TM-5-6115-332-14
DEPARTMENT OF THE ARMY
TECHNICAL
TM
5-6115-332-14
MANUAL
DEPARTMENT OF THE NAVY
P-8-614-14
PUBLICATION
DEPARTMENT OF THE AIR FORCE
TO
35C2-3-424-1
TECHNICAL ORDERS
TECHNICAL
MANUAL
OPERATOR, ORGANIZATIONAL, INTERMEDIATE
(FIELD), (DIRECT SUPPORT AND GENERAL SUPPORT),
AND DEPOT LEVEL MAINTENANCE MANUAL
GENERATOR
SET,
TACTICAL,
GASOLINE
ENGINE:
AIR
COOLED,
5 KW, AC, 120/240V SINGLE PHASE,
120/208V 3 PHASE, SKID MOUNTED,
TUBULAR FRAME (LESS ENGINE) MILITARY DESIGN
DOD MODEL
MEP-017A
MEP-022A
CLASS
UTILITY
UTILITY
This
copy
pages
is
from
a
reprint
HERTZ
60
400
which
Changes 1
includes
through
NSN
6115-00-017-8240
6115-00-017-8241
current
9.
PUBLISHED UNDER THE AUTHORITY OF THE DEPARTMENTS OF THE ARMY,
AIR FORCE AND NAVY
DECEMBER 1977
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
C 10
CHANGE
NO. 10
HEADQUARTERS
DEPARTMENTS OF THE ARMY, THE NAVY AND THE AIR FORCE
WASHINGTON, D C, 23 September 1996
OPERATOR, ORGANIZATIONAL, INTERMEDIATE (FIELD),
(DIRECT SUPPORT AND GENERAL SUPPORT), AND DEPOT LEVEL
MAINTENANCE MANUAL
GENERATOR SET, TACTICAL, GASOLINE ENGINE: AIR COOLED,
5 KW, AC, 120/240V SINGLE PHASE,
120/208V 3 PHASE, SKID MOUNTED,
TUBULAR FRAME (LESS ENGINE) MILITARY DESIGN
DOD MODEL
MEP-017A
MEP-022A
CLASS
UTILITY
UTILITY
HERTZ
60
400
NSN
6115-00-017-8240
6115-00-017-8241
DISTRIBUTION STATEMENT A: Approved for public release, distribution is unlimited
TM 5-6115-332-14/P-8-614-14/TO 35C2-3-424-1, 9 December 1977, is changed as follows.
1.
Remove and insert pages as indicated below. New or changed text material Is indicated by a vertical bar in the
margin. An illustration change Is indicated by a miniature pointing hand.
Remove pages
i and i
1-1 and 1-2
3-3 and 3-4
4-15 and 4-16
5-3 and 5-4
FO-2
2.
Retain this sheet in front of manual for reference purposes.
Insert pages
i and ii
1-1 and 1-2
3-3 and 3-4
4-15 and 4-16
5-3 and 5-4
FO-2
ARMY TM 5-6115-332-14
NAVFAC P-8-614-14
AIR FORCE TO 35C2-3-424-1
C9
HEADQUARTERS,
DEPARTMENTS OF THE ARMY, NAVY AND AIR FORCE
WASHINGTON, D.C., 10 January 1991
CHANGE
NO.
9
Operator, Organizational, Intermediate (Field)
(Direct Support and General Support),
and Depot Level Maintenance Manual
GENERATOR SET, TACTICAL, GASOLINE ENGINE, AIR COOLED,
5 kW, AC, 120/240 V SINGLE PHASE, 120/280 V 3 PHASE, SKID MOUNTED,
TUBULAR FRAME (LESS ENGINE) MILITARY DESIGN
DOD MODEL
CLASS
HERTZ
NSN
MEP-017A
MEP-022A
UTILITY
UTILITY
60
400
6115-00-017-8240
6115-00-017-8241
Approved for public release; distribution is unlimited
TM 5–6115–332–14/P-8-614-14/TO 35C2–3-424-1, 9 December 1977 is changed as follows:
1. Remove and insert pages as indicated below. New or changed text material is indicated by a vertical bar in
the margin. An illustration change is indicated by a miniature pointing hand.
Remove pages
Insert pages
7–1 and 7–2
7-2.1/(7–2.2 blank)
7-3 and 7-4
7–1 and 7–2
7-2.1/(7–2.2 blank)
7–3 and 7-4
2. Retain this sheet in front of manual for reference purposes.
ARMY TM 5-6115-332-14
NAVFAC P-8-614-14
AIR FORCE TO 35C2-3-424-1
C9
By Order of the Secretaries of the Army, Air Force, and Navy:
CARL E. VUONO
General, United States Army
Chief of Staff
Official:
THOMAS F. SIKORA
Brigadier General, United States Army
The Adjutant General
MERRILL A. McPEAK
General USAF
Chief of Staff
Official:
CHARLES C. MCDONALD
General, USAF
Commander, Air Force Logistics Command
DAVID E. BUTTORFF
Rear Admiral, CEC, US Navy
Commander
Navy Facilities Engineering Command
DISTRIBUTION:
To be distributed in accordance with DA Form 12-25E, (qty rqr block no. 0889).
*TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
TECHNICAL MANUAL
NO. 5-6115-332-14
HEADQUARTERS
DEPARTMENTS OF THE ARMY, THE NAVY AND THE AIR FORCE
WASHINGTON, D.C., 9 December 1977
OPERATOR, ORGANIZATIONAL, INTERMEDIATE (FIELD),
(DIRECT SUPPORT AND GENERAL SUPPORT), AND DEPOT LEVEL
MAINTENANCE MANUAL
GENERATOR SET, TACTICAL, GASOLINE ENGINE: AIR COOLED,
5 KW, AC, 120/240V SINGLE PHASE,
120/208V 3 PHASE, SKID MOUNTED,
TUBULAR FRAME (LESS ENGINE) MILITARY DESIGN
DOD MODEL
MEP-017A
MEP-022A
CLASS
UTILITY
UTILITY
HERTZ
60
400
NSN
6115-00-017-8240
6115-00-017-8241
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 these
procedures, please let us know. Mail your letter or DA Form 2028 (Recommended Changes to
Publications and Blank Forms), or DA Form 2028-2 located in the back of this manual directly to:
Commander, US Army Aviation and Troop Command, ATTN: AMSAT-I-MP, 4300 Goodfellow Blvd., St.
Louis, MO 63120-1798. You may also submit your recommended changes by E-mail directly to
<mpmte/oavma2.8st-louis-emh7.army.mil>. A reply will be furnished directly to you. Instructions for
sending an electronic 2028 may be found at the back of this manual immediately preceding the hard copy
2028.
DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited
TABLE OF CONTENTS
PAGE
CHAPTER 1
Section I
Section II
CHAPTER 2
Section I
Section II
Section III
CHAPTER 3
Section I
Section II
Section III
Section IV
Section V
INTRODUCTION
General .....................................................................................................................................
Description and Data ................................................................................................................
OPERATING INSTRUCTIONS ................................................................................................
Operating Procedures...............................................................................................................
Operation of Auxiliary Equipment .............................................................................................
Operation Under Unusual Conditions .......................................................................................
OPERATOR/CREW MAINTENANCE INSTRUCTIONS
Consumable Operating and Maintenance Supplies .................................................................
Lubrication Instructions.............................................................................................................
Preventive Maintenance Checks and Services (PMCS)...........................................................
Troubleshooting ........................................................................................................................
Operator/Crew Maintenance Instructions .................................................................................
1-1
1-3
2-1
2-17
2-19
3-1
3-3
3-3
3-5
3-13
’This manual supersedes TM 5-6115-332-12, dated 12 August 1970 and TM 5-6115-332-34, dated 10 August 1970.
Change 10 I
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
CHAPTER 4
Section I
Section II
Section III
Section IV
Section V
Section VI
Section VII
Section VIII
Section IX
Section X
CHAPTER 5
Section I
Section II
Section III
CHAPTER 6
CHAPTER 7
Section I
Section II
Section III
CHAPTER 8
Section I
Section II
Section III
APPENDIX A
APPENDIX B
APPENDIX C
ii Change 10
ORGANIZATIONAL MAINTENANCE INSTRUCTIONS
Service Maintenance Instructions.............................................................................................
Movement to a New Worksite...................................................................................................
Repair Parts, Special Tools and Equipment ............................................................................
Lubrication Instructions ............................................................................................................
Preventive Maintenance Checks and Services (PMCS) ..........................................................
Troubleshooting .......................................................................................................................
Radio Interference Suppression ...................................... ........................................................
Maintenance of the Engine Electrical System ..........................................................................
Maintenance of the Generator Electrical System ....................................................................
Maintenance of the Frame Assembly ......................................................................................
INTERMEDIATE (FIELD), (DIRECT AND GENERAL SUPPORT) AND
DEPOT MAINTENANCE INSTRUCTIONS
Repair Parts, Special Tools and Equipment ............................................................................
Direct Support and General Support Troubleshooting .............................................................
General Maintenance ...............................................................................................................
REMOVAL AND INSTALLATION OF MAJOR COMPONENTS
MAINTENANCE OF THE GENERATOR SET
Control Box Assembly .............................................................................................................
Maintenance of the Generator .................................................................................................
Maintenance of the Frame Assembly ......................................................................................
GENERATOR SET TEST AND INSPECTION AFTER REPAIR AND
OVERHAUL
General Requirements .............................................................................................................
Inspection .................................................................................................................................
Operational Tests .. ..................................................................................................................
REFERENCES .........................................................................................................................
BASIC ISSUE ITEMS LIST AND ITEMS TROOP INSTALLED OR
AUTHORIZED LIST ..........................................................................................................
MAINTENANCE ALLOCATION CHART (FOR ARMY AND MARINE
CORPS ONLY)...................................................................................................................
4-1
4-12
4-13
4-14
4-15
4-17
4-41
4-42
4-52
4-64
5-1
5-1
5-8
7-1
7-12
7-24
8-1
8-1
8-1
A-1
B-1
C-1
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
List of Illustrations
Figure
Title
Page
1-1.
1-2.
1-3.
1-4.
1-5.
1-6.
1-7.
2-1.
2-2.
2-3.
2-4.
2-5.
2-6.
2-7.
2-8.
2-9.
2-10.
2-11.
3-1.
3-2.
3-3.
3-4.
4-1.
4-2.
4-3.
4-4.
4-5.
4-6.
4-7.
4-8.
4-9.
4-9.
4-9.
4-10.
4-11.
4-12.
4-13.
4-14.
4-14.
4-14.
4-15.
4-16.
4-16.
4-16.
4-17.
4-17.
4-17.
4-18.
4-19.
Generator Set, Left Rear, Three-Quarter View (Model MEP-017A, 60 Hertz) . . . . . . . . .
Generator Set, Right Front, Three-Quarter View (Model MEP-017A, 60 Hertz) . . . . . . .
Generator Set, Left Rear, Three-Quarter View (Model MEP-022A, 400 Hertz) . . . . . . . .
Generator Set, Right Front, Three-Quarter View (Model MEP-022A, 400 Hertz) . . . . . .
Base Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Panel A Wiring Diagram (MEP-017A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Selector Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Choke Control Governor Control and Air Cleaner Intake Shutter . . . . . . . . . . . . . . . . . . .
Generator Control Panel, Controls, Instruments and Panel Lights . . . . . . . . . . . . . . . . . .
Output Selector Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator Field Flash Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator Frequency Meter (Model MEP-022A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electric Starting Instructions, Local Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manual Starting Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote Control Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stopping Instructions, Local Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blowtorch Operation and Service Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Cables, Starter Cable and Grommet and Terminal Stud . . . . . . . . . . . . . . . . . . . .
Fuses, Removal and Installation (Model MEP-017A) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Panel Light Lamp, Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Can, Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Revetment, Top Plan View.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Revetment, Side Plan View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Revetment, Isometric Plan View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Revetment, Perspective Without Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Revetment, Front View.... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Revetment, Left Side View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Revetment, Exhaust Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Types of Multimeters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
“Zeroing’’ the Multimeters (Sheet 1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
“Zeroing’’ the Multimeters (Sheet 2 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
“Zeroing’’ the Multimeters (Sheet 3 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TS 352 Continuity Test.... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing for Shorts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reading the OHM Scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DC Volts Scale (Sheet 1 of 3).... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DC Volts Scale (Sheet 2 of 2)... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DC Volts Scale (Sheet 3 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Measuring DC Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reading DC Voltage (Sheet 1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reading DC Voltage (Sheet 2 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reading DC Voltage (Sheet 3 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AC Volt Scale (Sheet 1 of 3)..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AC Volt Scale (Sheet 2 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AC Volt Scale (Sheet 3 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Measuring AC Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reading AC Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3
1-4
1-5
1-6
1-8
1-11
1-12
2-2
2-2
2-4
2-6
2-7
2-8
2-12
2-14
2-15
2-16
2-18
3-7
3-10
3-12
3-14
4-5
4-6
4-6
4-7
4-8
4-9
4-10
4-18
4-20
4-21
4-22
4-23
4-24
4-25
4-26
4-27
4-28
4-29
4-30
4-31
4-31
4-32
4-33
4-34
4-35
4-36
4-37
iii
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
List of Illustrations
Figure
Title
Page
4-20.
4-21.
Replacement of Radio Interference Suppression Components . . . . . . . . . . . . . . . . . . . . . .
Battery Cables, Starter Cable and Grommet and Terminal Stud, Removal and
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery and Battery Frame, Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . .
Slave Receptacle and Bracket, Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Panel Controls, Instruments and Panel Lights, Removal and Installation . . . . .
Fuseholder, Removal and Installation (Model MEP-017A) . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Breaker, Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Relays, Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Relay, Internal Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Outlet Receptacle (J1)(Model MEP-017A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Top Resilient Mounts, Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Toolbox, Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Box Bracket, Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Guard Frame, Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lifting Eye and Lifting Bracket, Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . .
Ground Terminal Stud Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Box, Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator, Removal and Installation (Model MEP-017A) . . . . . . . . . . . . . . . . . . . . . . . . .
Generator, Removal and Installation (Model MEP-022A) . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Hoses, Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starter Cable, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine, Removal and Installation.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Box Components, Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Voltage Regulator, Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Voltage Regulator, Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Voltage Regulator, Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Load Terminal Board, Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote Control Terminal Board, Removal and Installation (TB3) . . . . . . . . . . . . . . . . . .
Terminal Board, Removal and Installation (TB2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Generator Stator and Housing Assembly, Disassembly (Model MEP-0l7A) . . . . .
Main Generator Stator and Housing Assembly, Disassembly (Model MEP-022A) . . . . .
Exciter Field Frame Assembly, Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alternator Stator, Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Generator Rotor, Assembly, Disassembly (Model MEP-0l7A) . . . . . . . . . . . . . . . . .
Main Generator Rotor Assembly, Disassembly (Model MEP-022A) . . . . . . . . . . . . . . . . .
Exciter Rotor, Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alternator Rotor Assembly Test... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Support and Drip Pan, Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Can Brackets, Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring Diagram (Model MEP-017A). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator Set, Schematic Diagram (Model MEP-017A) . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring Diagram (Model MEP-022A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator Set, Schematic Diagram (Model MEP-022A) . . . . . . . . . . . . . . . . . . . . . . . .
4-41
4-22.
4-23.
4-24.
4-25.
4-26.
4-27.
4-28.
4-29.
4-30.
4-31.
4-32.
4-33.
4-34.
4-35.
6-1.
6-2.
6-3.
6-4.
6-5.
6-6.
7-1.
7-2.
7-3.
7-4.
7-5.
7-6.
7-7.
7-8.
7-9.
7-10.
7-11.
7-12.
7-13.
7-14.
7-15.
7-16.
7-17.
FO-1.
FO-2.
FO-3.
FO-4.
i v
Change 6
4-43
4-45
4-47
4-49
4-55
4-56
4-57
4-58
4-60
4-61
4-62
4-63
4-64
4-66
4-67
6-1
6-3
6-6
6-9
6-10
6-11
7-2
7-5
7-6
7-7
7-8
7-9
7-11
7-13
7-15
7-17
7-18
7-20
7-21
7-22
7-23
7-25
7-26
TM 5-6115-332-14
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TO 35C2-3-424-1
List of Tables
Table
Title
Page
1-1.
1-2.
2-1.
2-2.
3-1.
3-2.
3-4.
4-1.
4-2.
4-3.
5-1.
8-1.
Operational and Organizational Tabulated Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Direct Support and General Support Tabulated Data . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Controls and Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Voltmeter Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Consumable Maintenance and Operating Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operator/Crew Preventive Maintenance Checks and Services . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Output Selector Switch Positions and Load Cable Connections . . . . . . . .
Preventive Maintenance Checks and Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Organizational Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Direct Support and General Support Troubleshooting . . . . .
Visual and Operational Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-9
1-13
2-9
2-10.1
3-2
3-4
3-6
4-3
4-16
4-38
5-2
8-2
Change 6
v/(vi blank)
TM 5-6115-332-14
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TO 35C2-3-424-1
WARNING
All cautions and warnings contained in this manual should be strictly adhered to. Otherwise, severe injury, death
and/or damage to the equipment may result.
WARNING
HIGH VOLTAGE
is used in the operation of this equipment.
DEATH ON CONTACT
may result if personnel fail to observe safety precautions. Learn the areas containing high-voltage in each piece
of equipment. Be careful not to contact high-voltage connections when installing or operating this equipment.
Before working on the equipment, stop the generator set.
WARNING
When servicing the battery, do not smoke or use an open flame in the vicinity. Slave receptacle is to be used
when extra cranking power is required for starting unit. Other methods are not authorized. Use extreme care
when handling electrolyte. Do not operate the generator set in an enclosed building unless the exhaust gases
are piped to the outside. Carbon-monoxide fumes area colorless, odorless and deadly gas. These gases could cause
permanent brain damage or death, if highly concentrated in any certain area. The symptoms ,are headache, dizziness, loss of muscular control, apparent drowsiness and coma. If exposure symptoms exist, move afflicted person or personnel to properly ventilated area and provide artificial respiration, if necessary.
WARNING
If generator set is shut down by the operation of a safety device, do not attempt to operate unit until the cause
has been determined.
I
WARNING
I
Operating noise level of this equipment can cause hearing damage. Ear protection as recommended by the medical
or safety officer must be worn when working near this equipment.
a
TM 5-6115-332-14
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TO 35C2-3-424-1
Before starting engine or operating any of the components insure that no loose bars, tools, or parts are lying
in or on any part of the equipment, as they could cause serious damage to equipment or bodily injury to personnel. Never wear loose clothing, or hanging appendages from person or clothing, while inspecting running engine,
moving shafts, or like machinery. Disconnect the spark plug cables prior to engine maintenance to prevent accidental starting and severe shock. Before starting engine, insure that all operating levers and controls are in
proper operating positions and the engine units are properly supported. Failure to do these could result in damage
to the engine, and equipment. Always provide metal-to-metal contact between fuel container and fuel tank, while
refueling, to avoid igniting fuel vapors with a static spark. Before refueling, insure that adequate fire fighting
equipment is serviceable and is standing by for immediate use in event of fire or explosion. During engine operation, proper fire fighting equipment should be serviceable and kept near in the event that fire is developed by
electrostatic spark or detonation of the gas fumes. Do not smoke or use an open flame in vicinity of these gasoline
vapor hazards. Do not refuel while engine is in operation. Do not touch the ignition system harness during starting or while in operation. Severe shocks or burns could result, and personnel maybe severely injured. Never
touch engine or engine accessories with bare hands during operation, or before they have cooled sufficiently.
Severe burns can be caused through carelessness.
Clean all parts in a well-ventilated area. Avoid inhalation of solvent fumes and prolonged exposure of skin to
cleaning solvent. Wash exposed skin thoroughly. Dry cleaning solvent (Fed. Spec. P-D-680 Type II) used to clean
parts is potentially dangerous to personnel and property. Do not use near open flame or excessive heat. Flash
point of solvent 140°F (60 °C).
Serious eye injury can result from the starter rope knot. Wear eye protection when pull starting engine.
b
Change 6
TM 5-6115-332-14
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TO 35C2-3-424-1
CHAPTER 1
INTRODUCTION
SECTION I. GENERAL
Scope
a. This manual is for your use In operating and
maintaining the Military Designed DOD Models MEP017A and MEP-022A Generator Sets. Information is
provided on the operation, preventive maintenance
checks and services, troubleshooting, operator/crew,
organizational, Intermediate (Field), (Direct Support and
General Support) and Depot Maintenance
b. This manual is primarily concerned with the
operation and maintenance of the generator sets less
engine However, where It becomes necessary for
understanding, portions of the maintenance and
operation Instruction which apply to the engine are
Included For complete maintenance information on the
engine, refer to the engine manuals In Appendix A.
c. Appendix A contains a list of reference
publications applicable to this manual. Appendix B
contains the Basic Issue Items List and Items Troop
Installed or Authorized List. Appendix C contains the
Maintenance Allocation Chart (MAC), which determines
the level of maintenance responsibility for Army and
Marine Corps users
(4) DA Form 2408-9 (Equipment Control
1-1.
1-2.
Limited Applicability
Some portions of this publication are not
applicable to all services. These portions are prefixed to
Indicate the services to which they pertain, (A) for Army,
(F) for Air Force (N) For Navy and (MC) for Marine
Corps. Portions not prefixed are applicable to both
services.
1-3.
Maintenance Forms and Records
a. This technical manual is used by the Army,
Air Force, Navy and Marine Corps. The use of forms In
compliance with directives as stated herein will be
accomplished only by the personnel of the Service to
which they apply.
b. (A) Forms and records used by the Army
and prescribed by DA PAM 738-750 are as follows:
(1) DA
Assembly Records)
Form
2408
(Equipment
Log
(2) DA Form 2408-1 (Equipment Daily and
Monthly Log).
(3) DA
Modification Record)
Form
2408-5
(Equipment
Record).
(5) DA
Form
2408-10
(Equipment
Component Register)
(6) DA Form 2408-14 (Uncorrected Fault
Record).
c. (F) Maintenance forms and records used
by Air Force personnel are prescribed In AFM66-1 and the applicable 00-20 Series Technical Orders.
d. (MC) Those used by the Marine Corps will
be those prescribed by TM 4700-15/1
e. (N) Navy users should refer to appropriate
specification /publications for equipment maintenance
forms and records
1-4.
Reporting of Errors
a. Reporting of errors, omissions, and
recommendations for Improvement of this publication by
the Individual user is encouraged. Response should be
submitted as follows’
(1) (F) Air Force. AFTO Form 22 in
accordance with T.O. 00-5-1, direct to: Commander,
Sacramento Air Logistics Center, ATTN: SM-ALCMMEDTA, McClellen Air Force Base, CA 95652-5609.
(2) (A) Army.
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 Aviation and
Troop Command, ATTN AMSAT-I-MP, 4300 Goodfellow
Boulevard, St. Louis, MO 63120-1798. A reply will be
furnished directly to you.
(3) (N) Navy.
Letter, direct to:
Commanding Officer, Naval Construction Battalion
Center, ATTN: Code 15741, Port Hueneme, CA
93043-5000.
(4) (MC) Marine Corps. NAVMC Form
10772 direct to: Commandant, U.S. Marine Corps
Logistic Base, ATTN: Code 850, Albany, GA 317045000.
b. A) Applicable Army Forms, excluding
Standard Form 46 (United States Government Motor
Vehicles Operator’s Identification Card) which is carried
by the operator, shall be kept In manual compartment
mounted on equipment.
Change 10 1-1
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TO 35C2-3-424-1
1-5. Levels of Maintenance Accomplishments
a. (A,MC) Army and Marine Corps users shall
refer to the Maintenance Allocation Chart (MAC)
for tasks and levels of maintenance to be performed.
b. (F) Air Force users shall accomplish maintenance at the user level consistent with their
capability in accordance with policies established
in AFM 66-1.
c. (N) Navy users shall determine their maintenance levels in accordance with their service
directives.
1-6. (A, MC) Destruction of Materiel
To Prevent Enemy Use
a. Fire. Use fire to destroy equipment when
quantities of fuel and flammable materials are at
hand.
Burn assemblies and components on a
priority basis, if possible. Proper concentration
of equipment to be burned will produce a hotter,
more destructive fire. Fires should be lit after
mechanical destruction has been accomplished.
Fire on equipment with the
b. Gunfire.
heaviest weapons available aiming at the major
assemblies and controls. Continue fire until the
equipment is completely destroyed.
c. Mechanical Destruction.
Using an axe,
pick, mattock, sledge or any other heavy implements, damage or destroy all vital elements such as
controls, and any other major assemblies and
components.
d. For further information, refer to TM 750244-3 (Procedures for Destruction of Equipment to Prevent Enemy Use for U.S. Army.
1-7. Administrative Storage
If the generator sets must be placed in administrative storage, proceed as follows:
a. (A) Army.
(1) Store equipment so as to provide maximum protection from the elements and to provide
access for inspection, maintenance, and exercising.
Anticipate removal or deployment problems
For example,
and take suitable precautions.
strategically locate recovery vehicles, snowplows,
slave-units, and similar items, likely to be needed
on short notice.
(2) Take into account environmental conditions, such as extreme heat or cold; high humidity; blowing sand, dust, or loose debris; soft
ground; mud; heavy snows; earthquakes; or combinations thereof and take adequate precautions.
(3) Establish a fire plan and provide for
adequate fire fighting equipment and personnel.
1-2
Change 8
(4) For further information, refer to TM
740-90-1 (Administrative Storage).
b. (AF) Air Force. Refer to TO 35-1-4 (Processing and Inspection of Aerospace Ground
Equipment).
c. (MC) Marine Corps. Refer to MCO-P4450-7.
1-8. Preparation For Shipment and Storage
a. (A) Army. Shipment and storage for U.S.
Army will be in accordance with the following:
(1) Select the best available site for administrative storage. Separate stored equipment from
equipment in use. Conspicuously mark the area
“Administrative Storage.”
(2) Covered space is preferred. When sufficient covered space for all items to be stored
is not available, priority should be given to items
which are most susceptible to deterioration from
the elements.
(3) Open site should be improved hardstand, if available. Unimproved sites should be
firm, well drained, and kept free of excessive
vegetation.
(4) Truck, vans, Conex containers, and
other containers may be used if they provide the
best available protection.
(5) Prior to storage, perform the next
scheduled major preventive maintenance service.
(6) For further information, refer to
TB 740-97-2 (Preservation of USATSARCOM
Mechanical Equipment for Shipment and Storage).
b. (F) Air Force. Reference TO 35-1-4 for end
item generator set and TO 38-1-5 for installed
engine.
c. (N, MC) Navy and Marine Corps. Reference
individual service directives for requirements.
d. Placement of equipment in administrative
storage should be for short periods of time when a
storage of maintenance effort exists. Items should
be in mission readiness within 24 hours or within
the time factors are determined by the directing
authority. During the storage period appropriate
maintenance records will be kept.
e. Before placing equipment in administrative
storage, current maintenance services and equipment serviceable criteria (ESC) evaluations should
be corrected and all modification work orders
(MWO’s) should be applied.
f. Storage site selection. 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.
TIM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
Section II.
DESCRIPTION AND DATA
1-9. Description
a. General. The Department of Defense generator
sets, DOD model MEP-017A (fig. 1-1 and 1-2) and
DOD model MEP-022A (fig. 1-3 and 1-4) are powered
by a gasoline-fueled, 10-horsepower, Military
Standard Engine, either the Model 2A042-2 or the
Model 2A042-3. The engine is directly coupled to the
generator.
Figure 1-1. Generator set, left rear, three-quarter view (Model MEP-017A, 60 Hertz)
Change 6 1-3
Change 6
Figure 1-2. Generator set, right front, three quarter view (Model MEP-017A, 60 Hertz)
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
1-4
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
TS 6115-332-14/1-3
Figure 1-3.
Generator set, left rear, three-quarter view (Model MEP-022A, 400 Hertz)
1-5
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
1-6
TS 6115-332-14/1-4
Figure 1-4.
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
b. Engines. For description of the Military Standard Engines refer to TM 5-2805-258-14.
c. Generators.
(1) Generator Set Model MEP-017A. The
generator (fig. 1-1) provided with the Model MEP017A generator set has a 2-pole rotor with a brushless rotating exciter rotor section mounted on the
same shaft. The generator is rated at 5 kw (kilowatts), 0.8 pf (power factor), 60 HZ (hertz) at 3,6000
rpm (revolutions per minute). The generator output
characteristics are as follows: 120/240 volts, single
phase, two wire; 120 volts, three phase, three wire;
and 120/208 volts, three phase, four wire.
(2) Generator Set Model MEP-022A. The
generator (fig. 1-3) provided with the model MEP022A generator set has a 14-pole rotor with a brushless rotating exciter rotor section mounted on the
same shaft. The generator is rated at 5 kw, 0.8 pf,
400 hz at a speed of approximately 3428 rpm. The
generator output characteristics are as follows: 120/
240 volts, single phase, two wire; 120 volts, three
phase, three wire; and 120/208 volts, three phase,
four wire.
d. Control Boxes. The control box for each of the
generator sets is similar. They contain the necessary controls, instruments and other electrical components that are required for operation of the electrical portion of the generator sets.
1-10. Tabulated Data
a. Identification. The generator sets are provided with three identification plates. The information contained on thses plates and their location
is as follows:
(1) U.S. Army Identification Plate. This
plate is located on the top of the control box bracket
near the tool box. It specifies:
Generator set model number.
Stock No. (number).
Generator set serial No.
Mfr. (manufacturer).
Generator model number.
Operating volts, ph (phase) amp (amperes)
kw kilowatts), kva (kilovolt-amperes), pf
(power factor), cy (cycles) or hz (hertz) and
rpm (revolutions per minute). Cont. No.
(contract number).
Lg (length), width, hgt (height), and wt
(weight). Eng mfg (engine manufacturer)
model, and ser No.
(2) Generator Nameplate. The plate is located on the right side of the generator stator housing at a point above the support bracket. It
specifies:
NSN (National stock number)
KW (kilowatts).
Cps or Hz (cycles per second or hertz).
PF (power factor).
Mfr (manufacturer).
Serial No. (number).
(3) Engine Nameplate. The engine plate is
located on the upper side of the flywheel housing. It
contains information on the manufacturer, model,
nomenclature, National stock number and displacement.
b. Wiring Diagram. Refer to figure FO-1 and
FO-2 for the wiring diagram for the Model MEP017A generator set and to figure FO-3 and FO-4 for
the wiring diagram for the Model MEP-022A generator set.
c. Engine Electrical System. The engine electrical system functions in conjunction with several
of the generator set controls and other components.
The system is of the 24-volt, negative, ground-type.
d. Dimensions and Weight.
(1) Model MEP-017A. For dimensions and
weight, refer to figure 1-1.
(2) Model MEP-022A. For demensions and
weight, refer to figure 1-3.
e. Base Plan. The base plan provides dimensions
for a base that may be prepared in advance of the installation of the generator set. The base may be constructed of wood planking or a concrete pad may be
prepared, as desired. For the base plan, refer to figure 1-5.
1-7
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
TS 6115-332-14/1-5
Figure 1-5. Base plan.
f. Data. Refer to Table 1-1 for Operator and Organizational Data, and to Table 1-2 for Direct Support and General Support data.
1-8
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
Table 1-1 Operational and Organizational Tabulated Data
1. Generator Set, 60 HZ Unit, NSN 6115-00-017-8240.
Contract Numbr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DS400-71-C-4381, serial number range FA71-00001 through
FA71-01093
Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Onan, Division of Studebaker Corporation
DOD Model MEP-017A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Formerly, Onan Model 5GF-8XR/3100 and Military Design
Model SF-5.-MD
Part Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MERDC 13211E6695
National stock number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6115-00-017-8240, formerly 6115-00-074-8830
Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MIL-G-52279C, formerly MIL-G-52279-B(ME)
Contract number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA11-184-AMC-71
Serial number range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EA-63-00001 through EA-63-06500
Contract number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA23-195-AMC-00432
Serial number range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EA-66-00001 through EA-66-05242
Contract number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DAAK01-67-C-0899
Serial number range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EA-67-01001 through EA-67-06000
Contract number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DAAK01-68-C-8051
Serial number range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EA-68-00001 through EA-68-09129
Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fermont Division of Dynamics Corporation of America
DOD Model MEP-017A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Formerly, Fermont Model J-117 and Military Design Model SF5.-MD
Part number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MERDC 13211E6695
National stock number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6115-00-017-8240, formerly 6115-00-999-7291
Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MIL-G-52279C, formerly MIL-G-55279-B(ME)
Contract number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA-23-195-AMC-00201
Serial number range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FA-65-00001 through FA-65-01469
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
FA-66-00001 through FA-66-01200
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
FA-67-00001 through FA-67-01469
2. Generator Set, 400 HZ, Unit, NSN 6115-00-017-8241.
Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Onan, Division of Studebaker Corporation
DOD Model MEP-022A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
Formerly, Onan Model 5GFE-408XR/3101A and
Military Design Model HS-5.-MD
Part number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MERDC 13212E8925
National stock number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6115-00-017-8241, formerly 6115-00-930-4816
Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MIL-F-52279C, formerly MIL-G-52419 (MO)
Contract number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA-23-195-AMC-00738
Serial number range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EB-66-00001 through EB-66-00392
1-9
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
Contract number . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Serial number range . . . . . . . . . . . . . . . . . . . . . . . . .
DAAK01-68C-8051
EB-68-00001 through EB-68-00290
3. Generator Assembly, 60 Hertz (Model MEP-017A)
Voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Amperes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Kilowatts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Kilovolt amperes . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hertz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Phases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
120/240 1 phase or120/208 3phase
52 at 120 volts, 1 phase; 26 at 240 volts, 1 phase;
30/17.3 at 120-208 volts, 3 phase, 3 wire; and 30 at 120
volts, 3 phase, 4 wire
5
6.25
60
0.8
1 and 3
3,600
4. Generator Assembly, 400 Hertz (Model MEP-022A).
120/240 1 phase or 120/208 3 phase
52 at 120 volts, 1 phase; 26 at 240 volts, 1 phase;
30/17.3 at 120/208 volts, 3 phase 3 wire; and 30 at 120
volts, 3 phase, 4 wire
Kilowatts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
6.25
Kilovolt amperes . . . . . . . . . . . . . . . . . . . . . . . . . . . .
