
(2), and nuts (1).
(8)
Close engine compartment access doors.
DCS Control Box Top Panel.
a.
Removal.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Refer to
paragraphs 4.6.2 and 4.6.3.
(3)
Remove DCS control box door (Figure 1-3). Refer to paragraph 4.7.1.
(4)
Release DCS control panel (4, Figure 1-30) by turning two fasteners, and lower panel slowly.
(5)
Remove bolts (1, Figure 4-6), lockwashers (2), and washers (3) from top panel (4).
NOTE
For ease of access in step 6, remove the CIM. Refer to paragraph 4.8.16.b.
(6)
Remove locknuts (5) and bolts (6) from top panel (4). Close DCS control panel (4, Figure 1-30).
CAUTION
The top panel is attached to the generator set housing with a silicone sealant to
prevent water from entering the control box. Care must be taken not to bend
or scratch the top panel when separating it from the housing. Failure to
comply can cause damage to equipment.
4-60
(7)
Carefully separate top panel (4) from generator. Remove control box top panel.
(8)
Remove nuts (7), lockwashers (8), washers (9), and bolts (10) from DCS control box assembly.
(9)
Remove locknuts (12), bolts (13), door ring retainer (14), and door ring (15) from top panel (4).
(10)
Remove old sealant from door ring retainer (14).
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
FIGURE 4-6. DCS CONTROL BOX TOP PANEL
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MARINE CORPS TM 09249A/09246A-14
b.
c.
Inspection.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Inspect top panel (4, Figure 4-6) for dents, cracks, loose paint, corrosion, and missing mounting
hardware.
Repair.
__________
WARNING
CARC paint is a health hazard. Wear protective eyewear, mask and gloves
when sanding CARC painted surfaces. Failure to comply can cause personal
injury.
d.
4.7.3
(1)
Repair all dents and cracks, and remove loose paint.
(2)
Remove light corrosion with fine grit abrasive paper (Item 16, Appendix E).
(3)
Repaint surfaces in accordance with TM 43-0139.
Installation.
(1)
Apply tear drop gasket (Item 18, Appendix E) to mating surface of door ring retainer (14, Figure 46). Position door ring (15) and door ring retainer on top panel (4), and install bolts (13) and
locknuts (12).
(2)
Install stiffener (11), bolts (10), washers (9), lockwashers (8), and nuts (7) on DCS control box
assembly.
(3)
Install top panel (4) on control box with bolts (6) and locknuts (5).
(4)
Install washers (3), lockwashers (2), and bolts (1) on top panel (4).
(6)
Raise and secure DCS control panel with two fasteners.
(7)
Install DCS control box door. Refer to paragraph 4.7.1.
(8)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
Top Housing Section.
a.
Removal.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable .
(3)
Remove DCS control box top, paragraph 4.7.2.
_________
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WARNING
Top housing panels can get very hot. Allow panels to cool down before
performing maintenance. Failure to comply can result in severe burns to
personnel.
(4)
Remove bolts (1, Figure 4-7), lockwashers (2), washers (3), mount (4), and exhaust cover (5) from
top housing panel (12).
(5)
Remove bolts (6 and 9), lockwashers (7 and 10), washers (8 and 11), and top housing panel (12)
from generator set.
(6)
Disconnect radiator fill hose and overflow hose from radiator fill panel (13), and remove panel from
generator set.
(7)
Remove bolts (14), lockwashers (15), washers (16), and roof stiffener assembly (17) from side
panels (35 and 36).
(8)
Remove muffler. Refer to paragraph 4.9.1.
(9)
Remove locknuts (18), bolts (19), and air duct channels (20 and 21) from floor panel (37).
(10)
Remove locknuts (22 and 24), bolts (23 and 25), and duct panel (26) from floor panel (37) and side
panels (35 and 36).
(11)
Remove locknuts (27) and bolts (28) from side panels (35 and 36).
(12)
Remove bolts (29), lockwashers (30), and washers (31) from side panels (35 and 36).
(13)
Remove bolts (32), lockwashers (33), and washers (34) from front panel (40).
(14)
Remove side panels (35 and 36) with floor panel (37) from generator set.
(15)
Remove locknuts (38), bolts (39), and front panel (40) from floor panel (37).
(16)
Remove locknuts (41), bolts (42), and support (43) from front panel (40).
(17)
Remove locknuts (44), bolts (45), and side panels (35 and 36) from floor panel (37).
(18)
Remove locknut (46), bolt (47), and bracket (48) from angle (51).
(19)
Open output box access door (Figure 1-2), and remove locknuts (49), bolts (50), and angle (51)
from generator set.
(20)
Remove clip halves (52) and insulation (53 through 63) from top panel (12).
(21)
Remove clip halves (64) and insulation (65 and 66) from side panels (35 and 36).
4-63
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
FIGURE 4-7. TOP HOUSING SECTION (SHEET 1 OF 3)
4-64
ARMY TM 9-6115-671-14
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MARINE CORPS TM 09249A/09246A-14
FIGURE 4-7. TOP HOUSING SECTION (SHEET 2 OF 3)
4-65
ARMY TM 9-6115-671-14
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MARINE CORPS TM 09249A/09246A-14
FIGURE 4-7. TOP HOUSING SECTION (SHEET 3 OF 3)
b.
c.
Inspection.
(1)
Remove top housing section, step a above.
(2)
Inspect all top housing section panels for dents, cracks, loose paint, and corrosion.
(3)
Inspect cage nuts (67 through 75, Figure 4-7) for cracking or stripped threads.
(4)
Inspect insulation (53 through 63, 65, and 66) for damage and missing clip halves (52, 64, 76, and
78) and push-on nuts (77 and 79).
(5)
Inspect seal (80) and door seals (81 and 82) for tears, looseness, and deterioration.
Repair.
__________
WARNING
CARC paint is a health hazard. Wear protective eyewear, mask and gloves
when sanding CARC painted surfaces. Failure to comply can cause personal
injury.
(1)
4-66
Repair all dents and cracks, and remove loose paint.
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
d.
(2)
Remove light corrosion with fine grit abrasive paper (Item 16, Appendix E).
(3)
Repaint surfaces in accordance with TM 43-0139.
(4)
Replace cage nuts (67 through 75, Figure 4-7) that are stripped or cracked.
(5)
Replace damaged insulation (53 through 63, 65, and 66).
(6)
Replace missing or damaged clip halves (52, 64, 76, and 78) and push-on nuts (77 and 79).
(7)
Replace damaged seal (80) or door seals (81 and 82). Refer to Appendix E.
Installation.
(1)
Install insulation (65 and 66, Figure 4-7) on side panels (35 and 36) with clip halves (64).
(2)
Install insulation (53 through 63) on top panel (12) with clip halves (52).
(3)
Install angle (51) on generator set with bolts (50) and locknuts (49). Close output box access door.
(4)
Install bracket (48), bolt (47), and locknut (46) on angle (51).
(5)
Install side panels (35 and 36), bolts (45), and locknuts (44) on floor panel (37).
(6)
Install support (43), bolts (42), and locknuts (41) on front panel (40).
(7)
Install front panel (40), bolts (39), and locknuts (38) on floor panel (37).
(8)
Position side panels (35 and 36) with floor panel (37) on generator set.
(9)
Secure front panel (40) to generator set with washers (34), lockwashers (33), and bolts (32).
(10)
Secure side panels (35 and 36) to generator set with washers (31), lockwashers (30), and bolts (29).
(11)
Secure side panels (35 and 36) to generator set with bolts (28) and locknuts (27).
(12)
Install duct panel (26), bolts (23 and 25), and locknuts (22 and 24) on floor panel (37) and side
panels (35 and 36).
(13)
Install air duct channels (20 and 21), bolts (19), and locknuts (18) on floor panel (37).
(14)
Install muffler. Refer to paragraph 4.9.1.
(15)
Install roof stiffener assembly (17), washers (16), lockwashers (15), and bolts (14) on side panels
(35 and 36).
(16)
Position radiator fill panel (13) on generator set, and connect radiator fill hose and overflow hose to
panel.
(17)
Install top housing panel (12), washers (8 and 11), lockwashers (7 and 10), and bolts (6 and 9) on
generator set.
(18)
Install exhaust cover (5), mount (4), washers (3), lockwashers (2), and bolts (1) on top housing
panel (12).
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4.7.4
Install DCS control box top panel, paragraph 4.7.2.
(20)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
Front Housing Section.
a.
4-68
(19)
Removal.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Remove BATTERY ACCESS door. Refer to paragraph 4.7.1. Remove batteries, paragraph 4.6.3,
and NATO SLAVE RECEPTACLE, paragraph 4.6.4.
(3)
Remove engine compartment access doors. Refer to paragraph 4.7.1.
(4)
Remove top housing section, paragraph 4.7.3.
(5)
Remove bolts (1, Figure 4-8) and ground rod sections (2) from brackets (56).
(6)
Remove nuts (3), lockwashers (4), washers (5), and bolts (6) from door sills (22 and 23) and front
housing (14).
(7)
Remove nuts (7), lockwashers (8), washers (9), and bolts (10) from front housing (14) and skid
base.
(8)
Remove bolts (11), lockwashers (12), washers, (13) and front housing (14) from skid base.
(9)
Remove nuts (15), lockwashers (16), washers (17), and bolts (18), from doors sills (22 and 23) and
generator set.
(10)
Remove bolts (19), lockwashers (20), washers (21), and door sills (22 and 23) from skid base.
(11)
Remove clip halves (24) and insulation (25) from front housing (14).
(12)
Remove locknuts (26) and bolts (27) from air deflector (31) and front housing (14).
(13)
Remove bolts (28), lockwashers (29), washers (30), and air deflector (31) from front housing (14).
(14)
Remove bolts (32), lockwashers (33), washers (34), and radiator panels (35 and 36) from front
housing (14).
(15)
Remove locknuts (37), bolts (38), and supports (39 and 40) from radiator panels (35 and 36).
(16)
Remove bolts (41), lockwashers (42), washers (43), and panel (44) from front housing (14).
(17)
Remove locknuts (45), bolts (46), and support (47) from panel (44).
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
FIGURE 4-8. FRONT HOUSING SECTION (SHEET 1 OF 2)
4-69
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MARINE CORPS TM 09249A/09246A-14
FIGURE 4-8. FRONT HOUSING SECTION (SHEET 2 OF 2)
b.
4-70
(18)
Remove locknuts (48), bolts (49), and support channel (50) from front housing (14).
(19)
Remove locknuts (51), bolts (52), and SLAVE RECEPTACLE box (53) from front housing (14).
(20)
Remove locknuts (54), bolts (55), and brackets (56) from door sill (22) and front housing (14).
Inspection.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Inspect all front housing section panels for dents, cracks, loose paint, corrosion, and other damage.
(3)
Inspect cage nuts (57 through 62, Figure 4-8) for cracking or stripped threads.
(4)
Inspect insulation (25) for damage and missing clip halves (24 and 63) and push-on nuts (64).
(5)
Inspect seals (65 through 67) for tears, looseness, and deterioration.
(6)
Inspect identification plates (68, 70, and 72) for readability and loose or missing rivets (69, 71, and
73).
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
c.
Repair.
__________
WARNING
CARC paint is a health hazard. Wear protective eyewear, mask and gloves
when sanding CARC painted surfaces. Failure to comply can cause personal
injury.
d.
(1)
Repair all dents and cracks, and remove loose paint.
(2)
Remove light corrosion with fine grit abrasive paper (Item 16, Appendix E).
(3)
Repaint surfaces in accordance with TM 43-0139.
(4)
Replace stripped or cracked cage nuts (57 through 62, Figure 4-8).
(5)
Replace damaged insulation (25) and missing or damaged clip halves (24 and 63) or push-on nuts
(64).
(6)
Replace damaged seals (65 through 67). Refer to Table E.
(7)
Replace damaged or unreadable identification plates (68, 70, and 72).
(8)
Replace loose or missing rivets (69, 71, and 73).
Installation.
(1)
Install brackets (56, Figure 4-8), bolts (55), and locknuts (54) on front housing (14) and door sill
(22).
(2)
Install SLAVE RECEPTACLE box (53), bolts (52), and locknuts (51) on front housing (14).
(3)
Install support channel (50), bolts (49), and locknuts (48) on front housing (14).
(4)
Install support (47), bolts (46), and locknuts (45) on panel (44).
(5)
Install panel (44), washers (43), lockwashers (42), and bolts (41) on front housing (14).
(6)
Install supports (39 and 40), bolts (38), and locknuts (37) on radiator panels (35 and 36).
(7)
Install radiator panels (35 and 36), washers (34), lockwashers (33), and bolts (32) on front housing
(14).
(8)
Install air deflector (31), washers (30), lockwashers (29), and bolts (28) on front housing (14).
(9)
Secure air deflector (31) to front housing (14) with bolts (27) and locknuts (26).
(10)
Install insulation (25) on front housing (14) with panel clips (24), clip halves (63), and push-on nuts
(64).
(11)
Install door sills (22 and 23), washers (21), lockwashers (20), and bolts (19) on skid base.
(12)
Secure door sills (22 and 23) to generator set with bolts (18), washers (17), lockwashers (16), and
nuts (15).
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MARINE CORPS TM 09249A/09246A-14
4.7.5
Install front housing (14), washers (13), lockwashers (12), and bolts (11) on skid base.
(14)
Secure front housing (14) to skid base with bolts (10), washers (9), lockwashers (8), and nuts (7).
(15)
Install bolts (6), washers (5), lockwashers (4), and nuts (3) on front housing (14) and door sills (22
and 23).
(16)
Position ground rod sections (2) in brackets (56), and install bolts (1).
(17)
Install top housing section, paragraph 4.7.3.
(18)
Install engine compartment access doors. Refer to paragraph 4.7.1.
(19)
Install BATTERY ACCESS door. Refer to paragraph 4.7.1.
(20)
Install NATO SLAVE RECEPTACLE, paragraph 4.6.4, and batteries, paragraph 4.6.3.
Rear Housing Section.
a.
4-72
(13)
Removal.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Remove DCS control box assembly, paragraph 4.8.1.
(3)
Remove air cleaner assembly, paragraph 4.9.2.
(4)
Remove output box access door, load terminal board access door, rear engine compartment access
doors, and air cleaner access door. Refer to paragraph 4.7.1.
(5)
Remove fuel tank filler neck, paragraph 4.11.3.
(6)
Remove auxiliary fuel pump, paragraph 4.11.2.
(7)
Remove ether solenoid valve, paragraph 4.11.8.
(8)
Remove top housing panel. Refer to paragraph 4.7.3.
(9)
Remove output box. Refer to paragraph 5.8.
(10)
Remove nuts (1, Figure 4-9), lockwashers (2), washers (3), and bolts (4) from rear panel (8) and
skid base.
(11)
Remove bolts (5), lockwashers (6), washers (7), and rear panel (8) from corner post (40) and left
side rear panel (19).
(12)
Remove locknuts (9), bolts (10), and load terminal access box (11) from rear panel (8).
(13)
Remove nuts (12), lockwashers (13), washers (14), and bolts (15), from left side rear panel (19) and
engine compartment door sill (61).
(14)
Remove bolts (16), lockwashers (17), washers (18), and left side rear panel (19) from skid base.
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
b.
(15)
Remove locknuts (20), bolts (21), and air baffle (22) from left side rear panel (19).
(16)
Remove clip halves (23) and insulation (24) from air baffle (22).
(17)
Remove locknuts (25), bolts (26), and filler neck panel (27) from left side rear panel (19).
(18)
Remove locknuts (30), bolts (31), and output box sill (32) from corner post (40) and panel (50).
(19)
Remove locknuts (33) and bolts (34) from door sill (39), corner post (40), and panel (50).
(20)
Remove nuts (35), lockwashers (36), washers (37), bolts (38), door sill (39), and corner post (40)
from skid base. Scrape sealant from mating surfaces of corner post and output box top.
(21)
Remove nuts (43), lockwashers (44), washers (45), and bolts (46) from panel (50).
(22)
Remove bolts (47), lockwashers (48), washers (49), and panel (50) from skid base. Scrape sealant
from mating surfaces of panel and output box top.
Inspection.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Inspect rear housing section panels for dents, cracks, loose paint, corrosion, and other damage.
(3)
Inspect cage nuts (51 through 54, Figure 4-9) for cracking or stripped threads.
(4)
Inspect insulation (24), clip halves (23,55), and push-on nuts (56) for damage or missing pieces.
(5)
Inspect output box EMI seals (57) for tears, looseness, and deterioration.
(6)
Inspect door seals (58 through 61) for tears, looseness, and deterioration.
(7)
Inspect data plates (63 and 65) for readability and loose or missing rivets (62 and 64).
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FIGURE 4-9. REAR HOUSING SECTION (SHEET 1 OF 2)
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FIGURE 4-9. REAR HOUSING SECTION (SHEET 2 OF 2)
c.
Repair.
__________
WARNING
CARC paint is a health hazard. Wear protective eyewear, mask and gloves
when sanding CARC painted surfaces. Failure to comply can cause personal
injury.
(1)
Repair all dents and cracks, and remove loose paint.
(2)
Remove light corrosion with fine grit abrasive paper (Item 16, Appendix E).
(3)
Repaint surfaces in accordance with TM 43-0139.
(4)
Replace stripped or cracked cage nuts (51 through 54, Figure 4-9).
(5)
Replace damaged insulation (24) and missing or damaged clip halves (23 and 55) or push-on nuts
(56).
(6)
Replace damaged door seals (58 through 61) attach with adhesive (1, Appendix E).
(7)
Using adhesive (1, Appendix E), replace loose or damaged EMI seals (57). Ensure closed side of
seal faces outward.
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(8)
d.
4-76
Replace damaged or unreadable data plates (63 and 65) and loose or missing rivets (62 and 64).
Installation.
(1)
Install panel (50, Figure 4-9), washers (49), lockwashers (48), and bolts (47) on skid base.
(2)
Secure panel (50) with bolts (46), washers (45), lockwashers (44), and nuts (43).
(3)
Install corner post (40), door sill (39), bolts (38), washers (37), lockwashers (36), and nuts (35) on
skid base.
(4)
Apply industrial sealant (18, Appendix E) to edges and cracks at mating surfaces of corner post
(40), panel (50), and control box top.
(5)
Secure door sill (39) to corner post (40) and panel (50) with bolts (34) and locknuts (33).
(6)
Install output box sill (32), bolts (31), and locknuts (30) on corner post (40) and panel (50).
(7)
Install filler neck panel (27), bolts (26), and locknuts (25) on left side rear panel (19).
(8)
Install insulation (24) on air baffle (22) with clip halves (23).
(9)
Install air baffle (22), bolts (21), and locknuts (20) on left side rear panel (19).
(10)
Secure left side rear panel (19) to skid base with bolts (16), lockwashers (17), and washers (18).
(11)
Secure left side rear panel (19) and engine compartment door sill (61) with bolts (15), washers (14),
lockwashers (13), and nuts (12).
(12)
Install load terminal access box (11), bolts (10), and locknuts (9) on rear panel (8).
(13)
Install rear panel (8), washers (7), lockwashers (6), and bolts (5) on corner post (40) and left side
rear panel (19).
(14)
Secure rear panel (8) to skid base with bolts (4), washers (3), lockwashers (2), and nuts (1).
(15)
Install output box. Refer to paragraph 5.8.
(16)
Install top housing panel. Refer to paragraph 4.7.3.
(17)
Install ether solenoid valve, paragraph 4.11.8.
(18)
Install auxiliary fuel pump, paragraph 4.11.2.
(19)
Install fuel tank filler neck, paragraph 4.11.3.
(20)
Install output box access door, load terminal board access door, rear engine compartment access
doors, and air cleaner access door. Refer to paragraph 4.7.1.
(21)
Install air cleaner assembly, paragraph 4.9.2.
(23)
Install DCS control box assembly, paragraph 4.8.1.
ARMY TM 9-6115-671-14
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MARINE CORPS TM 09249A/09246A-14
4.7.6
4.8
Housing Data Plates.
a.
Inspection. Inspect data plates for readability and loose or missing rivets. Refer to paragraph 2.16 for
locations of data plates on housing.
b.
Replacement.
(1)
Drill out rivets, and remove data plate from housing. Refer to paragraph 2.16.
(2)
Install data plate on housing with rivets.
MAINTENANCE OF DCS CONTROL BOX ASSEMBLY
__________
WARNING
When disconnecting or removing batteries, disconnect the negative lead that
connects directly to the grounding stud first. Disconnect the negative end of
the interconnection cable next. When installing batteries, reverse the
connection sequence. Failure to comply can cause serious personal injury.
__________
WARNING
Electronic components of the DCS and CIM are static sensitive. Ensure that
no static discharge occurs when you come in contact with those components.
Failure to comply can cause damage to electronic components.
4.8.1
DCS Control Box
a.
b.
Inspection.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Inspect DCS control box for cracks, breaks, corrosion, loose paint, and missing parts.
Removal.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable .
(3)
Remove DCS control box top panel, paragraph 4.7.2.
(4)
Remove bolts (1, Figure 4-10), lockwashers (2), and washers (3) securing DCS control box
assembly (12) to top of output box assembly (Figure 5-3).
(5)
Open output box access door (Figure 1-2).
(6)
Remove locknuts (4, Figure 4-10) and bolts (5) securing DCS control box assembly (12) to
generator set.
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FIGURE 4-10. DCS CONTROL BOX
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.
c.
(7)
Remove bolts (6 and 9), lockwashers (7 and 10), washers (8 and 11).
(8)
Slide DCS control box forward, disconnect two wiring harness connectors at rear of DCS control
box assembly (12, Figure 4-10) and remove DCS control box assembly (12) from generator set.
Repair
Repair DCS control box assembly by replacing damaged terminals, damaged or missing mounting
hardware, and damaged or defective components. Refer to paragraphs 4.8.2 through 4.8.43.
d.
4.8.2
Installation.
(1)
Install DCS control box assembly (12) to generator set by sliding DCS control box backward, and
connecting two wiring harness connectors at rear of DCS control box assembly (12, Figure 4-10).
(2)
Secure DCS control box assembly (12) to generator set with bolts (6 and 9), lockwashers (7 and 10),
and washers (8 and 11).
(3)
Install bolts (5) and locknuts (4).
(4)
Close output box access door (Figure 1-2).
(5)
Secure DCS control box assembly (12, Figure 4-10) to top of output box assembly with washers (3),
lockwashers (2), and bolts (1).
(6)
Connect two wiring harness connectors at rear of DCS control box assembly (12).
(7)
Install DCS control box top panel, paragraph 4.7.2.
(8)
Connect negative battery cable to battery, and close BATTERY ACCESS door (Figure 1-2).
Panel Lights DS1 through DS3.
a.
Inspection.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Remove directional cap (1, Figure 4-11) from panel light housing (5).
(3)
Remove light bulb (2) from panel light housing (5).
(4)
Set multimeter to ohms, and check light bulb for continuity across base and threads. Multimeter
should indicate continuity.
(5)
If multimeter does not indicate continuity, replace light bulb (2).
(6)
Inspect directional caps (1) for cracks, corrosions, stripped threads, and other damage.
(7)
Release DCS control panel by turning two fasteners, and lower panel slowly.
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b.
c.
4-80
(8)
Inspect panel light housings (5) on DCS control panel (6) for cracks, corrosion, stripped threads,
and other damage.
(9)
Install light bulb (2) in panel light housing (5).
(10)
Install directional cap (1) on panel light housing (5).
(11)
Raise and secure DCS control panel.
(12)
Remove DCS control box top panel, paragraph 4.7.2.
(13)
Inspect panel light housing (5) on DCS control panel frame (7) for cracks, corrosion, stripped
threads, and other damage.
(14)
Install DCS control box top panel, paragraph 4.7.2.
Repair.
(1)
Remove directional cap (1, Figure 4-11) from panel light housing (5).
(2)
Remove light bulb (2) from panel light housing (5).
(3)
Install light bulb (2) in panel light housing (5).
(4)
Install directional cap (1) in panel light housing (5).
Replacement.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable .
(3)
If defective panel light is on DCS control panel (6, Figure 4-11), release DCS control panel by
turning two fasteners, and lower panel slowly.
(4)
If defective panel light is on DCS control panel frame (7), remove DCS control box top panel,
paragraph 4.7.2.
(5)
Tag and disconnect panel light housing (5) electrical leads.
(6)
Remove jamnut (3), washer (4), and panel light housing (5) from DCS control panel (6) or DCS
control panel frame (7).
(7)
Install panel light housing (5), washer (4), and jamnut (3) on DCS control panel frame (7) or DCS
control panel (6).
(8)
Connect panel light housing (5) electrical leads. Remove tags.
(9)
If removed, install DCS control box top panel, paragraph 4.7.2.
(10)
If lowered, raise and secure DCS control panel.
(11)
Connect negative battery cable to battery, and close BATTERY ACCESS doors.
ARMY TM 9-6115-671-14
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FIGURE 4-11. DCS CONTROL BOX PANEL LIGHTS DS1 THROUGH DS3
AND NETWORK FAILURE LIGHT DS5
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4.8.3
NETWORK FAILURE Light DS5.
a.
b.
c.
4.8.4
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Release DCS control panel by turning two fasteners, and lower panel slowly.
(3)
Inspect light housing (11, Figure 4-11) for cracks, corrosion, evidence of shorting, and other
damage.
(4)
Raise and secure DCS control panel.
Repair.
(1)
Unscrew to remove press-to-test light (8, Figure 4-11) from light housing (11).
(2)
Screw press-to-test light (8) into light housing (11) to install.
Replacement.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable .
(3)
Release DCS control panel by turning two fasteners, and lower panel slowly.
(4)
Tag and disconnect light housing (11, Figure 4-11) electrical leads.
(5)
Remove press-to-test light (8), jamnut (9), washer (10), and light housing (11) from DCS control
panel (6).
(6)
Install light housing (11), washer (10), jamnut (9), and press-to-test light (8) on DCS control panel
(6).
(7)
Tighten jamnuts (9 and 12) to secure light housing (11) to DCS control panel (6).
(8)
Connect light housing (11) electrical leads. Remove tags.
(9)
Raise and secure DCS control panel.
(10)
Connect negative battery cable to battery, and close BATTERY ACCESS doors.
Time Meter (TOTAL HOURS) M3.
a.
4-82
Inspection.
Inspection.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Release DCS control panel by turning two fasteners, and lower DCS control panel slowly.
(3)
Inspect time meter (3, Figure 4-12) for broken lens, cracked housing, and other damage.
ARMY TM 9-6115-671-14
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MARINE CORPS TM 09249A/09246A-14
(4)
b.
c.
Raise and secure DCS control panel.
Testing.
(1)
Turn ENGINE CONTROL switch (8, Fig 4-12) to PRIME & RUN position.
(2)
Release DCS control panel by turning two fasteners, and lower DCS control panel slowly.
(3)
Set multimeter for DC volts, and connect across terminals 1 and 2 of time meter (3, Figure 4-12).
(4)
If 24 VDC is present, watch for indicator movement. In approximately six minutes, time meter (3)
should move 1/10 hour. If time meter does not operate properly, meter is defective and must be
replaced.
(5)
Raise and secure DCS control panel.
(6)
Turn Engine Control switch (8, Fig 4-12) to off position.
Replacement.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable .
(3)
Release DCS control panel by turning two fasteners, and lower DCS control panel slowly.
(4)
Tag and disconnect electrical leads from the time meter (3, Figure 4-12).
(5)
Remove nuts (1), screws (2), and time meter (3) from DCS control panel.
(6)
Install time meter (3), screws (2), and nuts (1) on DCS control panel.
(7)
Connect electrical leads to time meter (3), and remove tags.
(8)
Raise and secure DCS control panel with two fasteners.
(9)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
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FIGURE 4-12. TIME METER AND SWITCHES
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4.8.5
ENGINE CONTROL Switch S1.
a.
b.
c.
Inspection.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Release DCS control panel by turning two fasteners, and lower DCS control panel slowly.
(3)
Inspect ENGINE CONTROL switch (8, Figure 4-12) for loose connections and mounting hardware,
and other damage.
(4)
Raise and secure DCS control panel with two fasteners.
Testing.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable .
(3)
Release DCS control panel by turning two fasteners, and lower DCS control panel slowly.
(4)
Tag and disconnect ENGINE CONTROL switch (8, Figure 4-12) electrical leads.
(5)
Set multimeter for ohms, and check switch for continuity. Refer to schematic, FO-1, to determine
circuits made to corresponding switch position.
(6)
Check continuity for all four positions.
(7)
If open circuit is noted at any switch position, switch is unserviceable and must be replaced.
(8)
Connect electrical leads to ENGINE CONTROL switch (8), and remove tags.
(9)
Raise and secure DCS control panel with two fasteners.
(10)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
Replacement.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable .
(3)
Release DCS control panel by turning two fasteners, and lower DCS control panel slowly.
(4)
Remove screw (4, Figure 4-12) and knob (5) from ENGINE CONTROL switch (8).
(5)
Tag and disconnect electrical leads from ENGINE CONTROL switch (8).
(6)
Remove nuts (6), screws (7), and ENGINE CONTROL switch (8) from DCS control panel.
(7)
Install ENGINE CONTROL switch (8), screws (7), and nuts (6) on DCS control panel.
(8)
Connect electrical leads to ENGINE CONTROL switch (8), and remove tags.
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4.8.6
Install knob (5) and screw (4) on ENGINE CONTROL switch (8).
(10)
Raise and secure DCS control panel with two fasteners.
(11)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
ETHER START Switch S9.
a.
b.
c.
4-86
(9)
Inspection.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Release DCS control panel by turning two fasteners, and lower DCS control panel slowly.
(3)
Inspect ETHER START switch (11, Figure 4-12) for loose connections and mounting hardware, and
other damage.
(4)
Raise and secure DCS control panel with two fasteners.
Testing.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable .
(3)
Release DCS control panel by turning two fasteners, and lower DCS control panel slowly.
(4)
Tag and disconnect electrical leads from ETHER START switch (11, Figure 4-12).
(5)
Set multimeter for ohms, and connect across ETHER START switch (11) terminals. Multimeter
should indicate open circuit. Refer to Schematic FO-1.
(6)
Hold ETHER START switch (11) in ON position. Multimeter should indicate continuity.
(7)
If indications are not as above, replace ETHER START switch.
(8)
Connect electrical leads to ETHER START switch (11), and remove tags.
(9)
Raise and secure DCS control panel with two fasteners.
(10)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
Replacement.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable .
(3)
Release DCS control panel by turning two fasteners, and lower DCS control panel slowly.
(4)
Tag and disconnect ETHER START switch (11, Figure 4-12) electrical leads.
(5)
Remove jamnut (9) and toothed washer (10) securing ETHER START switch (11) to DCS control
panel.
ARMY TM 9-6115-671-14
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MARINE CORPS TM 09249A/09246A-14
4.8.7
(6)
Remove ETHER START switch (11) and tab washer (12) from DCS control panel.
(7)
Position tab washer (12) and ETHER START switch (11) on DCS control panel.
(8)
Secure ETHER START switch (11) to DCS control panel with toothed washer (10) and jamnut (9).
(9)
Connect electrical leads to ETHER START switch (11), and remove tags.
(10)
Raise and secure DCS control panel with two fasteners.
(11)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
AC CIRCUIT INTERRUPT Switch S5.
a.
b.
Inspection.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Release DCS control panel by turning two fasteners, and lower DCS control panel slowly.
(3)
Inspect AC CIRCUIT INTERRUPT switch (16, Figure 4-12) for loose connections and mounting
hardware, and other damage.
(4)
Raise and secure DCS control panel with two fasteners.
Testing.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Release DCS control panel by turning two fasteners, and lower DCS control panel slowly.
(4)
Tag and disconnect electrical leads from AC CIRCUIT INTERRUPT switch (16, Figure 4-12).
(5)
Set multimeter for ohms and check for open circuits between terminals 1 and 2, terminals 2 and 3,
and terminals 1 and 3. Refer to Schematic FO-1.
(6)
Place and hold AC CIRCUIT INTERRUPT switch (16) in CLOSED position.
(7)
Check for continuity between terminals 1 and 2.
(8)
Hold AC CIRCUIT INTERRUPT switch (16) in OPEN position.
(9)
Check for continuity between terminals 2 and 3.
(10)
If indications are not as above, replace AC CIRCUIT INTERRUPT switch (16).
(11)
Connect electrical leads to AC CIRCUIT INTERRUPT switch (16), and remove tags.
(12)
Raise and secure DCS control panel with two fasteners.
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(13)
c.
4.8.8
Replacement.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Release DCS control panel by turning two fasteners, and lower DCS control panel slowly.
(4)
Tag and disconnect AC CIRCUIT INTERRUPT switch (16, Figure 4-12) electrical leads.
(5)
Remove jamnut (14) and toothed washer (15) securing AC CIRCUIT INTERRUPT switch (16) to
DCS control panel.
(6)
Remove AC CIRCUIT INTERRUPT switch (16), and tab washer (17) from DCS control panel.
(7)
Position tab washer (17), and AC CIRCUIT INTERRUPT switch (16) on DCS control panel.
(8)
Secure AC CIRCUIT INTERRUPT switch (16) to DCS control panel with toothed washer (15) and
jamnut (14).
(9)
Connect electrical leads to AC CIRCUIT INTERRUPT switch (16), and remove tags.
(10)
Raise and secure DCS control panel with two fasteners.
(11)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
FAULT RESET Switch S4.
a.
b.
4-88
Connect negative battery cable to battery, and close BATTERY ACCESS door.
Inspection.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Release DCS control panel by turning two fasteners, and lower DCS control panel slowly.
(3)
Inspect FAULT RESET switch (21, Figure 4-12) for loose connections and mounting hardware, and
other damage.
(4)
Raise and secure DCS control panel with two fasteners.
Testing.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable .
(3)
Release DCS control panel by turning two fasteners, and lower DCS control panel slowly.
(4)
Tag and disconnect electrical leads from FAULT RESET switch (21, Figure 4-12).
(5)
Set multimeter for ohms, and connect across FAULT RESET switch (21) terminals 2 and 3.
Multimeter should indicate continuity. Refer to Schematic FO-1.
ARMY TM 9-6115-671-14
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c.
4.8.9
(6)
Hold FAULT RESET switch (21) in ON position. Multimeter should indicate continuity between
terminals 1 and 2 and an open circuit between terminals 2 and 3.
(7)
If indications are not as above, replace FAULT RESET switch (21).
(8)
Connect electrical leads to FAULT RESET switch (21), and remove tags.
(9)
Raise and secure DCS control panel with two fasteners.
(10)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
Replacement.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Release DCS control panel by turning two fasteners, and lower DCS control panel slowly.
(4)
Tag and disconnect electrical leads from FAULT RESET switch (21, Figure 4-12).
(5)
Remove jamnut (19) and toothed washer (20) securing FAULT RESET switch (21) to DCS control
panel.
(6)
Remove FAULT RESET switch (21) and tab washer (22), from DCS control panel.
(7)
Position tab washer (22) and FAULT RESET switch (21) on DCS control panel.
(8)
Secure FAULT RESET switch (21) to DCS control panel with toothed washer (20) and jamnut (19).
(9)
Connect electrical leads to FAULT RESET switch (21), and remove tags.
(10)
Raise and secure DCS control panel with two fasteners.
(11)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
MASTER CONTROL Switch S3.
a.
b.
Inspection.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Release DCS control panel by turning two fasteners, and lower DCS control panel slowly.
(3)
Inspect MASTER CONTROL switch (3, Figure 4-13) for loose connections and mounting
hardware, and other damage.
(4)
Raise and secure DCS control panel with two fasteners.
Testing.
(1)
Shut down generator set, paragraph 2.11.2.
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MARINE CORPS TM 09249A/09246A-14
4-90
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable .
(3)
Release DCS control panel by turning two fasteners, and lower DCS control panel slowly.
(4)
Tag and disconnect electrical leads from MASTER CONTROL switch (3, Figure 4-13).
(5)
Set multimeter for ohms, and connect across MASTER CONTROL switch (3) terminals. Refer to
Schematic FO-1.
(6)
Place MASTER CONTROL switch (3) in ON position. Multimeter should indicate continuity on
terminals 5 and 6.
(7)
Place MASTER CONTROL switch (3) in OFF position. Multimeter should indicate open circuit on
terminal 5 and 6.
(8)
If indications are not as above, replace MASTER CONTROL switch (3).
(9)
Connect electrical leads to MASTER CONTROL switch (3), and remove tags.
(10)
Raise and secure DCS control panel with two fasteners.
(11)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
FIGURE 4-13. DCS CONTROL PANEL COMPONENTS
4-91
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c.
4.8.10
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable .
(3)
Release DCS control panel by turning two fasteners, and lower DCS control panel slowly.
(4)
Tag and disconnect electrical leads from MASTER CONTROL switch (3, Figure 4-13).
(5)
Remove jamnut (1) and toothed washer (2) securing MASTER CONTROL switch (3) to DCS
control panel.
(6)
Remove MASTER CONTROL switch (3) and tab washer (4) from DCS control panel.
(7)
Position tab washer (4) and MASTER CONTROL switch (3) on DCS control panel.
(8)
Secure MASTER CONTROL switch (3) to DCS control panel with toothed washer (2) and jamnut
(1).
(9)
Connect electrical leads to MASTER CONTROL switch (3), and remove tags.
(10)
Raise and secure DCS control panel with two fasteners.
(11)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
VOLTAGE ADJUST Switch S18.
a.
b.
4-92
Replacement.
Inspection.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Release DCS control panel by turning two fasteners, and lower DCS control panel slowly.
(3)
Inspect VOLTAGE ADJUST switch (8, Figure 4-13) for loose connections and mounting hardware,
and other damage.
(4)
Raise and secure DCS control panel with two fasteners.
Testing.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Release DCS control panel by turning two fasteners, and lower DCS control panel slowly.
(4)
Tag and disconnect electrical leads from VOLTAGE ADJUST switch (8, Figure 4-13).
(5)
Set multimeter for ohms, and connect across VOLTAGE ADJUST switch (8) terminals. Multimeter
should indicate open circuit between terminals 1 and 2, 2 and 3, and 1 and 3. Refer to Schematic
FO-1.
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
c.
4.8.11
(6)
Hold VOLTAGE ADJUST switch (8) in UP position. Multimeter should indicate continuity on
terminals 2 and 3.
(7)
Hold VOLTAGE ADJUST switch (8) in DOWN position. Multimeter should indicate continuity on
terminals 2 and 1.
(8)
If indications are not as above, replace VOLTAGE ADJUST switch.
(9)
Connect electrical leads to VOLTAGE ADJUST switch (8), and remove tags.
(10)
Raise and secure DCS control panel with two fasteners.
(11)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
Replacement.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable .
(3)
Release DCS control panel by turning two fasteners, and lower DCS control panel slowly.
(4)
Tag and disconnect electrical leads from VOLTAGE ADJUST switch (8, Figure 4-13).
(5)
Remove jamnut (6) and toothed washer (7) securing VOLTAGE ADJUST switch (8) to DCS
control panel.
(6)
Remove VOLTAGE ADJUST switch (8) and tab washer (9) from DCS control panel.
(7)
Position tab washer (9) and VOLTAGE ADJUST switch (8) on DCS control panel.
(8)
Secure VOLTAGE ADJUST switch (8) to DCS control panel with toothed washer (7) and jamnut
(6).
(9)
Connect electrical leads to VOLTAGE ADJUST switch (8), and remove tags.
(10)
Raise and secure DCS control panel with two fasteners.
(11)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
FREQUENCY ADJUST Switch S19.
a.
b.
Inspection.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Release DCS control panel by turning two fasteners, and lower DCS control panel slowly.
(3)
Inspect FREQUENCY ADJUST switch (13, Figure 4-13) for loose connections and mounting
hardware, and other damage.
(4)
Raise and secure DCS control panel with two fasteners.
Testing.
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c.
4.8.12
4-94
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Release DCS control panel by turning two fasteners, and lower DCS control panel slowly.
(4)
Tag and disconnect electrical leads from FREQUENCY ADJUST switch (13, Figure 4-13).
(5)
Set multimeter for ohms, and connect across FREQUENCY ADJUST switch (13) terminals.
Multimeter should indicate open circuit between terminals 1 and 2, 2 and 3, and 1 and 3. Refer to
Schematic FO-1.
(6)
Hold FREQUENCY ADJUST switch (13) in UP position. Multimeter should indicate continuity on
terminals 2 and 3.
(7)
Hold FREQUENCY ADJUST switch (13) in the DOWN position. Multimeter should indicate
continuity on terminals 2 and 1.
(8)
If indications are not as above, replace FREQUENCY ADJUST switch.
(9)
Connect electrical leads to FREQUENCY ADJUST switch (13), and remove tags.
(10)
Raise and secure DCS control panel with two fasteners.
(11)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
Replacement.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Release DCS control panel by turning two fasteners, and lower DCS control panel slowly.
(4)
Tag and disconnect electrical leads from FREQUENCY ADJUST switch (13, Figure 4-13).
(5)
Remove jamnut (11) and toothed washer (12) securing FREQUENCY ADJUST switch (13) to DCS
control panel.
(6)
Remove FREQUENCY ADJUST switch (13) and tab washer (14) from DCS control panel.
(7)
Position tab washer (14) and FREQUENCY ADJUST switch (13) on DCS control panel.
(8)
Secure FREQUENCY ADJUST switch (13) to DCS control panel with toothed washer (12) and
jamnut (11).
(9)
Connect electrical leads to FREQUENCY ADJUST switch (13), and remove tags.
(10)
Raise and secure DCS control panel with two fasteners.
(11)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
PANEL LIGHTS Switch S2.
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
a.
b.
c.
Inspection.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Release DCS control panel by turning two fasteners, and lower DCS control panel slowly.
(3)
Inspect PANEL LIGHTS switch (18, Figure 4-13) for loose connections and mounting hardware,
and other damage.
(4)
Raise and secure DCS control panel with two fasteners.
Testing.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable .
(3)
Release DCS control panel by turning two fasteners, and lower DCS control panel slowly.
(4)
Tag and disconnect electrical leads from PANEL LIGHTS switch (18, Figure 4-13).
(5)
Set multimeter for ohms, and connect across PANEL LIGHTS switch (18) terminals 5 and 6 and 2
and 3. Refer to Schematic FO-1.
(6)
Place PANEL LIGHTS switch (18) in ON position. Multimeter should indicate continuity between
terminals 2 and 3, and 5 and 6.
(7)
Place PANEL LIGHTS switch (18) in OFF position. Multimeter should indicate open circuit
between terminals 2 and 3, and 5 and 6.
(8)
If indications are not as above, replace PANEL LIGHTS switch (18).
(9)
Connect electrical leads to PANEL LIGHTS switch (18), and remove tags.
(10)
Raise and secure DCS control panel with two fasteners.
(11)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
Replacement.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Release DCS control panel by turning two fasteners, and lower DCS control panel slowly.
(4)
Tag and disconnect electrical leads from PANEL LIGHTS switch (18, Figure 4-13).
(5)
Remove jamnut (16) and toothed washer (17) securing PANEL LIGHTS switch (18) to DCS control
panel.
(6)
Remove PANEL LIGHTS switch (18) and tab washer (19) from DCS control panel.
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4.8.13
Position tab washer (19) and PANEL LIGHTS switch (18) on DCS control panel.
(8)
Secure PANEL LIGHTS switch (18) to DCS control panel with toothed washer (17) and jamnut
(16).
(9)
Connect electrical leads to PANEL LIGHTS switch (18), and remove tags.
(10)
Raise and secure DCS control panel with two fasteners.
(11)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
BATTLE SHORT Switch S7.
a.
b.
c.
4-96
(7)
Inspection.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Release DCS control panel by turning two fasteners, and lower DCS control panel slowly.
(3)
Inspect BATTLE SHORT switch (24, Figure 4-13) for loose connections and mounting hardware,
and other damage.
(4)
Raise and secure DCS control panel with two fasteners.
Testing.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Release DCS control panel by turning two fasteners, and lower DCS control panel slowly.
