army tm 9-6115-639-13 air force to 35c2-3-386-51

army tm 9-6115-639-13 air force to 35c2-3-386-51

ARMY TM 9-6115-639-13

AIR FORCE TO 35C2-3-386-51

MARINE CORPS TM 10155A-13/1

OPERATOR’S, UNIT, AND DIRECT SUPPORT

MAINTENANCE MANUAL

OPERATING

INSTRUCTIONS 2-1

OPERATOR

TROUBLESHOOTING 3-3

UNIT LEVEL PMCS

4-7

UNIT LEVEL

TROUBLESHOOTING 4-12

UNIT MAINTENANCE

PROCEDURES 4-27

DIRECT SUPPORT

TROUBLESHOOTING 5-3

DIRECT SUPPORT

MAINTENANCE 5-4

MAINTENANCE

ALLOCATION CHART B-1

3KW TACTICAL QUIET GENERATOR SET

MEP 831A (60 HZ) (NSN: 6115-01-285-3012) (EIC: VG6)

MEP 832A (400 HZ) (NSN: 6115-01-287-2431) (EIC: VN7)

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited.

DESTRUCTION NOTICE: Destroy by any method that will prevent disclosure of contents or reconstruction of the document.

HEADQUARTERS, DEPARTMENTS OF THE ARMY,

AIR FORCE AND MARINE CORPS

1 November 2000

PCN 182 101550 00

TM 9-6115-639-13

CHANGE

HEADQUARTERS

DEPARTMENTS OF THE ARMY,

No. 1

AIR FORCE AND MARINE CORPS

WASHINGTON, D.C., 15 September 2002

OPERATOR’S, UNIT, AND DIRECT SUPPORT

MAINTENANCE MANUAL

FOR

3KW TACTICAL QUIET GENERATOR SET

MEP 831A (60 HZ) (NSN: 6115-01-285-3012) (EIC: VG6)

MEP 832A (400 HZ) (NSN: 6115-01-287-2431) (EIC: VN7)

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited.

TM 9-6115-639-13 / TO 35C2-3-386-51 / TM 10155A-13/1, dated 1 NOV 00, 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 vertical bar next to the figure title.

Remove

i and

1-11

2-3 and 2-4

1-21

2-3 and 2-4

2-15

2-18 2-15

and

A-2

B-8

2. Retain this sheet in front of manual for reference purposes.

By Order of the Secretary of the Army:

ERIC K. SHINSEKI

General, United States Army

Official: Chief of Staff

0224009

By Order of the Secretary of the Air Force:

JOHN P. JUMPER

General, United States Air Force

Chief of Staff

Official:

GEORGE T. BABBITT

General, United States Air Force

Commander, AFMC

By Order of the Secretary of the Navy:

WALTER H. CANTRELL

Rear Admiral, United States Navy

Commander, Space and Naval Warfare

Systems Command

By Order of the Secretary of the Marine Corps:

RANDALL P. SHOCKEY

Marine Command

DISTRIBUTION:

To be distributed in accordance with the initial distribution number (IDN) 256631 requirements for TM 9-6115-639-13.

WARNING SUMMARY

ARMY TM 9-6115-639-13

AIR FORCE TO 35C2-3-386-51

MARINE CORPS TM 10155A-13/1

The following safety precautions are for personnel to understand and apply during many phases of operation and maintenance. Disregard of these warnings and precautionary information can result in serious injury or death.

Warning statements have been strategically placed throughout this manual prior to the operating or maintenance procedures considered essential to the protection of personnel. Prior to starting any task, the warning included in the text for that task must be reviewed and understood.

This manual describes physical and chemical processes which may require the use of chemicals, solvents, paints, or other commercially available material. The user of this manual should obtain the material safety data sheets

(Occupational Safety and Heath Act (OSHA) Form 20 or equivalent) from the manufacturer or suppliers of materials to be used. The user must be completely familiar with the manufacturer/supplier information and adhere to the procedures, recommendations, warnings, and cautions of the manufacturer/supplier for the safe use, handling, storage, and disposal of these materials.

WARNING

KEEP AWAY FROM LIVE CIRCUITS

Do not replace components or make adjustments with the voltage supply turned on. Dangerous potentials may exist under certain conditions when the power control is in the off position.

Avoid casualties by always removing power and discharging and grounding a circuit before touching it. Failure to observe this warning can result in severe personal injury.

WARNING

HIGH VOLTAGE

High voltage is produced when the unit is in operation. Use care when working around an open control panel with the generator set operating. Improper operation and/or failure to follow this warning could result in personal injury or death by electrocution.

WARNING

Never attempt to start the generator set if it is not properly grounded. Equipment must be grounded in accordance with the procedures in Paragraph 2-6. Failure to observe this warning can result in personal injury or death by electrocution.

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WARNING

Generator battle short mode is for emergency operation only. Prolonged use under this mode could damage the generator set or pose potential shock hazard to personnel.

WARNING

DC voltages are present at generator set electrical components even with the generator set shut down. Avoid shorting any positive terminal with ground or negative. If no DC voltage is required, always disconnect DC power source to the generator set before working on it. Failure to observe this warning can result in personal injury.

WARNING

Never attempt to connect or disconnect load cables while the unit is running. Failure to observe this warning could result in severe personal injury or death by electrocution.

WARNING

Never service or perform maintenance on the generator set while the engine is running. Always shut down the unit before servicing. Allow engine to cool before handling components. Failure to observe this warning can result in severe burn or injury.

WARNING

Never reach into the enclosure to service or adjust the equipment alone. Make sure to work with someone who can render aid in case of an emergency.

WARNING

Shut down the generator set at first sign of failure. Continued operation can result in injury to personnel and will cause damage to equipment. If the generator set is shut down by the activation of a safety device, do not operate again until the cause of the shut down has been determined and eliminated. Failure to observe this warning can result in equipment damage and/or potential personal injury.

ARMY TM 9-6115-639-13

AIR FORCE TO 35C2-3-386-51

MARINE CORPS TM 10155A-13/1

WARNING

If damaged or defective components are discovered, repair must be performed before operation can begin. Perform required repairs and adjustments before proceeding. Do not operate the generator set with damaged components. Personal injury can occur if damaged parts are left unfixed. Failure to observe this warning can result in personal injury and/or equipment damage.

WARNING

DANGEROUS CARBON MONOXIDE GASES

Exhaust discharge contains deadly gases including carbon monoxide. Do not operate generator set in enclosed area unless exhaust discharge is properly vented outside. Position as far away from personnel, shelters, and occupied vehicles as possible. Failure to observe this warning could result in severe personal injury or death due to carbon monoxide poisoning.

FOR ARTIFICIAL RESPIRATION, REFER TO FM 21-11.

THE BEST DEFENSE AGAINST CARBON MONOXIDE POISONING

IS GOOD VENTILATION.

WARNING

Fuel used in this generator set is flammable and toxic to skin, eyes, and respiratory tract. Avoid repeated or prolonged contact. Handle only in well ventilated area. Keep away from sparks, open flames, or other sources of ignition. Do not splash fuel on hot components. Do not fuel generator set while it is operating. Do not over fill the tank. Ensure the unit is properly grounded before fueling. Failure to observe this warning can result in personal injury and equipment damage due to potential fuel ignition and possible explosion. Ensure approved gloves and face shield are worn during handling.

WARNING

LIQUIDS UNDER PRESSURE

Liquids under pressure are generated as a result of operation of this generator set. High pressure leaks could cause severe personal injury or death.

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WARNING

Cleaning solvents are flammable and toxic to eyes, skin, and respiratory tract. Skin and eye protections are required when working in contact with cleaning solvents. Avoid prolonged or repeated contact. Work in well ventilated area only. Keep away from heat, sparks, and open flame. Do not smoke while using cleaning solvent. Failure to observe this warning can result in injury or death to personnel.

WARNING

The adhesives used in maintenance of the generator set (see Appendix E) are flammable and toxic. Vapors may ignite explosively. Avoid breathing in vapors. Provide adequate ventilation to prevent vapor concentrations in excess of permissible exposure levels. Keep away from heat, sparks, and open flame. Do not smoke. Extinguish all flames and turn off non-explosion-proof electrical equipment during use until vapors are dissipated. Close containers tightly.

WARNING

Use caution when lifting or moving the generator set to prevent injury to personnel and damage to equipment. Six persons are required for manual lifting. Use lifting rings for lifting device and forklift pockets for forklift only. Do not lift object over personnel. Failure to observe this warning can result in personal injury and/or equipment damage.

WARNING

Avoid contacting metal items with bare skin in extreme cold weather. Failure to observe this warning can result in personal injury.

WARNING

REMOVE ALL JEWELRY BEFORE WORKING ON THE EQUIPMENT

Metal jewelry can conduct electricity. Remove metal jewelry before working on electrical system or components. Failure to observe this warning can result in severe personal injury from electric shock.

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MARINE CORPS TM 10155A-13/1

WARNING

Jewelry and other loose and dangling articles and clothing can be caught in moving parts.

Remove jewelry and loose and dangling articles and clothing before working on the engine.

Failure to observe this warning can result in injury to personnel.

WARNING

CARC paint dust is a heath hazard. Wear protective eyewear, mask, and gloves when sanding

CARC painted surfaces. Failure to observe this warning can result in personal injury.

WARNING

If battery is not installed, battery cable ends must be isolated from each other and positive end must be isolated from ground. Failure to isolate battery cable ends can result in severe electrical discharge.

WARNING

With any access door open, the noise level of the generator set when operating could cause hearing damage. Hearing protection must be worn when working near the generator set while running.

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LIST OF EFFECTIVE PAGES

INSERT LATEST CHANGED PAGES, DESTROY SUPERSEDED PAGES

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NOTE: The portion of the text affected by the changes is indicated by a vertical line in the outer margins of the page. Changes to illustrations are indicated by miniature pointing hands. Changes to wiring diagrams are indicated by shaded areas.

Dates of issue for original and changed pages are:

Original..........0 ............. 01 Nov 00

Change 1........1 ............. 15 Sep 02

Change

No. No.

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TECHNICAL MANUAL

ARMY TM 9-6115-639-13

HEADQUARTERS

DEPARTMENTS OF THE ARMY,

AIR FORCE TO 35C2-3-386-51 AIR FORCE AND MARINE CORPS

MARINE CORPS TM 10155A-13/1 WASHINGTON D.C. 1 November 2000

OPERATOR’S, UNIT, AND DIRECT SUPPORT

MAINTENANCE MANUAL

FOR

3KW TACTICAL QUIET GENERATOR SET

MEP 831A (60 HZ) (NSN: 6115-01-285-3012) (EIC: VG6)

MEP 832A (400 HZ) (NSN: 6115-01-287-2431) (EIC: VN7)

REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS

You can help improve this manual. If you find any mistakes, or if you know of a way to improve the procedures, please let us know. Mail your letter, DA Form 2028 (Recommended Changes to

Publications and Blank Form) or DA Form 2028-2 located in the back of this manual directly to:

Commander, US Army Communications and Electronics Command (CECOM), ATTN: AMSEL-

LC-LEO-D-CS-CFO, Fort Monmouth, NJ 07703-5000. The FAX number is 732-532-1413,

DSN 992-1413. You can also E-mail your recommendations to AMSEL-LC-LEO-PUBS-CHG

@cecom3.monmouth.army.mil.

For Air Force, submit AFTO Form 22 (Technical Order System Publication Improvement Report and Reply) in accordance with paragraph 6-5, Section VI, TO 00-5-1. Forward direct to prime

ALC/MST.

For Marine Corps units, submit NAVMC 10772 (Recommended Changes to Technical

Publications) to: Commanding General, Marine Corps Logistics Base (Code 850), Albany,

Georgia 31704-5000.

A reply will be furnished directly to you.

TABLE OF CONTENTS

HOW TO USE THIS MANUAL ......................................................................................................... vi

Section I

General Information ..........................................................................................1-1

Section II

Section III

Equipment Description......................................................................................1-5

Principles of Operation ...................................................................................1-21

Change 1 i

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TABLE OF CONTENTS

CHAPTER 2

Section I

Section II

OPERATING INSTRUCTIONS.................................................................... 2-1

Description and Use of Operator’s Controls and Indicators ........................... 2-2

Operator Preventive Maintenance Checks and Services (PMCS) .................. 2-8

Section III

Operation Under Usual Conditions............................................................... 2-19

Section IV

Operation Under Unusual Conditions........................................................... 2-28

CHAPTER 3

Section I

OPERATOR MAINTENANCE INSTRUCTIONS ....................................... 3-1

Lubrication Instructions .................................................................................. 3-2

Section II

Operator Troubleshooting Procedures ............................................................ 3-3

Section III

Operator Maintenance Procedures .................................................................. 3-9

CHAPTER 4 UNIT MAINTENANCE INSTRUCTIONS ....................................................4-1

Section I

Section II

Lubrication Instructions ...................................................................................4-3

Repair Parts; Tools; Special Tools; Test, Measurement and ...........................4-6

Diagnostic Equipment (TMDE); and Support Equipment

Section III

Service Upon Receipt of Equipment................................................................4-6

Section IV

Unit Preventive Maintenance Checks and Services (PMCS) ..........................4-7

Section V

Unit Level Troubleshooting Procedures ........................................................4-12

Section VI

Unit Maintenance Procedures........................................................................4-27

Section VII

Preparation for Shipment and Storage .........................................................4-140

CHAPTER 5

Section I

Section II

DIRECT SUPPORT MAINTENANCE INSTRUCTIONS.............................5-1

Repair Parts; Tools; Special Tools; Test, Measurement and ...........................5-2

Diagnostic Equipment (TMDE); and Support Equipment

Service Upon Receipt of Equipment................................................................5-2

Section III

Direct Support Level Troubleshooting Procedures .........................................5-3

Section IV

Direct Support Maintenance Procedures .........................................................5-4

Appendix B MAINTENANCE ALLOCATION CHART (MAC) ..................................... B-1

Appendix C COMPONENTS OF END ITEM (COEI) AND BASIC ISSUE .................... C-1

ITEMS (BII) LISTS

Appendix D

Appendix E

ADDITIONAL AUTHORIZATION LIST (AAL) ITEMS............................D-1

EXPENDABLE AND DURABLE ITEMS LIST........................................... E-1

Appendix F

Appendix G

Appendix H

ILLUSTRATED LIST OF MANUFACTURED ITEMS................................F-1

TORQUE LIMITS ..........................................................................................G-1

MANDATORY REPLACEMENT PARTS ...................................................H-1

ARMY TM 9-6115-639-13

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LIST OF ILLUSTRATIONS

Figure No.

1-1

1-2

Title Page

3kW Tactical Quiet Generator Set...................................................................................1-3

Location of Generator Set Components...........................................................................1-7

4-17

4-18

4-19

4-20

4-21

4-22

4-23

4-24

4-25

4-26

4-27

4-28

4-29

1-3

1-4

1-5

1-6

2-1

2-2

2-3

2-4

3-1

4-1

4-2

4-3

4-4

4-5

4-6

4-7

4-8

4-9

4-10

4-11

4-12

4-13

4-14

4-15

4-16

Engine / Generator Assembly ..........................................................................................1-9

Generator Set Fuel System.............................................................................................1-11

Generator Set Data, Instruction, and Warning Plates ....................................................1-14

Fuel System Schematic ..................................................................................................1-25

Generator Set Controls and Indicators.............................................................................2-5

Ground Rod and Cable Installation................................................................................2-21

Manual Engine Starting .................................................................................................2-31

Air Filter Replacement...................................................................................................3-11

Engine Oil Servicing........................................................................................................4-5

Diagnostic Test Points ...................................................................................................4-13

Control Box Assembly...................................................................................................4-29

Control Panel Assembly ................................................................................................4-33

FUEL LEVEL Gauge ....................................................................................................4-35

Fault Indicator Module ..................................................................................................4-38

EMERGENCY STOP Switch........................................................................................4-41

DC CIRCUIT BREAKER .............................................................................................4-43

CIRCUIT INTERRUPTER Indicator Light ..................................................................4-44

VOLTAGE ADJUST Rheostat......................................................................................4-46

Control Box Relays........................................................................................................4-48

Terminal Blocks, Fuse, Diodes......................................................................................4-51

Control Box Wiring Harness .........................................................................................4-55

AC Circuit Interrupter Contactor ...................................................................................4-56

Battery Charging Regulator ...........................................................................................4-58

Ground Fault Circuit Interrupter....................................................................................4-62

Output Terminals / Filter ...............................................................................................4-66

Engine Oil Drain Assembly ...........................................................................................4-75

Engine Temperature Switch...........................................................................................4-76

Lubrication Oil Pressure Switch ....................................................................................4-78

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LIST OF ILLUSTRATIONS - cont.

Figure No.

4-30

4-31

Title Page

Fuel Level Switch ..........................................................................................................4-80

4-32

4-33

4-34

4-35

Fuel Tank Pickup Tube..................................................................................................4-84

Primary Fuel Pump ........................................................................................................4-85

4-36

4-37

4-38

4-39

Main Access Cover......................................................................................................4-101

High Temperature Switch and Cooling Fan Removal .................................................4-113

Low Temperature Switch and Cooling Fan Removal..................................................4-115

Low Temperature Switch and Cooling Fan Installation ..............................................4-117

High Temperature Switch and Cooling Fan Installation .............................................4-119

4-40

4-41

4-42

4-43

4-44

4-45

4-46

4-47

4-48

4-49

4-50

4-51

5-1

Fuel Filter / Water Separator........................................................................................4-121

Fuel Fill Cap and Pocket..............................................................................................4-123

Auxiliary Fuel Pump....................................................................................................4-126

Power Inverter / Converter...........................................................................................4-129

DC Magnetic Contactors..............................................................................................4-133

Governor Actuator Adjustment....................................................................................4-134

Governor Control Module ...........................................................................................4-135

Engine / Alternator Assembly..........................................................................................5-5

Permanent Magnet Alternator........................................................................................5-11 5-2

5-3

FO-1

FO-2

FO-3

FO-4

FO-5

FO-6

Generator Set Electrical Schematic............................................................................... FP-1

Generator Set Wiring Diagram ..................................................................................... FP-5

Engine Wiring Harness Diagram, 60 Hz .................................................................... FP-13

Engine Wiring Harness Diagram, 400 Hz .................................................................. FP-17

Control Box Wiring Harness Diagram, 60 Hz............................................................ FP-21

Control Box Wiring Harness Diagram, 400 Hz.......................................................... FP-27

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LIST OF TABLES

Table No.

1-1

1-2

2-1

3-1

3-2

3-3

Title Page

Operator Preventive Maintenance Checks and Services................................................2-12

Lubricant Table for Generator Set MEP 831A/832A ......................................................3-2

Malfunction Index (Operator Troubleshooting) ..............................................................3-3

Operator Level Troubleshooting......................................................................................3-4

4-1

4-2

4-3

4-4

Lubricant Table for Generator Set ...................................................................................4-3

Unit Level Preventive Maintenance Checks and Services.............................................4-10

Malfunction Index (Unit Troubleshooting) ...................................................................4-12

Unit Level Troubleshooting Procedures ........................................................................4-14

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How to Use This Manual

1. DESCRIPTION OF THE MANUAL

.

a

.

Chapter Organization. This manual has five chapters covering: introductory information, principles of operation, operator maintenance instruction, unit maintenance instructions, and direct support maintenance instructions. Each chapter is divided into sections. These sections contain the cleaning, inspection, troubleshooting, and repair tasks appropriate for the specific maintenance level. Each chapter contains a table of

contents containing the tasks within that chapter. See the overall Table of Contents (page i) for the chapters and

sections of this manual.

b

.

Paragraph and Task Numbering. All paragraphs and maintenance tasks are numbered. This helps

you find what you need when you need it. Use the Table of Contents (page i) or alphabetical index (at the back

of the manual) to find the paragraph or task you need.

c

.

Appendices. The appendices in this manual contain both general maintenance information and specific data for this generator set. They list reference manuals and materials, components of the generator set, additional authorization list items, expendable supplies and materials, torque limits, and mandatory replacement

parts. Refer to the Table of Contents (page i) for a complete list of the appendices used in this manual.

2

. HOW TO FIX A GENERATOR SET MALFUNCTION.

a.

Determining the Cause

.

Figuring out the cause of the malfunction, or troubleshooting, is the first step in fixing the generator set and returning it to operation. Follow these steps to determine the root of your problem:

(1) Turn to the Table of Contents section in this manual (page i).

(2) Locate “Troubleshooting” for your maintenance level and turn to the page indicated.

(3) In the Troubleshooting section, find the troubleshooting symptom for the component affected by the malfunction. Refer to the Symptom Index for help.

NOTE

If the specific symptom is not addressed, the maintenance required is most likely more detailed than authorized for your level. Notify personnel at a higher maintenance level.

(4) Begin troubleshooting. Carefully work your way down through the troubleshooting table to try and determine what the problem is.

(5) Once the trouble has been determined, go to the maintenance task called out. Remedy the malfunction, test the generator set, and return it to service.

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Preparing for a Task

.

NOTE

You must familiarize yourself with the entire maintenance procedure before starting any maintenance task. Ensure all parts, materials, and tools are handy. Read through all steps before beginning.

(1) PAY ATTENTION TO WARNINGS, CAUTIONS, AND NOTES.

(2) Maintenance tasks are arranged in a logical disassembly/assembly sequence and address only the component or assembly to be replaced. Locator illustrations are included for removal and installation.

These illustrations show you the area of the generator set to be worked on.

(3) All mandatory replacement parts are listed, including gaskets, packings, cotter pins, and lockwashers.

They are listed by the Repair Parts and Special Tools List (RPSTL) name. Expendable supplies and support materials are listed, including solvents, rags, grease, and safety wire.

(4) Tools, tool kits or shop sets needed to do the task are listed. If tools from a repairman’s kit are needed, the kit is listed. Tools that are not in a kit or set are listed by name, type, and size. Special tools and test equipment are listed by part number.

(5) Related TM’s needed to accomplish the task are listed. The steps tell when these TM’s are needed.

(6) Read the entire task carefully before starting. DO NOT START A TASK UNTIL:

You know what replacement parts, tools, and supplies are needed

You have the things you need

You understand what to do

c.

How To Do The Task. Before starting, read the entire task. Familiarize yourself with the entire procedure before you begin the task. The following are considered standard maintenance practices. Instructions about these practices will not normally be included in the task steps. Task steps will tell you when standard maintenance practices do not apply. As you read, remember the following:

(1) Electrical wiring must be tagged before it is disconnected.

(2) Used packings, retainers, gaskets, cotter pins, lockwashers, and safety wire shall be discards. Do not reuse. New parts shall be installed.

(3) Packings shall be coated with lubricant before installation in accordance with task instructions.

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(4) Disassembly procedures list all steps required to support total authorized repair of a component. You may not need to disassemble a part as far as described in the task. Follow the steps to disassemble as far as required to replace worn or damaged parts.

(5) Before components or the disassembled parts of a component are inspected, they must be cleaned as required.

(6) Components and mating surface areas must be inspected for serviceable condition before installation.

(7) When a nut is tightened or loosened on a bolt, the bolt head must be held with a wrench.

(8) A special torque will be cited when the words TORQUE TO are used in the task. Standard torques are

used at all other times. Refer to Torque Limits, Appendix G, for information.

(9) When tightening hardware, observe compliance with the drag torque as required. To determine drag torque, thread nut onto bolt until at least two threads protrude. The nut must not contact the mating part.

The torque required to begin turning the nut is the drag torque.

(10) After maintenance, inspect for foreign objects.

NOTE

Remember, this manual is divided by maintenance level (operator, unit, and direct support). If you cannot find a generator set malfunction in the troubleshooting section for your maintenance level, or cannot find the appropriate corrective actions in the maintenance section, notify personnel at a higher maintenance level.

3. REPAIR PARTS AND SPECIAL TOOLS LIST.

Refer to TM 9-6115-639-23P for the Generator Set Repair Parts and Special Tools List (RPSTL). The RPSTL contains exploded view illustrations and parts lists keyed to the illustrations. It lists part number, part name, and quantity used in each application. Use the RPSTL to identify and order replacement parts.

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CHAPTER 1

INTRODUCTION

Section I

GENERAL INFORMATION ..................................................................................1-2

1-1 Scope........................................................................................................................1-2

1-2 Consolidated Index of Army Publications and Blank Forms...................................1-2

1-3

1-4

1-5

1-6

Maintenance Forms and Records .............................................................................1-2

Corrosion Prevention and Control (CPC) ................................................................1-2

Destruction of Army Material to Prevent Enemy Use .............................................1-4

Reporting Equipment Improvement Recommendations (EIR’s) .............................1-4

Section II

Section III

EQUIPMENT DESCRIPTION................................................................................1-5

1-10 Equipment Characteristics, Capabilities, and Features ............................................1-5

1-11 Location and Description of Major Components.....................................................1-6

1-12 Differences Between Models .................................................................................1-10

1-14 Identification and Instruction Plates ......................................................................1-10

PRINCIPLES OF OPERATION............................................................................1-21

1-15 Principles of Operation ..........................................................................................1-21

1-17 Direct Current System............................................................................................1-21

1-18 Alternating Current System ...................................................................................1-23

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Section I. GENERAL INFORMATION

1-1. SCOPE.

a. This manual provides instructions on operation, troubleshooting and maintenance of the 3kW

Tactical Quiet Generator Set, MEP 831A (60 Hz), NSN 6115-01-285-3012, and MEP 832A (400 Hz), NSN

6115-01-287-2431. Information is provided on principles of operation, controls and indicators, preventive

maintenance checks and services, lubrication, operation, troubleshooting, and maintenance. Refer to Figure 1-1

for full view illustration of the Generator Set showing features pertinent to set operation and maintenance. b. Refer to TM 9-2815-257-24 for detailed information regarding the operation and maintenance of the

Diesel Engine Assembly, Model Number L70AE-DEGFR, NSN 2815-01-465-5993, manufactured by Yanmar

Diesel Engine Company, Ltd.

1-2. CONSOLIDATED INDEX OF ARMY PUBLICATIONS AND FORMS.

Refer to the latest issue of DA Pam 25-30 to determine whether there are new additions, changes, or additional publications pertaining to the equipment.

1-3. MAINTENANCE FORMS, RECORDS, AND REPORTS.

a. Reports of Maintenance and Unsatisfactory Equipment. Department of the Army forms and procedures used for equipment maintenance will be those prescribed by DA Pam 738-750, The Army

Maintenance Management System (TAMMS). Air Force personnel will use AFR 66-1 for maintenance reporting and TO 00-35D54 for unsatisfactory equipment reporting. Marine Corps personnel refer to the on-line

MCPDS Index of Technical Publications. Refer to TM 4700-15/1 for disposition of forms and records required for Marine Corps equipment. b. Reporting of Item and Packaging Discrepancies. Fill out and forward SF 364 (Report of

Discrepancy (ROD)) as prescribed in AR 735-11-2, AFR 400-54, or MCO 4430.3J. c. Transportation Discrepancy Report (TDR) (SF 361). Fill out and forward Transportation

Discrepancy Report (TDR) (SF 361) as prescribed in AR 55-38, AFR 75-18, or MCO P4610.19D.

1-4. CORROSION PREVENTION AND CONTROL (CPC).

a. Corrosion Prevention and Control (CPC) of Army materiel is a continuing concern. It is important that any corrosion problems with the engine assembly be reported so that the problem can be corrected and improvements can be made to prevent the problem in future engine assemblies. b. While corrosion is typically associated with rusting of metals, it can also include deterioration of other materials, such as rubber or plastic. Unusual cracking, softening, swelling, or breaking of these materials may be a corrosion problem.

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c. If a corrosion problem is identified, it can be reported using Standard Form 368, Product Quality

Deficiency Report. Use of keywords such as “corrosion”, “rust”, “deterioration”, or “cracking” will ensure that the information is identified as a CPC problem. d. Submit Form 368 to address specified in DA Pam 738-750. Air Force personnel will use TO 25-1-3.

Figure 1-1. 3kW Tactical Quiet Generator Set

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1-5. DESTRUCTION OF ARMY MATERIAL TO PREVENT ENEMY USE.

For destruction of Army material to prevent enemy use, refer to TM 750-244-3.

1-6. REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR’s).

a. Army. If your engine assembly needs improvement, let us know. Send us an EIR. You are the only one who can tell us what you do not like about your equipment. Put it on a SF 368 (Product Quality Deficiency

Report). Mail it to: Commander, US Army Communications and Electronics Command (CECOM), ATTN:

AMSEL-LC-LEO-D-CS-CFO, Fort Monmouth, NJ 07703-5000. We will send you a reply. b. Air Force. Air Force personnel are encouraged to submit EIR’s in accordance with AFR 900-4.

Quality Deficiency Report Manual. Submit to: Commanding General, Marine Corps Logistics Base (Code

850), Albany, Georgia 31704-5000.

1-7. WARRANTY INFORMATION.

The 3kW generator set components are warranted in accordance with the component manufacturer’s latent defect commercial warranty. The warranty starts on the date found in block 23, DA Form 2408-9 in the log book. Report all defects in material and workmanship to your supervisor who will take appropriate action.

Refer to Appendix I for information on manufacturer’s component warranties and conditions.

1-8. NOMENCLATURE CROSS-REFERENCE LIST.

Shortened nomenclature is used in this manual to make procedures easier for you to read. A cross-

reference between the shortened nomenclature and the official nomenclature is shown in Table 1-1.

Common Name

Table 1-1. Nomenclature Cross-Reference

Official Nomenclature

Generator Set 3kW Tactical Quiet Generator Set, MEP 831A / 832A

1-9. ADMINISTRATIVE STORAGE

Administrative storage of equipment issued to and used by Army activities will have Preventive

Maintenance Checks and Services (PMCS) performed before storing. When removing the equipment from administrative storage, the PMCS checks should be performed to assure operational readiness.

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Section II. EQUIPMENT DESCRIPTION

1-10. EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES.

a. Characteristics.

• 3kW, 60Hz (MEP 831A) / 400Hz (MEP 832A), Tactical Quiet Generator (TQG)

• Skid mounted with forklift provisions

• Six lifting handles, four tie-down rings

• Hinged enclosure allows quick access for preventive and scheduled maintenance

• Thermostatically controlled, two fan enclosure cooling system

• 24VDC cranking system

• Single cylinder, air cooled, direct injection, four-stroke cycle diesel engine

• Permanent magnet AC generator with power inverter / converter

• Four-gallon fuel tank (allowing 8 hours of continuous operation at full load)

b. Capabilities and Features.

• 3000 to 3450 RPM operating speed

• 3.0 kilowatt, 1 phase, 2 wire, 120VAC or 1 phase, 3 wire, 120/240VAC

• Rated engine horsepower of 6.7 HP at 3600 RPM

• Equipped with a 24VDC NATO slave receptacle

• Equipped with a two-plug 120VAC convenience receptacle with Ground Fault Circuit Interrupter

(GFCI) for the 120VAC convenience receptacle (MEP 831A, 60 Hz only)

• Audio noise rating less than 72dBA at 23 feet from enclosure, less than 85dBA at operator’s position

• Weight: Dry = 304.0 pounds (maximum), Wet (fuel tank full) = 334.0 pounds (maximum)

• Dimensions: 34.8 x 27.8 x 26.5 inches

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1-11. LOCATION AND DESCRIPTION OF MAJOR COMPONENTS (Figure 1-2).

The 3kW Tactical Quiet Generator Set, MEP 831A (60 Hz), NSN 6115-01-285-3012, and MEP 832A

(400 Hz), NSN 6115-01-287-2431, hereafter referred to as generator set, is a portable unit capable of being mounted on a trailer for transportation. The generator set is designed to provide a quiet source of AC power under temperature ranges from -25 to +120

° F (-32 to +49° C), at any level of relative humidity and at altitudes of up to 8000 feet (2440 meters) above sea level.

The generator set consists of an enclosure assembly (1, Figure 1-2), one-cylinder diesel engine (2),

permanent magnet AC generator (3), control box assembly (18), output / load panel (16), welded skid base assembly (17), primary and auxiliary fuel systems, enclosure cooling and ventilation system, engine exhaust assembly, a 24VDC battery, and associated wiring harnesses, electrical connectors, fuel and oil hoses. cooling air system, and exhaust assembly components. It protects the engine, generator, and other internal components from damage. It incorporates a fire retardant acoustical insulation to reduce noise levels, and acts as a shield to reduce electromagnetic pulse effects on generator set components.

A hinged cover (4) allows easy access for inspection and maintenance of the generator set system.

Two latches (6) lock the cover in place when it is closed. Air ducts in the cover and enclosure housing allow for ventilation of hot exhaust air. of the enclosure assembly allow for engine cooling using external air. Two thermostatically controlled fans (5,

Figure 1-2) mounted in the enclosure assembly activate during high temperature conditions to drive hot exhaust

air through openings in the enclosure. generator set. The engine / generator assembly is mounted to the skid base with vibration isolators which isolate engine generated vibrations from the rest of the generator set. The generator set’s plastic fuel tank is contained within the skid base, as is the 24VDC battery.

The skid base contains four swing-out lifting handles (7), two standard lifting handles (9), four tiedown rings (8), and two forklift openings (12). An oil drain plug (10) and fuel drain plug (11) protrude through openings on the skid base, on the right side of the generator set. A 24VDC slave receptacle (14) and load terminal connections (behind cover (16)) are mounted to the skid base at the rear of the generator set. as DC power for the control system. The battery’s location in the skid base permits easy servicing. Openings in the enclosure assembly vent escaping battery gases to the atmosphere, preventing gas build-up inside the enclosure.

Engine exhaust exits the generator set through an opening in the top of the enclosure assembly. Insulating material on exhaust system components protects maintenance personnel against potential burn hazards and reduces heat rejection into the enclosure assembly.

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3. Generator 10. Oil Drain Plug

11. Fuel Drain Plug

12. Forklift Opening

13. Ground Fault Circuit

Interrupter (60 Hz only)

14. Slave Receptacle

15. Convenience Receptacle

(60 Hz only)

16. Output/Load Terminal Cover

17. Skid Base

18. Control Box Assembly

19. Power Inverter/Converter

20. Exhaust System

Figure 1-2. Location of Generator Set Components

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the generator set. Instruments, controls, and indicators required to operate the generator set are located on the

control box assembly. The control box assembly consists of a control panel (18, Figure 1-2), ground fault

circuit interrupter (13) (60 Hz only), and convenience receptacle (15) (60 Hz only). Internal components include the governor control module, control logic relays and diodes, voltage surge arrestors, diagnostic test points, and associated wiring harnesses and electrical connectors.

The control panel (18) portion of the box is hinged to allow access for testing and maintenance. The control panel contains the following instruments and switches: HOURS meter, FUEL LEVEL gauge,

VOLTAGE meter, LOAD meter, START / RUN / STOP switch, EMERGENCY STOP switch, AUX FUEL switch, PREHEAT switch, VOLTAGE ADJUST potentiometer, CIRCUIT INTERRUPTER switch, DC

CIRCUIT BREAKER switch, BATTLE SHORT switch, and a fault indicator module. The fault indicator module contains lights that indicate the following generator set conditions: ENGINE HIGH TEMP, LOW OIL

PRESSURE, NO FUEL, OVERVOLTAGE, OVERLOAD SHORT CIRCUIT, and BATTLE SHORT ON.

Refer to paragraph 2-1, Operator’s Controls and Indicators, for a complete explanation of each instrument and

switch.

on the generator set skid base, just below the control box assembly. A hinged cover (16, Figure 1-2) allows

access to the three load terminals and single ground terminal. An insulated wrench, used for connecting wires to the terminals, is secured to the rear of the hinged cover. A filter mounted to the back of the load terminals prevents electro-magnetic interference (EMI). The generator set’s 24VDC slave receptacle is mounted to the skid base, to the right of the output terminals. cylinder diesel engine (14), permanent magnet generator (5), and associated electrical, fuel, and oil components.

The engine / generator assembly is mounted to the skid base (8) with vibration mounts (7) to prevent engine vibration from affecting the operation of other generator set components. A fuel drain plug (9) and oil drain plug (10) allow maintenance personnel to drain engine fluids.

cycle, diesel engine (14, Figure 1-3). The engine is designed to operate between 3000 and 3600 RPM, with an

output of 6.7 horsepower at 3600 RPM. An electric governor sets the no load speed at 3000 to 3050 RPM.

The engine has self-contained oil lubrication and fuel systems. A mechanical governor (13) is set for

3800 RPM, maximum, and is controlled by an electrical governor for variable speed operation. The engine is equipped with an air filter (2), muffler (3), 24VDC starter motor (4), manifold heater (15), engine high temperature switch (6), engine oil low pressure switch (12), and oil fill cap and gauge (11). A rope pull recoil system (1) permits manual start of the engine without the battery.

Engine cooling is provided by a flywheel fan, which forces air over the cylinder fins and engine components. The fan is completely guarded to prevent inadvertent contact during operation. output windings. Voltage output is proportional to engine speed (approximately 190VAC at 3kW, 3450 RPM).

The rotating portion of the generator is mounted directly to the engine, on the engine crankshaft extension, without a bearing. The generator stator is direct mounted to the engine, and uses Class H insulation.

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LEFT SIDE VIEW

VIEW FROM REAR

3. Muffler

5. Generator

1

8 7

13

2

15

14

3

6

2

12

3

5

4

10

9

1

11

9. Fuel Drain Plug

10. Oil Drain Plug

Figure 1-3. Engine / Generator Assembly.

11. Oil Fill Cap / Gauge

12. Oil Pressure Switch

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the skid base, between the control box and generator. The power converter consists of rectifiers, a power inverter, and associated electronics. It provides the regulated 120VAC, 2 wire, or 120 / 240VAC, 3 wire (single phase only) output. Voltage regulation is maintained within one percent, throughout specified voltage ranges, from no load to rated load. An output control signal from the converter is connected to the governor control unit to vary engine speed depending on load condition. This enables the generator set to operate at lower engine speeds for light-load conditions while maintaining the required output voltage. provides enough fuel to operate the unit for eight hours at full load. The tank is mounted within the skid base.

The tank’s filler assembly consists of a filler neck (2), fuel strainer (3), and vented fill cap (4). The tank contains a fuel pick-up connection (5), fuel return connection (6), fuel drain connection (7), fuel-gap sending unit (8), and fuel level switch (9).

An electric fuel pump (10) feeds fuel from the tank (1), through a combination fuel filter / water separator (11), on to the engine’s fuel injection pump (12). The electric fuel pump (10) provides automatic fuel system priming and bleeding. An electronic governor actuator is connected, by linkage, to the fuel injection pump rack and is used for engine shutdown control.

An auxiliary fuel transfer pump (13) allows the generator set to operate using an auxiliary fuel source.

A fuel strainer (14) is provided between the auxiliary fuel input connection (15) and the transfer pump. The transfer pump is controlled by the level switch, which allows fuel transfer from the auxiliary fuel source to the generator set fuel tank (1). Auxiliary fuel operations are controlled by the AUX FUEL switch (located on the

generator set control panel). Refer to Paragraph 2-1, Operator’s Controls and Indicators, for a complete

explanation of each instrument and switch.

1-12. DIFFERENCES BETWEEN MODELS.

Generator set model MEP 831A is a 60 Hz generator set. MEP 832A is a 400 Hz generator set. In

addition, MEP 831A (60 Hz) is equipped with both a ground fault circuit interrupter (13, Figure 1-2) and a

convenience receptacle (15). MEP 832A does not contain these components.

1-13. EQUIPMENT DATA.

Refer to Table 1-2, Equipment Data, for a summary of specific capabilities, limitations, and critical data

for operation and maintenance of the generator set.

1-14. IDENTIFICATION AND INSTRUCTION PLATES.

Figure 1-5 illustrates all operating instruction plates, information / data plates, and warning / caution plates

found on the generator set.