400
Hertz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.8
1 and 3
Phases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3,428 (approximately)
RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Amperes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5. Wiring Diagram. Refer to figure 1-6.
1-10
Change 6
Figure 1-6.
1-11
TM 5-6115-332-14
P-8-614-14
35C2-3-424-1
TO
CHANGE 6
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
FIGURE 1-7 PANEL "A" WIRING DIAGRAM (MEP-017A)
1-12
Change 4
M 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
Table 1-2. Direct Support and General Support Tabulated Data
1. Generator Classification and Rating. (Model MEP-017A and Model MEP-022A).
Rating, voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
120/240 1 phase 120/280 3 phase
Amperage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 at 120 volts, 1 phase 26 at 240 volts, 1-phase
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30/17.3 at 120/208 volts, 3 phase
Rating, kva (kilovolt amperes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.25
Rating, kw (kilowatts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Hertz = cycles per second: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Model MEP-017A -60
.............................................................................................................................
Model-022A -400
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Model MEP-022A -400
Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 and 3
Power factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.8
Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Direct
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. ... . . . . . . . . . . . . . . . . . . . . . Fan
2. Torque Data.
Generator rotor drive disk mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
90 to 110 in.- lb 16074-19646 cm
Exciter rotor mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
90 to 110 in.- lb 16074-19646 cm
Exciter diode rectifiers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12 to 15 in.- lb 2143.2-2679 cm
Exciter pole mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30 to 34 in.-lb 5358-6072.4 cm
Generator housing-to-flywheel
housing adapter mounting
bolts (Model MEP-022A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18 to 22 ft.-lb 2.5-3.0 kgm
Rotor-to-fan hub adapter mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18 to 22 ft.-lb. 2.5-3.0 kgm
Rotor drive disk-to-fan hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
adapter mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18 to 22 ft.-lb 2.5-3.0 kgm
Generator housing mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 to 22 ft.-lb 2.5-3.0 kgm
Fan mounting bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14 to 16 ft.-lb 1.9-2.2 kgm
1-11. Differences Between Models
This manual covers the DOD Model MEP-017A
and DOD Model MEP-022A generator sets. Where
differences exist, each model is covered separately
in the applicable portions of this manual.
1-13
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
CHAPTER 2
Section I.
OPERATING PROCEDURES
2-1. Controls and Instruments
a. General. This section describes the various
controls and instruments and provides the operator
with sufficient information to ensure proper operation of the generator set. All controls and instruments are identical on both the Model MEP-017A
and the Model MEP-022A generator sets, with the
single exception of the frequency meters. Although
both of these are similar in the external appearance
and are mounted in the same location, they are calibrated differently. The two frequency meters are
covered separately within the controls and instruments paragraph.
b. Controls and Instruments. The generator
controls and instruments and their normal reading
are illustrated in figures 2-1, 2-2, 2-3, 2-4, 2-5 and 26. Refer to table 2-1 for the model applicability and
use of the various controls and instruments required for proper operation of the generator set.
(1) Fuel Selector Valve. The fuel selector
valve (fig. 2-1) is a four-position rotary-type valve
located at the right side immediately behind the
engine.
2-1
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
TS 6115-332-14/2-1
Figure 2-1. Fuel selector valve.
2-2
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
(2) Choke Control. The choke control (fig. 22) is a pull-type control located at the top center of
the engine next to the engine governor.
TS 5 6115-332-14/2-2
Figure 2-2. Choke control, governor control, and air cleaner intake shutter.
(3) Governor Control. The governor control
(fig. 2-2) is a sliding, friction-lock type control located at the top center of the engine next to the engine governor.
(4) Air Cleaner Intake Shutter. The air intake shutter (fig. 2-2) is a sliding-type control, located in the bottom front of the air cleaner.
2-3
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
(5) Oil Pan Baffle Rod (fig. 2-7). The oil pan
baffle rod is a rotating- type control located at the
lower right side near the rear of the engine. It
should be positioned toward the rear of the engine
when ambient tmeperature is 0°F (-17.8°C) or
above. It should be positioned toward the front of
the engine when the ambient temperature is below
0°F (17.8°C). (Refer to figure 2-7).
(6) Panel Lights Switch. A two-position toggle switch (fig. 2-3) located at the top center of the
control panel.
TS 6115-332-14/2-3
Figure 2-3. Generator control panel, controls, instruments, and panel lights.
2-4
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
(7) Remote-Local Switch. The remote-local
switch (fig. 2-3) is a two- position toggle switch located slightly left of center in the upper part of the
control panel.
(8) Emergency Run-Stop Switch. The emergency stop-run switch (fig. 2-3) is a three-position
toggle switch, located at the left center of the control panel.
(9) Start-Stop Switch. The start-stop switch
(fig. 2-3) is a three- position, momentary-type toggle switch that is located left of center at the bottom of the control panel.
(10) Oil Pressure Indicator. The oil pressure
indicator (fig. 2-3) is calibrated from 0 to 60 psi and
is located at the left center of the control panel. The
normal readings range from 20 psi at approximately
1/4 rated speed to a maximum of 60 psi at rated governed speed.
(11) Time Totalizing Meter. The time totalizing meter (fig. 2-3) is located at the upper left corner of the control panel.
(12) Battery Charging Ammeter. The battery charging ammeter (fig. 2-3) is located at the
lower left corner of the control panel. The instrument is calibrated from 0 to +15 and 0 to -15 amperes. When the battery is fully charged and the
unit is operating, the ammeter needle should normally rest at a position slightly on the + side of 0.
(13) Output Selector Switch. The output selector switch (fig. 2-4) is a four-position rotary-type
switch located inside the control box near the central right side of the control box.
2-5
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
TS
Figure 2-4. Output selector switch.
(14) Field Flash Switch. The field flash
switch (fig. 2-5) a two position momentary-type toggle switch and is located inside the control box near
the control left side.
2-6
5-6115-332-14/2-4
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
TS
6115-332-14/2-5
Figure 2-5. Generator fIeld flash switch.
Voltage Selector Switch.
The voltage selector switch (fig. 2-3) a
six-position, rotary-type, switch is
located slightly to the right of center
in the upper part of the control panel.
The voltages indicated should be as
shown in Table 2-2 for the appropriate
position of the output selector switch.
(15)
(16) Voltmeter. The voltmeter
(fig. 2-3) is located in the upper right
corner of the control panel.
The
voltmeter is calibrated for 0 to 250
volts and is redlined at 240 volts, a
value that should not be exceeded.
2-7
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
(17) Voltage Adjusting Rheostat. The voltage adjusting rheostat (fig. 2-3) is located just to
the right of the center of the control panel. To increase the voltage turn the control clockwise to decrease the voltage turn the control counterclockwise.
(18) Circuit Breaker. The circuit breaker
(fig. 2-3) is located to the right of the upper part of
the control panel. It is a two position, toggle-type
control.
(19) Ammeter Phase Selector Switch. The
ammeter phase selector switch (fig. 2-3), a threeposition rotary-type switch, is located to the right of
center in the lower part of the control panel.
(20) Current Indicator Meter. The current
indicator meter (fig. 2-3) is located in the lower
right corner of the control panel. It is calibrated
from 0 to 125 percent. The scale is redlined in that
scale area above 100 percent. The scale is also
marked with aline at the 80 percent position that is
marked 100 percent at 1.0 power factor (unity).
(21) Frequency Meter (Model MEP017A). The frequency meter (fig. 2-3) is located at
the right center of the control panel. The scale of
the meter is graduated from 55 to 65 cycles per second (Hertz).
(22) Frequency Meter (Model MEP022A). The frequency meter (fig. 2-6) is located at
the right center of the control panel. The scale of
the meter is graduated from 380 to 420 cycles per
second (Hertz).
TS 6115-332-14/2-6
Figure 2-6. Generator frequency meter, (Model MEP-022A).
2-8
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
Table 2-1. Controls and Instruments
NOMENCLATURE
DOD MODEL
USE
Fuel Selector Valve
All
To turn fuel supply off,
or to select between an
external fuel supply and the
fuel can located on unit.
Choke Control
All
To choke the engine during
starts made when the
engine is cold.
Governor Control
All
To control the governor
for starting and operation.
Air Cleaner Intake Shutter
All
Oil Pan Baffle Rod
All
To provide preheated air
to the carburetor when the
ambient temperature falls
below 25ºF. (-3.9°C).
Controls the flow of cooling air to the oil pan.
Panel Lights Switch
All
Control operation of the
panel lights.
Remote - Local Switch
All
To switch the unit into
either the LOCAL or REMOTE
mode of operation.
Emergency Run-Stop Switch
All
To put the engine safety
controls in or out of
circuit and also to provide for stopping the
unit when under emergency
conditions.
Start-Stop Switch
All
To stop or start the
engine when the unit is
in the local mode of
operation.
Oil Pressure Indicator
All
Indicates the engine oil
pressure.
Time Totalizing Meter
All
Indicates the total engine
running time in hours and
tenths of an hour.
2-9
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
Table 2-1. Controls and Instruments
(Cont’d)
NOMENCLATURE
DOD MODEL
USE
Battery Charging Ammeter
All
Indicates the battery
charging rate.
Output Selector Switch
All
To reconnect the generator
phase windings to provide
the different output
characteristics.
Field Flash Switch
All
To flash the generator
field momentarily with
battery current.
Voltage Selector Switch
All
To select the phase winding on which a voltage
reading is wanted.
Voltmeter
All
Indicates the voltage of
the generator phase that
has been selected using the
voltage selector switch.
Voltage Adjusting Rheostat
All
To increase or decrease
the voltage.
Circuit Breaker
All
To connect and disconnect
the load.
Ammeter Phase Selector Switch
All
To select the phase of
the generator on which a
current reading is wanted.
The indication will be
shown on the current
indicator meter.
Current Indicator Meter
All
Indicates the current in
the generator phase that
has been selected using
the ammeter phase selector
switch.
Frequency Meter
MEP-017A
Indicates the frequency
of the generated power.
Frequency Meter
MEP-022A
Indicates the frequency
of the generated power,
2-10
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424.1
Table 2-2. Voltmeter Indications
NOTE
The voltages listed in the VOLTMETER INDICATION column are intended to
be read only from the generator set voltmeter. Any voltage reading below the 50
volt mark (in the suppressed portion of the meter) is listed in Table 2-2 as Zero.
Using any voltage indication except Zero below the 50 volt mark will result in
false readings.
OUTPUT
SELECTOR SWITCH
VOLTAGE
SELECTOR SWITCH
VOLTMETER
INDICATION
240 Volt 1 Phase
2 Wire L2 L3
V0-1
V0-2
V0-3
V1-3
V1-2
V2-3
Zero
60-70
60-70
60-70
60-70
240
120 Volt 1 Phase
2 Wire L2 L3
V0-1
V0-2
VO-3
V1-3
V1-2
V2-3
Zero
Zero
Zero
Zero
Zero
117
120 Volt 3 Phase
3 Wire L1 L2 L3
V0-1
V0-2
V0-3
V1-3
V1-2
V2-3
60-70
60-70
60-70
117
117
117
102/208 Volt 3 Phase
4 Wire L0 L1 L2 L3
V0-1
V0-2
V0-3
V1-3
V1-2
V2-3
117
117
117
208
208
208
Change 5
2-10.1/(2-10.2 blank)
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P-8-614-14
TO 35C2-3-424-1
2-2. Operations Under Usual Conditions
a. General.
CAUTION
Do not operate at idle speed. At idle speed,
frequency drops below 60Hz, exciter field
voltage increases, thereby causing voltage
regulator to operate at maximum output.
This causes overloading of power
transistor.
(1) The instructions in this paragraph are for the
information and guidance of the personnel that are
responsible for the operation of the generator set.
(2) The operator must know how to perform
every operation of which the generator set is capable.
This section contains instructions on starting and
stopping the generator set, on operation of the
generator set, and on co-ordinating the basic motions
to perform the specific tasks for which the equipment
is designed.
(c) The generator set must be grounded prior
to operation. The ground can be in order of preference
an underground metallic water pipe system, a driven
metal rod or a buried metal plate. A ground rod must
have a minimum diameter of 5/8 inch if solid or ¾ inch
if pipe; and must be driven to a minimum depth of 8
feet. A ground plate must have a minimum area of 9
square feet and be buried at a minimum depth of 4
feet. The ground lead must be copper wire, minimum
size no. 6 AWG (American Wire Gage), which should
be bolted or clamped to the rod, plate, or piping
system and to the generator ground terminal stud (fig.
1-1 or 1-3).
Do not operate the generator set until the
ground stud terminal has been connected
to suitable ground. Electrical faults in the
generator set, load lines, or load equipment
can cause death by electrocution from contact with an ungrounded system.
b. Starting.
(1) Preparation for Starting.
(a) Perform the daily preventive maintenance
services (para. 3-6).
(b) If an auxiliary fuel source is to be used, connect the auxiliary fuel line.
(d) Select the proper voltage output to meet
load requirements and connect the proper load cables.
(e) Position circuit breaker in OFF position.
(2). Electric Starting (Local). Refer to figure 2-7
for local mode electric starting instructions.
Change 6
2-11
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P-8-614-14
TO 35C2-3-424-1
Figure 2-7. Electric starting instructions, local made.
2-12
Change 6
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
(3) Manual Starting.
Serious eye injury can result from the
starter rope knot. Wear eye protection
when pull starting engine.
Refer to figure 2-8 for manual starting instructions.
Change 6
2-13
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P-8-614-14
TO 35C2-3-424-1
Figure 2-8. Manual starting instructions.
2-14
Change 6
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P-8-614-14
TO 35C2-3-424-1
STEP 5. POSITION REMOTE-LOCAL SWITCH
IN LOCAL POSITION.
STEP 6. POSITION EMERGENCY RUN-STOP
SWITCH TO EMERGENCY RUN POSITION.
STEP 7. POSITION CHOKE CONTROL ABOUT
¾ CLOSED.
Serious eye injury can result from the
starter rope knot. Wear eye protection
when pull starting engine.
STEP 8. TAKE ONE QUICK STEADY PULL
WITH THE STARTER ROPE. IF THE
ENGINE DOES NOT START, CLOSE
CHOKE ALL THE WAY. PULL
STARTER ROPE UNTIL ENGINE
STARTS.
STEP 9.
WHEN ENGINE OIL PRESSURE
REACHES OPERATING PRESSURE,
PLACE EMERGENCY RUN-STOP
SWITCH TO NORMAL POSITION. AT
THE SAME TIME, MOMENTARILY
PLACE THE START-STOP SWITCH
TO THE START POSITION.
If the engine was started in the
START/IDLE position, bring the engine to
the governed speed as soon as possible.
Idling can damage the voltage regulator.
STEP 10. ADJUST CHOKE CONTROL AS NECESSARY AS ENGINE WARMS UP.
STEP 11. POSITION GOVERNOR CONTROL IN
GOVERN/RUN POSITION. BRING TO
RATED SPEED AND WARM UP FOR
THREE MINUTES.
Figure 2-8. Manual starting instructions.
Change 6
2-14.1/(2-14.2 blank)
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
(4) Remote Mode Starting. The remote control terminal board (fig. 2-9) is located on the right
rear of the control box. It provides the connection
points required for starting and stopping the generator set from a remote position.
TS 6115-332-14/2-9
Figure 2-9. Remote control terminals.
(a) Position the REMOTE-LOCAL switch
(fig. 2-7) in the REMOTE position.
(b) To start the generator set from a remote positon, make contact between the start terminal and the common terminal of the remote control terminal board (fig. 2-9). As soon as the unit
starts, break contact.
(5) Cold Weather Starting. When the ambient temperature is -25°F (-31.7°C) and below it will
be necessary to preheat the engine using a blowtorch (see para. 2-4). After preheating the engine,
proceed with electrical or manual starting as outlined in (2) and (3), above.
c. Stopping.
(1) Local Mode Stopping. Refer to figure 210 for local mode stopping instructions.
2-15
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
Figure 2-10. Stopping instructions, local mode.
2-16
Change 3
TS 6115-332-14/2-10
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
(2) Remote Mode Stopping. To stop the generator set from a remote position, make contact between the stop terminal and common terminal of
the remote control terminal board (fig. 2-9). A soon
as the unit stops, break contact.
d. Operation of Equipment.
(1) General. When the unit is operating and
is connected to a load the generator normally operates at the selected voltage, a value that will be indicated by the voltmeter. The operator must be observant of the generator set, pay particular
attention to any unusual sounds that may indicate
malfunction. In case of such an event, stop the unit
and report the condition to organizational maintenance.
(2) Operation.
(a) Start the engine (para. 2-2b).
(b) Adjust the governor to achieve a reading
of 60 Hz on the model MEP-017A unit or a reading
of 400 Hz on the model MEP-022A unit (fig. 2-12).
(c) Observe the voltmeter (fig. 2-3). Turn
the knob of the voltage adjusting rheostat (fig. 2-3).
if necessary, until the proper voltage is attained, as
indicated by the voltmeter.
Section II.
NOTE
If voltage does not build up. exercising care not to
touch electrical contacts, momentarily depress the
field flash switch (fig.2-5).
(d) Position the circuit breaker (fig. 2-3) in
the ON position.
(e) Again, observe the voltmeter and adjust
the voltage adjusting rheostat to attain the proper
voltage, if necessary.
(f) Position the ammeter phase selector
switch (fig. 2-3) in each of the three positions in
turn, and at the same time observe the current indicator meter (fig. 2-3). The meter should not give an
indication greater than 100% in any phase with any
type load. With a straight, resistive load, such as incandescent lighting, it should not exceed 80% (100%
at 1.0 power factor). If the meter indicates a load
greater than these values in any phase, reduce the
load. Balance the load on each of the three phases, if
possible.
(g) Position the voltage selector switch
(fig. 2-3) in each of the six positions, in turn, and obtain a voltmeter reading in each of the six positions.
NOTE
If the voltage drops under load, the voltage regulator is defective. Report the condition to or
ganizational maintenance.
OPERATION OF AUXILIARY EQUIPMENT
2-3. General
A blowtorch that is specifically designed for preheating the engine is available for issue. It is normally to be used at temperatures below -25°F
(-31.7°C). Refer to paragraph 2-4 for the operating
instructions and special precautions that apply to
the use of the blowtorch.
2-4. Blowtorch
a. Description. The blowtorch is a multifuel
pump-type torch. It has a fuel capacity of one pint.
It is used to preheat the engine crankcase, cylinder
heads, intake manifold, and aid intake preheater.
CAUTION
When using a torch for preheating,
play the flame back and forth. Do not
hold the flame in any one spot. Keep
heat and flame away from nonmetallic parts. When cranking with
the starter, do not crank longer than 8
seconds. Allow 2 minutes for the
starter to cool, between cranking
periods.
b. Operation and Service. For blowtorch operation and service instructions, refer to figure 2-11.
NOTE
Play the flame back and forth over the cylinder
heads and intake manifold, briefly, then play the
flame over the air intake preheater for 1 or 2
minutes. While still applying heat, crank the engine. If the engine fails to start after several tries,
apply heat to the drive end of the magnets briefly
and then to the exposed surfaces of the oil pan for
about 5 minutes. Extended cranking with the choke
“closed’” will cause flooding of the engine. If this
happens, remove, dry and reinstall the spark plugs.
Change 5
2-17
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
TS 6115-332-14/2-11
Figure 2-11. Blowtorch operation and service instructions.
2-18
FIG. 2-3
TABLE 2-3
TABLE 2-3
Figure 2-12. Governor Adjustment Procedures
Table 2-3. Engine Speed/Frequency
2-18.1/(2-18.2 blank)
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
Section III.
OPERATION UNDER UNUSUAL CONDITIONS
2-5. Operation in Extreme Cold (Below
O°F) (-17.8°C)
a. General. The generator sets are designed to
operate at temperatures as low as -65°F (-53.8°C).
To operate the unit at temperatures below 0°F, position the air cleaner intake shutter (fig. 2-7) in the
WINTER position and move the oil pan baffle rod
(fig. 2-7) to the position toward the front of the engine,
b. Engine Preheating. When the ambient temperature is -25°F (-31.7°C) and below, preheat the
engine. For instructions on preheating the engine
using a blowtorch, refer to paragraph 2-4.
c. Lubrication. The generator does not require
lubrication. For engine lubrication instructions
refer to LO 5-2805-258-12 and TM 5-2805-258-14.
Additionally, lubricate the ball joints at each end of
the throttle control rod with a light oil suitable for
use at 0°F to -65°F; order NSN 9150-00-257-5449,
MIL-L-10295.
d. Battery. Keep the battery fully charged.
After adding water to the battery, charge the battery by external means or by running the engine for
a period of at least one hour.
e. Fuel System. When not in operation, keep
fuel supply cans or other containers full to prevent
condensation of moisture. Be careful to prevent ice,
snow, and moisture from entering the fuel system.
Accumulated moisture will freeze and clog the system. Inspect the fuel filter for accumulated moisture after each operating period and if any is found,
service the fuel filter. Refer to TM 5-2805-258-14
for service instructions.
f. Electrical Systems. Keep wiring and electrical components free of ice, snow, and moisture.
g. Operation. Allow the engine to warm thoroughly before applying load.
h. Protection. Provide as much protection for
the equipment as is practical, at all times. When the
equipment is not in use, cover it with canvas or
other protective covering.
2-6. Operation in Extreme Heat
a. General. When operating the equipment at a
time when ambient temperatures are high, efficient
cooling and adequate lubrication are vitally important.
b. Cooling. Provide maximum ventilation at all
times. Keep the equipment clean, paying particular
attention to the engine shrouds and cooling fins and
the generator blower cover. See that all air passages
are free of obstructions. Make certain the air
cleaner shutter (fig. 2-7) is in the SUMMER position and that the oil pan baffle rod (fig. 2-7) has
been moved to the position toward the rear of the
engine.
c. Operation. Do not load the generator beyond
its rated capacity. If possible, keep the generator
load to a minimum. Make frequent meter readings
to detect any overload. If an overload is indicated,
reduce the load or stop the unit and take corrective
action.
d. Battery. The water in the electrolyte evaporates during normal battery use. At high temperatures, the loss of water is accelerated. Inspect
the electrolyte level more frequently and add water
as required to maintain the water level above
plates.
CAUTION
Disturb wiring as little as possible
during cold weather. Insulation on
wiring becomes brittle when cold and
will break easily.
2-7. Operation in Dusty or Sandy
Areas
a. General. When the unit is operated in dusty
or sandy areas, take special precautions to keep the
unit. clean and adequately lubricated.
b. Fuel System. Use care to prevent dust and
sand from entering the fuel system. Inspect the fuel
filter after each operating period. Refer to TM 52805-258-14 for filter service instructions.
2-19
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
c. Lubrication. For engine lubrication instructions
refer to LO 5-2805-258-12 and TM 5-2805-258-14. (F)
Air force personnel refer to the lubrication section of
application TO 35C2-3-1-426 WC-Series Workcards.
d. Air Cleaner. When the equipment is being
operated, observe the air cleaner restriction indicator
frequently. Service the air cleaner when the indicator
shows red. Refer to TM 5-2805-258-14 for air cleaner
service instructions.
e. Protection. At all times, provide as much protection for the equipment as is practical. Take advantage, if possible, of natural barriers or erect an improvised barrier. When it is not in use, cover the unit
with canvas or other protective covering.
2-8. Operation Under Rainy or Humid Conditions
a. Fuel System. Use care to prevent moisture from
entering the fuel system. Inspect the fuel filter for accumulated moisture after each period of operation.
Refer to TM 5-2805-258-14 for filter service
instructions.
b. Lubrication. (F) Air Force personnel refer to the
lubrication section of applicable TO 35C2-3-1-426 WCSeries Workcards.
c. Electrical System. Keep electrical system components and wiring clean and dry, to prevent corrosion, deterioration, and short circuits.
d. Protection. At all times, provide as much protection for the equipment as is practical. When the
unit is not in use, cover it with canvas or other protective covering. During dry periods, remove the cover
long enough to allow all the equipment to dry
thoroughly.
2-9. Operation in Salt Water Areas
a. General. Wash the equipment frequently with
fresh water and follow the instructions in paragraph
2-8. Protect electrical components when washing.
b. Protection. Coat exposed metal parts with
general purpose grease, MIL-G-10924
2-20
Change 6
2-10. Operation at High Altitudes
The generator sets are rated 5KW at altitudes up
to 5,000 feet (1525m) and are rated 4KW at an altitude
of 8,000 feet (2438m). To calculate the usable output
rating for an altitude above 8,000 feet (2438m) use the
following formula:
6% x (actual altitude – 5,000)x 5KW = derating factor
1,000
5KW – derating factor = Usable output
EXAMPLE: Solution for 10,000 ft (3048 m).
6% X (10,000 – 5,000)x 5KW = derating factor
1,000
0.06 x 5 x 5KW = derating factor = 1.5KW
5KW – 1.5KW = 3.5KW (Usable output at
10,000 ft. (3048 m) altitude.
2-11. Operation Using NATO Slave Cable
The existing Army Slave Cable has end connectors
with two pins to mate with the Slave Receptacle on
the Generator Set (fig. 1-1). The NATO Slave Cable
has end connectors with one pin. In order to utilize the
NATO Slave Cable on the Generator Set, an Adapter
Connector must be used. See Additional Authorization List (AAL) for Adapter Connector.
Before you use any cable, make sure the
master battery switches and all electrical
switches in both the live and dead equipment are in the OFF position. If you attempt to install the cable into live
operating equipment, arcing can occur.
You can get burned and your cable will be
damaged.
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
CHAPTER 3
OPERATOR/CREW MAINTENANCE INSTRUCTIONS
Section I.
CONSUMABLE OPERATING AND MAINTENANCE SUPPLIES
3-1. General
This section contains the consumable maintenance and operating supplies required to operate
and maintain the generator set. Refer to Table 3-1.
3-2. Explanation of Columns in the
Tabular List of Consumable
Maintenance and Operating Supplies
a. Component Application. This column identifies the component application of each maintenance or operating supply item.
b. National Stock Number. This column indicates the National Stock Number assigned to the
item and will be used for requisitioning purposes.
c. Description. This column indicates the item
name and brief description.
d. Quantity Required for Initial Operation. This column indicates the quantity of each
maintenance or operating supply item required for
initial operation of the equipment.
e. Quantity Required for Eight Hours Operation. This column indicates the estimated quantities required for an average 8 hours of operation.
f. Notes. This column indicates informative
notes keyed to data appearing in a preceding
column.
3-1
TM 5-6115-332-14
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TO 35C2-3-424-1
Table 3-1. Consumable Maintenance and Operating Supplies
(2)
(1)
(3)
National
stock number
Component
application
Description
(4)
(5)
(6)
Quantity
required
F/initial
operation
Quantity
required
F/8 hrs
operation
Notes
PROTECTIVE MATERIAL
GENERATOR
SET (1)
GREASE, ALL PURPOSE
MIL-G-10924
FUEL SYSTEM
GASOLINE, AUTOMOTIVE:
5 gal (19 liters) pail, as follows:
FUEL TANK
(can)
9130-00-160-1817
91A (2)
5 gal (4)
(19 liters)
10.72
gal (5)
(40.7
liters)
9130-00-160-1831
91C
5 gal (4)
(19 liters)
10.72
gal (5)
(40.7
liters)
CLEANING SOLVENT
GENERATOR
SET (5)
6850-00-274-5421
3 - 2 Change 5
CLEANING SOLVENT,
5 gal (19 liters)
(1) To be used to
coat exposed metal
parts.
(2)
For
temperature above
30°F.
(3) Average fuel
consumption is
1.34 gph (5.1 liters)
in
continuous
operation.
(4)
For
temperatures consistently below 32°F.
(5) As required for
cleaning purposes.
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
Section II.
LUBRICATION INSTRUCTIONS
3-3. General
a. The generator is equipped with a sealed bearing
that does not require lubrication.
b. (F) Air Force personnel refer to the lubrication
section of applicable TO 35C2-3-1-426 WC-Series
Workcards.
Section III.
3-4. Detailed Lubrication Information
Refer to TM 5-2805-258-14 for detailed lubrication
instructions covering the 10 hp MIL-STD Engine.
PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
3-5. General
To insure the generator is ready for operation at all
times, it must be inspected systematically so that
defects may be discovered and corrected before they
result in serious damage or failure. The necessary
preventive maintenance services will be performed
before operation. Defects discovered during operation
will be noted for future correction, to be made as soon
as operation has ceased. Stop operation immediately
if a deficiency is noted during operation that would
damage the equipment if operation were continued.
All deficiencies and shortcomings will be recorded,
together with the corrective action taken on the applicable form, at the earliest possible opportunity.
Marine Corps users should refer to current issue of
TM 11275-15/1.
3-6. Operator’s Preventive Maintenance Checks and
Services
Tables 3-2 list the preventive Checks and Services
which must be performed by the operator in the intervals and sequence indicated.
Class I
Seepage of fluid (as indicated by
wetness or discoloration) not great
enough to form drops.
Class II
Leakage of fluid great enough to form
drops but not enough to cause drops
to drip from item being checked/
inspected.
Class 11:
Leakage of fluid great enough to form
drops that fall from the item being
checked/inspected.
Equipment operation is allowable with
minor leakages (Class I or II). Of course,
you must consider the fluid capacity in the
item/system being checked/inspected.
When in doubt, notify your supervisor.
When operating with Class I or Class II
leaks, continue to check fluid levels as required in your PMCS.
NOTE
Leakage definitions for operator/crew
PMCS shall be classified as follows:
Change 6 3 - 3
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TO 35C2-3-424-1
Table 3-2. OPERATOR/CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES
B-BEFORE OPERATION
D-DURING OPERATION
INTERVAL
ITEM
NO.
B
1
•
D
A-AFTER OPERATION
A
ITEM
TO BE
INSPECTED
PROCEDURES
CHECK FOR HAVE REPAIRED
OR ADJUSTED AS NECESSARY
•
Generator Set
a. Visually inspect the generator set for
fuel and oil leaks
b. Check engine oil level. Add od as
necessary.
c. Check for proper ground connection.
•
•
•
d. .Inspect for loose, damaged, or missing
parts and unusual wear or deterioration
Clean unit as necessary.
•
e. Insure load terminal wires are tightened
f. Check battery for tight terminals and
missing parts.
•
•
•
•
g. Visually inspect all controls for serviceability before starting generator
•
EQUIPMENT IS
NOT READY/
AVAILABLE IF:
Class III oil or Class I
fuel leak is detected.
Generator is not properly grounded.
Any loose, damaged.
or missing parts: (i.e.,
spark plugs, manifolds, starter, or other
items).
Loose load terminal
wires.
Unserviceable or loose
battery terminals and
missing parts.
Loose wire connections or broken meter
glass.
h. Inspect for cracked or broken welds.
NOTE
Start generator after visual PMCS; insure generator operates as stated in paragraph 2-1.
2
•
3-4 Change 10
Controls and
Instruments
a. Frequency
Instruments shall indicate within specifled limits (para 2-1).
60/400 Hz
Fequency cannot be
properly adjusted.
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
Section IV.
TROUBLESHOOTING
3-7. General
a. 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 you to determine probable causes and
corrective actions to take. You should perform the
tests/inspections and corrective actions in the order
listed.
b. This manual cannot list all malfunctions that
may occur, nor all tests or inspections and corrective
actions. If a malfunction is not listed or cannot be corrected by listed corrective actions, notify organizational maintenance personnel.
3-8. Operator’s Troubleshooting
Refer to table 3-4 for troubleshooting procedures.
NOTE
Before you use this table, be sure you have
performed all applicable operating checks.
3-5
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P-8-614-14
TO 35C2-3-424-1
Table 3-4. Troubleshooting
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
1. STARTER FAILS TO CRANK ENGINE OR CRANKS TOO SLOWLY
Step 1.
Check to see if the remote-local switch is in the wrong position. Refer to figure 2-3.
If the switch is in the wrong position, simply push it to the desired mode of operation (local
or remote). If switch is already in the correct mode of operation, go on to Step 2.
Step 2.
Check visually for built up corrosion on battery terminals. Move cables slightly to see if they are
loose. Refer to fig. 3-1 and tighten connections.
Low Battery
Refer to paragraph 2-2, figures 2-7 and 2-8.
Slave receptacle is to be used when extra cranking power is required for starting unit.
Other methods are not authorized!
Be sure that wire brush does not short across terminals or from positive terminal to
ground.
If corrosion is present use a soda and water solution to remove the corrosion, then
clean terminals with a wire brush.
Step
3.
Check K4 relay (fig. 1-7) and/or receptacle for broken wiring or loose connections.
Report to organizational maintenance.
3-6
Change 6
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P-8-614-14
TO 35C2-3-424-1
Table
3-4.
Troubleshooting
(Cont'd)
Figure 3-1. Battery cables, starter cable and grommet, and terminal stud.
Change 4 3 - 7
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
Table 3-4. Troubleshooting (Cont'd)
Malfunction
Test or Inspection
Corrective Action
2. GENERATOR FAILS TO SUPPLY POWER TO LOAD
Step 1.
Check for low generator field by depressing and then releasing the field flash switch, figure 2-5.
If the cause indicates that the generator field is not built up, depressing the switch could resolve the
malfunction. Depressing the switch will flash the generator field momentarily with battery current.
If this does not resolve the problem, go to Step 2.
Step 2.
Check for a load cable that is burned, has broken strands, or has insulation worn away. Location will depend upon
the external source it is connected to.
If cable is burned, broken, or has no insulation, report the deficiency to organizational
maintenance.
3. VOLTMETER FAILS TO SHOW VOLTAGE
Step 1.
Check for a broken dial and bent indicator. Refer to figure 2-3 for location of the voltmeter.
