TM-5-6115-593-12
DEPARTMENT OF THE ARMY TECHNICAL MANUAL
DEPARTMENT OF THE AIR FORCE TECHNICAL ORDER
*TM 5-6115-593-12
TO-35C2-3-463-1
TECHNICAL MANUAL
Operator and Organizational
Maintenance Manual
GENERATOR SET, DIESEL ENGINE DRIVEN, TACTICAL
SKID MTD., 500 KW, 3 PHASE, 4 WIRE, 120/208 AND 240/416 VOLTS
DOD MODELS
MEP-029A
MEP-029B
CLASS
HERTZ
UTILITY
UTILITY
50/60
50/60
NSN
6115-01-030-6085
6115-01-318-6302
INCLUDING OPTIONAL KITS
DOD MODELS
MEP-029AHK
MEP-029ACM
MEP-029ARC
MEP-029ACC
NOMENCLATURE
HOUSING KIT
AUTOMATIC CONTROL MODULE
REMOTE CONTROL MODULE
REMOTE CONTROL CABLE
NSN
6115-01-070-7550
6115-01-275-7912
6110-01-070-7553
6110-01-087-4127
Approved for public release; distribution is unlimited.
*This manual supersedes TM 5-6115-593-12/NAVFAC P-8-631-1/2TO-35C2-3-463-1, dated 21
September 1981, including all changes.
PUBLISHED UNDER THE AUTHORITY OF THE DEPARTMENTS OF THE ARMY & AIR FORCE
17 JULY 1990
TM 5-6115-593-12
TO 35C2-3-463-1
WARNING
HIGH VOLTAGE
is produced when this generator set is in operation,
DEATH
or severe burns may result if personnel fail to observe safety precautions. Do not operate this generator
set until the ground terminal stud has been connected to a suitable ground. Disconnect the battery
ground cable before removing and installing components on the engine or in the electrical control panel
system.
Do not attempt to service or otherwise make any adjustments, connections or reconnections of wires or
cables until generator set is shut-down and completely de-energized.
WARNING
DANGEROUS GASES
Batteries generate explosive gas during charging; therefore, utilize extreme caution, do not smoke, or
use open flame in vicinity when servicing batteries.
Exhaust discharge contains noxious and deadly fumes. Do not operate generator sets in enclosed areas
unless exhaust discharge is properly vented to the outside.
When filling fuel tank, maintain metal to metal contact between filler nozzle and fuel tank. Do not smoke
or use an open flame in the vicinity.
WARNING
LIQUIDS UNDER PRESSURE
are generated as a result of operation of the generator set. Do not expose any part of the body to a high
pressure leak in the fuel or hydraulic system of the generator set.
Relieve pressure from radiator before removing radiator cap.
WARNING
Shutters will snap shut rapidly with considerable force when generator set is stopped. Ensure all
personnel are clear of shutters before placing MASTER switch to STOP. Serious injury could result.
a
TM 5-6115-593-12
TO 35C2-3-463-1
WARNING
NOISE HAZARD
Operation of this equipment presents a noise hazard to personnel in the area. The noise level exceeds
the allowable limits for unprotected personnel. Wear ear muffs or ear plugs which were fitted by a
trained professional.
WARNING
All specific cautions and warning contained in this manual shall be strictly adhered to. Otherwise,
severe injury, death and/or damage to the equipment may result.
WARNING
Disconnect all input bars, bussing, cables and control circuits to breaker before starting test procedure.
WARNING
Before performing maintenance and accidental cranking set MAINTENANCE LOCKOUT switch to
LOCKOUT. Disconnect negative cable from batteries. Remove external power by opening CB101 and
disconnecting load terminals of generator set circuit breaker (CB2) may still be energized with the bus
voltage.
WARNING
Do not operate the generator set unless the ground terminal stud has been connected to a suitable
ground. Electrical faults in the generator set, load lines or load equipment, can cause injury or
electrocution with an ungrounded system.
WARNING
Make sure that no tools, parts or loose items are on any part of the engine since they might cause bodily
harm to personnel when the engine is started.
WARNING
Placing AC PWR CKT BKR to CLOSE applies power to output load terminals and load lines. Ensure all
personnel are clear of output load terminals. Serious injury or death could result from contact with output
voltage.
b
DEPARTMENT OF THE ARMY TECHNICAL MANUAL
DEPARTMENT OF THE AIR FORCE TECHNICAL ORDER
*TM 5-6115-593-12
TO-35C2-3-463-1
HEADQUARTERS
DEPARTMENTS OF THE ARMY, NAVY & AIR FORCE
WASHINGTON, D.C., 17 July 1990
Operator and Organizational
Maintenance Manual
GENERATOR SET, DIESEL ENGINE DRIVEN, TACTICAL
SKID MTD., 500 KW, 3 PHASE, 4 WIRE, 120/208 AND 240/416 VOLTS
DOD MODELS
CLASS
HERTZ
NSN
MEP-029A
MEP-029B
UTILITY
UTILITY
50/60
50/60
6115-01-030-6085
6115-01-318-6302
INCLUDING OPTIONAL KITS
DOD MODELS
MEP-029AHK
MEP-029ACM
MEP-029ARC
MEP-029ACC
NOMENCLATURE
HOUSING KIT
AUTOMATIC CONTROL MODULE
REMOTE CONTROL MODULE
REMOTE CONTROL CABLE
NSN
6115-01-070-7550
6115-01-275-7912
6110-01-070-7553
6110-01-087-4127
Approved for public release; distribution is unlimited.
*This manual supersedes TM 5-6115-593-12/NAVFAC P-8-631-12/TO-35C2-3-463-21, dated 21 September
1981, including all changes.
i
TM 5-6115-593-12
TO 35C2-3-463-1
TABLE OF CONTENTS
Paragraph
CHAPTER
Section
CHAPTER
Section
1.
I
II
III
2.
I
II
III
CHAPTER
Section
3.
I
II
III
IV
V
CHAPTER
Section
4.
I
II
III
IV
V
VI
VII
VIII
IX
X
XI
XII
XIII
XIV
XV
XVI
XVII
XVIII
XIX
XX
XXI
XXII
XXIII
XXIV
INTRODUCTION
General
Description and Data
System operation
OPERATING INSTRUCTIONS
Operating Procedures
Operation of auxiliary material used
in conjunction with the equipment
Operation Under Unusual Conditions
OPERATOR/CREW MAINTENANCE INSTRUCTIONS
Consumable operating and maintenance
supplies
Lubrication instructions
Preventive maintenance checks and
services (PMCS)
Troubleshooting
Operator/crew maintenance
ORGANIZATIONAL MAINTENANCE
Service upon receipt of equipment
Movement to a new worksite
Repair parts; special tools;
special test measurement and
diagnostic equipment (TMDE); and
special support equipment
Lubrication instructions
Preventive maintenance checks and
services (PMCS)
Troubleshooting
Radio interference suppression
Maintenance of batteries and
related items
Maintenance of muffler and exhaust
Maintenance of external power box
assembly
Maintenance of AC-DC control box
assembly
Maintenance of control cubicle
Maintenance of air cleaner
Maintenance of tool box assembly
Maintenance of document compartment
Maintenance of support frame assembly
Maintenance of radiator assembly
Maintenance of fuel lines and fittings
Maintenance of engine preheat
Maintenance of fuel transfer pump
Maintenance of fuel tank assembly
Maintenance of interconnecting
electrical wiring harness
Maintenance of generator and
reconnection assembly
Maintenance of electric hydraulic
actuator
ii
1-1
1-9
1-13
2-1
Page
1-1
1-1
1-2
1-23
2-1
2-1
2-8
2-11
2-20
2-46
3-1
3-1
3-2
3-1
3-3
3-3
3-5
3-6
4-1
4-5
3-3
3-3
3-10
4-1
4-1
4-14
4-6
4-8
4-15
4-15
4-9
4-10
4-11
4-17
4-17
4-17
4-13
4-17
4-34
4-37
4-19
4-38
4-28
4-40
4-42
4-45
4-46
4-47
4-49
4-50
4-51
4-52
4-54
4-50
4-58
4-71
4-74
4-76
4-76
4-76
4-82
4-82
4-88
4-90
4-57
4-95
4-59
4-95
4-64
4-96
TM 5-6115-593-12
TO 35C2-3-463-1
TABLE OF CONTENTS - CONTINUED
Paragraph
CHAPTER
4.
Section XXV
XXVI
XXVII
CHAPTER
Section
5.
I
II
III
IV
V
Page
Maintenance of ether kit
Maintenance of engine assembly
Maintenance of base assembly
4-65
4-66
4-88
4-98
4-99
4-127
AUXILIARY EQUIPMENT USED IN CONJUNCTION
WITH THE GENERATOR SET
Introduction
Remote control module
Remote control cable assembly
Automatic control module
Housing kit
5-1
5-2
5-10
5-12
5-30
5-1
5-1
5-1
5-13
5-13
5-20
APPENDIX
A.
REFERENCES
A-1
APPENDIX
B.
BASIC ISSUE ITEM LIST AND ITEMS TROOP
INSTALLED OR AUTHORIZED LIST
Introduction
Integral components of end item
Basic issue items
Troop installed or authorized list
B-1
B-1
B-2
B-3
B-4
Section
APPENDIX
Section
I
II
III
IV
C.
I
II
III
IV
APPENDIX
Section
D.
I
II
MAINTENANCE ALLOCATION CHART (MAC)
Introduction
Maintenance allocation chart
Tools, test and support equipment
requirements
Remarks
C-1
C-1
C-3
ADDITIONAL AUTHORIZATION LIST
Introduction
Additional authorization list
D-1
D-1
D-2
iii
C-16
C-17
TM 5-6115-593-12
TO 35C2-3-463-1
LIST OF ILLUSTRATIONS
Figure
Title
Page
1-1.
1-2.
1-3.
1-4.
1-5.
1-6.
1-7.
1-8.
1-9.
Generator Set, Left Side ..................................................................................................
Generator Set, Right Side ................................................................................................
Generator Set, Rear.........................................................................................................
Generator Set, Top ..........................................................................................................
Remote Control Module ...................................................................................................
Automatic Control Module ................................................................................................
Housing Kit, Installed on Generator Set ...........................................................................
Fuel System Diagram.......................................................................................................
Instruction Plate Locations ...............................................................................................
1-3
1-4
1-5
1-6
1-7
1-8
1-9
1-20
1-21
2-1.
2-2.
2-3.
2-4.
2-5.
2-6.
2-7.
2-8.
2-9.
2-10.
2-3
2-5
2-9
2-11
2-12
2-15
2-18
2-19
2-20
2-19.
2-20.
2-21.
Engine Control Panel (Part of Control Cubicle).................................................................
Generator Control Panel (Part of Control Cubicle)............................................................
AC-DC Control Panel .......................................................................................................
External Power Box Control Panel ...................................................................................
Preparation for Starting (3 Sheets) ...................................................................................
Starting Instructions (3 Sheets) ........................................................................................
Stopping Instructions........................................................................................................
Single Generator Unit, Operating Instructions...................................................................
Preparation for Starting with Housing Kit Installed (3 Sheets) ...........................................
Starting Instructions when Ambient Temperature is from
40°F to -25°(4.4°C to -320C) and Housing Kit
is installed (3 Sheets).................................................................................................
Stopping Instructions with Housing Kit Installed................................................................
Single Generator Unit, Operating Instructions with
Housing Kit Installed ..................................................................................................
Remote Control Module Panel .........................................................................................
Jumper Connections to be Removed when a Remote Control
Module is Connected .................................................................................................
Preparation for Starting Using Remote Control Module ....................................................
Starting Instructions Using Remote Control Module (2 Sheets).........................................
Stopping Instructions Using Remote Control Module ........................................................
Operating Instructions, Single Generator Unit Using Remote
Control Module ..........................................................................................................
Automatic Control Module ................................................................................................
Jumper Connections When Automatic Control Module is Used ........................................
Operating Instructions, Manually Operated in parallel (2 Sheets)......................................
3-1.
3-2.
Air Cleaner, Exploded View..............................................................................................
Fuel Transfer Pump Inspection Points..............................................................................
3-11
3-13
4-1.
4-2.
4-3.
4-4.
4-5.
4-6.
4-7.
4-8.
4-8A.
4-9.
4-10.
4-11.
4-12.
4-13.
4-14.
Fan Belt Tension Check ...................................................................................................
Cooling System Drain and Shut-off Cock .........................................................................
Location of Engine Water Drains......................................................................................
Location of Engine Crankcase Drain and Drain Valve ......................................................
Location of Fuel Tank Drain Cock ....................................................................................
Installation Plan................................................................................................................
Grounding Procedures (3 Sheets) ....................................................................................
Output Voltage Conversion Connections ..........................................................................
Crankcase Breather .........................................................................................................
Batteries and Related Items, Exploded View ....................................................................
Battery Cable Fabrication.................................................................................................
Muffler and Exhaust, Exploded View ................................................................................
External Power Box Assembly, Exploded View ................................................................
External Power Box Assembly, Control Panel, Exploded View .........................................
Contactors K107, K108, K109 and Main Circuit Breaker CB2
Schematic..................................................................................................................
Main Circuit Breaker, CB2................................................................................................
iv
4-2
4-3
4-4
4-5
4-6
4-8
4-9
4-14
4-16
4-35
4-36
4-39
4-40
4-42
2-11.
2-12.
2-13.
2-14.
2-15.
2-16.
2-17.
2-18.
4-15.
2-23
2-26
2-27
2-29
2-32
2-33
2-34
2-36
2-37
2-40
2-42
2-43
4-45
4-46
TM 5-6115-593-12
TO 35C2-3-463-1
LIST OF ILLUSTRATIONS-CONTINUED
Figure
4-16.
Title
4-20.
4-21.
4-22.
4-23.
4-24.
4-25.
4-26.
4-27.
4-28.
4-29.
4-30.
4-31.
4-32.
4-33.
4-34.
4-35.
4-36.
4-37.
4-38.
4-39.
4-40.
4-41.
4-42.
4-43.
4-44.
4-45.
4-46.
4-47.
4-48.
4-49.
4-50.
4-51.
4-52.
4-53.
4-54.
4-55.
4-56.
4-57.
4-58.
4-59.
4-60.
4-61.
External Power Box Assembly, Plate and Sleeve Assembly
Exploded View ..........................................................................................................
AC-DC Control Box Assembly, Exploded View ................................................................
AC-DC Control Box Assembly, Component Panel Assembly,
Exploded View ..........................................................................................................
AC-DC Control Box Assembly, Component Panel Assembly,
Exploded View ..........................................................................................................
Control Cubicle, (3 Sheets) .............................................................................................
Control Cubicle, Engine Panel, Exploded View ................................................................
Control Cubicle, Generator Panel, Exploded View (2 Sheets) ..........................................
Air Cleaner and Related Parts .........................................................................................
Tool Box Assembly .........................................................................................................
Document Compartment .................................................................................................
Support Frame Assembly.................................................................................................
Radiator Assembly, Exploded View .................................................................................
Fan Belt Adjustment and Replacement ...........................................................................
Fuel Lines (2 Sheets) ......................................................................................................
Engine Preheat Installation (2 Sheets) .............................................................................
Fuel Transfer Pump Installation, Exploded View .............................................................
Fuel Transfer Pump Contractor K20 ................................................................................
Fuel Tank Assembly, Exploded View ...............................................................................
Fuel Level Switch Test Data.............................................................................................
Liquid Quantity Transmitter .............................................................................................
Generator and Reconnection Board ................................................................................
Electric Hydraulic Actuator ..............................................................................................
Ether Kit ..........................................................................................................................
Ether Installation .............................................................................................................
Engine Components (2 Sheets)........................................................................................
Water Pump Belt Adjustment ..........................................................................................
Speed Switch ..................................................................................................................
Oil Level Sight Gauge and Filler .....................................................................................
Starter Assembly .............................................................................................................
Oil Pressure Transmitter ..................................................................................................
Pressure Switches ...........................................................................................................
Oil Filters .........................................................................................................................
Secondary Fuel Filter .......................................................................................................
Lube Oil Cooler ................................................................................................................
Fuel Injector .... ................................................................................................................
Turbocharger ...................................................................................................................
Water Pump and Idler Pulley Assembly ..........................................................................
Thermostat Removal........................................................................................................
Coolant Temperature Transmitter.....................................................................................
Coolant Temperature Switch ............................................................................................
Intercooler........................................................................................................................
Exhaust Manifold .............................................................................................................
Water Manifold ...............................................................................................................
Rocker Arm and Shaft Assembly......................................................................................
Base Assembly, Exploded View .......................................................................................
Breather Lines and Fittings...............................................................................................
5-1.
5-2.
5-3.
5-4.
5-5.
Remote Control Module ...................................................................................................
Remote Control Module, Plate Assembly ........................................................................
Remote Control Module, Annunciator Control Assembly .................................................
Actuator Control Relay Assembly ....................................................................................
Housing Kit, Installed on Generator Set ...........................................................................
4-17.
4-18.
4-19.
v
Page
4-49
4-51
4-53
4-55
4-59
4-63
4-65
4-72
4-75
4-77
4-78
4-79
4-80
4-84
4-86
4-91
4-92
4-93
4-94
4-94
4-96
4-97
4-98
4-100
4-101
4-103
4-104
4-105
4-107
4-108
4-108
4-110
4-111
4-112
4-114
4-115
4-117
4-118
4-120
4-121
4-123
4-124
4-125
4-126
4-129
4-132
5-2
5-11
5-12
5-23
5-24
TM 5-6115-593-12
TO 35C2-3-463-1
LIST OF ILLUSTRATIONS-CONTINUED
Figure
Title
Page
B-1.
Basic Issue Items ............................................................................................................
B-3
FO-1.
FO-2.
FO-3.
FO-4.
FO-5.
FO-6.
FO-7.
FO-8.
FO-9.
FO-10.
FO-11.
FO-12.
FO-13.
FO-14.
FO-15.
FO-16.
FO-17.
DC Schematic .................................................................................................................
AC Schematic .................................................................................................................
DC Wiring Diagram (Troubleshooting)............................................. .................................
AC Wiring Diagram (Troubleshooting) .............................................................................
AC/DC Control Box Wiring Diagram (Troubleshooting) ...................................................
External Power Box Wiring Diagram (Troubleshooting) ...................................................
Unit Control Box Wiring Diagram (Troubleshooting) ........................................................
Remote Control Module Schematic .................................................................................
Remote Control Module Wiring Diagram (Troubleshooting) .............................................
Generator Reconnection Box Wiring Diagram (Troubleshooting) .....................................
Engine Accessories Wiring Diagram (Troubleshooting) ...................................................
Automatic Control Module Schematic ..............................................................................
Automatic Control Module Wiring Diagram (Troubleshooting) .........................................
Remote Control Module Interconnect Wiring Diagram .....................................................
Automatic Control Module Wiring Interconnect Diagram .................................................
Louver Control Schematic ...............................................................................................
Louver Control Harness .................................................................................................
FO-1
FO-2
FO-3.1
FO-4.1
FO-5.1
DO-6.1
FO-7.1
FO-8
FO-9.1
FO-10
FO-11
FO-12.1
FO-13
FO-14
FO-15
FO-16
FO-17
vi
TM 5-6115-593-12
TO 35C2-3-463-1
LIST OF TABLES
Figure
Title
Page
1-1.
Torque Data ....................................................................................................................
1-22
2-1.
2-2.
2-3.
2-4.
2-5.
2-6.
Engine Control Panel, Controls and Instruments .............................................................
Generator Control Panel, Controls and Instruments .........................................................
AC-DC Control Panel, Controls and Instruments .............................................................
External Power Box Control Panel, Controls and Instruments...........................................
Remote Control Panel, Controls and Instruments ............................................................
Automatic Control Module, Controls and Instruments ......................................................
2-2
2-4
2-8
2-10
2-28
2-41
3-1.
3-2.
3-3.
Consumable Operating and maintenance Supplies .........................................................
Preventive Maintenance Checks and Services ................................................................
Troubleshooting ...............................................................................................................
3-1
3-4
3-6
4-1.
Freezing Points, Composition, and Specific Gravities of
Military Antifreeze ......................................................................................................
Preventive Maintenance Checks and Services ................................................................
Troubleshooting ...............................................................................................................
4-7
4-18
4-20
4-2.
4-3.
5-1.
5-2.
5-3.
5-4.
5-5.
5-6.
5-7.
5-8.
Preventive Maintenance Checks and Services, Remote
Control Module .........................................................................................................
Remote Control Module Troubleshooting
(Operator/Crew Level) ..............................................................................................
Remote Control Module Troubleshooting
(Organizational Level) ...............................................................................................
Preventive Maintenance Checks and Services,
Automatic Control Module .........................................................................................
Automatic Control Module Troubleshooting
(Operator/Crew Level) ..............................................................................................
Automatic Control Module Troubleshooting
(Organizational Level)................................................................................................
Preventive Maintenance Checks and Services, Housing Kit ............................................
Housing Kit Troubleshooting.............................................................................................
vii/(viii blank)
5-3
5-4
5-7
5-16
5-16
5-17
5-22
5-22
TM 5-6115-593-12
TO 35C2-3-463-1
CHAPTER 1
INTRODUCTION
Section I. GENERAL
Command, ATTN: AMSTR-MCTS, 4300
Goodfellow Boulevard, St. Louis, MO 631201798
b. (F) Air Force - AFTO Form 22 directly to:
Commander, Sacramento Air Logistics Center,
ATTN: SM-ALC-MMEDTA, McClellan Air Force
Base, CA 95652-5609 in accordance with TO-005-1.
c. (N) Navy - by letter directly to: Commanding
Officer, Naval Construction Battalion Center,
ATTN: Code 15741 Bldg. 43, Port Hueneme, CA
93043-5000.
d. (MC) Marine Corps - by NAVMC Form 10772
directly to: Commanding General, Marine Corps
Logistics Base, (Code 850) Albany, GA 317045000.
1-5. LEVELS OF MAINTENANCE ACCOMPLISHMENT.
The authorized maintenance and repair functions will be
accomplished as follows:
a. (AMC) Army and Marine Corps users shall refer
to the Maintenance Allocation Chart (MAC) for
tasks and levels of maintenance to be performed.
b. (F) Air Force users shall accomplish maintenance
at the user level consistent with their capability in
accordance with policies established in AFM-66-1.
c. (N) Navy users shall determine their maintenance
levels in accordance with their service directives.
1-1. SCOPE. This manual is for your use in operating
and maintaining the 500 KW Diesel Engine Driven
Generator Set. The 50/60 Hertz, (Mode I) Tactical Utility
(Type I, Class 2A) Set is used in applications where
precise power is not required. This manual also includes
a description of accessory modules and their functions in
relations to other components.
1-2. LIMITED APPLICABILITY. Some portions of this
publication are not applicable to all services. These
portions are prefixed to indicate the services to which they
pertain: (A) for Army, (F) for Air Force, (N) for Navy, and
(MC) for Marine Corps.
Portions not prefixed are
applicable to all services.
1-3. MAINTENANCE FORMS AND RECORDS. The
forms and records used for maintenance purposes by the
various services are specified as follows:
a. (A) Maintenance forms and records used by Army
personnel are prescribed by DA PAM 738-750.
b. (F) Maintenance forms and records used by Air
Force personnel are prescribed in AFM-66-1 and
the applicable 00-20 Series Technical Orders.
c. (N) Navy users should refer to their service
peculiar directives to determine applicable
maintenance forms and records to be used.
d. (MC) Maintenance forms and records used by
Marine Corps personnel are prescribed by TM
4700-15/1
1-4. REPORTING OF ERRORS. Report of errors,
omissions, and recommendations for improvement of this
publication by the individual user is encouraged. Reports
should be submitted as follows:
a. (A) Army - DA Form 2028 directly to:
Commander, U.S. Army Troop Support
1-6. DESTRUCTION OF ARMY MATERIEL. (AMC)
Demolition of material to prevent enemy use will be in
accordance with the requirements of TM750-244-3.
(Procedures For Destruction of Equipment to Prevent
Enemy Use).
1-1
TM 5-6115-593-12
TO 35C2-3-463-1
should be corrected, and all modification work
orders (MWO's) should be applied.
1-7. ADMINISTRATIVE STORAGE. (A,F,MC) Detailed
information pertaining to administrative storage for the
various services is contained in the following documents.
Processing and Inspection of Aerospace Ground
Equipment for Storage and Shipment, T035-1-4 is
applicable to Air Force personnel, MCOP4450.7 is
applicable to Marine Corps personnel and for Army
personnel:
c.
Storage site selection. Inside storage is preferred
for items selected for administrative storage. If
inside storage is not available, trucks, vans,
conex containers and other containers may be
used.
1-8. PREPARATION FOR SHIPMENT AND STORAGE.
The requirements pertaining to the preparation for
shipment and storage for the various services are
contained in the following documents.
a. Placement of equipment in administrative storage
should be for short periods of time when a storage
of maintenance effort exists. Items should be in
mission readiness within 24 hours or within the
time factors are determined by the directing
authority. During the storage period appropriate
maintenance records will be kept.
a. (A) Army - Refer to TB740-97-2.
b. (F) Air Force - Refer to T035-1-4 for end item
generator sets and T038-1-5 for installed engine.
b. Before placing equipment in administrative
storage, current maintenance services and
equipment serviceable criteria (ESC) evaluations
c.
(N,MC) Navy and Marine Corps refer to individual
service directives for requirements.
Section II. DESCRIPTION AND DATA
1-9. DESCRIPTION.
and remote control cable are also available for
use with the generator set. The automatic control
module provides for parallel operation of up to
four generator sets. The automatic control
module senses and initiates the unattended
sequence when the normal 120V AC supply
voltage varies more than plus or minus 10
percent and/or the frequency varies more than
3.0 percent. The remote control module permits
remote start, stop, monitor, and control of the
generator set from a location up to 100 feet (30
meters) via the remote control cable.
a. General. The generator set, military model MEP029A and MEP-029B (figures 1-1, 1-2, 1-3, and 14), is a skid-mounted, self- contained unit. The
generator is provided with controls, instruments
and accessories necessary for operation as a
single unit, or in parallel, with up to three
additional units of the same class and mode.
Housing kit (military model MEP-029 AHK) is
available for field installation. The housing kit
encloses the top, sides, and ends of the set and is
removable to provide access for overhaul or
replacement of the major components. The
housing kit is attached to a skid base by bolted
construction to provide a rain proof enclosure.
When the doors, covers, and louvers are closed,
rain, snow, and sand are excluded from the
interior of the housing. An automatic control
module (ACM), remote control module (RCM),
b. Generator Set. A brief description of the major
components comprising the generator set is
provided in the following paragraphs:
(1) Engine. The engine is a liquid-cooled, 12cylinder,
1-2
TM 5-6115-593-12
TO 35C2-3-463-1
60 Hz output can be generated according to
engine rpm.
1710 cubic inch (28 liter) displacement, four-stroke cycle,
turbocharged diesel engine.
(3) Control Cubicle. The control cubicle contains
the engine control panel and the generator
control panel. The engine control panel has
controls, switches, and instruments necessary
to start, stop, operate, and monitor the
engine. The
(2) Generator. The 50/60 Hz generator is a
417/500 kw, brushless, permanent magnet,
single bearing, air-cooled, open drip-proof
unit. It is a reconnectable generator capable
of producing different voltages. Either 50 or
Figure 1-1. Generator Set, Left Side
1-3
TM 5-6115-593-12
TO 35C2-3-463-1
charger. The control panel contains switches,
circuit breaker, potentiometers, and
receptacles. The governor controller has a load
sharing and speed control unit consisting of an
electric governing control that provides
isochronous control with load sharing for parallel
operations. The voltage regulator regulates
generator control panel has controls, switches,
and instruments necessary to operate and
monitor the generator.
(4) AC-DC Control Box Assembly. The AC-DC
control box assembly consists of a control
panel, governor controller, voltage regulator,
motor- operated potentiometers, and battery
Figure 1-2. Generator Set, Right Side
1-4
TM 5-6115-593-12
TO 35C2-3-463-1
phase 120/240V AC, 50/60 Hz external
source to energize its circuits when internal
power is not available. The battery charger
and convenience receptacle circuits
automatically transfer from internal power to
external power when internal power is not
available and the circuit breaker is closed.
generator voltage and has controls to adjust
stability, voltage, and voltage range. The
motor-operated potentiometers are used to
adjust voltage and speed settings.
(5) External Power Box Assembly. The external
power box assembly provides a means of
accepting a supply of power from a single
Figure 1-3. Generator Set, Rear
1-5
TM 5-6115-593-12
TO 35C2-3-463-1
c.
Mode ................................. 50/60 Hertz, 3
phase, 4 wire
Class ................................. Utility
Operating temperature range
Unhoused .................... 125 to 32°F
(52 to 0°C)
Housed ........................ 125 to -25°F
(52 to 0°C)
Power output ..................... 417 kw at 50 Hz
500 kw at 60 Hz
Voltage output ................... 120/208 volts and
240/416 volts
Power factor ...................... 0.8 pf lagging
Parallel operation ............... Not more than 2
(zero speed droop)
percent voltage
droop
Accessory Items. Accessory items consist of a
remote control module (figure.1-5); remote control
cable assembly; a automatic control module
(figure 1-6); and, if required, a housing kit (figure
1-7).
1-10. TABULATED DATA
a. Generator Set
DOD Drawing Number .......76-029
Manufacturer ......................Fermont Division Dynamics
Corporation of
America
Model .................................MEP-029A and MEP-029B
Figure 1-4. Generator Set, Top
1-6
TM 5-6115-593-12
TO 35C2-3-463-1
Overall width ............... 88 inches
(226 centimeters)
Overall height .............. 120 inches
(with muffler)
(304.8 centimeters
Dry weight ................... 32,550 pounds
(14,764 kilograms)
Net weight ................... 34,050 pounds
(filled)
(15,445 killograms)
Cubage .............................. 1,337 cubic feet
(40 cubic
meters)
Parallel operation ................Not more than 3
(3 percent speed
percent voltage
droop)
droop
Capacities
Fuel system .................117 gallons
(443 liters)
Cooling system ..................52 gallons
(197.6 liters)
Lubricating oil .....................18 gallons
(68 liters)
Dimensions and weights
Overall length ..............219 inches
(556 centimeters)
Figure 1-5. Remote Control Module
1-7
TM 5-6115-593-12
TO 35C2-3-463-1
Batteries
DOD Drawing Number..76-11252
Type ............................ Lead acid, 174
plates
Rating ......................... 12 volt, 200 ampere-hours, 20
hour rate
Weight (wet) ...................... 150 pounds
(67.5 kilograms)
b. Batteries and Cables.
Cables
76-11424-01........ Blk ............ 81
76-11424-02........ Blk ............ 96
76-11422-01........ Red........... 91
76-11422-02........ Red......... 101
76-11423............. Red.......... 7.5
76-11423............. Blk ........... 7.5
in ......... 206
in.. ....... 244
in.. ....... 231
in. .... .256.6
in ........... 19
in ........... 19
cm
cm
cm
cm
cm
cm
Figure 1-6. Automatic Control Module
1-8
TM 5-6115-593-12
TO 35C2-3-463-1
at 208V AC, 868
amps, continuos at
416V AC, 60 Hz.
Motor.................................. Ratings: 114/143V
AC at 50/60 Hz
Number in gen- .............Four, serieserator set
parallel, 24V DC
c.
External Power Box Assembly
Motor-Operator Circuit Breaker
DOD Drawing Number ..76-11205
Main contacts ...............3 pole breaker
rated 2000 amps.
Minimum current
ratings: 1734
amps, continuous
Heater System Contactors
DOD Drawing Number.. 76-11202
Type ............................ AC magnetic,
open, NEMA Size
1
Coil voltage ................. 120V AC, 50/60
.....................................
Hz, 2 pole
Figure 1-7. Housing Kit, Installed on Generator Set
1-9
TM 5-6115-593-12
TO 35C2-3-463-1
76-11214
76-11213
Resistance ...................... 500 ohm, 3 watt,
3 turn
Motor .............................. 24V DC, reversing, 1/20 hp
Clutch ............................. Adjusted for 20
±5 inch-ounces
(0.08 joules)
torque
76-11214
Resistance ...................... 250 ohm, 3 watt,
3 turn
Motor .............................. 24V DC, reversing, 1/20 hp
Clutch ............................. Adjusted for 20
±5 inch-ounces
(0.08 joules)
torque
e. Control Cubicle Assembly
Frequency Transducer
DOD Drawing Number ..... 69-578
AC input ......................... 120V AC, single
phase, 50/60 Hz
Transfer Contactor
DOD Drawing Number ..... 76-11203
Type ............................... AC reversing,
open, NEMA Size
2
Coil voltage ..................... 120V AC, 50/60
Hz, 3 pole,
electrically and
mechanically
interlocked
d. AC-DC Control Box Assembly.
AC-DC Control Relay Assembly
DOD Drawing Number ..... 76-11300
Eight relays ..................... 10 amp, DPDT
Type ............................... .M5757/23-003
(MIL-R-5757)
Battle Short and Run-Stop Relays
DOD Drawing Number ..... 76-11302
Type ................................ 24V DC coil, 14
pin, 6 pole (4
pole NO, 2 pole
NC)
Contacts ......................... 10 amp
Fuel Transfer Pump Relay
DOD Drawing Number ..... 70-1140
Type ............................... 24V DC coil, 50
to 60 ohms
Contacts ......................... 50 amp, 2 NO
contacts
Integrated Time Delay Modules
DOD Drawing Number ..... 76-11304-1 and
76-11305
Types .............................. 76-11304-1
24V DC, 30
second turn on
delay
76-11305
24V DC, times on
and off periods
averaging 5
second delay
Manual Potentiometer
DOD Drawing Number ..... 76-11210
Type ............................... Wire wound,
500 ohm
Power rating .................... 2 watts at
158°F (70°C)
0 watts at
248°F
(125°C)
Shunt .............................. MS91586-1
Type ............................... MSA300
Current rating .................. 30 amps
Voltage rating .................. 50 millivolts
Motor Operated Potentiometers
DOD Drawing Number ..... 76-11213 and
NOTE
Transducer and meter furnished only as a
matched set which consists of the
transducer and frequency meter.
Thermal Watt Converter
DOD Drawing Number..69-589
Volts ............................... 100/130V AC
Current ........................... 1 ampere
Elements ........................ 3
Phase ............................. 3
Number of wires ............ 4
Output ............................ 20MV DC, open
circuit
Output circuit .................. 4.97 ohms
resistance
Watts per element .................. 96.26
Accuracy ............................... Measure 1 percent
full scale
Potential Transformer
DOD Drawing Number ..... 76-11237, 600V AC
25VA at 50/60 Hz
Secondary volts ..................... 115V AC
Voltage Input with Primary Connected:
Parallel ........................... 240 input
Series ............................. 480 input
Voltage output ....................... 120 output
secondary
1-10
TM 5-6115-593-12
TO 35C2-3-463-1
Contact rating ........................ 10 amperes, 28V
DC
Frequency ...................... 50/400 Hz
Temperature range .......... 65 to 170°F
(-54 to 77°C)
Temperature effect. ................ .-65 to 77°F
on trip point ..................... (-54 to 25°C) ±2
percent max change
77 to 170°F
+3 percent max
change
Synchronizing Check Relay
DOD Drawing Number ..... 76-11239
Input ............................... 120V AC
10 volts
50/60 Hz
Output ............................ Isolated contact,
SPDT, NO, 10 amps
at 115V AC
Temperature range ................ 25 to 125°F
(-31 to 520C)
Undervoltage Relay
DOD Drawing Number ..... 70-1120
Nominal input ................. 120 volts, 50 to
400 Hz, 100
milliamperes max
Dropout voltage .............. 99 volts 4± volts
Frequency range ............. 50 to 400 Hz
Temperature limits........... -65 to 170°F
(-54 to 77°C)
Time delay ...................... 6 ±2 seconds
above 72 volts,
instantaneous
below 48 volts
Pull-in voltage ................. 110V AC ±3V AC
Integrated Time Delay Module
DOD Drawing Number ..... 76-11304-2
Type ............................... 24V DC, 4 second
turn on delay
Coolant Temperature Gauge
DOD Drawing Number ..... 76-11229, used
with 76-11249
sender and
76-11230 resistor
for 24V DC
operation.
160°F (71°C) 161 ohms, 280°F
(138°C) - 48.8
ohms
Scale .............................. 100 to 280°F
50 to 100°C
DC Ammeter
DOD Drawing Number ..... 76-11233
Range ............................. 25-0-50MV
Scale .............................. 10/0/20 amps,
-10 to 0 amps-red
0 to 20 amps-green
24V DC Relay
DOD Drawing Number ..... 76-11302
Plug-in type ..................... 24V DC coil,
4P-NO, 2P-NC, 10
ampere contacts
Overvoltage Relay
DOD Drawing Number ..... 70-1138
Nominal voltage .............. 120 volts, 50 to
450 Hz. Operates
at 153 ±3 volts
for frequencies
50 to 450 Hz
Time delay ...................... Operates when
overvoltage
condition is
sustained for a
minimum of 200
milliseconds
Trip time ......................... Less than 1
second after
voltage reaches
and stays in
pull-in value
Contact rating ................. 10 ampere, 28.5
volts, resistance
Temperature limits ........... -65 to 170°F
(-54 to 77°C)
Temperature effect.................. 77 to -65°F
on pull-in.......................... (25 to -54°C)
voltage............................. decreases 1
volt,
77 to 170°F
(25 to 77°C)
changes ±1 volt
Phase Sequence Relay
DOD Drawing Number ..... 76-11238
Input ............................... 190 to 520V AC, 3
phase, line-toline, 50/60 Hz
Operating temper-............
.-67 to 365°F
ature range
............
(-40 to 185°C)
Reverse Power Relay
DOD Drawing Number ..... 76-11240
Input voltage ................... 120V AC ±10V AC,
50/60 Hz
Input current ................... 0-5 amps from CT
secondary
Power requirement ........... 18VA
Trip point ........................ 2 to 20 percent
adjustment
of full load
Output ............................ SPDT, 10 amps at
115V AC
Temperature range........... .-25 to 125°F
(-31 to 52°C)
Short Circuit Relay
DOD Drawing Number ..... 70-1137
Trip voltage ..................... 24 volts ±1V, any
phase to neutral
1-11
TM 5-6115-593-12
TO 35C2-3-463-1
tor for 24V DC
operation.
200°F (93°C)
- 548 ohms
300°F
(149°C) - 108
ohms
Scale .............................. 150 to 350°F
(100 to 150°C)
Lube Oil Pressure Gauge
DOD Drawing Number ..... 76-11227, used
with 76-11255
sender and
76-11230
resistor for 24V
DC operation.
0 psi - 240 ohms
80 psi - 60.3
ohms
Scale .............................. 0 to 100 psig
Oil Pressure Gauge
DOD Drawing Number..76-11104
Pressure range ......10 to 150 psi
(0.7 Jo 10.5
kg/cm2)
Mechanism ............................ C" shape bourbon
tube
Power Factor Meter
DOD Drawing Number ..... 76-11216
Power ............................. 120V AC ±10 percent, 50/60 Hz
Sensing Input ................. 0.25 to 5.0 amps
from current
transformer
Accuracy ........................ ±1 percent full
scale
Scale .............................. 7 inch, 250
degree
deflection
Time Totalizing Meter
DOD Drawing Number ..... 73-0507
Type ............................... Indicates total
hours of running
time
Scale .............................. 0 to 9999
Voltage Meter
DOD Drawing Number. ....
.69-599
Type ................. ..............
250 degree, 0 to
500 volt scale,
each scale,
division: 5
volts
Accuracy ........................ 2-1/2 percent of
full scale
(integral
rectifiers)
DC Voltmeter
DOD Drawing Number ..... 76-11234
Scale .............................. 0 to 30V DC
Accuracy ......................... ± 2 percent
Frequency Meter
DOD Drawing Number ..... 69-595
Scale .............................. 48 to 53 Hz and
57 to 62 Hz; 250
degree scale
calibrated in Hz
from 48 to 62
Hz, scale
divisions of 0.1
Hertz
Input ............................... 120 volts, 1
phase 50/60 Hz
(matched with
frequency
transducer
69-578)
Fuel Level Gauge
DOD Drawing Numbe....... 69-575
Input ............................... 24V DC
Type ............................... Fuel, empty to
full, calibrated
1/4, 1/2, 3/4
Sender resistance. ........... Empty - 0 ohms,
1/2 full - 15
ohms, full - 30
ohms
Kilowatt Meter
DOD Drawing Number ..... 70-4012
Scale .............................. Percent power,
blue mark at 83
percent, red
mark at 100 percent; full scale
0 to 133 percent
Accuracy ......................... 2 percent full
scale
Kilovar Meter
DOD Drawing Number ..... 76-11215
Type ............................... Percent kilovar
Scale .............................. Blue mark at 83
percent, red
mark at 100
percent, full
scale 0 to 133
percent
Lube Oil Temperature Gauge
DOD Drawing Number ..... 76-11228, used
with 76-11249
sender and
76-11230 resis-
tor for 24 V DC
operation.
1-12
TM 5-6115-593-12
TO 35C2-3-463-1
pole, 2-NC, 1-NO
AR420A, (7711005)* twopole, 2-NO
AR401A, (7711004)* single
pole, 1-NC
DOD Drawing Number............ 77-11007
(Respectively) ................. 77-11005
77-11004
f. Radiator/Fan Motor
Under/Overvoltage Device
Manufacturer ................... Wilmar Electronics
Inc. (77-11003)*
Part Number ................... 250-12X
Voltage rating................... 120V AC, single
phase, 50 to 400
Hz
Undervoltage trip.............. .95 to 120V,
adjustable
Overvoltage trip .............. .120 to 140V,
adjustable
Contacts ......................... SPDT
DOD Drawing Number ........... 76-11059
Type ...................................... Remote radiator,
electric motor
driven
Heat rejection ........................ 500 kw output:
at generator
390.0 BTU/sec set output
23,400 BTU/min
550 kw output:
429.1 BTU/sec 25 750 BTU/min
Top tank ................................ 200°F (93°C)
temperature
at 500 kw output
210°F (99°C)
at 550 kw output
Motor ..................................... 15 hp
Underfrequency Device
Manufacturer ................... Wilmar Electronics
Inc. (77-11002)*
Part number .................... 20-050-17X
Voltage rating .................. 120V AC, 50/60 Hz
Trip ................................. 50 Hz - adjustable 45 - 50 Hz
60 Hz - adjustable 54 - 60 Hz
Contacts ......................... SPDT
Overfrequency Device
Manufacturer ................... Wilmar Electronics
Inc. (77-11001)*
Part number .................... 20-060-5X
Voltage rating .................. 120V AC, 50/60 Hz
Trip ................................. 50 Hz - adjustable 50 - 55 Hz
60 Hz - adjustable 60 - 66 Hz
Contacts ......................... SPDT
Speed/Voltage Matching Synchronizer
Manufacturer ................... Konell Enterprise
(77-11006)*
Part number .................... SRM-60EV-MSTG
DOD Drawing Number ..... .77-11006
Voltage rating .................. 120V AC, Single
phase, 50/60 Hz
Input voltages ........................ One from generator. One from
buss output
Automatic mode .............. Frequency differential ±0.1 Hz,
phase differential ±10 degrees
voltage differential ±10 percent
Control Relay
Manufacturer ................... Westinghouse
Electric Corp.
Voltage rating .................. 110/120V AC,
50/60 Hz
Coil Burden ..................... 96VA
Contact rating ................. 120V AC, 6 amps
inductive
Type ............................... AR412A, three-
NOTE
Unit to operate at any loads between no
load and rated load at the following line-toline voltages.
Voltage operating .................. Between 395 and
range...................................... 500 volts for
the 240/416 volt
connection and
between 197 and
250 volts for
the 120/208 volt
connection for
60 Hz operation.
Between 380 and
426 volts for
the 240/416 volt
connection and
between 190 and
213 volts for
the 120/208 volt
connection for
50 Hz operation
g. Engine Preheat System
DOD Drawing Number ........... 76-11092
Type ...................................... Electric, thermostatically
controlled
Ambient temperature .............. 32 to 125°F (6
range, starting
to 52°C); -25
to 125°F (-32
to 52°C) with
housing kit)
*DOD Drawing Number
1-13
TM 5-6115-593-12
TO 35C2-3-463-1
range for 60 Hz................ for 240/416
operation (line- ................ volts, 197 to
to-line .............................. 250 volts for
120/208 volts
Flywheel and ......................... SAE 0
coupling disc
Coupling disc ......................... SAE S14 J162
arrangement
Weight
Complete gener- .............. .4000 lbs (1814
ator
kg)
Complete rotor ...................... 1900 lbs (862 kg)
k. Electric Hydraulic Actuator
Lube Oil Heater
DOD Drawing Number ..... 77-11019-02
Water Heater
DOD Drawing Number ..... 77-11019-01
h. Fuel Transfer Pump
DOD Drawing Number ........... 76-11076
Delivery ................................. Up to 75 gallons
(284 liters) per
hour and pressures to 22 psi
(1.8 kg/cm2)
Lift capacity ........................... 12 feet (3.7
meters) through
25 feet (7.6
meters) of No. 6
hose
Temperature .......................... -65 to 155°F
(-54 to 68°C)
Motor ..................................... 24V DC, 3.25 amps
i. Fuel Tank
Fuel Level Switch
DOD Drawing Number ..... 76-11247-1, -2
Electrical rating ................ 0.5 amp resistive
or inductive at
6 to 32V DC
Fuel Level Transmitter
Type ............................... MS500040-3
Resistance
Empty ...................... 0-00 to 0.50 ohms
Full .......................... 29.50 to 31.50
ohms
j. Generator
DOD Drawing Number ........... 76-11329
Manufacturer ......................... Kato Engineering
Company
Model .................................... 4P4-1950
Rating .................................... 417/500 kw
Power factor .......................... 0.8 lagging
Voltage .................................. 120/208 or
240/416V AC
Current rating ......................... 1449 amps
(50 Hz)
Current rating ......................... 1736 amps
(60 Hz)
Phase .................................... 3 phase
Frequency .............................. 50 or 60 Hz
Poles ..................................... Four
Speed .................................... 1500 rpm at 50 Hz
1800 rpm at 60 Hz
Voltage operating ................... 380 to 426 volts
range for 50 Hz ................ for 240/416
operation (line-................. volts, 190 to
to-line) ............................. 213 volts for
120/208 volts
DOD Drawing Number ........... 76-11251
Manufacturer ......................... Woodward Governor
Company
Model .................................... 8240-792-EGB-1P
Operating pressure . ............... 330 to 375 psi
(325 psi plus
inlet pressure)
Useful work ........................... 1.5 foot-pounds
capacity
at 350 psi
0.85 foot-pounds
at 200 psi
Max work ............................... 25 foot-pounds
capacity........................... at 350 psi
Supply pressure ..................... Min 10 in (water)
suction
max 50 psi
Control characteristics
Steady state ................... ±0.25 percent of
speed band...................... rated speed
Variable speed ....................... 2400 to 3600 rpm
range
Drop ...................................... Normally set 3 to
6 percent over
full output
travel
Operating temper- .................. to 200°F (-18
ature................................ to 93°C)
Transducer ............................ Undirectional DC
control signal
Transducer coil ...................... 30 to 35 ohms at
68°F (20°C)
Max current ........................... 400 milliamps
Nominal input ........................ 20 to 160 millirange
amps
1. Engine and Controls
DOD Drawing Number ........... 76-11063
Manufacturer ......................... Cummins Engine
Company, Inc.
Model .................................... VTA28-G1
Type ...................................... Four-stroke
cycle, liquidcooled, turbocharged diesel
Number of cylinders...12
Voltage operating ................... 395 to 500 volts
1-14
TM 5-6115-593-12
TO 35C2-3-463-1
Contact rating ................. 4 amp at 24V DC
Circuit ............................. NO contact to
close on rising
pressure at 4
psi (9.28
kg/cm2
Displacement ......................... 1710 cubic inches
(28.027 cubic
centimeters)
Horsepower ........................... 750 at 1800 rpm
Rotation ................................. Clockwise, viewed
from radiator
(front) end
Coolant Temperature Sender
DOD Drawing Number ..... 76-11249-1
Maximum operating ......... 300°F (149°C)
temperature
Nominal value ................. 190°F (88°C)
0 -143 ±14.5
ohms
Coolant Temperature Switch
DOD Drawing Number ..... 76-11308
Rating ............................. 10 amp, 28V DC
Connector ....................... MS3102E-14S-2P
Circuit ............................. Two independent
double-break
circuits, one NO
and one NC
Temperature range .......... NC contact opens
at 222 ±3 F
(105 ±1'°C); NO
contact closes
at 212 +3°F
(100 ±1°C)
m. Remote Control Cable
CAUTION
Fuel JP5 is considered an emergency fuel only.
Fuel ................Diesel fuel
VV-F-800 or JP5
Overspeed Switch
DOD Drawing Number ..... 70-1105-5
Type ............................... Centrifugal, 3element; 2 auto
reset, 1 manual
reset
Operating temper.................... -65 to 150°F
ature range
(-54 to 66°C)
Element No. 1 ................ Transfer to 290
to 310 rpm
rising speed,
auto reset 100
rpm max below
trip speed
Element No. 2 ................ Transfer at 590
to 610 rpm
rising speed,
auto reset 100
rpm max below
trip speed
Element No. 3 ................ Transfer at 1100
to 1150 rpm
rising speed,
manual reset
Starter Motor
Type ............................... Heavy duty
Operating voltage............. 24V DC
Current rating of starter:
Brushes .................... Eight brushes in
four brush
holders
Rotation ................................. Clockwise, drive
end
Actuation ............................... Shifting solenoid, mounted on
motor
Oil Pressure Sender
DOD Drawing Number ............ 76-11255
0 psi ................................ 227 to 257 ohms
25 psi .............................. 142 to 162.5 ohms
75 psi .............................. 58.2 to 74.4 ohms
Oil Pressure Switch
DOD Drawing Number ..... 76-11385
Type ............................... Single circuit
open switch
DOD Drawing Number............ 76-11025
Length ................................... 1,000 feet (300
meters)
n. Remote Control Module
DOD Drawing Number............ 76-11339
Dimensions and weight:
Length ............................ 33.8 inches
(86 centimeters)
Width ............................. 23.5 inches
(60 centimeters)
Height ............................. 58.8 inches
(149 centimeters)
Weight ............................ 371 pounds
(168 kilograms)
Frequency Transducer
DOD Drawing Number ..... 69-578
AC input ......................... 120V AC, single
phase, 50/60 Hz
NOTE
Transducer
and
meter
furnished
only
asmatched set which consists of the transducer
and frequency meter.
Thermal Watt Converter
DOD Drawing Number ..... 69-589
Volts ............................... 100/130V AC
1-15
TM 5-6115-593-12
TO 35C2-3-463-1
Reverse Power Relay
DOD Drawing Number ..... 76-11240
Input voltage ................... 120V AC ±10V AC,
50/60 Hz
Input current ................... 0-5 amps from CT
secondary
Power requirement........... 18VA
Trip point ........................ 2 to 20 percent
adjustment
of full load
Output ............................ SPDT, 10 amps at
115V AC
Temperature range. ................ .-25 to 125°F
(-31 to 52°C)
Short Circuit Relay
DOD Drawing Number ..... 70-1137
Trip voltage .................... 24 volts ±1, any
phase to neutral
Contact rating .................. 10 amperes, 28V
DC
Frequency ...................... 50/400 Hz
Temperature range .......... ...-65 to 170°F
(-54 to 77°C)
Temperature effect ................. ..-65 to 77°F
on trip point
(-54 to 25°C)
±2 percent max
change
77 to 170°F
(25 to 77°C)
+3 percent max
change
Synchronizing Check Relay
DOD Drawing Number ..... 76-11239
Input ............................... 120V AC ±10
volts, 50/60 Hz
Output ............................ Isolated contact
SPDT, NO, 10
amps at 115V AC
Temperature range .......... ...-25 to 125°F
(-31 to 52°C)
Undervoltage Relay
DOD Drawing Number ..... 70-1120
Nominal input ................. 120 volts, 50 to
400 Hz, 100
milliamperes max
Dropout Voltage .............. 99 volts ±4 volts
Frequency range ............. 50 to 400 Hz
Temperature limits........... ..-65 to 170°F
(-54 to 77°C)
Time delay ...................... 6 ±2 seconds
above 72 volts,
instantaneous
below 48 volts
Pull-in voltage ................. 110V AC ±3V AC
Current ........................... 1 ampere
Elements ......................... 3
Phase ............................. 3
Number of wires .............. 4
Output ............................ 20MV DC, open
circuit
Output circuit .................. 4.97 ohms
resistance
Watts per element............ 96.26
Accuracy ......................... Measure 1 percent
full scale
Potential Transformer
DOD Drawing Number ..... 76-11237, 600V AC
25VA at 50/60 Hz
Voltage input ................... 240/480V
Voltage output ................. 120V
secondary
24V DC Relay
DOD Drawing................... Number..76-11302
Plug-in type ..................... 24V DC coil,
4P-NO, 2P-NC, 10
ampere contacts
Overvoltage Relay
DOD Drawing Number ..... ..70-1138
Nominal voltage .............. 120 volts, 50 to
450 Hz. Operates
at 153 ±3 volts
for frequencies
50 to 450 Hz
Time delay ...................... Operates when
overvoltage condition is sustained for a
minimum of 200
milliseconds
Trip time ......................... Less than 1
second after
voltage reaches
and stays in
pull-in value
Contact rating . ................ 10 ampere, 28.5
volts, resistance
Temperature limits..-65 to 170°F
(-54 to 77°C)
Temperature effect..77 to -65°F (25
on pull-in
to -54°C) devoltage
creases 1 volt,
77 to 170°F
(25 to 77°C)
changes ±1 volt
Phase Sequence Relay
DOD Drawing Number ..... -11238
Input ............................... 190 to 520V AC, 3
phase, line-toline, 50/60 Hz
Operating temper-................... -40 to 185°F
ature range
(-40 to 82°C)
Integrated Time Delay Module
DOD,Drawing Number ..... ..76-11304-2
Type ............................... 24V DC, 4 second
turn on delay
1-16
TM 5-6115-593-12
TO 35C2-3-463-1
Accuracy ........................ 2 percent full
scale
Kilovar Meter
DOD Drawing Number ..... 76-11215
Type ............................... Percent kilovar
Scale .............................. Blue mark at 83
percent, red
mark at 100
percent, full
scale 0 to 133
percent
Coolant Temperature Gauge
DOD Drawing Number ..... ..76-11229, used
with 76-11249
sender and
76-11230
resistor for 24V
DC operation.
160°F (71°C)
- 161 ohms,
280°F
(138°C) - 48,8
ohms
Scale .............................. 100 to 280°F
(50 to 100°C)
DC Ammeter
DOD Drawing Number ..... 76-11233
Range ............................. 25-0-50MV
Scale .............................. 10/0/20 amps, -10
to 0 amps - red,
0 to 20 amps green
DC Voltmeter
DOD Drawing Number ..... 76-11234
Scale .............................. 0 to 30V DC
Accuracy ......................... 2 percent
Frequency Meter
DOD Drawing Number ..... ..69-595
Scale .............................. 48 to 53 Hz and
57 to 62 Hz; 250
degree scale
calibrated in Hz
from 48 to 62
Hz, scale divisions of 0.1
Hertz
Input ............................... 120 volts, 1
phase 50/60 Hz
(matched with
frequency transducer 69-578)
Fuel Level Gauge
DOD Drawing Number ..... 69-575
Input ............................... 24V DC
Type ............................... Fuel, empty to
full, calibrated
1/4, 1/2, 3/4
Sender resistance ............ Empty - 0 ohms,
1/2 full - 15
ohms, full - 30
ohms
Lube Oil Temperature Gauge
DOD Drawing Number ..... 76-11228, used
with 76-11249
sender and
76-11230
resistor for 24V
DC operation.
200°F (93°C)
- 548 ohms
300°F
(149°C) - 108
ohms
Scale .............................. 150 to 350°F
(100 to 150°C)
Lube Oil Pressure Gauge
DOD Drawing Number..76-11227, used
with 76-11255
sender and
76-11230 resistor for 24V DC
operation.
0 psi - 240 ohms
80 psi - 60.3
ohms
Scale .............................. 0 to 100 psig
Oil Pressure Gauge
DOD Drawing Number ..... 76-11104
Pressure range ............... 10 to 150 psi
(0.7 So 10.5
2
kg/cm )
Mechanism ............................ “C" shape bourbon
tube
Power Factor Meter
DOD Drawing Number ..... ..76-11216
Power ............................. 120V AC ±10 percent, 50/60 Hz
Sensing input ........................ 0.25 to 5.0 amps
from current
transformer
Accuracy . .............................. ±1 percent full
scale
Scale ..................................... 7 inch, 250
degree
deflection
Time Totalizing Meter
DOD Drawing Number ..... 73-0507
Kilowatt Meter
DOD Drawing Number ..... 70-4012
Scale .............................. Percent power,
blue mark at 83
percent, red
mark at 100
percent; full
scale 0 to 133
percent
1-17
TM 5-6115-593-12
TO 35C2-3-463-1
Type ........................................ Indicates total
house of running
time
Scale ....................................... 0 to 9999
Overfrequency Device
Manufacturer ........................... Wilmar Electronics
Inc.
Part Number ............................ 20-060-5X
Voltage ...... .............................. 120V AC, 50/60 Hz
Trip .......................................... 50 Hz - adjustable
50 to 55 Hz,
60 Hz - adjustable
60 to 66 Hz
Contacts .................................. SPDT
Voltage Meter
DOD Drawing Number............. 69-599
Type ........................................ 250 degree, 0 to
500 volt scale,
each scale division: 5 volts
Accuracy ................................. 2-1/2 percent of
full scale (integral rectifiers)
o.
Time Delay Relay
Manufacturer ........................... Agastat Division
of Amerace
Corp.
Part Number ............................ 7022-AC
Voltage .................................... 120V AC, 50/60 Hz
Type ........................................ Delay on drop out,
timed off 604 sec,
adjustable 1.5 to
15 sec
Contacts .................................. DPDT
Automatic Control Module
DOD Drawing Number....81-11022
Dimensions and weight:
Length ..................................... 30.8 inches
(78 centimeters)
Width ...................................... 13.3 inches
(34 centimeters)
Height ...................................... 66.4 inches (169
centimeters)
Weight .................................... 267 pounds
(121 kilograms)
Electrical In .............................. Sensing, 120
terface
volt, single
phase
Control Relay
Manufacturer ........................... Westinghouse
Electric Corp.
Voltage .................................... 110/120V AC,
50/60 Hz
Coil Burden ............................. 96VA
Contact rating .......................... 120V AC inductive
at 6 amps
Type ........................................ AR420A, one-pole,
1-NO
AR633A, fivepole, 3 NC, 2-NO
AR421A, threepole, 1 NC, 2 NO
Under/Overvoltage Device
Manufacturer ........................... Wilmar Electronics
Inc.
Part Number ............................ 250-12X
Voltage trip .............................. 120V AC, single
phase, 50 to 400
Hz
Undervoltage trip ...................... 95 to 120V,
adjustable
Overvoltage trip ....................... 120 to 140 V,
adjustable
Contacts .................................. SPDT
Diode Packs
R1-DOD Drawing No.
R2-DOD Drawing No.
R3-DOD Drawing No.
R4-DOD Drawing No.
Underfrequency Device
Manufacturer ........................... Wilmar Electronics
Inc.