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9. Fuel Level Switch

10. Electric Fuel Pump

11. Fuel Filter / Water

Separator

Figure 1-4. Generator Set Fuel System

12. Fuel Injection Pump

13. Auxiliary Fuel Transfer

Pump

15. Auxiliary Fuel Input

Connection

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Table 1-2. Equipment Data

WEIGHTS AND DIMENSIONS

Weight (dry)

Weight (wet) (full fuel tank)

Length

Width

Height

GENERAL SPECIFICATIONS

Output power source

Alternate starting aid

Battery

Frequency rating:

MEP 831A

MEP 832A voltage:

1 phase, 2 wire

1 phase, 3 wire

Voltage adjustment range

Current output

Audio noise rating

FUEL REQUIREMENTS

Diesel

A-A-52557, Type 1-D

A-A-52557, Type 2-D

Turbine fuel:

JP-8

Fuel tank capacity

Auxiliary fuel system

Fuel consumption rate

TRANSPORTATION

Manual transport

Truck, rail, air, and trailer transport

Inclined transport angle

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304.0 pounds (138.0 kilograms) maximum

334.0 pounds (151.6 kilograms) maximum

34.8 inches (88.4 centimeters)

27.8 inches (70.6 centimeters)

26.5 inches (67.3 centimeters)

120 VAC convenience receptacle (60 Hz only)

24 VDC slave receptacle

24 VDC, lead-acid type

60 Hz

400 Hz

120 VAC

120 / 240 VAC

114 to 126 V for the 120 V connection

228 to 252 V for the 240 V connection

31 Amps for 120

16 Amps for 120/240

72 dBA (max.) at 23 feet (7 meters) from perimeter

of set, 47.25 inches (1.2 meters) above ground

85 dBA (max.) at operator’s position

-25

°F to +20°F (-31°C to -7°C)

+20

°F to +120°F (-7°C to +49°C)

-25

°F to +120°F (-31°C to +49°C)

4.0 gallons (15.1 liters)

Continual replenishment

0.5 gallons per hour at rated load

Up to 6 personnel required (handles provided)

4 tie-down rings provided

25

° (max.) any direction

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Table 1-2. Equipment Data (continued)

PERFORMANCE CHARACTERISTICS

Generator Set

Kilowatt capacity at altitude / temperature:

1000 ft (718.1 mm Hg) at 107

4000 ft (656.3 mm Hg) at 95

°F (35.0°C) 2.7

8000 ft (564.9 mm Hg) at 95

°F (41.7°C) 3.0 kilowatts

°F (35.0°C) 2.3

Output terminals:

Alternating

Neutral

Ground

Diesel Engine

Manufacturer

Model

Weight (dry)

Length

Width

Height

L1

L2

N

GND

Yanmar Diesel Engine Co., Ltd.

L70AE-D/DE

86.0 pounds (39.0 kilograms)

15.08 inches (38.3 centimeters)

16.58 inches (42.1 centimeters)

17.72 inches (45.0 centimeters)

Horsepower

Operating RPM

Maximum RPM

No load RPM (governor controlled)

Rated load RPM (governor controlled)

Engine cooling system

Oil requirements:

MIL-L-46167,

MIL-L-2104,

MIL-L-2104,

MIL-L-2104,

Oil

Engine

OE/HDO-40

Oil consumption rate

Compression

Bore x stroke ratio

Cylinder

Displacement

6.7 horsepower (at operating speed)

3000 to 3600 RPM

3800 RPM

3000 to 3050 RPM

3400 to 3450 RPM

Forced air cooling

-25

+5

-15

°F to +120°F (-15°C to +49°C)

+15

+30

°F to +40°F (-31°C to +5°C)

°F to +40°F (-26°C to +5°C)

°F to +90°F (-9°C to +32°C)

°F to +120°F (-1°C to +49°C)

1.2 quarts (1.1 liters)

0.04 ounces (1.18 milliliters) per hour at rated load

19.5

3.07 x 2.44 inches (78 x 62 millimeters)

1 in

3

(296 cm

3

)

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Figure 1-5. Generator Set Data, Instruction, and Warning Plates

(Sheet 1 of 7)

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Figure 1-5. Generator Set Data, Instruction, and Warning Plates

(Sheet 2 of 7)

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Figure 1-5. Generator Set Data, Instruction, and Warning Plates

(Sheet 3 of 7)

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Figure 1-5. Generator Set Data, Instruction, and Warning Plates

(Sheet 4 of 7)

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Figure 1-5. Generator Set Data, Instruction, and Warning Plates

(Sheet 5 of 7)

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Figure 1-5. Generator Set Data, Instruction, and Warning Plates

(Sheet 6 of 7)

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Figure 1-5. Generator Set Data, Instruction, and Warning Plates

(Sheet 7 of 7)

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Section III. PRINCIPLES OF OPERATION

1-15. PRINCIPLES OF OPERATION.

The theory behind the operation of the generator set is described in the following paragraphs. Each system is dependent upon the other for efficient operation of the generator set. The information contained herein will assist direct support and general support maintenance personnel in understanding how the generator set functions. This knowledge will assist in isolating components which have failed.

1-16. ELECTRICAL SYSTEM.

The generator set has two electrical systems, direct current (DC), and alternating current (AC) (Figure FO-

1). The DC system provides generator control circuitry, relay logic, and engine cranking. The AC system

produces voltage for load application. Five test points (on terminal board TB3) provide malfunction isolation for critical components of the generator set.

1-17. DIRECT CURRENT SYSTEM. (Figure FO-1)

a. The direct current system (Figure FO-1) is powered by a 24 VDC battery (BT1). The battery is

charged by the battery charging regulator (A9) when the engine is running. Engine cranking is initiated by placing the START / RUN / STOP switch (Sl, located on the control panel) in the START position. This signals engine start contactor (K2) to actuate the engine start solenoid (L4) and energize the starter motor (Bl). b. With the START / RUN / STOP switch (Sl) in the START or RUN position, the engine fuel transfer pump (E2) is energized, allowing fuel to be injected into the engine. Placing the START / RUN / STOP switch in the RUN position de-energizes the starter motor (Bl). Placing the START / RUN / STOP switch in STOP position opens the circuit to the engine fuel transfer pump (E2) and the governor control (A5), stopping fuel flow to the engine. DC voltage is removed from the AC circuit interrupter coil, causing the contactor to open. c. Pressing the EMERGENCY STOP switch (S19, located on the control panel) opens the AC circuit interrupter (K1) and disconnects power to the governor control (A5), which causes the generator set to shut down. d. The generator set is equipped with an engine preheat system to help in cold-weather operation (below

+20

°F (-6.6°C)). Prior to starting the engine, the preheat mode may be actuated by placing the PREHEAT switch (S18, located on the control panel) in the ON position. This signals the engine preheat contactor (K13) to energize air heaters (H1 and H2). The air heater heats intake air which, in turn, assists in igniting fuel when injected into the engine combustion chamber. e. Should engine oil temperature exceed normal operating temperature (+265

°F), a heat sensitive temperature switch (HT) closes the circuit to energize the fault lockout relay (K12) and shut down the engine.

The ENGINE HIGH TEMP indicator on the malfunction indicator module (A2) will illuminate. The fault lockout relay (K12) will lockout power to the engine until the FAULT RESET / LAMP TEST button on A2 is depressed. This safety mechanism prevents the operator from using the generator set until the malfunction has been corrected.

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f. Should engine oil pressure drop below 15 psi, a low oil pressure switch (OP) closes the circuit to energize the fault lockout relay (K12) and shut down the engine. The LOW OIL PRESS indicator on the malfunction indicator module (A2) will illuminate. The FAULT RESET / LAMP TEST switch must be depressed to reset the fault lockout relay. g. Relay K8, located in the power inverter / converter (A8), is energized if a short circuit or overload condition exists. The overload condition may be either a current overload or a real power (kW) overload. The

AC circuit interrupter (K1) opens, disconnecting power from the load. The OVERLOAD SHORT CIRCUIT indicator on the malfunction indicator module (A2) will illuminate. Once the malfunction has been corrected, the malfunction indicator can be reset by depressing the FAULT RESET / LAMP TEST button. AC circuit interrupter (K1) can be closed. h. Relay K6, located in the power converter (A8), is energized if a short circuit condition exists. The fault lockout relay (K12) will energize, stopping the engine. The system is reset by placing the START / RUN /

STOP switch in the STOP position. i. Relay K3, Located in the power converter (A8), is energized if an overvoltage condition exists. The fault lockout relay (K12) is energized, stopping the engine. The AC circuit interrupter (K1) opens, disconnecting power from the load. The OVER VOLTAGE indicator on the malfunction indicator module (A2) will illuminate. The fault lockout relay (K12) will lockout power to the engine until the FAULT RESET /

LAMP TEST button on A2 is depressed. j. The engine is supplied with a conventional mechanical governor. The maximum no load, mechanically governed speed is factory set to 3800 RPM. An electric governing system overrides the mechanical governor, regulating no load speed to 3000 to 3050 RPM and rated load speed to 3400 to 3450

RPM. During manual starting, the electric governor actuator is locked in position close to the full fuel position and the mechanical governor takes over. k. In an emergency situation, the BATTLE SHORT switch (S7) can be activated to allow generator set operation under certain fault conditions. Placing the switch (located on the control panel) in the ON position bypasses all faults except the overload short circuit condition. The BATTLE SHORT indicator on the malfunction indicator module (A2) will illuminate. The generator set will continue to operate under high temperature, low oil pressure, low fuel, overvoltage, or overload short circuit condition. The appropriate indicator light on A2 will illuminate. The engine cannot be started with the BATTLE SHORT switch in the ON position. l. In generator set model MEP 832A (400 Hz), two thermostatically controlled DC ventilation fans (B2 and B3) are mounted in the generator set enclosure assembly. These fans provide internal cooling of the generator set under high temperature operating conditions. The fan temperature switches (S20 and S21) are set to turn on fan B2 when internal air temperature reaches 85

°F (29°C), and fan B3 when internal air temperature reaches 110

°F (43°C).

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1-18. ALTERNATING CURRENT SYSTEM. (Figure FO-1)

a. The power for the alternating current electrical system (Figure FO-1) is provided by the permanent

magnet generator (G1). The power converter (A8) converts this AC power electronically to 120 / 240V, 60 Hz or 400 Hz power.

NOTE

A8 is not waterproof. Water in the A8 can cause the A8 to short out, thereby creating a catastrophic failure. b. In generator set model MEP 831A (60 Hz), a duplex convenience receptacle (Jl) provides power for common 120VAC appliance or tool loads. A ground fault circuit interrupter (CB3) protects both the convenience receptacle circuitry and the connected appliance should a ground fault occur. c. Once the generator set reaches normal operating voltage (114 to 126 V for 120 V connection, 228 to

252 V for 240 V connection), the CIRCUIT INTERRUPTER switch (S5, located on the control panel) is placed in the CLOSED position. The AC circuit interrupter (Kl) closes, applying power converter output voltage to the output load terminal board (TB2, terminals Ll, L2, and N). Placing CIRCUIT INTERRUPTER switch (S5) in the OPEN position opens AC circuit interrupter, removing power converter output voltage from load terminals. d. Voltage adjustment is accomplished using the VOLTAGE ADJUST rheostat (Rl), located on the control panel. Output from the power converter is displayed on a LOAD meter (M2) and a VOLTAGE meter

(M1). Both meters are located on the control panel. e. In generator set model MEP 831A (60 Hz), two thermostatically controlled AC ventilation fans (B2 and B3) are mounted in the generator set enclosure assembly. These fans provide internal cooling of the generator set under high temperature operating conditions. The fan temperature switches (S20 and S21) are set to turn on fan B2 when internal air temperature reaches 85

°F (29°C), and fan B3 when internal air temperature reaches 110

°F (43°C).

1-19. GENERATOR. (Figure FO-1)

a. The AC generator (G1, Figure FO-1) is a direct coupled, permanent magnet generator. The rotor and

fan are dynamically balanced at all speeds up to 125 percent rated speed to minimize vibration. The windings and coils in the stator assembly use Class H insulating material. Temperature rise of the windings is limited to a change of 221

°F (105°C) (max.). b. The generator produces voltage by rotating permanent magnets in the rotor past a stator winding. The magnetized poles of the rotor have alternate north and south polarity. The magnetic flux lines leave each north pole of the rotor, pass through the stator, and return to the adjacent south poles of the rotating field.

NOTE

The power inverter / converter (A8) converts generator output to a 120 / 240V, 60 Hz or 400 Hz output, regardless of engine speed. The electric governor varies the engine speed in proportion to the kilowatt load on the generator set.

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c. As the rotor turns, voltage is induced in the stator windings. The stator voltage output is connected to the static power inverter / converter (A8). Voltage output can be varied using the VOLTAGE ADJUST rheostat

(R1). Frequency output is not adjustable.

1-20. FUEL SYSTEM. (Figure 1-6)

a. The generator set fuel system (Figure 1-6) consists of a 4.0 gallon (15.1 liter) fuel supply tank, fuel

transfer pumps, fuel filter / water separator, auxiliary fuel intake system, and engine fuel components. The fuel tank is sized to contain enough fuel to operate the generator set for eight (8) hours at full load using any of the specified fuels. The tank is connected to a fuel fill pocket, which contains a vented fill cap (4), fuel filler neck, and fuel strainer (5). A tank drain valve (11) is located at the base of the tank. b. The engine fuel supply line passes fuel from the fuel tank, through a fuel filter / water separator (13), a fuel transfer pump (12), and a fuel injection pump (7), into the fuel injector (6). The fuel filter / water separator removes micro-particles and separates water from the fuel flow. Water collects in the filter / water separator bowl where it can be drained. c. The generator set fuel system is equipped with two fuel transfer pumps: primary (12) and auxiliary (1).

The primary fuel transfer pump (12) feeds fuel from the fuel tank to the engine injection system. When the

START / RUN / STOP switch (S1, Figure FO-1) is placed he START or RUN position, the primary fuel transfer

pump is energized. Fuel flows to the fuel injection pump (7, Figure 1-6). The pump provides the pressurized

fuel to operate the fuel injector (6). d. For generator set operation from an auxiliary fuel source, the auxiliary fuel hose is connected to the set at the auxiliary fuel connection (2). The AUX FUEL switch (14, located on the control panel) is placed in the

ON position. A three-position float switch (3) monitors tank fuel level and controls auxiliary fuel system components. If fuel is below float switch FL2B, the auxiliary fuel transfer relay (15) energizes and activates the auxiliary fuel pump (1). The auxiliary fuel pump will begin operation and draw fuel from the auxiliary source until the fuel level in the tank rises above float switch FL2A. Once the fuel level rises above switch FL2A, the switch will open and de-energize the relay (15). The level monitoring / servicing cycle will continue until the

AUX FUEL switch (14) is placed in the OFF position. e. If, at any time during operation, the tank fuel level drops below float switch FL1, the fault lockout relay (10) will open and de-energize the governor control (9) and governor actuator (8), cutting off fuel to the engine. This prevents the fuel system from running dry, causing loss of prime in the fuel injection pump (7).

The NO FUEL indicator on the fault isolation module will illuminate and the generator set will immediately shut down. Once the fault lockout relay (10) has been actuated, the engine will not run until the FAULT

RESET button on the malfunction indicator module has been depressed. f. If fuel level drops below float switch FL2B and an auxiliary fuel source is not available, the generator set will continue to operate for 3 to 4 hours before float switch FL1 is actuated and shutdown occurs.

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1. Auxiliary Fuel Pump

Connection

10. Fuel Lockout Relay

11. Tank Drain Valve

Figure 1-6. Fuel System Schematic

12. Fuel Transfer Pump

13. Fuel Filter / Water

Separator

14. AUX FUEL Switch

15. Auxiliary Fuel Transfer

Relay

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Intentionally

Left blank

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CHAPTER 2

OPERATING INSTRUCTIONS

Section I

Section II

DESCRIPTION AND USE OF OPERATORS CONTROLS ..............................................2-2

2-1 Operators Controls and Indicators ...........................................................................2-2

OPERATOR PREVENTIVE MAINTENANCE CHECKS

AND SERVICES (PMCS).......................................................................................2-8

Section III

2-5 Leakage Definitions for Operator PMCS...............................................................2-11

OPERATION UNDER USUAL CONDITIONS................................................................2-19

2-6

2-7

Assembly and Preparation for Use.........................................................................2-19

Initial Adjustments, Daily Checks, and Self Test ..................................................2-23

2-8 Procedures.............................................................................................2-24

2-9 Generator Set Shut Down ......................................................................................2-26

2-10 Emergency Shut Down ..........................................................................................2-26

2-11 Operation of Auxiliary Equipment ........................................................................2-26

Section IV

2-12 Operating Instructions on Decals and Instruction Plates .......................................2-26

OPERATION IN UNUSUAL CONDITIONS....................................................................2-28

2-13

2-14

2-15

2-16

Battle Short Operation ...........................................................................................2-28

Operation in Unusual Weather...............................................................................2-28

Nuclear, Biological, and Chemical (NBC) Decontamination Procedures .............2-29

Hand Starting (Manual Engine Cranking) .............................................................2-30

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Section I. DESCRIPTION AND USE OF OPERATORS

CONTROLS AND INDICATORS

2-1. OPERATORS CONTROLS AND INDICATORS.

Prior to placing the generator set into operation, personnel must be familiar with the location and function of all switches, controls, and indicators. Controls and indicators required for generator set operation are

described below and identified in Figure 2-1. Refer to the generator set electrical schematic, Figure FO-1, for

1 HOURS Meter (M3)

Indicates hours of generator set operation.

2 FUEL LEVEL Meter (M5)

Indicates amount of fuel remaining in the generator set fuel tank.

3 VOLTAGE Meter (M1)

Indicates generator set output voltage.

4 LOAD Meter (M2)

Indicates generator load in kilowatts.

5 DC CIRCUIT BREAKER (CB1)

Trips to stop generator set operation in case of electrical surge in DC control system. Push to

6 Fault Indication Module (A2)

Contains lights that indicate generator set operating conditions. Includes the following

2-2

ENGINE HIGH TEMP fault (red)

LOW OIL PRESSURE fault (red)

NO FUEL fault (red)

OVERVOLTAGE fault (red)

OVERLOAD SHORT CIRCUIT fault (red)

BATTLE SHORT ON operation (yellow)

Dual purpose FAULT RESET / PUSH TEST switch allows operator to test indicator lights before operation, and reset fault isolation module after fault has been remedied.

7 BATTLE SHORT Switch (S7)

Two-position switch that allows generator set operation under certain fault conditions.

ON position bypasses all faults except short circuit conditions. BATTLE SHORT indicator on fault indicator module A2

(see item 6) will light when switch is in

OFF position returns generator set to normal operating mode, allowing faults to halt generator set operation.

8 Convenience Receptacle (J1) (60Hz only)

Single phase duplex receptacle which allows

120VAC appliance or tool connection.

9 GROUND FAULT CIRCUIT

INTERRUPTER (GFCI) (CB3) (60Hz only)

Provides automatic circuit interruption and circuit protection for the convenience

10 SLAVE RECEPTACLE (SR1)

Allows for 24VDC auxiliary power connec- tion for starting generator set. NATO style.

Generator set ground terminal.

12 L1, L2, N Terminals

Generator set alternating current (L1, L2) and neutral (N) terminals.

13 CIRCUIT INTERRUPTER Switch (S5)

Two position switch that applies generator voltage to the output load terminal board.

CLOSED position signals AC circuit interrup- ter K1 to close, applying voltage to the

OPEN position opens AC circuit interrupter

K1, terminating current to the load.

14 CIRCUIT INTERRUPTER Indicator (DS6)

Lights when CIRCUIT INTERRUPTER switch S5 is in CLOSED position, indicating load is being applied to the terminal board.

15 VOLTAGE ADJUST Rheostat (R1)

Allows operator to adjust generator set output

voltage.

16 START / RUN / STOP Switch (S1)

Three-position switch that controls generator

START position activates engine starter B1.

Spring loaded. Must be held in position.

RUN position cuts electrical power to the starter. Energizes all circuits required for

OFF position opens the circuit to engine fuel transfer pump E2 and governor control A5, stopping fuel flow to the engine and shutting down the generator set.

17 PREHEAT Switch (S18)

Two-position switch that controls the engine

ON position sends a signal to engine preheat contactor K13 to energize the engine air heater. Used during cold weather operation.

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OFF position de-energizes the engine air heater, halting engine preheat operations.

18 AUX FUEL Switch (S17)

Two-position switch that allows the generator set to operate using an auxiliary fuel source.

ON position allows a three-position fuel level switch (FL, mounted in the generator set fuel tank) to regulate auxiliary fuel flow into the fuel tank. See item 25 for details.

OFF position de-energizes auxiliary fuel circuit, preventing auxiliary fuel pump E1

19 EMERGENCY STOP Switch (S19)

A push-button switch that opens AC circuit interrupter K1 and disconnects power to governor control A5, which causes generator set to shut down. For emergencies only.

20 Engine Start Handle

Allows for manual start of the generator set engine. Activates engine’s recoil starter

assembly.

21 Fuel Drain Plug

Allows personnel to drain generator set fuel tank. Connected to a fuel drain line.

22 Engine Oil Drain Plug

Allows personnel to drain engine oil sump. Connected to an oil drain line.

23 Temperature Switch (S21)

Monitors temperature inside the generator set enclosure. Activates ventilation fan B3 when temperature reaches 110

°F (43°C).

24 Temperature Switch (S20)

Monitors temperature inside the generator set enclosure. Activates ventilation fan B2 when temperature reaches 85

°F (29°C).

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25 Fuel Level Switch (FL)

Three-position float switch that monitors fuel level in the generator set fuel tank. Controls auxiliary fuel transfer relay K14 when the

AUX FUEL switch (see item 18) is in ON

position.

When fuel level is below switch FL2B, auxiliary fuel transfer relay K14 energizes and activates auxiliary fuel pump E1 to begin fuel

pumping.

When fuel level rises above switch FL2A, transfer relay opens, deactivating pump.

If fuel drops below switch FL1, fault lockout relay K12 will open and de-energize governor control A5 (see item 28), cutting off fuel to engine. The NO FUEL indicator on fault indicator module A2 will light (see item 6).

26 Fuel Level Sender (MT5)

Sends generator set fuel tank level data to

FUEL LEVEL meter M5 (see item 2).

27 Lubricating Oil Pressure Switch (OP)

Monitors engine oil pressure. If oil pressure drops below 15 psi, the switch closes the circuit to energize fault lockout relay K12 and shut down engine. The LOW OIL

PRESSURE indicator on fault indicator module A2 will light (see item 6).

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28 Governor Control (A5)

Controls engine’s mechanical governor to adjust engine speed.

29 Engine Temperature Switch (HT)

Monitors engine temperature. If engine temperature rises above 265

°F (129°C), the switch closes the circuit to energize fault lockout relay K12 and shut down engine. The

ENGINE HIGH TEMP indicator on fault indicator module A2 will light (see item 6).

30 Engine Oil Fill Cap and Gauge

Allows for engine oil servicing. Gauge in cap measures crankcase oil level.

31 Fuel Fill Cap

Allows for generator set fuel servicing using a fill tank or fuel nozzle. Includes a mesh fuel strainer.

32 Auxiliary Fuel Cap

Allows for connection of an auxiliary fuel

hose.

33 Voltage Selection Switch

Allows selection of 120VAC or 120/240 VAC on MEP-831A sets. Voltage Selection Switch is located on top of Power Inverter/Converter

(A8).

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Figure 2-1. Generator Set Controls and Indicators

(Sheet 1 of 3)

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Figure 2-1. Generator Set Controls and Indicators

(Sheet 2 of 3)

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Figure 2-1. Generator Set Controls and Indicators

(Sheet 3 of 3)

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Section II. OPERATOR PREVENTIVE MAINTENANCE CHECKS

AND SERVICES (PMCS)

2-2. GENERAL

.

Operator Preventive Maintenance Checks and Services (PMCS) means systematic caring, inspecting, and servicing of equipment to keep it in good condition and to prevent breakdowns. As the generator set operator, your mission is to ensure that the generator set is ready for operation at all times. It must be inspected so that defects can be discovered and corrected before they result in damage or failure. a. Be sure to perform your PMCS as indicated. Always do your PMCS in the same order, so it gets to be a habit. Once you have had some practice, you will quickly spot anything wrong. b. Do your BEFORE (B) PMCS before you operate the generator set. Pay attention to WARNINGS,

CAUTIONS, and NOTES. c. Do your DURING PMCS while you operate the generator set. Monitor the generator set and its related components while it is actually being operated. Pay attention to WARNINGS, CAUTIONS, and

NOTES. d. Do your AFTER PMCS right after operating the generator set. Pay attention to WARNINGS,

CAUTIONS, and NOTES. e. Do your WEEKLY PMCS once a week.

f. If your equipment does not perform as required, refer to Chapter 3, under Troubleshooting, for

possible problems. Use DA Form 2404 (Equipment Inspection and Maintenance Worksheet) to record any faults you discover before, during, or after operation. g. Be prepared to assist unit maintenance when they lubricate the generator set. Perform any other services when required by unit maintenance.

2-3. PMCS PROCEDURES

.

a. Your Preventive Maintenance Checks and Services, Table 2-1, lists inspections and care required to

keep your generator set in good operating condition. It is set up so you can make your BEFORE (B)

OPERATION checks as you walk around the generator set. b. Item No. Column.

The Item No. column in Table 2-1 lists each check / service in chronological

order. based on operating hours, unless otherwise noted. d. Location Column. The Location: Item to Check / Service column directs maintenance personnel to the general area on the generator set where the check or service is to be performed.

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e.

The Procedure column of Table 2-1 tells you how to do required checks and

services. Tolerances, adjustment limits, and instrument readings are included as applicable. When replacement or repair of a component is required, the procedures column will direct you to the appropriate task.

NOTE

Terms “ready/available” and “mission capable” refer to same status:

Equipment is on hand and ready to perform its combat missions. (See

DA Pam 738-750). you when your generator set is non-mission capable and why the engine assembly cannot be used.

g. If the generator set does not perform as required, refer to Chapter 3, Troubleshooting.

h. If anything looks wrong and you cannot fix it, write it on your DA Form 2404. IMMEDIATELY report it to your supervisor. i. When you perform PMCS you will always need a rag or two. Following are checks that are common to the entire generator set:

(1) Keep It Clean. Dirt, grease, oil, and debris only get in the way and may cover up a serious problem. Clean as you work and as needed. Use dry cleaning solvent on all metal surfaces. Use soap and water when you clean rubber or plastic material.

(2) Rust and Corrosion. Check components for rust and corrosion. If any bare metal or corrosion exists, clean, and apply a thin coat of oil. Report it to your supervisor.

(3) Bolts, Nuts, and Screws. Check them for obvious looseness, missing, bent, or broken condition.

You cannot try them all with a tool, but look for chipped paint, bare metal, or rust around bolt heads. If you find a bolt, nut, or screw you think is loose, tighten it or report it to your supervisor.

(4) Welds. Look for loose or chipped paint, rust, or gaps where parts are welded together. If you find a bad weld, report it to your supervisor.

(5) Electric Wires and Connectors. Look for cracked, frayed, or broken insulation, bare wires, and loose or broken connectors. Tighten loose connectors. Report any damaged wires to your supervisor.

(6) Hoses and Fluid Lines. Look for wear, damage, and leaks, and make sure clamps and fittings are tight. Wet spots show leaks, but a stain around a fitting or connector can also mean a leak. If a leak comes from a loose fitting or connector, tighten it. If something is broken or worn out, report it to your supervisor. j. When you check for “operating condition” you look at the component to see if it is serviceable.

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2-4. CLEANING AGENTS.

WARNING

Cleaning solvents are flammable and toxic to eyes, skin, and respiratory tract. Skin and eye protections are required when working in contact with cleaning solvents. Avoid prolonged or repeated contact. Work in well ventilated area only. Keep away from heat, sparks, and open flame. Do not smoke while using cleaning solvent. Failure to observe this warning can result in injury or death to personnel

CAUTION

When cleaning inside of enclosure, engine must be COLD (same temperature as outside air). DO NOT point water stream directly at any electrical connection. DO NOT use high pressure water supply system. Damage to engine, electrical system, and other components may result.

NOTE

Only use those authorized cleaning solvents or agents listed in

Appendix E, Expendable and Durable Items List.

a. When using water to clean the generator set enclosure, always cover all air ducts and exhaust ports with waterproof material. Cover NATO receptacle, fuel fittings, control box assembly, and output panel. Use water pressure and volume similar to a standard household water supply (50 PSI maximum, 3 gallons per minute). b. After cleaning, allow generator set to air dry. Do not use compressed air to dry unit. Do not run engine to decrease drying time. c. Remove all waterproof material applied in step a. from ducts and other components before starting generator set.

CAUTION

Keep cleaning solvents, gasoline, and lubricants away from rubber or soft plastic parts. They will deteriorate material. d. When cleaning grease buildup or rusty places, use a cleaning solvent, then apply a thin coat of light oil to affected area.

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2-5. LEAKAGE DEFINITIONS FOR OPERATOR PMCS

.

It is necessary for you to know how fluid leakage affects the generator set. Following are types/classes of leakage an operator needs to know to be able to determine the status of the generator set. Learn these leakage definitions and remember: When in doubt, notify your supervisor.

WARNING

Class III oil leaks should be reported IMMEDIATELY to your supervisor. Fuel leaks of any kind require immediate system shutdown. Failure to observe this warning can result in personal injury.

CAUTION

Equipment operation is allowable with Class I or Class II oil leakage. Of course, consideration must be given to fluid capacity in the item/system being checked/inspected. When in doubt, notify your supervisor.

When operating with Class I or II oil leaks, continue to check fluid levels as required in your PMCS. a. CLASS I - Seepage of fluid (as indicated by wetness or discoloration) not great enough to form drops. b. CLASS II - Leakage of fluid great enough to form drops but not enough to cause drops to drip from item being checked/inspected. c. CLASS III - Leakage of fluid great enough to form drops that fall from item being checked/inspected.

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Table 2-1. Operator Preventive Maintenance Checks and Services for MEP 831A / 832A

Item

No.

Not Fully Mission

Capable If:

1

2

3

Interval Location:

Before

Item to

Check/

Service

Overall generator set

Before

Before

Generator set enclosure

Control box and output panel

Procedure

a. Inspect for cracks, dents, and corrosion

in accordance with para. 3-5.

b. Inspect for loose or missing hardware. a. Inspect top lifting cover for security of

attachment in accordance with para. 3-5.

b. Inspect air intake and exhaust ducts for

obstructions and blockages. Clear

obstructions and check for damage. a. Inspect for secure attachment. Check that

hinged panel is closed and locked. b. Inspect switches, meters, indicators, and

terminals. Conduct fault lamp test by

depressing FAULT RESET / PUSH TEST

switch. Refer to para. 3-6.

c. Inspect electrical wires for damage, corr-

osion, or electrical short. Check for bent,

broken, or missing pins.

Significant cracks in any generator set component.

Cover is not secure.

Latches do not lock, allowing cover to rattle excessively.

Intake or exhaust are blocked, or damaged.

Any switch is not operable or any meter is damaged. Fault indicator is defective or lamp does not light.

Wires or connectors are damaged.

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Table 2-1. Operator Preventive Maintenance Checks and Services for MEP 831A / 832A (continued)

Item Interval Location: Procedure Not Fully Mission

4

5

6

No.

Before

Before

Before

Item to

Check/

Service

Convenience receptacle

(60Hz only)

NATO slave receptacle

Output panel

Inspect receptacle for damage. Check for signs of electrical short or corrosion.

Inspect receptacle for damage. Check for signs of electrical short or corrosion. a. Inspect output panel door for security.

Check that locking latch operates properly.

WARNING:

Ensure generator set is properly grounded prior to starting. Failure to properly ground can result in serious injury or death through electrocution. b. Check load and ground terminals for

security of attachment. Inspect for

signs of electrical short or corrosion. c. Check ground rod cable for proper

installation. Check for correct connection.

Capable If:

Receptacle damaged, shorted, or corroded.

Receptacle damaged, shorted, or corroded.

Terminals are loose, disconnected, shorted, damaged, or corroded.

Set is not grounded properly.

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Table 2-1. Operator Preventive Maintenance Checks and Services for MEP 831A / 832A (continued)

Item

No.

Not Fully Mission

Capable If:

7

8

9

10

Interval Location:

Before

Item to

Check/

Service

Exhaust system

Before

Before

Fuel fill ports

Fuel tank and hoses

Procedure

a. Inspect exhaust system for cracks, holes,

or dents. Ensure secure attachment. b. Inspect muffler for obvious damage. a. Inspect fill neck strainer for damage.

Remove obstructions or blockage. b. Inspect vented fuel cap and auxiliary fuel

connection for obvious damage or leakage.

Check that caps are securely attached.

Inspect generator set and engine fuel system components for damage or leaks in accord-

ance with para. 3-7.

Before Fuel filter / water separator

Inspect and drain filter / separator in

accordance with para. 3-8.

Exhaust system is damaged to the extent it will effect operation or safety of personnel.

Strainer is damaged.

Fuel cap is damaged to the point where fuel leakage is likely.

Fuel leaks of any kind are present. Fuel line is cut or damaged.

Water and fuel are mixed. Separator is damaged or leaking.

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Item

No.

Table 2-1. Operator Preventive Maintenance Checks and Services for MEP 831A / 832A (continued)

11

12

Interval Location:

Item to

Before

Check/

Service

Skid base

Before Battery

Procedure Not Fully Mission

Capable If:

a. Inspect oil and fuel drain ports for damage.

Ensure drain plugs are securely attached. b. Inspect lifting handles and tie down rings

for damage. Check security of attachment. c. Inspect engine vibration mounts for

cracks, wear, or deterioration.

Drain ports are damaged to the extent they will leak.

Lifting handles do not operate or are loose.

Vibration mounts are damaged or worn. a. Open enclosure cover, inspect battery

cables for corrosion, evidence of

electrical short, and obvious damage.

Check for cuts, tears, or exposed wires. b. Inspect battery terminals and battery posts for corrosion and damage. Check for security of attachment and that the battery terminal quick release feature is functional.

Notify next higher level of maintenance. c. Inspect battery for cracks, corrosion, or evidence of leakage.

NOTE: A battery that will not provide power to the electrical starter motor or that is missing does not make the generator

Not Mission Capable.

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Table 2-1. Operator Preventive Maintenance Checks and Services for MEP 831A / 832A (continued)

Not Fully Mission

Capable If:

Item Interval Location: Procedure

No. Item to

Check/

Service

13

14

Before

Before

A8

Engine oil

Open enclosure cover. Inspect A8 and area around A8 for signs of water. If water is present, thoroughly dry out A8 before starting generator. a. Open enclosure cover. Remove oil fill cap

and check oil level. If servicing is

required, refer to para. 3-1.

b. Inspect areas around oil filter and oil drain

hose for leaks.

15 Before Engine air filter Inspect air filter for clogging in accordance

with para. 3-9.

Water is in A8

Class III oil leaks are present. Refer to leakage class defini-

tions (para. 2-5).

Filter is clogged. and

LOAD meters

(control panel)

Monitor output levels during generator set operation. Adjust output as required using

VOLTAGE ADJUST rheostat.

LEVEL

Meter (located on control panel) a. Monitor fuel level during generator set

operation.

WARNING:

Never service generator set while engine is running. Shut down unit before filling with fuel. Injury to personnel can occur if proper procedures are not followed. b. Replenish fuel as follows: Shut down

generator set. Remove fuel fill cap and

fill with proper fuel. Install fuel fill cap.

Adjustments cannot be made.

Fuel level is empty or level meter is inoperable.

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Table 2-1. Operator Preventive Maintenance Checks and Services for MEP 831A / 832A (continued)

Item

No.

18

19

Interval Location:

Item to

During

(After 8 hours of continual use)

During

(After 8 hours of continual use)

Check/

Service

Engine oil

Fuel filter / water separator

Procedure

WARNING:

Never service generator set while engine is running. Shut down unit before servicing oil.

Injury to personnel can occur if proper procedures are not followed. a. Shut down generator set. Open enclosure

cover. b. Remove engine oil fill cap and check oil

level. Service as required in accordance

with para. 3-1.

WARNING:

Never service generator set while engine is running. Shut down unit before draining filter separator. Injury to personnel can occur if proper procedures are not followed. a. Shut down generator set. Open enclosure

cover. b. If water is present, drain water from fuel

filter / water separator by turning valve.

Not Fully Mission

Capable If:

Oil level is at or below minimum oil level mark on dipstick.

Water and fuel are mixed. Separator is damaged or leaking.

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22

21

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Table 2-1. Operator Preventive Maintenance Checks and Services for MEP 831A / 832A (continued)

Item

No.

Not Fully Mission

Capable If:

20

Interval Location:

After

Item to

Check/

Service

Fuel lines

Procedure

Open enclosure cover. Inspect all fuel lines for cuts, tears, loose connections, or evidence of leakage.

After Overall generator set a. Inspect for cracks, dents, and corrosion in

accordance with para. 3-5.

b. Inspect for loose hardware.

Fuel leaks of any kind are present. Lines are cut, torn, loose, or damaged.

Significant cracks in enclosure.

After

After

Data plates

Engine

Check for legibility a. Inspect engine fuel piping for damage,

kinks, or evidence of leakage. b. Inspect hoses for evidence of wear,

cracking, or deterioration. Check

connections for tightness.

Fuel leaks of any kind are present. Pipes or hose are damaged.

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Section III. OPERATION UNDER USUAL CONDITIONS.

2-6. ASSEMBLY AND PREPARATION FOR USE.

WARNING

Use caution when lifting or moving the generator set to prevent injury to personnel and damage to equipment. Use lifting rings for lifting device and forklift pockets for forklift only. Do not lift object over personnel. Failure to observe this warning can result in personal injury and/or equipment damage.

WARNING

If damaged or defective components are discovered, repair must be performed before operation can begin. Perform required repairs and adjustments before proceeding. Do not operate the generator set with damaged components. Personnel injury can occur if damaged parts are left unfixed. Failure to observe this warning can result in personal injury and/or equipment damage.

NOTE

Prior to placing the generator set into service, operating personnel must be familiar with the location and function of all switches, controls, and

indicators. Refer to Paragraph 2-1, Operators Controls and Indicators, and

Figure 2-1 before continuing with this procedure.

a. Using a 500 pound capacity hoist or similar lifting device, remove the generator set from its shipping container. Place on a suitable work surface. b. Remove packing material from generator set. c. Inspect the generator set for damage incurred during shipping. If the equipment has been damaged, report the damage on the appropriate form as required. d. Check the generator set against the packing slip to ensure that the shipment is complete. Report all discrepancies in accordance with the instructions of DA PAM 738-750.

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e. Check all tags and forms accompanying the generator set for special instructions. Do not remove any forms or tags until the unit is installed and ready for operation. When the unit is installed, remove forms and tags and forward to Quality Control (QC) section office.

WARNING

Never attempt to start the generator set if it is not properly grounded.

Failure to observe this warning could result in serious injury or death by electrocution. f. Connect ground rod and cable as follows:

(1)

Open load terminal cover. Insert ground cable (1, Figure 2-2) through slot on generator set

GND load terminal (2). Tighten terminal nut using wrench.

(2) Connect coupling (3) to ground rod (4) and screw driving stud (5) into coupling. Make sure that driving stud seats on ground rod.

NOTE

For ease of removal, install ground rod at a 45

° angle.

(3) Drive ground rod (4) into ground on a 45

° angle until coupling (3) is just above the ground surface.

(4) Remove driving stud (5) and install another section of ground rod (4). Install another coupling

(3) and driving stud.

(5) Drive ground rod (4) down until new coupling (3) is just above the ground surface.

(6) Repeat steps (4) and (5) until ground rod has been driven 8 feet or deeper, providing an effective ground.

(7) Connect clamp (6) and ground cable (1) to ground rod (4). Tighten clamp screw securely to prevent movement.

g. If required, drain preservative oil from engine crankcase in accordance with para. 3-1. h. Fill engine crankcase with oil in accordance with para. 3-1.

i. If battery installation is required, refer to next higher maintenance level. Ensure battery cables are properly connected.

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2. GND Load Terminal

3. Coupling

6. Clamp

Figure 2-2. Ground Rod and Cable Installation

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WARNING

If battery is not installed, ensure battery cable ends are isolated from each other, and positive cable end is isolated from ground. Mounting posts on generator set enclosure are provided for this purpose. Failure to isolate battery cable ends can result in severe electrical discharge.

j. If auxiliary power is required, connect auxiliary power cable to SLAVE RECEPTACLE (6, Figure 2-

3).