If the voltmeter has broken dial and bent indicator, refer to organizational maintenance for replacement. The operator, not knowing if the voltmeter is the cause of the malfunction, should go on to
Step 2 and isolate another or the only cause of the malfunction.
Step 2.
If voltmeter is not visually damaged, check for an out-of-adjustment voltage adjusting rheostat which could indicate low or no voltage on the meter.
To correct the above, turn the knob on the rheostat (fig. 2-3) until the proper voltage is attained, as
indicated by the voltmeter. If voltage does not build up go on to Step 3.
Step 3.
If the generator does not build up, check the field flash switch (fig. 2-5).
Momentarily depress the field flash switch. The action could correct the malfunction by flashing
the generator field momentarily with battery current. If malfunction is still not corrected, the problem should be reported to organizational maintenance.
4. GENERATOR FAILS TO BUILD UP RATED VOLTAGE
Check the generator field build up by depressing the field flash switch (fig. 2-5).
This action could correct the problem by flashing the generator field with battery current. If depressing switch doesn’t correct the problem, report to organizational maintenance.
5. VOLTMETER READING TOO HIGH OR TOO LOW
3-8
Step 1.
Check the voltage adjusting rheostat by visually examining position of knob. Refer to figure 2-3. The rheostat is
located just to the right of the center of the control panel.
If the rheostat appears to be in the wrong position, turn it one way first, then turn it the other way.
The voltage should increase when the control is turned clockwise. If this does not correct the voltmeter reading, go on to Step 2.
Step 2.
Refer to figure 2-3 and observe the position of the voltage selector switch. The voltage selector switch is located
slightly to the right of center in the upper part of the control panel.
To correct the problem, move the switch to each position until the voltmeter reading is corrected.
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
Table 3-4. Troubleshooting (Cont'd)
Malfunction
Test or Inspection
Corrective Action
NOTE
The switch may be bent, broken, rusted or immovable. If this is the case, report to organizational maintenance for
replacement.
6.
GENERATOR VOLTAGE DROPS WHEN LOAD IS APPLIED OR INCREASEDl; VOLTAGE
FLUCTUATES
Check to see if generator
tions in turn, and at the
cation greater than 100%
ing, it should not exceed
is overloaded. Position the ammeter phase selector switch (fig. 2-3) in each of the three posisame time observe the current indicator meter (fig. 2-3). The meter should not give an indiin any phase with any type load. With a straight resistive load, such as incandescent light80% (100% at 1.0 power factor).
If the meter indicates a load greater than these values in any phase, reduce the load. Balance the
load on each of the three phases, if possible. Position the voltage selector switch (fig. 2-3) in each of
the six positions, in turn, and obtain a voltmeter reading in each of the six positions.
NOTE
If the voltage drops under load, the voltag regulator is defective. Report the condition to organizational maintenance
7.
NO POWER AVAILABLE AT OUTLET RECEPTACLE (MODEL MEP-017A)
Check to see if the fuse is burned, broken, or cracked. Open the front of the control box by unlocking the five fasteners located near
the top and at the sides of the control panel.
If the fuse has any evidence of the above, replace fuse. Refer to figure 3-2.
3-9
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
Table 3-4. Troubleshooting (Cont'd)
TS6115-332-14/3-2
Figure
3-10
3-2.
Fuses,
removal
and
installation
(MEP-017A).
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
Table 3-4.
Troubleshooting
(Cont'd)
Malfunction
Test or Inspection
Corrective Action
8. GENERATOR OVERHEATS
Step
1.
Check to see if the generator is overloaded. Position the ammeter phase selector switch (fig. 2-3) in each of the
three positions in turn, and at the same time observe the current indicator meter (fig. 2-3). The meter should not
give an indication greater than 100% in any phase with any type load. With a straight resistive load, such as incandescent lighting, it should not exceed 80%, (100% at 1.0 power factor).
If the meter indicates a load greater than the above values in any phase, reduce the load. Balance
the load on each of the three phases, if possible. Position the voltage selector switch (fig. 2-3), in each
of the six positions, in turn, obtain a voltmeter reading in each of the six positions.
NOTE
If the voltage, drops under load, the voltage regulator is defective. Report the condition to organizational maintenance.
If this procedure does not correct the malfunction, go on to Step 2.
Step 2.
Check the shelter where the generator set is located for obstructions that would disrupt air flow. See if there are
outlets for heated air and exhaust fumes.
Even though the generator set is weather resistant, it should be located in an adequate shelter that
will protect it from inclement weather. Provide a shelter that is ventilated to allow heated air and
exhaust fumes to escape. Depending upon the ambient temperature range and upon whether the installation is to be temporary, semi-permanent, or permanent, provide facilities to maintain a reasonable temperature in the area around the unit. If the unit is used in a closed building or other closed
shelter, pipe the exhaust gases to the outside.
9. PANEL LIGHTS FAIL TO LIGHT
Check for a broken filament or corroded socket in the lamp.
If lamp is damaged, as above. replace lamp. Refer to figure 3-3.
3-11
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
Table 3-4. Troubleshooting (Cont'd)
Malfunction
Test or Inspection
Corrective Action
TS 6115-332-14.3-3
Figure 3-3. Panel light lamp, removal and installation.
10. OIL PRESSURE INDICATOR FAILS TO REGISTER OR GIVES LOW READING
Step 1.
Check the crankcase oil level. Refer to LO 5-2805-258-12 for location of crankcase oil fill and level cap.
If oil is low, fill crankcase to full level as stated in LO 5-2805-258-12. If oil is not low, go on to Step 2.
Step 2.
Check the oil pressure indicator for broken dial, bent indicator hand, or bad connections. The oil pressure indicator
(fig. 2-3) is calibrated from 0 to 60 psi (4.2 kg per sq cm). Located at the left center of the control panel, it
indicates the engine oil pressure. The normal readings range from 20 psi (1.4 kg per sq cm) at approximately 1/4
rated speed to a maximum of 60 psi (4.2 kg per sq cm) at rated governed speed.
If the indicator is damaged, as stated above, report to organizational maintenance.
3-12
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
Section V.
OPERATOR/CREW MAINTENANCE INSTRUCTIONS
3-9. General
This section provides maintenance instructions
that apply to the personnel that are responsible for
the oepration of the generator set. Unless otherwise
specified, these instructions apply to both the Model
MEP-017A and the Model MEP-022A generator
sets.
Always shut down the equipment before performing any maintenance
operations on components of the electrical system. Failure to observe this
warning can lead to death by
electrocution.
lzl
3-10. OIL DRAIN ASSEMBLY AND
MUFFLER
a. Inspect oil drain and muffler for cracks, holes
and wear.
b. For replacement,
maintenance.
report to organizational
3-11. Fuel System
a. Inspect fuel can, lines, strap, adapter. and selector valve for damage.
b. For removal and installation of fuel can, refer
to figure 3-4 and the following instructions.
(1) Removal.
(a) Lift locking handle on the fuel can
adapter and remove the fuel can adapter.
(b) Lift clamp to loosen strap and remove
strap from buckle.
(c) Remove fuel can.
(2)
Installation.
Position fuel can in place and secure by
tightening strap. Depress clamp to lock strap in
place.
(b) Place fuel can adapter in tank and secure by depressing locking handle.
(a)
3-13
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
Figure 3-4. Fuel can, removal and installation.
3-12. Electrical System
a. Inspect the battery cable, hold down frame, starter
cable, and slave receptacle for damage.
b. For replacement, report to organizational
maintenance.
3-13. Battery
a. Inspection. Inspect battery for cracks and for
proper electrolyte level.
b. Service.
When servicing the battery, do not
smoke or use an open flame in the
vicinity. Batteries generate a highly
explosive gas.
NOTE
The 6TN and 6TL batteries can be mixed or
matched. However, maintenance-free batteries
cannot be mixed or matched with military
batteries. The 6TN and or the 6TL batteries will
perform properly in hot weather as long as
electrolyte levels are carefully monitored. If the
electrolyte expands and causes the level to rise,
some fluid must be removed. If the level becomes
too low due to evaporation, distilled water may be
3-14
Change 8
used to obtain the proper level. A good grade of
drinking water (excluding mineral waters) may be
used if distilled water is not available.
Electrolyte (NSNs 6810-00-249-9354 and
6810-00–843-1640) have a specific gravity of
1.280 and should be used in these batteries. Do
NOT adjust the electrolyte in wet batteries to a
lower specific gravity.
Remove the battery vent caps and fill each cell of the
battery to the proper level with distilled water. The correct
level is 3/8 inch (0.95 cm) above the plates. Install the vent
caps.
c. Utilize slave receptacle to supply external power
for charging batteries and extra cranking power.
3-14. Control Box Assembly
a. Removal.
(1) Open the front of the control box by unlocking
the five fasteners located near the top and at the sides of the
control panel.
(2) For removal of fuse (Model MEP-017A), refer
to figure 3–2.
(3) For removal of the lamps, refer to figure 3-3.
b. CIeaning. Clean the fuses and the lamps with a
clean, lint free cloth.
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
c. Inspection. Inspect the fuses, lamps, and the
following control box components for breaks, wear,
corrosion, and other defects.
(1) Incandescent lamps (fig. 3-3).
(2) Panel light assembly (fig. 2-3).
(3) Time totalizing meter (fig. 2-3).
(4) Battery charging ammeter (fig. 2-3).
(5) Oil pressure indicator (fig. 2-3).
(6) Toggle switch (fig. 2-3).
(7) Voltage selector switch (fig. 2-3).
(8) Voltage adjusting resistor (fig. 2-3).
(9) Ammeter phase selector switch (fig. 2-3).
(10) AC voltmeter (fig. 2-3).
(11) AC current meter (fig. 2-3).
(12) Frequency indicator (fig. 2-6).
(13) Fuse holder (fig. 3-2).
(14) Circuit breaker (fig. 2-3).
(15) Voltage regulator (fig. 5-2).
(16) Relay panel assembly (fig. 5-1).
(17) Armature relay (fig. 4-32).
(18) Current transformer (fig. 5-1).
(19) Remote control board assembly (fig. 2-9).
(20) Load terminal (fig. 4-35).
(21) Load terminal board assembly (fig. 4-35).
(22) Outlet receptacle (fig. 4-29).
(23) Radio interference suppression capacitor
(fig. 4-20).
(24) Lower and upper vibration mount (fig. 430).
(25) Control box bracket (fig. 4-32).
(26) Control panel assembly (fig. 2-3).
d.
Installation.
(1) Install the lamps, refer to figure 3-3.
(2) Install the fuses, refer to figure 3-2.
(3) Lock the fasteners on the control box, refer
to figure 2-3.
3-15. Generator Assembly
a. Inspection.
(1) Inspect the generator for cracks, breaks,
and other damage.
(2) Inspect the air intake grille (fig. 6-3) for
breaks, tears and wear.
b. Service.
(1) Perform the operator’s preventive mainte-
nance checks and services, Tables 3-2 and 3-3.
(2) Remove all tape and tags, cloth, and other
barrier material.
(3) Correct all deficiencies that are found or
report the condition to organizational maintenance.
3-16. Frame Assembly
a. Inspect the frame guard, lifting bracket,
grounding stud, skid base assembly, toolbox and
plates for wear, cracks, breaks and other damage.
b. If replacement is required, report to organizational maintenance.
3-15
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
CHAPTER 4
ORGANIZATIONAL MAINTENANCE INSTRUCTIONS
Section I.
SERVICE MAINTENANCE INSTRUCTIONS
4-1. Inspecting and Servicing the
Equipment
Inspecting the Equipment.
Inspect the identification
(1)
plate for positive identification of the
generator set.
(2) Make a thorough inspection of
the generator set for any damage that
may have occurred during shipment.
(3) Compare the equipment with the
packing list to make certain that all
items are accounted for and are in
serviceable condition.
(4) Inspect the entire unit carefully for loose and missing hardware.
(5) Turn the engine over by hand
to make certain that all moving parts in
the engine and generator move freely.
(6) Correct all deficiencies. All
deficiencies noted beyond the responsibility of organizational maintenance
shall be reported to Direct Support
maintenance.
b. Servicing the Equipment.
(1) Unit Service.
Perform the weekly,
(a)
monthly, and semi-annual preventive
maintenance services (table 4-2).
(b) Remove all tags and tape,
cloth, and other barrier material.
(A, MC) Lubricate the en(c)
gine of the generator set in accordance
with the instructions in the current
lubrication order for the engine, refer
to TM 5-2805-258-14.
(F) Air Force
personnel refer to the lubrication
section of applicable TO 35C2-3-1-426 WC
Series Workcards.
(d) Correct all deficiencies
that are found or report the condition
to direct support maintenance.
(2) Battery Service.
a.
When servicing the battery, do
not smoke or use an open flame
in the vicinity. Batteries
generate a highly explosive
gas. Use extreme care when
handling electrolyte.
Electrolyte contains sulfuric acid
and will cause severe burns
upon contact with the skin.
If electrolyte comes in contact with the skin, clothing,
or painted surfaces, immediately flush the area with
water to wash away all traces
of acid.
The electrolyte for the
(a)
battery is shipped in a separate container.
When the unit is ready for
operation, unpack the electrolyte,
remove the battery vent caps, and fill
each cell of the battery to the proper
level with electrolyte. The correct
level is 3/8 inch (0.95 cm) above the
plates. Install the vent caps.
(b) Install the battery cables,
making certain that the correct polarity
is observed.
4-2. Installation
a. Procedure.
(1) General. The generator set is
normally shipped from the depot or
supply point in an operationally ready
condition, except that it is drained and
preserved.
Before any attempt is made
to operate the unit, service it.
Pay
particular attention to any attached
Set up the
tags, decals, or notices.
Change 1 4 - 1
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
unit for operation as described in the
subparagraphs that follow:
(2) Site Selection. Consider the
following factors when selecting and
preparing an installation site for the
generator set.
(a) Distance to Load. To reduce transmission line voltage losses,
position the generator set as close as
is reasonably possible to the load.
(b) Shelter. Even though the
generator set is weather resistant, it
should be located in an adequate shelter
that will protect it from inclement
Provide a shelter that will
weather.
protect it from inclement weather.
Provide a shelter that is ventilated to
allow heated air and exhaust fumes to
Depending upon the ambient
escape.
temperature range and upon whether the
installation is to be temporary, semipermanent, or permanent, provide
facilities to maintain a reasonable
temperature in the area around the
If the unit is used in a
unit.
closed building or other closed shelter,
pipe the exhaust gases to the outside.
When a spark arrester is required
installation procedure will be on
instruction sheet furnished with
spark arrester kit located on page
TM 5-6115-332-24P.
The United States Forestry
Service requires that any engine driven equipment operating within National Forests
or Parks be provided with
spark arresters for the avoidance of forest fires.
Do not operate the generator
set in an enclosed building
unless the exhaust gases are
piped to the outside. Exhaust
gases contain carbon monoxide,
a poisonous, odorless, colorless gas.
4-2
Change 1
the
the
the
25,
(c) Access. Provide enough
clearance around the generator set to
facilitate operation and maintenance
activities.
(d) Fuel Supply. Provide an
adequate supply of clean fuel to meet
requirements based on operation time.
Consider installation of the tanks
underground if the installation will be
longer that temporary. Locate the tanks
as near the shelter as practicable and
be certain that the bottoms of the tanks
are not lower than four feet (120 cm)
from the fuel pump on the installed
generator set.
Connect the fuel line
from the external source to the fuel
selector valve. Provide for the exclusion of dirt and moisture.
( e ) S u p p o r t . Be certain that
the bearing surface used can support the
weight of the generator set.
(f) Foundation. Since the unit
is of the portable type, no foundation
should normally be required.
However,
position the unit on reasonable firm,
dry ground using planks, timbers, or a
suitable gravel base, as available
conditions warrant.
Provide for water
drainage away from the unit.
(g) Mounting. Position t h e
unit so that it is level in both planes
and so that the frame is supported on
its entire bottom surface.
If necessary, the frame may be secured to a
suitable base.
Electrical Connections.
(3)
All internal electrical connections for
proper operation of the generator sets
have been made at the time of manufacture.
If it appears that changes have
been made in the wiring, refer
the
matter to Direct Support Maintenance.
(a) Power Transmission Cables.
Use cable with a minimum wire size of
This size will give a
No. 8 AWG.
voltage drop of about 1 volt per 25 feet
(750 cm) of cable when the unit is
operated at full load. If the distance
to the load is great, increase the wire
size to No. 6 to No. 4 to minimize
voltage drop.
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
Before attempting to connect
the load cables, make sure the
generator set is completely
shut-down.
Power Output Connection.
(b)
Position the circuit breaker in the OFF
position and connect the load transmission cables to the load terminals of
the load terminal board (figs. 1-1 and
1-3), in accordance with the output
voltage and phase requirements, as shown
by table 4-1. Refer to figure 2-4 for
the output selector switch.
Change 1
4-2.1/(4-2.2 blank)
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
Table 4-1. Output Selector Switch Positions and Load Cable Connections (1).
Switch
Position
1
2
3(2)
4(2)
Generator Output
240 V, 1 phase, 2 wire
120 V, 1 phase, 2 wire
120 V, 3 phase, 3 wire
120/208 V, 3 phase, 4 wire
Cable
Connections
L2 and L3
L2 and L3
L1, L2, and L3
LO, L1, L2 and L3
(1) Switch positions are found by facing the
switch. For No. 1 position, turn the knob clockwise
to the limit of its travel. Switch positions 2,3, and 4
may then be found by turning the knob
counterclockwise.
(2) When connecting for a 3-phase, 3-wire, or
3-phase, 4-wire operation, the phase sequence may
be incorrect on some equipment causing motors to
run backward. If the sequence is found to be incorrect, switch positions of any two of the load leads either L1, L2, and L3. Do not switch load lead LO.
4-3
TM 5-6115-332-14
P-8-614-14
TO 36C2-3-424-1
(c) Ground Connections.
(See Chap. 2-2, para. C)
4-4
Change 7
b. Revetment Construction
(1) General. The generator sets are designed
to be operated in the open, with unrestricted ventilation. In some situations, however, it may be
necessary to operate the equipment under the protection of a revetment. This subparagraph provides
information on the major details applicable to the
construction of a revetment, should it be necessary.
(2) Dimensions.
(a) The minimum inside dimensions and
height are shown by figures 4-1 and 4-2.
(b) The entrance of the revetment, shown
by figure 4-3 should be 0.6 meter (2.0 feet) wide with
a sill at the bottom not higher than 0.3 meter (1.0
foot). The minimum dimensions given here are
based solely on considerations applicable to engine
cooling and ventilation, with an allowance made for
the minimum practicable space for service and
maintenance.
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
Figure 4-1. Revetment, top plan view.
4-5
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
TS 6115-332-14/4-2
Figure 4-2. Revetment, side plan view.
TS 6115-332-14/4-3
Figure 4-3. Revetment, isometric plan view
4 - 6
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
(3) Foundation and Drainage. If the generator set is attached to a shipping pallet, the pallet
will provide an adequate foundation. If not, use
planks, timbers, logs, ammunition boxes, or other
available material to prevent the skids of the frame
from sinking into soft earth or sand. In no case
should the foundation exceed a height of 6 icnhes
(15.2 cm) nor should the generator set be tilted at
an angle of more than 15 degrees in any direction.
Provide drainage to ensure runoff of any water in a
direction away from the generator set and out of the
revetment through drain holes located at the inside
ground level. Where there is no natural slope for the
water to run away from the revetment, provide a
sump and drainage trench for each drain hole in a
location outside of the revetment.
(4) Wall Construction. The walls of the revetment may be constructed of sand bags, ammunition boxes filled with sand or dirt, or any other material available. The wall height should not exceed
0.9 meter (3.0 feet), as shown by figure 4-3 and the
walls should be constructed as shown by figure 4-4.
(5) Roof Construction. The roof may be suported by any means available, but should be 0.3
meter (1.00 foot) above the wall of the revetment
and should provide as much open space around the
top of the wall as possible. Refer to figures 4-2, 4-3,
4-4, 4-5 ,and 4-6. Preferred materials for use in roof
construction consists of 2 pieces of lumber (4 x 4
inches) (10.2 cm) or logs (4 inches in diameter) (10.2
cm) meters (10.0 feet) long, and the necessary cross
pieces of lumber, logs, or steel plating to cover the
entire roof area as shown by figure 4-6. These cross
pieces should be about 2.4 meters (8.0 feet) long. If
the above materials are not readily available, any
available material of a similar nature may be used.
The thickness of the roof (figs. 4-2 and 4-5) will depend upon the amount and type of protection desired. Take care to ensure that the roof is properly
supported to carry the additional weight, when ad-
ding additional protective material.
TS 6115-332-14/4-4
Figure 4-4. Revetment, perspective without roof.
4-7
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
4-8
Figure 4-5.
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
Figure 4-6. Revetment, left side view.
(6) Miscellaneous Construction. Construct
a compartment for fuel storage outside of the revetment, as shown by figure 4-1 and 4-4. The size of
the fuel storage area will depend upon the size of
the fuel container to be used. Since the temperature
within the revetment will build up considerably
above the outside ambient temperature, when the
generator set is operating, always locate the fuel
supply outside the revetment to minimize the hazard associated with gasoline stored at high temperatures. For the same reason, it is recommended
that the fuel can located on the generator set not be
used when the generator set is used in a revetment
or a revetted area. Pipe the exhaust gases from the
engine to the outside of the revetment. The installa-
tion should be similar to that shown by figure 4-7. If
flexible pipe is not available for use in exhaust extension, a piece of exhaust pipe or other similar pipe
may be used. The point at which the exhaust discharge will go through the revetment will depend
entirely upon the material that is available. The exhaust gases may or may not be discharged into an
external exhaust chimney constructed as shown by
figure 4-1. Such a chimney aids in carrying the exhaust gases away from the revetment and will reduce the noise level. Construct a revetment doorway
shield, as shown by figures 4-1, 4-2 and 4-6. This
shield is to be a wall, 0.9 meter (3.0 feet) high and
2.3 meters (7.5 feet) long, constructed in a manner
similar to the revetment walls to prevent the direct
entrance of projectiles or fragments.
4-9
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
Figure 4-7. Revetment, exhaust piping.
4-10
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
(7) Orientation Instructions. When constructing the revetment, the orientation of the
structure will be such that its entrance will face the
prevailing wind (fig. 4-1). The generator will be
centered within the revetment and will be positioned so that the long axis of the generator set is
parallel to the long axis of the revetment. In addition, the generator end of the generator set will be
positioned next to the entrance. These instructions
are very important and will be observed so that
proper cooling and ventilation will be obtained
when the unit is operated in a revetment.
(8) Multiple-Unit Installation. No more
than one generator set will be operated in a revetment. Also, no other heat generating equipment
will be placed in a revetment with a generator set.
4-3. Equipment Conversion.
For conversion of the generator set to a different
voltage or phasing requirement, refer to figure 2-4
and to table 4-1.
4-11
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
Section II.
MOVEMENT TO A NEW WORKSITE
4-4. Dismantling for Movement.
a. Preparation for Movement.
(1) Stop the generator set as follows:
(a) Local Mode Stopping. Refer to figure
2-10 for local mode stopping instructions.
(b) Remote Mode Stopping. To stop the
generator set from a remote position, make contact
between the stop terminal and common terminal of
the remote control terminal board (fig. 2-9). As soon
as the unit stops, break contact.
(2) Disconnect the load cable and ground cable.
(3) Disconnect the auxiliary fuel hose and exhaust piping, as applicable.
4-12
(4) Remove all anchoring devices.
(5) See that all tools and equipment assigned
to the unit are clean and are in serviceable condition.
b. Handling Equipment.
(1) If the site for operation is reasonably close,
the generator set may be carried or skidded.
(2) If the generator set is to be transported by
carrier, see that it is properly blocked and tied down
to prevent damage by its shifting during transit.
4-5. Reinstallation after Movement.
The instructions for reinstallation after movement are the same as outlined in paragraph 4-2.
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
Section III.
REPAIR PARTS, SPECIAL TOOLS AND EQUIPMENT
4-6. Tools and Equipment.
Tools, equipment, and repair parts that are issued with or authorized for the generator set are
listed in the basic issue items list.
4-7. Special Tools and Equipment.
4-8. Maintenance Repair Parts.
(A) Repair parts and equipment are listed and illustrated in the repair parts and special took list
covering the generator set, TM 5-6115-332-34P. For
engine repair parts, refer to TM 5-2805-258-24P.
(F) Air Force users refer to TO 38G2-89-34.
No special tools or equipment will be required by
organizational maintenance for the maintenance of
the generator sets.
4-13
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
Section IV.
LUBRICATION INSTRUCTIONS
4-9. General.
The generator is equipped with a sealed bearing
that does not require lubrication.
4-10. Detailed Lubrication Information.
Refer to TM 5-2805-258-14 for detailed lubri-
4-14
cation information on the MIL-STD Engines.
4-11. Air Cleaner Service.
Refer to TM 5-2805-258-14 to service the air
cleaner.
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
Section V.
PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
4-12. General.
a. The generator set shall be inspected and ser-
viced to ensure that it is ready for use at all times.
The necessary weekly, monthly, and semi-annual
preventive maintenance services to be performed
are listed in table 4-2. The item numbers indicate
the sequence of the minimum inspection requirements. All faults noted during the inspection or service will be recorded on DA Form 2404. TM 38-750
should be consulted for complete information on use
of DA Form 2404.
b. Defects discovered during operation will be
noted for future correction. Stop operation immediately if a deficiency is noted which would damage
the equipment. All deficiencies and shortcomings
will be recorded together with the corrective actions
taken on the applicable form. Air Force users shall
refer to the applicable inspection manuals and work
card sets in the TO 35C2-3-1-426 series for periodic
requirements and table 4-2 for detailed procedures.
Marine Corps users should refer to current issue of
TM 11275-15/1.
c. (A, N, MC) Preventive Maintenance Checks
and Services.
Table 4-2 contains a. tabulated listing of PMCS
which shall be performed by the Organizational personnel. The item numbers are listed consecutively
and indicate the sequence of minimum
requirements.
4-13. Organizational Maintenance
Preventive Maintenance Checks
and Services.
For preventive maintenance checks and services
that are applciable to organizational maintenance,
refer to table 4-2.
4-15
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
Table 4-2. ORGANIZATIONAL PREVENTIVE MAINTENANCE CHECKS AND SERVICES
W-WEEKLY (40 HOURS)
M-MONTHLY (100 HOURS)
INTERVAL
INTERVAL
ITEM
NO.
W
1
2
M
H
•
•
ITEM
TO BE
INSPECTED
S-SEMIANNUAL (500 HOURS)
H-HOURS (AS INDICATED)
PROCEDURES
CHECK FOR HAVE REPAIRED
OR ADJUSTED AS NECESSARY
Battery
Check battery electrolyte level. Perform a hydrometer check of the battery electrolyte prior to adding water
(use distilled water if available). Recharge or replace battery if specific
gravity is low. Clean battery connections as necessary (para 3-13).
Fuel filter
Remove and dean fuel filter and sediment bowl (fig. 3-3, TM
5-2805-2581 4).
3
50
Engine oil
Change lubricating oil every 50 hours
(LO 5-2805-258-14)
4
50
Oil filter
Replace lubricating oil filter every 50
hours (fig. 3-1, TM 5-2805-258-14).
4-16 Change 10
EQUIPMENT IS
NOT READY/
AVAILABLE IF:
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
Section VI.
TROUBLESHOOTING
4-14. General.
4-15. Organizational Troubleshooting.
a. This section contains troubleshooting information for locating and correcting most of the operating troubles which may develop in the generator
set. Each malfunction for an individual component,
unit, or system is followed by a list of test or inspections which will help you to determine the
probable causes and corrective actions to take. You
should perform the test/inspections and corrective
actions in the order listed.
b. This manual cannot list malfunctions that
may occur, nor all tests or inspections and corrective actions. I f a malfunction is not listed or is
not corrected by listed corrective actions, notify
your supervisor.
Refer to table
troubleshooting.
4-3
for
organizational
NOTE
Before you use this table, be sure you have performed all applicable operating checks.
4-16. General Instructions for use of
Multimeters.
a. Introduction. In electrical troubleshooting,
the Simpson 160, the TS-352B/U, and the AN/URM105 will do the same job. Therefore, your shop sets
may contain any one of these multimeters (fig. 4-8).
Any of these three multimeters can be used to troubleshoot your equipment’s electrical system. This
section shows how.
4-17
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P-8-614-14
TO 35C2-3-424-1
Figure 4-8. Types of multimeters.
4-18
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
NOTE
The Simpson 160 is only available in new shop sets
as a substitute for the TS-352B/U or AN/URM-105.
b. Using the Ohms Scale. The ohms scale is
used to make tests for continuity, shorts and
resistance.
(1) “Zeroing” the Meter (Figure 4-9). The
multimeter must be set up and “zeroed” before
making these tests. Do the following steps that
match the multimeter you have:
4-19
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
Figure 4-9. "Zeroing" the multimeters.
(Sheet 1 of 3).
4-20
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
Figure 4-9. "Zeroing” the multimeters.
(Sheet 2 of 3)
4-21
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
Figure 4-9 "Zeroing" the multimeters.
(Sheet 3 of 3).
4-22
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P-8-614-14
TO 35C2-3-424-1
NOTE
If the needle will not “zero”, replace the batteries. If
the needle still will not “zero” after replacing the
batteries, turn the meter in for repair.
(2) Continuity Tests. Continuity tests are
made to check for breaks in a circuit (such as the
switch, light bulb, or electrical cable (fig. 4-10). To
make a continuity check, do the following steps:
Figure 4-10. TS-352 continuity test.
4-23
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TO 35C2-3-424-1
(a)
Set up and “zero” the multimeter (fig. 4-
9)
CAUTION
Failure to do the following step can
damage the multimeter.
(b) Disconnect the circuit being tested. To be
safe, disconnect the battery ground strap.
(c) Connect the meter probes to both terminals of the circuit being tested. (The TS-352B/U is
illustrated (fig. 4-10), but the probes are connected
to the circuit the same way with all three multimeters.
(d) Look at the meter needle.
1. If the needle swings to the far right
over the “O” on the top scale (on all three multimeters), the circuit has continuity.
2. If the needle doesn’t move, the circuit
is open (broken).
Figure 4-11.
4-24
3. If the needle jumps or flickers there
is a loose connection in the circuit being tested.
(3) Testing for Shorts. A short (or short circuit) occurs when two circuits that should not be
connected have metal to metal contact with each
other. A short also occurs when a circuit that should
not touch the ground has metal to metal contact
with ground. To check for shorts, do the following
steps:
(a) Set up and “zero” the multimeter (fig. 49).
CAUTION
Failure to do the following step can
damage the multimeter.
(b) Disconnect the circuit being tested. To be
safe, disconnect the battery ground strap.
(c) Using either type of multimeter, connect
one probe to one circuit and the other probe to the
other circuit or ground (if checking for a short to
ground). The example (fig. 4-11) shows a check to
see if wire “A” is shorted to wire “B” in the wiring
harness.
Testing for shorts.
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
(d) Look at the needle.
1. If the needle swings to the far right
over the “O” on the top scale, the circuits are shorted.
2. If the needle doesn’t move, the circuits are not shorted.
3. If the needle jumps or flickers, the
circuits are occasionally shorted.
(4) Testing Resistance. To measure resistance in a circuit, do the following steps:
(a) Set up and “zero” the multimeter (fig. 49).
CAUTION
Failure to do the following steps can
damage the multimeter.
(e) Read the meter (fig. 4-13). If the meter
switch is on the “RX1” or “X1” range, the reading is
taken directly from the top scale. If the meter
switch is on a different range, multiply the reading
on the scale according to the table below.
Ohms Switch Setting
X1 or RX1
X10 or RX10
X100 or RX100
X1K or RX1K
X10K or RX10K
You Do
Read number on scale.
Multiply reading by 10.
Multiply reading by 100.
Multiply reading by 1,000.
Multiply reading by 10,000.
(Remember: K = 1,000)
(b). Disconnect the circuit being tested. To
be safe, disconnect the battery ground strap.
(c) If the test in this manual calls for an
“ohms range” different than “RX1” or “X1”, set the
selector switch to that range (such as “RX10” or
“X10”).
NOTE
“Zero” the meter whenever you change ranges.
(d) Using either type of multimeter, connect
the probes across the circuit or item to be measured.
The example (fig. 4-12) shows measuring the resistance of a temperature sending unit.
Figure 4-12. Testing resistance.
4-25
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TO 35C2-3-424-1
Figure 4-13. Reading the ohm scale.
c. Using the DC Volts Scale (Figure 4-
14). The DC scale is used tomeasure all voltage on
4-26
the equipment except the AC voltage.
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
Figure 4-14. DC volts scale.
(Sheet 1 of 3).
4-27
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
Figure 4-14. DC volts scale.
(Sheet 2 of 3).
4-28
TM 5-6115-332-14
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TO 35C2-3-424-1
Figure 4-14. DC
(Sheet 3 of 3).
(1) Before using the multimeter to measure
DC voltage, do the following steps that match the
multimeter you have:
(a) AN/URM-105. Set meter switch to DC
volts range given in TM. (To measure 24 volts DC,
set switch on “100 DC VOLTS” range.)
4-29
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TO 35C2-3-424-1
(b) TS-352B/U.
1. Set FUNCTION switch to “DIRECT”.
(Range switch can be at any position).
2. Put black lead in “-DC/+AC/OHMS”
jack.
3. To measure 24 volts DC, plug red lead
into “50V” jack on left side of meter. (If measuring
less than 10 volts DC, use “10V” jack. If measuring
less than 2.5 volts DC, use “2.5V” jack.)
(c) Simpson 160.
1. Connect black lead to “COM-” jack.
2. Connect red lead to “+” jack.
3. To measure 24 volts DC, set selector
switch to “V/DC 50” position. (If measuring less
than 10 volts DC, set selector switch to “V/DC 10”
position. If measuring less than 2.5 volts DC, set se
lector switch to “V/DC 2.5” position).
4. Set polarity reversing switch to the
“+DC” position.
(2) To measure DC volts, do the following
steps:
(a) Set up multimeter (paragraph (1) above).