Part Number ............................ 20-050-17X
Voltage .................................... 120V AC, 50/60 Hz
Trip .......................................... .......50 Hz - adjustable
45 to 50 Hz
60 Hz - adjustable
54 to 60 Hz
Contacts .................................. SPDT
88-11046
88-11045
88-11044
88-11043
Control Relays
Manufacturer ........................... Westinghouse
Electric Corp.
Voltage .................................... 110/120V AC,
50/60 Hz
Coil burden .............................. 96VA
Contact Rating ........................ 120V AC, 6 amps
inductive
Type ........................................ AR422A, 2-NC,
2-NO AR422L, (DC
coil), 2-NC,
2-NO
1-18
TM 5-6115-593-12
TO 35C2-3-463-1
p.
Fuel System Diagram. See figure 1-8 for
the generator set fuel system diagram.
NOTE: Contacts to be arranged per wiring diagrams.
Time Delay Relay
Manufacturer ...................Agastat Division
of Amerace
Corp.
Part number.....................7012AH
Voltage ............................120V AC, 50/60 Hz
Type ................................Time delay on
energize
adjustable, 3 to
30 min.
Contacts ..........................DPDT
q.
Instruction Plate Information. The generator
set has instruction plates located throughout the set.
See Figure 1-9 for the location of the plates. The
document compartment contains lamination of all
instruction plates. On unhoused sets, several of the
plates can be found only in the document compartment.
r.
Schematics and Wiring Diagrams. FO-1
through FO-16 are the schematic and wiring diagrams
for the generator set major components and auxiliary
equipment.
Time Delay Relay
Manufacturer ..................Agastat Division
of Amerace
Corp.
Part number ....................70220K
Voltage ...........................24V DC
Type ................................Time delay on deenergize, adjustable, 5 min.
Contacts .........................DPDT
1-11. TORQUE DATA.
Torque data applicable to
operator/crew and organizational maintenance is given
in Table 1-1.
1-12. DIFFERENCE BETWEEN MODELS. Differences
between generator sets are delineated in the Repair
Parts and Tools List, TM5-6115-593-24P, Intermediate
(Field) (Direct and General Support) and Depot Level
Maintenance TM5-6115-593-34, and in this manual.
Time Delay Relay
Manufacturer ...................Westinghouse
Electric Corp.
Part number.....................ARPT-20
Type ................................Mechanical
Contacts .........................1-NO, 1-NC
NOTE
Throughout this technical manual MEP029A is referred to as code A and MEP029B is referred to as Code B.
1-19
TM 5-6115-593-12
TO 35C2-3-463-1
NOTES
1.
2.
FUEL SOLENOID IS CONTROLLED BY THE
FUEL LEVEL SWITCH AND IS USED IN
CONJUNCTION WITH FUEL PUMPS TO KEEP
FUEL TANK FULL.
REPLACEMENT ELEMENTS ARE MIL-F-20627,
TYPE 11, CLASS 11, NSN: 2910-287-1912.
3.
ELEMENT CAN BE WASHED AND REUSED
4.
ENTIRE FUEL SYSTEM IS VENTED THROUGH
THE FILLER CAP. THE VENT VALVE ON THE
FILLER CAP MUST BE LEFT IN OPEN
POSITION WHEN SET IS RUNNING (VALVE IS
ON UNDER SIDE OF CAP).
Figure 1-8. Fuel System Diagram
1-20
TM 5-6115-593-12
TO 35C2-3-463-1
1. Fuel system instruction plate
2. Lifting instruction plate
3. Operating instructions plate
4.
5.
6.
7.
Reconnection box instruction plate
Battery instruction plate
Information plate
Document compartment containing
plastic laminations
Figure 1-9. Instruction Plate Locations
1-21
TM 5-6115-593-12
TO 35C2-3-463-1
Table 1-1. Torque Data
NOTE
Lubricate threads prior to torquing.
TORQUE VALUE
COMPONENT
FT/LBS
JOULES
20
27
Spin-on filters
Mounting capscrew
25 to 35
34 to 47
Fuel filter capscrews
20 to 25
27 to 34
Injector hold-down capscrews
in increments of
11 to 12
4
15 to 16
5
Turbocharger
V-Band clamp tension
Lubricating oil drain fitting
Diffuser plate capscrew
32 to 36*
50
5 to 7
3.6 to 4.1
68
7 to 10
Intercooler capscrews
in increments of
30 to 35
15
41 to 47
20
35
8
47
11
Oil Pressure Switches
Exhaust Manifold capscrews
in increments of
* In-lbs
Section III. SYSTEM OPERATION
These systems are multipurposed in that there is some
overlapping functions from one system to another.
Certain operations may be described, to avoid
redundancy, under one system where as they actually
function within two or more systems.
1-13. GENERAL.
This section covers theory of
operation for the following *generator set systems:
a.
DC Electrical and Control System
b.
AC Power Generation and Control System
c.
Fuel System
d.
Cooling System
e.
Lube Oil System
1-14. DC ELECTRICAL AND CONTROL SYSTEM.
(See FO-1.)
a.
1-22
Introduction. The DC electrical and control
system's primary function is to enable the
starting, stopping and operation of the diesel
engine under a variety of operating
conditions.
TM 5-6115-593-12
TO 35C2-3-463-1
b.
c.
Engine Starting. When the operator toggles
spring-loaded MASTER SWITCH S1 to the
START position, normal start/stop/run/ relay
K5 becomes energized through normally
closed contacts 5 and 6, and normally open
contacts 3 and 2 of S1. Upon release of S1,
relay K5 is held in its energized state by its
selflatching contacts 2 and 4. With K5
energized, run pilot relay K54 energizes
through the normally open contacts 1 and 5
of K5, and as a result normally open
contacts 1 and 2 of K54 close. Starter crank
limit relay K3 now energizes through
forward-biased CR1 and the following
closed contacts: K19, speed switch SS1,
K6, K50, and K54. At this time magnetizing
current is applied to start solenoid L4
(through K3 contacts 1 and 2), and the
heavy duty contactors of L4 close, bringing
current to starter motor B2 causing it to
crank the engine. Simultaneous with the
previously described action, fuel solenoid L1
and engine run relay K1 are both activated
(through normally closed contacts K21, K19,
K6, K50, diode CR23, and contacts 1 and 2
of K54), allowing the passage of fuel to the
engine. Prior to starting, K1 normally closed
contacts place a short across terminals 22
and 23 of governor controller A106. This
ultimately sets the engine's hydraulic
governor for zero fuel output. Energizing
K1 at start time negates this function and
allows the passage of fuel.
thereby preventing the possible burnout of
starter motor B2. Initially, when cranking
begins, time delay relay assembly TD1 is
turned on (through closed contacts of SS1,
K6, K50, and K54) and the timing process
commences. After a period of about 30
seconds, TD1 stops timing and connects
overcrank shutdown relay K19 to +24V DC
through contacts of SS1, K6, K50, and K54
thereby energizing K19. K19 now energized,
opens its normally closed contacts in series
with cranking relay K3 causing K3 to
deenergize, and subsequently, power is
removed from B2. To indicate that this has
occurred, OVER CRANK lamp DS51 lights
when it is returned to +24V DC through the
normally open contacts of K19 (in series
with DS51) and the path consisting of SS1,
K6, K50, and K54. If, as was previously
mentioned, engine speed goes over 600
rpm, SS1 opens and the just described
action does not occur.
Starter Motor Protection. Depending on
which occurs first, cranking power will be
applied until the engine reaches a speed in
excess of 600 rpm or total cranking time
exceeds 30 seconds. When the engine
attains a speed over 600 rpm (in less than
30 seconds), speed switch SS1 opens,
subsequently deenergizing K3 and, then,
L4. With L4 deactivated, cranking action
ceases when the contactors of L4
disconnect power from starter motor B2. If
the engine does not start, that is, does not
reach a speed in excess of 600 rmp, and
cranking time exceeds approximately 30
seconds, cranking will automatically cease
1-23
d.
Ether Starting. As an aid to cold weather
starting, provisions are made to inject ether
into both of the engine air intake manifolds
while the engine is being cranked. The
application of this highly volatile fluid is
controlled by the ether solenoid, ether aid
control relay K24, and START AID switch
S2. During crank time, K24 is energized
through closed contacts of K6, K50, and
K54.
At this time the normally open
contacts of K24, which are in series with the
ether aid control S2, close. Operating S2 to
the ON position activates the ether aid
control solenoid causing a measured
amount of ether to be loaded into the ether
aid device. Upon release of S2, this
measured amount of ether is forcefully
injected into the air intake manifolds. The
ether aid device may be used at any engine
speed up to 1200 rpm and for approximately
5 seconds afterwards (the 5-second delay is
explained in subparagraph 1-14th(2),
below).
e.
Louver Operation (Housed
auxiliary housing kit
Sets).
The
TM 5-6115-593-12
TO 35C2-3-463-1
contains four motor-operated louvers which
open during engine operation and close at
engine shutdown. Louver control relays K60
through K63, louver motor pilot travellimiting switches S60 through S63, and
louver motors B10 through B13 (each
capable of two-way operation) control the
four louver assemblies. When the engine
starts, each louver control relay energizes
and 24V DC is applied, by way of the louver
motor pilot switches, to the louver motors
and the louvers open. Upon reaching their
full-open position the louvers set the travellimit switches to their opposite position,
deactivating the louver motors. Louver
operation at the shut down is exactly the
same except that the motors operate in the
reverse direction and 24V DC is applied
through the normally closed contacts of the
deenergized louver control relays.
f.
g.
stream of air to the engine. When the
engine shuts down, oil pressure switch OP3
opens and disconnects 24V DC from L2 and
L22. A second set of K21 contacts removes
+24V DC from solenoid L1 and cuts off the
engine's fuel supply.
h.
Engine Stopping. When it is required to
stop the engine after a period of normal
operation, the operator momentarily sets the
spring loaded MASTER SWITCH S1 to the
STOP position, thereby deenergizing relay
K5. With K5 now deenergized, run pilot
relay K54 drops out, its contacts 1 and 2
open and +24V DC magnetizing voltage is
removed from fuel solenoid L1. After the
small amount of fuel remaining in the lines
past the point of fuel cutoff is consumed, the
engine comes to a halt.
Emergency Stopping. When an emergency
exists, such as might pose a threat to
personnel or equipment, as quick a
shutdown as possible is required. To ensure
this, the air boxes in series with the air
intake manifolds are closed and the fuel
supply is shut off, thus interrupting the
engine's air and fuel supply and quickly
bringing the engine to a stop. Operating
EMERGENCY SHUTDOWN switch S22 to
ON, energizes emergency stop relay K21
and, when solenoids L2 and L22 are
actuated (through normally open contacts of
K21) the air boxes close interrupting the
1-24
Engine Protection. Operation will continue
as long as no fault condition occurs which
might cause damage to the engine. Once
such a condition does occur, engine
operation is automatically brought to a halt.
The following subparagraphs describe the
fault which will stop the engine and by what
circuitry this stoppage is implemented.
(1)
Engine Overspeed. If engine speed
increases to a point where damage
may occur, overspeed switch SS3 (set
to operate at approximately 2250
rpm) closes activating overspeed
relay K31. As a result, the normally
open contacts of K31 (in parallel with
EMERGENCY SHUTDOWN SWITCH
S22) close and energize relay K21.
The action from this point on is the
same as for emergency stopping.
(2)
Low Oil Pressure.. If lubricating oil
pressure falls below 21 ±2 psi (1.5
kg/cm ) the contacts of oil pressure
switch OP1 open and remove power
from fuel solenoid L1.
Because
engine oil does not build to its
required pressure immediately, the
engine may shut down "thinking" a
fault has occurred. To avoid this
premature operation, time delay
assembly TD3 inhibits the operation
of relay K6 for 5 seconds--allowing
pressure to build.
(3)
Oil Temperature. If lubricating oil
temperature rises above 255 ±3°F
(124 +1° C), damage to the engine
may occur.
To prevent this, oil
temperature switch OT1
TM 5-6115-593-12
TO 35C2-3-463-1
(when it senses this condition) opens
its normally closed contacts, thereby
deenergizing fuel solenoid L1.
S13, OT2 and K28) and as a result the horn
activates via normally open contacts K26
and normally closed contacts K25B.
(4)
Coolant Temperature. If the engine
coolant rises above 213 +3°F (100
+0.7°C), engine damage may occur.
Water temperature switch WT1
senses coolant temperature and
operates to an open position when
this temperature becomes too high.
(5)
Low Fuel Level. In addition to the fact
that engine damage may occur, if the
engine ran completely out of fuel,
trying to restart the engine with a new
supply of fuel would require an
elaborate
and
time-consuming
"bleeding" procedure. To avoid this,
fuel level switch FL1 is used to sense
when there is only enough fuel for one
more hour of engine operation and
shuts the engine down by deactivating
relay K8 (K8 contacts open the circuit
holding fuel solenoid L1 energized).
When ANNUNCIATOR TEST switch S13 is
set to on, the horn is activated to its test
position through contacts 8 and 15 of S13.
To test indicator lamp DS28, -24V DC is
applied through contacts 7 and 4, diode
CR6, DS28, and back to +24V DC through
contacts 2 and 3 of S13 (the path consisting
of CR7 and K28 is disconnected from +24V
DC by open contacts 6 and 11 of S13).
Occasionally it may be beneficial to silence
the annunciator by toggling ALARM
SILENCE switch S12 to the on position.
With S12 on, relay K25A and K25B
energize. The contacts of K25A hold the
K25A and K25B coil energized when S12 is
released and the contacts K25B disconnect
the horn circuit. Operating ANNUNCIATOR
RESET switch S14 to on disconnects K25A
and K25B from -24V DC and re-enables the
horn circuit.
j.
i.
Engine Fault Indicators. If an engine fault
occurs, the engine will shut down and one of
several indicator lamps (mounted on the
Generator Control Panel) will light.
In
addition to the indicator lamp an
annunciator (horn) will sound to alarm crew
members not in the immediate vicinity. To
ensure proper operation of these faults
indicators, a means whereby the lamps and
the annunciator may be tested is provided.
Since all of these circuits act in a similar
manner only one will be described.
If a high oil temperature condition exists, the
normally open contacts of switch OT2 will
close, applying +24-volts dc to energize
K28. Relay K28 is held energized by selflatching contacts in parallel with OT2. At
this time ENG FAULT indicator lamp DS28
lights as 24V DC is applied to closed
contacts of S14, thermal fuse FC1, diode
CR30 through DS28, CR7, and relay
contacts K28 to the 24 volt return.
Coincident with this action relay K28
energizes (through normally closed contacts
1-25
Engine Operation. Once the engine is
running it is only necessary to monitor
various operating parameters and to vary
engine speed as required to set the
generator output frequency.
(1)
Engine Speed. Controlling engine
speed is achieved by varying engine
fuel intake by means of an electro
hydraulic governor. The operation of
this
governor
is
electrically
determined by governor controller
A106.
Engine speed may be
manually
adjusted
by
setting
FREQUENCY ADJUST switch S5 to
either INCREASE or DECREASE. S5
controls two-way motor B4 which is
mechanically
coupled
to
potentiometer R102.
R102 is
electrically connected to A106 and
affects its operation.
(2)
Engine Monitoring. Located on the
Engine Control Panel are four gauges
M1 through M4 which, respectively,
monitor
TM 5-6115-593-12
TO 35C2-3-463-1
circuits not
operation:
the
following
engine
operating
conditions:
oil
pressure,
oil
temperature, water temperature and
fuel level. Transmitters MT1 through
MT4 which are connected to gauges
M1 through M4, are actually variable
resistors whose resistance changes as
a function of the parameter being
monitored. Once the engine starts all
of these circuits are activated through
normally open contacts 3 and 4 of
relay K1. Meter M5 is an elapsed
time meter which is energized by K1
contacts only when the engine is
running.
(3)
(4)
k.
Fuel Transfer. Prolonged operation of
the engine generator set is obtained
by the use of additional fuel tanks.
The transfer of fuel from these tanks
to the day tank is controlled
automatically by fuel level switches
FL1 and FL2. FL2 senses when day
tank fuel falls below a certain level
and closes to energize relay K20
through FUEL PUMP AUTO-OFF
switch S9 and high-level switch FL1.
With K20 energized, motor B1 starts
pumping fuel to the day tank. When
full, FL1 opens, deenergizing K20
which subsequently stops motor B1.
FUEL PUMP indicator lamp DS1
connected across B1, lights anytime
fuel is being pumped.
directly
related
to
engine
(1)
BATTERY CHRG AMPS meter M21
monitors battery charging current. It
is connected in series with the battery
charger.
(2)
BATTERY CHRG VOLTS meters M20
monitors
DC
electrical
system
voltage.
(3)
The digital CLOCK M111 indicates
daily time.
Switch S52 (50 Hz)
enables clock operation at either 50 or
60 Hertz.
(4)
The panel lights are controlled by
PANEL LT SW S11.
(5)
24V
DC
CONTROL
CIRCUIT
BREAKER
CB1
controls
the
application of 24V DC to the DC
Electrical Control System and may be
used to shut down the engine during
an emergency.
(6)
OPERATION-MAINTENANCE
LOCKOUT switch S2 prevents the
engine from being started during
maintenance. It may also be used for
emergency shut down.
1-15. AC POWER GENERATION AND CONTROL
SYSTEM. (See FO-2.)
Battle Short. During battle conditions,
the requirement of continued engine
operation may override the need to
protect the engine. BATTLE SHORT
switch S7 when set to ON, energizes
selfholding relay K50.
Closed
contacts 3 and 4 of K50 bypass the
fault-sensing contacts of low fuel relay
K8, water temperature switch WT1, oil
temperature switch OT1, oil pressure
switch OP1, and overvoltage relay
K32.
a.
Miscellaneous.
The
following
subparagraphs briefly describe those DC
1-26
Introduction. The purpose of the engine
generator set is to produce an electrical
output. To accomplish this end, an AC 3phase, brushless-type generator is directly
coupled to the diesel engine. The AC power
generator and control system monitors and
controls the generator set to ensure that a
constant output in terms of amplitude,
phase, and frequency is maintained under
all permissible load conditions and modes of
operation. The following paragraphs explain
and describe the various functions of this
control system.
TM 5-6115-593-12
TO 35C2-3-463-1
b.
exciter field. The extent of this control
is determined by voltage regulator
VR101 which senses generator output
voltage. The source of the control
current is a permanent magnet
generator mounted on the same shaft
as the main generator exciter. After
being made proportional to the G1
output voltage by VR101, the
permanent magnet generator output
(in addition to supplying short circuit
current) is used to determine exciter
field current.
A motor-driven
potentiometer R101 (controlled by
VOLT ADJ switch S6) is used to
manually adjust main generator
output voltage. This potentiometer
which is driven by B5, is connected to
VR 101.
Single Unit Operation. Once the engine has
stabilized and is running normally, the load
may be applied to the main generator G1
output terminals through the heavy duty
contacts of motor driven circuit breaker
CB2.
CB2 closes when relay K22 is
energized through a series circuit which
consists of various relay contacts of the
generator fault protection circuit and AC
PWR CKT BKR switch S3. With K22
energized, the motor of CB2 is activated,
closing its contacts and applying main
power to the load.
(1)
(2)
Output Frequency Regulation. With
the AC output now applied to the load,
the generator output frequency must
be maintained at either the 50 or 60
Hz required by the load. Generator or
output frequency is controlled by
adjusting engine speed (frequency is
directly proportional to engine speed).
A magnet imbedded in the magnetic
pickup PU1, which is mounted in
close proximity to the flywheel,
induces a series of voltage pulses for
every revolution of the engine. These
voltage pulses, whose number per
minute indicates engine rpm, are sent
to governor actuator controller A106.
A106 processes and amplifies these
pulses in conjunction with other
generator load sensing inputs (such
as a generator current and voltage)
and generates a control voltage
proportionate to engine speed and
generator output requirements. This
output is applied to governor actuator
solenoid L101. In response, L101
varies the amount of control placed
on the fuel injection pump by the
electro hydraulic governor actuator.
The fuel injection pump regulates
engine speed by adjusting the
engine's rate of fuel consumption.
c.
Parallel Operation. To increase the total
available power, the generator set may be
operated in parallel with as many as three
additional generator sets.
During the
parallel mode of operation the phase,
frequency, and amplitude of the generator
sets must be made to coincide. Amplitudes
can be made to coincide by manually
adjusting and comparing the outputs of the
various generator sets.
The phase sequence of one generator set
must first be determined and then compared
with the phase sequence of the set to be
paralleled. This is accomplished by PHASE
SEQUENCE switch S103 and relays K103-1
and K103-2. If the phase sequence of the
generator windings are 1-2-3, relay K10-13
will energize, closing its 4-5 contacts
causing the 1-2-3 indicator lamp DS41 to
light. If the phase sequence is 1-3-2, relay
K103-2 will energize and the 1-3-2 indicator
lamp DS42 will light. Switch S103
determines whether the generator windings
or the generator buss is to be monitored.
Output
Voltage
Regulation.
Generator G1 output voltage is
indirectly controlled by the amount of
current flowing in the generator's
After phase sequence has been established,
the operator must set switch S8 to
PARALLEL
OPERATION,
thereby
energizing relay K23 and
1-27
TM 5-6115-593-12
TO 35C2-3-463-1
lighting PARALLEL indicator lamp DS7 (K23
is held energized by self-latching contacts 5
and 6). With K23 energized, power is
applied (through K23 contacts 9, 10, 11, and
12) from power transformers T101 and T102
to the frequency paralleling circuit K106, DS
101, DS102, and K106 is a synchronizing
check relay which only allows the AC power
CKT BKR (CB2) to close to a dead bus or to
a
"synchronized"
energized
bus,
SYNCHROSCOPE M109.
K106 is a
synchronizing check relay which only allows
the AC power CKT BKR (CB2) to close to a
dead bus or to a "synchronized" energized
bus.
various fault-sensing devices have been
wired into the AC generator and control
circuit. All of the generator fault circuit
relays K32 through K36 and indicator lamps
DS32 through DS36, respectively, are
selflatching, that is, they will stay energized
even though the fault which caused them to
operate will no longer manifest itself when
the main contactors open. Therefore, when
a fault does occur, the crew should note
which fault indicator lamp is lit prior to
operating the ANNUNCIATOR RESET
switch S14. Also when any fault occurs,
alarm horn Al will sound when relay K26
energizes and its normally open contacts
complete the 24-volt return of Al. Current
transformers are used in many of the
generator fault sensing circuits. The faults,
how they are monitored, and how damage is
prevented are described in the following
paragraphs:
Power transformer T102 senses the bus
voltage, and power transformer T101
senses the output of the incoming
generator. SYNC light DS101 is connected
from the output terminal T101 to the output
terminal of T102.
DS102 is similarly
connected across the remaining outputs.
The greater the frequency difference of the
generator sets, the greater the voltage
across the SYNC lights and the greater the
rate of which they will blink on and off. As
the sets approach a zero frequency
difference, the lights dim and finally
extinguish.
SYNCHROSCOPE
M109
performs essentially the same function and
also indicates relative frequency between
the generators to be paralleled. When
SYNCHROSCOPE M109 points to 12
O'clock, the generator is in sync with the
energized buss. If the droop (regulation)
characteristics of the separate generators
involved in parallel operation are different,
their ability to equally share the load is
diminished.
To compensate for these
inherent differences in droop, REACTIVE
LOAD COMPENSATION CONTROL R104
allows the operator to offset the output
voltage of a particular generator. When
connected to a load, this generator will
droop to a voltage level that will enable
equal load sharing. Similar readings of each
generator set's AMMETER will reflect this
equal load sharing.
d.
Generator Faults. As a means of either
protecting the generator set and/or the load,
1-28
(1)
Overvoltage Protection.
If engine
speed were to become excessive or
voltage regulator VR101 malfunction,
the generator output voltage might
rise to a level harmful to either the
load, the generator, or engine
controls. To prevent this, overvoltage
relay K102 (connected across one of
the generator output windings) senses
when this occurs, and activates to
initiate the following sequence: K32
energizes (OVERVOLTAGE indicator
lamp DS32 lights); the engine fault
circuit opens; fuel solenoid L1
deactivates (shutting down the
engine); and K1 deenergizes opening
the AC POWER CKT BKR (CB2)
(disconnecting the load).
(2)
Undervoltage Protection.
It is
possible that voltage regulator VR101
could malfunction in such manner as
to create an undervoltage condition
capable of damaging the load.
Connected across one of the
generator output windings, relay Kill
senses if the output voltage becomes
too
TM 5-6115-593-12
TO 35C2-3-463-1
to interrupt the generator circuit
breaker control circuit. As before,
when this occurs, the generator output
is immediately disconnected from the
main buss. Generator G1 is capable
of safe operation while overloaded for
short periods of time. This accounts
for the delayed operation of K114.
low and deenergizes when it does.
Contacts 7 and 8 of K11 open
deenergizing the CB2 trip coil which in
turn, disconnects the generator from
the load. Simultaneous with this
action, K11 contacts 3 and 4 close
activating
relay
K33
and
UNDERVOLTAGE indicator lamp
DS33. A false undervoltage condition
will, of course, exist while the engine
is shut down or is in the process of
picking up speed. To prevent the
needless disconnecting of generator
G1, relay K11 contacts 3 and 4 have
been placed in series with normally
open contacts 7 and 9 of K52. Relay
K52 will not energize until engine
speed is in excess of 1200 rpm and
speed switch SS2 closes.
(3)
(4)
Reverse Power Protection. While in a
parallel mode of operation, an out-ofphase or an undervoltage situation
could cause the current of one
generator to feed the second
generator. Such a condition might
either burn out the second generator
or cause it to "motor" (the generator
functions as motor).
Relay K112
activates upon sensing a reversepower condition and through its
normally open contacts 3 and 5,
energizes K34 and lights REVERSE
POWER indicator lamp DS34. Relay
K34 normally closed contacts, in
series with the generator circuit
breaker control circuit, open and
subsequently
disconnect
the
generator from the main buss.
Overload Protection. If the output
current of any phase winding of G1
exceeds an amount that might
possibly be harmful to the generator,
thermal relay K114, after a short
period
of
time,
activates.
Consequently, relay K35 and indicator
lamp DS35 both energize, and
normally closed contacts of K34 open
1-29
(5)
Short Circuit Protection. In the event
of a short circuit, the generator must
be immediately disconnected from the
load.
Relay K113, upon sensing
excessive current, will energize and
close its contacts 7 and 8; then, relay
K36 and short circuit indicator lamp
DS36 will energize. Normally closed
contacts of K36, in series with the
generator circuit breaker control
circuit, open and consequently CB2
disconnects the generator from the
main buss.
(6)
Generator Output Monitoring. The
voltage, current, frequency, power,
KVAR, and power factor of the output
must be continually monitored to
ensure proper use of the generator.
The voltage and current are
measured by voltmeter M101 and
ammeter M102 and switched, as
required, by S101 and S102
respectively from one generator
winding to another. Output frequency
is monitored by a circuit consisting of
A103 and M103. A103 is a frequency
converter which produces a voltage
analog of the output frequency. This
voltage is applied to and metered by
M103 which indicates the output
frequency in Hertz. Power (kilowatts)
and
KVAR
(kilovolts-amperes
reactive) are measured by KW meter
M107 and KVAR meter M108 in
conjunction with converters A107 and
A108, respectively. A107 and A108
convert current and voltage into an
output
TM 5-6115-593-12
TO 35C2-3-463-1
parts. Oil pressure gauges are connected at the input
and output sides of the fuel filter assembly to ensure its
proper operation. As insurance against the interruption
of this flow by a dirty or clogged line, an automatic
bypass valve is mounted in the filter assembly. In
addition to the oil level dipstick, an oil level sight gauge
provides the operator with a visual readout of the lube
oil level while the engine is running. Oil pressure is
monitored by a meter located on the Engine Control
Panel.
proportional to their product. Power
factor, the ratio of actual power to
apparent power, is measured by
POWER FACTOR meter M110.
e.
f.
Preheat System. To facilitate cold weather
starting, a means is provided whereby
engine temperature may be maintained at a
predetermined value. To achieve this, two
electrical heating coils are immersed in the
engine coolant and one heating element
located in the engine oil. Constant coolant
temperature is maintained by thermostatic
switch S301 in series with relay K109, the
contacts of which are in series with H101,
H102 and H103. PREHEAT SYSTEM switch
S105 controls the application of external AC
power to relay K107 (engine run relay K1
contacts 1 and 2 inhibit this function when
the engine is running). The contactors of
K107, in turn, control the application of
external AC power to the preheat system.
1-17. COOLING SYSTEM. The purpose of the engine
cooling system is to remove excessive heat created by
normal engine operation. To accomplish this, a liquid
coolant is circulated through liners located around the
engine cylinders, cylinder heads, and fuel injector
sleeves. The coolant, driven by an engine-mounted
centrifugal pump, removes the heat generated at these
points and carries it to the radiator assembly where it is
dissipated by air forced into motion by an electric motor
B102 (powered by main generator G1) and a fan.
Optimum engine operating temperature is obtained by a
thermostatic control valve which regulates coolant flow.
In order to keep the engine warm in preparation for coldweather starting, the coolant water is electrically
preheated and circulated throughout the engine by the
preheat system. A small amount of coolant from the
main channel is passed through a combination filtering
and treating assembly which acts to inhibit the formation
of rust. During severe cold weather conditions (with the
housing kit installed), the radiator louvers are indirectly
controlled by coolant temperature.
As coolant
temperature drops, the louver doors are automatically
moved toward the closed position by a hydraulically
operated actuator.
Battery Charger.
Battery Charger BC1
maintains the generator set starting
batteries at full charge. The source of AC
power for BC 1 is either external or from the
generator.
Relays K108A and K108B
ensure that BC1 receives power from only
one of the sources or that the external
source will be used when both options are
available.
1-16. LUBE OIL SYSTEM. Lubricating oil is used to
reduce wear and overheating due to friction and to
enable close tolerances and ease of movement between
engine parts moving adjacent to each other. The engine
is pressure lubricated, pressure being supplied by .a
gear-type, self-regulating pump mounted inside the oil
pan and mechanically coupled to the engine crankshaft.
Because overheated oil loses some of its lubricating
properties, the oil, prior to being filtered is fed to an oil
cooler located on the right-hand side of the engine. The
oil is then filtered by three full-flow filters which are
mounted just below the oil cooler. The filtered oil is
supplied to the engine's main oil header and moving
1-18. FUEL SYSTEM. (See figure 1-8.) The prime
purpose of the fuel system is to bring the fuel (under
pressure) from a point of temporary storage (the day
tank) to the point of final use -the engine's combustion
chamber. A second and equally important function is to
regulate engine speed by controlling the rate of fuel
consumption. A fuel injection pump at the side of the
engine takes fuel from the day, or
1-30
TM 5-6115-593-12
TO 35C2-3-463-1
supply tank then runs it through a filter and
delivers it, under pressure, to the individual
cam-operated injectors of each cylinder.
The fuel injectors receive fuel from the
pump under pressure, meter a small portion
of it, and then inject it into the combustion
chambers in the form of fine spray. Engine
speed regulation is accomplished by a
hydraulic actuator which is mechanically
linked to the fuel injection pump. The
actuator, in turn, is controlled by governor
controller A106 which senses engine speed
by means of a magnetic pickup. Any time
engine speed varies, A106 outputs a control
voltage to the actuator. The actuator, in
response, affects the rate of fuel output
from
the
fuel
injection
pump.
1-31/(1-32 blank)
TM 5-6115-593-12
TO 35C2-3-463-1
CHAPTER 2
OPERATING INSTRUCTIONS
Section I. OPERATING PROCEDURES
other abnormality is observed, notify higher level
maintenance personnel.
2-1. GENERAL.
a.
Instructions in this section are provided for
information and guidance for personnel responsible for
operation of the generator set.
2-5. STOPPING.
a.
Normal Stopping.
(See figure 2-7).
Preventive maintenance procedures to be performed
after equipment operation are provided in table 3-2.
b.
The operator must know how to perform
every operation of which the generator set is capable of
performing. This section describes and illustrates the
various controls and instruments required to operate the
generator set, and step-by-step instructions with
supporting illustrations for operating the generator set
under normal conditions.
b.
Stopping by Safety Devices. The generator
set is equipped with safety device electrical circuits that
automatically stop the engine and simultaneously open
the main AC circuit breaker in the case of: (1) high
coolant temperature, (2) low oil pressure, (3) engine
overspeed, (4) overvoltage, (5) no fuel, or (6) high oil
temperature. A short circuit, overload, or reverse power
protective relay will automatically open the main AC
circuit breaker but will not stop the engine. Undervoltage
relay protective circuit will similarly open the main AC
circuit breaker but will also not stop the engine. A
specific fault indicator (five for the engine and five for
the generator, figure 2-2) will light when any of these
abnormal conditions occur. Once the generator set has
been stopped due to the action of one of these safety
devices, the problem must be corrected before the
generator set is placed back in operation.
2-2. The purpose and location of generator set controls
and instruments are described in tables 2-1 through 2-4
and illustrated in figures 2-1 through 2-4.
2-3. NORMAL OPERATING CONDITIONS WITHOUT
HOUSING KIT INSTALLED. The following paragraphs
provide step-by-step procedures with supporting
illustrations. Preparation for starting (figure 2-5), starting
instructions (figure 2-6), stopping instructions (figure 27), and operating instructions for a single generator unit
(figure 2-8). See par. 2-9 for operation with housing kit
installed.
c.
Emergency Stopping. To stop the generator
set in an emergency, open the 24V DC CONTROL
CIRCUIT BREAKER (figure 2-7) or EMERGENCY
SHUT DOWN switch (figure 2-3).
2-4. STARTING.
a.
Preparation for Starting. Instructions to be
followed when preparing to start the engine generator
set are shown in figure 2-5. Preventive maintenance
procedures to be performed before operation are
provided in table 3-2.
2-6. OPERATION OF EQUIPMENT.
a.
Remote Control Module Operation. See par.
2-10.
b.
Starting. After performing the preparation
for starting procedure, start the engine generator set as
shown in figure 2-6. If the engine will not start, or if any
b.
Automatic Control Module Operation. See
par. 2-11.
2-1
TM 5-6115-593-12
TO 35C2-3-463-1
c.
Single Engine Generator Set Operation.
See figure 2-8 for single generator set
operating instructions.
d.
Emergency Operation. If any emergency
situation requires continued operation of the
generator set after being shut down by one
of the safety device electrical circuits, the
BATTLE SHORT switch can be used to
override all safety devices, except reverse
power, overload, overspeed and short
circuit, as follows:
(1)
Place BATTLE SHORT switch in OFF
position (figure 2-7).
(2)
Hold MASTER SWITCH in START
position (figure 2-5) and start engine.
(3)
Place BATTLE SHORT switch to the
ON position.
(4)
Release MASTER SWITCH from
START position, and place BATTLE
SHORT switch in OFF position as
soon as possible after emergency has
passed.
2-7. EXERCISE OF ENGINE ON STANDBY
SERVICE. An engine on standby service, customarily
operated under optimum conditions, should be
exercised at least on a monthly basis. However, under
environmental
conditions
involving
extreme
temperatures, humidity, dust, sand, etc., it may be
necessary to shorten the interval between exercise
periods to as often as weekly. Exercise period should be
long enough so that the engine attains normal operating
temperature (160-200°°F, (71 to 93°C) and if possible,
with at least 50 percent of its normal load. Exercise
engine as follows:
a.
Perform the preparation for starting
instructions shown in figure 2-5. Make
complete visual inspection of unit to be sure
it is in proper operating condition.
b.
Start engine as shown in figure 2-6. After
the warmup period, run engine at rated
speed with whatever load is available, up to
full load, for the period of time required to
obtain two consecutive water temperature
readings of 160°F (71°C) minimum taken at
15-minute intervals. Continue to operate
engine for 30 minutes. Check and correct
any coolant or oil leaks.
NOTE
The BATTLE SHORT switch may be
actuated, in emergency, any time the
generator set is operating.
FIGURE,
INDEX NO.
Table 2-1. Engine Control Panel, Controls and Instruments
CONTROL AND INSTRUMENT
FUNCTION
NORMAL
READING/SETTING
2-1,1
MASTER SWITCH START-STOP
Switch starts and stops the
generator set.
Neutral
2-1,2
FUEL gauge
Indicates level of fuel in tank
Midrange
2-1,3
FUEL PUMP AUTO-OFF switch
Activates fuel
required).
AUTO
2-1,4
ENGINE OIL TEMP gauge
Indicates temperature of oil
200 to 220°F (93 to 104°C)
2-1,5
ENGINE OIL PRESS gauge
Indicates engine oil pressure
60 to 80 psi (42,186 to 56,248
kgs/m2)
2-1,6
BATTERY CHRG AMPS meter
Indicates
current.
Positive range
2-1,7
ELAPSED TIME meter
Indicates operating time of
generator set.
2-2
transfer
battery
(as
charging
— — —
TM 5-6115-593-12
TO 35C2-3-463-1
Figure 2-1. Engine Control Panel (Part of Control Cubicle)
2-3
TM 5-6115-593-12
TO 35C2-3-463-1
FIGURE,
INDEX NO.
Table 2-1. Engine Control Panel, Controls and Instruments-Continued
CONTROL AND INSTRUMENT
FUNCTION
NORMAL
READING/SETTING
2-1,8
Panel lamp
Illuminates engine panel.
— — —
2-1,9
Panel lamp
Illuminates engine panel.
— — —
2-1,10
BATTERY CHRG VOLTS meter
Indicates dc system voltage
26.8V DC
2-1,11
WATER TEMP gauge
Indicates
temperature
2-1,12
FUEL PUMP ON lamp
Illuminates indicating fuel transfer
pump is in operation.
Cycles On and Off
2-1,13
START AID ON-OFF switch
Actuates either starting aid as
required while engine is cranking at
speeds up to 1200 rpm.-
OFF
2-1,14
OVER CRANK lamp
Indicates cranking time has been
exceeded.
OFF
2-1,15
AUTO/MAN OPERATION switch
Select whether operation is to be
via control panel or automatic
control module
MAN
engine
coolant
180 to 200°F (356 to
382°C)
Table 2-2. Generator Control Panel, Controls and Instruments
FIGURE,
INDEX NO.
CONTROL AND INSTRUMENT
FUNCTION
NORMAL
READING/SETTING
2-2,1
VOLTS AC meter
Indicates AC output voltage.
120/208 or 240/416
2-2,2
Panel lamp
Illuminates panel.
— — —
2-2,3
1-2-3 lamp
Lights
to
indicate
sequence 1,2,3
2-2,4
AMMETER switch
Selects phase 1,2, or 3 voltage.
As desired.
2-2,5
KW meter
Indicates power output of 3
phase, 4 wire generator.
Less than 100 percent nominal.
2-2,6
AMMETER meter
Indicates percent rated current
for selected phase.
Less than 100 percent.
2-2,7
Panel lamp
Illuminates panel.
— — —
2-2,8
ANNUNCIATOR RESET
Resets annunciating
OFF
2-2,9
ALARM SILENCE switch
Silences alarm.
OFF
2-4
phase
On
TM 5-6115-593-12
TO 35C2-3463-1
Figure 2-2. Generator Control Panel (Part of Control Cubicle)
2-5
TM 5-6115-593-12
TO 35C2-3463-1
Table 2-2. Generator Control Panel, Controls and Instruments-Continued
FIGURE,
INDEX NO.
CONTROL AND INSTRUMENT
FUNCTION
NORMAL
READING/SETTING
2-2,10
Clock 50 HZ switch
Allows clock operation on 60
HZ
As applicable.
2-2,11
ENG FAULT INDICATORS
Indicates engine fault.
OFF
HI COOL TEMP
Lights if coolant temperature OFF
rises above -213 ± 3°F (100 ±
0.7°C)
HI LUBE TEMP
Lights if lube temperature rises
above 255 ± 3°F (124 ± 1°C).
OFF
LOW OIL PRESS
Lights if oil pressure drops
below 21 ± 2 psi (1.5 kg/cm2).
OFF
LOW FUEL LEVEL
Lights indicating fuel in day
tank is at a low level (1-hour
operation).
OFF
OVERSPEED
Lights if engine rpm reaches
2200 to 2300 rpm.
OFF
2-2,12
CLOCK
Digital clock, indicates time in
hours, minutes, and seconds.
— — —
2-2,13
CLOCK HR ADJ switch
Adjusts clock hour setting.
engine is cranking at
OFF
2-2,14
GEN FAULT indicators
Indicates cranking time
OFF
OVERLOAD
Lights if any phase current
exceeds 110 percent rated
load.
OFF
OVERVOLT
Indicates
condition
an
overvoltage
OFF
UNDERVOLT
Indicates
condition.
an
undervoltage
OFF
REVERSE POWER
Indicates a
condition.
SHORT CIRCUIT
Indicates a short circuit.
OFF
2-2,15
Panel lamp
Illuminates panel.
— — —
2-2,16
ANNUNCIATOR TEST switch
Activates audible alarm and
checks indicator bulbs.
OFF
2-2,17
HOLD TIME switch
Holds clock time.
2-6
OFF
2-2,11
reverse
power
OFF
TM 5-6115-593-12
TO 35C2-3-463-1
FIGURE,
INDEX NO.
Table 2-2. Generator Control Panel, Controls and Instruments-Continued
CONTROL AND INSTRUMENT
FUNCTION
NORMAL
READING/SETTING
2-2,18
CLOCK MIN ADJ switch
Adjusts clock minute setting.
2-2,19
POWER FACTOR meter
Indicates power
generator set load.
2-2,20
KVAR meter
Indicates KVAR of 3-phase, 4wire circuits.
Less than 75 percent
2-2,21
PARALLEL OPERATION- SINGLE
UNIT OPERATION switch
In PARALLEL OPERATION
position, activates all parallel
circuits; in SINGLE UNIT
OPERATION
position,
it
deactivates all parallel circuits.
As required
2-2,22
PARALLEL lamp
Lights
indicating
PARALLEL
switch
PARALLEL position.
OFF
factor
is
OFF
of
that
in
0.8 lagging to 1.0
2-2,23
Panel lamp
Illuminates panel.
OFF
2-2,24
AC PWR CKT BKR-CLOSE- OPEN
circuit
Closes/opens AC power circuit
breaker
Neutral
2-2,25
AC PWR CKT BRK-CLOSED lamp
Indicates AC power circuit
breaker is in closed position.
— — —
2-2,26
24V DC CONTROL
BREAKER switch
Controls application of 24V DC
to control circuits.
ON
2-2,27
SYNC light lamps
Indicates synchronization
frequency for paralleling
generator set.
of
of
OFF
2-2,28
SYNCHROSCOPE meter
Indicates synchronization
frequency for paralleling
generator set.
of
of
Floats
2-2,29
PANEL LT SW ON-OFF switch
Switches panel lamps on and
off.
— –—
2-2,30
BATTLE SHORT ON-OFF switch
Bypasses
generator
set
protective circuits during an
emergency, except overspeed
and short circuits.
OFF
2-2,31
TEL JACK
Allows telephone connection to
remote control module.
— — —
2-2,32
BATTLE SHORT lamp
Indicates BATTLE
switch is ON.
OFF
CIRCUIT
2-7
SHORT
TM 5-6115-593-12
TO 35C2-3-463-1
Table 2-2. Generator Control Panel, Controls and Instruments-Continued
FIGURE,
INDEX NO.
CONTROL AND INSTRUMENT
FUNCTION
2-2,33
VOLT ADJ INCREASE- DECREASE
switch
Switch to adjust generator set
voltage.-
Neutral
2-2,34
FREQ
ADJ
DECREASE switch
Switch to adjust generator set
frequency
Neutral
2-2,35
HERTZ frequency meter
Indicates generator set frequency
in Hz
50Hz: 48.2-51-8 Hz
INCREASE-
NORMAL
READING/SETTING
60 Hz: 58.2-61.8 Hz
2-2,36
1-3-2 lamp
2-2,37
VOLTMETER-BUSS
VOLT switch
2-2,38
PHASE SEQUENCE-BUSS- OFF
switch
VOLT-
GEN
Lights to indicate phase sequence
1,3,2
OFF
Selects BUSS 1-2, GEN 1-2, GEN
2-3, BUSS 2-3 GEN 3-1, and
BUSS 3-1.
— — —
Selects buss, generator, or off.
— — –
Table 2-3. AC-DC Control Panel, Controls and Instruments
FIGURE,
INDEX NO.
CONTROL AND INSTRUMENT
2-3,1
120V RECEPTACLE
RECEP.
2-3,2
BREAKER
FUNCTION
NORMAL
READING/SETTING
Controls power to CONV
ON
REACTIVE
LOAD
COMPENSATION CONTROL -
Adjusts reactive load sharing of
generator sets in parallel.
— — —
2-3,3
EMERGENCY
OFF switch
Shuts down generator set during
an emergency and activates air
boxes on engine.
OFF
2-3,4
FREQUENCY SELECTOR 50 Hz-60
Hz switch
Selects either 50 Hz or 60 Hz
— — —
2-3,5,6
REACTIVE
LOAD
COMPENSATION receptacles -
Receptacles
to
voltage regulators.
interconnect
— — —
2-3,7,8,9
GOVERNOR
PARALLELING
CIRCUIT receptacles
Receptacles
to
interconnect
governors for paralleling generator
sets with paralleling cables.
— — —
2-3,10
REACTIVE
LOAD
COMPENSATION receptacle -
With shorting plug in place allows
droop voltages parallel operation.
— — —
2-3,11
FREQUENCY
ISOCHRONOUS switch
Allows selection of either droop or
isochronous operation.
2-8
— — —
SHUTDOWN-ON-
DROOP-
TM 5-6115-593-12
TO 35C2-3-463-1
Figure 2-3. AC-DC Control Panel
2-9
TM 5-6115-593-12
TO 35C2-3-463-1
FIGURE,
INDEX NO.
CONTROL AND INSTRUMENT
2-3,12
MAINTENANCE
OPERATION switch
LOCKOUT-
2-3,13
CONV RECEPT receptacle
FUNCTION
NORMAL
READING/SETTING
Used
during
maintenance.
When switch is in LOCK-OUT
position, prevents energizing of
all
circuits
energized
by
external power.
OPERATION
Provides 120V AC at generator
set operating frequency.
— — —
Table 2-4. External Power Box Control Panel, Controls and Instruments
FIGURE,
INDEX NO.
CONTROL AND INSTRUMENT
FUNCTION
NORMAL
READING/SETTING
2-4,1
120V RECEPTACLE BREAKER
Protects 120V AC to CONV
RECEPT.
2-4,2
CONV RECP
120V AC convenience outlet.
2-4,3
EXTERNAL
ON-OFF
BREAKER-
Switches external power on and
off.
OFF
2-4,4
PREHEAT SYSTEM ON-OFF switch
Switches preheat system on
and off.
OFF
2-4,5
EXTERNAL POWER
Receptacle for 120/240V AC
external power.
— — —
POWER
2-10
ON
TM 5-6115-593-12
TO 35C2-3-463-1
Figure 2-4. External Power Box Control Panel
2-11
TM 5-6115-593-12
TO 35C2-3-463-1
STEP
1.
CHECK LUBRICATING COOLANT LEVELS.
STEP
2.
CHECK AIR BOX DAMPER POSITION AND RESET MANUALLY TO OPEN (SEE DETAIL A) IF REQUIRED.
STEP
3.
CHECK BATTERY TERMINALS, MINUS (-) TO GROUND.
STEP
4.
PLACE 24V DC CONTROL CIRCUIT BREAKER TO ON POSITION ON GENERATOR PANEL.
STEP
5.
ENSURE MAINTENANCE SWITCH IS IN OPERATION POSITION ON AC-DC CONTROL PANEL.
STEP
6.
CHECK FUEL LEVEL BY PLACING BATTLE SHORT SWITCH IN THE ON POSITION ON GENERATOR PANEL AND THEN THE
MASTER SWITCH IN START POSITION ON ENGINE PANEL.
STEP
7.
RETURN MASTER SWITCH TO STOP AND THEN THE BATTLE SHORT SWITCH TO OFF.
STEP
8.
CHECK ENG FAULT INDICATORS AND ANNUCIATOR BY PLACING ANNUCIATOR TEST SWITCH IN TEST POSITION ON
GENERATOR PANEL. IF NONE OF THE LIGHTS ARE ON AFTER BEING TESTED, PROCEED WITH THE NEXT STEP. IF A
LIGHT DOES NOT COME ON, CORRECT THE INDICATED FAULT BEFORE PROCEEDING.
STEP
9.
CHECK VOLTAGE AND FREQUENCY REQUIREMENTS OF THE LOAD AGAINST THE VOLTAGE AND FREQUENCY
CONNECTION OF THE SET.
STEP
10.
PLACE AUTO/TRIP/MAN SWITCH IN MAN POSITION.
Figure 2-5. Preparation for Starting (Sheet 1 of 3)
2-12
TM 5-6115-593-12
TO 35C2-3-463-1
Figure 2-5. Preparation for Starting (Sheet 2 of 3)
2-13
TM 5-6115-593-12
TO 35C2-3-463-1
WARNING
DO NOT OPERATE THE GENERATOR SET UNLESS THE GROUND TERMINAL STUD HAS BEEN
CONNECTED TO A SUITABLE GROUND. ELECTRICAL FAULTS IN THE GENERATOR SET, LOAD
LINES, OR LOAD EQUIPMENT, CAN CAUSE INJURY OR ELECTROCUTION WITH AN
UNGROUNDED SYSTEM.
WARNING
MAKE SURE THAT NO TOLLS, PARTS, OR LOOSE ITEMS ARE ON ANY PART OF THE ENGINE
SINCE THEY MIGHT CAUSE BODILY HARM TO PERSONNEL WHEN THE ENGINE IS STARTED.
CAUTION
IF ENGINE DOES NOT START IN 45 SECONDS, OVERCRANK PROTECTION WILL TERMINATE THE
CRANKING CYCLE. RESET AND ALLOW 1-MINUTE REST BEFORE STARTING ANOTHER CRANK
CYCLE.
Figure 2-5. Preparation for Starting (Sheet 3 of 3)
2-14
TM 5-6115-593-12
TO 35C2-3-463-1
A.
STARTING WHEN AMBIENT TEMPERATURE IS ABOVE 40°F (4°) C) AND THE PREHEAT SYSTEM HAS NOT BEEN USED:
STEP
1.
TOGGLE THE MASTER SWITCH TO THE START POSITION ON THE ENGINE PANEL.
STEP
2.
WHEN THE AIR TEMPERATURE IS ABOVE 40°F (4°C), AND THE PREHEATER HAS NOT BEEN USED, ENGINE ETHER PRIMER
MAY BE REQUIRED. TO USE ETHER PRIMER, MOMENTARILY PLACE START AID SWITCH IN THE ON POSITION AND
RELEASE WHILE CRANKING THE ENGINE. EACH TIME START AID SWITCH IS CYCLED, ETHER IS INJECTED INTO THE
ENGINE AIR INTAKE SYSTEM. AFTER START OCCURS, IF ENGINE SPEED OR FREQUENCY BEGIN TO DECREASE,
ADDITIONAL ETHER CAN BE INJECTED BY CYCLING START AID SWITCH AS LONG AS THE ENGINE RPM IS BELOW 1200
RPM.
STEP
3.
WARM ENGINE FOR AT LEAST 15 MINUTES AT NO LOAD AFTER IT HAS STARTED.
STEP
4.
WHEN ENGINE HAS BEEN WARMED UP, ADJUST THE FREQUENCY AND THE VOLTAGE TO THE DESIRED VALUES. REF. 33
AND 34, FIG. 2-2.
Figure 2-6. Starting Instructions (Sheet 1 of 3)
2-15
TM 5-6115-593-12
TO 35C2-3-463-1
STEP
5.
PRIOR TO CLOSING THE MAIN CIRCUIT BREAKER (AS EXPLAINED IN STEP 7, BELOW), CHECK GEN FAULT INDICATORS
AND ANNUCIATOR BY PLACING ANNUCIATOR TEST SWITCH IN THE TEST POSITION. IF NONE OF THE LIGHTS ARE ON
AFTER BEING TESTED PROCEED WITH STEP 6. IF A LIGHT DOES CONE ON. CORRECT THE INDICATED FAULT BEFORE
PROCEEDING.
STEP
6.
PLACE THE PARALLEL/SINGLE UNIT OPERATION SWITCH IN THE SINGLE UNIT OPERATION POSITION.
WARNING
PLACING AC PWR CKT BKR TO CLOSE APPLIES POWER TO OUTPUT LOAD TERMINALS AND LOAD
LINES. ENSURE ALL PERSONNEL ARE CLEAR OF OUTPUT LOAD TERMINALS. SERIOUS INJURY OR
DEATH COULD RESULT FROM CONTACT WITH THE OUTPUT VOLTAGES.
STEP
7.
PLACE THE AC PWR CKT BKR TO CLOSE POSITION FOR APPROXIMATELY 2 OR 3 SECONDS TO CLOSE THE MAIN CIRCUIT
BREAKER. CLOSED INDICATOR SHOULD COME ON.
Figure 2-6. Starting Instructions (Sheet 2 of 3)
2-16
TM 5-6115-593-12
TO 35C2-3-463-1
B. STARTING WHEN AMBIENT TEMPERATURE IS ABOVE 40°F (4°C) AND THE PREHEAT SYSTEM HAS BEEN
USED:
STEP 1. ENSURE THAT THE PREHEAT SYSTEM HAS BEEN OPERATED A MINIMUM OF 6 HOURS PRIOR TO
STARTING. THE PREHEAT SYSTEM IS ACTIVATED AS FOLLOWS:
(A)
ENSURE THAT JUMPER IS CONNECTED BETWEEN TERMINALS 1 AND 3 ONLY IF THE
GENERATOR SET IS PERMANENTLY CONNECTED TO EXTERNAL POWER TO PERMIT BATTERY
CHARGE OPERATION, AS SHOWN BELOW ON TERMINAL BOARD TB20 LOCATED IN THE AC-DC
CONTROL BOX.
(B) CONNECT 120/240 VAC EXTERNAL POWER SOURCE TO ETERNAL POWER RECEPTACLE ON
EXTERNAL POWER BOX CONTROL PANEL.
(C) SWITCH EXTERNAL POWER BREAK TO ON.
(D) SWITCH PREHEAT SYSTEM SWITCH TO ON.
STEP 2. TOGGLE THE MASTER SWITCH TO THE START POSITION ON ENGINE PANEL.
STEP 3. PROCEED AS IN A, ABOVE, STEPS 4 THROUGH 7.
Figure 2-6. Starting Instructions (Sheet 3 of 3)
2-17
TM 5-6115-593-12
TO 35C2-3-463-1
STEP 1. PLACE AC PWR CKT BKR IN OPEN POSITION APPROXIMATELY 2 OR 3 SECONDS; THE AC PER CKT
BKR CLOSED LIGHT, SHOULD GO OUT.
WARNING
SHUTTERS WILL SNAP SHUT RAPIDLY WITH CONSIDERABLE FORCE WHEN GENERATOR SET
IS STOPPED. ENSURE ALL PERSONNEL ARE CLEAR OF SHUTTERS BEFORE PLACING MASTER
SWITCH TO STOP. SERIOUS INJURY COULD RESULT.
STEP 2. PLACE MASTER SWITCH IN STOP POSITION AFTER ALLOWING TO COOL BY OPERATING AT NO
LOAD FOR APPROXIMATELY 5 MINUTES.
STEP 3. AFTER ENGINE STOPS, REMOVE DC CONTROL POWER BY SETTING 24V DC CONTROL CIRCUIT
BREAKER TO OFF POSITION.
Figure 2-7. Stopping Instructions
2-18
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TO 35C2-3-463-1
STEP 1.
STEP 2.
STEP 3.
STEP 4.
PREPARE GENERATOR SET FOR STARTING (FIGURE 2-5).
START GENERATOR SET (FIGURE 2-6).
ROTATE AMMETER SWITCH TO EACH PHASE POSITION, WHILE OBSERVING AMMETER. IF MORE
THAN 100 PERCENT RATED CURRENT IS INDICATED IN ANY PHASE POSITION, REDUCE THE LOAD.
IF MORE THAN 100 PERCENT LOAD IS INDICATED OK THE KW METER, REDUCE THE LOAD.
Figure 2-8. Single Generator Unit, Operating Instructions
2-19
TM 5-6115-593-12
TO 35C2-3-463-1
Section II. OPERATION OF AUXILIARY MATERIAL USED IN CONJUNCTION
WITH THE EQUIPMENT
2-8. GENERAL. This section provides step-by-step
procedures with supporting illustrations for operating the
generator set in conjunction with the auxiliary housing
kit, the remote control module and cable, and the
automatic control module.
2-9. OPERATION WITH THE HOUSING KIT. The
auxiliary housing kit encloses the top, sides, and ends of
the generator set and is removable to provide access for
overhaul or replacement of major components of the
generator set. The housing is attached to the base
assembly and the support frame assembly to provide a
rain-proof enclosure, and prevent rain, snow, or sand
from entering the interior of the housing. The housing
doors allow access to the inside of the generator set.
The shutter assembly at the radiator end of the
generator set is automatically controlled and opens as
necessary to facilitate air circulation. Installation of the
housing kit extends the operational capability of the
generator set down to temperatures from 40°F to -25°F
(4.4°C to -32°C). Preparation procedures for starting
the generator set with the housing kit installed are given
in figure 2-9.
STEP 1.
STEP 2.
STEP 3.
STEP 4.
STEP 5.
STEP 6.
CHECK LUBRICATING AND COOLANT LELS.
CHECK AIR BOX DAMPER POSITION AND RESET MANUALLY TO OPEN IF P E. S FIG. 2-5 SHEET 1.
CHECK BATTERY TERMINALS, S (-) TO GROUND.
PLACE 24V DC CONTROL CIRCUIT BREAKER TO ON POSITION ON GENERATOR PANEL.
ENSURE MAINTENANCE SWITCH IS IN OPERATION POSITION ON AC-DC CONTROL PANEL.
CHECK FUEL LEVEL AND SIDE DOOR SHUTTER OPERATION BY PLACING BATTLE SHORT SWITCH
IN THE ON POSITION ON GENERATOR PANEL AND THEN THE MASTER SWITCH IN START
POSITION ON ENGINE PANEL.
STEP 7.
RETURN MASTER SWITCH TO STOP AND THEN THE BATTLE SHORT SWITCH TO OFF.
STEP 8. CHECK ENG FAULT INDICATORS BY PLACING ANNUNCIATOR TEST SWITCH IN TEST POSITION ON
GENERAL PANEL.. IF NONE OF THE LIGHTS ARE ON AFTER BEING TESTED PROCEED WITH THE
NEXT STEP.
IF A LIGHT DOES COME ON, CORRECT THE INDICATED FAULT BEFORE
PROCEEDING.
STEP 9.
CHECK VOLTAGE AND FREQUENCY OF THE LOAD AGAINST THE VOLTAGE AND FREQUENCY
CONNECTION OF THE SET.
STEP 10. ENSURE THAT THE SHUTTERS ON THE RADIATOR END OF THE SET ARE NOT MANUALLY LOCKED
OPEN.
STEP 11. CLOSE ALL DOORS EXCEPT CONTROL BOX END.
STEP 12. PLACE AUTO/TRIP/MAN SELECTOR SWITCH IN MAN POSITION.
Figure 2-9. Preparation for Starting with Housing
Kit Installed (Sheet 1 of 3)
2-20
TM 5-6115-593-12
TO 35C2-3-463-1
NOTE
paragraph 2-14 have been complied with.