NOTE

If auxiliary fuel source is to be used, perform procedure outlined in step l below. k. Fill fuel tank as follows:

WARNING

Fuel used in this generator set is flammable and toxic to skin, eyes, and respiratory tract. Avoid repeated or prolonged contact. Handle only in well ventilated area. Keep away from sparks, open flames, or other sources of ignition. Do not splash fuel on hot components. Do not fuel generator set while it is operating. Do not over fill the tank. Ensure the unit is properly grounded before fueling. Failure to observe this warning can result in personal injury and equipment damage due to potential fuel ignition and possible explosion. Ensure approved gloves and face shield are worn during handling.

(1)

Remove fuel fill cap (31, Figure 2-1) from fuel tank.

(2) Connect a static ground line (provided with the fueling source) between generator set ground stud and fueling source.

(3) Fill fuel tank with up to 4 gallons of recommended fuel.

(4) Remove static ground line and install fuel fill cap (31).

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l. If auxiliary fuel source is to be used, connect as follows:

WARNING

Fuel used in this generator set is flammable and toxic to skin, eyes, and respiratory tract. Avoid repeated or prolonged contact. Handle only in well ventilated area. Keep away from sparks, open flames, or other sources of ignition. Do not splash fuel on hot components. Do not fuel generator set while it is operating. Ensure the unit is properly grounded before fueling. Failure to observe this warning can result in personal injury and equipment damage due to potential fuel ignition and possible explosion.

(1)

Remove auxiliary fuel cap (32, Figure 2-1) from auxiliary fuel connection.

(2) Connect auxiliary fuel line to auxiliary fuel connection. Ensure proper fuel type is used.

2-7. INITIAL ADJUSTMENTS, DAILY CHECKS, AND SELF TEST.

a. Initial Adjustments. No initial adjustments are required for operation of the generator set. perform the following procedure:

(1)

Ensure DC CIRCUIT BREAKER (9, Figure 2-3) is pushed in.

(2) Ensure that EMERGENCY STOP switch (13) is pulled out.

(3) Place START / RUN/ STOP switch (7) in RUN position.

(4) Depress the FAULT RESET / PUSH TEST button (15) on the fault indicator module and the

CIRCUIT INTERRUPTER indicator (12) on the control panel to check indicators. All indicator lights shall illuminate. If CIRCUIT INTERRUPTER indicator does not illuminate, replace bulb. If any malfunction light does not illuminate, refer malfunction to Unit maintenance.

(5) Place START / RUN/ STOP switch (7) in STOP position.

(6) Repeat steps (1) through (3) to verify malfunction was corrected.

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2-8. OPERATING PROCEDURES.

WARNING

Make sure that personnel are familiar with the generator set before operating. Follow proper procedures. Failure to observe this warning can result in injury to personnel and damage to equipment.

WARNING

Exhaust discharge contains deadly gases including carbon monoxide. Do not operate generator set in enclosed area unless exhaust discharge is properly vented outside. Position as far away from personnel, shelters, and occupied vehicles as possible. Failure to observe this warning could result in severe personal injury or death due to carbon monoxide poisoning.

FOR ARTIFICIAL RESPIRATION, REFER TO FM 21-11.

THE BEST DEFENSE AGAINST CARBON MONOXIDE POISONING

IS GOOD VENTILATION.

WARNING

Shut down the generator set at first sign of failure. Continued operation can result in injury to personnel and will cause damage to equipment. If the generator set is shut down by the activation of a safety device, do not operate again until the cause of the shut down has been determined and eliminated. Failure to observe this warning can result in equipment damage and/or potential personal injury.

WARNING

With any access door open, the noise level of the generator set when operating could cause hearing damage. Hearing protection must be worn when working near the generator set while running.

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a. Open load terminal cover to access load and ground terminals (1, 2, Figure 2-3). Connect load cables

in accordance with TERMINAL VOLTAGE nameplate mounted on the inside of cover (120/240 volts, 3 wire or

120 volts, 2 wire). Close terminal cover and lock.

WARNING

Ensure voltage selector switch setting matches load cable voltage connections. Mismatch will cause damage to equipment and may result in injury to personnel. b. Set voltage selector switch to match load cable voltage connections as follows:

(1) Unlock generator set main access cover latches and lift cover to open.

(2) Locate voltage selector switch access door (3) on top of power inverter / converter (4). Open access door and place voltage selector switch in desired position (120/240 volts, 3 wire or 120 volts, 2 wire). Close and lock door.

NOTE

Voltage selector switch access door (3) must be closed securely, or generator set will not produce power.

(3) Close generator set main access cover and lock using latches. c. If auxiliary fuel source is connected, place the AUX FUEL switch (5) in the ON position. d. If auxiliary power is required, connect auxiliary power cable to SLAVE RECEPTACLE (6).

WARNING

If battery is not installed, ensure battery cable ends are isolated from each other, and positive cable end is isolated from ground. Mounting posts on generator set enclosure are provided for this purpose. Failure to isolate battery cable ends can result in severe electrical discharge. e. If ambient temperature is below +20

°F (-6.6°C), refer to para. 2-14.

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CAUTION

Do not crank engine for more than 15 seconds. Damage to starter motor can occur. Wait 15 seconds before attempting to crank again. If engine does not run after third attempt, refer to Troubleshooting. f. Ensure DC CIRCUIT BREAKER (9) is pushed in. Ensure EMERGENCY STOP switch (13) is pulled out. Place START / RUN / STOP switch (7) in the RUN position. Ensure LOW OIL PRESSURE indicator

(16) is illuminated. Place START/RUN/STOP switch (7) in the START position to crank engine. Switch is spring loaded and must be held in place. Release switch to RUN position once engine starts. g. Adjust generator set voltage as required using the VOLTAGE ADJUST rheostat (10). h. Place the CIRCUIT INTERRUPTER switch (11) in the CLOSED position. The CIRCUIT

INTERRUPTER indicator (12) will illuminate when load is connected.

2-9. GENERATOR SET SHUT DOWN.

a. Place the CIRCUIT INTERRUPTER switch (11, Figure 2-3) in the OPEN position. The CIRCUIT

INTERRUPTER indicator (12) will go out when load is disconnected. Allow unit to run in this condition for approximately 3-5 minutes to cool down the engine. b. Place the START / RUN / STOP switch (7) in the STOP position to shut down generator set. c. Pull out DC CIRCUIT BREAKER (9).

2-10. EMERGENCY SHUT DOWN.

To stop the generator set under emergency conditions, push the EMERGENCY STOP switch (13, Figure 2-

3). Place the START / RUN / STOP switch (7) in the STOP position. The EMERGENCY STOP switch is

maintained in the stop position and must be pulled out prior to restarting the generator set.

2-11. OPERATION OF AUXILIARY EQUIPMENT.

No auxiliary equipment exists for the generator set.

2-12. OPERATING INSTRUCTIONS ON DECALS AND INSTRUCTION PLATES.

Refer to Figure 1-5 for operating instruction plates, information/data plates, and warning/caution plates

found on the generator set.

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16

1. Load Terminals 8. PREHEAT Switch 13. EMERGENCY STOP

2. Ground Terminal 9. DC CIRCUIT BREAKER Switch

3. Access Door 10. VOLTAGE ADJUST Rheostat 14. BATTLE SHORT Switch

4. Power Inverter / Converter 11. CIRCUIT INTERRUPTER 15. FAULT RESET / PUSH

5. AUX FUEL Switch Switch TEST Switch

6. SLAVE RECEPTACLE 12. CIRCUIT INTERRUPTER 16. LOW OIL PRESSURE

7. START / RUN / STOP Switch Indicator Indicator

Figure 2-3. Operating Procedures

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Section IV. OPERATION UNDER UNUSUAL CONDITIONS

2-13. BATTLE SHORT OPERATION.

WARNING

Generator battle short mode is for emergency operation only. Prolonged use under this mode could damage the generator set or pose potential shock hazard to personnel. a. The generator set is capable of emergency operation under fault conditions. The BATTLE SHORT

switch (14, Figure 2-3) allows the set to override anticipated system fault shutdowns in order to maintain

operation. The overload short circuit fault cannot be overridden. b. To operate the set in battle short mode, lift protective cover and place the BATTLE SHORT switch

(14) in the ON position while the generator set is running.

2-14. OPERATION IN UNUSUAL WEATHER.

a. The generator set is designed to operate within a temperature range of -25

° to +120°F (-32° to +49°C).

The set should not be operated in ambient temperatures outside this range. b. If ambient temperature is below +20

°F (-6.6°C), activate engine preheat system as follows:

(1) Ensure DC CIRCUIT BREAKER (9, Figure 2-3) is pushed in. Ensure EMERGENCY STOP

switch (13) is pulled out. Place the START / RUN / STOP switch (7) in the RUN position.

(2) Place the PREHEAT switch (8) in the ON position. Hold for 10 seconds if temperature is just below +20

°F, 20 seconds if temperature is well below +20°F.

(3) Continue to hold the PREHEAT switch (8) in the ON position while cranking engine (step (4)).

Release PREHEAT switch once engine has started and reached operating speed.

CAUTION

Do not crank engine for more than 15 seconds. Damage to starter motor can occur. Wait 15 seconds before attempting to crank again. If engine does not run after third attempt, refer to Troubleshooting.

(4) Place START / RUN / STOP switch (7) in the START position to crank engine. Switch is spring loaded and must be held in place. Release switch to RUN position once engine starts. c. Altitude also plays a role in the performance of the generator set. Refer to the KILOWATT

CAPACITY placard (Figure 1-5) for generator load derating.

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2-15. NUCLEAR, BIOLOGICAL, AND CHEMICAL (NBC) DECONTAMINATION PROCEDURES.

The generator set is capable of being operated by personnel wearing Nuclear, Biological, or Chemical

(NBC) protective clothing without special tools or support equipment. Refer to FM 3-5, NBC Decontamination, for information on decontamination procedures. Specific procedures for the generator set are the following: a. Control panel indicators sealing gaskets, gaskets at output terminal door, control panel gaskets, rubber tubing within the engine compartment, muffler thermal blanket, coverings for electrical conduits, and fuel drain tubing will absorb and retain chemical agents. Replacement of these items is the recommended method of decontamination. b. Lubricants, fuel, or battery fluid may be present on the external surfaces of the generator set or components due to leaks or normal operation. These fluids will absorb NBC agents. The preferred method of decontamination is removal of these fluids using conventional decontamination methods in accordance with FM

3-5. c. Continued decontamination of external generator set surfaces with supertropical bleach (STB) and decontaminating solution number 2 (DS2) will degrade clear plastic indicator coverings to a point where reading indicators will be impossible. This problem will become more evident for soldiers wearing protective masks.

The use of STB or DS2 decontaminants in these areas should be minimized. Indicators should be decontaminated with warm, soapy water. d. External surfaces of the control panel assembly that are marked with painted or stamped lettering will not withstand repeated decontamination with STB or DS2 without degradation of the lettering. The recommended method of decontamination for these areas is warm, soapy water. e. Areas that will entrap contaminants, making efficient decontamination extremely difficult, include the following: space behind knobs and switches on the control panel, exposed heads on screws, hinged areas of access doors, spaces behind externally mounted equipment specification data plates, areas around external oil drain and fuel drain valves, fuel caps, load output terminal access door, slave receptacle, areas around tie-down / lifting rings, and external screens covering ventilation areas. Replacement of these items, if available, is the preferred method of decontamination. Conventional decontamination methods should be used on these areas, while stressing the importance of thoroughness and the probability of some degree of continuing contact and vapor hazard. f. In a NBC contamination environment, the generator set should be operated with all access doors closed to reduce the effects of contamination. g. The use of overhead shelters or chemical protective covers are recommended as an additional means of protection against contamination in accordance with FM 3-5. If using covers, care should be taken to provide adequate space for airflow and exhaust. h. Refer to FM 3-3 and 3-4 for additional NBC information. All other services will use their applicable directives.

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2-16. HAND STARTING (MANUAL ENGINE CRANKING).

a. Push in DC CIRCUIT BREAKER (7, Figure 2-4).

b. Pull out EMERGENCY STOP switch (8) . c. Place the START / RUN / STOP switch (5) in the RUN position. d. Open the generator set main access cover. e. Lift actuator lever (1) to the maximum fuel position and press in lock pin (2) on the side of the actuator. Release actuator lever (1). Engine speed will temporarily be controlled by the engine’s mechanical governor. f. Pull out recoil starter handle (3) to the point where you feel strong resistance, then return handle to the starting position. g. Pull decompression lever (4) down. The lever will return automatically. h. Pull out recoil starter handle (3) briskly with both hands. Pull hard and fast, all the way out. Engine will start. i. Place the START / RUN / STOP switch (5) in the START position, then move it back to the RUN position to allow the engine to keep running. j. Once the engine has started, lift actuator lever (1) to the maximum fuel position (allowing the lock pin to come out). Slowly lower the lever, allowing the electronic governor to take over.

NOTE

If the generator set has an operational battery installed it will be necessary to reset the LOW OIL PRESSURE fault on the malfunction indicator module before releasing the lock pin. If fault is not reset the generator set will shutdown.

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8

3. Recoil Starter Handle

5. START / RUN / STOP

Switch

6. Speed Control Knob

7. DC CIRCUIT BREAKER

8. EMERGENCY STOP

Switch

Figure 2-4. Manual Engine Starting

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CHAPTER 3

OPERATOR MAINTENANCE INSTRUCTIONS

Section I

LUBRICATION INSTRUCTIONS.........................................................................3-2

Section II

OPERATOR TROUBLESHOOTING PROCEDURES ..........................................3-3

3-2 General.....................................................................................................................3-3

3-3 Troubleshooting .......................................................................................................3-3

Section III

OPERATOR MAINTENANCE INSTRUCTIONS.................................................3-9

3-4 General.....................................................................................................................3-9

3-5

3-6

Generator Set Enclosure and Cover .........................................................................3-9

Control Box and Output Panel Assemblies..............................................................3-9

3-8 Fuel Filter / Water Separator..................................................................................3-10

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Section I. LUBRICATION INSTRUCTIONS

3-1. LUBRICATION INSTRUCTIONS.

a. These lubrication instructions are for operator level personnel. Lube intervals (on-condition or hard time) are based on normal operation. Lube more during constant use, and less during inactive periods. Use correct grade of lubricant for seasonal temperature expected.

CAUTION

Always wipe clean oil filler components before starting your lube service. Use correct type or grade of oil. Overfilling will cause spillage and harm engine components. b. For equipment under manufacturer’s warranty, hard time oil service intervals shall be followed.

Intervals shall be shortened if lubricants are known to be contaminated or if operation is under adverse conditions (such as longer than usual operating hours, extended idling periods, or extreme dust). c. Remove engine oil fill cap. Fill engine with required oil until oil level reaches threaded opening of oil

fill cap (up to 1.2 quarts (1.1 liters)). Refer to Table 3-1 for recommended oils. Install oil fill cap.

Table 3-1. Lubricant Table for Generator Set MEP 831A / 832A

Lubrication Mil. Symbol

Specification

MIL-L-46167, OEA

MIL-L-2104, OE/HDO-15/40

MIL-L-2104, OE/HDO-10

MIL-L-2104, OE/HDO-30

MIL-L-2104, OE/HDO-40

Temperature Range

-25

°F to +40°F (-31°C to +5°C)

+5

°F to +120°F (-15°C to +49°C)

-15

°F to +40°F (-26°C to +5°C)

+15

°F to +90°F (-9°C to +32°C)

+30

°F to +120°F (-1°C to +49°C)

System

Capacity

1.2 qts. (1.1 ltrs.)

1.2 qts. (1.1 ltrs.)

1.2 qts. (1.1 ltrs.)

1.2 qts. (1.1 ltrs.)

1.2 qts. (1.1 ltrs.)

Interval

100 hours

100 hours

100 hours

100 hours

100 hours

Man- hours

0.25

0.25

0.25

0.25

0.25

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Section II. OPERATOR TROUBLESHOOTING PROCEDURES

3-2. GENERAL.

This section contains operator troubleshooting for the generator set. Each malfunction or trouble symptom is addressed and is followed by a series of inspections or tests necessary to determine the probable cause and corrective action.

3-3. TROUBLESHOOTING.

a. This chapter does not list all possible malfunctions that may occur, all tests or inspections that may be performed, or all corrective actions for each malfunction. Only those checks and tests authorized for the operator level are covered. If a malfunction is not listed, or is not remedied by corrective actions, notify personnel at a higher maintenance level. b. If a malfunction or failure occurs during operation or performance check, perform troubleshooting in

accordance with Table 3-3. Refer to Table 3-2, Malfunction Index, for determining applicable troubleshooting

procedure in Table 3-3.

Table 3-2. Malfunction Index

Trouble

Engine will not crank

Engine cranks but will not start

Engine starts and stops

Generator set fails to build up to rated voltage

Generator set fails to supply load

ENGINE HIGH TEMP indicator illuminates

LOW OIL PRESSURE indicator illuminates

NO FUEL indicator illuminates

Generator set causes radio interference

Engine emits white smoke

Engine emits black smoke

Engine will not start in cold weather

No power at convenience receptacle

Procedure

1

2

3

4

5

6

7

8

9

10

11

12

13

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Table 3-3. Operator Level Troubleshooting

MALFUNCTION

TEST OR INSPECTION

1. ENGINE WILL NOT CRANK a Check that EMERGENCY STOP switch is not engaged.

Pull out switch to disengage. b. Check that START / RUN / STOP switch is in START position.

Place switch in START position. c. Check if DC CIRCUIT BREAKER is tripped.

Reset by depressing pushbutton. d. Check malfunction indicator module for system fault light.

Refer to applicable troubleshooting procedure for fault condition. e. Check battery wires for proper / secure connection.

Tighten f. Refer trouble to unit level maintenance.

2.

ENGINE CRANKS BUT WILL NOT START a. Check if PREHEAT switch was actuated for cold weather operation.

Place switch in proper position. b. Check that mechanical governor speed control knob is in START position and tightened.

Adjust control knob and tighten (see item 6, Figure 2-4).

c. With the START/RUN/STOP switch in the RUN position, ensure Governor Actuator Lever (see

item 1) is releasing from magnet.

If not, refer trouble to unit level maintenance.

d. Check fuel tank level (refer to para. 3-7).

Service fuel tank as required. Press FAULT RESET pushbutton to reset fault indicator module. e. If operating on AUX FUEL, check that AUX FUEL switch is in ON position.

Place switch in ON position. Press FAULT RESET pushbutton to reset fault indicator module. f. Inspect for crimped or pinched fuel lines.

Straighten flexible fuel lines. Refer to unit level maintenance if fuel line is damaged.

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Table 3-3. Operator Level Troubleshooting (continued)

MALFUNCTION

TEST OR INSPECTION

2. ENGINE CRANKS BUT WILL NOT START (continued)

g. Check for water in fuel filter / water separator (refer to para. 3-8).

Drain water from filter separator by turning valve. h. Refer trouble to unit level maintenance.

3.

ENGINE STARTS AND STOPS a. Check that electrical connections are properly tightened.

Tighten b. Inspect for crimped, pinched, or leaking fuel lines.

Straighten flexible fuel lines. Refer to unit level maintenance if fuel line is damaged.

c. Check for water in fuel filter / water separator (refer to para. 3-8).

Drain water from filter separator by turning valve. d. Refer trouble to unit level maintenance.

4.

GENERATOR SET FAILS TO BUILD UP TO RATED VOLTAGE a. Check that GROUND FAULT CIRCUIT INTERRUPTER (GFCI) is not tripped.

Reset GFCI by depressing button. b. Check that VOLTAGE ADJUST rheostat is properly set.

Adjust rheostat to achieve rated voltage.

c. Check that voltage selector switch access door is fully closed and secured (refer to para. 2-8).

Close and secure access door. d. Refer trouble to unit level maintenance.

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Table 3-3. Operator Level Troubleshooting (continued)

MALFUNCTION

TEST OR INSPECTION

5.

GENERATOR SET FAILS TO SUPPLY POWER TO THE LOAD a. Check that CIRCUIT INTERRUPTER switch is not in OPEN position.

Move switch to CLOSED position. b. Check that GROUND FAULT CIRCUIT INTERRUPTER (GFCI) is not tripped.

Reset GFCI by depressing button. c. Check that load hook-up is correct.

Match generator voltage output (voltage selector switch position) with load

requirement (refer to para. 2-8). Set wiring in accordance with TERMINAL

VOLTAGE data plate (Figure 1-5).

d. Refer trouble to unit level maintenance.

6.

ENGINE HIGH TEMP INDICATOR ILLUMINATES a. Check air inlet ducts for clogging or obstructions.

Clear restrictions and blockages. Press FAULT RESET pushbutton to reset fault indicator b. Check air inlet grill on recoil starter for clogging or obstructions.

Clear restrictions and blockages. Press FAULT RESET pushbutton to reset fault indicator c. Check air filter for clogging.

Remove filter and inspect (para. 3-9). Replace filter as required.

d. Check if generator set is overloaded.

Reduce load. Press FAULT RESET pushbutton to reset fault indicator module. e. Refer trouble to unit maintenance level.

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Table 3-3. Operator Level Troubleshooting (continued)

MALFUNCTION

TEST OR INSPECTION

7.

LOW OIL PRESSURE INDICATOR ILLUMINATES DURING OPERATION a. Check engine oil level.

Service as required (para. 3-1). Press FAULT RESET pushbutton to reset fault

indicator b. Refer trouble to unit level maintenance.

8. NO FUEL INDICATOR ILLUMINATES

a. Check fuel tank level (refer to para. 3-7).

Service fuel tank as required. Press FAULT RESET pushbutton to reset fault indicator module. b. If operating on AUX FUEL, check that AUX FUEL switch is in ON position.

Place switch in ON position. Press FAULT RESET pushbutton to reset fault indicator module. c. Refer trouble to unit level maintenance.

9.

GENERATOR SET CAUSES RADIO INTERFERENCE a. Check that load terminals and cables are connected tightly.

Tighten connections using load wrench supplied. b. Check that ground wire is connected tightly.

Tighten connection using load wrench supplied. c. Check that ground rod is properly installed and operational.

Replace ground rod. d. Refer trouble to unit maintenance level.

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Table 3-3. Operator Level Troubleshooting (continued)

MALFUNCTION

TEST OR INSPECTION

10. ENGINE EMITS WHITE SMOKE a. Check engine oil level to see if it is too high.

Refer trouble to unit maintenance level to drain and service engine oil.

b. Check for water in fuel filter / water separator (refer to para. 3-8).

Drain water from filter separator by turning valve. c. Refer trouble to unit level maintenance.

11. ENGINE EMITS BLACK SMOKE

a. Check air filter for clogging or dirt.

Remove filter and inspect (para. 3-9). Replace filter as required.

b. Has engine run for prolonged periods at idle speed (no load)?

Operate engine at rated load only. c. Refer trouble to unit maintenance level.

12. ENGINE WILL NOT START IN COLD WEATHER a. Check that PREHEAT switch is in ON position.

Place switch in ON position. b. Check that proper fuel is being used for cold weather operation.

Use proper fuel as noted on FUEL CAPACITY data plate (Figure 1-5).

c. Check for crimped or pinched fuel lines. Check for clogs or frozen water in fuel lines, filter separator.

Straighten flexible fuel lines. Refer to unit level maintenance if fuel line or filter separator is frozen or damaged. d. Refer trouble to unit level maintenance.

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Table 3-3. Operator Level Troubleshooting (continued)

MALFUNCTION

TEST OR INSPECTION

13. NO POWER AT CONVENIENCE RECEPTACLE a. Check that GROUND FAULT CIRCUIT INTERRUPTER (GFCI) is not tripped.

Reset GFCI by depressing button. b. Check that 10 amp circuit breaker (located on back of GFCI) is not tripped.

Reset circuit breaker if tripped c. Refer trouble to unit level maintenance.

Section III. OPERATOR MAINTENANCE PROCEDURES

3-4. GENERAL.

This section contains information on the generator set maintenance tasks that are the responsibility of the operator. If a procedure is not located in this chapter, you are not authorized to perform it.

WARNING

Never service, inspect, or perform maintenance on the generator set while the engine is running. Always shut down the unit before servicing.

Allow engine to cool before handling components. Failure to observe this warning can result in severe burn or injury.

3-5. GENERATOR SET ENCLOSURE AND COVER.

a. Inspect the enclosure assembly for missing or loose components, cracks, dents, or other damage. b. Check cover latches to ensure that they are properly secured. Check for proper operation, free of binding. Ensure that latches lock cover securely. c. Open enclosure cover. Check that pistons hold cover in place. Inspect cover insulating material for damage and security of attachment. Close enclosure cover and lock using latches. d. If damage is found, notify unit level maintenance personnel for repair.

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3-6. CONTROL BOX AND OUTPUT PANEL ASSEMBLIES.

a. Inspect control panel switches for ease of operation. Ensure that switches spring back to position. b. Clean hour, fuel level, and voltage meters with a clean dry cloth. Inspect meters for broken glass or improper indication. c. Conduct fault module indicator self test by depressing the FAULT RESET / PUSH TEST pushbutton.

All indicator lights should illuminate. d. Open control panel. Check rear of controls and indicators for obvious damage and evidence of electrical short. Inspect sealing gasket for cuts, tears, and security of attachment. Close control panel. e. Inspect convenience receptacle cover for security of attachment. Inspect slave receptacle for damage.

Make sure that cover is securely attached. f. Inspect load and ground terminals for cracks, missing surge arrestors, or other obvious damage. g. If damage is found, notify unit level maintenance personnel for repair.

3-7. FUEL SYSTEM.

a. Open enclosure cover and inspect inside of enclosure for evidence of fuel leakage. Inspect fuel tank for signs of damage. Check that tank is securely attached to skid base. b. Inspect fuel hoses for cuts, tears, or evidence of deterioration. Check that hoses are securely fastened to fittings. c. Close enclosure cover and lock using latches. d. Inspect fuel tank fill cap and auxiliary fuel connection cap for security of attachment. e. Remove fuel tank fill cap from filler neck. Remove fuel strainer and inspect for collected contaminants. Clean strainer and install. Install fuel tank fill cap and tighten. f. If damage is found, notify unit level maintenance personnel for repair.

3-8. FUEL FILTER / WATER SEPARATOR.

a. Open enclosure cover to gain access to fuel filter / water separator. b. Inspect filter / separator drain valve for damage or evidence of leakage. If leak or damage is found, notify unit level maintenance personnel for repair.

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c. Inspect filter / separator bowl for trapped water. Drain water by turning valve. After water is drained, close valve. d. Close enclosure cover and lock using latches.

3-9. AIR FILTER.

a. Unlock main access cover latches and lift cover to open.

b. Remove cover (1, Figure 3-1) from air filter housing (2) by removing wing nut (3) and washer (4).

Remove filter (5) from housing (2). c. Install new filter (5) into housing (2). Install cover (1) onto housing using wing nut (3) and washer

(4). d. Close main access cover and lock in place using latches.

Figure 3-1. Air Filter Replacement

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CHAPTER 4

UNIT MAINTENANCE INSTRUCTIONS

Section I

LUBRICATION INSTRUCTIONS.........................................................................4-3

4-1 General.....................................................................................................................4-3

Section II REPAIR PARTS; TOOLS; SPECIAL TOOLS; TEST,

MEASUREMENT, AND DIAGNOSTIC EQUIPMENT (TMDE);

AND SUPPORT EQUIPMENT ..............................................................................4-6

4-2 Common Tools and Equipment ...............................................................................4-6

4-3 Special Tools, TMDE, and Support Equipment.......................................................4-6

Section III

SERVICE UPON RECEIPT OF EQUIPMENT......................................................4-6

4-5 General.....................................................................................................................4-6

Section IV UNIT PREVENTIVE MAINTENANCE CHECKS

AND SERVICES (PMCS).......................................................................................4-7

4-6 General.....................................................................................................................4-7

Section V

UNIT LEVEL TROUBLESHOOTING PROCEDURES......................................4-12

4-9 General...................................................................................................................4-12

Section VI

UNIT MAINTENANCE PROCEDURES .............................................................4-27

4-12 Control Box Assembly Maintenance .....................................................................4-28

4-13 Control Panel Assembly Maintenance ...................................................................4-32

4-14 HOURS Meter Maintenance ..................................................................................4-34

4-15 FUEL LEVEL Gauge Maintenance .......................................................................4-35

4-16 VOLTAGE Meter Maintenance.............................................................................4-36

4-17 LOAD Meter Maintenance ....................................................................................4-37

4-18 Fault Indicator Module Maintenance.....................................................................4-38

4-19 Operator Switch Maintenance................................................................................4-39

4-21 DC CIRCUIT BREAKER Maintenance................................................................4-43

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Section VI UNIT MAINTENANCE PROCEDURES (continued)

4-22 CIRCUIT INTERRUPTER Indicator Light Maintenance .....................................4-44

4-23 VOLTAGE ADJUST Rheostat Maintenance ........................................................4-46

4-24 Control Box Relay Maintenance............................................................................4-48

4-25 Control Box Fuse, Diode, and Terminal Block Maintenance ................................4-50

4-27 Control Box Wiring Harness Maintenance ............................................................4-54

4-28 AC Circuit Interrupter Contactor Maintenance......................................................4-56

4-29 Battery Charging Regulator Maintenance..............................................................4-58

4-30 Convenience Receptacle Maintenance (60 Hz, MEP 831A only) .........................4-60

4-31 Ground Fault Circuit Interrupter Maintenance (60 Hz, MEP 831A only) .............4-62

4-32 SLAVE RECEPTACLE Maintenance...................................................................4-64

4-33 Output Terminals and EMI Filter Maintenance .....................................................4-66

4-35 Lifting Handle Maintenance ..................................................................................4-72

4-36 Engine Oil Drain Assembly Maintenance..............................................................4-74

4-38 Lubrication Oil Pressure Switch Maintenance.......................................................4-78

4-39 Fuel Level Switch Assembly Maintenance............................................................4-80

4-40 Fuel Sender Maintenance.......................................................................................4-82

4-41 Fuel Pickup Tube Assembly Maintenance.............................................................4-84

4-42 Primary Fuel Pump Maintenance...........................................................................4-85

4-43 Muffler Assembly Maintenance.............................................................................4-88

4-45 Battery Cable Assembly Maintenance ...................................................................4-96

4-46 Main Access Cover Maintenance.........................................................................4-100

4-48 Cooling Fan and Temperature Switch Maintenance ............................................4-112

4-49 Fuel Filter / Water Separator Maintenance ..........................................................4-120

4-50 Fuel Fill Cap and Fill Pocket Maintenance..........................................................4-123

4-51 Auxiliary Fuel Pump Maintenance ......................................................................4-126

4-52 Power Inverter / Converter Maintenance .............................................................4-128

4-53 DC Magnetic Contactor Maintenance..................................................................4-132

Section VII PREPARATION FOR SHIPMENT AND STORAGE .......................................4-140

4-55 General.................................................................................................................4-140

4-57 Short Term Storage (30 days or less)...................................................................4-140

4-58 Intermediate Term Storage (more than 30 days)..................................................4-140

4-59 Shipment ..............................................................................................................4-140

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Section I. LUBRICATION INSTRUCTIONS

4-1. GENERAL.

a. These lubrication instructions are for unit level maintenance personnel. Lube intervals (on-condition or hard time) are based on normal operation. Lube more during constant use, and less during inactive periods.

Use correct grade of lubricant for seasonal temperature expected.

CAUTION

Always wipe clean oil filler components before starting your lube service. Use correct type or grade of oil. Overfilling will cause spillage and harm engine components. b. The engine oil filter shall be changed as applicable when:

(1) It is known to be contaminated or clogged.

(2) The prescribed hard time interval has arrived. c. This generator set is not enrolled in the Army Oil Analysis Program (AOAP). Hard time service intervals apply. d. For equipment under manufacturer’s warranty, hard time oil service intervals shall be followed.

Intervals shall be shortened if lubricants are known to be contaminated or if operation is under adverse conditions (such as longer than usual operating hours, extended idling periods, or extreme dust).

Table 4-1. Lubricant Table for Generator Set MEP 831A / 832A

Temperature Range Interval Lubrication Mil. Symbol

Specification

MIL-L-46167, OEA

MIL-L-2104, OE/HDO-15/40

MIL-L-2104, OE/HDO-10

MIL-L-2104, OE/HDO-30

MIL-L-2104, OE/HDO-40

-25

°F to +40°F (-31°C to +5°C)

+5

°F to +120°F (-15°C to +49°C)

-15

°F to +40°F (-26°C to +5°C)

+15

°F to +90°F (-9°C to +32°C)

+30

°F to +120°F (-1°C to +49°C)

System

Capacity

1.2 qts. (1.1 ltrs.)

1.2 qts. (1.1 ltrs.)

1.2 qts. (1.1 ltrs.)

1.2 qts. (1.1 ltrs.)

1.2 qts. (1.1 ltrs.)

100 hours

100 hours

100 hours

100 hours

100 hours

Man- hours

0.25

0.25

0.25

0.25

0.25

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e. Drain and service engine oil and filter as follows:

(1) Unlock main access cover latches and lift cover to open.

(2) Place oil catch pan under oil drain plug (1, Figure 4-1).

(3) Remove engine oil fill cap (2) to vent engine crankcase while draining.

(4) Remove oil drain plug (1). Move oil drain valve (7) to the OPEN position and drain oil from crankcase.

(5) Once oil is drained, replace drain plug (1) and move valve (7) to CLOSE position. Remove oil catch pan. Dispose of oil In accordance with local ordinance.

(6) Remove oil filter (3) from crankcase cover (4) by removing bolt (5). Remove and discard O-ring

(6).

(7) Inspect oil filter (3) for obvious damage. Check filter’s mesh material for damage. Clean out clogging dirt and residue. Replace as required and dispose of in accordance with local ordinance.

(8) Inspect area around oil filter port for evidence of leakage. Clean area of dirt and accumulated grime using a clean rag.

(9) Apply a light coat of lubricating oil to new O-ring (6) and install into oil filter port.

CAUTION

Do not overtighten bolt (5). Damage to filter will occur.

(10) Slide oil filter (3) into crankcase cover (2) and secure using bolt (5).

(11) Fill engine with required oil until level reaches threaded opening of oil fill cap (2) (up to 1.2

quarts (1.1 liters)). Refer to Table 4-1 for recommended oils.

(12) Install oil fill cap (2).

(13) Close main access cover and secure using latches.

4-4

1. Oil Drain Plug

2. Oil Fill Cap

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Figure 4-1. Engine Oil Servicing

5. Bolt

6. O-Ring

7. Oil Drain Valve

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Section II. REPAIR PARTS; TOOLS; SPECIAL TOOLS;

TEST, MEASUREMENT, AND DIAGNOSTIC EQUIPMENT (TMDE);

AND SUPPORT EQUIPMENT

4-2. COMMON TOOLS AND EQUIPMENT

. a. For authorized common tools and equipment, refer to the Modified Table of Organization and

Equipment (MTOE), CTA 50-970, or CTA 8-100, as applicable to your unit. b. Tool Kit, General Mechanics; Automotive, Supply Catalog SC5180-90-CL-N26, is the primary supply source for tools used in maintenance of the generator set.

4-3. SPECIAL TOOLS, TMDE, AND SUPPORT EQUIPMENT

.

Refer to TM 9-6115-639-23P, Generator Set Repair Parts and Special Tools List, for complete data on special tools and equipment required for generator set maintenance. Refer to the Maintenance Allocation Chart

(MAC), Appendix B, for special tools and equipment used at the unit maintenance level.

4-4. REPAIR PARTS

.

a. Refer to Appendix H for a list of Mandatory Replacement Parts required for unit level maintenance of

the generator set. b. Repair parts are listed and illustrated in TM 9-6115-639-23P, Generator Set Repair Parts and Special

Tools List.

Section III. SERVICE UPON RECEIPT OF EQUIPMENT

4-5. GENERAL

.

Refer to paragraph 2-6 for instructions on unpacking, assembly, and servicing of generator set components.

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Section IV. UNIT PREVENTIVE MAINTENANCE CHECKS

AND SERVICES (PMCS)

4-6. GENERAL

.

Unit Preventive Maintenance Checks and Services (PMCS) means systematic caring, inspecting, and servicing of equipment to keep it in good condition and to prevent breakdowns to ensure that the generator set is ready for operation at all times. It must be inspected so that defects can be discovered and corrected before they result in damage or failure. This section lists PMCS required for the generator set and authorized for the unit maintenance level. a. Be sure to perform your PMCS in the same order, so it gets to be a habit. Once you have had some practice, you will quickly spot anything wrong. b. Pay attention to WARNINGS, CAUTIONS, and NOTES.

c. Perform PMCS tasks at the intervals noted in Table 4-2. Do not skip PMCS intervals.

d. Use DA Form 2404 (Equipment Inspection and Maintenance Worksheet) to record any faults you discover, unless you can fix them. You DO NOT need to record faults that you fix.

4-7. PMCS PROCEDURES

.

Your Preventive Maintenance Checks and Services, Table 4-2, lists inspections and care required to

keep your generator set in good operating condition. It is set up so you can make your BEFORE (B)

OPERATION checks as you walk around the generator set. a. Item No. Column.

The Item No. column in Table 4-2 lists each check / service in chronological order.

b. Interval Column. The Interval column tells you when to do a certain check or service. Intervals are based on operating hours, unless otherwise noted. c. Location Column. The Location: Item to Check / Service column directs maintenance personnel to the general area on the generator set where the check or service is to be performed.

d.

The Procedure column of Table 4-2 tells you how to do required checks and

services. Tolerances, adjustment limits, and instrument readings are included as applicable. When replacement or repair of a component is required, the procedures column will direct you to the appropriate task.

NOTE

Terms “ready/available” and “mission capable” refer to same status:

Equipment is on hand and ready to perform its combat missions. (See

DA Pam 738-750).

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you when your generator set is non-mission capable and why the engine assembly cannot be used.

If the generator set does not perform as required, refer to Section V, Troubleshooting.

If anything looks wrong and you cannot fix it, write it on your DA Form 2404. IMMEDIATELY report it to your supervisor.

When you perform PMCS you will always need a rag or two. Following are checks that are common to the entire generator set:

(1) Keep It Clean. Dirt, grease, oil, and debris only get in the way and may cover up a serious problem. Clean as you work and as needed. Use dry cleaning solvent on all metal surfaces. Use soap and water when you clean rubber or plastic material.

(2) Rust and Corrosion. Check components for rust and corrosion. If any bare metal or corrosion exists, clean, and apply a thin coat of oil. Report it to your supervisor.

(3) Bolts, Nuts, and Screws. Check them for obvious looseness, missing, bent, or broken condition.

You cannot check them all with a tool, but look for chipped paint, bare metal, or rust around bolt heads. If you find a bolt, nut, or screw you think is loose, tighten it or report it to your supervisor.

(4) Welds. Look for loose or chipped paint, rust, or gaps where parts are welded together. If you find a bad weld, report it to your supervisor.

(5) Electric Wires and Connectors. Look for cracked, frayed, or broken insulation, bare wires, and loose or broken connectors. Tighten loose connectors. Report any damaged wires to your supervisor.

(6) Hoses and Fluid Lines. Look for wear, damage, and leaks, and make sure clamps and fittings are tight. Wet spots show leaks, but a stain around a fitting or connector can also mean a leak. If a leak comes from a loose fitting or connector, tighten it. If something is broken or worn out, report it to your supervisor.

4-8. CLEANING AGENTS.

WARNING

Cleaning solvents are flammable and toxic to eyes, skin, and respiratory tract. Skin and eye protections are required when working in contact with cleaning solvents. Avoid prolonged or repeated contact. Work in well ventilated area only. Keep away from heat, sparks, and open flame.

Do not smoke while using cleaning solvent. Failure to observe this warning can result in injury or death to personnel

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CAUTION

When cleaning inside of enclosure, engine must be COLD (same temperature as outside air). DO NOT point water stream directly at any electrical connection. DO NOT use high pressure water supply system.

Damage to engine, electrical system, and other components may result.

NOTE

Only use those authorized cleaning solvents or agents listed in Appendix

E, Expendable and Durable Items List.

a. When using water to clean the generator set enclosure, always cover all air ducts and exhaust ports using waterproof material to prevent damage to components. Cover control box and output panel components.

Use water pressure and volume similar to a standard household water supply (50 PSI, maximum, 3 gallons per minute). b. After cleaning, allow generator set to air dry. Do not use compressed air to dry unit. Do not run engine to decrease drying time. c. Remove all component covers before starting the generator set.