(4)
Tag and disconnect electrical leads from BATTLE SHORT switch (24, Figure 4-13).
(5)
Place BATTLE SHORT switch (24) in ON position.
(6)
Set multimeter for ohms, and check for continuity between terminals 2 and 3, and an open circuit
between terminals 4 and 5. Refer to Schematic FO-1.
(7)
Place BATTLE SHORT switch (24) in OFF position.
(8)
Check for continuity between terminals 4 and 5, and an open circuit between terminals 2 and 3.
(9)
If open circuit is indicated, replace BATTLE SHORT switch (24).
(10)
Connect electrical leads to BATTLE SHORT switch (24), and remove tags.
(11)
Raise and secure DCS control panel with two fasteners.
(12)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
Replacement.
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
4.8.14
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Release DCS control panel by turning two fasteners, and lower DCS control panel slowly.
(4)
Tag and disconnect electrical leads from BATTLE SHORT switch (24, Figure 4-13).
(5)
Remove jamnut (21), toothed washer (22), and cover (23) securing BATTLE SHORT switch (24) to
DCS control panel.
(6)
Remove BATTLE SHORT switch (24) and tab washer (25) from DCS control panel.
(7)
Position tab washer (25) and BATTLE SHORT switch (24) on DCS control panel.
(8)
Secure BATTLE SHORT switch (24) to DCS control panel with cover (23), toothed washer (22),
and jamnut (21).
(9)
Connect electrical leads to BATTLE SHORT switch (24), and remove tags.
(10)
Raise and secure DCS control panel with two fasteners.
(11)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
EMERGENCY STOP Switch S17.
a.
b.
Inspection.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Release DCS control panel by turning two fasteners, and lower DCS control panel slowly.
(3)
Inspect EMERGENCY STOP switch (29, Figure 4-13) for loose connections and mounting
hardware, and other damage.
(4)
Raise and secure DCS control panel with two fasteners.
Testing.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Release DCS control panel by turning two fasteners, and lower DCS control panel slowly.
(4)
Tag and disconnect electrical leads from EMERGENCY STOP switch (29, Figure 4-13).
(5)
Ensure EMERGENCY STOP switch (29) is in normal (out) position.
(6)
Set multimeter for ohms, and connect across EMERGENCY STOP switch (29) terminals.
Multimeter should indicate continuity.
(7)
Push EMERGENCY STOP switch (29) to (in) position. Multimeter should indicate no continuity.
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c.
4.8.15
If indications are not as above, replace EMERGENCY STOP switch.
(9)
Connect electrical leads to EMERGENCY STOP switch (29), and remove tags.
(10)
Raise and secure DCS control panel with two fasteners.
(11)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
Replacement.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Release DCS control panel by turning two fasteners, and lower DCS control panel slowly.
(4)
Tag and disconnect electrical leads from EMERGENCY STOP switch (29, Figure 4-13).
(5)
Unscrew and remove knob (27) and collar (28) from EMERGENCY STOP switch (29), and remove
switch from DCS control panel.
(6)
Position EMERGENCY STOP switch (29) on DCS control panel and secure with collar (28) and
knob (27).
(7)
Connect electrical leads to EMERGENCY STOP switch (29), and remove tags.
(8)
Raise and secure DCS control panel with two fasteners.
(9)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
GROUND FAULT CIRCUIT INTERRUPTER CB3.
a.
4-98
(8)
Inspection.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Release DCS control panel by turning two fasteners, and lower DCS control panel slowly.
(3)
Inspect GROUND FAULT CIRCUIT INTERRUPTER (32, Figure 4-13) for cracks, corrosion,
frayed wires, and other damage.
(4)
Raise and secure DCS control panel with two fasteners.
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
b.
c.
Testing.
(1)
Start generator set, paragraph 2.11.1. Operate generator set at rated voltage and frequency.
(2)
Set multimeter for AC volts, press TEST button on GROUND FAULT CIRCUIT INTERRUPTER
(32, Figure 4-13), and check for zero voltage at the CONVENIENCE RECEPTACLE (23, Figure 414) by inserting multimeter leads into one of the outlets.
(3)
Press RESET button on GROUND FAULT CIRCUIT INTERRUPTER (32, Figure 4-13), and use
multimeter to check for 120 VAC at the CONVENIENCE RECEPTACLE (23, Figure 4-14).
(4)
If indications are other than the above, replace GROUND FAULT CIRCUIT INTERRUPTER (32,
Figure 4-13).
Replacement.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable .
(3)
Remove DCS control box top panel, paragraph 4.7.2.
(4)
Tag and disconnect GROUND FAULT CIRCUIT INTERRUPTER (32, Figure 4-13) electrical
leads from TB5 and CONVENIENCE RECEPTACLE (23, Figure 4-14).
(5)
Remove nuts (30, Figure 4-13), screws (31), and GROUND FAULT CIRCUIT INTERRUPTER
(32) from DCS control panel.
(6)
Install GROUND FAULT CIRCUIT INTERRUPTER (32), screws (31), and nuts (30) on DCS
control panel.
(7)
Connect GROUND FAULT CIRCUIT INTERRUPTER (32) electrical leads to CONVENIENCE
RECEPTACLE (23, Figure 4-14) and TB5. Refer to Schematic FO-1. Remove tags.
(8)
Install DCS control box top panel, paragraph 4.7.2.
(9)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
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FIGURE 4-14. CIM AND RECEPTACLES
4.8.16
Computer Interface Module (CIM).
a.
4-100
Inspection.
(1)
Shut down Generator set, Paragraph 2.11.2
(2)
Remove DCS control box top panel, paragraph 4.7.2.
(3)
Inspect CIM (3, Figure 4-14) for cracks, corrosion, dents, or other damage.
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
(4)
b.
Install DCS control box top panel, paragraph 4.7.2.
Removal.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable .
(3)
Remove DCS control box top panel, paragraph 4.7.2.
CAUTION
CIM has two multi-pin electrical connectors. Pins can be damaged or broken if
connectors are pulled from or inserted in CIM sockets at an angle. Use care
when connecting or disconnecting wiring harnesses from CIM. Failure to
comply can cause damage to equipment and malfunction of the CIM.
NOTE
CIM has two connectors from the CIM wiring harness. The smaller connector
provides power to the CIM. The large connector is for data exchange. Both
connectors are secured in place with fasteners.
(4)
Loosen two screws, and disconnect power connector (25, fig 4-14) from CIM.
(5)
Loosen two thumbscrews, and disconnect data connector (24) from CIM.
CAUTION
CIM is mounted in DCS control panel frame suspended by mounting
hardware. If mounting hardware is removed without support being provided
for the CIM, the CIM and frame may be damaged. Have an assistant support
CIM during removal. Failure to comply can cause damage to equipment.
c.
(6)
While providing adequate support for CIM, remove bolts (2) and CIM (3) from DCS control panel
frame (4).
(7)
If necessary, drill out rivet nuts (1) from DCS control panel frame.
Installation.
(1)
If removed, install rivet nuts (1, Figure 4-14) with rivet gun.
CAUTION
CIM mounts in DCS control panel frame suspended by mounting hardware.
Have an assistant support the CIM during installation. Failure to comply can
cause damage to equipment.
(2)
While providing adequate support, install CIM (3, Figure 4-14) and bolts (2) on DCS control panel
frame (4).
(3)
Connect data connector (24) to CIM (3). Tighten two thumbscrews.
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4.8.17
(4)
Connect power connection to CIM (3). Tighten two screws.
(5)
Install DCS control box top panel, paragraph 4.7.2.
(6)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
Keypad Assembly KP.
CAUTION
Electronic components containing printed circuit boards are extremely
sensitive to electrostatic discharge (ESD). Wear an ESD wrist strap connected
to ground whenever coming in contact with ESD-sensitive components. Failure
to comply can cause severe damage to equipment.
a.
b.
Inspection.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Remove DCS control box top panel, paragraph 4.7.2.
(3)
Attach ESD wrist strap and connect to ground.
(4)
Inspect keypad assembly (7, Figure 4-14) for sticking or non-responsive buttons, corrosion, loose
and damaged wires or other damage.
(5)
Disconnect ESD wrist strap from ground, and remove wrist strap.
(6)
Install DCS control box top panel, paragraph 4.7.2.
Replacement.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Remove DCS control box top panel, paragraph 4.7.2.
(4)
Remove CIM. Refer to Paragraph 4.8.16.
(5)
Attach ESD wrist strap and connect to ground.
CAUTION
Keypad assembly has two electrical connectors. Pins can be damaged or
broken if connectors are pulled from or inserted at an angle. Use care when
connecting or disconnecting wiring harnesses from keypad assembly. Failure
to comply can cause damage to equipment.
NOTE
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Keypad assembly has two electrical connectors. One multi-pin serial connector on a
wire harness from the keypad provides data exchange and connects to the CIM
wiring harness. One single-contact push-on connector on the DCS wiring harness
provides power and connects directly to the keypad assembly.
4.8.18
(6)
Remove two ground straps from keypad assembly (7, Figure 4-14). Tag and disconnect keypad
wires from PS-1, terminals 1 and 2. Refer to Schematic FO-1.
(7)
Disconnect data exchange connector P26 from J26.
(8)
Remove locknuts (5), bolts (6), and keypad assembly (7) from DCS control panel frame (4).
(9)
Install keypad assembly (7), bolts (6), and locknuts (5) on DCS control panel frame (4).
(10)
Connect data exchange connector P26 to J26.
(11)
Connect keypad wires to PS-1 terminals 1 and 2. Remove tags.
(12)
Disconnect ESD wrist strap from ground, and remove wrist strap.
(13)
Install DCS control box top panel, paragraph 4.7.2.
(14)
Install CIM. Refer to Paragraph 4.8.16.
(15)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
COMMUNICATION RECEPTACLE.
a.
b.
Inspection.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Remove DCS control box top panel, paragraph 4.7.2.
(3)
Inspect COMMUNICATION RECEPTACLE (11, Figure 4-14) for cracks, corrosion, stripped or
damaged threads, evidence of shorting, and other damage.
(4)
Inspect cap (10) for cracks, corrosion, and broken chain.
(5)
Inspect gasket (12) for tears and deterioration.
(6)
Replace defective parts.
(7)
Install control box top panel, paragraph 4.7.2.
Replacement.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Remove DCS control box top panel, paragraph 4.7.2.
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4.8.19
Tag and desolder electrical leads from COMMUNICATION RECEPTACLE (11, Figure 4-14) and
groundwire. Refer to Schematic FO-1.
(5)
Remove locknuts (8), screws (9), cap (10), COMMUNICATION RECEPTACLE (11), and gasket
(12) from DCS control panel frame (4).
(6)
Install gasket (12), COMMUNICATION RECEPTACLE (11), cap (10), screws (9), and locknuts
(8) on DCS control panel frame (4).
(7)
Solder electrical leads to COMMUNICATION RECEPTACLE (11) and connect ground wire.
Refer to Schematic FO-1. Remove tags.
(8)
Install control box top panel, paragraph 4.7.2.
(9)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
PARALLELING RECEPTACLE J2.
a.
b.
4-104
(4)
Inspection.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Remove DCS control box top panel, paragraph 4.7.2.
(3)
Inspect PARALLELING RECEPTACLE (16, Figure 4-14) for cracks, corrosion, stripped or
damaged threads, evidence of shorting, and other damage.
(4)
Inspect cap (15) for cracks, corrosion, and broken chain.
(5)
Inspect gasket (17) for tears and deterioration.
(6)
Replace defective parts.
(7)
Install control box top panel, paragraph 4.7.2.
Replacement.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Remove DCS control box top panel, paragraph 4.7.2.
(4)
Tag and disconnect electrical leads from PARALLELING RECEPTACLE (16, Figure 4-14) by
inserting removal tool (Appendix B, Section III) into pins of connector.
(5)
Remove locknuts (13), screws (14), cap (15), PARALLELING RECEPTACLE (16), and gasket
(17) from DCS control panel frame (4).
(6)
Install gasket (17), PARALLELING RECEPTACLE (16), cap (15), screws (14), and locknuts (13)
on DCS control panel frame (4).
(7)
Connect electrical leads to PARALLELING RECEPTACLE (16) using insertion tool (Appendix B,
Section III). Remove tags.
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
4.8.20
(8)
Install control box top panel, paragraph 4.7.2.
(9)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
CONVENIENCE RECEPTACLE J1.
a.
b.
c.
Inspection.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Remove DCS control box top panel, paragraph 4.7.2.
(3)
Inspect CONVENIENCE RECEPTACLE (23, Figure 4-14) for cracks, breaks, corrosion, bent
terminals, and other indications of damage.
(4)
Inspect cover (20) for cracks, corrosion, and damaged springs.
(5)
Replace defective parts.
(6)
Install DCS control box top panel, paragraph 4.7.2.
Testing.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Remove DCS control box top panel, paragraph 4.7.2.
(3)
Remove locknuts (18, Figure 4-14), screws (19), and cover (20) from DCS control panel frame (4).
(4)
Remove locknuts (21), screws (22), and CONVENIENCE RECEPTACLE (23) from DCS control
panel frame (4).
(5)
Tag and disconnect electrical leads from CONVENIENCE RECEPTACLE (23).
(6)
Set multimeter for ohms, and check for continuity between upper side terminals and lower side
terminals of each plug outlet.
(7)
Replace CONVENIENCE RECEPTACLE if continuity is not indicated between terminals.
(8)
Connect electrical leads to CONVENIENCE RECEPTACLE (23), and remove tags.
(9)
Install DCS control box top panel, paragraph 4.7.2.
Replacement.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Remove DCS control box top panel, paragraph 4.7.2.
(4)
Remove locknuts (18, Figure 4-14), screws (19), and cover (20) from DCS control panel frame (4).
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4.8.21
(5)
Remove locknuts (21), screws (22), and CONVENIENCE RECEPTACLE (23) from DCS control
panel frame (4).
(6)
Tag and disconnect electrical leads from CONVENIENCE RECEPTACLE (23).
(7)
Connect electrical leads to CONVENIENCE RECEPTACLE (23). Remove tags.
(8)
Install CONVENIENCE RECEPTACLE (23), screws (22), and locknuts (21) on DCS control panel
frame (4).
(9)
Install cover (20), screws (19), and locknuts (18) on DCS control panel frame (4).
(10)
Install DCS control box top panel, paragraph 4.7.2.
(11)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
DCS Load Sharing Synchronizer A2.
CAUTION
Electronic components containing printed circuit boards are extremely
sensitive to electrostatic discharge (ESD). Wear an ESD wrist strap connected
to ground whenever coming in contact with ESD-sensitive components. Failure
to comply can cause severe damage to equipment.
a.
b.
4-106
Inspection.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Remove DCS control box top panel, paragraph 4.7.2.
(3)
Attach ESD wrist strap and connect to ground.
(4)
Inspect DCS load sharing synchronizer (5, Figure 4-15) for loose or missing mounting hardware and
any obvious damage.
(5)
Disconnect ESD wrist strap, and remove wrist strap.
(6)
Install DCS control box top panel, paragraph 4.7.2.
Testing.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Connect negative battery cable to battery and close battery access door.
(3)
Start generator set, paragraph 2.11.1.
(4)
Close contactor. Ensure the CONTACT POSITION status indicator on CIM reads CLOSED. On
load sharing synchronizer (5, Figure 4-15) check that PARALLEL ENABLE LED is lit. If
PARALLEL ENABLE LED is not lit, replace load sharing synchronizer.
(5)
Set multimeter to VDC. Connect positive lead to P24-11 and negative lead to P24-10. Refer to
Schematic FO-1.
ARMY TM 9-6115-671-14
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MARINE CORPS TM 09249A/09246A-14
c.
(6)
Multimeter reading at 100% load should be 6 VDC. If not, replace load sharing synchronizer (5).
(7)
Disconnect multimeter leads from P24-11 and P24-10.
(8)
Shut down generator set, paragraph 2.11.2.
(9)
Install DCS control box top panel, paragraph 4.7.2.
Removal.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable .
(3)
Remove DCS control box top panel, paragraph 4.7.2.
(4)
Attach ESD wrist strap and connect to ground.
(5)
Remove locknuts (1, Figure 4-15), screws (3), washers (2), and lockwashers (4) securing DCS load
sharing synchronizer (5) to DCS control box rear panel.
CAUTION
DCS load sharing synchronizer is connected to backplane module by a multipin electrical connector. Use care to pull DCS load sharing synchronizer
straight out from backplane module to avoid damage to electrical connector.
Failure to comply can cause damage to equipment.
(6)
Carefully remove DCS load sharing synchronizer (5) from backplane module (20) by pulling
straight out.
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FIGURE 4-15. DCS CONTROL BOX BACK PANEL COMPONENTS
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d.
Installation.
CAUTION
DCS load sharing synchronizer is connected to backplane module by a multipin electrical connector. Use care to push DCS load sharing synchronizer
straight onto backplane module to avoid damage to electrical connector.
Failure to comply can cause damage to equipment.
4.8.22
(1)
Carefully align DCS load sharing synchronizer (5, Figure 4-15) with electrical connector on
backplane module (20), and press module connector into backplane connector.
(2)
Secure DCS load sharing synchronizer (5) to DCS control box rear panel and backplane module
(20) with lockwashers (4), washers (2), screws (3), and locknuts (1).
(3)
Disconnect ESD wrist strap, and remove wrist strap.
(4)
Install DCS control box top panel, paragraph 4.7.2.
(5)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
DCS Speed Control Unit A3.
CAUTION
Electronic components containing printed circuit boards are extremely
sensitive to electrostatic discharge (ESD). Wear an ESD wrist strap connected
to ground whenever coming in contact with ESD-sensitive components. Failure
to comply can cause severe damage to equipment.
a.
b.
Inspection.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Remove DCS control box top panel, paragraph 4.7.2.
(3)
Attach ESD wrist strap and connect to ground.
(4)
Inspect DCS speed control unit (8, Figure 4-15) for loose or missing mounting hardware and any
obvious damage.
(5)
Disconnect ESD wrist strap, and remove wrist strap.
(6)
Install DCS control box top panel, paragraph 4.7.2.
Testing.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Remove DCS control box top panel, paragraph 4.7.2.
(3)
Start generator set, paragraph 2.11.1.
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c.
(4)
Ensure the CONTACT POSITION status indicator reads CLOSED. Check that PARALLEL
ENABLE LED is lit. If PARALLEL ENABLE LED is not lit, replace load sharing synchronizer.
(5)
Set multimeter to VDC. Connect positive lead to P24-11 and negative lead to P24-10.
(6)
Multimeter reading at 100% load should be 6 VDC. If not, replace load sharing synchronizer (5,
Figure 4-15).
(7)
Disconnect multimeter leads from P24-11 and P24-10.
(8)
Shut down generator set, paragraph 2.11.2.
(9)
Install DCS control box top panel, paragraph 4.7.2.
Removal.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Remove DCS control box top panel, paragraph 4.7.2.
(4)
Attach ESD wrist strap and connect to ground.
(5)
Remove locknuts (6, Figure 4-15) and washers (7) securing DCS speed control unit (8) to backplane
module (20).
CAUTION
DCS speed control unit is connected to backplane module by a multi-pin
electrical connector. Use care to pull DCS speed control unit straight out from
backplane module to avoid damage to electrical connector. Failure to comply
can cause damage to equipment.
(6)
d.
Carefully remove DCS speed control unit (8) from backplane module (20) by pulling straight out.
Installation.
CAUTION
DCS load sharing synchronizer is connected to backplane module by a multipin electrical connector. Use care to push DCS load sharing synchronizer
straight onto backplane module to avoid damage to electrical connector.
Failure to comply can cause damage to equipment.
4-110
(1)
Carefully align DCS speed control unit (8, Figure 4-15) with electrical connector on backplane
module (20), and press module connector into backplane connector.
(2)
Secure DCS speed control unit (8) to backplane module (20) with washers (7) and locknuts (6).
(3)
Disconnect ESD wrist strap, and remove wrist strap.
(4)
Install DCS control box top panel, paragraph 4.7.2.
(5)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
4.8.23
Automatic Voltage Regulator A4.
CAUTION
Electronic components containing printed circuit boards are extremely
sensitive to electrostatic discharge (ESD). Wear an ESD wrist strap connected
to ground whenever coming in contact with ESD-sensitive components. Failure
to comply can cause severe damage to equipment.
a.
b.
Inspection.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Remove DCS control box top panel, paragraph 4.7.2.
(3)
Attach ESD wrist strap and connect to ground.
(4)
Inspect automatic voltage regulator (11, Figure 4-15) for loose or missing mounting hardware and
any obvious damage.
(5)
Disconnect ESD wrist strap, and remove wrist strap.
(6)
Install DCS control box top panel, paragraph 4.7.2.
Testing.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Remove DCS control box top panel, paragraph 4.7.2.
(3)
Attach ESD wrist strap and connect to ground.
(4)
Set multimeter to ohms, and connect leads to P9-5 and P9-6. Refer to Wiring Diagram FO-3.
(5)
Measure resistance between P9-5 and P9-6. If resistance is other than 28±3 ohms, test back plane
module, paragraph 4.7.24.
(6)
Disconnect multimeter leads from P9-5 and P9-6.
(7)
Set multimeter to VDC. Connect positive lead to P9-5 and negative lead to P9-6.
(8)
Disconnect ESD wrist strap, and remove wrist strap.
(9)
Hold ENGINE CONTROL switch in START position and start generator set. Record VDC
reading. Reading should be approximately 8 VDC. If not, test the field flash relay K23 using the
procedure described in paragraph 4.8.34.
(10)
Release ENGINE CONTROL switch, and disconnect multimeter leads from P9-5 and P9-6.
(11)
Connect positive multimeter lead to J24-1 and negative lead to P24-2. If reading is above 20 VDC,
replace automatic voltage regulator (11).
(12)
Disconnect multimeter leads from P24-1 and P24-2.
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c.
(13)
Check DC SUPPLY, AC SENSING, and FIELD VOLTAGE LEDs on automatic voltage regulator
(11, Figure 4-15). If LEDs are not lit, test backplane module, paragraph 4.8.24.
(14)
If measurement recorded in step (9) is above 15 VDC and LEDs checked in step (11) are lit,
automatic voltage regulator (11) is okay.
(15)
Shut down generator set, paragraph 2.11.2.
(16)
Install DCS control box top panel, paragraph 4.7.2.
Removal.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Remove DCS control box top panel, paragraph 4.7.2.
(4)
Remove CIM. See paragraph 4.8.16.
(5)
Attach ESD wrist strap and connect to ground.
(6)
Remove P24 and P9. Refer to Schematic FO-1.
(7)
Remove locknuts (9, Figure 4-15) and washers (10) securing automatic voltage regulator (11) to
backplane module (20).
(8)
Disconnect leads from R16 and R17.
CAUTION
Automatic voltage regulator is connected to backplane module by a multi-pin
electrical connector. Use care to pull automatic voltage regulator straight out
from backplane module to avoid damage to electrical connector. Failure to
comply can cause damage to equipment.
(9)
d.
4-112
Carefully remove automatic voltage regulator (11) from backplane module (20) by pulling straight
out.
Installation.
(1)
Carefully align automatic voltage regulator (11, Figure 4-15) with electrical connector on backplane
module (20), and press module connector into backplane connector.
(2)
Secure automatic voltage regulator (11) to backplane module (20) with washers (10) and locknuts
(9).
(3)
Connect leads to R16 and R17.
(4)
Disconnect ESD wrist strap, and remove wrist strap.
(5)
Install DCS control box top panel, paragraph 4.7.2.
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
(6)
4.8.24
Connect negative battery cable to battery, and close BATTERY ACCESS door.
Backplane Module A1.
CAUTION
Electronic components containing printed circuit boards are extremely
sensitive to electrostatic discharge (ESD). Wear an ESD wrist strap connected
to ground whenever coming in contact with ESD-sensitive components. Failure
to comply can cause severe damage to equipment.
a.
b.
Inspection.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Remove DCS control box top panel, paragraph 4.7.2.
(3)
Remove DCS load sharing synchronizer, paragraph 4.8.21.
(4)
Remove DCS speed control unit, paragraph 4.8.22.
(5)
Remove automatic voltage regulator, paragraph 4.8.23.
(6)
Inspect backplane module (20, Figure 4-15) for damaged or missing connectors and components.
(7)
Install automatic voltage regulator, paragraph 4.8.23.
(8)
Install DCS speed control unit, paragraph 4.8.22.
(9)
Install DCS load sharing synchronizer, paragraph 4.8.21.
(10)
Install DCS control box top panel, paragraph 4.7.2.
Testing.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Remove DCS control box top panel, paragraph 4.7.2.
(3)
Attach ESD wrist strap and connect to ground.
(4)
Set multimeter to VDC. Connect positive lead to P24-6 and negative lead to P24-7. Refer to
Wiring Diagram FO-3.
(5)
Ensure MASTER CONTROL switch is set to ON. Record VDC reading.
(6)
If reading in step (5) is not approximately 24 VDC, connect positive multimeter lead to P5-R and
negative lead to P5-c. Record VDC reading. Refer to Schematic FO-1.
(7)
If reading is step (6) is 24 VDC, test DCS control box wiring harness, paragraph 4.8.41.
(8)
Start generator set, paragraph 2.11.1.
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NOTE
Polarity of signal between J9-8 and J9-11 must be correct. Check wiring polarity at
current transformer in output box prior to test.
(9)
Start generator set, paragraph 2.11.1.
NOTE
Polarity of signal between P9-8 and P9-11 must be correct. Check wiring polarity at
current transformer in output box prior to test. Refer to Schematic FO-1.
c.
(10)
Connect multimeter leads to P24-5 and P9-8. At full load, reading should be approximately 4 VAC.
At no load, the reading should be approximately 0 VAC. If either of these readings are different,
replace backplane module (20).
(11)
Disconnect multimeter leads from P24-5 and P9-8.
(12)
Shut down generator set, paragraph 2.11.2.
(13)
Install DCS control box top panel, paragraph 4.7.2.
Replacement.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Remove DCS control box top panel, paragraph 4.7.2.
(3)
Remove DCS load sharing synchronizer, paragraph 4.8.21.
(4)
Remove DCS speed control unit, paragraph 4.8.22.
(5)
Remove automatic voltage regulator, paragraph 4.8.23.
(6)
Disconnect wiring harness connectors (12).
(7)
Remove screws (13), lockwashers (14), and washers (15) securing backplane connectors (16) to
DCS control box rear panel.
CAUTION
Backplane module is connected to the CIM wiring harness by multi-pin
electrical connectors. Use care when disconnecting and connecting the wiring
harness to the backplane module. Failure to comply can cause damage to
equipment.
4-114
(8)
Disconnect P23 ribbon cable assembly (17) and P8 ribbon cable assembly (33) from backplane
module (20).
(9)
Tag and disconnect electrical leads from A1-TB1. Refer to Wiring Diagram FO-1.
(10)
Remove locknuts (18), washers (19), backplane module (20), and standoffs (21) from DCS control
box rear panel.
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
4.8.25
(11)
Install standoffs (21), backplane module (20), washers (19), and locknuts (18) on DCS control box
rear panel.
(12)
Connect P23 (17) and P8 (33) ribbon cable assemblies to backplane module (20).
(13)
Secure backplane connectors (16) to DCS control box rear panel with washers (15), lockwashers
(14), and screws (13).
(14)
Connect wiring harness connectors (12).
(15)
Install automatic voltage regulator, paragraph 4.8.23.
(16)
Install DCS speed control unit, paragraph 4.8.22.
(17)
Install DCS load sharing synchronizer, paragraph 4.8.21.
(18)
Install DCS control box top panel, paragraph 4.7.2.
I/O Interface Module A5.
CAUTION
Electronic components containing printed circuit boards are extremely
sensitive to electrostatic discharge (ESD). Wear an ESD wrist strap connected
to ground whenever coming in contact with ESD-sensitive components. Failure
to comply can cause severe damage to equipment.
a.
Inspection
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Remove DCS control box top panel, paragraph 4.7.2.
(3)
Attach ESD wrist strap and connect to ground.
(4)
Inspect I/O interface module (25, Figure 4-15) for damaged or missing connectors and components.
(5)
Disconnect ESD wrist strap, and remove wrist strap.
(6)
Install DCS control box top panel, paragraph 4.7.2.
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b.
Testing
NOTE
There is no indication that the I/O Module has failed in its installed location, other
than the “HEARTBEAT” indicator (36) Figure 2-3, is off when DC Power is
applied to the Module, or the indicator remains continuously on at any time.
(1) The heartbeat Indicator (36) Figure 2-3, is normally “ON” blinking when DC power is applied to the
module. It is also normally “ON” blinking when the Generator set is operating (engine is running )
and the I/O Module is functioning properly. If the indicator is either steady state ON or steady state
OFF, with the CIM on and the engine running, this indicates there is a problem in the I/O module, and
it should be replaced.
c.
Replacement
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable .
(3)
Remove DCS control box top panel, paragraph 4.7.2.
(4)
Remove CIM. See paragraph 4.8.16.
(5)
Attach ESD wrist strap and connect to ground.
CAUTION
I/O interface module is connected to the CIM and DCS wiring harnesses
module by multi-pin electrical connectors. Use care when disconnecting and
connecting the wiring harness to the I/O interface module. Failure to comply
can cause damage to equipment.
4-116
(6)
Tag and disconnect electrical connectors P20, P21, P17 and P25. Refer to Schematic FO-1.
(7)
Disconnect ribbon cable assemblies P23 (17) and P8 (33) from I/O interface module (25).
(8)
Remove screws (23), lockwashers (24), and I/O interface module (25) from DCS control box rear
panel.
(9)
Set I/O Interface Module Configuration Switch for the proper Generator Set Application. See
paragraph 4.16.
(10)
Install I/O interface module (25), lockwashers (24), and screws (23) on DCS control box rear panel.
(11)
Install ribbon cable assemblies P23 (17) and P8 (33), to I/O interface module (25).
(12)
Connect electrical connectors P20, P21, P17, and P25 to I/O interface module (25) and remove tags.
Refer to Schematic FO-1.
(13)
Disconnect ESD wrist strap, and remove wrist strap.
(14)
Install CIM. See paragraph 4.8.16.
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
4.8.26
(15)
Install DCS control box top panel, paragraph 4.7.2.
(16)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
DC CONTROL POWER Fuse.
a.
b.
c.
Inspection.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open DCS control panel.
(3)
Inspect DC CONTROL POWER fuseholder (3, Figure 4-16) for loose connections and mounting
hardware, cracked housing, and other damage.
(4)
Close DCS control panel.
Testing.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Release DCS Control Panel by turning two quick turn fasteners.
(3)
Remove cap (1, Figure 4-16) and fuse (2) from DC CONTROL POWER fuseholder (3) and remove
fuse from cap.
(4)
Set multimeter for ohms and connect across fuse ends. If fuse is good, multimeter will indicate
continuity.
(5)
If indications are not as above, replace fuse with one of identical size and rating.
(6)
Install good fuse (2) into cap and install cap (1) and fuse (2) into fuseholder (3).
(7)
Close DCS CONTROL PANEL and secure with two quick turn fasteners.
Replacement.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Remove DCS Control box top panel, paragraph 4.7.2
(4)
Tag and disconnect electrical leads from DC CONTROL POWER fuseholder (3, Figure 4-16).
(5)
Remove cap (1) and fuse (2) from fuseholder (3). Remove jamnut (24), which secures fuseholder to
auxiliary control bracket (18) and slide fuseholder thru auxiliary control bracket.
(6)
Install DC CONTROL POWER fuseholder (3, Figure 4-16), and secure with jamnut (24).
(7)
Connect electrical leads to DC CONTROL POWER fuseholder (3), and remove tags. Install cap (1)
and fuse (2), in fuseholder (3).
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4.8.27
Install DCS control box top panel, paragraph 4.7.2.
(9)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
FREQUENCY SELECT Switch S12.
a.
b.
4-118
(8)
Inspection.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Remove DCS control box top panel, paragraph 4.7.2.
(3)
Inspect FREQUENCY SELECT switch (6, Figure 4-16) for loose connections and mounting
hardware and other damage.
(4)
Install DCS control box top panel, paragraph 4.7.2.
Testing.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable .
(3)
Remove DCS control box top panel, paragraph 4.7.2.
(4)
Remove FREQUENCY SELECT switch. Refer to paragraph 4.8.27.c.
(5)
Set multimeter for ohms, and connect across switch terminals.
(6)
Place FREQUENCY SELECT switch (6) in UP (60 Hz) position. Multimeter should indicate
continuity.
(7)
Place FREQUENCY SELECT switch (6) in DOWN (50 Hz) position. Multimeter should indicate
open circuit.
(8)
If indications are other than above, FREQUENCY SELECT switch (6) is defective and must be
replaced.
(9)
Install FREQUENCY SELECT switch. Refer to paragraph 4.8.27.c.
(10)
Install DCS control box top panel, paragraph 4.7.2.
(11)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
FIGURE 4-16. DCS CONTROL BOX FLOOR COMPONENTS (SHEET 1 OF 2)
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FIGURE 4-16. DCS CONTROL BOX FLOOR COMPONENTS (SHEET 2 OF 2)
c.
4.8.28
4-120
Replacement.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Remove DCS control box top panel, paragraph 4.7.2.
(4)
Tag and disconnect electrical leads from FREQUENCY SELECT switch (6, Figure 4-16).
(5)
Remove jamnut (4), lockwasher (5), and FREQUENCY SELECT switch (6) from auxiliary control
bracket (18).
(6)
Install FREQUENCY SELECT switch (6, Figure 4-16), lockwasher (5), and jamnut (4) on auxiliary
control bracket (18).
(7)
Connect electrical leads to FREQUENCY SELECT switch (6), and remove tags.
(8)
Install DCS control box top panel, paragraph 4.7.2.
(9)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
REACTIVE CURRENT ADJUST Rheostat R5.
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
a.
b.
Inspection.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Remove DCS control box top panel, paragraph 4.7.2.
(3)
Inspect REACTIVE CURRENT ADJUST rheostat (8, Figure 4-16) for loose connections and
mounting hardware, and other damage.
(4)
Install DCS control box top panel, paragraph 4.7.2.
Testing.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Remove DCS control box top panel, paragraph 4.7.2.
(4)
Desolder wires 236A, 236B, and 236C. Refer to wiring diagram FO-3.
(5)
Mark reading of REACTIVE CURRENT ADJUST rheostat (8, Figure 4-16) to reposition at
conclusion of testing steps.
(6)
Set multimeter for ohms, and connect to wires 236B and 236A. Multimeter reading should be
between 4.5 and 5.5 ohms.
(7)
Connect multimeter to wires 236A and 236C, and turn REACTIVE CURRENT ADJUST rheostat
(8) to full clockwise position. Multimeter reading should be approximately 0 ohms. Turn
REACTIVE CURRENT ADJUST rheostat slowly to full counterclockwise position, and observe
multimeter. Multimeter reading should evenly increase up to between 4.5 and 5.5 ohms.
(8)
Connect multimeter to wires 236B and 236C, and turn REACTIVE CURRENT ADJUST rheostat
(8) to full clockwise position. Multimeter reading should be between 4.5 and 5.5 ohms. Turn
REACTIVE CURRENT ADJUST rheostat slowly to full counterclockwise position, and observe
multimeter. Multimeter reading should evenly decrease to approximately 0 ohms.
(9)
If multimeter readings are other than above, replace REACTIVE CURRENT ADJUST rheostat (8).
(10)
Reposition REACTIVE CURRENT ADJUST rheostat (8) as marked in step (5).
(11)
Solder wires 236A, 236B, and 236C.
(12)
Install DCS control box top panel, paragraph 4.7.2.
(13)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
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AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
c.
4.8.29
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Remove DCS control box top panel, paragraph 4.7.2.
(4)
Desolder and tag electrical leads from REACTIVE CURRENT ADJUST rheostat (8, Figure 4-16).
(5)
Mark reading of REACTIVE CURRENT ADJUST rheostat (8) to reposition at installation.
(6)
Remove nuts(7 and 45) and REACTIVE CURRENT ADJUST rheostat (8) from auxiliary control
bracket.
(7)
Reposition REACTIVE CURRENT ADJUST rheostat (8) as marked in step (5), and secure with
nuts (7and 45).
(8)
Solder electrical leads to REACTIVE CURRENT ADJUST rheostat (8). Remove tags.
(9)
Install DCS control box top panel, paragraph 4.7.2.
(10)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
Diode CR1-CR10
a.
b.
4-122
Replacement.
Inspection.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Remove DCS control box top panel, paragraph 4.7.2.
(3)
Inspect diode (9, Figure 4-16) for cracks, breaks, corrosion, bent terminals, and other damage.
(4)
Install DCS control box top panel, paragraph 4.7.2.
Testing.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable .
(3)
Remove DCS control box top panel, paragraph 4.7.2.
(4)
Tag and remove diode from circuit. Refer to Schematic FO-1.
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
(5)
Connect positive lead of multimeter to cathode side and negative lead to anode side of diode (9,
Figure 4-16). Refer to Figure 4-17. Multimeter should indicate open loop for diode.
FIGURE 4-17. DIODE IDENTIFICATION
c.
(6)
Reverse multimeter leads so positive lead is connected to anode and negative lead is connected to
cathode side of diode. Multimeter should indicate continuity for diode.
(7)
If any indications are other than above, replace diode.
(8)
Install DCS control box top panel, paragraph 4.7.2.
(9)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
Replacement.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Remove DCS control box top panel, paragraph 4.7.2.
NOTE
Soldering applies only to CR1. All other diodes are installed with screws.
(4)
For CR2-CR10, tag and remove diode from unit. Refer to Schematic FO-1.
(5)
Tag and desolder electrical leads from terminals (20, Figure 4-16).
(6)
Desolder diode (9) from terminals (20).
(7)
Solder diode (9) to terminals (20).
(8)
Solder electrical leads to terminals (20). Remove tags.
(9)
Install CR2-CR10 and remove tags. Refer to Schematic FO-1.
(10)
Install DCS control box assembly, paragraph 4.8.1.
4-123
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
(11)
4.8.30
Resistor R1.
a.
b.
c.
4-124
Connect negative battery cable to battery, and close BATTERY ACCESS door.
Inspection.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Remove DCS control box top panel, paragraph 4.7.2.
(3)
Inspect resistor (10, Figure 4-16) for cracks, breaks, corrosion, bent terminals, and other damage.
(4)
Install DCS control box top panel, paragraph 4.7.2.
Testing.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable .
(3)
Remove DCS control box top panel, paragraph 4.7.2.
(4)
Tag and remove R1 (10, Figure 4-16).
(5)
Set multimeter for ohms, and measure resistance across resistor (10). Multimeter indication should
be between 1235 and 1365 ohms.
(6)
If any indications are other than above, replace resistor.
(7)
Install R1 and remove tags.
(8)
Install DCS control box top panel, paragraph 4.7.2.
(9)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
Replacement.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable .
(3)
Remove DCS control box top panel, paragraph 4.7.2.
(4)
Tag and desolder electrical leads from resistor (10, Figure 4-16).
(5)
Remove resistor (10) from auxiliary control bracket (18).
(6)
Install resistor (10) to auxiliary control bracket (18).
(7)
Solder electrical leads to resistor (10). Remove tags.
(8)
Install DCS control box top panel, paragraph 4.7.2.
(9)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
4.8.31
Resistor R2.
a.
b.
c.
4.8.32
Inspection.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Remove DCS control box top panel, paragraph 4.7.2.
(3)
Inspect resistor (13, Figure 4-16) for cracks, breaks, corrosion, bent terminals, and other damage.
(4)
Install DCS control box top panel, paragraph 4.7.2.
Testing.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Remove DCS control box top panel, paragraph 4.7.2.
(4)
Set multimeter for ohms, and measure resistance across resistor (13, Figure 4-16). Multimeter
indication should be between 310 and 350 ohms.
(5)
If any indications are other than above, replace resistor.
(6)
Install DCS control box top panel, paragraph 4.7.2.
(7)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
Replacement.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Remove DCS control box top panel, paragraph 4.7.2.
(4)
Tag and desolder electrical leads from resistor (13, Figure 4-16).
(5)
Remove nuts (11), lockwashers (12), resistor (13), sleeving (14), screws (15), and lockwashers (16)
from auxiliary control bracket (18).
(6)
Install lockwashers (16), screws (15), sleeving (14), resistor (13), lockwashers (12), and nuts (11)
on auxiliary control bracket (18).
(7)
Solder electrical leads to resistor (13). Remove tags.
(8)
Install DCS control box top panel, paragraph 4.7.2.
(9)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
Auxiliary Control Bracket.
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MARINE CORPS TM 09249A/09246A-14
a.
Inspection.
Inspect auxiliary control bracket (18, Figure 4-16) for dents, cracks, loose paint, and corrosion.
b.
c.
Removal.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Remove DCS control box top panel, paragraph 4.7.2.
(4)
Remove auxiliary control bracket components, paragraphs 4.8.26 through 4.8.31.
(5)
Remove bolts (17, Figure 4-16) and auxiliary control bracket (18) from floor of DCS control box
assembly.
(6)
Remove screws (19) and terminals (20) from auxiliary control bracket (18).
Repair.
(1)
As necessary, remove components from auxiliary control bracket (18, Figure 4-16), paragraphs
4.8.26 through 4.8.31.
_________
WARNING
CARC paint is a health hazard. Wear protective eyewear, mask and gloves
when sanding CARC painted surfaces. Failure to comply can cause personal
injury.
d.
4.8.33
Repair all dents and cracks, and remove loose paint.
(3)
Remove light corrosion with fine grit abrasive paper (Item 16, Appendix E).
(4)
Repaint surfaces in accordance with TM 43-0139.
(5)
Install components removed in step (1), paragraphs 4.8.26 through 4.8.31.
Installation.
(1)
Install terminals (20, Figure 4-16) and screws (19) on auxiliary control bracket (18).
(2)
Install auxiliary control bracket (18) and bolts (17) on floor of DCS control box assembly.
(3)
Install auxiliary control bracket components, paragraphs 4.8.26 through 4.8.31.
(4)
Install DCS control box top panel, paragraph 4.7.2.
(5)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
VOLTAGE SELECTION Switch S20.
a.
4-126
(2)
Inspection.
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
b.
c.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Remove DCS control box top panel, paragraph 4.7.2.
(3)
Inspect VOLTAGE SELECTION switch (23, Figure 4-16) for loose connections and mounting
hardware and other damage.
(4)
Install DCS control box top panel, paragraph 4.7.2.
Testing.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Remove DCS control box top panel, paragraph 4.7.2.
(4)
Remove jamnut (21), lockwasher (22), and VOLTAGE SELECTION switch (23) from bracket (18).
(5)
Tag and disconnect electrical leads from VOLTAGE SELECTION switch (23, Figure 4-16).
(6)
Set multimeter for ohms, and connect across switch terminals.
(7)
Place VOLTAGE SELECTION switch (23) in UP position. Multimeter should indicate continuity.
(8)
Place VOLTAGE SELECTION switch (23) in DOWN position. Multimeter should indicate open
loop.
(9)
If indications are other than above, VOLTAGE SELECTION switch (23) is defective and must be
replaced.
(10)
Connect electrical leads to VOLTAGE SELECTION switch (23).
(11)
Install VOLTAGE SELECTION switch (23, Figure 4-16), lockwasher (22), and jamnut (21) on
bracket (18).
(12)
Install DCS control box top panel, paragraph 4.7.2.
(13)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
Replacement.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Remove DCS control box top panel, paragraph 4.7.2.
(4)
Tag and disconnect electrical leads from VOLTAGE SELECTION switch (23, Figure 4-16).
(5)
Remove jamnut (21), lockwasher (22), and VOLTAGE SELECTION switch (23) from bracket (18).
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MARINE CORPS TM 09249A/09246A-14
4.8.34
(6)
Install VOLTAGE SELECTION switch (23, Figure 4-16), lockwasher (22), and jamnut (21) on
bracket (18).
(7)
Connect electrical leads to VOLTAGE SELECTION switch (23), and remove tags.