NOTE
If you are unsure of the voltage to be measured on
the equipment, always start on the highest range.
This will protect the meter.
(b) Using either type of multimeter, connect
the red probe to the positive (+) side of the circuit
and the black probe to the negative (-) side. The example (fig. 4-15) shows 24 volts DC being measured
across the batteries.
Figure 4-15. Measuring DC voltage.
4-30
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
Thus the meter (fig. 4-16) (2) is showing the fol(c) Read the meter. (The examples (fig. 4-16)
shows how to read all three multimeters). If the lowing readings:
needle tries to move off the scale to the left, reverse
the probes on the circuit.
1. Simpson 160. Read the “DC” volts
scale for the range the selector switch is set at.
Switch Setting
Scale
V/DC 50
0-50
0-10
V/DC 10
V/DC 2.5
0-25 (and divide by 10)
Thus, the meter (fig. 4-16) (1) is showing the following readings:
Figure 4-16. Reading DC voltage.
(Sheet 2 of 3).
Figure 4-16. Reading DC voltage.
(Sheet 1 of 3).
straight-lined portion of the “AC and DC volts”
scale for the range the selector switch is set at.
Switch Setting
1000 DC Volts
100 DC Volts
10 DC Volts
Scale
0-10 (and multiply by 100)
0-10 (and multiply by 10)
0-10 (and divide by 10)
Thus, the meter (fig. 4-16) (3) is showing the following readings:
2. TS-352B/U. Read the “DC” volts
scale for the range the red lead is plugged in at.
Range
50V
Scale
0-5 (and multiply by 10)
10V
0-10
2.5V
0-2.5
4-31
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P-8-614-14
TO 35C2-3-424-1
d. If the AC Volts Scale is Used. The AC volts
scale is used to measure the AC voltage.
(1) Before using the multimeter to measure
AC voltage, do the following steps that match the
multimeter you have. Refer to figure 4-17.
(a) AN/URM-105. Set meter switch to
“1000 AC volts”.
Figure 4-16. Reading DC voltage.
(Sheet 3 of 3).
4-32
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P-8-614-14
TO 35C2-3-424-1
Figure 4-17. AC volts scale.
(Sheet 1 of 3).
4-33
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P-8-614-14
TO 35C2-3-424-1
(b)) TS-352B/U.
1. Set’’FUNCTION” switch to “AC volts”. (“RANGE” switch can be at any setting.) (A, fig.
4-17) (Sheet 2 of 3).
Figure 4-17. AC volt scale.
(Sheet 2 of 3).
2. Put black lead in “-DC/AC/OHMS”
jack (B, fig. 4-17, sheet 2 of 3).
3. Put red lead in “250V” jack on right
side of meter.
4-34
(c) Simpson 160.
1. Put black lead in “COM-” jack.
2. Put red lead in “+” jack.
3. Set selector switch to “V/AC 250”
position.
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
Figure 4-17. AC volt scale.
(Sheet 3 of 3).
(2) To measure AC voltage, do the following
steps:
(a) Set up multimeter (fig. 4-17).
(b) Using either type of multimeter, connect
one probe to one side of the circuit and the other
probe to the other side. The example (fig. 4-18)
shows AC voltage being measured across an AC
light circuit.
4-35
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
Figure 4-18. Measuring AC voltage.
(c) Read meter on the “AC” scale. Figure 4-
19 shows a reading of 115 volts on all meters.
4-36
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
Figure 4-19. Reading AC voltage.
4-37
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
Table 4-3. Organizational Troubleshooting
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
1. STARTER CRANKS ENGINE BUT STOPS WHEN START SWITCH IS RELEASED
Step 1.
Test for defective K1 relay. Refer to paragraph 4-42c for test procedures.
Replace defective relay. Refer to paragraph 4-42 for removal and installation instructions.
Step 2.
Check for defective oil pressure indicator.
If indicator is defective, refer to paragraph 4-26 for removal and installation instructions.
2. GENERATOR FAILS TO SUPPLY POWER TO LOAD
Check for a broken, burned, or cracked circuit breaker. Check for broken and worn wiring. Also, test the circuit
breaker with a multimeter.
If circuit breaker is damaged or defective, refer to paragraph 4-41 for removal and installation instructions.
NOTE
To facilitate installation of the circuit breaker, before removal of the wire leads from
the terminal at the back of the unit, make a diagram that shows the exact position
of each lead. It will be found that if the leads are allowed to turn from their original
position they will be too short to enable the successful installation of the circuit
breaker.
3. FREQUENCY METER FAILS TO SHOW FREQUENCY
Check for loose connections or broken wiring.
Refer to paragraph 4-39 for repair instructions.
4. VOLTMETER FAILS TO SHOW VOLTAGE
4-38
Step 1.
See malfunction 3, above. If that does not correct the problem, go on to step 2.
Step 2.
Check for a broken or cracked voltmeter. Inspect wiring for breaks and wear. Test voltmeter by
connecting an additional voltmeter to load terminals of generator set and taking comparative
readings to establish validity of generator set voltmeter.
If voltmeter is defective, refer to paragraph 4-33 for removal and installation instructions.
Step 3.
Check for a broken or cracked voltage selector switch. Inspect wiring for breaks and wear. Test
with a multimeter for continuity of switch contacts.
If voltage selector switch is damaged or defective, refer to paragraph 4-37 for removal and
installation instructions.
Change 6
TM 5-6115-332-14
P-6-614-14
TO 35C2-3-424-1
Table 4-3. Organizational Troubleshooting
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
5. GENERATOR FAILS TO BUILD UP RATED VOLTAGE
1.
Check for loose, cut, broken, and worn wiring.
If connections are loose, tighten them. If wiring is damaged, repair it. Refer to paragraph 4-39
for repair instructions.
Step 2.
Check for a broken or cracked voltage selector switch.
Check for damaged wiring.
If the voltage selector switch is damaged or defective, refer to paragraph 4-37 for removal and
installation instructions.
Step 3.
Inspect the variable resistor for cracks, corrosion, loose connections and other damage. Test the
variable resistor as follows:
Step
a. Stop the generator set and disconnect terminal 26 of the voltage regulator terminal board.
b. With a multimeter, check resistance across the variable resistor terminals by varying the
resistor from full counterclockwise to full clockwise position. This reading should move smoothly
from 0 to 750 ohms ± 10% as the variable resistor is rotated to the full clockwise position.
NOTE
On sets manufactured prior to 1968, this reading will be 0 to 250 ohms ± 10%.
Replace the variable resistor (para 4-16) if the reading is not within specifications.
Step 4.
Check the voltage regulator for loose wires, corrosion, metal to metal contact, or incorrect wiring.
6. VOLTMETER READING TOO HIGH OR TOO LOW
Step 1.
Check for a broken or cracked voltage adjusting rheostat switch. Inspect for broken wiring or
loose connections around the switch.
If voltage adjusting rheostat switch is damaged or defective, refer to paragraph 4-38 for
removal and installation instructions.
Step 2.
Check for broken or cracked voltmeter. Inspect for broken wiring or loose connections. Test
voltmeter by connecting an additional voltmeter to load terminals of generator set and taking
comparative readings to estblish validity of generator set voltmeter.
If voltmeter is damaged or defective, refer to paragraph 4-33 for removal and installation
instructions.
7. NO POWER AVAILABLE AT OUTLET RECEPTACLE (MODEL MEP-017A)
Step 1.
Check for loose connections by visually observing or by grasping wires and tugging slightly.
Also, check for broken or worn wiring.
If damage or loose connections are found, refer to paragraph 4-39 for repair instructions. If
there are no loose connections or damaged wiring, go on to step 2.
Step 2.
Check for cracked or broken outlet receptacle.
If receptacle is damaged, refer to paragraph 4-43 for removal and installation instructions.
Change 7
4-39
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
Table 4-3. Organizational Troubleshooting
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
8. GENERATOR OVERHEATS
Check the engine shrouds and cooling fins by observation.
See if there is a blockage or obstruction.
If air passages are obstructed, clean them.
9. GENERATOR SET NOISY
Check the mounts by moving slightly.
If mounts are loose or cracked, refer to paragraph 4-44 for removal and installation
instructions.
10. PANEL LIGHTS FAIL TO OPERATE
Step 1.
Check for loose connections. Inspect for worn or broken wiring.
Refer to paragraph 4-39 for repair instructions.
Step 2.
Check for a broken or cracked panel light switch. Check for worn or broken wiring.
Refer to paragraph 4-31 for removal and installation instructions.
11. TIME TOTALIZING METER FAILS TO OPERATE OR IS INACCURATE
Step 1.
Check for loose connections and broken or worn wiring.
Refer to paragraph 4-39 for repair instructions.
Step 2.
Check for a broken or cracked time toalizing meter.
Check for loose or broken wiring.
Refer to paragraph 4-25 for removal and installation instructions.
12. BATTERY CHARGING AMMETER GIVES NO READING OR GIVES INACCURATE
READING
Step 1.
Check for loose connections at the wiring by observing or slightly moving the harness. Also
check for broken or worn wiring.
Refer to paragraph 4-39 for repair instructions.
Step 2.
Check for cracked or broken battery charging ammeter. Test ammeter leads with a multimeter,
for continuity.
Refer to paragraph 4-29 for removal and installation instructions.
13. OIL PRESSURE INDICATOR FAILS TO INDICATE OR GIVES LOW READING
Step 1.
Check for loose connections by observing visually or move harness slightly to indicate loose connecting points.
Check all wiring to see if it is worn or broken,
Refer to paragraph 4-39 for repair instructions.
Step 2.
Check indicator for cracked or broken glass, bent needle, or damaged wiring.
Refer to paragraph 4-26 for removal and installation instructions.
Step 3.
Check for proper operation of relay K2 and K4.
Refer to paragraph 4-42 for removal and installation instructions.
4-40
Change 7
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
Section VII.
RADIO INTERFERENCE SUPPRESSION
4-17. General Methods Used to Attain
Proper Suppression.
4-18. Interference Suppression Components.
Essentially, suppression is attained by providing a
low resistance path to ground for stray currents.
The methods used include shielding the ignition
and high frequency wires, grounding the frame
with bonding straps, and using capacitors and resistors. For general information on radio suppression, refer to TM 11-483.
The generator set is provided with four
capacitors as primary radio interference suppression components. These are connected to each of
the three generator phases and to the neutral line.
The capacitors are each rated at 0.1 uf, 500 vac.
They are shown in figure 4-20.
Figure 4-20. Replacement of radio interference suppression components.
4-19. Replacement of Suppression
Components.
a. Removal. For replacement of radio interference suppression components, refer to figure 4-20
and the following instructions to remove the capaci-
tors.
(1) Tag and disconnect electrical leads from
the capacitor.
(2) Remove the nuts, washers, and screws securing the capacitor to the control box,
(3) Remove the capacitor.
(4) Remove the remaining capacitors in a sim.
ilar manner.
b. Cleaning, Inspection and Repair.
(1) Clean the capacitors using a clean lint free
cloth,
(2) Inspect capacitors for corroded terminals,
cracked case or for evidence of overheating.
(3) Replace damaged or defective capacitors
as required,
c. Installation
(1) Position capacitor in place in control box
and secure with screws, waahera, and nuts.
(2) Reconnect leads,
(3) Install remaining capacitors in the same
manner.
4-41
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
Radio
4-20. Testing of
Suppression Components.
Interference
Replace capacitors that fail to give a reading
within 10 percent of the value in microfarads
given in paragraph 4-18.
Test the capacitors for leaks, shorts,
and open circuits, using a capacitor tester.
Section VIII. MAINTENANCE OF THE ENGINE ELECTRICAL SYSTEM
4-21. General
maintenance
This
covers
section
instructions for the battery and battery
and battery cables, and slave receptacle,
switches, panel lights and meters. Unless
otherwise specified, these instructions apply
to both the model MEP-017A and model
MEP-022A generator sets. For electrica1
system maintenance t h a t a p p l i e s t o t h e
engine, refer to TM 5-2805-258-14.
4-22.
Battery Cables, Starter Cable and
Stud,
Terminal
and
Grommet,
Terminal Cover
a. Removal.
(1) Refer to figure 3-4 and remove
the fuel can as follows:
(a) Lift locking handle and remove
the fuel can adapter from the fuel can.
(b) Lift clamp to loosen strap securing
the fuel can in fuel can bracket.
(c) Remove strap from fuel can and
remove fuel can from bracket.
(2) Refer to figure 4-21 and the following
instructions to remove the terminal cover,
battery cables, starter cable and grommet,
and terminal stud.
( a ) R e m o v e terminal cover, loosen
nut securing the negative battery cable
to the battery terminal and disconnect battery
cable.
(b) Remove nuts, lockwashers, and
screws securing the other end of the negative
battery cable to the skid and remove negative
cable.
4-42
Change 4
(c) Disconnect starter cable at starter
and remove grommet from engine shroud.
(d) Remove nut and lockwasher securing
the starter cable to the terminal stud and
disconnect cable.
NOTE
Exercise care when removing starter
cable to prevent possible damage
when withdrawing cable from the
engine shroud.
(e) Remove starter cable.
(f) Loosen nut securing positive cable
to the battery terminal and disconnect the
positive battery cable.
Remove the nut, lockwasher,
(g)
insulating washers, and terminal stud securing
other end of battery cable to the skid base
and remove cable.
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
Figure
4-21.
Battery
cables,
starter
cable
and
grommet,
and
terminal
stud,
removal
and
installation.
Change 4
4-43
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P-8-614-14
TO 35C2-3-424-1
b. Cleaning, Inspection and Repair.
WARNING
Clean all parts in a well-ventilated area.
Avoid inhalation of solvent fumes and
prolonged exposure of skin thoroughly. Dry
cleaning solvent (Fed. Spec. P-D-680 Type
II) used to clean parts is potentially
dangerous to personnel and property. Do
not use near open flame or excessive heat.
Flash point of solvent is 140°F (60°C).
(1) Clean items with cleaning solvent, Fed. Spec.
P–D-680 or Type II, and dry thoroughly.
(2) Inspect the cables for cracked, frayed, or missing
sections of insulation.
(3) Inspect for corroded, burned, or damaged cable
ends.
(4) Inspect the terminal stud for signs of burned areas
or stripped threads.
(5) Inspect the grommet for cracks.
(6) Replace all defective parts.
Relays K1, K2, K3, and K4 furnish starting, stopping,
safety, and operational control for the generator. The relays
are mounted on printed circuit board TB3.
(1) Relay K1 is used to start the generator engine by
energizing the starter solenoid through the normally closed
contacts of relay K3.
(2) Relay K2 is used to stop the engine. The relay is
energized by the S1 stop switch and S5 remote-local switch.
When relay K2 is energized, relay K3 and K4 are
de-energized, thereby removing the battery charger from
the circuit and grounding the magneto through the normally
closed contacts or relay K4.
(3) Relay K3 is energized by the battery charger
rectifier through the normalIy closed contacts of K4, and
de-energized by low oil pressure.
(4) Relay K4 is energized through the normally
closed contacts of relay K2 and the silicon diode, CR1. This
occurs when start and stop switch, S1 is activated.
4-23. Battery and Battery Frame.
a.
Testing
WARNING
Make sure that battery terminal covers are
installed on both battery terminals before
installing cables.
c. Installation
(1) Position terminal stud in place on skid base and
install insulating washers on stud.
(2) Secure one end of positive battery cable to
terminal stud with lockwasher and nut.
(3) Place battery terminal cover over positive battery
terminal. Place other end of positive cable over positive
terminal on battery and secure by tightening nut.
(4) Install rubber grommet in engine shroud.
(5) Thread starter cable thru grommet.
(6) Secure starter cable to terminal stud with
lockwasher and nut.
(7) Secure other end of starter cable to the engine
starter.
(8) Secure end of negative battery cable to skid base
with screws, lockwashers, and nuts.
(9) Place battery terminal cover over negative battery
terminal. Place other end of negative cable over negative
terminal on battery and secure by tightening nut.
(10) Place fuel can in bracket and install fuel can strap.
(11) Secure by depressing clamp.
(12) Install fuel can adapter in fuel can and lock by
depressing locking handle.
4-22.1 Relays and Resistors (Model MEP017A)
4-44
Change 8
●
Do not smoke or use an open flame near
batteries. Batteries generate an explosive
gas.
●
Electrolyte contains sulfuric acid and can
cause severe burns. Handle it with care. If the
solution comes in contact with the body or
clothing, rinse immediately with clean water.
The 6TN and 6TL batteries can be mixed or matched.
However, maintenance–free batteries cannot be mixed or
matched with military batteries. The 6TN and or the 6TL
batteries will perform properly in hot weather as long as
electrolyte levels are carefully monitored. If the electrolyte
expands and causes the level to rise, some fluid must be
removed. If the level becomes too low due to evaporation,
distilled water may be used to obtain the proper level. A
good grade of drinking water (excluding mineral waters)
may be used if distilled water is not available.
and
Electrolyte
6810-00-249-9354
(NSNs
6810-00-843-1640) have a specific gravity of 1.280 and
should be used in these batteries. Do NOT adjust the
electrolyte in wet batteries to a lower specific gravity.
(1) The battery should be tested with a hydrometer
and kept to a specific gravity of 1.250 or above.
NOTE
Before testing the battery remove the terminal
cover.
(2) Always test a battery for degree of charge before
gravity between
adding water. The specific
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TO 35C2-3-424-1
the cells should be within .025. A dangerously low
point of charge indicated by a hydrometer reading
of 1.150 or less will permit the battery to freeze at
temperatures only a few degrees below the freezing
point of water. A specific gravity 1.250 will permit
the battery to withstand temperatures as low as
-65°F without freezing.
(3) The electrolyte level should be maintained
inch (0.95 cm) above the separators or insulators
by addition of distilled water or “approved water”
Change 7
4-44.1/(4-44.2 blank)
TM 5-6115-332-14
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TO 35C2-3-424-1
Figure 4-22. Battery and battery frame, removal and installation.
C h a n g e
5 4-45
TM 5-6115-332-14
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TO 35C2-3-424-1
(water free from impurities by analys i s ) . Do not overfill the cells of the
battery as either has a detrimental
effect on battery life.
(4) Use of a mirror is recommended
when checking electrolyte level in
batteries. The charging rate is correct
when the battery maintains a minimum
specific gravity of 1.250 and does not
require the addition of more than 1
ounce (28 grams) of water per cell per
week or 50 service hours.
b. R e m o v a l . R e f e r t o f i g u r e 4 - 2 2
and the following instructions to remove
the battery and battery frame.
Remove terminal cover, dis(1)
connect battery cables.
(2) Remove nuts and washers which
secure the upper battery frame to the
hook bolts.
(3) Remove upper battery frame and
hook bolts.
(4) Lift battery from frame.
(5) Remove nuts, lockwashers, and
screws which secure the lower battery
frame to the skid and r e m o v e f r a m e .
c. Cleaning, Inspection and Repair.
(1) Brush all corrosion from battery and battery frame.
WARNING
Clean all parts in a well-ventilated
area. Avoid inhalation of solvent
fumes and prolonged
exposure
of skin to cleaning solvent. Wash
exposed
skin
thoroughly.
Dry
cleaning solvent (Fed. Spec. P-D-680
Type II) used to clean parts is
potentially dangerous to personnel
and property. Do not use near
open flame or excessive h e a t .
Flash point of solvent is 140°F
(60°C).
4-46 Change 5
(2) Clean the frame and hardware items
with cleaning solvent, Fed. Spec. P-D-680
Type II, and dry thoroughly.
(3) Inspect the battery frame for cracks,
broken welds, distortion, and excessively
corroded areas.
(4) Inspect the hook bolts for damaged
threads and other defects.
d. Installation.
(1) Position lower battery frame in
place on skid and secure with screws,
lockwashers and nut.
(2) Position battery in place in battery
frame.
(3) Position hook bolts in place.
(4) Place upper battery frame over
hook bolts and secure with washers and
nuts.
(5) Install battery terminal covers on
both battery terminals. Reconnect battery
cables.
4-24. Slave Receptacle and Bracket.
a. Removal. Refer to figure 4-23 and
the following instructions to remove the
slave receptacle and bracket.
( 2 ) R e m o v e nuts, lockwashers, and
screws securing the slave receptacle to
the mounting bracket and remove the slave
receptacle.
(3) Remove nuts, lockwashers, and
screws securing the slave receptacle mounting
bracket to the skid base and remove the
mounting bracket.
TM 5-6115-332-14
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TO 35C2-3-424-1
Figure 4-23. Slave receptacle and bracket, removal and installation.
4-47
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TO 35C2-3-424-1
b. Cleaning, Inspection and Repair.
cable.
(5) Replace a defective slave receptacle or
bracket.
Clean all parts in a well-ventilated area.
Avoid inhalation of solvent fumes and
prolonged exposure of skin to cleaning
solvent. Wash exposed skin thoroughly.
Dry cleaning solvent (Fed. Spec. P-D-680,
Type II) used to clean parts is potentially
dangerous to personnel and property. Do
not use near open flame or excessive heat.
Flash point of solvent is 140° (60°C).
(1) Clean metal items with cleaning solvent,
Fed. Spec. P-D-680 Type II, and dry thoroughly.
(2) Inspect the bracket for cracks.
(3) Inspect the slave receptacle for worn insulation on the cables, cracks, burned contacts, and
burned or deteriorated rubber insert.
(4) Replace a broken or excessively burned
contact by withdrawing the cable and contact from
the rubber insert and soldering a new contact on the
4-48
Change 5
c. Installation.
(1) Position the slave receptacle mounting
bracket in place on the skid and secure with screws,
lockwashers, and nuts.
(2) Secure slave receptacle in mounting
bracket with screws, lockwashers, and nuts.
(3) Reconnect leads.
4-25. Time Totalizing Meter (M4).
CAUTION
When working inside the control panel, disconnect plug P1 to prevent battery voltage arcing.
a. Removal. Refer to figure 4-24 and the following instructions to remove the time totalizing meter.
(1) Tag and disconnect electrical leads from
the time totalizing meter.
(2) Remove nuts, washer, and screws securing
the time totalizing meter to the control panel.
(3) Remove meter.
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
Figure 4-24. Control panel controls, instruments, and panel lights, removal and installation.
b. Cleaning, Inspection and Repair.
(1) Carefully and thoroughly clean the exterior of the time totalizing meter with a clean lint
free cloth.
(2) Inspect meter for signs of burned areas,
damaged threads, dents, loosened or corroded contacts, and for chipped or broken glass.
(3) Replace a defective time totalizing meter.
CAUTION
When installing the time totalizing
meter be certain that all wire leads
are returned to the correct terminals.
If these instructions are not followed,
serious damage will result.
c. Installation.
(1) Position the time totalizing meter in place
on the control panel.
(2) Secure with screws, washers, and nuts.
(3) Reconnect leads.
4-49
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TO 35C2-3-424-1
4-26. Oil Pressure Indicator (M2).
CAUTION
When working inside the control panel, disconnect plug P1 to prevent battery voltage arcing.
a. Removal. Refer to figure 4-24 and the following instructions to remove the oil pressure
indicator.
(1) Tag and disconnect electrical leads from
the oil pressure indicator.
(2) Remove nuts, washers and shield securing
the oil pressure indicator to the control panel.
(3) Remove oil pressure indicator.
b. Cleaning, Inspection and Repair.
(1) Carefully and thoroughly clean the exterior of the time totalizing meter with a clean lint
free cloth.
(2) Inspect oil pressure indicator for signs of
burned areas, damaged threads, loose or corroded
terminals, and for chipped or broken glass.
(3) Replace a defective oil pressure indicator.
c. Installation.
CAUTION
When installing the oil pressure indicator be certain that all wire leads are
returned to the correct terminals. If
these instructions are not followed,
serious damage will result.
(1) Position the oil pressure indicator in place
on the control panel.
(2) Secure to panel with shield, washers and
nuts.
(3) Reconnect leads.
d. Testing. Test with a multimeter for
continuity.
4-27. Remote-Local Switch (S5).
CAUTION
When working inside the control panel, disconnect plug P1 to prevent battery voltage arcing.
a. Removal. Refer to figure 4-24 and the following instructions to remove the remote-local switch.
4-50
(1) Tag and disconnect all electrical leads
from the remote-local switch.
(2) Remote nut and washer securing remotelocal switch to the control panel.
(3) Remove remote-local switch.
b. Cleaning, Inspection and Repair.
(1) Clean the remote-local switch with a clean
lint free cloth.
(2) Inspect switch for corroded terminals,
loose contacts, signs of burned areas, thread damage, or cracks.
(3) Replace a damaged or defective remotelocal switch.
c. Installation.
CAUTION
When installing the remote-local
switch be certain that all wire leads
are returned to the correct terminals.
If these instructions are no followed,
serious damage will result.
(1) Position remote-local switch in place on
control panel and secure with washer and nut.
(2) Reconnect leads.
d. Testing. Test with a multimeter for continuity of switch contacts.
4-28. Start-Stop Switch (S4).
CAUTION
When working inside the control panel, disconnect plug P1 to prevent battery voltage arcing.
a. Removal. Refer to figure 4-24 and the following instructions to remove the start-stop switch.
(1) Tag and disconnect leads from the startstop switch.
(2) Remove nut and washer securing the
start-stop switch to the control panel.
(3) Remove start-stop switch.
b. Cleaning, Inspection and Repair.
(1) Clean the start-stop switch with a clean
lint free cloth.
(2) Inspect switch for corroded terminals,
loose contacts, signs of burned areas, thread damage, or cracks.
(3) Inspect switch for proper operation.
(4) Replace a damaged or defective switch.
TM 5-6115-332-14
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TO 35C2-3-424-1
c. Installation.
CAUTION
When installing the start-stop switch
be certain that all wire leads are returned to the correct terminals. If
these instructions are not followed,
serious damage will result.
(1) Position start-stop switch in position on
the control panel and secure with washer and nut.
(2) Reconnect all leads.
d. Testing. Test with a multimeter for continuity of switch contacts.
4-29.
Battery Charging Ammeter (M3).
CAUTION
When working inside the control panel, disconnect plug P1 to prevent battery voltage arcing.
a. Removal. Refer to figure 4-24 and the following instructions to remove the battery charging ammeter.
(1) Tag and disconnect electrical leads from
the battery charging ammeter.
(2) Remove nuts, washers, and shield securing
the battery charging ammeter to the control panel.
(3) Remove ammeter.
b. Cleaning, Inspection and Repair.
(1) Carefully and thoroughly clean the exterior of the battery charging ammeter with a clean
lint free cloth.
(2) Inspect the battery charging ammeter for
signs of burned areas, damaged threads, loose or
corroded terminals, and for chipped or broken glass.
(3) Replace a damaged or defective ammeter.
c. Installation.
CAUTION
When installing the battery charging
ammeter, be certain that all wire
leads are returned to the correct terminals. If these instructions are not
followed, serious damage will result.
(1) Position the battery charging ammeter in
place on the control panel and secure with shield,
washers, and nuts.
(2) Reconnect all leads.
d. Testing. Test battery charging ammeter
leads with a multimeter for continuity.
4-30. Emergency
(S6).
Stop-Run Switch
CAUTION
When working inside the control panel, disconnect plug P1 to prevent battery voltage arcing.
a. Removal. Refer to figure 4-24 and the following instructions to remove the emergency stop-run
switch.
(1) Tag and disconnect electrical leads from
the emergency stop-run switch.
(2) Remove nut and washer (from the front of
the control panel) securing the emergency stop-run
switch to the control panel.
(3) Remove emergency stop-run switch.
b. Cleaning, Inspection and Repair.
(1) Clean the emergency stop-run switch with
a clean lint free cloth.
(2) Inspect switch for signs of burned areas,
loose or corroded terminals, cracks, or thread damage.
(3) Inspect switch for proper operation.
(4) Replace a defective emergency stop-run
switch.
c. Installation.
CAUTION
When installing the emergency stoprun switch, be certain that all wire
leads are returned to the correct terminals. If these instructions are not
followed, serious damage will result.
(1) position the emergency stop-run switch in
place on the control panel and secure with washer
and nut.
(2) Reconnect leads.
d. Testing. Test leads with a multimeter for
continuity.
4-31. Panel Lights Switch (S7).
CAUTION
When working inside the control panel, disconnect plug P1 to prevent battery voltage arcing.
a. Removal. Refer to figure 4-24 and the following instructions to remove the panel lights switch.
(1) Tag and disconnect electrical leads from
the panel lights switch.
4-51
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TO 35C2-3-424-1
(2) Remove nut and washer (from the front of
the control panel) securing the panel lights switch
to the control panel.
(3) Remove panel lights switch.
b. Cleaning, Inspection and Repair.
(1) Clean the panel lights switch with a clean
lint free cloth.
(2) Inspect switch for signs of burned areas,
loose or corroded terminals, cracks, or thread damage.
(3) Inspect switch for proper operation.
(4) Replace a damaged or defective switch.
c. Installation.
CAUTION
When installing the panel lights
switch be certain that all wire leads
are returned to the correct terminals.
If these instructions are not followed,
serious damage will result.
(1) Position panel lights switch in place on
control panel and secure with washer and nut.
(2) Reconnect all leads.
d. Testing. Test with a multimeter for continuity of switch contacts.
4-32. Panel Light (XDS1 and XDS2).
CAUTION
When working inside the control panel, disconnect plug P1 to prevent battery voltage arcing.
a. Removal. Refer to figure 4-24 and the following instructions to remove the panel light.
(1) Tag and disconnect electrical leads from
the panel light.
(2) Remove panel light shield (from the front
of the control panel) by pulling straight out.
Section IX.
(3) Remove panel light bulb by depressing and
turning counterclockwise.
(4) Remove nut and washer (from back of control panel) securing panel light to the control panel.
(5) Remove Panel light.
(6) Remove the other panel light in the same
manner.
b. Cleaning, Inspection and Repair.
(1) Clean the panel light(s) using a clean lint
free cloth.
(2) Inspect light(s) for loose contacts, cracks,
breaks, or burned sockets.
(3) Inspect bulb for corroded pins or base and
for a burned out condition.
(4) Replace damaged or defective panel light
or bulb.
c. Installation.
CAUTION
When installing the panel light(s), be
certain that all wire leads are returned to the correct terminals. The
lead from the switch must go to the
positive, or center, terminal of the
panel light. If these instructions are
not followed, serious damage will
result.
(1) Position panel light in place on control
panel and secure with washer and nut.
(2) Insert panel light bulb into light socket.
Depress bulb and with a clockwise motion secure in
lamp socket.
(3) Install light shield by pushing straight in
until shield snaps into place.
(4) Reconnect leads.
(5) Install the other light in the same manner.
d. Testing. Test with a multimeter for continuity of switch contacts.
MAINTENANCE OF THE GENERATOR ELECTRICAL SYSTEM
4-33. AC Voltmeter (M6).
Always stop the generator set before
performing maintenance on the electrical system copmonents. Failure to
observe this warning may lead to
severe injury or to death by
electrocution.
4-52
a. Removal. Refer to figure 4-24 and the following instructions to remove the AC Voltmeter.
(1) Tag and disconnect leads from the AC voltmeter.
(2) Remove nuts, washers, and screws securing the AC voltmeter to the control panel.
(3) Remove the voltmeter.
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
b. Cleaning, Inspection and Repair.
(1) Carefully and thoroughly clean the exterior of the voltmeter with a clean lint free cloth.
(2) Inspect the voltmeter for signs of burned
areas, damaged threads, loosened contacts, and for
loose or broken glass.
(3) Replace a damaged or defective voltmeter.
c. Installation.
(1) Secure voltmeter to the control panel with
screws, washers, and nuts.
(2) Reconnect wiring.
d. Testing. Test voltmeter by connecting an additional voltmeter to load terminals of generator set
and taking comparative reading to establish validity of generator set voltmeter.
4-34. Frequency Meter (M1).
a. Removal. Refer to figure 4-24 and the following instructions to remove the frequency meter.
(1) Tag and disconnect leads from the frequency meter.
(2) Remove nuts, washers, and screws securing the frequency meter to the control panel.
(3) Remove frequency meter.
b. Cleaning, Inspection and Repair.
(1) Carefully and thoroughly clean the exterior surfaces of the frequency meter with a clean
lint free cloth.
(2) Inspect the frequency meter for signs of
burned areas, damaged threads, loosened contacts,
and for loose or broken glass.
(3) Replace a damaged or defective frequency
meter.
c. Installation.
(1) Position frequency meter in place on control panel and secure with screws, washers, and
nuts.
(2) Reconnect leads.
d. Testing.
(1) Disconnect frequency meter leads and connect a frequency meter of known quality and take
comparative readings to establish validity of generator set frequency meter.
(2) Reconnect leads.
4-35. Current Indicator Meter (M5).
a. Removal. Refer to figure 4-24 and the following instructions to remove the current indicator meter.
(1) Tag and disconnect leads.
(2) Remove nuts, washers, and screws securing the current indicator meter to the control pan-
(3) Remove the current indicator meter.
b. Cleaning, Inspection and Repair.
(1) Carefully and thoroughly clean the exterior surfaces of the current indicator meter with a
clean lint free cloth.
(2) Inspect the current indicator meter for
signs of burned areas, damaged threads, loosened
terminals, and for loose & broken glass.
(3) Replace a damaged or defective current indicator meter.
c. Installation.
(1) Position the current indicator meter in
place on the control panel and secure with screws,
washers, and nuts.
(2) Reconnect leads.
d. Testing.
(1) Disconnect current indicator meter and
connect a current indicator meter of known quality
and take comparative readings to establish validity
of generator set current indicator meter.
(2) Reconnect leads.
4-36. Ammeter Phase Selector Switch
(S2).
a. Removal. Refer to figure 4-24 and the following instructions to remove the ammeter phase selector switch.
(1) Tag and disconnect leads from the ammeter phase selector switch.
(2) Loosen setscrew securing control knob on
the ammeter phase selector switch and remove
knob.
(3) Remove locking nut and washer securing
the ammeter phase selector switch to the control
panel.