CAUTION

Keep cleaning solvents, gasoline, and lubricants away from rubber or soft plastic parts. Solvents will deteriorate these materials.

d. When cleaning grease build-up or rusty places, use cleaning solvent (Item 7, App. E), then apply a thin coat of light oil (Item 6, App. E) to affected area.

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Table 4-2. Unit Level Preventive Maintenance Checks and Services for MEP 831A / 832A

Item

No.

1

2

3

4

5

Interval Location:

100 hours

Item to

Check/

Service

Engine lubricating oil system

100 hours

100 hours

300 hours

Engine air filter

Battery electrolyte level

Fuel filter / water separator

Procedure

NOTE:

First service occurs after 25 hours of engine operation. Follow 100 hours intervals thereafter.

Service engine lubricating oil and clean filter.

Refer to Lubrication Instructions (Para. 4-1).

a. Open enclosure cover to gain access to

engine air filter case.

b. Remove air filter (Para. 3-9).

c. Inspect air filter for dirt, clogging, or

obstruction. Replace as required.

d. Install air filter (Para. 3-9).

e. Close enclosure cover and lock using

latches.

Check battery electrolyte and gravity level

(wet cell battery only). Service as required

(Para. 4-44).

Remove and replace filter / separator element

(Para. 4-49).

300 hours

Electrical system Inspect electrical receptacles for damage, corrosion, or evidence of electrical short.

Check for bent, broken, or missing pins.

Clean deposits from receptacles.

Not Fully Mission

Capable If:

Engine oil has not been changed or filter has not been cleaned.

Air filter is clogged, dirty, or damaged.

Battery electrolyte level is low.

Filter / separator element has not been replaced.

Receptacles are damaged or burned.

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7

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Table 4-2. Unit Level Preventive Maintenance Checks and Services for MEP 831A / 832A (continued)

Item

No.

Not Fully Mission

Capable If:

10

Interval Location:

Item to

500 hours

Check/

Service

Power Inverter/

Converter (A8)

500 hours

500 hours

500 hours

Engine air filter

Engine fuel injection pump

Engine valves

Procedure

a. Check area around Power Inverter/

Converter for water. Test gaskets for

water sealage (see para. 4-46A). b. Refer to para. 4-46 to replace gaskets.

Remove and replace engine air filter

(Para. 3-9).

a. Inspect fuel injection pump for damage

and evidence of leakage. Check area

around pump sealing gasket for leaks. b. Refer to TM 9-2815-257-24 for pump and

gasket replacement.

Adjust engine valve clearance in accordance with TM 9-2815-257-24.

1000 hours

Engine fuel injector nozzle

Remove and replace fuel injector nozzle in accordance with TM 9-2815-257-24.

Gaskets are loose or not sealing properly.

Engine air filter has not been replaced.

Fuel injection pump is damaged or leaking.

Pump sealing gasket leaking.

Engine valves are not properly adjusted, causing improper engine operation.

Fuel injector nozzle has not been replaced.

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Section V. UNIT LEVEL TROUBLESHOOTING PROCEDURES

4-9. GENERAL.

This section contains unit level troubleshooting and tests for the generator set. Each malfunction or trouble symptom is addressed and is followed by a series of inspections or tests necessary to determine the probable cause and corrective action.

4-10. TROUBLESHOOTING.

a. This chapter does not list all possible malfunctions that may occur, all tests or inspections that may be performed, or all corrective actions for each malfunction. Only those checks and tests authorized for the unit level are covered. If a malfunction is not listed, or is not remedied by corrective actions, notify personnel at a higher maintenance level. b. Prior to using troubleshooting table, be sure you have performed all normal operational checks. Refer

to the system electrical schematic (Figure FO-1), system wiring diagram (Figure FO-2), generator set wiring

harness diagrams (Figures FO-3 and FO-4), control panel wiring harness diagrams (Figures FO-5 and FO-6),

and Diagnostic Test Points (Figure 4-2) for assistance in troubleshooting electrical components. Conduct

continuity checks on suspect wiring / harnesses as required utilizing these schematics and diagrams. c. These troubleshooting procedures assume that electrical wires are undamaged and wiring harnesses are operable. Conduct continuity checks on suspect wiring / harnesses as required prior to performing

troubleshooting procedures in Table 4-4.

d. Refer to Table 4-3, Malfunction Index, for determining applicable troubleshooting procedure located

in Table 4-4.

Table 4-3. Malfunction Index

Trouble

Procedure

Engine will not crank 1

Engine cranks but will not start

Engine cranks slowly, battery runs down prior to starting

Engine starts and stops

Engine will not start in cold weather

Engine will not stop when EMERGENCY STOP switch is pressed

Engine starts, no generator voltage reading

Generator set fails to supply power to the load

No kW reading when load is applied

No power at convenience receptacle

Generator set causes radio interference

10

11

Circuit interrupter will not close 12

Circuit interrupter will not remain closed when CIRCUIT INTERRUPTER switch released 13

6

7

8

9

2

3

4

5

Auxiliary fuel system will not energize

BATTLE SHORT indicator will not illuminate when BATTLE SHORT switch in ON

14

15

4-12

ARMY TM 9-6115-639-13

AIR FORCE TO 35C2-3-386-51

MARINE CORPS TM 10155A-13/1

Table 4-3. Malfunction Index (continued)

Fan (B2) does not operate at high temperature

Fan (B3) does not operate at high temperature

Engine emits white smoke

Engine emit black smoke

Malfunction indicators do not illuminate when PUSH TEST switch is pressed

ENGINE HIGH TEMP indicator illuminates

LOW OIL PRESSURE indicator illuminates

NO FUEL indicator illuminates

16

17

18

19

20

21

22

23

Figure 4-2. Diagnostic Test Points

4-13

ARMY TM 9-6115-639-13

AIR FORCE TO 35C2-3-386-51

MARINE CORPS TM 10155A-13/1

Table 4-4. Unit Level Troubleshooting

MALFUNCTION

TEST OR INSPECTION

1. ENGINE WILL NOT CRANK a. Check battery for loose connections, corrosion, damaged cable.

Clean battery terminals and tighten connections. b. Check battery voltage as follows:

(1)

(2)

Connect positive (+) probe of multimeter to terminal board TB3, test point TP30.

Connect negative (-) probe to TB3, test point TP31.

(3) Place START / RUN / STOP switch in START position.

(4) 20 to 32 VDC present?

If not present, service battery (Para. 4-44). Replace as required.

c. Check START / RUN / STOP switch as follows:

(1) Connect positive (+) probe of multimeter to terminal board TB5, pin 11.

(2) Connect negative (-) probe to TB3, test point TP31.

(3) Place START / RUN / STOP switch in START position.

(4) 20 to 32 VDC present?

If not present, remove and replace START / RUN / STOP switch (Para. 4-19).

d. Check diode CR1 as follows:

(1) Connect positive (+) probe of multimeter to terminal board TB5, pin 9.

(2) Connect negative (-) probe to TB3, test point TP31.

(3) Place START / RUN / STOP switch in START position.

(4) 20 to 32 VDC present?

If not present, remove and replace diode (Para. 4-25).

e. Check relay K15 as follows:

(1) Place START / RUN / STOP switch in STOP position.

(2) Remove relay K15 and ohm out pins 1 and 9.

(3) Zero ohms at relay K15, pins 1 and 9?

If not zero ohms, remove and replace relay (Para. 4-24).

f. Check engine start contactor K2:

(1)

(2)

(3)

Disconnect wires from K2, terminals 1 and 2.

Connect multimeter probes to K2, X1 and X2.

Resistance should be approximately 55 ohms.

If multimeter indicates infinity or 0 ohms, replace K2. (Para. 4-28).

4-14

Change 1

ARMY TM 9-6115-639-13

AIR FORCE TO 35C2-3-386-51

MARINE CORPS TM 10155A-13/1

Table 4-4. Unit Level Troubleshooting (continued)

MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

1. ENGINE WILL NOT CRANK (continued)

g. Check engine solenoid L4:

(1) Connect positive (+) probe of multimeter to K2-A2.

(2) Connect negative (-) probe of multimeter to TP31.

(3) Continuity of approximately 1.4 ohms?

If not, remove and replace solenoid L4 in accordance with TM 9-2815-257-24. h. Remove and replace engine starter motor in accordance with TM 9-2815-257-24. i. Refer trouble to direct support level maintenance.

2.

ENGINE CRANKS BUT WILL NOT START a. Check for clogged fuel filter / water separator element.

Remove and replace filter / separator element (Para. 4-49).

b. Check that fuel pump assembly is operating when START / RUN / STOP switch is placed in

RUN position (audible sound).

Remove and replace fuel pump assembly (Para. 4-42).

c. Check diode CR2 as follows:

(1) Connect positive (+) probe of multimeter to terminal board TB3, test point TP32.

(2) Connect negative (-) probe to TB3, test point TP31.

(3) Place START / RUN / STOP switch in RUN position.

(4) 20 to 32 VDC present?

If not present, remove and replace diode (Para. 4-25).

d. Check fault lockout relay K12 as follows:

(1) Connect positive (+) probe of multimeter to A5-F.

(2) Connect negative (-) probe to terminal board TB3, test point TP31.

(3) Place START / RUN / STOP switch in START position.

(4) 20 to 32 VDC present?

If not present, remove and replace relay (Para. 4-24).

e. Check EMERGENCY STOP switch as follows:

(1) Connect positive (+) probe of multimeter to S19-A2.

(2) Connect negative (-) probe to terminal board TB3, test point TP31.

(3) Place START / RUN / STOP switch in START position.

(4) 20 to 32 VDC present?

If not present, remove and replace EMERGENCY STOP switch (Para. 4-20).

Change 1

4-15

ARMY TM 9-6115-639-13

AIR FORCE TO 35C2-3-386-51

MARINE CORPS TM 10155A-13/1

Table 4-4. Unit Level Troubleshooting (continued)

MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

2. ENGINE CRANKS BUT WILL NOT START (continued)

f. Check governor control A5 as follows:

(1)

(2)

(3)

Connect positive (+) probe of multimeter to A5-H.

Connect negative (-) probe to A5-J.

Place START / RUN / STOP switch in START position.

(4) 20 to 32 VDC present?

If not present, remove and replace governor control (Para. 4-26).

g. Check malfunction indicator module as follows:

(1)

(2)

Disconnect electrical connector P4 from fault indicator module.

Attempt to start engine.

If engine starts, remove and replace fault indicator module (Para. 4-18).

h. Refer trouble to direct support level maintenance.

3. ENGINE CRANKS SLOWLY, BATTERY RUNS DOWN PRIOR TO STARTING

a. Inspect and test regulator fuse FU1.

Remove and replace defective fuse (Para. 4-25).

b. Check generator G1 as follows:

(1) Connect positive (+) probe of multimeter to FU1-2.

(2) Connect negative (-) probe to terminal board TB4-9.

(3) Start generator set.

(4) Reading shall be 36 VAC minimum.

If not 36 VAC minimum, refer to direct support level maintenance for replacement of permanent magnet alternator. c. Check battery charging regulator A9 as follows:

(1)

(2)

Disconnect battery cable from negative (-) battery terminal.

Start set using recoil start, set should continue to run.

If unit shuts down, remove and replace regulator (Para. 4-29).

d. Refer trouble to direct support level maintenance.

4-16

Change 1

ARMY TM 9-6115-639-13

AIR FORCE TO 35C2-3-386-51

MARINE CORPS TM 10155A-13/1

Table 4-4. Unit Level Troubleshooting (continued)

MALFUNCTION

TEST OR INSPECTION

4.

ENGINE STARTS AND STOPS a. Check fuel lines for obstructions, kinks, or clogging. Inspect for leaks.

Remove and replace damaged or defective fuel lines. b. Possible air in fuel system. Check for loose or damaged connections.

Tighten connections. Remove and replace damaged components as required. c. Check for clogged fuel filter / water separator element.

Remove and replace filter / separator element (Para. 4-49).

d. Adjust engine valve clearance in accordance with TM 9-2815-257-24. e. Refer trouble to direct support level maintenance.

5.

ENGINE WILL NOT START IN COLD WEATHER a. Check for continuity of air heaters H1 and H2.

Remove and replace air heater in accordance with TM 9-2815-257-24. b. Check engine preheat relay K13 as follows:

(1)

(2)

Connect positive (+) probe of multimeter to relay K13-A2.

Connect negative (-) probe to terminal board TB3, test point TP31.

(3) Place PREHEAT switch in ON position.

(4) 20 to 32 VDC present?

If not present, remove and replace relay (Para. 4-24).

c. Check PREHEAT switch S18 as follows:

(1) Connect positive (+) probe of multimeter to switch S18-1.

(2) Connect negative (-) probe to terminal board TB3, test point TP31.

(3) Place PREHEAT switch in ON position.

(4) 20 to 32 VDC present?

If not present, remove and replace PREHEAT switch (Para. 4-19).

Change 1

4-17

ARMY TM 9-6115-639-13

AIR FORCE TO 35C2-3-386-51

MARINE CORPS TM 10155A-13/1

Table 4-4. Unit Level Troubleshooting (continued)

MALFUNCTION

TEST OR INSPECTION

6.

ENGINE WILL NOT STOP WHEN EMERGENCY STOP SWITCH IS PRESSED a. Check EMERGENCY STOP switch S19 as follows:

(1) Connect positive (+) probe of multimeter to terminal board TB3, test point TP32.

(2) Connect negative (-) probe to terminal board TB3, test point TP31.

(3) Place START / RUN / STOP switch in RUN position.

(4) Press EMERGENCY STOP switch.

(5) Reading shall go from 24 VDC to zero VDC.

If it does not drop to zero VDC, replace EMERGENCY STOP switch (Para. 4-20).

b. If voltage does drop to zero VDC and engine still runs, governor fuel linkage is not moving to the fuel shutoff position.

Visually check linkage and push lever to the off position.

7. ENGINE STARTS, NO VOLTAGE READING

a. Set voltage select switch to 120V/240V and then check that power inverter / converter A8 voltage reconnection cover is closed.

Close and latch cover to activate power converter. b. Measure voltage at power inverter / converter A8 output terminal as follows:

(1) Start generator set.

(2) Connect multimeter to terminal L1-N.

(3) Voltage reading shall be 120 VAC.

(4) Connect multimeter to terminal L2-N.

(5) Voltage reading shall be 120 VAC.

(6) Connect multimeter to terminal L1-L2.

(7) Voltage reading shall be 240 VAC if in 120/240 V connection configuration, zero VAC if in 120 V connection configuration.

If voltages not correct, refer trouble to direct support level maintenance. c. If voltages in b. are correct, check for voltage at VOLTAGE meter.

If voltage is present, remove and replace VOLTAGE meter (Para. 4-16).

4-18

Change 1

MALFUNCTION

TEST OR INSPECTION

ARMY TM 9-6115-639-13

AIR FORCE TO 35C2-3-386-51

MARINE CORPS TM 10155A-13/1

Table 4-4. Unit Level Troubleshooting (continued)

8. GENERATOR SET FAILS TO SUPPLY POWER TO THE LOAD

NOTE

Start generator set and check while running.

a. Using a multimeter, check generator set output voltage at load terminals L1, L2 and N (Figure 1-5).

If voltages are correct and all faults are reset, problem is not with the generator set. b. Check for proper output voltage readings at power inverter / converter terminals L1, L2, N.

If voltages are incorrect, replace power inverter / converter (Para. 4-52).

c. Check load contactor relay K1 as follows:

(1) Connect positive (+) probe of multimeter to K1 terminal 1(+).

(2) Connect negative (-) probe to K1 terminal 2(-).

(3) Is 24 VDC present?

If present, remove and replace relay K1 (Para. 4-24).

d. Hold CIRCUIT INTERRUPTER switch S5 in closed position. Is 24 VDC present now?

If present, replace relay K1 (Para. 4-24).

e. Close BATTLE SHORT switch and hold CIRCUIT INTERRUPTER switch in closed position.

Is 24 VDC present now? Does relay K1 now close?

If present, remove and replace power inverter / converter (Para. 4-52).

9.

NO KW READING WHEN LOAD IS APPLIED

Disconnect P17 from A8 and perform the following tests: a. Set multimeter to read resistance and check for 100 ohms at LOAD meter terminal.

If not present, remove and replace LOAD meter (Para. 4-17).

b. If 100 ohms is present at LOAD meter, check wiring between LOAD meter and P17.

Remove and replace damaged wiring as required.

Change 1

4-19

ARMY TM 9-6115-639-13

AIR FORCE TO 35C2-3-386-51

MARINE CORPS TM 10155A-13/1

Table 4-4. Unit Level Troubleshooting (continued)

MALFUNCTION

TEST OR INSPECTION

10. NO POWER AT CONVENIENCE RECEPTACLE a. Check that GROUND FAULT CIRCUIT INTERRUPTER (GFCI) is properly reset.

(1) Start

(2) Press TEST button.

(3) Press RESET button. b. Check that CB3 on GFCI (inside set) is not tripped.

Reset c. Check GFCI CB3 at TB4 as follows:

(1) Connect positive (+) probe of multimeter to terminal board TB4, pin 1.

(2) Connect negative (-) probe to terminal board TB4, pin 3.

(4)

(3) Start generator set.

120

If voltage is present, remove and replace GFCI (Para. 4-31).

d. Defective convenience receptacle.

Remove and replace convenience receptacle (Para. 4-30).

11. GENERATOR SET CAUSES RADIO INTERFERENCE

a. Defective EMI filter.

Remove and replace EMI filter (Para. 4-33).

b. Defective power inverter / converter.

Remove and replace power inverter / converter (Para. 4-52).

12. CIRCUIT INTERRUPTER WILL NOT CLOSE

a. Check relay K8 (part of power inverter / converter A8) as follows:

(1) Start generator set.

(2) Place BATTLE SHORT switch in ON position.

(3) Does circuit interrupter close?

If not, remove and replace power inverter / converter (Para. 4-52).

b. Check fault lockout relay K12 as follows:

(1) Connect positive (+) probe of multimeter to K12-12.

(2) Connect negative (-) probe to K12-4.

(3) Place START / RUN / STOP switch in STOP position.

(4) Zero ohms reading?

If not zero ohms, remove and replace relay (Para. 4-24).

4-20

Change 1

MALFUNCTION

TEST OR INSPECTION

ARMY TM 9-6115-639-13

AIR FORCE TO 35C2-3-386-51

MARINE CORPS TM 10155A-13/1

Table 4-4. Unit Level Troubleshooting (continued)

12. CIRCUIT INTERRUPTER WILL NOT CLOSE (continued)

c. Check CIRCUIT INTERRUPTER switch S5 as follows:

(1) Connect positive (+) probe of multimeter to S5-2.

(2)

(3)

(4)

(5)

Connect negative (-) probe to S5-5.

Place START / RUN / STOP switch in STOP position.

Hold CIRCUIT INTERRUPTER switch in CLOSED position.

Zero ohms reading?

If not zero ohms, remove and replace CIRCUIT INTERRUPTER switch (Para. 4-19).

d. Check coil resistance of K1 between K1 X1 and X2. Resistance should be approximately 55 ohms.

If infinity or 0 ohms, replace relay K1 (Para. 4-24).

e. Check relays K1 and K15 as follows:

(1) Start generator set.

(2) Connect positive (+) probe of multimeter to S5-2.

(3) Connect negative (-) probe to terminal board TB3, test point TP31.

(4) Hold CIRCUIT INTERRUPTER switch in CLOSED position.

(5) Check voltage reading.

If voltage is 0 VDC, remove and replace relay K1 (Para. 4-24).

If voltage is 20 to 32 VDC, remove and replace relay K15 (Para. 4-24).

13. CIRCUIT INTERRUPTER WILL NOT REMAIN CLOSED WHEN CIRCUIT INTERRUPTER

SWITCH IS RELEASED a. Check CIRCUIT INTERRUPTER switch S5 as follows:

(1) Connect positive (+) probe of multimeter to S5-2.

(2) Connect negative (-) probe to S5-5.

(3) Place START / RUN / STOP switch in STOP position.

(4) Hold CIRCUIT INTERRUPTER switch in CLOSED position.

(5) Zero ohms reading?

(1)

(2)

(3)

(4)

If not zero ohms, remove and replace CIRCUIT INTERRUPTER switch (Para. 4-19).

b. Check EMERGENCY STOP switch as follows:

Connect positive (+) probe of multimeter to S19-2, wire 5A16.

Connect negative (-) probe to S19-1, wire 16A16.

Place START / RUN / STOP switch in STOP position.

Zero ohms reading?

If not zero ohms, remove and replace EMERGENCY STOP switch (Para. 4-20).

c. Relay K1 auxiliary is defective.

Remove and replace relay (Para. 4-24).

Change 1

4-21

ARMY TM 9-6115-639-13

AIR FORCE TO 35C2-3-386-51

MARINE CORPS TM 10155A-13/1

Table 4-4. Unit Level Troubleshooting (continued)

MALFUNCTION

TEST OR INSPECTION

14. AUXILIARY FUEL SYSTEM WILL NOT ENERGIZE WHEN GENERATOR FUEL TANK IS

LOW ON FUEL

a. Check AUX FUEL switch S17 as follows:

(1) Connect positive (+) probe of multimeter to terminal board TB5, pin 1.

(2) Connect negative (-) probe to terminal board TB3, test point TP31.

(3) Place START / RUN / STOP switch in RUN position.

(4) Place AUX FUEL switch in the ON position.

(5) 20 to 32 VDC present?

If not present, remove and replace AUX FUEL switch (Para. 4-19).

b. Check diode CR3 as follows:

(1)

(2)

(3)

(4)

(5) c. Check fuel level switch FL2 as follows:

(1)

(2)

Connect positive (+) probe of multimeter to terminal board TB5, pin 1.

Connect negative (-) probe to terminal board TB3, test point TP31.

Place START / RUN / STOP switch in RUN position.

Place AUX FUEL switch in the ON position.

20 to 32 VDC present?

If not present, remove and replace diode (Para. 4-25).

Connect positive (+) probe of multimeter to TB 5-3.

Connect negative (-) probe to terminal board TB3, test point TP31.

(3) Place START / RUN / STOP switch in RUN position.

(4) Place AUX FUEL switch in the ON position.

(5) 20 to 32 VDC present?

If not present, remove and replace fuel level switch (Para. 4-39).

d. Check auxiliary fuel transfer relay K14 as follows:

(1)

(2)

(3)

(4)

(5)

Connect positive (+) probe of multimeter to fuel transfer relay K14-9.

Connect negative (-) probe to terminal board TB3, test point TP31.

Place START / RUN / STOP switch in RUN position.

Place AUX FUEL switch in the ON position.

20 to 32 VDC present?

If not present, emove and replace relay (Para. 4-24).

e. Defective auxiliary fuel pump E1.

Remove and replace auxiliary fuel pump (Para. 4-51).

4-22

Change 1

ARMY TM 9-6115-639-13

AIR FORCE TO 35C2-3-386-51

MARINE CORPS TM 10155A-13/1

Table 4-4. Unit Level Troubleshooting (continued)

MALFUNCTION

TEST OR INSPECTION

15. BATTLE SHORT INDICATOR WILL NOT ILLUMINATE WHEN BATTLE SHORT SWITCH

a. Press FAULT RESET/PUSH TEST.

If indicator does not illuminate, replace fault indicator module (Para. 4-18).

b. Check BATTLE SHORT switch S7 as follows:

(1)

(2)

Connect positive (+) probe of multimeter to switch S7-3.

Connect negative (-) probe to terminal board TB3, test point TP31.

(3) Place START / RUN / STOP switch in RUN position. Place S7 to On position.

(4) Zero VDC reading?

If not zero VDC, remove and replace BATTLE SHORT switch (Para. 4-19).

c. Defective fault indicator module A2.

Remove and replace fault indicator module (Para. 4-18).

16. FAN (B2) DOES NOT OPERATE AT HIGH TEMPERATURE a. Check temperature switch S20 as follows (60 Hz model MEP 831A):

(1) Connect positive (+) probe of multimeter to switch at S20-2.

(2) Connect negative (-) probe to terminal board TB3, test point TP35.

(3) Start generator set. Enclosure temperature must be above 100

°F.

120

If not present, remove and replace temperature switch (Para. 4-48).

b. Check temperature switch S20 as follows (400 Hz model MEP 832A):

(1)

(2)

(3)

Connect positive (+) probe of multimeter to switch at S20-2.

Connect negative (-) probe to terminal board TB3, test point TP31.

Place START / RUN / STOP switch in RUN position. Enclosure temperature must be

(4) 20 to 32 VDC present?

If not present, remove and replace temperature switch (Para. 4-48).

c. Defective fan B2.

Remove and replace fan (Para. 4-48).

Change 1

4-23

ARMY TM 9-6115-639-13

AIR FORCE TO 35C2-3-386-51

MARINE CORPS TM 10155A-13/1

Table 4-4. Unit Level Troubleshooting (continued)

MALFUNCTION

TEST OR INSPECTION

17. FAN (B3) DOES NOT OPERATE AT HIGH TEMPERATURE a. Check temperature switch S21 as follows (60 Hz model MEP 831A):

(1) Connect positive (+) probe of multimeter to switch at S21-2.

(2) Connect negative (-) probe to terminal board TB3, test point TP35.

(3) Start generator set. Enclosure temperature must be above 100

°F.

± 2 VAC present?

If not present, remove and replace temperature switch (Para. 4-48).

b. Check temperature switch S21 as follows (400 Hz model MEP 832A):

(1) Connect positive (+) probe of multimeter to switch S21-2.

(2) Connect negative (-) probe to terminal board TB3, test point TP31.

(3) Place START / RUN / STOP switch in RUN position. Enclosure temperature must be

above

(4) 20 to 32 VDC present?

If not present, remove and replace temperature switch (Para. 4-48).

c. Defective fan B3.

Remove and replace fan (Para. 4-48).

18. ENGINE EMITS WHITE SMOKE a. Check engine oil level to see if it is too high.

If high, drain and service engine lubricating oil (Para. 4-1).

b. Check for contaminants in the oil system.

If contaminated, drain and service engine lubricating oil (Para. 4-1).

c. Check for clogged fuel filter / water separator element.

If clogged, remove and replace filter / separator element (Para. 4-49).

d. Adjust engine valve clearance in accordance with TM 9-2815-257-24. e. Refer trouble to direct support level maintenance.

4-24

ARMY TM 9-6115-639-13

AIR FORCE TO 35C2-3-386-51

MARINE CORPS TM 10155A-13/1

Table 4-4. Unit Level Troubleshooting (continued)

MALFUNCTION

TEST OR INSPECTION

19. ENGINE EMITS BLACK SMOKE a. Check for clogged, sticking, or worn fuel injector nozzle.

If faulty, remove and replace in accordance with TM 9-2815-257-24. b. Refer trouble to direct support maintenance level.

20. MALFUNCTION INDICATORS DO NOT ILLUMINATE WHEN PUSH TEST SWITCH

a. Check for 20 to 32 DC voltage at fault indicator module A2.

If not present, remove and replace fault indicator module (Para. 4-18).

21. ENGINE HIGH TEMP INDICATOR ILLUMINATES a. Check engine cylinder fins for accumulated dirt and grime. Check for blockages.

Remove blockages. Clean dirty fins in accordance with TM 9-2815-257-24. b. Refer trouble to direct support level maintenance.

22. LOW OIL PRESSURE INDICATOR ILLUMINATES a. Check for engine oil leaks.

Refer to TM 9-2815-257-24 for engine maintenance. b. Clogged or defective engine oil filter.

Remove and replace engine oil filter in accordance with TM 9-2815-257-24. c. Check engine oil pressure switch OP as follows:

(1) Disconnect two wires from oil pressure switch.

(2) Check for continuity between switch terminals.

(3) With the generator set shut down, the switch should be closed.

(4) With the generator set running, the switch should be open.

(5) Does switch operate properly?

Remove and replace engine oil pressure switch in accordance with TM 9-2815-257-24.

4-25

ARMY TM 9-6115-639-13

AIR FORCE TO 35C2-3-386-51

MARINE CORPS TM 10155A-13/1

Table 4-4. Unit Level Troubleshooting (continued)

MALFUNCTION

TEST OR INSPECTION

23. NO FUEL INDICATOR ILLUMINATES a. Conduct visual check to verify that fuel is in tank.

Service fuel as required. b. Check fuel level switch FL1 as follows:

(1) Connect positive (+) probe of multimeter to P4-10.

(2) Connect negative (-) probe to terminal board TB3, test point TP31.

(3) Place START / RUN / STOP switch in RUN position.

(4) 20 to 32 VDC present?

If not present, remove and replace fuel level switch (Para. 4-39).

4-26

Change 1

ARMY TM 9-6115-639-13

AIR FORCE TO 35C2-3-386-51

MARINE CORPS TM 10155A-13/1

Section VI. UNIT LEVEL MAINTENANCE PROCEDURES

4-11. GENERATOR SET MAINTENANCE

This task covers general generator set inspection and repair procedures.

INITIAL SETUP

Tools: Condition:

Generator set shut down (Para. 2-9)

Tool Kit, General Mechanic’s Automotive

(Item 2, App. B, Sect. III)

Parts/Materials:

Paint, CARC, Green (Item 10, App. E)

Paint, CARC, Black (Item 11, App. E)

A. INSPECTION.

1. Inspect generator set enclosure for dents, cracks, warping, or other damage. Check all covers, ducts, and panels for damage and security of attachment.

2. Inspect painted surfaces for chips, scratches, bare metal, roughness, or corrosion.

3. Inspect cover and panel latches for proper operation. Latches should operate smoothly, free of binding.

4. Open enclosure cover and inspect insulation material for damage. Ensure insulation is securely attached to component.

5. Inspect generator set lifting and tie down devices for security of attachment.

B. REPAIR.

WARNING

CARC paint dust is a heath hazard. Wear protective eyewear, mask, and gloves when sanding CARC painted surfaces. Failure to observe this warning can result in personal injury.

1. Repair painted surfaces of enclosure by removing loose or chipped paint. Sand surfaces until smooth and remove all evidence of corrosion. Mask unpainted surfaces before painting. Paint generator set using

CARC paint, color green 383, in accordance with MIL-T-704, Type G for aluminum, and Type F for steel.

2. Stencil markings shall be applied using CARC paint, color black, in accordance with MIL-C-46168.

3. Repair of parts, other than painting, is limited to the removal and replacement of damaged components.

Refer to applicable paragraphs in this chapter for instructions.

4-27

ARMY TM 9-6115-639-13

AIR FORCE TO 35C2-3-386-51

MARINE CORPS TM 10155A-13/1

4-12. CONTROL BOX ASSEMBLY MAINTENANCE

This task covers removal, inspection, and installation.

INITIAL SETUP

Tools:

Tool Kit, General Mechanic’s Automotive

(Item 2, App. B, Sect. III)

Condition:

Battery charging regulator removed (Para. 4-29)

A. REMOVAL.

1.

Remove rear panel (1, Figure 4-3) by removing thirteen screws (2), lockwashers (3), and washers (4).

2. Remove left side panel (5) by removing eight screws (6), eight washers (7), and eight locknuts (8).

Remove four screws (9), four screws (12), eight washers (10), and eight locknuts (11).

3. Remove two screws (13), washers (14), locknuts (15), and spacer (16) from left side cover support mounting bracket (17). Fold support up to gain clearance for control box.

4.

Remove convenience receptacle (Para. 4-30).

5.

Remove ground fault circuit interrupter (Para. 4-31).

6. Disconnect and tag wires from terminal boards TB4 and TB6, contactor K1, and fuse FU1 located on rear of control box (24). Disconnect J7 connector.

7. Remove five screws (18), washers (19), and locknuts (20) from right side panel (21).

8. Remove two screws (22), washers (23), and locknuts (20) from control box (24).

9. Remove two screws (25), lockwashers (26), and washers (27) from bracket (28).

10. Remove four screws (29), washers (30), locknuts (31), and terminal wrench (32).

11. Remove screw (33), washer (34), and locknut (35).

12. Slide control box (24) out of enclosure. Remove shim (36).

B. INSPECTION.

1. Inspect controls and indicators for corrosion and obvious damage. Inspect meters for broken glass.

2. Inspect external relays and terminal boards for evidence of electrical short. Inspect for electrical burn marks, corrosion, and damage.

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4-12. CONTROL BOX ASSEMBLY MAINTENANCE - cont.

Figure 4-3. Control Box Assembly

(Sheet 1 of 2)

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4-12. CONTROL BOX ASSEMBLY MAINTENANCE - cont.

3. Inspect connector J7 for damaged pin receptacles. Check for corrosion. Ensure connector is securely attached to rear of control panel.

4. Inspect control panel gaskets for cuts, tears, deterioration, or other damage. Inspect gasket on rear of housing where left side panel mounts. Ensure gaskets are securely attached. Replace as required.

5. Remove and replace any component that is damaged to the extent that it will effect the safe operation of the generator set.

C. INSTALLATION.

NOTE

Loosely install control box attaching parts. Tighten once control box is properly aligned and all mating components are attached.

1.

Install control box (24, Figure 4-3) and shim (36) into enclosure.

2. Install screw (33), washer (34), and locknut (35).

3. Install four screws (29), washers (30), locknuts (31), and terminal wrench (32).

4. Install two screws (25), lockwashers (26), and washers (27) onto bracket (28).

5. Install two screws (22), washers (23), and locknuts (20).

6. Install five screws (18), washers (19), and locknuts (20) into right side panel (21).

7. Connect electrical wires to terminal boards TB4 and TB6, contactor K1, and fuse FU1 located on rear of control box (24). Connect connector J7.

8.

Install ground fault circuit interrupter (Para. 4-31).

9.

Install convenience receptacle (Para. 4-30).

10. Install two screws (13), washers (14), locknuts (15), and spacer (16) onto left side cover support mounting bracket (17).

11. Install left side panel (5) using eight screws (6), eight washers (7), and eight locknuts (8). Install four screws (9), four screws (12), eight washers (10), and eight locknuts.

12. Install rear panel (1) using thirteen screws (2), washers (3), and lockwashers (4).

13. Install battery charging regulator (Para. 4-29).

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4-12. CONTROL BOX ASSEMBLY MAINTENANCE - cont.

Figure 4-3. Control Box Assembly

(Sheet 2 of 2)

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4-13. CONTROL PANEL ASSEMBLY MAINTENANCE

This task covers removal, inspection, and installation.

INITIAL SETUP

Tools:

Tool Kit, General Mechanic’s Automotive

(Item 2, App. B, Sect. III)

Generator set shut down (Para. 2-9)

Battery cables disconnected

Cable disconnected for SLAVE RECEPTACLE

A. REMOVAL.

NOTE

It is not necessary to remove the control panel to remove control panel components. See specific tasks to remove control panel components.

1.

Turn quarter-turn fasteners (1, Figure 4-4) to unlock and open control panel (2).

2. Tag and disconnect electrical wiring from rear of control panel components.

3. Release cable lanyard (3) from control panel (1) by removing attaching screw (4), washer (5), and locknut

(6).

4. Remove control panel hinges (7) and hinge spacers (8) from control box by removing four nuts (9).

5. Remove hinges from control panel (2) by removing two nuts (9).

B. INSPECTION.

1. Inspect controls and indicators for corrosion and obvious damage. Inspect meters for broken glass.

2. Inspect for evidence of electrical short, electrical burn marks, corrosion, and damage.

3. Inspect electrical wiring for cuts, crimps, bare wire, or other damage. Ensure connectors are securely attached. Check for bent, broken, or missing pins.

4.

Inspect control panel gaskets (7, Figure 4-4) for cuts, tears, permanent set, deterioration, or other damage.

Ensure gasket is securely attached. Replace as required.

5. Remove and replace any component that is damaged to the extent that it will effect the safe operation of the generator set.

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C. INSTALLATION.

1.

Attach two hinges (7, Figure 4-4) to control panel (2) using two nuts (9).

2. Install hinge spacers (8) onto hinges (7). Mate hinges to control box and secure using four nuts (9).

3. Connect cable lanyard (3) to control panel (2) using attaching screw (4), washer (5), and locknut (6).

4. Connect electrical wires to rear of control panel components.

5. Close control panel (2) and lock in place using quarter-turn fasteners (1).

Figure 4-4. Control Panel Assembly

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4-14. HOURS METER MAINTENANCE

This task covers removal, inspection, and installation.

INITIAL SETUP

Tools:

Tool Kit, General Mechanic’s Automotive

(Item 2, App. B, Sect. III)

A. REMOVAL.

1. Turn quarter-turn fasteners (1, Figure 4-5) to

unlock and open control panel (2).

2. Tag and disconnect electrical wiring from the rear of HOURS meter (3).

3. Remove HOURS meter (3) from control panel (2) by removing two screws (4), lockwashers (5), and nuts (6).

B. INSPECTION.

1. Inspect HOURS meter for corrosion and obvious damage. Inspect for broken glass.

2. Inspect electrical wiring for cuts, crimps, bare wire, or other damage. Ensure connectors are securely attached.

3. Remove and replace any component that is damaged to the extent that it will effect the safe operation of the generator set.

C. INSTALLATION.

1. Mate HOURS meter (3, Figure 4-5) to control

panel (2). Secure using two screws (4), lockwashers (5), and nuts (6).

2. Connect electrical wiring to the rear of HOURS meter (3).

3. Close control panel (2) and lock in place using quarter-turn fasteners (1).

Condition:

Generator set shut down (Para. 2-9)

Battery cables disconnected

Cable disconnected for SLAVE RECEPTACLE

Figure 4-5. HOURS Meter

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4-15. FUEL LEVEL GAUGE MAINTENANCE

This task covers removal, inspection, and installation.

INITIAL SETUP

Tools:

Tool Kit, General Mechanic’s Automotive

(Item 2, App. B, Sect. III)

A. REMOVAL.

1. Turn quarter-turn fasteners (1, Figure 4-6) to

unlock and open control panel (2).

2. Tag and disconnect electrical wiring from the rear of FUEL LEVEL gauge (3).

3. Remove FUEL LEVEL gauge (3) from control panel (2) by removing two nuts (4), lockwashers

(5), and bracket (6).

B. INSPECTION.

1. Inspect FUEL LEVEL gauge for corrosion and obvious damage. Inspect for broken glass.

2. Inspect electrical wiring for cuts, crimps, bare wire, or other damage. Ensure connectors are securely attached.

3. Remove and replace any component that is damaged to the extent that it will effect the safe operation of the generator set.

C. INSTALLATION.

1. Install FUEL LEVEL gauge (3, Figure 4-6) onto

control panel (2) using two nuts (4), lockwashers

(5), and bracket (6).

2. Connect electrical wiring to the rear of FUEL

LEVEL gauge (3).

3. Close control panel (2) and lock in place using quarter-turn fasteners (1).

Generator set shut down (Para. 2-9)

Battery cables disconnected

Cable disconnected for SLAVE RECEPTACLE

Figure 4-6. FUEL LEVEL Gauge

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4-16. VOLTAGE METER MAINTENANCE

This task covers removal, inspection, and installation.

INITIAL SETUP

Tools:

Tool Kit, General Mechanic’s Automotive

(Item 2, App. B, Sect. III)

A. REMOVAL.

1. Turn quarter-turn fasteners (1, Figure 4-7) to

unlock and open control panel (2).

2. Tag and disconnect electrical wiring from the rear of VOLTAGE meter (3).

3. Remove VOLTAGE meter (3) from control panel

(2) by removing three screws (4), lockwashers

(5), and nuts (6).

B. INSPECTION.

1. Inspect VOLTAGE meter for corrosion and obvious damage. Inspect for broken glass.

2. Inspect electrical wiring for cuts, crimps, bare wire, or other damage. Ensure connectors are securely attached.

3. Remove and replace any component that is damaged to the extent that it will effect the safe operation of the generator set.

C. INSTALLATION.

1.

Mate VOLTAGE meter (3, Figure 4-7) to control

panel (2). Secure using three screws (4), lockwashers (5), and nuts (6).

2. Connect electrical wiring to the rear of

VOLTAGE meter (3).