Figures 2-10, 2-11, and 2-12 provide
starting,
stopping,
and
operating
instructions for housed generator sets.
Prior to starting the generator set in
temperatures down to -25°F (-32°C), also
ensure that the requirements of
Figure 2-9. Preparation for Starting with Housing
Kit Installed (Sheet 2 of 3)
2-21
TM 5-6115-593-12
TO 35C2-3-463-1
WARNING
DO NOT OPERATE THE GENERATOR SET UNLESS THE GROUND TERMINAL STUD HAS BEEN
CONNECTED TO A SUITABLE GROUND. ELECTRICAL FAULTS IN THE GENERATOR SET, LOAD
LINES OR LOAD EQUIPMENT, CAN CAUSE INJURY OR LOAD LINES OR LOAD EQUIPMENT, CAN
CAUSE INJURY OR ELECTROCUTION WITH AN UNGROUNDED SYSTEM.
WARNING
MAKE SURE THAT NO TOOLS, PARTS OR LOOSE ITEMS ARE ON ANY PART OF THE ENGINE
SINCE THEY MIGHT CAUSE BODILY HARM TO PERSONNEL WHEN THE ENGINE IS STARTED.
CAUTION
IF ENGINE DOES DOT START IN 45 SECONDS, OVERCRANK PROTECTION WILL TERMINATE THE
CRANKING CYCLE. RESET AND ALLOW 1-MINUTE REST BEFORE STARTING ANOTHER CRANK
CYCLE.
Figure 2-9. Preparation for Starting with Housing
Kit Installed (Sheet 3 of 3)
2-22
TM 5-6115-593-12
TO 35C2-3-463-1
STEP 1. ENSURE THAT THE PREHEAT SYSTEM HAS BEEN OPERATED A MINIMUM OF 6 HOURS PRIOR TO
STARTING. THE PREHEAT SYSTEM IS ACTIVATED AS FOLLOWS:
A.
ENSURE THAT JUMPER IS ON BETWEEN TERMINALS 1 AND 3 ON TERMINAL BOARD 20
(LOCATED IN THE AC-DC CONTROL BOX) AS SHOWN BELOW, ONLY IF THE GENERATOR SET IS
PERMANENTLY CONNECTED TO EXTERNAL POWER TO PERMIT BATTERY CHARGE
OPERATION.
B. CONNECT 120/240V AC ETERNAL POWER SOURCE TO EXTERNAL POWER RECEPTACLE ON
EXTERNAL POWER BOX CONTROL PANEL.
C. SWITCH EXTERNAL POWER BREAKER TO ON.
D. SWITCH PREHEAT SYSTEM SWITCH TO ON.
Figure 2-10. Starting Instructions when Ambient Temperature is from 40°F to
-25°F (4.4°C to -32°C) and Housing Kit is Installed (Sheet 1 of 3)
2-23
TM 5-6115-593-12
TO 35C2-3-463-1
STEP 2. TOGGLE THE MASTER SWITCH TO THE START POSITION ON ENGINE PANEL.
Figure 2-10. Starting Instructions when Ambient Temperature is from 40°F to
-25°F (4.4°C to -32°C) and Housing Kit is Installed (Sheet 2 of 3)
2-24
TM 5-6115-593-12
TO 35C2-3-463-1
STEP 3.
STEP 4.
STEP 5.
STEP 6.
WHEN THE ENGINE HAS STARTED, ADJUST THE FREQUENCY AND VOLTAGE TO THE DESIRED
VALUES.
PRIOR TO CLOSING THE MAIN CIRCUIT BREAKER (AS EXPLAINED IN STEP 6, BELOW), CHECK GEN
FAULT INDICATORS BY PLACING ANNUNCIATOR TEST SWITCH IN THE TEST POSITION. IF NONE
OF TEE LIGHTS ARE ON AFTER BEING TESTED, PROCEED WITH STEP 5. IF A LIGHT DOES CONE
ON, CORRECT THE INDICATED FAULT BEFORE PROCEEDING.
PLACE THE PARALLEL/SINGLE UNIT OPERATION SWITCH IN THE SINGLE UNIT OPERATION
POSITION.
PLACE THE AC PWR CKT BKR TO CLOSE POSITION FOR APPROXIMATELY 2 OR 3 SECONDS TO
CLOSE THE MAIN CIRCUIT BREAKER. CLOSED INDICATOR SHOULD CONE ON.
Figure 2-10. Starting Instructions when Ambient Temperature is from 40°F to
-25°F (4.4°C to -32°C) and Housing Kit is Installed (Sheet 3 of 3)
2-25
TM 5-6115-593-12
TO 35C2-3-463-1
STEP 1. PLACE AC PWR CKT BKR IN OPEN POSITION APPROXIMATELY 2 OR 3 SECONDS; THE AC PWR CKT
BKR CLOSED LIGHT SHOULD GO OUT.
WARNING
Shutters will snap shut rapidly with considerable force when generator set is stopped. Ensure all
personnel are clear of shutters before placing MASTER switch to STOP. Serious injury could
result.
STEP 2. PLACE MASTER SWITCH IN STOP POSITION AFTER ALLOWING ENGINE TO COOL BY OPERATING AT
NO LOAD FOR APPROXIMATELY 5 MINUTES.
STEP 3. AFTER ENGINE STOPS, REMOVE DC CONTROL POWER BY SETTING 24V DC CONTROL CIRCUIT
BREAKER TO OFF POSITION.
Figure 2-11. Stopping Instructions with Housing Kit Installed.
2-26
TM 5-6115-593-12
TO 35C2-3-463-1
STEP 1.
STEP 2.
STEP 3.
STEP 4.
PREPARE GENERATOR SET FOR STARTING (FIGURE 2-9).
START GENERATOR SET (FIGURE 2-10).
ROTATE AMMETER TO EACH PHASE POSITION, WHILE OBSERVING AMMETER. IF MORE THAN 100
PERCENT RATED CURRENT IS INDICATED IN ANY PHASE POSITION, REDUCE THE LOAD.
IF MORE THAN 100 PERCENT LOAD IS INDICATED ON THE KW METER REDUCE THE LOAD.
Figure 2-12. Single Generator Unit, Operating Instructions with
Housing Kit Installed
2-27
TM 5-6115-593-12
TO 35C2-3-463-1
2-10. OPERATION WITH THE REMOTE CONTROL MODULE AND CABLE. Addition of the remote control module
and cable allows operation of the engine/generator set from distances of up to 100 feet (30 meters). The purpose and
location of controls on the remote control module panel are described in table 2-5 and illustrated in figure 2-13. It should
be noted that the controls on the remote control module are almost identical to those on the generator control panel.
a. Connection Procedure for Using Remote Control Module and Cable.
WARNING
Do not attempt to make connections to the control cubicle while generator set is in operation.
(1) Connect the remote control cable to the remote control module by connecting plug P4 to receptacle J4, plug P1
to receptacle J1, and plug P2 to receptacle J2.
(2)
Connect the other end of the remote control cables to the back side of generator set control cubicle by
connecting plug P4 to receptacle J4, plug P1 to receptacle J1, and plug P2 to receptacle J2.
(3) Remove terminal board jumper connections in control cubicle as shown in figure 2-14.
b. Use of Remote Control Module. Figures 2-15, 2-16, 2-17, and 2-18 provide preparation, starting, stopping and
operating instructions for generator set equipped with a remote control module.
c.
Emergency Stopping. To stop the generator set from the remote control module in an emergency, place the
EMERGENCY SHUT-DOWN switch in the ON position.
FIGURE,
INDEX NO.
Table 2-5. Remote Control Panel, Controls and Instruments
NORMAL
CONTROL AND INSTRUMENT
FUNCTION
2-13,1
VOLT ADJ INCREASEDECREASE
2-13,2
BATTLE SHORT lamp
2-13,3
VOLTMETER-BUSS VOLT-GEN
VOLT switch
2-13,4
FREQ ADJ INCREASEDECREASE
2-13,5
VOLTS AC meter
2-13,6
48.2-
HERTZ frequency meter
2-13,7
AMMETER switch
READING/SETTING
Permits adjustment of
generator set voltage
output.
Indicates BATTLE SHORT
switch is ON.
Selects BUSS 1-2, GEN
1-2, GEN 2-3, BUSS
2-3, GEN 3-1, and
BUSS 3-1.
Switch to adjust generator at frequency
Neutral
Indicates AC output
voltage.
Indicates generator set.
frequency in Hz.
120/208 or
240/416
50 Hz:
51.8 Hz 58.2
60 Hz:
61.8 Hz
As desired.
Selects phase 1, 2 or 3.
2-28
OFF
— —
Neutral
TM 5-6115-593-12
TO 35C2-3-463-1
Figure 2-13. Remote Control Module Panel
Table 2-5. Remote Control Panel, Controls and Instruments-Continued
FIGURE,
INDEX NO.
CONTROL AND INSTRUMENT
FUNCTION
NORMAL
READING/SETTING
2-13,8
MASTER SWITCH STARTSTOP switch
Switch starts and stops
generator operation.
Neutral
2-13,9
START AID ON-OFF
switch
Actuates ether starting
aid as required while
engine is cranking at
speeds up to 1200 rpm.
OFF
2-29
TM 5-6115-593-12
TO 35C2-3-463-1
Table 2-5. Remote Control Panel, Controls and Instruments-Continued
FIGURE,
INDEX NO.
2-13,10
CONTROL AND INSTRUMENT
AMMETER meter
FUNCTION
Indicates percent rated
current for selected
phase.
2-13,11
KW meter
Indicates power output
of 3-phase, 4-wire
generator
Less than 100%
2-13,12
OVER CRANK lamp
Lights if cranking time
has been exceeded.
OFF
2-13,13
ENG FAULT indicators
Indicates engine fault.
OFF
HI COOL TEMP
Lights if coolant
temperature rises
above 213 ± 3°F
(100 + 0.7xC).
OFF
HI LUB TEMP
Lights if lube temperature rises above 255
± 3°F (124 ± 1°C).
OFF
LOW OIL PRESS
Lights if oil pressure
drops below 21± 2 psi
(1.47 kg/cm2 ).
OFF
LOW FUEL LEVEL
Lights indicating fuel
in day tank at a low
level (1-hour operation).
OFF
OVERSPEED
Lights if engine speed
reaches 2200 to
2300 rpm.
OFF
2-13,14
ANNUNCIATOR RESET
switch
Resets annunciating
system.
OFF
2-13,15
ALARM SILENCE switch
Silences alarm
OFF
2-13,16
ANNUNCIATOR TEST
switch
Activates audible
alarm and checks
indicator bulbs.
OFF
2-13,17
GEN FAULT indicators
Indicates generator
fault
OFF
OVERLOAD
Lights if any phase current exceeds 110 percent rated load.
OFF
OVERVOLT
Indicates an overvoltage
condition.
OFF
UNDERVOLT
Indicates an undervoltage condition.
Indicates a reverse
power condition.
2-30
OFF
REVERSE POWER
NORMAL
READING/SETTING
Less than 100%
OFF
TM 5-6115-593-12
TO 35C2-3-463-1
Table 2-5. Remote Control Panel, Controls and Instruments-Continued
FIGURE,
INDEX NO.
CONTROL AND INSTRUMENT
FUNCTION
NORMAL
READING/SETTING
2-13,17
(cont'd)
SHORT CIRCUIT
Indicates a short
circuit.
OFF
2-13,18
KVAR meter
Indicates KVAR of 3phase, 4-wire circuits.
Less than 100%
2-13,19
Panel lamps
Four lamps to illuminate
panel.
— —
2-13,20
SYNC lamps
Indicates synchronizetion of frequency for
paralleling of generator set.
OFF
2-13,21
POWER FACTOR meter
Indicates power factor of
generator set load.
0.8 lagging to
1.0
2-13,22
PARALLEL lamp
Lights indicating that
PARALLEL switch is on
parallel position.
OFF
2-13,23
PARALLEL OPERATIONSINGLE UNIT OPERATION
In PARALLEL OPERATION
position activates all
parallel circuits; in
SINGLE UNIT OPERATION
position it deactivates
all parallel circuits.
As required.
2-13,24'
SYNCHROSCOPE meter
Indicates synchronization
of frequency of paralleling of generator set.
Floats
2-13,25
AC PWR CKT BKR-CLOSED
lamp
2-13,26
AC PWR CKT BKR-CLOSEDOPEN circuit breaker
switch
Closes/opens AC power
circuit breaker.
Neutral
2-13,27
BATTLE SHORT ON-OFF
switch
Bypasses generator set
protective circuits
during an emergency
except over-speed and
short circuits.
OFF
2-13,28
READY-TO-LOAD
Indicates unit is ready
for loading.
— —
2-13,29
EMERGENCY SHUT-DOWNON-OFF switch
Controls 24V DC to control circuits to shut
down engine.
— —
2-13,30
TELJACK
Allows telephone connection from generator set.
— —
2-13,31
PANEL LT SW ON-OFF
switch
Switches panel lamps on
and off.
2-31
— —
Indicates AC PWR CKT BKR
is in CLOSED position.
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Figure 2-14. Jumper Connections to be Removed when a
Remote Control Module is Connected
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STEP 1. PERFORM STEPS 1 THROUGH 7 OF FIGURE 2-5.
STEP 2. ON THE REMOTE CONTROL MODULE PANEL CHECK ENGINE AND GEN FAULT INDICATORS BY
PLACING ANNUNCIATOR TEST SWITCH IN TEST POSITION TO VERIFY THAT ALL INDICATORS LIGHT.
STEP 3. CHECK VOLTAGE AND FREQUENCY REQUIREMENTS OF THE LOAD AGAINST THE VOLTAGE AND
FREQUENCY CONNECTIONS ON THE SET.
WARNING
MAKE CERTAIN THAT NO TOOLS, PARTS, OR LOOSE ITEMS ARE ON ANY PART OF THE ENGINE
SINCE THEY MIGHT CAUSE BODILY INJURY TO PERSONNEL WHEN THE ENGINE IS STARTED.
Figure 2-15. Preparation for Starting Using Remote Control Module
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Figure 2-16. Starting Instructions Using Remote Control Module
(Sheet 1 of 2)
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A. STARTING WHEN AMBIENT TEMPERATURE IS ABOVE 40°F (4°C) AND PREHEAT HAS NOT BEEN USED:
STEP 1.
TOGGLE MASTER SWITCH TO THE START POSITION.
STEP 2. WHEN THE AIR TEMPERATURE IS ABOVE 40°F (4°C) AND THE PREHEAT SYSTEM HAS NOT BEEN
USED, ENGINE ETHER PRIMER MAY BE REQUIRED. DO USE ETHER PRIMER, MOMENTARILY PLACE
START AID SWITCH IN THE ON POSITION AND RELEASE WHILE CRANKING ENGINE. EACH TIME
START AID SWITCH IS CYCLED, ETHER IS INJECTED INTO THE ENGINE AIR INTAKE SYSTEM. AFTER
START OCCURS, IF ENGINE SPEED OR FREQUENCY BEGIN TO DECREASE, ADDITIONAL ETHER CAN
BE INJECTED BY CYCLING START AID SWITCH AS LONG AS ENGINE RPM IS BELOW 1200 RPM.
STEP 3. CHECK ERG FAULT INDICATORS AND ANNUNCIATOR BY PLACING ANNUNCIATOR TEST SWITCH IN
TEST POSITION. IF NONE OF THE LIGHTS ARE ON AFTER BEING TESTED, PROCEED WITH THE
NEXT STEP. IF A LIGHT DOES CONE ON, THE INDICATED FAULT BEFORE PROCEEDING.
STEP 4. VOLTS AC METER SHOULD INDICATE 208 OR 416 VOLTS IF VOLTMETER SWITCH IS SET AT GEN 1-2,
GEN 2-3, OR GEN 3-1.
STEP 5.
ALLOW ENGINE TO WARM UP FOR 15 MINUTES AT NO LOAD.
STEP 6. SET VOLT ADJ SWITCH AS REQUIRED TO OBTAIN PROPER VOLTAGE OUTPUT STATED IN STEP 4,
ABOVE.
STEP 7.
OPERATE FREQ ADJ SWITCH TO OBTAIN PROPER FREQUENCY.
STEP 8. PRIOR TO CLOSING THE MAIN CIRCUIT BREAKER (AS EXPLAINED IN STEP 9, BELOW), CHECK GEN
FAULT INDICATOR AND ANNUNCIATOR BY PLACING ANNUNCIATOR TEST SWITCH IN THE TEST
POSITION. IF NONE OF THE LIGHTS ARE ON AFTER BEING TESTED PROCEED WITH STEP 9. IF A
LIGHT DOES COME ON, CORRECT THE INDICATED FAULT BEFORE PROCEEDING.
WARNING
PLACING AC PWR CKT BKR TO CLOSE APPLIES POWER TO OUTPUT LOAD TERMINALS AND
LOAD LINES. ENSURE ALL PERSONNEL ARE CLEAR OF OUTPUT LOAD TERMINALS. SERIOUS
INJURY OR DEATH COULD RESULT.
STEP 9. TOGGLE THE AC PWR CKT BKR SWITCH TO THE CLOSE POSITION FOR 2 OR 3 SECONDS TO CLOSE
MAIN CIRCUIT BREAKER. CLOSED INDICATOR SHOULD CONE ON.
B.
STARTING WHEN AMBIENT TEMPERATURE IS ABOVE 40°F (4°C) AND PREHEAT IS USED:
NOTE
ENGINE PREHEAT SYSTEM COT BE ACTIVATED FROM THE RBE CONTROL MODULE.
STEP 1.
STEP 2.
STEP 3.
ENSURE THAT PREHEAT SYSTEM HAS BEEN OPERATED A MINIMUM OF 6 HOURS PRIOR TO
START-UP. (STEP B1(A), (B), (C) AND (D) OF FIGURE 2-6.)
TOGGLE MASTER SWITCH ON R CONTROL NODULE TO THE START POSITION.
CONTINUE AS IN STEPS 3 THROUGH 9, ABOVE.
NOTE
WHEN ENGINE PREHEAT AT SYSTEM HAS BEEN USED, NO ADDITIONAL WARN-UP TIME IS
NEEDED.
Figure 2-16. Starting Instructions Using Remote Control Module
(Sheet 2 of 2)
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STEP 1. PLACE AC PWR CKT BKR SWITCH IN OPEN POSITION FOR APPROXIMATELY 2 OR 3 SECONDS, THE
AC PWR CKT BKR CLOSED LIGHT SHOULD GO OUT.
WARNING
WILL SNAP SHUT RAPIDLY WITH CONSIDERABLE FORCE WHEN GENERATOR SET IS STOPPED.
ENSURE ALL PERSONNEL ARE CLEAR OF SHUTTERS BEFORE PLACING MASTER SWITCH TO
STOP. SERIOUS INJURY COULD RESULT.
STEP 2. PLACE MASTER SWITCH IN STOP POSITION AFTER ALLOWING ENGINE TO COOL BY OPERATING AT
NO LOAD FOR APPROXIMATELY 5 MINUTES.
STEP 3. AFTER ENGINE HAS STOPPED, REMOVE DC POWER CONTROL BY SETTING 24V DC CONTROL
CIRCUIT BREAKER (ON GENERATOR CONTROL PANEL) TO OFF POSITION. (ON GENERATOR
CONTROL PANEL) TO OFF POSITION.
Figure 2-17. Stopping Instructions Using Remote Control Module
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STEP 1.
STEP 2.
STEP 3.
STEP 4.
STEP 5.
CONNECT REMOVE CONTROL MODULE AND CABLE (PARA. 2-10A).
PREPARE GENERATOR SET/REMOTE CONTROL MODULE FOR STARTING (FIGURE 2-15).
START GENERATOR (FIGURE 2-16).
ROTATE AMMETER SWITCH TO EACH PHASE POSITION WHILE OBSERVING AMMETER. IF MORE
THAN 100 PERCENT RATED CURRENT IS INDICATED IN ANY PHASE POSITION, REDUCE THE LOAD.
IF MORE THAN 100 PERCENT LOAD IS INDICATED ON THE KW METER, REDUCE THE LOAD.
Figure 2-18. Operating Instructions, Single Generator Unit Using
Remote Control Module
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±. The addition of a automatic control module allows unattended control of one to four generator sets. The automatic
control module monitors the bus (utility) power source, and controls the starting and sequential loading of one to four
generator sets whenever the bus voltage or frequency fails or deviates from a pre-set value. Only those generators with
the AUTO/MAN selector switch in the AUTO position will be controlled via the automatic control module. The controls
are illustrated in figure 2-19 and described in table 2-6. Reference also Chapter 5 Section IV.
a. Connecting the Automatic Control Module
(1) Change jumper connections as shown in figure 2-20.
(2) Interconnect generator set and automatic control module by wiring supplied J3 connector plug on back of control
cubicle (to be wired by user) on rear of generator control box to TB1 thru TB4 terminal boards in automatic
control module in accordance with FO-15. Connect the load feeder breakers (supplied by user) to the
appropriate control contacts (via TB4). See FO-15 for all interconnection wiring instructions.
NOTE
LR1, LRTD1 are No. 1 priority feeder controls. They will activate first regardless of which
generator first comes on line. LR energizes instantly, LRTD energizes 2-5 seconds after LR. LR2,
LRTD2 are No. 2 priority feeder controls and will activate only when a second generator comes on
line. Priority No. 3 and No. 4 feeder controls work in a similar manner when generator 3 and 4
come on line. The total load to be supplied to any one load feeder breaker 1 thru 8 shall not
exceed 250 KW.
(3) Set the NO RETURN/TD RETURN/
INSTANT RETURN mode selector switch S1 and the FREQ. SELECT 50 HZ/60 HZ switch S2 to the appropriate or
desired position.
(4) Connect 120V AC from the line side of the utility breaker to TB1-5 and TB1-6 of the automatic control module.
The neutral wire should be connected to TB1-5.
NOTE
The over/under voltage relay is normally set for a ± 10% deviation of a L-N voltage of 120V AC. The
over and under frequency relays are normally set for a ± 3% deviation of a bus frequency of either
50 or 60 Hz.
b. ACM Operating Procedure
(1) Manual Operation If manual operation and control of the generators is desired, place the AUTO/TRIP/ MAN
switch (S53) located on the generator set control panel, to MAN position. Place the NO RETURN/TD
RETURN/INSTANT RETURN mode selector switch (S1) located on the ACM, to NO RETURN. The generator
set will not be under control of the ACM and the set controls will be strictly manual via generator control panel.
No relays will be caused to energize or deenergize in the ACM, thereby precluding any effect to the utility
breaker or feeder control relays. If manual paralleling is desired, place the generator set parallel switch to
parallel.
(2) Automatic Operation If automatic operation is desired, first insure that 120 VAC utility power is available to
ACM by indication of the UTILITY POWER AVAILABLE lamp. Determine which type of automatic power
transfer is desired (instant, time delay or no return) and set
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selector switch S1 accordingly. Set FREQ. SELECT 50 Hz/60 Hz switch to applicable position. Place all AUTO-TRIPMAN switches (S53) on generator set control panels to AUTO, figure 2-6. Place parallel switches on all units to
PARALLEL. The 24 V DC control circuit breaker (located on the generator control panel) must be left ON in the
automatic mode.
The external power connector (generator set power box control panel) should be connected to station (utility) power and
the external power breaker to ON. Place the PRE HEAT SYSTEM switch ON (figure 2-6). Pre heat must be in operation
six hours prior to generator set start up. All units are now ready to start in the event of a utility power failure. If the units
have been automatically started on line and it's desired to shut one unit down, simply turn that unit's AUTO-TRIP-MAN
switch (S53) to the MAN position. As the switch passes through the TRIP position, that unit's circuit breaker and the least
priority feeder breakers will open. After five minutes, allowing for engine cool-down, simply place the master STARTSTOP switch (S1) to the STOP position as you normally would in manual operation.
If any unit, which has been automatically started and paralleled to the bus, develops a fault and trips off the bus, always
switch that unit's AUTO-TRIP-MAN switch to MAN first then back to AUTO after resetting the fault indicator. Do not
switch NO RETURN/TD RETURN/ INSTANT RETURN mode selector switch S1 to the NO RETURN position while units
are running during a cool-down cycle.
When the utility (normal) power becomes available (NORMAL POWER AVAILABLE light ON) and the mode selector
switch is at NO RETURN, the generator set(s) will continue supplying power. The TD RETURN position allows a 330
minute (adjustable) delay until the generator set(s) automatically trip off the bus. The INSTANT RETURN position
immediately trips the generator set(s) off the bus. After the generator set(s) are automatically disconnected from the bus
an automatic five minute (adjustable) engine cool-down cycle occurs before the generator set(s) stop.
(3) Optional Uses
Terminal board points TB1-7, 8, and 9 are available for customer use as remote indication of utility power.
Additional normally closed contacts of the BR relays are available between TB3-9 thru TB3-16 for remote indication
of each units circuit breaker status (in automatic operation only).
Each generator has governor control summing junctions available through J3-H (Shield) J3-G and J3-F whenever a
units circuit breaker is closed (in automatic operation only). Future use of these terminals are dependent upon
the user.
J3-S, on the generator set, is for remote indication or T-7 winding (120 VAC) available whenever the generator is
running, regardless of circuit breaker being closed or open. Functional use is dependent upon user.
Terminal board points TB3-17-18-19 can be wired to control an electrically operated utility breaker and/or transfer
switch.
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Figure 2-19. Automatic Control Module
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FIGURE,
INDEX NO.
Table 2-6. Automatic Control Module, Controls and Instruments
NORMAL
CONTROL AND INSTRUMENT
FUNCTION
READING/SETTING
2-19,1
UTILITY POWER AVAILABLE
LAMP
Indicates availability
of utility/bus voltage
within proper limits.
ON
2-19,2
MODE SELECTOR switch
Selects whether load
will be transferred
back to utility after
a predetermined time
delay, instantly, or
will not transfer at
all until manually
selected.
T.D. Return
2-19,3
FREQUENCY SELECT switch
Selects the proper trip
points of the over
and under frequency
relays.
As required
by system
running
frequency.
2-19,4
A.C. UTILITY POWER FUSE
15A
Protects wiring of
utility monitoring
circuit.
— —
2-19,5
BR1-4 A.C. Fuses 5A
Protects wiring of BR1
thru BR4 circuitry.
— —
2-19,6
Unit 1-4 D.C. Fuses 5A
Protects D.C. 'sensing
wires between units
1 thru 4 and automatic control module.
— —
2-19,7
MR1-4 A.C. Fuses 5A
Protects wiring of MR1
thru MR4 circuitry.
— —
2-19,8
MASTER CONTROL RELAY
(MR1-MR4)
Closes the generator
circuit breaker only
on the first unit to
reach acceptable
voltage and frequency.
— —
2-19,9
LOAD RELAYS LR
1 thru 4 and LRTD
1 thru 4
Relay contacts will
control customer load
feeder breakers.
LRTD time delay relays adjustable from
0.2 to 20 seconds.
— —
2-19,10
OVER/UNDER VOLTAGE RELAY
(27/59)
Senses utility voltage
at 120 ± 10%. Trips
at 108V AC (under) and
132V AC (over) voltage.
— —
2-19,11
TIME DELAY RELAY
(SDT)
Allows generator(s) to
continue to run (cool
down) after utility
power has returned.
(Adjustable 1-300
sec.)
2-41
As desired.
TM 5-6115-593-12
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Table 2-6. Automatic Control Module, Controls and Instruments - Continued
FIGURE,
INDEX NO.
CONTROL AND INSTRUMENT
FUNCTION
NORMAL
READING/SETTING
2-19,12
UNDERFREQUENCY RELAY
(81U)
Senses utility frequency
and trips at 58.2 or
48.5 Hz.
— —
2-19,13
OVERFREQUENCY RELAY
(810)
Senses utility frequency
and trips at 61.8 or
51.5 Hz.
— —
2-19,14
BREAKER CONTROL RELAY
(BR1-BR4)
Upon generator circuit
breaker closure will
provide steering
logic for load relay
circuitry. Auxiliary
contacts provided for
future customer use
of generator circuit
breaker closure indication.
— —
2-19,15
TIME DELAY RELAY (TD)
Delays start of generator(s) upon loss of
utility power.
(Adjustable 1.5-15 sec.)
As desired.
2-19,16
RUN RELAY (RR)
When de-energized, contacts initiate start
of generator(s).
— —
2-19,17
DIODE PACKS (R1-R4)
Diodes act as logic
steering or blocking
for internal circuitry.
— —
2-19,18
TIME DELAY RELAY (UTR)
Disallows load to be
transferred back to
utility source until
timed out, if TD
RETURN mode is selected.
minutes)
As desired
(Adjustable 3-30
TERMINAL BOARD 20, AC-DC CONTROL BOX
REMOVE JUMPER BETWEEN TERMINALS 1 AND 2 OF TERMINAL
BOARD 20, AND INSTALL JUMPER BETWEEN TERMINALS 1 AND 3.
Figure 2-20. Jumper Connections When Automatic Control Module is Used
2-42
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2-12.
PARALLEL OPERATION OF GENERATOR
SETS.
Engine/generator sets may be manually
operated in parallel in two ways, frequency droop or
isochronous, or operated in parallel automatically. The
automatic control module provides an unattended
automatic control system. When an automatic system of
one to four generator sets is necessary only one
automatic control module is required.
a.
provided in figure 2-21 for droop
paralleling
and
isochronous
paralleling
(paralleling
cables
required).
b. Automatic Operation in Parallel. Ref.
paragraph 2-11b, ACM Operating
Instructions.
Figure 2-21. Operating Instructions,
Manually Operated
in Parallel (Sheet 1 of 3)
Manual Operation in Parallel.
Instructions for the manual operation
of generator sets in parallel are
Figure 2-21. Operating Instructions, Manually Operated
in Parallel (Sheet 1 of 3)
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A. DROOP PARALLELING
STEP 1.
ENSURE THAT A SHORTING PLUG IS INSTALLED IN ONE REACTIVE LOAD COMPENSATION
CONNECTOR OR ON EACH SET AND THAT ALL FREQUENCY DROOP-ISOCHRONOUS SWITCHES
ARE IN DROOP POSITION. DESIGNATE ONE SET AS MASTER AND SECOND SET AS ONCOMING.
WARNING
USE EXTREME CAUTION. LOAD TERMINALS OF GENERATOR SET CIRCUIT BREAKER (CB2)
MAY STILL BE ENERGIZED WITH THE BUS VOLTAGE. SERIOUS INJURY OR DEATH COULD
RESULT.
STEP 2. INERCONNECT POWER OUTPUT TERMINALS (LO-LO, L1-L1, L2-L2, L3-L3) OF THE TWO SETS. [THESE
INTERCONNECTS SHOULD BE MADE VIA 3-PHASE DISCONNECT SWITCH (STATION SWITCH GEAR)
ON THE LOAD SIDE OF EACH GENERATOR SET CIRCUIT BREAKER (CB2)].
WARNING
DEATH OR SERIOUS INJURY NAY RESULT IF PERSONNEL FAIL TO OBSERVE SAFETY
PRECAUTIONS. DO NOT ATTEMPT TO MAKE ANY CONNECTIONS UNTIL GENERATOR SET IS
COMPLETELY SHOT DOWN AND MAINTENANCE LOCKOUT SWITCH IS IN LOCKOUT POSITION.
STEP 3.
STEP 4.
STEP 5.
STEP 6.
STEP 7.
STEP 8.
STEP 9.
STEP 10.
STEP 11.
STEP 12.
STEP 13.
PREPARE AND START MASTER SET PER INSTRUCTIONS GIVEN IN FIGURES 2-5 AND 2-8.
ONCE AC PWR CKT BKR IS CLOSED, PLACE THE PARALLEL OPERATION-SINGLE UNIT OPERATION
SWITCH IN THE PARALLEL POSITION.
START ONCOMING SET PER FIGURES 2-5 AND 2-8.
CHECK PHASE SEQUENCE OF ONCOMING SET USING PHASE SEQUENCE 1-2-3 AND 1-3-2 LAMPS.
ENSURE THAT SETS ARE IN SEQUENCE BEFORE PROCEEDING.
PLACE PARALLEL OPERATION-SINGLE UNIT OPERATION SWITCH ON ONCOMING SET TO
PARALLEL OPERATION POSITION.
SYNC LIGHTS AND SYNCHROSCOPE ON ONCOMING SET SHOULD NOW INDICATE THE
DIFFERENCES IN VOLTAGE AND FREQUENCY BETWEEN THE TWO SETS.
ADJUST THE FREQUENCY OF ONCOMING SET UNTIL THE SYNC LIGHTS ARE BLINKING VERY
SLOWLY AND/OR SYNCHROSCOPE INDICATES THAT THE SETS ARE IN PHASE. THE ONCOMING
SET FREQUENCY SHOULD BE SLIGHTLY HIGHER AS INDICATED BY THE SYNCHROSCOPE.
ADJUST THE VOLTAGE OF THE ONCOMING; SET USING VOLTMETER SELECTOR SWITCH AND
VOLTMETER UNTIL THE VOLTAGES ARE IDENTICAL.
CLOSE THE AC PWR CKT BKR ON THE ONCOMING SET THE SYNCH LIGHTS ARE DARK AND THE
SYNCHROSCOPE NEEDLE IS IN THE 12 O'CLOCK POSITION.
TRIM THE VOLTAGE AND FREQUENCY TO BALANCE THE LOAD ON BOTH SETS AS INDICATED BY
THE KVAR AND KW METERS.
IF LOAD SHIFTS BETWEEN UNITS TRIM REACTIVE LOAD
COMPENSATION CONTROL AND LOAD GAIN SETTING ON GOVERNOR CONTROLLER.
IF INCOMING SET IS ALREADY HOOKED UP, REPEAT STEPS 5 THRU 12.
B. ISOCHRONOUS PARALLELING.
STEP 1. REMOVE SHORTING PLUGS FROM ALL SETS AND INTERCONNECT REACTIVE LOAD COMPENSATION
AND GOVERNOR PARALLELING CIRCUIT CABLES.
STEP 2. ENSURE THAT FREQUENCY DROOP-ISOCHRONOUS SWITCH IS IN THE ISOCHRONOUS POSITION.
STEP 3.
PROCEED AS IN A., ABOVE, STEPS 2 THROUGH 12.
Figure 2-21. Operating Instructions, Manually Operated
in Parallel (Sheet 2 of 3)
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Figure 2-21. Operating Instructions, Manually Operated
in Parallel (Sheet 3 of 3)
2-45
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Section III. OPERATION UNDER UNUSUAL CONDITIONS
2-13. OPERATION IN COLD (40°F to -25°F) (4.4 to 32°C).
a.
2-14. OPERATION IN EXTREME HEAT (UP TO
125°F) (52°C).
a. Keep the cooling system free from rust and
scale by changing water filters. Keep cooling
system filled with clean coolant. Avoid use of
alkaline water or salt water, which causes the
accumulation of rust and scale. Inspect belts
for proper adjustment.
Be sure engine
generator set is free of dust and dirt. Check
for obstructions in radiator cooling fins and
make sure shutter controls are operating
properly.
General. The generator set operates in
temperatures down to -25° (-32°C) with the
housing kit installed. To operate successfully
down to this temperature, the engine is heated
by an integrally mounted preheat system which
receives auxiliary power from an external
source.
b. Fuel System. Be sure proper grade of fuel is
used for existing temperatures. Service fuel
filters and strainers more frequently then
normal. Remove ice, snow, and moisture from
the filler cap and filler neck. At end of day's
operation, drain water from fuel tank and from
the fuel filters.
b. Lubricate in accordance with the instructions in
Chapter 3, Section II.
c. Engine Electrical System. Clean batteries and
cables and inspect for cracked or damaged
cases. Be sure the battery terminals are tight,
clean and lightly greased. See that the battery
cap vent holes are open. The electro-lyte level
must be 3/8 inch (9.5 mm) above the plates.
See that batteries are kept fully charged.
Inspect all electrical wiring for cracks, breaks,
and fraying. Tighten loose connections.
NOTE
c.
Inspect battery electrolyte level daily. The
plates should be covered with 3/8 inch (9.5
mm) of water. Add water if necessary.
d.
Be sure generator set is free of airflow
restrictions. When operating indoors, make
provisions for adequate ventilation and the
venting of exhaust fumes to the outside.
e. Keep external surface of engine clean.
f. Run generator set at no load, for 5 minutes, to
allow the engine to cool prior to shutdown.
2-15. OPERATION IN DUSTY OR SANDY AREAS.
After adding water to the batteries in
freezing temperatures, operate the
battery charger for at least 1 hour.
a. Housing kit must be installed.
b. Where water is available, keep the immediate
area wetted down. Keep the unit as clean as
possible, paying special attention to screens
and grilles.
d. Lubrication. Lubricate in accordance
with instructions in Chapter 3, Section II.
c. Clean filters and strainers more frequently than
under normal conditions. Be sure that all
lubricant containers are tightly sealed and
stored in an area free from dust and sand.
e. Cooling System. Inspect level of coolant in
radiator by checking sight glass. Inspect cooling system
for leaks, paying particular attention to gaskets and hose
connections.
Verify that antifreeze mixture is in
accordance
with
table
3-1.
d. Take all necessary precautions to
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keep dirt and grit out of the fuel tank.
2-16.
OPERATION UNDER RAINY OR HUMID
CONDITIONS. The housing kit must be installed for
operation under rainy or humid conditions. During dry
periods when the set is not operating, open the doors
and allow the set to dry out. Drain water and sediment
from fuel tank more frequently.
adjustment or reduction in load. A reduction in the load at
higher altitudes may be necessary, since engines are more
likely to overheat. The following derating factors are
applicable.
60 Hz
500 KW to 1500 ft ( 457 m) at 125°F (52°C)
400 KW to 5000 ft (1410 m) at 100°F (39°C)
375 KW to 8000 ft (2435 m) at 90°F (32°C)
2-17. OPERATION IN SALT WATER AREAS.
a.
Housing Kit must be installed.
b.
Salt water causes corrosive action on metal.
Care must be taken to avoid equipment contact with salt
water. If contact is made, or if the unit is exposed to salt
spray, wash the generator set frequently with clean,
fresh water.
c.
Remove rust or other corrosion and paint all
damaged pre-painted surfaces in accordance with
service requirements.
2-18.
OPERATION AT HIGH ALTITUDES.
The
generator set will operate at elevations up to 1500 feet
(457 meters) above seal level without special
50 Hz
417 KW to 1500 ft ( 457 m) at 1250F (52°C)
332 KW to 5000 ft (1410 m) at 100°F (39°C)
312 KW to 8000 ft (2435 m) at 90°F (32°C)
2-19. OPERATION IN SNOW. The housing kit must be
installed for operation in snow. Drain water and sediment
from fuel tank more frequently. Check coolant anti-freeze
protection and check batteries. Ensure that drifting snow
does not obstruct normal cooling air flow.
2-20.
EMERGENCY OPERATION ON JP5 FUEL.
Engine/generator sets require no adjustments to engine
timing or fuel injectors for operation on JP5 fuel. When
JP5 fuel is used, power output is reduced by a factor of 20
percent.
2-47/(2-48 blank)
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CHAPTER 3
OPERATOR/CREW MAINTENANCE INSTRUCTIONS
Section I. CONSUMABLE OPERATING AND MAINTENANCE SUPPLIES
3-1.
Refer to table 3-1 for a listing
of the consumable operating and maintenance supplies.
Table 3-1. Consumable Operating and Maintenance Supplies
COMPONENT
APPLICATION
Tank, Fuel
Ether
Starting
System
NATIONAL STOCK
NUMBER
DESCRIPTION
QTY
REQUIRED
FOR INITIAL
OPERATION
QTY
REQUIRED
8 HOURS
OPERATION
NOTES
9130-00-273-2379(1)
Fuel JP5
MIL-T-5624
(3)
(4)
(1) See Federal
Supply Catalog
C9100-1L for
additional requisitioning data
9140-00-286-5294(1)
Regular
Grade, DF2
(3)
(4)
(2) See Federal
Supply catalog
C6800-1L for
9140-00-286-5283(1)
Artic
Grade, DFA
(3)
(4)
additional requisitioning data.
2910-00-209-4997
Tank, ether
(5)
(5)
(3) Tank Capacity
117 gal. (442.8)
Crankcase
(4) Average Fuel
Consumption
a. 1/4 load 11.4
gal./hr (43.3
1/hr)
b. 1/2 load 19.2
gal./hr (73 1/hr)
c. 3/4 load 27
gal./hr (103 1/hr)
d. Full load 37
gal./hr (141 1/hr)
Oil Lubricating
5 gal.
(19 1) pail
9150-00-265-9435(1)
Grade,
OE/HDO 30
MIL-L-2140
(6)
3-1
(9)
(5) One tank, if
required for cold
weather starting
TM 5-6115-593-12
TO 35C2-3-463-1
Table 3-1. Consumable Operating and Maintenance Supplies - Continued
COMPONENT
APPLICATION
Crankcase
(Cont'd)
NATIONAL STOCK
NUMBER
DESCRIPTION
QTY
REQUIRED
FOR INITIAL
OPERATION
QTY
REQUIRED
8 HOURS
OPERATION
NOTES
9150-00-265-9435(1)
Grade,
OE/HDO 30
MIL-L-2140
(6)
(9)
(5) One tank, if
required for cold
weather starting
9150-00-265-9428(1)
Grade,
OE/HDO 10
MIL-L-2104
(6)
(9)
9150-00-242-7603(1)
55 Gal Drum
(209 1)
9150-00-265-9436(1)
Grade,
OE/HDO 30
MIL-L-2104
(6)
(9)
(6) Crankcase
Capacity 19 gal.
(68 1)
9150-00-191-2972(1)
Grade,
OE/HDO 10
MIL-L-2104
(6)
(9)
9150-00-242-7604(1)
Grade OES
MIL-L-10295
(5)
(9)
Electric
Hydraulic
Actuator
9150-00-242-7604(1)
Grade OES
MIL-L-10295
(10)
(9)
(7) Cooling System
Capacity 52 gal.
(197 1)
(8) See LO for
lube points
(9) See LO for
grade application
and replenishment
intervals.
(10) Electric
Hydraulic Actuator
Sump Capacity
1 gal. (3.7 1)
Parts,
Cleaning
6950-00-281-1985(2)
Solvent
(1 gal
3.8 1) Can
FED-P-D-680
Batteries
6810-00-249-9354
Electrolyte
Radiator
6850-00-243-1992(2)
Coolant
Anti-Freeze
Inhibited
Glycol
6850-00-174-1806
Anti-Freeze
Compound
Artic
.
(10)
(10) Requires
3 1/2 gal. fill
batteries
(7)
(7)
3-2
(7)
(7)
TM 5-6115-593-12
TO 35C2-3-463-1
Section II. LUBRICATION INSTRUCTIONS
3-1. This section contains lubrication instructions which
are supplement to, and not covered in the lubrication
order. Refer to Lubrication Order L05-6115-593-12 for
lubrication instructions.
Refer to DA PAM 310-4 (Army) and SL-1-3 (MC) to
ensure the latest edition of the LO is used.
WARNING
To avoid accidental cranking to startup, set
MAINTENANCE LOCKOUT switch (12, figure 2-3)
to LOCKOUT position, disconnect negative cable
from battery negative terminal, and remove
external power, prior to servicing the generator
set. Reconnect cable at completion of service
procedure.
Section III. PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
Air Force users shall refer to the applicable inspection
manuals and work card sets in T.O. 35C2-3-Series for
periodic preventive maintenance requirements and table
3-2 for detailed procedures. Marine Corps users should
refer to the current issue of TM 11275-15/1.
3-3. GENERAL. To ensure that the generator set is
ready for operation at all times, it must be inspected
systematically so that defects may be discovered and
corrected before they result in serious damage or failure.
The necessary preventive maintenance services to be
performed are listed and described in table 3-2 (A,MC).
Item numbers indicate the sequence of minimum
inspection requirements.
Defects discovered during
operation of the unit shall be noted for future correction,
to be made as soon as operation has ceased. Stop
operation immediately if a deficiency is noticed which
would damage the equipment if operation were continued.
3-4. PREVENTIVE MAINTENANCE CHECKS AND
SERVICES (A,MC). Table 3-2 contains a tabulated listing
of PMCS which shall be performed by the operator crew
personnel. The item numbers are listed consecutively
and indicate the sequence of minimum requirements.
Section IV. TROUBLESHOOTING
3-5.
GENERAL.
b.
a. Table 3-3 contains troubleshooting information for
locating and correcting operating troubles which
may develop in the generator set.
Each
malfunction for an individual component, unit, or
system is followed by a list of tests or inspections
which will help you to determine probable causes
and corrective actions to take. You should perform
the tests/inspections and corrective actions in the
order listed.
This manual cannot list all malfunctions that may
occur, nor all tests or inspections and corrective
actions. If a malfunction is not listed or cannot be
corrected by listed corrective actions, notify your
supervisor.
NOTE
Before you use table 3-3, be sure you have
performed all applicable operating checks.
3-3
TM 5-6115-593-12
TO 35C2-3-463-1
TABLE 3-2. OPERATOR/CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES
NOTE:
Within designated interval, these checks are to be performed in the order listed.
B-BEFORE
D-DURING
A-AFTER
INTERVAL
ITEM
NO.
B
1
D
o
2
o
4
o
Muffler and
exhaust
Ground Terminal
o
PROCEDURES
CHECK FOR AND HAVE REPAIRED
OR ADJUSTED AS NECESSARY
Controls and
instruments
Engine Panel
Check batteries for electrolyte level and check for
security. Ref par. 2-13C.
Inspect exhaust installation
for condition, security, and
leakage. Check that rain
caps move freely.
Check for proper ground
connection
Inspect for damage and loose
mounting. Operate press-totest indicator. Check the
following for proper
operation.
Battery charging volts.
Battery charging ammeter
green portion of scale.
Generator Panel
4
o
EQUIPMENT IS
NOT READY/
AVAILABLE IF:
A
Batteries and
related items
o
3
ITEM TO BE
INSPECTED
Fuel level gauge.
Coolant temperature gauge
180 to 200 F (81 to 93 C).
Oil Pressure Gauge
30 to255 psi (2.1 to 3.5
kg/cm ).
AC Voltmeter
120/208, 240/416 volts*
AC Ammeter
Not to exceed 100%
Kilowatt Meter
Not to exceed 100%
Frequency Meter
50-60 Hz*
Fault Indictors
All lamps out during operation. Check lamp operation
using press to test switch.
* These values are nominal, refer to paragraph 1-10 for permissible voltage or frequency operating range for unusual installations.
3-4
Cables are loose
Electrolyte level low
Rain caps are stuck
closed.
Unit is not grounded
TM 5-6115-593-12
TO 35C2-3-463-1
TABLE 3-2. OPERATOR/CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES
NOTE:
Within designated interval, these checks are to be performed in the order listed.
B-BEFORE
D-DURING
A-AFTER
INTERVAL
ITEM
NO.
B
D
ITEM TO BE
INSPECTED
PROCEDURES
CHECK FOR AND HAVE REPAIRED
OR ADJUSTED AS NECESSARY
A
5
o
Air Cleaners
Check service indicator
6
o
Radiator Assembly
CAUTION
Relieve pressure in radiator
by loosening radiator cap
and waiting two minutes
before removing cap.
Check for leaks
Check and service radiator
(using sight gauge) for
sufficient coolant.
Check louvers for freedom
of operation
Check fan belts for wear
and proper tension
Check radiator fins for
damage or obstruction.
7
o
o
o
Fuel System
Check fuel lines for leaks
and security
WARNING
When handling diesel fuel,
always provide a metal-tometal contact between the
container and fuel tank.
This will prevent a spark
from being generated as
fuel flows over the metal
surface.
Never service generator set
when in operation.
After operation, assure that
tank is full to prevent
moisture condensation.
Check position of valve to
OPEN on inside of fuel
filler neck cap.
o
o
o
EQUIPMENT IS
NOT READY/
AVAILABLE IF:
Add fuel as required
Drain water and sediment
from filters.
Inspect filters.
3-5
Indicator in Red
Ref. par. 2-13e
No coolant showing in
sight gauge
TM 5-6115-593-12
TO 35C2-3-463-1
TABLE 3-3. OPERATOR/CREW TROUBLESHOOTING
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
1.
ENGINE FAILS TO CRANK OR CRANKS SLOWLY WHEN MASTER SWITCH IS MOVED TO START.
Step 1.
Check BATTERY CHRG AMPS and BATTERY CHRG VOLTS
meters on Engine Control Panel. Current and voltage reading
should be within 0 and 2 and 22 to 26, respectively.
If readings are within limits indicated, refer malfunction to next
higher level of maintenance. If not proceed to steps 2, 3, and 4,
as required.
Step 2.
Check for defective, corroded, or loose
battery cables and battery terminals.
If cables or terminals are defective, refer to next higher
maintenance for repair. Step 3. Check electrolyte level of
batteries. Level should be at bottom of fill hole for each battery
cell.
If necessary add distilled or clean water to
required level.
Step 4
2.
Check OVER CRANK indicator lamp. If lit, wait until light goes out
and try cranking again. If light is lit and will not go out, refer
malfunction to next higher level of maintenance.
ENGINE CRANKS BUT WILL NOT START.
Step 1.
Visually check for closed air boxes.
Manually reset to open position if required.
Step 2.
Inspect air cleaner assembly for excessive dirt.
If excessive dirt is present,
maintenance replacement.
Step 3.
refer
to
next
higher
Inspect all fuel lines and fittings for leaks, loose connections, and
any signs of obvious damage.
If fuel lines or fittings are loose or damaged, refer to next higher
maintenance for replacement.
3-6
TM 5-6115-593-12
TO 35C2-3-463-1
TABLE 3-3. OPERATOR/CREW TROUBLESHOOTING
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
2.
ENGINE CRANKS BUT WILL NOT START - Continued
Step 4.
Check LOW FUEL LEVEL indicator lamp on Generator
Control Panel.
If lit, temporarily set BATTLE SHORT switch to ON. If
engine starts set MASTER SWITCH to STOP and check fuel
oil levels in auxiliary tanks. Set FUEL PUMP switch to AUTO
if not already in this position. If LOW FUEL LEVEL indicator
lamp is not lit refer malfunction to next higher level of
maintenance.
3.
ENGINE SHUTS DOWN SOON AFTER STARTING.
Check engine fault indicators.
Check for low fuel oil level in day tank.
Add fuel oil as required.
4.
ENGINE SHUTS DOWN AND WILL NOT RESTART.
Step 1.
Check ENG FAULT indicator lamps on Generator
Control Panel.
If any one of them is lit refer to appropriate
subsequent step.
Step 2.
If HI COOL TEMP indicator lamp is lit, check coolant
level at radiator sight glass.
If low add coolant (as required by weather
conditions).
WARNING
Remove radiator cap slowly to permit pressure to escape prior to removal of cap.
If coolant level normal, refer to next higher level of maintenance.
Step 3.
If HI LUB TEMP indicator lamp is lit, check lube oil level using oil
level sight gauge.
Add lube oil as required.
Step 4.
If LOW OIL PRESS indicator lamp is lit, check lube oil level using oil
level sight gauge.
Add lube oil as required.
3-7
TM 5-6115-593-12
TO 35C2-3-463-1
TABLE 3-3. OPERATOR/CREW TROUBLESHOOTING
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
4.
ENGINE SHUTS DOWN AND WILL NOT RESTART-Continued
Step 5.
If LOW FUEL LEVEL indicator lamp is lit, check level of fuel in
auxiliary tank.
If empty, refill as required.
Step 6.
Check OVERSPEED indicator lamp.
If lit, refer to next higher level of maintenance.
5.
ENGINE RUNS ERRATICALLY OR MISFIRES.
Step 1.
Check engine fuel oil for contamination.
If contaminated, drain fuel system and fill
with proper fuel.
Step 2.
Inspect air cleaner assembly for excessive dirt.
If excessive dirt is present, refer to next
higher maintenance for replacement.
6. ENGINE EXHAUST EXCESSIVELY BLACK.
Step 1.
Inspect air cleaner assembly for excessive dirt.
If excessive dirt is present, refer to next
higher maintenance for replacement.
Step 2.
Check KW meter on Generator Control Panel.
Reduce load to rated level. If KW meter
reading is within rated level, refer to next
higher level of maintenance.
7.
ENGINE EXHAUST WHITE OR BLUE.
Step 1.
Check for improper fuel.
Drain fuel system and fill with proper fuel.
Step 2.
Check for excessive lube oil using dipstick or
sight gauge.
Drain crankcase until proper level is
indicated.
3-8
TM 5-6115-593-12
TO 35C2-3-463-1
TABLE 3-3. OPERATOR/CREW TROUBLESHOOTING
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
8.
GENERATOR OUTPUT FREQUENCY INCORRECT.
Check HERTZ meter on Generator Control Panel.
If incorrect, set FREQ ADJ switch to either INCREASE or
DECREASE as required, to return HERTZ meter reading
to correct frequency. If adjustment cannot be made refer
to next higher level of maintenance.
9.
GENERATOR OUTPUT VOLTAGE INCORRECT.
Check VOLTS AC meter on Generator Control Panel.
If incorrect, set VOLT ADJ switch to either INCREASE or
DECREASE as required, to return VOLTS AC meter
reading to correct voltage. If adjustment cannot be made
refer to next higher level of maintenance.
10.
GEN or ENG FAULT INDICATOR LAMPS FAIL TO LIGHT.
Check FAULT indicator lamps by using ANNUNCIATOR
TEST switch
If any lamps fail to light or light dimly, replace
lamp. If replacing lamp fails to correct
problem, refer to next higher level of
maintenance.
11.
HIGH COOLANT TEMPERATURE.
Step 1.
Coolant level low.
Add coolant.
Step 2.
Low oil level.
Add lube oil.
Step 3.
Generator set overloaded.
Reduce load to rated level.
3-9
TM 5-6115-593-12
TO 35C2-3-463-1
Section V. OPERATOR/CREW MAINTENANCE
3-6.
GENERAL. Instructions in this section are
provided to assist the operator/crew in maintaining the
generator set.
If during inspections defective
components are noted, refer to higher level
maintenance for replacement or repair.
3-7.
MAINTENANCE
RELATED ITEMS.
OF
BATTERIES
AND
b. Inspect metal hoses for rust and dents.
c.
Inspect entire exhaust system for evidence of
leaks, particularly around gasket areas.
d. Inspect weather cap for proper operation. Cap
must open and close freely.
e. Inspect entire assembly for loose nuts and bolts.
a. Inspection
(1) Inspect cables and connectors for corrosion
and looseness.
(2) Inspect batteries for damage or cracked
3-9 MAINTENANCE OF EXTERNAL POWER BOX
ASSEMBLY. See figure 4-12 and inspect receptacles,
circuit breakers, switches, and plate and sleeve
assembly for loose mounting and loose electrical
connections.
cases.
b. Service. Service at intervals shown in table 3-2.
(1) Check electrolyte level of batteries. If low,
fill with distilled water to 3/8 inch (9.5 mm)
above plates. Refer to next higher level of
maintenance.
(2) Apply grease to cable connectors to prevent
corrosion. If connectors are corroded, clean
prior to applying grease.
(3) Replace
batteries when cracked. Refer to next higher
level of maintenance.
(4) Tighten loose cable connectors.
next higher level of maintenance.
Refer to
3-10. MAINTENANCE OF AC-DC CONTROL BOX
ASSEMBLY. Inspect the AC-DC Control Box Assembly
as follows (see figure 4-17):
a. Inspect circuit breaker, switches, potentiometer,
and DC amp shunt for cracks, breaks, corroded
terminals and loose electrical connections.
b. Inspect receptacles and shorting plug for
damaged threads, bent, loose or missing pins.
c.
Inspect wiring for defective insulation.
3-11. MAINTENANCE OF CONTROL CUBICLE. See
figures 4-20 and 4-22 and proceed as follows:
a. Inspection.
3-8.
MAINTENANCE
EXHAUST.
OF
MUFFLER
AND
(1) Inspect transformers, switches, and circuit
breakers for cracks, breaks, corroded terminals,
and loose electrical connections.
WARNING
Be certain that the exhaust is not fed back into
the system, or back into the immediate area of
working personnel. Exhaust may be injurious to
the health of personnel. Inspect the mufflers
and exhaust system as follows (see figure 4-11):
a. Inspect mufflers
damage.
for
looseness,
rust,
and
(2) Inspect gauges and instruments for damage.
(3) Inspect lamps for loose electrical connections.
(4) Inspect receptacles for damaged threads, bent,
loose, or missing pins. Inspect telephone jack
for loose mounting.
3-10
TM 5-6115-593-12
TO 35C2-3-463-1
(b) Remove the hex nut and
flat washer attaching jack to
panel and remove jack.
3-12. MAINTENANCE OF AIR CLEANER.
figure 3-1)
(5) Inspect wiring for defective
insulation.
b. Replacement.
(1) Replace
defective
bulbs
in
lamp
assemblies. Refer to next higher level of
maintenance.
a. Inspect
air
cleaner
service
indicator (17, figure 3-1) for a red
restriction indication.
(2) Replace defective telephone jack as follows:
Refer to next higher level of maintenance.
b. Inspect service indicator for
loose mounting and damage.
(a) Tag and remove wires
connected to the jack.
c.
Inspect air cleaner filter
elements (4 and 7,
figure 3-1) for signs of
blocking and holes.
Figure 3-1. Air Cleaner, Exploded view
3-11
(See
TM 5-6115-593-12
TO 35C2-363-1
d. Inspect gasket (2, figure 3-1),
dust cap (13) and O-ring (14)
for damage.
e. Remove and empty dust cap (13).
type of coolant presently in
radiator. Refer to table 3-1 for
proper coolant.
(3) Open radiator cap access door on top of
unit and fill radiator until coolant level is 2
inches (51 mm) below filter neck (center of
sight glass).
f.
Inspect air cleaner for loose
induction system
connections.
3-13. MAINTENANCE OF RADIATOR ASSEMBLY.
(4) Fasten tag near radiator cap indicates date,
type of coolant, and level of protection.
Replace cap and close access door.
a. Inspection. (See figure 4-27.)
(1) Inspect radiator core, sight
glass, piping, and hose
connections for leaks.
3-14. MAINTENANCE OF FUEL LINES AND
FITTINGS. See figure 4-29 and inspect all fuel lines
and fittings for loose connections, leaks, and breaks.
(2) Inspect hoses for leaks.
3-15. MAINTENANCE OF FUEL TRANSFER PUMP
ASSEMBLIES.
(3) Inspect motor for evidence
of overheating and loose
mounting.
a. Inspection. See figure 3-2 and inspect fuel
transfer pump for leaks at elbows, connectors,
drain cocks, and filters. Tighten as necessary.
Inspect motor for overheating indications.
(4) Inspect fan belt guard and
fan guard for loose
mounting.
b. Service. Service the filter and strainers as
follows (see figure 4-31):
(5) Remove fan guard mounting
nuts and fan guard, figure 428. Inspect fan belt for tears,
breaks, or frayed edges.
(1) Remove screw (24), washer (25),
large can (26), and filter element
(27) in can and install with gasket
(28), washer (25), and screw (24).
Tighten securely. Replace gasket
(28) if defective.
(6) Check fan belts to see that
they do not move more
than 1/2 inch (12.7mm)
when applying pressure
with the thumb against
each belt (see figure 4-1).
(2) Remove nut (30), washer (31),
small can (32), and metal
strainer (33). Replace strainer
and tighten strainer assembly
with nut (30). Removal and
replacement of both strainers
are the same.