(4) Remove the ammeter phase selector
switch.
b. Cleaning, Inspection and Repair.
(1) Carefully and thoroughly clean the exterior surfaces of the ammeter phase selector switch
using a clean lint free cloth.
(2) Inspect switch for signs of burned areas,
damaged threads, cracks, or loosened contacts.
(3) Replace a damaged or defective ammeter
phase selector switch.
c. Installation.
(1) Position the ammeter phase selector
switch in place on the control panel and secure with
washer and nut.
(2) Place control knob over end of switch shaft
and secure by tightening setscrew.
(3) Reconnect leads.
el.
4-53
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TO 35C2-3-424-1
d. Testing. Using a multimeter check for continuity of switch contacts in all positions.
4-37. Voltage Selector Switch (S3).
a. Removal. Refer to figure 4-24 and the following instructions to remove the voltage selector
switch.
(1) Tag and disconnect leads from the voltage
selector switch.
(2) Loosen setscrew securing control knob on
the voltage selector switch and remove control
knob.
(3) Remove locking nut and washer securing
the voltage selector switch to the control panel.
(4) Remove the voltage selector switch.
b. Cleaning, Inspection and Repair.
(1) Carefully and thoroughly clean the exterior surfaces of the voltage selector switch with a
clean lint free cloth.
(2) Inspect the switch for signs of burned areas, damaged threads, cracks or for loosened or corroded contacts.
(3) Replace a damaged or defective voltage selector switch.
c. Installation.
(1) Position the voltage selector switch in
place on the control panel and secure with washer
and locking nut.
(2) Place control knob over end of switch shaft
and secure by tightening setscrew.
(3) Reconnect leads.
d. Testing. Using a multimeter, check for continuity of switch contacts in all positions.
4-38. Voltage Adjusting Rheostat (R1).
a. Removal. Refer to figure 4-24 and the following instructions to remove the voltage adjusting
rheostat.
(1) Tag and disconnect the leads from the
voltage adjusting rheostat.
(2) Loosen the setscrew securing the voltage
adjusting rheostat knob on the rheostat and remove
the control knob.
(3) Remove locking nut and washer securing
the voltage adjusting rheostat to the control panel.
(4) Remove the voltage adjusting rheostat.
4-54
b. Cleaning, Inspection and Repair.
(1) Carefully and thoroughly clean the exterior surfaces of the voltage adjusting rheostats
using a clean lint free cloth.
(2) Inspect rheostat for signs of burned areas,
damaged threads and for loosened or corroded contacts.
(3) Replace a damaged or defective rheostat.
c. Installation.
(1) Position the voltage adjusting rheostat in
place on the control panel and secure with washer
and locking nut.
(2) Place rheostat knob over end of shaft and
secure with setscrew.
(3) Reconnect leads.
d. Testing. Test voltage adjusting rheostat as
follows:
(1) With the electrical leads disconnected
from the rheostat connect a multimeter to the two
outside terminals. The resistance should measure
not more than 11 or not less than 9 ohms.
(2) Connect the multimeter between the center terminal and one of the outside terminals. Turn
the shaft of the rheostat from one extreme position
to the other. The resistance should vary smoothly
from zero to maximum.
4-39. Wiring Harness.
The wiring harness and wire leads used on these
generator sets consist of individual wire leads and
terminals, and wire leads strapped into a harness by
plastic wire straps. Repair worn, damaged, or broken individual wire leads. Follow the wiring diagrams, shown as figures FO-1 and FO-3 and tag for
proper identification all wire leads that are to be
repaired.
4-40. Fuseholder (XF) (Model MEP017A).
a. Removal. Refer to figure 4-25 and the following instructions to remove the fuseholder.
(1) Tag and disconnect electrical leads as necessary.
(2) Remove fuses.
(3) Remove nuts, lockwashers and screws securing the fuseholder and remove fuseholder.
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
Figure 4-25. Fuseholder, removal and installation (Model MEP-017A).
4-55
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
b. Cleaning, Inspection and Repair.
Clean all parts in a well-ventilated area.
Avoid inhalation of solvent fumes and
prolonged exposure of skin to cleaning
solvent. Wash exposed skin thoroughly.
Dry cleaning solvent (Fed. Spec. P-D-680,
Type II) used to clean parts is potentially
dangerous to personnel and property. Do
not use near open flame or excessive heat.
Flash point of solvent is 140 °F (60ºC).
NOTE: LOOSEN CIRCUIT BREAKER
FROM CONTROL PANEL
THEN IDENTIFY AND
DISCONNECT LEADS, SEE
NOTE IN TEXT.
(1) Clean fuseholder and mounting hardware
items with cleaning solvent, Fed. Spec. P-D-680,
Type II, and dry thoroughly.
(2) Inspect the fuseholder for burned, loose, or
broken clips.
(3) Inspect the body of the fuseholder for
cracks and other damages.
(4) Replace a defective fuseholder.
c. Installation.
NOTE
Be sure fuses are the correct size and rating.
(1) Position fuseholder in place and secure
with screws, lockwashers, and nuts.
(2) Install fuses.
4-41. Circuit Breaker (CB).
NOTE
To facilitate installation of the circuit breaker, before removal of the wire leads from the terminals at
the back of the unit, make a diagram that shows the
exact position of each lead. It will be found that if
the leads are allowed to turn from their original
position they will be too short to enable the successful installation of the circuit breaker.
a. Removal. Refer to figure 4-26 and the following instructions to remove the circuit breaker.
(1) Tag and disconnect leads.
(2) Remove screws and lockwashers securing
the circuit breaker to the control panel and remove
the circuit breaker.
Figure 4-26. circuit breaker, removal and installation.
b. Cleaning.
Clean all parts in a well-ventilated area.
Avoid inhalation of solvent fumes and
prolonged exposure of skin to cleaning
solvent. Wash exposed skin thoroughly.
Dry cleaning solvent (Fed. Spec. P-D-680,
Type II) used to clean parts is potentially
dangerous to personnel and property. Do
not use near open flame or excessive heat.
Flash point of solvent is 140°F (60°C).
(1) Clean the exterior portion of the circuit
breaker with a cloth dampened in cleaning solvent,
Fed. Spec. P-D-680, Type II, and dry thoroughly.
(2) Inspect the circuit breaker for a cracked
case and for signs of scorched or burned areas.
4-56
Change 5
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TO 35C2-3-424-1
(3) Inspect the terminals for damage and
stripped threads.
(4) Operate the unit and inspect for proper
operation. When moved to the ON position, the
breaker should hold and should not trip OFF.
(5) Replace a defective circuit breaker.
c. Installation.
(1) Position circuit breaker in place and secure with lockwashers and screws.
(2) Reconnect all leads.
4-42. Control Relays (K1, K2, K3, and
K4).
a. Removal. Refer to figure 4-27 and the following instructions to remove the control relays.
(1) Remove screws and lockwashers securing
the control relays in the relay sockets.
(2) Remove relays by pulling straight out.
Figure 4-27. Control relays, removal and installation-
4-57
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TO 35C2-3-424-1
b. Cleaning, Inspection and Repair.
Clean all parts in a well-ventilated area.
Avoid inhalation of solvent fumes and
prolonged exposure of skin to cleaning
solvent. Wash exposed skin thoroughly.
Dry cleaning solvent (Fed. Spec. P-D-680,
Type II) used to clean parts is potentially
dangerous to personnel and property. Do
not use near open flame or excessive heat.
Flash point of solvent is 140°F (60°C).
(1) Clean the exterior of the control relays
carefully with a cloth dampened in cleaning solvent,
Fed. Spec. P-D-680, Type II, and dry thoroughly.
(2) Inspect for burned, broken, or missing contact pins.
(3) Inspect the cases for cracks, breakage and
other damage.
(4) Replace a damaged control relay.
c. Testing.
(1) Refer to figure 4-28 for identification of
the contact pins.
Figure 4-28. Relay, internal connection diagram.
4 - 5 8
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NOTE
The bases of two of the pins are colored black and
enable the user to properly orient the unit. The pine
are not actually numbered on the relay, but are
numbered on the illustration so the individual pins
can be identified in the text.
(2) Use a multimeter and test between 2 and
4. There should be continuity. Then, test between 2
and all other pins except 4. There should be no continuity.
(3) Test between pins 5 and 7. There should be
continuity. Now, test between pin 7 and all other
pins except 5. There should be no continuity between pin 7 and the other pins.
(4) Apply a source of 24-volt dc power to pins 3
and 6. This should operate the relay.
CAUTION
When testing the relay with a source
of power, do not allow the test probes
to contact pins 3 and 6 as damage to
the test instrument may result.
(5) With the power applied, test between pins
2 and 8. There should be continuity. Next, test between pins 2 and pins 4, and 5. There should be no
continuity.
(6) Continue the test with the power applied
and test between pins 7 and 1. There should be continuity. Now, test between pin 7 and pins 5,4, and 8.
There should be no continuity.
(7) Replace a relay that fails to pass any of the
tests above.
d. Installation.
NOTE
When installing relays, push straight in. Do not
twist as pins will be damaged.
(1) Install relays.
(2) Secure relays in socket with lockwashers
and screws.
4-43. Outlet Receptacle (J1). (Model
MEP-017A).
a. Removal. Refer to figure 4-29 and the following instructions to remove the outlet receptacle.
(1) Remove screws and lockwashers securing
the receptacle cover to the control box.
(2) Remove receptacle cover and gasket.
(3) Remove screws and lockwashers securing
the duplex receptacle.
(4) Slide receptacle forward. Tag and disconnect electrical leads and remove the receptacle.
4-59
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TO 35C2-3-424-1
Figure 4-29. Outlet receptacle (J1) (Model MEP-017A)
b. Cleaning, Inspection and Repair.
Clean all parts in a well-ventilated area.
Avoid inhalation of solvent fumes and
prolonged exposure of skin to cleaning
solvent. Wash exposed skin thoroughly.
Dry cleaning solvent (Fed. Spec. P-D-680,
Type II) used to clean parts is potentially
dangerous to personnel and property. Do
not use near open flame or excessive heat.
Flash point of solvent is 140°F (60°C).
(1) Clean the exterior surfaces with a clean
cloth dampened in cleaning solvent, Fed. Spec. P-D680, Type II, and dry thoroughly.
(2) Inspect the receptacle for burned contacts
4-60
Change 5
and for cracks and other damage.
(3) Replace a defective outlet receptacle.
c. Installation.
(1) Reconnect electrical leads to the duplex receptacle.
(2) Secure receptacle in the control box with
lockwashers and screws.
(3) Position receptacle cover gasket and cover
in place on control box and secure with lockwashers
and screws.
4-44. Top Resilient Mounts.
a. Removal. Refer to figure 4-30 and the following instructions to remove the resilient mounts.
(1) Remove screws and washers securing the
top resilient mounts to the control box.
(2) Remove nuts, washers, and screws securing the resilient mounts to the control box bracket.
(3) Remove the resilient mounts.
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424.1
Figure 4-30. Top resilient mounts, removal and installation.
b. Cleaning, Inspection and Repair.
Clean all parts in a well-ventilated area.
Avoid inhalation of solvent fumes and
prolonged exposure of skin to cleaning
solvent. Wash exposed skin thoroughly.
Dry cleaning solvent (Fed. Spec. P-D-680,
Type II) used to clean parts is potentially
dangerous to personnel and property. Do
not use near open flame or excessive heat.
Flash point of solvent is 140 ‘F (60 ‘C).
Fed. Spec. P-D-680, Type II, and dry thoroughly.
(2) Inspect the top resilient mounts for
stripped threads, loose threaded inserts, and for
cracks and deterioration of the mount body.
(3) Replace a defective resilient mount.
c. Installation.
(1) Position top resilient mounts in place on
the control box bracket and secure with screws,
lockwashers and nuts.
(2) Install washers and screws securing the
top resilient mounts to the control box.
4-45. Control Box Bracket.
a. Removal.
(1) Clean item with cleaning solvent,
(1) Remove the nuts, lockwashers and screws
that secure the toolbox on the toolbox bracket.
Refer to figure 4-31.
Change 5
4-61
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Figure 4-31. Toolbox, removal and installation.
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(2) Remove the top resilient mounts (para 444).
(3) Refer to figure 4-32, View A, and remove
the screw and lockwashers securing the control box
bracket to the side of the generator housing.
(4) Refer to figure 4-32, View B, and remove
the lifting eye and screw and lockwasher securing
the control box bracket to the top of the generator
housing.
(6) Remove the control box bracket.
Figure 4-32. Control box bracket, removal and installation.
b. Cleaning, Inspection and Repair.
Clean all parts in a well-ventilated area.
Avoid inhalation of solvent fumes and
prolonged exposure of skin to cleaning
solvent. Wash exposed skin thoroughly.
Dry cleaning solvent (Fed. Spec. P-D-680,
Type II) used to clean parts is potentially
dangerous to personnel and property. Do
not use near open flame or excessive heat.
Flash point of solvent is 140° F (60° C).
Change
54-63
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P-8-614-14
TO 35C2-3-424-1
(1) Clean items with cleaning solvent, Fed.
Spec. P-D-680 Type II, and dry thoroughly.
(3) Refer to paragraph 4-44 and install the top
resilient mounts.
(2) Inspect the bracket for dents, cracks and
distortion.
(4) Install the screws, lockwashers, and nuts
that secure the toolbox to the toolbox bracket. Refer
to figure 4-31.
(3) Straighten a distorted or dented bracket.
(4) Weld cracks and grind the welds smooth.
(5) Replace a defective control box bracket.
c. Installation.
(1) Position the control box bracket in place
and install lockwasher and screw and lifting eye to the
top of the generator housing.
(2) Install lockwashers and screws that secure
the control box bracket to the side of the generator
housing.
4-64
Change 6
4-45A. Replace Lost or Broken Terminal Clip
(Retainer, Safety Clip).
The terminal clip is a component of both the load
terminal and the ground terminal. If terminal clip is
lost or broken, fabricate as follows: Requisition bull
wire NSN 9505-01-049-0144, 0.050 inch diameter. Cut
off about 3 inches of the wire. Cut the wire short
enough to keep the clips from touching another ter
minal or the generator frame in the open or closed
position. Slip the wire through the hole in the terminal
and proceed as shown in the following views.
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
Section X.
MAINTENANCE OF THE FRAME ASSEMBLY
4-46. General.
4-47. Guard Frame.
This section covers organizational maintenance
for the lifting eye and lifting eye bracket, guard
frame, and toolbox. These items are all identical on
both the model MEP-017A and the model MEP022A generator sets.
a. Removal. Refer to figure 4-33 and the following instructions to remove the guard frame.
(1) Remove the nuts, washers, and screws securing the guard frame to the skid base.
(2) Remove the screw and lockwasher that secures the guard frame to the flywheel housing.
(3) Remove guard frame from the generator
set.
Figure 4-33. Guard frame, removal and installation.
4-64.1/4-64.2 blank
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
b. Cleaning, Inspection and Repair.
Clean all parts in a well-ventilated area.
Avoid inhalation of solvent fumes and
prolonged exposure of skin to cleaning
solvent. Wash exposed skin thoroughly.
Dry cleaning solvent (Fed. Spec. P-D-680,
Type II) used to clean parts is potentially
dangerous to personnel and property. Do
not use near open flame or excessive heat.
Flash point of solvent is 140°F (60°C).
(1) Clean items with cleaning solvent, Fed.
Spec. P-D-680, Type II, and dry thoroughly.
(2) Inspect the guard frame for dents, bent areas, cracks, and broken welds.
.(3) Weld cracks and broken welds. Smooth up
the welds by grinding.
(4) Straighten any bent or twisted areas.
(5) Replace a defective guard frame.
c. Installation.
(1) Position the guard frame in place and in-
stall lockwasher and screw that secures the guard
frame to the flywheel housing.
(2) Install screws, lockwashers and nuts that
secure guard frame to the skid base.
4-48. Lifting Eye and Lifting Bracket.
a. Removal. Refer to figure 4-34 and the following instructions to remove the lifting eye and lifting bracket.
(1) Loosen nut that secures the lifting eye to
the toolbox bracket. Unscrew lifting eye.
(2) Remove screws and lockwashers which secure the lifting bracket to the flywheel housing the
remove the lifting bracket.
Change 5
4-65
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TO 35C2-3-424-1
Figure 4-34. Lifting eye and lifting bracket, removal and installation.
4-66
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P-8-614-14
TO 35C2-3-424-1
b. Cleaning, Inspection and Repair.
Clean all parts in a well-ventilated area.
Avoid inhalation of solvent fumes and
prolonged exposure of skin to cleaning
solvent. Wash exposed skin thoroughly.
Dry cleaning solvent (Fed. Spec. P-D-680,
Type II) used to clean parts is potentially
dangerous to personnel and property. Do
not use near open flame or excessive heat.
Flash point of solvent is 140° F (60 °C).
(1) Clean items with cleaning solvent Fed.
Spec. P-D-680 Type II, and dry thoroughly.
(2) Inspect the lifting eye and lifting eye
bracket for cracks and distortion.
(3) Inspect the lifting eye for stripped or damaged threads.
(4) Replace all defective parts.
c. Installation.
(1) Install the lifting bracket to the flywheel
housing with lockwashers and screws.
(2) Thread lifting eye into hole provided on
tool box bracket. Tighten nut to secure.
4-49.
a.
Ground Stud Terminal.
Removal. To remove the ground stud termi-
nal (fig. 4-35), remove the nut and lockwasher that
secure it to the skid base and remove the terminal.
Figure 4-35. Ground terminal stud, removal and
installation.
Change 5
4-67
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TO 35C2-3-424-1
b. Cleaning, Inspection and Repair.
(1) Remove the nuts, lockwashers, and screws
which secure the toolbox to the toolbox mounting
bracket.
(2) Remove the toolbox.
Clean all parts in a well-ventilated area.
Avoid inhalation of solvent fumes and prolonged exposure of skin to cleaning solvent. Wash exposed skin thoroughly. Dry
cleaning solvent (Fed. Spec. P-D-680, Type
II) used to clean parts is potentially
dangerous to personnel and property. Do
not use near open flame or excessive heat.
Flash point of solvent is 140” F (60° C).
(1) Clean items with cleaning solvent Fed.
Spec. P-D-680 Type II, and dry thoroughly.
(2) Inspect studs for cracks, breaks and wear.
b. Cleaning, Inspection and Repair.
WARNING
Clean all parts in a well-ventilated area.
Avoid inhalation of solvent fumes and prolonged exposure of skin to cleaning solvent. Wash exposed skin thoroughly. Dry
cleaning solvent (Fed. Spec. P-D-MO, Type
11) used to clean parts is potentially
dangerous to personnel and property. Do
not use near open flame or excessive heat.
Flash point of solvent is 140° F (60° C).
(3) Replace a damaged stud.
c. Installation. Install ground terminal stud to
skid base using lockwasher and nut.
d. Replace lost or broken terminal clip (Retainer,
safety clip). For fabrication procedures, see paragraph
4-45A.
(1) Clean items with cleaning solvent Fed.
Spec. P-D-680 Type H, and dry thoroughly.
(2) Inspect the toolbox for dents, broken welds
and other damage.
(3) Weld cracks and grind the weld smooth.
4-50. Toolbox
a. Removal. Refer to figure 4-31 and the following instructions to remove the toolbox.
(4) Straighten dents.
(5) Replace a defective toolbox.
c. Installation.
(1) Position toolbox in place on toolbox mounting bracket.
(2) Secure with screws, lockwashers and nuts.
4-68
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TO 35C2-3-424-1
CHAPTER 5
INTERMEDIATE (FIELD), (DIRECT AND GENERAL SUPPORT) AND
DEPOT MAINTENANCE INSTRUCTIONS
Section I.
REPAIR PARTS, SPECIAL TOOLS AND EQUIPMENT
5-1. Special Tools and Equipment
There are no special tools or equipment required by
Direct and General Support Maintenance to Repair/
Overhaul the generator set.
NOTE
Air Force users may perform maintenance within
the scope of their capability.
Section II.
5-3. General
5-2. Direct and General Support Maintenance Repair Parts
(A) Direct and General Support Maintenance Repair Parts are listed and illustrated in TM 5-6115332-34P.
(F) Air Force users refer to TO 38G-89-34,
DS AND GS TROUBLESHOOTING
rective actions. If a malfunction is not listed or is
not corrected by listed corrective actions, notify
your supervisor.
a. This section contains troubleshooting in formation for locating and correcting most of the DS
and GS troubles which may develop in the gener5-4. Troubleshooting
ator set. Each malfunction for an individual component, unit, or system is followed by a list of tests
NOTE
or inspections which will help you to determine the
Before you use this table, be sure you have perprobable causes and corrective actions in the order
formed all applicable operating checks.
listed.
Refer to Table 5-1 for direct and general-support
b. This manual cannot list all malfunctions that
maintenance
troubleshooting.
may occur, nor all tests or inspections and cor-
5-1
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
Table 5-1. DS and GS Troubleshooting
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
1. GENERATOR FAILS TO BUILD UP RATED VOLTAGE
Step 1.
Check to see if the field flash switch is broken or cracked. Test as follows: Using a multimeter,
check for continuity of the switch contacts. Test the field flash switch for continuity while the
switch is held in the closed (ON) position.
If the field flash switch is damaged or defective replace it. Refer to paragraph 7-4 for removal
and installation. If the switch is not defective, go on to Step 2.
Step 2.
Test for a defective resistor as follows:
a. Disconnect the current transformer leads and remove the three resistors.
Never disconnect the leads of a current transformer, either at the transformer or at
a meter connected to the transformer, when the equipment is energized. The three
resistors used with this equipment are connected across the secondary windings of
the current transformer and they ordinarily prevent an open circuit condition. But,
if a resistor were to fail and then the secondary was to be open circuited by disconnecting its load (the meter), extremely high voltages would be induced in the windings.
Serious damage to the equipment and possibly the death of personnel could result.
b. Use a multimeter set on the RX1 scale and test between terminals A1 and A2, B1 and B2,
arid Cl and C2. Continuity should be shown in all three tests.
c. Now, test between terminal A1 and B1, between A1 and C1, and between B1 and C1. There
should be no continuity indicated in any of these three tests.
d. Connect the multimeter, in turn, across the terminals of each resistor and measure the
resistance. The resistance should measure within one percent above or below 305 ohms.
If test shows resistors are defective, replace them. Refer to paragraph 7-5 for removal and
installation of the resistors. If the malfunction is not caused by faulty resistors, go on to
Step 3.
Step 3.
5-2
Determine if the voltage regulator is defective by performing voltage regulator on-equipment
test as described below.
a. Put output selector switch to desired output setting (fig. 2-4) and disconnect the load cables.
b. Start the generator set (fig 2-7 or fig. 2-8). Place the circuit breaker to the ON position and
check output selector switch to indicate load terminals where output voltage is applied.
c. Check set voltmeter for correct setting. Using a multimeter, check load terminals to verify
reading on set voltmeter. If voltage is low and the variable resistor on the control panel will not
correct the deficiency, check exciter voltage across terminals 20 and 21 of the voltage regulator
terminal board. This voltage will vary but should be about 30 volts. If voltage at terminals 20
and 21 of the voltage regulator terminal board fails to meet specifications, the voltage regulator
is defective and should be replaced.
d. Using a multimeter as a check against the set voltmeter, test the output terminals of the
generator set against all position settings of the voltage switch.
e. Stop the generator set and connect the load cables.
f. Repeat steps 2 and 3 above.
If the regulator is faulty replace it. Refer to figure 7-3 for voltage regulator with PN
13211E6975 (97403) or 13212E8950 (97403) and to figure 7-4 for voltage regulator PN
13219E0883 (97403). Refer to paragraph 7-6 for removal and installation instructions. If faulty
voltage regulator is not the cause of the malfunction, go on to Step 4.
Change 6
TM 5-6115-332-14
P-8-614- 14
TO 35C23-424-1
Table 5-1. DS and GS Troubleshooting (Cont’d)
Malfunction
Test or Inspection
Corrective Action
Step 4.
2.
Test the generator as follows:
a. General.
On-equipment electrical test procedures may provide a basis for
determining the necessity and extent of generator repair. The resistance values and tolerances
contained in this paragraph should be used only as a general guide. Take into consideration the
test instrument used, test lead resistance, and the ambient temperature at the tune of the test If
more precise measurements are required, use an instrument such as a Kelvin Balance or a
Wheatstone Bridge and make comparative measurements between the suspected component
and like item that is known to be good.
b. Stator.
(1) Disconnect the plug connector (P2) at the rear of the control box.
(2) Use a multimeter that has been set on the RX1 scale and test for continuity
between plug pins A and B, D and E, and C and F If continuity is not indicated (full deflection) on
any of the tests, remove the plug at the generator and repeat the tests at the generator. If again,
continuity is not shown, the stator is defective and must be replaced. Refer to para. 7-14.
c. Rotor.
(1) Remove the blower cover and fan (par 6-2 or 6-3).
(2) Use a multimeter that has been set on the RX1 scale and test between the rotor
field windings terminal and the case of the rotor. If the resistance is not within five percent above
or below the following values, the rotor must be removed for further testing (TM 5-764):
Model MEP 01 7A (60 Hertz)
8.8 ohms
Model MEP4-022A (400 Hertz)
0.615 ohms
d. Exciter Field Windings.
(1) Disconnect the plug connector (PI) at the rear of the control box.
(2) Use a multimeter that has been set on the RXI scale and test for continuity
between plug pins G and H. If the resistance is not within five percent above or below 54.4 ohms.
the windings are defective and must be replaced. Refer to para 7-14.
GENERATOR VOLTAGE TOO HIGH
Step 1.
Test the voltage regulator as follows:
a. Put output selector switch to desired output setting (fig. 2-4) and disconnect the load
cables.
b. Start the generator set (fig. 2-7 or fig. 2-8). Place the circuit breaker to the ON
position and check output selector switch to indicate load terminals were output voltage is applied.
c. Check set voltmeter for correct setting. Using a multimeter, check load terminals to
verify reading on set voltmeter. If voltage is low and the variable resistor on the control panel will
not correct the deficiency, check exciter voltage across terminals 20 and 21 of the voltage
regulator terminal board . This voltage will vary but should be about 30 volts. If voltage at
terminals 20 and 21 of the voltage regulator terminal board fails to meet specifications, the voltage
regulator is defective and should be replaced
d. Using a multimeter as a check against the set voltmeter, test the output terminals of
the generator set against all position settings of the voltage selector switch
e. Stop the generator set and connect the load cables.
f. Repeat steps 2 and 3 above. If the voltage regulator does not pass the test, replace
it.
Refer to figure 7-3 for voltage regulator PN 13211E6975(97403) or
13212ES950(97403) or to figure 7-4 for voltage regulator PN 13219E0883(97403)
and to paragraph 7-6 for removal and installation. If the tests show the regulator is
not damaged, go on to step 2.
Change 10 5-3
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
Table 5-1. DS and GS Troubleshooting (Cont ‘d)
Malfunction
Test or Inspection
Corrective Action
Step 2.
Test the generator as follows:
a. General. On-equipment electrical test procedure may provide a basis for determining the necessity and
extent of generator repair. The resistance values and tolerances contained in this paragraph should be used only
as a general guide. Take into consideration the test instrument used, test lead resistance. and the ambient temperature at the time of the test. If more precise measurements are required, usc an instrument such as a Kelvin
Balance or a Whetstone Bridge and make comparative measurements between the suspected component and a
like item that is known to be good.
b.
Stator.
(1) Disconnect the plug connector (P1) at the rear of the control box.
(2) Use a multimeter that has been set on the RX1 scale and test for continuity between plug pins A and B,
D and E, and C and F. If continuity is not indicated (full deflection) on any of the tests, remove the plug at the
generator and repeat the tests at the generator. If, again, continuity is not shown, the stator is defective and must
be replace.
c. Rotor.
(1) Remove the blower cover and fan (para. 6-2 or 6-3).
(2) Use a multimeter that has been set on the RX1 scale and test between the rotor field windings terminal
and the case of the rotor. If the resistance is not within five percent above or below the following values, the rotor
must be removed for further testing (TM 5-764):
8.8 o h m s
Model MEP-017A (60 Hertz)
0.615 ohms
Model MEP-022A (400 Hertz)
d. Exciter Field Windings.
(1) Disconnect the plug connector (P1) at the rear of the control box.
(2) Use Multimeter that has been set on the RX1 scale and tcst for continuity between plug pins G and H. If
the resistance is not within five percent above or below 54-4 ohms, the windings are defective and must be replaced. Refer to para. 7-14.
3. GENERATOR FREQUENCY FLUCTUATES OR DROPS UNDER LOAD
Check frequency converter for breaks or cracks. C h e c k f o r b u r n e d , b r o k e n , o r w o r n w i r i n g T e s t t h e f r e q u e n c y
meter with a multimeter, refer to paragraph 4-16.
If the meter does not pass the tests and inspections given above, replace it. Refer to paragraph 7-2
for instructions.
4. AC VOLTMETER FAILS TO INDICATE VOLTAGE OR CURRENT INDICATOR METER FAILS
TO INDICATE CURRENT
Step 1.
Perform the following tests:
a. Tag and disconnect all output selector switch leads.
b. Use a multimeter set on the RX1 scale and test the switch for continuity as outlined in c through f. below.
c. Turn the switch to the “120/208v, 3 phase” position. In this position there should be continutiy indicated between terminals 7 and 8,9 and 10, 2 and 6, and 13 and 14 of the switch.
d. Turn the switch to the “120v, 3 phase” position. Continuity should be indicated between terminals 8 and 9.
2 and 4, 5 and 6, and 13 and 15.
e. Position the switch in the “120v, 1 phase” position. Continuity should he indicated between terminals 8 and
10, 2 and 4, 1 and 3, 5 and 6, and 11 and 13 of the switch.
f. Turn the switch to the 240v, 1 phase position. Continuity should be indicated between terminals 8 and 10, 2
and 6, 1 and 3, and 12 and 13 of the switch.
If the switch does not pass the test above, replace it. Refer to figure 5-1 for removal and installation.
If the switch passes the above test, go on to Step 2.
5-4
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
Table 5-1. DS and GS Troubleshooting (Cont’d)
Malfunction
Test or Inspection
Corrective Action
Step 2.
Test the current transformer as follows:
a. Disconnect the current transformer leads and remove the three resistors.
WARNING
Never disconnect the leads of a current transformer or at a meter connected to
the transformer, when the equipment is energized. The three resistors used
with this equipment are connected across the secondary windings of the current transformer and they ordinarily prevent an open circuit condition. But, if
a resistor were to fail and then the secondary was to be open circuited by disconnecting its load (the meter), extremely high voltages would be induced in
the windings. Serious damage to the equipment andd possibly the death of personnel could result.
b. Use a multimeter set on the RX1 scale and test between transformer terminals A1 and A2, B1 and B2, and
Cl and C2. Continuity should be shown all three tests.
c. Now, test between transformer terminal A1 and B1, between Al and C1. and between B1 and C1. There
should be no continuity indicated in any of these three tests.
d. Connect the meter, in turn, across the terminals of each resistor and measure the resistance. The resistance
should measure within one percent above or below 305 ohms.
If the transformer does not pass the above test, replace it. Refer to paragraph 7-5 for removal and
installation.
5. FREQUENCY METER FAILS TO INDICATE FREQUENCY
Inspect for a cracked or broken meter. Check for broken, burned, or worn wire. Test the frequency converter to determine its condition as follows:
a. Model MEP-017A.
(1) Apply AC input of 120 volts, 60 hertz current across terminals marked “L”.
(2) With panel (M3) connected to output side meter reading should indicated 60 hertz + 0.5 hertz.
(3) For test with panel meter disconnected, direct output current of the converter shall be 100
microampere
+ 10 microampere with 1100 ohm load across positive and negative terminals.
b. Model MEP-022A. With generator set operating at 3428 rpm, remove screw in the face of the frequency
converter and adjust the potentiometer for a reading of 400 HZ on the frequency meter. If proper reading is not
obtained, proceed as follows:
(1) Disconnect the lead from the Positive (+) and negative (-) terminals on the frequency meter.
(2) Attach a multimeter with the scale set to read at least 200 microampere, to the + and terminals on the
frequency meter.
(3) Operate generator set at 3428 rpm and turn adjusting screw to obtain a 100 microamperes on the multimeter scale.
(4) If reading is accomplished, the frequency meter on the control panel is faulty and must be replaced.
(5) If reading of 100 microamperes cannot be obtained, disconnect the wire leads from the two L terminals
on the frequency converter. Test the wire leads. If no defect is discovered, replace frequency converter and operate
generator set. Turn adjusting screw to obtain 400 HZ reading.
If frequency meter does not pass the above test, replace it. Refer to paragraph 7-2 and replace the
meter to the applicable model generator set.
5-5
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
Table 5-1. DS and GS Troubleshooting (Cont’d)
Malfunction
Test or Inspection
Corrective Action
6. GENERATOR FREQUENCY FLUCTUATES OR DROPS UNDER LOAD
Test the frequency converter to determine its condition. Test as follows:
a. Model MEP-017A.
(1) apply AC input of 120 volts, 60 hertz current across terminals marked “L”.
(2) With panel meter (M3) connected to output side meter reading should indicate 60 hertz + 0.5 hertz.
(3) For test with panel meter disconnected, direct output current of the converter shall be 100
microampere
+ 10 microampere with 1100 ohm load across positive and negative terminals.
b. Model MEP-022A. With generator set operating at 3428 rpm, remove screw in the face of the frequency
converter and adjust the potentiometer for a reading of 400 HZ on the frequency meter. If proper reading is not
obtained, proceed as follows:
(1) Disconnect the lead from the positive (+) and negative (-) terminals on the frequency meter.
(2) Attach a multimeter with the scale set to read at least 200 microampere. to the + and terminals on the
frequency converter.
(3) Operate generator set at 3428 rpm and turn adjusting screw to obtain a 100 microampere reading on the
multi meter scale.
(4) If reading is accomplished. the frequency meter on the control panel is faulty and must be replaced.