3. Close control panel (2) and lock in place using quarter-turn fasteners (1).

Condition:

Generator set shut down (Para. 2-9)

Battery cables disconnected

Cable disconnected for SLAVE RECEPTACLE

Figure 4-7. VOLTAGE Meter

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MARINE CORPS TM 10155A-13/1

4-17. LOAD METER MAINTENANCE

This task covers removal, inspection, and installation.

INITIAL SETUP

Tools:

Tool Kit, General Mechanic’s Automotive

(Item 2, App. B, Sect. III)

A. REMOVAL.

1. Turn quarter-turn fasteners (1, Figure 4-8) to

unlock and open control panel (2).

2. Tag and disconnect electrical wiring from the rear of LOAD meter (3).

3. Remove LOAD meter (3) from control panel (2) by removing three screws (4), lockwashers (5), and nuts (6).

B. INSPECTION.

1. Inspect LOAD meter for corrosion and obvious damage. Inspect for broken glass.

2. Inspect electrical wiring for cuts, crimps, bare wire, or other damage. Ensure connectors are securely attached.

3. Remove and replace any component that is damaged to the extent that it will effect the safe operation of the generator set.

C. INSTALLATION.

1. Mate LOAD meter (3, Figure 4-8) to control

panel (2). Secure using three screws (4), lockwashers (5), and nuts (6).

2. Connect electrical wiring to the rear of LOAD meter (3).

3. Close control panel (2) and lock in place using quarter-turn fasteners (1).

Condition:

Generator set shut down (Para. 2-9)

Battery cables disconnected

Cable disconnected for SLAVE RECEPTACLE

Figure 4-8. LOAD Meter

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MARINE CORPS TM 10155A-13/1

4-18. FAULT INDICATOR MODULE MAINTENANCE

This task covers removal, inspection, and installation.

INITIAL SETUP

Tools:

Tool Kit, General Mechanic’s Automotive

(Item 2, App. B, Sect. III)

A. REMOVAL.

1. Turn quarter-turn fasteners (1, Figure 4-9) to

unlock and open control panel (2).

2. Tag and disconnect electrical wiring from the rear of fault indicator module (3).

3. Remove fault indicator module (3) from control panel (2) by removing four screws (4), washers

(5), and locknuts (6).

B. INSPECTION.

1. Inspect fault indicator module for corrosion and obvious damage. Inspect for broken indicator lights.

2. Inspect electrical wiring for cuts, crimps, bare wire, or other damage. Ensure connectors are securely attached.

3. Remove and replace any component that is damaged to the extent that it will effect the safe operation of the generator set.

C. INSTALLATION.

1. Mate fault indicator module (3, Figure 4-9) to

control panel (2). Secure using four screws (4), washers (5), and locknuts (6).

2. Connect electrical wiring to the rear of fault indicator module (3).

3. Close control panel (2) and lock in place using quarter-turn fasteners (1).

Condition:

Generator set shut down (Para. 2-9)

Battery cables disconnected

Cable disconnected for SLAVE RECEPTACLE

Figure 4-9. Fault Indicator Module

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MARINE CORPS TM 10155A-13/1

4-19. OPERATOR SWITCH MAINTENANCE

This task covers removal, inspection, and installation.

INITIAL SETUP

Tools:

Tool Kit, General Mechanic’s Automotive

(Item 2, App. B, Sect. III)

A. REMOVAL.

1. Turn quarter-turn fasteners (1, Figure 4-10) to

unlock and open control panel (2).

2. Tag and disconnect electrical wiring from the rear of operator switches (3, 6, 9, 12, 15) as required.

3. Remove AUX FUEL switch (3) from control panel (2) by removing attaching nut (4) and lockwasher (5).

4. Remove PREHEAT switch (6) from control panel

(2) by removing attaching nut (7) and lockwasher

(8).

5. Remove START / RUN / STOP switch (9) from control panel (2) by removing attaching nut (10) and lockwasher (11).

6. Remove CIRCUIT INTERRUPTER switch (12) from control panel (2) by removing attaching nut

(13) and lockwasher (14).

Generator set shut down (Para. 2-9)

Battery cables disconnected

Cable disconnected for SLAVE RECEPTACLE

Figure 4-10. Operator Switches

(Sheet 1 of 2)

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4-19. OPERATOR SWITCH MAINTENANCE - cont.

7. Remove BATTLE SHORT switch (15) and switch guard (16) from control panel (2) by removing attaching nut (17) and lockwasher (18).

B. INSPECTION.

1. Inspect switches for obvious damage. Check for corrosion or evidence of electrical short.

2. Inspect electrical wiring for cuts, crimps, bare wire, or other damage. Ensure connectors are securely attached.

3. Remove and replace any component that is damaged to the extent that it will effect the safe operation of the generator set.

C. INSTALLATION.

1. Install AUX FUEL switch (3, Figure 4-10) onto

control panel (2) using attaching nut (4) and lockwasher (5).

2. Install PREHEAT switch (6) onto control panel

(2) using attaching nut (7) and lockwasher (8).

3. Install START / RUN / STOP switch (9) onto control panel (2) using attaching nut (10) and lockwasher (11).

4. Install CIRCUIT INTERRUPTER switch (12) onto control panel (2) using attaching nut (13) and lockwasher (14).

5. Remove BATTLE SHORT switch (15) and switch guard (16) from control panel (2) by removing attaching nut (17) and lockwasher (18).

6. Connect electrical wiring to the rear of switches

(3, 6, 9, 12, 15).

7. Close control panel (2) and lock in place using quarter-turn fasteners (1).

Figure 4-10. Operator Switches

(Sheet 2 of 2)

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MARINE CORPS TM 10155A-13/1

4-20. EMERGENCY STOP SWITCH MAINTENANCE

This task covers removal, inspection, and installation.

INITIAL SETUP

Tools:

Tool Kit, General Mechanic’s Automotive

(Item 2, App. B, Sect. III)

A. REMOVAL.

1. Turn quarter-turn fasteners (1, Figure 4-11) to

unlock and open control panel (2).

2. Tag and disconnect electrical wiring from the rear of EMERGENCY STOP switch (3).

3. Remove yellow locking tab (4) from side of switch (3). Rotate lever (5) on switch to unlock position and remove switch from rear of control panel (2).

NOTE

Observe orientation of push button (6) before removing to aid in assembly.

4. Remove push button (6) from control panel (2) by removing locknut (7) and gasket (8).

B. INSPECTION.

1. Inspect EMERGENCY STOP switch for corrosion and obvious damage. Inspect electrical connectors for damage and evidence of short.

2. Depress switch shaft to check for proper operation. Switch must depress and reset smoothly.

3. Inspect electrical wiring for cuts, crimps, bare wire, or other damage. Ensure connectors are securely attached.

Condition:

Generator set shut down (Para. 2-9)

Battery cables disconnected

Cable disconnected for SLAVE RECEPTACLE

Figure 4-11. EMERGENCY STOP Switch

(Sheet 1 of 2)

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4-20. EMERGENCY STOP SWITCH MAINTENANCE - cont.

4. Remove and replace any component that is damaged to the extent that it will effect the safe operation of the generator set.

C. INSTALLATION.

1. Install push button (6, Figure 4-11) onto control

panel (2) using locknut (7), and gasket (8).

2. Install EMERGENCY STOP switch (3) onto rear of control panel (2). Rotate lever (5) to lock switch in place. Install locking tab (4).

3. Connect electrical wiring to the rear of

EMERGENCY STOP switch (3).

4. Close control panel (2) and lock in place using quarter-turn fasteners (1).

Figure 4-11. EMERGENCY STOP Switch

(Sheet 2 of 2)

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4-21. DC CIRCUIT BREAKER MAINTENANCE

This task covers removal, inspection, and installation.

INITIAL SETUP

Tools:

Tool Kit, General Mechanic’s Automotive

(Item 2, App. B, Sect. III)

A. REMOVAL.

1. Turn quarter-turn fasteners (1, Figure 4-12) to

unlock and open control panel (2).

2. Tag and disconnect electrical wiring from the rear of DC CIRCUIT BREAKER switch (3).

3. Remove DC CIRCUIT BREAKER switch (3) from control panel (2) by removing attaching nut

(4) and lockwasher (5).

B. INSPECTION.

1. Inspect DC CIRCUIT BREAKER switch for corrosion and obvious damage.

2. Inspect electrical wiring for cuts, crimps, bare wire, or other damage. Ensure connectors are securely attached.

3. Remove and replace any component that is damaged to the extent that it will effect the safe operation of the generator set.

C. INSTALLATION.

1.

Mate DC CIRCUIT BREAKER switch (3, Figure

4-12) to rear of control panel (2). Secure using

nut (4) and lockwasher (5).

2. Connect electrical wiring to the rear of DC

CIRCUIT BREAKER switch (3).

3. Close control panel (2) and lock in place using quarter-turn fasteners (1).

Condition:

Generator set shut down (Para. 2-9)

Battery cables disconnected

Cable disconnected for SLAVE RECEPTACLE

Figure 4-12. DC CIRCUIT BREAKER

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MARINE CORPS TM 10155A-13/1

4-22. CIRCUIT INTERRUPTER INDICATOR LIGHT MAINTENANCE

This task covers removal, inspection, and installation.

INITIAL SETUP

Tools:

Tool Kit, General Mechanic’s Automotive

(Item 2, App. B, Sect. III)

Soldering Iron (Item 6, App. B, Sect. III)

Heat Gun (Item 7, App. B, Sect. III)

Parts / Materials:

Solder (Item 12, App. E)

Heat Shrink Tubing (Item 13, App. E)

Condition:

Generator set shut down (Para. 2-9)

Battery cables disconnected

Cable disconnected for SLAVE RECEPTACLE

A. REMOVAL.

1. Turn quarter-turn fasteners (7, Figure 4-13) to

unlock control panel (2).

2. Replace indicator light bulb (3) by removing cap

(4) from CIRCUIT INTERRUPTER indicator light (5). Unscrew bulb (3) from light (5).

3. Peel back heat shrink tubing to expose electrical wires on rear of indicator light (5). Using a soldering iron, detach electrical wires from rear of indicator light.

4. Remove indicator light (5) from control panel (2) by removing attaching nut (6) and lockwasher

(1).

B. INSPECTION.

1. Inspect indicator light for corrosion and obvious damage.

2. Inspect electrical wiring for cuts, crimps, bare wire, or other damage. Ensure connectors are securely attached.

Figure 4-13. CIRCUIT INTERRUPTER

Indicator Light (Sheet 1 of 2)

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4-22. CIRCUIT INTERRUPTER INDICATOR LIGHT MAINTENANCE - cont.

3. Remove and replace any component that is damaged to the extent that it will effect the safe operation of the generator set.

C. INSTALLATION.

1. Install CIRCUIT INTERRUPTER indicator light

(5, Figure 4-13) onto control panel (2) using

attaching nut (6) and lockwasher (1).

CAUTION

Remove bulb (3) from indicator light (5) prior to soldering.

2. Connect electrical wiring to the rear of indicator light (5) and secure using soldering iron. Using a heat gun, adhere heat shrink tubing to wire connectors.

3. Screw indicator light bulb (3) into indicator light

(5). Install cap (4).

4. Close control panel (2) and lock in place using quarter-turn fasteners (7).

Figure 4-13. CIRCUIT INTERRUPTER

Indicator Light (Sheet 2 of 2)

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ARMY TM 9-6115-639-13

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4-23. VOLTAGE ADJUST RHEOSTAT MAINTENANCE

This task covers removal, inspection, and installation.

INITIAL SETUP

Tools:

Tool Kit, General Mechanic’s Automotive

(Item 2, App. B, Sect. III)

Soldering Iron (Item 6, App. B, Sect. III)

Heat Gun (Item 7, App. B, Sect. III)

Parts / Materials:

Solder (Item 12, App. E)

Heat Shrink Tubing (Item 13, App. E)

Generator set shut down (Para. 2-9)

Battery cables disconnected

Cable disconnected for SLAVE RECEPTACLE

A. REMOVAL.

1. Remove knob (4, Figure 4-14) from shaft of

VOLTAGE ADJUST rheostat (3) by loosening setscrews (5).

2. Turn quarter-turn fasteners (1) to unlock and open control panel (2).

3. Remove rheostat (3) from control panel (2) by removing attaching nut (6) and lockwasher (7).

4. Peel back heat shrink tubing to expose electrical wires on rear of rheostat (3). Using a soldering iron, detach electrical wires from rear of rheostat.

B. INSPECTION.

1. Inspect rheostat for corrosion and obvious damage. Rotate rheostat shaft to ensure smooth operation.

2. Inspect electrical wiring for cuts, crimps, bare wire, or other damage. Ensure connectors are securely attached.

Figure 4-14. VOLTAGE ADJUST Rheostat

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4-23. VOLTAGE ADJUST RHEOSTAT MAINTENANCE - cont.

ARMY TM 9-6115-639-13

AIR FORCE TO 35C2-3-386-51

3. Remove and replace any component that is damaged to the extent that it will effect the safe operation of the generator set.

C. INSTALLATION.

1. Connect electrical wiring to the rear of VOLTAGE ADJUST rheostat (3, Figure 4-14) and secure using

soldering iron. Cover connection with heat shrink tubing and secure using heat gun.

2. Mate rheostat (3) to rear of control panel (2) and install using lockwasher (7) and nut (6).

3. Close control panel (2) and lock in place using quarter-turn fasteners (1).

4. Secure knob (4) to shaft of rheostat (3) by tightening setscrews (5).

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MARINE CORPS TM 10155A-13/1

4-24. CONTROL BOX RELAY MAINTENANCE

This task covers removal, inspection, and installation.

INITIAL SETUP

Tools:

Tool Kit, General Mechanic’s Automotive

(Item 2, App. B, Sect. III)

A. REMOVAL.

1. Turn quarter-turn fasteners to unlock and open control panel.

2. Remove holdown springs (4, Figure 4-15) to

release relays (3) from relay sockets (1).

3. Tag and disconnect electrical wiring from fault lockout relay K12, auxiliary fuel transfer relay

K14, and starter cutout relay K15.

NOTE

Note orientation of diode on relay socket

(1) before removing socket. Socket must be oriented the same way when installed in order to function properly.

4. Remove relay sockets (1) from rear wall of control box by removing screws (2).

B. INSPECTION.

1. Inspect relays for corrosion, evidence of electrical short, and obvious damage. Ensure terminal lugs are intact and secure.

2. Inspect electrical wiring for cuts, crimps, bare wire, or other damage. Ensure connectors are securely attached.

3. Remove and replace any component that is damaged to the extent that it will effect the safe operation of the generator set.

Condition:

Generator set shut down (Para. 2-9)

Battery cables disconnected

Cable disconnected for SLAVE RECEPTACLE

Figure 4-15. Control Box Relays

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MARINE CORPS TM 10155A-13/1

4-24. CONTROL BOX RELAY MAINTENANCE - cont.

C. INSTALLATION.

1.

Mate relay sockets (1, Figure 4-15) to rear wall of control box. Secure using screws (2) and nuts (3).

2. Connect electrical wiring to relays K12, K14, and K15.

3. Insert relays (3) into relay sockets (1). Secure using holdown springs (4).

4. Close control panel and lock in place using quarter-turn fasteners.

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4-25. CONTROL BOX FUSE, DIODE, AND TERMINAL BLOCK MAINTENANCE

This task covers removal, inspection, and installation.

INITIAL SETUP

Tools:

Tool Kit, General Mechanic’s Automotive

(Item 2, App. B, Sect. III)

Condition:

Generator set shut down (Para. 2-9)

Battery cables disconnected

Cable disconnected for SLAVE RECEPTACLE

A. REMOVAL.

1. To remove fuse (15, Figure 4-16), turn quarter-turn fasteners to unlock and open control panel. Unscrew

cap (16) from fuse holder (17) and remove fuse.

2. Tag and disconnect electrical wiring from terminal blocks TB5 (1) and TB3 (2).

3. Remove terminal blocks TB5 (1) and TB3 (2) from inside wall of control box by removing screw and captive washer assemblies (5).

4. Remove five diodes (6).

5. To remove terminal blocks TB4 (3) and TB6 (4), unlock main access cover latches and open cover.

6. Remove clear plastic covers (7, 8) from terminal blocks TB4 (3) and TB6 (4) by removing screws (9) and lockwashers (10).

7. Tag and disconnect electrical wiring from terminal blocks TB4 (3), and TB6 (4).

8. Remove terminal blocks TB4 (3) and TB6 (4) from rear of control box by removing standoffs (11) and lockwashers (12). Remove identification plates (13, 14).

9. Remove fuse holder (17) from control box by removing nut (18).

B. INSPECTION.

1. Inspect terminal blocks and diodes for corrosion, evidence of electrical short, and obvious damage. Ensure terminal connectors are intact and secure.

2. Inspect four diodes on terminal block TB5 for obvious damage. Check security of attachment.

3. Inspect electrical wiring for cuts, crimps, bare wire, or other damage. Ensure connectors are secure.

4. Remove and replace any component that is damaged to the extent that it will effect the safe operation of the generator set.

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4-25. CONTROL BOX FUSE, DIODE, AND TERMINAL BLOCK MAINTENANCE - cont.

C. INSTALLATION.

1.

Install fuse holder (17, Figure 4-16) onto control box using nut (18). Install fuse (15) and cap (16).

2. Mate terminal blocks TB4 (3) and TB6 (4), and identification plates (13, 14) to rear of control box. Secure using standoffs (11) and lockwashers (12).

3. Connect electrical wiring to terminal blocks TB4 (3) and TB6 (4). Install clear plastic covers (7, 8) using screws (9) and lockwashers (10).

4. Close main access cover and lock in place using latches.

5. Install diodes (6) onto terminal block TB5 (1).

6. Mate terminal blocks TB5 (1) and TB3 (2) to inside wall of control box. Secure using screw and captive washer assemblies (5).

7. Connect electrical wiring to terminal blocks TB5 (1) and TB3 (2).

8. Close control panel and lock in place using quarter-turn fasteners.

Figure 4-16. Terminal Blocks, Fuse, and Diodes

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4-26. GOVERNOR CONTROL MAINTENANCE

This task covers removal, inspection, and installation.

INITIAL SETUP

Tools:

Tool Kit, General Mechanic’s Automotive

(Item 2, App. B, Sect. III)

A. REMOVAL.

1. Turn quarter-turn fasteners to unlock and open control panel.

2. Tag and disconnect electrical wiring from

governor control (1, Figure 4-17).

3. Remove governor control (1) from inside wall of control box by removing screw and captive washer assemblies (2).

B. INSPECTION.

1. Inspect governor control for corrosion, evidence of electrical short, and obvious damage.

2. Inspect electrical wiring for cuts, crimps, bare wire, or other damage. Ensure connectors are securely attached.

3. Remove and replace any component that is damaged to the extent that it will effect the safe operation of the generator set.

C. INSTALLATION.

1. Mate governor control (1, Figure 4-17) to inside

wall of control box. Secure using screws and captive washer assemblies (2).

2. Connect electrical wiring to governor control (1).

3. Close control panel and lock in place using quarter-turn fasteners.

Condition:

Generator set shut down (Para. 2-9)

Battery cables disconnected

Cable disconnected for SLAVE RECEPTACLE

Figure 4-17. Governor Control

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4-27. CONTROL BOX WIRING HARNESS MAINTENANCE

This task covers removal, inspection, and installation.

INITIAL SETUP

Tools:

Tool Kit, General Mechanic’s Automotive

(Item 2, App. B, Sect. III)

Condition:

Generator set shut down (Para. 2-9)

Battery cables disconnected

Cable disconnected for SLAVE RECEPTACLE

A. REMOVAL.

1. Unlock main access cover latches and lift cover to open.

2. Disconnect generator set wiring harness plug P7 from control box harness connector J7 (1, Figure 4-18),

located on rear of control box assembly.

3. Unlock and open control panel (2) by turning quarter-turn fasteners (3).

4.

Tag and disconnect control box harness wires from control box components. Refer to Figures FO-3, 60Hz

Control Box Wiring Harness, and FO-4, 400 Hz Control Box Wiring Harness, for information.

5. Release harness connector J7 (1) from inside wall of control box by removing four screws with captive washers (5).

6. Remove clamp (6) by removing screw and captive washer assembly (7) and washer (8). Screw (7) secures panel cable to control box wall.

7. Remove clamp (9) from rear of control panel (2) by removing nut (10) and lockwasher (11). Remove control box wiring harness (4) from control box.

B. INSPECTION.

1. Inspect harness connector J7 (1) for corrosion, evidence of electrical short, and obvious damage. Check for bent, broken, or missing pins.

2. Inspect electrical wiring for cuts, crimps, bare wire, or other damage. Ensure connectors and terminal lugs are securely attached.

3.

Conduct continuity check on suspect wires using a multimeter. Refer to Figures FO-3 and FO-4 for wiring

diagrams and wire run lists.

4. Remove and replace any component that is damaged to the extent that it will effect the safe operation of the generator set.

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4-27. CONTROL BOX WIRING HARNESS MAINTENANCE - cont.

C. INSTALLATION.

1. Mate control box harness connector J7 (1, Figure 4-18) to inside wall of control box. Secure using four

screws with captive washers (5).

2.

Connect control box harness wires to control box components. Refer to Figures FO-3, 60Hz Control Box

Wiring Harness, and FO-4, 400 Hz Control Box Wiring Harness, for information.

3. Install clamp (6) using screw and captive washer assembly (7) and washer (8). Install clamp (0) using nut

(10) and lockwasher (11).

4. Close control panel (2) and lock in place using quarter-turn fasteners (3).

5. Connect generator set wiring harness plug P7 to control box harness connector J7 (1).

6. Close main access cover and lock in place using latches.

Figure 4-18. Control Box Wiring Harness

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4-28. AC CIRCUIT INTERRUPTER CONTACTOR MAINTENANCE

This task covers removal, inspection, and installation.

INITIAL SETUP

Tools:

Tool Kit, General Mechanic’s Automotive

(Item 2, App. B, Sect. III)

Condition:

Generator set shut down (Para. 2-9)

Battery cables disconnected

Cable disconnected for SLAVE RECEPTACLE

A. REMOVAL

NOTE

There are two different contactor (4, Figure 4-19) configurations for the 3kW

generator sets. Where noted, follow the procedures below for the configuration

shown in Figure 4-19 which matches the generator set on which you are

performing maintenance. If you are replacing the contactor, the Configuration B contactor must be installed.

1. Unlock main access cover latches and lift cover to open.

A: Remove protective plate (1, Figure 4-19) from bracket (9) by removing screws (2) and

lockwashers (3).

Configuration B: Remove protective plate (1, Figure 4-19) by removing screws (2) and lockwashers (3).

3. Tag and disconnect electrical wiring from AC circuit interrupter contactor K1 (4).

4. Configuration and captive washer assemblies (5) and washers (6).

Configuration washer assemblies (5) and washers (6).

5. Configuration assemblies (7).

A: Remove microswitch (8) from contactor K1 (4) by removing screw and captive washer

B. INSPECTION.

1. Inspect contactor for corrosion, evidence of electrical short, and obvious damage.

2. Inspect electrical wiring for cuts, crimps, bare wire, or other damage. Ensure connectors are securely attached.

3. Remove and replace any component that is damaged to the extent that it will effect the safe operation of the generator set.

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C. INSTALLATION.

screw and captive washer assemblies (7). captive washer assemblies (5) and washers (6). assemblies (5) and washers (6).

3. Connect electrical wiring to contactor K1 (4).

A: Install protective plate (1) onto bracket (9) using screws (2) and lockwashers (3).

Configuration B: Install protective plate (1) onto contactor K1 (4) using screws (2) and lockwashers (3)

5. Close main access cover and lock in place using latches.

Figure 4-19. AC Circuit Interrupter Contactor

Change 1

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4-29. BATTERY CHARGING REGULATOR MAINTENANCE

This task covers removal, inspection, and installation.

INITIAL SETUP

Tools:

Tool Kit, General Mechanic’s Automotive

(Item 2, App. B, Sect. III)

Generator set shut down (Para. 2-9)

Battery cables disconnected

Cable disconnected for SLAVE RECEPTACLE

A. REMOVAL.

1. Turn quarter-turn fasteners to unlock and open control panel.

2. Unlock main access cover latches and lift cover to open.

3. Disconnect electrical plug from battery charging

regulator (1, Figure 4-20).

4. Remove battery charging regulator (1) from top of control box by removing screws (2), washers

(3), and locknuts (4).

B. INSPECTION.

1. Inspect battery charging regulator for corrosion, evidence of electrical short, and obvious damage.

2. Inspect electrical wiring for cuts, crimps, bare wire, or other damage. Ensure terminal lugs are securely attached.

3. Remove and replace any component that is damaged to the extent that it will effect the safe operation of the generator set.

Figure 4-20. Battery Charging Regulator

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4-29. BATTERY CHARGING REGULATOR MAINTENANCE - cont.

C. INSTALLATION.

1. Mate battery charging regulator (1, Figure 4-20) to top of control box. Secure using screws (2), washers

(3), and locknuts (4).

2. Connect electrical plug to battery charging regulator (1).

3. Close main access cover and lock in place using latches.

4. Close control panel and lock in place using quarter-turn fasteners.

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4-30. CONVENIENCE RECEPTACLE MAINTENANCE (60 HZ, MEP 831A ONLY)

This task covers removal, inspection, and installation.

INITIAL SETUP

Tools:

Tool Kit, General Mechanic’s Automotive

(Item 2, App. B, Sect. III)

Generator set shut down (Para. 2-9)

Battery cables disconnected

Cable disconnected for SLAVE RECEPTACLE

A. REMOVAL.

1. Unlock main access cover latches and lift cover to open.

2. Remove screw (1, Figure 4-21) to disconnect

receptacle cover (2) from convenience receptacle

(3). Remove cover and rubber gasket (6) by removing four screw and captive washer assemblies (4).

CAUTION

Ensure wire leads on receptacle terminals are not damaged when pulling on receptacle.

3. Remove convenience receptacle (3) from control box by removing two screws (5).

4. Tag and disconnect electrical wiring from the rear of convenience receptacle (3).

B. INSPECTION.

1. Inspect convenience receptacle for corrosion, evidence of electrical short, and obvious damage.

Check terminal connectors for damage.

Figure 4-21. Convenience Receptacle

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4-30. CONVENIENCE RECEPTACLE MAINTENANCE (60 HZ, MEP 831A ONLY) - cont.

2. Inspect electrical wiring for cuts, crimps, bare wire, or other damage. Ensure connectors are securely attached.

3. Remove and replace any component that is damaged to the extent that it will effect the safe operation of the generator set.

C. INSTALLATION.

1.

Connect electrical wiring to convenience receptacle (3, Figure 4-21).

2. Mate convenience receptacle (3) to control box and secure using two screws (5)

3. Mate cover (2) and rubber gasket (6) to control box and secure using four screw and captive washer assemblies (4). Install screw (1).

4. Close main access cover and lock in place using latches.

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4-31. GROUND FAULT CIRCUIT INTERRUPTER MAINTENANCE (60 HZ, MEP 831A ONLY)

This task covers removal, inspection, and installation.

INITIAL SETUP

Tools:

Tool Kit, General Mechanic’s Automotive

(Item 2, App. B, Sect. III)

Convenience receptacle removed (Para. 4-30)

Cover removed from TB4 (Para. 4-25)

A. REMOVAL.

1. Unlock main access cover latches and lift cover to open.

2. Tag and disconnect ground fault circuit

interrupter (1, Figure 4-22) wiring from terminal

block TB4.

3. Remove ground fault circuit interrupter (1) from control box by removing screws (2), washers (3), and nuts (4).

B. INSPECTION.

1. Inspect ground fault circuit interrupter for corrosion, evidence of electrical short, and obvious damage. Depress RESET and TEST buttons to ensure smooth operation.

2. Inspect electrical wiring for cuts, crimps, bare wire, or other damage. Ensure connectors are securely attached.

3. Remove and replace any component that is damaged to the extent that it will effect the safe operation of the generator set.

Figure 4-22. Ground Fault

Circuit Interrupter

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4-31. GROUND FAULT CIRCUIT INTERRUPTER MAINTENANCE (60 HZ, MEP 831A ONLY)

- cont.

C. INSTALLATION.

1. Mate ground fault circuit interrupter (1, Figure 4-22) to back of control box. Secure using screws (2),

washers (3), and nuts (4).

2. Connect ground fault circuit interrupter (1) electrical wiring to terminal board TB4. Install cover onto TB4

(Para. 4-25).

3.

Install battery and tray (Para. 4-45). Install convenience receptacle (Para. 4-30).

4. Close main access cover and lock in place using latches.

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4-32. SLAVE RECEPTACLE MAINTENANCE

This task covers removal, inspection, and installation.

INITIAL SETUP

Tools:

Tool Kit, General Mechanic’s Automotive

(Item 2, App. B, Sect. III)

A. REMOVAL.

1. Unlock main access cover latches and lift cover to open.

2. Tag and disconnect electrical wiring from the rear

of SLAVE RECEPTACLE (1, Figure 4-23).

4. Remove SLAVE RECEPTACLE (1) and attached cap from generator set skid base by removing screws (2), washers (3), and nuts (4).

B. INSPECTION.

1. Inspect receptacle for corrosion, evidence of electrical short, and obvious damage. Check terminal connectors for damage.

2. Inspect electrical wiring for cuts, crimps, bare wire, or other damage. Ensure terminal lugs are securely attached.

3. Remove and replace any component that is damaged to the extent that it will effect the safe operation of the generator set.

Battery removed (Para. 4-44)

Figure 4-23. SLAVE RECEPTACLE

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4-32. SLAVE RECEPTACLE MAINTENANCE - cont.

C. INSTALLATION.

1. Mate SLAVE RECEPTACLE (1, Figure 4-23) and attached cap to skid base. Secure using screws (2),

washers (3), and nuts (4).

2. Connect electrical wiring to rear of SLAVE RECEPTACLE (1).

3.

Install battery (Para. 4-44).

4. Close main access cover and lock in place using latches.

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4-33. OUTPUT TERMINALS AND EMI FILTER MAINTENANCE

This task covers removal, inspection, and installation.

INITIAL SETUP

Tools:

Tool Kit, General Mechanic’s Automotive

(Item 2, App. B, Sect. III)

Condition:

Generator set shut down (Para. 2-9)

Battery cables disconnected

Cable disconnected for SLAVE RECEPTACLE

A. REMOVAL.

1. Unlock generator set enclosure cover latches and lift cover to open.

2. Turn lock (2, Figure 4-24) and open output panel

cover (1).

3. Disconnect load and ground wires from load terminals using load wrench (3).

4. Release load wrench (3) lanyard from output box by removing screw (4), washer (5), and locknut

(6). Remove lanyard from wrench only if replacement is required.

5. Tag and disconnect EMI filter (9) electrical connectors. Remove EMI filter from load and ground terminals (10, 11) by removing four nuts

(7) and washers (8).

6. Remove load board (15) from generator set skid base by removing four screws (16), washers (17), and locknuts (18).

7. Remove load terminals (10) by removing nuts

(12) and washers (13). Remove ground terminal

(11) by removing nut (14) and washers (13).

Figure 4-24. Output Terminals / Filter

(Sheet 1 of 4)

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4-33. OUTPUT TERMINALS AND EMI FILTER MAINTENANCE - cont.

Figure 4-24. Output Terminals / Filter

(Sheet 2 of 4)

B. INSPECTION.

1. Inspect load and ground terminals for corrosion, evidence of electrical short, and obvious damage. Check for crossed, stripped, or flattened threads.

2. Inspect EMI filter for obvious damage. Inspect electrical wiring for cuts, abrasions, or bare wire. Ensure connectors are securely fastened.

3. Inspect output panel cover for dents, cracks, or other damage. Check security of attachment. Ensure cover lock operates smoothly, free of binding.

4. Remove and replace any component that is damaged to the extent that it will effect the safe operation of the generator set.

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4-33. OUTPUT TERMINALS AND EMI FILTER MAINTENANCE - cont.

Figure 4-24. Output Terminals / Filter

(Sheet 3 of 4)

C. INSTALLATION.

1. Install load terminals (10, Figure 4-24) using nuts (12) and washers (13). Install ground terminal (11,

lower right hand hole) using nut (14) and washers (13).

2. Mate load board (15) to generator set skid base. Secure using four screws (16), washers (17), and locknuts

(18).

3. Install EMI filter (9) onto load and ground terminals (10, 11). Secure using four nuts (7) and washers (8).

Connect EMI filter connectors.

4. Connect electrical cables to load and ground terminals (10, 11) using load wrench. Neutral terminal is upper right. Ground terminal is lower right.

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4-33. OUTPUT TERMINALS AND EMI FILTER MAINTENANCE - cont.

5. Attach load wrench (3, Figure 4-23) lanyard to

output box using screw (4), washer (5), and nut

(6).

6. Close output panel cover (1) and engage lock (2).

7. Close main access cover and lock in place using latches.

Figure 4-24. Output Terminals / Filter

(Sheet 4 of 4)

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4-34. VOLTAGE RESISTOR MAINTENANCE

This task covers removal, inspection, and installation.

INITIAL SETUP

Tools:

Tool Kit, General Mechanic’s Automotive

(Item 2, App. B, Sect. III)

A. REMOVAL.

1. Unlock main access cover latches and lift cover to open.

2. Turn lock (2, Figure 4-25) and open output panel

cover (1).

3. Disconnect electrical wiring from the rear of three voltage resistors (3).

4. Remove three voltage resistors (3) from the back of the output box by removing screws (4), washers (5), and locknuts (6).

B. INSPECTION.

1. Inspect resistors for corrosion, evidence of electrical short, and obvious damage.

2. Inspect electrical wiring for cuts, crimps, bare wire, or other damage. Ensure terminal lugs are securely attached.

3. Remove and replace any component that is damaged to the extent that it will effect the safe operation of the generator set.

Condition:

Generator set shut down (Para. 2-9)

Battery cables disconnected

Cable disconnected for SLAVE RECEPTACLE

Figure 4-25. Voltage Resistors

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4-34. VOLTAGE RESISTOR MAINTENANCE - cont.

C. INSTALLATION.

1.

Mate three voltage resistors (3, Figure 4-25) to back of output box. Secure using screws (4), washers (5),

and locknuts (6).

2. Connect electrical wiring to voltage resistors (3).

3. Close output panel cover (1) and engage lock (2).

4. Close main access cover and lock in place using latches.

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4-35. LIFTING HANDLE MAINTENANCE

This task covers removal, inspection, and installation.

INITIAL SETUP

Tools:

Tool Kit, General Mechanic’s Automotive

(Item 2, App. B, Sect. III)

A. REMOVAL.

1. Remove lifting handle (1, Figure 4-26) from

generator set skid base by removing screw (2), washers (3, 4), and locknut (5).

2. Unlock main access cover latches and lift cover to open.

3. Remove lifting handle (6) from skid base by removing two screws (7), washers (8), locknuts

(9), and three screws (10), washers (11), and locknuts (12).

B. INSPECTION.

Inspect lifting handles for corrosion and obvious damage. Inspect lifting handle bracket for cracks or deformation. Replace handle if damaged.

C. INSTALLATION.

1. Install lifting handle (6, Figure 4-26) onto skid

base using two screws (7), washers (8), locknuts

(9), and three screws (10), washers (11), and locknuts (12).

2. Install lifting handle (1) onto skid base using screw (2), washers (3, 4), and locknut (5).

3. Close main access cover and lock in place using latches.

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Figure 4-26. Lifting Handles

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4-36. ENGINE OIL DRAIN ASSEMBLY MAINTENANCE

This task covers removal, inspection, and installation.

INITIAL SETUP

Tools:

Tool Kit, General Mechanic’s Automotive

(Item 2, App. B, Sect. III)

Generator set shut down (Para. 2-9)

Battery cables disconnected

Cable disconnected for SLAVE RECEPTACLE

A. REMOVAL.

1.

Confirm that drain valve (4, Figure 4-27) is closed (valve handle perpendicular to valve).

2. Disconnect hose (1) from drain valve (4) and adapter (5) loosening hose clamps (3). Remove adapter (5) from elbow (2).

NOTE

Nut on outside of skid base, adjacent to plug, is welded in place and not removable.

3. Unscrew plug (8) from elbow (2). Release chain (9) from skid base by removing screw (10), washers (11), and locknut (12). Remove chain (9) from plug only if replacement is required.

4. Remove elbow (2) from skid base by removing nut (6) and star washer (7).

5. If removal of drain valve (4) is required, engine must be removed from generator set. Refer to Direct

Support maintenance level.

B. INSPECTION.

1. Inspect oil drain hose for cuts, cracks, deterioration, or other damage. Inspect for evidence of leakage.

2. Inspect drain valve for clogging or obstruction. Ensure valve handle operates smoothly and that valve shuts completely.

3. Inspect elbow, fitting, and plug for damage. Inspect for crossed, stripped, or damaged threads.

4. Remove and replace any component that is damaged to the extent that it will effect the safe operation of the generator set.

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4-36. ENGINE OIL DRAIN ASSEMBLY MAINTENANCE - cont.

C. INSTALLATION.

1.

Install elbow (2, Figure 4-27) into skid base and secure using nut (6) and star washer (7). Install plug (8)

and secure chain (9) to skid base using screw (10), washers (11), and locknut (12).

2. Install adapter (5) onto elbow (2).

3. Connect hose (1) to drain valve (4) and adapter (5) and tighten hose clamps (3).

4. Close drain valve (4) by turning handle perpendicular to valve.

5.

Service engine oil (Para. 4-1).

Figure 4-27. Engine Oil Drain Assembly

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4-37. ENGINE TEMPERATURE SWITCH MAINTENANCE

This task covers removal, inspection, and installation.

INITIAL SETUP

Tools:

Tool Kit, General Mechanic’s Automotive

(Item 2, App. B, Sect. III)

Parts / Materials:

Teflon Tape (Item 19 App. E)

Generator set shut down (Para. 2-9)

Battery cables disconnected

Cable disconnected for SLAVE RECEPTACLE

Engine oil drained (Para. 4-1)

A. REMOVAL.

1. Disconnect electrical plug (1, Figure 4-28) from

engine temperature switch (2).

2. Using a 1-inch open end wrench, remove engine temperature switch (2) from engine crankcase.

B. INSPECTION.

1. Inspect engine temperature switch for corrosion, evidence of electrical short, and obvious damage.

2. Inspect electrical wiring for cuts, crimps, bare wire, or other damage. Ensure plug is securely attached.

3. Remove and replace any component that is damaged to the extent that it will effect the safe operation of the generator set.

Figure 4-28. Engine Temperature Switch

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4-37. ENGINE TEMPERATURE SWITCH MAINTENANCE - cont.

C. INSTALLATION.

CAUTION

Temperature switch (2) is fragile. Do not overtighten. Apply light pressure while tightening to prevent switch from breaking off in engine.

1. Apply teflon tape to the threads of engine temperature switch (2, Figure 4-28). Install switch into engine

crankcase.

2. Connect electrical plug (1) to engine temperature switch (2).

3.

Service engine oil (Para. 4-1).

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4-38. LUBRICATION OIL PRESSURE SWITCH MAINTENANCE

This task covers removal, inspection, and installation.

INITIAL SETUP

Tools:

Tool Kit, General Mechanic’s Automotive

(Item 2, App. B, Sect. III)

Parts / Materials:

Teflon Tape (Item 19 App. E)

Generator set shut down (Para. 2-9)

Battery cables disconnected

Cable disconnected for SLAVE RECEPTACLE

A. REMOVAL.

1. It is not necessary to drain oil if a suitable plug is used to plug port when lubrication oil pressure

switch (2, Figure 4-29) is removed. If required,

drain oil (Para. 4-1).

2. Tag and disconnect electrical wires (1) from pressure switch (2).

3. Remove lubrication oil pressure switch (2) from engine crankcase.

B. INSPECTION.

1. Inspect pressure switch for corrosion, evidence of electrical short, and obvious damage.

2. Inspect electrical wiring for cuts, crimps, bare wire, or other damage.

3. Remove and replace any component that is damaged to the extent that it will effect the safe operation of the generator set.

Figure 4-29. Lubrication Oil Pressure Switch

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4-38. LUBRICATION OIL PRESSURE SWITCH MAINTENANCE - cont.

C. INSTALLATION.

CAUTION

Pressure switch (2) is fragile. Do not overtighten. Apply light pressure while tightening to prevent switch from breaking off in engine.