(7) Reinstall fan guard and
mounting screws and
nuts.
b. Service. Service the radiator as
follows:
3-16. MAINTENANCE OF FUEL TANK ASSEMBLY.
(See figures 4-33, 4-34, and 4-35)
WARNING
Remove radiator cap slowly to permit
pressure to escape prior to removal of
cap.
a. Fuel Level Switches.
(1) Inspect the wires to the switch for
secure connection.
(1) Check coolant level at sight
glass. If low, remove cap
and add coolant.
(2) Inspect, for loose terminals or
other signs of damage.
(2) Check coolant strength with a
hydrometer for winterization
protection. If weak, add same
(3) If defective, refer to
next higher
maintenance.
3-12
TM 5-6115-593-12
TO 35C2-363-1
3-17. MAINTENANCE OF INTERCONNECTION
ELECTRICAL HARNESS.
b. Fuel Level Indicator Transmitter.
(1) Inspect the wires to the
switch for looseness
and damage.
CAUTION
Disconnect the battery ground cable from
the battery before inspecting the wiring.
Inspect wiring for defective insulation.
(2) Inspect wires to
transmitter.
Inspect connectors for damaged threads,
bent, loose, or missing pins.
(3) If defective, refer to
next higher
maintenance.
Figure 3-2. Fuel Transfer Pump Inspection Points
3-13
TM 5-6115-593-12
TO 35C2-3-463-1
broken glass. Check
seal in oil level gauge
cap for tears.
3-18. MAINTENANCE OF ELECTRIC HYDRAULIC
ACTUATOR. See figure 4-37 and inspect sump tank for
leaks, cracks, or distortion. Inspect linkage for binding.
d. Inspect the oil filler for dents,
damaged threads, damaged oil
filler cap, or damaged seal.
3-19. MAINTENANCE OF ETHER KIT. (See
figure 4-38.)
a. Inspection.
e. Inspect the starter assembly for
cracks, dents, loose, damaged
electrical connections, and
loose mounting.
(1) Inspect all lines from ether
tank to engine for damage.
(2) Inspect all clamps securing
lines for looseness.
f.
(3) Inspect ether tank and
solenoid valve for secure
mounting.
g. Inspect the oil filter for leaks,
cracks, breaks, and dents.
b. Service.
3-20.
(1) Remove ether tank. Shake
the ether tank to determine
existing supply. If empty,
replace ether tank.
h. Inspect the primary fuel filter
for breaks or cracks. Inspect
threaded parts for damaged or
stripped threads.
(2) Replace the
support frame.
i.
Inspect the temperature transmitter
for leaks, cracks, breaks, and loose
connections.
j.
Inspect the oil pan assembly drain
fittings, valves, and hose connections
for leaks, cracks, and loose mounting.
Inspect hose for deterioration, and
tears. Inspect oil pan for cracks, dents,
and leaks.
k.
Inspect fuel injection pump for leaks,
cracks, loose mounting and loose
connections.
l.
Inspect the secondary fuel
filters.
tank
in
MAINTENANCE OF THE ENGINE ASSEMBLY.
Refer to figure 4-40 and inspect the engine
assembly as follows:
a. Inspect water pump belt for looseness, signs of wear, and oil soaking.
Inspect the water pump for leaks,
cracks, breaks, and loose mounting.
b. Inspect the speed switch connector by
removing the connector and examining
for corrosion to pins, connectors, wires,
and connections.
c.
Inspect the oil pressure
transmitter for leaks, cracks,
loose mounting and loose
electrical connections.
Inspect oil level gauge
for
m. Inspect oil breathers on rocker
arm assembly covers. Refer
to par. 4-8 a (5).
3-14
TM 5-6115-593-12
TO 35C2-3-463-1
CHAPTER 4
ORGANIZATIONAL MAINTENANCE
Section I. SERVICE UPON RECEIPT OF EQUIPMENT
4-1.
UNLOADING THE GENERATOR SET.
b. Servicing.
WARNING
Use the slings provided and a lifting device with a
capacity of 20 tons (18,000 kg). Do not allow the
generator set to swing while it is suspended.
Failure to observe this warning may result in
serious injury or death to personnel.
WARNING
Do not smoke or use an open flame
in the vicinity when filling fuel tank.
(1) Fill fuel tank with
appropriate fuel. (See
Appendix B for quantity
and type of fuel required.)
4-2.
INSPECTION AND SERVICING THE
EQUIPMENT.
(2) Fill radiator with arctic
antifreeze solution in
accordance with table 4-1.
a. Inspection.
(1) Inspect radiator for
damage.
WARNING
(2) Inspect radiator fan drive belt
for proper tension (figure 4-1).
Code A.
Do not smoke or use an open flame in
the vicinity when servicing batteries.
Batteries generate a highly explosive
hydrogen gas during charging.
Electrolyte is sulfuric acid diluted with
water and can cause severe acid burns
when spilled on skin or clothing. Use
extreme care in handling while
servicing batteries. When servicing
batteries reference TM 9-6140-200-14.
(3) Check that pulley guard and
vibration damper guard are
secure.
(4) Inspect all air cleaner
connections for tightness.
(5) Inspect the fuel, water, and
coolant lines for cracks and
leaks.
(3) Batteries are shipped in a dry state.
Battery electrolyte must be
requisitioned separately. See table
3-1 for quantity and electrolyte stock
number. To activate the battery,
remove cell caps and fill battery
cells 3/8 inch (9.5 mm) above plates
with electrolyte. Make sure vent
holes in cell caps are open, and
replace caps. The electrolyte level
must be rechecked approximately
30 minutes after initial filling as the
plates and separators will absorb
the solution, thus resulting in
(6) Inspect that the cooling system
shut-off cock (figure 4-2) is
closed and the three engine
water drain points (figure 4-3)
are closed.
(7) Make certain that the crankcase
drain is closed (figure 4-4).
(8) Inspect that fuel tank drain cock
(figure 4-5) is closed.
(9) Make a thorough visual
inspection of the entire
generator set and accessories
for loose or missing mounting
hardware, fuses, bulbs, or
damaged or other missing parts.
Report all damaged or missing
parts.
4-1
TM 5-6115-593-12
TO 35C2-3-463-1
a lower level. If the battery is
not to be used within 12 hours
after initial filling, it should be
put on a charger and brought
up to the correct specific
gravity of 1.250 or higher at
80°F (27°C).
(4)
ventilation. Site must be within 100
feet (30 m) of any generator set to
be paralleled with, and 24 feet (7.3
m) of any auxiliary fuel supply, and
1000 feet (300 m) of any remote
control area. Refer to intermediate
(Field) (Direct and General Support)
and Depot Maintenance Manual,
Chapter 17, for general installation
practices.
Check crankcase oil level and
add oil as necessary in
accordance with the lubrication
order.
(5)
Install ether tank.
(6)
Perform the "before
operation" preventive
maintenance services
specified in table 3-2.
b.
4-3. INSTALLATION.
a. General. The generator set should
be installed on a level site, clear of
obstacles, and with ample
Outdoor Installation. When preparing for
a permanent installation, be sure that the
base is solid enough to support the weight
of the unit. See figure 4-6 for dimensions
of the generator set. Select a location
where there will be sufficient space on all
sides for service and operation for the
engine generator set. When preparing a
temporary installation, move the engine
generator set as close to the worksite as
practical. Use suitable planks, logs, or
other material for a base in an area where
the ground is soft.
Figure 4-1. Fan Belt tension Check
4-2
TM 5-6115-593-12
TO 35C2-3-463-1
Figure 4-2. Cooling System Drain and Shut -off Cock
4-3
TM 5-6115-593-12
TO 35C2-3-463-1
Figure 4-3. Location of Engine Water Drains
4-4
TM 5-6115-593-12
TO 35C2-3-463-1
Figure 4-4. Location of Engine Crankcase
Drain and Drain Valve
4-5
TM 5-6115-593-12
TO 35C2-3-463-1
Figure 4-5. Location of Fuel Tank Drain Cock
4-6
TM 5-6115-593-12
TO 35C2-3-463-1
Table 4-1. Freezing Points, Composition, and Specific Gravities of Military Antifreeze
LOWEST
EXPECTED
AMBIENT
TEMPERATURE
OF (0C)
+20 (-6.7)
+10 (-12.2)
0 (-17.8)
-10 (-23.3)
-20 (-28.9)
-30 (-34.4)
-40 (40.0)
-50 (-45.6)
-60 (-51.1)
-75 (-59.4)
PINTS (LITERS OF
INHIBITED
GLYCOL PER
GALLONS (LITERS) OF
1
COOLANT
PINTS LITERS
1-1/2 (0.7098)
2 (0.9464)
2-3/4 (1.3013)
3-1/4 (1.5379)
3-1/2 (1.6562)
4 (1.8927)
4-1/4 (2.0111)
ARTIC
ANTIFREEZE
PREFERRED
COMPOUNT, ANTIFREEZE
2
ARTIC
ETHYLENE GLYCOL
COOLANT SOLUTION
SPECIFIC GRAVITY
AT
680F (200C)
Issued full strength
and ready mixed for
0 to-65°F (-17.8 to
-54°C) temperatures
for both initial installation and replenishment
of losses
DO NOT DILUTE
WITH WATER OR
ANY OTHER SUBSTANCE
1. Maximum protection is obtained at 60 percent volume (4.8 pints (2.27
liters)) of ethylene glycol per gallon (3.785 liters) of solution.
2. Military Specification MIL-A-11755 Arctic type, nonvolatile antifreeze
compound is intended for use in the cooling system of liquid-cooled
internal combustion engines. It is used for protection against freezing
primarily in Arctic regions where ambient temperature remains for
extended periods close to -40°F (-40°C) or drops below, to as low as -75°F
(-59.4°C).
3. Fasten a tag near the radiator filler cap indicating the type antifreeze.
4-7
1.022
1.036
1.047
1.055
1.062
1.067
.1.073
TM 5-6115-593-12
TO 35C2-3-463-1
Figure 4-6. Installation Plan
4-8
TM 5-6115-593-12
TO 35C2-3-463-1
WARNING
DO NOT OPERATE ENGINE GENERATOR SET UNLESS A GROUND CABLE HAS BEEN CONNECTED TO
THE GROUND TERMINAL STUD AND THEN TO A SUITABLE GROUND. ELCRICAL FAULTS IN THE
GENERATOR SET, LOAD LINES, OR LOAD EUIPMENT, CAN CAUSE INJURY OR ELECTROCUTION
FROM CONTACT WITH AN UNGROUNDED SYSTEM.
STEP 1. INSERT GROUND CABLE INTO SLOT IN GROUND TERMINAL A STUD AND TIGHTEN NOT.
STEP 2. PERFORM EXCAVATION TO EXPOSE WATER PIPE FOR AT LEAST 10 FEET AS SHOWN AND CHECK
THAT NO INSULATED SECTION APPEARS WITHIN THE 10 FEET. IF INSULATED SECTIONS EXIST,
PROCEDURE OF SHEET 2 OR 3 MUST ALSO BE PERFORMED.
STEP 3. ATTACH GROUND CABLE TO GROOND ROD USING GROD ROD AND CLAIP AS SHOW, BY
TIGHTENING SCREW ON CLAMP.
STEP 4. SECURE GROUND ROD TO WATER PIPE AND CEBK THAT A GOOD KLECAICAL BOND IS ACHIEVED.
Figure 4-7. Grounding Procedures (Sheet 1 of 3)
4-9
TM 5-6115-593-12
TO 35C2-3-463-1
WARNING
DO NOT OPERATE ENGINE GENERATOR SET UNLESS A GROUND CABLE HAS BEEN TO THE GOUND
TERMINAL STUD AND THEN TO A SUITABLE GROUND. ELECTRICAL FAULTS IN THE GENERATOR
SET, LOAD LINES OR LOAD EQUIPMENT, CAN CAUSE INJURY OR ELECTROCUTION FROM
CONTACT WITH AN UNGROUNDED SYSTEM.
NOTE: FOLLOW SLIDE HAMMER PROCEDURE IN PARAGRAPH 4.3 f.
STEP 1.
STEP 2.
STEP 3.
STEP 4.
INSERT GROOUND CABLE INTO SLOT IN GROURD TERMINAL STUD AND TIGHTEN NUT.
CONNECT COUPLING TO GROUND ROD AND INSERT SLIDE HAMMER IN COUPLING.
DRIVE GROUND ROD INTO GROUND UNTIL COUPPLING IS JUST ABOVE TH GROUND LEVEL.
CONNECT ADDITIONAL GROUND RODS, AS REQUIRED, BY REMOVING SLIDE HAMMER FROM
COUPLING AND INSTALLING ANOTHER GROUND ROD IN COUPLING. MAKE SURE EACH NEW
GROUND ROD IS BOTTOMED ON ROD PREVIOUSLY INSTALLED. CONNECT ANOTHER
COUPLING ON NEW GROUND ROD AND INSERT SLIDE HAMMER.
STEP 5. AFTER GROUND RODS HAVE BEEN DRIVEN INTO THE GROUND REMOVE SLIDE HAMMER AND
TOP COPLING.
STEP 6. CONNECT CLAMP AND GROUND CABLE TO TOP OF EPOSED GROUD ROD AND SECURE BY
TIGHTENING SCREW.
Figure 4-7. Grounding Procedures (Sheet 2 of 3)
4-10
TM 5-6115-593-12
TO 35C2-3-463-1
WARNING
DO NOT OPERATE ENGINE GENERATOR SET UNLESS A GROUND CABLE HAS BEEN CONNECTED TO
THE GROUND TERMINAL STUD AND THEN TO A SUITABLE GROUND. ELECTRICAL FAULTS IN THE
GENERATOR SET, LOAD LINES, OR LOAD EQUIPMENT, CAN CAUSE INJURY OR ELECTROCUTION
FROM CONTACT WITH AN UNGROUNDED SYSTEM.
Figure 4-7. Grounding Procedures (Sheet 3 of 3)
STEP 1. INSERT GROUND CABLE INTO SLOT IN GROUND TERMINAL STUD AND TIGHTEN NUT.
STEP 2. PERFORM EXCAVATION AND BURY A METAL PLATE AS SHOWN.
STEP 3. ATTACH GROUND CABLE TO METAL PLATE AND CHECK THAT GOOD ELECTRICAL BOND IS
ACHIEVED. .
4-11
TM 5-6115-593-12
TO 35C2-3-463-1
c. Indoor Installation. Keep the area well
ventilated at all times, so that the engine
generator set will receive a maximum supply
of air. If a free supply of fresh air is not
available, provide duct work, with an opening
at least as large as the radiator, to the outside
of the installation. If louvers are used at the
air entrance, increase the duct work size by
25 to 50 percent. Loosen the screw and nut
which secure the weather cap to the exhaust
outlet and remove the weather cap. Install a
gas-tight metal pipe exhaust outlet to the
outside of the installation. The termination of
the exhaust pipe shall be such that hot gases
or sparks will be discharged harmlessly and
will not be directed against combustible
material or into an area containing flammable
gases or vapors. Use as few bends in the
pipe and as short a pipe as possible. The
exhaust pipe should include a low point with
suitable means for draining of condensate.
Provide metal shields, 12 inches (305 mm)
larger in diameter than the exhaust pipe
where the line passes through flammable
walls. Wrap the exhaust pipe with asbestos if
there is any danger of anyone touching it.
Refer to figure 4-6 for dimensions, air flow
requirements.
rod ground or a buried metal plate ground. A
driven metal ground rod must have a
minimum diameter of 5/8 inch (16 mm), if
solid, or 3/4 inch (19 mm) if pipe, and driven
to a minimum depth of 8 feet (2.4 m). A
buried metal ground plate must have a
minimum area of 9 square feet (0.8 m ),
minimum thickness of 1/4 inch (6.4 mm), and
be buried at a minimum depth of 4 feet (1.2
m). The ground lead must be at least No. 6
AWG copper wire. The procedures for
making a ground connection are shown in
figure 4-7.
f. Slide Hammer Procedure.
WARNING
Nuts must be tight on the slide hammer rod.
Loose hardware may result in serious injury.
CAUTION
The slide hammer (figure 4-7, sheet 2) striker
plate and top nut must be tightened to the end
of the threads on the slide hammer rod. The
slide hammer rod and ground rod section
must make firm contact inside the ground rod
coupler. Damage to rods, plate and couplers
could result if left loose.
WARNING
Do not operate the engine generator set
in an enclosed area unless the exhaust
gases are piped to the outside. Inhalation
of exhaust fumes will result in serious
illness or death.
NOTE
If the slide hammer is assembled, go to
step (b).
(a) Connect the slide hammer striker plate (1) to
bottom of the slide hammer rod (2). Tighten
to the end of threads. Connect lockwasher (3)
and nut (4) to bottom of the slide hammer rod
(2). Tighten firmly against the striker plate
(1). Connect the ground rod coupler (5) to the
bottom of the slide hammer rod (2). Connect
the ground rod section (6) to the other end of
the ground rod coupler (5). Tighten the
ground rod section (6) to make firm contact
with the slide hammer rod (2).
d. Leveling. Set up the unit as level as possible
(within 5 degrees), and keep it as level as
possible during operation.
e. Grounding. The engine generator set must be
grounded prior to operation. The ground can
be, in order of preference: (1) an underground
metallic water piping system, (2) a driven
metal rod, or (3) a buried metal plate (figure
4-7). If the effectively grounded portion of
the buried metallic water pipe is less than 10
feet (3 m) due to insulated sections or joints,
this preferred grounding method must be
supplemented by an additional driven metal
(b) Remove nut (4) from the top of
4-12
TM 5-6115-593-12
TO 35C2-3-463-1
the slide hammer rod (2) if necessary, and
place the slide hammer (7) on top of the slide
hammer rod. Slide down until it rests on the
striker plate (1). Attach nut (4) to the top of
the slide hammer rod. Tighten to the end of
the threads.
Refer to FO-14 and FO-9 for interconnecting
information. Allow at least 3 feet (91 cm) in
front and behind module for access during
maintenance. Refer to par. 2-10.
h. Connecting Automatic Control Module. Refer
to FO-15 for interconnecting diagram. Refer
to par. 2-11.
(c) While holding in a vertical position, lift the
slide hammer (7). Slide it downward to drive
the ground rod section (6) into the ground.
Continue driving the ground rod section (6)
until approximately 4 inches (10 centimeters)
remains above ground level.
4-4. EQUIPMENT CONVERSION.
a. To convert generator set output voltage from
120/280V AC to 240/416V AC, refer to figure
4-8 and proceed as follows:
(d) Disconnect the slide hammer assembly (8)
from the ground rod coupler (5).
WARNING
(e) Attach the ground rod section (6) to the
ground rod coupler (5). Attach another
ground rod coupler (5) to the top of a new
ground rod section (6). Connect the slide
hammer assembly (8) to the new ground rod
coupler (5).
When making any electrical connections,
make sure that the MAINTENANCE LOCKOUT
switch is in the MAINTENANCE position.
(1) Unscrew fasteners on reconnection box cover
and lift cover to obtain access to the movable
jumpers.
(f) Repeat steps (c), (d) and (e) until at least 8
feet (2.4 meters) of ground rod is buried.
Disconnect nut (4), and remove the slide
hammer (7) from the slide hammer assembly
(8). Disconnect the top ground rod coupler
(5).
(2) Remove attaching hardware and adjust
jumper bars for low wye, 120/208V AC (A,
figure 4-8) or high wye, 240/416V AC (B,
figure 4-8) configuration.
(3) Securely reinstall attaching hardware and
close reconnection box cover.
(g) Connect a clamp (9) to top of the ground rod
and reconnect the ground rod coupler (5).
Connect loose end of the ground wire
assembly to the clamp. Tighten the clamp
screw (10). Ensure that all ground wire
connections are tight.
b. To convert generator set from 50 to 60 Hz,
move the FREQUENCY SELECTOR switch
(4, figure 2-3) to the desired position. Also, if
using the automatic control module switch the
frequency select switch to the corresponding
position.
g. Connecting Remote Control Module. The
remote control module can be located up to
1000 feet (300 m) from the generator set.
4-13
TM 5-6115-593-12
TO 35C2-3-463-1
Figure 4-8. Output Voltage Conversion Connections
Section II. MOVEMENT TO A NEW WORKSITE
4-5. DISMANTLING FOR MOVEMENT.
anticipated or the distance to be traveled is great.
(5) Disconnect the ground lead.
(6) Disconnect any other external hoses, lines,
and cables, if used.
(7) Close and secure all doors and panels.
WARNING
Make certain that generator set is not operating
in a standby mode, or connected to a parallel
buss.
WARNING
Unit weight is approximately 36,000
pounds (16,329 kg). Use the slings
supplied and lifting device with a capacity
of 20 tons (18,000 kg).
a. Preparation for Movement.
(1) Disconnect, insulate and secure negative
battery cable.
(2) Disconnect the load cables and tag for
identification. (3) If applicable, disconnect
wiring to automatic control module.
b. Movement. Refer to installation procedures,
par. 4-3.
(4) Drain fuel and coolant if transportation by
railroad is
4-14
TM 5-6115-593-12
TO 35C2-3-463-1
Section III. REPAIR PARTS; SPECIAL TOOLS; SPECIAL TEST MEASUREMENT
AND DIAGNOSTIC EQUIPMENT (TMDE);
AND SPECIAL SUPPORT EQUIPMENT
parts and equipment are listed and illustrated in the
Organization, Intermediate (Field) (Direct and General
Support) and Depot Maintenance Repair Parts and
Special Tools List, (A) TM5-6115-593-24P.
4-6. TOOLS AND EQUIPMENT. No special tools or
equipment are required by organizational maintenance
personnel for maintenance of the generator set.
4-7. MAINTENANCE REPAIR PARTS. Repair
Section IV. LUBRICATION INSTRUCTIONS
4-8.
GENERAL.
This section contains special
organizational lubrication instructions not included in the
lubrication order. Army personnel should refer to DA
PAM 310-4 and Marine Corps personnel to SL-1-3 to
ensure the latest edition of the lubrication order L056115-593-12 is being used.
gauge high level marker (2, figure 4-43)
while engine is not running and dipstick
shows oil at "H" (full). Set sight gauge low
level marker (4, figure 4-43) to indicate oil
level while engine is running. The sight
gauge will then show both operating and
nonoperating levels. Recheck oil level on
dipstick after setting sight gauge markers
to ensure that no oil was leaking during
the setting of the markers. After setting
sight gauge level markers, use the sight
gauge rather than the dipstick to monitor
oil levels.
WARNING
To avoid accidental engine cracking or
startup,
place
MAINTENANCE
LOCKOUT
switch
in
the
MAINTENANCE LOCKOUT position
prior to servicing the generator set.
Return switch to OPERATION position
only after completion of service
procedures.
(3) Keep oil free of water and abrasives by
proper handling and storage.
(4) Inspect engine for evidence of oil leaks.
a. Lubrication Information.
(5) After each operating interval of 300 hours,
remove breather and clean with cleaning
solvent, blow out with compressed air,
and reinstall on engine. See figure 4-8A.
(1) When the engine is not running, the oil
level gauge (dip stick) (figure 4-40) allows
the operator to check the oil level. The
gauge is stamped with an "H" (high, full)
and an "L" (low) level mark to indicate
lubricating oil supply.
The crankcase
should be filled to the "H" mark on the
dipstick.
b. Lubricating Instructions. Oil shall be changed
every 300 hours or 3 months, whichever comes
first. Oil may require changing more frequently
than usual because contamination by dilution
and sludge formation will increase under cold
weather operation conditions.
CAUTION
Never fill crankcase above "H" mark
on dipstick.
(1) Before draining the oil system, operate
the engine
(2) When the engine is running, check the oil
level using the sight gauge. Set sight
4-15
TM 5-6115-593-12
TO 35C2-3-463-1
as replacing the filters.
until a minimum coolant temperature of
160°F (71°C) is obtained. Then shut
engine off and move MAINTENANCE
LOCKOUT switch to MAINTENANCE
LOCKOUT position.
(2) Service spin-on type oil filters (see figure
4-47) as follows:
NOTE
Oil pressure drop reading across filters is
the best way to determine change
periods. If pressure drop from inlet to
outlet exceeds pressure logged after
latest installation of spin-on oil falters by
more than 10 psi (0.7 kg/cm ) with 140°F
(60°C) oil temperature, change the filters.
(2) Remove oil drain plug on skid base (figure
1-1), then open engine oil drain valve and
allow oil to drain into a container.
(3) Install drain plug and close oil drain valve.
Add oil to full mark.
(4) Move MAINTENANCE LOCKOUT switch
to OPERATION position.
Start and
operate engine for approximately 5
minutes.
(a) Drain the oil system, par. 4-8b.
(b) Unscrew, remove, and discard the filters
and gaskets.
(5) Stop engine and allow oil to drain back
into crankcase before rechecking oil level
using dipstick. Check for leaks.
(c) Fill new filters with proper lubricant (see
table 3-1), attach new gaskets and screw
on new filters. Hand tighten, then turn an
additional three-fourths of a turn.
NOTE
Do not remove dipstick when engine is
operating. Use oil level sight gauge to
monitor oil level while engine is running.
(d) Fill engine to "H" mark on dipstick.
(e) Run engine and check for leakage.
c. Oil Filter Service. (See figure 4-47).
(f) Stop engine and allow several minutes for
oil to drain back to oil crankcase, then
recheck level.
(1) Refer to Chapter 13 of the Intermediate
(Field) (Direct and General Support) and
Depot Level Maintenance Manual (A)
TM5-6115-593-34 for servicing of the
bypass oil filters. Note that the service
function is the same
(g) Run engine and record oil pressure
reading.
(h) Check/reset sight gauge per par. 4-8 a
(2).
1.Wing nut
2. Washer
3. Gasket
4. Upper body
5. Element
6. Vapor
Element
7. Gasket
8. Gasket
9. Lower
Body
Figure 4-8A. Crankcase Breather
4-16
TM 5-6115-593-12
TO 35C2-3-463-1
Section V. PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
4-9. GENERAL. To ensure that the equipment is ready for operation at all times, it must be inspected systematically so
that defects may be discovered and corrected before they result in serious damage or failure. This section contains
information pertinent to organizational maintenance. Table 4-2 contains a tabulated listing of preventive maintenance
checks and services which must be performed by organizational maintenance personnel at weekly, monthly and
semiannual intervals.
Section VI. TROUBLESHOOTING
4-10. GENERAL.
a. Table 4-3 contains troubleshooting information for locating and correcting operating troubles which may develop in
the generator set. Each malfunction for an individual component unit, or system, is followed by a list of tests or
inspections which will help you to determine probable causes and corrective actions to take. Perform the tests,
inspections, and corrective actions in the order listed.
b. This manual cannot list all malfunctions that may occur, nor all tests or inspections and corrective actions. If a
malfunction cannot be corrected by listed corrective actions, notify your supervisor.
Section VII. RADIO INTERFERENCE SUPPRESSION
4-11. GENERAL METHODS USED TO ATTAIN PROPER SUPPRESSION. Essentially suppression is attained by
providing a low resistance path to ground for stray currents. The methods used include shielding the wires, grounding the
frame with bonding straps, and using filtering systems.
4-12. INTERFERENCE SUPPRESSION COMPONENTS.
a. Primary Suppression Components. The primary suppression components are those whose function is to
suppress radio interference. The voltage regulator contains an electromagnetic interference (EMI) suppression
assembly to suppress EMI from this assembly
b. Secondary Suppression Components. These components have radio suppression functions which are incidental
or secondary to their primary function. No secondary suppression components are included in this generator set.
4-17
TM 5-6115-593-12
TO 35C2-3-463-1
TABLE 4-2. ORGANIZATIONAL PREVENTIVE MAINTENANCE CHECKS AND SERVICES.
NOTE: Within designated interval, these checks are to be performed in the order listed.
W-WEEKLY (40 HRS)
M-MONTHLY (100 HRS)
PROCEDURES
CHECK FOR AND HAVE
REPAIRED OR ADJUSTED AS
NECESSARY
INTERVAL
ITEM
NO.
ITEM TO BE
INSPECTED
W
1
M
Controls and
instruments
Air Cleaner
2
-
o
Inspect for damage and loose
mounting
Replace or clean the primary
element when service indicator indicates a red restriction indication
Do not clean safety element.
Replace safety element after
third primary element change
or cleaning.
Support Frame
Inspect for breaks, cracks,
loose mounting, loose or
missing hardware, corrosion
and rust.
4
o
Radiator Assembly
Inspect radiator fan motor.
Check for excessive noise or
evidence of overheating.
Ref. par. 4-49.
5
o
Engine Preheat
Inspect thermo switch heaters
and pump for poor electrical
connections and loose mounting. Ref. par. 4-51.
6
o
Fuel Transfer Pump
wear.
Inspect motor brushes for
Replace if less than
1/4 inch (6 mm) long. Ref. par. 4-52.
O
7
o
Change oil filter and
strainers.
Generator and
Reconnection
Assembly
0
8
o
Restricted
Inspect and empty dust cup.
When reinstalling, make sure
dust cup seals entirely
around the air cleaner body.
Ref. par. 4-42.
-Inspect and clean cyclone
tubes with a stiff fiber
brush
0
3
Equipment is Not
Ready/Available If:
S
o
0
S-SEMIANNUALLY (500 HRS)
Inspect reconnection board
and buss bars for looseness
or corrosion. Ref. par. 4-59.
Inspect generator for noisy
or overheated bearings and
any other signs of damage
Hydraulic Sump
Governor
Check fluid level. Add fluid required. Ref. par. 4-64.
4-18
No fluid is present
TM 5-6115-593-12
TO 35C2-3-463-1
TABLE 4-2. ORGANIZATIONAL PREVENTIVE MAINTENANCE CHECKS AND SERVICES.
NOTE: Within designated interval, these checks are to be performed in the order listed.
W-WEEKLY (40 HRS)
M-MONTHLY (100 HRS)
PROCEDURES
CHECK FOR AND HAVE
REPAIRED OR ADJUSTED AS
NECESSARY
INTERVAL
ITEM
NO.
ITEM TO BE
INSPECTED
W
M
S
o
9
o
10
Drain and refill sump
Ether Kit
Engine Assembly
o
o
o
11
o
o
Check ether tank for fullness
Shake to determine contents:
if empty then replace tank.
Ref. par. 4-65.
Ref. Section XXVI.
Inspect water pump belt for
wear and proper adjustment.
Ref. par. 4-67.
Inspect engine for loose
connections, leaks in oil,
fuel, and water system.
Change fuel filters.
Ref. par. 4-53 and 4-75.
Clean crankcase breather
Ref. par. 4-8a (5).
Check valve tappet clearance
and reset, if necessary.
Ref. par. 4-87 b.
o
Inspect oil pressure switch,
(par. 4-73), lube oil cooler
(par. 4-76), injectors (par.
4-78) for signs of damage.
o
Inspect temperature switch
(par. 4-82), vibration damper (par. 4-83), intercooler
(par. 4-84), exhaust manifold
(par. 4-85), and water manifold (par. 4-86) for signs
of damage.
o
Inspect rocker arm shaft and
rocker arm assemblies for
evidence of misalignment
or damage. Ref. par. 4-87.
o
o
S-SEMIANNUALLY (500 HRS)
Check oil filter pressure
differential. Pressure drop
from inlet to outlet should
not exceed pressure logged
after latest installation
of spin-on oil filters by
more than 10 psi
2
(0.7 kg/cm ) with 140°F
(60°C) oil temperature
Service water filter.
Ref. par.-4-68.
4-19
Equipment is Not
Ready/Available If:
TM 5-6115-593-12
TO 35C2-3-463-1
Table 4-3. Organizational Troubleshooting
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
1. ENGINE FAILS TO CRANK WHEN MASTER SWITCH IS MOVED TO START.
Step 1. Using a hydrometer, measure the specific gravity of the electrolyte in each cell (refer to paragraph 4-16)
If batteries are not charged, ensure that the battery charger is operating and allow sufficient time
to charge. If batteries fail to hold charge, refer malfunction to next higher level of maintenance.
Step 2. Check OVER CRANK indicator lamp.
If OVER CRANK indicator lamp is lit, wait until light goes out. If light fails to go out after 1 minute,
disconnect terminal 4 of the time delay relay (15, figure 4-19) from -24V DC.
If OVER CRANK indicator goes out, then TD1 may be defective and must be referred to next
higher maintenance.
If the light remains lit, timing overcrank shutdown relay K19 (part of AC-DC control relay
assembly, 18, figure 4-19) may be defective and must be referred to next higher maintenance.
Step 3. Using a multimeter, check for 24V DC across coil of start/stop/run relay K5 (located on TB10, 92, figure 420, sheet 2).
If 24V DC is absent, then test MASTER SWITCH (38, figure 4-21) and replace if defective (see
paragraph 4-40).
If 24V DC is present, proceed to next stop.
Step 4. Using a multimeter, check for 24V DC across coil or relay K54 (part of AC-DC control relay assembly, 18,
figure 4-19).
If voltage is absent, K5 may be defective and must be referred to next high maintenance.
If 24V DC is present, check for 24V DC across contacts 1 and 2 of K54. If 24V DC is present, K54
may be defective and must be referred to next higher maintenance.
If reading is zero, proceed to next step.
4-20
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TO 35C2-3-463-1
Table 4-3. Organizational Troubleshooting -Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
1. ENGINE FAILS TO CRANK WHEN MASTER SWITCH IS MOVED TO START-continued
Step 5 Test starter and starter solenoid (L4) using operational test (see paragraph 4-71).
If starter solenoid emits an audible noise each time the MASTER SWITCH is cycled into START
position, and engine does not turn over, the starter assembly must be referred to next higher
maintenance for repair.
If no noise is heard, cranking relay K3 may be defective, and must be referred to next higher
maintenance.
Step 6. Using a multimeter, check for 24V DC across speed switch, SS1 (see figure 4-40 and 4-42).
NOTE
To check this component refer to FO-3 to determine where these points are electrically accessible
to meter probes.
If 24V DC is present, SS1 may be defective and must be referred to next higher maintenance.
If 24V DC is absent, proceed to next step.
Step 7. Using a multimeter, check for 24V DC across diode CR1 (part of AC-DC control relay assembly, 18, figure
4-19)
If voltage is present, CR1 may be defective, and must be referred to next higher maintenance. If
voltage is absent, proceed to next step.
Step 8.
Using a multimeter, check for 24V DC across timing relay crank disconnect relay K6 (part of AC-DC
control relay assembly, 18, figure 4-19).
If voltage is present, K6 may be defective and must be referred to next higher maintenance.
If voltage is absent, the malfunction is beyond the scope of organizational level maintenance and
must be referred to the next higher level of maintenance.
2. ENGINE CRANKS AT NORMAL SPEED BUT WILL NOT START.
Step 1. Check LOW FUEL LEVEL indicator lamp on Generator Control Panel and fuel oil level in auxiliary tank.
4-21
TM 5-6115-593-12
TO 35C2-3-463-1
Table 4-3. Organizational Troubleshooting-Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
2. ENGINE CRANKS AT NORMAL SPEED WILL NOT START-continued
If there is fuel in auxiliary tank, test fuel transfer pump (see paragraph 4-52).
If the fuel transfer pump is functioning, check for clogged lines between transfer pump and day
tank, and between the day tank and fuel filter assembly.
Step 2. Check that fuel oil is reaching fuel injectors as the engine is being cranked.
Disconnect fuel return line going to fuel tank (see figure 4-29). Use a suitable container to catch
fuel oil.
If fuel oil is present at fuel return, refer malfunction to next higher level of maintenance.
If fuel oil is absent, reconnect fuel return. Disconnect fuel line at input of secondary fuel filters
(see figures 4-40 and 4-48), and check for the presence of fuel oil.
If fuel oil is present, replace secondary fuel filters (see paragraphs 4-75).
Step 3. Check EMERGENCY SHUT DOWN switch S22 (20, figure 4-18).
Check that switch is in OFF position; if ON, replace switch (see paragraph 4-32).
Step 4. Check ENG FAULT OVERSPEED indicator lamp.
If lamp is lit, operate ANNUNCIATOR RESET switch. If lamp goes out, recrank engine. If lamp
remains lit check for 24V DC across coils of speed switch SS3 (see figures 4-40 and 4-42).
NOTE
To check this component refer to FO-3 to determine where these points are electrically accessible
to meter probes.
If voltage is present, SS3 may be defective and must be referred to next higher maintenance.
Step 5. Using a multimeter, check for 24V DC across fuel solenoid L1 (see figure 4-40).
4-22
TM 5-6115-593-12
TO 35C2-3-463-1
Table 4-3. Organizational Troubleshooting-Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
2. ENGINE CRANKS AT NORMAL SPEED WILL NOT START-continued
NOTE
To check this component, refer to FO-3 to determine where these points are electrically accessible
to meter probes.
If present, L1 may be defective and must be referred to next higher maintenance.
If 24V DC is absent, diode CR23 (part of AC-DC control relay assembly, 18, figure 4-19) may be
defective and must be referred to higher maintenance.
3. ENGINE SHUTS DOWN SOON AFTER STARTING.
Step 1. Using a multimeter, check 24V DC across the starter solenoid L1 (see figure 4-40) and crank engine until it
starts. Note voltage reading across L1 when engine shuts down.
NOTE
To check this component refer to FO-3 to determine where these points are electrically accessible
to meter probes.
If reading remains at 24V DC after shut down, L1 may be defective and must be referred to next
higher maintenance.
If reading drops to zero as engine shuts down, proceed to next step.
Step 2. Place a temporary short across oil pressure switch OP1 (see figures 4-40 and 4-46) and, using a
multimeter, check for presence of 24V DC across contacts 3 and 4 or run-stop relay K1 (7, figure 4-19).
NOTE
To check this component refer to FO-3 to determine where these points are electrically accessible
to jumper.
If present, K1 may be defective and should be referred to next higher level of maintenance. If 24V
DC is present, proceed to next step.
4-23
TM 5-6115-593-12
TO 35C2-3-463-1
Table 4-3. Organizational Troubleshooting-Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
3. ENGINE SHUTS DOWN SOON AFTER STARTING-continued
Step 3. Remove short from OP1, and use multimeter to check for presence of 24V DC across oil pressure switch
OP1 while engine is being cranked.
If 24V DC is present, check lube oil level. If level is low, add oil as required, and proceed to next
step. If voltage across OP1 reads zero at any time during test, proceed to next step.
Step 4. Place temporary short across oil pressure switch OP1 and use multimeter to check for presence of 24V DC
across oil temperature switch OT1 (see figure 4-40)
NOTE
To check this component refer to FO-3 to determine where these points are electrically accessible
to jumper. If 24V DC is present, switch OT1 may be defective and must be referred to next higher
maintenance. If voltage is absent, proceed to next step.
Step 5. Use a multimeter to check for presence of 24V DC across coolant temperature switch WT1 (see figure 440).
NOTE
To check this component refer to FO-3 to determine where these points are electrically accessible
to jumper.
If 24V DC is present, test coolant temperature switch and replace if defective (see paragraph 482).
If 24V DC is absent, proceed to next step.
Step 6. Use a multimeter to check for presence of 24V DC across contacts of low fuel shutdown relay K8 (part of
AC-DC control relay assembly, 18, figure 4-19).
If 24V DC is present, proceed to next step.
If voltage is absent, remove temporary short from OP1 and refer to paragraph 4-50 on fuel line
maintenance and proceed to Malfunction 2, Step 2.
4-24
TM 5-6115-593-12
TO 35C2-3-463-1
Table 4-3. Organizational Troubleshooting-Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
3. ENGINE SHUTS DOWN SOON AFTER STARTING-continued
Step 7. Remove temporary short from oil pressure switch OP1 and use multimeter to check for presence of 24V
DC across fuel level switch FL4 (see figures 4-33 and 4-34).
If 24V DC is present, test the fuel level switch, and replace switch if defective (see paragraph 455).
If 24V DC is absent, low fuel shutdown relay K8 may be defective and must be referred to higher
maintenance.
Step 8.
Check oil pressure gauges (see figure 4-40).
If INPUT gauge reading is normal and OUTPUT gauge reads low, check and service spin-on oil
filter (see paragraph 4-8 c (2).
If INPUT gauge read low and OUTPUT gauge reads normal, check lube oil lines for damage or
blockage. Replace defective hoses and fittings.
If both gauges are normal, refer to next higher level of maintenance.
4. ENGINE SHUTS DOWN AND WILL NOT RESTART.
Step 1. If HI COOL TEMP indicator lamp is lit, and coolant level is normal, test thermostats (paragraph 4-80).
Replace thermostats if defective.
If high coolant temperature condition persists, refer to next step.
Step 2. Refer to paragraph 4-49 on radiator assembly maintenance and check fan belt tension, Code A only. No
fan belt on Code B.
Adjust or replace belts as necessary, Code A.
If high coolant temperature condition persists, refer to next step.
Step 3. If HI LUBE TEMP indicator lamp is lit, and lube oil level is normal, check INPUT and OUTPUT OIL
PRESSURE GAUGES (figure 4-40).
If INPUT GAUGE reading is normal, and OUTPUT GAUGE is low, or if INPUT GAUGE reading is
low and OUTPUT GAUGE is normal, refer to Malfunction 3, Step 8.
If both gauges are normal, refer to next higher level of maintenance.
4-25
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TO 35C2-3-463-1
Table 4-3. Organizational Troubleshooting-Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
4. ENGINE SHUTS DOWN AND WILL NOT RESTART-continued
Step 4. If OVERSPEED indicator lamp is lit, check for 24V DC across emergency stop relay K21 (part of AC-DC
control relay assembly, 18, figure 4-19).
If 24V,DC is present, proceed to next step. If voltage is absent, K21 may be defective and must
be referred to next higher level of maintenance.
Step 5. Use a multimeter to check for 24V DC across speed switch SS3 (see figures 4-40 and 4-42).
NOTE
To check this component refer to FO-3 to determine where these points are electrically accessible
to meter probes.
If 24V DC is absent, SS3 or its shutdown relay K31 (part of annunciator control assembly, 76,
figure 4-20) may be defective and must be referred to next higher level of maintenance.
5. ENGINE RUNS ERRATICALLY OR MISFIRES.
Step 1. Refer to paragraph 4-50, and check fuel lines into and out of the fuel injection pump for damage or
blockage.
If fuel lines are defective, refer to paragraph 4-50 for replacement procedures.
If fuel lines are free of obstruction or defect, refer malfunction to next higher level of maintenance.
Step 2. Check the air intake system (see figure 4-23), especially air valves (27), air cleaners (29), service indicator
(28), hoses (25), and adapters (26). Inspect turbochargers (see paragraph 4-78) and intercoolers (see
paragraph 4-84).
Clear any blockages, or service air intake system components as necessary (see paragraphs 4-42,
4-43, and 4-44). Clear obstructions in turbochargers or intercoolers, or replace if defective (see
paragraphs 4-78 and 4-84).
If air intake system appears to be working properly, refer to next higher level of maintenance.
Step 3. If feasible, temporarily disconnect the generator load by
4-26
TM 5-6115-593-12
TO 35C2-3-463-1
Table 4-3. Organizational Troubleshooting-Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
5. ENGINE RUNS ERRATICALLY OR MISFIRES-continued
setting AC PWR CKT BKR to OPEN.
If engine now runs smoothly, reconnect load by setting AC PWR CKT BKR to CLOSE, and
proceed to next step.
Step 4.
Check KW and KVAR readings on Generator Control Panel.
If readings indicate excessive power draw, rearrange load distribution to restore normal power
consumption.
If KW and KVAR reading are normal, refer to next higher level of maintenance.
6. ENGINE EXHAUST EXCESSIVELY BLACK
Visually check fuel; if contaminated with water or dirt, drain fuel and fill with clean fuel. If fuel is
not contaminated, refer to Malfunction 5, Steps 1 through 4.
7. ENGINE EXHAUST WHITE OR BLUE
Step 1. Check for excessive lube oil using sight gauge, then dipstick.
If lube oil level too high, drain crankcase (see paragraph 4-8) until proper level is indicated.
Step 2. Visually check engine fuel for contamination (see Malfunction 6).
If contaminated, replace fuel.
8. GENERATOR OUTPUT FREQUENCY INCORRECT
Test FREQ ADJ switch S5 (88, figure 4-22) in accordance with paragraph 4-40).
Replace FREQ ADJ switch S5 if defective (see paragraph 4-40).
NOTE
If S5 is not defective, inspect motoroperated potentiometer B4 (2, figure 4-19) according to
paragraph 4-35 and refer to next higher level of maintenance for testing.
4-27
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TO 35C2-3-463-1
Table 4-3. Organizational Troubleshooting-Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
9. GENERATOR OUTPUT VOLTAGE INCORRECT.
Test VOLT ADJ switch S6 (88, figure 4-22) in accordance with paragraph 4-40.
Replace VOLT ADJ switch S6 if defective (see paragraph 4-40).
NOTE
If S6 is not defective, inspect motoroperated potentiometer B5 (4, figure 4-19) according to
paragraph 4-35 and refer to next higher level of maintenance for testing.
10. ENGINE WILL NOT START IN COLD WEATHER
NOTE
If following procedures indicate cold weather starting devices are functioning, refer to
troubleshooting procedures listed under ENGINE CRANKS AT NORMAL SPEED BUT WILL NOT
START.
Step 1. Refer to paragraph 4-65, and disconnect tubing from bottom end of ether kit assembly. Toggle START
AID switch to ON position.
WARNING
Ether is highly flammable fuel. Do not expose to open flame, lit cigarettes, or hot surfaces.
If ether is ejected out of opened end of ether kit assembly, perform inspection procedures in
paragraph 3-19.
If no ether appears, proceed to next step.
Step 2. Test ether tank by shaking tank to determine if empty.
If empty, replace with new ether tank.
If there is still ether in tank, test START AID switch S2 (20, figure 4-21) and replace if defective
(see paragraph 4-40).
4-28
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TO 35C2-3-463-1
Table 4-3. Organizational Troubleshooting-Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
10. ENGINE WILL NOT START IN COLD WEATHER-continued
If S2 is not defective, the ether aid control relay K24 (part of AC-DC control relay assembly, 18,
figure 4-19) or the ether solenoid (14, figure 4-39) may be defective. The ether solenoid can be
replaced as part of the ether kit (see paragraph 4-65). Relay K24 must be referred to next higher
level of maintenance for testing or replacement.
Step 3. Check WATER TEMP gauge. Coolant temperature should read between 60 and 110°F (16°and 43°C).
If temperature is below range, proceed to next step.
If temperature is within range, the preheat system is functioning normally and malfunction must be
referred to next higher level of maintenance.
Step 4. Use a multimeter to check for 120V AC across the coil of preheat contactor relay K107 (54, figure 4-12).
If 120V AC is present, proceed to next step.
If 120V AC is absent, test PREHEAT SYSTEM switch S105 (27, figure 4-13) and replace if
defective (see paragraph 4-22).
If S105 is not defective, check run/stop relay K1 (7, figure 4-19) for 24V DC across contacts 3 and
4.
If 24V DC is present K1 may be defective and should be referred to next higher level of
maintenance for testing.
Step 5. Test preheat contactor relay K107 according to paragraph 4-23.
Replace K107 if defective (see paragraph 4-23).
If K107 is not defective, proceed to next step.
Step 6. Test heater contactor K109 (54, figure 4-12) according to paragraph 4-23.
Replace K109 if defective, (see paragraph 4-23).
If K109 is not defective, proceed to next step.
Step 7. Test thermo immersion switch, S30 (13, figure 4-30A) according to paragraph 4-51.
4-29
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TO 35C2-3-463-1
Table 4-3. Organizational Troubleshooting-Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
10. ENGINE WILL NOT START IN COLD WEATHER-continued
Replace switch if defective (see paragraph 4-51). If S30 is not defective proceed to next step.
Step 8. Test heater elements H101 and H102 (6 and 41, figure 4-30A) according to paragraph 4-51.
Replace heaters if defective (see paragraph 4-51). If heaters are not defective, refer malfunction
to next higher level of maintenance.
11. GENERATOR AC PWR CKT BKR CLOSED LAMP GOES OUT (LOAD DISCONNECTS).
Step. 1. Check AMMETER and KW meter to see if unit is delivering power.
If generator set is delivering power check and replace AC PWR CKT BKR CLOSED indicator lamp
DS6 (16, figure 4-22).
If generator set is not delivering power proceed to next step.
Step 2. Use a multimeter to check for 24V DC across main circuit breaker CB2 (44, figure 4-12) trip coil.
If present, shut down engine and test CB2 according to paragraph 4-24.
Replace main circuit breaker CB2 if defective (see paragraph 4-24).
If CB 2 is not defective, undervoltage relay K111 (78, figure 4-20) or short circuit relay K113 (71,
figure 4-20) may be defective and must be referred to next higher level of maintenance for testing.
Step 3. If OVERLOAD indicator lamp is lit, set AC PWR CKT BKR to OPEN. Toggle ANNUNCIATOR RESET
switch to up position, and observe OVERLOAD indicator lamp.
If lamp goes out, refer to next higher level of maintenance, as problem exists.
If lamp stays lit, overload relay K114 (62, figure 4-20) or relay K35 (part of annunciator control
assembly, 76, figure 4-20) may be defective and must be referred to next higher level of
maintenance for testing or replacement.
4-30
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TO 35C2-3-463-1
Table 4-3. Organizational Troubleshooting-Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
11. GENERATOR AC PWR CKT BKR CLOSED LAMP GOES OUT (LOAD DISCONNECTS)-continued
Step 4 If UNDERVOLT indicator lamp is lit, toggle ANNUNCIATOR RESET switch to up position and observe
UNDERVOLT indicator lamp.
If lamp goes out, refer to next higher level of maintenance, as problem exists.
If lamp remains lit, check VOLT AC meter for each generator winding.
If normal undervoltage relay K111 (78, figure 4-20) or relay K33 (part of annunciator control
assembly, 76, figure 4-20) may be defective and must be referred to next higher level of
maintenance for testing.
If VOLTS AC meter reads low, refer voltage regulator VR1 (48, figure 4-17) to next higher level of
maintenance for testing.
Step 5 If REVERSE POWER indicator lamp is lit, toggle PARALLEL OPERATION switch to SINGLE UNIT
OPERATION; toggle ANNUNCIATOR RESET switch to up position; toggle AC PWR CKT BKR to CLOSE;
observe REVERSE POWER indicator lamp.
If lamp goes out, check that controls have been properly set for parallel operation.
If malfunction persists, refer malfunction to next higher level of maintenance.
If lamp remains lit, relay K34 (part of annunciator control relay assembly, 76, figure 4-20) or
reverse power sensing relay K112 (67, figure 4-20) may be defective and must be referred to next
higher maintenance for testing.
Step 6. If SHORT CIRCUIT indicator lamp is lit, toggle ANNUNCIATOR RESET switch to up position and observe
SHORT CIRCUIT indicator lamp.
If lamp goes out, refer external load circuits to the next higher level of maintenance.
If lamp stays lit, relay K36 (annunciator control relay assembly, 76, figure 4-20) or short circuit
relay K113 (71, figure 4-20) may be defective and must be referred to next higher level of
maintenance for testing.
4-31
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TO 35C2-3-463-1
Table 4-3. Organizational Troubleshooting-Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
12. CLOCK FAILS TO OPERATE.
Step 1. Use multimeter to check for 24V DC across recrank inhibit relay K6 (part of AC-DC control relay assembly,
18, figure 4-19).
If present, refer K6 to next higher level of maintenance for testing.
If 24V DC is absent, proceed to next step.
Step 2. Use a multimeter (set for AC voltage) to check for 120V AC at terminals 1 and 2 of digital clock M111 (78,
figure 4-22).
If 120V AC is absent, check wiring connections.
If 120V AC is present, refer digital clock to next higher level of maintenance for testing.
13. CLOCK CANNOT BE ADJUSTED
Step 1. Test 50/60 Hz switch S52 (9, figure 4-22) according to paragraph 4-40.
If defective, replace switch (see paragraph 4-40).
Step 2. Test HR ADJ switch S51 (10, figure 4-22) according to paragraph 4-40.
If defective, replace switch (see paragraph 4-40).
Step 3. Test MIN ADJ switch S50 (10, figure 4-22) according to paragraph 4-40.
If defective, replace switch (see paragraph 4-40).
Step 4. Test HOLD TIME switch S49 (10, figure 4-22) according to paragraph 4-40.
If defective, replace switch (see paragraph 4-40).
If malfunction persists, refer digital clock M111 (78, figure 4-22) to next higher level of
maintenance for testing.
14. GENERATORS CANNOT BE SET UP IN PARALLEL (DROOP).
NOTE
This malfunction assumes that each generator functions properly as a single unit.
4-32
TM 5-6115-593-12
TO 35C2-3-463-1
Table 4-3. Organizational Troubleshooting-Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
14. GENERATORS CANNOT BE SET UP IN PARALLEL (DROOP)-continued
Visually inspect the parallel and governor control cables.
Repair as required.
4-33
TM 5-6115-593-12
TO 35C2-3-463-1
Section VIII. MAINTENANCE OF BATTERIES AND RELATED ITEMS
4-13. GENERAL. This section contains information on
the batteries, battery tray, and battery cables of the
engine generator set. Four 12-volt, 200 ampere hour,
20-hour rate, lead-acid type batteries in series-parallel
connection supply 24V DC for starting the engine in the
generator set.
4-15. CABLE FABRICATION.
a. Cable Construction. There are six separate
battery cables (five different lengths and terminations)
constructed as follows:
4-14. CABLES.
(1) Materials required:
a. Replacement. (See Figure 4-9)
Wire, electrical, 4/0 (P/N MIL-C-5756)
Terminal lug (P/N MS25036-141)
WARNING
Battery terminal lug (P/N 76-11294-01 and 76-1129402).
Remove negative battery cables first,
and insulate and secure.
Insulation, sleeving 1-1/2 in. (38. 1 mm) ID, red and
black
(1) Disconnect all negative cables first then
positive, and jumper cables from the
batteries. Disconnect the battery leads
from the starter motor (see figure 4-44).
(2) Cable P/N 76-11424-01, see figure 4-10,
detail A.
(2) Reconnect positive cables (4 and 3, figure
4-9) numbered P140XX and P140H to the
positive post of batteries BR3 and BT2.
a. Cut wire to 81 inches (206 cm) and
strip insulation from both ends.
Strip 0. 62 inch (15. 7 mm) at
terminal lug end, and 0. 75 inch (19
mm) at battery terminal lug end.
(3) Reconnect two jumpers (1) between the
negative and positive post of batteries
BT1 and BT2; and BT3 and BT4.
b. Attach battery terminal lugs on ends
of wire as shown. Orient the lugs as
shown, then crimp the terminals
securely.
(4) Reconnect negative cables (5 and 2)
numbered P55XX and P55YY to the
negative post of batteries BT1 and BT4
and to ground post P2 on engine block.
c. Push sleeving up to terminals and
apply heat of 400°F (204°C) for 3 to
5 seconds to obtain proper
shrinkage.
b. Repair.
(1) If terminals are damaged, remove
damaged
terminals
and
insulation
sleeving, and clean wire lead.
NOTE
Cables 76-11424-02, 76-11422-01, and
76-11422-02 can be constructed the
same way, only length of wire differs.
(2) Orient new terminal in same position as
the one removed, and crimp terminal onto
cable.
(3) Cable P/N 76-11423 is fabricated similar
to other cables, except that the wire has
battery terminal lugs at both ends, see
figure 4-10, detail B.
(3) Tape connection so that no bare wire is
exposed.
(4) If wire is damaged, replace entire cable
assembly.
4-34
TM 5-6115-593-12
TO 35C2-3-463-1
Figure 4-9. Batteries and Related Items, Exploded View
4-35
TM 5-6115-593-12
TO 35C2-3-463-1
4-16. BATTERIES
a. Cut two pieces of sleeving one
black and one red 2 inches (5 cm)
long, and place them over wire
ends.
WARNING
Do not smoke or use an open flame in
the vicinity when servicing batteries.
Batteries generate a highly explosive
hydrogen
gas
during
charging.
Electrolyte is sulfuric acid diluted with
water and can cause severe acid burns
when spilled on skin or clothing. Use
extreme care in handling while
servicing batteries. When servicing
batteries reference TM9-6140-200-14.
b. Attach terminal lug on end of wire that
was previously stripped 0. 62 inch (15. 7
mm). Orient the lug as shown, then crimp
the terminal securely.
c. Attach battery terminal lug on other end of
wire. Orient the lug as shown, then crimp
the terminal securely.
d. Push sleeving up to terminals and apply
heat of 400°F (204°C) for 3 to 5 seconds
to obtain proper shrinkage.
Figure 4-10. Battery Cable Fabrication
4-36
TM 5-6115-593-12
TO 35C2-3-463-1
a. Battery Testing. Test batteries with hydrometer.
Always test a battery before adding water. The
specific gravity between the cells should be
within 0.025. A dangerously low point of charge
indicated by a hydrometer reading of 1.150 or
less will cause the batteries to freeze at 5°F (15°C). With specific gravity of 1.280 the batter
will withstand temperatures as low as -65°F (53.88°C) without freezing.
An acceptable
hydrometer reading of 1.270 to 1.280 at 80°F
(26.66°C) will be obtained from a fully charged
battery (2.2 to 2.4 volts DC per cell).
(2) Remove the eight nuts (6) and washers
(7) and remove the four battery hold-down
channels (8). It is necessary to remove
studs (9).
(3) Lift batteries out.
(4) Reinstall batteries in tray (install so that
terminals are oriented as shown).
(5) Install the batter hold-down channels (8)
onto studs (9) with washers (7) and nuts
(6).
b. Replacement. (See figure 4-9). (1) Disconnect
both battery negative cables (2 and 5) both
positive cable (3 and 4) and both jumper cables
(1) from storage batteries (10).
(6) Connect cables as shown in figure 4-9.
Section IX. MAINTENANCE OF MUFFLER AND EXHAUST
b. Remove the four screws (5) securing the front
mounting brackets, the four split lockwashers
(6), and muffler (8).
4-17. GENERAL. The muffler and exhaust, figure 4-11,
expel engine exhaust gases from the engine manifold
through the turbochargers, metal exhaust hoses,
mufflers, and out through the muffler rain caps. The
rain
caps
include
a
balancing
device
for
counterbalancing rain cap opening and closing.
c. Remove rain cap (7) from the muffler (8).
d. Separate and remove the upper and lower
gaskets (4).
WARNING
e. Remove the eight screws (9), lockwashers (10),
and nuts (11) which attach metal exhaust hose
(12) to exhaust elbow (16) and remove metal
exhaust hose (12).
Be sure that the exhaust is not fed
back into the system, or back into the
immediate area of working personnel.
Exhaust may be injurious to health.
f. Remove gasket (14).
4-18. MUFFLER AND EXHAUST REPLACEMENT.
(See figure 4-11).
g. Repeat steps a. through f. for the other side of
the exhaust system.
WARNING
h. Reassemble gasket (14) between exhaust elbow
(16) and metal exhaust hose (12).
Allow exhaust pipe and muffler to cool
if engine has been running.
i. Install eight screws (9), lockwashers (10), and
nuts (11).
a. Remove the eight screws (1), the eight split
lockwashers (2) and the eight hex nuts (3).
4-37
TM 5-6115-593-12
TO 35C2-3-463-1
l. Install eight screws (1), lockwashers (2), and
nuts (3) to secure muffler to frame and exhaust
hose.
j. Install gasket (4) between frame and top of
metal exhaust hose (12) and another gasket (4)
on top of frame between the muffler (8) and
frame.
m. Install four screws (5) and front mounting
bracket, and four lockwashers (6).
k. Install rain cap (7) on muffler (8).
n. Repeat steps h. through m. for reassembly of
other side of the exhaust system.