(5) If reading of 100 microamperes cannot be obtained. disconnect the wire leads from the two L terminals
on the frequencv converter. Test the wire leads. If no defect is discovered, replace frequency converter and operate
generator set. Turn adjusting screw to obtain 400 HZ meter reading.
If frequency meter does not pass the above test, replace it. Refer to paragraph 7-2 and replace
the meter in the applicable model generator set.
7. GENERATOR NOISY
Step 1.
Remove the generator, paragraph 6-2 or 6-3, Disassemble the generator, paragraphs 7-13 and 7-14, to the extent
necessary to inspect the bearing, Inspect bearing for leakage, looseness, and smoothness when turned. Inspect for
evidence of wear.
If the bearing does not pass the inspection above, replace it. Assemble the generator, paragraphs 713 and 7-14. Reinstall the generator, paragraph 6-2 or 6-3. If the bearing passes the above inspection,
go on to Step 2.
Step 2.
Remove the generator, paragraph 6-2 or 6-3. Disassemble the generator, paragraph 7-13 and 7-14, to the extent
necessary to inspect the fan and rotor adapter. Inspect for looseness, cracks, wear, and other physical damage.
If the fan and rotor adapter does not pass the above inspection, replace them. Reassemble the generator, paragraph 7-13 and 7-14. Reinstall the generator, paragraph 6-2 or 6-3.
8. GENERATOR OVERHEATS
Step 1.
Inspect the fan for cracks, breaks, insufficient mounting, and looseness.
If fan condition does not pass the above inspection, replace it. Refer to paragraph 6-2 or 6-3 for removal and installation. If fan passes the inspection, go on to Step 2.
Step 2.
5-6
Test the stator as follows:
a. Disconnect the plug connector (P1) at the rear of the control box.
b. Use a multimeter that has been set on the RX1 scale and test for continuity between plug pins A and B, D
and E, and C and F. If continuity is not indicated (full deflection) on any of the tests, remove the plug at the
generator and repeat the tests at the generator.
TM 5-6115-332-14
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TO 35C2-3-424-1
Table 5-1. DS and GS Troubleshooting (Cont’d)
Malfunction
Test or Inspection
Corrective Action
If continuity is shown, the cable is defective and must be replaced. If continuity is not shown, the
stator is defective and must be replaced. Remove the generator, paragraph 6-2 or 6-3. Disassemble
the generator, paragraphs 7-13 and 7-14, to the extent necessary to replace the stator. If the stator
passes the above test, go on to Step 3.
Step 3.
Test the rotor as follows:
a. Remove the blower cover and fan, para. 6-2 or 6-3.
b. Use a multimeter that has been set on the RX1 scale and test between the rotor field windings terminal and
the case of the rotor. If the resistance is not wit bin five percent above or below the following values, the rotor
must be removed for further testing (TM 5-764):
8.8 ohms
Model MEP-017A (60 Hertz)
0.615 ohms
Model MEP-022A (400 Hertz)
If the rotor does not pass the above test, replace it. Refer to paragraph 6-2 or 6-3 and remove the generator. Refer to paragraph 7-13 and 7-14, disassemble the generator to the extent necessary to replace the rotor.
5-7
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Section III.
GENERAL MAINTENANCE
5-5. General
Refer to Chapters 2 and 3 for operator preventive
maintenance checks and services and service the
generator set.
5-6. General Disassembly Procedures
a. Components to be repaired shall be disassembled to the extent required for complete serviceability.
b. Serviceable, precision, matched or mated
parts shall be marked, handled and stored to preclude damage and’ to insure reassembly and installation in their matched and mated positions in the
same assembly or component.
5-8
5-7. General Repair and/or Replacement Criteria
a. In-process inspection shall be performed on
each assembly, subassembly and component parts
being repaired to insure strict adherence to criteria
established by this manual.
b. Welding shall assure complete fusion and
penetration and be in compliance with specifications and standards referenced herein.
5-8. General Reassembly Procedures
a. General precautions shall be adhered to during reassembly to insure that all internal parts
have been properly installed and necessary lerance
checks performed.
b. upon completion of reassembly, generator set
shall be lubricated in accordance with Lubrication
Order. Refer to DA-PAM-310-4 for current listing.
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
CHAPTER 6
REMOVAL AND INSTALLATION OF MAJOR COMPONENTS
6-1. Control Box
a. Removal. Refer to figure 6-1 and the follow-
ing instructions to remove the control box.
(1) Disconnect electrical cables from the control box.
(2) Remove the ground strap from the control
box.
(3) Remove the screws and washers which secure the control box to the generator housing.
(4) Remove the screws and washers that secures the control box to the bottom resilient mounts
and remove the control box.
b. Installation.
(1) Position the control box in place on the resilient mounts and secure with washers and screws.
(2) Secure control box to the generator housing with washers and screws.
(3) Install ground strap.
(4) Reconnect electrical cables.
Figure 6-1. Control box, removal and installation.
6-1
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6-2. Generator (Model MEP-017A)
a. Removal.
(1) Lift the locking handle (fig. 3-4) and remove the fuel can adapter from the fuel can.
(2) Lift clamp and loosen the strap securing
the fuel can in the fuel can bracket sufficiently to
allow for removal of the fuel can.
(3) Disconnect the battery cables (fig. 4-22).
(4) Remove nuts and washers which secure
the upper battery frame and remove frame and
hook bolts.
(5) Remove battery from battery frame.
(6) Remove the nuts, lockwashers and screws
(fig. 4-33) that secure the guard frame to the skid
base.
(7) Remove the screw and lockwasher that secures the guard frame to the flywheel housing and
remove guard frame from the generator.
(8) Remove the nuts, lockwashers and screws
(fig. 4-31) which secure the toolbox to the toolbox
bracket and remove the toolbox.
(9) Remove the nuts, washers and screws (fig.
4-30) which secure the resilient mounts to the control box bracket.
6-2
(10) Remove the resilient mounts.
(11) Remove the screws and lockwashers (fig.
4-32, View A) that secure the control box bracket to
the side of the generator housing.
(12) Remove the lifting eye (fig. 4-32, View B)
and screw and screw and lockwasher securing the
control box bracket to the top of the generator housing.
(13) Remove the control box bracket.
(14) Disconnect the electrical cables from the
control box.
(15) Remove the ground strap.
(16) Remove the screws and washers (fig. 6-1)
which secure the control box to the generator housing.
(17) Remove the screws and washers that secure the control box to the bottom resilient mounts
and remove the control box.
(18) Disconnect electrical cable from the generator housing (fig. 6-2).
(19) Remove screws and washers securing the
fan cover (fig. 4-22) to the generator housing and
remove the fan cover.
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TO 35C2-3-424-1
Figure 6-2. Generator, removal and installation (Model MEP-017A).
6-3
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(20) Remove screw and washers securing the
blower fan and remove blower fan.
(21) Remove the ground strap.
(22) Remove screws and washers which secure
the generator housing to the support brackets.
NOTE
Block up engine with suitable cribbing before removing screws and lockwashers securing the generator to the flywheel housing. Attach a suitable sling
around the generator housing and with a hoist raise
housing until a slight tension is felt.
(23) Remove the screws and lockwashers securing the generator to the flywheel housing.
(24) Shale generator housing to the rear and
remove the housing. Remove air inlet grille from
housing.
(25) Straighten tang on locks and remove the
screws and locks securing the drive disk to the
adapter and remove drive disk and rotor.
(26) Straighten tang on locks and remove
screws and locks securing the adapter to the flywheel and remove adapter from the flywheel.
b. Installation.
(1) Position adapter in place on the flywheel
and secure with locks and screws.
NOTE
Bend tang up over screws.
(2) Position the drive disk in place on the
adapter and secure with locks and screws.
NOTE
Bend tang up over screws.
(3) Place air inlet grille around the generator
housing and secure housing and grille to the flywheel housing with lockwashers and screws.
NOTE
Torque screws to 13 to 16 FT. LB. (1.80 to 2.21
kgm).
(4) Install the ground strap.
(5) Position blower fan in place and secure
with washers and screws.
NOTE
Torque screws to 14 to 16 FT. LB. (1.94 to 2.21
kgm).
(6) Install the fan cover to the generator housing with washers and screws.
6-4
(7) Reconnect electrical cable to generator.
(8) Position the control box in place on the
bottom resilient mounts and secure with washers
and screws.
(9) Secure the control box to the generator
housing with washers and screws.
(10) Install ground strap.
(11) Reconnect electrical cables to control
box.
(12) Position the control box bracket in place
and secure to the top of the generator housing with
washers and screws.
(13) Install lifting eye.
(14) Secure bracket to side of the generator
housing with washers and screws.
(15) Install resilient mounts to control box
bracket with screws, washers, and nuts.
(16) Place toolbox in position and secure with
screws, lockwashers, and nuts.
(17) Place guard frame over generator set and
secure to the flywheel housing with screws, lockwashers, and nuts.
(18) Secure guard frame to the skid base
using screws, lockwashers, and nuts.
(19) Place battery in battery frame and position hook bolt in place.
(20) Install upper battery frame with washers
and nuts.
(21) Reconnect battery cables.
(22) Place fuel can in fuel can bracket and secure with strap. Depress clamp to secure.
(23) Place fuel can adapter in fuel can and secure by depressing the locking handle.
6-3. Generator (Model MEP-022A)
a. Removal.
(1) Lift the locking handle (fig. 3-4) and remove the fuel can adapter from the fuel can.
(2) Lift clamp and loosen the strap securing
the fuel can in the fuel can bracket sufficiently to
allow for removal of the fuel can.
(3) Disconnect the battery cables (fig. 4-22).
(4) Remove nuts and washers which secure
the upper battery frame and remove frame and
hook bolts.
(5) Remove battery from battery frame.
(6) Remove the nuts, lockwashers and screws
(fig. 4-33) that secure the guard frame to the skid
base.
(7) Remove the screw and lockwasher that secures the guard frame to the flywheel housing and
remove guard frame from the generator.
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TO 35C2-3-424-1
(8) Remove the nuts, lockwashers and screws
(fig. 4-31) which secure the toolbox to the toolbox
bracket and remove the toolbox.
(9) Remove the nuts, washers and screws (fig.
4-30) which secure the resilient mounts to the control box bracket.
(10) Remove the resilient mounts.
(11) Remove the screws and lockwashers (fig.
4-32, View A) that secure the control box bracket to
the side of the generator housing.
(12) Remove the lifting eye (fig. 4-32, View B)
and screw and lockwasher securing the control box
bracket to the top of the generator housing.
(13) Remove the control box bracket.
(14) Disconnect the electrical cables from the
control box.
(15) Remove the ground strap.
(16) Remove the screws and washers (fig. 6-1)
which secure the control box to the generator housing.
(17) Remove the screws and washers that secure the control box to the bottom resilient mounts
and remove the control box.
(18) Disconnect electrical cable from the generator housing (fig. 6-2).
(19) Remove screws and washers securing the
fan cover (fig. 4-22) to the generator housing and
remove the fan cover.
6-5
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TO 35C2-3-424-1
Figure 6-3. Generator, removal and installation (Model MEP-022A).
6 - 6
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(20) Remove screw and washers securing the
blower fan and remove blower fan.
(21) Remove the ground strap.
(22) Remove screws and washers which secure
the generator housing to the support brackets.
NOTE
Block up engine with suitable cribbing before removing screws and lockwashers securing the generator to the flywheel housing. Attach a suitable sling
around the generator housing and with a hoist
housing until a slight tension is felt.
(23) Remove the screws and lockwashers securing the generator to the flywheel housing.
(24) Slide generator housing to the rear and
remove the housing. Remove air- inlet grille from
housing.
(25) Straighten tang on locks and remove the
screws and locks securing the drive disk to the
adapter and remove drive disk and rotor.
(26) Straighten tang on locks and remove
screws and locks securing the adapter to the flywheel and remove adapter from the flywheel.
b. Installation.
(1) Position adapter in place on the flywheel
and secure with lock and screws.
NOTE
Bend tang up over screws.
(2) Position the drive disk in place on the
adapter and secure with locks and screws.
NOTE
Bend tang up over screws.
(3) Place air inlet grille around the generator
housing and secure housing and grille to the flywheel housing with lockwashers and screws.
NOTE
Torque screws to 13 to 16 FT. LB. (1.80 to 2.21
k g m ) .
(4) Install the ground strap.
(5) Position blower fan m place and secure
with washers and screws.
NOTE
Torque screw to 14 to 16 FT. LB. (1.94 to 2.21
kgm).
(6) Install the fan cover to the generator housing with washers and screws.
(7) Reconnect electrical cable to generator.
(8) Position the control box in place on the
bottom resilient mounts and secure with washers
and screws.
(9) Secure the control box to the generator
housing with washers and screws.
(10) Install ground strap.
(11) Reconnect electrial cables to control box.
(12) Position the control box bracket in place
and secure to the top of the generator housing with
washers and screws.
(13) Install lifting eye.
(14) Secure bracket to side of the generator
housing with washers and screws.
(15) Install resilient mounts to control box
bracket with screws, washers, and nuts.
(16) Place toolbox in position and secure with
screws, lockwashers, and nts.
(17) Place guard frame over generator set and
secure to the flywheel housing with screws, lockwashers, and nuts.
(18) Secure guard frame to the skid base
using screws, lockwashers, and nuts.
(19) Place battery in battery frame and position hook bolt in place.
(20) Install upper battery frame with washers
and nuts.
(21) Reconnect battery cables.
(22) Place fuel can in fuel can bracket and secure with strap. Depress clamp to secure.
(23) Place fuel can adapter-in fuel can and secure by depressing the locking handle.
6-4. Engine
a. Removal.
(1) Lift the locking handle (fig. 3-4) and remove the fuel can adapter from the fuel can.
(2) Lift clamp and loosen the strap securing
the fuel can in the fuel can bracket sufficiently to
allow for removal of the fuel can.
(3) Disconnect the battery cables (fig. 4-22).
(4) Remove nuts and washers which secure
the upper battery frame and remove frame and
hook bolts.
(5) Remove battery from battery frame.
(6) Remove the nuts, lockwashers and screws
(fig. 4-33) that secure the guard frame to the skid
base.
(7) Remove the screw and lockwasher that secures the guard frame to the flywheel housing and
remove guard frame from the generator.
(8) Remove the nuts, lockwashers and screws
(fig. 4-31) which secure the toolbox to the toolbox
bracket and remove the toolbox.
(9) Remove the nuts, washers and screws (fig.
4-30) which secure the resilient mounts to the control box bracket.
6-7
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TO 35C2-3-424-1
(10) Remove the resilient mounts.
(11) Remove the screws and lockwashers (fig. 4-32,
View A) that secure the control box bracket to the side
of the generator housing.
(12) Remove the lifting eye (fig. 4-32, View B) and
screw and lock-washer securing the control box
bracket to the top of the generator housing.
(13) Remove the control box bracket.
(14) Disconnect the electrical cables from the control box.
(15) Remove the ground strap.
(16) Remove the screws and washers (fig. 6-1)
which secure the control box to the generator housing.
(17) Remove the screws and washers that secure
the control box to the bottom resilient mounts and
remove the control box.
(18) Disconnect electrical cable from the generator
housing (fig. 6-2).
(19) Remove screws and washers securing the fan
cover (fig. 4-22) to the generator housing and remove
the fan cover.
(20) Remove screw and washers securing the
blower fan and remove blower fan.
6-8
Change 7
(21) Remove the ground strap.
(22) Remove screws and washers which secure the
generator housing to the support brackets.
NOTE
Block up engine with suitable cribbing before
removing screws and lockwashers securing
the generator to the flywheel housing. Attach
a suitable sling around the generator housing
and with a hoist raise housing until a slight
tension is felt.
(23) Remove the screws and lockwashers securing
the generator to the flywheel housing.
(24) Slide generator housing to the rear and
remove the housing. Remove air inlet grille from
housing.
(25) Straighten tang on locks and remove the
screws and locks securing the drive disk to the
adapter and remove drive disk and rotor.
(26) Straighten tang on locks and remove screws
and locks securing the adapter to the flywheel and
remove adapter from the flywheel.
(27) Disconnect the fuel hoses (fig. 6-4) and starter
cables (fig. 6-5).
(28) Drain oil from engine and remove oil drain
cock prior to the removal of the engine.
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Figure 6-4. Fuel hoses, removal and installation.
6 - 9
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TO 35C2-3-424-1
Figure 6-5. Starter cable, removal.
6 - 1 0
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TO 35C2-3-424-1
(29) Disconnect the engine control cable at the
rear of the engine.
(30) Attach a sling to the engine lifting eye and
with the aid of a suitable hoist, raise engine until a
slight tension is felt.
(31) Remove the nut, lockwasher, flat washer and
screw securing the engine to the engine support (fig.
6-6). Remove engine oil drain assembly and remove
engine. Detach hoist.
Figure 6-6. Engine, removal and installation.
Change 7
6-11
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TO 35C2-3-424-1
b. Installation.
(1) Attach a sling to the engine lifting eye and with
the aid of a suitable hoist, lower engine into position
on mounting bracket. Secure with screw, flat washer,
lockwasher and nut.
(2) Connect the engine control cable to the rear of
the engine.
(3) Connect the fuel hoses and starter cables.
(4) Position adapter in place on the flywheel and
secure with lock and screws.
NOTE
Bend tang up over screws.
(5) Position the drive disk in place on the adapter
and secure with locks and screws.
NOTE
Bend tang up over screws.
(6) Place air inlet grille around the generator housing and secure housing and grille to the flywheel housing with lockwashers and screws.
NOTE
Torque screws to 13 to 16 FT. LB. (1.80 to 2.21
kgm).
(7) Install the ground strap.
(8) Position blower fan in place and secure with
washers and screw.
NOTE
Torque screws to 14 to 16 FT. LB. (1.94 to 2.21
kgm).
(9) Install the fan cover to the generator housing
with washers and screws.
6-12
Change 7
(10) Reconnect electrical cable to generator.
(11) Position the control box in place on the bottom resilient mounts and secure with washers and
screws.
(12) Secure the control box to the generator housing with washers and screws.
(13) Install ground strap.
(14) Reconnect electrical cables to control box.
(15) Position the control box bracket in place and
secure to the top of the generator housing with
washers and screws.
(16) Install lifting eye.
(17) Secure bracket to side of the generator housing with washers and screws.
(18) Install resilient mounts to control box
bracket with screws, washers, and nuts.
(19) Place toolbox in position and secure with
screws, lockwashers, and nuts.
(20) Place guard frame over generator set and
secure to the flywheel housing with screw,
lockwashers, and nuts.
(21) Secure guard frame to the skid base using
screws, lockwashers, and nuts.
(22) Place battery in battery frame and position
hook bolt in place.
(23) Install upper battery frame with washers and
nuts.
(24) Install battery terminal covers on both battery terminals. Reconnect battery cables.
(25) Place fuel can in fuel can bracket and secure
with strap. Depress clamp to secure.
(26) Place fuel can adapter in fuel can and secure
by depressing the locking handle.
(27) Ensure replacement of drain cock. Add oil as
required.
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TM 5-6115-332-14
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TO 35C2-3-424-1
CHAPTER 7
MAINTENANCE OF THE GENERATOR SET
Section I. CONTROL BOX ASSEMBLY
7-1. General
This section covers direct support and general
support maintenance of the control box and components. It includes the frequency converter,
output selector switch, relay panel, field flash
switch, current transformer and resistors, voltage
regulator and wiring. All components are accessible
either by lowering the upper hinged panel or by
removal of the lower access cover. Test procedures are included when applicable.
CAUTION
When plug P1 is connected, many of
the meters are still active and need
only a path to ground to complete
circuit.
7-2. Frequence Converter
a. General. The frequency converter is located
near the center of the control box. It receives an
ac signal of 120 volts from one of the generator
coil groups and converts this signal voltage to a dc
voltage that is proportionate to the frequency of
the generator output. The frequency meter is fed
this.dc voltage and the meter indicates the output
frequency in Hertz.
b. Testing. Teat the frequency converter as
follows:
(1) Model MEP-071A.
(a) Apply AC input of 120 volts, 6 0
hertz current across terminals marked “L”.
(b) With panel (M3) connected to output
side meter reading should indicate 60 hertz +
0.5 hertz.
(c) For teat with panel meter discon-
nected, direct output current of the converter
shall be 100 microamperes + 10 microamperes
with 1100 ohm load across positive and negative terminals.
(2) Model MEP-022A.
With generator set
operating at 3428 rpm, remove screw in the
face of the frequency converter, and adjust the
potentiometer for a reading of 400 HZ on the
frequency meter.
If proper reading is not
obtained, proceed as follows:
(a) Disconnect the lead from the positive
(+) and negative (-) terminals on the frequency
meter.
(b) Attach a multimeter with the scale
set to read at least 200 microampere, to the +
and - terminals on the frequency meter.
(c) Operate generator set at 3428 rpm
and turn adjusting screw to obtain a 100 microampere on the multimeter scale.
(d) If reading is accomplished, the frequency meter on the control panel is faulty and
must be replaced.
(e) If reading of 100 microampere cannot
be obtained, disconnect the wire leads from the
two L terminals on the frequency converter,
Test the wire leads. If no defect is discovered,
replace frequency converter and operate generator
set. Turn adjusting screw to obtain 400 HZ
reading. If frequency meter does not pass the
above test, replace it. Refer to figure 5-1 and
replace the meter to the applicable model generator set.
c. Removal. Refer to figure 7-1 and the following instructions to remove the frequency converter.
Change 7
7-1
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Figure 7-1. Control box components, removal and installation.
(1) Tag and disconnect all wiring from the
frequency converter.
(2) Remove the screws and washers securing the
frequency converter in the control box.
(3) Remove the frequency converter.
d. Cleaning and Inspection.
(1) Wipe the outer surface of the frequency
converter clean using a clean lint-free cloth.
(2) Inspect frequency converter housing for
cracks, burned areas, and for evidence of over–heating.
(3) Inspect contacts for corrosion, pitting, cracks,
breaks or other damage.
7 - 2 Change
9
Repair. Replace a defective frequency converter.
Installation.
(1) Position frequency converter in place on
control box.
e.
f .
(2) Secure with washers and screws.
(3) Reconnect all wiring.
7-3. Output Selector Switch
a. Removal. Refer to Figure 7-1 and the following
procedures to remove the output selector switch. On trailer
mounted units, remove the control box assembly first using
steps 1 through 5, then proceed with steps 6 through 9. On
skid mounted units, start with step 6.
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TO 35C2–3-424-1
NOTE
Replacement switches may not have the
terminals in the same location. To assure
proper installation, follow the terminal diagram
printed on the switch. Wire extension maybe
necessary to accommodate a replacement
switch. The wires that need to be lengthened
are: X7A10, X7C18, X6B10C, and Xl1A10A.
Ensure materials needed to lengthen wires are
on hand when ordering switch to reduce nonmission-capable (NMC) time.
(1) Remove power cable from load terminals.
(2) Disconnect cannon plugs from control box
assembly.
(3) Remove ground strap from control box
assembly.
(4) Remove control box assembly from generator
frame.
(5) Remove control box access cover and open
control panel door.
(6) Remove screws and washers securing output
selector switch mounting brackets to control box assembly.
(7) Tag and remove leads from output selector
switch.
(8) Remove output selector switch from control
box assembly.
(9) Remove top and bottom mounting brackets
from output selector switch.
b. Cleaning. Clean the output selector switch using
a clean lint free cloth to remove any foreign material.
c. Inspection.
(1) Inspect the voltage selector switch to insure
there is no binding or sticking in the various positions.
(2) Inspect contacts for pitting,
evidence of burning or other damage.
corrosion,
Replacement switches may not have the
terminals in the same location. The terminal
diagram on the switch must be followed. When
facing the switch terminal diagram, the far
terminals are the terminal rows farthest from
the diagram and the near terminal rows are the
closest. For proper connection of the switch, it
may be necessary to lengthen four wires:
X7A10, X7C18, X6B10C, and Xl1A10A.
Testing.
(1) Refer to paragraph 7-3a and remove output
selector switch.
d.
(2) Refer to switch terminal diagram located on
switch and Table 7–1. Use multimeter set on RX 1 scale and
test terminals A through L for continuity in all four
positions. Readings should match those indicated in Table
7–1. Replace switch that does not pass this test.
Change 9
7-2.1/(7-2.2 blank)
Repair. Replace a defective output selector
e.
switch.
f. Installation.
(1) Install top and bottom mounting brackets to
output selector switch.
(4)
(5)
(6)
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
Secure switch to control box assembly.
Install access cover on control box assembly.
Install control box assembly on generator
frame.
Install ground straps.
Connect cannon plugs.
Install power cable.
(lo) Test generator set operation.
(7)
(8)
(9)
(2) Position output selector switch in control box
assembly.
(3) Reconnect all leads on output selector switch.
TABLE 7-1
7-4 Relay Panel and Field Flash Switch
a. Removal. Refer to Figure 7–1 and the following
instructions to remove the relay panel and field flash switch.
(1) Tag and disconnect leads from the relay panel
and the field flash switch.
(2) Remove the nuts, washers, and screws that
secure the relay panel to the control box.
(3) Remove the relay panel.
(4) Remove the locking nut that secures the field
flash switch to the relay panel.
(5) Remove the field flash switch.
d. Repair. Replace a damaged or defective field
flash switch or relay panel.
e. Installation.
(1) Position the field flash switch in place on the
relay panel and secure with locking nut.
(2) Position the relay panel in place in the control box and secure with screws, washers, and nuts.
(3) Reconnect leads.
7-5. Current Transformer (CT) and Resistors
a.
On-Equipment Testing.
(1) Disconnect the current transformer leads and
remove the three resistors.
b.
Cleaning and Inspection.
(1) Clean the field flash switch and relay panel
using a clean lint free cloth to remove any accumulated
deposits.
(2) Inspect switch contact for corroded or burned
terminal.
(3) Inspect terminal board for cracks, breaks,
corroded terminals, or other apparent damage.
(4) Inspect relays and resistors for signs of
overheating or other damage.
Testing.
(1) Refer to figure FO-2 for resistor rating. Use a
multimeter and test on the appropriate resistance (ohm)
scale.
c.
(2) Test the field flash switch for continuity while
the switch is held in the closed (ON) position. -
Never disconnect the leads of a current
transformer, either at the transformer or at a
meter connected to the transformer, when the
equipment is energized. The three resistors
used with this equipment are connected across
the secondary windings of the current
transformer and they ordinarily prevent an open
circuit condition. But, if a resistor were to fail
and then the secondary were to be
open-circuited by disconnecting its load (the
meter), extremely high voltages would be
induced in the windings. Serious damage to the
equipment and possibly the death of personnel
could result.
Change 9
7-3
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
(2) Use a multimeter set on the RX1 scale and
test between transformer terminals Al and A2, B1
and B2, and C1 and C2. Continuity should be
shown all three tests.
(3) Now, test between transformer terminal A1
and B1, between Al and Cl, and between B1 and
Cl. There should be no continuity indicated in any
of these three tests.
(4) Connect the meter, in turn, across the terminals of each resistor and measure the resistance.
The resistance should measure within one percent
above or below 305 ohms (301.95-308.05 ohms).
b. Removal. Refer to figure 7-1 and the following instructions for removal of the current
transformer.
(1) Tag and disconnect leads from the resistors
and the current transformer.
(2) Remove the screws, washers,
and
transformer mounting strap securing the current
transformer to the control panel.
(3) Remove the current transformer.
c. Cleaning and Inspection.
(1) Clean the current transformer using a clean
lint free cloth to remove any residue.
(2) Inspect current transformer and resistors
for evidence of overheating.
(3) Inspect transformer case for cracks,
breaks, or other damage and resistor mounting
studs for corrosion or thread damage.
d. Repair. Replace a damaged or defective current transformer or resistor(s) as required.
e. Installation.
(1) Position current transformer in place in the
control box.
(2) Secure with transformer mounting strap,
washers and screws.
(1) Remove screws and washers securing access panel and remove panel (fig 7-2).
(2) Tag and disconnect all electrical leads.
(3) Remove four (4) screws and lockwashers.
(4) Remove the Voltage Regulator.
c. Test Equipment and Material Required:
(1) Multimeter - TS 352, 1M105 or equivalent.
(2) Resistor, Fixed: 30 OHMS tolerance at
minimum 25 Watt rating.
(3)Rheostat, Variable; 750 OHMS at 25 Watt
rating (Rheostat supplied with serviceable Voltage
Regulators).
(4) Soldering Iron: Small tip, 500-700 Degree
Fahrenheit rated.
(5) Solder, Rosin Core.
(6) Voltage Source: 110-120 Volts AC, single
phase, 60 HZ.
d. Test Procedures.
Extreme care should be taken while conducting test involving use of the 110-120
60 HZ Voltage Source for safety of personnel, and damage to equipment being
used.
CAUTION
While using a soldering iron, caution
should be taken to prevent damage to
components, and printed Circuit board
from excessive prolonged applied heat.
Damage could result to replacement
items, rendering them unsuitable for
operation.
(3) Reconnect leads to the current transformer
and field flash switch.
7.6 Bench Test and Repair Procedure (Voltage
Regulator).
a. General. This paragraph provides instructions covering test and repair procedures for
Voltage Regulator NSN: 6110-00-764-7621; P/N
13219E0883(97403).
b. Removal. Using figure 7-2 as a guide, remove
the Voltage Regulator as follows:
7-4
Change 5
(1) With Voltage Regulator removed from the
generator set, place multimeter being used on
OHMS position RX 100.
(2) Remove two (2) screws located on the extreme Left and Right side of the terminal strip,
TB1. Gently pull the terminal strip along with the
Circuit board upward making sure that wiring
leads are free from regulator housing and corn
ponents.
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
NOTE
Before any point to point checks can be
made, scrape ends of items being checked to insure that a good electrical contact can be made. Recoat with varnish
after repair or test.
(3) Locate CR5, 1N414 D10DE, measure
resistance, reverse test leads and measure
resistance again. Acceptable limits are LOW
resistance of 9-11 OHMS one way, and more than
100,000 OHMS the other way. If LOW or HIGH
resistance is measured in both directions, remove
and replace CR5.
(4) Locate CR6, 1N5296/1N5297 Current
Regulating Diode and perform tests in paragraph
d., (3) above. If resistance is LOWER than 800
OHMS in both directions, locate Q1 2N2405
Transistor, remove and replace it. After replacing
Q1, measure the resistance of CR6. If readings are
still not within limits, remove CR6, then replace it.
(5) Locate Q2 2N3442 Power Transistor,
located on back of regulating housing. Remove two
(2) screws securing Q2 to the housing. Pull straight
from housing, being careful not to damage the
micro spacer beneath the body of Q2.
(6) Set the multimeter to RX 10,000 OHMS,
Resistance Test. Position Q2 2N3442 with the two
(2) pins of the device pointing toward individual,
line up the pins so they are in the lower half of the
device with the two (2) mounting holes at the top
and bottom. While in this position the pin on the
left hand side is the Emitter, the pin on the right
hand side is the base and case of the device, and is
the Collector. Test with the Black lead of the
multimeter on the transistor body and Red lead on
the LEFT pin, then the RIGHT hand pin of the transistor. There should not be any movement of
multimeter point. Reverse the leads and perform
same procedures. Readings should indicate no
movement of the multimeter pointer on Left hand
pin should read between 10,000 OHMS, to 20,000
OHMS on Right hand pin. LOW or HIGH
resistance on both pins as a result of the above two
checks, indicate either an open or shorted junction
within Q2, replace Q2. Replace Q2 along with the
mica insulator located between the transistor body
and the regulator housing.
CAUTION
Do not remove the white paste from the
micro spacer or regulator housing. If
this dielectric heat transfer paste is
removed, destruction of Q2 will occur.
(7) Connect the 30 OHM, 25 Watt resistor to
terminals 20 and 21 of TB1. Connect two (2) 12-18
AWG insulated wires to the 750 OHM Rheostat as
follows:
(a) First position Rheostat with shaft control
toward individual and three (3) terminal lugs in
back at 12:00 O’Clock position. Connect one (1)
wire to middle lug and one (1) wire to the right hand
lug. If the Rheostat has a jumper wire connected
across any two (2) terminals, remove the jumper
wire. Conenct the 750 OHM Rheostat to terminals
26 and 28 of TB1 on the Voltage Regulator. Turn
the shaft of the Rheostat clockwise to its maximum
rotation.
(b) Connect the 110-12060 HZ AC Voltage
Source to terminals 24 and 27 of TB1.
(c) Set the multimeter on 50 DC Volt range.
Test for 26-32 DC Volts between terminals 20 and
21 of TB1. Positive polarity on terminal 20, and
Negative polarity on terminal 21. Rotate shaft of
Rheostat counter clockwise to approximately
eighty (80) percent of rotation, somewhere in this
position the voltage at terminals 20 and 21 of TB1
should collapse to Zero volts. Rotate the shaft of
Rheostat clockwise until somewhere near eighty
(80) percent of rotation, the voltage should reappear on terminals 20 and 21 to the 26-32 DC Volt
range. In the event that there is a pause longer
than two seconds before the voltage increases or
decreases when resetting of the Rheostat, then an
adjustment of R6 must be made.
(d) Locate R6 on the circuit board. By turning the adjustment screw of R6 counter clockwise,
the voltage will be on at terminals 20 and 21 of
TB1. By turning clockwise, the voltage will collapse to Zero.
NOTE
There will not be an adjustment of R6 to
where the voltage at terminals 20 and 21
can be made to viny. Either the voltage
will be ON or OFF.
Change 3
7-4.1
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
Adjust R6 accordingly to subparagraph d., (7), (c).
Once this is accomplished there are no further
tests required.
(e) Should the voltage at terminals 20 and 21
of TB1 remain ON, regardless what position the
750 OHM Rheostat is in, then proceed with the
following steps:
NOTE
This also applies if NO voltage is
detected at terminals 20 and 21 of TB1.
Turn OFF Electrical Power before inspection and repair.
Step 1. Inspect the circuit board for burned
or broken printed circuit paths. Bridge all open circuit paths with solid 22 AWG wire, making certain
that adjacent circuit paths are not shorted by
solder flow.