1. Apply teflon tape to the threads of lubrication oil pressure switch (2, Figure 4-29). Install switch into

engine crankcase.

2. Connect electrical wires (1) to pressure switch (2).

3.

Service engine oil (Para. 4-1) as required.

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4-39. FUEL LEVEL SWITCH ASSEMBLY MAINTENANCE

This task covers removal, inspection, and installation.

INITIAL SETUP

Tools:

Tool Kit, General Mechanic’s Automotive

(Item 2, App. B, Sect. III)

Shop Equipment, Automotive Maintenance

And Repair, Field Basic, Less Power

(Item 4, App. B, Sect. III)

A. REMOVAL.

1. Unlock main access cover latches and lift cover to open.

NOTE

Note position of level switch (4) and gasket

(7) prior to removing from fuel tank (6).

2. Disconnect level switch electrical plugs (5 and 9,

Figure 4-30).

3. Remove five screws (1), lockwashers (2), and washers (3) from level switch (4). Remove switch (4) and gasket (7) from fuel tank (6).

B. INSPECTION.

1. Inspect fuel level switch for corrosion and obvious damage.

2. Inspect electrical wiring for cuts, crimps, bare wire, or other damage. Ensure electrical connector plugs are securely attached.

3. Remove and replace any component that is damaged to the extent that it will effect the safe operation of the generator set.

Generator set shut down (Para. 2-9)

Battery cables disconnected

Cable disconnected for SLAVE RECEPTACLE

Figure 4-30. Fuel Level Switch

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4-39. FUEL LEVEL SWITCH ASSEMBLY MAINTENANCE - cont.

C. INSTALLATION.

NOTE

If new switch (4, Figure 4-30) has electrical connector plugs (5, 9), omit step 1 below.

1. Proceed as follows if electrical connector plugs (5 and 9) need to be installed on switch (4), otherwise skip to step 2: a. Strip 1/8 inch insulation from five switch (4) wires and crimp male contacts (8) onto ends of wires. b. Insert blue wire into position 1, black wire into position 2, and yellow wire into position 3 of three-circuit connector plug (5). c. Insert red wires into positions 1 and 2 of two-circuit electrical connector plug (9).

2. Align mounting holes on level switch (4) with holes in gasket (7) prior to mounting into fuel tank (6).

3. Install level switch (4) and gasket (7) into fuel tank (6). Secure using five screws (1), lockwashers (2), and washers (3).

4. Connect level switch electrical connector plugs (5 and 9).

5. Close main access cover and lock in place.

Change 1

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4-40. FUEL SENDER MAINTENANCE

This task covers removal, inspection, and installation.

INITIAL SETUP

Tools:

Tool Kit, General Mechanic’s Automotive

(Item 2, App. B, Sect. III)

A. REMOVAL.

1. Unlock main access cover latches and lift cover to open.

NOTE

Note position of fuel sender (2) and gasket

(10) prior to removing from fuel tank (5).

2. Tag and disconnect electrical wire (1, Figure 4-

31) from fuel sender (2) by removing captive nut

and washer (3) from stud (4) on sender.

3. Remove fuel sender (2) and gasket (10) from fuel tank (5) by removing five screws (6), lockwashers (7), and washers (8). Remove remaining wires (9).

B. INSPECTION.

1. Inspect sender for corrosion and obvious damage.

2. Inspect electrical wiring for cuts, crimps, bare wire, or other damage.

3. Remove and replace any component that is damaged to the extent that it will effect the safe operation of the generator set.

Generator set shut down (Para. 2-9)

Battery cables disconnected

Cable disconnected for SLAVE RECEPTACLE

Figure 4-31. Fuel Sender

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4-40. FUEL SENDER MAINTENANCE - cont.

C. INSTALLATION.

1. Align mounting holes on fuel sender (2, Figure 4-31) with holes in gasket (10) prior to mounting into fuel

tank (5).

2. Install fuel sender (2) and gasket (10) onto fuel tank (5). Secure sender and wire (9) using five screws (6), lockwashers (7), and washers (8).

3. Connect electrical wire (1) to stud (4) on sender using nut and captive washer (3).

4. Close main access cover and lock in place.

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4-41. FUEL TANK PICKUP TUBE MAINTENANCE

This task covers removal, inspection, and installation.

INITIAL SETUP

Tools:

Tool Kit, General Mechanic’s Automotive

(Item 2, App. B, Sect. III)

Condition:

Generator set shut down (Para. 2-9)

Battery cables disconnected

Cable disconnected for SLAVE RECEPTACLE

A. REMOVAL.

1. Unlock main access cover latches and lift cover to open.

2.

Disconnect hose (1, Figure 4-32) from elbow (2).

3. Remove fuel tank pickup tube (3) and gasket (8) from fuel tank (4) by removing three screws (5), lockwashers (6), and washers (7).

B. INSPECTION.

1. Inspect pickup tube for corrosion and obvious damage.

2. Inspect fuel hose for cuts, cracks, deterioration, or other damage. Check for evidence of leakage.

Inspect for crossed, stripped, or damaged threads.

3. Remove and replace any component that is damaged to the extent that it will effect the safe operation of the generator set.

C. INSTALLATION.

1. Install fuel tank pickup tube (3, Figure 4-32) and

gasket (8) onto fuel tank (4). Secure using three screws (5), lockwashers (6), and washers (7).

2. Connect hose (1) to elbow (2).

Figure 4-32. Fuel Tank Pickup Tube

3. Close main access cover and lock in place.

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4-42. PRIMARY FUEL PUMP MAINTENANCE

This task covers removal, inspection, and installation.

INITIAL SETUP

Tools:

Tool Kit, General Mechanic’s Automotive

(Item 2, App. B, Sect. III)

Parts / Materials:

Teflon Tape (Item 19, App. E)

A. REMOVAL.

1. Unlock main access cover latches and lift cover to open.

2.

Disconnect fuel pump electrical plug (7, Figure 4-

33).

3. Disconnect fuel hose (1) from fuel filter (2) by loosening clamp (3). Remove filter from fuel pump (11).

4. Disconnect fuel hose (4) from fitting (6) by loosening clamp (5). Remove fitting (6) from fuel pump (11).

5. Remove fuel pump (11) from enclosure wall by removing two screws (8), lockwashers (9), and washers (10).

B. INSPECTION.

1. Inspect fuel pump for cracks, corrosion, evidence of leakage, and obvious damage.

Generator set shut down (Para. 2-9)

Battery cables disconnected

Cable disconnected for SLAVE RECEPTACLE

Figure 4-33. Primary Fuel Pump

(Sheet 1 of 2)

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4-42. PRIMARY FUEL PUMP MAINTENANCE - cont.

2. Inspect electrical wiring for cuts, crimps, bare wire, or other damage. Ensure terminal lugs are securely attached.

3. Remove and replace any component that is damaged to the extent that it will effect the safe operation of the generator set.

C. INSTALLATION.

1. Apply teflon tape to the threads of fuel filter (2,

Figure 4-33) and fitting (6). Install filter and

fitting onto fuel pump (11).

2. Mate fuel pump (11) to wall of enclosure. Secure using two screws (8), lockwashers (9), and washers (10).

3. Connect fuel hoses (1) to fuel filter (2) and fitting

(6). Tighten clamps (3).

4. Connect fuel pump electrical plug (7).

5. Close main access cover and lock in place using latches.

(Sheet 2 of 2)

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4-43. MUFFLER ASSEMBLY MAINTENANCE

This task covers removal, inspection, and installation.

INITIAL SETUP

Tools:

Tool Kit, General Mechanic’s Automotive

(Item 2, App. B, Sect. III)

Generator set shut down (Para. 2-9) and cool

Battery cables disconnected

Cable disconnected for SLAVE RECEPTACLE

A. REMOVAL.

1. Unlock main access cover latches and lift cover to open.

2.

Remove access plate (1, Figure 4-34) from left side panel (2) by removing six screws (3), lockwashers (4),

and washers (5).

3. Remove deflector panel (6) from left side panel (2) by removing four screws (7), lockwashers (8), and washers (9).

4. Remove mounting plate (10) from left side panel (2) by removing four screws (11), lockwashers (12), and washers (13).

5. Remove thermal wrap (14) from muffler (27) by removing lockwire. Remove two nuts (15) from cylinder head studs (16).

6. Remove four screws (17), lockwashers (18), and washers (19). Remove bellows (20) and gasket (21) from flange (22).

7. Remove two screws (23), lockwashers (24), washers (25), muffler (27), and gasket (26) from engine block.

8. Remove flange (22) from muffler (27) by removing three screws (28), lockwashers (29), and nuts (30).

9. Remove thermal wrap (31) and thermal blanket (32) from muffler (27) by removing lockwire.

10. Remove bellows (20), flange (33), and gasket (37) from duct (38) by removing screws (34), lockwashers

(35), and washers (36).

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4-43. MUFFLER ASSEMBLY MAINTENANCE - cont.

Figure 4-34. Muffler Assembly

(Sheet 1 of 2)

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4-43. MUFFLER ASSEMBLY MAINTENANCE - cont.

B. INSPECTION.

1. Inspect muffler, bellows, and flanges for cracks, dents, corrosion, and obvious damage. Check for holes or evidence of deterioration.

2. Remove and replace any component that is damaged to the extent that it will effect the safe operation of the generator set

C. INSTALLATION.

1. Install bellows (20, Figure 4-34), flange (33), and gasket (37) onto duct (38) using screws (34),

lockwashers (35), and washers (36).

2. Install flange (22) onto muffler (27) using three screws (28), lockwashers (29), and nuts (30).

3. Mate muffler (27)and gasket (26) to engine block and secure using two screws (23), lockwashers (24), and washers (25).

4. Install thermal wrap (31) and thermal blanket (32) onto muffler (27). Secure using lockwire.

5. Install bellows (20) and gasket (21) onto flange (22). Install four screws (17), lockwashers (18), and washers (19).

6. Install two nuts (15) onto cylinder head studs (16). Torque nuts to 14 to 16 ft-lbs. Install thermal wrap

(14) and secure using lockwire.

7. Install mounting plate (10) onto left side panel (2) using four screws (11), lockwashers (12), and washers

(13).

8. Install deflector panel (6) onto left side panel (2) using four screws (7), lockwashers (8), and washers (9).

9. Install access plate (1) onto left side panel (2) using six screws (3), lockwashers (4), and washers (5).

10. Close main access cover and lock in place using latches.

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4-43. MUFFLER ASSEMBLY MAINTENANCE - cont.

Figure 4-34. Muffler Assembly

(Sheet 2 of 2)

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4-44. BATTERY MAINTENANCE

This task covers removal, inspection, installation, and servicing (as applicable).

INITIAL SETUP

Tools:

Tool Kit, General Mechanic’s Automotive

(Item 2, App. B, Sect. III)

Tester, Battery Electrolyte (Item 7, App. B, Sect. III)

Condition:

Generator set shut down (Para. 2-9)

Cable disconnected for SLAVE RECEPTACLE

Parts / Materials:

Distilled Water (Item 20, App. E)

A. REMOVAL.

1. Unlock main access cover latches and lift cover to open.

WARNING

Batteries give off flammable gas. Do not smoke or use open flame when performing maintenance. Flames and explosion could result in severe personal injury or death. Do not allow battery acid to contact skin or clothing. Contact of skin with battery acid liquid or inhalation of battery acid mist can cause severe burns, respiratory tract infection, and chronic bronchitis. If any battery acid liquid or mist contacts skin or eyes, immediately flush affected areas thoroughly with water. If vapors are inhaled, go to fresh air. Seek medical help immediately.

WARNING

When disconnecting battery cables, always remove negative cable first and positive cable last. Connect cable ends to enclosure ground lugs to prevent contact. Failure to observe this warning can result in personal injury.

2. Disconnect negative battery cable (1) from negative (-) battery post (2). Connect cable end to enclosure ground lug

3.

Disconnect positive battery cable (1, Figure 4-35) from positive (+) battery post (2). Connect cable end to

enclosure ground lug.

4. Remove battery tie-down (3) from hold down rods (4) by removing six nuts (5) and three washers (6).

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4-44. BATTERY MAINTENANCE - cont.

5. Carefully remove battery (7) from battery tray

(8). Remove battery tray.

B. INSPECTION.

1. Inspect battery cables for corrosion, evidence of electrical short, and obvious damage. Check for

cuts, tears, or exposed wires. Refer to Para. 4-45

for detailed inspection, cleaning, and repair or battery cables.

2. Inspect battery for cracks, corrosion, or evidence of leakage. Inspect battery posts for corrosion.

Remove corrosion from cable terminals and battery posts using a wire terminal brush.

3. Remove and replace any component that is damaged to the extent that it will effect the safe operation of the generator set.

C. INSTALLATION.

1.

Install battery tray (8, Figure 4-35) and battery (7).

2. Install battery tie-down (3) and secure to hold down rods (4) using six nuts (5) and three washers (6).

WARNING

When connecting battery cables, always connect positive cable first and negative cable last. Failure to observe this warning can result in personal injury.

3. Connect positive battery cable (1) to positive (+) battery post (2).

4. Connect negative battery cable (1) to negative (-) battery post (2).

5. Close main access cover and lock in place using latches.

ARMY TM 9-6115-639-13

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Figure 4-35. Battery

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4-44. BATTERY MAINTENANCE - cont.

D. SERVICING.

The generator set is designed to accept and operate with either a standard wet cell battery or a sealed maintenance free battery. If a standard wet cell battery is used, check the electrolyte level and service as follows:

1. Remove caps from battery.

2. Check electrolyte level of cells. Ensure proper charge using electrolyte solution tester. Specific gravity reading shall be between 1.2767 and 1.2853.

3. Service cells as required using distilled water.

4. Install caps on battery and return generator set to service.

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4-45. BATTERY CABLE ASSEMBLY MAINTENANCE

This task covers removal, inspection, and installation.

INITIAL SETUP

Tools:

Tool Kit, General Mechanic’s Automotive

(Item 2, App. B, Sect. III)

Condition:

Generator set shut down (Para. 2-9)

Cable disconnected for SLAVE RECEPTACLE

A. REMOVAL.

1. Unlock main access cover latches and lift cover to open.

WARNING

Batteries give off flammable gas. Do not smoke or use open flame when performing maintenance. Flames and explosion could result in severe personal injury or death. Do not allow battery acid to contact skin or clothing. Contact of skin with battery acid liquid or inhalation of battery acid mist can cause severe burns, respiratory tract infection, and chronic bronchitis. If any battery acid liquid or mist contacts skin or eyes, immediately flush affected areas thoroughly with water. If vapors are inhaled, go to fresh air. Seek medical help immediately.

WARNING

When disconnecting battery cables, always remove negative cable first and positive cable last. Failure to observe this warning can result in personal injury.

2. Disconnect negative battery cable (6) from negative (-) battery post (7). Disconnect opposite end of cable from engine ground lug by removing screw (9), lockwasher (10), and washer (11). Leave electrical cable

(8) in place on ground lug.

3.

Disconnect positive battery cable (1, Figure 4-36) from positive (+) battery post (2). Disconnect opposite

end of cable from starter’s positive terminal (3) by removing nut (4) and washer (5).

B. INSPECTION.

1. Inspect battery cables for corrosion, evidence of electrical short, and obvious damage. Check for cuts, tears, or exposed wires.

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Figure 4-36. Battery Cables

(Sheet 1 of 2)

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4-45. BATTERY CABLE ASSEMBLY MAINTENANCE - cont.

2. Inspect battery terminals and crimp lugs for corrosion and damage. Check for security of attachment.

Inspect insulation sleeving for deterioration.

3. Inspect battery for cracks, corrosion, or evidence of leakage. Inspect battery posts for corrosion. Remove corrosion from cable terminals and battery posts using a wire terminal brush.

4. Replace any component that is damaged to the extent that it will effect the safe operation of the set.

C. INSTALLATION.

1. Ensure battery is secure in battery tray. Tighten hold down rods as required.

WARNING

When connecting battery cables, always connect positive cable first and negative cable last.

Failure to observe this warning can result in personal injury.

2. Connect positive battery cable (1, Figure 4-36) to starter’s positive terminal (3) using nut (4) and washer

(5). Connect opposite end of cable to positive (+) battery post (2).

3. Connect negative battery cable (6) and cable (8) to engine ground lug using screw (9), lockwasher (10), and washer (11). Connect opposite end of cable (6) to negative (-) battery post (7).

4. Close main access cover and lock in place using latches.

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Figure 4-36. Battery Cables

(Sheet 2 of 2)

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4-46. MAIN ACCESS COVER MAINTENANCE

This task covers test, removal, inspection, and installation.

INITIAL SETUP

Tools:

Tool Kit, General Mechanic’s Automotive

(Item 2, App. B, Sect. III)

Generator set shut down (Para. 2-9)

Personnel Required:

A. TEST

1.

To test for water leakage, unlock main access cover latches (2, Figure 4-37) and lift cover (1) to open.

2.

Cover Power Inverter/Converter (A8) (19, Figure 1-2) with plastic.

3.

Close main access cover latches (2, Figure 4-37) and lock in place using latches.

4. Spray water (low pressure) over cover.

5. Wipe exterior of cover to remove water.

6. Unlock main access cover latches (2) and lift cover (1) to open.

7. Inspect for new signs of water.

8.

If water is present, dry the inside of the generator thoroughly and replace gaskets (Para. 4-46.D.)

B. REMOVAL.

1.

Unlock generator set main access cover latches (2, Figure 4-37).

2. Disconnect electrical plug (22) from fan (23). Remove two wire clamps (24) by removing screws (25), lockwashers (26), and washers (27).

3. Release two cover supports (3) from cover (1) by removing screws (4), lockwashers (5), and washers (6).

4. Remove cover hinges (7, 11) from cover (1) by removing four screws (12), washers (13), and locknuts

(14). Lift cover (1) off generator set and place on a clean work surface for further maintenance.

5. Remove cover hinges (7, 11) from left side panel by removing six screws (8), washers (9), and locknuts

(10).

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Figure 4-37. Main Access Cover

(Sheet 1 of 5)

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4-46. MAIN ACCESS COVER MAINTENANCE - cont.

6. Remove swivel joints (15) from cover supports (3)

by removing washers (16) and locknuts (17).

7. If right side cover support (3) must be removed,

remove rear panel (Para. 4-12).

8. Remove cover supports (3) by removing screws

(18), washers (19), and locknuts (20). Remove

spacers (21).

9. Remove cover latches (28) from cover (1) by

removing screws (29), washers (30), and locknuts

(31).

10. Remove keeper plates (32) from right side panel

by removing screws (33), washers (34), and

locknuts (35).

11. Remove air outlet panel (36) from the underside of cover (1) by removing nine screws (37), washers (38), and locknuts (39).

12. Remove air louver (40) from air outlet insulation

(36) by removing four screws (41), lockwashers

(42), and washers (43).

Figure 4-37. Main Access Cover

(Sheet 2 of 5)

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13. Remove laminated cards (44) from document tray

(48) by removing screw (45), lockwasher (46), and washer (47).

14. Remove document tray (48) from cover (1) by removing screws (49), lockwashers (50), and washers (51). Remove insulation (53).

15. Remove four spacers (52) from cover (1) by removing screws (54), lockwashers (55), and washers (56).

C. INSPECTION.

1. Inspect main access cover for corrosion, cracks, dents, scratches, or other obvious damage.

Inspect air inlet grate for damage.

2. Inspect cover latches for corrosion and damage.

Check for smooth operation, free of binding.

3. Inspect cover insulation for cuts, tears, deterioration, or other damage. Ensure insulation is clean, free of dirt, grime, or grease.

4. Inspect cover identification and caution plates for legibility and security of attachment.

5. Remove and replace any component that is damaged to the extent that it will effect the safe operation of the generator set.

6. Inspect gaskets and seals for deterioration or other damage.

D. INSTALLATION.

1. Install four spacers (52, Figure 4-37) onto

underside of main access cover (1) using screws

(54), lockwashers (55), and washers (56).

2. Install insulation (53) and document tray (48) over four spacers (52). Secure using three screws

(49), lockwashers (50), and washers (51).

3. Secure laminated cards (44) to document tray

(48) using screw (45), lockwasher (46), and washer (47).

ARMY TM 9-6115-639-13

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Figure 4-37. Main Access Cover

(Sheet 3 of 5)

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4-47. MAIN ACCESS COVER MAINTENANCE - cont.

4. Install air louver (40) onto air outlet insulation

(36) using four screws (41), lockwashers (42), and washers (43).

5. Install air outlet panel (36) to the underside of cover (1) using nine screws (37), washers (38), and locknuts (39).

6. Install keeper plates (32) onto right side panel using screws (33), washers (34), and locknuts

(35)

7. Install cover latches (28) onto cover (1) using screws (29), washers (30), and locknuts (31).

Figure 4-37. Main Access Cover

(Sheet 4 of 5)

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8. Install cover supports (3) to skid base using screws (18), washers (19), locknuts (20), and spacers (21).

9. Install swivel joints (15) onto cover supports (3) using washers (16) and locknuts (17).

NOTE

Be sure to check hinge gaskets (57, 58) and cover seal (59) for evidence of deterioration or damage. Replace as required. The wide or bubble portion of the seal (59) should be installed towards the hinge side of the cover (1).

10. Secure cover hinges (7, 11) to left side panel using six screws (8), washers (9), and locknuts (10).

11. Lift up cover (1) and place onto generator set, aligning hinge mounting holes. Install hinges onto cover (1) using four screws (12), washers (13), and nuts (14).

12. Attach two cover supports (3) to cover (1) using screws (4), lockwashers (5), and washers (6).

13. Connect electrical plug (22) to fan (23). Secure electrical wiring to inside of cover (1) using two wire clamps (24), screws (25), washers (26), and lockwashers (27).

14. Close main access cover (1) and lock latches (2).

Change 1

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Figure 4-37. Main Access Cover

(Sheet 5 of 5)

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4-47. ENCLOSURE PANEL MAINTENANCE

This task covers removal, inspection, and installation.

INITIAL SETUP

Tools:

Tool Kit, General Mechanic’s Automotive

(Item 2, App. B, Sect. III)

Parts / Materials:

Sealant, RTV (Item 14, App. E)

Condition:

Control box removed (Para. 4-12)

Main access cover removed (Para. 4-46)

High temperature cooling fan and switch

removed (Para. 4-48)

Fuel fill pocket removed (Para. 4-50)

Power inverter / converter removed (Para. 4-52)

DC magnetic contactors removed (Para. 4-53)

Muffler disengaged from left side panel

A. REMOVAL.

1.

Remove three screws (2, Figure 4-38), washers (3), and locknuts (4) to release left side panel (1) from air

inlet panel (20).

2. Remove five screws (5), ten washers (6), and five locknuts (7). Remove screw (8), two washers (9), and locknut (10). Remove screws (11, 12) to release left side panel (1) from skid base.

3. Remove two screws (13), washers (14), and locknuts (15) to release left side panel (1) from bracket (16).

Carefully lift left side panel off skid base.

4. Remove angle bracket (16) from air inlet panel (25) by removing two screws (17), washers (18), and locknuts (19).

5. Remove air inlet cover (20) from air inlet panel (25) by removing nine screws (21), lockwashers (22), and washers (23) from captive nuts (24). Remove acoustic insulation (33).

6. Remove air inlet panel (25) from skid base by removing four screws (26), washers (27), and locknuts (28), and four screws (29), washers (30), lockwashers (31), and captive nuts (32).

7. Remove air outlet panel (34) from left side panel (1) by removing eleven screws (35), washers (36), and locknuts (37).

8. Remove louver (38) from air outlet panel (34) by removing four screws (39), lockwashers (40), and washers (41).

9. Remove acoustic insulation (42).

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4-47. ENCLOSURE PANEL MAINTENANCE - cont.

B. INSPECTION.

1. Inspect enclosure panels for corrosion, cracks, dents, scratches, or other obvious damage. Inspect fuel fill pocket for evidence of fuel leakage.

2. Inspect acoustic insulation for cuts, tears, rips, or deterioration.

3. Remove and replace any component that is damaged to the extent that it will effect the safe operation of the generator set.

Figure 4-38. Enclosure Panels

(Sheet 1 of 2)

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4-47. ENCLOSURE PANEL MAINTENANCE - cont.

C. INSTALLATION.

1.

Install acoustic insulation (42, Figure 4-38).

2. Apply RTV Sealant to top edge of louver (38). Install louver (38) onto air outlet panel (34) using four screws (39), lockwashers (40), and washers (41).

3. Apply RTV Sealant to the flange of the air outlet panel (34) that mates with the left side panel (1). Install air outlet panel (34) onto left side panel (1) using eleven screws (35), washers (36), and locknuts (37).

4. Install acoustic insulation (33). Install air inlet cover (20) onto air inlet panel (25) using nine screws (21), lockwashers (22), washers (23), and captive nuts (24).

5. Install angle bracket (16) onto air inlet panel (25) using two screws (17), washers (18), and locknuts (19).

6. Install air inlet panel (25) onto skid base using four screws (26), washers (27), and locknuts (28), and four screws (29), washers (30), lockwashers (31), and captive nuts (32).

7. Position left side panel (1) onto skid base. Secure using five screws (5), ten washers (6), and five locknuts

(7). Install screw (8), two washers (9), and locknut (10). Install screws (11, 12).

8. Attach left side panel (1) to air inlet panel (20) using three screws (2), washers (3), and locknuts (4).

9. Attach left side panel (1) to bracket (16) using two screws (13), washers (14), and locknuts (15).

10. Install high temperature cooling fan and switch (Para. 4-48).

11. Install control box (Para. 4-12).

12. Install main access cover (Para. 4-46).

13. Install DC magnetic contactors (Para. 4-53).

14. Install power inverter / converter (Para. 4-52).

15. Install fuel fill pocket (Para. 4-50).

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4-47. ENCLOSURE PANEL MAINTENANCE - cont.

Figure 4-38. Enclosure Panels

(Sheet 2 of 2)

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4-48. COOLING FAN AND TEMPERATURE SWITCH MAINTENANCE

This task covers removal, inspection, and installation.

INITIAL SETUP

Tools:

Tool Kit, General Mechanic’s Automotive

(Item 2, App. B, Sect. III)

Generator set shut down (Para. 2-9)

Battery cables disconnected

Cable disconnected for SLAVE RECEPTACLE

A. REMOVAL.

1. Unlock generator set main access cover latches and lift cover to open.

2.

Tag and disconnect two electrical wires (18, 19, Figure 4-39) from high temperature switch S20 (17) (110

°

F). Remove temperature switch (17) from rear wall of enclosure by removing two screws (14), lockwashers (15), and washers (16).

3. Disconnect fan power cord (6) from generator set wiring harness.

4. Remove high temperature fan (2) from rear wall of enclosure by removing two screws (8), lockwashers (9) and washers (10).

NOTE

Remove finger guard (1) only if fan (2) is to be replaced. Finger guard must be retained for use on new fan.

5. Remove finger guard (1) from fan (2) by removing two screws (3), washers (4), and nuts (5).

6. Disconnect electrical wire (7) from fan (2) by removing screw (11), lockwasher (12), and washer (13).

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4-48. COOLING FAN AND TEMPERATURE SWITCH MAINTENANCE - cont.

Figure 4-39. High Temperature Switch and Cooling Fan Removal

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4-48. COOLING FAN AND TEMPERATURE SWITCH MAINTENANCE - cont.

7.

Tag and disconnect two electrical wires (18, 19, Figure 4-40) from low temperature switch S21 (17) (85

°

F). Remove temperature switch from main access cover by removing two screws (14), lockwashers (15), and washers (16).

8. Disconnect fan power cord (6) from generator set wiring harness.

9. Remove low temperature fan (2) from main access cover by removing two screws (8), lockwashers (9) and washers (10).

NOTE

Remove finger guard (1) only if fan (2) is to be replaced. Finger guard must be retained for use on new fan.

10. Remove finger guard (1) from fan (2) by removing two screws (3), washers (4), and nuts (5).

11. Disconnect electrical wire (7) from fan (2) by removing screw (11), lockwasher (12), and washer (13).

B. INSPECTION.

1. Inspect finger guards and cooling fans for obvious damage. Manually operate fan blades to ensure smooth operation, free from binding.

2. Inspect temperature switches for obvious damage. Check that electrical terminals are securely attached and free of corrosion.

3. Inspect electrical wiring for cuts, crimps, bare wire, or other damage. Ensure terminal lugs are securely attached. Inspect fan power cords for damage. Check that electrical connectors are securely attached.

4. Remove and replace any component that is damaged to the extent that it will effect the safe operation of the generator set.

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4-48. COOLING FAN AND TEMPERATURE SWITCH MAINTENANCE - cont.

Figure 4-40. Low Temperature Switch and Cooling Fan Removal

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4-48. COOLING FAN AND TEMPERATURE SWITCH MAINTENANCE - cont.

C. INSTALLATION.

1. Mate low temperature switch S21 (17, Figure 4-41) (85

° F) to main access cover and secure using two screws (14), lockwashers (15), and washers (16). Connect two electrical wires (18, 19) to temperature switch.

2. Mate low temperature fan (2) to main access cover and secure using two screws (8), lockwashers (9), and washers (10). Left hand screw (8) secures electrical wire (7).

3. Connect fan power cord (6) to generator set wiring harness. Connect wire (7) to fan using screw (11), lockwasher (12), and washer (13).

4. Install finger guard (1) onto low temperature fan (2) using two screws (3), washers (4), and nuts (5).

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4-48. COOLING FAN AND TEMPERATURE SWITCH MAINTENANCE - cont.

Figure 4-41. Low Temperature Switch and Cooling Fan Installation

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4-48. COOLING FAN AND TEMPERATURE SWITCH MAINTENANCE - cont.

5. Mate high temperature switch S20 (17, Figure 4-42) (110

° F) to rear wall of enclosure and secure using two screws (14), lockwashers (15), and washers (16). Connect two electrical wires (18, 19) to temperature switch.

6. Mate high temperature fan (2) to rear wall of enclosure and secure using two screws (8), lockwashers (9), and washers (10). Left hand screw (8) secures electrical wire (7).

7. Connect fan power cord (6) to generator set wiring harness. Connect wire (7) to fan using screw (11), lockwasher (12), and washer (13).

8. Install finger guard (1) onto fan (2) using two screws (3), washers (4), and nuts (5).

9. Close main access cover and lock in place using latches.

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4-48. COOLING FAN AND TEMPERATURE SWITCH MAINTENANCE - cont.

Figure 4-42. High Temperature Switch and Cooling Fan Installation

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4-49. FUEL FILTER / WATER SEPARATOR MAINTENANCE

This task covers preventive maintenance servicing (PMCS), removal, inspection, and installation.

INITIAL SETUP

Tools:

Tool Kit, General Mechanic’s Automotive

(Item 2, App. B, Sect. III)

Parts / Materials:

Sealant, Thread (Item 15, App. E)

Teflon Tape (Item 19, App. E)

Generator set shut down (Para. 2-9)

Battery cables disconnected

Cable disconnected for SLAVE RECEPTACLE

A. SERVICING.

1. Unlock main access cover latches and lift cover to open.

2. Open filter / separator drain valve (1, Figure 4-

43) and drain fluid through hose (2). Close valve

(1) and disconnect hose (2) when drained.

3. Using a filter wrench, unscrew clear bowl (3) and filter (5) from filter head. Remove gasket (6).

4. Remove filter (5) from bowl (3). Remove gasket

(4) and drain excess fuel.

5. Install new filter (5) and gasket (4) onto bowl (3).

6. Install bowl (3), filter (5), and gasket (6) onto filter head. Hand tighten.

7. Connect hose (2) to bowl (3) and close drain valve (1).

Figure 4-43. Filter Servicing

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4-49. FUEL FILTER / WATER SEPARATOR MAINTENANCE - cont.

B. REMOVAL.

1. Unlock main access cover latches and lift cover to open.

2. Open filter / separator drain valve (13, Figure 4-

44) and drain fluid through hose (4). Close valve

(13) and disconnect hose (4).

3. Disconnect fuel hoses (1) from elbows (3) by loosening hose clamps (2).

4. Remove elbows (3) from filter / separator (5).

5. Remove filter / separator (5) from bracket (6) by removing two screws (7), washers (8), and locknuts (9).

6. If removal of bracket (6) is required, remove air

inlet cover (Para. 4-47).

7. Remove bracket (6) from enclosure by removing two screws (10), washers (11), and locknuts (12).

C. INSPECTION.

1. Inspect filter / separator for cracks, corrosion, evidence of leakage, and obvious damage.

2. Inspect fuel hoses for cuts, cracks, or other damage.

3. Remove and replace any component that is damaged to the extent that it will effect the safe operation of the generator set.

Figure 4-44. Fuel Filter / Water Separator

(Sheet 1 of 2)

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4-49. FUEL FILTER / WATER SEPARATOR MAINTENANCE - cont.

D. INSTALLATION.

1. Apply sealant to threads of three screws (7,

Figure 4-44). Install filter / separator (5) onto

bracket (6) using two screws (7), washers (8), and locknuts (9).

2. Apply teflon tape to threads of elbows (3). Install

elbows into filter / separator (5).

3. Mate bracket (6) to enclosure. Secure using two screws (10), washers (11), and locknuts (12).

4. Connect fuel hoses (1) to elbows (3) and secure by tightening hose clamps (2).

5. Connect drain hose (4) to filter / separator (5).

Close drain valve (13).

6. Reconnect battery. Close main access cover and lock in place using latches.

7. Place START / RUN/ STOP switch in RUN position until fuel bowl is filled. Check for evidence of leaks.

Figure 4-44. Fuel Filter / Water Separator

(Sheet 2 of 2)

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4-50. FUEL FILL CAP AND FILL POCKET MAINTENANCE

This task covers removal, inspection, and installation.

INITIAL SETUP

Tools:

Tool Kit, General Mechanic’s Automotive

(Item 2, App. B, Sect. III)

Parts / Materials:

Teflon Tape (Item 19, App. E)

A. REMOVAL.

1. Unlock main access cover latches and lift cover to open.

2. Remove fuel fill cap (1, Figure 4-45) from fuel

fill throat (2). Remove fuel strainer assembly (3).

3. Release fuel cap chain (4) from fill pocket wall by

removing screw (5) washer (6), and locknut (7).

Generator set shut down (Para. 2-9)

Battery cables disconnected

Cable disconnected for SLAVE RECEPTACLE

Figure 4-45. Fuel Fill Cap and Pocket

(Sheet 1 of 2)

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4-50. FUEL FILL CAP AND FILL POCKET MAINTENANCE - cont.

4. Loosen two clamps (10) and remove fill port collar (11) from fill pocket (8) and fuel tank (9).

5. Disconnect hose (12) from tee (17) by loosening clamp (13).

6. Disconnect hose (14) from fitting (15) by loosening clamp (16). Remove fitting (15), tee (17), and pipe

(18) from fill pocket (8).

7.

If removal of fill pocket (8) is required, remove auxiliary fuel pump and connectors (Para. 4-51) and power

inverter / converter (Para. 4-52).

8. Remove fill pocket (8) from enclosure by removing eight screws (19), lockwashers (20), and washers (21).

B. INSPECTION.

1. Inspect fuel fill cap for obvious damage. Inspect for crossed, stripped, or damaged threads.

2. Inspect fuel strainer assembly for dirt, clogging, and corrosion. Check that all screen material is intact and free from damage. Ensure that screen is securely attached to lip.

3. Inspect fuel fill pocket for cracks, dents, or evidence of leakage. Inspect for corrosion.

4. Inspect fill port collar and fuel tank for cracks, dents, or evidence of leakage. Inspect for corrosion.

5. Remove and replace any component that is damaged to the extent that it will effect the safe operation of the generator set.

C. INSTALLATION.

1. Apply teflon tape to threads of all fitting threads prior to installation.

2.

Connect pipe (18, Figure 4-45), tee (17), and fitting (15) to fill pocket (8).

3. Install collar (11) onto fill pocket (8) and fuel tank (9). Secure by tightening two clamps (10).

4. Install fill pocket (8) using eight screws (19), lockwashers (20), and washers (21).

5. Secure collar (11) to fill pocket (8) and fuel tank (9) using two clamps (10).

6. Connect hose (14) to fitting (15) and tighten clamp (16). Connect hose (12) to tee (17) and tighten clamp

(13).

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4-50. FUEL FILL CAP AND FILL POCKET MAINTENANCE - cont.

7. Install fill cap chain (4) to fill pocket using screw

(5), washer (6), and locknut (7).

8. Carefully install fuel strainer assembly (3) into fuel throat (2), making sure not to damage screen.

Screw cap (1) onto throat (2).

9. Install auxiliary fuel pump and fuel connection

(Para. 4-51).

10. Install power inverter / converter (Para. 4-52).

11. Close main access cover and lock in place using latches.

Figure 4-45. Fuel Fill Cap and Pocket

(Sheet 2 of 2)

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4-51. AUXILIARY FUEL PUMP MAINTENANCE

This task covers removal, inspection, and installation.

INITIAL SETUP

Tools:

Tool Kit, General Mechanic’s Automotive

(Item 2, App. B, Sect. III)

Parts / Materials:

Teflon Tape (Item 19, App. E)

A. REMOVAL.

1. Unlock main access cover latches and lift cover to open.

2. Disconnect plug to auxiliary fuel pump electrical wires.

3.

Disconnect fuel hose (1, Figure 4-46) from elbow

(12) by loosening clamp (2).

4. Disconnect fuel hose (4) from fuel strainer (6) by loosening clamp (5).

5. Remove auxiliary fuel pump (7) from fill pocket

(8) by removing two screws (9), washers (10), and locknuts (11).

6. Remove elbow (12) from auxiliary fuel pump (7).

Remove fuel strainer (6).

7. Disconnect fuel hose (4) from fitting (13) by loosening clamp (5).

8. Remove fitting (13) from elbow (14). Remove cap (17), nut (16), washer (15), and elbow (14) from fill pocket (8).

Generator set shut down (Para. 2-9)

Battery cables disconnected

Cable disconnected for SLAVE RECEPTACLE

Personnel Required:

Figure 4-46. Auxiliary Fuel Pump

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4-51. AUXILIARY FUEL PUMP MAINTENANCE - cont.

B. INSPECTION.

1. Inspect auxiliary fuel pump and fuel strainer for cracks, corrosion, evidence of leakage, and obvious damage.

2. Inspect fuel hoses for cuts, cracks, or other damage.

3. Inspect fuel fittings for crossed, stripped, or damaged threads.

4. Inspect electrical wiring for cuts, crimps, bare wire, or other damage. Ensure terminal lugs are securely attached.

5. Remove and replace any component that is damaged to the extent that it will effect the safe operation of the generator set.

C. INSTALLATION.

1. Apply teflon tape to threads of all fitting prior to installation.

2. Install elbow (14, Figure 4-46), washer (15), nut (16), and cap (17) onto fill pocket (8). Connect fitting

(13) to elbow (14).

3. Install elbow (12) and fuel strainer (6) into auxiliary fuel pump (7).

4. Mate auxiliary fuel pump (7) to fill pocket (8) and secure using two screws (9), washers (10), and locknuts

(11).

5. Connect fuel hose (4) to fuel strainer (6) and fitting (13). Secure by tightening clamps (5).

6. Connect fuel hose (1) to elbow (12). Secure by tightening clamp (2).

7. Close main access cover and lock in place using latches.

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4-52. POWER INVERTER / CONVERTER MAINTENANCE

This task covers removal, inspection, and installation.

INITIAL SETUP

Tools:

Tool Kit, General Mechanic’s Automotive

(Item 2, App. B, Sect. III)

AC circuit interrupter contactor removed

(Para. 4-28)

A. REMOVAL.

1. Unlock main access cover latches and lift cover to open.

2.

Tag and disconnect three electrical connectors from power inverter / converter (5, Figure 4-47). Remove

two wire clamps (24) by removing screws (25).

3. Remove wire cover plate (1) from inverter / converter (5) by removing four screw and captive washer assemblies (2). Tag and disconnect electrical wires (4) by loosening screws (3). Reinstall screws and cover plate to prevent loss.

4. To prevent damage, tag and disconnect electrical harness connector J7 from rear of control box.

5. Open control panel by turning quarter-turn fasteners. Remove two screws (6), lockwashers (7), and washers (8) that secure control box to bracket (9).