(8)
Install DCS control box top panel, paragraph 4.7.2.
(9)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
Relays K15, K17, K19, K22, K23.
a.
b.
c.
d.
Inspection.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Remove DCS control box top panel, paragraph 4.7.2.
(3)
Inspect relay (Figure 4-16) for cracks, loose mounting, and other damage.
(4)
Install DCS control box top panel, paragraph 4.7.2.
Removal.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Remove DCS control box top panel, paragraph 4.7.2.
(4)
Release wire clip (26, Figure 4-16), and remove relay from socket.
Testing.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Remove relay K15, see paragraph 4.8.34.b.
(3)
Set multimeter for ohms, and check for open circuits between terminals 7 and 4, 8 and 5, and 9 and
6. Check for closed circuits between terminals 7 and 1, 8 and 2, and 9 and 3.
(4)
Connect multimeter between terminals A and B, and check for indication of 427.5 to 522.5 ohms.
(5)
Apply battery voltage across terminals A and B. Using multimeter, check for open circuits between
terminals 7 and 1, 8 and 2, and 9 and 3. Check for closed circuits between terminals 7 and 4, 8 and
5, and 9 and 6. Refer to Wiring Diagram FO-3.
(6)
If indications are other than above, relay is defective and must be replaced.
(7)
Install relay, see paragraph 4.8.34.d.
Installation.
(1)
4-128
Install relay (Figure 4-16) in socket, and secure with wire clip (26).
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
4.8.35
(2)
Install DCS control box top panel, paragraph 4.7.2.
(3)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
Resistors R16 and R17.
a.
b.
c.
Inspection.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Remove DCS control box top panel, paragraph 4.7.2.
(3)
Inspect resistors (35 and 36, Figure 4-16) for cracks, loose mounting, and other damage.
(4)
Install DCS control box top panel, paragraph 4.7.2.
Testing.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Remove DCS control box top panel, paragraph 4.7.2.
(4)
Set multimeter for ohms, and measure resistance across resistor R16 (35). Multimeter indication
should be 50 ohms.
(5)
Set multimeter for ohms, and measure resistance across resistor R17 (36). Multimeter indication
should be 50 ohms.
(6)
If indications are other than above, one or both resistors is defective and must be replaced.
(7)
Install DCS control box top panel, paragraph 4.7.2.
(8)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
Replacement.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Remove DCS control box top panel, paragraph 4.7.2.
(4)
Remove CIM control box assembly, paragraph 4.8.16.
(5)
Remove air baffle. Refer to paragraph 4.8.41.
(6)
Tag and desolder electrical leads from resistors (35 and 36, Figure 4-16).
(7)
Remove nuts (32), lockwashers (33), screws (34) and resistors (35 and 36) from air baffle (30,
Figure 4-18) of DCS control box assembly.
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MARINE CORPS TM 09249A/09246A-14
4.8.36
Install resistors (36 and 35, Figure 4-16), screws (34), lockwashers (33), and nuts (32) on air baffle
(30, Figure 4-18) of DCS control box assembly.
(9)
Solder electrical leads to resistors (36 and 35, Figure 4-16). Remove tags.
(10)
Install air baffle, refer to paragraph 4.8.41.
(11)
Install CIM, refer to paragraph 4.8.16.
(12)
Install DCS control box top panel, paragraph 4.7.2.
(13)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
Resistor R6.
a.
b.
4-130
(8)
Inspection.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Remove DCS control box top panel, paragraph 4.7.2.
(3)
Inspect resistor (41, Figure 4-16) for cracks, breaks, corrosion, bent terminals, and other damage.
(4)
Install DCS control box top panel, paragraph 4.7.2.
Testing.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Remove DCS control box top panel, paragraph 4.7.2.
(4)
Set multimeter for ohms, and measure resistance across resistor (41, Figure 4-16). Multimeter
indication should be 40 ohms.
(5)
If any indications are other than above, replace resistor.
(6)
Install DCS control box top panel, paragraph 4.7.2.
(7)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
c.
4.8.37
Replacement.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Remove DCS control box top panel, paragraph 4.7.2.
(4)
Tag and desolder electrical leads from resistor (41, Figure 4-16).
(5)
Open output box access door (Figure 1-2) to access nuts (37).
(6)
Remove nuts (37), lockwashers (38), screws (39), lockwashers (40), resistor (41), and sleeving (42)
from floor of DCS control box assembly.
(7)
Install sleeving (42), resistor (41), lockwashers (40), screws (39), lockwashers (38), and nuts (37)
on floor of DCS control box assembly.
(8)
Close output box access door.
(9)
Solder electrical leads on resistor (41). Remove tags.
(10)
Install DCS control box top panel, paragraph 4.7.2.
(11)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
DCS Control Box Wiring Harness.
CAUTION
Electronic components containing printed circuit boards are extremely
sensitive to electrostatic discharge (ESD). Wear an ESD wrist strap connected
to ground whenever coming in contact with ESD-sensitive components. Failure
to comply can cause severe damage to equipment.
a.
b.
Inspection.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Remove DCS control box top panel, paragraph 4.7.2.
(3)
Attach ESD wrist strap and connect to ground.
(4)
Inspect DCS wiring harness (43, Figure 4-16) for burned, bent, corroded, and broken terminals.
(5)
Inspect connectors for cracks, corrosion, stripped threads, bent or broken pins, and obvious damage.
(6)
Inspect wire insulation for burns, deterioration, and chafing.
(7)
Disconnect ESD wrist strap, and remove wrist strap.
(8)
Install DCS control box top panel, paragraph 4.7.2.
Testing.
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MARINE CORPS TM 09249A/09246A-14
c.
4.8.38
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Remove DCS control box top panel, paragraph 4.7.2.
(4)
Attach ESD wrist strap and connect to ground.
(5)
Set multimeter for ohms, and test individual wires of DCS wiring harness (43, Figure 4-16) for
continuity. Refer to wiring diagram, FO-3, for wire identification. If continuity is not found,
perform step c below to repair wiring harness. Notify higher level of maintenance if it is necessary
to replace wiring harness.
(6)
Disconnect ESD wrist strap, and remove wrist strap.
(7)
Install DCS control box top panel, paragraph 4.7.2.
(8)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
Repair.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Remove DCS control box top panel, paragraph 4.7.2.
(4)
Attach ESD wrist strap and connect to ground.
(5)
Replace damaged terminals, wires, and securing hardware on DCS wiring harness (43, Figure 4-16).
Refer to Schematic, FO-3.
(6)
Disconnect ESD wrist strap, and remove wrist strap.
(7)
Install DCS control box top panel, paragraph 4.7.2.
(8)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
CIM Wiring Harness.
CAUTION
Electronic components containing printed circuit boards are extremely
sensitive to electrostatic discharge (ESD). Wear an ESD wrist strap connected
to ground whenever coming in contact with ESD-sensitive components. Failure
to comply can cause severe damage to equipment.
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MARINE CORPS TM 09249A/09246A-14
a.
b.
Inspection.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Remove DCS control box top panel, paragraph 4.7.2.
(3)
Attach ESD wrist strap and connect to ground.
(4)
Inspect connectors on CIM wiring harness (44, Figure 4-16) for cracks, corrosion, bent or broken
pins, and obvious damage.
(5)
Inspect ribbon cable insulation for burns, deterioration, chafing, and splitting.
(6)
Disconnect ESD wrist strap, and remove wrist strap.
(7)
Install DCS control box top panel, paragraph 4.7.2.
Removal.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Remove DCS control box top panel, paragraph 4.7.2.
(4)
Remove CIM. Refer to paragraph 4.8.16.
(5)
Attach ESD wrist strap and connect to ground.
CAUTION
CIM wiring harness has multi-pin electrical connectors. Pins can be damaged
or broken if connectors are pulled from or inserted into sockets at an angle.
Use care when connecting or disconnecting wiring harness to components.
Failure to comply can cause damage to equipment and malfunction of the CIM.
(6)
c.
Carefully disconnect CIM wiring harness connectors from components, and remove CIM wiring
harness (44, Figure 4-16) from DCS control box assembly.
Testing.
(1)
Remove CIM wiring harness, 4.8.38. b. Leave ESD wrist strap on.
(2)
Set multimeter for ohms, and test individual wires of CIM wiring harness (44, Figure 4-16) for
continuity by testing pin-to-pin at wiring harness connectors. Refer to Wire Harness FO-7. If
continuity is not indicated, replace wiring harness.
(3)
Install CIM wiring harness, 4.8.38.d.
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MARINE CORPS TM 09249A/09246A-14
d.
Installation.
CAUTION
CIM wiring harness has multi-pin electrical connectors. Pins can be damaged
or broken if connectors are pulled from or inserted into sockets at an angle.
Use care when connecting or disconnecting wiring harness to components.
Failure to comply can cause damage to equipment and malfunction of the CIM.
4.8.39
(1)
Position CIM wiring harness (44, Figure 4-16) in DCS control box assembly. Carefully connect
wiring harness connectors to components.
(2)
Disconnect ESD wrist strap, and remove wrist strap.
(3)
Install CIM, refer to paragraph 4.8.16.
(4)
Install DCS control box top panel, paragraph 4.7.2.
(5)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
DCS Control Panel Assembly.
a.
b.
Removal.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Release DCS control panel by turning two fasteners, and lower panel.
(4)
Remove components from DCS control panel assembly (6, Figure 4-18). Refer to paragraphs 4.8.2
through 4.8.15.
(5)
Remove locknut (1), screw (2), and panel holder (3) from DCS control panel assembly (6 ).
Remove hook on panel holder from hole in DCS control panel frame (14).
(6)
Remove locknuts (4), bolts (5), and DCS control panel assembly (6) from hinge (9).
(7)
Remove locknuts (7), bolts (8), and hinge (9) from DCS control panel frame (14).
Inspection.
Inspect DCS control panel assembly (6, Figure 4-18) for dents, cracks, loose paint, and corrosion.
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c.
Repair.
(1)
As necessary, remove components from DCS control panel assembly (6), paragraphs 4.8.2 through
4.8.15.
_________
WARNING
CARC paint is a health hazard. Wear protective eyewear, mask and gloves
when sanding CARC painted surfaces. Failure to comply can cause personal
injury.
d.
4.8.40
(2)
Repair all dents and cracks, and remove loose paint.
(3)
Remove light corrosion with fine grit abrasive paper (Item 16, Appendix E).
(4)
Repaint surfaces in accordance with TM 43-0139.
(5)
Install components removed in step (1), paragraphs 4.8.2 through 4.8.15.
Installation.
(1)
Install hinge (9, Figure 4-18), bolts (8), and locknuts (7) on DCS control panel frame (14).
(2)
Install DCS control panel assembly (6), bolts (5), and locknuts (4) on hinge (9).
(3)
Install hook on panel holder (3) in hole in DCS control panel frame (14). Install panel holder (3),
screw (2), and locknut (1) on DCS control panel assembly (6).
(4)
Install components, paragraphs 4.8.2 through 4.8.15.
(5)
Raise and secure DCS control panel.
(6)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
DCS Control Panel Frame.
a.
Inspection.
Inspect DCS control panel frame (14, Figure 4-18) for dents, cracks, loose paint, and corrosion.
b.
Removal.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Remove DCS control box assembly, paragraph 4.8.1.
(4)
Remove CIM, paragraph 4.8.16.
(5)
Remove keypad assembly, paragraph 4.8.17.
(6)
Remove DCS control panel assembly, paragraph 4.8.39.
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c.
(7)
Remove COMMUNICATION RECEPTACLE, paragraph 4.8.18. Do not disconnect electrical
leads from COMMUNICATION RECEPTACLE.
(8)
Remove PARALLELING RECEPTACLE, paragraph 4.8.19. Do not disconnect electrical leads
from PARALLELING RECEPTACLE.
(9)
Remove CONVENIENCE RECEPTACLE, paragraph 4.8.20.
(10)
Remove locknuts (10 and 12, Figure 4-18), bolts (11 and 13), and DCS control panel frame (14)
from DCS control box assembly (Figure 4-10).
(11)
If necessary, drill out rivets (15 and 17, Figure 4-18), and remove data plates (16 and 18).
Repair.
__________
WARNING
CARC paint is a health hazard. Wear protective eyewear, mask and gloves
when sanding CARC painted surfaces. Failure to comply can cause personal
injury.
d.
4-136
(1)
Repair all dents and cracks, and remove loose paint.
(2)
Remove light corrosion with fine grit abrasive paper (Item 16, Appendix E).
(3)
Repaint surfaces in accordance with TM 43-0139.
Installation.
(1)
If removed, install data plates (16 and 18, Figure 4-18) on DCS control panel (14) with rivets (15
and 17).
(2)
Apply continuous bead, approximately .12 inch in diameter, of sealant (Item 18, Appendix E) to
mating surfaces of DCS control panel frame (14), DCS control box bottom (42), and side panels (26
and 27). Immediately install DCS control panel frame (14), bolts (13 and 11), and locknuts (12 and
10) on DCS control box assembly (Figure 4-10).
(3)
Install CONVENIENCE RECEPTACLE, paragraph 4.8.20.
(4)
Install PARALLELING RECEPTACLE, paragraph 4.8.19.
(5)
Install COMMUNICATION RECEPTACLE, paragraph 4.8.18.
(6)
Install DCS control panel assembly, paragraph 4.8.39.
(7)
Install keypad assembly, paragraph 4.8.17.
(8)
Install CIM, paragraph 4.8.16.
(9)
Install DCS control box assembly, paragraph 4.8.1.
(10)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
FIGURE 4-18. DCS CONTROL BOX PANELS
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4.8.41
DCS Control Box Side Panels.
a.
b.
c.
Removal.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Remove DCS control box top panel, paragraph 4.7.2.
(4)
Remove locknuts (12, Figure 4-18) and bolts (13) securing side panels (26 and 27) to DCS control
panel frame (14).
(5)
Open output box access door (Figure 1-2), and remove locknuts (19) and bolts (20) securing side
panel (27) to generator set.
(6)
Remove bolts (21), lockwashers (22), and washers (23) securing side panels (26 and 27) to
generator set.
(7)
Remove locknuts (24), bolts (25), and side panels (26 and 27) from DCS control box assembly.
(8)
Remove locknuts (28), bolts (29), and air baffle (30) from side panel (27).
Inspection.
(1)
Inspect DCS control panel frame (14, Figure 4-18) for dents, cracks, loose paint, and corrosion.
(2)
Inspect for missing or damaged cage nuts (31).
Repair.
__________
WARNING
CARC paint is a health hazard. Wear protective eyewear, mask and gloves
when sanding CARC painted surfaces. Failure to comply can cause personal
injury.
d.
4-138
(1)
Repair all dents and cracks, and remove loose paint.
(2)
Remove light corrosion with fine grit abrasive paper (Item 16, Appendix E).
(3)
Repaint surfaces in accordance with TM 43-0139.
(4)
Replace missing or damaged cage nuts (31).
Installation.
(1)
Apply continuous bead, approximately .12 inch in diameter, of sealant (Item 18, Appendix E) to
mating surfaces of air baffle (30, Figure 4-18) and side panel (27). Immediately install air baffle
(30), bolts (29), and locknuts (28) on side panel.
(2)
Install side panels (27 and 26), bolts (25), and locknuts (24) on DCS control box assembly.
ARMY TM 9-6115-671-14
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MARINE CORPS TM 09249A/09246A-14
4.8.46
(3)
Secure side panels (27 and 26) to generator set with washers (23), lockwashers (22), and bolts (21).
(4)
Secure side panel (27) to generator set with bolts (20) and locknuts (19). Close output box access
door (Figure 1-2).
(5)
Apply continuous bead, approximately .12 inch in diameter, of sealant (Item 18, Appendix E) to
mating surfaces of side panels (27 and 26, Figure 4-18). Immediately secure side panels (26 and 27)
to DCS control panel frame (14) with bolts (13) and locknuts (12).
(6)
Install DCS control box top panel, paragraph 4.7.2.
(7)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
DCS Control Box Bottom.
a.
b.
Removal.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Remove DCS control box assembly, paragraph 4.8.1.
(4)
Remove control box components, paragraphs 4.8.21 through 4.8.36.
(5)
Remove DCS control panel frame, paragraph 4.8.40.
(6)
Remove DCS control box side panels, paragraph 4.8.41.
(7)
Remove bolts (32, Figure 4-18), lockwashers (33), washers (34), and mounting bracket (35) from
DCS control box bottom (42).
(8)
Remove locknuts (36), screws (37), and relay track (38) from DCS control box bottom (42).
(9)
Remove locknuts (39), screws (40), and latch plate (41) from DCS control box bottom (42).
(10)
Remove screws (30, Figure 4-15), lockwashers (31), washers (32), and standoffs (21 and 26) from
DCS control box bottom (42, Figure 4-18).
Inspection.
(1)
Inspect DCS control panel bottom (42, Figure 4-18) for dents, cracks, loose paint, and corrosion.
(2)
Inspect for missing or damaged cage nuts (43).
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c.
Repair.
__________
WARNING
CARC paint is a health hazard. Wear protective eyewear, mask and gloves
when sanding CARC painted surfaces. Failure to comply can cause personal
injury.
d.
4.8.43
4-140
(1)
Repair all dents and cracks, and remove loose paint.
(2)
Remove light corrosion with fine grit abrasive paper (Item 16, Appendix E).
(3)
Repaint surfaces in accordance with TM 43-0139.
(4)
Replace missing or damaged cage nuts (43).
Installation.
(1)
Install standoffs (21 and 26, Figure 4-15), washers (32), lockwashers (31), and screws (30) on DCS
control box bottom (42, Figure 4-18).
(2)
Install latch plate (41), screws (40), and locknuts (39) on DCS control box bottom (42).
(3)
Install relay track (38), screws (37), and locknuts (36) on DCS control box bottom (42).
(4)
Install mounting bracket (35), washers (34), lockwashers (33), and bolts (32) on control box bottom
(42).
(5)
Install DCS control box side panels, paragraph 4.8.41.
(6)
Install DCS control panel frame, paragraph 4.8.40.
(7)
Install control box components, paragraphs 4.8.21 through 4.8.36.
(8)
Install DCS control box assembly, paragraph 4.8.1.
(9)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
DCS Data Plates.
a.
Inspection. Inspect data plates for readability and loose or missing rivets. Refer to paragraph 1.11.2,
Figure 1-3, for locations of data plates on DCS control box assembly.
b.
Replacement.
(1)
Drill out rivets, and remove data plate from DCS control box assembly. Refer to paragraph 1.11.2,
Figure 1-3.
(2)
Install data plate on housing with rivets.
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
4.9
MAINTENANCE OF AIR INTAKE AND EXHAUST SYSTEM.
__________
WARNING
When disconnecting or removing batteries, disconnect the negative lead that
connects directly to the grounding stud first. Disconnect the negative end of
the interconnection cable next. When installing batteries, reverse the
connection sequence. Failure to comply can cause serious personal injury.
4.9.1
Muffler and Exhaust Pipe.
__________
WARNING
Exhaust system can get very hot. Allow system to cool before performing
maintenance. Failure to comply can cause severe burns and injury to
personnel.
a.
b.
Inspection.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Remove top housing panel. Refer to paragraph 4.7.3.
(3)
Open engine compartment access doors (Figures 1-2 and 1-3). Inspect muffler assembly (3, Figure
4-19) and exhaust pipe (8) for cracks, excessive corrosion, clogging, and other damage.
(4)
Replace damaged parts, refer to paragraph 4.9.1.b.
(5)
Install top housing panel. Refer to paragraph 4.7.3.
(6)
Close engine compartment access doors.
Replacement.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Remove top housing panel and roof stiffener assembly. Refer to paragraph 4.7.3.
(4)
Remove muffler clamp (1, Figure 4-19) from exhaust pipe (8).
(5)
Remove bands (2) from muffler assembly (3) and supports (7).
(6)
Separate exhaust pipe (8) from muffler assembly (3), and remove muffler assembly from generator
set.
(7)
Remove bolts (4), lockwashers (5), washers (6), and supports (7) from top section floor panel.
(8)
Loosen V-band clamp (9) at turbocharger outlet.
(9)
Remove exhaust pipe (8) and V-band clamp (9) from turbocharger outlet.
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4-142
(10)
Inspect muffler assembly (3, Figure 4-19) and exhaust pipe (8) for cracks, excessive corrosion,
clogging, and other damage.
(11)
Position V-band clamp (9) and exhaust pipe (8) on turbocharger outlet. Tighten clamp.
(12)
Install supports (7), washers (6), lockwashers (5), and bolts (4) on top section floor panel.
(13)
Install muffler (3) and bands (2) on supports (7).
(14)
Position exhaust pipe (8) on muffler (3), and install muffler clamp (1).
(15)
Install roof stiffener assembly and top housing panel. Refer to paragraph 4.7.3.
(16)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
FIGURE 4-19. MUFFLER AND EXHAUST PIPE
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4.9.2
Air Cleaner Assembly.
a.
b.
c.
4-144
Inspection.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Remove DCS control box assembly, paragraph 4.8.1.
(4)
Inspect air cleaner assembly (1, Figure 4-20) and mounting bracket (2) for cracks, dents, blockage,
debris, and other damage.
(5)
Install DCS control box assembly, paragraph 4.8.1.
(6)
Connect negative cable to battery. Close BATTERY ACCESS door.
Service.
(1)
Remove air cleaner filter element, Paragraph 4.9.4.
(2)
Wipe inside of air cleaner housing (3, Figure 4-20) with cleaning cloth (Item 8, Appendix E).
(3)
Install new air cleaner filter element, Paragraph 4.9.4.
Removal.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Remove DCS control box assembly, paragraph 4.8.1.
(4)
Loosen hose clamp (4, Figure 4-20), and remove elbow (5) from air cleaner housing (3).
(5)
Remove nuts (6), lockwashers (7), washers (8), bolts (9), and air cleaner assembly (1) from
generator set.
(6)
Remove nuts (10), lockwashers (11), bolts (12), and mounting bracket (2) from air cleaner housing
(3).
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
FIGURE 4-20. AIR CLEANER ASSEMBLY
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d.
4.9.3
Installation.
(1)
Using removed components, install mounting bracket (2, Figure 4-20), bolts (12), lockwashers (11),
and nuts (10) on air cleaner housing (3).
(2)
Using removed components, install air cleaner assembly (1), bolts (9), washers (8), lockwashers (7),
and nuts (6) on generator set.
(3)
Position elbow (5) and hose clamp (4) on air cleaner housing (3). Tighten hose clamp.
(4)
Install DCS control box assembly, paragraph 4.8.1.
(5)
Connect negative battery cable to battery. Close BATTERY ACCESS door.
Restriction Indicator.
a.
Inspection.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open left side engine compartment access doors (Figure 1-3).
__________
WARNING
Exhaust system can get very hot. Allow system to cool before performing
maintenance. Failure to comply can cause severe burns and injury to
personnel.
NOTE
Restriction indicator is located halfway between the left side engine access door and
the rear of the generator set. It may be necessary to use a flashlight to see the
indicator.
b.
(3)
Inspect restriction indicator (13, Figure 4-20) for cracks, stripped threads, or other damage.
(4)
Close engine compartment access doors.
Replacement.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open left side engine compartment access doors (Figure 1-3).
NOTE
Restriction indicator is located halfway between the left side engine access
door and the rear of the generator set. It may be necessary to use a flashlight to
see the indicator.
(3)
4-146
Remove restriction indicator (13, Figure 4-20) from air cleaner housing (3).
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
4.9.4
Install restriction indicator (13) on air cleaner housing (3). Tighten indicator fingertight.
(5)
Close engine compartment access doors.
Air Cleaner Filter Element.
a.
b.
c.
4.9.5
(4)
Removal.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open AIR CLEANER ACCESS door (Figure 1-3).
(3)
Loosen wing nut (14, Figure 4-20), and remove end cap assembly (15) from rod (16) in air cleaner
housing (3).
(4)
Remove wing nut (17) and filter element (18) from rod (16).
Inspection.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Remove air cleaner filter element, step a above.
(3)
Inspect filter element (18, Figure 4-20) for debris and damage. Replace as necessary.
(4)
Inspect vacuator valve (19) for clogging and debris. Clear as necessary.
(5)
Wipe inside of air cleaner housing (3) with clean, lint-free cloth (Item 8, Appendix E).
(6)
Install air cleaner filter element, step c below.
Installation.
(1)
Install filter element (18, Figure 4-20) and wing nut (17) on rod (16).
(2)
Install end cap assembly (15) on rod (16). Tighten wing nut (14) fingertight.
(3)
Close AIR CLEANER ACCESS door.
Air Cleaner Hoses.
a.
Inspection.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open left side engine compartment access doors (Figure 1-3).
(3)
Inspect all hoses and tubing (5, 21, 22, and 23, Figure 4-20) for cracks, tears, and holes.
(4)
Inspect hose clamps (4 and 20) for cracks.
(5)
Replace parts as necessary.
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(6)
b.
c.
d.
4.9.6
Removal.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open left side engine compartment access doors (Figure 1-3).
(3)
Loosen hose clamps (4 and 20, Figure 4-20).
(4)
Remove elbow (5) from air cleaner housing (3) and tube assembly (21).
(5)
Remove tube assembly (21) from breather hose (23) and hump hose (22).
(6)
Remove hump hose (22) from turbocharger.
(7)
Remove breather hose (23) from oil breather outlet on valve cover.
Service.
(1)
Remove air cleaner hoses, step b above.
(2)
Clean hoses and tubing with cleaning cloth (Item 8, Appendix E) and with water.
(3)
Install air cleaner hoses, step d below.
Installation.
(1)
Position hose clamp (20, Figure 4-20) on breather hose (23), and install breather hose on oil
breather.
(2)
Position hose clamp (4) on hump hose (22), and install hump hose on turbocharger.
(3)
Position hose clamp (4) on hump hose (22), and install hump hose on tube assembly (21).
(4)
Position hose clamp (20) on breather hose (23), and install breather hose on tube assembly (21).
(5)
Position hose clamps (4) on elbow (5), and install elbow on air cleaner housing (3) and tube
assembly (21).
(6)
Tighten hose clamps (4 and 20).
(7)
Close engine compartment access doors.
Crankcase Breather Filter Assembly.
a.
4-148
Close engine compartment access doors.
Inspection.
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
(1)
Shut down generator set, paragraph 2.11.2.
__________
WARNING
Exhaust system can get very hot. Allow system to cool before performing
maintenance. Failure to comply can cause severe burns and injury to
personnel.
b.
(2)
Open right side engine compartment access doors (Figure 1-2).
(3)
Inspect sight glass (1, Figure 4-21). If fluid is visible, drain by positioning suitable container under
crankcase breather filter assembly (18) and loosening drain valve (2). Tighten drain valve when
complete. Properly dispose of fluid.
(4)
Inspect flex hoses (10 and 21), heater tape (11 and 12), and insulation (14) for cracks, holes, dry rot,
and damaged or missing hose clamps (9 and 13).
(5)
Inspect crankcase breather filter assembly (18) and bracket (17) for cracks, excessive corrosion, and
other damage.
(6)
Clean light corrosion from bracket (17) and hose attaching points with fine grit abrasive paper (Item
16, Appendix E).
(7)
Replace damaged parts.
(8)
Close engine compartment access doors.
Service.
__________
WARNING
Exhaust system can get very hot. Allow system to cool before performing
maintenance. Failure to comply can cause severe burns and injury to
personnel.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open right side engine compartment access doors (Figure 1-2).
(3)
While supporting housing (4, Figure 4-21), loosen collar (3), and remove housing from head (5).
(4)
Remove o-ring (27), end cap (6), filter (7), and filter holder (8) from head (5). Discard filter.
(5)
Install filter holder handtight (8), new filter (7), and end cap (6) in head (5).
(6)
Position housing (4) on head (5) with sight glass (1) visible, and secure with collar (3) handtight.
(7)
Close engine compartment access doors.
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FIGURE 4-21. CRANKCASE BREATHER FILTER ASSEMBLY
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c.
d.
Test.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open output control box door, refer to Figure 1-2.
(3)
Test heater by disconnecting wires 351A16 and 350A16 at TB7-B10.
(4)
Measure resistance between heater wire 350A16 (HTR1) and ground. Resistance should be 199233 ohms. Replace heater if resistance is out of tolerance.
(5)
Measure resistance between heater wire 351A16 (HTR2) and ground. Resistance should be 370432 ohms. Replace heater if resistance is out of tolerance.
(6)
Disconnect heater thermostat at terminals TB7-A8 and TB7-A10 and remove from generator set.
Test heater thermostat by checking continuity. Thermostat switch should open at temperatures
above 20° F. Expose thermostat to temperature below 15° F. Thermostat should close and have
continuity. Replace if defective.
Removal.
(1)
Shut down generator set, paragraph 2.11.2.
__________
WARNING
Exhaust system can get very hot. Allow system to cool before performing
maintenance. Failure to comply can cause severe burns and injury to
personnel.
e.
(2)
Open right side engine compartment access doors (Figure 1-2).
(3)
Peel back insulation (14, Figure 4-21) as required to expose heater tapes (11 and 12). Unwind
heater tapes from assembly and remove from generator set.
(4)
Loosen hose clamps (9 and 13), and remove flex hoses (10 and 21) from crankcase filter assembly
(18).
(5)
While supporting crankcase filter assembly (18), remove screws (15), lockwashers (16), from
bracket (17). Note position of arrow on head of assembly in relation to the bracket for installation
later. Remove crankcase filter assembly (18) from generator set.
(6)
As required, remove flex hose (10) from crankcase breather and flex hose (21) from exhaust pipe.
Remove bracket (17) from engine air intake pipe (20).
(7)
As required, remove nipple (26), elbow (25), nipple (24) elbow (23) and adapter (22) from head (5)
of crankcase breather filter (18). On other side of head (5), remove adapter (19).
Installation.
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NOTE
In step (1), apply sealing compound (Item 22, Appendix E) to pipe threads of
components as they are installed.
4.10
(1)
Install nipple (26), elbow (25), nipple (24) elbow (23) and adapter (22) to head (5) of crankcase
breather filter (18). On other side of head (5), install adapter (19) to crankcase breather filter (18).
(2)
Install flex hose (10) to crankcase breather and flex hose (21) to exhaust pipe.
(3)
Position bracket (17) on crankcase breather filter assembly (18) with arrow aligned as noted in step
(5), and secure with lockwashers (16) and screws (15).
(4)
Position bracket (17) on engine air intake pipe (20), and secure bracket to pipe with hose clamps
(13).
(5)
Connect flex hoses (10 and 21) to adapters (19 and 22), and secure with hose clamps (9 and 13).
(6)
Close engine compartment access doors.
MAINTENANCE OF ENGINE COOLING SYSTEM
__________
WARNING
When disconnecting or removing batteries, disconnect the negative lead that
connects directly to the grounding stud first. Disconnect the negative end of
the interconnection cable next. When installing batteries, reverse the
connection sequence. Failure to comply can cause serious personal injury.
4.10.1
Engine Cooling System.
a.
Testing.
(1)
Shut down generator set, paragraph 2.11.2.
__________
WARNING
Cooling system operates at high temperature and pressure. Contact with high
pressure steam and/or liquids can result in burns and scalding. Shut down
generator set, and allow system to cool before performing checks, services, and
maintenance. Failure to comply can cause injury to personnel.
4-152
(2)
Slowly remove radiator cap (1, Figure 4-22) from filler neck (2).
(3)
Install cooling system pressure tester (Appendix B, Section III) in filler neck (2).
(4)
Open engine compartment access doors (Figures 1-2 and 1-3).
(5)
Pump pressure tester until 8 psi is indicated. Check cooling system for leaks.
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
FIGURE 4-22. COOLING SYSTEM (SHEET 1 OF 2)
4-153
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AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
FIGURE 4-22. COOLING SYSTEM (SHEET 2 OF 2)
b.
4-154
(6)
Install radiator cap (1) on pressure tester, and pump tester until 10±1 psi is indicated. Ensure
radiator cap releases.
(7)
Release pressure from pressure tester, and remove tester from filler neck (2) and radiator cap (1)
from tester.
(8)
Install radiator cap (1) on filler neck (2).
(9)
Close engine compartment access doors.
Service.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open left side engine compartment access doors (Figure 1-3).
(3)
Flush or drain cooling system in accordance with Preventive Cleaning procedures contained in TM
750-254.
(4)
Close engine compartment access doors.
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
4.10.2
Filler Hose and Panel.
a.
Removal.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open engine compartment access doors (Figures 1-2 and 1-3).
(3)
Remove top housing panel. Refer to paragraph 4.7.3.
__________
WARNING
Cooling system operates at high temperature and pressure. Contact with high
pressure steam and/or liquids can result in burns and scalding. Shut down
generator set, and allow system to cool down before performing checks,
services, and maintenance. Failure to comply can cause injury to personnel.
b.
(4)
Slowly remove radiator cap (1, Figure 4-22) from filler neck (2).
(5)
Open coolant drain valve (33), and drain coolant/antifreeze into suitable container to a level below
filler hose (4) connection at radiator. Properly dispose of fluid.
(6)
Loosen hose clamps (3), and remove filler hose (4) and hose clamps from radiator and filler neck
(2).
(7)
Loosen hose clamp (5), and disconnect overflow hose (6) from filler neck (2).
(8)
Remove radiator fill panel (7) and filler neck (2) from generator set.
(9)
Remove locknuts (8), bolts (9), chain (10), and filler neck (2) from radiator fill panel (7).
Inspection.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Remove filler hose and panel, step a above.
(3)
Inspect filler hose (4, Figure 4-22) for cracks, holes, and dry rot.
(4)
Inspect radiator filler panel (7), filler neck (2), and radiator cap (1) for cracks, excessive corrosion,
and other damage.
(5)
Clean light corrosion from filler hose attaching points with fine grit abrasive paper (Item 16,
Appendix E).
(6)
Replace damaged parts.
(7)
Install filler hose and panel, step c below.
4-155
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
c.
4.10.3
Installation.
(1)
Install filler neck (2, Figure 4-22), chain (10), bolts (9), and locknuts (8) on radiator fill panel (7).
(2)
Position radiator fill panel (7) and filler neck (2) in generator set.
(3)
Position overflow hose (6) and hose clamp (5) on filler neck (2). Tighten hose clamp.
(4)
Position filler hose (4) and hose clamps (3) on filler neck (2) and radiator. Tighten hose clamps.
(5)
Close coolant drain valve (33), and add coolant/antifreeze to proper level at the filler neck (2).
(6)
Install radiator cap (1) on filler neck (2).
(7)
Install top housing panel. Refer to paragraph 4.7.3.
(8)
Start generator set, paragraph 2.11.1. Allow unit to reach operating temperature, and check for
leaks.
(9)
Add coolant/antifreeze to overflow bottle as required, paragraph 3.3.4.
(10)
Close engine compartment access doors.
Fan Guards.
CAUTION
Fan shroud must be installed when operating Generator Set.
a.
4-156
Removal.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Open right side engine compartment access doors (Figure 1-2).
(4)
Remove bolts (1, Figure 4-23), washers (2), lockwashers (3), and right fan guard (5) from brackets
(10, and 11).
(5)
Remove bolt (14), lockwasher (13), washer (12), and bracket (9) from engine.
(6)
Remove bolts (14), lockwashers (13), washers (12), and brackets (10 and 11) from shroud.
(7)
Open left side engine compartment access doors (Figure 1-3).
(8)
Remove bolts (1), washers (2), lockwashers (3), and left fan guard (4) from brackets (6, 7, and 8).
(9)
Remove bolt (14), lockwasher (13), washer (12), and bracket (6) from engine.
(10)
Remove bolts (14), lockwashers (13), washers (12), and brackets (7 and 8) from shroud.
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
FIGURE 4-23. FAN GUARDS
4-157
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AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
b.
c.
4.10.4
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open engine compartment access doors (Figures 1-2 and 1-3).
(3)
Inspect fan guards (4 and 5, Figure 4-23), brackets (6, 7, 8, 9, 10 and 11), and attaching hardware
for damage, corrosion, and loose or missing hardware.
(4)
Replace all damaged and missing components. Tighten all loose attaching hardware.
(5)
If necessary, install new protective edging (15), cut to fit.
(6)
Close engine compartment access doors.
Installation.
(1)
Install brackets (7 and 8, Figure 4-23), washers (12), lockwashers (13), and bolts (14) on shroud.
(2)
Install bracket (6), washer (12), lockwasher (13), and bolt (14) on engine.
(3)
Install left fan guard (4), lockwashers (3), washers (2), bolts (1) on brackets (6, 7, and 8).
(4)
Close left side engine compartment doors.
(5)
Install brackets (10 and 11), washers (12), lockwashers (13), and bolts (14) on shroud.
(6)
Install bracket (9), washer (12), lockwasher (13), and bolt (14) on engine.
(7)
Install right fan guard (5), lockwashers (3), washers (2), bolts (1) on brackets (10 and 11).
(8)
Close right side engine compartment access doors.
(9)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
Coolant Hoses, Upper
a.
4-158
Inspection.
Removal.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Open engine compartment access doors (Figures 1-2 and 1-3).
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
__________
WARNING
Cooling system operates at high temperature and pressure. Contact with high
pressure steam and/or liquids can result in burns and scalding. Shut down
generator set, and allow system to cool down before performing checks,
services, and maintenance. Failure to comply can cause injury to personnel.
b.
c.
(4)
Slowly remove radiator cap (1, Figure 4-22) from filler neck (2).
(5)
Remove fan guards, paragraph 4.10.3.
(6)
Open coolant drain valve (33), and drain coolant/antifreeze into suitable container.
(7)
Loosen hose clamps (11). Remove upper coolant hose (49) and hose clamps from radiator (32) and
copper “T” (47).
(8)
Loosen hose clamps (11). Remove upper coolant hose (12) and hose clamps from copper “T” (47)
and thermostat housing opening.
(9)
Loosen hose clamp (3). Remove copper “T” (47).
Inspection.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Remove upper coolant hoses, step a above.
(3)
Inspect upper coolant hose (12 and 49, Figure 4-22) for cracks, holes, and rotting.
(4)
Clean light corrosion from upper coolant hose attaching points with fine grit abrasive paper (Item
16, Appendix, E).
(5)
Install upper coolant hoses, step c below.
Installation.
(1)
Install copper “T” (47) and tighten clamp (3).
(2)
Position upper coolant hose (12, Figure 4-22) and hose clamps (11) on thermostat housing opening
and copper “T” (47). Tighten hose clamps.
(3)
Position upper coolant hose (49) and hose clamps (11) on copper “T” (47) and radiator (32).
Tighten Clamps.
(4)
Close coolant drain valve (33), and add coolant/antifreeze to proper level at the filler neck (2).
(5)
Install fan guards, paragraph 4.10.3.
(6)
Install radiator cap (1) on filler neck (2).
(7)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
4-159
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
(8)
Start generator set, paragraph 2.11.1. Allow unit to reach operating temperature, and check for
leaks.
(9)
Add coolant/antifreeze to overflow bottle as required.
(10)
Close engine compartment access doors.
(11)
4.10.5
Shutdown generator set.
Coolant Hose, Lower
a.
Removal.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Open engine compartment access doors (Figures 1-2 and 1-3).
__________
WARNING
Cooling system operates at high temperature and pressure. Contact with high
pressure steam and/or liquids can result in burns and scalding. Shut down
generator set, and allow system to cool before performing checks, services, and
maintenance. Failure to comply can cause injury to personnel.
b.
c.
4-160
(4)
Slowly remove radiator cap (1, Figure 4-22) from filler neck (2).
(5)
Remove fan guards, paragraph 4.10.3.
(6)
Open coolant drain valve (33), and drain coolant/antifreeze into suitable container.
(7)
Loosen hose clamps (13). Remove lower coolant hose (14) and hose clamps from radiator outlet
opening and water pump opening.
Inspection.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Remove lower coolant hose, step a above.
(3)
Inspect lower coolant hose (14, Figure 4-22) for cracks, holes, and rotting.
(4)
Clean exterior of lower radiator outlet tube with fine grit abrasive paper (Item 16, Appendix, E).
(5)
Install lower coolant hose, step c below.
Installation.
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
4.10.6
(1)
Position lower coolant hose (14, Figure 4-22) and hose clamps (13) on water pump opening and
radiator outlet opening. Tighten hose clamps.
(2)
Close coolant drain valve (33), and add coolant/antifreeze to proper level at the filler neck (2).
(3)
Install fan guards, paragraph 4.10.3.
(4)
Install radiator cap (1) on filler neck (2).
(5)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
(6)
Start generator set, paragraph 2.11.1. Allow unit to reach operating temperature, and check for
leaks.
(7)
Add coolant/antifreeze to overflow bottle as required.
(8)
Close engine compartment access doors.
(9)
Shut down generator set.
Coolant Overflow and Drain Hoses.
a.
b.
c.
Removal.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Open engine compartment access doors (Figures 1-2 and 1-3).
(4)
Open coolant drain valve (33, Figure 4-22), and drain coolant/antifreeze into suitable container.
(5)
Locate overflow or drain hose to be removed as shown in Figure 4-22.
(6)
Disconnect hose at both ends, and remove from generator set.
Inspection.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open engine compartment access doors (Figures 1-2 and 1-3).
(3)
Inspect hoses (15, Figure 4-22) for cracks, holes, and rotting.
(4)
Close engine compartment access doors.
Installation.
(1)
Install overflow or drain hose (15, Figure 4-22) in generator set as removed.
(2)
Close coolant drain valve (33), and add coolant/antifreeze to proper level at the filler neck (2).
(3)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
4-161
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AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
4.10.7
(4)
Start generator set, paragraph 2.11.1. Allow unit to reach operating temperature, and check for
leaks.
(5)
Add coolant/antifreeze to overflow bottle as required.
(6)
Close engine compartment access doors.
(7)
Shut down generator set.
Radiator.
a.
Removal.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open engine compartment access doors (Figures 1-2 and 1-3).
(3)
Remove top housing section, paragraph 4.7.3.
__________
WARNING
Cooling system operates at high temperature and pressure. Contact with high
pressure steam and/or liquids can result in burns and scalding. Shut down
generator set, and allow system to cool before performing checks, services, and
maintenance. Failure to comply can cause injury to personnel.
__________
WARNING
DC voltages are present at the generator set electrical components even when
the generator set is shut down. Avoid shorting any positive with a ground
negative. Failure to comply can cause injury or death.
4-162
(4)
Slowly remove radiator cap (1, Figure 4-22) from filler neck (2).
(5)
Remove fan guards, paragraph 4.10.3.
(6)
Open coolant drain valve (33), and drain coolant/antifreeze into suitable container.
(7)
Remove filler hose and panel, paragraph 4.10.2.
(8)
Remove upper coolant hoses, paragraph 4.10.4.
(9)
Remove lower coolant hose, paragraph 4.10.5.
(10)
Remove bolts (16), lockwashers (17), and washers (18), and allow shroud (19) to rest on fan (40).
(11)
Remove nuts (20), lockwashers (21), bolts (22), washers (23), and support tie-rods (24) from
bracket on engine.
(12)
Remove bolts (25), lockwashers (26), support tie-rods (24), and spacers (27) from radiator (32).
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
b.
(13)
Loosen hose clamp (28), and disconnect drain hose (29) from coolant drain valve (33).
(14)
Remove locknuts (30) and washers (31) securing radiator (32) to radiator support (37).
(15)
Lift radiator (32) up and out of generator housing.
(16)
Remove coolant drain valve (33) from radiator (32).
(17)
If necessary, remove nuts (34), lockwashers (35), bolts (36), and radiator support (37) from
generator set.
Service.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Remove radiator, step a above.
(3)
Inspect radiator for excessive corrosion and scale.
(4)
Check inside of radiator for corrosion and scale.
__________
WARNING
Cleaning with compressed air can cause flying particles. When using
compressed air, wear protective glasses and use clean, low pressure air, less
than 30 psi (206.8 kPa). Failure to comply can cause eye injury.
c.
(5)
Clean dirt particles from radiator core air passages using filtered, compressed air, 30 psi maximum.