Section X. MAINTENANCE OF EXTERNAL POWER BOX ASSEMBLY
direction.
Replace in step b (Testing) as
indicated in following paragraphs.
4-19. GENERAL. This section contains inspection, test,
and replacement information for the external power box
assembly. See figure 4-12 and 4-13 and proceed as
follows:
4-20. PANEL MOUNTED CIRCUIT BREAKER CB101
and CB102. (See figure 4-13. )
a. Inspection. Inspect components of the external
power assembly for defective, broken, or
cracked components. Inspect wiring for loose
connections.
a. Test.
(1) Position CB101 circuit breaker (14, figure
4-13) and CB102 circuit breaker (23) to
ensure that they are in the reset position.
b. Testing. Testing of components of the external
power assembly is described under the
appropriate heading in paragraph 4-20 through
4-24.
(2) At the rear of the panel, remove terminal
leads from one side of circuit breaker on
each circuit breaker.
c. Repair. Repair by replacement of components
which do not function properly during testing.
(3) With an ohmmeter (Rxl scale), test circuit
breakers for closed contacts. If meter
indicates an open circuit in either circuit
breaker replace circuit breaker.
WARNING
Set MAINTENANCE LOCKOUT switch
to LOCKOUT. Disconnect negative
cable from batteries. Remove external
power by opening EXTERNAL POWER
BREAKER CB101 and disconnecting
power cable from EXTERNAL POWER
receptacle J101. Load terminals of
generator set circuit breaker (CB2)
may still be energized with bus
voltage.
(4) Position circuit breakers in open position.
With ohmmeter on same setting, test
breakers for open contacts. If meter
indicates closed circuit in either circuit
breaker, replace circuit breaker.
b. Replacement.
Replace defective circuit
breakers CB101 and CB102 (14 and 23, figure
4-13) as follows:
(1) Removal.
d. Replacement.
If a component needs
replacement, gain access to the inside of the
external power box assembly by loosening the
captive screws and permitting the panel (4,
figure 4-12) to pivot about its hinges in a forward
a. At rear of panel, tag and remove wires to CB101
and CB102.
b. Remove CB101 (14) by removing screws (12)
and nuts (13).
4-38
TM 5-6115-593-12
TO 35C2-3-463-1
Figure 4-11. Muffler and Exhaust, Exploded View
4-39
TM 5-6115-593-12
TO 35C2-3-463-1
Figure 4-12. External Power Box Assembly, Exploded View
4-40
TM 5-6115-593-12
TO 35C2-3-463-1
LEGEND FOR FIGURE 4-12
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
Screw
Nut
Spacer bar
Panel control assy
Weather stripping
Screw
Plate and sleeve assy
Screw
Neutral bar assy
Screw
Nut
Lockwasher
Washer
Compression lug
Plate
Bracket
Screw
Lockwasher
Compression lug
Locknut
Washer
Connector
Screw
Nut
Cover
Screw
Nut
Screw
Nut
Screw
Clamp
Screw
Clamp
Harness assy
Screw
Washer
Bolt
Lockwasher
Nut
Buss bar
Buss bar
Buss bar
Screw
Circuit breaker
Screw
Terminal board
Screw
Terminal board
Screw
Lockwasher
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
64.
65.
66.
67.
68.
69.
70.
71.
72.
73.
74.
75.
76.
77.
78.
79.
80.
81.
82.
83.
84.
85.
86.
87.
88.
89.
90.
91.
92.
93.
94.
95.
96.
97.
98.
99.
4-41
Transfer contactor K108
Screw
Lockwasher
Heater contactor K107 and K109
Screw
Lockwasher
Motor starter relay contactor K120
Screw
Spacer
Terminal block assy
Nut
Lockwasher
Washer
Nut
Bolt
Terminal block
Terminal block assy
Nut
Lockwasher
Washer
Jam nut
Bolt
Terminal block
Bushing
Bushing
Screw
Lockwasher
Clamp assy
Cushion
Clamp
Screw
Washer
Nut
Relay board assy
Screw
Lockwasher
Screw
Washer
Lockwasher
Nut
Screw
Lockwasher
Nut
Box and door assy
Screw
Nut
Door assy
Seal
Enclosure
TM 5-6115-593-12
TO 35C2-3-463-1
LEGEND
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Rivet
Nameplate
Screw
Nut
Cover
Gasket
Screw
Nut
Receptacle
Rivet
Nameplate
Screw
Nut
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
Circuit breaker
Rivet
Nameplate
Screw
Washer
Screw
Padlock device
Screw
Nut
Circuit breaker
Bracket
Rivet
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
Nameplate
Toggle switch
Rivet
Nameplate
Rivet
Nameplate
Screw
Nut
Dust cap
Receptacle
Panel
Screw
Figure 4-13. External Power Box Assembly, Control Panel, Exploded View
4-42
TM 5-6115-593-12
TO 35C2-3-463-1
(1) Toggle switch (27, figure 4-13) to the ON
position.
c. Remove CB102 (23) by removing screws (17)
and lockwashers (18) to release circuit breaker
and bracket (24) from the panel. Remove screw
(19) to remove circuit breaker padlock device
(20), then remove screw (21) and nut (22) to
free CB102 (23) from bracket (24).
(2)
(2) At the rear of the panel, remove one lead
from the switch.
(3) With an ohmmeter (Rxl scale), test switch
for closed circuit. If meter indicates an
open circuit, replace switch.
Installation.
a. Install CB101 (14) using screws (12)
and nuts (13).
(4) Place toggle switch to OFF position.
Using ohmmeter on Rxl scale, test switch
for open circuit. If meter indicates a
closed circuit, replace switch.
b. Prepare CB102 (23) for installation
by securing padlock device (20) to
the face of the circuit breaker with
screws (19), and then securing
CB102 to its mounting bracket (24)
with screws (21) and nuts (22).
Mount CB102 (23) by securing
bracket (24) to panel (37) with
screws (17) and lockwashers (18).
b. Replacement. Replace defective toggle switch
S105 (27, figure 4-13) as follows:
(1) Removal.
(a) At rear of panel, tag leads and
remove wires to switch.
c. Reconnect wires to circuit breakers,
and remove tags.
(b) Remove switch mounting hardware
and remove switch.
4-21. PANEL MOUNTED RECEPTACLES.
(2) Installation. Install switch onto panel with mounting
hardware. Attach wires to switch and
remove tags.
Replace defective receptacles J101 and J102 (9 and 35,
figure 4-13) as follows:
4-23. CONTACTORS K107, K108, K109 AND K120.
a. Removal
a. Inspect. Inspect contactors K107 and K109 (54,
figure 4-12) and K108 (51) for damage to
phenolic and metal parts. Inspect K108 for
binding or damaged mechanical interlock.
Inspect K120 (57) for damage. Refer to TM56115-593-34 for maintenance of K120.
(1) At rear of panel tag and remove wires from
receptacles.
(2) Remove J101 and J102 receptacle mounting
hardware and remove receptacle.
b. Installation. Install receptacles onto
front panel with mounting hardware.
Attach wires to J102 with screws
and washers. Carefully solder wires
to J101. Remove wire tags.
WARNING
Use extreme care when connecting
power supply to avoid electrical
shock.
4-22. PREHEAT SWITCH S105.
b. Test. Disconnect and tag wires to contactors
K107, K108, and K109 and proceed as follows:
a. Test
(1) Wire contactors K107 and K108 into test set-up as shown in figure 4-14.
4-43
TM 5-6115-593-12
TO 35C2-3-463-1
(2) Plug test set-up into 120V AC power
supply.
4-24. MAIN CIRCUIT BREAKER CB2.
a. Inspect. Inspect main circuit breaker CB2 (44,
figure 4-12) for loose or broken wires and
damaged case.
(3) Observe that neither of the 120V AC test
lamps light.
(4) Depress and hold pushbutton A; lamp A
should light and lamp B should remain
extinguished.
b. Removal. Remove circuit breaker CB2 (44,
figure 4-12) as follows:
WARNING
(5) Release pushbutton A and depress and
hold pushbutton B; lamp A should
extinguish and lamp B should light.
Set MAINTENANCE LOCKOUT switch
to
MAINTENANCE
LOCKOUT.
Disconnect negative cable from
batteries. Remove external power by
opening CB101 and disconnecting.
Load terminals of generator set circuit
breaker (CB2) may still be energized
with the bus voltage. (1) Disconnect
input bars from reconnection panel to
CB2.
(6) Depress and hold pushbutton A and then
also depress and hold pushbutton B; note
that transfer does not take place.
(7) Wire contactor K109 into test set-up as
shown in figure 4-14.
(8) Plug test set-up into 120V AC power
supply.
(2) Disconnect buss bars (40, 41, and 42) by
removing bolts (37) and screws (35),
washers (38) and nuts (39).
(9) Observe that test lamp does not light.
(10) Depress and hold pushbutton; test lamp
should light.
(3) Free upper set of circuit breaker buss bars
by removing fastening hardware.
(11) Release pushbutton; test lamp should
extinguish.
(4) Remove circuit breaker CB2 (44) from
enclosure (99) by removing eight screws
(38).
(12) Refer to next higher maintenance for
repair of any defective contactors.
c. Test. Refer to figures 4-14 and 4-15 and
proceed as follows:
c. Replacement. Replace defective contactors as
follows:
WARNING
(1) Remove contactors K107 and K109 (54)
by disconnecting and tagging lead wires,
and removing screws (52) and washers
(53).
Disconnect all input bars, bussing,
cables and control circuits to breaker
before starting test procedure.
NOTES
(2) Remove contactor K108 (51) by
disconnecting and tagging lead wires, and
removing screws (49) and washers (50).
1. Manual operation of circuit breaker disorders the
sequence of electrical control, Do not attempt to
operate the breaker from OPEN (OFF) to
CLOSED
(ON)
without
energizing
the
undervoltage trip. To restore electrical mode of
operation, the breaker must be cycled into
CLOSED (ON) or OPEN (OFF) position as
indicated
on
motor
cover.
(3) Install contactors K107 and K109 (54)
using screws (52) and washers (53) to
secure contactors side wall of external
power enclosure (94). Connect wires and
remove tags.
(4) Install contactor K108 (51) using screws
(49) and washers (50) to mount contactor.
Connect wires and remove tags.
4-44
TM 5-6115-593-12
TO 35C2-3-463-1
Figure 4-14. Contactors K107, K108, K109 and Main Circuit Breaker CB2, Schematic
4-45
TM 5-6115-593-12
TO 35C2-3-463-1
2.
To cycle the breaker to CLOSED, connect a 120V
AC (12 amps or greater) power supply between the
yellow and white leads.
3.
To cycle the breaker to OPEN (ON), connect a 120 V
AC (12 amps or greater) power supply between the
brown and white leads.
Figure 4-15. Main Circuit Breaker, CB2
4-46
TM 5-6115-593-12
TO 35C2-3-463-1
yellow and white leads.
should point to ON.
CAUTION
When operating the breaker electrically, do
not disconnect the voltage source until the
motor operator arm has reached the end of
its travel and stopped.
(1)
(2)
(12) Verify that all poles are closed.
(14) Verify that all poles are open.
(15) Disconnect all voltage supplies.
(16) Refer to next higher maintenance for
repair if necessary.
Using an ohmmeter, verify that all poles
are open by checking for continuity
between line and load of each pole.
Verify that all auxiliary switches are
open by checking between each pair
(one red and one white wire in tubing)
and between both yellow wires.
(4)
Connect 24V DC (0.5 amp or greater)
supply to under- voltage trip (blue
leads).
d. Installation.
(1)
Verify that all poles and auxiliary
switches are closed (see steps 2 and 3,
above).
(7)
Trip breaker by removing voltage from
undervoltage trip.
(8)
Check that all poles and auxiliary
switches are open.
Reconnect
24V
DC
supply
undervoltage trip (blue leads).
Install circuit breaker CB2 (44, figure 412) using eight screws (43). Connect
buss bars (40, 41 and 42) using bolts
(37) and screws (35), washers (36 and
38) and nuts (39).
NOTE
Indicator on cover shows position of
operator arm and not motor operator drive,
except when sequence is proper.
Cycle breaker to CLOSED (ON) by
connecting 120V AC supply between
yellow and white leads. Wait for motor
operator arm to stop moving before
disconnecting power source.
(6)
(9)
(13) Turn breaker OFF (OPEN) by
connecting 120V AC supply between
brown and white leads.
Indicator
should point to OFF.
Disconnect all input bars, bussing,
cables and control circuits to breaker
CB2. The circuit breaker should be
OPEN (OFF) or tripped position. If not,
cycle breaker to OPEN (OFF) by
connecting 120V AC to brown and white
leads.
(3)
(5)
Indicator
CAUTION
Manual operation of circuit breaker CB2
can be achieved by removing operator arm
retaining device, removing operator arm,
and installing arm onto indicator hub nut. If
arm is to be manually operated from OFF
to ON (OPEN to CLOSED), the
undervoltage trip (blue leads) must be
energized.
(2)
to
(10) Reset breaker to OPEN by connection
120V AC to supply between brown and
white leads. Indicator should point to
OFF (OPEN).
(11) Turn breaker ON (CLOSED) by
connection 120V AC supply between
4-47
Refer to figure 4-15 and manually
restore electrical sequence by removing
operator arm retaining device and
removing operator arm, then install arm
onto indicator hub nut and connect a
24V DC (0.5 amp or greater) power
supply to the undervoltage tro[ (blue
leads). Manually operate the breaker
by moving the operator arm.
TM 5-6115-593-12
TO 35C2-3-463-1
a.
1.
Motor
runs-Breaker
(OPEN) as shown
sequence is proper.
2.
Motor runs-Breaker not cycled to OFF
(OPEN) per motor indicator.
To
engage drive, electrically cycle motor
operator to ON (CLOSED), and then
OFF (OPEN). Drive is engaged and
breaker will be turned OFF per motor
operator indicator. Sequence is proper.
3.
b.
operator OFF leads. Motor will run to
OFF position and stop. Again switch
supply power to motor operator ON
leads. Motor runs, breaker cycles ON
as shown by motor operator indicator.
Sequence is proper.
If motor operator indicates ON (CLOSED),
supply power to off leads (brown and white)
and check for proper sequencing as follows:
cycles
OFF
by indicator,
NOTE
Due to the switching arrangement, the
motor operator must run to the limit of its
travel in one direction before it will run in
the opposite direction. However, it will
always run in one direction or the other. If
motor operator will run in neither direction,
problems other than sequence exist.
Motor does not run - Sequence is out of
order, switch supply power to motor
operator ON .leads. Motor will run to
ON position and stop. Again switch
supply power to motor operator OFF
leads. Motor operator will run to OFF
position and stop. Breaker will be
turned OFF per motor operator
indicator. Sequence is proper.
(3)
4-25. PLATE AND SLEEVE ASSEMBLY.
Replace the plate and sleeve assembly (7, figure 4-12) as
follows:
a.
Removal.
Remove plate and sleeve
assembly (7) from enclosure (99) by
removing eight screws (6). Referring to figure
4-16, sleeves may be removed by removing
four screws (1) and four nuts (2) attaching
retainer plate (3). Remove bushing (4) and
sleeve (5).
b.
Installation. Install plate and sleeve assembly
(7, figure 4-12) onto enclosure (99) with eight
screws (6). Replace sleeves by installing
sleeve (5, figure 4-16) with bushing (4) into
plate hole. Fasten with retainer plate (3), four
screws (1), and four nuts (2).
If motor operator indicates OFF (OPEN),
supply power to ON (CLOSED) leads (yellow
and white) and check for proper sequencing
as follows:
1.
2.
3.
Replace operator arm as shown in
figure 4-15.
Motor runs-Breaker cycles ON as
shown by motor operator indicator.
Sequence is proper.
Motor runs-Breaker not cycled to ON
per motor operator indicator. Drive is
not engaged. To engage drive
electrically, cycle motor operator to
OFF and then to ON. Drive is engaged
and breaker will be turned ON per
motor operator indicator. Sequence is
proper.
4-26. WEATHER STRIPPING AND SEALS.
a.
Motor does not run - Sequence is out of
order. Switch supply power to motor
4-48
Inspection.
Inspect weather stripping (5,
figure 4-12) and door seal (98) for signs of
excessive wear, rot, or damage.
TM 5-6115-593-12
TO 35C2-3-463-1
(5)
c.
1.
2.
3.
Screw
Nut
Retainer
Figure 4-16.
b.
(2)
Replacement of Door Seals
(1)
Remove door by removing screws
(95, figure 4-12 and nuts (96).
(2)
Separate seal (98) from door (97).
(3)
Install fresh seal (98) onto door (97).
(4)
Install door (97) using screws (95) and
nuts (96).
LEGEND
4-27. HARNESS ASSEMBLY.
4.
5.
6.
a. Inspection.
Bushing
Sleeve
Plate cover
WARNING
Set MAINTENANCE LOCKOUT switch to
LOCK- OUT. Disconnect negative cable
from batteries, Remove external power
by opening CB101 (120V RECEPTACLE
BREAK- ER).
Load terminals of
generator set circuit breaker (CB2) may
still be energized with the bus voltage.
External Power Box
Assembly, Plate and
Sleeve Assembly,
Exploded View
Replacement of Weather Stripping.
(1)
Connect wires to circuit breakers (14
and 23), receptacle (9), and toggle
switch (27). Remove wire tags.
Tag and disconnect wires to circuit
breakers (14 and 23, figure 4-13)
receptacle (9), and toggle switch (27).
Remove receptacle (35) from the
panel by unscrewing dust cap (34)
and removing screws (32) and nuts
(33).
Remove external power control panel
(4, figure 4-12 by removing screws (1,
figure 4-12) and nuts (2). Spacer bar
(3) and weather stripping (5) are now
easily removable.
NOTE
Weather stripping (5) consists of four separate pieces.
(3)
Position spacer bar (3) and fresh
weather stripping (5) on panel (4)
using screws (1). Mount panel (4),
with spacer bar and weather stripping,
on external power box enclosure and
secure with nuts (2).
(4)
Install receptacle (35, figure 4-13
using screws (32) and nuts (33).
Screw dust cap (34) into place.
(1)
Inspect all connectors for damaged
threads and bent, loose, or missing
pins.
(2)
Inspect all connections for security
and condition.
(3)
Inspect all
insulation.
for
defective
b.
Test. Perform continuity check, using an
ohmmeter between connecting points in the
wiring harness (see FO-6, External Power
Box, Wiring Diagram). Check for short
circuits between connector pins of the same
receptacle, plug, or terminal board.
c.
Repair.
(1)
4-49
wiring
If a broken wire is accessible, remove
sufficient insulation from each side of
the break to allow a good connection
of the bared ends
TM 5-6115-593-12
TO 35C2-3-463-1
by twisting them together. Solder the
connection and wrap with electrical
tape.
(2)
(3)
If a break in the wire is inaccessible
within the wiring harness, disconnect
it at both ends and tape both ends.
Lace a new lead of the same gauge
and insulation outside the harness
and connect it to the proper terminals
or pins. Properly tag both ends of all
replacement wires.
(4)
If more than 30 percent of the harness
wires are defective, refer to next
higher level of maintenance for
replacement.
If a wire is broken from a terminal lug,
replace the lug. If a wire is broken
from a connector, resolder and
reassemble.
CAUTION
Under no condition
connection exposed.
leave
the
bare
Section XI. MAINTENANCE OF AC-DC CONTROL BOX ASSEMBLY
breaker (CB2 may still be energized with
bus voltage.
4-28. GENERAL. This section contains inspection,
test, and replacement information for the AC-DC Control
Box Assembly. See figure 4-17, 4-18 and 4-19 and
proceed as follows:
a.
Gain access to the components of the ACDC Control Box by loosening six captive
screws on the AC-DC control panel (3,
figure 4-17).
Use the top and bottom
latches to release and open the side door
(73, figure 4-17) to the AC-DC Control Box.
b.
Inspection. Inspection components of the
AC-DC Control Box Assembly for defective,
broken, or cracked components. Inspect
wiring for loose connections.
c.
d.
e.
Replacement. Replace components which
do not function properly in step c (Testing)
as indicated in following paragraphs.
Replace control panel (3) by first loosening
six captive screws, then tag and disconnect
leads and remove screws (1). Install new
cover panel by installing panel using screws
(1), then reconnect leads, remove tags, and
tighten captive screws.
4-29. CIRCUIT BREAKER CB103 (42, figure 4-18)
a.
Testing. Testing of components of the ACDC Control Box Assembly is described
under the appropriate heading in paragraphs
4-29 through 4-35.
Repair.
Repair by replacement of
components which do not function properly
during testing. Small dents in the control
panel may be hammered out and refinished.
WARNING
Set MAINTENANCE LOCKOUT switch to
LOCKOUT. Disconnect negative cable
from batteries. Remove external power.
Load terminals of generator set circuit
4-50
Test.
(1)
Place circuit breaker switch to the ON
(closed) position.
(2)
At the rear of the panel, remove leads
from one side of circuit breaker.
(3)
With an ohmmeter (Rx1 scale), test
circuit breaker for closed contacts. If
meter indicates an open circuit,
replace circuit breaker.
(4)
Place circuit breaker in OFF position
(open).
Using ohmmeter on Rx1
scale, test circuit breaker for open
contacts. If meter indicates a closed
circuit
replace
circuit
breaker.
TM 5-6115-593-12
TO 35C2-3-463-1
Figure 4-17. AC-DC Control Box Assembly, Exploded View
4-51
TM 5-6115-593-12
TO 35C2-3-463-1
LEGEND FOR FIGURE 4-17
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
Screw
Nut
AC-DC control panel
Spacer bar
Weather stripping
Screw
Cover
Connector
Washer
Lock nut
Screw
Nut
Screw
Nut
Screw
Nut
Clamp
Clamp
Clamp
Clamp
Screw
Clamp
Harness assy
Screw
Nut
Terminal board
Jumper
Diode
Terminal lug
Terminal board
Screw
Nut
Relay
Screw
Nut
Lug
Standoff
Resistor
Screw
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
64.
65.
66.
67.
68.
69.
70.
71.
72.
73.
74.
75.
76.
77.
4-52
Nut
Clip
Screw
Compartment panel assy
Screw
Battery charger
Screw
Washer
Voltage regulator
Screw
Nut
Clamp
Screw
Nut
Potentiometer
Shaftlock
Governor
Plastic sleeve
Capacitor
Screw
Clip
Screw
Bracket
Screw
Washer
Nut
Nut
Screw
Washer
Nut
AC-DC box assy
Screw
Nut
Door
Door seal
Enclosure assy
Resistor assy
Lockwasher
TM 5-6115-593-12
TO 35C2-3-463-1
Figure 4-18. AC-DC Control Box Assembly, Component
Panel Assembly, Exploded View
4-53
TM 5-6115-593-12
TO 35C2-3-463-1
LEGEND FOR FIGURE 4-18
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
Screw
Nut
Dust cover
Plug
Screw
Nut
Receptacle
Rivet
Nameplate
Screw
Nut
Dust cover
Screw
Nut
Receptacle
Rivet
Nameplate
Rivet
Nameplate
Toggle switch
Guard
Rivet
Nameplate
Rivet
Nameplate
Toggle switch
Rivet
Nameplate
Rivet
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
4-54
Nameplate
Toggle switch
Rivet
Nameplate
Rivet
Nameplate
Toggle switch
Guard
Rivet
Nameplate
Screw
Nut
Circuit breaker
Rivet
Nameplate
Rivet
Nameplate
Potentiometer
Screw
Nut
Cover
Gasket
Screw
Nut
Rceptacle
Rivet
Nameplate
Plate
Screw
TM 5-6115-593-12
TO 35C2-3-463-1
LEGEND
1.
2.
3.
4.
5.
6.
7.
8.
Screw
Potentiometer
Screw
Potentiometer
Screw
Shunt
Relay
Screw
9.
10.
11.
12.
13.
14.
15.
Socket
Screw
Nut
Time delay module TD3
Screw
Bracket
Time delay module TD1
16.
17.
18.
19.
20.
21.
22.
Screw
Nut
AC-DC control relay assy
Screw
Bracket
Jumper
Panel
Figure 4-19. AC-DC Control Box Assembly
Component Panel Assembly, Exploded View
4-55
TM 5-6115-593-12
TO 35C2-3-463-1
b.
Replacement.
Replace defective circuit
breaker CB103 (42, figure 4-18) as follows:
(1)
a.
Test. With an ohmmeter (Rx1 scale) check
for continuity between pins A and B. If
meter indicates an open circuit, replace
short plug.
b.
Replacement. To remove shorting plug (4)
remove screw (1) which attaches the chain,
then unscrew the shorting plug from the
receptacle.
Removal.
a.
b.
(2)
4-31. SHORTING PLUG (4, figure 4-18)
At rear of panel, tag wire leads
and
remove
screws
and
washers which secure leads to
the circuit breaker.
Remove
circuit
breaker
mounting hardware (40 and 41)
and remove circuit breaker.
4-32. PANEL MOUNTED SWITCHES S22, S21, S106
and S20 (20, 26, 31, and 36, figure 4-18).
Installation.
Install circuit breaker
onto panel with mounting hardware
(40 and 41). Attach wires with screws
and washers. Remove tags from
wires.
a.
4-30. PANEL MOUNTED RECEPTACLES J103 AND
J104 THROUGH J109 (54, 7 and 15, figure 4-18).
Test.
(1)
Check switches for continuity in one
direction and an open circuit when
operated in the other direction.
(2)
At rear of panel, remove one lead
from switch.
(3)
With an ohmmeter (Rx1 scale), test
switch as indicated in step (1). If
switch fails to meet this test, replace
switch.
NOTE
Defective receptacles may be replaced
individually, as necessary.
a.
Removal.
b.
(1)
(2)
(3)
b.
At rear of panel, tag and remove
wires from receptacle J103 (54). Tag
and unsolder wires from receptacles
J104 through J109 (7 and 15).
Replacement S22, S21, S106 and S20.
Replace defective switches (20, 26, 31, and
36, figure 4-18) as follows:
(1)
Remove receptacle J103 (54) by
removing screws (48), nuts (49),
cover (50), gasket (51), screws (52),
and nuts (53).
To remove receptacles J104 through
J109 (7 and 15), unscrew dust cover
(3 or 12) and remove mounting
hardware (13 and 14).
(2)
Installation. Install receptacle J103 (54)
with screws (52), and nuts (53). Then
position gasket (51) and cover (50) and
secure with screws (48) and nuts (49).
Resolder wires and remove wire tags.
Install receptacles J104 through J109 (7 and
15) with mounting hardware (13 and 14).
Reconnect wires and then remove wire tags.
4-56
Removal.
(a)
At rear of panel, tag leads and
remove wires to switch.
(b)
Remove
switch
mounting
hardware and guards (21 and
37) and remove switch.
Installation.
(a)
Install switches S21 and S106
(26 and 31) onto front panel
with mounting hardware.
(b)
Attach wires to S21 and S106
switches (26 and 31) and
remove tags.
(c)
Install switches S22 and S20
(20 and 36)
TM 5-6115-593-12
TO 35C2-3-463-1
moves erratically, the potentiometer is
defective and should be replaced.
with guards (21 and 37) onto
front panel with mounting
hardware.
b.
(d)
Attach wires to switches S22
and S20 (20 and 36) and
remove tags.
Replacement.
Replace
potentiometer (54) as follows:
(1)
Removal. Tag and remove wires.
Remove shaftlock (55) to remove
potentiometer.
(2)
Installation. Install potentiometer (54)
and secure with shaftlock. Solder
wires and remove tags.
4-33.
POTENTIOMETER R104 REACTIVE LOAD
COMPENSATION CONTROL (47, figure 4-18).
a.
Test
(1)
b.
Tag and unsolder leads from R104
(47, figure 4-18).
(2)
Connect an ohmmeter (Rx1 scale to
each of the terminals on the
potentiometer.
(3)
Turn potentiometer slowly throughout
its range (0 to 1 ohm).
As
potentiometer
is
rotated,
the
ohmmeter reading should move at the
same rate as the rotating shaft. If
ohmmeter pointer does not move, or
moves erratically the potentiometer is
defective and should be replaced.
Replacement.
Replace
potentiometer (47) as follows:
4-35. MOTOR-OPERATED POTENTIOMETERS B4
(2, figure 4-19) and B5 (4, figure 4-19). Inspect motoroperated potentiometers B4 (2, figure 4-19) and B5 (4,
figure 4-19) for loose connections, broken leads,
cracking, or loose mounting.
4-36. DC AMP SHUNT (6, figure 4-19).
a.
Test.
(1)
Connect a 0 to 30 amp DC power
supply to the terminals of the DC amp
shunt (6, figure 4-19).
(2)
Connect a 0 to 0.10 volt DC meter to
the terminals of the DC amp shunt.
(3)
Increase power to 30 amps; the
voltmeter should read 0.05 volts +10
percent.
(4)
If correct reading is not obtained,
refer to next higher level of
maintenance.
defective
(1)
Removal. Tag leads and remove
mounting hardware.
(2)
Installation. Install potentiometer in
panel with mounting hardware.
Solder wires and remove tags.
4-37. RELAYS. Inspect K20, K1 and K50 relays (33,
figure 4-17 and 7 and 18, figure 4-19) respectively for
loose mounting, loose connections, cracking, or
damaged castings.
4-34. POTENTIOMETER R103 (54, FIGURE 4-17).
a.
defective
Test. This potentiometer is located at the top
of the governor controller assembly (56,
figure 4-17).
(1)
Tag and unsolder leads from R103
(54).
(2)
Connect an ohmmeter to each of the
terminals on the potentiometer.
(3)
Turn potentiometer slowly throughout
its range (0 to 500 ohms). As the
potentiometer is rotated, the ohmmeter reading should move at the
same rate as the rotating shaft. If the
ohmmeter pointer does not move, or
4-38. HARNESS ASSEMBLY.
WARNING
Set MAINTENANCE LOCKOUT switch to
LOCKOUT. Disconnect negative cable
from batteries. Remove external power
by opening CB101 (120V RECEPTACLE
BREAKER). Load terminals of generator
set circuit breaker (CB2) may still be
energized with bus voltage.
4-57
TM 5-6115-593-12
TO 35C2-3-463-1
a.
(1)
Inspect connectors for damaged
threads and bent, loose, or missing
pins.
(2)
Inspect connections for security and
condition.
(3)
b.
c.
it at both ends and tape both ends.
Lace a new lead of the same gauge
and insulation outside the harness
and connect it to the proper terminals
or pins. Properly tag both ends of all
replacement wires.
Inspection.
(4)
Inspect wiring for defective insulation.
Test.
Perform continuity check, using
ohmmeter between connecting points in the
wiring harness. (See FO-5, AC-DC Control
Box, Wiring Diagram.) Check for short
circuits between connector pins of the same
receptacle or terminal board.
4-39. WEATHER STRIPPING
Repair.
(1)
(2)
If more than 30 percent of the harness
wires are defective, refer to next
higher maintenance for replacement.
If a broken wire is accessible,
remove sufficient insulation from each
side of the break to allow a good
connection of the bared ends by
twisting them together. Solder the
connection and wrap with electrical
tape.
If a wire is broken from a terminal lug,
replace the lug. If a wire is broken
from a connector, resolder and
reassemble.
a.
Inspection. Inspect weather stripping (5,
figure 4-17) around cover (7), AC-DC
control panel (3) and seal (74) on door (73)
for signs of excessive wear, rot, or damage.
b.
Replacement of Weather Stripping.
(1)
Remove door (73) by removing
screws (71) and nuts (72).
(2)
Remove seal (74) from door (73).
(3)
Remove weather stripping (5) from
AC-DC box (70) and enclosure (75),
AC-DC control panel (3) or cover (7).
(4)
Install four pieces of fresh weather
stripping (5) on AC-DC box (70) and
enclosure (75), panel (3) or cover
(7).
(5)
Install new seal (74) on door (73).
(6)
Reinstall door (73), screws (71) and
nuts (72).
CAUTION
Under no condition
connection exposed.
(3)
leave
the
bare
If a break in the wire is inaccessible
within the wiring harness, disconnect
Section XII. MAINTENANCE OF CONTROL CUBICLE
4-40.
The control cubicle contains four major
assemblies, the engine control panel (see figure 4-21),
the generator control panel (figure 4-22), the component
shelf (see figure 4-20, sheet 2) and the rear relay panel
(see figure 4-20, sheet 3).
4-58
(2)
Inspect two lamps on engine panel,
and four lamps on generator panel.
(3)
Inspect transducers, relays, and time
delay modules for looseness and poor
TM 5-6115-593-12
TO 35C2-3-463-1
Figure 4-20. Control Cubicle, (Sheet 1 of 3 )
4-59
TM 5-6115-593-12
TO 35C2-3-463-1
Figure 4-20. Control Cubicle, (Sheet 2 of 3)
4-60
TM 5-6115-593-12
TO 35C2-3-463-1
mounting, and loose wires.
b.
(2)
Inspect two lamps on engine panel, and four lamps on generator panel.
(3)
Inspect transducers, relays, and time delay modules for looseness and poor connection.
(4)
Inspect flasher for security in terminal box . Inspect terminal box.
Test. Test 24V DC control circuit breaker CB1 (87, figure 4-22, sheet 2) as follows:
LEGEND
1.
2.
3.
4.
5.
Screw
BCR relay
Synch relay
BTR realy
Terminal Block
6.
7.
8.
9.
10.
CR relay
Over/under voltage realy
Overfrequency relay
Underfrequency relay
Mounting plate
Figure 4-20. Control Cubicle, (Sheet 3 of 3)
4-61
TM 5-6115-593-12
TO 35C2-3-463-1
LEGEND FOR FIGURE 4-20
Sheet 1 and Sheet 2
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
Screw
Nut
Door holder
Screw
Nut
Engine Panel
Spacer
Screw
Nut
Door holder
Screw
Nut
Generator panel
Spacer
Screw
Lockwasher
Washer
Horn
Screw
Flasher
Terminal block
Screw
Nut
Terminal board
Diode
Resistor
Lug
Jumper
Screw
Nut
Transducer
Screw
Nut
Receptacle cover
Screw
Nut
Receptacle cover
Screw
Nut
Receptacle cover
Screw
Clamp
Screw
Clamp
Screw
Clamp
Screw
Clamp
Harness assy
Locknut
Connector
Screw
Nut
Relay assy
55.
56.
57.
58.
59.
60.
61.
62.
63.
64.
65.
66.
67.
68.
69.
70.
71.
72.
73.
74.
75.
76.
77.
78.
79.
80.
81.
82.
83.
84.
85.
86.
87.
88.
89.
90.
91.
92.
93.
94.
95.
96.
97.
98.
99.
100.
101.
102.
103.
104.
105.
106.
107.
108.
Screw
Transformer
Screw
Transformer
Screw
Phase sequence relay
Screw
Overload device
Relay
Screw
Relay socket
Screw
Reverse power relay
Screw
Overvoltage relay
Screw
Short circuit relay
Screw
Bracket
Screw
Nut
Annunciator control assy
Screw
Undervoltage relay
Screw
Transformer
Screw
Sync check relay
Screw
Bracket
Screw
Nut
Integrated time delay module
Screw
Bracket
Screw
Nut
Control relay assy
Screw
Transducer
Screw
Resistor assy
Terminal lug
Screw
Nut
Terminal board
Screw
Nut
Rectifier
Bracket
Screw
Lockwasher
Washer
Nut
4-62
109.
110.
111.
112.
113.
114.
115.
116.
Screw
Washer
Lockwasher
Nut
Control box
Flasher
Screw
Socket
TM 5-6115-593-12
TO 35C2-3-463-1
Figure 4-21. Control Cubicle, Engine Panel, Exploded View
4-63
TM 5-6115-593-12
TO 35C2-3-463-1
LEGEND FOR FIGURE 4-21
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
Rivet
Nameplate
Light assy
Lamp
Rivet
Nameplate
DC voltmeter
Running time meter
Rivet
Nameplate
Meter
Resistor
Lube oil temperature gauge
Gauge resistor
Lube oil pressure gauge
Resistor
Coolant temperature gauge
Rivet
Nameplate
Toggle switch
Guard
Rivet
Nameplate
Rivet
Nameplate
Lamp assy
Lamp
Rivet
Nameplate
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
4-64
Toggle switch
Rivet
Nameplate
Fuel level gauge
Rivet
Nameplate
Rivet
Nameplate
Toggle switch
Rivet
Nameplate
Rivet
Nameplate
Lamp assy
Lamp
Screw
Clamp
Screw
Nut
Clamp
Switch
Rivet
Nameplate
Panel
Screw
Nut
Hinge
Screw
Sheet
TM 5-6115-593-12
TO 35C2-3-463-1
Figure 4-22. Control Cubicle, Generator Panel, Exploded View (Sheet 1 of 2)
4-65
TM 5-6115-593-12
TO 35C2-3-463-1
Figure 4-22. Control Cubicle, Generator Panel, Exploded View (Sheet 2 of 2)
4-66
TM 5-6115-593-12
TO 35C2-3-463-1
LEGEND FOR FIGURE 4-22
Sheet 1
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
Screw
Nut
Jumper
Terminal block
Lamp assy
Lamp
Toggle switch
Toggle switch
Toggle switch
Toggle switch
Toggle switch
Ammeter
Kilowatt meter
Kilovar meter
Power factor meter
Lamp assy
Bulb
Lamp assy
Rotary switch
Lamp assy
Lamp
Rivet
Nameplate
Rivet
Nameplate
Rivet
Nameplate
Rivet
Nameplate
Rivet
Nameplate
Rivet
Nameplate
Rivet
Nameplate
Rivet
Nameplate
Rivet
Nameplate
Rivet
Nameplate
Rivet
Nameplate
Rivet
Nameplate
Rivet
Nameplate
Rivet
Nameplate
Rivet
Nameplate
Rivet
Nameplate
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
Rivet
Nameplate
Rivet
Nameplate
Rivet
Nameplate
Rivet
Nameplate
Rivet
Nameplate
Sheet 2
64.
65.
66.
67.
68.
69.
70.
71.
72.
73.
74.
75.
76.
77.
78.
79.
80.
81.
82.
83.
84.
85.
86.
87.
88.
89.
90.
91.
92.
93.
94.
95.
96.
97.
98.
99.
100.
101.
102.
Screw
Nut
Shield
Gasket
Fault indicator
Terminal lug
Lamp
Lamp assy
Screw
Shield
Plate
Plate
Gasket
Light control film
Digital clock
Switch
Voltmeter
Frequency meter
Synchroscope
Guard
Toggle switch
Screw
Bracket
Circuit breaker
Toggle Switch
Switch
Telephone jack
Toggle switch
Rivet
Nameplate
Rivet
Nameplate
Rivet
Nameplate
Rivet
Nameplate
Rivet
Nameplate
Rivet
4-67
103.
104.
105.
106.
107.
108.
109.
110.
111.
112.
113.
114.
115.
116.
117.
118.
119.
120.
121.
122.
123.
124.
125.
126.
127.
128.
129.
130.
131.
132.
133.
134.
135.
136.
137.
138.
139.
140.
141.
142.
143.
144.
145.
Nameplate
Rivet
Nameplate
Rivet
Nameplate
Rivet
Nameplate
Rivet
Nameplate
Rivet
Nameplate
Rivet
Nameplate
Rivet
Nameplate
Rivet
Nameplate
Rivet
Nameplate
Rivet
Nameplate
Rivet
Nameplate
Rivet
Nameplate
Screw
Nut
Clamp
Screw
Clamp
Screw
Nut
Clamp
Fault indicator
Terminal lug
Lamp
Lamp assy
Control box panel
Screw
Nut
Hinge
Screw
Sheet
TM 5-6115-593-12
TO 35C2-3-463-1
(2)
WARNING
Set MAINTENANCE LOCKOUT switch to
LOCKOUT. Disconnect negative cable
from batteries. Remove external power
by opening CB101 and disconnecting
power from receptacle J101.
Load
terminals of generator set circuit breaker
(CB2) may still be energized with bus
voltage.
(1)
Position circuit breaker CB1 (87,
figure 4-22, sheet 2) in the ON
position.
(2)
At rear of panel, remove and tag
leads to circuit breaker.
(3)
Using an ohmmeter (Rx1 scale), test
breaker for closed contacts. If meter
indicates an open circuit, replace
breaker.
(4)
(3) With switch in down (OFF) position,
check that contacts 1-2 and 4-5 have
continuity.
e.
Position circuit breaker in open
position.
With ohmmeter at Rx1
scale, test breaker for open contacts.
If meter indicates a closed circuit,
replace breaker.
Toggle switch to the ON position.
(2)
At the rear of the panel, remove one
lead from the switch.
(3)
Using an ohmmeter (Rx1 scale), test
switch for a closed circuit. If meter
indicates an open circuit, replace
switch.
(4)
d.
Toggle switch to OFF position. Using
ohmmeter on Rx1 scale, test for open
circuit. If meter indicates a closed
circuit, replace switch.
Test for SPTT (double-pole, triple-throw)
toggle switches.
(1)
With switch in center (neutral)
position, check that contacts 1-2 and
5-6 have continuity.
Ohmmeter
should be set to Rx1 scale.
4-68
Test for BATTERY CHRG AMPS meter (11,
figure 4-21).
(1)
Disconnect
minus
lead
from
BATTERY CHRG AMPS meter M21.
(2)
Observing
polarity,
connect
a
multimeter (set to measure DC amps)
in series with disconnected minus
lead and open terminal of meter M21.
(3)
Meter M21 reading should be within
+10 percent of multimeter reading.
(4)
Disconnect test equipment
reconnect lead to step (1).
and
f.
Test of ELAPSED TIME meter (8, figure 421). To test ELAPSED TIME meter M5,
check against any time source standard
such as a wristwatch or a wall clock. Meter
M5 should be within +5 percent of time
sourge.
g.
Test of BATTERY CHRG VOLTS (7, figure
4-21). To test BATTERY CHRG VOLTS
meter M20, connect a multimeter across
meter M20 terminals. Meter M20 should be
within +5 percent of multimeter reading.
h.
Test of ENGINE OIL TEMP meter (13,
figure 4-21).
c.
Test for SPST (single-pole, single-throw)
toggle switches.
(1)
With switch in up (ON) position, check
that contacts 2-3 and 5-6 have
continuity.
(1)
Disconnect negative lead
ENGINE OIL TEMP meter M2.
from
(2)
Connect one end of a precision (+1
percent) 1,096-ohm resistor to open
terminal of meter M2.
(3)
Connect positive side of 24V DC
source to the resistor connected to the
positive terminal of meter M2.
(4)
Connect open end of precision
resistor to minus side of 24V DC
source.
TM 5-6115-593-12
TO 35C2-3-463-1
Meter M2 should read 200°F (93°C)
±4 percent.
(5)
Disconnect all test equipment and reconnect
lead of step (1).
i.
Test of ENGINE OIL PRESS meter (15,
figure 4-21).
(1)
Disconnect negative lead from
ENGINE OIL PRESS meter M1.
(2)
Connect one end of a precision (±1
percent) 120-ohm resistor to open
terminal of meter M1.
(3)
Connect positive side of 24V DC
source to the resistor connected to the
positive terminal of meter M2.
(4)
(3)
Connect positive side of 24V DC
source to positive terminal of meter
M4.
(4)
Connect open end of precision
resistor to minus side of 24V DC.
Meter M4 should read F (full); meter
pointer should be over some part of
letter F.
(5)
Disconnect all test equipment and
reconnect lead to step (1).
Test of AMMETER (12, figure 4-22).
Disconnect
either
AMMETER M102.
(2)
Connect a test AC ammeter (full-scale
reading of 1 ampere) in series with
disconnected lead and open terminal
of meter M102.
Test of WATER TEMP meter (17, figure 421).
(3)
Meter M102 reading should be within
+3 percent of test ammeter reading.
(1)
Disconnect negative lead
WATER TEMP meter M3.
(4)
Disconnect all test equipment and
reconnect lead to step (1).
(2)
Connect one end of precision (+1
percent) 97.6-ohm resistor to open
terminal of meter M3.
(3)
(4)
(5)
k.
Connect open end of precision
resistor to minus side of 24V DC
source. Meter M1 should read 80 psi
+4 percent.
Connect one end of precision (+1
percent) 30-ohm resistor to open
terminal of meter M4.
(1)
(5)
j
l.
(2)
Disconnect all test equipment and
reconnect lead to step (1).
from
m.
from
Test of KW meter (13, figure 4-22).
(1)
Disconnect minus lead from KW
meter M107.
(2)
Connect open end of precision
resistor to minus side of 24V DC
source. Meter M2 should read 280°F
(1390C) +4 percent.
Observing
polarity,
connect
a
multimeter (set to measure 0-1
milliamp
DC)
in
series
with
disconnected minus lead and open
terminal of meter M107.
(3)
Meter reading should be within +3
percent of multimeter reading.
Disconnect all test equipment and
reconnect lead to step (1).
(4)
Disconnect test equipment
reconnect lead to step (1).
Connect positive side of 24V DC
source to the resistor connected to the
positive terminal of meter M3.
Test of FUEL LEVEL meter (33, figure 421).
(1)
lead
n.
Disconnect negative lead from FUEL
LEVEL meter M4.
4-69
Test of KVAR meter (14, figure 4-22.
and
TM 5-6115-593-12
TO 35C2-3-463-1
(1)
(2)
(3)
(2)
Installation.
(a)
Mount gauges and switches
onto control panel with mounting
hardware.
Observing
polarity,
connect
a
multimeter (set to measure 0-1
miliamp
DC)
in
series
with
disconnected minus lead and open
terminal of meter M108.
(b) Reconnect wires and remove
tags.
Meter reading should be within ±3
percent of multimeter reading.
(3)
Removal of circuit breaker CB1.
and
(a)
Tag and remove wires to CB1
(87, figure 4-22).
Test of POWER FACTOR meter (15, figure
(b)
Remove
bracket
mounting
screws (86) to release circuit
breaker (87) from panel.
(c)
Remove
circuit
breaker
mounting screws (85) to release
circuit breaker from mounting
bracket (86).
(4)
o.
Disconnect minus lead from KVAR
meter M108.
Disconnect test equipment
reconnect lead to step (1).
4-22).
(1)
(2)
(3)
(4)
p.
Using an ohmmeter set to Rx1 scale,
measure resistance across terminals
1 and 2. Reading should be less than
1 ohm.
(4)
Using an ohmmeter set to Rx100
scale, measure resistance across
terminals 3 and 4. Reading should be
950 ohms +20 percent.
Installation of CB1.
(a)
Install mounting bracket (86)
onto circuit breaker (87) with
screws (85).
(b)
Mount circuit breaker (87) by
securing mounting bracket (86)
to panel with screws.
(c)
Connect lead wires and remove
wire tags.
Remove tags and reconnect leads to
meter terminals.
Test of VOLTS AC meter (80, figure 4-22).
(1)
(2)
q.
Tag and disconnect all leads
connected to meter terminals 1
through 4.
Connect a multimeter (set to measure
AC volts) across terminals of VOLTS
AC meter M101.
4-41. HARNESS ASSEMBLY.
a.
Meter reading should be within +3
percent of multimeter reading.
WARNING
Set MAINTENANCE LOCKOUT switch to
LOCKOUT. Disconnect negative cable
from batteries. Remove external power
by opening CB101 (120V RECEPTACLE
BREAKER). Load terminals of generator
set circuit breaker (CB2) may still be
energized with bus voltage.
Replacement.
(1)
Inspection.
Replace inoperative or defective
gauges and switches on control
panels as follows:
(a)
Tag wires to gauges, switches
or circuit breaker.
(b)
Remove wires.
(c)
Remove mounting hardware.
(1)
4-70
Inspect connectors for damaged
threads and bent, loose, or missing
pins.
TM 5-6115-593-12
TO 35C2-3-463-1
b.
c.
(2)
Inspect connections for security and
condition.
(3)
Inspect wiring for defective insulation.
Test.
Perform continuity check, using
ohmmeter between connecting points in the
wiring harness. (See FO-7, Control Cubicle,
Wiring Diagram.) Check for short circuits
between connector pins of the same
receptacle or terminal board.
Remove both air cleaners as
(1)
Loosen eight hose clamps (24).
(2)
Remove six screws (15), nuts (16),
and lockwashers (17) from mounting
brackets (18 and 19).
(3)
Remove air cleaners (29).
Repair.
(1)
(1)
Remove and empty dust cup (13)
when three-quarters full.
(2)
Reinstall dust cup (13) and O-ring
(14).
(3)
Clean air cleaner tubes with a stiff
brush. If heavy plugging is evident,
remove lower body section (15) and
clean with compressed air or water
not exceeding 1600F (71°C).
If a broken wire is accessible, remove
sufficient insulation from each side of
the break to allow a good connection
of the bared ends by twisting them
together. Solder the connection and
wrap with electrical tape.
If a wire is broken from a terminal
lug, replace the lug. If a wire is
broken from a connector, resolder and
reassemble.
CAUTION
Under no condition leave
connection exposed.
(3)
b.
Removal.
Service. Check the air cleaner service
indicator. If indicator is in red, proceed as
follows (see figure 3-1):
(2)
d.
a.
follows:
CAUTION
the
bare
Never clean air cleaner tubes with
compressed air unless both filter
elements are installed in the air cleaner.
Do not steam clean air cleaner tubes.
If a break in the wire is inaccessible
within the wiring harness, disconnect
it at both ends and tape both ends.
Lace a new lead of the same gauge
and insulation outside the harness
and connect it to the proper terminals
or pins. Properly tag both ends of all
replacement wires.
(4)
Unfasten cover latches and remove
cover (1). Remove wing nut (3) and
remove primary filter element (4).
(5)
Remove cotter pin (5), castellated nut
(6), and safety filter element
(7).Replace with new element at
interval indicated in table 4-2 and
secure with castellated nut (6) and
cotter pin (5). Do not clean safety
filter element (7).
(6)
Clean primary filter element (4) by
either method (a) or (b), as follows:
Replacement. If 30 percent of the harness
wires are defective, refer to next higher
level of maintenance for replacement.
Section XIII. MAINTENANCE OF AIR CLEANER
4-42. AIR CLEANER. (See figure 4-23.)
4-71
TM 5-6115-593-12
TO 35C2-3-463-1
Figure 4-23. Air Cleaner and Related Parts
4-72
TM 5-6115-593-12
TO 35C2-3-463-1
(2)
CAUTION
Do not clean in gasoline or other
petroleum products.
(a)
(b)
Washing with Water. Soak 15
minutes in water with mild
deter- gent. Rinse until clean.
Air dry. Do not use compressed
air.
c.
(1)
Tag and disconnect lead wires to
valve.
(2)
Valve is normally open. Trip valve by
applying 24V DC across leads: valve
should close.
(3)
Remove 24V DC; valve should open.
Replacement.
Replace defective gaskets or O-rings.
(8)
Replace primary filter element (4),
gasket (2), secure with wing nut (3),
and secure cover (1) with cover
latches.
(1)
Tag and disconnect lead wires.
(2)
Loosen clamps (24) at either end of
valve (27).
Reset service indicator to green.
(3)
Remove mounting screws (30) and
nuts (31) which hold valve to bracket
(22 and 23).
(4)
Remove valve (27) by sliding adapter
hose (26) and then duct hose (25)
away from valve.
(5)
Install valve (27) by sliding one end
into adapter hose (26), other into duct
hose (25).
(6)
Secure to bracket (22 and 23) using
mounting screws (30) and nuts (31).
(7)
Tighten clamps (24) at either end of
valve.
(8)
Connect lead wires and remove wire
tags.
c.
Replacement of Air Cleaner Element. Refer
to paragraph b, above.
d.
Replacement of Indicator. Remove the
indicator (28, figure 4-23) by unscrewing it
from the air cleaner assembly. Screw a new
indicator in place.
Replacement of Air Cleaner.
(1)
Be sure hose clamps (24) are in their
proper location as shown in figure 423.
(2)
Attach air cleaner (29) to mounting
brackets (18 and 19) with six screws
(15), lockwashers (17) and nuts (16).
(3)
Attach hoses to air cleaner and
tighten hose clamps (24).
4-44. DUCTS AND HOSES.
a.
4-43. AIR SHUT-OFF VALVE. (27, figure 4-23.)
a.
Test
(7)
(9)
e.
b.
Compressed
Air.
Direct
compressed air (100 psi max)
through filter element opposite
airflow direction.
Check springs, shafts, and mountings
for security, mechanical defects
(stretched springs, bent shafts), and
freedom from binding.
Inspect
(1)
Check all lead wires for secure
connection.
4-73
Inspect.
(1)
Loosen clamps (24) holding adapter
hose (26).
(2)
Check inside hose for accumulation of
dirt.
TM 5-6115-593-12
TO 35C2-3-463-1
a.
(3)
Check hose for cracking or leakage.
(4)
Loosen clamps (24) holding duct hose (25).
(5)
Check inside hose for accumulation of dirt.
(6)
Check hose for cracking or leakage.
(7)
If hoses are damaged, then replace as follows. If no damage is found tighten all clamps (24) to secure
hoses.
Replacement.
(1)
Remove duct hose (25) by sliding it off valve (27) and away from air cleaner (29).
(2)
Remove adapter hose (26) by sliding it off valve (27) and away from turbocharger.
(3)
Install adapter hose (26) by sliding it over valve (27) and onto turbocharger. Secure with clamps (24).
(4)
Install duct hose (25) by sliding it over valve (27) and onto air cleaner (29). Secure with clamps (24).
Section XIV. MAINTENANCE OF TOOL BOX ASSEMBLY
4-45. TOOL BOX ASSEMBLY. (See figure 4-24)
a.
b.
Replacement. The tool box assembly is mounted on the right side of the main frame assembly next to the
engine.
(1)
Removal. Remove two screws (1), washers (2), lock- washers (3), and nuts (4), at the bottom of the
tool box supporting it to the frame.
(2)
Installation. Install tool box in place on frame, line up two holes at bottom of tool box with holes in
frame, and secure with two screws (1), washers (2), lockwashers (3), and nuts (4).
Repair.
(1)
Replace latches (11) by removing screws (9) and nuts (10).
(2)
If box is dented, straighten box. If any signs of rust or corrosion, sand and clean area and repaint tool
box.
4-74
TM 5-6115-593-12
TO 35C2-3-463-1
LEGEND
1.
2.
3.
4.
5.
6.
Screw
Washer
Lockwasher
Nut
Screw
Nut
7.
8.
9.
10.
11.
Cover
Tool box
Screw
Nut
Latch
Figure 4-24. Tool Box Assembly
4-75
TM 5-6115-593-12
TO 35C2-3-463-1
Section XV. MAINTENANCE OF DOCUMENT COMPARTMENT
Attach six screws (1), lockwashers (2), and
nuts (3).
4-46. DOCUMENT COMPARTMENT. (See
figure 4-25.)
a.
b.
Replacement. The document compartment
is mounted above the control cubicle.
(1)
(2)
Removal. Remove six screws (1),
lockwashers (2), and nuts (3)
supporting document compartment of
the control cubicle.
Repair.
(1)
Replace gasket (12) if defective.
(2)
Replace latches (8) by removing
screws (6), nuts (7) and spacer (9).
(3)
If dented, straighten out. If any signs
of rust or corrosion, sand and clean
area,
and
repaint
document
compartment.
Installation.
Install
document
compartment on top of the control
cubicle.
Line up six holes in
document compartment with holes on
top of control cubicle.
Section XVI. MAINTENANCE OF SUPPORT FRAME ASSEMBLY
4-48. INSPECTION. Inspect the tie bars, front frame,
center frame, and rear frame for loose mounting,
breaks, cracks, loose or missing hardware, and
corrosion. Refer to higher level maintenance for repair
of replacement.
4-47. GENERAL. The support frame assembly (figure
4-26) provides support for major assemblies of the
generator set, acts as a spreader bar when lifting the
set, and provides a frame for the housing kit (when the
kit is used).
Section XVII. MAINTENANCE OF RADIATOR ASSEMBLY
4-49.
RADIATOR ASSEMBLY.
a.
Using a hydrometer, verify that antifreeze is in
accordance with table 3-1.
Preliminary
Inspection.
Preliminary
inspections consist of checking for leaks
(especially at hose connections), and
coolant level may be checked at the sight
glass. If coolant level is below sight glass,
remove radiator cap and check level in
upper tank.
b.
Fan Belt Adjustment (Code A).
(1)
Refer to figure 4-28 and remove two
halves of fan belt guard (3) by removing screws (1) and
nuts (2).
(2)
Check tension of each of the three fan
belts (see figures 4-1 and 4-28). Apply thumb pressure
at center of belt and check for no more than 1/2 inch (13
mm) movement, as shown in figure 4-28.
WARNING
Whenever generator set has just been shut down,
remove radiator cap slowly to allow pressure to
escape before removing cap.
(3)
motor mount
Refill radiator with proper cool- ant to
approximately 2 inches (50 mm) below
filler neck level.
4-76
If belts require tensioning, tighten
TM 5-6115-593-12
TO 35C2-3-463-1
LEGEND
1. Screw
2. Lockwasher
3. Washer
4. Nut
5. Box assy
6. Screw
7. Nut
8. Fastener
9. Spacer
10. Screw
11. Nut
12. Gasket
13. Door
Figure 4-25. Document Compartment
4-77
TM 5-6115-593-12
TO 35C2-3-463-1
LEGEND
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
Screw
Lockwasher
Nut
Support frame
Support frame
Support frame
Tie bar
Screw
Lockwasher
Nut
Tie bar
Tie bar
Tie bar
Screw
Lockwasher
Nut
Step
18.
19.
20.
21.
22.
23.
24.
25.
26.
Screw
Washer
Nut
Support frame
Support frame
Support frame
Support frame
Support frame
Support frame
Figure 4-26. Support Frame Assembly
4-78
TM 5-6115-593-12
TO 35C2-3-463-1
LEGEND
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Screw
Nut
Clamp
Clamp
Extrusion
Clamp
Clamp
Hose
Reducer
Nipple
Fitting
Hose
Clamp
Figure 4-27.
14. Bracket
15. Fitting
16. Hose
17. Nipple
18. Reducer
19. Nut
20. Lockwasher
21. U-bolt
22. Clamp
23. Pipe connection
24. Hose
25. Hose
26. Clamp
Radiator Assembly, Exploded View
4-79
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
Hose
Valve (Code A Only)
Clamp
Screw
Lockwasher
Clamp
Hose
Fitting
Drain cock
Nipple
Elbow
Sight indicator
(Code B only)
TM 5-6115-593-12
TO 35C2-3-463-1
Figure 4-28. Fan Belt Adjustment and Replacement, Code A
4-80
TM 5-6115-593-12
TO 35C2-3-463-1
adjustment bolt (see figure 4-28) to increase
belt tension.
CAUTION
Be sure engine has been shut down
sufficiently long to allow engine coolant
to cool off before changing hoses.
Loosen and then remove radiator cap.
NOTE
All three belts should have same tension.
If not, remove and replace belts as a set
of three.
(a)
Drain coolant into clean container using
coolant drain cock (see figure 4-2). Save
coolant for reuse.
(b)
To remove hose (8), remove clamps (3, 4,
6, and 7). Remove hose (9) from radiator
assembly.
(c)
To remove hose (12), unscrew fittings (11)
from nipples (10).
(d)
To remove hose (16), remove clamp (13),
unscrew fittings (15) from reducers (18).