6. Detach inverter / converter (5) from bracket (9) by removing two screws (10), lockwashers (11), and washers (12).

7. Release inverter / converter (5) from rear wall of enclosure (13) by removing six screws (14), lockwashers

(15), and washers (16).

8. Remove bracket (17) from skid base by removing four screws (18), lockwashers (19), and washers (20).

9. Remove bracket (17) from power inverter / converter (5) by removing two screws (21), lockwashers (22), and washers (23).

10. Carefully lift inverter / converter (5) up and out of generator set enclosure.

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4-52. POWER INVERTER / CONVERTER MAINTENANCE - cont.

B. INSPECTION.

1. Inspect power inverter / converter for obvious damage. Inspect for corrosion and evidence of electrical short. Check air ducts for clogs or obstructions. Clear obstructions.

2. Inspect electrical wiring for cuts, crimps, bare wire, or other damage. Ensure terminal lugs are securely attached.

3. Repair of the power inverter / converter is limited to removal and replacement of the assembly. All adjustments are factory set and may not be altered.

4. Remove and replace any component that is damaged to the extent that it will effect the safe operation of the generator set.

C. INSTALLATION.

1. Carefully install power inverter / converter (5,

Figure 4-47) into generator set enclosure.

2. Install bracket (17) onto inverter / converter (5) using two screws (21), lockwashers (22), and washers (23). Secure bracket to skid base using four screws (18), lockwashers (19), and washers

(20).

3. Mate inverter / converter (5) to rear wall of enclosure (13). Secure using six screws (14), lockwashers (15), and washers (16).

4. Attach inverter / converter (5) to bracket (9) using two screws (10), lockwashers (11), and washers

(12).

5. Secure control box to bracket (9) using two screws (6), lockwashers (7), and washers (8).

Figure 4-47. Power Inverter / Converter

(Sheet 1 of 2)

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4-52. POWER INVERTER / CONVERTER MAINTENANCE - cont.

6. Connect electrical harness connector J7 to rear of control box. Connect three electrical connectors to inverter / converter (5).

7. Connect electrical wires (4) using screws (3).

Install cover plate (1) using four screw and captive washer assemblies (2).

8. Secure two wire clamps (24) to inverter / converter (5) using screws (25).

9. Install AC circuit interrupter contactors (Para. 4-

28).

10. Close main access cover and lock in place using latches.

Figure 4-47. Power Inverter / Converter

(Sheet 2 of 2)

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4-53. DC MAGNETIC CONTACTOR MAINTENANCE

This task covers removal, inspection, and installation.

INITIAL SETUP

Tools:

Tool Kit, General Mechanic’s Automotive

(Item 2, App. B, Sect. III)

Generator set shut down (Para. 2-9)

Battery cables disconnected

Cable disconnected for SLAVE RECEPTACLE

A. REMOVAL.

1. Unlock main access cover latches and lift cover to open.

2.

Remove two DC magnetic contactors (7, Figure 4-48) from wall of enclosure (8) by removing screws (9),

washers (10), and locknuts (11).

3. Tag and disconnect electrical wires (1, 2) from DC magnetic contactors (7) by removing nuts (3, 5) and washers (4, 6). Remove voltage suppressors (12).

B. INSPECTION.

1. Inspect DC magnetic contactors for obvious damage. Inspect for corrosion and evidence of electrical short.

2. Inspect electrical wiring for cuts, crimps, bare wire, or other damage. Ensure terminal lugs are securely attached.

3. Remove and replace any component that is damaged to the extent that it will effect the safe operation of the generator set.

C. INSTALLATION.

1. Connect electrical wires (1, 2, Figure 4-48) and voltage suppressors (12) to DC magnetic contactors (7)

using nuts (3, 5) and washers (4, 6).

2. Mate two DC magnetic contactors (7) to the rear wall of enclosure (8). Secure using screws (9), washers

(10), and locknuts (11).

3. Close main access cover and lock in place using latches.

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Figure 4-48. DC Magnetic Contactors

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4-54. GOVERNOR ACTUATOR MAINTENANCE

This task covers adjustment, removal, disassembly, inspection, assembly, and installation.

INITIAL SETUP

Tools:

Tool Kit, General Mechanic’s Automotive

(Item 2, App. B, Sect. III)

Generator set shut down (Para. 2-9)

Battery cables disconnected

Cable disconnected for SLAVE RECEPTACLE

A. GOVERNOR SYSTEM ADJUSTMENT.

1. Loosen lock nut, (5, Figure 4-49) on bottom of

actuator linkage rod (3) and adjust spherical nut

(4) so that one thread shows on bottom of spherical nut (4). Tighten the lock nut (5) against spherical nut (4).

2. Make sure the actuator lever (2) reaches its stop just prior to the engine fuel lever (6) reaching its stop. Adjust length by loosening lock nut (7) on top of linkage rod (3) and turn actuator linkage rod in or out of ball joint (1). Tighten lock nut

(7).

NOTE

If governor actuator linkage adjustment (steps

1 and 2) results in satisfactory operation, steps

3 through 13 are not required. Perform these procedures only if further adjustment is necessary.

Figure 4-49. Governor Actuator Adjustment

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4-54. GOVERNOR ACTUATOR MAINTENANCE - cont.

3. Open the control box panel to gain access to the governor control module.

4. Connect a multimeter between control module terminals A and B.

5.

Start the generator set (paragraph 2-8) and run in

no load condition. Adjust control module SPEED

pot (4, Figure 4-50) to obtain a PMA frequency

of 254 Hz (3050 RPM) or a voltage of 178 +/- 2 volts AC. Clockwise rotation of the SPEED pot increases frequency and voltage. Counterclockwise rotation decreases frequency and voltage.

CAUTION

DO NOT loosen or adjust governor actuator

(2, Figure 4-51) magnet. The position of the

magnet is factory set.

Figure 4-50. Governor Control Module

6.

With engine running, check the gap between lever plate (19, Figure 4-51) and governor actuator magnet.

Gap shall be 5/16 inch. Adjust gap by loosening locknut (23) and screwing linkage rod (22) in or out of ball joint (3). Check gap and tighten locknut (23).

7. Turn the STABILITY pot (1, Figure 4-50) and

GAIN pot to the full counterclockwise position.

8. Rotate control module STABILITY pot (1, Figure 4-50) clockwise until engine becomes unstable, then

counterclockwise until it stabilizes, and then a little further counterclockwise.

9. Rotate control module GAIN pot (2) clock clockwise until engine becomes unstable, then counterclockwise until it stabilizes, and then a little further counterclockwise.

10. Close load contactor and apply full rated load. Adjust control module BOOST pot (3) to obtain a PMA frequency of 288 Hz (3450 RPM) or a voltage of 193 +/-2 volts AC. Clockwise rotation of the BOOST pot decreases frequency and voltage. Counterclockwise rotation increases frequency and voltage.

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4-54. GOVERNOR ACTUATOR MAINTENANCE - cont.

11. Check the no load to rated load operation by opening and closing the CIRCUIT INTERRUPTER switch

and observing the actuator magnet and plate (19, Figure 4-51). If the actuator magnet makes contact with

the plate during the on/off load operation, reduce gain slightly by rotating GAIN pot (2, Figure 4-50)

clockwise.

NOTE

When applying rated load the engine speed should increase without a large initial drop in engine speed. When removing load the engine speed should decrease without a large initial surge in speed.

12. At no load, lift actuator lever (4, Figure 4-51) and lock it in the manual start position. The PMA

frequency shall be 317 Hz (3800 RPM) or the voltage shall be 219 +/-2 volts AC.

13. Shutdown generator set and disconnect multimeter. Close and lock control panel.

B. REMOVAL.

1. Unlock main access cover latches and lift cover to open.

2.

Disconnect electrical plug (1, Figure 4-51) from governor actuator (2).

3. Disconnect ball joint (3) on engine linkage from lever (4) on governor actuator by removing screw (5), washer (6), and locknut (7).

4. Remove governor actuator (2) by removing two screws (8), lockwashers (9), and washers (10).

C. DISASSEMBLY.

1. Remove lever (17, Figure 4-51) from lever (4) by removing screw (11), washer (12), and nut (13).

2. Release lever (4) from governor actuator (2) by loosening screw (14), washer (15), and nut (16).

3. Remove screw (18), plate (19), washer (20), and nut (21) from lever (17).

4. Remove ball joint (3) from linkage rod (22). Remove nuts (23, 26, 27) and spherical washer (24). Remove link bracket (25) from engine only if replacement is required.

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4-54. GOVERNOR ACTUATOR MAINTENANCE - cont.

DO NOT loosen or adjust magnet.

Position is factory set.

'

Figure 4-51. Governor Actuator

(Sheet 1 of 2)

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4-54. GOVERNOR ACTUATOR MAINTENANCE - cont.

D. INSPECTION.

1. Inspect governor actuator for obvious damage. Inspect for corrosion and evidence of electrical short.

Inspect linkage components for obvious damage or defects.

2. Inspect electrical wiring for cuts, crimps, bare wire, or other damage. Ensure connector plug is securely attached.

3. Remove and replace any component that is damaged to the extent that it will effect the safe operation of

the generator set.

E. ASSEMBLY.

1. Install nuts (23, 26, 27, Figure 4-51), spherical washer (24), and ball joint (3) onto linkage rod (22). Attach

link bracket (25) to engine.

2. Install screw (18), plate (19), washer (20), and nut (21) onto lever (17).

3. Mate levers (4) to governor actuator (2). Secure by tightening screw (14), washer (15), and nut (16).

4. Mate lever (17) to lever (4). Secure using screw (11), washer (12), and nut (13).

F. INSTALLATION.

1.

Install governor actuator (2, Figure 4-51) using two screws (8), lockwashers (9), and washers (10).

2. Adjust actuator / governor linkage as required in accordance with step A, ADJUSTMENT.

3. Connect ball joint (3) on engine linkage with lever (4) using screw (5), washer (6), and locknut (7). Ensure

that the linkage and actuator lever are in the same plane (vertical when viewed from control box end of

generator set).

4. Connect electrical plug (1) to actuator (2).

5. Close main access cover and lock in place using latches.

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Figure 4-51. Governor Actuator

(Sheet 2 of 2)

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Section VII. PREPARATION FOR SHIPMENT AND STORAGE

4-55. GENERAL.

This section provides instructions for short term and intermediate storage or shipment of the generator set.

Administrative storage shall be in accordance with AR 750-1.

4-57. SHORT TERM STORAGE (30 days or less).

a. Check engine oil level and service as required. b. Conduct a general inspection of the unit to ensure all components are present and securely fastened.

Close all doors and lids and lock in position. c. Stow the generator set on a level surface in an area protected from the elements. Cover as required depending upon weather conditions.

4-58. INTERMEDIATE TERM STORAGE (more than 30 days).

a. Start the generator set and operate for 10 minutes at full speed to bring engine to normal operating temperature. Shutdown the generator set. b. Drain the engine oil. Fill crankcase to proper level with preservative oil, MIL-L-21260 (Item 17,

Appendix E). c. Close air intake and exhaust openings with moisture proof tape, PPP-T-60 (Item 18, Appendix E).

d. Stow the generator set on a level surface in an area protected from the elements. Cover as required depending upon weather conditions. e. Before returning generator set to service, drain preservative oil and service the engine.

4-59. SHIPMENT.

a. Close air intake and exhaust openings with moisture proof tape, PPP-T-60 (Item 18, Appendix E).

b. Attach to the generator set all forms, tags, and records applicable to the unit. c. Load the generator set onto carrier and attach shipping tiedowns.

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CHAPTER 5

DIRECT SUPPORT MAINTENANCE INSTRUCTIONS

Section I REPAIR PARTS; TOOLS; SPECIAL TOOLS; TEST,

MEASUREMENT, AND DIAGNOSTIC EQUIPMENT (TMDE);

AND SUPPORT EQUIPMENT ..............................................................................5-2

5-1 Common Tools and Equipment ...............................................................................5-2

5-2 Special Tools, TMDE, and Support Equipment.......................................................5-2

Section II

SERVICE UPON RECEIPT OF EQUIPMENT......................................................5-2

5-4 General.....................................................................................................................5-2

Section III

DIRECT SUPPORT LEVEL TROUBLESHOOTING PROCEDURES.................5-3

5-5 General.....................................................................................................................5-3

5-6 Troubleshooting .......................................................................................................5-3

Section IV

DIRECT SUPPORT MAINTENANCE PROCEDURES........................................5-4

5-7

5-8

5-9

Engine / Alternator Assembly Maintenance ............................................................5-4

Permanent Magnet Alternator Maintenance ..........................................................5-10

Fuel Tank Maintenance..........................................................................................5-14

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Section I. REPAIR PARTS; TOOLS; SPECIAL TOOLS;

TEST, MEASUREMENT, AND DIAGNOSTIC EQUIPMENT (TMDE);

AND SUPPORT EQUIPMENT

5-1. COMMON TOOLS AND EQUIPMENT

. a. For authorized common tools and equipment, refer to the Modified Table of Organization and

Equipment (MTOE), CTA 50-970, or CTA 8-100, as applicable to your unit. b. Tool Kit, Master Mechanic, Supply Catalog SC5180-90-CL-N05, is the primary supply source for tools used in direct support maintenance of the generator set.

5-2. SPECIAL TOOLS, TMDE, AND SUPPORT EQUIPMENT

.

Refer to TM 9-6115-639-23P, Generator Set Repair Parts and Special Tools List, for complete data on special tools and equipment required for generator set maintenance. Refer to the Maintenance Allocation Chart

(MAC), Appendix B, for special tools and equipment used at the direct support maintenance level.

5-3. REPAIR PARTS

.

a. Refer to Appendix H for a list of Mandatory Replacement Parts required for direct support level

maintenance of the generator set. b. Repair parts are listed and illustrated in TM 9-6115-639-23P, Generator Set Repair Parts and Special

Tools List.

Section II. SERVICE UPON RECEIPT OF EQUIPMENT

5-4. GENERAL

.

Refer to paragraph 2-6 for instructions on unpacking, assembly, and servicing of generator set components.

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Section III. DIRECT SUPPORT LEVEL TROUBLESHOOTING

PROCEDURES

5-5. GENERAL.

This section contains direct support level troubleshooting information for the generator set.

5-6. TROUBLESHOOTING.

a. Results of troubleshooting tests and inspections performed at the unit maintenance level (Chapter 4)

are to be used in performing additional inspections at the direct support maintenance level. This chapter does

not list all malfunctions noted in Chapter 4, all tests or inspections that may have been performed by unit level

personnel, or all corrective actions taken for each malfunction.

b. Refer to the system electrical schematic (Figure FO-1), system wiring diagram (Figure FO-2),

generator set wiring harness diagrams (Figures FO-3 and FO-4), and control panel wiring harness diagrams

(Figures FO-5 and FO-6) for assistance in troubleshooting electrical components. Conduct continuity checks on

suspect wiring / harnesses as required utilizing these schematics and diagrams. c. Refer to TM 9-2815-257-24 for troubleshooting of the diesel engine and its components.

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Section IV. DIRECT SUPPORT MAINTENANCE PROCEDURES

5-7. ENGINE / ALTERNATOR ASSEMBLY MAINTENANCE

This task covers removal, inspection, and installation.

INITIAL SETUP

Tools:

Tool Kit, Master Mechanic’s

(Item 3, App. B, Sect. III)

Hoist, Lifting (Item 5, App. B, Sect. III)

Personnel Required:

Two (2) maintenance personnel

Generator set shut down (Para. 2-9)

Muffler assembly removed (Para. 4-43)

A. REMOVAL.

1.

Disconnect two cover supports from main access cover (Para. 4-46). Fully open access cover.

2. Tag and disconnect electrical wiring from engine components, including the oil pressure switch, starter

(positive terminal), and two air heater plugs. Refer to Figures FO-3 and FO-4 for wire locations.

3.

Disconnect fuel return line (1, Figure 5-1) from fuel injector. Disconnect fuel line (2) from fuel tank to tee.

Disconnect fuel line (3) from fuel filter / water separator outlet.

4. Disconnect oil drain line (4) from oil drain valve (12) by loosening clamp (13).

WARNING

The engine / alternator assembly is heavy. Provide adequate lifting device to support the weight. Do not lift object over personnel. Enlist the help of an aide to prevent damage to equipment. Failure to observe this warning can result in personal injury.

5. Attach lifting hoist to engine lifting cable (10). Raise hoist to remove slack.

6. Release engine / alternator assembly (23) from three vibration isolators (14) by removing screws (15), lockwashers (16), and washers (17).

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5-7. ENGINE / ALTERNATOR ASSEMBLY MAINTENANCE - cont.

Figure 5-1. Engine / Alternator Assembly

(Sheet 1 of 3)

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5-7. ENGINE / ALTERNATOR ASSEMBLY MAINTENANCE

CAUTION

End of starter rope can be quickly drawn into recoil winding mechanism, making it difficult to remove. To prevent this, ensure end of starter rope is knotted or otherwise secured after removing tee handle.

7. Disconnect tee handle from starter pull rope by removing knot. Feed end of rope through hole in skid base

(27).

8. Carefully lift engine / alternator assembly (23) up and out of generator set enclosure. Place on a flat work surface for further maintenance. If engine is to be replaced, remove lifting cable (10) by removing screws

(11), lockwasher (12), and washer (13). Retain for future use.

9. If required, remove engine / alternator assembly (23) from base (18) by removing four screws (19), eight washers (20), and four nuts (21).

10. Remove three vibration isolators (14) from skid base (27) by removing screws (24), washers (25), and nuts

(26).

11. If engine is being replaced, remove and retain the following engine components for use on the new engine: engine air filter assembly, engine oil drain valve, governor actuator, and engine lifting cable.

B. INSPECTION.

1. Inspect engine and alternator for obvious damage. Clean as required to view all components carefully.

Look for signs of fluid leakage. Check all sealing areas and surfaces.

2. Inspect engine fuel and oil lines for cracks, cuts, abrasions, evidence of leakage, and obvious damage.

Check fluid fittings and connectors for security of attachment.

3. Inspect electrical wiring for cuts, crimps, bare wire, or other damage. Inspect wiring insulation for damage. Ensure all connectors and terminal lugs are securely attached.

4. Conduct a detailed inspection of suspect components in accordance with the appropriate maintenance paragraph.

5. Remove and replace any component that is damaged to the extent that it will effect the safe operation of the generator set.

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5-7. ENGINE / ALTERNATOR ASSEMBLY MAINTENANCE - cont.

Figure 5-1. Engine / Alternator Assembly

(Sheet 2 of 3)

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C. INSTALLATION.

WARNING

The engine / alternator assembly is heavy. Provide adequate lifting device to support the weight. Do not lift object over personnel. Enlist the help of an aide to prevent damage to equipment. Failure to observe this warning can result in personal injury.

1.

Install engine lifting cable (10, Figure 5-1) onto engine / alternator assembly (23) using screws (11).

2.

Attach lifting hoist to engine lifting cable (10, Figure 5-1). Raise hoist to remove slack.

3. Carefully lift engine / alternator assembly (23) and mate to plate (18). Secure using four screws (19), eight washers (20), and four nuts (21). Torque screws to 30 ft-lbs.

4. Install three vibration isolators (14) to skid base (27) using screws (24), washers (25), and nuts (26).

5. Lift engine / alternator assembly (23) and carefully lower into generator set enclosure. Mate mounting holes on plate (18) with vibration isolators (14).

6. Attach engine / alternator assembly (23) to vibration isolators (14) using screws (15), lockwashers (16), and washers (17). Torque screws to 30 ft-lbs.

7. Connect oil drain line (4) to drain valve (12) and secure by tightening clamp (13). If removed, secure drain plug (6) to skid base (27) using screw (7), washers (8), and nut (9).

8. Feed recoil winding mechanism starter rope through hole in skid base (27). Install tee handle and knot rope to secure handle.

9. Connect fuel line (3) to fuel filter / water separator outlet. Connect fuel line (2) from fuel tank to tee.

Connect fuel return line (1) to fuel injector.

10. Connect electrical wiring to engine components.

11. Attach support rods to main access cover (4-46).

12. Install muffler assembly (Para. 4-43).

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5-7. ENGINE / ALTERNATOR ASSEMBLY MAINTENANCE - cont.

Figure 5-1. Engine / Alternator Assembly

(Sheet 3 of 3)

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5-8. PERMANENT MAGNET ALTERNATOR MAINTENANCE

This task covers removal, inspection, and installation.

INITIAL SETUP

Tools:

Tool Kit, Master Mechanic’s

(Item 3, App. B, Sect. III)

Shop Equipment, Automotive Maintenance

(Item 4, App. B, Sect. III)

Puller, Mechanical (Item 6, App. B, Sect. III)

Condition:

Generator set shut down (Para. 2-9)

Battery cables disconnected

Cable disconnected for SLAVE RECEPTACLE

Parts/Materials:

Adhesive, Loctite (Item 16, App. E)

A. REMOVAL.

1.

Tag and disconnect alternator output leads (1, 2, 3, 4, Figure 5-2).

2. Using a #4 metric allen wrench, remove cover (5) by removing six screws (6). Use care when removing cover to prevent damage to alternator output leads.

NOTE

Rotor assembly (11) is held in stator (14) by magnets. The rotor assembly must be completely removed from stator, or magnets will pull it back into place.

3. Release rotor assembly (11) from engine shaft by removing screw (9) and washer (10). Using a mechanical puller, remove rotor assembly (11) completely from stator (14).

4. Loosen clamping ring (13). Remove stator (14) from engine adapter (18) by removing six screws (12).

5. Remove engine adapter (18) from engine by removing four screws (15), lockwashers (16), and washers

(17).

B. INSPECTION.

1. Inspect alternator components for obvious damage. Clean as required to view all components carefully.

Look for signs of excessive wear or electrical short.

2. Inspect electrical wiring for cuts, crimps, bare wire, or other damage. Inspect wiring insulation for damage. Ensure all connectors and terminal lugs are securely attached.

3. Inspect all components for corrosion. Check attaching parts for crossed, stripped, or damaged threads.

4. Inspect edge gasket (8) for damage. Inspect label (7) for legibility. Replace as required.

5. Remove and replace any component that is suspect.

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Figure 5-2. Permanent Magnet Alternator

(Sheet 1 of 2)

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C. INSTALLATION.

1. Apply loctite to threads of four screws (15, Figure 5-2). Install engine adapter (18) onto engine using

screws (15), lockwashers (16), and washers (17). Torque screws to 15 ft-lbs.

2. Install stator (14) into engine adapter (18). Stator must be installed so that the alternator output leads (1, 2,

3, 4) are at the bottom, positioned for their exit through cover (5). Secure stator (14) using six screws (12) and clamping ring (13).

WARNING

Rotor assembly (11) is held in stator (14) by magnets. Rotor will snap into place in stator when installed. Use care to prevent injury to fingers.

3. Hold rotor assembly (11) so that no part of your fingers will be between the rotor and stator (14).

Carefully insert rotor assembly (11) into stator (14). The rotor will cock slightly as it is drawn into the stator and stick in place. Using a rubber hammer, lightly tap the high side of the rotor until it slams into place.

4. Apply loctite to threads of screw (9). Install screw (9) and washer (10). Torque screw to 15 ft-lbs.

5. Using a feeler gage, check that clearance between rotor assembly (11) and stator (14) is 0.010 inch

(minimum) at all points. If clearance is less than 0.010 inch, remove rotor assembly (11) and reinstall.

6. Feed alternator output leads (1, 2, 3, 4) through cover (5). Leads must exit cover without the possibility of abrasion. Secure cover (5) using six screws.

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Figure 5-2. Permanent Magnet Alternator

(Sheet 2 of 2)

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5-9. FUEL TANK MAINTENANCE

This task covers removal, inspection, and installation.

INITIAL SETUP

Tools:

Tool Kit, Master Mechanic’s

(Item 3, App. B, Sect. III)

Condition:

Engine / Alternator assembly removed

(Para. 5-7)

Auxiliary fuel pump removed (Para. 4-51)

A. REMOVAL.

1. Place a suitable container (4 gallon capacity) beneath fuel drain. Open drain valve (1, Figure 5-3) and

drain fuel into container. Close drain valve.

2 Tag and disconnect electrical wiring from fuel tank components.

3. Remove jam nut (3) and washer (4) from hold down bracket (2). Carefully pry pin (5) from pin well to remove hold down bracket.

4. Disconnect fuel drain line (6) from bulkhead fitting (8). Remove bulkhead fitting, elbow (9), and nut (10).

5. Disconnect fuel return line (11) from fitting (12) by loosening hose clamp (13). Disconnect opposite end of line (to fuel injector) from tee.

6. Remove rubber hose (15) from fuel tank filler neck and fuel pocket (16) by loosening clamps (17, 18).

7. Remove tank bracket (22) from skid base by removing screws (19), lockwashers (20), and washers (21).

8. Slide fuel tank (14) towards drain valve (1) and lift rear of tank to remove from skid base.

9. Disconnect fuel drain line (6) from elbow (7). Remove elbow (7), drain valve (1), and fitting (12) from fuel tank (14).

B. INSPECTION.

1. Inspect fuel tank for cracks, dents, cuts, or evidence of leakage. Inspect for corrosion.

2. Inspect fuel hoses for cuts, cracks, or other damage. Check for deterioration.

3. Inspect fuel fittings for crossed, stripped, or damaged threads.

4. Remove and replace any component that is damaged to the extent that it will effect the safe operation of the generator set.

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5-9. FUEL TANK MAINTENANCE - cont.

C. INSTALLATION.

1.

Install drain valve (1, Figure 5-3), elbow (7), and fitting (12) into fuel tank (14). Connect fuel drain line

(6) to elbow (7).

2. Place fuel tank (14) into skid base and slide into place. Secure tank bracket (22) using screws (19), lockwashers (20), and washers (21). Torque screws to 30 ft-lbs.

3. Connect rubber hose (15) between fuel tank filler neck and fuel pocket (16). Tighten clamps (17, 18).

4. Connect fuel return line (11) to fitting (12) and tighten hose clamp (13). Connect opposite end of line (to fuel injector) to tee.

5. Install bulkhead fitting (8), elbow (9), and nut (10) onto skid base. Connect drain hose (6) to fitting (8).

6. Install hold down bracket (2) using jam nut (3), washer (4), and pin (5).

7. Connect electrical wiring to fuel tank components.

8.

Install engine / alternator assembly (Para. 5-7). Install auxiliary fuel pump (Para. 4-51).

Figure 5-3. Fuel Tank

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Left blank

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APPENDIX A

REFERENCES

A-1. Scope.

This appendix lists all forms, field manuals, and technical manuals referenced in this manual or used in conjunction with the generator set.

Forms

Recommended Changes to Publications DA Form 2028

Recommended Changes to Equipment

Technical Manuals DA Form 2028-2

Equipment Inspection and Maintenance Worksheet

Product Quality Deficiency Report

Transportation and Travel Record of Transportation Discrepancies

Report of Item and Packaging Discrepancies

Quality Deficiency Reports

Recommended Changes to Technical Publications

Field Manuals

First Aid for Soldiers

Theater of Operations Electrical Systems

Chemical and Biological Contamination Avoidance

NBC Contamination

NBC Decontamination

Painting Requirements

Color, Marking, and Preparation of Equipment for Shipment

Color and Marking of Army Material

Technical Bulletins

Noise and Conservation of Hearing

Hand Portable Fire Extinguishers Approved for Army Use

Specification List of Standard Liquid Fuels,

Lubricants, Preservatives, and Related

Products Authorized for Use by US Army

DA Form 2404

DA Form 368

MCO P4610.19

MCO 4430.0

MCO 4855.10

NAVMC 10772

FM 21-11

FM 5-424

FM 3-3

FM 3-4

FM 3-5

AR 740-1

AR 746-5

TB MED 251

TB 5-4200-200-10

TB 703-1

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Technical Manuals

The Army Maintenance Management System (TAMMS)

Ground Equipment Record Procedures

Administrative Storage of Equipment

Procedures for Destruction of Equipment to Prevent Enemy Use

Unit, Direct Support, and General Support Maintenance Manual,

Diesel Engine Assembly

Unit, Direct Support, and General Support Repair Parts and

Special Tools List (RPSTL), Diesel Engine Assembly

Unit, Direct Support, and General Support Repair Parts and

DA PAM 738-750

TM 4700-15/1

TM 740-90-1

TM 750-244-3

TM 9-2815-257-24

TM 9-2815-257-24P

Special Tools List (RPSTL), Generator Set

Operator, Unit and Direct Support Maintenance Manual (Including

Repair Parts and Special Tools List), Power Plant, Diesel Driven

1-Ton Trailer Mounted (With Racks) 3kW, 60 Hz, AN/MJQ-43

TM 9-6115-639-23P

TM 9-6115-658-13&P

Corrosion Prevention, Painting and Marking of USAF Support

Equipment (SE)

TO 35-1-3

Processing and Inspection of Support Equipment for Storage and Shipment TO 35-1-4

A-2 Change 1

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APPENDIX B

MAINTENANCE ALLOCATION CHART (MAC)

Section I. INTRODUCTION

B-1. General.

a. This section provides a general explanation of all maintenance and repair functions authorized at various maintenance categories. b. The Maintenance Allocation Chart (MAC) in Section II designates overall authority and responsibility for the performance of maintenance functions on the identified end item or component. The application of the maintenance functions to the end item or component will be consistent with the capacities and capabilities of the designated maintenance levels, which are shown in the MAC in column (4) as:

Unit - includes two subcolumns, C (operator/crew) and O (unit) maintenance.

Direct Support - includes an F subcolumn.

General Support - includes an H subcolumn.

Depot - includes a D subcolumn. c. Section III lists the tools and test equipment (both special tools and common tool sets) required for each maintenance function as referenced from Section II. d. Section IV contains supplemental instructions and explanatory notes for a particular maintenance function.

B-2. Maintenance Functions.

Maintenance functions are limited to and defined as follows:

a. electrical characteristics with established standards through examination (e.g., by sight, sound, or feel).

b. Test. To verify serviceability by measuring the mechanical, pneumatic, hydraulic, or electrical characteristics of an item and comparing those characteristics with prescribed standards.

c. Service. Operations required periodically to keep an item in proper operating condition; e.g., to clean

(includes decontaminate, when required), to preserve, to drain, to paint, or to replenish fuel, lubricants, chemical fluids, or gases.

Adjust. To maintain or regulate, within prescribed limits, by bringing into proper position, or by setting the operating characteristics to specified parameters.

Align. To adjust specified variable elements of an item to bring about optimum or desired performance.

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f. Calibrate. To determine and cause corrections to be made or to be adjusted on instruments or test, measuring, and diagnostic equipment used in precision measurement. Consists of comparisons of two instruments, one of which is a certified standard of known accuracy, to detect and adjust any discrepancy in the accuracy of the instrument being compared.

Remove/Install. To remove and install the same item when required to perform service or other maintenance functions. Install may be the act of emplacing, seating, or fixing into position a spare, repair part, or module (component or assembly) in a manner to allow the proper functioning of an equipment or system.

Replace. To remove an unserviceable item and install a serviceable counterpart in its place. "Replace" is authorized by the MAC and assigned maintenance level is shown as the 3rd position code of the SMR code.

i. Repair. The application of maintenance services(1) including fault location/troubleshooting(2), removal/installation, and disassembly/assembly(3) procedures, and maintenance actions(4) to identify troubles and restore serviceability to an item by correcting specific damage, fault, malfunction, or failure in a parts, subassembly, module (component or assembly), end item, or system.

j. Overhaul. That maintenance effort (service/action) prescribed to restore and item to a completely serviceable/operational condition as required by maintenance standards in appropriate technical publications

(i.e., DMWR). Overhaul is normally the highest degree of maintenance performed by the Army. Overhaul does not normally return an item to like new condition.

k. 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 (e.g., hours/miles) considered in classifying Army equipment/components.

B-3. Explanation of Columns in the MAC, Section II. a. Column 1, Group Number. Column 1 lists functional group code numbers, the purpose of which is to identify maintenance significant components, assemblies, subassemblies, and modules with the next higher assembly.

Column 2, Component/Assembly. Column 2 contains the item names of components, assemblies, subassemblies, and modules for which maintenance is authorized.

(1) Services - Inspect, test, service, adjust, align, calibrate, and/or replace.

(2) Fault location/troubleshooting - The process of investigating and detecting the cause of equipment malfunctioning; the act of isolating a fault within a system or unit under test (UUT).

(3) Disassembly/assembly - The step-by-step breakdown (taking apart) of a spare/functional group coded item to the level of its least component, that is assigned an SMR code for the level of maintenance under consideration (i.e., identified as maintenance significant).

(4) Actions - Welding, grinding, riveting, straightening, facing, machining, and/or resurfacing.

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c.

Column 2. (For detailed explanation of these functions, see paragraph B-2).

d. each function listed in Column 3, by indicating work time required (expressed as man-hours in whole hours or decimals) in the appropriate subcolumn. This work-time figure represents the active time required to perform that maintenance function at the indicated level of maintenance. If the number or complexity of the tasks within the listed maintenance function vary at different maintenance levels, appropriate work-time figures are shown for each level. The work-time figure represents the average time required to restore an item (assembly, subassembly, component, module, end item, or system) to a serviceable condition under typical field operating conditions. This time includes preparation time (including any necessary disassembly/assembly time), troubleshooting/fault location time, and quality assurance time in addition to the time required to perform the specific tasks identified for the maintenance functions authorized in the maintenance allocation chart. the symbol designations for the various maintenance levels are as follows:

C Operator or crew maintenance

O Unit maintenance

F Direct support maintenance

L Specialized Repair Activity (SRA)(5)

H General support maintenance

D Depot maintenance e. Column 5, Tools and Test Equipment Reference Code. Column 5 specifies, by code, the common tool sets (not individual tools), common TMDE, and special tools, special TMDE, and special support equipment required to perform the designated function. Codes are keyed to tools and test equipment in Section

III. f. Column 6, Remarks. When applicable, this column contains a letter code, in alphabetical order, which is keyed to the remarks contained in Section IV.

B-4. Explanation of Columns in Tool and Test Equipment Requirements, Section III.

a. Column 1, Reference Code. The tool and test equipment reference code correlates with a code used in the MAC, Section II, Column 5. b. Column 2, Maintenance Level. The lowest level of maintenance authorized to use the tool or test equipment. c. Column 3, Nomenclature. Name or identification of the tool or test equipment. d. Column 4, National Stock Number. The National Stock Number of the tool or test equipment. e. Column 5, Tool Number. The manufacturer's part number, model number, or type number.

(5) This maintenance level is not included in Section II, Column 4 of the MAC. Functions to this level of maintenance are identified by a work-time figure in the "H" column in Section II, Column 4, and an associated reference code is used in the Remarks column. This code is keyed to Section IV, remarks, and the SRA complete repair application is explained there.

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B-5. Explanation of Columns in Remarks, Section IV.

a. Column 1, Remarks Code. The code recorded in Column 6, Section II. b. Column 2, Remarks. This column lists information pertinent to the maintenance function being performed as indicated in the MAC, Section II.

B-4

(1)

Group

Number

00

01

0101

010101

010102

0102

010201

010202

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Section II. MAINTENANCE ALLOCATION CHART

FOR GENERATOR SET (3KW TQG, MEP 831A/832A)

(2)

Component/Assembly

(3)

Maintenance

Function

Oper

(4)

Unit

Maintenance Level

Direct

Support

F

General

Support

H

Depot

D

(5)

Tools and

Equipment

Ref Code

GEN. SET, 3KW

GENERATOR SET

ASSY

CONTROL BOX

ASSY

CONTROL PANEL

ASSY

WIRING HARNESS,

CONTROL BOX

ENGINE / GEN /

BASE ASSY

ENGINE, DIESEL

ALTERNATOR,

PERMANENT

MAGNET, 3KW

TEST

REM/INST

REPAIR

INSPECT

SERVICE

REM/INST

REPAIR

INSPECT

SERVICE

REM/INST

REPAIR

INSPECT

REM/INST

REPAIR

INSPECT

SERVICE

ADJUST

TEST

REPAIR

INSPECT

SERVICE

ADJUST

TEST

REPAIR

INSPECT

TEST

REPAIR

REM/INST

INSPECT

TEST

REM/INST

REPAIR

INSPECT

0.4

0.1

0.1

0.5

0.1

0.1

0.1

0.1

0.1

0.1

0.1

0.1

0.2

1.5

0.3

0.3

0.5

0.5

0.3

0.3

0.5

0.5

0.1

0.1

0.5

0.8

0.1

0.2

1.5

0.2

0.3

0.5

0.5

0.1

0.1

0.5

0.8

0.4

0.8

1.2

0.4

0.8

1.2

1.0

8.0

1.8

6.0

2.0

0.2

2.0

1.5

1, 2, 7

1 - 6

1, 2, 7

1 - 6

1, 2

1 - 4

1, 2

1, 2

1, 2

1, 2

1, 2

1, 2

1, 2

1, 2

1, 2

3, 4, 5

1 – 4

1, 2

3, 4, 5, 6

1 - 4

1, 2

3, 4, 6

3, 4

A

C

E

A

C

E

A

C

Remarks

Code

A

A, D

A

A, D

A

A, D

E

E

F

A

A, D

(6)

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(1) (2) (3)

Group

Number

010203

010204

010205

0103

0104

0105

Component/Assembly

BATTERY CABLES

LOAD WRENCH

ASSY

GOVERNOR

ACTUATOR ASSY

FAN, MODIFIED

WIRING HARNESS,

GENERATOR SET

FUEL TANK

Maintenance

Function

INSPECT

REM/INST

REPAIR

INSPECT

TEST

REM/INST

REPAIR

REM/INST

SERVICE

INSPECT

REPAIR

INSPECT

REM/INST

REPAIR

INSPECT

REM/INST

REPAIR

INSPECT

REM/INST

REPAIR

Oper

0.1

0.1

0.1

0.1

0.1

0.1

0.1

0.5

0.3

0.1

0.3

0.5

0.5

0.8

Unit

(4)

Maintenance Level

Direct General

Support Support

F H

0.1

0.3

0.5

0.3

0.3

Depot

D

0.5

0.5

10.0

(5)

1, 2

1, 2

1, 2

1, 2

Tools and

Equipment

Ref Code

1, 2

3, 4

1, 2

1, 2

1, 2

1, 2

1, 2

3, 4

1, 2

A

E

A

C

E

E

E

(6)

Remarks

Code

A

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Tool or Test

Equipment

Ref Code

1

2

3

4

5

6

7

Remarks

Code

A

B

C

D

E

F

Section III. TOOLS AND TEST EQUIPMENT

FOR GENERATOR SET (3KW TQG, MEP 831A/832A)

Maintenance

Level

O

O

F

F

F

Nomenclature

SHOP EQUIPMENT, AUTOMOTIVE

MAINTENANCE AND REPAIR

TOOL KIT, GENERAL MECHANIC’S

AUTOMOTIVE

TOOL KIT, MASTER MECHANIC’S

SHOP EQUIPMENT, AUTOMOTIVE

MAINTENANCE AND REPAIR,

FIELD BASIC, LESS POWER

HOIST, 500 LB CAPACITY

PULLER, MECHANICAL

National

Stock Number

4910-00-754-0654

5180-00-177-7033

5180-00-699-5273

4910-00-754-0705

Tool Number

SC4910-95-CL-

A74

SC5180-95-CL-

N26

SC5180-90-CL-

N05

SC4910-95-CL-

A31

F

F TESTER, BATTERY ELECTROLYTE

SOLUTION

Section IV. REMARKS

5180-00-423-1596

6630-00-663-4501

FOR GENERATOR SET (3KW TQG, MEP 831A/832A)

GGG-P-781

TS765U

Remarks

PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)

TEST BY DEPRESSING SWITCH TO TEST INDICATOR LIGHTS

TROUBLESHOOTING TEST/CHECK USING MULTIMETER

SERVICE IN ACCORDANCE WITH LUBRICATION INSTRUCTIONS, CHAPTER 4, SECTION I

REPAIR IS LIMITED TO REPLACEMENT OF DAMAGED PARTS

REFER TO TM 9-2815-257-24 FOR ENGINE REPAIR

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APPENDIX C

COMPONENTS OF END ITEM (COEI) AND BASIC ISSUE ITEMS (BII) LIST

Section I. INTRODUCTION

C-1. Scope.

This appendix list components of end item and basic issue items for the generator set to help you inventory the items for safe and efficient operation of the equipment.