(6)
Clean exterior surface of radiator with soap and water.
(7)
Install radiator, step d below.
Repair.
Reference Paragraph 5.6.1.
d.
Installation.
(1)
If removed, install radiator support (37, Figure 4-22), bolts (36), lockwashers (35), and nuts (34) on
generator set.
(2)
Install coolant drain valve (33) on radiator (32).
(3)
Position radiator (32) on radiator support (37), and install washers (31) and locknuts (30).
(4)
Install shroud (19), washers (18), lockwashers (17), and bolts (16).
(5)
Position hose clamp (28) and drain hose (29) on coolant drain valve (33). Tighten hose clamp.
(6)
Install spacers (27), support tie-rods (24), lockwashers (26), and bolts (25) on radiator (32).
4-163
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AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
4.10.8
Install support tie-rods (24), washers (23), bolts (22), lockwashers (21), and nuts (20) on bracket on
engine.
(8)
Install lower coolant hose, paragraph 4.10.5.
(9)
Install upper coolant hose, paragraph 4.10.4.
(10)
Install fan guards, paragraph 4.10.3.
(11)
Install top section housing, paragraph 4.7.3.
(12)
Install filler hose and panel, paragraph 4.10.2.
(13)
Close coolant drain valve (33), and add coolant/antifreeze to proper level, paragraph 3.3.4.
(14)
Install radiator cap (1) on filler neck (2).
(15)
Start generator set, paragraph 2.11.1. Allow unit to reach operating temperature, and check for
leaks.
(16)
Add coolant/antifreeze to overflow bottle as required.
(17)
Close engine compartment access doors.
Fan.
a.
b.
4-164
(7)
Removal.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Open engine compartment access doors (Figures 1-2 and 1-3).
(4)
Remove fan guards, paragraph 4.10.3.
(5)
Remove bolts (16, Figure 4-22), lockwashers (17), and washers (18), and allow shroud (19) to rest
on fan (40).
(6)
Remove bolts (38), lockwashers (39), fan (40), and spacer (41) from engine water pump.
(7)
Remove locknuts (42), screws (43), stiffeners (44), supports (45), and seals (46) from shroud (19).
Inspection.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Remove fan, step a above.
(3)
Inspect fan (40, Figure 4-22) and blades for cracks, bends, loose rivets, or other damage.
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
FIGURE 4-24. FAN BELT
(4)
Inspect spacer (41) for cracks or other damage.
(5)
Inspect seals (46), supports (45), and stiffeners (44) for damage.
NOTE
If installing new seals, screw holes need to be match drilled at assembly.
c.
(6)
Replace damaged parts.
(7)
Install fan, step c below.
Installation
(1)
Install seals (46, Figure 4-22), supports (45), stiffeners (44), screws (43), and locknuts (42) on
Shroud (19).
(2)
Position spacer (41), fan (40), and shroud (19) in generator set.
4-165
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
(3)
Secure fan (40) and spacer (41) to engine water pump with lockwashers (39) and bolts (38). Torque
bolts to 24 ft-lb (32 Nm).
4.10 .9 Fan Belt
a.
b.
Inspection
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS doors (Figure 1-2).
(3)
Disconnect negative battery cable.
(4)
Open engine compartment access doors (Figures 1-2 and 1-3).
(5)
Remove fan guards, paragraph 4.10.3.
(6)
Inspect fan belt (1, Figure 4-24) for fraying, cracks, oil soaking or other damage.
(7)
Replace fan belt that shows any damage or cannot be adjusted for proper tension.
(8)
Install fan guards, paragraph 4.3.10.
(9)
Close engine compartment access doors.
(10)
Connect negative battery cable to battery and close BATTERY ACCESS doors.
Adjustment.
NOTE
Run engine for 5 minutes if belt is cold. If belt is hot, let cool for 10 to 15 minutes.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Open engine compartment access doors (Figures 1-2 and 1-3).
(4)
Remove fan guards, paragraph 4.10.3.
(5)
Check fan belt (1, Figure 4-24) for 1/2 inch (1.27 cm) deflection between alternator pulley (2) and
fan pulley (6).
(6)
If fan belt needs adjustment, loosen alternator mounting bolt (4) and nut (5).
CAUTION
Do not pry against alternator rear frame. Failure to comply can cause
damage to alternator or mounting brackets.
(7)
4-166
Apply outward pressure to alternator front frame until belt tension is correct.
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
c.
(8)
Tighten alternator mounting bolt (4) and nut (5).
(9)
Install fan guards, paragraph 4.10.3.
(10)
Close engine compartment access doors.
(11)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
Replacement.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Open engine compartment access doors (Figures 1-2 and 1-3).
(4)
Remove fan guards, paragraph 4.10.3.
(5)
Loosen alternator mounting bolt (4, Figure 4-24) and nut (5).
(6)
Pivot alternator to relieve tension on fan belt (1), and remove belt from alternator pulley (2),
crankshaft pulley (3), and fan pulley (6).
(7)
Slip fan belt (1) over fan (40, Figure 4-22), and remove fan belt from generator set.
(8)
Slip new fan belt (1, Figure 4-24) over fan (40, Figure 4-22).
(9)
Install new fan belt (1, Figure 4-24) onto alternator pulley (2), crankshaft pulley (3), and fan pulley
(6).
(10)
Adjust tension on fan belt (1), step b above.
(11)
Install fan guards, paragraph 4.10.3.
(12)
Close engine compartment access doors.
(13)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
4-167
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
4.10.10 Coolant Recovery System.
a.
b.
Inspection.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open left side engine compartment access doors (Figure 1-2).
(3)
Inspect coolant recovery system components for cracks, holes, or other damage.
(4)
Replace damaged parts.
(5)
Close engine compartment access doors.
Removal.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open left side engine compartment access doors (Figure 1-2).
__________
WARNING
Cooling system operates at high temperature and pressure. Contact with high
pressure steam and/or liquids can result in burns and scalding. Shut down
generator set, and allow system to cool before performing checks, services, and
maintenance. Failure to comply can cause injury to personnel.
c.
4-168
(3)
Loosen hose clamp (3, Figure 4-25). Disconnect hose (4) from overflow bottle (5), and drain
coolant into suitable container.
(4)
Loosen hose clamp (1), and disconnect hose (2) from overflow bottle (5).
(5)
Remove overflow bottle (5) from wire holder (10).
(6)
Remove nuts (6), lockwashers (7), washers, (8), bolts (9), and wire holder (10) from mounting
bracket (13).
(7)
Remove bolts (12), lockwashers (11), and mounting bracket (13) from engine.
Installation.
(1)
Install mounting bracket (13, Figure 4-25), lockwashers (11), and bolts (12) on engine.
(2)
Install wire holder (10), washers (8), bolts (9), lockwashers (7), and nuts (6) on mounting bracket
(13).
(3)
Install overflow bottle (5) in wire holder (10).
(4)
Position hose clamps (1 and 3) and hoses (2 and 4) on overflow bottle (5). Tighten hose clamps.
(5)
Fill overflow bottle (5) with coolant to the COLD level. Refer to Table 3-2 for proper coolant.
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
(6)
Start generator set, paragraph 2.11.1. Check for leaks, and run until normal operating temperature is
reached.
(7)
Add coolant to HOT level of overflow bottle (5).
(8)
Close engine compartment access doors.
FIGURE 4-25. COOLANT RECOVERY SYSTEM
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4.11
MAINTENANCE OF FUEL SYSTEM.
__________
WARNING
When disconnecting or removing batteries, disconnect the negative lead that
connects directly to the grounding stud first. Disconnect the negative end of
the interconnection cable next. When installing batteries, reverse the
connection sequence. Failure to comply can cause serious personal injury.
4.11.1
Low Pressure Fuel Lines and Fittings.
a.
b.
4.11.2
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Open engine compartment access doors (Figures 1-2 and 1-3).
(4)
Inspect fuel lines and fittings for damage or leaking condition. Damaged components must be
replaced. Identify components, refer to Figure 4-26.
Replacement.
(1)
Inspect low pressure lines and fittings. Identify damaged components found during inspection.
Damaged lines and fittings must be replaced. Refer to Figure 4-26.
(2)
Disconnect fuel line at both ends, and remove any clamps.
(3)
Remove fuel line or fitting from generator set.
(4)
Cover or cap all openings.
(5)
Remove any caps, and position fuel line or fitting in generator set.
(6)
Install any clamps as removed, and connect fuel line at both ends. Tighten clamps.
(7)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
(8)
Start generator set, paragraph 2.11.1. Check for fuel leaks.
(9)
Shut down generator set, paragraph 2.11.2.
(10)
Close engine compartment access doors.
Auxiliary Fuel Pump E1.
a.
4-170
Inspection.
Inspection.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open left side engine compartment access doors (Figure 1-3).
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
FIGURE 4-26. FUEL TANK FILLER NECK AND LOW PRESSURE FUEL SYSTEM (SHEET 1 OF 2)
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FIGURE 4-26. FUEL TANK FILLER NECK AND LOW PRESSURE FUEL SYSTEM (SHEET 2 OF 2)
b.
(3)
Inspect auxiliary fuel pump (11, Figure 4-26) for leaks, cracks, missing hardware, loose
connections, and other damage.
(4)
Close engine compartment access doors.
Testing.
(1)
Shut down generator set, paragraph 2.11.2.
NOTE
Ensure auxiliary fuel supply is no more than 6 feet (1.83 m) below generator
set.
4-172
(2)
Connect generator set to auxiliary fuel supply.
(3)
Open left side engine compartment access doors (Figure 1-3).
(4)
Disconnect auxiliary fuel pump outlet line (5, Figure 4-26) at fuel tank fitting, and place
disconnected end in measuring container.
(5)
Move generator set ENGINE CONTROL switch to PRIME & RUN AUX FUEL position for one
minute, and return ENGINE CONTROL switch to OFF position.
(6)
Measuring container should collect at least 36 ounces (1.06 liters) of fuel. Properly dispose of fuel.
(7)
Replace auxiliary fuel pump (11) if delivery amount is less than above.
(8)
Connect auxiliary fuel pump outlet line (5) at fuel tank fitting.
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
c.
(9)
Disconnect generator set from auxiliary fuel supply.
(10)
Close engine compartment access doors.
Replacement.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Open left side engine compartment access doors (Figure 1-3).
(4)
Tag and disconnect auxiliary fuel pump (11, Figure 4-26) electrical connector.
(5)
Loosen hose clamps (1). Disconnect fuel inlet hose (2) from fuel strainer (4), fitting (3) from fitting
(14), and fuel inlet hose from fitting (3). Cap fuel inlet hose.
(6)
Remove fuel strainer (4) from auxiliary fuel pump (11).
(7)
Disconnect auxiliary fuel outlet line (5) from elbow (12).
(8)
Remove nuts (6), lockwashers (7), bolts (8), washers (9), cap and chain assembly (10), and auxiliary
fuel pump (11) from filler neck panel.
(9)
Remove elbow (12) from auxiliary fuel pump (11).
(10)
If necessary, remove locknut (13) and fitting (14) from filler neck panel.
(11)
If removed, install fitting (14) and locknut (13) on filler neck panel.
(12)
Install elbow (12) on auxiliary fuel pump (11).
(13)
Install auxiliary fuel pump (11), chain assembly (10), washers (9), bolts (8), lockwashers (7), and
nuts (6) on filler neck panel.
(14)
Connect auxiliary fuel outlet line (5) on elbow (12).
(15)
Install fuel strainer (4) on auxiliary fuel pump (11).
(16)
Remove caps from fuel inlet hose (2), and position hose clamps (1) on fuel inlet hose. Connect fuel
inlet hose to fitting (3), fitting (3) to fitting (14), and fuel inlet hose to fuel strainer (4). Tighten
hose clamps.
(17)
Connect auxiliary fuel pump (11) electrical connector. Remove tags.
(18)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
(19)
Move generator set ENGINE CONTROL switch to PRIME AND RUN AUX FUEL position, and
check for fuel leaks.
(20)
Return ENGINE CONTROL switch to OFF position.
(21)
Close engine compartment access doors.
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4.11.3
Fuel Tank Filler Neck.
a.
Removal.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable .
__________
WARNING
Diesel fuel is flammable and toxic to eyes, skin, and respiratory tract. Skin and
eye protection are required when working in contact with diesel fuel, and avoid
repeated or prolonged contact. Failure to comply can cause injury or death to
personnel.
b.
4-174
(3)
Remove cap (28, Figure 4-26), open fuel drain valve (30), and drain fuel into a suitable container.
(4)
Open left side engine compartment access doors (Figure 1-3).
(5)
Remove filler neck tube and cap assembly (15) from filler neck (24).
(6)
Loosen hose clamp (16), and disconnect hose (17) from connector (18).
(7)
Remove connector (18) from reducer (21).
(8)
Remove seal nut (19), washer (20), and reducer (21) from side of filler neck (24).
(9)
Remove locknuts (22) and bolts (23) securing filler neck (24) to filler neck panel.
(10)
Loosen hose clamps (25 and 26). Remove filler neck (24), fuel fill hose (27), and hose clamps from
generator set.
Inspection.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Remove fuel tank filler neck, step a above.
(3)
Inspect fuel fill hose (27, Figure 4-26) for cracking, wear, or other damage.
(4)
Inspect filler neck (24) for corrosion, cracking, or other damage.
(5)
Inspect filler neck tube and cap assembly (15) for damage.
(6)
Replace damaged parts.
(7)
Install fuel tank filler neck, step c below.
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
c.
4.11.4
Installation.
(1)
Position fuel fill hose (27, Figure 4-26), clamps (25 and 26), and filler neck (24) on fuel tank.
(2)
Secure filler neck (24) to filler neck panel with bolts (23) and locknuts (22).
(3)
Tighten hose clamps (25 and 26).
(4)
Install reducer (21), washer (20), and seal nut (19) on side of filler neck (24).
(5)
Install connector (18) on reducer (21).
(6)
Position hose clamp (16) on hose (17). Connect hose to connector (18), and tighten hose clamp.
(7)
Install filler neck tube and cap assembly (15) in filler neck (24).
(8)
Close engine compartment access doors.
(9)
Close fuel drain valve (30), install cap (28), and service fuel tank. Refer to Table 4-2 for proper
fuel.
(10)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
Fuel Drain Valve.
Replacement.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Open left side engine compartment access doors (Figure 1-3).
(4)
Remove cap (28, Figure 4-26) from adapter (29).
__________
WARNING
Diesel fuel is flammable and toxic to eyes, skin, and respiratory tract. Skin and
eye protection are required when working in contact with diesel fuel, and avoid
repeated or prolonged contact. Failure to comply can cause injury or death to
personnel.
(5)
Open fuel drain valve (30), and drain fuel into a suitable container.
(6)
Remove adapter (29) from fuel drain valve (30), and fuel drain valve from elbow (31).
(7)
If necessary, remove elbow (31) and connector (32) from fuel tank fitting.
(8)
If removed, install connector (32) and elbow (31) on fuel tank fitting.
(9)
Install fuel drain valve (30) on elbow (31), and adapter (29) on fuel drain valve.
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4.11.5
(10)
Ensure fuel drain valve (30) is closed, and service fuel tank. Refer to Table 4-2 for proper fuel.
(11)
Check fuel drain valve (30) and fitting for leakage.
(12)
Install cap (28) on adapter (29).
(13)
Close engine compartment access doors.
(14)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
Fuel Level Sender MT5.
a.
b.
Inspection.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open right side engine compartment access doors (Figure 1-2).
(3)
Inspect fuel level sender (39, Figure 4-26) for loose connections and mounting, and other damage.
(4)
Close engine compartment access doors.
Removal.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), disconnect negative battery cable from battery.
(3)
Open right side engine compartment access doors (Figure 1-3).
(4)
Remove nut (33, Figure 4-26) and electrical lead (34) from fuel level sender (39). Tag lead.
NOTE
Mark position of float when removing sender. Float must be in same position when
installed to ensure clearance with fuel tank.
c.
4-176
(5)
Remove screws (35), lockwashers (36), washers (37), electrical lead (38), fuel level sender (39), and
gasket (40) from generator set fuel tank. Tag lead.
(6)
Cover opening in fuel tank.
Testing.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Remove fuel level sender, step b above.
(3)
Position fuel level sender in vertical position, similar to position as installed in fuel tank.
(4)
Set multimeter for ohms. Connect positive lead to fuel level sender terminal and negative lead to
fuel level sender ground.
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
d.
4.11.6
(5)
With fuel level sender arm resting freely in what would be an empty position, multimeter should
indicate between 216 and 264 ohms.
(6)
Move fuel level sender arm up to what would be a full position. Multimeter should indicate
between 29.7 and 36.3 ohms.
(7)
Replace fuel level sender if indications are not as above.
(8)
Install fuel level sender, step d below.
Installation.
(1)
Remove cover from fuel tank opening.
(2)
Thoroughly clean mating surfaces for new gasket (40, Figure 4-26). Ensure no foreign material
enters fuel tank. Apply sealant (Item 21, Appendix E) to both sides of gasket. Position gasket on
fuel tank.
(3)
Position fuel level sender (39) in fuel tank. Ensure float is in same position as removed.
(4)
Remove tag from electrical lead (38), and secure fuel level sender (39) and lead to fuel tank with
washers (37), lockwashers (36), and bolts (35).
(5)
Remove tag, and install electrical lead (34) on fuel level sender (39).
(6)
Close engine compartment access doors.
(7)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
Fuel Pickup.
a.
Removal.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), disconnect negative battery cable from battery.
(3)
Open right side engine compartment access doors (Figure 1-2).
(4)
Disconnect hose (41, Figure 4-26) from adapter (47).
NOTE
Mark position of fuel pickup before removing.
b.
(5)
Remove screws (42), lockwashers (43), washers (44), fuel pickup (45), and gasket (46) from fuel
tank.
(6)
Remove adapter (47) from fuel pickup (45).
(7)
Cover opening in fuel tank.
Inspection.
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c.
4.11.7
Shut down generator set, paragraph 2.11.2.
(2)
Remove fuel pickup, step a above.
(3)
Inspect fuel pickup for clogs, stripped threads, and other damage.
(4)
Replace damaged parts.
(5)
Install fuel pickup, step c below.
Installation.
(1)
Remove cover from fuel tank opening.
(2)
Thoroughly clean mating surfaces for new gasket (46, Figure 4-26). Ensure no foreign material
enters fuel tank. Apply sealant (Item 21, Appendix E) to both sides of gasket. Position gasket on
fuel tank.
(3)
Install adapter (47) on fuel pickup (45).
(4)
Install fuel pickup (45), washers (44), lockwashers (43), and screws (42) on fuel tank.
(5)
Connect hose (41) to adapter (47).
(6)
Close engine compartment access doors.
(7)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
Ether Cylinder Assembly.
a.
b.
4-178
(1)
Removal.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open right side engine compartment access doors (Figure 1-2).
(3)
Loosen wingnut (1, Figure 4-27), and unscrew ether cylinder (2) from ether solenoid valve (3).
(4)
Install cap (4) on ether solenoid valve (3).
(5)
Remove nuts (5), lockwashers (6), washers (7), cylinder bracket assembly (8), and bolts (9) from
generator set housing.
Inspection.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open right side engine compartment access doors (Figure 1-2).
ARMY TM 9-6115-671-14
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MARINE CORPS TM 09249A/09246A-14
FIGURE 4-27. ETHER START SYSTEM
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NOTE
Cylinder bracket assembly is located on the inside wall of the generator housing and
cannot be adequately inspected when installed.
c.
4.11.8
(3)
Remove ether cylinder, step a above.
(4)
Inspect cylinder bracket assembly (8, Figure 4-27) for cracks, corrosion, stripped or damaged
threads, and other damage.
(5)
Shake ether cylinder, and listen for liquid. If there is little or no sound of liquid in cylinder, replace
cylinder.
(6)
Install ether cylinder assembly, step c below.
Installation.
(1)
Install bolts (9, Figure 4-27), cylinder bracket assembly (8), washers (7), lockwashers (6), and nuts
(5) on generator set housing.
(2)
Remove cap (4) from ether solenoid valve (3).
(3)
Insert ether cylinder (2) through cylinder bracket assembly (8), and screw cylinder into ether
solenoid valve (3).
(4)
Close clamp of cylinder bracket assembly (8), and tighten wingnut (1).
(5)
Close engine compartment access doors.
Ether Solenoid Valve L6.
a.
Removal.
(1)
Shut down generator set, paragraph 2.11.2.
__________
WARNING
DC voltages are present at generator set electrical components even with
generator shut down. Avoid shorting any positive terminal with
ground/negative. Failure to comply can cause injury to personnel and damage
to equipment.
4-180
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Open right side engine compartment access doors (Figure 1-2).
(4)
Tag and disconnect electrical leads from ether solenoid valve (3, Figure 4-27).
(5)
Disconnect tube assembly (10) from adapter (19) and spray nozzle (11).
(6)
Loosen wingnut (1), and unscrew ether cylinder (2) from ether solenoid valve (3).
(7)
Install cap (4) on ether solenoid valve (3).
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
b.
c.
(8)
Remove nuts (12), lockwashers (13), washers (14), relay (16), and bolts (15) from generator set
housing.
(9)
Remove bolts (17) from bracket (18) and remove solenoid (3) from bracket.
(10)
Remove adapter (19) from solenoid (3).
(11)
Remove spray nozzle (11) from engine intake manifold.
(12)
Close engine compartment doors.
Inspection.
(1)
Remove ether solenoid valve, step a above.
(2)
Inspect ether solenoid valve (3, Figure 4-27) for cracks, corrosion, damaged threads, and other
damage.
(3)
Inspect tube assembly (10) for cracks, breaks, pinching, damaged threads, and other damage.
(4)
Inspect spray nozzle (11) for cracks, corrosion, clogging, and other damage.
(5)
Replace any defective parts.
(6)
Install ether solenoid valve, step c below.
Installation.
(1)
Open right side engine compartment access doors (Figure 1-2).
(2)
Install spray nozzle (11, Figure 4-27) on engine intake manifold.
(3)
Install adapter (19) into solenoid (3).
(4)
Install solenoid (3) to bracket (18) with bolts (17).
(5)
Install relay (16), bolts (15), washers (14), lockwashers (13), and bolts (12) on generator set
housing.
(6)
Remove cap (4) from ether solenoid valve (3).
(7)
Insert ether cylinder (2) through cylinder bracket assembly (8), and screw cylinder into ether
solenoid valve (3).
(8)
Close clamp of cylinder bracket assembly (8), and tighten wingnut (1).
(9)
Connect tube assembly (10) to adapter (19) and spray nozzle (11).
(10)
Connect electrical leads to ether solenoid valve (3). Remove tags.
(11)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
(12)
Close engine compartment access doors.
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4.11.9
Ether Solenoid Relay.
a.
b.
c.
d.
Inspection.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open right side engine compartment access doors (Figure 1-2).
(3)
Inspect ether solenoid relay (16, Figure 4-27) for cracks, loose mounting and other damage.
(4)
Replace damaged parts.
(5)
Close engine compartment access doors.
Removal.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open battery access door (Figure 1-2) and disconnect negative battery cable.
(3)
Open right side engine access doors.
(4)
Tag and disconnect electrical wires from ether solenoid relay (16).
(5)
Remove nut (12), lockwasher (13), washer (14), bolt (15), and ether solenoid relay (16).
Testing.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Tag and disconnect electrical leads to the ether solenoid relay (16, Figure 4-27) and remove from
generator set.
(3)
Set multimeter for ohms, and connect leads between terminals 85 and 86, and check for an
indication of 288 to 352 ohms.
(4)
If indications are other than above, relay is defective and must be replaced.
(5)
Attach electrical leads to ether solenoid relay K24 (16) and remove tags.
Installation.
(1)
Install ether solenoid relay (16, Figure 4-27) with bolts (15), washers (14), lockwashers (13), and
nuts (12).
(2)
Attach electrical leads to ether solenoid relay (16) and remove tags.
(3)
Connect negative battery cable to battery, and close battery access door (Figure 1-2) and right side
engine access doors (Figure 1-2).
4.11.10 Fuel Filter/Water Separator.
a.
4-182
Inspection.
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
(1) Shut down Generator set , Paragraph 2.11.2
(2) Open right side engine compartment access doors (Figure 1-3).
(3) Inspect Fuel Filter/Water Separator Assembly (25, Fig 1-30) for proper mounting, physical damage,
leaks, and loose fuel lines.
(4) Close Engine compartment access door.
b.
Service.
(1) Shut down Generator set, Paragraph 2.11.2
(2) Open right side engine compartment access doors (Figure 1-2).
(3) Open drain cock (2, Fig 3-5) and Air Vent (1, Fig 3-5), and drain water and sediment into suitable
container.
(4) Close Drain Cock (2, Fig 3-5) and Air Vent (1, Fig 3-5).
(5) Close Engine Compartment access doors.
c.
Removal.
(1) Refer to Engine Manual 9-2815-259-24, Paragraph 3.12.2.
d.
Installation.
(1) Refer to Engine Manual 9-2815-259-24, Paragraph 3.12.2.
4.12
MAINTENANCE OF OUTPUT BOX ASSEMBLY.
__________
WARNING
When disconnecting or removing batteries, disconnect the negative lead that
connects directly to the grounding stud first. Disconnect the negative end of
the interconnection cable next. When installing batteries, reverse the
connection sequence. Failure to comply can cause serious personal injury.
4.12.1
Voltage Reconnection Terminal Board TB1.
a.
Inspection.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open battery access door (Figure 1-2) and disconnect negative cable.
(3)
Open output box access door (Figure 1-2).
(4)
Inspect protective cover (3, Figure 4-28) and moveable terminal board (6) for cracks, breaks,
corrosion, and other damage.
(5)
Replace defective parts.
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b.
c.
4.12.2
(6)
Connect negative battery cable to battery and close battery access door.
(7)
Close output box access door.
Removal.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Open output box access door (Figure 1-2).
(4)
Remove locknuts (1, Figure 4-28), washers (2), and protective cover (3) from standoffs (4).
(5)
Remove locknuts (5) and moveable terminal board (6) from terminal studs (7).
Installation.
(1)
Install moveable terminal board (6, Figure 4-28) and locknuts (5) on terminal studs (7).
(2)
Install protective cover (3), washers (2), and locknuts (1) on standoffs (4).
(3)
Close output box access door.
(4)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
Output Box Wiring Harness.
a.
Inspection.
(1)
Shut down generator set, paragraph 2.11.2.
(2) Open output box access door (Figure 1-2).
4-184
(3)
Inspect wiring harness (8, Figure 4-28) for burned, bent, corroded, and broken terminals.
(4)
Inspect connectors for cracks, corrosion, stripped threads, bent or broken pins, and obvious damage.
(5)
Inspect wire insulation for burns, deterioration, and chafing.
(6)
Close output box access door.
ARMY TM 9-6115-671-14
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MARINE CORPS TM 09249A/09246A-14
FIGURE 4-28. OUTPUT BOX ASSEMBLY
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b.
c.
4.12.3
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Open output box and engine compartment access doors (Figures 1-2 and 1-3).
(4)
Set multimeter for ohms, and test individual wires of wiring harness (8, Figure 4-28) for continuity.
Refer to wiring diagram, FO-3, for wire identification.
(5)
Close output box and engine compartment access doors.
(6)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
Repair.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Open applicable access doors (Figures 1-2 and 1-3).
(4)
Replace damaged terminals and securing hardware.
(5)
Close access doors.
(6)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
Current Transformer CT1, CT2, CT3.
a.
b.
4-186
Testing.
Inspection.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open output box access door (Figure 1-2).
(3)
Inspect current transformer (9, Figure 4-28) for security, cracked housing, broken or stripped
terminals, and loose or missing hardware.
(4)
Close output box access door.
Testing.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Open output box access door (Figure 1-2).
(4)
Tag and disconnect electrical leads from current transformer (9, Figure 4-28) secondary terminals
A1, A2, B1, B2, C1 and C2.
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
4.12.4
Set multimeter for ohms, and check for continuity between secondary terminals A1 and A2, B1 and
B2, and C1 and C2.
(6)
If continuity is not present, current transformer is defective. Notify next higher level of
maintenance.
(7)
If continuity is present, connect electrical leads to secondary terminals A1, A2, B1, B2, C1, and C2.
Remove tags.
(8)
Close output box access door.
(9)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
Droop Current Transformer CT5.
a.
4.12.5
(5)
Inspection.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open output box access door (Figure 1-2).
(3)
Inspect droop current transformer (10, Figure 4-28) for security, cracked housing, broken wire
terminals, and loose or missing hardware. If testing or replacement is required, notify next higher
level of maintenance.
(4)
Close output box access door.
Power Potential Transformer T1.
a.
Inspection.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open output box access door (Figure 1-2).
(3)
Inspect potential power transformer (11, Figure 4-28) for security, cracked housing, broken wire
terminals, and loose or missing hardware. If testing or replacement is required, notify next higher
level of maintenance.
(4)
Close output box access door.
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4.12.6
AC Circuit Interrupter K1.
a.
b.
c.
4-188
Inspection.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open output box access door (Figure 1-2).
(3)
Inspect AC circuit interrupter (17, Figure 4-28) for security, cracked housing, broken wire terminals,
and loose or missing hardware.
(4)
Close output box access door.
Testing.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Open output box access door (Figure 1-2).
(4)
Set multimeter for ohms, and check for open circuits between AC circuit interrupter (17, Figure 428) terminals A1 and A2, B1 and B2, C1 and C2, and 11 and 12.
(5)
Connect jumper wire from cranking relay (20) terminal A1 to AC circuit interrupter (17) terminal X.
(6)
Connect negative battery cable to battery.
(7)
Check for closed circuits (continuity) between AC circuit interrupter (17) terminals A1 and A2, B1
and B2, C1 and C2, and 11 and 12.
(8)
Disconnect negative battery cable.
(9)
Replace AC circuit interrupter if indications are other than as specified above.
(10)
If replacement is not necessary, remove jumper wire from terminal A1 of cranking relay (20) to
terminal X of AC circuit interrupter (17).
(11)
Close output box access door.
(12)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
Replacement.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Open output box and load terminal board access doors (Figure 1-2).
(4)
Remove rear panel. Refer to paragraph 4.7.5.
(5)
Remove screws (12, Figure 4-28), washers (13), and cover (14) from AC circuit interrupter (17).
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
4.12.7
(6)
Tag and disconnect electrical leads from AC circuit interrupter (17).
(7)
Remove locknuts (15), screws (16), and AC circuit interrupter (17) from output box.
(8)
Install AC circuit interrupter (17, Figure 4-28), screws (16), and locknuts (15) on output box.
(9)
Connect electrical leads to AC circuit interrupter (17). Remove tags.
(10)
Install cover (14), washers (13), and screws (12) on AC circuit interrupter (17).
(11)
Install rear panel. Refer to paragraph 4.7.5.
(12)
Close output box and load terminal board access doors.
(13)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
Cranking Relay K2.
a.
b.
Inspection.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open output box access door (Figure 1-2).
(3)
Inspect cranking relay (20, Figure 4-28) for security, cracked housing, broken wire terminals, and
loose or missing hardware.
(4)
Close output box access door.
Testing.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Open output box access door (Figure 1-2).
(4)
Tag and disconnect wires from terminals X1, X2, and A2 of cranking relay (20, Figure 4-28).
(5)
Connect a jumper wire between terminals A1 and X1 of cranking relay (20).
(6)
Connect negative battery cable to battery.
(7)
Connect X2 wires disconnected in step 4 to cranking relay (20) terminal X2. Listen for audible
actuation.
(8)
Set multimeter for ohms, and check for continuity between terminals A1 and A2 of cranking relay
(20). If no continuity is indicated, cranking relay is defective. Notify next higher level of
maintenance.
(9)
If cranking relay (20) is not defective, disconnect negative battery cable.
(10)
Remove jumper wire from cranking relay (20).
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c.
4.12.8
Connect wires to terminals X1 and A2 of cranking relay (20). Remove tags.
(12)
Close output box access door.
(13)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
Replacement.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Open output box and right side engine compartment access doors (Figure 1-2).
(4)
Tag and disconnect electrical leads from cranking relay (20, Figure 4-28).
(5)
Remove locknuts (18), screws (19), and cranking relay (20) from output box.
(6)
Install cranking relay (20), screws (19), and locknuts (18) on output box.
(7)
Connect electrical leads to cranking relay (20). Remove tags.
(8)
Close output box and right side engine compartment access doors.
(9)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
Load Output Terminal Board TB2.
a.
4-190
(11)
Removal.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Open load terminal board access door (Figure 1-2), and disconnect load output cables L1, L2, L3,
and N from load output terminal board.
(4)
Remove rear housing panel. Refer to paragraph 4.7.5.
(5)
Remove locknut (1, Figure 4-29), bolt (2), and lockwashers (3) securing ground strap (20) to skid
base.
(6)
Remove bolts (4), lockwashers (5), and washers (6) securing load output terminal board (11) to
supports (34 and 35).
(7)
Remove locknuts (7), brass washers (8), electrical leads (9), and varistor leads (10) from load
terminals (14). Tag leads.
(8)
Remove terminal load board (11) from generator set.
(9)
Remove jamnuts (12), brass washers (13), and load terminals (14) from load output terminal board
(11).
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
b.
(10)
Remove locknuts (15), washers (16), and bus bar (17) from terminal studs (21 and 26).
(11)
Remove locknut (18), lockwasher (19), ground strap (20), and terminal stud (21) from load output
terminal board (11).
(12)
Remove locknut (22), washer (23), ground bus bar (24), EMI filter (25), and terminal stud (26) from
load output terminal board (11).
(13)
Disconnect varistor leads (10) from varistors (29).
(14)
Remove locknuts (27), bolts (28), varistors (29), EMI filters (30), and ground plane bar (31) from
load output terminal board (11).
(15)
Remove locknuts (32), bolts (33), and terminal board supports (34 and 35) from generator set.
(16)
Remove locknuts (36), bolts (37), cord (38), insulated wrench (39), and bracket (40) from terminal
board support (34).
Inspection.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open load output terminal board access door (Figure 1-2).
(3)
Inspect load output terminal board (11, Figure 4-29) for cracks, corrosion, and obvious damage.
(4)
Inspect load terminals (14) for stripped threads or other obvious damage.
(5)
Inspect varistor leads (10) for damaged insulation and loose terminals.
(6)
Inspect and test varistors (29) as follows:
(a)
Inspect varistors (29) for obvious external damage.
(b)
Remove varistors, refer to paragraph 4.12.8.a.
(c)
Set multimeter for ohms, and test each varistor by connecting multimeter to varistor terminals
1 and 2. Note multimeter indication.
(d)
Reverse multimeter leads, and note multimeter indication.
(e)
Multimeter indications should be infinite in both directions.
(f)
If indications are other than above, varistors (29) are defective and must be replaced.
(g)
Install varistors, refer to 4.12.8.d.
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FIGURE 4-29. LOAD OUTPUT TERMINAL BOARD ASSEMBLY (SHEET 1 OF 2)
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FIGURE 4-29. LOAD OUTPUT TERMINAL BOARD ASSEMBLY (SHEET 2 OF 2)
c.
(7)
Inspect cage nuts (41) for cracking or stripped threads.
(8)
Replace damaged and defective parts.
(9)
Close load output terminal board access door.
Repair.
Repair load output terminal board assembly by replacing damaged or defective wires, load terminals, EMI
filters, and varistors.
d.
Installation.
(1)
Install bracket (40, Figure 4-29), insulated wrench (39), cord (38), bolts (37), and locknuts (36) on
terminal board support (34).
(2)
Install terminal board supports (34 and 35), bolts (33), and locknuts (32) on generator set.
NOTE
Position EMI filters to align with mounting holes for load terminals L1, L2, and
L3 respectively.
(3)
Install ground plane bar (31), EMI filters (30), varistors (29), bolts (28), and locknuts (27) on load
output terminal board (11).
(4)
Connect varistor leads (10) to varistors (29).
(5)
Install terminal stud (26), EMI filter (25), ground bus bar (24), washer (23), and locknut (22).
(6)
Install terminal stud (21), ground strap (20), lockwasher (19), and locknut (18) on load output
terminal board (11). Do not tighten locknut.
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4.13
(7)
Install bus bar (17), washers (16), and locknuts (15) on terminal studs (21 and 26).
(8)
Install load terminals (14), brass washers (13), and jamnuts (12) on load output terminal board (11).
(9)
Position load output terminal board (11) in generator set.
(10)
Install varistor leads (10), electrical leads (9), brass washers (8), and locknuts (7) on load terminals
(14). Remove tags.
(11)
Secure load output terminal board (11) to terminal board supports (34 and 35) with washers (6),
lockwashers (5), and bolts (4).
(12)
Apply a thin coat of antiseize compound (6, Appendix E) to skid base at ground strap mating
surface.
(13)
Secure ground strap (20) to skid base with lockwashers (3), bolt (2), and locknut (1). Tighten
locknut (18).
(14)
Install rear housing panel. Refer to paragraph 4.7.5.
(15)
Connect load output cables L1, L2, L3, and N to load output terminal board assembly, and close
load terminal board access door.
(16)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
MAINTENANCE OF ENGINE ACCESSORIES.
__________
WARNING
When disconnecting or removing batteries, disconnect the negative lead that
connects directly to the grounding stud first. Disconnect the negative end of
the interconnection cable next. When installing batteries, reverse the
connection sequence. Failure to comply can cause serious personal injury.
4.13.1
Oil Pressure Sender MT7.
a.
4-194
Testing.
(1)
Start generator set, paragraph 2.11.1.
(2)
Open left side engine compartment access doors (Figure 1-3).
(3)
Set multimeter to VDC. Place positive lead of multimeter on the black wire lead of the oil pressure
sender connector, and the negative lead to ground. Readings shall be between 1 and 5 VDC.
(4)
Shut down generator set, paragraph 2.11.2.
(5)
If indications are not as above, replace oil pressure sender (1), refer to paragraph 4.13.1. b and d.
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
FIGURE 4-30. ENGINE SWITCHES AND SENDERS
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b.
Removal.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Open left side engine compartment access doors (Figure 1-3).
(4)
Disconnect electrical plug connector from oil pressure sender (1, Figure 4-30).
(5)
c.
Remove oil pressure sender (1) from adapter (10).
Service.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Remove oil pressure sender, refer to paragraph 4.13.1.b.
__________
WARNING
Cleaning with compressed air can cause flying particles. When using
compressed air, wear protective glasses and use clean, low pressure air, less
than 30 psi (206.8 kPa). Failure to comply can cause eye injury.
__________
WARNING
Dry cleaning solvent is flammable and toxic to eyes, skin, and respiratory tract.
Skin and eye protection are required when working in contact with dry
cleaning solvent. Avoid repeated or prolonged contact. Work in ventilated
area only. Failure to comply can cause injury or death to personnel.
d.
(3)
Clean oil pressure sender with dry, filtered compressed air, and wipe with a clean, lint-free cloth
(Item 8, Appendix E) lightly moistened with dry cleaning solvent (Item 20, Appendix E).
(4)
Inspect oil pressure sender for cracked casing, stripped or damaged threads, corrosion, or other
damage.
(5)
Replace oil pressure sender if damaged.
(6)
Install oil pressure sender, refer to paragraph 4.13.1.d.
Installation.
CAUTION
Use care not to introduce pipe thread sealing compound into the pressure
orifice in the end of the oil pressure sender. Sealing compound in the pressure
orifice can cause the oil pressure sender to malfunction and result in damage to
equipment.
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4.13.2
(1)
Apply sealing compound (Item 22, Appendix E) to threads of oil pressure sender (1, Figure 4-30),
and install switch on adapter (10).
(2)
Connect electrical plug connector to oil pressure sender (1). Remove tags.
(3)
Close engine compartment access doors.
(4)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
Coolant Temperature Sender MT6.
a.
b.
Testing.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Open left side engine compartment access doors (Figure 1-3).
(4)
Remove dead crank switch plate, refer to paragraph 4.14.4.
(5)
Disconnect electrical plug connector from coolant temperature sender (2, Figure 4-30) by
unscrewing retaining ring.
(6)
Set multimeter for ohms, and connect positive lead to temperature sender terminal and negative lead
to pin 4. Multimeter should indicate as follows:
At 70°F, ohm range is 108-111ohms. For each +10°F, add two ohms to either end of range. For
each -10°F, subtract two ohms.
Example:
At 80°F range, should equal 110-113 ohms.
At 60°F, range should equal 106-109 ohms.
(7)
Connect negative battery cable to battery.
(8)
Start up generator set, paragraph 2.11.1.
(9)
Allow engine to operate while observing multimeter. Ohms indication should decrease as
temperature rises.
(10)
Shut down generator set, paragraph 2.11.2.
(11)
Disconnect negative battery cable.
(12)
If indications are not as above, replace coolant temperature sender (2). Refer to paragraph 4.13.2.
b.
(13)
If coolant temperature sender (2) meets above requirements, connect electrical plug connector to
sender by tightening retaining ring.
(14)
Close engine compartment access doors.
(15)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
Removal.
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(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
__________
WARNING
Cooling system operates at high temperature and pressure. Contact with high
pressure steam and/or liquids can result in burns and scalding. Shut down
generator set, and allow system to cool before performing checks, services, and
maintenance. Failure to comply can cause injury or death to personnel.
c.
(3)
Slowly remove radiator cap (1, Figure 4-22) from filler neck (2).
(4)
Open left side engine compartment access doors (Figure 1-3), open engine block drain valve (3,
Figure 4-30), and drain coolant into suitable container.
(5)
Close engine block drain valve (3).
(6)
Disconnect electrical plug connector from coolant temperature sender (2).
(7)
Remove coolant temperature sender (2) from engine head.
Service.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Remove coolant temperature sender, refer to paragraph 4.13.2. b.
__________
WARNING
Cleaning with compressed air can cause flying particles. When using
compressed air, wear protective glasses and use clean, low pressure air, less
than 30 psi (206.8 kPa). Failure to comply can cause eye injury.
__________
WARNING
Dry cleaning solvent is flammable and toxic to eyes, skin, and respiratory tract.
Skin and eye protection are required when working in contact with dry
cleaning solvent. Avoid repeated or prolonged contact. Work in ventilated
area only. Failure to comply can cause injury or death to personnel.
d.
4-198
(3)
Clean coolant temperature sender with dry, filtered compressed air, and wipe with a clean, lint-free
cloth (Item 8, Appendix E) lightly moistened with dry cleaning solvent (Item 20, Appendix E).
(4)
Inspect coolant temperature sender for cracked casing, stripped or damaged threads, corrosion, or
other damage.
(5)
Replace coolant temperature sender if damaged.
(6)
Install coolant temperature sender, 4.13.2.d.
Installation.
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
4.13.3
(1)
Apply sealing compound (Item 22, Appendix E) to threads of coolant temperature sender (2, Figure
4-30), and install switch on engine block.
(2)
Connect electrical plug connector to coolant temperature sender (2).
(3)
Add coolant/antifreeze to proper level at the filler neck (2, Figure 4-22).
(4)
Install radiator cap (1) on filler neck (2).
(5)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
(6)
Start generator set, paragraph 2.11.1. Allow unit to reach operating temperature, and check for
leaks.
(7)
Add coolant/antifreeze to overflow bottle as required.
(8)
Close engine compartment access doors.
Magnetic Pickup MPU.
a.
b.
Removal.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Open left side engine compartment access doors (Figure 1-3).
(4)
Disconnect electrical plug connector from magnetic pickup (4, Figure 4-30).
(5)
Loosen locknut (5), and remove magnetic pickup (4) from flywheel housing.
Service.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Remove magnetic pickup, refer to paragraph 4.13.3.a.
WARNING
Cleaning with compressed air can cause flying particles. When using
compressed air, wear protective glasses and use clean, low pressure air, less
than 30 psi (206.8 kPa). Failure to comply can cause eye injury.
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__________
WARNING
Dry cleaning solvent is flammable and toxic to eyes, skin, and respiratory tract.