Step 2. If no open circuit paths or loose con
nections of components exist, locate RI, R2, VR1
and VR2. With the 110-120 Volts AC Source connected to TB1, terminals 24 and 27, a reading of 28
Volts DC should be detected with Positive polarity
at R1 to VR1 junction, and Negative polarity at R2
to VR2 junction.
Step 3. If the voltage is lower or higher than
28 Volts DC, check the voltage across VR1 and
CR2.
Step 5. After replacing any one of the two (2)
diodes or if there is no voltage detected across
either or both diodes, check the AC Voltage between terminal lugs 7 and 8 of TI Power
Transformer.
NOTE
Change setting of Multimeter to (AC
Volt, 50 Volt range).
Voltage reading between 36-40 Volts AC should be
present. If voltage is not present, T1 Power
Transformer should be checked to make certain
that 110-120 AC input voltage is connected properly, and all wiring connections to T1 are not loose or
disconnected. If this procedure proves all wiring
connections to be correct, replace T1.
Step 6. After verifying that 36-40 Volts AC
present, locate CR5 and CR9 on the circuit board.
Remove the 110-120 Volt AC voltage and disconnect one end of each CR8, or CR9 nine (9) diodes.
Set multimeter on the RX 10,000 OHMS scale. A
good diode will have no meter movement (High
Resistance) with test leads applied, in any direction and LOW Resistance with test leads reversed.
Remove and replace CR8, or CR9 if any of the two
tests prove defective. Install serviceable diodes.
Step 7. Locate Cl, and C2 on the reverse
side of the circuit board. With one end of each
capacitor disconnected from the circuit board,
check the resistance of each capacitor with the
multimeter set for RX 10,000. Connect test lead of
the multimeter to the POSITIVE scaled end of C 1.
CAUTION
If either diode is removed from the circuit board, do not apply the 110-120 AC
Voltage Source at any time after diode is
removed, until the replacement is connected to the circuit Failure to observe
this precaution could cause the supply
voltage being increased beyond a maximum limit for ARI causing complete
failure of the device.
Step 4. After checking the voltage across
each diode, replace either one of the two or both,
that does not regulate the supply voltage to fourteen (14) DC Volts across each diode.
7-4.2
Change 3
NOTE
The meter pointer should deflect to the
right half side of scale, then slowly
return to somewhere past mid-scale
toward left half of scale. If capacitor is
shorted or leaky, the pointer will remain
on the right lower half of the scale. If
capacitor is Open there will be no movement of the pointer. Cheek C2 using the
above method. Remove and replace Cl
and (72, if found to be defective. If in
doubt compare the tests of C1 and C2
with a new capacitor, using the results of
the comparison for future tests.
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
f. Locate VR3 and apply the 110-120 Voltage
Source on terminals 24 and 27 of TB1. Check the
voltage across VR3. This is a 4.7 Volt Zener diode.
Remove VR3 and replace if the voltage is higher
than 4.7 Volts. If no voltage can be detected across
VR3, located R3, 1K OHM resistor. Check the
voltage at R3 to VR2 junction. There should be a
Negative 14 DC Volts present with respect to F terminal on TB1. If Negative 14 DC Volts present
with respect to F terminal on TB1. If Negative 14
Volts is present and there is still no voltage across
VR3, remove and replace VR3.
g. In the event that none of the above checks and
replacement of components cause the regulator to
perform in acceptable limits, then AR1 is defective
and needs to be replaced.
CAUTION
Extreme care must be used while removing AR1 from the circuit board.
There are seven (7) connecting pins on the body of
AR1, locate the two (2) pins on one side and apply
the tip of the soldering iron alternately to both
pins while prying up the body of AR1 with a small
flat tip screwdriver. Once one side of AR1 is free,
repeat the same procedure on the remaining pins
and again pry upward until AR 1 is free of the circuit board.
NOTE
While replacing AR1, it is good practice
to clean the circuit paths of solder where
the seven (7) pins of AR1 protrudes
through the circuit board.
h. Refer to the schematic diagrams for circuit
review and analysis. If replacement parts are required, order by part number and manufacturers
code as indicated on fold-outs FO5 and FO6,
located in the back of the manual.
i. After all tests, repair or replacement of parts
have been accomplished, recoat using Varnish
(MIL-I-24092, Type M, Class 155).
Change 5
7-4.3/(7-4.4 blank)
Figure
7-2
Voltage
regulator
removal
and
installation.
Change
5
7-5
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
Figure
7 - 6
7-3.
Voltage
regulator
removal
and
installation.
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
e. Cleaning and Inspection.
(1) Clean the voltage regulator using a clean
lint free cloth.
(2) On old style regulators inspect saturable
reactor, filter reactor, stepdown transformer and
voltage regulator for cracks, breaks, evidence of
overheating or other damage.
f. Repair. Replace a damaged or defective voltage
regulator.
g. Installation.
(2) Connect electrical connectors to the voltage
regulator.
(3) Position access panel in place on control
box and secure with washers and screws.
(4) Place voltage regulator (PN 13211E6975
(97403) or 13212E8950 (97403))in place in control
box and secure with washers and screws.
(5) Reconnect wiring.
(6) Position access cover in place on control
box and secure with washers and screws.
(1) Place voltage regulator (PN 13219E0883
(97403)) in position in the control box and secure
with washers and screws.
Figure 7-4. Voltage regulator, removal and installation, PN 13219E0883 (97403).
7-7. Wiring and Wire Harness
a. General. All of the generator set wiring can
be identified by identification numbers on the wire.
The wiring can be systematically checked by reference to the wiring diagrams (figs. FO-2 and FO-4).
b. Testing and Replacement. To test, disconnect both ends of the wire under test. Touch the
probes of the multimeter to each end of the wire. If
an open circuit is indicated, replace the wire. Always use a wire of at least equal size. Individual
wires may be substituted for the defective wires in a
wiring harness by running a new wire along side
the harness. Tape, lace, or use plastic wire straps to
secure the wire and make it an integral part of the
harness.
Change
5
7-7
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
7-8. Load Terminal Board (TB1)
a. Removal. Refer to figure 7-5 and the following instructions to remove the load terminal board.
(1) Tag and disconnect electrical leads as necessary.
(2) Remove the nuts, washers and screws
which secure the load terminal board to the control
box.
(3) Remove the load terminal board.
Figure 7-5. Load terminal board, removal and installation.
b. Cleaning, Inspection and Repair.
Clean all parts in a well-ventilated area.
Avoid inhalation of solvent fumes and
prolonged exposure of skin to cleaning
solvent. Wash exposed skin thoroughly.
Dry cleaning solvent (Fed. Spec. P-D-680,
Type 11) used to clean parts is potentially
7 - 8
Change 5
dangerous to personnel and property. Do
not use near open flame or excessive heat.
Flash point of solvent is 140°F(60°C).
(1) Clean the load terminal board thoroughly
with a clean cloth dampened in cleaning solvent,
Fed. Spec. P-D-680 Type II, and dry thoroughly.
(2) Inspect the load terminal board for cracks,
and burned areas,
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
(3) Inspect the terminals for damaged
threads.
(4) Replace a damaged load terminal board.
c. Installation.
(1) Position the load terminal board in place
on the control box.
(2) Secure the load terminal board with washers, screws and nuts.
(3) Reconnect electrical leads.
7-9. Remote Control Terminal Board
(TB3)
a. Removal. Refer to figure 7-6 and the follow.
ing instructions to remove the remote control terminal board.
(1) Tag and disconnect electrical leads as nec-
essary.
(2) Remove the nuts, screws, and washers
which secure the remote control terminal board to
the control box.
(3) Remove the remote control terminal
board.
Figure
7-6.
Remote
control
terminal
board,
removal
and
installation
(TB3).
7-9
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
(3) Inspect the terminals for stripped threads.
(4) Replace a damaged terminal board.
b. Cleaning, Inspection and Repair.
c.
Clean all parts in a well-ventilated area.
Avoid inhalation of solvent fumes and
prolonged exposure of skin to cleaning
solvent. Wash exposed skin thoroughly.
Dry cleaning solvent (Fed. Spec. P-D-680,
Type II) used to clean parts is potentially
dangerous to personnel and property. Do
not use near open flame or excessive heat.
Flash point of solvent is 140 ‘F (60 ‘C).
(1) Clean items with a cloth dampened in cleaning solvent, Fed. Spec. P-D-680 Type II, and dry
thoroughly.
(2) Inspect for burned areas and cracks.
7-10
Change
5
Installation.
(1) Position the remote control terminal board
in place on the control box.
(2) Secure the remote control terminal board
to the control box with screws, washers, and nuts.
(3) Reconnect electrical leads.
7-10.
Terminal
Board
(TB2)
a. Removal. Refer to figure 7-7 and the following instructions to remove the terminal board.
(1) Tag and disconnect electrical leads as necessary.
(2) Remove the nuts, washers, and screws
which secure the terminal board to the control box.
(3) Remove the terminal board.
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
Figure 7-7. Terminal board, removal and installation (TB2).
b. Cleaning, Inspection and Repair.
(1) Clean the terminal board thoroughly.
(2) Inspect for burned areas, cracks, and damaged terminals.
(3) Replace a defective terminal board.
c.
Installation.
(1) Position terminal board in place on the
control box.
(2) Secure the terminal board with screws,
washers and nuts.
(3) Reconnect electrical leads as required.
7-11
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
Section II.
MAINTENANCE OF THE GENERATOR
7-11. General
The generator housing is mounted directly on the
flywheel housing (Model MEP-017A) or mounted on
the flywheel housing by use of an adapter (Model
MEP-022A). The rotor is mounted on a flexible
drive disk that, in turn, is mounted on the engine
flywheel. The rotor is made up electrically of two
sections, the alternator field and the brushless, rotating exciter section. The generator housing
houses both the generator (alternator) stator windings and the dc exciter frame and field windings.
7-12. On-Equipment Testing
a. General. On-equipment electrical test procedures may provide a basis for determining the necessity and extent of generator repair. The resistance values and tolerances contained in this
paragraph should be used only as a general guide.
Take into consideration the test instrument used,
test lead resistance, and the ambient temperature
at the time of the test. If more precise measurements are required, use an instrument such as
a Kelvin Balance or a Wheatstone Bridge and make
comparative measurements between the suspected
component and a like item that is known to be good.
b. Stator.
(1) Disconnect the plug connector (Pi) at the
rear of the control box.
(2) Use a multimeter that has been set on the
RX1 scale and test for continuity between plug pins
A and B, D and E, and C and F. If continuity is not
indicated (full deflection) on any of the tests, remove the plug at the generator and repeat the tests
at the generator. If, again, continuity is not shown,
the stator is defective and must be replaced. If continuity is shown the cable is defective and must be
replaced.
c. Rotor.
(1) Remove the blower cover and fan (para 6-2
or 6-3).
(2) Use a multimeter that has been set on the
RX1 scale and test between the rotor field windings
terminal and the case of the rotor. If the resistance
is not within five percent above or below the following values, the rotor must be removed for further
testing (TM 5-764):
7-12
Model MEP-017A (60 Hertz) . . . . . . . . . . .
Model MEP-022A (400 Hertz) . . . . . . . . .
8.8 ohms
0.615 ohms
d. Exciter Field Windings.
(1) Disconnect the plug connector (Pi) at the
rear of the control box.
(2) Use a multimeter that has been set on the
RX1 scale and test for continuity between plug pins
G and H. If the resistance is not within five percent
above or below 54.4 ohms, the windings are defective and must be replaced.
7-13. Main Generator Stator and
Housing Assembly
a. Removal. For generator removal instructions, refer to paragraphs 6-2 and 6-3.
NOTE
It is also possible to remove the engine and generator as a unit. If this is to be accomplished, refer to
paragraph 6-4 and follow the instructions on removal of the engine from the skid.
b. Disassembly.
(1) Model MEP-017A.
(a) Tag and disconnect all leads.
(b) Remove screws (1, fig. 7-8) and lockwashers (2) and remove the wire clips (3) from the
exciter frame (24).
(c) Remove screws (4) and lockwashers (5)
and remove the wiring harness (6) from the housing
(25) .
(d) Disassemble the wiring harness (6) by
removing connector (7) at clamp (8) and adapter (9)
at clamp (10) from the leads and sleeving (11).
(e) Remove the air inlet grille (12) from the
housing (25).
(f) Remove the lifting eyebolt (13) and nut
(14) from the housing (25).
(g) Remove capscrew (15) and lockwashers
(16) and remove the stator (17).
(h) Remove capscrews (18) and lockwashers (19) and remove the exciter frame assembly (24) from the housing (25).
(i) Remove screws (20) and lockwashers
(21) and remove the exciter pole (22) and exciter
coil (23) from the exciter frame assembly (24).
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
7-13
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
1. Screw
2. Lockwasher
3. Clip
4. Screw
5. Lockwasher
6. Wiring harness
7. Connector
8.Clamp
9. Adapter
10. Clamp
11. Sleeving
12. Grille
13. Eye bolt
Figure 7-8. Main generator stator and housing assembly, disassembly (Model MEP-017A).
(2) Model MEP-022A.
(a) Tag and disconnect all leads.
(b) Remove screws (1, fig. 7-9) and lockwashers (2) and remove the wire clips (3) from the
exciter frame (27).
(c) Remove screws (4) and lockwashers (5)
and remove the generator wiring harness (6) from
the housing (28).
(d) Disassemble the wiring harness (6) by
removing connector (7) at clamp (8) and adapter (9)
at clamp (10) from the leads and sleeving (11).
(e) Remove the lifting eyebolt (12) and nut
7-14
(13) from the housing (28).
(f) Remove capscrews (14) and lockwashers
(15) and remove the generator housing adapter (16)
and air inlet grille (17) from the housing (28).
(g) Remove capscrews (18) and lockwashers (19) and remove the stator (20).
(h) Remove capscrews (21) and lockwashers (22) and remove the exciter frame assembly (27) from the housing (28).
(i) Remove screws (23) and lockwashers
(24) and remove the exciter pole (25) and exciter
coil (26) from the exciter frame assembly (27).
TM
TO
5-6115-332-14
P-8-614-14
35C2-3-424-1
7-15
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
15. Lockwasher
16. Adapter
17. Grille
18. Capscrew
19. Lockwasher
20. Stator
21. Capscrew
22. Lockwasher
23. Screw
24. Lockwasher
25. Pole
26. Coil
27. Frame assembly
28. Housing
1. Screw
2. Lockwasher
3. Clip
4. Screw
5. Lockwasher
6. Wiring harness
7. Connector
6. Clamp
9. Adapter
10. Clamp
11. sleeving
12. Eyebolt
13. Nut
14. Capscrew
TS 6115-332-14/7-9
Figure 7-9. Main generator stator and housing assembly, disassembly (Model MEP-022A).
c. Cleaning.
Clean all parts in a well-ventilated area.
Avoid inhalation of solvent fumes and
prolonged exposure of skin to cleaning
solvent. Wash exposed skin thoroughly.
Dry cleaning solvent (Fed. Spec. P-D-680,
Type II) used to clean parts is potentially
dangerous to personnel and property. Do
not use near open flame or excessive heat.
Flash point of solvent is 1400 F (600 C).
Clean items with cleaning solvent, Fed. Spec. PD-680 Type II, and dry thoroughly.
d. Inspection.
(1) Inspect the stator windings and leads for
broken or damaged wires.
(2) Inspect the main frame and exciter frame
7 - 1 6
for damage, broken welds and cracks at the mounting flanges.
(3) Inspect the exciter coils and field windings
for signs of burned areas, abrasion and other damage.
(4) Inspect the generator housing for cracks,
wear and other physical wear.
(5) Check for missing and damaged hardware.
e. Repair.
(1) Remove and replace all defective wiring
that can be replaced without disturbing the stator
windings. Windings that show only very minor
abrasion and no breakage may be repaired by revarnishing.
NOTE
Be certain that bare windings are not touching be.
fore applying electrical varnish.
(2) Dipping and baking varnish can be accomplished by following steps (a) through (j) below,
and figures 7-10 and 7-11.
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
Figure
7-10.
Exciter
field
frame
assembly,
repair.
7-17
TM
5-6115-332-14
P-8-614-14
TO
35C2-3-424-1
Figure
7-18
7-11.
Alternator
startor,
repair.
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
NOTE
Do not bake the rotating rectifier assembly. Keep
all varnish from the rotor shaft.
(a) Maintain the viscosity of the varnish at
the manufacturer’s recommended value.
(b) The part shall be clean and free of all
foreign matter.
(c) Preheat the part for two hours at a temperature of 290 to 310°F. (143 to 154°C.).
(d) Cool the part to a temperature of 120 to
250°F. (49 to 121°C.) before dipping.
(e) Dip in varnish for two minutes or until
bubbling ceases, then drain for 6 to 8 minutes.
(f) Bake for 3 hours at a temperature of 290
to 300°F. (143 to 149°C.).
(g) Repeat steps (d) through (f).
(h) Repeat steps (d) through (e).
(i) ‘Bake for 6 hours at a temperature of 290
to 300°F. (143 to 149°C.).
(j) Cool to room temperature.
(3) Replace a defective stator.
(4) Replace damaged main frame and exciter
frame.
(5) Replace damaged generator housing.
(6) Replace missing and damaged hardware.
f. Assembly.
(1) Model MEP-022A.
(a) Install the exciter pole (25, fig. 7-9) and
exciter coil (26) on the exciter frame assembly (27);
secure with lockwashers (24) and screws (23).
(b) Install the exciter frame assembly (27,
fig. 7-9) on the housing (28) and secure with lockwashers (22) and capscrews (21).
(c) Install stator (20) and secure it with
lockwashers (19) and capscrews (18).
(d) Install the air inlet grille (17) and
adapter (16) on the housing (28); secure with lockwashers (15) and capscrews (14).
(e) Install the eybolt (12) and nut (13).
(f) Install sleeving (11), clamp (10),
adapter (9), clamp (8), connector (7) and wiring harness (6).
(g) Install the wiring harness assembly on
the housing (28) and secure it with lockwashers (5)
and screws (4).
(h) Install wire clips (3) on exciter frame
(27) and secure them with lockwashers (2) and
screws (1).
(i) Connect all leads.
(2) Model MEP-017A.
(a) Install exciter coil (23, fig. 7-8) and exciter pole (22) on the exciter frame (24) and secure
them with lockwashers, (21) and screws (20).
(b) Install the exciter frame assembly (24)
on the housing (25) and secure it with lockwashers
(19) and capscrews (18).
(c) Install stator (17), lockwashers (16),
and capscrew (15).
(d) Install nut (14) and lifting eyebolt (13).
(e) Install the air inlet grille (12).
(f) Reassemble the wiring harness (6). Install sleeving (11), clamp (10), adapter (9), clamp
(8), and connector (7).
(g) Install the wiring harness (6, fig. 7-8)
on the housing (25) and secure it with lockwashers
(5) and screws (4).
(h) Install the wire clips (3) and secure
them with lockwashers (2) and screws (l).
g. Test.
(1) Test the exciter stator (G1) (field windings) for continuity. Use contacts G and H on the
generator cable receptacle. If continuity is not indicated, each coil must be tested individually to locate
the shorted or open windings. (Refer to wiring schematic diagram FO-1 or FO-2.)
(2) Test alternator stator (G1) windings for
continuity. (Refer to wiring schematic diagram,
FO-1 or FO-2.) Test across contacts F and C, E and
D, and A and B. An open coil that shall be repaired
or replaced is indicated by failure to obtain continuity.
(3) Using a megohmeter, test between the
frame and one lead of each winding in the stator.
Use the appropriate pins on the generator receptacle on the alternator stator and test between one
coil lead and a lead from each coil group, in turn. A
reading of less than 1.0 megohm obtained in any
test indicates that the insulation is faulty. The defective winding shall be repaired or replaced.
h. Installation. Refer to paragraphs 6-2, 6-3 or
6-4 and reinstall the generator.
7-14. Main Generator Rotor Assembly
a. Removal. For generator removal instructions, refer to paragraphs 6-2 and 6-3.
NOTE
It is also possible to remove the engine and generator as a unit. If this is to be accomplished, refer to
paragraph 6-4 and follow the instructions on removal of the engine from the skid.
b. Disassembly.
(1) Model MEP-017A.
(a) Remove the blower fan Woodruff key
(1, fig. 7-12) from its slot in the rotor shaft.
(b) Remove bearing clip (2) and with the
use of a puller, remove the bearing (3) from the
7-19
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
rotor shaft,
bly (8) from the alternator rotor assembly ( 12).
(c) Remove the controlled silicon rectifiers (d) Remove capscrews (9) and lockplates
(4), capscrews (5) and lockwashers (6), pull the ex(10) and remove the generator drive disc (11) from
titer rotor assembly out, remove the exciter rotor
the alternator assembly (12).
lead screw (7) and remove the exciter rotor assem-
1. Key
2. Clip
3. Bearing
4. Rectifier
5. Capscrew
6. Lockwasher
7. Screw
8. Rotor ay
9. Capscrew
10. Lockplate
11. Disc
12. Alternator ay
Figure 7-12. Main generator rotar assembly, disassembly (Model MEP-017A).
(2) Model MEP-022A. Follow the same procedure as listed for Model MEP-017A when disas-
7-20
sembling the Model MEP-022A rotor assembly (fig,
7-13).
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
Figure 7-13. Main generator rotor assembly, disassembly (Model MEP-022A).
Cleaning.
Clean all parts in a well-ventilated area.
Avoid inhalation of solvent fumes and
prolonged exposure of skin to cleaning
solvent. Wash exposed skin thoroughly.
Dry cleaning solvent (Fed. Spec. P-D-680,
Type II) used to clean parts is potentially
dangerous to personnel and property. Do
not use near open flame or excessive heat.
Flash point of solvent is 140°F (60 °C).
(1) Clean items with cleaning solvent, Fed.
Spec. P-D-680 Type II, and dry thoroughly.
d. Inspection.
(1) Inspect the fan, drive disk, and disk
adapter for cracks and defective threads.
(2) Rotate the bearing to check for binding
and roughness. Inspect the seal and retaining clip.
(3) Inspect the rotor shaft for nicks, rust,
wear, damage to the keyway, and defective internal
threads on the end of the shaft.
(4) Inspect the windings and leads for evidence of overheating, deterioration of the varnish,
and other damage.
(5) Inspect the rotating rectifier for broken
connections and damaged diodes.
e. Repair.
(1) Replace a defective rotor assembly or component.
(2) A reusable bearing shall be carefully removed from the shaft by applying pressure to the
inner race, only. A defective bearing shall be replaced.
(3) If any windings must be replaced or if imbalance is detected, balance the rotor assembly to
within a value of 0.5 ounce inches.
(4) Refer to paragraph 7-13e (2) for baking
data and to figures 7-14 and 7-15 for winding data.
Change 5
7-21
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424.1
Figure 7-14. Exciter rotor, test.
7-22
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
Figure 7-15. Alternator rotor assembly, test.
7-23
TM 5-6115-332-4
P-8-614-14
TO 35C2-3-424-1
f. Assembly.
(1) Model MEP-022A (fig. 7-13). Follow the
same assembly procedures as Model MEP-017A, below.
(2) Model MEP-017A (fig. 7-12).
(a) Install the generator drive disc (11, fig.
7-12 or 7-13) on the alternator assembly (12) and secure with lockplates (10) and capscrews (9).
(b) Install exciter rotor assembly (8) on the
alternator rotor assembly (12); secure with lead
screw (7). Install the assembly. Install lockwashers
(6), capscrews (5), and silicon rectifiers (4).
(c) Install ball bearing (3) and bearing clip
(2).
(d) Install key (l).
g. Test.
(1) Rotating Rectifier.
(a) Tag and disconnect the rotor winding
Section III.
MAINTENANCE OF THE FRAME ASSEMBLY
7-15. General
The instructions contained in this section cover
removal and installation of the engine front support, engine drip pan, and skid base. The skid base
serves as the mounting platform for the generator
set components.
7-16. Engine Support and Drip Pan
a. Removal.
(1) Remove the engine (para 6-4).
7-24
leads. Remove the rectifier assembly from the rotor
shaft. See figures 7-14 and 7-15.
(b) Check the front-to-back resistance ratio
of each rectifier with an ohmmeter. The ratio
should be at least 100,000/1 with the forward resistance being 10 ohms maximum.
(2) Rotors.
(a) Using the disconnected leads from the
rotating rectifier, test the continuity of the rotor
windings by use of a test lamp or multimeter. If continuity is not indicated, an open or short is present
and shall be isolated.
(b) Use a megohmeter to test the coil insulation. Test between the shaft and each lead on both
rotors. A reading of less than 1.0 megohm indicates
that the insulation is faulty.
h. Installation. Refer to paragraphs 6-2 and 63 or 6-4 and install the generator.
(2) Refer to figure 7-16 and the following instructions for engine support and drip pan removal.
(a) Remove the nuts, lockwashers, screws,
and flatwashers securing the engine support to the
skid base.
(b) Remove the engine support.
(c) Remove the nuts, lockwashers, and
screws which secure the drip pan to the skid base.
(d) Remove the drip pan.
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
Figure 7-16. Engine Support and drip pan, removal and installation.
b. Cleaning, Inspection and Repair.
Clean all parts in a well-ventilated area.
Avoid inhalation of solvent fumes and
prolonged exposure of skin to cleaning
solvent. Wash exposed skin thoroughly.
Dry cleaning solvent (Fed. Spec. P-D-680,
Type II) used to clean parts is potentially
dangerous to personnel and property. Do
not use near open flame or excessive heat.
Flash point of solvent is 140 “F (60 ‘C).
distortion. Straighten distorted or dented areas.
Weld cracks and grind the welds’ smooth.
(3) Inspect the engine support for cracks and
other damage.
(4) Replace defective parts.
c. Installation.
(1) Secure the drip pan to the skid base with
screws, lockwashers and nuts.
(2) Position the engine support in place on the
skid base.
(3) Secure with flatwashers, screws, lockwashers and nuts.
(4) Install the engine (para 6-4).
7-17. Skid Base
(1) Clean items with cleaning solvent, Fed.
Spec. P-D-680 Type II, and dry thoroughly.
(2) Inspect the drip pan for cracks, dents, and
a. Removal.
(1) Remove the engine, paragraph 6-4, and
generator, paragraph 6-2 or 6-3.
(2) Remove the engine support and drip pan,
Change 5
7-25
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
paragraph 7-16.
(3) Remove the lower battery frame, paragraph 4-23.
(4) Remove the screws, lockwashers, and nuts
(fig. 7-17) securing the fuel can bracket to the skid
base.
(5) Remove the fuel can bracket.
Figure 7-17. Fuel can brackets, removal and installation.
7-26
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
(6) Remove the fuel drum adapter and clips
from the skid base by withdrawing the adapter from
the two clips. Remove the clips by removing four
nuts, lockwashers and screws.
b. Cleaning, Inspection and Repair.
Clean all parts in a well-ventilated area.
Avoid inhalation of solvent fumes and
prolonged exposure of skin to cleaning
solvent. Wash exposed skin thoroughly.
Dry cleaning solvent (Fed. Spec. P-D-680,
Type II) used to clean parts is potentially
dangerous to personnel and property. Do
not use near open flame or excessive heat.
Flash point of solvent is 140°F (60)0C).
(1) Clean items with cleaning solvent, Fed
Spec. P-D-680 Type II, and dry thoroughly.
(2) Inspect for cracks, breaks, broken welds,
and twisted or distorted areas.
(3) Straighten distorted areas, weld cracks or
broken welds, and grind the welds smooth.
(4) Replace a defective skid base.
c. Installation.
(1) To install the clips and fuel drum adapter,
position the clips on the skid base and secure with
screws, lockwashers, and nuts. Snap the adapter
into position in the clips.
(2) Position the fuel can brackets in place on
the skid base and secure with screws, lockwashers
and nuts.
(3) Install the lower battery frame, paragraph
4-23.
(4) Install the engine support and drip pan,
paragraph 7-16.
(5) Install the engine, paragraph 6-4, and generator, paragraph 6-2 or 6-3.
Change
5
7-27/(7-28 blank)
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
CHAPTER 8
GENERATOR SET TEST AND INSPECTION AFTER REPAIR
AND OVERHAUL
Section I.
GENERAL REQUIREMENTS
The activity performing the repair or overhaul is
responsible for the performance of all applicable
tests and inspections specified herein. Activities
performing maintenance on any portion of the gen-
Section II.
a. All material, repair parts, assemblies, components, welding, refinishing and other workmanship shall be sampled in accordance with MIL-STD105D to assure compliance with standards established in this manual.
b. overhaul inspection procedures for disassembled components and subassemblies are contained
throughout the manual where applicable. All data
Section III.
erator set must perform those tests and inspections
required by the applicable component or system repair instruction.
lNSPECTION
necessary to determine serviceability of each component or subassembly such as dimensional data,
fits, tolerances, and surface finish information is
contained herein.
c. Used components and repair parts recovered
as products of disassembly will be examined 100%
by the activity performing the repair to determine
serviceability.
OPERATIONAL TESTS
a. Using the visual and operational check list
(Table 8-1), visually inspect and operationally test
the generator set for a minimum of four hours as
follows:
(1) 1/4 hour warm up.
(2) 1 hour 1/2 load at .8 power factor-.
(3) 2-1/4 hours full load at .8 power factor.
(4) 1/4 hour 125% load at .8 power factor.
(5) 1/4 hour idle.
b. During the test period, the following operational checks will be made.
(1) The proper operation of all components
under no load and full capacity load conditions.
(2) Proper function and adjustment of all instruments, controls and gages.
( 3 ) O v e r h e a t i n g , vibration
and
unusual
noises.
(4) Record voltage, current, power, factor, frequency and temperature readings at the above
loads.
(5) Check operation of control and protective
equipment while conducting the test run and when
the test run periods are completed and the load
gradually removed, shut down the unit, after the 1/
4 hour idle period.
(6) Oil and fuel.
CAUTION
If during the operational test, excessive noise or vibration is observed or
any overheating or malfunctions
occur which may cause damage to the
equipment, stop operation immediately until necessary repairs are
made.
(7) If the malfunction is minor and will not
damage the generator set, the tests may continue
and defects corrected upon-completion of tests.
(8) Inspect for proper functioning, components which have been overhauled or repaired.
(9) Presence of one or more defects shall be
cause for rejection until acceptable repair has been
made. If repair is required to a major component, repeat the entire operational test.
8 - 1
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
Table 8-1. Visual and Operational Inspection
Inspection Point
1. Data Plates
Condition
a. M u s t b e t i g h t l y a f f i x e d a n d l e g i b l e .
b. Missing plates must be replaced.
2. Overall
a. All lines, hoses, wiring, and covers shall be properly attached and in good condition.
b. All bolts and screws shall be of the proper size,
have the required washers and be securely tightened.
c. Grease fittings shall be undamaged.
3. Basic Issue Items
All items must be accounted for, and in good condition, comparable to new.
4. Battery
a. Cables and mountings should be tightened.
b. Remove corrosion from battery.
5. Engine
The engine must operate efficiently with no unusual
noises and should show no signs of overheating during or after operating under full load for a period of one
hour.
6. Fuel System
a. Fuel tank must be free of contamination and
rust.
b. Fuel cap gasket must be in good condition and
strainer must be clean.
c. Fuel lines must be secure and free of sharp
bends.
d. There must be no evidence of leaks.
e. Fuel Selector Valve. Move selector valve handle
to SET TANK position and ensure engine will run.
Move selector valve handle to AUXILIARY position
and ensure engine will run.
7. Engine Electrical System
a. All wiring must be adequately insulated and
securely fastened.
b. Cables shall be comparable to new condition and
wiring harness shall be securely attached.
8. Control Box and Instruments
a. Control box shall be securely attached.
b. Gages shall be clean and legible.
c. All gages, switches, and instrument panel lights
must function properly.
d. Gage face will be free from cracks, scratches and
discoloration. Gages will be free from moisture, rust
or dirt.
e. Switches and controls shall operate freely.
f. Wiring and wiring harness shall be attached
securely.
g. Ensure all gage readings are normal. Refer to
chapter 2 for correct operating procedures and gage
readings.
NOTE
The hourmeter, where applicable, will
not be changed for the purpose of bringing
it back to a zero reading.
8-2
Change 6
TM
5-6115-332-14
TO
35C2-3-424-1
P-8-614-14
Table
Inspection Point
9. Generator
8-1.
Visual
and
Operational
Inspection
(Cont'd)
Condition
a. Generator must be securely mounted and the rotor exciter
shaft securely attached to the flywheel.
b. During operation, there shall be no excessive noise or
vibration.
c. Conduct u Ioad test to insure that the set is operable and
that all meters are functioning properly.
d. Output should be in accordance with specifications.
e . W i r i n g t e r m i n a l s s h a l l be clean, wiring will not be burnt.
chafed, broken, cracked, cut or bare.
f. All connections must be tight and free from dirt, rust,
grease, oil, and corrosion,
g. Switches and contacts shall not be burnt, corroded or show
signs of wear.
h. No excessive end play or vibration of rotor shaft is allowed.
replace bearing i f necessary.
i. Frames shun not be crocked or broken.
j. There shun be no missing or loose parts.
k. The exciter rotor, stator, main rotor and stator, shall be free
of any obvious or visually apparent defects. Apply a dielectric insulation or megger test when deemed necessary.
10.
Radio
Interference
Suppression
11. Skid Base, Frame and Components
All interference suppression components shall be installed and
securely
fastened.
a. The frame and supports shall he securely attached, and
shall support the generator and engine without buckling when
raised, moved or skidded.
b. Welded parts shall he free from breaks or cracks at the
weld.
c. All mounting brackets shall be securely attached.
d. Paint shall be as specified for all components of the generator set.