C-2. General.

The Components of End Item (COEI) and Basic Issue Items (BII) lists are divided into the following sections: a. Section II, Components of End Item. This listing is for information purposes only, and is not authority to requisition replacements. These items are part of the generator set. As part of the end item, these items must be with the end item whenever it is issued or transferred between property accounts. Items of COEI are removed and separately packaged for transportation or shipment only when necessary. Illustrations are furnished to help you find and identify the items. b. Section III, Basic Issue Items. These essential items are required to place the generator set in operation, operate it, and to do emergency repairs. Although shipped separately packaged, BII must be with the generator set during operation and when it is transferred between property accounts. This list is your authority to request/requisition them for replacement based on authorization of the end item by the TOE/MTOE.

Illustrations are furnished to help you find and identify the items.

C-3. Explanation of Columns.

a. Column 1, Illus Number, gives you the number of the item illustrated. b. Column 2, National Stock Number, identifies the stock number of the item to be used for requisitioning purposes. c. Column 3, Description and Usable On Code, identifies the Federal item name (in all capital letters) followed by a minimum description when needed. The last line below the description is the Commercial and

Government Entity Code (CAGEC) (in parentheses) and the part number. d. Column 4, U/I (Unit of Issue), indicates how the item is issued for the National Stock Number shown in Column (2). e. Column 5, Qty Rqd, indicates the quantity required.

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(1)

Illus

Number

Section II. COMPONENTS OF END ITEM

(2)

National Stock

Number

(3)

Description

CAGEC and Part Number

NOT APPLICABLE

Section III. BASIC ISSUE ITEMS

(1)

Illus

Number

1

2

3

4

5

(2)

National Stock

Number

N/A

N/A

N/A

(3)

Description

CAGEC and Part Number

TECHNICAL MANUAL, TM 9-6115-639-13

REPAIR PARTS AND SPECIAL TOOLS MANUAL,

TM 9-6115-639-23P

TECHNICAL MANUAL, TM 9-2815-257-24

N/A

5975-00-878-3791

REPAIR PARTS AND SPECIAL TOOLS MANUAL,

TM 9-2815-257-24P

ROD, GROUND (82370) P/N A104

6 4720-00-021-3320 HOSE ASSEMBLY, AUXILIARY FUEL (30554)

P/N FA1493FFF3000

C-2

Change 1

(4)

U/M

(5)

Qty

Rqr

(4)

U/M

EA

(5)

Qty

Rqr

1

EA 1

EA

EA

1

1

EA

EA

1

1

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APPENDIX D

ADDITIONAL AUTHORIZATION LIST (AAL)

Section I. INTRODUCTION

D-1. Scope.

This appendix lists additional items that you are authorized for the support of the generator set.

D-2. General.

This list identifies items that do not accompany the generator set and that do not have to be turned in with it.

These items are all authorized by CTA, MTOE, TDA, or JTA.

D-3. Explanation of Listing.

National Stock Numbers, descriptions, and quantities are provided to help identify and request the additional items required to support the generator set. These items are listed in alphabetical sequence by item name under the type of document (ie, CTA, MTOE, TDA, or JTA) which authorizes the item(s).

D-1

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Section II. ADDITIONAL AUTHORIZATION LIST

(1)

National Stock

Number

7240-00-222-3088

(2)

Description Usable

CAGEC and Part Number On Code

CAN, FUEL, MILITARY

4210-00-270-4512

5120-01-013-1676

7240-00-177-6154

2910-00-066-1235

EXTINGUISHER, FIRE, CARBON DIOXIDE

(81348) P/N O-E-910

SLIDE HAMMER, GROUND

(97403) P/N 13226E7741

SPOUT, CAN, FLEXIBLE

ADAPTER, CONTAINER

(3)

U/I

EA

EA

(4)

Qty

Reqd

1

1

EA 1

EA

EA

1

1

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APPENDIX E

EXPENDABLE AND DURABLE ITEMS LIST

Section I. INTRODUCTION

E-1. Scope.

This appendix lists expendable and durable items that you will need to operate and maintain the generator set.

This listing is for information only and is not authority to requisition the listed items. These items are authorized to you by CTA 50-790, Expendable/Durable Items (except medical, class V repair parts, and heraldic items), or CTA 8-100, Army Medical Department Expendable/Durable Items.

E-2. Explanation of Columns.

a. Column 1, Item Number. This number is assigned to the entry in the listing and is referenced in the

narrative instructions to identify the item (e.g., Cleaning Compound (Item 5, App. E)).

b. Column 2, Level. This column identifies the lowest level of maintenance that requires the item. c. Column 3, National Stock Number. This is the national stock number assigned to the item which you can use to requisition it. d. Column 4, Item Name, Description, CAGEC, Part Number. This provides the other information you need to identify the item. e. Column 5, UM. This code shows the physical measurement or count of an item, such as gallon, dozen, pound, or gross.

E-1

E-2

5

4

6

7

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Section II. EXPENDABLE/DURABLE SUPPLIES AND

REQUIREMENTS LIST

(1)

Item

Number

(2)

Level

(3)

National Stock

Number

(4)

Item Name, Description

CAGEC, Part Number

1 O, F 9150-00-402-2372 OIL, ENGINE, MIL-L-46167, OEA

3

2 O, F

O, F

9150-00-491-7197

9150-00-189-6727

OIL, ENGINE, MIL-L-2104, OE/HDO-15/40

OIL, ENGINE, MIL-L-2104, OE/HDO-10

8

O, F

O, F

O, F

O, F

O, F

9150-01-092-3205

9150-01-433-7970

6850-01-160-3868

6850-00-264-9038

7920-01-338-3329

OIL, ENGINE, MIL-L-2104, OE/HDO-30

OIL, ENGINE, MIL-L-2104, OE/HDO-40

OIL, INHIBITOR, CORROSION

SOLVENT, CLEANING, DRY (81349) P/N PD-

680, TPE II OR III

CLOTH, CLEANING

9

10

11

O, F

O, F

O, F

9150-00-663-1770

8010-01-229-7547

8010-01-340-5175

GREASE, GENERAL PURPOSE, 630AA

PAINT, CARC, MIL-C-46168, COLOR GREEN

383, NO. 34094

PAINT, CARC, MIL-C-46168, COLOR BLACK,

NO. 37038

QT

QT

QT

QT

(5)

U/M

QT

QT

CN

BG

OZ

GL

GL

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O, F

O, F

(2)

Level

O, F

O, F

O, F

O, F

F

O, F

F

(1)

Item

Number

12

13

14

15

16

17

18

19

20

(3)

National Stock

Number

3439-00-974-1873

8040-00-843-0802

8030-01-025-1692

9150-00-111-201

7510-00-836-0810

8030-00-889-355

6810-00-107-1510

(4)

Item Name, Description

CAGEC, Part Number

SOLDER, TIN ALLOY

TUBING, HEAT SHRINK

SEALANT, RTV 108

SEALANT, THREAD, PERMATEX 70-1536

SEALING COMPOUND, ADHESIVE, LOCTITE

242

OIL, LUBRICATING, ENGINE, PE 30, MIL-L-

21260

TAPE, PRESSURE SENSITIVE ADHESIVE, PPT-

T-60

TAPE, ANTISEIZING, TEFLON

WATER, DISTILLED

QT

RL

EA

DR

IN

OZ

OZ

SL

(5)

U/M

OZ

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APPENDIX F

ILLUSTRATED LIST OF MANUFACTURED ITEMS

NOT APPLCABLE

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APPENDIX G

TORQUE LIMITS

Section I. INTRODUCTION

G-1. Scope.

This appendix lists torque ratings for fasteners used on the generator set. When torque values are called out in

the maintenance procedures, those torques supersede the torques specified in this appendix. Table G-1 lists

torque limits for standard fasteners installed dry. Table G-2 provides formulas for converting the dry torque

values to wet. Table G-3 lists torque limits for standard metric fasteners installed dry.

Section II. TORQUE LIMITS

Table G-1. Torque Limits for Dry Fasteners

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Table G-1. Torque Limits for Dry Fasteners - cont.

Table G-2. Effect of Lubrication on Torque

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Table G-3. Torque Limits for Dry Fasteners (Metric)

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APPENDIX H

MANDATORY REPLACEMENT PARTS

Section I. INTRODUCTION

H-1. Scope.

This appendix lists all mandatory replacement parts referenced in the maintenance procedures in this manual.

These are items that must be replaced during maintenance whether they have failed or not. This includes items based on usage intervals such as time, operating hours, etc.

Section II. MANDATORY REPLACEMENT PARTS

(1)

Item

No.

(2)

Part

Number

(3)

National Stock

Number

(4)

Nomenclature

(5)

Qty

1 MS3367-5-9 5975-00-111-3208 STRAP,TIEDOWN,ELECTRIC V

2 H1104 5975-00-727-5153 STRAP,TIEDOWN,ELECTRIC V

3 MS51844-23

5975-01-128-0390 STRAP,TIEDOWN,ELECTRIC

2

V

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APPENDIX I

WARRANTY INFORMATION

Section I. INTRODUCTION

I-1. Scope.

a. This appendix provides information on manufacturer’s warranties for generator set components. The warranty period begins on the date of end item shipment to the government, as defined by the warranty date on

the end item data plate, unless otherwise noted in Table I-1.

b. Warranty service may be obtained with two methods. 1) Warranty service can be obtained by contacting the actual warranted component manufacturer listed in column 1. Each manufacturer will provide instructions on filing a claim. 2) Fill out a warranty claim per DA PAM 738-750. The preferred warranty claim form is the SF368, Product Quality Deficiency Report. The DA Form 2407, Maintenance Request, is also acceptable. c. Troubleshooting should be performed to the level of warranted component, but no further.

Troubleshooting to the failed part inside warranted components may invalidate the warranty. d. If you have difficulty with or questions about the warranty process, contact your local CECOM LAR or the CECOM Generator Branch, DSN 992-1313, (732) 532-1313.

Section II. WARRANTY INFORMATION

Table I-1. Manufacturer’s Warranties

(1)

Manufacturer

Fermont

141 North Ave

Bridgeport, CT 06606

Phone: 203-366-5211

Fax: 203-367-3642

CAGE: 93742

(2)

Component Under Warranty

Alternator Assembly, 3KW Permanent Magnet

(PN: 98-19634, VPN: 692497)

(3)

Warranty Period

1 Year or 1800 Hours

I-1

ARMY TM 9-6115-639-13

AIR FORCE TO 35C2-3-386-51

MARINE CORPS TM 10155A-13/1

(1)

Manufacturer

Technology Research Corporation

5250 140 th

Ave North

Clearwater, FL 33760

Phone: 727-535-0572, ext. 327

Fax: 727-535-4828

CAGE: 60177

Yanmar Diesel America Corp

Mack Boring and Parts Company

2365 Route 22 West

Union, NJ 07083

Phone: 908-964-0700

Fax: 908-964-5032

E-mail: [email protected]

CAGE: S4163

Comair Rotron Inc.

2675 Custom House Ct

San Ysidro, CA 92173

Phone: 619-661-6688

Fax: 619-661-6051

CAGE: 5Y921

Governors of America Corporation

720 Silver Street

Agawam, MA 01001

Phone: 413-786-5600

Fax: 413-786-5666

CAGE: 0BXW5

I-2

Change 1

(2)

Component Under Warranty

Power Inverter/Converter, 60 Hz

(PN: 98-19604-01, VPN: 29350)

Power Inverter/Converter, 400 Hz

(PN: 98-19604-02, VPN: 29340)

Regulator, Battery Charger (PN: 98-19626,

VPN: 29380)

Module, Fault Indicator (PN: 98-19527,

VPN: 29390)

Interrupter, Ground Fault (PN: 19541,

VPN: 29410)

Engine, Diesel (PN:: 98-19513,

VPN: L70AE-DEGFR )

Fan, 115VAC, 60 Hz (PN: 98-19512-01,

VPN: 031842)

Fan, 24VDC (PN: 98-19512-02,

VPN: 031843)

Actuator, Governor, 24VDC (PN: 98-19580,

VPN: ACD150)

Controller, Governor, 24VDC (P/N 98-19539,

VPN: SLC100)

(3)

Warranty Period

18 Months

18 Months

1 Year

1 Year

1 Year

1 Year

1 Year

1 Year

ARMY TM 9-6115-639-13

AIR FORCE TO 35C2-3-386-51

MARINE CORPS TM 10155A-13/1

(1)

Manufacturer

Nelson Industries Inc.

Universal Silencer Div

1801 Hwy 51/138 West

Stoughton, WI 53589

Phone: 608-873-2422

Fax: 608-873-2409

CAGE: 0TW02

Madison Company

27 Business Park Drive

Branford, CT 06405

Phone: 203-488-4477, x103

Fax: 203-481-5036

CAGE: 21603

Purolator Products Co.

Motor Components Division

3 Miracle Mile, PO Box 1502

Elmira, NY 14902

Phone: 607-737-8284

Fax: 607-737-8335

CAGE: 72850

Prestolite Electric Inc.

Hwy 20 W, PO Box 2205

Decatur, AL 35602

Phone: 734-913-6614

Fax: 734- 913-6654

CAGE: 7E656

Contact Industries Inc.

25 Lex-Industrial Drive, PO Box 3086

Lexington, OH 44904

Phone: 419-884-9788

Fax: 419-884-9767

CAGE: 01XD4

(2)

Component Under Warranty

Muffler Assembly, Exhaust (PN: 98-19607,

VPN: 270583N)

Switch, Fuel Level (PN: 98-19519, VPN:

M3770)

Pump, Fuel Auxiliary (PN: 88-21738,

VPN: 40194)

Contactor, 2-Pole, 100 Amp (PN: 98-19523,

VPN: E033845)

Contactor, 2-Pole, 100 Amp (PN: 98-19755,

VPN: CT100D24C1S)

(3)

Warranty Period

1 Year

1 Year from Date of

Shipment from

Madison

1 Year from Date of

Shipment from

Purolator

1 Year

1 Year

Change 1 I-3

I-4

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MARINE CORPS TM 10155A-13/1

This page

Intentionally

Left blank

ARMY TM 9-6115-639-13

AIR FORCE TO 35C2-3-386-51

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ALPHABETICAL INDEX

A

AC Circuit Interrupter Contactor Maintenance.............................................................................................4-56

Access Cover Maintenance .........................................................................................................................4-100

Actuator Maintenance, Governor................................................................................................................4-134

Additional Authorization List (AAL) Items................................................................................................... D-1

Administrative Storage....................................................................................................................................1-4

Air Filter Maintenance ..................................................................................................................................3-11

Alternating Current System...........................................................................................................................1-23

Alternator Maintenance, Permanent Magnet ................................................................................................5-10

Assembly and Preparation for Use................................................................................................................2-19

Auxiliary Equipment.....................................................................................................................................2-26

Auxiliary Fuel Pump Maintenance .............................................................................................................4-126

B

Battery Cable Assembly Maintenance ..........................................................................................................4-96

Battery Charging Regulator Maintenance.....................................................................................................4-58

Battery Maintenance .....................................................................................................................................4-92

Battle Short Operation...................................................................................................................................2-28

BREAKER Maintenance, DC CIRCUIT ......................................................................................................4-43

C

Charging Regulator Maintenance, Battery....................................................................................................4-58

CIRCUIT BREAKER Maintenance..............................................................................................................4-43

Circuit Interrupter Contactor Maintenance ...................................................................................................4-56

CIRCUIT INTERRUPTER Indicator Light Maintenance ............................................................................4-44

Circuit Interrupter Maintenance, Ground Fault.............................................................................................4-62

Cleaning Agents ............................................................................................................................................2-10

Cleaning Agents ..............................................................................................................................................4-8

Common Tools and Equipment ......................................................................................................................4-6

Components Of End Item (COEI) And Basic Issue Items (BII) Lists ........................................................... C-1

Consolidated Index of Army Publications and Blank Forms..........................................................................1-2

Contactor Maintenance, AC Circuit Interrupter............................................................................................4-56

Contactor Maintenance, DC Magnetic........................................................................................................4-132

Control Box and Output Panel Assemblies Maintenance ...............................................................................3-9

Control Box Assembly Maintenance ............................................................................................................4-28

Control Box Fuse, Diode, and Terminal Block Maintenance .......................................................................4-50

Control Box Relay Maintenance ...................................................................................................................4-48

Control Box Wiring Harness Maintenance ...................................................................................................4-54

Control Maintenance, Governor....................................................................................................................4-52

INDEX-1

ARMY TM 9-6115-639-13

AIR FORCE TO 35C2-3-386-51

MARINE CORPS TM 10155A-13/1

C – continued

Control Panel Assembly Maintenance ..........................................................................................................4-32

Controls and Indicators ...................................................................................................................................2-2

Convenience Receptacle Maintenance..........................................................................................................4-60

Converter Maintenance, Power Inverter .....................................................................................................4-128

Cooling Fan and Temperature Switch Maintenance ...................................................................................4-112

Corrosion Prevention and Control (CPC) .......................................................................................................1-2

Cover Maintenance .........................................................................................................................................3-9

Cover Maintenance, Main Access...............................................................................................................4-100

Cross-Reference List.......................................................................................................................................1-4

D

Daily Checks .................................................................................................................................................2-23

DC CIRCUIT BREAKER Maintenance .......................................................................................................4-43

DC Magnetic Contactor Maintenance.........................................................................................................4-132

Decontamination Procedures, (NBC)............................................................................................................2-29

Destruction of Army Material to Prevent Enemy Use ....................................................................................1-4

Differences Between Models ........................................................................................................................1-10

Diode and Terminal Block Maintenance ......................................................................................................4-50

Direct Current System...................................................................................................................................1-21

Direct Support Troubleshooting......................................................................................................................5-3

Drain Assembly Maintenance .......................................................................................................................4-74

E

Electrical System...........................................................................................................................................1-21

Emergency Shut Down .................................................................................................................................2-26

EMERGENCY STOP Switch Maintenance .................................................................................................4-41

EMI Filter Maintenance ................................................................................................................................4-66

Enclosure and Cover Maintenance..................................................................................................................3-9

Enclosure Panel Maintenance .....................................................................................................................4-108

End Item (COEI) And Basic Issue Items (BII) Lists, Components Of .......................................................... C-1

Engine / Alternator Assembly Maintenance ...................................................................................................5-4

Engine Oil Drain Assembly Maintenance.....................................................................................................4-74

Engine Temperature Switch Maintenance ....................................................................................................4-76

Equipment Characteristics, Capabilities, and Features ...................................................................................1-5

Equipment Data.............................................................................................................................................1-10

Equipment Improvement Recommendations (EIR’s) .....................................................................................1-4

Expendable And Durable Items List .............................................................................................................. E-1

Fan and Temperature Switch Maintenance.................................................................................................4-112

F

Fault Indicator Module Maintenance ............................................................................................................4-38

Fill Cap and Fill Pocket Maintenance .........................................................................................................4-123

Fill Pocket Maintenance..............................................................................................................................4-123

INDEX-2

ARMY TM 9-6115-639-13

AIR FORCE TO 35C2-3-386-51

MARINE CORPS TM 10155A-13/1

F – continued

Filter / Water Separator Maintenance, Fuel ................................................................................................4-120

Filter Maintenance, Air .................................................................................................................................3-11

Filter Maintenance, EMI ...............................................................................................................................4-66

Forms and Records..........................................................................................................................................1-2

Fuel Fill Cap and Fill Pocket Maintenance.................................................................................................4-123

Fuel Filter / Water Separator Maintenance ...................................................................................................3-10

Fuel Filter / Water Separator Maintenance .................................................................................................4-120

FUEL LEVEL Gauge Maintenance ..............................................................................................................4-35

Fuel Level Switch Assembly Maintenance...................................................................................................4-80

Fuel Pickup Tube Assembly Maintenance....................................................................................................4-84

Fuel Pump Maintenance, Auxiliary ............................................................................................................4-126

Fuel Pump Maintenance, Primary.................................................................................................................4-85

Fuel Sender Maintenance..............................................................................................................................4-82

Fuel System Maintenance .............................................................................................................................3-10

Fuel System...................................................................................................................................................1-24

Fuel Tank Maintenance.................................................................................................................................5-14

Fuse, Diode, and Terminal Block Maintenance ............................................................................................4-50

G

Gauge Maintenance, FUEL LEVEL .............................................................................................................4-35

Generator Set Enclosure and Cover Maintenance...........................................................................................3-9

Generator Set Maintenance ...........................................................................................................................4-27

Generator Set Shut Down..............................................................................................................................2-26

Generator.......................................................................................................................................................1-23

Governor Actuator Maintenance.................................................................................................................4-135

Governor Control Maintenance.....................................................................................................................4-52

Ground Fault Circuit Interrupter Maintenance..............................................................................................4-62

H, I, J, K

Hand Starting (Manual Engine Cranking) ....................................................................................................2-30

HOURS Meter Maintenance .........................................................................................................................4-34

Identification and Instruction Plates..............................................................................................................1-10

Illustrated List Of Manufactured Items...........................................................................................................F-1

Index of Army Publications and Blank Forms................................................................................................1-2

Indicator Light Maintenance, CIRCUIT INTERRUPTER ...........................................................................4-44

Initial Adjustments, Daily Checks, and Self Test .........................................................................................2-23

Instruction Plates...........................................................................................................................................1-10

Intermediate Term Storage (more than 30 days).........................................................................................4-140

Inverter / Converter Maintenance ...............................................................................................................4-128

INDEX-3

ARMY TM 9-6115-639-13

AIR FORCE TO 35C2-3-386-51

MARINE CORPS TM 10155A-13/1

L

Leakage Definitions for Operator PMCS......................................................................................................2-11

Level Switch Assembly Maintenance, Fuel..................................................................................................4-80

Lifting Handle Maintenance .........................................................................................................................4-72

List of Abbreviations.......................................................................................................................................1-4

LOAD Meter Maintenance ...........................................................................................................................4-37

Location and Description of Major Components............................................................................................1-6

Lubrication Instructions ..................................................................................................................................3-2

Lubrication Oil Pressure Switch Maintenance..............................................................................................4-78

M, N

Magnetic Contactor Maintenance ...............................................................................................................4-132

Main Access Cover Maintenance................................................................................................................4-100

Maintenance Allocation Chart (MAC)........................................................................................................... B-1

Maintenance Forms and Records ....................................................................................................................1-2

Major Components, Location and Description of...........................................................................................1-6

Mandatory Replacement Parts ....................................................................................................................... H-1

Manufactured Items ........................................................................................................................................F-1

Meter Maintenance, HOURS ........................................................................................................................4-34

Meter Maintenance, LOAD ..........................................................................................................................4-37

Meter Maintenance, VOLTAGE...................................................................................................................4-36

Module Maintenance, Fault Indicator ...........................................................................................................4-38

Muffler Assembly Maintenance....................................................................................................................4-88

Nomenclature Cross-Reference List ...............................................................................................................1-4

Nuclear, Biological, and Chemical (NBC) Decontamination Procedures ....................................................2-29

O

Oil Drain Assembly Maintenance .................................................................................................................4-74

Oil Pressure Switch Maintenance .................................................................................................................4-78

Operating Instructions on Decals and Instruction Plates...............................................................................2-26

Operating Procedures ....................................................................................................................................2-24

Operation in Unusual Weather......................................................................................................................2-28

Operation of Auxiliary Equipment................................................................................................................2-26

Operation, Principles of ................................................................................................................................1-21

Operator PMCS Procedures ............................................................................................................................2-8

Operator Switch Maintenance.......................................................................................................................4-39

Operator Troubleshooting ...............................................................................................................................3-3

Operators Controls and Indicators...................................................................................................................2-2

Output Panel Assemblies Maintenance...........................................................................................................3-9

Output Terminals and EMI Filter Maintenance ............................................................................................4-66

INDEX-4

ARMY TM 9-6115-639-13

AIR FORCE TO 35C2-3-386-51

MARINE CORPS TM 10155A-13/1

P, Q

Permanent Magnet Alternator Maintenance .................................................................................................5-10

Pickup Tube Assembly Maintenance............................................................................................................4-84

Plates, Identification and Instruction.............................................................................................................1-10

PMCS Procedures, Operator ...........................................................................................................................2-8

PMCS Procedures, Unit ..................................................................................................................................4-7

Power Inverter / Converter Maintenance ....................................................................................................4-128

Preparation for Use .......................................................................................................................................2-19

Pressure Switch Maintenance, Lubrication Oil.............................................................................................4-78

Primary Fuel Pump Maintenance..................................................................................................................4-85

Principles of Operation .................................................................................................................................1-21

Pump Maintenance, Auxiliary Fuel ............................................................................................................4-126

Pump Maintenance, Primary Fuel.................................................................................................................4-85

R

Receptacle Maintenance, Convenience.........................................................................................................4-60

RECEPTACLE Maintenance, SLAVE .........................................................................................................4-64

References ...................................................................................................................................................... A-1

Regulator Maintenance, Battery Charging....................................................................................................4-58

Relay Maintenance, Control Box..................................................................................................................4-48

Repair Parts .....................................................................................................................................................4-6

Replacement Parts, Mandatory ...................................................................................................................... H-1

Reporting Equipment Improvement Recommendations (EIR’s) ....................................................................1-4

Resistor Maintenance, Voltage .....................................................................................................................4-70

Rheostat Maintenance, VOLTAGE ADJUST ..............................................................................................4-46

S

Scope...............................................................................................................................................................1-2

Self Test ........................................................................................................................................................2-23

Shipment .....................................................................................................................................................4-140

Short Term Storage (30 days or less) ..........................................................................................................4-140

Shut Down.....................................................................................................................................................2-26

Shut Down, Emergency ................................................................................................................................2-26

SLAVE RECEPTACLE Maintenance ..........................................................................................................4-64

Special Tools, TMDE, and Support Equipment..............................................................................................4-6

Starting (Manual Engine Cranking) ..............................................................................................................2-30

Storage, Administrative...............................................................................................................................4-140

Storage, Intermediate Term (more than 30 days)........................................................................................4-140

Storage, Short Term (30 days or less) .........................................................................................................4-140

Support Equipment, Special............................................................................................................................4-6

Switch Assembly Maintenance, Fuel Level..................................................................................................4-80

Switch Maintenance, EMERGENCY STOP ................................................................................................4-41

Switch Maintenance, Engine Temperature ...................................................................................................4-76

Switch Maintenance, Lubrication Oil Pressure.............................................................................................4-78

Switch Maintenance, Operator......................................................................................................................4-39

Switch Maintenance, Temperature..............................................................................................................4-112

INDEX-5

ARMY TM 9-6115-639-13

AIR FORCE TO 35C2-3-386-51

MARINE CORPS TM 10155A-13/1

T

Tank Maintenance, Fuel................................................................................................................................5-14

Temperature Switch Maintenance...............................................................................................................4-112

Temperature Switch Maintenance.................................................................................................................4-76

Terminal Block Maintenance........................................................................................................................4-50

TMDE .............................................................................................................................................................4-6

Tools and Equipment, Common .....................................................................................................................4-6

Torque Limits................................................................................................................................................. G-1

Troubleshooting, Direct Support.....................................................................................................................5-3

Troubleshooting, Operator ..............................................................................................................................3-3

Troubleshooting, Unit ...................................................................................................................................4-12

Tube Assembly Maintenance, Fuel Pickup...................................................................................................4-84

U, V

Unit PMCS Procedures ...................................................................................................................................4-7

Unit Troubleshooting ....................................................................................................................................4-12

Unusual Weather, Operation in.....................................................................................................................2-28

VOLTAGE ADJUST Rheostat Maintenance ...............................................................................................4-46

VOLTAGE Meter Maintenance....................................................................................................................4-36

Voltage Resistor Maintenance ......................................................................................................................4-70

W, X, Y, Z

Warranty Information......................................................................................................................................1-4

Warranty Information.......................................................................................................................................I-1

Water Separator Maintenance .......................................................................................................................3-10

Water Separator Maintenance .....................................................................................................................4-120

Wiring Harness Maintenance, Control Box ..................................................................................................4-54

INDEX-6

ARMY TM 9-6115-639-13

AIR FORCE TO 35C2-3-386-51

MARINE CORPS TM 10155A-13/1

Figure FO-1. Generator Set Electrical Schematic (sheet 1 of 2)

Change 1 FP-1 / (FP-2 blank)

ARMY TM 9-6115-639-13

AIR FORCE TO 35C2-3-386-51

MARINE CORPS TM 10155A-13/1

Figure FO-1. Generator Set Electrical Schematic (Sheet 2 of 2)

Change 1

FP-3 / (FP-4 blank)

ARMY TM 9-6115-639-13

AIR FORCE TO 35C2-3-386-51

MARINE CORPS TM 10155A-13/1

Figure FO-2. Generator Set Wiring Diagram (Sheet 1 of 4)

FP-5 / (FP-6 blank)

ARMY TM 9-6115-639-13

AIR FORCE TO 35C2-3-386-51

MARINE CORPS TM 10155A-13/1

Figure FO-2. Generator Set Wiring Diagram (Sheet 2 of 4)

FP-7 / (FP-8 blank)

ARMY TM 9-6115-639-13

AIR FORCE TO 35C2-3-386-51

MARINE CORPS TM 10155A-13/1

Figure FO-2. Generator Set Wiring Diagram (Sheet 3 of 4)

FP-9 / (FP-10 blank)

ARMY TM 9-6115-639-13

AIR FORCE TO 35C2-3-386-51

MARINE CORPS TM 10155A-13/1

Figure FO-2. Generator Set Wiring Diagram (Sheet 4 of 4)

FP-11 / (FP-12 blank)

ARMY TM 9-6115-639-13

AIR FORCE TO 35C2-3-386-51

MARINE CORPS TM 10155A-13/1

Figure FO-3. Engine Wiring Harness Diagram, 60 Hz (Sheet 1 of 2)

FP-13 / (FP-14 blank)

ARMY TM 9-6115-639-13

AIR FORCE TO 35C2-3-386-51

MARINE CORPS TM 10155A-13/1

Figure FO-3. Engine Wiring Harness Diagram, 60 Hz (Sheet 2 of 2)

FP-15 / (FP-16 blank)

ARMY TM 9-6115-639-13

AIR FORCE TO 35C2-3-386-51

MARINE CORPS TM 10155A-13/1

Figure FO-4. Engine Wiring Harness Diagram, 400 Hz (Sheet 1 of 2) FP-17/ (FP-18 blank)

ARMY TM 9-6115-639-13

AIR FORCE TO 35C2-3-386-51

MARINE CORPS TM 10155A-13/1

Figure FO-4. Engine Wiring Harness Diagram, 400 Hz (Sheet 2 of 2)

FP-19 / (FP-20 blank)

ARMY TM 9-6115-639-13

AIR FORCE TO 35C2-3-386-51

MARINE CORPS TM 10155A-13/1

Figure FO-5. Control Box Wiring Harness Diagram, 60 Hz (Sheet 1 of 3)

FP-21 / (FP-22 blank)

Figure FO-5. Control Box Wiring Harness Diagram, 60 Hz (Sheet 2 of 3)

ARMY TM 9-6115-639-13

AIR FORCE TO 35C2-3-386-51

MARINE CORPS TM 10155A-13/1

FP-23 / (FP-24 blank)

ARMY TM 9-6115-639-13

AIR FORCE TO 35C2-3-386-51

MARINE CORPS TM 10155A-13/1

Figure FO-5. Control Box Wiring Harness Diagram, 60 Hz (Sheet 3 of 3) FP-25 / (FP-26 blank)

ARMY TM 9-6115-639-13

AIR FORCE TO 35C2-3-386-51

MARINE CORPS TM 10155A-13/1

Figure FO-6. Control Box Wiring Harness Diagram, 400 Hz (Sheet 1 of 3)

FP-27 / (FP-28 blank)

ARMY TM 9-6115-639-13

AIR FORCE TO 35C2-3-386-51

MARINE CORPS TM 10155A-13/1

Figure FO-6. Control Box Wiring Harness Diagram, 400 Hz (Sheet 2 of 3)

FP-29 / (FP-30 blank)

ARMY TM 9-6115-639-13

AIR FORCE TO 35C2-3-386-51

MARINE CORPS TM 10155A-13/1

Figure FO-6. Control Box Wiring Harness Diagram, 400 Hz (Sheet 3 of 3)

FP-31 / (FP-32 blank)

By Order of the Secretary of the Army:

ERIC K. SHINSEKI

General, United States Army

Official: Chief of Staff

0024102

By Order of the Secretary of the Marine Corps:

RANDALL P. SHOCKEY

Marine Command

By Order of the Secretary of the Air Force:

MICHAEL E. RYAN

General, United States Air Force

Chief of Staff

Official:

GEORGE T. BABBITT

General, United States Air Force

Commander, AFMC

DISTRIBUTION:

To be distributed in accordance with the initial distribution number (IDN) 256631 requirements for TM 9-6115-639-13.

RECOMMENDED CHANGES TO EQUIPMENT TECHNICAL PUBLICATIONS

SOMETHING WRONG

WITH THIS PUBLICATION

THEN ... JOT DOWN THE INFO

ABOUT IT ON THIS FORM.

CAREFULLY TEAR IT OUT.

FOLD IT AND DROP IT IN THE

MAIL.

FROM: (PRINT YOUR UNIT'S COMPLETE ADDRESS)

Commander

Stateside Army Depot

ATTN: AMSTA-US

Stateside, N.J. 07703-5007

DATE SENT

10 July 1975

PUBLICATION NUMBER PUBLICATION DATE PUBLICATION TITLE

TM 11-5840-340-20 23 Jan 74 Radar Set AN/PRC-76

IN THIS SPACE TELL WHAT IS WRONG

AND WHAT SHOULD BE DONE ABOUT IT:

BE EXACT PIN-POINT WHERE IT IS

PAGE

NO

PARA

GRAPH

FIGURE

NO

2-25 2-28

TABLE

NO

Recommend that the installation antenna alignment procedure be changed throughout to specify a 20 IFF antenna lag rather than 10.

REASON: Experience has shown that with only a 10 lag, the antenna servo system is too sensitive to wind gusting in excess of 25 knots, and has a tendency to rapidly accelerate and decelerate as it hunts, causing strain to the drive train.

Hunting is minimized by adjusting the lag to 20 without degradation of operation.

3-10

5-6

3-3

5-8

FO-3

3-1 Item 5, Functional column. Change •2 dB" to •3 dB".

REASON: The adjustment procedure for the TRANS POWER

FAULT indicator calls for a 3 dB (500 watts) adjustment to light the TRANS POWER FAULT indicator.

Add new step f.1 to read, •Replace cover plate removed in step e.1, above."

REASON: To replace the cover plate.

Zone C 3. On J1-2, change •+24 VDC" to •+5 VDC".

REASON: This is the output line of the 5 VDC power supply.

+24 VDC is the input voltage.

PRINTED NAME, GRADE OR TITLE AND TELEPHONE NUMBER

SSG I. M. DeSpiritof 999-1776

PREVIOUS EDITIONS

ARE OBSOLETE

SIGN HERE

P.S. - IF YOUR OUTFIT WANTS TO KNOW ABOUT YOUR

RECOMMENDATION MAKE A CARBON COPY OF THIS

AND GIVE IT TO YOUR HEADQUARTERS.

REVERSE OF DA FORM 2028-2

FILL IN YOUR

UNIT'S ADDRESS

DEPARTMENT OF THE ARMY

OFFICIAL BUSINESS

FOLD BACK

Commander

U.S. Army Communications-Electronics Command

and Fort Monmouth

ATTN: AMSEL-LC-LEO-D-CS-CFO

Fort Monmouth, New Jersey 07703-5006

PLEASE

AFFIX

STAMP

POSTAGE

REQUIRED

RECOMMENDED CHANGES TO EQUIPMENT TECHNICAL PUBLICATIONS

SOMETHING WRONG

WITH THIS PUBLICATION

FROM: (PRINT YOUR UNIT'S COMPLETE ADDRESS)

THEN ... JOT DOWN THE INFO

ABOUT IT ON THIS FORM.

CAREFULLY TEAR IT OUT.

FOLD IT AND DROP IT IN THE

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DATE SENT

PUBLICATION DATE PUBLICATION TITLE PUBLICATION NUMBER

BE EXACT PIN-POINT WHERE IT IS

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TABLE

NO

IN THIS SPACE TELL WHAT IS WRONG

AND WHAT SHOULD BE DONE ABOUT IT:

PRINTED NAME, GRADE OR TITLE AND TELEPHONE NUMBER

PREVIOUS EDITIONS

ARE OBSOLETE

SIGN HERE

P.S. - IF YOUR OUTFIT WANTS TO KNOW ABOUT YOUR

RECOMMENDATION MAKE A CARBON COPY OF THIS

AND GIVE IT TO YOUR HEADQUARTERS.

REVERSE OF DA FORM 2028-2

FILL IN YOUR

UNIT'S ADDRESS

DEPARTMENT OF THE ARMY

OFFICIAL BUSINESS

FOLD BACK

Commander

U.S. Army Communications-Electronics Command

and Fort Monmouth

ATTN: AMSEL-LC-LEO-D-CS-CFO

Fort Monmouth, New Jersey 07703-5006

PLEASE

AFFIX

STAMP

POSTAGE

REQUIRED

RECOMMENDED CHANGES TO EQUIPMENT TECHNICAL PUBLICATIONS

SOMETHING WRONG

WITH THIS PUBLICATION

FROM: (PRINT YOUR UNIT'S COMPLETE ADDRESS)

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ABOUT IT ON THIS FORM.

CAREFULLY TEAR IT OUT.

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DATE SENT

PUBLICATION DATE PUBLICATION TITLE PUBLICATION NUMBER

BE EXACT PIN-POINT WHERE IT IS

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TABLE

NO

IN THIS SPACE TELL WHAT IS WRONG

AND WHAT SHOULD BE DONE ABOUT IT:

PRINTED NAME, GRADE OR TITLE AND TELEPHONE NUMBER

PREVIOUS EDITIONS

ARE OBSOLETE

SIGN HERE

P.S. - IF YOUR OUTFIT WANTS TO KNOW ABOUT YOUR

RECOMMENDATION MAKE A CARBON COPY OF THIS

AND GIVE IT TO YOUR HEADQUARTERS.

REVERSE OF DA FORM 2028-2

FILL IN YOUR

UNIT'S ADDRESS

DEPARTMENT OF THE ARMY

OFFICIAL BUSINESS

FOLD BACK

Commander

U.S. Army Communications-Electronics Command

and Fort Monmouth

ATTN: AMSEL-LC-LEO-D-CS-CFO

Fort Monmouth, New Jersey 07703-5006

PLEASE

AFFIX

STAMP

POSTAGE

REQUIRED

RECOMMENDED CHANGES TO EQUIPMENT TECHNICAL PUBLICATIONS

SOMETHING WRONG

WITH THIS PUBLICATION

FROM: (PRINT YOUR UNIT'S COMPLETE ADDRESS)

THEN ... JOT DOWN THE INFO

ABOUT IT ON THIS FORM.

CAREFULLY TEAR IT OUT.

FOLD IT AND DROP IT IN THE

MAIL.

DATE SENT

PUBLICATION DATE PUBLICATION TITLE PUBLICATION NUMBER

BE EXACT PIN-POINT WHERE IT IS

PAGE

NO

PARA

GRAPH

FIGURE

NO

TABLE

NO

IN THIS SPACE TELL WHAT IS WRONG

AND WHAT SHOULD BE DONE ABOUT IT:

PRINTED NAME, GRADE OR TITLE AND TELEPHONE NUMBER

PREVIOUS EDITIONS

ARE OBSOLETE

SIGN HERE

P.S. - IF YOUR OUTFIT WANTS TO KNOW ABOUT YOUR

RECOMMENDATION MAKE A CARBON COPY OF THIS

AND GIVE IT TO YOUR HEADQUARTERS.

REVERSE OF DA FORM 2028-2

FILL IN YOUR

UNIT'S ADDRESS

DEPARTMENT OF THE ARMY

OFFICIAL BUSINESS

FOLD BACK

Commander

U.S. Army Communications-Electronics Command

and Fort Monmouth

ATTN: AMSEL-LC-LEO-D-CS-CFO

Fort Monmouth, New Jersey 07703-5006

PLEASE

AFFIX

STAMP

POSTAGE

REQUIRED

PIN: 078443-001

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