Skin and eye protection is required when working in contact with dry cleaning
solvent. Avoid repeated or prolonged contact. Work in ventilated area only.
Failure to comply can cause injury or death to personnel.
c.
d.
4-200
(3)
Clean magnetic pickup with dry, filtered compressed air, and wipe with a clean, lint-free cloth (Item
8, Appendix E) lightly moistened with dry cleaning solvent (Item 20, Appendix E).
(4)
Inspect magnetic pickup for cracked casing, stripped or damaged threads, corrosion, and bent or
broken connector pins.
(5)
Replace magnetic pickup if damaged.
(6).
Install magnetic pickup, 4.13.3.c.
Installation.
(1)
Screw magnetic pickup (4, Figure 4-30) into flywheel housing until pickup bottoms out on flywheel.
Back magnetic pickup out 1 1/2 turns. Tighten locknut (5).
(2)
Connect electrical plug connector to magnetic pickup (4). Remove tags.
(3)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
(4)
Adjust magnetic pickup (4), 4.13.3.d.
(5)
Close engine compartment access doors.
Testing.
(1)
Disconnect P13 from receptacle J13 at magnetic pickup. Refer to FO-1.
(2)
Set multimeter for VAC, and connect multimeter positive lead to terminal B of P13 and negative
lead to terminal A.
(3)
Set MASTER CONTROL switch to ON and crank engine with DEAD CRANK switch. Observe
multimeter. Indication should be between 1.0 and 1.5 VAC.
(4)
If indications are not as above, replace magnetic pickup. Refer to paragraph 4.13.3.
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
4.13.4
DEAD CRANK Switch S10.
a.
b.
4.13.5
Testing.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Open left side engine compartment access doors (Figure 1-3).
(4)
Remove DEAD CRANK switch from plate. Refer to paragraph 4.13.4.b.
(5)
Tag and disconnect electrical leads from DEAD CRANK switch (9, Figure 4-30).
(6)
Set multimeter for ohms and with switch in NORMAL position, check for continuity between
contacts 2 and 3.
(7)
Move switch to CRANK position, and check for continuity between contacts 1 and 2.
(8)
If DEAD CRANK switch (9) fails continuity checks, replace switch.
(9)
If DEAD CRANK switch (9) meets above requirements, connect electrical leads to switch.
(10)
Attach DEAD CRANK switch to plate. Refer to paragraph 4.13.4.b.
(11)
Close engine compartment access doors.
(12)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
Replacement.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Open left side engine compartment access doors(Figure 1-3).
(4)
Remove nut (6), lockwasher (7), key washer (8), and DEAD CRANK switch (9) from DEAD
CRANK bracket (11).
(5)
Tag and disconnect electrical leads from DEAD CRANK switch (9, Figure 4-30).
(6)
Connect electrical leads to DEAD CRANK switch (9). Remove tags.
(7)
Attach DEAD CRANK switch (9), key washer (8), lockwasher (7), and nut (6) to DEAD CRANK
bracket (11).
(8)
Close engine compartment doors.
(9)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
Battery Current Transducer BCT.
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a.
b.
c.
4-202
Inspection.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open right side engine compartment access door, (Figure 1-2).
(3)
Verify that BCT (1, Figure 4-31) housing is not damaged and is securely mounted to its bracket.
(4)
Check plug P1 (2) and wires for broken or chaffed wires.
(5)
Close right side engine compartment access door, (Figure 1-2).
Testing.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open battery access door, (Figure 1-2). Disconnect negative battery cable.
(3)
Disconnect P1 (2) from J1 (3) at the battery current transducer. Refer to Schematic FO-1.
(4)
Apply 12VDC at P1 (2) positive DC to red wire, and negative DC to black wire.
(5)
Set multimeter to VDC and place positive test lead to green wire on P1(2). Place negative test lead
to black wire P1. Multimeter should indicate 5.9 VDC - 6.1 VDC.
(6)
If multimeter indicates value other than above, replace Battery Current Transducer (1).
Replacement.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open battery access door, (Figure 1-2). Disconnect negative battery cable.
(3)
Open right side engine compartment access door, (Figure 1-2).
(4)
Disconnect P1 (2) from J1 (3) at the battery current transducer.
(5)
Tag and remove wire number 310A16 (FO-1) from positive post of alternator by removing nut (4),
washer (5), terminal washer (6) and isolating washer (7).
(6)
Cut ring terminal (8) from wire number 310A16 and feed wire through the top of the battery current
transducer (1).
(7)
Tag and remove wire number 145C16 from the positive post of battery number one.
(8)
Cut ring terminal from wire number145C16 and feed the wire through the top of the battery current
transducer (1).
(9)
Remove the bolts (9), washer (10) and nuts (11) on the battery current transducer.
ARMY TM 9-6115-671-14
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MARINE CORPS TM 09249A/09246A-14
FIGURE 4-31. BATTERY CURRENT TRANSDUCER
4-203
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4.14
(10)
Place new battery current transducer on bracket (12). Verify that holes line up with mounting
bracket (12).
(11)
Attach battery current transducer (1) to bracket (12) with bolts (9), washer (10) and nuts (11).
(12)
Feed wire number 310A16 through the battery current transducer.
(13)
Strip 1/4 " of insulation from the end of wire 310A16.
(14)
Crimp ring terminal (8) to the end of wire 310A16.
(15)
Attach wire number 310A16 to the positive post of the alternator with isolating washer (7), terminal
washer (6), washer (5) and nut (4).
(16)
Feed wire number 145C16 through the top of the battery current transducer (1) and route to the
battery compartment.
(17)
Strip 1/4 " of insulation from the end of wire 145C16.
(18)
Crimp ring terminal to the end of wire 145C6.
(19)
Attach wire number 145C16 to the positive post of battery number one. Refer to Schematic FO-1.
(20)
Reconnect negative cable to battery.
(21)
Close battery access door, (Figure 1-2).
(22)
Close right side engine compartment access door, (Figure 1-2).
MAINTENANCE OF LUBRICATION SYSTEM.
__________
WARNING
When disconnecting or removing batteries, disconnect the negative lead that
connects directly to the grounding stud first. Disconnect the negative end of
the interconnection cable next. When installing batteries, reverse the
connection sequence. Failure to comply can cause serious personal injury.
4.14.1
Oil Drain Valve.
a.
4-204
Inspection.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS and right side engine compartment access doors (Figure 1-2).
(3)
Inspect oil drain line for cracks, holes, loose or missing hardware, or other damage.
(4)
Close BATTERY ACCESS and right side engine compartment access doors.
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
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b.
Replacement.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Open right side engine compartment access doors (Figure 1-2).
(4)
Remove plug (1, Figure 4-32), open drain valve (4), and drain engine oil into suitable container.
(5)
Loosen hose clamps (2), and remove oil drain hose from adapters (3 and 7).
(6)
Remove adapter (3) from drain valve (4).
(7)
Remove drain valve (4) from pipe fitting (5).
(8)
Remove pipe fitting (5) from skid base fitting (6).
(9)
Apply sealing compound (Item 22, Appendix E) to threads of pipe fitting (5, Figure 4-32). Install
pipe fitting (5) on skid base fitting (6), and drain valve (4) on pipe fitting.
(10)
Apply sealing compound (Item 22, Appendix E) to pipe threads of adapters (3 and 7). Install
adapter on drain valve (4).
(11)
Position hose clamp (2) on oil drain hose. Connect hose to adapters (3 and 7), and tighten hose
clamp.
(12)
Apply sealing compound (Item 22, Appendix E) to threads of plug (1). Install plug on skid base
fitting (6).
(13)
Service lubrication system, paragraph 3.3.8.
(14)
Check engine oil drain line and valve for leakage.
(15)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
(16)
Close engine compartment access doors.
4-205
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FIGURE 4-32. OIL DRAIN VALVE
4-206
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SECTION VII. PREPARATION FOR SHIPMENT AND STORAGE
4.15
PREPARATION FOR SHIPMENT AND STORAGE.
4.15.1
Preservation.
Preserve generator set in accordance with levels A, B, or C of MIL-G-28554.
Preserve generator set cooling systems in accordance with method II of MIL-G-28554 or the antifreeze and
winter procedure of MIL-E-10062.
4.15.2
Packing.
Pack generator sets in accordance with levels A, B, or C of MIL-G-28554.
4.15.3
Marking.
Mark for shipment or storage in accordance with MIL-STD-129.
4.15.4
Use of Corrosion-Preventive Compounds, Moisture Barriers, and Desiccant Materials.
Refer to corrosion and Corrosion Prevention/Metal, MIL-HDBK-729.
4.15.5
Special Instructions for Administrative Storage.
Placement of equipment in administrative storage should be for short periods of time when a shortage of
maintenance effort exists. Items should be in mission readiness within 24 hours or within the time factors as
determined by the directing authority. During the storage period, appropriate maintenance records shall be
kept.
Before placing the equipment in administrative storage, current preventive maintenance checks and services
should be completed, shortcomings and deficiencies should be corrected, and all Modification Work Orders
(MWO) should be applied.
Inside storage is preferred for items selected for administrative storage. If inside storage is not available,
trucks, vans, conex containers, and other containers may be used.
4.15.6
General Storage.
For storage information refer to TB 740-97-2.
4-207
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4.16
CIM CONFIGURATION SWITCH
An eight position DIP Switch illustrated below is located beneath a protective plastic cover on the front of
the Computer Interface Module. This switch defines the configuration of the generator set for the
Computer Interface Module. The generator set configuration is defined in two ways: Output power
(KW) rating, and Frequency rating. This switch must be set to a specific configuration
corresponding to the table below prior to the module’s use in the generator set. Unless this switch is
properly configured, the generator set can experience a malfunction.
Configuration Switches Description:
There are eight rocker-type switches in one switch assembly, which is accessible from the front of the module. Each switch is
numbered left to right when viewing the module from the front. Each may be placed in either a “up” (on) or “down” (off) position,
which correspond to a logical “1” or “0” configuration.
SWITCH NUMBER
1- 4
5
6-8
WHAT CONFIGURATION IS CONTROLLED BY THESE SWITCHES
Power rating (30, 60 KW)
Frequency (50/60 or 400 Hz)
Not assigned.
The switch positions applicable to the 30 KW TQG sets are as follows:
Input/Output Module, Model TCM100:
SWITCH
Setting
1
off
2
off
3
off
4
off
5
off
6
off
7
off
8
off
GEN SET TYPE
30 KW, 50/60 Hz MEP-805B
Input/Output Module, Model TCM400:
SWITCH
Setting
4-208
1
off
2
off
3
off
4
off
5
on
6
off
7
off
8
off
GEN SET TYPE
30 KW, 400 Hz MEP-815B
ARMY TM 9-6115-671-14
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CHAPTER 5
DIRECT SUPPORT MAINTENANCE INSTRUCTIONS
CHAPTER INDEX
SECTION I
REPAIR PARTS, TOOLS, TEST, MEASUREMENT AND DIAGNOSTIC
(TMDE, AND SUPPORT EQUIPMENT......................................................................................5-1
SECTION II
LUBRICATION PROCEDURES..................................................................................................5-1
SECTION III
TROUBLESHOOTING.................................................................................................................5-2
SECTION IV
DIRECT SUPPORT MAINTENANCE PROCEDURES............................................................5-14
NOTE
Procedures may require CD-ROM. See Appendix C.
SECTION I. REPAIR PARTS; TOOLS; TEST, MEASUREMENT
AND DIAGNOSTIC (TMDE); AND SUPPORT EQUIPMENT
5.1
INTRODUCTION.
5.1.1
Maintenance Repair Parts. Repair parts and equipment are listed and illustrated in the Repair Parts and
Special Tools List (RPSTL) manual TM 9-6115-671-24P.
5.1.2
Tools and Equipment. There are no special tools or support equipment required to perform direct support
level of maintenance on the generator set. A list of recommended tools and support equipment required to
maintain the generator set is contained in Appendix B, Section III.
5.1.3.
Fabrication of Tools and Equipment. No requirement exists for fabrication of tools and equipment for
maintenance of the generator set.
SECTION II. LUBRICATION PROCEDURES
5.2
DIRECT SUPPORT LUBRICATION INSTRUCTIONS. There are no special lubrication instructions
required to perform direct support level of maintenance. Refer to LO 9-6115-644-12 for generator set
lubrication requirements.
5-1
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MARINE CORPS TM 09249A/09246A-14
SECTION III. TROUBLESHOOTING
5.3
GENERAL.
This section contains troubleshooting information for locating and correcting operating troubles which may
develop in the generator set. Each malfunction for an individual component unit or system is followed by a
list of tests or inspections which will help to determine probable causes and corrective actions to take.
Perform the tests/inspections in the order listed.
Table 5-1 is provided for direct support troubleshooting. This table cannot list all malfunctions that may
occur, nor all tests or inspections and corrective actions. If a malfunction is not listed, or is not corrected by
listed corrective actions, notify your supervisor.
NOTE
Before using this table, PMCS and lower level troubleshooting must be
performed.
NOTE
Refer to paragraph 2.4 for diagnostic controls and indicators.
SYMPTOM INDEX
Page
Engine Cranks, But Fails To Start ..............................................................................................................................5-3
Engine Runs Erratically or Stalls Frequently..............................................................................................................5-4
Engine Does Not Develop Full Power........................................................................................................................5-4
Abnormal Engine Noise..............................................................................................................................................5-5
Black or Gray Exhaust Smoke ....................................................................................................................................5-6
Blue or White Exhaust Smoke....................................................................................................................................5-6
Engine Misfiring .........................................................................................................................................................5-7
Coolant In Crankcase or Oil In Coolant......................................................................................................................5-7
Generator Set Fails To Generate Sufficient Voltage...................................................................................................5-8
Generator Set Output Fluctuates.................................................................................................................................5-9
Generator Noisy When Running...............................................................................................................................5-10
Engine Oil Pressure Low ..........................................................................................................................................5-11
Engine Oil Pressure High .........................................................................................................................................5-11
FAULT INDICATOR Displays WARNING - UNDERVOLTAGE or CONTACTOR TRIP UNDERVOLTAGE...........................................................................................................................................5-12
FAULT INDICATOR Displays SHUTDOWN - OVERSPEED..............................................................................5-13
5-2
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TABLE 5-1. DIRECT SUPPORT TROUBLESHOOTING
ENGINE CRANKS BUT FAILS TO START
Engine cranks but fails to start.
Not OK
Adjust fuel injection pump
timing. Refer to TM
9-2815-259-24.
Verify fuel injection
pump timing. Refer to TM
9-2815-259-24.
Not OK
Replace electric
actuator
(para 5.9.1).
OK
Test electric actuator
(see para 5.9.1).
OK
Refer to TM
9-2815-259-24.
5-3
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TABLE 5-1. DIRECT SUPPORT TROUBLESHOOTING (CONTINUED)
ENGINE RUNS ERRATICALLY OR STALLS FREQUENTLY
Engine runs erratically or
stalls frequently.
Refer to TM
9-2815-259-24.
ENGINE DOES NOT DEVELOP FULL POWER
Engine does not
develop full power.
Not OK
Replace fuel injection
nozzles. Refer to TM
9-2815-259-24.
Test fuel injection
nozzles. Refer to TM
9-2815-259-24.
OK
Refer to TM
9-2815-259-24.
5-4
OK
Test actuator A6
(see para. 5.9.1).
Not OK
Replace actuator A6
(see para. 5.9.1).
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TABLE 5-1. DIRECT SUPPORT TROUBLESHOOTING (CONTINUED)
ABNORMAL ENGINE NOISE
Abnormal engine noise.
Not OK
Replace engine mounts
(see para. 5.4.2).
Visually check for split or
cracked rubber on engine
mounts. Refer to figure 5-1.
Not OK
Tighten drive disc bolts
(Eng to Gen).
OK
Check your
drive disc bolts
(Eng to Gen).
OK
Refer to TM
9-2815-259-24.
5-5
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TABLE 5-1. DIRECT SUPPORT TROUBLESHOOTING (CONTINUED)
BLACK OR GRAY EXHAUST SMOKE
Black or gray
exhaust smoke.
Refer to TM
9-2815-259-24.
BLACK OR WHITE EXHAUST SMOKE
Black or White
exhaust smoke.
Refer to TM
9-2815-259-24.
5-6
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TABLE 5-1. DIRECT SUPPORT TROUBLESHOOTING (CONTINUED)
ENGINE MISFIRING
Engine misfiring.
Refer to TM
9-2815-259-24.
COOLANT IN CRANKCASE OR OIL IN COOLANT
Coolant in crankcase
or oil in coolant.
Refer to TM
9-2815-259-24.
5-7
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TABLE 5-1. DIRECT SUPPORT TROUBLESHOOTING (CONTINUED)
GENERATOR SET FAILS TO GENERATE
SUFFICIENT VOLTAGE
Generator set fails to generate
sufficient voltage.
Not OK
Check for low engine
speed. Refer to
TM 9-2815-259-24.
OK
Refer to TM
9-2815-259-24.
OK
Test power potential
transformer (see para. 5.8.6).
Not OK
Test generator main
stator (see para. 5.10.7).
Replace defective components.
5-8
Not OK
Replace power potential
transformer (see para.
5.8.6).
ARMY TM 9-6115-671-14
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TABLE 5-1. DIRECT SUPPORT TROUBLESHOOTING (CONTINUED)
GENERATOR SET OUTPUT FLUCTUATES
Generator set output fluctuates.
Not OK
Check for irregular
engine speed. Refer to
TM 9-2815-259-24.
OK
Refer to TM
9-2815-259-24.
OK
Check for loose
terminations or load
connections.
Test generator
(see para. 5.10).
Start generator set (see para.
2.12.1). If output still fluctuates,
replace generator assembly (see
para. 5.10.1).
Not OK
Not OK
Tighten
terminations and
load connections.
Replace defective
component.
5-9
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TABLE 5-1. DIRECT SUPPORT TROUBLESHOOTING (CONTINUED)
GENERATOR NOISY WHEN RUNNING
Generator noisy when running.
OK
Not OK
Remove end bell (see para.
5.10.2). Check main bearing Not OK
for leaks, rough operation, and
other signs of damage.
Check for loose mounting
hardware between
generator and engine
(see para. 5.4.2).
Tighten engine/ generator
mounting hardware
(see para. 5.4.2).
OK
Not OK
Replace components as
required.
5-10
Replace main bearing
(see para. 5.10.2).
Inspect generator
assembly (see para. 5.10.)
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TABLE 5-1. DIRECT SUPPORT TROUBLESHOOTING (CONTINUED)
ENGINE OIL PRESSURE LOW
Engine oil pressure low.
Refer to TM
9-2815-259-24.
ENGINE OIL PRESSURE HIGH
Engine oil pressure high.
Refer to TM
9-2815-259-24.
5-11
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TABLE 5-1. DIRECT SUPPORT TROUBLESHOOTING (CONTINUED)
FAULT INDICATOR DISPLAYS WARNING - UNDERVOLTAGE
OR CONTACTOR TRIP - UNDERVOLTAGE
FAULT INDICATOR displays WARNING UNDERVOLTAGE or CONTACTOR TRIP UNDERVOLTAGE.
Not OK
Repair engine. Refer to
TM 9-2815-259-24.
Check for low engine
speed. Refer to TM
9-2815-259-24.
OK
Test generator main
stator (see para. 5.10.7).
OK
Test potential transformer
(see para. 5.8.6)
Not OK
Replace components
(see para 5.10.7).
5-12
Not OK
Replace potential transformer
(see para 5.8.6).
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TABLE 5-1. DIRECT SUPPORT TROUBLESHOOTING (CONTINUED)
FAULT INDICATOR DISPLAYS
SHUTDOWN - OVERSPEED
FAULT INDICATOR displays
SHUTDOWN - OVERSPEED
Not OK
Replace electric actuator
(see para. 5.9.1).
Test electric actuator
(see para. 5.9.1).
OK
Refer to TM
9-2815-259-24.
5-13
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SECTION IV. DIRECT SUPPORT MAINTENANCE PROCEDURES
__________
WARNING
Batteries give off a flammable gas. Do not smoke or use open flame when
performing maintenance. Failure to comply can cause injury or death to
personnel and equipment damage due to flames and explosion.
__________
WARNING
Battery acid can cause burns to unprotected skin. Wear protective gloves
and safety goggles. Failure to comply can cause personal injury.
5.4
REMOVAL AND INSTALLATION OF MAJOR COMPONENTS.
__________
WARNING
When disconnecting or removing batteries, disconnect the negative lead
that connects directly to the grounding stud first. Disconnect the negative
end of the interconnection cable next. When installing batteries, reverse the
connection sequence. Failure to comply can cause serious personal injury.
5.4.1
General.
The engine and generator are bolted together at the engine flywheel and flywheel housing adapter. The
engine and generator may be removed as an assembly or separately. The engine and generator assembly is
mounted on the skid base at four points. There are also brackets installed on both sides of the engine when
removing the generator separately.
5.4.2
Engine and Generator Assembly.
__________
WARNING
Generator is heavy. Obtain assistance when moving generator with hoist.
Failure to comply can cause injury to personnel.
a.
Removal.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
CAUTION
Engine and oil drain line can be damaged if oil drain line is not
disconnected from engine before removing engine from skid base. Engine
oil must be drained and drain line disconnected before removing engine
from skid base. Failure to comply can cause damage to equipment.
(3)
5-14
Remove oil drain plug, open drain valve, and drain engine oil into a suitable container. Refer to
Figure 4-1.
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(4)
Totally drain radiator and coolant bottle, refer to paragraph 4.10.
(5)
Remove DSC control box, refer to paragraph 4.7.2.
(6)
Remove top housing section, refer to paragraph 4.7.3.
(7)
Remove air filter assembly, refer to paragraph 4.9.2.
NOTE
Disconnect wire ties and wire clamps as needed. Note position of removed wire
ties and reinstall after repair is complete.
NOTE
Note location of wiring harnesses as removed. Tag connectors prior to removal
to aid in reconnection.
(8)
Disconnect radiator drain hose (paragraph 4.10.7).
(9)
Disconnect engine coolant drain hose at engine petcock (Figure 4-22).
(10)
Disconnect coolant overflow bottle drain line and remove bracket from engine.
(11)
Disconnect fuel water separator drain line.
NOTE
Ensure the tie straps are removed as required.
(12)
Remove dead crank switch (save all washers) (paragraph 4.13.4).
(13)
Tag and disconnect fuel float switch (paragraph 4.11.5).
(14)
Tag and disconnect oil pressure sender (4.13.1).
(15)
Unplug electric actuator, P10.
(16)
Unplug magnetic pickup, P12.
(17)
Unplug auxiliary fuel pump, P13.
(18)
Disconnect fuel rail return line and cap (Figure 4-25).
(19)
Disconnect auxiliary pump output line and cap (Figure 4-25).
(20)
Loosen hose clamp (Figure 4-25, 25) from fuel collar fill hose (27).
(21)
Disconnect battery charging alternator output wire. Remove battery charging alternator current
sensor bracket from alternator.
5-15
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(22)
Tag and disconnect crankcase ventilation hose heater wires (4).
(23)
Tag and disconnect wiring harness wires at battery.
(24)
Disconnect ether tube.
(25)
Tag and disconnect wiring harness from ether injection solenoid and relay.
(26)
Tag and disconnect wires to starter, including the ground wires.
(27)
Disconnect fuel line to engine mechanical fuel pump.
(28)
Disconnect fuel vent line at fuel filler neck from t-connection above starter.
(29)
Disconnect main alternator output wires, T1 through T12, from voltage reconnection switch.
NOTE
Note location, number of wraps, direction of wraps and which wires are wrapped
through the current transformer (CT1) and droop current transformer (CT5) prior
to removal.
(30)
Remove main alternator output wires, T1 through T12, from current Transformer (CT1) and
droop current transformer (CT5).
(31)
Disconnect rotor exciter wires, F1 and F2 from TB8.
(32)
Remove rear generator housing section (paragraph 4.7.5).
(33)
Pull main alternator output wires, T1 through T12, and rotor exciter wires, F1 and F2 through
hole in bottom of output box.
(34)
Disconnect main output terminal board ground strap from skid.
(35)
Remove right and left side generator housing panels as complete assemblies.
(36)
Remove locknuts (1, Figure 5-1), washers (2), snubbing washers (3), washers (5), bolts (4), and
engine supports (22) from skid base.
(37)
Remove locknuts (6), washers (7), snubbing washers (10), Belleville washers (9) and bolts (8)
from generator and skid base.
CAUTION
Rated capacity of overhead hoist should be at least 2000 lbs (907 kg).
Arrange lifting device so that it supports both engine and generator to
avoid undue stress on the engine and generator coupling. Failure to comply
can cause damage to equipment.
5-16
(38)
Attach lifting harness to engine and generator lifting points. Raise engine and generator
assembly from skid base.
(39)
Remove shock mounts (18) from generator mounting points on skid base.
(40)
Remove bolt (45), lockwasher (46), and rear engine lifting bracket (47) from engine.
(41)
Remove bolts (42), lockwashers (43), and front engine lifting bracket (44) from engine.
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b.
(42)
Remove nuts (11), washers (12), plates (16), angles (17), washers (14), nuts (15), and bolts (13)
from generator.
(43)
Remove bolts (19), lockwashers (20), washers (21), and engine supports (22) from engine.
(44)
Remove bolts (23), lockwashers (24), washers (25), and rear engine supports (26).
(45)
Remove locknuts (27), washers (28), bolts (29) and engine mounts (30) from skid base.
Installation.
(1)
Install engine mounts (30, Figure 5-1), bolts (29), washers (28), and locknuts (27) on skid base.
(2)
Install rear engine supports (26), washers (25), lockwashers (24), and bolts (23) on engine.
(3)
Install engine supports (22), washers (21), lockwashers (20), and bolts (19) on engine. Torque
bolts to 120 ft-lb (162.6 Nm).
(4)
Position shock mounts (18) at generator mounting points on skid base.
(5)
Install angles (17), plates (16), nuts (15), washers (14), bolts (13), washers (12), and nuts (11)
on generator.
(6)
Install front engine lifting bracket (44), lockwashers (43), and bolts (42).
(7)
Install rear engine lifting bracket (47), lockwashers (46), and bolts (45).
CAUTION
Rated capacity of overhead hoist should be at least 2000 lbs (907 kg). Arrange lifting device to
that it supports both engine and generator to avoid undue stress on the engine and generator
coupling. Failure to comply can cause damage to equipment.
(8)
Attach lifting harness to engine and generator lifting points. Raise engine and generator
assembly from maintenance stand or fixture.
(9)
Position engine and generator assembly on skid base with mounting holes and brackets aligned.
(10)
Cut cable ties from generator power leads (48).
5-17
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FIGURE 5-1. ENGINE AND GENERATOR ASSEMBLY (SHEET 1 OF 2)
FIGURE 5-1. ENGINE AND GENERATOR ASSEMBLY (SHEET 2 OF 2)
5-18
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(11)
Secure generator to skid base with snubbing washers (10), Belleville washers (9), bolts (8),
washers (7), and locknuts (6). Torque bolts to 210 ft-lb (284.9 Nm).
(12)
Secure engine supports (22) to skid base with washers (5), bolts (4), snubbing washers (3),
washers (2), and locknuts (1). Torque locknuts to 75 ft-lb (101.7 Nm).
(13)
Adjust nuts (11 and 15) to obtain 0.5 in. minimum clearance between ends of bolts (13) and skid
base. Torque bolts to 150 ft-lb (203 Nm).
(14)
Install right and left side generator housing panels as complete assemblies.
(15)
Connect main output terminal board ground strap to skid.
(16)
Pull main alternator output wires, T1 through T12, and rotor exciter wires, F1 and F2 through
hole in bottom of output box.
(17)
Install rear generator housing section (paragraph 4.7.5).
(18)
Connect rotor exciter wires, F1 and F2 to TB8.
(19)
Install main alternator output wires, T1 through T12, to current Transformer (CT1) and droop
current transformer (CT5).
(20)
Connect main alternator output wires, T1 through T12, to voltage reconnection switch.
(21)
Connect fuel vent line at fuel filler neck to t-connection above starter.
(22)
Connect fuel line to engine mechanical fuel pump.
(23)
Connect wires to starter, including the ground wires. Remove tags.
(24)
Connect wiring harness to ether injection solenoid and relay. Remove tag.
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5-20
(25)
Connect ether tube.
(26)
Connect wiring harness wires at battery. Remove tags.
(27)
Connect crankcase ventilation hose heater wires (4). Remove tags.
(28)
Connect battery charging alternator output wire. Install battery charging alternator current
sensor bracket to alternator.
(29)
Tighten hose clamp (Figure 4-25, 25) to fuel collar fill hose (27).
(30)
Connect auxiliary pump output line and cap (Figure 4-25).
(31)
Connect fuel rail return line and cap (Figure 4-25).
(32)
Plug in auxiliary fuel pump, P13.
(33)
Plug in magnetic pickup, P12.
(34)
Plug in electric actuator, P10.
(35)
Connect oil pressure sender (4.13.1). Remove tag.
(36)
Connect fuel float switch (paragraph 4.11.5). Remove tag.
(37)
Install dead crank switch and saved washers (paragraph 4.13.4).
(38)
Connect fuel water separator drain line.
(39)
Connect coolant overflow bottle drain line and install bracket to engine.
(40)
Connect engine coolant drain hose at engine petcock (Figure 4-22).
(41)
Connect radiator drain hose (paragraph 4.10.7).
(42)
Install air filter assembly, refer to paragraph 4.9.2.
(43)
Install top housing section, refer to paragraph 4.7.3.
(44)
Install DSC control box, refer to paragraph 4.7.2.
(45)
Service engine lubrication system, paragraph 3.3.7.
(46)
Service coolant system, paragraph 3.3.4.
(47)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
(48)
Start generator set, paragraph 2.11.1. Check for proper operation.
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
5.4.3
Engine/Generator Disassembly.
NOTE
Refer to engine manual TM 9-2815-259-24 for information concerning repair of
the engine.
NOTE
When removing generator only, refer to paragraph 5.10.
a.
Old Component Removal Prior to Installation.
The following components may not be supplied with the new engine and must be removed from the old
engine. Install on the new engine prior to its installation in the generator set.
b.
(1)
Remove governor actuator (if replacing the engine).
(2)
Remove temperature sender.
(3)
Remove oil pressure sensor.
(4)
Remove engine coolant drain cock.
(5)
Remove speed sensor and bushing.
(6)
Remove dead crank switch bracket.
(7)
Remove engine legs on bell housing.
(8)
Remove cable on fuel injector pump and bracket.
(9)
Remove bracket for fan guards.
(10)
Remove radiator and brackets.
(11)
Remove breather, breather hoses, heaters and insulation.
(12)
Remove ether injector.
(13)
Remove oil drain from oil pan.
(14)
Remove fan blade and extension hub.
(15)
Remove bracket clamp bolts.
(16)
Remove fuel pump fittings.
(17)
Remove oil sampling valves.
Compare New and Old Engine.
Compare new and old engines. Remove components unique to the old engine and install
these on the new engine prior to installation in the generator set.
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c. Removal.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Remove engine and generator assembly, paragraph 5.4.2.
CAUTION
Generator is heavy. Rated capacity of overhead hoist should be at least
1,000 lb. (454 kg). Failure to comply can cause damage to equipment.
d.
(4)
Attach lifting harness to overhead hoist and generator lifting eye. Take up slack on harness.
(5)
Remove nuts (31, Figure 5-1), lockwashers (32), screws (33), washers (34), and band cover (35)
from generator case.
(6)
Scribe mark on generator drive disc and engine flywheel for alignment of bolts during
installation.
(7)
Remove bolts (36), lockwashers (37), and washers (38) securing generator drive disc to engine
flywheel.
(8)
Remove bolts (39), lockwashers (40), and washers (41) securing generator to engine flywheel
housing.
(9)
Lift generator slowly from engine. Ensure engine flywheel and generator separate smoothly,
avoiding any undue stress.
(10)
Remove bolts (42), lockwashers (43), and front engine lifting bracket (44) from engine.
(11)
Remove bolt (45), lockwasher (46), and rear engine lifting bracket (47) from engine.
Installation.
(1)
Install rear engine lifting bracket (47, Figure 5-1), lockwasher (46), and bolt (45) on engine.
(2)
Install front engine lifting bracket (44), lockwashers (43), and bolts (42) on engine.
__________
WARNING
Generator is heavy. Obtain assistance when moving generator with hoist.
Failure to comply can cause injury to personnel.
CAUTION
Generator is heavy. Rated capacity of overhead hoist should be at least
1,000 lb. (454 kg). Failure to comply can cause damage to equipment.
5-22
(3)
Attach lifting harness to overhead hoist and generator lifting eye. Take up slack on harness.
(4)
Position generator to mount onto engine. Ensure generator drive disc (22, Figure 5-9) is aligned
with engine flywheel. Partially install three bolts (39), lockwashers (40), and washers (41) into
generator housing. Note scribe mark made at removal.
(5)
Secure generator drive disc (22) to engine flywheel with washers (38), lockwashers (37), and
bolts (36). Torque bolts to 25 ft-lb (33.9 Nm).
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
5.5
(6)
Secure generator to engine flywheel housing with washers (41), lockwashers (40), and bolts
(39). Torque bolts to 25 ft-lb (33.9 Nm).
(7)
Install band cover (35), washers (34), screws (33), lockwashers (32), and nuts (31) on generator
case.
(8)
Detach lifting device from generator lifting eye.
(9)
Install engine and generator assembly, paragraph 5.4.2.
MAINTENANCE OF DCS CONTROL BOX ASSEMBLY.
__________
WARNING
When disconnecting or removing batteries, disconnect the negative lead
that connects directly to the grounding stud first. Disconnect the negative
end of the interconnection cable next. When installing batteries, reverse the
connection sequence. Failure to comply can cause serious personal injury.
5.5.1
DCS Control Box Wiring Harness.
CAUTION
Electronic components containing printed circuit boards are extremely
sensitive to electrostatic discharge (ESD). Wear an ESD wrist strap
connected to ground whenever coming in contact with ESD-sensitive
components. Failure to comply can cause severe damage to equipment.
a.
b.
Inspection.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Remove DCS control box top panel, paragraph 4.7.2.
(3)
Attach ESD wrist strap and connect to ground.
(4)
Inspect DCS wiring harness for burned, bent, corroded, and broken terminals. Refer to Figure 416.
(5)
Inspect connectors for cracks, corrosion, stripped threads, bent or broken pins, and obvious
damage.
(6)
Inspect wire insulation for burns, deterioration, and chafing.
(7)
Disconnect ESD wrist strap, and remove wrist strap.
(8)
Install DCS control box top panel, paragraph 4.7.2.d.
Testing.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Remove DCS control box top panel, paragraph 4.7.2.a.
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c.
5.5.2
5-24
Attach ESD wrist strap and connect to ground.
(5)
Set multimeter for ohms, and test individual wires of DCS wiring harness for continuity. Refer
to wiring diagram, FO-3, for wire identification.
(6)
Disconnect ESD wrist strap, and remove wrist strap.
(7)
Install DCS control box top panel, paragraph 4.7.2.d.
(8)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
Replacement.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Remove DCS control box top panel, paragraph 4.7.2.a.
(4)
Attach ESD wrist strap and connect to ground.
(5)
Disconnect DCS control box wiring harness connectors and terminals from components, and
remove wiring harness from DCS control box assembly. Refer to Wiring Diagram FO-3.
(6)
Position DCS control box wiring harness in DCS control box, and connect wiring harness
connectors and terminals to components. Refer to Wiring Diagram FO-3.
(7)
Disconnect ESD wrist strap, and remove wrist strap.
(8)
Install DCS control box top panel, paragraph 4.7.2.d.
(9)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
Resistor R1.
a.
5.5.3
(4)
Replacement.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Remove DCS control box top panel, paragraph 4.7.2.
(4)
Remove sleeving (14), tag and desolder electrical leads from resistor (10, Figure 4-16). Refer to
Schematic FO-1.
(5)
Remove resistor (10) from auxiliary control bracket (18).
(6)
Install resistor (10) to auxiliary control bracket (18).
(7)
Install sleeving (14) and solder electrical leads to resistor (10). Remove tags.
(8)
Install DCS control box top panel, paragraph 4.7.2.
(9)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
Resistor R2
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
a.
Replacement.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Remove DCS control box top panel, paragraph 4.7.2.
(4)
Tag and desolder electrical leads from resistor (13, Figure 4-16).
(5)
Remove nuts (11), lockwashers (12), resistor (13), sleeving (14), screws (15), and lockwashers
(16) from auxiliary control bracket (18).
(6)
Install lockwashers (16), screws (15), sleeving (14), resistor (13), lockwashers (12), and nuts
(11) on auxiliary control bracket (18).
(7)
Solder electrical leads to resistor (13). Remove tags.
(8)
Install DCS control box top panel, paragraph 4.7.2.
(9)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
5.6
MAINTENANCE OF COOLING SYSTEM.
5.6.1
Radiator.
Repair radiator in accordance with TM 750-254.
5.7
MAINTENANCE OF FUEL SYSTEM.
__________
WARNING
When disconnecting or removing batteries, disconnect the negative lead
that connects directly to the grounding stud first. Disconnect the negative
end of the interconnection cable next. When installing batteries, reverse the
connection sequence. Failure to comply can cause serious personal injury.
5.7.1
Fuel Tank.
a.
Removal.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
__________
WARNING
Diesel fuel is flammable and toxic to eyes, skin, and respiratory tract. Skin
and eye protection are required when working in contact with diesel fuel,
and avoid repeated or prolonged contact. Provide adequate ventilation.
Failure to comply can cause injury or death to personnel.
NOTE
Refer to Figure 1-30 for general location of fuel drain valve assembly.
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(3)
Remove cap (28), Figure 4-25), open fuel drain valve (30), and drain fuel into a suitable
container.
b.
5-26
(4)
Remove engine and generator assembly, paragraph 5.4.2.
(5)
Remove fuel drain valve, paragraph 4.11.4.
(6)
Remove nuts (1, Figure 5-2), lockwashers (2), washers (3), bolts (4), washers (5), and holddown
assemblies (6) securing fuel tank (7) to skid base.
(7)
Lift fuel tank (7) from skid base.
(8)
Remove fuel level sender, paragraph 4.11.5.
(9)
Remove fuel pickup, paragraph 4.11.6.
(10)
Remove fittings (8) from fitting studs (10) on right side of fuel tank (7).
(11)
Remove fitting (13) from tee (9).
(12)
Remove tee (9) from fitting stud (10) on left side of tank (7).
(13)
Remove fittings studs (10), washers (11), and bushings (12) from fuel tank (7).
(14)
Cover all openings in fuel tank (7).
Inspection.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Remove fuel tank, step 5.7.1a .
(3)
Inspect fuel tank (7, Figure 5-2) for leaks, cracks, missing hardware, and other damage.
(4)
If damage is found, replace fuel tank (7).
(5)
Install fuel tank, step 5.7.1c.
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
c.
Installation.
(1)
Uncover openings in fuel tank (7, Figure 5-2).
(2)
Apply sealing compound (Item 22, Appendix E) to threads of fitting studs (10). Install bushings
(12), washers (11), and fitting studs on fuel tank (7). Torque fitting studs to 40 inch-pounds.
(3)
Apply sealing compound (Item 22, Appendix E) to threads of tee (9). Install tee on fitting stud
(10) on left side of fuel tank (7).
(4)
Apply sealing compound (Item 22, Appendix E) to threads of fittings (8). Install fittings on
fitting studs (10) on right side of fuel tank (7).
(5)
Apply sealing compound (Item 22, Appendix E) to threads of fitting (13). Install fitting on tee
(9) on left side of fuel tank (7).
(6)
Install fuel pickup, paragraph 4.11.6.
(7)
Install fuel level sender, paragraph 4.11.5.
(8)
Position fuel tank (7) in skid base.
(9)
Secure fuel tank (7) to skid base with holddown assemblies (6), washers (5), bolts (4), washers
(3), lockwashers (2), and bolts (1).
(10)
Install fuel drain valve, paragraph 4.11.4.
(11)
Install engine and generator assembly, paragraph 5.4.2.
(12)
Service fuel tank. Refer to Table 4-1 for proper fuel.
(13)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
5-27
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AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
FIGURE 5-2. FUEL TANK
5-28
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MARINE CORPS TM 09249A/09246A-14
5.8
MAINTENANCE OF OUTPUT BOX ASSEMBLY.
__________
WARNING
When disconnecting or removing batteries, disconnect the negative lead
that connects directly to the grounding stud first. Disconnect the negative
end of the interconnection cable next. When installing batteries, reverse the
connection sequence. Failure to comply can cause serious personal injury.
5.8.1
Output Box Assembly.
a.
Removal.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Remove DCS control box assembly, paragraph 4.8.1.
(4)
Remove top housing section, paragraph 4.7.3.
(5)
Remove air cleaner assembly, paragraph 4.9.2.
(6)
Remove output box access door. Refer to paragraph 4.7.1.
(7)
Remove rear housing panel. Refer to paragraph 4.7.5.
(8)
Open left side engine compartment access doors (Figure 1-3).
(9)
Tag and disconnect electrical leads from fuel injection pump (refer to TM 9-2815-259-24),
electric actuator (refer to paragraph 5.9.1), DEAD CRANK switch (refer to paragraph 4.13.4),
oil pressure sender (refer to paragraph 4.13.1), coolant temperature sender (refer to paragraph
4.13.2), auxiliary fuel pump (refer to paragraph 4.11.2), fuel pickup (refer to paragraph 4.11.6),
and magnetic pickup (refer to paragraph 4.13.3). Disconnect crankcase breather assembly wire
(refer to paragraph 4.9.6).
(10)
Open right side engine compartment access doors (Figure 1-2).
(11)
Tag and disconnect electrical leads from battery charging alternator, starter, ether solenoid
valve, fuel level sender (refer to paragraph 4.11.5), and slave cables and battery cables (4.6.2).
Refer to paragraph 4.11.9 and TM 9-2815-259-24.
(12)
Remove locknuts (1, Figure 5-3), screws (2), and loop clamps (3) from side panel (32) and
wiring harness (31).
(13)
Remove voltage reconnection terminal board, paragraph 5.8.2.
(14)
Remove locknuts (4), bolts (5), and top panel (6) from output box assembly.
NOTE
Record number and direction of wraps when removing main generator cables
from transformer for installation later.
(15)
Unwrap main generator cables from droop current transformer (33) and current transformer (34).
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b.
5-30
(16)
Remove screws (7), washers (8), and cover (9) from AC circuit interrupter (35).
(17)
Tag and disconnect output cables from terminals A2, B2, and C2 of AC circuit interrupter (35).
(18)
Tag and disconnect exciter leads F1 and F2 from terminals 1 and 2 of terminal board (29).
(19)
Remove locknuts (10), bolts (11), and output box assembly from generator set.
Installation.
(1)
Install output box assembly on generator set with bolts (11, Figure 5-3) and locknuts (10).
(2)
Connect exciter leads F1 and F2 to terminals 1 and 2 of terminal board (29). Remove tags.
(3)
Connect output cables to terminals A2, B2, and C2 of AC circuit interrupter (35). Remove tags.
(4)
Install cover (9), washers (8), and screws (7) on AC circuit interrupter (35).
(5)
Install main generator cables on current transformer (34) and droop current transformer (33) the
same number of wraps recorded during removal.
(6)
Install output box top panel (6), bolts (5), and locknuts (4) on output box assembly.
(7)
Install voltage reconnection terminal board, paragraph 5.8.2.
(8)
Install loop clamps (3), screws (2), and locknuts (1) on wiring harness (31) and side panel (32).
(9)
On right side of engine, connect electrical leads from battery charging alternator, starter, ether
solenoid valve, crankcase breather assembly heater wires, slave cables and battery cables. Refer
to paragraph 4.11.9 and TM 9-2815-259-24. Remove tags.