(e)
To remove hose (24), remove clamps (22),
then remove hose (24) from pipe connection
(23).
(f)
Motor. Inspect motor for loose mounting, signs of
overheating, or other damage. Run the generator
set and determine that the motor is operating by
observing that the fan is rotating. Check for
excessive noise.
To remove hose (25), remove clamps (22),
then remove hose (25) from pipe connection
(23) and then radiator assembly.
(g)
To remove overflow hose (27), remove
clamp (26), then remove hose from radiator
assembly.
Sight Indicator and Valves. (See figure 4-27)
(h)
To remove hose (33), remove clamps (29
and 32), then unscrew hose from fittings
(34).
(i)
Install hose (33) by attach- ing hose (33) to
fittings (34). Secure with clamps (29 and
32).
(j)
Install overflow hose (27) by attaching hose
(27) to radiator assembly, then secure with
clamp (26).
(k)
Install hose (25) by attach- ing hose (25) to
radiator assembly, then to pipe connection
(23). Secure with clamps (22).
(4)
c.
Replace guard (3), screws (1), and nuts (2).
Fan Belt Replacement (Code A). To remove fan
belts proceed as follows:
(1)
d.
e.
(1)
(2)
f.
Remove two halves of belt guard (3,
figure 4-28) by removing six screws
(1) and nuts (2).
(2)
Loosen motor mount adjusting bolt
and relieve tension on belts. Remove
by manually rotating fan.
3)
Install new belts, and adjust for proper
tension.
(4)
Replace belt guard.
Inspect Code B sight indicator (38) and
Code A shut-off valves (28) for leakage,
loose connection, or loose mounting.
Inspect sight indicator for cracking.
Hoses.
(1)
(2)
Inspect all hoses (8, 12, 16, 24, 25, 27, and
33) for loose mounting or loose connections,
leakage, cracking, or rot.
Replace hoses as follows:
4-81
TM 5-6115-593-12
TO 35C2-3-463-1
(l)
Install hose (24) by attaching clamps (22)
and securing to pipe connection (23).
(n)
Install hose (12) by attaching fittings (11) to
nipples (10).
(m)
Install hose (16) by attaching fittings (15) to
reducers (18), then install clamp (13).
(o)
Install hose (8) by attaching to radiator
assembly. Secure with clamps (3, 4, 6, and
7).
Section XVIII. MAINTENANCE OF FUEL LINES AND FITTINGS
4-50. FUEL LINES. The generator set fuel lines
(figure 4-29) are hose assemblies connecting the fuel
tank and fuel transfer pump, and the engine.
(2)
Remove spring clamps, or unscrew
assembly from adapters, tees, etc.
as
necessary.
a.
Visually inspect all lines and fittings for leakage or
deformity, signs of rot or physical damage.
Inspect screen which is welded inside filler neck
assembly (47) for tears or damage.
(3)
Separate defective lines or fittings from
assembly.
(4)
Install new lines or fittings onto assembly.
Replace defective lines and fittings as follows:
(5)
Install hose assemblies using spring clamps
or attaching hardware (fittings).
(6)
Install clamps securing hose assembly to
generator set.
(7)
Recycle fuel if not contaminated in any way.
b.
(1)
Remove lines by removing clamps
supporting defective hose assemblies to the
generator set.
Section XIX. MAINTENANCE OF ENGINE PREHEAT
4-51. ENGINE PREHEAT.
The engine preheat
assembly (see figure 4-30) is mounted to the base
assembly under the forward end of the engine. The
preheat system maintains the engine in a preheated,
ready-to-start condition by heating the coolant and oil.
This requires an external power source.
a.
b.
Testing.
(1)
Inspection. Inspect thermostatic switch S30 (25,
figure 4-30), heaters H101, H102, H103 (18) and
(53 and heater power control contactor K109 (54,
figure 4-12) for loose mounting, loose electrical
connections, loose hose assemblies and general
signs of overheating. Inspect hose assemblies for
loose connections, leakage, wear or rotting.
4-82
Thermostatic switch S30 (13,.figure 4-30).
(a)
Close both shutoff cocks (4).
(b)
Install a temperature measuring
instrument (thermocouple) as close to
the thermostatic switch (13) as
possible.
(c)
Switch on heater system. Observe
that heater system automatic- ally
turns off when temperature measuring
TM 5-6115-593-12
TO 35C2-3-463-1
point 7 should be 50 ohms. (Refer to
Engine Accessories Wiring Diagram FO-11)
instrument reaches approximately 120°F 5
(50°C 2).
(2)
(d)
As the water begins to cool, note that heater
automatically comes on at approximately
100°F 5 (38°C 2).
(e)
If switch fails to meet above test, it should
be replaced.
(f)
Open both shutoff cocks.'
(d)
c.
Place EXTERNAL POWER BREAKER and
PREHEAT switch to the off position. (figure
2-10).
(b)
Locate terminal board within heater
electrical enclosure (40 figure 4-30) and
remove wires X173H and X174H from
terminal points 6 and 7. Isolate 12 gauge
and 14 gauge wires from terminal point 7.
(c)
Using an ohmmeter, check resistance between terminal point 4 and 12 gauge wire
isolated from terminal point 7. Resistance
should be 8.0 ohms. Resistance between
terminal point 4 and 6 should also be 8.0
ohms. Resistance between terminal point 4
and 14 gauge wire isolated from terminal
Replacement.
CAUTION
Shut off engine/generator set and allow
sufficient time for engine coolant to cool
before handling hoses and fittings. Use
suitable containers to prevent loss of
coolant. Switch off EXTERNAL POWER
BREAKER.
Heater H101, H102 and H103 (18 and 53, figure
4-30).
(a)
If the above tests are not met, one or more
of the heater elements are defective and
must be replaced.
4-83
(1)
Close both shutoff cocks (4), drain coolant
from preheat system by disconnecting
heater hose going to highest point on engine
and carefully lowering into suitable
container.
(2)
To remove coolant heater assembly,
remove the wires going to heater element
(18) and (53). Remove heater coolant
hoses. Remove four bolts, nuts and washers
(34).
(3)
To remove oil heater, oil must first be
drained from oil sump. Remove bell cap
(38) then disconnect wires from end of
heater element. Refill engine crankcase with
oil once heating element has been replaced.
(4)
Open both shutoff cocks when coolant
heater repair or replacement have been
accomplished.
TM 5-6115-593-12
TO 35C2-3-463-1
1. Screw
2. Nut
3. Clamp
4. Screw
5. Nut
6. Clamp
7. Clamp
8. Screw
9. Nut
LEGEND
10. Clamp bracket
11. Fitting
12. Hose
Figure 4-29. Fuel Lines (Sheet 1 of 2)
4-84
13. Elbow
14. Fitting
15. Hose
16. Elbow
TM 5-6115-593-12
TO 35C2-3-463-1
Figure 4-29. Fuel Lines (Sheet 2 of 2)
4-85
TM 5-6115-593-12
TO 35C2-3-463-1
1.
2.
3.
4.
Hose
Hose
Adapter
Shutoff cock
5.
6.
7.
b.
Elbow
Nipple
Tee
Nipple
9. Screw
10. Lockwasher
11. Washer
12. Heater assembly kit
Figure 4-30. Preheat Installation (Sheet 1 of 2)
4-86
TM 5-6115-593-12
TO 35C2-3-463-1
Figure 4-30. Preheat Installation (Heater) (Sheet 2 of 2)
4-87
TM 5-6115-593-12
TO 35C2-3-463-1
LEGEND FOR FIGURE 4-30 (SHEET 2)
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
Heater assy
Cord grip
Reducer
Cover
O-ring
Heater element
Swivel adapter
Cap
Washer
Grommet
Cap
Set screw
Sensing unit
Swivel adapter
Burr
Nipple
Clamp
Hose
Screw
EC flange and valve assy
Gasket
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
Bolt assy
EB tank
Cord grip
Seal ring
Cord grip
Seal ring
Terminal block
Ground lug
Plate
Bolt assy
Junction box
Mounting plate
Lub oil heater assy
Cap
Washer
Grommet
Cap
Burr
Reducer
Heater element
Section XX. MAINTENANCE OF FUEL TRANSFER PUMP
4-52. FUEL TRANSFER PUMP. The fuel transfer
pump (figure 4-31) has a DC operated motor and is
used to transfer fuel from an auxiliary source to the
generator set fuel tank. Pumping is automatically
controlled by a float level switch in the generator set fuel
tank when the FUEL PUMP switch on engine control
panel (see figure 2-1) is in the AUTO position. The
pump (16, figure 4-31) is mounted on the support
bracket (51) on the generator set base assembly.
a.
Inspection.
(1)
Inspect pump for leaks, loose connections,
dents, and cracks.
(2)
Remove fuel line from pump inlet
connection and inspect filter assembly for
accumulated dirt, cracks, breaks which
would cause restriction to fuel flow.
(3)
b.
4-88
Test.
Inspect the motor for overheating or other
visible signs of damage.
Transfer pump testing consists of an
operational test as follows:
(1)
Place 24V DC CONTROL CIRCUIT
BREAKER on generator panel to OFF, and
FUEL PUMP switch on engine panel to OFF
position.
(2)
Disconnect hose assembly connected to
pump connector (10, figure 4-31).
(3)
Attach a length of hose of this connector
and place in a container of adequate size.
(4)
Connect an external fuel supply to the fuel
transfer pump connection on the outside of
the base assembly.
TM 5-6115-593-12
TO 35C2-3-463-1
(5)
(6)
c.
4-53.
strainer assembly (39). (6) Drain the
fuel into a suitable container.
If fuel tank is 1/2 full or more, jump
out contactor K20 (33, figure 4-17) by
momentarily
connecting
small
terminal A to large terminal P140C
with a jumper cable (see figure 4-32).
With 24V DC CONTROL CIRCUIT
BREAKER set ON, and the FUEL
PUMP switch in AUTO, check the flow
of fuel. It should pump approximately
1 gallon per minute (3.8 1 per
minute). Set FUEL PUMP switch to
OFF, flow should stop. Refer to next
higher maintenance if flow rate is not
met or pump fails to stop.
b.
(7)
Remove hose connections
elbows (8), remove elbows.
(8)
Remove four screws (37) and
lockwashers (38) securing strainer
assembly to support bracket (51).
Remove strainer assembly (32).
Replacement.
(1)
Install filter and strainer assembly (22)
on support bracket (51) with four
screws (20) and lockwashers (21).
(2)
Attach two elbows (8) and (11) to filter
and strainer assembly.
Removal.
(3)
Attach hose connections to elbows.
(1)
Open drain cocks (23 and 29) on the
filter and strainer assembly (22).
(4)
Install strainer assembly (39) to
support bracket (51) with four screws
(37) and lockwashers (38).
(2)
Drain the
container.
(5)
Attach two elbows (8) to the strainer
assembly.
(6)
Connect hose to elbows (8).
(7)
Close drain cocks (23, 29, and 40).
Service. None required.
FILTER AND STRAINER. (See figure 4-31).
a.
from
(3)
(4)
(5)
fuel
into
a
suitable
Remove hose connections from
elbows (8) and (11) and remove
elbows.
Remove four screws (20) and
lockwashers (21) securing filter and
strainer assembly (22) to support
bracket (51).
Remove filter and
strainer assembly (22).
NOTE
For filter and strainer servicing, refer
to paragraph 3-15.
Open drain cock (40) on
4-89
TM 5-6115-593-12
TO 35C2-3-463-1
Section XXI. MAINTENANCE OF FUEL TANK ASSEMBLY
4-54. GENERAL. The fuel tank assembly (figure 433) is located at the rear end of the base assembly,
under the control cubicle. It is equipped with two fuel
level switches and one liquid level transmitter.
NOTE
Switch part numbers are located on unit.
(7)
a.
Inspection of Fittings. Inspect elbow fittings
(1, 2, and 3) for leaks or obvious damage.
b.
b.
Replacement of Fittings. Remove fittings
(1, 2, and 3) and install new fittings using sealing
compound (MIL-S-7916C).
4-55.
FUEL LEVEL SWITCH.
If switches are defective, replace
them.
Replacement.
(1)
Remove connector from switch and
remove switch.
(2)
Install switch in the tank using sealant
compound and attach connector.
a. Test. (See figures 4-33 and 4-34.)
(1)
Inspect the wires to the switch for
secure connection.
(2)
Inspect for loose terminals or other
signs of damage.
(3)
NOTE
Both fuel level switches are similar. Be
sure to install in proper location on fuel
tank.
4-56. LIQUID QUANTITY TRANSMITTER. Remove
liquid quantity transmitter in accordance with paragraph
4-56b prior to testing.
Remove connector from switch (4,
figure 4-33) and remove switch from
fuel tank.
(4)
Connect ohmmeter (set on Rx1 scale)
to pins A and B (figure 4-34). Move
upper float to upper stop at top of the
switch. Ohmmeter shall show open
circuit (no continuity). Move upper
float down to lower stop. Ohmmeter
shall show closed circuit (continuity).
(5)
Connect ohmmeter to pins C and D.
Move lower float to upper stop.
Ohmmeter shall show no continuity.
Move lower float down to lower stop.
Ohmmeter shall show continuity.
(6)
Repeat test procedure (steps 3
through 5) with second fuel level
switch.
4-90
a.
Test. Connect ohmmeter between case of
transmitter and the transmitter connector pin
as shown in figure 4-35. With sensing arm
of transmitter in lowered position (A),
ohmmeter shall read between 0.00 and 0.90
ohms and with sensing arm of transmitter in
raised position (B), ohmmeter shall read
between 29.8 and 31.3 ohms. Disconnect
ohmmeter. Reinstall transmitter.
b.
Replacement. (See figure 4-33.) Tag and
disconnect wiring and remove transmitter by
removing five screws (6) and transmitter (8),
and gasket (7). Install transmitter on tank
using sealing compound (MIL-S-7916C).
Reinstall gasket (7), transmitter (8), and five
screws (6). Connect wires by securely
pushing pin on wire into connector
receptacle.
TM 5-6115-593-12
TO 35C2-3-463-1
Figure 4-31. Fuel Transfer Pump Installation, Exploded View.
4-91
TM 5-6115-593-12
TO 35C2-3-463-1
LEGEND FOR FIGURE 4-31.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
Screw
Nut
Bevel washer
Lockwasher
Washer
Bracket
Transfer pump-filter assy
Elbow
Hose
Connector
Hose
Hose
Screw
Washer
Nut
Pump
Elbow
Screw
Valve
Screw
Lockwasher
Filter-strainer assy
Drain cock
Screw
Washer
Can
Filter element
Gasket
Drain cock
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46
47.
48.
49.
50
51.
52.
53.
54.
55.
56.
57.
58.
Nut
Washer
Can
Strainer
Rod assy
Nut
Filter-strainer heater
Screw
Washer
Washer
Drain cock
Nut
Washer
Can
Retainer
Strainer
Rod assy
Nut
Gasket
Strainer heater
Screw
Nut
Clamp
Bracket
Screw
Bevel washer
Lockwasher
Nut
Channel
Figure 4-32. Fuel Transfer Pump Contactor K20
4-92
TM 5-6115-593-12
TO 35C2-3-463-1
LEGEND
1.
2.
3.
4.
5.
Elbow
Elbow
Elbow
Switch
Switch
6.
7.
8.
9.
Screw
Gasket
Transmitter
Fuel tank
Figure 4-33. Fuel Tank Assembly, Exploded View.
4-93
TM 5-6115-593-12
TO 35C2-3-463-1
NOTE: FLOAT TRAVEL FROM SWITCH OPENING
TO SWITCH CLOSING TO BE 0.12 IN. (.31 CM)
Figure 4-34. Fuel level Switch Test Data
Figure 4-35. Liquid Quantity Transmitter
4-94
TM 5-6115-593-12
TO 35C2-3-463-1
Section XXII. MAINTENANCE OF INTERCONNECTING
ELECTRICAL WIRING HARNESS
4-57. GENERAL. This section contains information
on interconnecting wiring harnesses of the engine
generator and chassis. The wiring harnesses provide
electrical interconnection between major assemblies of
the generator set.
sufficient insulation from each side of the
break to allow a good connection of the
bared ends by twisting them together.
Solder the connection and wrap with
electrical tape.
4-58. TEST AND REPLACEMENT.
follows:
(2)
Proceed as
WARNING
WARNING
Set MAINTENANCE LOCKOUT switch to
LOCKOUT. Disconnect negative cable
from batteries. Remove external power
by opening CB101 (120V RECEPTACLE
BREAKER). Load terminals of generator
set circuit breaker (CB2) may still be
energized with bus voltage.
a.
Test.
Perform continuity check, using
ohmmeter between connecting points in the
wiring harness. Check for short circuits
between connector pins of the same
receptacle or terminal board.
b.
Repair.
(1)
If a wire is broken from a terminal lug,
replace the lug. If a wire is broken
from a connector, resolder and
reassemble.
Under no condition
connection exposed.
(3)
leave
the
bare
If a break in the wire is inaccessible
within the wiring harness, disconnect
it at both ends and tape both ends.
Lace a new lead of the same gauge
and insulation outside the harness
and connect it to the proper terminals
or pins. Properly tag both ends of all
replacement wires.
If a broken wire is accessible remove
Section XXIII. MAINTENANCE OF GENERATOR
AND RECONNECTION ASSEMBLY
4-59. GENERAL. The generator (figure 4-36) is a
synchronous, brushless device with an integral exciter.
It is directly driven from the engine shaft through a disc
coupling to provide line voltages at any load between no
load and rated load. The reconnection assembly allows
reconnection of generator windings to give specified
output voltage of 120/208 volts or 240/416 volts
operation.
during normal operation, by checking for peeling paint,
excessive noise, smoke, and abnormal odors. Refer to
next higher level of maintenance if overheating exists.
4-60. RECONNECTION BOARD AND BUSS. (See
figure 4-36.) Inspect for cracks, breaks, corrosion, and
loose mounting. If replacement is required, refer to next
higher level of maintenance.
4-63. DRIVE PLATE ASSEMBLY. Inspect the drive
plate assembly for distortion, excessive wear, and loose
mounting. If replacement is required, refer to higher
level maintenance.
4-61.
4-62. BEARING. Inspect the generator bearing for
signs of wear by checking for excessive unusual noise,
smoke, and abnormal odors. If replacement is required,
refer to higher level maintenance.
GENERATOR. Inspect for excessive heat
4-95
TM 5-6115-593-12
TO 35C2-3-463-1
Figure 4-36. Generator and Reconnection Board
Section XXIV. MAINTENANCE OF ELECTRIC HYDRAULIC ACTUATOR
4-64. GENERAL.
The electric hydraulic actuator
(figure 4-37) is part of a governing system to control
generator set speed, independently, in parallel, or with
commercial power. It is mechanically coupled to the
engine and electrically controlled by a load sharing
circuit assembly.
a.
connector for cracks or damage and wiring
connections for breaks.
b.
Inspection. Check all parts for wear, cracks,
nicks, and corrosion. Check the electrical
4-96
Service. The electric hydraulic actuator has
a reservoir (sump) containing engine oil.
Refer to Lubrication Order, LO5-6115-59312 and table 3-1 for proper oil. The sump is
equipped with a dipstick. Check level and
add oil, if necessary. Drain by removing
drain plug.
TM 5-6115-593-12
TO 35C2-3-463-1
Figure 4-37. Electric Hydraulic Actuator
4-97
TM 5-6115-593-12
TO 35C2-3-463-1
Section XXV. MAINTENANCE OF ETHER KIT
4-65. ETHER KIT. The ether kit (figure 4-38) contains
a solenoid- actuated ether tank to feed ether into the
engine intake manifold for cold condition starting. It is
mounted on the right hand center support frame.
a.
(3)
c.
Test. Refer to figure 4-39
Installation.
(1)
Attach ether line tubes on engine
assembly with clamps (3).
(2)
Install solenoid assembly (14) on
frame with two nuts (11) and washers
(17).
(3)
Install tee (5) on solenoid assembly
(14) and connect ether line tubes (1
and 2).
(4)
Reconnect electrical connector.
(5)
Install jet assemblies (4) in the engine
intake manifold. Connect ether line
tubes to jet assemblies.
Removal. Refer to figure 4-39.
(6)
Connect ether line tubes to tee (5).
(1)
Remove tank (6) by loosening clamp
(10).
(7)
Install ether tank (6) onto clamp
bracket (9) with clamp (10).
(2)
Disconnect tee (5) and electrical
connector, and remove solenoid
assembly (14) by removing two nuts
(11) and lockwashers (17).
WARNING
Ether is highly flammable fuel. Do not
expose to open flame, lit cigarettes, or
hot surfaces.
(1)
Remove tube (1) from tee (5).
(2)
Toggle START AID (13, figure 2-1)
switch to ON position.
(3)
Observe tee (5) for evidence of ether
being ejected.
(4)
b.
Remove ether line tubes on engine
assembly by removing six clamps (3).
Replace tube (1).
d.
Figure 4-38. Ether Kit
4-98
Repair. Repair the ether kit by replacement
of worn or defective components.
TM 5-6115-593-12
TO 35C2-3-463-1
Section XXVI. MAINTENANCE OF ENGINE ASSEMBLY
4-66. GENERAL. The engine provides mechanical
power to drive generator. The diesel engine is a 12cylinder, V-type, turbocharged, aftercooled type, rated at
750 hp at 1800 rpm. The engine air intake system
consists of a precleaner with a replaceable filter. The
engine is equipped with monitoring and control devices,
lube oil cooler, and an independent governing system.
See figure 4-40.
4-67.
(5)
b.
Replacement. (See figure 4-41. )
(1)
To replace water pump belts, remove
the screws and lockwashers which
secure the adjusting sheaves to the
fixed sheave.
(2)
Loosen the adjusting sheaves and
remove belts.
WATER PUMP BELT. (See figure 4-41)
NOTE
All generator sets with engine serial
numbers 10605201 and higher are equipped
with a new style water pump.
Sets
equipped with the new pump require no
belt adjustments. The following procedure
applies to serial number 10605201.
a.
NOTE
Always replace belts in complete sets to
prevent early failure and provide efficient
operation. Belt riding depth should not
vary over 1/16 inch (1.59 mm) on new belt
sets.
Adjustment.
(1) Remove screws and
lockwashers on front adjusting sheave.
(2)
Turn engine over manually to roll
belts outward on pulley as pulley
sheaves are turned in to obtain
desired belt tension. The engine can
be turned manually as follows:
(a)
Remove cotter pin from manual
engine crank bolt.
(b)
Push bolt toward generator to
engage gear.
(c)
Use a wrench to turn bolt.
(3)
Turn front and rear adjusting sheaves
while securing hub in stationary
position to obtain desired belt tension.
(4)
Lock front and rear adjusting sheaves
in position with lockwashers and
screws.
Check belt tension by applying
pressure of the index finger at the
center of the longest span of the belt.
Deflection should be approximately 1
inch (25 mm).
(3)
Belts should not bottom on pulley
grooves and should not protrude over
3/32 inch (2. 4 mm) above top of
edge of groove.
(4)
Install new water pump belts to
pulleys and secure in position with the
adjusting sheaves, lockwashers, and
screws.
(5)
Adjust the water pump belt tension as
described in paragraph a, above.
4-68. SERVICING DCA WATER FILTERS.
figure 4-40. )
(See
NOTE
New engines are shipped with a DCA precharge element. At first oil change (see
Lubrication Order) replace pre-charge
element with normal DCA Service Element.
Replace filter element at each oil change. If
coolant is drained and the coolant is
replaced, install a DCA pre-charge element
and repeat cycle. To test coolant corrosion
inhibitor use Fleetguard DCA, Part Number
3300846-S, or Cummins Coolant, Part
Number 3375 208, Test Kit.
4-99
TM 5-6115-593-12
TO 35C2-3-463-1
LEGEND
1.
2.
3.
4.
5.
6.
7.
8.
9.
Tube
Tube
Clamp
Jet assy
Tee
Tank
Screw
Nut
Clamp bracket
10.
11.
12.
13.
Clamp
Screw
Nut
Solenoid and
connector assy
14. Solenoid assy
15. Connector
16. Tiedown
Figure 4-39. Ether Installation
4-100
TM 5-6115-593-12
TO 35C2-3-463-1
Figure 4-40. Engine Components (Sheet 1 of 2)
4-101
TM 5-6115-593-12
TO 35C2-3-463-1
Figure 4-40. Engine Components (Sheet 2 of 2)
4-102
TM 5-6115-593-12
TO 35C2-3-463-1
a.
Drain collant into clean container via coolant
drain (see figure 4-2). Save coolant for
reuse.
b.
Unscrew water filter from filter mounting
head. Discard filter.
c.
Clean filter mounting head with solvent (see
table 3-1). Dry with compressed air.
connector (1, figure 4-42).
(2)
b.
Unscrew switch from adapter (3), and
remove switch (2). (3) Install switch
(2) to adapter (3).
(4) Connect
electrical cable to switch connector
(1).
Test (Static).
d.
Inspect filter mounting head for cracks and
mutilated threads.
(1)
Remove
electrical
cable
connector (1, figure 4-42).
e.
Install new filter by screwing filter to filter
mounting head.
(2)
f.
Replace coolant, then check coolant level; if
low add proper coolant (see table 3-1).
Using ohmmeter set to Rx1 scale,
check that continuity exists between
terminals A-B and H-G on mechanical
type speed switch only.
(3)
With ohmmeter set to Rx1000 scale,
check for infinite resistance at
terminals A-C, D-E, and F-J, on
mechanical type speed switch only.
(4)
Reconnect electrical cable to switch
connector (1).
4-69. SPEED SWITCH. (See figures 4-40 and 4-42.)
The speed switch is driven by the engine camshaft. It
provides overspeed protection and starter lockout
protection. Testing of the speed switch requires a
variable speed device and is performed by a higher
level of maintenance. Replace the speed switch as
follows:
from
(5) For additional tests refer to next higher
level of maintenance.
a.
Removal and Installation
(1)
Remove electrical cable to
Figure 4-41. Water Pump Belt Adjustment
4-103
TM 5-6115-593-12
TO 35C2-3-463-1
h.
Add oil as necessary.
4-71. STARTER ASSEMBLY. The starter assembly
(figure 4-44) is a 24V DC clutch-type unit with a starter
solenoid assembly.
a.
Test.
Testing the starter and starter
solenoid is an operational test as follows:
(1)
Check that
charged.
(2)
Check the battery connector and the
terminals
contact
surfaces
for
corrosion.
(3)
Tighten battery connectors securely.
(4)
Check that all leads to the starter and
the starter solenoid are tightened
securely.
(5)
Operate the starter while observing
starter motor operation. Refer to the
starting instructions (figure 2-6) for
starting the generator set.
(6)
If the starter solenoid emits an audible
noise each time the MASTER
SWITCH START-STOP is cycled into
the START position, and the engine
does not turn over, the starter
assembly must be replaced.
LEGEND
1. Connector
2. Sped switch
3. Adapter
Figure 4-42. Speed Switch
b.
4-70. OIL LEVEL SIGHT GAUGE AND FILLER. (See
figure 4-43. ) Replace oil level sight gauge as follows:
a.
Remove clamp (8), then disconnect hose (9) from
oil filler tube (7). Plug hole to prevent leakage.
b.
Drain oil from hose into a suitable container.
c.
d.
Remove oil level sight gauge (1) by unscrewing
fitting (10).
Remove hose (9) from gauge (1).
e.
Install hose (9) onto gauge (1).
f.
Screw gauge (1) onto fitting (10). g. Remove
plug and connect hose (9) to filler tube (7).
4-72.
battery
is
fully
Inspection. Visually inspect starter for loose
wires, corrosion, or cracked housing. Brush
inspection should be referred.
to next
higher level of maintenance.
OIL PRESSURE TRANSMITTER. (See figure
4-40).
a.
4-104
the
Test. (See figure 4-45).
(1)
Remove nut and washers and
electrical lead from the threaded
terminal.
(2)
Using
an
ohmmeter,
measure
resistance between transmitter screw
terminal and ground. If measured
resistance on the Rx1 scale is not
between 227 and 257
TM 5-6115-593-12
TO 35C2-3-463-1
LEGEND
1.
2.
3.
4.
5.
Oil level sight gauge
High level marker
High level adjust
Low level marker
Low level adjust
6.
7.
8.
9.
10.
Figure 4-43. Oil Level Sight Gauge and Filler
4-105
Oil filler cap
Oil filler tube
Clamp
Hose
Fitting
TM 5-6115-593-12
TO 35C2-3-463-1
ohms, replace the transmitter.
Crank
engine to determine that resistance
decreases to approximately 70 ohms. If
resistance does not decrease, replace
transmitter.
d. Test OP3. (See figure 4-46 and FO-3.)
(1) With generator set at shutdown, connect
ohmmeter from terminal 18 of TB20 to any
convenient ground connection; ohmmeter
reading should be infinite ohms.
b. Replacement. (See figure 4-45.)
(2) Crank engine and observe ohmmeter;
ohmmeter reading should drop to less than
1 ohm almost immediately.
(1) Remove nut, washers, and lead from
transmitter threaded terminal.
(2) Unscrew transmitter from engine block.
e. Replacement. (See figure 4-46.)
(3) Install transmitter onto engine block.
(1) Disconnect leads from switch (1, 2, or 3).
(2) Unscrew switch (1 or 2) from engine block.
(3) For reassembly, screw switch into engine
block and tighten to 20 foot- pounds (27
joules). Reconnect leads to switch.
(4) Reconnect electrical lead using nut and
washers.
4-73. PRESSURE SWITCH. (See figure 4-40.) There
are three pressure switches labeled no. 1, 2, and 3 on
figure 4-46.
4-74. OIL FILTERS. (See figure 4-47.)
a. Inspection.
Inspect pressure switches (see
figure 4-46) for loose mounting, loose
connection, dents, and leakage.
a. Spin-on Type Filters. Refer to paragraph 4-8 c
for replacement of spin-on type oil filters.
b. Bypass Oil Filters. (See figure 4-47.) Inspect
filter case for dents, cracks, and oil leaks. If
damaged, refer to higher maintenance.
b. Test OP1. (See figure 4-46 and FO-3.)
(1) With generator set at shutdown and
MAINTENANCE LOCKOUT switch set to
OPERATION, connect miltimeter (set to
measure DC volts) from terminal 26 of TB6
to terminal 12 of TB9; multimeter should
read 24V DC.
4-75. SECONDARY FUEL FILTER ELEMENT.
(See figure 4-40.)
a. Service and replacement of the secondary fuel
filter element is as follows (see figure 4-48).
(2) Crank engine and observe miltimeter;
multimeter reading should drop to zero
almost immediately.
c.
(1) Unscrew and remove the filter case and
discard filter element and gasket.
Test OP2. (See figure 4-46 and FO-3.)
(2) Inspect the filter case for dents and cracks
that affect proper sealing when reinstalled.
If damaged, replace unit.
(1) With generator set at shutdown, connect an
ohmmeter (set to Rx1 scale) from terminal 7
to terminal 12 of TB22; multimeter reading
should be less than 1 ohm.
(3) Clean filter case. Handle or store in manner
to prevent out-of-round.
(4) Insert new element in filter case seating it
securely.
(2) As engine is being cranked, ohmmeter
reading should jump to infinite ohms.
4-106
TM 5-6115-593-12
TO 35C2-3-463-1
Figure 4-44. Starter Assembly.
4-107
TM 5-6115-593-12
TO 35C2-3-463-1
Figure 4-45. Oil Pressure Transmitter
Figure 4-46. Pressure Switches
4-108
TM 5-6115-593-12
TO 35C2-3-463-1
(4) Remove water inlet tube (2) from housing
(4). Separate and discard gasket (3).
(5) Fill filter assembly with fuel (see table 3-1).
(6) Install new top gasket and position filter
case to filter head. Tighten by hand until
gasket touches filter head, then turn an
additional one-half to three-fourths of a turn.
(5) Remove water outlet connection
Separate and discard gasket (3).
(6) Remove oil transfer tubes (6).
and discard gaskets (7).
(7) Check the fuel filter for leakage and be
certain that the filter case and gasket are
properly installed.
(5).
Separate
(7) Remove capscrews (8) and washers (9) to
release cooler housing (4) from bracket
(10). Separate and discard gaskets (11).
4-76. LUBE OIL COOLER. (See figure 4-40.)
(8) Install new gaskets (11).
a. Inspection. (See figure 4-49.)
(9) Position cooler housing (4) onto bracket
(10).
Secure with capscrews (8) and
washers (9).
CAUTION
Engines which have encountered major
types of failures, where excessive
amounts of metal particles have
circulated through the system, cannot be
properly cleaned; therefore, replacement
of oil cooler is mandatory.
(10) Install new gaskets (7). Install oil transfer
tubes (6).
(11) Install new gaskets (3). Install water outlet
connection (5) and water inlet tube (2) into
housing (4).
Inspect the cooler housing (4), and all
connections for cracks, leaks, dents, and
breaks.
(12) Install oil filter assemblies (1).
(13) Close engine oil drain valve.
b. Replacement.
(14) Fill lubricating system with oil using oil filler
tube (figure 4-40).
(1) Drain coolant into a clean container via
coolant drain (see figure 4-2). Save coolant
for reuse.
(15) Run engine, check for leaks, recheck engine
oil level; add oil (see table 3-1) as
necessary to bring oil level to FULL mark on
oil level gauge (dipstick).
(2) Drain lubricating oil by removing oil drain
plug and opening engine oil drain valve.
Collect oil in suitable container for reuse.
(16) Replace coolant, then check coolant level; if
low add proper coolant (see table 3-1.
(3) Unscrew oil filter assemblies (1).
4-109
TM 5-6115-593-12
TO 35C2-3-463-1
Figure 4-47. Oil Filters
4-110
TM 5-6115-593-12
TO 35C2-3-463-1
Figure 4-48. Secondary Fuel Filter
4-111
TM 5-6115-593-12
TO 35C2-3-463-1
LEGEND
1.
2.
3.
4.
5.
6.
Oil filter assy
Inlet tube
Gasket
Cooler housing
Outlet connection
Tubes
7.
8.
9.
10.
11.
Figure 4-49. Lube Oil Cooler
4-112
Gasket
Cap screw
Washer
Bracket
Gasket
TM 5-6115-593-12
TO 35C2-3-463-1
(15 to 16 joules) increments of 4 footpounds (5 joules).
4-77. INJECTOR. (See figure 4-50.)
a. Inspection. Inspect injector for looseness and
signs of leakage or smoking.
(9) Refer to paragraph 4-87 and adjust rocker
arm associated with fuel injector being
replaced.
b. Replacement.
CAUTION
(10) Install rocker arm housing (see figure 4-59).
Cleanliness is extremely important when
working with fuel injectors.
Infection
nozzle service troubles are, in most
instances, caused by dirt. Use clean paper
on the work bench and place components
in a container of clean diesel fuel as they
are removed.
(11) Install gear case cover (7, figure 4-59) using
bolts (5) and washers (4).
4-78. TURBOCHARGER. (See figure 4-40.)
a. Inspection. (See figure 4-51.)
(1) Operate engine at approximate rated output
and listen for unusual turbocharger noise
and check for excessive black smoke. Do
not mistake whine heard during rundown for
one that indicates impeller shaft bearing
failure during operation. Other unusual
noises can result from improper clearance
between turbine impeller and turbine
housing. If such noises are heard, replace
turbocharger. For repair of turbo charger,
refer to next higher level of maintenance.
(1) Remove rocker housing cover (7, figure 459) by removing bolts (5) and washers (4).
(2) Remove rocker arm housing (8) by lifting
straight up. Mark its position for best fit
during reassembly.
(3) Remove screws (1, figure 4-50), clamp (2),
and link (3).
CAUTION
(2) Inspect for an accumulation of dirt on the
compressor impeller vanes and in the
compressor housing.
Use care when removing injectors to
prevent damage to the tip.
(3) Clean the turbocharger and surrounding
area with cleaning solvent, Federal
Specification P-D-680, Type II.
(4) Remove injector from cylinder head using
an injector puller or by using two small pry
bars, or by using a slide hammer with an
adapter.
(4) Loosen the clamps which secure air hose to
the turbocharger and remove the hose from
the turbocharger. Remove air hose from air
cleaner outlet to turbocharger inlet.
(5) Tag and number injectors by cylinder from
which they were moved.
(6) Refer to next higher level of maintenance
for injector testing, repair, and calibration.
(5) Inspect the turbocharger compressor wheel
and compressor housing for dirt. If the
coating of dirt is light and even, cleaning the
compressor wheel is not necessary. An
uneven buildup of dirt will disturb the
balance of rotating parts and lead to failure
of the turbocharger. If the coating
(7) Position injector in cylinder head.
(8) Install capscrew (1), clamp (2), and link (3).
Tighten capscrews to 11 to 12 foot-pounds
4-113
TM 5-6115-593-12
TO 35C2-3-463-1
Figure 4-50. Fuel Injector
4-114
TM 5-6115-593-12
TO 35C2-3-463-1
LEGEND
1. Clamp
2. Hose
3. Screw
4. Lockwasher
5. Washer
6. Support
7. Elbow
8. Adapter
9. Hose
10. Elbow
11. Adapter
12. Clamp
13. Hose
14. Elbow
15. Hose
16. Clamp
17. Hose
18. Clamp
19. Nuts
20. Mounting stud
21. Turbocharger
22. Exhaust elbow
23. Gasket
Figure 4-51. Turbocharger
4-115
TM 5-6115-593-12
TO 35C2-3-463-1
(11)
of dirt is uneven, excessive, or
approaching the appearance of a layer
which might flake off, cleaning is
necessary.
If this cannot be cleaned
satisfactorily, replace turbocharger.
Connect oil inlet line (15) using elbow
(14).
4-79. WATER PUMP. (See figure 4-40.)
NOTE
(6) Replace hoses and clamps.
All generator sets with engine serial
number 10605201 and higher are equipped
with a new style water pump (with idler
assembly). The new pump is removed in
the same manner as the old pump.
b. Replacement.
(1) Disconnect and remove oil inlet line (15)
and elbow (14). Plug line to minimize
leakage.
a. Replacement of Water Pump.
52.)
(2) Disconnect and remove oil return line (9)
and adapter (8). Plug line to minimize
leakage.
(3) Loosen clamps (1, 16, and 18).
hoses (2 and 17).
Remove
(4) Remove
nuts
(19)
which
turbocharger to exhaust manifold.
secure
(See figure 4-
(1) Drain engine coolant.
(2) Remove drive belts in accordance with
paragraph 4-67 b.
(3) Remove coolant hoses.
(4) To remove water pump remove eight
mounting bolts (on pumps not equipped with
idler assemblies) or five mounting bolts (on
pumps with idler assemblies).
(5) Remove turbocharger by separating unit
from exhaust elbow (22) and lifting clear of
engine.
CAUTION
While turbocharger is off the engine,
keep all intake and exhaust manifold
openings covered. This will prevent
foreign objects from accidentally getting
into the manifolds and damaging the
turbocharger or engine when the engine
is again put into operation.
(5) Install water pump with mounting hardware.
(6) Attach hoses.
(7) Install and adjust belts in accordance with
paragraph 4-67 b.
(8) Refill engine coolant; refer to tables 3-1 and
4-1.
(6) Position turbocharger on exhaust manifold.
Slide onto exhaust elbow (22).
(7) Secure turbocharger with nuts (19).
b. Inspection of Idler Assembly. Refer to figure 452 and visually inspect locator spring (14) and
spring (15) for cracks or damage.
(8) Install hoses (2 and 17).
c.
(9) Tighten all clamps (1, 16, and 18).
(10) Connect oil return line (9) using adapter (8).
4-116
Replacement of Idler Assembly. After removing
water pump in accordance with paragraph a,
above, the idler assembly may be removed by
removing four screws (1) and washers (2).
Install new idler pulley assembly with four
screws (1) and washers (2).
TM 5-6115-593-12
TO 35C2-3-463-1
Figure 4-52. Water Pump and Idler Pulley Assembly
4-117
TM 5-6115-593-12
TO 35C2-3-463-1
Figure 4-53. Thermostat Removal
4-118
TM 5-6115-593-12
TO 35C2-3-463-1
(7) Secure gasket (11) and outlet (7)
washers (6) and bolts (5). Attach hose
with one clamp (9). Attach tee (8)
remaining clamp (9) and secure
washers (6) and bolts (5).
4-80.
THERMOSTAT.
(See figure 4-53.) The
thermostats are inside the thermostat housing mounted
at the top front of the engine.
a. Removal. Drain coolant and remove assembly
(figure 4-53) as follows:
with
(10)
with
with
(8) Refill cooling system; refer to tables 3-1 and
4-1.
(1) Remove bolts (1), washers (2), connection
(3), gasket (4), bolts (5), and washers (6).
4-81. COOLANT TEMPERATURE TRANSMITTER .
(See figure 4-40.) To remove the coolant temperature
transmitter, drain coolant into a suitable container by
removing coolant drain plug and opening draincock.
Refer to figure 4-54 and remove the nut, electrical lead,
and washers; then unscrew the temperature transmitter
from the water manifold.
(2) Loosen clamps (9), then remove outlet (7),
tee (8), hose (10), and gasket (11).
(3) Remove thermostat (13) and gasket (14)
from housing (12).
b. Test.
a. Inspection. Inspect transmitter for corrosion and
leakage, and ensure that the connection is
secure. The transmitter is not repairable and
replacement is necessary when it fails to
operate. If the engine is not overheating and
unit shuts down as though it were, or if the
engine continues to operate when running hot,
the transmitter should be removed and tested as
a possible cause of trouble.
(1) Suspend thermostat in a container of clean
water. Thermostat must be must be
completely immersed but not touching
bottom of container.
(2) Heat water gradually and stir so heat is
evenly distributed.
(3) Check temperature of water with reliable
thermometer. Do not overheat. Observe
thermostat as temperature increases. If the
thermostat is functioning properly it should
begin to open between 175 to 182°F (79 to
83°C) and be fully open at 205 F (96°C).
b. Test.
The coolant temperature transmitter
senses the temperature of the engine coolant to
operate temperature indicator on control panel.
(1) Suspend transmitter in a container of clean
water. Transmitter should be inserted so
that sensing element is completely
immersed but connector end is out of water.
(4) The thermostat is not adjustable. If it does
not operate within the above limits, it should
be replaced.
(5) Install a new gasket (14) and thermostat
(13) in housing (12). Be sure hole in
thermostat is "up".
(2) Set ohmmeter to Rx10 scale and connect
ohmmeter between single conductor and
case. Heat water gradually and stir so heat
is evening distributed.
(6) Install gasket (4), connection (3), washers
(2), and bolts (1).
(3) Check temperature of water with reliable
thermometer. Do not overheat.
4-119
TM 5-6115-593-12
TO 35C2-3-463-1
a. Inspection. Inspect switch for corrosion and
leakage, and ensure that the electrical
connector is secure.
The switch is not
repairable and replacement is necessary when it
fails to operate. If the engine is not overheating
and the units shuts down as though it were, or if
the engine continues to operate when running
hot, the switch should be removed and tested as
a possible cause of trouble.
b. Removal. (See figure 4-55.) Loosen connector,
pull wiring plug, and unscrew temperature
switch from water manifold.
c.
Test.
(1) Connect ohmmeter set to Rx1 scale across
switch contacts.
Figure 4-54. Coolant Temperature Transmitter
(2) Suspend switch in a container of antifreeze.
Switch should be inserted so that sensing
element is completely immersed but
connector end is out of antifreeze.
Observe ohmmeter as temperature
increases. If the transmitter is functioning
properly, the resistance should read 143
±14 5 ohms at 120°G (49°C).
(3) Heat antifreeze gradually and stir so heat is
evenly distributed.
(4) The transmitter is not repairable. If it does
not indicate a resistance within the above
range, it should be replaced.
c.
(4) Check temperature of antifreeze with a
reliable thermometer.
Replacement.
(5) When antifreeze has reached 214°F (90°
C), the switch should open and the
ohmmeter should read less than 1 ohm.
(1) Screw temperature transmitter into water
manifold.
(2) Connect wire with washers and nut.
(6) Allow antifreeze to cool. As the temperature
drops to below 212°F (89°C) the switch
should close and the ohmmeter should read
infinite ohms.
(3) Plug drain and close draincock.
(4) Fill radiator with coolant in accordance with
table 4-1.
(7) The switch is not repairable. If it does not
operate within the above limits it should be
replaced.
4-82. TEMPERATURE SWITCH. (See figure 4-40.)
The temperature switch senses engine coolant
temperature. When coolant exceeds 217 ± 3°F (103 ±
2°C), the normally closed contacts open and the
normally open contacts close. This action results in
automatic shutdown of engine operation at coolant
temperatures exceeding 217 ± 3°F (103 ± 2°C).
b. VIBRATION DAMPER AND CRACKSHAFT
PULLEY.
(See figure 4-40.) The vibration
damper and crankshaft pulley are mounted on
the front end of the crankshaft. Inspect as
follows:
4-120
TM 5-6115-593-12
TO 35C2-3-463-1
Figure 4-55. Coolant Temperature Switch
d. Replacement. Screw temperature switch into
water manifold. Connect electrical connector.
Refill with coolant in accordance with table 4-1.
Check for leakage, tighten if necessary.
4-83.
VIBRATION DAMPER AND CRANKSHAFT
PULLEY. (See figure 4-40.) The vibration damper and
crankshaft pulley are mounted on the front end of the
crankshaft. Inspect as follows:
b.
Inspect pulley belt grooves around total
circumference of pulley for cracks or distortion.
c.
Inspect hub area for cracks.
d. For replacement refer to next higher level of
maintenance.
4-84.
INTERCOOLER.
(See figure 4-40.) The
intercoolers are mounted on top of the engine on each
side as shown in figure 4-40.
a. Inspect pulley belt grooves for step wear along
sides and bottom of groove, indicating
excessive wear.
a. Inspection. (See figure 4-56.)
4-121
TM 54115-593-12
TO 35C2-3-463-1
tee (6) using bolt (8) and washers (9 and
10). Secure fitting (13) to intercooler (29)
using bolt (11) and washer (12). Secure
tubing (7) to hose (3) using clamp (2).
(1) Drain cooling system by opening drain plug
and shut-off cock. Use suitable container to
store coolant for reuse.
(2) Disconnect water connection tube (1) by
loosening clamps (2), then separate hose
(3) from outlet (4).
(11) Secure water connection tube (11) to outlet
(4) using clamps (2).
(12) Close draincock and drain plug.
cooling system.
(3) Disconnect water transfer tube assembly (5)
by loosening clamps (2) and separating
transfer tubing (7) from hose (3). Remove
bolt (8) and washers (9 and 10) to loosen
tee (6). Remove bolt (11) and washer (12)
to separate fitting (13) from intercooler (29).
Remove assembly in one piece, or loosen
clamps (2) to disassemble tubing into
individual sections. Remove and discard
gaskets (14 and 15).
Refill
(13) Check all connections for security. Observe
closely during first use after replacement for
signs of leakage.
4-85. EXHAUST MANIFOLD. The exhaust manifold
(figure 4-57) provides for the routing of the engine
exhaust gases. Also, the exhaust gases serve as an
input to the turbocharger.
(4) Remove air balance tube assembly (16) by
removing bolts (17) and washers (18 and
19). Remove and discard gaskets (20).
Remove assembly as one piece, or loosen
clamps (2) to disassemble tubing into
individual sections.
a. Inspection. Inspect the exhaust manifold for
rust, loose mounting, cracks, and breaks.
b. Replacement.
(1) Refer to paragraph 4-78 and remove the
turbocharger.
(5) Loosen clamp (23) securing air intake
connection (24) to air hose (25).
(2) Disconnect and plug fuel and oil lines as
needed to facilitate removal.
(6) Remove bolts (26) and washers (27 and 28)
to free intercooler (29) from engine.
(3) Remove fuel injection lines.
(7) Mount intercooler (29) onto engine block
using bolts (26) and washers (27 and 28).
(4) Rem6ve bolts (1, figure 4-57), washers (2)
and spacers (3) attaching exhaust manifold
to engine.
(8) Secure air hose (25) to air intake connection
(24) with clamp (23).
(5) Remove gaskets (4)
manifold from engine.
(9) Install air balance tube assembly (16) by
replacing gaskets (20) and mounting tubing
using bolts (17) and
washers (18 and 19).
and
lift
exhaust
(6) Reinstall exhaust manifold with bolts (1),
washers (2), and spacers (3). Use new
gaskets (4). Replace injection lines and
(10) Install water transfer tube assembly (5) by
replacing gaskets (14 and 15), then mount
4-122
TM 54115-593-12
TO 35C2-3-463-1
LEGEND
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
Water connection tube
Clamp
Hose
Outlet
Transfer tube assy
Transfer tee
Transfer tube
Bolt
Washer
Washer
Bolt
Washer
Fitting
Gasket
Gasket
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
Figure 4-56. Intercooler
4-123
Air balance tube assy
Bolts
Washer
Washer
Gasket
Air tube
Air tube
Clamp
Air intake connection
Air hose
Bolts
Washer
Washer
Intercooler
TM 5-6115-593-12
TO 35C2-3-463-1
turbocharger (refer to paragraph 4-78).
Torque bolts (1) to 25 foot-pounds (33
joules) in 8 foot-pound (11 joules)
increments.
(c) Install clamp (3) with bolts (1) and
washers (2).
(d) Attach water manifold to engine block
with bolts (6) and washers (7). Install
new O-rings (8).
4-86. WATER MANIFOLD.
a. Inspection. Inspect water manifold (figure 4-58)
for corrosion, leaks, loose bolts, dents, and
cracks.
4-87. ROCKER ARM AND SHAFT ASSEMBLY. The
rocker arms are mounted on the rocker arm shaft which
is supported by the rocker arm housing. The rocker
arms are actuated by the pushrods and, in turn, operate
the valves.
b. Replacement.
(1) Disconnect
water
connections.
inlet
and
a. Inspection. (See figure 4-59)
outlet
(1) Remove gear case cover (7) and gasket (6)
by removing bolts and washers (4).
(2) Remove bolts (1, figure 4-58) and washers
(2).
(2) Inspect adjusting screw (1) end of rocker
arm (2) and shaft (3) for evidence of
physical damage. Refer to next higher
maintenance level for replacement of any
damaged items.
(3) Remove clamps (3) and tube (4) with O-ring
(5).
(4) Remove bolts (6) and washers (7). Remove
O-rings (8) and lift out water manifold.
NOTE
Adjusting screw nut be replaced
when more than 36 inch-pounds (4
joules) driving torque is required to
turn screw.
(5) Reinstall as follows:
(a) Install new O-rings (8).
(b) Attach tube (4) with new O-ring (5).
Figure 4-57. Exhaust Manifold
4-124
TM 5-6115-593-12
TO 35C2-3-463-1
LEGEND
1.
2.
3.
4.
Bolts
Washers
Clamp
Tube
5.
6.
7.
8.
O-ring
Bolts
Washers
O-rings
Figure 4-58. Water Manifold
(3) Inspect end of rocker arm adjusting screw
and end of rocker arms. If they are worn,
the rocker arm assemblies must be
replaced.
noise, and cause rapid wear on the valve
operating mechanism.
With engine normal
operating temperature or 160° F (71°C)
minimum, valve lash for both intake and
exhaust valves is 0.014-0.027 inch (0.36-0.69
mm). Adjust injector tappet (the middle lever in
each group of three levers) by loosening
adjusting screw one turn.
Using a torque
wrench, tighten adjusting screw to 70 inchpounds (7.96 joules) and tighten locknut to 40 to
45 ft.-pounds. After any mechanical work has
been done that may have disturbed the valve
lash adjustment, set valves "cold" at 0.018 inch
(0.45 mm) clearance so engine can be run and
allowed to warm to normal operating
b. Adjustment.
(See Figure 4-59.) Correct
clearance (valve lash) between end of intake
valve stem, exhaust valve stem, and related
rocker arms, is very important in diesel engine
performance because of high compression
developed within the cylinders.
Insufficient
valve lash will cause loss of compression,
misfiring, and eventually lead to burning of
valves and valve seats. Excessive valve lash
will result in faulty engine operation, valve lifter
4-125
TM 5-6115-593-12
TO 35C2-3-463-1
LEGEND
1.
2.
3.
4.
Adjusting screw
Rocker arm
Shaft
Washer
5.
6.
7.
8.
Bolts
Gasket
Rocker housing
Rocker arm housing
Figure 4-59. Rocker Arm and Shaft Assembly
4-126
TM 5-6115-593-12
TO 35C2-3-463-1
temperature. After engine has warmed up to
normal operating temperature, check valve lash
again for proper clearance.
and push rods from opening too far,
the pistons, will strike the valves
when the engine is turned over.
CAUTION
Observe the rocker arms of the
opposite cylinder. Rotate crank- shaft
until both rockers arms move
simultaneously then continue for
approximately 1/4 revolution. At this
point, both valves are closed and
valve lash may be adjusted.
After any mechanical work has been
done that may have disturbed the
valve lash adjustment, ensure the
rocker arm adjusting screws are
turned upward (counterclockwise)
high enough to prevent rocker arms
Section XXVII. MAINTENANCE OF BASE ASSEMBLY
(2) Clean the skid base with cleaning solvent,
Federal Specification P-D-680.
4-88. GENERAL. This base assembly, figure 4-60,
consists of a rigid frame skid base, fuel tank, and related
components. The tank is recess-mounted in the skid
base. The engine and generator are mounted on the
skid base assembly.
(3) Repair cracks in skid base by welding or
brazing. Fill or sand weld marks to an even
finish.
4-89. INSPECTION.
(4) Repair threads in tapped holes by retapping.
a. Inspect the skid base and frame assembly for
rust, corrosion, breaks and loose hardware.
(5) Repaint as necessary.
b. Fuel Tank. Warning switches and transmitter
must be removed before repairing fuel tank.
Refer to paragraphs 4-55 and 4-56 for test and
replacement of these items.
b. Inspect the fuel tank for dents, cracks, or
distortion.
c.
Inspect threaded holes in the base assembly for
damaged threads.
NOTE
d. Inspect the oil and fuel drain plug and hoses
between skid base and engine for leaks.
Whenever fittings are replaced on the
fuel tank, use sealing compound (MILS07916C).
e. Inspect ground studs for stripped threads and
looseness.
f.
(1) Drain all fuel from tank. Flush inside of tank
with steam under pressure. Rinse with hot
water and detergent to remove flakes or
other foreign matter.
Inspect coolant and oil drain plugs for stripped
threads, deformation, or leakage.
4-90. REPAIR.
(2) Fuel tank must withstand an internal
pressure of 0.5 psi. Seal all tank openings,
apply pressure, and check for leaks (use a
leak test solution or soapy water). Should
tank leak, weld in accordance with
a. Base Subassembly.
(1) With stiff bristle brush, remove heavily
concentrated grease and dirt.
4-127
TM 5-6115-593-12
TO 35C2-3-463-1
MIL-W-8611 using wire per MIL-R-5031,
Class 16. Paint tank or base assembly with
MIL-T-704 Type A, semigloss, olive drab
paint, color number X24087, if required.
removing two nuts (1 and 3) and washers (2
and 4).
(2) Remove drain cock (12), hose assembly (6),
elbow (9), coupling (10), and nipple (13).
4-91. REPLACEMENT OF TERMINALS, FITTINGS
AND HOSES.
b. Installation.
(1) Install drain cock (12), nipple (13), coupling
(10), elbow (9), and hose assembly (7).
a. Removal.
(1) Remove two ground terminals (5, figure 460), one on each side of base assembly by
(2) Install two ground terminals (5) with nuts (1
and 3) and washers (2 and 4).
4-128
TM 5-6115-593-12
TO 35C2-3-463-1
Figure 4-60. Base Assembly, Exploded View
4-129
TM 5-6115-593-12
TO 35C2-3-463-1
LEGEND FOR FIGURE 4-60
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
Nut
Lockwasher
Nut
Lockwasher
Ground terminal
Hose assy
Hose
Fitting
Elbow
Pipe coupling
Nipple
Drain cock
Nipple
Nut
Washer
Strap
Screw
Lockwasher
Nut
Screw
Lockwasher
Brace
Webbing
Fuel tank assy
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
4-130
Nut
Screw
Plate
Screw
Lockwasher
Plate
Screw
Lockwasher
Plate
Screw
Lockwasher
Angle
Screw
Lockwasher
Angle
Screw
Lockwasher
Support plate
Adapter
Plug
Plug
Base
Webbing
Coupling
Nipple
Flat washer
TM 5-6115-593-12
TO 35C2-3-463-1
(11) Remove nipple (5), nuts (4), screws (2),
washers (3), and breather (1).
4-92. BREATHER LINES AND FITTINGS.
(See figure 4-61.)
a. Inspection. Visually inspect all lines and fittings
for security of attachment, deformity, and signs
of physical damage.
(12) Install breather (1) onto panel with four
screws (2), washers (3), and nuts (4). Install
nipple (5).
b. Replacement.
(13) Install one bracket (6) and three brackets (7)
as shown in figure 4-49A using existing
hardware.
(1) Loosen clamps (29) and remove hose (28),
(14) Attach two elbows (9) to tee (8) using pipe
compound. Install adapters (10) to elbow
(9) using pipe compound. Install pipe nipple
(11) on tee (8) using pipe compound.
(2) Loosen clamps (23). Remove clamps (24)
by removing screws (25), washers (26), and
nuts (27). Remove hose (22).
(3) Remove brackets (7) and restore existing
hardware.
(4) Remove bracket (18) by removing screws
(19), washers (20) and nuts (21).
(15) Install mounting bracket (12) (over
assembled tee) onto the support frame
member using two screws (13), washers
(14), and nuts (15).
(5) Loosen clamps (17) and remove hose (16).
Remove bracket (6) and restore existing
hardware.
(16) Install 60-inch (150-cm) long hose (16)
between breather (1) and pipe nipple (11)
using two clamps (17).
(6) Remove mounting bracket (12) by removing
two screws (13), washers (14), and nuts
(15).
(17) Place bracket (18) over hose (16) and
attach to bracket (18) with screw (19),
washer (20), and nut (21).
(7) Disassemble adapters (10), elbows (9), and
pipe nipple (11) from tee (8).
(18) Install 66-inch (165-cm) long hose (22)
between adapter (10) and breather on
engine (as shown) using two clamps (24)
attached to brackets (7) with screws (25),
washers (26) and nuts (27). Tighten two
clamps (23) on hose.
(8) Remove clamps (24) by removing screws
(25), washers (26), and nuts (27).
(9) Loosen clamps (23) and remove hose (28).
(19) Install 78-inch (195-cm) long hose (28)
between adapter (10) and breather on
engine (as shown) using two clamps (29).
(10) Remove brackets (7) and restore existing
hardware.
4-131
TM 5-6115-593-12
TO 35C2-3-463-1
LEGEND
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
20.
Breather
Screw
Washer
Nut
Nipple
Bracket
Bracket
Tee
Elbow
Adapter
Washer
11.
12.
13.
14.
15.
16.
17.
18.
19.
Nipple
Bracket
Screw
Washer
Nut
Hose (60 in.)
(150 cm)
Clamp
Bracket
Screw
21.
22.
23.
24.
25.
26.
27.
28.
29.
Figure 4-61. Breather Lines and Fittings
4-132
Nut
Hose (66 in.) (165 cm)
Clamp
Clamp
Screw
Washer
Nut
Hose (78 in.) (195 cm)
Clamp
TM 5-6115-593-12
TO 35C2-3-463-1
CHAPTER 5
AUXILIARY EQUIPMENT USED IN CONJUNCTION WITH THE GENERATOR SET
Section I. INTRODUCTION
5-1.