8-3
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
APPENDIX A
REFERENCES
AMF 66-1 (F)
Air Force Maintenance Management
DA PAM 738-750
The Army Maintenance Management System
(TAMMS)
TM 4700-15/1 (MC)
Maintenance Management (Marine Corps)
TO 35-1-4 (F)
Administrative Storage (Air Force)
MCOP 4450.7 (MC)
Administrative Storage (Marine Corps)
TO 38-1-5 (F)
Administrative Storage (Air Force)
TO 35C2-3 (F)
Air Force Inspection Manuals
TM 11275-15/1 (MC)
Marine Corps Inspection Manuals
TM 11-483 (A)
Radio Interference Suppression
TM 5-2805-258-14 (A)
TO 38G2-89-21 (F)
NAVFAC P-8-614-14E (N)
Operator, Organization, Direct Support and
General Support Maintenance Manual, Engine,
Gasoline, 10 HP, Military Standard Model
2A042-2, 2A042-3 and 2A042-4.
TM 5-2805-258-24P (A)
TO 38G2-89-34 (F)
NAVFAC P-8-614E-24P (N)
Organizational, Direct Support, General Support
Maintenance Repair Parts, Special Tools for
Engine, Gasoline, 10 HP, Military Standard
Models 2A042-2, 2A042-3 and 2A042-4.
TM 5-764 (A)
Electric Motor and Generator Repair
TB 740-97-2 (A)
Preservation of USATROSCOM Mechanical Equipment for Shipment and Storage
TO 35C2-3-1A26 (F)
AF Inspection Manual
TO 35C2-3-1-426WC-3-2-1 (F)
AF Preventive Maintenance Workcards
TO 35-1-5 (F)
Processing and Inspection of Non-Mounted,
Non-Aircraft Gasoline and Disel Engines for
Storage and Shipment
Change 8
A-1
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
APPENDIX A
REFERENCES – Continued
TO 34Y19-1-111 (F)
Electric Motor and General Repair
TM 5-6115-332-24P (A)
TO 35C2-3-424-24
Organizational, Intermediate (Field), Direct
Support and General Support, Maintenance
Repair Parts and Special Tools List (Including
Depot Maintenance Repair Parts and Special
Tools) Generator Set, Gasoline Engine: Air
Cooled, 5KW, AC, 120/240 V Single Phase,
120/208 V 3 Phase Skid Mounted, Tubular
Frame (Less Engine) Military Design
MEP-017A, MEP-022A
A-2
Change 8
TM 5-6115-332-14
P-8-614-14
TO 35C3-424-1
APPENDIX B
BASIC ISSUE ITEMS LIST AND ITEMS
TROOP INSTALLED OR AUTHORIZED LIST
Section I.
INTRODUCTION
This Appendix lists Basic Issue Items, Items
Troop Installed or Authorized which accompany the
generator set and are required by the Crew/Operator for Operation, installation, or operator’s
maintenance.
B-2. General
This basic issue items, items troop installed or
authorized list is divided into the following sections:
a. Basic Issue Items List. Not applicable.
b. Items Troop Installed or Authorized List Section III. A list in alphabetical sequence of
items which at the discretion of the unit commander may accompany the end item. but are NOT
subject to be turned in with the end item.
B-3. Explanation of Columns
The following provides an explanation of col-
umns in the tabular list of Basic Issue Items List,
Section II, and Items Troop Installed or Authorized,
Section III.
a. Source, Maintenance and Recoverability
Code(s) (SMR). Not applicable.
b. National Stock Number. This column indicates the National Stock Number assigned to the
item and will be used for requisitioning purposes.
c. Description. This column indicates the Federal item name and any additional description of
the item required.
d. Unit of Measure (U/M). A two character alphabetic abbreviation indicating the amount or
quantity of the item upon which the allowances are
based, e.g., ft, ea, pr, etc.
e. Quantity Authorized (Items Troop Installed or Authorized Only). This column indicates the quantity of the item authorized to, be used
with the equipment:
B-1
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
Section III.
ITEMS TROOP INSTALLED OR AUTHORIZED LIST
National
Stock
Number
Description
U/M
Qty
Auth
2920-00-066-1235
Adapter: Drum, Fuel
EA
1
7510-00-889-3494
Binder, Loose-Leaf U.S. Army Equipment Log Book
EA
1
7520-00-559-9618
Case: Maintenance and Operator’s Manuals
EA
1
5935-00-258-9156
Connector: Plus, Slave Receptacle
EA
1
4210-00-555-8837
Extinguisher, Fire
EA
1
Hose, Fuel: Auxiliary-Make from:
B-2
4720-00-540-1962
Hose, Bulk
FT
AR
4730-00-497-4281
Adapter, Straight
EA
2
5975-00-878-3791
Rod Assembly: Ground
EA
1
5120-01-013-1676
Hammer, Slide
EA
1
5935-00-322-8959
Adapter Connector
EA
1
6115-00-945-7545
Cover, Canvas
EA
1
Change 6
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
APPENDIX C
MAINTENANCE ALLOCATION CHART (FOR ARMY AND MARINE
CORP ONLY)
Section I.
INTRODUCTION
C-1. General
a. This section provides a general explanation of
all maintenance and repair functions authorized at
various maintenance levels.
b. Section II - designates overall responsibility
for the performance of maintenance functions on
the identified end item or component and the work
measurement time required to perform the functions by the designated maintenance level. The implementation of the maintenance functions upon
the end item or component will be consistent with
the assigned maintenance functions.
c. Section III - lists the tools and test equipment
required for each maintenance function as referenced from Section II.
C-2. Explanation of Columns in Section H
a. Column 1. Group Number. Column 1 lists
group numbers to identify related components. assemblies, sub-assemblies, and modules with their
next higher assembly. The applicable groups are
listed in the MAC in disassembly sequence beginning with the first group removed.
b. Column 2. Component/Assembly. This column contains the noun names of components, assemblies, sub-assemblies and modules for which
maintenance is authorized.
c. Column 3. Maintenance Functions. T h i s
column lists the functions to be performed on the
item listed in column 2. The maintenance functions
are defined as follows:
(1) Inspect. To determine serviceability of an
item by comparing its physical, mechanical, and/or
electrical characteristics with established standards through examination.
(2) Test. To verify serviceability and detect
incipient failure by measuring the mechanical or
electrical characteristics of an item and comparing
those characteristics with prescribed standards.
(3) Service. Operating required periodically
to keep an item in proper operating condition, i.e., to
clean (decontaminated), to preserve, to drain, to
paint, or to replenish fuel, lubricants, hydraulic fluids, or compressed air supplies.
(4) Adjust. T O maintain within prescribed
limits, by bringing into proper or exact position, or
by setting the operating characteristics to specified
parameters.
(5) Align. To adjust specified variable elements of an item to bring about optimum or desired
performance.
(6) Calibrate. T O determine and cause corrections to be made or to be adjusted on instruments
or test measuring and diagnostic equipments used
in precision measurement. Consists of comparison
of two instruments, one of which is a certified standard of known accuracy, to detect and adjust any
discrepancy in the accuracy of the instrument being
compared.
(7) Install. The act of emplacing, seating, or
fixing into position an item, part of module (component or assembly) in a manner to allow the proper
functioning of an equipment or system.
(8) Replace. The act of substituting a serviceable like type part, sub- assembly, or module
(component or assembly) for an
unserviceable
counterpart.
C-1
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
(9) Repair. The application of maintenance
services (inspect, test, service, adjust, align, calibrate, or replace) or other maintenance actions
(welding, grinding, riveting, straightening, facing,
remachining or resurfacing) to restore serviceability to an item by correcting specific damage,
fault, malfunction, or failure in a part, sub-assembly, module (component or assembly), end item, or
system.
(10) Overhaul. That maintenance effort (service/action) necessary to restore an item to a completely serviceable/operational condition as prescribed by maintenance standards (i.e., DMWR) in
appropriate technical publications. Overhaul is normally the highest degree of maintenance performed
by the Army. Overhaul does not normally return an
item to a like new condition.
(11) 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 materiel 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.
d. Column 4. Maintenance Category. This column is made up of sub-columns for each category of
C-2
maintenance. Work time figures are listed in these
sub-columns for the lowest level of maintenance authorized to perform the function listed in Column 3.
These figures indicate the average active time required to perform the maintenance function at the
indicated category of maintenance under typical
field operating conditions.
e. Column 5. Tools and Equipment. This column is provided for referencing by code, the common tool sets (not individual tools) special tools,
test and support equipment required to perform the
designated function.
C-3. Explanation of Columns in Section III
a. Column 1. Reference Code. This column consists of an Arabic number listed in sequence from
Column 5 of Section II. The number references the
tool sets, special tools and test equipment requirements.
b. Column 2. Maintenance Category. This column shows the lowest category of maintenance authorized to use the special tools or test equipment.
c. Column 3. Nomenclature. This [column lists
the name or identification of the common tool sets,
special tools or test equipment.
d. C o l u m n 4 . N a t i o n a l / N A T O S t o c k N o .
(NSN). This column is provided for the NSN of
common tools sets, special tools and test equipment
listed in the Nomenclature column.
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
Section II. MAINTENANCE ALLOCATION CHART
For
Generator Set
NSNS 6115-00-017-8240,6115-00-017-8241
(2)
(3)
COMPONENT/
ASSEMBLY
MAINTENANCE
FUNCTION
(1)
GROUP
NUMBER
01
ENGINE
ASSEMBLY –
MIL-STD MDL,
2A042
02
FUEL SYSTEM
Adapter, Fuel Can
c
Replace
Inspect
Replace
INTERMEDIATE
o
DEPOT
D
(6)
TOOLS AND
EQUIPMENT
REMARKS
**
0.1
0.1
0.1
Strap, Fuel Can
Inspect
Replace
0.1
0.1
Inspect
Replace
0.1
Can, Fuel Supply
Inspect
Replace
0.1
0.1
Valve, Fuel
Selector
Inspect
Replace
0.1
Cable Assembly,
Battery
Inspect
Replace
Repair
0.1
Frame, Top,
Hold-Down
Inspect
Replace
Repair
Inspect
Test
Service
Replace
0.1
Cable Assembly,
Starter
Inspect
Replace
Repair
0.1
Receptacle
Assembly, Slave
Inspect
Replace
Repair
0.1
Inspect
Replace
Repair
0.1
0.1
0.1
0.2
ELECTRICAL
SYSTEM
0.1
0.2
0.2
0.3
5-1
0.2
1-B
0.1
0.1
0.2
0.2’
0.3
0.2
0.3
CONTROL BOX
ASSEMBLY
Box Assembly,
Control
0.6
H-GENERAL SUPPORT:
*
F
H
(5)
1.0
REFE RTOTM 5-2805-258-14
Inspect
Replace
Battery: Storage
04
UNIT
Fittings, Fuel
Lines
Hose Assembly,
Fuel
03
(4)
MAINTENANCE CATEGORY *
Indicates Worktime
(ManhouIs)
2-B
0.8
D-DEPOT
Required
Change 8 C - 3
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
Section II. MAINTENANCE ALLOCATION CHART (Cont’d)
For
Generator Set
NSNS 6115-00-017-8240, 6115-00-017-8241
(2)
COMPONENT/
ASSEMBLY
II
(3)
MAINTENANCE
FUNCTION
I
UNIT
c
INTERMEDIATE
o
Lamp, Incaridescent
Inspect
Replace
0.1
0.1
Light Assembly,
Panel
Inspect
Replace
0.1
Meters
Inspect
Test
Replace
0.1
0.2
0.2
Inspect
Test
Replace
0.1
Switchs
Resistor, Variable
I
(4)
MAINTENANCE CATEGORY *
F
H
(5)
DEPOT
TOOLS AND
D
EQUIPMENT
(6)
REMARKS
0.2
2.B
2-B
:::
Inspect
Test
Replace
:::
Meter, Frequency
Transducer
Inspect
Test
Replace
0.1
0.1
0.2
Switch,
output
Selector
Inspect
Test
Replace
0.1
2-B
2 -B
0.1
05
L.
*SUBCOLUMNS ARE AS FOLLOWS
* Indicates Worktime (Manhours) Rewired
C - 4 Change
8
C-OPERATOR/CREW:
H-GENERAL SUPPORT:
O-ORGANIZATIONAL
D-DEPOT
F-DIRECT SUPPORT
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
Section II.
MAINTENANCE ALLOCATION CHART (Cont’d)
For
Generator Set
NSNS 6115-00-017-8460, 6115-00-017-8241
(1)
(2)
(3)
GROUP
NUMBER
COMPONENT/
ASSEMBLY
MAINTENANCE
FUNCTION
Bracket, Control BOX
Inspect
Replace
Repair
Inspect
Replace
Repair
Panel Assembly,
Control
05
GENERATOR
ASSEMBLY
Generator
Assembly
Rdmr Assembly
Frame Assembly,
Exciter
Housing Assembly
Housing,
Generator
Stator Assembly
Fan, Cooling
Grille, Air Intake
Bearing, Shaft
Disk, Rotor Drive
“SUBCOLUMNS AREAS FOLLOWS:
(4)
MAINTENANCE CATEGORY*
1
c
[T
o
NTERMEDIATE DEPOT
F
H
D
(5)
(6)
TOOLS AND
EQUIPMENT
REMARKS
0.1
0.1
0.2
5-1
0.1
Inspect
Test
Replace
Repair
Inspect
Test
Replace
Repair
Inspect
Test
Replace
Repair
Inspect
Test
Replace
Repair
0.5
0.5
0.2
2-B
0.2
1.0
2.0
0.2
0.2
1.0
1.0
0.2
0.3
0.5
1.0
0.2
0.3
0.8
1.0
Insmct
0.1
Repair
Inspect
Test
Replace
Repair
Inspect
Replace
Inspect
Replace
Inspect
Replace
Repair
Inspect
Replace
1.0
0.3
0.3
2-B, 3-B
2-B
2-B
2-B, 3-B
2-B
2-B, 3-B
2-B
2-B, 3-B
3-B, 5-I
2.0
C-OPERATOR/CREW;
H-GENERAL SUPPORT;
5-I
2-B
2.0
2.0
0.1
0.8
0.1
0.2
0.2
0.5
0.5
0.2
0.8
O-ORGANIZATIONAL
D-DEPOT
3-B
4-H
5-I
F.DIRECT SUPPORT;
Change 6
C - 5
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
Section II.
MAINTENANCE ALLOCATION CHART (Cont’d)
For
Generator Set
NSNS 6115-00-017-8460, 6115-00-017-8241
(1)
(2)
(3)
GROUP
NUMBER
COMPONENTI
ASSEMBLY
MAINTENANCE
FUNCTION
06
Adapter, Disk
Starter
FRAME
ASSEMBLY
Guard, Frame
Bracket, Lifting
Stud, Grounding
Base Assembly,
Skid
Box Assembly,
Tool
● SUBCOLUMNS ARE AS FOLLOWS
(4)
MAINTENANCE CATEGORY*
Change 6
(6)
REMARKS
Inspect
Replace
Inspect
Replace
Repair
Inspect
Replace
Inepect
Replace
Inspect
Replace
Remir
Inspect
Replace
Repair
0.1
0.2
C-OPERATOR/CREW
H.GENERAL SUPPORT;
O-ORGANIZATIONAL
D-DEPOT
All data on page C-7 deleted
C-6
I
(5)
5-I
F-DIRECT SUPPORT;
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
Section III. TOOLS, TEST AND SUPPORT EQUIPMENT REQUIREMENTS
REFERENCE
CODE
MAINTENANCE
LEVEL
1-B
2-B
O
NOMENCLATURE
O
Tester, Battery, Electrolyte solution
Multimeter
3-B
O
Ohmmeter (megger)
4-H
F
Puller Kit
6-1
0
Torch outfit, cutting and welding
C-8 Change 8
NATIONAL
STOCK NO.
6630-00-171-6126
6 85-0 -581-2036
or equal
662500-581-2466
or equal
5180
-00-711-6753
or equal
34 3-0 -357-81 6
or equal
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
ALPHABETICAL INDEX
Page
AC Voltmeter (M6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........
Cleaning, Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .....
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .....
4-33
4-33b.
4-33c.
4-33a.
4-33d.
1-7
l-7b.
1-7a.
1-7c.
4-11
4-36
4-36b.
4-36c.
‘4-36a.
4-36d.
4-52
4-53
4-53
4-52
4-53
1-2
1-2
1-2
1-2
4-14
4-53
4-53
4-53
4-53
4-53
B
Basic Issue List and Items Troop Installed or . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Authorized List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .........B-1
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........... 3-13
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... 3-13a.
3-13b.
4-23
4-23c.
4-23d.
4-23b.
4-23a.
B-1
3-14
3-14
3-14
4-44
4-45
4-46
4-44
4-44
4-22
4-22b.
4-22c.
4-22a.
4-29
4-29b.
4-29c
4-29a.
4-29d.
2-4
2-4a.
2-4b.
4-42
4-44
4-44
4-42
4-51
4-51
4-51
4-51
4-51
2-17
2-17
2-17
4-41
4-41b.
4-41c.
4-41a.
3-14
3-14b.
3-14c.
3-14d.
3-14a.
6-1
6-1b
6-1a.
4-45
4-45b.
4-45c.
4-45a.
2-1
2-1b.
2-1a.
4-56
4-56
4-57
4-56
3-14
3-14
3-15
3-15
3-14
6-1
6-1
6-1
4-61
4-63
4-63
4-61
2-1
2-1
2-1
I-1
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
ALPHABETICAL INDEX (CON’T)
Paragraph
4-42
4-42b.
4-42d.
4-42a.
4-42c.
4-35
4-35b.
4-35c.
4-35a.
4-35d.
Current Transformer (CT) and Resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 7-5
Cleaning and Impaction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... 7-5c.
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... 7-5e.
On-Equipment Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... 7-5a.
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... 7-5d.
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... 7-5b.
Control Relays (K1, K2, K3 and K4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning, Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page
4-57
4-58
4-59
4-57
4-58
4-53
4-53
4-53
4-53
4-53
7-3
7-4
7-4
7-3
7-4
7-4
1-9
l-9d.
l-9b.
1-9a.
1-9c.
1-3
1-7
1-7
1-3
1-7
1-6
1-6a.
Gunfire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .....l-6b.
Mechanical Destruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6c.
3-4
Detailed Lubrication Information (Organizational . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... 4-10
Differences Between Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... 1-11
Direct and General Support Maintenance Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........ 5-2
Dismantling for Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Handling Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4-4b.
Preparation for Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4a
1-2
1-2
1-2
1-2
3-3
4-14
1-13
5-1
4-12
4-12
4-12
E
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ................3-12
Emergency Stop-Run Switch (S6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4-30
Cleaning, Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 4-30b.
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 4-30c.
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4-30a.
4-30d.
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... 6-4
6-4b.
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .......
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........ 6-4a
7-16
Engine Support and Drip Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
Cleaning, Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........... 7-16b.
Installtion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....... 7-16c.
7-16a.
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..........
4-3
Equipment Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...............
Explanation of Columns in the Tabular List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
of Consumable Maintenance and Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........... ......3-2
3-2a.
Component Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........ 3-2c.
3-2b.
National Stock Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ......
Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........ 3-2f.
Quantity Required for Eight Hours Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . 3-2e.
3-2d.
Quantity Required for Initial Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I-2
3-14
4-51
4-51
4-51
4-51
4-51
6-7
6-12
6-7
7-24
7-25
7-25
7-24
4-11
3-1
3-1
3-1
3-1
3-1
3-1
3-1
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
ALPHABETICAL INDEX (CON’T)
Paragraph
F
Frame Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... 3-16
Frequency Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .....
7-2
7-2d.
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .......... 7-2a.
Instillation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ......
7-2f.
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........... 7-2e.
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... 7-2c.
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....... 7-2b.
Frequency Meter (Ml) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........
4-34
4-34b
Cleaning, Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
4-34c.
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....... 4-34a.
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... 4-34d.
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 3-11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........ 3-11b. (2)
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... 3-11b. (1)
Fuseholder (XF) (Model MEP-017A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... 4-40
Cleaning, Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... 4-40b.
Instillation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... 4-40c.
Removal . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....... 4-40a.
Page
3-15
7-1
7-2
7-1
7-2
7-2
7-1
7-1
4-53
4-53
4-53
4-53
4-53
3-13
3-13
3-13
4-54
4-56
4-56
4-54
G
General Disassembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........... 5-6
General Methods Used to Attain Proper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . ...
Suppression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....... 4-17
General Instructions for Use of Multimeters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
If the AC Volta Scale is Used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... 4-16d.
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....4-16a.
Using the DC Volts Scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16c.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... .. 4-16b.
Using the Ohms Scale
General Repair and/or Replacement Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
3-15
Generator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....
3-15a.
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .......
Service . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 3-15b.
Generator (Model MEP-017A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....
6-2
Installation . ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... 6-2b.
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2a.
Generator (Model MEP.022A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .........
6-3
6-3b.
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .......
6-3a.
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ......
Ground Stud Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ......
4-49
Cleaning, Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........ 4-49b.
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... 4-49c.
R e m o v a. l. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ......... 4-49a.
Guard Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..............
4-47
Cleaning, Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ......... 4-47b.
4-47c.
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....... 4-47a.
4-41
4-17
4-32
4-17
4-26
4-19
5-8
3-15
3-15
3-15
6-2
6-4
6-2
6-4
6-7
6-4
4-67
4-68
4-68
4-67
4-64
4-65
4-65
4-64
I
Inspecting and Servicing the Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4-1
Inspecting the Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ......4-1a.
Servicing the Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .......... 4-1b.
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... 4-2
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .............. 4-2a
Revetment Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... 4-2b.
Interference Suppression Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... 4-18
4-1
4-1
4-1
4-1
4-1
4-4
4-41
5-8
I-3
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
ALPHABETICAL INDEX (CON’T)
Paragraph
L
Levels of Maintenance Accomplishments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Lifting Eye and Lifting Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .........
Cleaning, Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..........
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..........
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .....................
Limited Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ................
Load Terminal Board (TB1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...............
Cleaning, Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..........
Instillation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............................
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..........................
1-5
4-48
4-48b
4-48c.
4-48a.
1-2
7-8
7-8b.
7-8c.
7-8a.
M
7-14
Main Generator Rotor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .................
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .................. 7-14f.
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .................. 7-14c.
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...................... 7-14b.
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........................... 7-14d.
Instillation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ................................... 7-14h.
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........................ 7-14e.
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............................... 7-14a.
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ................................7-14g.
Main Generator Stator and Housing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...................................... 7-13f.
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........................7-13c.
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ................. 7-13b.
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .............. 7-13d.
Instillation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..................7-13h.
7-13e.
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..............
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ................... 7-13a.
7-13g.
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ......................
Maintenance Allocation Chart (For Army and . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Marine Corp Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .......................... C-1
Maintenance Forms and Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............... 1-3
Maintenance Repair Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .............. 4-8
1-2
4-65
4-67
4-67
4-65
1-1
7-8
7-8
7-9
7-8
7-19
7-24
7-21
7-19
7-21
7-24
7-21
7-19
7-24
7-12
7-19
7-16
7-12
7-16
7-19
7-16
7-12
7-19
C-1
1-1
4-13
o
Oil Drain Assembly and Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........... 3-10
Oil Pressure Indicator (M2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
Cleaning, Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .......... 4-26b.
4-26c.
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...................
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ................. 4-26a.
4-26d.
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...........
On-Equipment Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ................... 7-12
Exciter Field Windings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............... 7-12d.
7-12a.
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...............
7-12c.
Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .................
Stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ......................... 7-12b.
Operation at High Altitudes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .................. 2-10
2-7
Operation in Dusty or Sandy Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............
Air Cleaner.: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .................2-7d.
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 2-7b.
2-7a.
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..................
2-7c.
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..............
2-7e.
Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..............
Operation in Extreme Cold (Below 0° F) (-17.8C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2-5d.
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............
Electrical Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........ 2-5f.
2-5b.
Engine Preheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............
2-5e.
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...............
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .......... 2-5a.
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....... 2-5c.
3-13
4-50
4-50
4-50
4-50
4-50
7-12
7-12
7-12
7-12
7-12
2-20
2-19
2-20
2-19
2-19
2-20
2-20
2-19
2-19
2-19
2-19
2-19
2-19
2-19
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
ALPHABETICAL INDEX (CON’T)
Paragraph
Operation in Extreme Cold (Below 0° F) (-17.8C) (Con' t) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5g.
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ......................
Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............. 2-5h.
Operation in Extreme Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ................. 2-6
2-6d.
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..............
2-6b.
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...............
2-6a.
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............
2-6c.
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .........
Operation in Salt Water Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............. 2-9
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ................. 2-9a.
Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ......... 2-9b.
Operation Under Rainy or Humid Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
2-8c.
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..........
2-8a.
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .........
2-8b.
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .......
Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... 2-8d.
Operation Under Usual Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 2-2
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ......... 2-2a.
2-2d.
Operation and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..............
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........... 2-2b.
2-2c.
Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..........
Operator’s Preventive Maintenance Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
and Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .......... 3-6
3-8
Operator’s Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .....
Organizational Maintenance Preventive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
4-13
Maintenance Checks and Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ......
Organizational Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... 4-15
4-43
Outlet Receptacle (J1) (Model MEP-017A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . .
Cleaning, Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .......... 4-43b.
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .............. 4-43c.
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....... 4-43a.
Output Selector Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... 7-3
7-3b
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...............
7-3c.
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....... 7-3f.
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .......... 7-3e.
7-3a.
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..........
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....... 7-3d.
P
4-32
Panel Light (XDS1 and XDS2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .....
Cleaning, Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........ 4-32b.
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 4-32c.
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... 4-32a.
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... 4-32d.
Panel Lights Switch (S7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........4-31
4-31b.
Cleaning, Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..........
4-31c.
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ......
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31a.
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... 4-31d.
Preparation for Shipment and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... 1-8
l-8b.
Air Force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ......
Army . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...........1-8a.
1-8c.
Navy and Marine Corps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .................
Page
2-19
2-19
2-19
2-19
2-19
2-19
2-19
2-20
2-20
2-20
2-20
2-20
2-20
2-20
2-20
2-11
2-11
2-17
2-11
2-15
3-3
3-5
4-15
4-17
4-59
4-60
4-60
4-59
7-2
7-3
7-3
7-3
7-3
7-2
7-3
4-52
4-52
4-52
4-52
4-52
4-51
4-52
4-52
4-51
4-52
1-2
1-2
1-2
1-2
I-5
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
ALPHABETICAL INDEX (CON’T)
Paragraph
A-1
Reinstallation After Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
..
Relay Panel and Field Flash Swich . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........ 7-4b.
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 7-4e.
7-4d.
7-4a.
Teating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... 7-4c.
Remote Control Terminal Board (TB3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... 7-9
7-9b.
Cleaning, Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .........
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 7-9c.
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-9a.
. . ......
Remote-Local Switch (S5). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........... 4-27
Cleaning, Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........4-27b.
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... 4-27c.
4-27a.
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-27d.
Replacement of Suppression Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . 4-19
Cleaning, Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 4-19b.
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... 4-19c.
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... 4-19a.
Reporting of Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... 1-4
Page
A-1
4-12
7-3
7-3
7-4
7-4
7-3
7-4
7-9
7-10
7-10
7-9
4-50
4-50
4-50
4-50
4-50
4-41
4-41
4-41
4-41
1-1
s
1-1
7-17
Cleaning, Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... 7-17b.
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 7-17c.
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... 7-17a.
Slave Receptacle and Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 4-24
Cleaning, Impaction and Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .......... 4-24b.
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... 4-24c.
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... 4-24a.
Special Tools and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....... 4-7
Spatial Tools and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 5-1
Start-Stop Switch (S4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... 4-28
Cleaning, Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 4-28b.
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........ 4-28c.
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4-28a.
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... 4-28d.
Skid Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ......
1-1
7-25
7-27
7-27
7-26
4-46
4-48
4-48
4-46
4-13
5-1
4-50
4-50
4-51
4-50
4-51
T
Tabulated Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... 1-10
Base Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-100.
Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 1-10f.
Dimensions and Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .....1-10d.
Engine Electrical Syetem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10c.
.......
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... 1-10a.
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....... 1-10b.
Terminal Board (TB2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 7-10
Cleaning, Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10b.
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10c.
7-10a.
Testing of Radio Interference Suppression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Time Totalizing Meter (M4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4-25
4-25b.
Cleaning, Impaction and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..........
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 4-25c.
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 4-25a.
Toolbox. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-50
..
Cleaning, Inspection and Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . ......... 4-50b.
I-6
1-7
1-7
1-8
1-7
1-7
1-7
1-7
7-10
7-11
7-11
7-11
4-42
4-48
4-49
4-49
4-48
4-68
4-68
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
ALPHABETICAL INDEX (CON’T)
Paragraph
Page
4-50c.
4-50a.
4-6
4-44
4-44b.
4-44c.
4-44a.
5-4
4-68
4-68
4-13
4-60
4-61
4-61
4-60
5-1
4-38
4-38b.
4-38c.
4-38a.
4-38d.
7-6
7-6c. (2) (b)
7-6a.
7-6c. (2) (d)
7-6c. (2) (C)
7-6c. (1) (a)
7-6b.
7-6c.
4-37
4-37b.
4-37c.
4-37a.
4-37d.
4-54
4-54
4-54
4-54
4-54
7-4
7-5
7-4
7-5
7-5
7-5
7-4
7-5
4-54
4-54
4-54
4-54
4-54
4-39
7-7
7-7a.
7-7b.
4-54
7-7
7-7
7-7
I-7
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
By Order of the Secretaries of the Army, the Navy, and the Air Force:
Official:
BERNARD W. ROGERS
General, United States Army
Chief of Staff
J. C. PENNINGTON
Brigadier General, United States Army
The Adjutant General
D. G. ISELIN
Rear Admiral, CEC, U. S. Navy Commander
Naval Facilities Engineering Command
DAVID C. JONES, General USAF
Chief of Staff
JAMES J. SHEPARD, Colonel, USAF
Director of Administration
Distribution:
To be distributed in accordance with DA Form 12-25D, Operator maintenance requirements for Generator
Sets, Engine Driven: 5KW 60HZ and 5 KW 400 HZ.
U.S. GOVERNMENT PRINTING OFFICE : 1995 0 - 388-421 ( 00299)
TM 5-6115-332-14
FO-1.
FO-1
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
TS 5-6115-332-14/FO-2
FO-2. Generator Set, Schematic Diagram (Mode MEP-017A)
Change 10 FO-2
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
FO-3. Writing Diagram (Model MEP-022A)
Change 5
FO-3
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
FO-4. Generator Set, Schematic Diagram (Model MEP-022A)
TS 5-6115-332-14/FO-4
FO-4
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
C2
Figure FO-5. Wiring Diagram, Standard Voltage Regulator
(FMC97403 13219E0886) TS011947
Change
2
FO-5
TM 5-6115-332-14
P-8-614-14
TO 35C2-3-424-1
C2
Figure FO-6. Schematic Diagram, Standard Voltage Regulator
3KW, 5KW, 10KW, DC, 60, Hz, 400 Hz (FMC97403 13219E0887) TSO 11948
Change 2
F O - 6
The
Metric
System
and
Equivalents
Linear Measure
1
1
1
1
1
1
1
1
1
1
1
1
centimeter = 10 millimeters = .39 inch
decimeter = 10 centimeters = 3.94 inches
meter = 10 decimeters = 39.37 inches
dekameter = 10 meters = 32.8 feet
hectometer = 10 dekameters = 328.08 feet
kilometer = 10 hectometers = 3,280.8 feet
centiliter = 10 milliters = .34 fl. ounce
deciliter = 10 centiliters = 3.38 fl. ounces
liter = 10 deciliters = 38.82 fl. ounces
dekaliter = 10 liters = 2.64 gallons
hectoliter = 10 dekaliters = 26.42 gallons
kiloliter = 10 hectoliters = 264.18 gallons
Square Measure
Weights
1
1
1
1
1
1
1
1
1
1
1
1
1
1
centigram = 10 milligrams = .15 grain
decigram = 10 centigrams = 1.54 grains
gram = 10 decigrams = .035 ounce
dekagram = 10 grams = .35 ounce
hectogram = 10 dekagrams = 3.52 ounces
kilogram = 10 hectograms = 2.2 pounds
quintal = 100 kilograms = 220.46 pounds
metric ton = 10 quintals = 1.1 short tons
sq. centimeter = 100 sq. millimeters = .155 sq. inch
sq. decimeter = 100 sq. centimeters = 15.5 sq. inches
sq. meter (centare) = 100 sq. decimeters = 10.76 sq. feet
sq. dekameter (are) = 100 sq. meters = 1,076,4 sq. feet
sq. hectometer (hectare) = 100 sq. dekameters = 2.47 acres
sq. kilometer = 100 sq. hectometers = .386 sq. mile
Cubic Measure
1 cu. centimeter = 1000 cu. millimeters =. 06 cu. inch
1 cu. decimeter = 1000 cu. centimeters = 61.02 cu. inches
1 cu meter = 1000 cu. decimeters = 35.31 cu. feet
Approximate
To change
To
inches
feet
yards
miles
square inches
square feet
square yards
square miles
acres
cubic feet
cubic yards
fluid ounces
pints
quarts
gallons
ounces
pounds
short tons
pound-feet
pound-inches
Conversion
Multiply by
centimeters
meters
meters
kilometers
square centimeters
square meters
square meters
square kilometers
square hectometers
cubic meters
cubic meters
milliliters
liters
liters
liters
grams
kilograms
metric tons
newton-meters
newton-meters
2.540
.305
.914
1.609
6.451
.093
.836
2.590
.405
.028
.765
29,573
.473
.946
3.785
28.349
.454
.907
1.365
.11375
Temperature
°F
Fahrenheit
temperature
5/9 (after
subtracting 32)
Factors
To change
Multiply b y
ounce-inches
centimeters
meters
meters
kilometers
square centimeters
square meters
square meters
square kilometers
square hectometers
cubic meters
cubic meters
milliliters
liters
liters
liters
grams
kilograms
metric tons
newton-meters
inches
feet
yards
miles
square inches
square feet
square yards
square miles
acres
cubic feet
cubic yards
fluid ounces
pints
quarts
gallons
ounces
pounds
short tons
(Exact)
Celsius
temperature
°C
.007062
3.94
3.280
1.094
.621
.155
10.764
1.196
.386
2.471
35.315
1.308
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2.113
1.057
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2.205
1.102
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– Chicago Machinery Movers
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