(10)
Connect electrical leads to fuel injection pump (refer to TM 9-2815-259-24), electric actuator
(refer to paragraph 5.10.1), DEAD CRANK switch (refer to paragraph 4.13.4), oil pressure
sender (refer to paragraph 4.13.1), coolant temperature sender (refer to paragraph 4.13.2),
auxiliary fuel pump (refer to paragraph 4.11.2), fuel pickup (refer to paragraph 4.11.6), fuel
level sender (refer to paragraph 4.11.5), and magnetic pickup (refer to paragraph 4.13.3).
Remove tags.
(11)
Install rear housing panel. Refer to paragraph 4.7.5.
(12)
Install output box access door. Refer to paragraph 4.7.1.
(13)
Install air cleaner assembly, paragraph 4.9.2.
(14)
Install top housing section, paragraph 4.7.3.
(15)
Install DCS control box assembly, paragraph 4.8.1.
(16)
Close engine compartment access doors.
(17)
Connect negative battery terminal to battery, and close BATTERY ACCESS door.
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
FIGURE 5-3. OUTPUT BOX ASSEMBLY (SHEET 1 OF 2)
5-31
ARMY TM 9-6115-671-14
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FIGURE 5-3. OUTPUT BOX ASSEMBLY (SHEET 2 OF 2)
5.8.2
Voltage Reconnection Terminal Board TB1.
a.
Inspection.
Inspect voltage reconnection terminal board (22, Figure 5-3) for cracks, corrosion, stripped threads,
bent or broken terminal studs, and other obvious damage.
b.
5-32
Replacement.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Open output box and load terminal board access doors (Figure 1-2).
(4)
Remove locknuts (12, Figure 5-3), washers (13), and protective cover (14) from standoffs (15).
(5)
Remove standoffs (15), washers (16), bolts (17), washers (18), and mounts (19) from rear panel
(36) and voltage reconnection board (22).
(6)
Tag electrical cables, main generator cables, and capacitors (21) at voltage reconnection board
(22). Remove locknuts (20), cables, and capacitors (21) from voltage reconnection board.
(7)
Remove voltage reconnection board (22), with moveable terminal board (24) attached, from rear
panel (36).
(8)
Remove locknuts (23) and moveable terminal board (24) from terminal studs (26).
(9)
Remove nuts (25) and terminal studs (26) from voltage reconnection board (22).
(10)
Install terminal studs (26) and nuts (25) on voltage reconnection board (22). Torque nuts to 150200 in-lb (16.9-22.6 Nm).
(11)
Install moveable terminal board (24) and locknuts (23) on terminal studs (26).
(12)
Position voltage reconnection board (22) and moveable terminal board (24) on rear panel (36).
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
5.8.3
(13)
Install capacitors (21), electrical cables, main generator cables, and locknuts (20) on voltage
reconnection board (22). Remove tags.
(14)
Secure voltage reconnection board (22) to rear panel (36) with mounts (19), washers (18), bolts
(17), washers (16), and standoffs (15).
(15)
Install protective cover (14), washers (13), and locknuts (12) on standoffs (15).
(16)
Close output box and load terminal board access doors.
(17)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
Output Box Wiring Harness.
a.
Removal.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Remove DCS control box assembly, paragraph 4.8.1.
(4)
Remove output box top panel, paragraph 5.8.1.
(5)
Open left side engine compartment access doors (Figure 1-3).
(6)
Tag and disconnect crankcase breather assembly heater wires (refer to paragraph 4.9.6) and
slave and battery cables (refer to paragraph 4.6.2).
(7)
Tag and disconnect electrical leads from fuel injection pump (refer to TM 9-2815-259-24),
electric actuator (refer to paragraph 5.10.1), DEAD CRANK switch (refer to paragraph 4.13.4),
oil pressure sender (refer to paragraph 4.13.1), coolant temperature sender (refer to paragraph
4.13.2), auxiliary fuel pump (refer to paragraph 4.11.2), fuel pickup (refer to paragraph 4.11.6),
fuel level sender (refer to paragraph 4.11.5), and magnetic pickup (refer to paragraph 4.13.3).
(8)
Open right side engine compartment access doors (Figure 1-2).
(9)
Tag and disconnect electrical leads from battery charging alternator, starter, and ether solenoid
valve. Refer to paragraph 4.11.9 and TM 9-2815-259-24.
(10)
Open output box access door (Figure 1-2).
(11)
Remove screws (7, Figure 5-3), washers (8), and cover (9) from AC circuit interrupter (35).
(12)
Tag and disconnect electrical leads from cranking relay (37), current transformer (34), AC
circuit interrupter (35), potential power transformer (38), and voltage reconnection board (22).
(13)
Tag and disconnect electrical leads for droop current transformer (33) from terminal board (29).
(14)
Remove locknuts (27), screws (28), and terminal boards (29 and 30) from side panel (32).
(15)
Remove locknuts (1), screws (2), and loop clamps (3) from side panel (32) and wiring harness
(31).
(16)
Remove wiring harness (31) from output box and generator set.
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MARINE CORPS TM 09249A/09246A-14
b.
c.
Inspection.
(1)
Remove output box wiring harness, step 5.8.3.a above.
(2)
Inspect wiring harness for burned, bent, corroded, and broken terminals.
(3)
Inspect connectors for cracks, corrosion, stripped threads, bent or broken pins, and other
obvious damage.
(4)
Inspect wire insulation for burns, deterioration, and chafing.
(5)
Install output box wiring harness, step 5.8.3.e below.
Testing.
Set multimeter for ohms. Check individual wires, connectors, and terminal boards for continuity. Refer
to Wiring Diagram FO-3, for wire identification.
d.
e.
5-34
Repair.
(1)
Replace damaged cable assemblies, terminals, connectors, sockets, and terminal boards.
(2)
Replace wires with damaged insulation and those that do not indicate continuity.
Installation.
(1)
Position wiring harness (31, Figure 5-3) in output box and generator set.
(2)
Install loops clamps (3), screws (2), and locknuts (1) on wiring harness (31) and side panel (32).
(3)
Install terminal boards (30 and 29), screws (28), and locknuts (27) on side panel (32).
(4)
Connect electrical leads from droop current transformer (33) to terminal board (29). Remove
tags.
(5)
Connect electrical leads to AC circuit interrupter (35), current transformer (34), cranking relay
(37), power potential transformer (38), and voltage reconnection board (22). Remove tags.
(6)
Install cover (9), washers (8), and screws (7) on AC circuit interrupter (35).
(7)
On right side of engine, connect electrical leads from battery charging alternator, starter, and
ether solenoid valve. Refer to paragraph 4.11.9 and TM 9-2815-259-24. Remove tags.
(8)
Connect crankcase breather assembly heater wires (refer to paragraph 4.9.6) and slave and
battery cables (refer to paragraph 4.6.2). Remove tags.
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
5.8.4
(9)
Connect electrical leads to fuel injection pump (refer to TM 9-2815-259-24), electric actuator
(refer to paragraph 5.10.1), DEAD CRANK switch (refer to paragraph 4.13.4), oil pressure
sender (refer to paragraph 4.13.1), coolant temperature sender (refer to paragraph 4.13.2),
auxiliary fuel pump (refer to paragraph 4.11.2), fuel pickup (refer to paragraph 4.11.6), fuel
level sender (refer to paragraph 4.11.5), and magnetic pickup (refer to paragraph 4.13.3).
Remove tags.
(10)
Install output box top panel, paragraph 5.8.1.
(11)
Install DCS control box assembly, paragraph 4.8.1.
(12)
Close output box and engine compartment access doors.
(13)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
Current Transformer CT1, CT2, CT3.
a.
Removal.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Remove DCS control box assembly, paragraph 4.8.1.
(4)
Remove output box top panel, paragraph 5.8.1.
(5)
Open output box and right side engine compartment access doors (Figure 1-2 and 1-3).
(6)
Tag and disconnect electrical leads from current transformer (4, Figure 5-4).
(7)
Tag and disconnect main generator cables T2 and T8 from voltage reconnection board (34).
NOTE
Record number and direction of wraps when removing main generator cables
from transformer for installation later.
b.
(8)
Unwrap main generator cables from droop current transformer (7) and current transformer (4).
(9)
Remove locknuts (1), screws (2), washers (3), and current transformer (4) from rear panel (33).
Testing.
(1)
Remove current transformer, step 5.8.4.a above.
(2)
Set multimeter for ohms, and check for continuity between secondary terminals A1 and A2, B1
and B2, and C1 and C2. If continuity is present, continue with test. If continuity is not present,
current transformer is defective and must be replaced.
(3)
Set up a test circuit using 10 gauge wire as shown in Figure 5-5. Make 10 passes with wire
through phase A window.
(4)
Turn on power source and load bank. Adjust load bank until 27.7 amps is indicated on ammeter.
5-35
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
(5)
Set multimeter for amperes, and connect to secondary terminals A1 and A2. Multimeter
indication must be 0.9 to 1.1 amps.
c.
5-36
(6)
Repeat steps (3) through (5) using phase B window and secondary terminals B1 and B2.
(7)
Repeat steps (3) through (5) using phase C window and secondary terminals C1 and C2.
(8)
Replace current transformer if multimeter indication in any phase is other than stated in step (5).
(9)
Remove current transformer from test circuit.
(10)
Install current transformer, step 5.8.4.c below.
Installation.
(1)
Install current transformer (4, Figure 5-4), washers (3), screws (2), and locknuts (1) on rear
panel (33).
(2)
Install main generator cables on current transformer (4) and droop current transformer (7) the
same number of wraps recorded during removal.
(3)
Connect main generator cables T2 and T8 to voltage reconnection board (34). Remove tags.
(4)
Connect electrical leads to current transformer (4). Remove tags.
(5)
Install output box top panel, paragraph 5.8.1.
(6)
Install DCS control box assembly, paragraph 4.8.1.
(7)
Close output box and engine compartment access doors.
(8)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
FIGURE 5-4. OUTPUT BOX COMPONENTS
5-37
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
FIGURE 5-4. OUTPUT BOX COMPONENTS (SHEET 2 OF 2)
FIGURE 5-5. TESTING CURRENT TRANSFORMER
5.8.5
Droop Current Transformer CT5.
a.
Removal.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Open output box and right side engine compartment access doors (Figure 1-2).
(4)
Tag and disconnect main generator cables T2 and T8 from voltage reconnection board (34,
Figure 5-4).
NOTE
Record number and direction of wraps when removing main generator cables
from transformer for installation later.
5-38
(5)
Unwrap main generator cables from droop current transformer (7).
(6)
Tag and disconnect droop current transformer (7) electrical leads from terminal board (35).
(7)
Remove locknuts (5), screws (6), and droop current transformer (7) from rear panel (33).
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
b.
Testing.
(1)
Remove droop current transformer, step 5.8.5.a above.
(2)
Set multimeter for ohms, and check for continuity between secondary leads 1 and 2. If
continuity is present, continue with test. If continuity is not present, droop current transformer is
defective and must be replaced.
(3)
Set up a test circuit using 10 gauge wire as shown in Figure 5-6. Make 10 passes with wire
through window of droop current transformer.
(4)
Turn on power source and load bank. Adjust load bank until 20.8 amps is indicated on AC
ammeter.
(5)
Set multimeter for AC amperes, and connect to secondary leads 1 and 2. Multimeter indication
must be 0.9 to 1.1 amps.
(6)
Replace droop current transformer if multimeter indication in any phase is other than stated in
step (5).
FIGURE 5-6. TESTING DROOP CURRENT TRANSFORMER
c.
5.8.6
(7)
Remove droop current transformer from test circuit.
(8)
Install droop current transformer, step 5.8.5.c below.
Installation.
(1)
Install droop current transformer (7, Figure 5-4), screws (6), and locknuts (5) on rear panel (33).
(2)
Connect droop current transformer (7) electrical leads to terminal board (35). Remove tags.
(3)
Install main generator cables on droop current transformer (7) the same number of wraps
recorded during removal.
(4)
Connect main generator cables T2 and T8 to voltage reconnection board (34). Remove tags.
(5)
Close output box and engine compartment access doors.
(6)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
Power Potential Transformer T1.
5-39
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
a. Removal.
b.
c.
5-40
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Remove DCS control box assembly, paragraph 4.8.1.
(4)
Remove output box top panel, paragraph 5.8.1.
(5)
Tag and disconnect electrical leads from power potential transformer (10, Figure 5-4).
(6)
Remove locknuts (8), screws (9), and power potential transformer (10) from rear panel (33).
Testing.
(1)
Remove power potential transformer, step 5.8.6.a above.
(2)
Set multimeter for ohms, and take reading between terminals 1 and 2. Reading should be
between 2.1 and 2.6 ohms. If reading is not within these parameters, the transformer is defective
and must be replaced.
(3)
Take a reading between terminals 3 and 7. Reading should be between 2.2 and 2.8 ohms. If
reading is not within these parameters, the transformer is defective and must be replaced.
(4)
Take a reading between terminals 4 and 6. Reading should be between 4.2 and 5.2 ohms. If
reading is not within these parameters, the transformer is defective and must be replaced.
(5)
Check for an open circuit between terminals 1 and 3, 1 and 4, and 7 and 4. If continuity is
present between these points, the transformer is defective and must be replaced.
(6)
Turn on power source. Apply 208V RMS/60 Hz to terminals 1 and 2. Check voltage across
terminals 3 and 7. Reading should be between 139 and 171V RMS. Check voltage across
terminals 4 and 6. Reading should be between 23 and 29 V RMS. If reading is not within these
parameters, the transformers is defective and must be replaced.
(7)
Install power potential transformer, step 5.8.6.c below.
Installation.
(1)
Install power potential transformer (10, Figure 5-4), screws (9), and locknuts (8) on rear panel
(31).
(2)
Connect electrical leads to power potential transformer (10). Remove tags.
(3)
Install output box top panel, paragraph 5.8.1.
(4)
Install DCS control box assembly, paragraph 4.8.1.
(5)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
5.8.7
Output Box Panels.
a.
b.
Inspection.
(1)
Inspect output box panels (13, 24, 27, and 33, Figure 5-4) for cracks, dents, loose paint,
corrosion, and other damage.
(2)
Inspect grommets (28 and 29), protective edging (30), door seal (31), and EMI seal (32) for
looseness, tears, deterioration, and other damage.
Removal.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Remove DCS control box assembly, paragraph 4.8.1.
(4)
Remove rear housing panel. Refer to paragraph 4.7.5.
(5)
Remove output box access door. Refer to paragraph 4.7.1.
(6)
Remove air cleaner assembly, paragraph 4.9.2.
(7)
Remove locknuts (11, Figure 5-4), bolts (12), and top panel (13) from output box assembly.
(8)
Remove voltage reconnection terminal board, paragraph 5.8.2.
(9)
Remove droop current transformer, paragraph 5.8.5.
(10)
Remove power potential transformer, paragraph 5.8.6.
(11)
Remove current transformer, paragraph 5.8.4.
(12)
Remove output box wiring harness, paragraph 5.8.3.
(13)
Remove locknuts (14), screws (15), and AC circuit interrupter (16) from rear panel (33).
(14)
Remove locknuts (17), screws (18), and cranking relay (19) from side panel (27).
(15)
Remove locknuts (20), bolts (21), and output box panels (24, 27, and 33) from generator set.
(16)
Remove locknuts (22), bolts (23), and side panel (24) from rear panel (33).
(17)
Remove locknuts (25), bolts (26), and side panel (27) from rear panel (33).
(18)
Remove grommets (28 and 29) from rear panel (33).
5-41
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
c.
Repair.
__________
WARNING
CARC paint is a health hazard. Wear protective eyewear, mask and gloves
when sanding CARC painted surfaces. Failure to comply can cause
personal injury.
d.
5-42
(1)
Repair all dents and cracks, and remove loose paint.
(2)
Remove light corrosion with fine grit abrasive paper (Item 16, Appendix E).
(3)
Replace damaged grommets (28 and 29, Figure 5-4) and door seal (31).
(4)
Using adhesive (1, Appendix E), replace damaged protective edging (30).
(5)
Using adhesive (1, Appendix E), replace damaged EMI seal (32).
(6)
Repaint surfaces in accordance with TM 43-0139.
Installation.
(1)
Install grommets (28 and 29, Figure 5-4) in real panel (33).
(2)
Install side panel (27), bolts (26), and locknuts (25) on rear panel (33).
(3)
Install side panel (24), bolts (23), and locknuts (22) on rear panel (33).
(4)
Position output box panels (33, 27, and 24) in generator set, and secure with bolts (21) and
locknuts (20).
(5)
Install cranking relay (19), screws (18), and locknuts (17) on side panel (27).
(6)
Install AC circuit interrupter (16), screws (15), and locknuts (14) on rear panel (33).
(7)
Install output box wiring harness, paragraph 5.8.3.
(8)
Install current transformer, paragraph 5.8.4.
(9)
Install power potential transformer, paragraph 5.8.6.
(10)
Install droop current transformer, paragraph 5.8.5.
(11)
Install voltage reconnection terminal board, paragraph 5.8.2.
(12)
Install output box top panel (13), bolts (12), and locknuts (11) on output box assembly.
(13)
Install air cleaner assembly, paragraph 4.9.2.
(14)
Install output box access door. Refer to paragraph 4.7.1.
(15)
Install rear housing panel. Refer to paragraph 4.7.5.
(16)
Install DCS control box assembly, paragraph 4.8.1.
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
(17)
5.9
Connect negative battery cable to battery, and close BATTERY ACCESS door.
MAINTENANCE OF ENGINE ACCESSORIES.
__________
WARNING
When disconnecting or removing batteries, disconnect the negative lead
that connects directly to the grounding stud first. Disconnect the negative
end of the interconnection cable next. When installing batteries, reverse the
connection sequence. Failure to comply can cause serious personal injury.
5.9.1
Electric Actuator A6.
a.
Inspection.
Inspect electric actuator (11, Figure 5-7) for corrosion, dents, missing hardware, and obvious damage.
b.
Testing.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Disconnect output box wiring harness from electrical connector (1, Figure 5-7).
(4)
Set multimeter for ohms. Test continuity at contacts within electrical connector (1). Multimeter
should indicate continuity.
(5)
If multimeter reading is other than above, replace electric actuator (11, Figure 5-8).
(6)
Connect electrical connector (1) to output box wiring harness.
(7)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
5-43
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
FIGURE 5-7. ELECTRIC ACTUATOR
5-44
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
c.
Replacement.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Remove fan guard from left side of generator set. Refer to paragraph 4.10.3.
(4)
Remove dead crank switch plate (10, Figure 4-29).
(5)
Disconnect output box wiring harness from electrical connector (1, Figure 5-7).
(6)
Loosen coupling nut (2), and remove fuel line (3) and seal (4) from elbow (5).
(7)
Remove elbow (5), seal (6), adapter (7), seal (8), and adapter (9) from electric actuator (11).
NOTE
One cap screw is longer than the others. Note position of cap screws for
installation later.
(8)
Remove cap screws (10), electric actuator (11), and gasket (12) from engine.
(9)
Position gasket (12) and electric actuator (11) on engine. Secure with cap screws (10) as noted
in step (6).
(10)
Install adapter (9), seal (8), adapter (7), seal (6), and elbow (5) on electric actuator (11).
(11)
Position seal (4) and fuel line (3) on elbow (5). Tighten coupling nut (2).
(12)
Connect output box wiring harness to electrical connector (1).
(13)
Install fan guard from left side of generator set. Refer to paragraph 4.10.3.
(14)
Install dead crank switch plate (10, Figure 4-29).
(15)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
5-45
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
5.10
MAINTENANCE OF GENERATOR ASSEMBLY.
__________
WARNING
When disconnecting or removing batteries, disconnect the negative lead
that connects directly to the grounding stud first. Disconnect the negative
end of the interconnection cable next. When installing batteries, reverse the
connection sequence. Failure to comply can cause serious personal injury.
5.10.1
Generator Assembly.
__________
WARNING
High voltage is produced when this generator set is in operation. Make sure
unit is completely shut down and free of any power source before
attempting any repair or maintenance on the unit. Failure to comply can
cause injury or death to personnel.
a.
Removal.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Remove output box assembly, paragraph 5.8.1.
(4)
Remove rear housing section, paragraph 4.7.5.
(5)
Remove load output terminal board, paragraph 4.12.8.
(6)
Remove rear forklift guide. Refer to paragraph 5.11.1.
(7)
Loosen bolts (1, Figure 5-8), and lower engine support brackets (2) to contact skid base.
(8)
Tighten bolts. If necessary, place wooden shims under brackets to ensure contact.
CAUTION
Generator is heavy. Rated capacity of overhead hoist should be at least
1,000 lb. (454 kg). Failure to comply can cause damage to equipment.
5-46
(9)
Attach lifting harness to overhead hoist and generator lifting eye (27). Take up slack on harness.
(10)
Remove nuts (3), lockwashers (4), screws (5), washers (6), and band cover (7) from generator
case.
(11)
Remove bolts (8), lockwashers (9), and washers (10) securing generator drive disc (22, Figure 59) to engine flywheel.
(12)
Remove bolts (11), lockwashers (12), and washers (13) securing generator to engine flywheel
housing.
(13)
Remove locknuts (14), washers (15), bolts (16), Belleville washers (17), and snubbing washers
(18) securing generator to skid base.
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
b.
(14)
Lift generator slowly from skid base. Ensure engine flywheel and generator separate smoothly,
avoiding any undue stress.
(15)
Remove jamnuts (19), washers (20), bolts (21), washers (22), jamnuts (23),
plates (24), and angles (25) from generator.
(16)
Remove shock mounts (26) from skid base.
Installation.
(1)
Position shock mounts (26, Figure 5-8) on skid base.
(2)
Install angles (25), plates (24), jamnuts (23), washers (22), bolts (21), washers (20), and jamnuts
(19) on generator. Do not tighten jamnuts.
CAUTION
Generator is heavy. Rated capacity of overhead hoist should be at least
1,000 lb. (454 kg). Failure to comply can cause damage to equipment.
(3)
Attach lifting harness to overhead hoist and generator lifting eye (27).
(4)
Position generator on skid base with mounting holes aligned to angles (25) and engine flywheel
housing.
(5)
Secure generator to engine flywheel housing with washers (13), lockwashers (12), and bolts
(11). Tighten bolts slowly to ensure proper seating of generator case lip in flywheel housing.
Torque bolts to 25 ft-lb (33.9 Nm).
(6)
Secure generator to skid base with snubbing washers (18), Belleville washers (17), bolts (16),
washers (15), and locknuts (14). Torque bolts to 210 ft-lb (284.9 Nm).
(7)
Secure generator drive disc to engine flywheel with washers (10), lockwashers (9), and bolts (8).
Torque bolts to 25 ft-lb (33.9 Nm).
(8)
Install band cover (7), washers (6), screws (5), lockwashers (4), and nuts (3) on generator.
(9)
Adjust jamnuts (19 and 23) on generator mount to obtain 0.5 in. minimum clearance between
ends of bolts (21) and skid base. Torque nuts to 150 ft-lb (203.4 Nm).
(10)
Detach lifting device from generator lifting eye (27).
(11)
Raise engine support brackets (2) from skid base, and tighten bolts (1).
(12)
Install rear forklift guide. Refer to paragraph 5.11.1.
(13)
Install load terminal board, paragraph 4.12.8.
(14)
Install rear housing section, paragraph 4.7.5.
(15)
Install output box assembly, paragraph 5.8.1.
5-47
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
FIGURE 5-8. GENERATOR ASSEMBLY REMOVAL
(16)
5-48
Connect negative battery cable to battery, and close BATTERY ACCESS door.
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
(17)
5.10.2
Start generator set, paragraph 2.11.1. Check for proper operation.
End Bell and Main Bearing.
a.
Removal.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Remove rear housing panel. Refer to paragraph 4.7.5.
(4)
Remove bolts (1, Figure 5-9), lockwashers (2), top cover (3), and louvered covers (4) from end
bell (7).
CAUTION
The end bell supports the main rotor, thus the rotor will drop on the stator
once the end bell is removed. Prior to proceeding, bar engine by using
center bolt on harmonic balancer, TM 9-2815-259-24, until two main rotor
poles are vertical in generator stator. Having the rotor in this position will
limit the amount of drop, otherwise damage to rotor and/or stator could
occur.
(5)
Remove bolts (5) and lockwashers (6) from end bell (7).
(6)
Install two bolts (5) in back-out holes in end bell flange. Refer to Figure 5-10.
(7)
Loosen lead clamp assembly (33, Figure 5-9) clamping generator leads at side of generator
housing (11). Ensure wires F1 and F2 are free to slide in and out of generator housing.
(8) Remove end bell (7), with exciter stator (16) attached, by tightening bolts (5) evenly into back-out
holes. Remove bolts from back-out holes.
CAUTION
If bearing needs to be removed for any reason, always install new bearing.
Main bearing is easily damaged when removed from rotor shaft . Failure to
install a new bearing can cause damage to equipment.
(9) Using bearing puller, remove bearing (9) from main rotor shaft (10). Discard bearing.
5-49
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
FIGURE 5-9. GENERATOR ASSEMBLY
5-50
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
FIGURE 5-10. END BELL REMOVAL
b.
Installation.
CAUTION
If bearing needs to be removed for any reason, always install new bearing.
Main bearing is easily damaged when removed from rotor shaft. Failure to
install a new bearing can cause damage to equipment.
(1)
Heat new bearing (9, Figure 5-9) to expand diameter to fit on main rotor shaft (10). Install new
bearing (9) on main rotor shaft (10). Ensure bearing is seated squarely against shaft shoulder by
applying pressure to inner race only.
(2)
Position bearing (9) in end bell (7).
NOTE
It may be necessary to use a lifting device to raise and align end ball with
generator housing.
(3)
Position end bell (7), with exciter stator (16) attached, on generator housing (11) while pulling
slack of wires F1 and F2 through side of generator housing. Secure end bell with lockwashers
(6) and bolts (5). Torque bolts to 59-61 in-lb (6.7-7.0 Nm).
(4)
Tighten lead clamp assembly (33) at side of generator housing (11), ensuring generator leads are
clamped securely.
5-51
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
5.10.3
(5)
Install louvered cover (4), top cover (3), lockwashers (2), and bolts (1) on end bell (7).
(6)
Install rear housing panel. Refer to paragraph 4.7.5.
(7)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
Rotating Rectifier.
a.
Testing.
(1)
Shut down generator set, paragraph 2.11.2. Allow generator to cool to ambient temperature.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Remove rear housing panel. Refer to paragraph 4.7.5.
(4)
Remove end bell cover plates. Refer to paragraph 5.10.2.
NOTE
It will be necessary to bar (turn) engine in order to position a specific area of the
rotating rectifier at one of the end bell access holes. Use center bolt on harmonic
balancer to turn engine. Refer to TM 9-2815-259-24.
5-52
(5)
Tag main rotor and diode leads, and remove nuts (1, Figure 5-11), lockwashers (2), and leads
from terminal bolts (9).
(6)
Tag exciter rotor leads, and remove bolts (3), washers (4), and leads from rectifier mounting
plate (5).
(7)
Set multimeter for ohms, and connect positive lead to one side and negative lead to other side of
each diode (6). Record multimeter reading for each diode.
(8)
Repeat step (7) with multimeter leads reversed.
(9)
Resistance (ohms) readings should show continuity in one direction and no continuity in
reversed direction. If readings show continuity or no continuity in both directions, diode is
defective and must be replaced.
(10)
Install exciter rotor leads, washers (4), and bolts (3) on rectifier mounting plate (5). Remove
tags.
(11)
Install diode and main rotor leads, lockwashers (2), and nuts (1) on terminal bolts (9).
(12)
Install end bell cover plates. Refer to paragraph 5.10.2.
(13)
Install rear housing panel. Refer to paragraph 4.7.5.
(14)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
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b.
c.
Removal.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Remove rear housing panel. Refer to paragraph 4.7.5.
(4)
Remove end bell and main bearing, paragraph 5.10.2.
(5)
Remove nuts (1, Figure 5-11) and lockwashers (2) securing main rotor leads and rotating
rectifier diode leads to terminal bolts (9). Tag and remove leads.
(6)
Remove bolts (3) and washers (4) securing exciter rotor leads to rotating rectifier plate (5). Tag
and remove leads.
(7)
Remove bolts (12, Figure 5-9), lockwashers (13), and rotating rectifier (14) from rotor assembly
(28).
Replacement of Rotating Rectifier Diodes.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Remove rear housing panel. Refer to paragraph 4.7.5.
(4)
Remove end bell top cover and louvered covers. Refer to paragraph 5.10.2.
NOTE
It will be necessary to bar (turn) engine in order to position a specific area of the rotating rectifier
at one of the end bell access holes. Use center bolt on harmonic balancer to turn engine. Refer to
TM 9-2815-259-24.
(5)
Unsolder electrical lead from diode (6, Figure 5-11) to be removed.
(6)
Remove nut (7), lockwasher (8), and diode (6) from rotating rectifier plate (5) through access
hole in end bell.
(7)
Run bead of thermal-electrical contact compound (Item 9, Appendix E) around base of diode (6)
prior to installing. Do not coat threads.
(8)
Insert diode (6) through generator end bell access hole, and install on rotating rectifier plate (5)
with lockwasher (8) and nut (7). Torque nut to 28-30 inch-pounds (3.16-3.38 Nm).
(9)
Using soldering iron and solder (Item 19, Appendix E), solder electrical lead to diode (6).
(10)
Install end bell top cover and louvered covers. Refer to paragraph 5.10.2.
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FIGURE 5-11. RECTIFIER ASSEMBLY
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d.
5.10.4
(11)
Install rear housing panel. Refer to paragraph 4.8.5.
(12)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
Installation.
(1)
Install rotating rectifier (14, Figure 5-9), lockwashers (13), and bolts (12) on rotor assembly
(28).
(2)
Install exciter rotor leads, washers (4, Figure 5-11), and bolts (3) on rotating rectifier plate (5).
(3)
Install main rotor leads and rotating rectifier diode leads, lockwashers (2), and bolts (1) on
terminal bolts (9).
(4)
Install end bell and main bearing, paragraph 5.10.2.
(5)
Install rear housing panel. Refer to paragraph 4.7.5.
(6)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
Exciter Stator.
a.
b.
Inspection.
(1)
Shut down generator set, paragraph 2.11.2. Allow generator to cool to ambient temperature.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Open output box access door (Figure 1-2), visually inspect generator assembly for obvious
damage. Check exciter field leads for broken wires and signs of chaffing.
Testing.
(1)
Shut down generator set, paragraph 2.11.2. Allow generator to cool to ambient temperature.
Inspect Exciter Stator per paragraph 5.10.4 a.
(2)
Open output box access door (Figure 1-2), and disconnect exciter field leads F1 and F2 from
terminals 1 and 2 of terminal board TB8. Refer to Schematic FO-1.
(3)
Set multimeter for ohms, and connect between disconnected exciter field leads. Multimeter
reading should be as shown in Table 5-2.
(4)
Multimeter reading other than in Table 5-2 indicates open or shorted windings, and exciter stator
must be replaced.
(5)
Connect multimeter between each exciter field lead and generator frame in turn.
(6)
Multimeter reading of less than infinity indicates defective ground insulation, and exciter stator
must be replaced.
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TABLE 5-2. GENERATOR RESISTANCE VALUES AT 25° C (77° F)
Resistance
Component
MEP-805B
MEP-815B
Exciter Stator
Between 24.85 & 33.61 ohms
Between 24.7301 & 33.4583 ohms
Exciter Rotor
Between 0.202 & 0.274 ohms
Between 0.2082 & 0.2816 ohms
Generator Rotor
Between 0.52 & 0.70 ohms
Between 1.0835 & 1.4659 ohms
Generator Stator
Between 0.040 & 0.054 ohms
Between 0.015 & 0.0202 ohms
c.
5-56
(7)
Connect exciter field leads F1 and F2 to terminals 1 and 2 of terminal board TB8 (Refer to
Schematic FO-1), and close output box access door.
(8)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
Replacement.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Remove rear housing panel. Refer to paragraph 4.7.5.
(4)
Open output box access door (Figure 1-2), and disconnect exciter field leads F1 and F2 from
terminals 1 and 2 of terminal board TB8. Refer to Schematic FO-1.
(5)
Attach pieces of rigid wire with a hook bent into one end of each ("fish wires") to disconnected
F1 and F2 leads to aid in installation process.
(6)
Remove end bell. Refer to paragraph 5.10.2.
(7)
Remove bolt (15, Figure 5-10) and exciter stator (16) from end bell (7).
(8)
Detach "fish wires" once F1 and F2 leads clear generator housing (11).
(9)
Attach "fish wires" to F1 and F2 leads of exciter stator (16).
(10)
Gently pull on "fish wires" to pull F1 and F2 leads back through generator housing (11).
Disconnect "fish wires", and position F1 and F2 leads in output box, Figure 1-3.
(11)
Position exciter stator (16) in end bell (7). Secure exciter stator in place with bolt (15).
(12)
Install end bell. Refer to paragraph 5.10.2.
(13)
Connect exciter field leads F1 and F2 to terminals 1 and 2 of terminal board TB8 (Figure 5-9).
Close output box access door (Figure 1-2).
(14)
Install rear housing panel. Refer to paragraph 4.7.5.
(15)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
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5.10.5
Exciter Rotor .
a.
b.
Inspection.
(1)
Shut down generator set, paragraph 2.11.2. Allow generator to cool to ambient temperature.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Remove rear housing panel. Refer to paragraph 4.7.5.
(4)
Remove end bell top cover and louvered covers. Refer to paragraph 5.10.2.
(5)
Visually inspect generator assembly for obvious damage. Check exciter leads for broken wires
and signs of chaffing.
Testing.
(1)
Perform inspection per paragraph 5.10.5.a.
(2)
Tag exciter rotor leads, and remove bolts (3, Figure 5-11), lockwashers (4), and leads from
rotating rectifier plate (5).
NOTE
It will be necessary to bar (turn) engine in order to position a specific area of the
rotating rectifier at one end of the end bell access holes. Use center bolt on
harmonic balancer. Refer to TM 9-2815-259-24.
(3)
Connect resistance bridge between two exciter rotor leads, and note resistance reading.
Continue this procedure until readings are noted for each combination of leads (i.e., 1 and 2, 1
and 3, and 2 and 3).
NOTE
Ambient temperature must be expressed in °C. To convert °C to °F, use °F = °C
x 9 ÷ 5 + 32.
(a)
To determine the resistance values at current ambient temperature, use the following
formula:
R1 = R25 [1 + 0.00385 (T-25)]
Where:
R1 = Unknown resistance
R25 = Known resistance at 25° C (77° F)
T = Current ambient temperature
(b)
Example for exciter stator leads at 5° C (41° F):
R1 = 29.23 [1 + 0.00385 (5-25)]
R1 = 29.23 [1 + 0.00385 (-20)]
R1 = 29.23 [1 + (-0.077)]
R1 = 29.23 [0.923]
R1 = 26.98 ± 15% ohms
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(4)
Resistance readings should be as shown in Table 5-2 for each combination of leads. Readings
other than in Table 5-2 indicate open or shorted windings, and exciter rotor must be replaced.
Refer to paragraph 5.10.6.
5.10.6
(5)
Set multimeter for ohms, and connect between each exciter rotor lead and rotor shaft in turn.
(6)
Multimeter reading of less than infinity indicates defective ground insulation, and exciter rotor
must be replaced. Refer to paragraph 5.10.6.
(7)
Install exciter rotor leads, lockwashers (4), and bolts (3) on rotating rectifier plate (5).
(8)
Install end bell top cover and louvered covers. Refer to paragraph 5.10.2.
(9)
Install rear housing panel. Refer to paragraph 4.7.5.
(10)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
Generator Rotor Assembly.
a.
Testing.
(1)
Shut down generator set, paragraph 2.11.2. Allow generator to cool to ambient temperature.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Remove rear housing panel. Refer to paragraph 4.7.5.
(4)
Remove end bell top cover and louvered covers. Refer to paragraph 5.10.2.
(5)
Remove nuts (1, Figure 5-11) and lockwashers (2) securing main rotor leads to terminal bolts
(9). Tag and remove leads.
NOTE
It will be necessary to bar (turn) engine in order to position a specific area of the
rotating rectifier at one end of the end bell access holes. Use center bolt on
harmonic balancer. Refer to TM 9-2815-259-24.
b.
5-58
(6)
Set multimeter for ohms, and connect between disconnected main rotor leads. Multimeter
reading should be as shown in Table 5-2.
(7)
Reading other than in Table 5-2 indicates shorted or open windings, and main rotor must be
replaced.
(8)
Connect multimeter between each main rotor lead and rotor shaft in turn.
(9)
Multimeter reading of less than infinity indicates defective ground insulation, and main rotor
must be replaced.
(10)
Install securing main rotor leads and rotating rectifier diode leads, lockwashers (2), and bolts (1)
on terminal bolt (9).
(11)
Install end bell top cover and louvered covers. Refer to paragraph 5.10.2.
(12)
Install rear housing panel. Refer to paragraph 4.7.5.
(13)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
Removal.
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(1)
Shut down generator set, paragraph 2.11.2.
(2)
Remove generator assembly, paragraph 5.10.1.
(3)
Remove bolts (20, Figure 5-9), washers (21), and drive discs (22) from drive hub (26).
(4)
Remove bolts (23), lockwashers (24), and fan (25) from drive hub (26).
(5)
Attach a suitable rotor lifting device to drive hub (26) and overhead hoist as shown in Figure 512.
(6)
Remove end bell and main bearing. Refer to paragraph 5.10.2.
(7)
Remove rotating rectifier, paragraph 5.10.3
CAUTION
Special care should be taken when removing rotor assembly, winding
damage could result if rotor is allowed to hit main stator.
(8)
c.
Carefully remove rotor assembly (28) and attached components from main stator and generator
housing (11).
Installation.
(1)
Install rotating rectifier, paragraph 5.10.3.
(2)
Install main bearing. Refer to paragraph 5.10.2.
CAUTION
Special care must be taken installing rotor assembly. Winding damage
could result if rotor is allowed to hit main stator.
(3)
Attach suitable rotor lifting device to drive hub (26) and overhead hoist as shown in Figure 5-12.
(4)
Carefully install rotor assembly (28, Figure 5-9) and matched components into main stator and
generator housing (11).
(5)
Install end bell. Refer to paragraph 5.10.2. Remove rotor lifting device.
(6)
Install fan (25) on drive hub (26) with lockwashers (24) and bolts (23).
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FIGURE 5-12. ROTOR ASSEMBLY LIFTING DEVICE (TYPICAL)
NOTE
Make sure all disc mounting holes at the inner and outer diameter are properly
aligned.
5.10.7
Install drive discs (22), washers (21), and bolts (20) on drive hub (26). Torque bolts (20) to 35
ft-lb (47 Nm).
(8)
Install generator assembly, paragraph 5.10.1.
Generator Main Stator and Housing,
a.
5-60
(7)
Testing.
(1)
Shut down generator set, paragraph 2.11.2. Allow generator to cool to ambient temperature.
(2)
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
(3)
Remove rear housing, paragraph 4.7.5.
(4)
Remove voltage reconnection terminal board. Refer to paragraph 5.8.2.
(5)
Tag and disconnect wires from voltage reconnection terminal, paragraph 5.8.
(6)
Connect resistance bridge, and note readings between terminals T1 and T4, T2 and T5, T3 and
T6, T7 and T0, T8 and T0, and T9 and T0 of voltage reconnection terminal board. Refer to FO1.
(7)
All resistance readings should be as shown in Table 5-2.
(8)
If resistance is low, there are shorted windings. If resistance is high, stator windings are open.
In either case, stator must be replaced.
(9)
Set multimeter for ohms, and connect between each of the ten coil leads from generator clamp
assembly (3, Figure 5-9) and ground.
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b.
5.11
(10)
If multimeter indicates resistance on any connection, stator windings are grounded and stator
must be replaced.
(11)
Connect wires to voltage reconnection terminal board and remove tags. Refer to paragraph
5.8.2.
(12)
Install moveable terminal board and protective cover on voltage reconnection terminal board.
Refer to paragraph 5.8.2.
(13)
Install rear housing, paragraph 4.7.5.
(14)
Connect negative battery cable to battery, and close BATTERY ACCESS door.
Replacement.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Remove generator assembly, paragraph 5.10.1.
(3)
Remove generator rotor assembly, paragraph 5.10.6.
(4)
Install generator rotor assembly, paragraph 5.10.6.
(5)
Install generator assembly, paragraph, 5.10.1.
MAINTENANCE OF SKID BASE.
__________
WARNING
When disconnecting or removing batteries, disconnect the negative lead
that connects directly to the grounding stud first. Disconnect the negative
end of the interconnection cable next. When installing batteries, reverse the
connection sequence. Failure to comply can cause serious personal injury.
5.11.1
Skid Base.
a.
Inspection.
Inspect skid base for obvious signs of damage such as corrosion and dents.
b.
c.
Removal.
(1)
Shut down generator set, paragraph 2.11.2.
(2)
Remove engine and generator assembly, paragraph 5.4.2.
(3)
Remove fuel tank, paragraph 5.7.1.
(4)
Remove nuts (1, Figure 5-13), lockwashers (2), bolts (3), washers (4), and forklift guides (5)
from skid base.
(5)
Remove cable grommets (6 and 7) from skid base.
Repair.
Repair of skid base will be limited to corrosion control and spot welding minor cracks. If major
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structural damage has occurred, replace skid base. Repair surfaces in accordance with TM-43-0139.
d.
Installation.
(1)
Install cable grommets (7 and 6, Figure 5-13) in skid base.
(2)
Install forklift guides (5), washers (4), bolts (3), lockwashers (2), and nuts (1) on skid base.
(3)
Install fuel tank, paragraph 5.7.1.
(4) Install engine and generator assembly, paragraph 5.4.2.
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FIGURE 5-13. SKID BASE
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CHAPTER 6
GENERAL SUPPORT MAINTENANCE INSTRUCTIONS
NOTE
There are no general support level maintenance tasks for the generator set.
Refer to TM 9-2815-259-24 for engine repair at the general support level.
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APPENDIX A
REFERENCES
A.1
SCOPE. This appendix lists all forms, field manuals, technical manuals, and miscellaneous publications
referenced in this manual.
A.2
FORMS.
Equipment Inspection and Maintenance Work Sheet ................................................................DA Form 2404
Product Quality Deficiency Report ....................................................................................................... SF 368
Recommended Changes to Publications and Blank Forms........................................................DA Form 2028
Recommended Changes to DA Publications ......................................................................... DA Form 2028-2
A.3
FIELD MANUALS.
Electric Power Generation in the Field..............................................................................................FM 20-31
First Aid for Soldiers.........................................................................................................................FM 21-11
NBC Contamination Avoidance ............................................................................................................FM 3-3
NBC Decontamination ..........................................................................................................................FM 3-5
NBC Protection .....................................................................................................................................FM 3-4
Operation and Maintenance of Ordnance Material in Cold Weather (0° F to -65° F).......................FM 9-207
A.4
TECHNICAL MANUALS.
Cooling Systems: Tactical Vehicles .............................................................................................TM 750-254
Destruction of Materiel.............................................................................................................. TM 750-244-3
Painting Instruction for Army Materiel .........................................................................................TM 43-0139
Repair Parts and Special Tools List: Generator Set, Tactical Quiet,
30 kW, 50/60 and 400 Hz ..................................................................................TM 9-6115-671-24P
Unit, Direct Support and General support Maintenance Instructions:
Diesel Engine, 4 Cylinder .................................................................................... TM 9-2815-259-24
A.5
MISCELLANEOUS PUBLICATIONS.
Corrosion and Corrosion Prevention: Metals ........................................................................MIL-HDBK-729
Lubrication Order: Generator Set, Tactical Quiet, 30 kW, 50/60 and 400 Hz ...................LO 9-6115-644-12
Marking for Shipment and Storage............................................................................................ MIL-STD-129
Packaging of Generator Set, Mobile Power and Supplemental Equipment................................ MIL-G-28554
Preparation for Shipment and Storage of Engine ........................................................................MIL-E-10062
Preservation of USAMECOM Mechanical Equipment for Shipment and Storage....................... TB 740-97-2
The Army Maintenance Management System (TAMMS)................................................... DA PAM 738-750
Warranty Technical Bulletin ...............................................................................................TB 9-6115-645-24
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APPENDIX B
MAINTENANCE ALLOCATION CHART (MAC)
SECTION I. INTRODUCTION
B.1 GENERAL.
a.