Major auxiliary equipments for use with the
generator set are the remote control module, the remote
control cable and the automatic control module. Also
included as an auxiliary item is the generator set
housing kit.
Section II. REMOTE CONTROL MODULE
Allow approximately 24 inches (62 cm) clearance on all
sides of the unit for access during operation and
maintenance. See paragraph 2-10 for information on
the connection procedures for the remote control
module, FO-8 and FO-9 for wiring information, and FO14 for a connection diagram.
5-2. GENERAL. The remote control module (figures 51, 5-2, and 5-3), when used with the remote control
cable, allows remote starting and stopping, and
monitoring control of the set from a location up to 100
feet (30) away. With minor exceptions, the remote
control module is identical to the generator control
panel; the remote control module contains a MASTER
SWITCH, a START AID switch and a READY TO LOAD
indicator lamp, and does not contain a clock, phase
sequence indicator lights, or a 24V DC circuit breaker.
The theory of operation for the remote control module is
the same as that for the generator control panel as
described in Chapter 1, Section III (with the above noted
exceptions). When remote operation is required, the
controls and indicators of the remote control module are
connected in place of equivalent circuits in the generator
set.
5-4. LUBRICATION.
requires no lubrication.
The remote control module
5-5. PREVENTIVE MAINTENANCE CHECKS AND
SERVICES (A, N, MC). To ensure that the remote
control module is always ready for operation, inspect
systematically so that defects may be discovered and
corrected before they result in serious damage or
failure. Perform the preventive maintenance checks and
services in accordance with table 5-1. Air Force users
shall refer to the applicable inspection manuals and
work card sets in T.O. 35C2-3-series for periodic
preventive maintenance requirements and table 5-1 for
detailed procedures. Marine Corps users shall refer to
the current issue of TM 11275-15/1.
5-3. INSTALLATION. The remote control module is a
self-housed unit, suitable for either indoor or outdoor
operation. The unit should be placed as level as
possible, in a firm, dry, footing.
LEGEND FOR FIGURE 5-1
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Screw
Nut
Seal
Door assy
Screw
Nut
Lockwasher
Horn
Screw
Lockwasher
Nut
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
Plate assy
Screw
Lockwasher
Nut
Angle
Screw
Lockwasher
Nut
Angle
Screw
Nut
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
5-1
Dust Cap
Dust Cap
Screw
Nut
Screw
Nut
Screw
Lockwasher
Nut
Clamp
Harness assy
34.
35.
36.
37.
38.
39.
40.
41.
42.
Rivet
Plate, wiring
diagram
Rivet
Plate, wiring
diagram
Door holder
Screw
Nut
Clamp
Enclosure
TM 5-6115-593-12
TO 35C2-3-463-1
Figure 5-1. Remote Control Module
5-2
TM 5-6115-593-12
TO 35C2-3-463-1
Table 5-1. OPERATOR/CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES, REMOTE CONTROL
MODULE.
NOTE: Within designated interval, these checks are to be performed in the order listed.
B-Before
Item
No.
1
A-After
INTERVAL
B
D
A
o
ITEMS TO BE
INSPECTED
Remote
Control
Module
D-During
PROCEDURES
CHECK FOR AND HAVE REPAIRED
OR ADJUSTED AS NECESSARY
Inspect controls, gauges, lamps and
instruments daily for damage, loose
mounting or loose connections.
5-6.
OPERATOR/CREW TROUBLESHOOTING.
Table 5-2 contains troubleshooting information for use in
correcting operating troubles which may develop in the
generator set when used with the remote control
module. Each malfunction is followed by a list of tests
or inspections which will help to determine probable
causes and corrective actions to take. Perform the tests
or inspections and corrective actions in the order listed.
Any trouble beyond the scope of crew level
maintenance should be referred to the next higher
(organizational) level of maintenance.
EQUIPMENT IS
NOT READY/
AVAILABLE IF:
connections.
(3) Inspect the panel lamps (19, figure 2-14) for
loose mounting or loose connections.
(4) Inspect transformer (29, figure 5-2) for
cracking or damage, loose mounting or
loose connections.
b. Replacement.
(1) Replace
defective
assemblies.
NOTE
Before referring to table 5-2, be sure that all
applicable checks have been performed.
bulbs
in
lamp
(2) Replace defective telephone jack as follows:
(a) Tag and remove wires connected to the
jack.
(b) Remove the hex nut and flatwasher
attaching jack to panel, and remove jack.
(c) Install jack and secure with flatwasher
and hex nut.
(d) Connect wires and remove wire tags.
5-7.OPERATOR/CREW MAINTENANCE OF THE
REMOTE CONTROL MODULE.
This paragraph
includes instructions to assist the operator/crew in
maintaining the remote control module. If, during
inspections, defective components are noted, refer to
next higher level of maintenance for replacement or
repair.
5-8.
ORGANIZATIONAL TROUBLESHOOTING.
Table 5-3 provides information for locating and
correcting operating troubles which may develop in the
generator set when used with the remote control
module. Each malfunction is followed by a list of tests
or inspections which will help to determine probable
causes and corrective actions to take. Perform the tests
or inspections and corrective actions in the order listed.
Any trouble beyond the scope of
a. Inspection. Inspect components on the front
panel, inside the enclosure, and on the mounting plate
as follows:
(1) Inspect
all
gauges,
switches,
and
instruments on front panel for cracking or
damage,
loose
mounting
or
loose
connections.
(2) Inspect the telephone jack (30, figure 2-14)
for damage, loose mounting, or loose
5-3
TM 5-6115-593-12
TO 35C2-3-463-1
organizational maintenance shall be referred to the next
higher level of maintenance.
relays (2 and 4, figure 5-2), and alarm horn (8,
figure 5-1) for cracking or damage, loose
mounting or loose connections.
5-9.
ORGANIZATIONAL MAINTENANCE OF THE
REMOTE CONTROL MODULE.
b. Test.
a. Inspection. Inspect transducer (26, figure 5-2),
(1) Test all SPST (single-pole,
Table 5-2. Remote Control Module Troubleshooting
(Operator/Crew Level)
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
WARNING
Death or injury may result if proper
care is not taken while working with
the various voltages in and around
the generator set.
NOTE
To determine whether it is the remote
control module or the generator set that
is malfunctioning operate or monitor the
corresponding control or indicator on the
generator set to see if the correct
operation or indication is obtained. If
operation or indication is correct, the
remote control module is, most
probably, at fault. If the generator set
still does not operate properly it, most
probably, is at fault (refer to paragraph
3-5 for appropriate troubleshooting
procedures).
1. ENGINE GENERATOR SET SHUTS DOWN DUE TO HIGH COOLANT TEMPERATURE BUT HIGH COOLANT
INDICATOR IS NOT ILLUMINATED.
Check bulb with ANNUNCIATOR TEST switch (16, figure 2-2).
If bulb is defective, replace bulb.
2. ENGINE GENERATOR SET SHUTS DOWN DUE TO HIGH LUBE TEMPERATURE BUT HIGH OIL
TEMPERATURE INDICATOR IS NOT ILLUMINATED.
Check bulb with ANNUNCIATOR TEST switch (16, figure 2-2).
If bulb is defective, replace bulb.
5-4
TM 5-6115-593-12
TO 35C2-3-463-1
Table 5-2. Remote Control Module Troubleshooting
(Operator/Crew Level)-Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
3. ENGINE GENERATOR SET SHUTS DOWN DUE TO LOW OIL PRESSURE BUT LOW OIL PRESSURE
INDICATOR IS NOT ILLUMINATED.
Check bulb with ANNUNCIATOR TEST switch (16, figure 2-2).
If bulb is defective, replace bulb.
4. GENERATOR SET SHUTS DOWN DUE TO OVERSPEED CONDITION BUT OVERSPEED INDICATOR IS NOT
ILLUMINATED.
Check bulb with ANNUNCIATOR TEST switch (15, figure 2-2).
If bulb is defective, replace bulb.
5. AN OVERVOLTAGE CONDITION EXISTS BUT OVERVOLTAGE INDICATOR IS NOT ILLUMINATED.
Check bulb with ANNUNCIATOR TEST switch (15, figure 2-2).
If bulb is defective, replace bulb.
6. AN UNDERVOLTAGE CONDITION EXISTS BUT UNDERVOLTAGE INDICATOR IS NOT ILLUMINATED.
Check bulb with ANNUNCIATOR TEST switch (15, figure 2-2).
If bulb is defective, replace bulb.
7. A REVERSE POWER TRIP CONDITION EXISTS BUT REVERSE POWER INDICATOR IS NOT ILLUMINATED.
Check bulb with ANNUNCIATOR TEST switch (15, figure 2-2).
If bulb is defective, replace bulb.
8. AN OVERLOAD CONDITION EXISTS BUT OVERLOAD INDICATOR IS NOT ILLUMINATED.
Check bulb with ANNUNCIATOR TEST switch (15, figure 2-2).
If bulb is defective, replace bulb.
9. A SHORT CIRCUIT CONDITION EXISTS BUT SHORT CIRCUIT INDICATOR IS NOT ILLUMINATED.
Check bulb with ANNUNCIATOR TEST switch (15, figure 2-2).
If bulb is defective, replace bulb.
5-5
TM 5-6115-593-12
TO 35C2-3-463-1
Table 5-2. Remote Control Module Troubleshooting
(Operator/Crew Level)-Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
10. AMMETER DOES NOT INDICATE CORRECT CURRENT.
Set AMMETER select switch to each position and observe AMMETER indication.
If indication is incorrect in all positions of AMMETER select switch, the AMMETER is, most
probably, at fault (refer to next higher level of maintenance for replacement).
If AMMETER indication is correct in at least one position, refer to next higher level of
maintenance.
11. VOLTS AC METER DOES NOT INDICATE CORRECT VOLTAGE.
Set VOLTMETER select switch to each position and observe VOLTS AC meter indication.
If indication is incorrect in all positions of VOLTMETER select switch, the VOLT AC meter is,
most probably, at fault (refer to next higher level of maintenance for replacement).
If VOLTS AC indication is correct in at least one position, refer to next higher level of
maintenance.
check that contacts 1-2 and 5-6 have
continuity. Ohmmeter should be set to
R x 1 scale.
(b) With switch in up (on) position, check
that contacts 2-3 and 5-6 have
continuity.
(c) With switch in down (off) position, check
that contacts 1-2 and 4-5 have
continuity.
single-throw)
toggle
switches as follows:
(a) Operate toggle switch to the ON
position.
(b) At rear of the panel, remove one lead
from the switch.
(c) Using an ohmmeter (Rx1 scale), test
switch for a closed circuit. If meter
indicates an open circuit, replace switch.
(d) Operate toggle switch to OFF position.
Using an ohmmeter on Rx1 scale, test
for open circuit. If meter indicates a
closed circuit, replace switch.
(3) Activate ANNUNCIATOR TEST switch (16,
figure 2-14) to energize the alarm horn. If
alarm does not sound, test switch according
to (1), above. If switch is not defective,
connect 24V DC across terminals 1 and 2 of
alarm horn. If horn does not sound, it is
defective and should be replaced.
(2) Test all DPTT (double-pole, triple-throw)
toggle switches as follows:
(a) With switch in center (neutral) position,
5-6
TM 5-6115-593-12
TO 35C2-3-463-1
(c)
(4) Refer to paragraph 4-40 for test procedures
for gauges. Note that the gauges on the
remote control module are identical to those
on the generator control panel.
c.
(d)
(2) Replace alarm horn (8, figure 5-1) as
follows:
Replacement.
(a) Tag and disconnect wires to alarm horn.
(b) Remove nut (6), washers (7), and screw
(5) to remove horn (8).
(c) Install horn (8) with screw (5), washer
(7), and nut (6).
(d) Connect wires and remove tags.
(1) Replace gauges and switches on the front
panel as follows:
(a)
(b)
Install gauges and switches using
mounting hardware.
Connect wires and remove wire tags.
Tag and remove wires to gauges and
switches.
Remove mounting hardware to remove
gauges and switches.
Table 5-3. Remote Control Module Troubleshooting
(Organizational Level)
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
WARNING
Death or injury may result if proper
care is not taken while working with
the various voltages in and around
the remote control module.
1. GENERATOR SET DOES NOT START WHEN MASTER SWITCH IS MOVED TO START POSITION.
Set 24V DC CONTROL CIRCUIT BREAKER to OFF and, using multimeter, check for continuity of MASTER
SWITCH S1 in accordance with paragraph 5-9b(2).
Replace switch (see paragraph 5-9c), if defective.
2. START AID SWITCH IS SET TO ON BUT GENERATOR DOES NOT START.
Set 24V DC CONTROL CIRCUIT BREAKER (on generator control panel) to OFF, then, using a multimeter,
check for continuity across the terminals of START AID SWITCH S2 as it is toggled to each position.
Replace switch (see paragraph 5-9c), if it does not read zero ohms in one position and infinite in
the other position.
5-7
TM 5-6115-593-12
TO 35C2-3-463-1
Table 5-3. Remote Control Module Troubleshooting
(Organizational Level)-Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
3. AUDIBLE ALARM (HORN) DOES NOT SOUND DURING FAULT CONDITION.
Step 1. Toggle ANNUNCIATOR RESET switch to RESET position.
If audible alarm (horn) still does not sound, check for 24 V DC (using multimeter) across 1 and 2 contacts of
audible alarm Al (13, figure 5-2). If voltage is present, test Al (refer to paragraph 5-9b(3).
If voltage is absent, proceed to next step.
Step 2. Using a multimeter, inspect for 24V DC across coil of relay K26.
If absent, proceed to next step. If present, inspect for 24V DC across contacts of K26. If this reading is zero
volts, proceed to check and replace relay K25 (refer to next higher level of maintenance).
If this reading is 24V DC, inspect relay K26 (2, figure 5-3) and if replacement is required, refer to next higher
level of maintenance.
Step 3. Using a multimeter, check for 24V DC across contacts 4 and 5 of ANNUNCIATOR TEST switch S13.
If voltage reading is zero, refer malfunction to next higher level of maintenance; specifically, the diodes
associated with the energized fault circuit.
If voltage reading is 24V DC, set 24V DC CONTROL CIRCUIT BREAKER to OFF and check S13 for
continuity as it is switched to its various positions. If replacement is required, refer to paragraph 5-9.
4. HERTZ METER READS INCORRECTLY.
Using a multimeter, note voltage at pins 1 and 2 on frequency converter A103 on generator control panel.
Again, using multimeter check voltage at pins 1 and 2 of frequency converter A103 on remote control
module.
If readings are the same, replace HERTZ meter M103 (refer to paragraph 5-9). If readings are
not the same, refer replacement of A103 to next higher level of maintenance.
5-8
TM 5-6115-593-12
TO 35C2-3-463-1
Table 5-3. Remote Control Module Troubleshooting
(Organizational Level)-Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
5. VOLTS AC METER DOES NOT INDICATE CORRECT VOLTAGE.
Disconnect cables to remote control module and, using a multimeter, check for continuity across the
terminals of VOLTMETER select switch S101 as it is set to each position.
If multimeter does not read zero ohms when particular position is closed and infinite when open,
the switch should be replaced.
6. AMMETER DOES NOT INDICATE CORRECT CURRENT.
If feasible, disconnect cables to remote control module and, using a multimeter, check for continuity across
the terminals of AMMETER select switch S102 as it is set to each position.
If multimeter does not read zero ohms when particular position is closed and infinite when open,
the switch should be replaced.
7. WHEN OPERATED, FREQ ADJ SWITCH DOES NOT AFFECT OUTPUT FREQUENCY OF GENERATOR SET.
Set 24V DC CONTROL CIRCUIT BREAKER (on generator control panel) to OFF and, using a multimeter,
check for continuity across terminals of FREQ ADJ switch S5 as it is toggled to each position.
If switch does not read zero ohms in one position and infinite in the other it should be
replaced.
8. WHEN OPERATED, VOLT ADJ SWITCH DOES NOT AFFECT OUTPUT VOLTAGE OF GENERATOR SET.
Set 24V DC CONTROL CIRCUIT BREAKER )on generator control panel) to OFF and, using a multimeter,
check for continuity across terminals of VOLT ADJ switch S6 as it is toggled to each position.
If switch does not read zero ohms in one position and infinite in the other it should be replaced.
9. GENERATOR SETS DO NOT LOCK INTO OPERATION WHEN SWITCHED TO THIS MODE.
Set 24V DC CONTROL CIRCUIT BREAKER (on generator control panel) to OFF and, using a multimeter,
check for continuity across the terminals of PARAL LEL OPERATION switch S8 is toggled to this position.
If switch does not read zero ohms in one position and infinite in the other it should be replaced.
5-9
TM 5-6115-593-12
TO 35C2-3-463-1
Table 5-3. Remote Control Module Troubleshooting
(Organizational Level)-Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
10. EMERGENCY SHUT-DOWN SWITCH IS SET TO ON POSITION BUT GENERATOR SET DOES NOT SHUT
DOWN.
Set 24V DC CONTROL CIRCUIT BREAKER (on generator control panel) to OFF and, using a multimeter,
check for continuity across the terminals of EMERGENCY SHUT DOWN switch S22 as it is toggled to each
position.
If switch does not read zero ohms in one switch position and infinite in the other it should be
replaced.
11. START AID SWITCH IS SET TO ON BUT GENERATOR SET DOES NOT START.
Set 24V DC CONTROL CIRCUIT BREAKER (on generator control panel) to OFF and, using a multimeter,
check for continuity across the terminals of START AID switch S2 as it is toggled to each position.
If switch does not read zero ohms in one switch position and infinite in the other it should be
replaced.
5-10
TM 5-6115-593-12
TO 35C2-3-463-1
LEGEND
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Screw
Undervoltage relay
Screw
Underfrequency relay
Screw
Nut
Converter
Screw
Nut
Screw
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
Nut
Bracket
Annunciator
Resistor
Diode
Jumper
Screw
Nut
Terminal block
Screw
Nut
Figure 5-2. Remote Control Module, Plate Assembly
5-11
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
Terminal block
Flasher
Screw
Nut
Transducer
Screw
Nut
Transformer
Terminal lug
Plate
TM 5-6115-593-12
TO 35C2-3-463-1
LEGEND
1.
2.
3.
4.
5.
6.
Screw
Relay
Socket
Diode
Screw
Nut
7.
8.
9.
10.
Terminal board
Terminal board
Wire
Printed circuit
board
Figure 5-3. Remote Control Module, Annunciator Control Assembly
5-12
TM 5-6115-593-12
TO 35C2-3-463-1
Section III. REMOTE CONTROL CABLE ASSEMBLY
up to a maximum of 1000 feet (300 m). Refer to par. 210 for additional information.
5-10. GENERAL. The remote control cable assembly
is used to connect the remote control module to the
generator set. The cable assembly may be of any
length
Section IV. AUTOMATIC CONTROL MODULE
quality circuit (81G-0, 81G-U, 27/59G and CR) monitors
the condition of their respective set. This circuit has
identical voltage and frequency specifications as the
utility monitor circuit in the ACM and is only completely
functional if the generator set is in the automatic mode.
As each generator satisfies its own quality circuit,
control relay (CR) will energize and provide 120 VAC
through J3-N to TB2-5, 6, 7, or 8 to its applicable MR
relay (MR1, 2, 3, or 4) in the ACM. However, the first
MR to be energized will lock out all other MR relays and
also provide a closure to its generator circuit breaker
control circuit via its applicable normally open contact
(TB 3-1 through TB 3-8) through J3-D and J3-E. The
first set to close its circuit breaker via MR will also
energize its own breaker control relay (BCR) which now
disconnects its synchronizer to electric governor (2301)
connection which is no longer needed since this
generator is already on line. Once all other units have
satisfied their quality circuit and energized CR, their
respective synchronizers will be energized via CR
contacts at terminal one of the synchronizer. The fact
that all other MR relays have locked out and
synchronizers are now energized, enables the remaining
units circuit breakers to be closed only when proper
synchronization has taken place.
5-12. GENERAL. The automatic control module can
sense and initiate unattended sequence when an
interruption or deviation in the normal 120V AC supply
exceeds allowable values; start the generator sets;
disable and energize circuit breakers, and exercise the
automatic control system.
The automatic control
module is equipped with voltage and frequency sensing
devices which are normally set for a voltage deviation of
±10 percent and a frequency deviation of ±3 percent,
but can be reset as local conditions warrant.
5-13. FUNCTIONAL DESCRIPTION. (Ref. FO-12)
The ACM is designed to automatically control up to four
MEP-029A, 500 KW generator sets. The utility monitor
circuit which includes a 120 VAC over/under voltage
relay (27/59N), under frequency relay (81N-U), over
frequency relay (81N-0), 1.5-15 second (adjustable) time
delay relay (TD), 50/60Hz frequency select switch and a
run relay (RR), continually monitors the 120 VAC utility
voltage from the line side of the utility breaker.
When the utility power is normal, relays 27/59N, 81N-U
and TD are energized (81N-0 will only energize during
an over-frequency condition) and the normal power
available lamp will be on.
It should be noted that K106 sync check relay (N.O.
contacts 5 and 6) is always in the circuit breaker closure
circuit in series with MR closure contacts and/ or the
synchronizer closure contacts. This will preclude any
set circuit breaker closure, in automatic or manual
unsynchronized.
If the utility power completely fails or voltage varies by
more than ±10% and/or frequency varies more than
±3%, TD relay after a 1.5-15 second time delay will
allow all generators to begin a start-up cycle providing
the generators are in the automatic mode. Relays
27/59N, 81N-U, TD and RR deenergize allowing 24 volts
D.C. to energize the K5 engine start circuit via normally
closed contacts TD and RR through TB4-5, 6, 7, 8
through J3-B through the automatic position of the autotrip-manual switch (S53) on each set. The utility breaker
(located within user switchgear) will open via additional
sets of RR contacts at TB3-17, 18 and 19.
As each set circuit breaker (CB2) closes, its' auxiliary
contacts (CB2-5 will close allowing 120 V.A.C. via J3-P
to TB2-9, 10, 11 or 12 to energize each sets respective
BR1-BR4 relay. These BR relays along with the 24
VDC
As the generators run up to speed, each generator's
5-13
TM 5-6115-593-12
TO 35C2-3-463-1
available to LR1 (LRTD1) - LR4 (LRTD4) make up the
prioritized feeder breaker control circuits. The first set
to close to the bus will energize a BR relay which will
always close LR1 (Load Relay) and its 2-20 second
(adjust- able) time delay (LRTD1) secondly. Each LR
and LRTD should control loads not to exceed 250KW
each.
LRTD's allow a time delay between load
applications as to allow engine turbochargers to build up
speed. LR1 relay will always be the first relay to
energize on start-up and the last relay to de-energize
when the sets are shut down. Therefore, it is classified
as the #1 priority feeder breaker control. When LR1
relay energizes, it also prevents RR relay from being reenergized if utility power returns via LR1 normally
closed contacts in series with RR relay coil. This allows
all sets, which are in the automatic mode, to complete
their start-up and parallel cycles regardless of utility
power returning. As each remaining set is automatically
synchronized and paralleled to the bus, the remaining
LR and LRTD relays will energize in numerical order.
The ACM has a 3 position rotary switch labeled
"Instant", "Time Delay" (TD) and "No Return". This
switch allows the user three options as to what will
happen when the utility power returns after a failure. If
the switch is in the "Instant" return position, immediately,
when the utility power returns, the utility 120 VAC will be
supplied through energized T.D. relay normally open
contacts through S1 to TB2-1, 2, 3, and 4 to J3-C on all
units, energizing the breaker trip relay (BTR) which will
shunt trip each unit's circuit breaker (CB2). At this time,
all BR, LR and LRTD relays de-energize causing the
LR1 normally closed contact, in series with RR coil, to
reclose allowing RR relay to re-energize, thereby
allowing the utility breaker to close back to the load. In
the "TD" position, a 3-30 minute (adjustable) time delay
via UTR (Utility Trip Relay) allows a predetermined time
delay after the utility power returns before the unit circuit
breakers (CB2) are tripped. This insures utility power
has returned to stay, avoiding unnecessary transfer and
re-transfers of the utility breaker control. In the "no
return" position, the generators will carry the load until
switched off by the operator.
At the end of this time delay period, SDT N.O. contacts
re-open, removing the 24 VDC to TB4-5, 6, 7, 8 and J3B which in turn allows K5 relays to de-energize and stop
all units.
This completes the automatic start and shutdown cycle
of the generator set via the ACM.
5-14. INSTALLATION. The automatic control module
is a self-housed unit, for indoor or outdoor operation.
The unit should be placed as level as possible, on firm,
dry, footing. Allow approximately 24 inches (62 cm)
clearance on each side of the unit for access during
operation and maintenance. See paragraph 2-11 for
information on connecting the automatic control module,
FO-12 for a schematic, and FO-15 for a connection
diagram.
5-15. LUBRICATION. The automatic control module
requires no lubrication.
5-16. PREVENTIVE MAINTENANCE CHECKS AND
SERVICES (A, N, MC). To ensure that the automatic
control module is always ready for operation, inspect
systematically so that defects may be discovered and
corrected before they result in serious damage or
failure. Perform the preventive maintenance checks
and services in accordance with table 5-4. Air Force
users shall refer to the applicable inspection manuals
and work card sets in T.O. 35C2-3- series for periodic
preventive maintenance requirements and table 5-4 for
detailed procedures. Marine Corps users shall refer to
the current issue of TM 11275-15/1. See par. 2-11 and
fig. 2-19 for operation.
5-17. OPERATOR/CREW
TROUBLESHOOTING.
Table 5-5 contains troubleshooting information for use in
correcting operating troubles which may develop in the
generator set when used with the automatic control
module. Each malfunction is followed by a list of tests
or inspections which will help to determine probable
causes and corrective actions to take. Perform the tests
or inspections and corrective actions in the order listed.
Any trouble beyond the scope of crew level
maintenance shall be referred to the next higher
(organizational)
At the same instant when all units CB2's are tripped
open via BTR, SDT (Shut Down Timer) begins a 300
second (adjustable) time out before de-energizing. The
SDT relay allows the engines to continue to run and cool
down after the load has been removed.
5-14
TM 5-6115-593-12
TO 35C2-3-463-1
level of maintenance.
defective, and their replacement is beyond the
scope of organizational maintenance, refer to
the next higher level of maintenance.
NOTE
Before referring to table 5-5, be sure that all
applicable checks have been performed.
b. Testing
the
NO
RETURN/TD
RETURN/INSTANT RETURN Mode Selector
Switch..
5-18. OPERATOR/CREW MAINTENANCE OF THE
AUTOMATIC CONTROL MODULE. This paragraph
provides instructions to assist the operator/crew in
maintaining the automatic control module. If defective
components are noted during inspection, refer to next
higher level of maintenance for replacement or repair.
(See figure 2-19).
(1) Test the mode selector switch S1 by tagging
and removing wires, then removing switch
from panel.
(2) Refer to FO-12 sheet and connect one lead
of ohmmeter (set on low scale) to the arm
terminals 11 and 21) of the mode selector
switch. Connect the other ohmmeter lead to
the terminal set for that position. Meter
should indicate continuity for the set of
leads, no continuity for all others. Repeat
this step for the other terminals (rotate
switch to corresponding position). If switch
indicates an open or intermittent contact on
any of the closed switch positions, or a
closed circuit on an open position, replace
switch.
a. Inspection.
Inspect NORMAL POWER
AVAILABLE lamp for loose mounting or loose
connections. Inspect relays for loose mounting
or loose connections.
b. Replacement. Replace defective bulb in lamp
assembly.
5-19. ORGANIZATIONAL
TROUBLESHOOTING.
Table 5-6 provides information for locating and
correcting operating troubles which may develop in the
generator set when used with the automatic control
module. Each malfunction is followed by a list of tests
or inspections which will help to determine probable
causes and corrective actions to take. Perform the tests
or inspections and corrective actions in the order listed.
Any trouble beyond the scope of organizational
maintenance shall be referred to the next higher level of
maintenance.
(3) Install switch with mounting hardware and
connect wires. Remove wire tags.
c.
Testing Toggle switch.
(1) Test the toggle switch by tagging and
removing wires.
NOTE
5-20. ORGANIZATIONAL MAINTENANCE OF THE
AUTOMATIC CONTROL MODULE. (See figure 2-19).
The FREQ SELECT 50 HZ/60 HZ switch S2
must be removed from the panel for testing.
a. Inspection. Inspect the under/ over voltage
device, underfrequency device, overfrequency
device, relays, timers, switches, and fuseholders
for loose mounting, loose wires, cracking, or
damage.
If components are damaged or
(2) Using an ohmmeter (Rx1 scale), close
switch and check for continuity.
5-15
TM 5-6115-593-12
TO 35C2-3-463-1
Table 5-4. OPERATOR/CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES, AUTOMATIC CONTROL
MODULE.
NOTE: Within designated interval, these checks are to be performed in the order listed.
B-Before
Item
No.
1
A-After
INTERVAL
B
D
A
o
PROCEDURES
CHECK FOR AND HAVE REPAIRED
OR ADJUSTED AS NECESSARY
Inspect switches, fuses, relays and
lamps daily for damage, loose
mounting or loose connections.
ITEMS TO BE
INSPECTED
Automatic
Control
Module
D-During
EQUIPMENT IS
NOT READY/
AVAILABLE IF:
Table 5-5. Automatic Control Module Troubleshooting (Operator/Crew Level)
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
WARNING
Death or injury may result if proper care is not taken
while working with the various voltages in and
around the generator set.
1. GENERATOR SET DOES NOT START WHEN NORMAL POWER FAILS (SINGLE UNIT OPERATION, ACM
WIRED PER INTERCONNECTION FOR SET #1)
Step 1. Remove and check DC fuses (F6, F7, F8 or F9) for continuity.
If fuse is not defective, proceed to next step.
If fuse is defective, replace with 5-ampere fuse of same type as original.
If generator set still does not start, recheck fuse.
If new fuse is blown, automatic control module troubleshooting should be referred to next higher level of
maintenance.
5-16
TM 5-6115-593-12
TO 35C2-3-463-1
Table 5-5. Automatic Control Module Troubleshooting (Operator/Crew Level)-Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Step 2. Connect a jumper wire between TB4-1 and TB4-5 on automatic control module.
If generator set starts, automatic control module is probably at fault. Refer automatic control module to next
higher level of maintenance.
If generator set does not start, then it is most probably at fault (refer to paragraph 4-10).
2. GENERATOR SET STARTS BUT OUTPUT DOES NOT CONNECT TO MAIN POWER BUSS WHEN NORMAL
POWER FAILS (SINGLE UNIT OPERATION).
Step 1. Check AC voltmeter and frequency meter on generator set or remote control module.
If voltage or frequency is out of tolerance, (± 3 percent frequency, ± 10 percent voltage) then generator set is
most probably at fault (refer to paragraph 4-10).
If voltage and frequency is within tolerances, proceed to next step.
Step 2. Connect a jumper wire across TB3-1 and TB3-2 (assuming generator in suspect is connected to set #1
terminals per ACM/GEN interconnection diagram).
If generator set output connects to main power buss, automatic control module is most likely at fault
providing 120 V.A.C. is present at TB2-5. Refer automatic control module troubleshooting to next higher
level of maintenance.
If generator set out put does not connect to main power buss, then generator set is most probably at fault
(refer to paragraph 4-10).
Table 5-6. Automatic Control Module Troubleshooting (Organizational Level)
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
1. GENERATOR SET DOES NOT START WHEN NORMAL POWER FREQUENCY GOES OUT OF TOLERANCE
(SINGLE UNIT OPERATION).
5-17
TM 5-6115-593-12
TO 35C2-3-463-1
Table 5-6. Automatic Control Module Troubleshooting (Organizational Level)-Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
WARNING
Death or injury may result if proper care is not taken
while working with the various voltages in and
around the generator set.
NOTE
The frequency of normal power is observable at the
associated switchgear control.
Step 1. If frequency is over required rating and NORMAL POWER AVAILABLE indicator lamp is lit, inspect (using a
multimeter set to measure AC) for 120 V AC across Overfrequency Device 81N-0 relay 7-5 contacts (figure
2-19).
If 120V AC is present, refer testing and replacement of 81N-0 relay to next higher level of maintenance.
If 120V AC is absent, refer testing and replacement of TD relay to next higher level of maintenance.
Step 2. If frequency is under required rating and NORMAL POWER AVAILABLE indicator lamp is lit, inspect (using a
multimeter set to measure AC) for 120V AC across Underfrequency Device 81N-U relay 6-5 contacts (figure
2-19).
If 120V AC is present, refer testing and replacement of 81N-U relay to next higher level of maintenance.
If 120V AC is absent, refer testing and replacement of TD relay to next higher level of maintenance.
Step 3. If NORMAL POWER AVAILABLE indicator lamp is not lit, refer testing and replacement of Run Relay (RR)
to next higher level of maintenance.
2. GENERATOR SET DOES NOT START WHEN NORMAL POWER VOLTAGE GOES OUT OF TOLERANCE.
NOTE
The voltage level of normal power is observable at the
associated switchgear control.
5-18
TM 5-6115-593-12
TO 35C2-3-463-1
Table 5-6. Automatic Control Module Troubleshooting (Organizational Level)-Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Step 1. If NORMAL POWER AVAILABLE indicator lamp is lit, inspect (using a multimeter set to measure AC) for
120V AC across Undervoltage Device 27/59N relay 6-5 contacts.
If 12.OV AC is present, refer testing and replacement of 27/59N relay to next higher level of maintenance.
If 120V AC is absent, refer testing and replacement of TD relay to next higher level of maintenance.
Step 2. If NORMAL POWER AVAILABLE indicator lamp is not lit, refer testing and replacement of RR relay to
higher level of maintenance.
3. GENERATOR MAIN CIRCUIT BREAKER DOES NOT CLOSE DURING EMERGENCY SWITCHOVER (SINGLE
UNIT OPERATION).
NOTE
Generator set operation is assumed to be normal.
Step 1. Using a multimeter (set to measure DC), inspect for 24V DC across TB3-1 and TB3-2.
If 24V DC is present, refer testing and replacement of MR relay to higher level of maintenance.
If 24V DC is absent, proceed to next step.
Step 2. Connect a jumper across TB4-1 and TB3-1.
4. GENERATOR OUTPUT DOES NOT CONNECT TO CRITICAL LOAD (LRI).
Using a multimeter (set to measure DC) check for 24V DC at coil of LR1 relay.
If present, refer to testing and replacement of LRI relay to next higher level of maintenance.
If absent connect a jumper from TB4-1 to R1 diode pack terminal 5.
If critical load is activated, refer testing and replacement of BR1 relay to next higher level of maintenance.
If jumper does not correct problem, remove jumper and refer testing and replacement of R1 diode pack
assembly to next higher level of maintenance.
5-19
TM 5-6115-593-12
TO 35C2-3-463-1
Table 5-6. Automatic Control Module Troubleshooting (Organizational Level)-Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
5. ADDITIONAL GENERATOR OUTPUTS DO NOT CONNECT LESSER PRIORITY FEEDER BREAKERS.
Using a multimeter check for 24V DC at coil of LR2, 3 or 4 relays.
If present, refer to testing and replacement of LR2, 3 or 4 relays to next higher level of maintenance.
If absent connect a jumper from TB4-1 to R2 diode pack terminal 5 for checking LR2, or from TB4-1 to R2
diode pack terminal 2 for checking LR3.
If critical load is activated, refer testing and replacement of BR2, BR3 or BR4 relay to next higher level of
maintenance.
If jumper does not correct problem, remove jumper and refer testing and replacement of R2 diode pack
assembly to next higher level of maintenance.
6. GENERATOR OUTPUT CONNECTS TO FEEDER LINES BUT FEEDER LINES 2, 4, 6 OR 8 ARE INOPERATIVE.
Using a multimeter, check for 24V DC at LRTD1, 2, 3 or 4 whenever LR1, LR2, LR3 or LR4 is energized
respectively.
If voltage is present refer testing and replacement of LRTD relays to next higher level of maintenance.
Section V . HOUSING KIT
5-21. GENERAL.
The housing kit encloses the
generator set and is removable to provide access for
overhaul or replacement of major components. The
housing is attached to the base assembly and the
support frame assembly to provide a rain proof
enclosure, and prevent rain, snow, or sand from entering
the interior of the housing. With the housing kit
installed, the generator set can be operated at ambient
temperatures from 125°F (52°C) down to -25°F (-32°C).
The housing doors allow access to the inside of the
generator set. The shutter assembly at the radiator end
of the generator set is automatically controlled and
maintain correct operating temperatures for the
generator set. Major components of the housing kit
include panels, doors, shutters, electrical harness,
exhaust breather, and necessary hardware items for kit
assembly.
Louver control relays K60 through K63, and fuses F61
thru F63 in External Power Box (figure 5-4) louver motor
pilot switches S60 through S63, and louver motors B10
through B13 (capable of two way operation) control the
four louver assemblies. When the engine starts each
louver control relay energizes and 24 V DC is applied,
by way of the louver motor pilot switches, to the louver
motors and the louvers
5-20
TM 5-6115-593-12
TO 35C2-3-463-1
5-25. ORGANIZATIONAL
TROUBLESHOOTING.
Table 5-8 contains information for locating and
correcting operating troubles which may develop in the
generator set when equipped with the housing kit. Each
malfunction is followed by a list of tests or inspections to
determine probable causes and corrective actions.
Perform the tests or inspections and corrective actions
in the order listed. Any trouble beyond the scope of
organizational maintenance shall be referred to the next
higher level of maintenance.
open. Upon reaching their full-open position the louvers
set the travel-limit switches to their opposite position,
deactivating the louver motors. Louver operation at
shutdown is exactly the same except that the motors
operate in a reverse direction and 24V DC is applied
through the normally closed contacts of the deenergized
louver control relays.
The shutter assembly (there are two) is automatically
operated by a hydraulic control assembly (figure 5-5)
through which coolant is allowed to flow. With the
engine cold, the spring-loaded shutters are held closed
by the control assembly. As the coolant warms, the
hydraulic medium (wax) melts. The control assembly
relaxes its hold and allows the shutters to open. There
is a direct correlation between coolant temperature and
the extent of shutter opening.
5-26. ORGANIZATIONAL MAINTENANCE OF THE
HOUSING KIT.
a. Inspection. (See figure 5-5.)
(1) Inspect the louvers, door panels, and front
grille for cracks, loose mounting, loose or
missing hardware, rust or corrosion.
5-22. INSTALLATION. The housing kit is installed by
mounting its component sections directly onto the base
assembly and the support frame assembly in the
following sequence: door and shutter assembly, left
side, front (radiator end), right side, rear, top, and
electrical harness. Installation/assembly is normally
performed at the Direct Support Maintenance level.
(2) Inspect the weather stripping around each
door assembly for peeling of adhesive
backing, excessive wear, rot, or damage.
(3) Inspect all connectors in the wiring harness
for damaged threads, and bent, loose, or
missing pins. Check all connections for
security and condition. Check all wiring for
defective or worn insulation.
5-23. LUBRICATION.
The housing kit door and
shutter assemblies, access doors, and all moving parts
require lubrication in accordance with the lubrication
order LO5-6115-593-12. Army personnel shall refer to
DA PAM 310-4 and Marine Corps personnel to SL-1-3 to
ensure that the latest edition of the lubrication order
(LO) us being used.
WARNING
Set MAINTENANCE LOCKOUT switch to
LOCKOUT. Disconnect negative cable
from batteries. Remove external power
by opening CB101 (120V RECEPTACLE
BREAKER). Load terminals of generator
set circuit breaker (CB2) may still be
energized with the bus voltage.
5-24. PREVENTIVE MAINTENANCE CHECKS AND
SERVICES (A, N, MC). To ensure that the housing kit
is always ready for operation, inspect systematically so
that defects may be discovered and corrected before
they result in serious damage or failure. Perform the
preventive maintenance checks and services in
accordance with table 5-7. Air Force users shall refer to
the applicable inspection manuals and work card sets in
T.O.
35C2-3-series
for
periodic
maintenance
requirements and table 5-7 for detailed procedures.
Marine Corps users shall refer to the current issue of TM
11275-15/1.
b. Test. Refer to FO-17 and perform a continuity
check of the harness assembly using an
ohmmeter between connecting points in the
wiring harness. Check for short circuits between
connector pins of the same receptacle, plug, or
terminal board.
5-21
TM 5-6115-593-12
TO 35C2-3-463-1
Table 5-7. OPERATOR/CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES, HOUSING KIT.
NOTE: Within designated interval, these checks are to be performed in the order listed.
B-Before
D-During
A-After
ITEMS TO BE
Item
No.
1
INTERVAL
B
D
A
o
INSPECTED
Weather
Stripping
PROCEDURES
CHECK FOR AND HAVE REPAIRED
OR ADJUSTED AS NECESSARY
Excessive wear, rot or damage.
Inspect for breaks, cracks, loose
mounting, loose or missing hardware,
corrosion, or rust.
EQUIPMENT IS
NOT READY/
AVAILABLE IF:
Table 5-8. Housing Kit Troubleshooting
MALFUNCTION
TEST INSPECTION
CORRECTIVE ACTION
1. LOUVERS FAIL TO OPERATE PROPERLY.
Observe if one or all louvers fail to operate.
If all louvers fail to operate, check wiring harness between louver circuits and 24V DC buss.
If only one louver fails to operate, refer testing and replacement of relay (K60 through K63), limit switches
(S60 through S63), and motors (B10 through B13) associated with malfunctioning louver (refer to next higher
level of maintenance).
2. RADIATOR SHUTTER FAILS TO OPERATE.
Visually inspect shutter assembly for broken springs, jammed shutters, and leaking coolant or hydraulic fluid
at control assembly. Refer to paragraph 5-33 for housing kit maintenance procedure.
c.
Repair of Harness Assembly.
(2) If a wire is broken from a terminal lug,
replace the lug. If a wire is broken from a
connector, resolder and reassemble.
(1) If a broken wire is accessible, remove
sufficient insulation from each side of the
break to allow a good connection of the
bared ends by twisting them together.
Solder the connection and wrap with
electrical tape.
CAUTION
Under no condition
connection exposed.
5-22
leave
the
bare
TM 5-6115-593-12
TO 35C2-3-463-1
from a small (six-inch) section of the new
stripping and pressing into place. Peel off
additional backing as necessary, and
continue to press stripping into place until
completed.
(3) If a break in the wire is inaccessible within
the wiring harness, disconnect it at both
ends and tape both ends. Lace a new lead
of the same gauge and insulation outside
the harness and connect it to the proper
terminals or pins. Properly tag both ends of
all replacement wires.
NOTE
Do not "patch" one section of stripping on
any component panel. Replace the all
weather stripping around any panel.
d. Replacement.
(1) Weather stripping. If weather stripping is
damaged, rotten or defective, remove by
peeling stripping off the panel or access
door. Lightly scrape metal to remove any
pieces of stripping which remain. Install
fresh weather stripping by removing backing
(2) Harness assembly. If 30 percent of the
harness wires are defective, refer to next
higher
level
of
maintenance
for
replacement.
Figure 5-4. Actuator Control Relay Assembly
5-23
TM 5-6115-593-12
TO 35C2-3-463-1
Figure 5-5. Housing Kit, Installed on Generator Set.
5-24
TM 5-6115-593-12
TO 35C2-3-463-1
APPENDIX A
REFERENCES
A-1.
A-2.
A-3.
A-4.
A-5.
Fire Protection
TB 5-4200-200-10
Hand Portable Fire Extinguishers Approved by Army
Users.
Lubrication
C9100-IL
L0-5-6115-593-12
LI-6115-12/1
Identification List for Fuels, Lubricants, Oils and Waxes.
Lubrication Order
Painting
T.O. 35-1-3
Painting and Marking of USAF Aerospace Ground
Equipment.
TM 43-0139
Painting Instructions for Field Use.
Radio Suppression
MIL-STD-461
Radio Interference Suppression
TM 11-483
Radio Interference Suppression
Maintenance
T.O. 00-25-225
Repair of External Power Cables, Aerospace Ground
Equipment.
T.O. 00-25-234
General Shop Practice Requirements for the Repair,
Maintenance and Test of Electrical Equipment.
T.O. 1-1-1
Cleaning of Aerospace Equipment.
T.O. 1-1-2
Corrosion Control
Equipment.
T.O. 1-1A-14
Installation Practices for Aircraft Electric and Electronic
Wiring.
T.O. 35-1-75
General Maintenance practices.
T.O. 35-1-11
Organization,
Intermediate
and
Depot
Level
Maintenance for FSC 6115 Non-Airborne Equipment.
T.O. 35-1-12
Components and Procedures for Cleaning Aerospace
Ground Equipment.
T.O. 35-1-26
Repair/Replacement Criteria for FSC 6115 Aerospace
Ground Equipment.
T.O. 35-1-524
USAF Equipment Registration Number
Applicable to FSC 6115 Equipment.
TB 750-651
Use of Antifreeze Solutions and Cleaning Compounds in
Engine Cooling Systems.
A-1
and
Treatment
for
Aerospace
System
TM 5-6115-593-12
TO 35C2-3-463-1
APPENDIX A - CONTINUED
REFERENCES
A-5.
Maintenance (cont'd)
DA Pam 738-750
The Army Maintenance Management
System (TAMMS).
Operator/Crew and Organizational
Maintenance Manual.
TM5-6115-593-12
T.O. 35C2-3-463-1
NAVFAC P-8-631-12
A-6.
A-7.
A-8.
TM5-6115-593-34
T.O. 35C2-463-2
NAVFAC P-8-631-34
Intermediate (Field) (Direct and
General Support) and Depot Level
Maintenance Manual.
TM5-6115-593-24P
NAVFAC P-8-631-24P
TM9-6140-200-14
T.O. 35C2-3-463-4
Organizational, Intermediate (Field)
(Direct and General Support) and
Depot Maintenance Repair Parts and
Special Tools List.
Shipment and Storage
T.O. 35-1-4
Processing and Inspection of
Aerospace Ground Equipment for
Storage and Shipment.
T.O. 38-1-5
Processing and Inspection of NonMounted, Non-Aircraft Gasoline and
Diesel Engines for Storage and
Shipment.
TB 740-97-2
Preservation of USAMEC Mechancial
Equipment for Shipment and Storage.
TM 38-250
Packaging and Materials Handling,
Preparation of Hazardous Materials
for Military Air Shipment.
Destruction of Material
TM 750-244-3
Procedures for Destruction of
Equipment to Prevent Enemy Use.
Radioactive Material
TB 750-248
Instructions for Safe Handling,
Maintenance, Storage, and Disposal of
Radioactive Commodities Managed by
U.S. Army Mobility Equipment Command.
A-2
TM 5-6115-593-12
TO 35C2-3-463-1
APPENDIX B
BASIC ISSUE ITEM LIST AND ITEMS TROOP INSTALLED OR AUTHORIZED LIST
Section I. INTRODUCTION
national stock number assigned to the item
and which will be used for requisitioning.
B-1.
SCOPE.
This appendix lists integral
components of and basic issue items for the 500 KW
50/60 HZ DOD generator set to help you inventory items
required for safe and efficient operation.
(3) Part Number. Indicates the primary number
used by the manufacturer, which controls
the design and characteristics of the item by
means of its engineering drawing,
specifications, standards and inspection
requirements to identify an item or range of
items.
B-2.
GENERAL. This component of end item list is
divided into the following sections:
a. Section II. Integral Components of the End
Item. These items, when assembled, comprise
the 500 KW 50/60 HZ DOD generator set and
must accompany it whenever it is transferred or
turned in. The illustrations will help you identify
these items.
(4) Description. Indicates the Federal item
name and, if required, a minimum
description to identify the item.
(5) Location. The physical location of each
item listed is given in this column. The lists
are designed to inventory all items in one
area of the major item before moving on to
an adjacent area.
b. Section III. Basic Issue Items. These items are
furnished with 500 KW 50/60 HZ DOD generator
set and must accompany the generator set
when transferred between accountable officers.
This manual is your authority to requisition
replacement BII.
c.
B-3.
(6) Usable On Code. Usable on codes are
included to help you identify which
component items are used on the different
models. Items in the enclosed lists are used
on all models of the 500 KW 50/60 HZ DOD
generator set model MEP 029A.
Section IV. Troop Installed or Authorized List.
These items are authorized on and as required
basis.
This manual is your authority to
requisition troop installed or authorized items.
EXPLANATION OF COLUMNS.
(1) Illustration.
follows:
(7) Quantity Required (QTY Reqd.).
This
column lists the quantity of each item
required for a complete major item.
This column is divided as
(8) Quantity. This column is left blank for use
during an inventory. Under the RCV'D
column list the quantity you actually receive
on your major item. The date columns are
for your use when you inventory the major
item at a later date; such as for shipment to
another site.
(a) Figure number. Indicates the figure
number of the illustration on which the
item is shown.
(b) Item Number: The number used to
identify item called out in the illustration.
(2) National Stock Number.
Indicates the
B-1
TM 5-6115-593-12
TO 35C2-3-463-1
Section II. INTEGRAL COMPONENTS OF END ITEM
(1)
ILLUSTRATION
(a)
(b)
FIGURE
ITEM
NO.
NO.
(2)
(3)
(4)
(5)
(6)
(7)
NATIONAL
STOCK
NUMBER
PART NO.
DESCRIPTION
LOCATION
USABLE
ON
CODE
QTY
REQD
RCV'D
(8)
QUANTITY
DATE
DATE
DATE
RCV'D
(8)
QUANTITY
DATE
DATE
DATE
Section III. BASIC ISSUE ITEMS
(1)
ILLUSTRATION
(a)
(b)
FIGURE
ITEM
NO.
NO.
(2)
(3)
(4)
(5)
(6)
(7)
NATIONAL
STOCK
NUMBER
PART NO.
DESCRIPTION
LOCATION
USABLE
ON
CODE
QTY
REQD
B-1
1
MS28741
16-2880
(96906)
Hose
Fuel
Aux
1
B-1
2
76-11418
(30554)
Sling
Assy
2
B-1
3
Hammer,
Slide
1
B-1
4
Cable,
Ground
1
5120-01013-1676
13228E3
384
B-2
TM 5-6115-593-12
TO 35C2-3-463-1
Figure B-1. Basic Issue Items
Section IV. TROOP INSTALLED OR AUTHORIZED LIST
(1)
SMR CODE
(2)
NATIONAL STOCK
NUMBER
(3)
DESCRIPTION
(4)
UNIT OF
MEASURE
(5)
QUANTITY
AUTHORIZED
PAC
5975-00-878-3791
Rod, Ground, Assy
EA
1
PAC
4210-00-555-8837
Extinguisher
EA
1
EA
1
Fire,
MONOBROMOTRIFLUOROMETHANE,
with
Bracket, Operating Temperature
Range- Minus 50°F to plus 120°F
PAC
4210-00-708-0031
Replacement Cylinder for 421000-555-8837
B-3/(B-4 blank)
TM 5-6115-593-12
TO 35C2-3-463-1
APPENDIX C
MAINTENANCE ALLOCATION CHART
Section I. INTRODUCTION
C-1.
GENERAL.
(A through K) and indicates the lowest
maintenance category authorized to perform
these functions. The symbol designations for
the various maintenance categories are as
follows:
a. This section provides a general explanation of
all maintenance and repair functions authorized
at various maintenance levels.
b. Section II designates overall responsibility for
the performance of maintenance functions on
the identified end item or component. The
implementation of the maintenance functions
upon the end item or component will be
consistent with the assigned maintenance
functions.
c.
C - Operator or Crew
O - Organizational maintenance
F - Direct support maintenance
H - General support maintenance
D - Depot maintenance
The maintenance functions are defined as follows:
Section III lists the tools and test equipment
required for each maintenance function as
referenced from Section II.
A - Inspect. To determine serviceability of an
item by comparing its physical, mechanical,
and
electrical
characteristics
with
established standards.
d. Section IV contains supplemental instructions,
explanatory notes and/or illustrations required
for a particular maintenance function.
C-2.
II.
B - Test. To verify service-ability and to detect
electrical or mechanical failure by use of
test equipment.
EXPLANATION OF COLUMNS IN SECTION
C - Service. To clean, to preserve, to charge,
and to add fuel, lubricants, cooling agents,
and air. It if is desired that elements, such
as painting and lubricating, be defined
separately, they may be so listed.
a. Group Number. Column 1. The assembly
group is a numerical group assigned to each
assembly in a top down breakdown sequence.
The applicable assembly groups are listed on
the MAC in disassembly sequence beginning
with the first assembly removed in a top down
disassembly sequence.
D - Adjust. To rectify to the extent necessary to
bring into proper operating range.
E - Align. To adjust specified variable elements
of an item to bring to optimum performance.
b. Assembly Group. Column 2. The column
contains a brief description of the components
of each assembly group.
c.
F - Calibrate. To determine the corrections to
be made in the readings of instruments or
test
equipment
used
in
precise
measurement. Consists of the comparison
Maintenance Functions.
Column 3.
This
column lists the various maintenance functions
C-1
TM 5-6115-593-12
TO 35C2-3-463-1
d. Symbols. The uppercase letter placed in the
appropriate column indicates the lowest level at
which that particular maintenance function is to
be performed.
of two instruments, one of which is a
certified standard of known accuracy, to
detect and ad- just any discrepancy in the
accuracy of the instrument being compared
with the certified standard.
e. Tools and Equipment. Column 4. This column
is provided for referencing by code, the special
tools and test equipment (Section III) required to
perform the maintenance functions.
G - Install. To set up for use in an operational
environment such as an emplacement, site,
or vehicle.
H - Replace. To replace unserviceable items
with serviceable like items.
C-3.
f.
I - Repair.
Those maintenance operations
necessary to restore an item to serviceable
condition through correction of material
damage or a specific failure. Repair may be
accomplished at each category of
maintenance.
EXPLANATION OF COLUMNS IN SECTION III.
a. Reference Code. This column consists of a
number and a letter separated by a dash. The
number references the T and TE requirements
column on the MAC. The letter represents the
specific maintenance function the item is to be
used with.
The letter is representative of
columns A through K on the MAC.
J - Overhaul. Normally, the highest degree of
maintenance performed by the Army in
order to minimize time work in process is
consistent with quality and economy of
operation. It consists of that maintenance
necessary to restore an item to completely
serviceable condition as prescribed by
maintenance
standards
in
technical
publications for each item of equipment.
Overhaul normally does not return an item
to like new, zero mileage, or zero hour
condition.
C-4.
Remarks. Column 5. This column is provided
for referencing by code, the remarks (Section
IV) pertinent to the maintenance functions.
b. Maintenance Category. This column shows the
lowest level of maintenance authorized to use
the special tool or test equipment.
c.
Nomenclature. This column lists the name or
identification of the tool or test equipment.
d. Tool Number.
This column lists the
manufacturer's code and part number, or
National Stock Number of tools and test
equipment.
K - Rebuild. The highest degree of material
maintenance.
It consists of restoring
equipment as nearly as possible to new
conditions in accordance with original
manufacturing standards.
Rebuild is
performed
only
when
required
by
operational
considerations
or
other
paramount factors and then only at the
depot maintenance category.
Rebuild
reduces the zero the hours or miles the
equipment, or component thereof, has been
in use.
EXPLANATION OF COLUMNS IN SECTION IV.
a. Reference Code. This column consists of two
letters separated by a dash, both of which are
references to Section II.
The first letter
references column 5 and the second letter
references a maintenance function, column, A
through K.
C-2
TM 5-6115-593-12
TO 35C2-3-463-1
b. Remarks. This column lists information pertinent to the maintenance function being performed, as indicated on
the MAC, Section II.