This section provides a general explanation of all maintenance and repair functions authorized at
various maintenance levels under the standard Army Maintenance System concept.
b.
The Maintenance Allocation Chart (MAC) in section II designates overall authority and responsibility
for the performance of maintenance functions on the generator set and its components. The application
of the maintenance functions to the generator set or component will be consistent with the capacities
and capabilities of the designated maintenance categories.
c.
Section III lists the tools and test equipment (both special tools and common tool sets) required for
each maintenance function as referenced from section II.
d.
Section IV contains supplemental instructions and explanatory notes for particular maintenance
functions.
B.2 MAINTENANCE FUNCTIONS. Maintenance Functions are limited to and defined as follows:
a.
Inspect. To determine the serviceability of an item by comparing its physical, mechanical, and/or
electrical characteristics with established standards through examination (i.e., by sight, sound, or feel).
b.
Test. To verify serviceability by measuring the mechanical or electrical characteristics of an item and
comparing those characteristics with prescribed standards.
c.
Service. Operations required periodically to keep an item in proper operating condition, i.e., to clean
(includes decontamination, when required), preserve, drain, paint, or replenish fuel, lubricants,
chemical fluids, or gases.
d.
Adjust. To maintain or regulate, within prescribed limits, by bringing into proper position, or by
setting the operating characteristics to specified parameters.
e.
Align. To adjust specified variable elements of an item to bring about optimum or desired
performance.
f.
Calibrate. To determine and cause corrections to be made or to be adjusted on instruments or test,
measuring, and diagnostic equipment used in precision measurement. Consists of comparisons of two
instruments, one of which is a certified standard of known accuracy, to detect and adjust any
discrepancy in the accuracy of the instrument being compared.
g.
Remove/Install. To remove and install the same item when required to perform service or other
maintenance functions. Install may be the act of emplacing, seating, or fixing into position a spare,
repair part, or module (component or assembly) in a manner to allow the proper functioning of an
equipment or system.
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h.
Replace. To remove an unserviceable item and install a serviceable counterpart in its place. “Replace”
is authorized by the MAC and assigned as the third position code of the SMR code.
i.
Repair. The application of maintenance services, including fault location/troubleshooting,
removal/installation, and disassembly/assembly procedures, and maintenance actions to identify
troubles and restore serviceability to an item by correcting specific damage, fault, malfunction, or
failure in a part, subassembly, module (component or assembly), end item, or system.
j.
Overhaul. That maintenance effort (service/action) prescribed to restore an item to a completely
serviceable/operational condition as required by maintenance standards in appropriate technical
publications (i.e., DMWR). Overhaul is normally the highest degree of maintenance performed by the
Army. Overhaul does not normally return an item to like new condition.
k.
Rebuild. Consists of those services/actions necessary for the restoration of unserviceable equipment to
a like new condition in accordance with original manufacturing standards. Rebuild is the highest
degree of material maintenance applied to Army equipment. The rebuild operation includes the act of
returning to zero those age measurements (hours/miles, etc.) considered in classifying Army
equipment/components.
B.3 EXPLANATION OF COLUMNS IN THE MAC, SECTION II.
a.
Column 1, Group Number. Column 1 lists functional group code numbers, the purpose of which is to
identify maintenance significant components, assemblies, subassemblies, and modules with the next
higher assembly. End item group number shall be "00".
b.
Column 2, Component/Assembly. Column 2 contains the item names of components, assemblies,
subassemblies, and modules for which maintenance is authorized.
c.
Column 3, Maintenance Function. Column 3 lists the functions to be performed on the item listed in
column 2. (For detailed explanation of these functions, see paragraph B.2).
d.
Column 4, Maintenance Level. Column 4 specifies each level of maintenance authorized to perform
each function listed in column 3, by the indicating work time required (expressed as man-hours in
whole hours and decimals) in the appropriate subcolumn. This work-time figure represents the active
time required to perform that maintenance function at the indicated level of maintenance. If the
number or complexity of the tasks within the listed maintenance function vary at different maintenance
levels, appropriate work time figure will be shown for each level. The work time figure represents the
average time required to restore an item (assembly, subassembly, component, module, end item, or
system) to a serviceable condition under typical field operating conditions. This time includes
preparation time (continuation/follow-on tasks) (including any necessary disassembly/assembly time),
troubleshooting/fault location time, and quality assurance time in addition to the time required to
perform the specific tasks identified for the maintenance functions authorized in the MAC. The
symbol designations for the various maintenance levels are as follows:
NOTE
When a complete replace or repair task performed at higher
level maintenance includes lower level maintenance tasks
(equipment condition/follow on tasks), the lower level work
time figures in the MAC must be added to the higher level
work time shown in the MAC to determine the total to
accomplish that maintenance function.
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C..........................................................................................Operator or crew
O..........................................................................................Unit Maintenance
F ..........................................................................................Direct Support Maintenance
L ..........................................................................................Specialized Labor Activity (SRA)
H..........................................................................................General Support Maintenance
D..........................................................................................Depot Maintenance
e.
Column 5, Tools and Test Equipment Reference Code. Column 5 specifies, by code, those
common tool sets (not individual tools), common TMDE, and special tools, special TMDE, and
support equipment required to perform the designated function. Codes are keyed to tools and test
equipment in section III.
f.
Column 6, Remarks. When applicable, this column contains a letter code, in alphabetic order,
which shall be keyed to the remarks contained in section IV.
B-4
EXPLANATION OF COLUMNS IN TOOL AND TEST EQUIPMENT REQUIREMENTS,
SECTION III.
B.5
a.
Column 1, Reference Code. The tool and test equipment reference code correlates with a
code used in the MAC, Section II, Column 5.
b.
Column 2, Maintenance Level. The lowest level of maintenance authorized to use the tool or
test equipment.
c.
Column 3, Nomenclature. Name or identification of the tool or test equipment.
d.
Column 4, National Stock Number. The National Stock Number of the tool or test
equipment.
e.
Column 5, Tool Number. The manufacturer’s part number of the tool or test equipment.
EXPLANATION OF COLUMNS IN REMARKS, SECTION IV.
a.
Column 1, Reference Code. The code recorded in column 6, section II.
b.
Column 2, Remarks. This column, along with the related codes, should be used to clarify
maintenance and inspection functions by different military occupational specialties involved
in maintaining some components.
B-3
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
SECTION II. MAINTANANCE ALLOCATION CHART
FOR MEP-805B AND 815B (continued)
(1)
GROUP
NUMBER
00
01
(2)
COMPONENT/
ASSEMBLY
GENERATOR SET, 60 KW
(LESS ENGINE)
DC ELECTRICAL SYSTEM.
C
O
F
INSPECT
4.3
8.1
2.3
TEST
.1
6.6
7.6
SERVICE
1.7
2.7
BATTERIES
0103
02
0201
BATTERY AND SLAVE
RECEPTACLE CABLES.
.3
1
3.0
1,2,3,4
REMOVE
14.4 22.8
1,2,3
INSTALL
14.4 22.8
1,2,3
REPLACE
16.1 7.7
1,2
.1
5
REPAIR
.2
1,2,4
.1
.3
1,5
REMOVE
.5
1,2,4
INSTALL
.5
TEST
.1
5
REMOVE
.2
1
INSPECT
.1
.1
SERVICE
.1
.1
1
.2
1
INSPECT
ACCESS DOORS.
.1
REMOVE
.2
SERVICE
.2
1
REPAIR
.2
2,4
INSTALL
.2
1
.1
1
.1
REMOVE
.1
1
INSTALL
.1
1
INSPECT
.6
.8
REMOVE
4.3
1
REPAIR
4.3
1
INSTALL
4.3
1
REMOVE
.5
1
REPAIR
.5
1
INSPECT
INSTALL
B-4
.1
.1
F
.3
TEST
NATO SLAVE RECEPTACLE. INSPECT
HOUSING
1,2
9.7
.3
REMARKS
2,5
2.0
INSPECT
(6)
D
REPAIR
INSTALL
0102
H
(5)
TOOLS AND
EQUIP
ADJUST
SERVICE
0101
(4)
MAINTENANCE LEVEL
(3)
MAINTENANCE
FUNCTION
.1
.5
1
F
A,F
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
SECTION II. MAINTANANCE ALLOCATION CHART
FOR MEP-805B AND 815B (continued)
(1)
GROUP
NUMBER
(2)
COMPONENT/
ASSEMBLY
(4)
MAINTENANCE LEVEL
(3)
MAINTENANCE
FUNCTION
C
202
DCS CONTROL BOX TOP
PANEL.
REMOVE
INSPECT
0203
TOP HOUSING SECTION.
FRONT HOUSING SECTION.
0.1
1
1.0
1
03
DCS CONTROL BOX
ASSEMBLY
1.0
1.0
1
REMOVE
1.5
1
1.0
1
REMOVE
2.0
1
REPAIR
1.0
1
0.1
0.2
INSPECT
0.1
0.1
0303
0304
SWITCHES
GROUND FAULT CIRCUIT
INTERRUPTER
1
INSTALL
0.3
2
REMOVE
0.4
1,6
2.7
0.2
1.0
1,2
1
1.0
1.0
1
TEST
0.1
1.0
1.0
1,5
INSPECT
0.1
0.1
REPAIR
0.2
1
REPLACE
0.3
1
INSPECT
0.1
0.3
5
REPLACE
0.2
1
0.1
0.1
TEST
0.2
5
REPLACE
0.2
1
INSPECT
0.1
0.1
TEST
0.1
0.1
5
0.5
1
REPLACE
C
0.1
TEST
INSPECT
C
.1
0.4
REPLACE
TIME METER
1
2.0
INSTALL
0302
0.2
1.5
INSPECT
PANEL LIGHTS
1
INSTALL
REPAIR
0301
0.2
INSTALL
INSTALL
HOUSING DATA PLATES
1
REPAIR
INSPECT
0206
0.1
REMOVE
0.1
REMARKS
1
0.5
0.1
(6)
D
0.5
INSPECT
REAR HOUSING SECTION.
H
INSTALL
REPAIR
0205
F
REPAIR
INSPECT
0204
O
.5
(5)
TOOLS AND
EQUIP
B-5
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
SECTION II. MAINTANANCE ALLOCATION CHART
FOR MEP-805B AND 815B (continued)
(1)
GROUP
NUMBER
(2)
COMPONENT/
ASSEMBLY
(4)
MAINTENANCE LEVEL
(3)
MAINTENANCE
FUNCTION
C
0305
COMPUTER INTERFACE
MODULE (CIM).
0307
KEYPAD ASSEMBLY KP.
COMMUNICATION PORT.
0.3
1
0.3
1
INSPECT
0.1
0.2
INSPECT
0.1
0309
CONVENIENCE
RECEPTACLE
0.2
0311
0312
0313
0314
0315
0316
B-6
BACKPLANE MODULE
I/O INTERFACE MODULE
DC CONTROL POWER
CIRCUIT BREAKER
REACTIVE CURRENT
ADJUST RHEOSTAT
E
1
0.4
0.1
1
0.1
TEST
0.2
5
REPLACE
0.5
1
INSPECT
0.1
REMOVE
0.3
1,6
INSTALL
0.3
1.6
TEST
0.4
DCS SPEED CONTROL UNIT INSPECT
AUTOMATIC VOLTAGE
REGULATOR
1
0.1
REPLACE
INSPECT
REMARKS
0.1
REPLACE
PARALLELING RECEPTACLE INSPECT
(6)
D
REMOVE
0308
DCS LOAD SHARING
SYNCHRONIZER
H
0.1
REPLACE
0310
F
INSPECT
INSTALL
0306
O
(5)
TOOLS AND
EQUIP
E
0.1
REMOVE
0.3
1,6
INSTALL
0.3
1,6
TEST
0.4
INSPECT
0.1
REMOVE
0.3
1,6
INSTALL
0.3
1,6
TEST
0.6
INSPECT
0.1
REPLACE
1.0
TEST
0.5
INSPECT
0.1
REPLACE
1.0
E
E
1,6
E
1,6
E
TEST
0.2
INSPECT
0.1
TEST
0.2
5
REPLACE
0.5
1
INSPECT
0.1
TEST
0.2
5
REPLACE
0.5
1
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
SECTION II. MAINTANANCE ALLOCATION CHART
FOR MEP-805B AND 815B (continued)
(2)
COMPONENT/
ASSEMBLY
(1)
GROUP
NUMBER
(4)
MAINTENANCE LEVEL
(3)
MAINTENANCE
FUNCTION
C
317
0318
0319
0320
0321
DIODE
RESISTORS
AUXILIARY CONTROL
BRACKET.
RELAYS
O
TEST
0.2
5
REPLACE
0.5
1
INSPECT
0.1
TEST
0.2
5
REPLACE
0.5
1
INSPECT
0.1
0.2
1
REPAIR
0.5
1
INSTALL
0.5
1
INSPECT
0.1
REMOVE
0.2
1
TEST
0.3
5
INSTALL
0.2
1
0.2
0.1
1.0
1.0
1.0
REPLACE
0323
DCS CONTROL PANEL
FRAME AND PANELS
INSPECT
5
1
E
INSTALL
0.2
1
I
REMOVE
1.0
1
0.1
INSPECT
0.1
AIR INTAKE AND EXHAUST
SYSTEM.
0.1
1.0
1
1.0
1
0.1
0.3
REPAIR
0.3
INSPECT
0.2
REPLACE
0.4
TEST
04
0.2
0.2
REPLACE
KEYPAD POWER SUPPLY
1
REMOVE
INSTALL
0325
E
1.0
REPAIR
DCS DATA PLATES.
5
TEST
INSPECT
0324
D
1
8.0
0.1
REMARKS
0.1
REMOVE
0.1
(6)
D
0.1
DCS CONTROL BOX WIRING INSPECT
HARNESS.
TEST
CIM WIRING HARNESS.
H
INSPECT
REPAIR
0322
F
(5)
TOOLS AND
EQUIP
0.3
INSPECT
0.3
SERVICE
0.4
REPLACE
2
0.9
2
0.4
2
2.2
1
F
B-7
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
SECTION II. MAINTANANCE ALLOCATION CHART
FOR MEP-805B AND 815B (continued)
(2)
COMPONENT/
ASSEMBLY
(1)
GROUP
NUMBER
0401
MUFFLER AND EXHAUST
PIPE
(4)
MAINTENANCE LEVEL
(3)
MAINTENANCE
FUNCTION
INSPECT
C
O
0.1
0.5
REPLACE
0402
AIR CLEANER ASSEMBLY
REMOVE
CRANKCASE BREATHER
FILTER ASSEMBLY.
ENGINE COOLING SYSTEM.
RADIATOR
1
0.2
1
1.0
1
INSPECT
0.1
0.2
SERVICE
0.2
0.6
0.2
0.2
1
1.0
1
1.0
1
0.5
1
0.5
1
REMOVE
3.8
INSTALL
3.8
REPAIR
1.0
REPLACE
0.5
1
REMOVE
0.5
1
INSPECT
0502
1.0
0.2
SERVICE
HOSES
1
SERVICE
TEST
0501
1.5
0.2
INSPECT
0.1
0.5
1
REMOVE
2.0
1
0.1
SERVICE
FAN GUARDS.
0.5
0504
FAN.
2.0
1
0.5
1
INSTALL
0.5
1
1.0
1
0.1
0.1
0.1
0.1
INSTALL
0505
FAN BELT.
INSPECT
1.0
ADJUST
REPLACE
0506
COOLANT RECOVERY
SYSTEM.
INSPECT
0.1
1
0.5
1
0.5
1
0.1
REMOVE
0.5
1
INSTALL
0.5
1
SERVICE
B-8
0.1
REMOVE
INSPECT
0.2
F
2
REMOVE
0.1
F
1
1.0
INSTALL
INSPECT
F
0.2
REPAIR
0503
REMARKS
0.4
INSTALL
INSPECT
(6)
D
0.1
REPLACE
05
H
INSPECT
REPLACE
0403
F
(5)
TOOLS AND
EQUIP
1
F
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
SECTION II. MAINTANANCE ALLOCATION CHART
FOR MEP-805B AND 815B (continued)
(1)
GROUP
NUMBER
06
(2)
COMPONENT/
ASSEMBLY
FUEL SYSTEM.
(4)
MAINTENANCE LEVEL
(3)
MAINTENANCE
FUNCTION
INSPECT
C
O
0.5
1.0
INSTALL
2.3
TEST
1.0
REMOVE
2.3
REPLACE
0601
LOW PRESSURE FUEL
LINES AND FITTINGS.
0.8
INSPECT
0.1
0603
0604
0605
0606
0607
AUXILIARY FUEL PUMP
FUEL TANK FILLER NECK.
FUEL DRAIN VALVE.
FUEL LEVEL SENDER
FUEL PICKUP.
ETHER CYLINDER
ASSEMBLY.
0609
ETHER SOLENOID VALVE
FUEL TANK.
FUEL FILTER/WATER
SEPARATOR.
1,2
2
2.5
1
1
1
F
0.2
1
0.1
TEST
0.5
1
REPLACE
0.5
1
REMOVE
0.5
1
INSPECT
0.1
INSTALL
0.5
INSPECT
0.1
REPLACE
0.5
INSPECT
0.1
1
1
REMOVE
0.2
1
TEST
0.3
1,5
INSTALL
0.2
1
REMOVE
0.5
1
INSPECT
0.1
INSTALL
0.5
1
REMOVE
0.2
1
0.1
INSTALL
0.2
1
REMOVE
0.4
1
INSPECT
0.2
INSTALL
0.4
REMOVE
1
5.0
INSPECT
0.2
0.1
SERVICE
0.3
0.2
INSTALL
0610
2.5
0.5
0.1
REMARKS
D
INSPECT
INSPECT
0608
H
(6)
1
1.5
SERVICE
REPLACE
0602
F
(5)
TOOLS AND
EQUIP
0.2
1
5.0
INSPECT
0.1
0.1
SERVICE
0.5
0.2
2
F
2
1
F
B-9
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
SECTION II. MAINTANANCE ALLOCATION CHART
FOR MEP-805B AND 815B (continued)
(1)
GROUP
NUMBER
(2)
COMPONENT/
ASSEMBLY
(4)
MAINTENANCE LEVEL
(3)
MAINTENANCE
FUNCTION
C
0611
ETHER SOLENOID RELAY
INSPECT
0701
OUTPUT BOX ASSEMBLY.
REMOVE
0.2
TEST
0.2
VOLTAGE RECONNECTION
TERMINAL BOARD
INSPECT
OUTPUT BOX WIRING
HARNESS.
1.0
4.3
1,2
INSTALL
1.2
4.3
1,2
REPAIR
1.5
2.0
1,2
REPLACE
1.0
0.2
1,2
1,2
TEST
1.6
1.6
INSPECT
0.2
0.2
REMOVE
0.4
0.4
INSPECT
0.2
0.2
2.0
1
TEST
0.6
0.6
5
REPAIR
0.5
1.0
1,2
2.0
1
1.3
1
1.0
5
1.3
1
INSPECT
0.1
CRANKING RELAY
0.4
INSPECT
0.2
TEST
0.3
5
REPLACE
1.0
1
INSPECT
02
TEST
0.5
REPLACE
0706
OUTPUT BOX PANELS.
INSPECT
REMOVE
B-10
1,2
0.1
INSTALL
0705
1,2
INSTALL
TEST
AC CIRCUIT INTERRUPTER
RELAY
1,2
1.5
REMOVE
0704
0.6
1.2
INSTALL
TRANSFORMERS
D
REMOVE
REMOVE
0703
H
0.2
0.2
REPLACE
0702
F
0.1
INSTALL
07
O
(5)
TOOLS AND
EQUIP
5
0.5
0.1
1
0.1
1.4
2
REPAIR
1.0
1,2
INSTALL
1.4
2
(6)
REMARKS
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
SECTION II. MAINTANANCE ALLOCATION CHART
FOR MEP-805B AND 815B (continued)
(1)
GROUP
NUMBER
(2)
COMPONENT/
ASSEMBLY
(4)
MAINTENANCE LEVEL
(3)
MAINTENANCE
FUNCTION
C
0707
08
0801
LOAD OUTPUT TERMINAL
BOARD TB2.
ENGINE ACCESSORIES.
SENDERS
1.0
INSPECT
0.1
REPAIR
1.0
INSTALL
1.0
INSPECT
0.2
MAGNETIC PICKUP MPU.
0.1
REPLACE
0.5
0.5
INSTALL
1.0
TEST
1.5
REMOVE
1.0
SERVICE
1.0
INSPECT
0.1
DEAD CRANK SWITCH
0805
09
BATTERY CURRENT
TRANSDUCER
ELECTRIC ACTUATOR
LUBRICATION SYSTEM.
1
0.3
1
0.1
0.5
1
SERVICE
0.4
INSTALL
0.5
1
REMOVE
0.4
1
SERVICE
0.4
INSTALL
0.4
G
1
0.5
0.1
0.5
5
1
REPLACE
0.5
INSPECT
0.1
TEST
0.3
REPLACE
1.0
INSPECT
0.1
TEST
0.3
5
REPLACE
0.5
2
INSPECT
0.1
0.2
SERVICE
0.2
0.5
901
OIL DRAIN VALVE.
INSPECT
10
GENERATOR ASSEMBLY.
INSPECT
2
F
0.2
REPLACE
REMOVE
REMARKS
1
REMOVE
INSPECT
(6)
D
5
TEST
0804
H
0.5
TEST
0803
F
0.1
TEST
0802
O
REMOVE
(5)
TOOLS AND
EQUIP
0.5
0.2
2
1.4
9.0
2,3
INSTALL
9.0
2,3
TEST
5.0
2,5
REPLACE
6.0
B-11
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
SECTION II. MAINTANANCE ALLOCATION CHART
FOR MEP-805B AND 815B (continued)
(1)
GROUP
NUMBER
(2)
COMPONENT/
ASSEMBLY
(4)
MAINTENANCE LEVEL
(3)
MAINTENANCE
FUNCTION
C
1001
END BELL AND MAIN
BEARING
1002
ROTATING RECTIFIER
1003
1004
1005
EXCITER STATOR.
EXCITER ROTOR
GENERATOR ROTOR
ASSEMBLY.
REMOVE
GENERATOR MAIN STATOR
AND HOUSING,
2.0
1
TEST
1.0
REMOVE
2.5
1
INSTALL
2.5
1
INSPECT
0.3
TEST
0.5
REPLACE
4.4
INSPECT
0.5
TEST
1.0
INSPECT
5
REMOVE
3.0
1
INSTALL
3.0
1
INSPECT
0.1
1.0
10.0
0.1
REMOVE
INSTALL
12
SKID BASE.
INSPECT
REMOVE
B-12
REMARKS
0.1
1.0
INSPECT
(6)
D
INSTALL
REPLACE
ENGINE ASSEMBLY.
H
1
TEST
11
F
2.0
TEST
1006
O
(5)
TOOLS AND
EQUIP
0.1
4.0
2,3
H
4.0
2,3
H
0.1
6.0
2
REPAIR
1.0
2
INSTALL
6.0
2
SECTION III. TOOLS AND TEST EQUIPMENT
FOR
MEP-805B AND MEP-815B
TOOL OR TEST
EQUIPMENT
REF CODE
MAINTENANCE
LEVEL
NATIONAL
STOCK NUMBER
NOMENCLATURE
TOOL NUMBER
1
O, F
TOOL KIT, GENERAL
MECHANIC’S AUTOMOTIVE
5180-00-177-7033
SC 5180-90-CL-N26
(30 October 1986)
2
O, F
SHOP EQUIPMENT,
AUTOMOTIVE MAINT AND
REPAIR; ORGANIZATIONAL
MAINTENANCE, COMMON NO.
1 (LESS POWER)
4910-00-754-0654
SC 4910-95-A74
(10 Sept. 1994)
3
F
SHOP EQUIPMENT,
AUTOMOTIVE MAINT AND
REPAIR, FIELD MAINTENANCE,
WHEELED VEHICLES, POST
CAMP AND STATION, SET A
4910-00-348-7696
SC 4910-95-A02
(1 October 1989)
4
O, F
SHOP EQUIPMENT
ELECTRICAL REPAIR, SEMI
TRAILER MOUNTED
4940-00-294-9517
SC 4940-95-B05
LIN: T10275
5
O, F
MULTIMETER
6625-01-265-6000
AN/PSM-45A
6
O, F
STRAP, WRIST,
ELECTROSTATIC DISCHARGE
5920-01-112-9042
Fluke TL6-60
SECTION IV. REMARKS
FOR
MEP-805B AND MEP-815B
REMARKS
REFERENCE
CODE
A
Wet-cell batteries only.
B
(Not Used)
C
Repair is limited to replacement of light bulbs.
D
Repair is limited to replacement of installed items.
E
Use wrist strap when removing or replacing item in order to prevent possible damage to
components from electrostatic discharge.
F
Operator service function consists of adding fuel, adding oil, adding coolant to coolant recovery
bottle, adding water to wet-cell batteries, replacing air filter element, draining crankcase
breather filter, and draining water and sediment from fuel filter/water separator, as appropriate.
G
This service function involves cleaning of senders with a solvent.
H
Refer to TM 9-2815-259-24 (4-cylinder diesel engine manual).
I
This harness is the ribbon cable harness connecting the DCS modules to the CIM.
B-13/B-14 BLANK
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
THIS PAGE INTENTIONALLY LEFT BLANK
B-14
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
APPENDIX C
COMPONENTS OF END ITEM (COEI) AND BASIC ISSUE ITEMS (BII) LIST
SECTION I. INTRODUCTION
C.1
SCOPE.
This appendix lists components of the end item and basic issue items for the generator set to help inventory
the items for safe and efficient operation of the equipment.
C.2
GENERAL.
The Components of End Item (COEI) and Basic Issue Items (BII) lists are divided into the following
sections:
C.3
a.
Section II, Components of End Item. This listing is for information purposes only, and is not authority
to requisition replacements. These items are part of the generator set. As part of the end item, these
items must be with the end item whenever it is issued or transferred between property accounts. Items
of COEI are removed and separately packaged for transportation or shipment only when necessary.
Illustrations are furnished to help you find and identify the items.
b.
Section III, Basic Issue Items. These essential items are required to place the generator set in
operation, operate it, and to do emergency repairs. Although shipped separately packaged, BII must be
with the generator set during operation and when it is transferred between property accounts. This list
is your authority to request/requisition them for replacement based on authorization of the end item by
the TOE/MTOE. Illustrations are furnished to help you find and identify the items.
EXPLANATION OF COLUMNS.
The following provides an explanation of columns found in the tabular listing:
a.
Column (1), Illus Number, gives the identifying number of the item illustrated.
b.
Column (2), National Stock Number, identifies the stock number of the item to be used for
requisitioning purposes.
c.
Column (3), Description and Usable On Code, identifies the Federal item name (in all capital letters)
followed by a minimal description when needed. The last line below the description is the Commercial
and Government Entity Code (CAGEC) in parentheses and the part number.
d.
Column (4), U/I (unit of issue), indicates how the item is issued for the National Stock Number shown
in column (2).
e.
Column (5), Qty Rqd, indicates the quantity required.
SECTION II. COMPONENTS OF END ITEM
NONE
C-1
ARMY TM 9-6115-671-14
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SECTION III. BASIC ISSUE ITEMS
(1)
Illus
Number
1
(2)
National Stock Number
2
3
5975-00-296-5324
4
4720-00-021-3320
5
6150-01-406-9533
6
C-2
(3)
Description
Cage and Part Number
TECHNICAL MANUAL
TM 9-6115-671-14
WARRANTY TECHNICAL
BULLETIN
TB 9-6115-XXX-24
GROUNDING ROD
W-R-550
AUXILIARY FUEL LINE
69-668
PARALLELING CABLE
88-22209
CIM SOFTWARE
96-23569
(4)
Usable
On Code
U/I
EA
(5)
Qty
Reqd
1
EA
1
EA
1
EA
1
EA
1
EA
1
ARMY TM 9-6115-671-14
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1.
Technical Manual
2. Warranty Technical Bulletin
C-3
ARMY TM 9-6115-671-14
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3. Grounding Rod
4. Auxiliary Fuel Line
C-4
ARMY TM 9-6115-671-14
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5. Paralleling Cable
6. CIM Software
NOTE
CD is available from U.S. Army CECOM SEC,
ATTN: AMSEL-SE-OP-R, Fort Monmouth, NJ 07703
C-5/C-6 BLANK
ARMY TM 9-6115-671-14
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MARINE CORPS TM 09249A/09246A-14
APPENDIX D
ADDITIONAL AUTHORIZATION LIST (AAL)
SECTION I. INTRODUCTION
D.1
SCOPE.
This appendix lists additional items authorized for the support of the generator set.
D.2
GENERAL.
This list identifies items that do not have to accompany the generator set and that do not have to be turned
in with it. These items are all authorized by CTA, MTOR, TDA, or JTA.
D.3
EXPLANATION OF LISTING.
National Stock Numbers, descriptions, and quantities are provided to help identify and request the
additional items required to support the generator set. The items are listed in alphabetical sequence by item
name under the type document (i.e., CTA, MTOR, TDA, or JTA) which authorizes the item(s).
SECTION II. ADDITIONAL AUTHORIZATION LIST
(2)
National Stock
Number
4210-00-202-7858
5342-00-066-1235
7240-00-222-3088
7240-00-177-6154
5120-01-013-1676
(3)
Description
Cage and Part Number
FIRE EXTINGUISHER
FUEL ADAPTER
FUEL CAN
FLEXIBLE SPOUT
HAMMER, SLIDE
(4)
Usable
On Code
U/I
EA
EA
EA
EA
EA
(5)
Qty
Reqd
1
1
1
1
1
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MARINE CORPS TM 09249A/09246A-14
APPENDIX E
EXPENDABLE AND DURABLE ITEMS LIST
SECTION I. INTRODUCTION
E.1
SCOPE.
This appendix lists expendable supplies and materials required to operate and maintain the generator set.
These items are authorized by CTA 50-970, Expendable Items (except medical, Class V, repair parts, and
heraldic items).
E.2
EXPLANATION OF COLUMNS.
a.
Column (1), Item Number. Number assigned to an entry in the listing for reference within the technical
manual to identify the material, i.e. "Use cleaning compound (Item 5, Appendix E)".
b.
Column (2), Level. Identifies the lowest level of maintenance requiring the listed item.
c.
Column (3), National Stock Number (NSN). Standardized number assigned to an item for the purpose
of requisition.
d.
Column (4), Description. Federal item name and, if required, description of the item. The last line for
each applicable item indicates the Commercial and Government Entity (CAGE) code in parenthesis
followed by the part number.
e.
Column (5), Unit of Measure (U/M). Measure used in performing actual maintenance function.
Measure is expressed by a two character alphabetical abbreviation (i.e., ea, in, pr). If the unit of
measure differs from the unit of issue, requisition the lowest unit that will satisfy requirements.
SECTION II. EXPENDABLE AND DURABLE ITEMS LIST
(1)
Item
Number
Level
(3)
National Stock
Number
1
O, F
8040-00-390-7959
Adhesive, Seal, EC847
QT
2
O, F
6850-00-181-7929
Antifreeze, MIL-A-46153, 1 Gal. Can
GL
3
O, F
6850-00-181-7933
Antifreeze, MIL-A-46153, 5 Gal. Can
GL
4
O, F
6850-00-181-7940
Antifreeze, MIL-A-46153, 55 Gal. Can
GL
5
O, F
6850-00-174-1806
Antifreeze, MIL-A-11755, 1 Gal. Can
GL
6
O, F
8030-01-234-2792
Antiseize Compound, CP-8, 8 Oz. Can
OZ
7
O
2910-00-646-9727
Cartridge, Engine, Ether, MS39254
EA
8
O, F
7920-01-338-3329
Cloth, Cleaning, TX-1250
EA
9
F
8030-00-056-8673
Compound, Thermo, Pentrox A
OZ
(2)
(4)
(5)
Description
U/M
E-1
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SECTION II. EXPENDABLE AND DURABLE ITEMS LIST (continued)
(1)
Item
Number
10
(2)
Level
O, F
(3)
National Stock
Number
9150-00-663-1770
Description
Grease, General Purpose, 630AA, 6 Lb. Can
U/M
LB
11
O, F
6850-01-160-3868
Inhibitor, Corrosion, MIL-A-53009
QT
12
O, F
9150-00-152-4117
Lubricating Oil, Engine, MIL-L-2104, 15/40W
QT
13
O, F
9150-00-189-6727
Lubricating Oil, Engine, BRAYC0421C, 10W
QT
14
O, F
9150-00-186-6681
Lubricating Oil, Engine, ALIEDC030, 30W
QT
15
O, F
9150-00-402-2372
Lubricating Oil, Engine, MIL-L-46167, OEA
QT
16
O, F
5330-00-543-3600
Paper, Abrasive, ALOXGRIT 80
SH
17
O, F
8030-01-408-9944
Adhesive, Edge Seal, PES-821-B
QT
18
O, F
8040-00-843-0802
Sealant, RTV108
OZ
19
O, F
3439-00-974-1873
Solder, Tin Alloy, SN60WRAP2, 1 Lb. Spool
LB
20
O, F
6850-00-264-9038
Solvent, Dry Cleaning, P-D-680, 5 Gal. Can
GL
21
O, F
8030-00-849-0071
Sealing Compound, FORM GASKET 2
TU
22
O, F
8040-01-359-8441
Sealing Compound, MIL-S-22473, Grade HVV
OZ
E-2
(4)
(5)
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APPENDIX F
OPERATOR’S LUBRICATION INSTRUCTIONS
F.1
SCOPE.
This appendix lists operator lubrications and instructions for the generator set.
F.2
GENERAL.
Intervals (on-condition or hard time) and the related man-hour times are based on normal operation. The
man-hour time specified is the time you need to do all the services prescribed for a particular interval. Oncondition (OC) oil sample intervals shall be applied unless changed by the Army Oil Analysis Program
(AOAP) laboratory. Change the hard time interval if your lubricants are contaminated or if you are
operating the equipment under adverse operating conditions, including longer-than-usual operating hours.
The hard time interval may be extended during periods of low activity. If extended, adequate preservation
precautions must be taken. Hard time intervals will be applied in the event AOAP laboratory support is not
available.
F.3
LUBRICANTS.
NOTE
Operator level lubrication is limited to adding engine crankcase oil.
NOTE
For arctic operation, refer to FM 9-207.
LUBRICANTS
CAPACITY
OE/HDO-OIL, Engine
Heavy Duty
With Filter
14 quarts (13.24
liters)
OEA-OIL, Engine,
Sub-zero
Without Filter
13 quarts (12.30)
EXPECTED TEMPERATURES
+40°F (+4°C)
0°F (-17°C)
Above
to
to
+32° (0°C)
-10°F (-23°C)
-65°F (-53°C)
OE/HDO15/40
or
OE/HDO-30
OE-HDO-10
OEA
CAUTION
At 100 hours hard time, the oil and filter must be changed or the warranty may be voided.
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APPENDIX G
ILLUSTRATED LIST OF MANUFACTURED ITEMS
G.1
INTRODUCTION.
This appendix includes complete instructions for fabricating or assembling parts as required for these
generator sets.
NOTE
All dimensions are expressed in inches. Refer to Table G-1 for metric
conversion.
PARTS INDEX
Figure Number
Page
G-1
Cable Assembly, AC Power (P/N 88-22126-1 through 88-22126-7) ..........................................................G-2
G-2
Cable Assembly, Battery (P/N 88-22178) ...................................................................................................G-3
G-3
Cable Assembly, Battery (P/N 88-22127) ...................................................................................................G-4
G-4
Cable Assembly, Battery (P/N 88-22181) ...................................................................................................G-5
G-5
Cable Assembly, Battery (P/N 88-22179) ...................................................................................................G-6
G-6
Cable Assembly, Battery (P/N 88-22207) ...................................................................................................G-7
G-7
Holder, Control Panel (P/N 88-22120)........................................................................................................G-8
G-8
Hose Assembly (P/N 88-20191-6) ..............................................................................................................G-9
G-9
Insulation, Panel, Top (P/N 88-22582) .....................................................................................................G-10
G-10
Insulation, Baffle (P/N 88-22592) .............................................................................................................G-11
G-11
Insulation, Panel, Top (P/N 88-22593) .....................................................................................................G-12
G-12
Insulation, Top, Center (P/N 88-22584)....................................................................................................G-13
G-13
Insulation, Top, Rear (P/N 88-22585).......................................................................................................G-14
G-14
Insulation, Front Housing (P/N 88-22591)................................................................................................G-15
G-15
Insulation, Top, Front (P/N 88-22586)......................................................................................................G-16
G-16
Insulation, Top, Center (P/N 88-22587)....................................................................................................G-17
G-17
Insulation, Top, Center (P/N 88-22588)....................................................................................................G-18
G-18
Insulation, Top, Front (P/N 88-22583)......................................................................................................G-19
G-19
Pump Assembly, Fuel (P/N 88-22546)......................................................................................................G-20
G-20
Solenoid Assembly (P/N 88-22553)..........................................................................................................G-21
G-21
Switch Assembly (P/N 88-22548) .............................................................................................................G-22
G-22
Wire, Varistor (P/Ns 88-20305-1 through 88-20305-3 and 88-20305-5)..................................................G-23
G-1
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G.2
ILLUSTRATIONS.
NOTES:
1.
Dimensions shown are in inches.
2.
Refer to TM 9-6115-671-24P for materials required and length (L) of wire.
PROCEDURES:
1.
Cut wire (1) to length indicated.
2.
Strip 0.75 inch of insulation from each end of wire (1).
3.
Crimp terminal (2) on each end of wire (1).
Figure G-1. Cable Assembly, AC Power (P/Ns 88-22126-1 through 88-22126-7)
G-2
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NOTES:
1.
Dimensions shown are in inches.
2.
Refer to TM 9-6115-671-24P for materials required.
PROCEDURES:
1.
Cut wire (1) to length indicated.
2.
Strip 0.75 inch of insulation from each end of wire (1).
3.
Position insulation sleeving (2) on center of wire (1). Mark sleeving with wire number "100B0", and shrink to
fit.
4.
Crimp terminal (3) on each end of wire (1).
Figure G-2. Cable Assembly, Battery (P/N 88-22178)
G-3
ARMY TM 9-6115-671-14
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NOTES:
1.
Dimensions shown are in inches.
2.
Refer to TM 9-6115-671-24P for materials required.
PROCEDURES:
1.
Cut wire (1) to length indicated.
2.
Strip 0.75 inch of insulation from each end of wire (1).
3.
Position insulation sleeving (2) on center of wire (1). Mark sleeving with wire number "100A0", and shrink to
fit.
4.
Mark insulation sleeving (4) with "NEGATIVE", and slide over one end of wire (1).
5.
Crimp terminal (3) on each end of wire (1).
6.
Position insulation sleeving (4) as shown, and shrink to fit.
Figure G-3. Cable Assembly, Battery (P/N 88-22127)
G-4
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NOTES:
1.
Dimensions shown are in inches.
2.
Refer to TM 9-6115-671-24P for materials required.
PROCEDURES:
1.
Cut wire (1) to length indicated.
2.
Strip 0.75 inch of insulation from each end of wire (1).
3.
Position insulation sleeving (2) on center of wire (1). Mark sleeving with wire number "165B0", and shrink to
fit.
4.
Mark insulation sleeving (4) with "POSITIVE", and slide over one end of wire (1).
5.
Crimp terminal (3) on each end of wire (1).
6.
Position insulation sleeving (4) as shown, and shrink to fit.
Figure G-4. Cable Assembly, Battery (P/N 88-22181)
G-5
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MARINE CORPS TM 09249A/09246A-14
NOTES:
1.
Dimensions shown are in inches.
2.
Refer to TM 9-6115-671-24P for materials required.
PROCEDURES:
1.
Cut wire (1) to length indicated.
2.
Strip 0.75 inch of insulation from each end of wire (1).
3.
Position insulation sleeving (2) on center of wire (1). Mark sleeving with wire number "218A0", and shrink to
fit.
4.
Mark one insulation sleeving (4) with "NEGATIVE", the other "POSITIVE", and slide over each end of wire
(1).
5.
Crimp terminal (3) on each end of wire (1).
6.
Position insulation sleeving (4) as shown, and shrink to fit.
Figure G-5. Cable Assembly, Battery (P/N 88-22179)
G-6
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NOTES:
1.
Dimensions shown are in inches.
2.
Refer to TM 9-6115-671-24P for materials required.
PROCEDURES:
1.
Cut wire (1) to length indicated.
2.
Strip 0.75 inch of insulation from each end of wire (1).
3.
Position insulation sleeving (2) on center of wire (1). Mark sleeving with wire number "165A0", and shrink to
fit.
4.
Mark insulation sleeving (4) with "POSITIVE", and slide over each end of wire (1).
5.
Crimp terminal (3) on each end of wire (1).
6.
Position insulation sleeving (4) as shown, and shrink to fit.
Figure G-6. Cable Assembly, Battery (P/N 88-22207)
G-7
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NOTES:
1.
Dimensions shown are in inches.
2.
Refer to TM 9-6115-671-24P for materials required.
PROCEDURES:
1.
Cut rope (1) to length indicated.
2.
Slide insulation sleeving (2) over one end of rope (1).
3.
Crimp terminal (3) on each end of wire (1).
4.
Install hook (4) in one terminal, and close hook end to secure it to terminal.
5.
Position insulation sleeving (2) as shown, and shrink to fit.
Figure G-7. Holder, Control Panel (P/N 88-22120)
G-8
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NOTES:
1.
Dimensions shown are in inches.
2.
Refer to TM 9-6115-671-24P for materials required.
PROCEDURES:
1.
Cut hose (1) to obtain dimension shown with adapters (2) installed.
2.
Crimp adapter (2) on each end of hose (1).
Figure G-8. Hose Assembly (P/N 88-20191-6)
G-9
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MATERIALS
Description
Foam, Sound Absorbing
Part Number
FF40JM02
NOTES:
1.
Dimensions shown are in inches.
2.
Tolerances are 0.1 inch unless otherwise stated.
PROCEDURES:
1.
Cut foam to dimensions shown.
2.
Drill holes as shown.
Figure G-9. Insulation, Panel, Top (P/N 88-22582)
G-10
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MATERIALS
Description
Foam, Sound Absorbing
Part Number
FF40JM02
NOTES:
1.
Dimensions shown are in inches.
2.
Tolerances are 0.1 inch unless otherwise stated.
PROCEDURES:
1.
Cut foam to dimensions shown.
2.
Drill holes as shown.
3.
Coat edge indicated using sealant (Item 17, Appendix E).
Figure G-10. Insulation, Baffle (P/N 88-22592)
G-11
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MATERIALS
Description
Foam, Sound Absorbing
Part Number
FF40JM02
NOTES:
1.
Dimensions shown are in inches.
2.
Tolerances are 0.1 inch unless otherwise stated.
PROCEDURES:
1.
Cut foam to dimensions shown.
2.
Drill holes as shown.
Figure G-11. Insulation, Panel, Top (P/N 88-22593)
G-12
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MARINE CORPS TM 09249A/09246A-14
MATERIALS
Description
Foam, Sound Absorbing
Part Number
FF40JM02
NOTES:
1.
Dimensions shown are in inches.
2.
Tolerances are 0.1 inch unless otherwise stated.
PROCEDURES:
1.
Cut foam to dimensions shown.
2.
Drill holes as shown.
Figure G-12. Insulation, Top, Center (P/N 88-22584)
G-13
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MATERIALS
Description
Foam, Sound Absorbing
Part Number
FF40JM02
NOTES:
1.
Dimensions shown are in inches.
2.
Tolerances are 0.1 inch unless otherwise stated.
PROCEDURES:
1.
Cut foam to dimensions shown.
2.
Drill holes as shown.
3.
Coat indicated edge using sealant (17, Appendix E).
Figure G-13. Insulation, Top, Rear (P/N 88-22585)
G-14
ARMY TM 9-6115-671-14
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MARINE CORPS TM 09249A/09246A-14
MATERIALS
Description
Foam, Sound Absorbing
Part Number
FF40JM02
NOTES:
1.
Dimensions shown are in inches.
2.
Tolerances are 0.1 inch unless otherwise stated.
PROCEDURES:
1.
Cut foam to dimensions shown.
2.
Drill holes as shown.
Figure G-14. Insulation, Front Housing (P/N 88-22591)
G-15
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MARINE CORPS TM 09249A/09246A-14
MATERIALS
Description
Foam, Sound Absorbing
Part Number
FF40JM02
NOTES:
1.
Dimensions shown are in inches.
2.
Tolerances are 0.1 inch unless otherwise stated.
PROCEDURES:
1.
Cut foam to dimensions shown.
2.
Drill holes as shown.
Figure G-15. Insulation, Top, Front (P/N 88-22586)
G-16
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MARINE CORPS TM 09249A/09246A-14
MATERIALS
Description
Foam, Sound Absorbing
Part Number
FF40JM02
NOTES:
1.
Dimensions shown are in inches.
2.
Tolerances are 0.1 inch unless otherwise stated.
PROCEDURES:
1.
Cut foam to dimensions shown.
2.
Drill holes as shown.
Figure G-16. Insulation, Top, Center (P/N 88-22587)
G-17
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MARINE CORPS TM 09249A/09246A-14
MATERIALS
Description
Foam, Sound Absorbing
Part Number
FF40JM02
NOTES:
1.
Dimensions shown are in inches.
2.
Tolerances are 0.1 inch unless otherwise stated.
PROCEDURES:
1.
Cut foam to dimensions shown.
2.
Drill holes as shown.
Figure G-17. Insulation, Top, Center (P/N 88-22588)
G-18
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MATERIALS
Description
Foam, Sound Absorbing
Part Number
FF40JM02
NOTES:
1.
Dimensions shown are in inches.
2.
Tolerances are 0.1 inch unless otherwise stated.
PROCEDURES:
1.
Cut foam to dimensions shown.
2.
Drill holes as shown.
Figure G-18. Insulation, Top, Front (P/N 88-22583)
G-19
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NOTES:
1.
Dimensions shown are in inches.
2.
Refer to TM 9-6115-671-24P for materials required.
PROCEDURES:
1.
Remove and discard terminals supplied with fuel pump (1).
2.
Strip 0.125 inch of insulation from end of each fuel pump (1) lead.
3.
Crimp pin (2) on end of each lead.
4.
Insert pins (2) into housing (3) with red wire in position 1 and black wire in position 2.
5.
Mark strap (4) with "P11", and install in position shown.
Figure G-19. Pump Assembly, Fuel (P/N 88-22546)
G-20
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NOTES:
1.
Refer to TM 9-6115-671-24P for materials required.
2.
Solenoid wiring is not polarity sensitive, so position of terminals is not important.
PROCEDURES:
1.
Strip 0.25 inch of insulation from each solenoid (1) lead.
2.
Crimp terminal (2) on one lead end and terminal (3) on the other.
Figure G-20. Solenoid Assembly (P/N 88-22553)
G-21
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
NOTES:
1.
Dimensions are in inches.
2.
Refer to TM 9-6115-671-24P for materials required.
PROCEDURES:
1.
Strip 0.125 inch of insulation from end of each switch (1) lead.
2.
Crimp pin (2) on end of each lead.
3.
Insert pins into housing (3) with lead A in position 1, lead B in position 2, lead C in position 3, and lead D in
position 4.
4.
Mark "P12" on strap (4), and install in position shown.
Figure G-21. Switch Assembly (P/N 88-22548)
G-22
ARMY TM 9-6115-671-14
A AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
NOTES:
1.
Dimensions shown are in inches.
2.
Refer to TM 9-6115-671-24P for materials required.
PROCEDURES:
1.
Cut wire (1) to length indicated.
2.
Strip 0.50 inch of insulation from each end of wire (1).
3.
Crimp terminal (2) on one end of wire (1) and terminal (3) on other end.
Figure G-22. Wire, Varistor (P/Ns 88-20305-1 through 88-20305-3 and 88-20305-5)
G-23
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
TABLE G-1. METRIC CONVERSION
Part I. Fractional Equivalent
Fractional Inches
1/16
1/8
3/16
1/4
5/16
3/8
7/16
1/2
9/16
5/8
11/16
3/4
13/16
7/8
15/16
1
Decimal Inches
.0625
.1250
.1875
.2500
.3125
.3750
.4375
.5000
.5625
.6250
.6875
.7500
.8125
.8750
.9375
1
mm
1.587
3.175
4.762
6.350
7.937
9.525
11.112
12.700
14.287
15.875
17.462
19.050
20.637
22.225
23.812
25.400
Part II. Inches to Centimeters
Inches
1
2
3
4
5
6
7
8
9
10
20
30
40
50
60
70
80
90
100
G-24
cm
2.540
5.080
7.620
10.160
12.700
15.240
17.780
20.320
22.860
25.400
50.800
76.200
101.600
127.000
152.400
177.800
203.200
228.600
254.000
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
APPENDIX H
TORQUE LIMITS
SECTION I. INTRODUCTION
H.1
SCOPE .
Section II lists torque ratings for fasteners used on the generator set. When torque values are called out in
the maintenance procedures, whose supersede specified in this appendix. Table H-1 lists torque limits for
standard fasteners installed dry. Table H-2 provides formulas for converting the dry torque values to wet.
Table H-3 lists torque limits for metric fasteners installed dry.
SECTION II. TORQUE LIMITS
TABLE H-1. TORQUE LIMITS FOR DRY FASTENERS
SIZE
Diameter in
Inches
1/4
1/4
5/16
5/16
3/8
3/8
7/16
7/16
1/2
1/2
9/16
9/16
5/8
5/8
3/4
3/4
7/8
7/8
1
1
Threads Per
Inch
20
28
18
24
16
24
14
20
13
20
12
18
11
28
10
26
9
24
8
14
Millimeters
6.350
6.350
7.937
7.937
9.525
9.525
11.112
11.112
12.700
12.700
14.287
14.287
15.875
15.875
19.050
19.050
22.225
22.225
25.400
25.400
SAE GRADE 0-1-2
Foot
Newton
Pounds
Meters
6
8
7
9
12
16
13
18
20
27
22
30
32
43
35
47
47
64
51
69
69
94
75
102
96
130
105
142
155
210
169
229
206
279
225
304
310
420
338
458
TORQUE
SAE GRADE 3
Foot
Newton
Pounds
Meters
9
12
10
13
17
23
18
25
30
40
33
44
47
64
51
69
69
93
75
102
103
140
112
152
145
197
158
214
234
317
255
346
372
504
405
550
551
747
601
814
SAE GRADE 5
Foot
Newton
Pounds
Meters
10
14
11
15
19
26
21
28
33
45
36
49
54
73
59
80
78
106
85
115
114
155
124
168
154
209
168
228
257
348
280
380
382
518
416
565
587
796
640
867
See Table H-2 for the effect of lubrication on torque.
H-1
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
TABLE H-1. TORQUE LIMITS FOR DRY FASTENERS (CONTINUED)
SIZE
Diameter in
Inches
1/4
1/4
5/16
5/16
3/8
3/8
7/16
7/16
1/2
1/2
9/16
9/16
5/8
5/8
3/4
3/4
7/8
7/8
1
1
Threads Per
Inch
20
28
18
24
16
24
14
20
13
20
12
18
11
28
10
26
9
24
8
14
Millimeters
6.350
6.350
7.937
7.937
9.525
9.525
11.112
11.112
12.700
12.700
14.287
14.287
15.875
15.875
19.050
19.050
22.225
22.225
25.400
25.400
SAE GRADE 6
Foot
Newton
Pounds
Meters
13
17
14
18
24
33
26
35
43
58
47
64
69
94
75
102
106
144
116
157
150
203
164
222
209
283
228
309
350
475
382
517
550
746
600
813
825
1119
899
1219
TORQUE
SAE GRADE 7
Foot
Newton
Pounds
Meters
13
18
14
19
25
34
27
37
44
60
48
65
71
96
77
105
110
149
120
163
154
209
168
228
215
291
234
318
360
488
392
532
570
773
621
842
840
1139
916
1241
SAE GRADE 8
Foot
Newton
Pounds
Meters
14
19
15
21
29
39
32
43
47
64
51
69
78
106
85
115
119
161
130
176
169
229
184
250
230
312
251
340
380
515
414
562
600
813
654
887
900
1220
981
1330
See Table H-2 for the effect of lubrication on torque.
TABLE H-2. EFFECT OF LUBRICATION ON TORQUE
Lubricant
NO LUBE, Steel
Plated and cleaned
SAE 20 Oil
SAE 40 Oil
Plated and SAE 30
White Grease
White Moly Film
Graphite and Oil
TORQUE RATING IN FOOT-POUNDS
5/16-18 Thread/Inch
1/2-13 Thread/Inch
29
121
19 (66%)
90 (26%)
18 (38%)
87 (28%)
17 (41%)
83 (31%)
16 (45%)
79 (35%)
16 (45%)
79 (35%)
14 (52%)
66 (45%)
13 (55%)
62 (49%)
Use the above lubrication percentages to calculate the approximate decrease in torque rating for other bolt sizes.
H-2
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
TABLE H-3. TORQUE LIMITS FOR DRY FASTENERS (METRIC)
Diameter in
Millimeters
6
8
10
12
14
16
18
22
24
Coarse
Thread Pitch
1.00
1.00
1.25
1.25
1.25
2.00
2.00
2.50
3.00
Inches
Standard 5D
Ft-lb
Nm
Standard 8G
Ft-lb
Nm
0.2362
0.3150
0.3937
0.4624
0.5512
0.6299
0.7087
0.8771
0.9449
5
10
19
34
55
83
111
182
261
6
16
31
54
89
132
182
284
419
7
14
26
46
75
113
150
247
354
8
22
42
73
121
179
247
385
568
Standard 10K
Ft-lb
Nm
8
22
40
70
117
175
236
394
570
11
30
54
95
159
237
320
534
773
Standard 12K
Ft-lb
Nm
10
27
49
86
137
208
283
464
689
14
37
66
117
186
282
384
629
934
To determine torque rating for a fine thread bolt, increase the above coarse thread ratings by 9%. See Table H-2 for
the effect of lubrication on torque.
H-3/H-4 BLANK
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
THIS PAGE INTENTIONALLY LEFT BLANK
H-4
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
APPENDIX I
MANDATORY REPLACEMENT PARTS
SECTION I. INTRODUCTION
I.1
SCOPE. Section II of this appendix lists parts that must be replaced if removed during maintenance.
SECTION II. MANDATORY REPLACEMENT PARTS
Item No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
Part No.
88-22193
88-22704
88-20563-1
88-20286
5 070118
69-561-1
69-561-2
69-561-3
69-561-4
69-561-6
88-21674-1
88-21674-2
88-21674-3
88-22783
72-2061-1
88-20568-1
88-20568-2
88-20568-4
88-20568-5
88-20568-6
88-21930-1
88-21930-2
88-21930-3
88-21930-4
88-22786
MIL-R-6130
69-662-5
69-662-11
69-662-17
69-662-20
69-662-22
69-662-35
69-662-36
69-662-37
69-662-51
69-662-64
69-662-65
88-22705
NSN
5305-01-140-9118
(none)
(none)
5330-01-366-2836
(none)
5310-00-836-3520
5310-00-063-7360
5310-00-052-3632
5310-00-094-3421
5310-01-012-3595
(none)
(none)
(none)
(none)
5310-00-630-2383
(none)
(none)
(none)
(none)
(none)
5310-01-366-4412
5310-01-365-5788
(none)
5310-01-406-1672
(none)
9320-01-009-4856
5305-00-224-1092
(none)
5305-00-211-9344
5305-00-036-6972
5305-00-218-4864
5305-00-038-3103
5305-00-036-6902
5305-00-038-3145
5305-00-038-3148
5305-00-191-6226
5305-01-187-5878
(none)
Nomenclature
Bolt, Self-Locking, .375-16 x .875
Edging, Rubber
Gasket
Gasket, Fuel Tank
Locknut, Bulkhead, .500-20 UNF
Nut and Captive Washer Assembly, 4-40
Nut and Captive Washer Assembly, 6-32
Nut and Captive Washer Assembly, 8-32
Nut and Captive Washer Assembly, 10-24
Nut and Captive Washer Assembly, 10-32
Nut, Cage, 10-32, .064-.105 Grip
Nut, Cage, 10-32, .025-.063 Grip
Nut, Cage, .25-20, .025-.063 Grip
Nut, Push-On
Nut, Self-Locking, .38-16 UNC-2B
Nut, Self-Locking, .25-20 UNC-2B
Nut, Self-Locking, .375-16 UNC-2B
Nut, Self-Locking, .375-16 UNC-3B
Nut, Self-Locking, .500-13 UNC-3B
Nut, Self-Locking, .625-11 UNC-3B
Nut, Self-Locking, .375-16 UNC-2B
Nut, Self-Locking, .500-13 UNC-2B
Nut, Self-Locking, .164-32 UNC-2B
Nut, Self-Locking, .190-32 UNF-2B
Nut, Self-Locking, Prevailing Torque
Rubber, Cellular, .75 x 1.00 with PSA
Screw and Captive Washer Assy, 4-40 x .50
Screw and Captive Washer Assy, 4-40 x 1.50
Screw and Captive Washer Assy, 6-32 x .31
Screw and Captive Washer Assy, 6-32 x .50
Screw and Captive Washer Assy, 6-32 x .75
Screw and Captive Washer Assy, 8-32 x .50
Screw and Captive Washer Assy, 8-32 x. .62
Screw and Captive Washer Assy, 8-32 x .75
Screw and Captive Washer Assy, 10-24 x .62
Screw and Captive Washer Assy, 10-32 x .50
Screw and Captive Washer Assy, 10-32 x .62
Seal, Door
Quantity
8
AR
1
3
1
24
56
17
59
427
45
104
29
AR
13
4
2
8
2
2
2
5
20
30
15
AR
8
4
4
18
6
8
4
2
38
16
6
AR
I-1
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
SECTION II. MANDATORY REPLACEMENT PARTS (continued)
Item No.
39
40
41
42
43
44
45
46
47
48
I-2
Part No.
88-22708
88-22712
88-22792-2
AA55610-62
AA55610-63
AA55610-64
AA55610-65
AA55610-67
AA55610-68
AA55610-69
NSN
(none)
5330-01-384-3057
(none)
(none)
(none)
(none)
(none)
(none)
(none)
(none)
Nomenclature
Seal, EMI, Output Box Door
Seal, Shroud, Radiator
Washer, Lock, Intl and Ext Tooth, .375
Washer, Lock-Spring, Helical, .219
Washer, Lock-Spring, Helical, .25
Washer, Lock-Spring, Helical, .312
Washer, Lock-Spring, Helical, .375
Washer, Lock-Spring, Helical, .500
Washer, Lock-Spring, Helical, .562
Washer, Lock-Spring, Helical, .625
Quantity
74.8”
AR
3
152
148
12
54
5
1
4
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
INDEX
A
AC Circuit Interrupter K1
Inspection ........................................................................................................................................................4-188
Replacement ....................................................................................................................................................4-188
Testing .............................................................................................................................................................4-188
AC CIRCUIT INTERRUPT Switch S5
Inspection ..........................................................................................................................................................4-87
Replacement ......................................................................................................................................................4-87
Testing ...............................................................................................................................................................4-87
Access Doors
Inspection ..........................................................................................................................................................4-59
Installation .........................................................................................................................................................4-59
Removal ............................................................................................................................................................4-57
Repair ................................................................................................................................................................4-59
Air Cleaner Assembly
Inspection .............................................................................................................................................. 3-22, 4-144
Location and Description ..................................................................................................................................1-36
Removal ..........................................................................................................................................................4-144
Installation .......................................................................................................................................................4-145
Service ................................................................................................................................................... 3-20, 4-144
Air Cleaner Filter Element
Inspection ........................................................................................................................................................4-147
Installation .......................................................................................................................................................4-147
Removal ..........................................................................................................................................................4-147
Air Cleaner Hoses
Inspection ........................................................................................................................................................4-147
Installation .......................................................................................................................................................4-148
Removal ..........................................................................................................................................................4-148
Service .............................................................................................................................................................4-148
Air Intake and Exhaust System, Engine ...................................................................................................................1-23
Automatic Voltage Regulator A4
Inspection ........................................................................................................................................................4-111
Installation ........................................................................................................................................................4112
Removal ..........................................................................................................................................................4-112
Testing .............................................................................................................................................................4-111
Auxiliary Control Bracket
Inspection ........................................................................................................................................................4-126
Installation .......................................................................................................................................................4-126
Removal ..........................................................................................................................................................4-126
Repair ..............................................................................................................................................................4-126
Auxiliary Fuel Pump E1
Inspection ........................................................................................................................................................4-170
Replacement ....................................................................................................................................................4-173
Testing .............................................................................................................................................................4-172
B
Backplane Module A1
Inspection ........................................................................................................................................................4-113
Replacement ....................................................................................................................................................4-114
Testing .............................................................................................................................................................4-113
Index-1
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
Batteries BT1 and BT2
Inspection ................................................................................................................................................ 3-18, 4-54
Installation .........................................................................................................................................................4-54
Location and Description ..................................................................................................................................1-39
Removal ............................................................................................................................................................4-53
Service .............................................................................................................................................. 3-19, 4-2, 4-54
Testing ...............................................................................................................................................................4-53
Battery and SLAVE RECEPTACLE Cables
Inspection ..........................................................................................................................................................4-49
Installation .........................................................................................................................................................4-50
Removal ............................................................................................................................................................4-50
Repair ................................................................................................................................................................4-50
Service ...............................................................................................................................................................4-50
Battery Charging Alternator, Location and Description ...........................................................................................1-39
BATTLE SHORT Switch S7
Inspection ..........................................................................................................................................................4-96
Replacement ......................................................................................................................................................4-97
Testing ...............................................................................................................................................................4-96
C
CIM Wiring Harness
Inspection ........................................................................................................................................................4-133
Installation .......................................................................................................................................................4-134
Removal ..........................................................................................................................................................4-133
Testing .............................................................................................................................................................4-133
COMMUNICATION RECEPTACLE
Inspection ........................................................................................................................................................4-103
Location and Description ..................................................................................................................................1-36
Replacement ....................................................................................................................................................4-103
Computer Interface Module (CIM)
Controls and Indicators........................................................................................................................................2-4
Inspection ........................................................................................................................................................4-100
Installation .......................................................................................................................................................4-101
Location and Description ..................................................................................................................................1-36
Removal ..........................................................................................................................................................4-101
CONVENIENCE RECEPTACLE J1
Inspection ........................................................................................................................................................4-105
Location and Description ..................................................................................................................................1-36
Replacement ....................................................................................................................................................4-105
Testing .............................................................................................................................................................4-105
Coolant Hose, Lower
Inspection ........................................................................................................................................................4-160
Installation .......................................................................................................................................................4-161
Removal ..........................................................................................................................................................4-160
Coolant Hose, Upper
Inspection ........................................................................................................................................................4-159
Installation .......................................................................................................................................................4-159
Removal ..........................................................................................................................................................4-158
Coolant Overflow and Drain Hoses
Inspection ........................................................................................................................................................4-161
Installation .......................................................................................................................................................4-161
Removal ..........................................................................................................................................................4-161
Index-2
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
Coolant Recovery System
Inspection ........................................................................................................................................................4-168
Installation .......................................................................................................................................................4-168
Removal ..........................................................................................................................................................4-168
Coolant Temperature Sender MT6
Installation .......................................................................................................................................................4-199
Removal ..........................................................................................................................................................4-198
Service .............................................................................................................................................................4-198
Testing .............................................................................................................................................................4-197
Cooling System, Engine ...........................................................................................................................................1-25
Inspection ..........................................................................................................................................................3-24
Service ................................................................................................................................................... 3-24, 4-154
Testing .............................................................................................................................................................4-152
Cooling System, Generator Set.................................................................................................................................1-23
Crankcase Breather Filter Assembly
Inspection .............................................................................................................................................. 3-22, 4-149
Install ...............................................................................................................................................................4-152
Location and Description ..................................................................................................................................1-39
Removal ..........................................................................................................................................................4-151
Service ................................................................................................................................................... 3-22, 4-149
Test ..................................................................................................................................................................4-152
Cranking Relay K2
Inspection ........................................................................................................................................................4-189
Replacement ....................................................................................................................................................4-190
Testing .............................................................................................................................................................4-189
Current Transformer CT1, CT2, CT3
Inspection ........................................................................................................................................................4-186
Installation .........................................................................................................................................................5-36
Removal ............................................................................................................................................................5-35
Testing ................................................................................................................................................... 4-186, 5-35
D
DC CONTROL POWER Fuse F1
Inspection ........................................................................................................................................................4-117
Replacement ....................................................................................................................................................4-117
Testing .............................................................................................................................................................4-117
DCS Control Box Assembly
Inspection ..........................................................................................................................................................4-77
Installation .........................................................................................................................................................4-79
Location and Description ..................................................................................................................................1-36
Removal ............................................................................................................................................................4-77
Repair ................................................................................................................................................................4-79
DCS Control Box Bottom
Inspection ........................................................................................................................................................4-139
Installation .......................................................................................................................................................4-140
Removal ..........................................................................................................................................................4-139
Repair ..............................................................................................................................................................4-140
DCS Control Box Side Panels
Inspection ........................................................................................................................................................4-138
Installation .......................................................................................................................................................4-138
Removal ..........................................................................................................................................................4-138
Repair ..............................................................................................................................................................4-138
Index-3
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
DCS Control Box Top Panel
Inspection ..........................................................................................................................................................4-62
Installation .........................................................................................................................................................4-62
Removal ............................................................................................................................................................4-60
Repair ................................................................................................................................................................4-62
DCS Control Box Wiring Harness
Inspection .............................................................................................................................................. 4-131, 5-23
Repair ..............................................................................................................................................................4-132
Replacement ......................................................................................................................................................5-24
Testing ................................................................................................................................................... 4-132, 5-24
DCS Control Panel Assembly
Inspection ........................................................................................................................................................4-134
Installation .......................................................................................................................................................4-135
Removal ..........................................................................................................................................................4-134
Repair ..............................................................................................................................................................4-135
DCS Control Panel Frame
Inspection ........................................................................................................................................................4-135
Installation .......................................................................................................................................................4-136
Removal ..........................................................................................................................................................4-135
Repair ..............................................................................................................................................................4-136
DCS Controls and Indicators ......................................................................................................................................2-1
DCS Load Sharing Synchronizer A2
Inspection ........................................................................................................................................................4-106
Installation .......................................................................................................................................................4-109
Removal ..........................................................................................................................................................4-107
Testing .............................................................................................................................................................4-106
DCS Speed Control Unit A3
Inspection ........................................................................................................................................................4-109
Installation .......................................................................................................................................................4-110
Removal ..........................................................................................................................................................4-110
Testing ....................................................................................................................................................................4-109
Data Plates ..................................................................................................................................................................1-4
Data Plates, DCS
Inspection ........................................................................................................................................................4-140
Replacement ....................................................................................................................................................4-140
Data Plates, Housing
Inspection ..........................................................................................................................................................4-77
Replacement ......................................................................................................................................................4-77
DEAD CRANK Switch S10
Location and Description ..................................................................................................................................1-36
Replacement ....................................................................................................................................................4-201
Testing .............................................................................................................................................................4-201
Diagnostic Controls and Indicators.............................................................................................................................2-8
Digital Control System .............................................................................................................................................1-17
Dipstick, Location and Description ..........................................................................................................................1-39
Diode CR1
Inspection ........................................................................................................................................................4-122
Replacement ....................................................................................................................................................4-123
Testing .............................................................................................................................................................4-122
Droop Current Transformer CT5
Inspection ........................................................................................................................................................4-187
Installation .........................................................................................................................................................5-39
Removal ............................................................................................................................................................5-38
Testing ...............................................................................................................................................................5-39
Index-4
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
E
Electric Actuator A6
Inspection ..........................................................................................................................................................5-43
Replacement ......................................................................................................................................................5-45
Testing ...............................................................................................................................................................5-43
EMERGENCY STOP Switch S17
Inspection ..........................................................................................................................................................4-97
Replacement ......................................................................................................................................................4-98
Testing ...............................................................................................................................................................4-97
End Bell and Main Bearing
Installation .........................................................................................................................................................5-52
Removal ............................................................................................................................................................5-49
Engine and Generator Assembly
Installation .........................................................................................................................................................5-17
Removal ............................................................................................................................................................5-14
Engine/Generator Disassembly
Installation .........................................................................................................................................................5-22
Location and Description ..................................................................................................................................1-39
Removal ............................................................................................................................................................5-22
ENGINE CONTROL Switch S1
Inspection ..........................................................................................................................................................4-85
Replacement ......................................................................................................................................................4-85
Testing ...............................................................................................................................................................4-85
Ether Cylinder Assembly
Inspection ........................................................................................................................................................4-178
Installation .......................................................................................................................................................4-180
Removal ..........................................................................................................................................................4-178
Ether Solenoid Valve L6
Inspection ........................................................................................................................................................4-181
Installation .......................................................................................................................................................4-181
Removal ..........................................................................................................................................................4-180
ETHER START Switch S9
Inspection ..........................................................................................................................................................4-86
Replacement ......................................................................................................................................................4-86
Testing ...............................................................................................................................................................4-86
Exciter Rotor Testing................................................................................................................................................5-60
Exciter Stator
Inspection ..........................................................................................................................................................5-55
Replacement ......................................................................................................................................................5-56
Testing ...............................................................................................................................................................5-55
F
Fan
Inspection ........................................................................................................................................................4-165
Installation .......................................................................................................................................................4-166
Removal ..........................................................................................................................................................4-164
Fan Belt
Adjustment ......................................................................................................................................................4-166
Inspection ........................................................................................................................................................4-166
Location and Description ..................................................................................................................................1-36
Replacement ....................................................................................................................................................4-167
Index-5
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
Fan Guards
Inspection ........................................................................................................................................................4-158
Installation .......................................................................................................................................................4-158
Removal ..........................................................................................................................................................4-156
FAULT RESET Switch S4
Inspection ..........................................................................................................................................................4-88
Replacement ......................................................................................................................................................4-89
Testing ...............................................................................................................................................................4-88
Fault System .............................................................................................................................................................1-17
Field Flash Relay K23
Inspection ........................................................................................................................................................4-128
Installation .......................................................................................................................................................4-129
Removal ..........................................................................................................................................................4-128
Testing .............................................................................................................................................................4-128
Filler Hose and Panel
Inspection and Cleaning ..................................................................................................................................4-155
Installation .......................................................................................................................................................4-156
Removal ..........................................................................................................................................................4-155
FREQUENCY ADJUST Switch S19
Inspection ..........................................................................................................................................................4-93
Replacement ......................................................................................................................................................4-94
Testing ...............................................................................................................................................................4-94
FREQUENCY SELECT Switch S12 (MEP-805B only)
Inspection ........................................................................................................................................................4-118
Replacement ....................................................................................................................................................4-120
Testing .............................................................................................................................................................4-118
Fuel Drain Valve
Location and Description ..................................................................................................................................1-36
Replacement ....................................................................................................................................................4-175
Fuel Filter/Water Separator
Inspection .............................................................................................................................................. 3-29, 4-183
Install ...............................................................................................................................................................4-183
Location and Description ..................................................................................................................................1-39
Removal ..........................................................................................................................................................4-183
Service ................................................................................................................................................... 3-29, 4-183
Fuel Level Sender MT5
Inspection ........................................................................................................................................................4-176
Installation .......................................................................................................................................................4-177
Removal ..........................................................................................................................................................4-176
Testing .............................................................................................................................................................4-176
Fuel Lines and Fittings, Low Pressure
Inspection ........................................................................................................................................................4-170
Replacement ....................................................................................................................................................4-170
Fuel Pickup
Inspection ........................................................................................................................................................4-178
Installation .......................................................................................................................................................4-178
Removal ..........................................................................................................................................................4-177
Fuel System ..............................................................................................................................................................1-19
Fuel Tank
Inspection ................................................................................................................................................ 3-26, 5-26
Installation .........................................................................................................................................................5-27
Location and Description ..................................................................................................................................1-36
Removal ............................................................................................................................................................5-25
Service ....................................................................................................................................................... 3-28, 4-3
Index-6
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
Fuel Tank Filler Neck
Inspection ........................................................................................................................................................4-174
Installation .......................................................................................................................................................4-175
Removal ..........................................................................................................................................................4-174
Fuel Transfer Pump Level Relay K19
Inspection ........................................................................................................................................................4-128
Installation .......................................................................................................................................................4-129
Removal ..........................................................................................................................................................4-128
Testing .............................................................................................................................................................4-128
G
Generator Assembly, AC..........................................................................................................................................1-31
Installation .........................................................................................................................................................5-47
Location and Description ..................................................................................................................................1-36
Removal ............................................................................................................................................................5-46
Generator Set Controls .............................................................................................................................................1-33
Generator Set Installation
Indoor ................................................................................................................................................................2-22
Outdoor..............................................................................................................................................................2-21
Governor Control System .........................................................................................................................................1-19
GROUND FAULT CIRCUIT INTERRUPTER CB3
Inspection ..........................................................................................................................................................4-98
Replacement ......................................................................................................................................................4-99
Testing ...............................................................................................................................................................4-99
Grounding Rod, Installation of .................................................................................................................................2-24
H
Housing Section, Front
Inspection ..........................................................................................................................................................4-70
Installation .........................................................................................................................................................4-71
Removal ............................................................................................................................................................4-68
Repair ................................................................................................................................................................4-71
Housing Section, Rear
Inspection ..........................................................................................................................................................4-73
Installation .........................................................................................................................................................4-76
Removal ............................................................................................................................................................4-72
Repair ................................................................................................................................................................4-75
Housing Section, Top
Inspection ..........................................................................................................................................................4-66
Installation .........................................................................................................................................................4-67
Removal ............................................................................................................................................................4-62
Repair ................................................................................................................................................................4-66
I
I/O Interface Module A5
Inspection ........................................................................................................................................................4-115
Replacement ....................................................................................................................................................4-116
Testing .............................................................................................................................................................4-116
Initial Adjustments, Checks, and Self-Test ..............................................................................................................2-27
Inspecting and Servicing the Equipment ....................................................................................................................4-1
Index-7
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
K
K1 Auxiliary Relay K17
Inspection ........................................................................................................................................................4-128
Installation .......................................................................................................................................................4-129
Removal ..........................................................................................................................................................4-128
Testing .............................................................................................................................................................4-128
Keypad Assembly KP
Inspection ........................................................................................................................................................4-102
Replacement ....................................................................................................................................................4-102
L
Load Cables, Installation of......................................................................................................................................2-26
Load Output Terminal Board TB2
Inspection ........................................................................................................................................................4-191
Installation .......................................................................................................................................................4-193
Location and Description ..................................................................................................................................1-39
Removal ..........................................................................................................................................................4-190
Repair ..............................................................................................................................................................4-193
Load/Unload Relay K22
Inspection ........................................................................................................................................................4-128
Installation .......................................................................................................................................................4-129
Removal ..........................................................................................................................................................4-128
Testing .............................................................................................................................................................4-128
Lubrication System...................................................................................................................................................1-25
Inspection ..........................................................................................................................................................3-29
Service ....................................................................................................................................................... 3-31, 4-5
M
Magnetic Pickup MPU
Adjustment ......................................................................................................................................................4-200
Installation .......................................................................................................................................................4-200
Removal ..........................................................................................................................................................4-199
Service .............................................................................................................................................................4-199
Main Stator and Housing, Generator
Replacement ......................................................................................................................................................5-61
Testing ...............................................................................................................................................................5-60
MASTER CONTROL Switch
Inspection ..........................................................................................................................................................4-89
Replacement ......................................................................................................................................................4-92
Testing ...............................................................................................................................................................4-90
Mechanical System...................................................................................................................................................1-23
Muffler and Exhaust Pipe
Inspection ........................................................................................................................................................4-141
Replacement ....................................................................................................................................................4-141
Location and Description ..................................................................................................................................1-36
Index-8
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
N
NATO SLAVE RECEPTACLE
Inspection ..........................................................................................................................................................4-54
Installation .........................................................................................................................................................4-55
Location and Description ..................................................................................................................................1-39
Removal ............................................................................................................................................................4-55
NETWORK FAILURE Light DS5
Inspection ..........................................................................................................................................................4-82
Repair ................................................................................................................................................................4-82
Replacement ......................................................................................................................................................4-82
Nuclear, Biological, and Chemical (NBC) Decontamination...................................................................................2-45
O
Oil Drain Valve
Inspection ........................................................................................................................................................4-204
Location and Description ..................................................................................................................................1-36
Replacement ....................................................................................................................................................4-205
Oil Filter, Location and Description .........................................................................................................................1-39
Oil Pressure Sender MT7
Installation .......................................................................................................................................................4-196
Removal ..........................................................................................................................................................4-196
Service .............................................................................................................................................................4-196
Testing .............................................................................................................................................................4-194
Operation Under Unusual Conditions
Dusty or Sandy Areas........................................................................................................................................2-42
Emergency Stopping .........................................................................................................................................2-44
Extreme Cold Weather Below -25°F (-31°C)....................................................................................................2-41
Extreme Heat Above 120°F (48.8°C)................................................................................................................2-42
High Altitude Electromagnetic Pulse (HAEMP) Environment .........................................................................2-46
High Altitudes ...................................................................................................................................................2-44
NATO Slave Receptacle Start Operation ..........................................................................................................2-44
Rainy or Humid Conditions...............................................................................................................................2-43
Salt Water Areas................................................................................................................................................2-43
Using Battle Short Switch .................................................................................................................................2-44
While Contaminated ..........................................................................................................................................2-46
Output Box Assembly
Installation .........................................................................................................................................................5-30
Removal ............................................................................................................................................................5-29
Output Box Panels
Inspection ..........................................................................................................................................................5-41
Installation .........................................................................................................................................................5-42
Removal ............................................................................................................................................................5-41
Repair ................................................................................................................................................................5-42
Output Box Wiring Harness
Inspection .............................................................................................................................................. 4-184, 5-34
Installation .........................................................................................................................................................5-34
Removal ............................................................................................................................................................5-33
Repair .................................................................................................................................................... 4-186, 5-34
Testing ................................................................................................................................................... 4-186, 5-34
Output Supply System ..............................................................................................................................................1-29
Index-9
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
P
Panel Lights DS1 through DS3
Inspection ..........................................................................................................................................................4-79
Repair ................................................................................................................................................................4-80
Replacement ......................................................................................................................................................4-80
PANEL LIGHTS Switch S2
Inspection ..........................................................................................................................................................4-95
Replacement ......................................................................................................................................................4-95
Testing ...............................................................................................................................................................4-95
Parallel Unit Operation .............................................................................................................................................2-33
PARALLELING RECEPTACLE J2
Inspection ........................................................................................................................................................4-104
Replacement ....................................................................................................................................................4-104
Location and Description ..................................................................................................................................1-36
Power Potential Transformer T1
Inspection ........................................................................................................................................................4-187
Installation .........................................................................................................................................................5-40
Removal ............................................................................................................................................................5-40
Testing ...............................................................................................................................................................5-40
Preparation for Movement........................................................................................................................................2-39
Preparation for Shipment and Storage ....................................................................................................................4-207
R
Radiator
Installation .......................................................................................................................................................4-163
Location and Description ..................................................................................................................................1-36
Removal ..........................................................................................................................................................4-162
Repair ................................................................................................................................................... 4-163, 5-25
Service ..................................................................................................................................................... 4-2, 4-163
REACTIVE CURRENT ADJUST Rheostat R5
Inspection ........................................................................................................................................................4-121
Replacement ....................................................................................................................................................4-122
Testing .............................................................................................................................................................4-121
Remote Operation.....................................................................................................................................................2-36
Resistor R1
Inspection ........................................................................................................................................................4-124
Replacement .......................................................................................................................................... 4-124, 5-24
Testing .............................................................................................................................................................4-124
Resistor R2
Inspection ........................................................................................................................................................4-125
Replacement .......................................................................................................................................... 4-125, 5-25
Testing .............................................................................................................................................................4-125
Resistor R6
Inspection ........................................................................................................................................................4-130
Replacement ....................................................................................................................................................4-131
Testing .............................................................................................................................................................4-130
Resistors R116 and R17
Inspection ........................................................................................................................................................4-129
Replacement ....................................................................................................................................................4-129
Testing .............................................................................................................................................................4-129
Index-10
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
Restriction Indicator
Inspection ........................................................................................................................................................4-146
Replacement ....................................................................................................................................................4-146
Rotor Assembly, Generator
Installation .........................................................................................................................................................5-59
Removal ............................................................................................................................................................5-59
Testing ...............................................................................................................................................................5-58
Rotating Rectifier
Installation .........................................................................................................................................................5-55
Removal ............................................................................................................................................................5-53
Replacement of Rectifier Diodes.......................................................................................................................5-53
Testing ...............................................................................................................................................................5-52
S
Shut Down Generator Set .........................................................................................................................................2-31
Skid Base
Inspection ..........................................................................................................................................................5-61
Installation .........................................................................................................................................................5-62
Location and Description ..................................................................................................................................1-39
Removal ............................................................................................................................................................5-61
Repair ................................................................................................................................................................5-62
Start Generator Set....................................................................................................................................................2-30
Starter, Location and Description .............................................................................................................................1-39
Start Relay K15
Inspection ........................................................................................................................................................4-128
Installation .......................................................................................................................................................4-129
Removal ..........................................................................................................................................................4-128
Testing .............................................................................................................................................................4-128
T
Time Meter M3
Inspection ..........................................................................................................................................................4-82
Replacement ......................................................................................................................................................4-83
Testing ...............................................................................................................................................................4-83
V
VOLTAGE ADJUST Switch S18
Inspection ..........................................................................................................................................................4-92
Replacement ......................................................................................................................................................4-93
Testing ...............................................................................................................................................................4-92
Voltage Reconnection Terminal Board TB1
Inspection .............................................................................................................................................. 5-32, 4-183
Installation .......................................................................................................................................................4-184
Location and Description ..................................................................................................................................1-39
Removal ..........................................................................................................................................................4-184
Replacement ......................................................................................................................................................5-32
Voltage Regulation System ......................................................................................................................................1-19
Voltage Scale Switch
Inspection ........................................................................................................................................................4-127
Replacement ....................................................................................................................................................4-127
Testing .............................................................................................................................................................4-127
Index-11
ARMY TM 9-6115-671-14
AIR FORCE TO 35C2-3-446-32
MARINE CORPS TM 09249A/09246A-14
W
Water Pump, Location and Description....................................................................................................................1-39
Index-12
RECOMMENDED CHANGES TO EQUIPMENT TECHNICAL PUBLICATIONS
SOMETHING WRONG WITH THIS PUBLICATION
FROM: (PRINT YOUR UNIT'S COMPLETE
THEN ... JOT DOWN THE INFO
ABOUT IT ON THIS FORM.
CAREFULLY TEAR IT OUT.
FOLD IT AND DROP IT IN THE
MAIL.
PUBLICATION
2-25
2-28
10 July 1975
FIGURE
NO
PUBLICATION
Radar Set AN/PRC-
23 Jan 74
BE EXACT PIN-POINT WHERE IT
PARA
GRAPH
DATE SENT
PUBLICATION DATE
TM 11-5840-340-12
PAGE
NO
Commander
Stateside Army Depot
ATTN: AMSTA-US
Stateside, N.J. 07703-5007
IN THIS SPACE TELL WHAT IS WRONG
AND WHAT SHOULD BE DONE ABOUT IT:
TABLE
NO
Recommend that the installation antenna alignment
procedure be changed throughout to specify a 20 IFF
antenna lag rather than 10.
REASON: Experience has shown that with only a 10 lag,
the antenna servo system is too sensitive to wind gusting
excess of 25 knots, and has a tendency to rapidly accelerate
and decelerate as it hunts, causing strain to the drive train.
Hunting is minimized by adjusting the lag to 20
degradation of operation.
3-10
3-3
3-1
Item 5, Functional column. Change “2 dB" to “3 dB”.
REASON: The adjustment procedure for the TRANS POWER
FAULT indicator calls for a 3 dB (500 watts) adjustment to light
the TRANS POWER FAULT indicator.
5-6
Add new step f.1 to read, “Replace cover plate removed in
step e.1, above."
5-8
REASON: To replace the cover plate.
FO-3
Zone C 3. On J1-2, change “+24 VDC" to “+5 VDC".
REASON: This is the output line of the 5 VDC power supply.
+24 VDC is the input voltage.
PRINTED NAME, GRADE OR TITLE AND TELEPHONE
SSG I. M. DeSpiritof
FORM
DA 1 JUL 792028-2
SIGN HERE
999-1776
PREVIOUS
ARE OBSOLETE
P.S. - IF YOUR OUTFIT WANTS TO KNOW ABOUT
RECOMMENDATION MAKE A CARBON COPY OF
AND GIVE IT TO YOUR
REVERSE OF DA FORM 2028-2
FOLD BACK
DEPARTMENT OF THE ARMY
PLEASE
AFFIX
STAMP
POSTAGE
REQUIRED
OFFICIAL BUSINESS
Commander
U.S. Army Communications-Electronics Command
and Fort Monmouth
ATTN: AMSEL-LC-LEO-D-CS-CFO
Fort Monmouth, New Jersey 07703-5000
TEAR ALONG DOTTED LINE
FILL IN YOUR
UNIT'S ADDRESS
50
REVERSE OF DA FORM 2028-2
FOLD BACK
DEPARTMENT OF THE ARMY
PLEASE
AFFIX
STAMP
POSTAGE
REQUIRED
OFFICIAL BUSINESS
Commander
U.S. Army Communications-Electronics Command
and Fort Monmouth
ATTN: AMSEL-LC-LEO-D-CS-CFO
Fort Monmouth, New Jersey 07703-5000
TEAR ALONG DOTTED LINE
FILL IN YOUR
UNIT'S ADDRESS
50
REVERSE OF DA FORM 2028-2
FOLD BACK
DEPARTMENT OF THE ARMY
PLEASE
AFFIX
STAMP
POSTAGE
REQUIRED
OFFICIAL BUSINESS
Commander
U.S. Army Communications-Electronics Command
and Fort Monmouth
ATTN: AMSEL-LC-LEO-D-CS-CFO
Fort Monmouth, New Jersey 07703-5000
TEAR ALONG DOTTED LINE
FILL IN YOUR
UNIT'S ADDRESS
50
REVERSE OF DA FORM 2028-2
FOLD BACK
DEPARTMENT OF THE ARMY
PLEASE
AFFIX
STAMP
POSTAGE
REQUIRED
OFFICIAL BUSINESS
Commander
U.S. Army Communications-Electronics Command
and Fort Monmouth
ATTN: AMSEL-LC-LEO-D-CS-CFO
Fort Monmouth, New Jersey 07703-5000
TEAR ALONG DOTTED LINE
FILL IN YOUR
UNIT'S ADDRESS
By Order of the Secretary of the Army:
ERIC K. SHINSEKI
General, United States Army
Chief of Staff
Official:
0024403
By Order of the Secretary of the Marine Corps:
RANDALL P. SHOCKEY
Director, Program Support
Marine Corps Systems Command
By Order of the Secretary of the Air Force:
MICHAEL E. RYAN
General, United States Air Force
Chief of Staff
Official:
GEORGE T. BABBITT
General, United States Air Force
Commander, AFMC
DISTRIBUTION:
To be distributed in accordance with the initial distribution number (IDN) 256634 requirements
for TM 9-6115-671-14.
PIN: 078490-000
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