SECTION II. MAINTENANCE ALLOCATION CHART
(1)
G
R
O
U
P
N
O
01
02
03
(3)
MAINTENANCE FUNCTIONS
(2)
ASSEMBLY GROUP
A
B C
D
I
N
S
P
E
C
T
S
E
R
V
I
C
E
A
D
J
U
S
T
T
E
S
T
E
A
L
I
G
N
F
G
H
I
J
K
C
A
L
I
B
R
A
T
E
I
N
S
T
A
L
L
R
E
P
L
A
C
E
R
E
P
A
I
R
O
V
E
R
H
A
U
L
R
E
B
U
I
L
D
O
O
(4)
TOOLS
AND
EQUIPMENT
(5)
REMARKS
BATTERIES & RELATED ITEMS
Cables
C
Batteries
C O O
MUFFLER, EXHAUST
Muffler
O
O
A, B
1-B
C
C
O
A
Gaskets
C
O
A
Exhaust & Rain Cap
C
O
A
EXTERNAL POWER BOX ASSY
2-B&I
3-B&I
Control Panel
O
Receptacles
C
O
A
CB (CB101)
C O
O
A, E
Switch, Pre-Heat (S105)
C O
O
A, C
Circuit Breakers
C O
O
A, E
Plate & Sleeve Assy
C
O
A
Contractors, HTR
(K107) (K109)
O O
O
F
A, E
Transfer Cont (K108)
O O
O
F
A
Contactor, Motor
(K120)
O
F
F
E
Weather Stripping, Seals
O
Harness Assy
O
F
O
O
F
C-3
A, D
A
O
A, K
TM 5-6115-593-12
TO 35C2-3-463-1
SECTION II. MAINTENANCE ALLOCATION CHART (Cont)
(1)
G
R
O
U
P
N
O
04
(3)
MAINTENANCE FUNCTIONS
(2)
ASSEMBLY GROUP
A
B C
D
I
N
S
P
E
C
T
S
E
R
V
I
C
E
A
D
J
U
S
T
A
L
I
G
N
F
G
H
I
J
K
C
A
L
I
B
R
A
T
E
I
N
S
T
A
L
L
R
E
P
L
A
C
E
R
E
P
A
I
R
O
V
E
R
H
A
U
L
R
E
B
U
I
L
D
AC & DC CONTROL BOX ASSY
(5)
REMARKS
2-B&I
3-B&I
Control Panel
O
O
Recept (J104-J109)
C
O
A
Circuit Breaker CB103
C O
O
A
Conv, AC (J103)
C
O
A
Switches
C O
O
A
O
F
F
F
A, E
O
A
Harness Assy
Relays
O
Weather Stripping,
Seals
O
Battery Charger (BCI)
F
Diodes, Resistors,
Capacitors
Governor (A106)
F
F
F
F
F
F
A
O
A, K
F
A, D, E
E
F
A, K
F
F
F
A, E, K
Potentiometer,
Manual
C O
O
Voltage Regulator
F
F
F
Short Plug
C O
O
A, E
Shunt, DC amp
C O
F
A, F
Potentiometer, Motor
Driven
O
F
F
F
O
F
Circuit Cards
05
T
E
S
T
E
(4)
TOOLS
AND
EQUIPMENT
CONTROL CUBICLE
Transducer, Elect. Signal
H
A, D, F, K
H
A, F
2-B&I
3-B&I
O
Horn, Alarm
Transformers
A
C
F
F
A, K
F
F
A
F
F
A
C-4
TM 5-6115-593-12
TO 35C2-3-463-1
SECTION II. MAINTENANCE ALLOCATION CHART (Cont)
(1)
(3)
MAINTENANCE FUNCTIONS
(2)
ASSEMBLY GROUP
G
R
O
U
P
N
O
A
B C
D
I
N
S
P
E
C
T
S
E
R
V
I
C
E
A
D
J
U
S
T
T
E
S
T
E
A
L
I
G
N
F
G
H
I
J
K
C
A
L
I
B
R
A
T
E
I
N
S
T
A
L
L
R
E
P
L
A
C
E
R
E
P
A
I
R
O
V
E
R
H
A
U
L
R
E
B
U
I
L
D
F
F
(4)
TOOLS
AND
EQUIPMENT
(5)
REMARKS
CONTROL CUBICLE
(Continued)
Annunciator Control Assy
F
Relays
O
F
A
F
F
E
Flashing Circuit, PC
(FCI)
F
F
F
F
F
Time Delay Module
(TD2)
O
Gauges and Instruments
C
Switches
F
C
Harness Assy
07
F
Diodes, Resistors,
Capacitors
Digital Clock
06
F
F
O
Lamps
C
Synchroscope
F
F
A, G
O
A, K
F
F
O
A
F
O
A, K
C
A
F
F
A
Circuit BKR
C O
O
A, E
Telephone Jack
C
O
A
C C O
O
A
Air Shut-Off Valve
O O
O
A, F
Element
C
O
A
Indicator
C
O
A
Ducts and Hoses
O
O
A
AIR CLEANER ASSY
TOOL BOX ASSY
O
C-5
O
H
TM 5-6115-593-12
TO 35C2-3-463-1
SECTION II. MAINTENANCE ALLOCATION CHART (Cont)
(1)
G
R
O
U
P
N
O
08
DOCUMENT COMP
09
SUPPORT FRAME ASSY
10
(3)
MAINTENANCE FUNCTIONS
(2)
ASSEMBLY GROUP
A
B C
D
I
N
S
P
E
C
T
S
E
R
V
I
C
E
A
D
J
U
S
T
T
E
S
T
E
A
L
I
G
N
F
G
H
I
J
K
C
A
L
I
B
R
A
T
E
I
N
S
T
A
L
L
R
E
P
L
A
C
E
R
E
P
A
I
R
O
V
E
R
H
A
U
L
R
E
B
U
I
L
D
O
O
(4)
TOOLS
AND
EQUIPMENT
(5)
REMARKS
A
A
Tie Bars
O
F
Support Frame, Frt
O
F
Support Frame, Center
O
F
Support Frame, Rear
O
F
RADIATOR ASSY
Radiator
C
Indicator, Sight Valve
O
F
Hoses
O
O
Belt, Fan
C
Motor
O
Fan and Bearing
F
F
C
O
A
Switch, Thermo
O O
O
A
Heater, Coolant
O O
O
A, E
Heater, Lube
O O
O
A, E
F
F
F
11
FUEL LINE AND FITTINGS
12
ENGINE PREHEAT
Valves, Ball
F
C
F
O
F
F
4-B
5-B
A
O
F
F
Hose and Fittings
O
O
A
Junction Box
F
F
A, E
C-6
TM 5-6115-593-12
TO 35C2-3-463-1
SECTION II. MAINTENANCE ALLOCATION CHART (Cont)
(1)
G
R
O
U
P
N
O
13
(3)
MAINTENANCE FUNCTIONS
(2)
ASSEMBLY GROUP
A
B C
D
I
N
S
P
E
C
T
S
E
R
V
I
C
E
A
D
J
U
S
T
G
H
I
J
K
C
A
L
I
B
R
A
T
E
I
N
S
T
A
L
L
R
E
P
L
A
C
E
R
E
P
A
I
R
O
V
E
R
H
A
U
L
R
E
B
U
I
L
D
O O O
F
F
F
F
F
Solenoid Valve
15
16
A
L
I
G
N
FUEL TRANSFER PUMP
Pump
14
(5)
REMARKS
F
T
E
S
T
E
(4)
TOOLS
AND
EQUIPMENT
A
Filter & Strainer
C
C
O
A
Strainer
C
C
O
A
FUEL TANK ASSY
Level Switch, Fuel
C O
O
F
Transmitter
C O
O
F
Fittings
O
O
A
C O
F
O
Harness and Cable
F
F
F
Reconnection Board
O
F
A, K
F
E
F
A
A, K
INTERCONNECTING
ELECTRICAL HARNESS
2-B&I
E, K
GENERATOR &
RECONNECTION ASSY
Switch, Limit
F
A, K
Bus Bar
O
Current Transformer
F
F
F
Generator
O
F
F
Permanent Magnet
Stator & Frame Assy
F
F
F
Permanent Magnet
Rotor Assy
F
F
F
D D
A, R
Rectifier Rotating
F
F
F
F
A, K
C-7
F
H D
A, R
A, K
TM 5-6115-593-12
TO 35C2-3-463-1
SECTION II. MAINTENANCE ALLOCATION CHART (Cont)
(1)
G
R
O
U
P
N
O
16
(3)
MAINTENANCE FUNCTIONS
(2)
ASSEMBLY GROUP
A
B C
D
I
N
S
P
E
C
T
S
E
R
V
I
C
E
A
D
J
U
S
T
T
E
S
T
E
A
L
I
G
N
F
G
H
I
J
K
C
A
L
I
B
R
A
T
E
I
N
S
T
A
L
L
R
E
P
L
A
C
E
R
E
P
A
I
R
O
V
E
R
H
A
U
L
R
E
B
U
I
L
D
(4)
TOOLS
AND
EQUIPMENT
(5)
REMARKS
GENERATOR &
RECONNECTION ASSY
(Continued)
Bearing
O
F
A, K
Drive Plate Assy
O
F
A, K
Fan
F
F
A, K
Rotor Assy
F
F
F
D
D
A, K
Exciter Stator
F
F
F
D
D
A, K
Exciter Armature
F
F
F
D
D
A, K
Frame & Stator
Combination
F
F
F
D
D
A, K
F O
F
F
O
O
A, F
F
F
H H
A, K
O
O
17
ACTUATOR, ELECTRIC
HYDRAULIC
C
18
ETHER KIT
C O C
19
ENGINE ASSY
Engine
O
Belt, Water Pump
C
F
Filters, Water
C
F
H
A, K
A, K
O
I
Speed Switch and Drive
Speed Switch
C O
F
O
Adapter
C
F
Tach Drive
F
F
C-8
F
A
A
F
6-I
A
TM 5-6115-593-12
TO 35C2-3-463-1
SECTION II. MAINTENANCE ALLOCATION CHART (Cont)
(1)
G
R
O
U
P
N
O
19
(3)
MAINTENANCE FUNCTIONS
(2)
ASSEMBLY GROUP
A
B C
D
I
N
S
P
E
C
T
S
E
R
V
I
C
E
A
D
J
U
S
T
T
E
S
T
E
A
L
I
G
N
F
G
H
I
J
K
C
A
L
I
B
R
A
T
E
I
N
S
T
A
L
L
R
E
P
L
A
C
E
R
E
P
A
I
R
O
V
E
R
H
A
U
L
R
E
B
U
I
L
D
(4)
TOOLS
AND
EQUIPMENT
(5)
REMARKS
ENGINE ASSY
(Continued)
Oil Level Sight Gauge
and Filler
C
O
Starter Assy
C O
F
Brushes
F
F
A
F
H
A
A
Solenoid Starter
O
F
F
Armature Starter
F
F
F
Drive Starter
F
F
F
F
A
Field Assembly
F
F
F
F
A
Xmtr, Pressure
C O
O
A
Xmtr, coolant
C O
O
A
Switch, Pressure
O O
O
A
Switch, Temperature
O O
O
A
Filter, Element, Oil
(Spin-on)
C
C
O
A
Filter, Oil, Bypass
C
O
F
A
Secondary Fuel Filter
Element (Spin-on)
C
O
O
A
Lube Oil Cooler
O
Breather, Lines &
Fittings
O
Relief Valve
F
OIL FILTER AND SENSORS
F
O
F
O
F
F
C-9
A
A
F
A
TM 5-6115-593-12
TO 35C2-3-463-1
SECTION II. MAINTENANCE ALLOCATION CHART (Cont)
(1)
A
B C
D
I
N
S
P
E
C
T
T
E
S
T
S
E
R
V
I
C
E
A
D
J
U
S
T
Injector
O
F
Pump, Fuel Injection
C
F
Turbocharger
WATER PUMP
G
R
O
U
P
N
O
19
(3)
MAINTENANCE FUNCTIONS
(2)
ASSEMBLY GROUP
E
(4)
TOOLS
AND
EQUIPMENT
(5)
REMARKS
F
G
H
I
J
K
C
A
L
I
B
R
A
T
E
I
N
S
T
A
L
L
R
E
P
L
A
C
E
R
E
P
A
I
R
O
V
E
R
H
A
U
L
R
E
B
U
I
L
D
F
O
F
7-B&I
8-B&I
9-B&I
10-B&I
11-B&I
12-I
13-I
A, K
O
F
H H D
14-B, I
&J
15-B, I
&J
16-I&J
17-I&J
A, J, K
O
O
F
C
O
F
A
L
I
G
N
OIL FILTER AND SENSORS
(Continued)
F
A, K
18-1
A, K
THERMOSTAT AND HOUSING
Thermostat
O
O
F, K
Xmtr, Temperature
C O
O
A
Switch, Temperature
O O
O
A
O
F
A
Idler Pulley Assembly
O
O
A
Intercooler
O
O
A, K
Exhaust Manifold
O
O
A, K
Water Manifold
O
O
A, K
Engine Front Support
F
F
A
Oil Pan Assembly
C
F
F
A
Oil Pump
H H
H
H
A, F
Damper, Vibration &
Crankshaft Pulley
C-10
TM 5-6115-593-12
TO 35C2-3-463-1
SECTION II. MAINTENANCE ALLOCATION CHART (Cont)
(1)
G
R
O
U
P
N
O
19
(3)
MAINTENANCE FUNCTIONS
(2)
ASSEMBLY GROUP
A
B C
D
I
N
S
P
E
C
T
S
E
R
V
I
C
E
A
D
J
U
S
T
T
E
S
T
E
A
L
I
G
N
F
G
H
I
J
K
C
A
L
I
B
R
A
T
E
I
N
S
T
A
L
L
R
E
P
L
A
C
E
R
E
P
A
I
R
O
V
E
R
H
A
U
L
R
E
B
U
I
L
D
(4)
TOOLS
AND
EQUIPMENT
(5)
REMARKS
(Continued)
FLYWHEEL HOUSING,
VIBRATION DAMPER AND
CRANKSHAFT PULLEY
Flywheel Assembly
Ring Gear
H
H
A, K
Flywheel
H
H
A, K
C
H
Housing
H
H
A
Timing Gear and Cover
H
H
A, K
Rocker Arm Shaft Assy
O
F
Rocker Arm Assembly
O
Pushrod & Tappet
F
F
Cylinder Head Assy
F
F
F
Valve Intake and
Exhaust
F
F
F
F
Spring Valve
F
F
Seats Intake and
Exhaust Valves
Valve Spring
Vibration Damper and
Crankshaft Pulley
CYLINDER HEAD AND VALVE
OPERATING MECHANISM
O
F
A, K
F
O
19-D
A, K
A, K
H D
20-I
21-I
22-J
23-J
24-I&J
25-J
26-J
27-A, I,
&J
A, K
A, K
F
A, K
F
H
A, K
F
H
A, K
C-11
TM 5-6115-593-12
TO 35C2-3-463-1
SECTION II. MAINTENANCE ALLOCATION CHART (Cont)
(1)
G
R
O
U
P
N
O
19
(3)
MAINTENANCE FUNCTIONS
(2)
ASSEMBLY GROUP
A
B C
D
I
N
S
P
E
C
T
S
E
R
V
I
C
E
A
D
J
U
S
T
T
E
S
T
E
A
L
I
G
N
F
G
H
I
J
K
C
A
L
I
B
R
A
T
E
I
N
S
T
A
L
L
R
E
P
L
A
C
E
R
E
P
A
I
R
O
V
E
R
H
A
U
L
R
E
B
U
I
L
D
(4)
TOOLS
AND
EQUIPMENT
(5)
REMARKS
(Continued)
CYLINDER HEAD AND VALVE
OPERATING MECHANISM
(Continued)
Head, Cylinder
F
H
H D
A, K
Lifters, Valve
H
H
A, K
Camshaft
H
H
A, K
Piston Pin
H
H
A, K
Connecting Rod
H
H
A, K
Rod Bearing
H
H
A, K
Piston Rings
H
H
A, K
Piston
H
H
A, K
Cylinder Sleeves
H
H
A, K
Main Bearings
H
H
A, K
Crankshaft
H
H
A, K
Bushing, Camshaft
H
H
A, K
Cylinder Block
H
H
PISTON AND RINGS
CRANKSHAFT AND BLOCK
20
21
H H D
A, K
F
A, H
BASE ASSY
Skid Base
O
Terminals & Fittings
O
O
Hoses
O
O
F
F
REMOTE CABLE ASSY
C-12
A
F
A
TM 5-6115-593-12
TO 35C2-3-463-1
SECTION II. MAINTENANCE ALLOCATION CHART (Cont)
(1)
G
R
O
U
P
N
O
22
(3)
MAINTENANCE FUNCTIONS
(2)
ASSEMBLY GROUP
A
B C
D
I
N
S
P
E
C
T
S
E
R
V
I
C
E
A
D
J
U
S
T
A
L
I
G
N
F
G
H
I
J
K
C
A
L
I
B
R
A
T
E
I
N
S
T
A
L
L
R
E
P
L
A
C
E
R
E
P
A
I
R
O
V
E
R
H
A
U
L
R
E
B
U
I
L
D
REMOTE CONTROL MODULE
Transducer, Elect
Signal
(5)
REMARKS
2-B&I
3-B&I
O
F
F
A, K
Gauges & Instruments
C O
O
A, K
Transformers
D
F
F
A
Switches
C O
O
A
F
F
A
C
A
Diodes, Capacitors,
Resistors
Lamps
C
Time Delay Module
Synchroscope
F
Telephone Jack
C
Annunciator Control
Assy
F
F
F
F
F
A
A
A
F
F
F
A
Relays
O
F
F
A
Horn, Alarm
O O
O
A
F
F
A
Flashing Circuit (PC)
23
T
E
S
T
E
(4)
TOOLS
AND
EQUIPMENT
AUTOMATIC CONTROL MODULE
2-B&I
3-B&I
U/O Voltage Device
O
F
F
F
A
U/F Device
O
F
F
F
A
O/F Device
O
F
F
F
A
Time Delay Relay
O
F
F
F
A
Lamps
C
C
A
Relays
O
F
A
F
C-13
TM 5-6115-593-12
TO 35C2-3-463-1
SECTION II. MAINTENANCE ALLOCATION CHART (Cont)
(1)
G
R
O
U
P
N
O
23
(3)
MAINTENANCE FUNCTIONS
(2)
ASSEMBLY GROUP
A
B C
D
I
N
S
P
E
C
T
S
E
R
V
I
C
E
A
D
J
U
S
T
T
E
S
T
E
A
L
I
G
N
F
G
H
I
J
K
C
A
L
I
B
R
A
T
E
I
N
S
T
A
L
L
R
E
P
L
A
C
E
R
E
P
A
I
R
O
V
E
R
H
A
U
L
R
E
B
U
I
L
D
AUTOMATIC CONTROL MODULE
(Continued)
Switches
(5)
REMARKS
2-B&I
3-B&I
O O
O
A, E
O
O
E
F
A
Fuses
Fuse Holder
O
Synchronizer
O
F
F
Rectifiers
C
F
F
24
PARALLEL CABLE
ASSEMBLIES
F
25
HOUSING KIT
O
Weather Stripping,
Seals
(4)
TOOLS
AND
EQUIPMENT
F
O
F
F
A
A
F
F
A
F
F
A
O
A
F
F
Actuators, Louver
F
Switches, Limit
F
F
E
Relays
F
F
E
F
F
A
E
Shutter Assy
F
Harness Assy
O O
F
F
F
C-14
O
TM 5-6115-593-12
TO 35C2-3-463-1
SECTION II. MAINTENANCE ALLOCATION CHART (Cont)
(1)
G
R
O
U
P
N
O
26
(3)
MAINTENANCE FUNCTIONS
(2)
ASSEMBLY GROUP
A
B C
D
I
N
S
P
E
C
T
S
E
R
V
I
C
E
A
D
J
U
S
T
T
E
S
T
E
A
L
I
G
N
F
G
H
I
J
K
C
A
L
I
B
R
A
T
E
I
N
S
T
A
L
L
R
E
P
L
A
C
E
R
E
P
A
I
R
O
V
E
R
H
A
U
L
R
E
B
U
I
L
D
PARTS KITS
Gasket Set, Engine
F
Gasket Set, Cylinder
Head
F
Gasket Set, AFC Fuel
Pump
F
Kit, Cylinder Sleeve
H
Kit, Starter
F
Kit, Starter Relay
F
Kit, Brush, Electric
F
Kit, Starter Solenoid
F
C-15
(4)
TOOLS
AND
EQUIPMENT
(5)
REMARKS
TM 5-6115-593-12
TO 35C2-3-463-1
Section III. TOOLS, TEST AND SUPPORT EQUIPMENT REQUIREMENT
REFERENCE CODE
MAINTENANCE
CATEGORY
NOMENCLATURE
NSN
1-B
O
Tester, Battery, Electrolyte solution
6630-00-171-5126
2-B & I
O
Ohmmeter
6624-00-581-2466
3-B & I
F
Multimeter
6625-00-553-0142
4-B
C
Tester, Antifreeze solution
6630-00-247-2968
5-B
F
Tester, Radiator pressure
6-I
F
Oil Seal Assembly Tool
7-B & I
F
Test Stand, Injector
8-B & I
F
Plunger Extension
9-B & I
F
Tester, Injector leakage
10-B & I
F
Tester, Spray angle
11-B * I
F
Holding Fixture
12-1
F
Retainer Wrench
13-1
F
Crowfoot Wrench
14-B, I & J
F
Test Stand, Fuel pump
15-B, I & J
F
Spring Adjusting Tool
16-I & J
H
Blockplate, Gear Pump
17-I & J
H
Ream Fixture
18-1
F
Puller
19-D
O
Gage, Thickness
20-I
F
Holding Tool, Injector
21-I
F
Testing, Hydrostatic
22-J
H
Cutter Set
23-J
H
Cutter Seat
24-I & J
F
Adapter Wrench
25-J
H
Grinding Machine, Valve face
4910-00-540-4679
26-J
H
Grinding Kit, Valve seat
4910-00-473-6437
27-A, I & J
F
Micrometers, Inside and outside
C-16
5210-00-221-1999
TM 5-6115-593-12
TO 35C2-3-463-1
Section IV. REMARKS
Ref. Code
Remarks
A
Visual inspection
B
Repaired by fabricating new tables
C
Hydrometer test
D
Repair by replacement of components
E
Continuity test
F
Operational test
G
Repair by replacing defective component
H
Repair by straightening and welding
I
Service by replacement
J
Adjust on engine or using test stand
C-17/(C-18 blank)
TM 5-6115-593-12
TO 35C2-3-463-1
APPENDIX D
ADDITIONAL AUTHORIZATION LIST
Section I. INTRODUCTION
D-1.
D-2.
SCOPE. This appendix lists additional items you
are authorized and which may be required for
operation of the 500 KW 50/60 HZ DOD generator
set used in support of communications systems.
with it. This manual is your authorization to
requisition these items as required.
D-3.
GENERAL. This list identifies items that do not
have to accompany the 500 KW 50/60 HZ DOD
generator set and that do not have to be turned in
EXPLANATION OF LISTING. National stock
numbers, descriptions, and qualities are provided
to help you identify and request the additional
items you require to support equipment.
Section II. ADDITIONAL AUTHORIZATION LIST
(1)
(2)
NATIONAL
STOCK
NUMBER
DESCRIPTION
(3)
(4)
U/M
QTY
AUTH
Remote Control Cable Assy
76-11025 (30554)
EA
1
Remote Control Module
76-11339 (30554)
EA
1
Automatic Control Module
691031-001 (30554)
EA
1
Housing Kit
76-11000 (30554)
EA
1
PART NUMBER & FSCM
USABLE ON CODE
D-1/(D-2 blank)
TM 5-6115-593-12
TO 35C2-3-463-1
INDEX
Paragraph,
Figure, Table,
Number
Subject
A
AC-DC CONTROL BOX
Circuit Breaker
Inspect.............................................................................................................................................
Test ................................................................................................................................................
Replace. ..........................................................................................................................................
Control Panel
Inspect.............................................................................................................................................
Replace ...........................................................................................................................................
Repair .............................................................................................................................................
Convenience Receptacle, AC (J103)
Inspect.............................................................................................................................................
Replace ...........................................................................................................................................
Harness Assembly
Test ................................................................................................................................................
Repair .............................................................................................................................................
Potentiometer, Manual
Inspect ............................................................................................................................................
Test ................................................................................................................................................
........................................................................................................................................................
Replace. ..........................................................................................................................................
........................................................................................................................................................
Potentiometer, Motor Driven
Inspect.............................................................................................................................................
Receptacle (J04-J109)
Inspect ............................................................................................................................................
Replace ..........................................................................................................................................
Relays
Inspect ............................................................................................................................................
Short Plug
Inspect ............................................................................................................................................
Test ................................................................................................................................................
Replace ...........................................................................................................................................
Shunt, DC Amp
Inspect.............................................................................................................................................
Test ................................................................................................................................................
Switch
Inspect ............................................................................................................................................
Test ................................................................................................................................................
Replace ..........................................................................................................................................
ACTUATOR, ELECTRIC HYDRAULIC
Inspect...................................................................................................................................................
Service .................................................................................................................................................
ADMINISTRATIVE STORAGE.....................................................................................................................
AIR CLEANER
Inspect...................................................................................................................................................
Service. .................................................................................................................................................
Replace .................................................................................................................................................
Air Shut Off Valve
Inspect ............................................................................................................................................
Test ................................................................................................................................................
Replace. ..........................................................................................................................................
Ducts and Hoses
Inspect ............................................................................................................................................
Replace ..........................................................................................................................................
Index-1
3-10a
4-29a
4-29b
4-28b
4-28e
4-28d
3-10b
4-30
4-38b
4-38c
3-10a
4-33a
4-34a
4-33b
4-34b
4-35
3-10b
4-30
4-37
3-10b
4-31a
4-31b
3-10a
4-36a
3-10a
4-32a
4-32b
4-64a
4-64b
1-7
3-12a
4-42b
4-42e
4-43a
4-43b
4-43c
4-44a
4-44b
TM 5-6115-593-12
TO 35C2-3-463-1
INDEX-Continued
Paragraph,
Figure, Table,
Number
Subject
A-Continued
Element
Inspect.............................................................................................................................................
Replace ...........................................................................................................................................
Indicator
Inspect.............................................................................................................................................
Replace ...........................................................................................................................................
AUTOMATIC CONTROL MODULE
Component Inspection ...........................................................................................................................
Mode Selector Switch Test.....................................................................................................................
Toggle Switch Test ................................................................................................................................
3-12c
4-42c
3-12b
4-42d
5-20a
5-20b
5-20c
B
BASE ASSEMBLY
Inspect...................................................................................................................................................
Replace .................................................................................................................................................
Hoses
Inspect.............................................................................................................................................
Replace ...........................................................................................................................................
Terminals and Fittings
Inspect.............................................................................................................................................
Replace ...........................................................................................................................................
BATTERIES AND RELATED ITEMS
Batteries
Inspect.............................................................................................................................................
Test .................................................................................................................................................
Service ............................................................................................................................................
Install...............................................................................................................................................
Replace ...........................................................................................................................................
Cables
Inspect.............................................................................................................................................
Replace ...........................................................................................................................................
Repair..............................................................................................................................................
4-89
4-90
4-89d
4-91
4-89e
4-91
3-7a
4-16a
3-7b
4-16b
4-16b
3-7a
4-14a
4-14b
C
CONTROL CUBICLE
Circuit Breaker
Inspect.............................................................................................................................................
Test .................................................................................................................................................
Replace ...........................................................................................................................................
Gauges and Instruments
Inspect.............................................................................................................................................
Replace ...........................................................................................................................................
Harness Assembly
Test .................................................................................................................................................
Repair..............................................................................................................................................
Lamps
Inspect.............................................................................................................................................
Replace .................................................................................................................................................
Index-2
3-11a
4-40b
4-40q
3-11a
4-40q
4-41b
4-41c
3-11a
3-11b
TM 5-6115-593-12
TO 35C2-3-463-1
INDEX-Continued
Paragraph,
Figure, Table,
Number
Subject
C-Continued
Relays
Inspect.............................................................................................................................................
Switches
Inspect.............................................................................................................................................
Replace ...........................................................................................................................................
Telephone Jack
Inspect.............................................................................................................................................
Replace ...........................................................................................................................................
Time Delay Module (TD2)
Inspect.............................................................................................................................................
Transducer, Electrical Signal
Inspect.............................................................................................................................................
Transformers
Inspect.............................................................................................................................................
4-40a
3-11a
4-40q
3-11a
3-11b
4-40a
4-40a
3-11a
D
DESTRUCTION OF ARMY MATERIEL........................................................................................................
DISMANTLING FOR MOVEMENT...............................................................................................................
DOCUMENT COMPARTMENT
Replace ...........................................................................................................................................
Repair..............................................................................................................................................
1-6
4-5
3-11a
4-40q
E
ENGINE ASSEMBLY
Belt, Water Pump
Inspect.............................................................................................................................................
Adjust ..............................................................................................................................................
Replace ...........................................................................................................................................
Cylinder Head and Valve Operating Mechanism
Rocker Arm Assembly
Inspect.............................................................................................................................................
Adjustment ......................................................................................................................................
Rocker Arm Shaft Assembly
Inspect.............................................................................................................................................
Filters, Water
Service ..................................................................................................................................................
Injector
Inspect...................................................................................................................................................
Replace .................................................................................................................................................
Lube Oil Cooler
Inspect...................................................................................................................................................
Replace .................................................................................................................................................
Oil Filters and Sensors
Breather, Lines and Fittings
Inspect.............................................................................................................................................
Replace ...........................................................................................................................................
Filter, Element, Oil (Spin-on)
Inspect.............................................................................................................................................
Service ............................................................................................................................................
Replace ...........................................................................................................................................
Index-3
3-20a
4-67a
4-67b
4-87a
4-87b
4-87a
4-68
4-77a
4-77b
4-76a
4-76b
4-92a
4-92b
4-20
4-8c
4-74a
TM 5-6115-593-12
TO 35C2-3-463-1
INDEX-Continued
Paragraph,
Figure, Table,
Number
Subject
E-Continued
Filter, Oil, Bypass
Inspect ............................................................................................................................................
Service ............................................................................................................................................
Oil Level Gauge and Filler
Inspect.............................................................................................................................................
Replace ...........................................................................................................................................
Switch, Pressure
Inspect.............................................................................................................................................
Test .................................................................................................................................................
Replace ...........................................................................................................................................
Transmitter, Pressure
Inspect.............................................................................................................................................
Test .................................................................................................................................................
Replace ...........................................................................................................................................
Pump, Fuel Injector
Inspect...................................................................................................................................................
Secondary Fuel Filter Element (Spin-on)
Inspect.............................................................................................................................................
Service ............................................................................................................................................
Replace ...........................................................................................................................................
Solenoid Starter
Test .......................................................................................................................................................
Speed Switch and Drive
Adapter
Inspect ............................................................................................................................................
Speed Switch
Inspect.............................................................................................................................................
Test .................................................................................................................................................
Replace ...........................................................................................................................................
Starter Assembly
Inspect.............................................................................................................................................
Test .................................................................................................................................................
Thermostat and Housing
Damper, Vibration and Crankshaft Pulley
Inspect.............................................................................................................................................
Exhaust Manifold
Inspect. .......................................................................................................................................................
Replace........................................................................................................................................................
Idler Pulley Assembly
Inspect 4-79b
Replace........................................................................................................................................................
Intercooler
Inspect 4-84a
Replace........................................................................................................................................................
Oil Pan Assembly
Inspect.............................................................................................................................................
Switch, Temperature
Inspect.............................................................................................................................................
Test .................................................................................................................................................
Replace ...........................................................................................................................................
Thermostat
Test .................................................................................................................................................
Water Manifold
Inspect.............................................................................................................................................
Replace ...........................................................................................................................................
Index-4
4-74b
4-8c
3-20d
4-70
4-73a
4-73b
4-73e
3-20j
4-72a
4-72b
3-201
3-20h
3-20m
4-75a
4-71
3-20b
3-20a
4-69b
4-69
3-20e
4-71a
4-83a
4-85a
4-85b
4-79c
4-84b
3-20k
4-82a
4-82c
4-82d
4-80a
4-86a
4-86b
INDEX- Continued
TM 5-6115-593-12
TO 35C2-3-463-1
Paragraph,
Figure, Table,
Number
Subject
E-Continued
Transmitter, Temperature
Inspect.............................................................................................................................................
Test .................................................................................................................................................
Replace ...........................................................................................................................................
Turbocharger
Inspect...................................................................................................................................................
Replace .................................................................................................................................................
Water Pump
Inspect.............................................................................................................................................
Replace ...........................................................................................................................................
ENGINE PREHEAT
Heater (H101 and H102)
Inspect.............................................................................................................................................
Test .................................................................................................................................................
Replace ...........................................................................................................................................
Hose and Fittings
Inspect.............................................................................................................................................
Replace ...........................................................................................................................................
Switch, Thermo Immersion (S30)
Inspect.............................................................................................................................................
Test .................................................................................................................................................
Replace ...........................................................................................................................................
EQUIPMENT CONVERSION .......................................................................................................................
ETHER KIT
Inspect...................................................................................................................................................
Test .......................................................................................................................................................
Service ..................................................................................................................................................
Replace .................................................................................................................................................
Repair....................................................................................................................................................
EXTERNAL POWER ASSEMBLY
Circuit Breaker (CB101)
Inspect.............................................................................................................................................
Test .................................................................................................................................................
Replace ...........................................................................................................................................
Circuit Breakers
Inspect.............................................................................................................................................
Test .................................................................................................................................................
Replace ...........................................................................................................................................
Contactors, Heater (K107) and (K109)
Inspect.............................................................................................................................................
Test .................................................................................................................................................
Replace ...........................................................................................................................................
Control Panel
Inspect.............................................................................................................................................
Repair..............................................................................................................................................
Harness Assembly
Test .................................................................................................................................................
Repair..............................................................................................................................................
Plate and Sleeve Assembly
Inspect.............................................................................................................................................
Replace ...........................................................................................................................................
Receptacles
Inspect.............................................................................................................................................
Replace ...........................................................................................................................................
Index-5
3-20j
4-81a
4-81b
4-78a
4-78b
3-20a
4-79a
4-51a
4-51b
4-51c
4-51a
4-51c
4-51a
4-51b
4-51c
4-4
3-19a
4-65a
3-19b
4-65d
4-65d
3-9
4-20a
4-20b
3-9
4-24a
4-20
4-23a
4-23b
4-23c
4-19a
4-19c
4-27a
4-27c
3-9
4-25
3-9
4-21
TM 5-6115-593-12
TO 35C2-3-463-1
INDEX-Continued
Paragraph,
Figure, Table,
Number
Subject
E-Continued
Switch, Pre-Heat (S105)
Inspect.............................................................................................................................................
Test .................................................................................................................................................
Replace ...........................................................................................................................................
Transfer Contactor (K108)
Inspect.............................................................................................................................................
Test .................................................................................................................................................
Replace ...........................................................................................................................................
Weather Stripping, Seals
Inspect.............................................................................................................................................
Replace ...........................................................................................................................................
3-9
4-22a
4-22b
4-23a
4-23b
4-23c
4-26a
4-26b
F
FUEL LINE AND FITTINGS
Inspect...................................................................................................................................................
Replace .................................................................................................................................................
FUEL TANK ASSEMBLY
Fittings
Inspect.............................................................................................................................................
Replace ...........................................................................................................................................
Level Switch, Fuel
Inspect.............................................................................................................................................
Test .................................................................................................................................................
Replace ...........................................................................................................................................
Transmitter
Inspect.............................................................................................................................................
Test .................................................................................................................................................
Replace ...........................................................................................................................................
FUEL TRANSFER PUMP
Filter and Strainer
Inspect.............................................................................................................................................
Service ............................................................................................................................................
Replace ...........................................................................................................................................
Pump
Inspect.............................................................................................................................................
Test .................................................................................................................................................
Strainer
Inspect ............................................................................................................................................
Service ............................................................................................................................................
Replace ...........................................................................................................................................
3-14
4-50b
4-54a
4-54b
3-16a
4-55a
4-55b
3-16b
4-56a
4-56b
3-15a
3-15b
4-53b
4-52a
4-52b
3-15a
3-15b
4-53b
G
GENERATOR AND RECONNECTION ASSEMBLY
Bearing
Inspect.............................................................................................................................................
Buss Bar
Inspect.............................................................................................................................................
Drive Plate Assembly
Inspect.............................................................................................................................................
Index-6
4-62
4-60
4-63
TM 5-6115-593-12
TO 35C2-3-463-1
INDEX-Continued
Paragraph,
Figure, Table,
Number
Subject
G-Continued
Generator
Inspect.............................................................................................................................................
Reconnection Board
Inspect.............................................................................................................................................
4-61
4-60
H
HOUSING KIT
Harness Assembly
Inspect.............................................................................................................................................
Test .................................................................................................................................................
Repair..............................................................................................................................................
Weather Stripping, Seals
Inspect.............................................................................................................................................
Replace ...........................................................................................................................................
5-26a
5-26b
5-26c
5-26a
5-26d
I
INSTALLATION OF THE GENERATOR SET ..............................................................................................
INTERCONNECTING ELECTRICAL HARNESS
Inspect...................................................................................................................................................
Test .......................................................................................................................................................
Repair....................................................................................................................................................
4-3
3-17
4-58a
4-58b
L
LEVELS OF MAINTENANCE ACCOMPLISHMENT.....................................................................................
LUBRICATION INSTRUCTIONS..................................................................................................................
1-5
F3-1b
M
MAINTENANCE FORMS AND RECORDS ..................................................................................................
MUFFLER, EXHAUST
Exhaust and Rain Cap
Inspect.............................................................................................................................................
Replace ...........................................................................................................................................
Gaskets
Inspect.............................................................................................................................................
Replace ...........................................................................................................................................
Muffler
Inspect.............................................................................................................................................
Replace ...........................................................................................................................................
1-3
3-8
4-18
3-8
4-18
3-18a
4-18
N
NORMAL OPERATING CONDITIONS
Starting ..................................................................................................................................................
Stopping ................................................................................................................................................
Index-7
2-4
2-5
TM 5-6115-593-12
TO 35C2-3-463-1
INDEX-Continued
Paragraph,
Figure, Table,
Number
Subject
O
OPERATING PROCEDURES
Emergency Operation ............................................................................................................................
Emergency Stopping..............................................................................................................................
Exercise of Engine on Standby ..............................................................................................................
Operation with Housing Kit.....................................................................................................................
Operation with Remote Control Module and Cable .......................................................................................
Operation with Automatic Control Module ....................................................................................................
Parallel Operation ........................................................................................................................................
Preparation for Starting ................................................................................................................................
Single Engine Generator Set Operation .......................................................................................................
Starting ........................................................................................................................................................
Stopping.......................................................................................................................................................
Stopping by Safety Devices .........................................................................................................................
Operation Under Unusual Conditions
Cold Weather.........................................................................................................................................
Dusty or Sandy Areas ............................................................................................................................
Emergency Operation on JP5 Fuel ........................................................................................................
Extreme Heat.........................................................................................................................................
High Altitudes ........................................................................................................................................
Salt Water Areas ...................................................................................................................................
Snow .....................................................................................................................................................
Rainy or Humid Conditions ....................................................................................................................
2-6b
2-5c
2-7
2-9
F2-9
F2-10
F2-11
F2-12
2-10
F2-14
F2-15
F2-16
F2-17
F2-18
2-11
2-12
F2-19
F2-20
F2-21
2-4a
F2-5
2-6a
F2-8
2-4b
F2-6
2-5a
F2-17
2-5b
2-13
2-15
2-20
2-14
2-18
2-17
2-19
2-16
P
PREPARATION FOR SHIPMENT AND STORAGE .....................................................................................
PREVENTIVE MAINTENANCE CHECKS AND SERVICES
PREVENTIVE MAINTENANCE CHECKS AND SERVICES
Operator/Crew .......................................................................................................................................
Organizational .......................................................................................................................................
Remote Control Module .........................................................................................................................
Automatic Control Module......................................................................................................................
Housing Kit ............................................................................................................................................
Index-8
1-8
T3-2
T4-2
T5-1
T5-4
T5-7
TM 5-6115-593-12
TO 35C2-3-463-1
INDEX-Continued
Paragraph,
Figure, Table,
Number
Subject
R
RADIATOR ASSEMBLY
Belt, Fan
Inspect.............................................................................................................................................
Adjust ..............................................................................................................................................
Replace ...........................................................................................................................................
Hoses
Inspect.............................................................................................................................................
Replace ...........................................................................................................................................
Indicator, Sight Valve
Inspect.............................................................................................................................................
Motor
Inspect.............................................................................................................................................
Radiator
Inspect.............................................................................................................................................
Service ............................................................................................................................................
RADIO INTERFERENCE SUPPRESSION...................................................................................................
REMOTE CONTROL MODULE
Gauges and Instruments
Inspect.............................................................................................................................................
Test .................................................................................................................................................
Replace ...........................................................................................................................................
Horn, Alarm
Inspect.............................................................................................................................................
Test .................................................................................................................................................
Replace ...........................................................................................................................................
Lamps
Inspect.............................................................................................................................................
Replace ...........................................................................................................................................
Relays
Inspect.............................................................................................................................................
Switches
Inspect.............................................................................................................................................
Test .................................................................................................................................................
Replace ...........................................................................................................................................
Telephone Jack
Inspect.............................................................................................................................................
Replace ...........................................................................................................................................
Transformers
Inspect.............................................................................................................................................
Transducer, Electrical Signal
Inspect.............................................................................................................................................
REPORTING OF ERRORS..........................................................................................................................
S
STANDBY SERVICE ...................................................................................................................................
SUPPORT FRAME ASSEMBLY
Support Frame, Center
Inspect.............................................................................................................................................
Support Frame, Front
Inspect.............................................................................................................................................
Support Frame, Rear
Inspect.............................................................................................................................................
Tie Bars
Inspect.............................................................................................................................................
Index-9
3-13a
4-49a
4-49b
4-49e
4-49e
4-49d
4-49c
3-13a
3-13b
4-11
5-7a
5-9a(4)
3-13b
5-9a
5-9b
5-9c
5-7a
5-7b
5-9a
5-9a
5-9b
5-9c
5-7a
5-7b
5-7a
5-9a
1-4
2-7
4-48
4-48
4-48
4-48
INDEX- Continued
TM 5-6115-593-12
TO 35C2-3-463-1
Paragraph,
Figure, Table,
Number
Subject
T
TABULATED DATA .....................................................................................................................................
TOOL BOX ASSEMBLY
Replace ................................................................................................................................................
Repair ...................................................................................................................................................
TROUBLESHOOTING
Operator/Crew. ......................................................................................................................................
Organizational ......................................................................................................................................
Remote Control Module, Operator/Crew ................................................................................................
Remote Control Module, Organizational.................................................................................................
Automatic Control Module, Operator/Crew ............................................................................................
Automatic Control Module, Organizational ............................................................................................
Housing Kit ............................................................................................................................................
1-10
4-45a
4-45b
T3-3a
T4-3b
T5-2a
T5-3
T5-5
T5-6
T5-8
U
UNLOADING THE GENERATOR SET.........................................................................................................
Index-10
4-1
TM 5-6115-593-12
TO 35C2-3-463-1
DESIGNATION
1.
2.
34.
5.
6.
7.
8.
9,
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
NOTES:
1. INTERPRET DWG PER DOD-STD-100.
2. 2. JUMPERS SEE A THRU F ATE TO BE REMOVED WHEN REMOTE
CONTROL BOX IS INSTALLED INTO SYSTEM
3. MOVE JUMPER L ON TB20 FROM POINT 1 RO POINT 2 WHEN
BATTERY CHARGER NOT ENGAGED IN STBY.
4. THIS CIRCUIT IS USED ONLY WHEN GENERATOR SET IS
ENCLOSED WITH LOUVERED DOORS.
5. J1, J2 J4 ARE REMOTE CONTROL BOX CONNECTIONS.
6. J3 AUTOMATIC CONTROL MODULE BOX CONNECTIONS.
7. FOR DC TROUBLE SHOOTING DIAGRAM SEE DWG 76-11436.
8. REMOVE JUMPER FOR 60 HZ OPERATION WHEN REMOTE
CONTROL BOX IS INSTALLED INTO SYSTE,.
24.
25.
26.
27.
28.
29
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52,
53,
54,
55.
56.
57.
58
59,
A1
A106
B1
B2
BC1
B4,5
B10-13
BCR
BTR
BT1-BT4
CB1
CB2
CR
C101
DESIGNATION
ANNUNCIATOR AUDIBLE ALARM
60.
M1
GOV CONTROLLER (SPEED CONT)
61.
M2
FUEL TRANSFER PUMP MOTOR
62.
STARTER MOTOR
63.
M4
BATTERY CHARGER
64.
M5
MOTOR OPERATED POTS
65.
M20
LOUVER MOTORS
66.
M21
RELAY, BREAKER CLOSE
67.
M111
RELAY, BREAKER TRIP
68.
MT1,2,3,4
BATTERY
DC POWER BREAKER
69.
OPI,2
AC BUS POWER (MOTOR OPERATED) BREAKER
70.
DIODES
71.
OT1,2
FILTER CAPACITOR
72.
R1,2,3
73.
R30
DS1
INDICATOR, FUEL PUMP 'ON'
DS2 3,4,5,10,11 PANEL LIGHTS
DS6
INDICATOR, CB2 POWER BREAKER 'CLOSED' 74.
S1
DS7
INDICATOR, PARALLEL CIRCUIT 'ON'
75.
S2
DS27-36
INDICATORS, FAULT
76.
S3
DS41
INDICATOR PHASE 1,2,3
77.
S5
DS42
INDICATOR, PHASE 1,3.2
78.
S6
DS50
INDICATOR BATTLE SHORT 'ON'
79.
S7
DS51
INDICATOR OVERCRANK
80.
S8
81.
S9
82.
S11
ETHER AID
STARTING AID SOLENOID
83.
S12
F60,61,62,63
FUSE
85
S13
FC1
FLASHER
86
S20
FC2
FLASHER-ANNUNCIATOR AUDIBLE ALARM
87
S21
FL1,2,3,4
FUEL LEVEL SWITCHES
88
S22
K1
RELAY, RUN STOP (6 PDT)
89
S49
K3
RELAY, CRANKING
90.
S50
K5
START/RUN/STOP PILOT
91.
S51
K5
RELAY, TIMING CRANK DISCONNECT
93.
S53
K8
RELAY, LOW FUEL SHUTDOWN
94.
S60-63
K19
RELAY, TIMING OVERCRANK SHUTDOWN
95.
SRM
K20
RELAY, FUEL TRANSFER PUMP
96 SS1,2,3
K21
RELAY, EMERGENCY STOP
97.
SHUNT
K22
RELAY, MAIN CIRCUIT BKR CONTROL (CB2-PILOT)
K23
RELAY, PARALLEL CONTROL (6PDT)
98.
TD1
K24
RELAY, ETHER AID CONTROL
99.
TD2
K25
RELAY, ALARM SILENCE CONTROL
100. TD3
K26
RELAY, ALARM 'ON' ARMING
K27-K36
RELAY, FAULT INDICATOR
K40
RELAY, FREQ SELECT
101. WT1,2
K50
RELAY, BATTLE SHORT CONTROL
K52
RELAY, ANNUNCIATOR DELAY
K54
RELAY, DC POWER PILOT
K60-63
RELAY, LOUVER CONTROL ASSY (TB303)
K102
RELAY, OVER VOLTAGE SENSING
K103-1,-2
RELAY, PHASE SEQUENCE
K106
RELAY, SYNC CHECK
K111
RELAY, UNDER VOLTAGE SENSING
K112
RELAY, REVERSE POWER SENSING
K113
RELAY, SHORT CIRCUIT SENSING
K114
RELAY, OVERLOAD SENSING
K130
RELAY, PARALLEL LINES (TP510)
L1
FUEL SOLENOID, (ENGINE)
L2,L22
AIR 80X SHUT-DOWN SOLENOID
L3
FUEL SOLENOID (FUEL TRANSFER PUMP)
L4
STARTER SOLENOID
FO-1 DC Schematic (Sheet 1 of 4)
FP-1/(FP-2 blank)
IDENTIFYING LEGEND
IDENTIFYING LEGEND
OIL PRESSURE GAGE
OIL TEMP GAGE
M3
WATER TEMP GAGE
FUEL LEVEL GAGE
ELLAPSED TIME METER
DC VOLTMETER
DC AMMETER
DIGITAL CLOCK
TRANSMITTERS FOR GAUGES
OIL PRESS SWITCH
OP3
OIL PRESS SWITCH (AIR POX SOL LOCKOUT)
OIL TEMP SWITCH
VOLT DROPPING RESISTORS (GAUGES)
RESISTOR, FLASHER BURDEN
START/STOP SWITCH
PRIMING SWITCH, ETHER
SWITCH, MAIN BUS CIRCUIT BKR, ON/Or F (C12)MANUAL FREQ ADJUST SWITCH
MANUAL VOLT ADJUST SWITCH
BATTLE SHORT SWITCH
PARALLELING SWITCH
FUEL TRANSFER SWITCH OFF-AUTO
PANEL LIGHT SWITCH
ALARM SILENCE SWITCH
ANNUNCIATOR TEST SWITCH
MAINT SW (DC POWER LOCKOUT)
FREQ SELECT SW (50/60 HZ OP)
EMERGENCY STOP SWITCH
SECONDS TIME ADJUST (CLOCK)
MINUTES TIME ADJUST (CLOCK)
HOURS TIME ADJUST (CLOCK)
AUTO/TRIP /MAN SWITCH
LOUVER MOTOR PILOT SWITCH
SYNCHRONIZING RELAY
SPEED SWITCH
D.C.
AMMETER
TIME
TIME
TIME
DELAY
DELAY
DELAY
WATER TEMP
ASSY
ASSY
ASSY
SWITCH
(30
SEC
DELAY
(5 SEC DELAY 'ON')
(5 SEC DELAY 'ON' a
5 SEC DELAY 'OFF')
'ON')
FO-1 DC Schematic (Sheet 2 of 4)
FP-3/(FP-4 blank)
TM 5-6115-593-12
TO 35C2-3-463-1
FP-5/(FP-6 blank)
FO-1 DC Schematic (Sheet 3 of 4)
TM 5-6115-593-12
TO 35C2-3-463-1
FP-7/(FP-8 blank)
FO-1 DC Schematic (Sheet 4 of 4)
TM 5-6115-593-12
TO 35C2-3-463-1
TM 5-6115-593-12
TO 35C2-3-463-1
FO-2 AC Schematic (Sheet 1 of 2)
FP-9/(FP-10 blank)
TM 5-6115-593-12
TO 35C2-3-463-1
FO-2 AC Schematic (Sheet 2 of 2)
FP-11/(FP-12 blank)
TM 5-6115-593-12
TO 35C2-3-463-1
LEGEND OF COMPONENTS
1.
Al
ANNUNCIATOR AUDIBLE ALARM
2.
A106
GOVERNOR CONTROLLER (SPEED CONTROL)
3,
BC1
BATTERY CHARGER
4.
BTI-4
BATTERIES
5,
BTR
RELAY, BREAKER TRIP
6.
B1
FUEL TRANSFER PUMP MOTOR
7.
B2
STARTER MOTOR
8.
B4
MOTOR OPERATOR, FREQ CONTROL
9B5
MOTOR OPERATOR, VOLTAGE CONTROL
10.
B10-13
LOUVER MOTORS
FO-3 DC Wiring Diagram (Sheet 1 of 5)
FP-13/(FP-14 blank)
11.
12.
13.
14.
CB1
CB2
CR
C101
D.C. POWER BREAKER
A.C. BUSS POWER (MOTOR OPERATED) BREAKER
DIODES
FILTER, CAPACITOR
15.
16.
17.
18.
19.
20.
21.
22
23
24.
DS1
DS2-5,10,11
DS6
DS7
DS27-36
DS41
DS42
DS50
DS51
ETHER
INDICATOR, FUEL PUMP 'ON'
PANEL LIGHTS
INDICATOR, CB2 POWER BREAKER 'CLOSED'
INDICATOR, PARALLEL CIRCUIT 'ON'
INDICATORS, FAULT
INDICATOR PHASE 1,2,3
INDICATOR' PHASE 1,3,2
lNDICATOR BATTLE SHORT 'ON'
INDICATOR, OVERCRANK
STARTING AID SOLENOID
25.
26.
27
F60-63
FCI
FL1-4
FUSES
FLASHER
FUEL LEVEL SWITCHES
28.
29.
J
J60-63
CONNECTORS
CONNECTOR, LOUVER MOTORS
30.
31.
32
33
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
64.
65.
67
68
69
K1
K3
K5
K6
K8
K19
K20
K21
K22
K23
K24
K25
K26
K27
K28
K29
K30
K31
K32
K33
K34
K35
K36
K40
K50
K52
K54
K103-1
K103-2
K102
K106
K111
K112
K113
K114
K130
L2,L22
L3
L4
RELAY, RUN, STOP, (6PDT)
CRANKING RELAY (D.C. CONTACTOR)
RELAY, CRANKING, RUN, STOP, PILOT
RECRANK INHIBIT RELAY (TIME CONTROLLED)
RELAY, LOW FUEL SHUTDOWN
OVERCRANK SHUTDOWN RELAY (TIME CONTROLLED-30 SEC)
FUEL PUMP CONTACTOR
EMERGENCY SHUT-DOWN RELAY
RELAY, MAIN POWER CIRCUIT BREAKER (CB2) PILOT CONTROL
RELAY, PARALLEL CONTROL (6PDT)
RELAY ETHER SOLENOID CONTROL
RELAY ALARM SILENCE CONTROL
RELAY, ALARM 'ON' ARMING
RELAY, HI WATER TEMP. PRE-ALARM
RELAY, HI OIL TEMP. PRE-ALARM
RELAY, LO OIL PRESSURE PRE-ALARM
RELAY, LO FUEL PRE-ALARM
RELAY, OVER SPEED SHUT-DOWN
RELAY, OVER VOLT SHUT-DOWN
RELAY, UNDER VOLT PRE-ALARM
RELAY, REVERSE POWER (A C. BREAKER OPEN) CONTROL
RELAY OVERLOAD (A.C. BREAKER OPEN) CONTROL
RELAY, SHORT CIRCUIT (A.C. BREAKER OPEN) CONTROL
RELAY, 50/60 HZ OPERATION CONTROL
RELAY, BATTLE SHORT CONTROL
RELAY, ANNUNCIATOR DELAY 'ON'
RELAY, D.C. POWER PILOT
RELAY PHASE SEQUENCE L2.3
RELAY PHASE SEQUENCE L3,2
RELAY, OVERVOLTAGE SENSING
RELAY SYNC CHECK CONTROL
RELAY UNDERVOLTAGE SENSING
RELAY, REVERSE POWER SENSING
RELAY, SHORT CIRCUIT SENSING
RELAY, OVERLOAD SENSING
RELAY, PARALLEL LINES (TB510)
FUEL SOLENOID (ENGINE)
FUEL SOLENOID (FUEL TRANFER PUMP)
STARTER SOLENOID
70.
71.
72.
73.
74.
75.
76.
77.
78.
79.
80.
81.
M1
M2
M3
M4
M5
M20
M21
MT1
MT2
MT3
MT4
M111
OIL PRESSURE GAUGE
OIL TEMP. GAUGE
WATER TEMP. GAUGE
FUEL LEVEL GAUGE
METER, TOTAL TIME
D.C. VOLTMETER
D.C. AMMETER
OIL PRESSURE TRANSMITTER
OIL TEMP. TRANSMITTER
WATER TEMP. TRANSMITTER
FUEL LEVEL TRANSMITTER
DIGITAL CLOCK
82.
83.
84.
85.
86.
87.
88.
OP1
OP2
OP3
OT1
OT2
R1,2,3
R30
OIL PRESSURE SHUT-DOWN SWITCH
OIL PRESSURE PRE-ALARM SWITCH
AIR BOX SOLENOIDS LOCKOUT SWITCH
OIL TEMP. SHUT-DOWN SWITCH
OIL TEMP. PRE-ALARM SWITCH
VOLTAGE DROPPING RESISTOR
RESISTOR FLASHER BURDEN
89.
90.
91.
92.
93.
94.
95.
96.
97.
98.
99.
100.
101.
102.
103.
104.
105.
106.
107.
108.
109.
110.
111.
112.
SHUNT
SRM
S1
52
S3
55
56
S7
S8
S9
S12
512
513
514
520
521
S22
S49
550
S51
S52
551,2.3
553
560-63
D.C. AMMETER
SYNCHRONIZING RELAY
STOP/RUN/START SWITCH (MASTER SWITCH)
ETHER PRIMING SWITCH
MAIN BUSS CIRCUIT BREAKER 'ON/OFF' SWITCH
FREQUENCY CONTROL SWITCH
VOLTAGE CONTROL SWITCH
BATTLE SHORT SWITCH
PARALLELING SWITCH
FUEL TRANSFER PUMP SWITCH
PANEL LIGHT SWITCH
ALARM SILENCE SWITCH
ANNUNCIATOR TEST SWITCH
ANNUNCIATOR RESET SWITCH
MAINTENANCE SWITCH (D.C. POWER
LOCKOUT)
FREQ SELECT SWITCH (50/60 HZ)
EMERGENCY STOP SWITCH,
SECONDS ADJUST SWITCH (DIGITAL CLOCK)
MINUTES ADJUST SWITCH (DIGITAL CLOCK)
HOURS ADJUST SWITCH (DIGITAL CLOCK)
50 HZ OPERATE (DIGITAL CLOCK)
MECHANICAL SPEED SWITCH
AUTO/TRIP/MAN SWITCH
LOUVER MOTOR PILOT SWITCH
113.
114.
115.
116.
117.
118.
119.
TB6
TB9
TB10
TB303
TD1
TD2
TD3
ANNUNCIATOR CIRCUIT ASSY (A20 PC BD)
RELAY CIRCUIT ASSY (P.C. BD) (A10)
RELAY CIRCUIT ASSY (P.C. BD) (A15)
LOUVER CONTROL ASSEMBLY
TIME DELAY ASSY (OVER-CRANK)
TIME DELAY ASSY (ANNUNCIATOR)
TIME DELAY ASSY (RE-CRANK INHIBIT)
120.
121.
WT1
WT2
HI WATER TEMP SHUT-DOWN SWITCH
HI WATER TEMP PRE-ALARM
SWITCH
122.
123.
81GU
FC2
RELAY, UNDER FREQ
FLASHER-ANNUNCIATOR
AUDIBLE ALARM
NOTES:
1. INTERPRET
DWG PER DOD-STD-100.
2. ITEMS NO. 10, 25, 29, a 116 FOR HOUSED UNIT ONLY.
3. REMOVE JUMPER FOR 60HZ OPERATION WHEN REMOTE CONTROL BOX
4. FOR D.C. SCHEMATIC DIAGRAM SEE DWG 76-11245.
TM 5-6115-593-12
TO 35C2-3-463-1
FO-3 DC Wiring Diagram (Sheet 2 of 5)
FP-15/(FP-16 blank)
TM 5-6115-593-12
TO 35C2-3-463-1
FO-3 DC Wiring Diagram (Sheet 3 of 5)
FP-17/(FP-18 blank)
TM 5-6115-593-12
TO 35C2-3-463-1
FO-3 DC Wiring Diagram (Sheet 4 of 5)
FP-19/(FP-20 blank)
TM 5-6115-593-12
TO 35C2-3-463-1
FO-3 DC Wiring Diagram (Sheet 5 of 5)
FP-21/(FP-22 blank)
TM 5-6115-593-12
TO 35C2-3-463-1
LEGEND OF COMPENENTS
1.
A103
CONVERTER, FREQUENCY
2.
A106
GOVERNOR CONTROL UNIT
3.
A107
CONVERTER - KW
4.
A108
CONVERTER, KVAR
5.
BC1
BATTERY CHARGER
6.
BCR
RELAY, BREAKER CLOSE
7.
BTR
RELAY, BREAKER TRIP
8.
B4
MOTOR OPERATED POT, FREQ CONTROL
9.
B5
MOTOR OPERATED POT, VOLTAGE CONTROL
10.
B102
RADIATOR FAN MOTOR
11.
CB2
CIRCUIT BRKR MAIN AC MOTOR OPERATED
12.
CB101
CIRCUIT BRKR COMMERCIAL POWER IN
13.
CB102-103
CIRCUIT BRKR CONVENIENCE RCPT
14.
CR
RELAY, CONTROL
15.
CT1,2,3
CURRENT XFMR FOR REMOTE'
THERMAL WATT CONVERTER
OVERLOAD RELAY
SHORT CIRCUIT RELAY
16.
CT4,5,6
CURRENT XFMR FOR,
GOVERNOR CONTROL
17.
CT7
CURRENT XFMR FOR
CROSS-CURRENT SENSING
18.
CT10
CURRENT XFMR FOR
POWER FACTOR METER &
REVERSE POWER RELAY
SELECTOR SWITCH
19.
CT11,12,13
CURRENT XFMR FOR
UNIT INSTRUMENTATION L OVERLOAD
& SHORT CKT RELAYS
20.
C1
CAPACITOR, GOV
21.
DS101,102
LIGHT, SYNCHRONIZING
22.
G1
GENERATOR, MAIN
23.
H101,102
HEATERS PREHEAT SYS.
24.
H103
LUBE OIL HEATER
25.
J101
RCPT EXTERNAL POWER
26.
J102,103
CONVENIENCE RCPT
27.
J104,105,106
RCPT REACTIVE PARALLELING
28.
J107,108,109
RCPT GOV. PARALLELING
29.
J110
TELEPHONE JACK
30.
K1
RELAY, RUN/STOP
31.
K22
RELAY, CB2 PILOT
32.
K23
RELAY, PARALLELING CONTROL
33.
K102
RELAY, OVERVOLTAGE SENSING
34.
K103-1,K103-2 RELAY, PHASE SEQUENCE
35.
K106
SYNC CHECK RELAY
36.
K107
CONTACTOR, PREHEAT POWER
37.
K108A,B
REVERSING CONTACTOR, BATTERY
CHARGE POWER
38.
K109
CONTACTOR, HEATERS
39.
K111
RELAY, UNDERVOLTAGE SENSING
40.
K112
RELAY, REVERSE POWER
41.
K113
RELAY, SHORT CIRCUIT
42.
K114
RELAY, OVERLOAD
43.
K120
FAN MOTOR STARTER
44.
K130
RELAY, PARALLEL LINES (TB510)
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
64.
65.
66.
67.
68.
69.
L101
M101
M102
M103
M107
M108
M109
M110
M111
PM
PU1
R101
R102
R103
R104
R116
R150
SRM
S21
553
5101
S102
S103
S105
S106
GOVERNOR ACTUATOR
VOLTMETER
AMMETER
FREQUENCY METER
KW METER
KVAR METER
SYNCHROSCOPE
POWER FACTOR METER
DIGITAL CLOCK
PERM. MAG GEN. VR101 POWER
MAGNETIC PICKUP
VOLTAGE ADJ POT
FREQ ADJ POT
50 HZ ADJ POT
DROOP ADJ POT
DROOP REACTIVE VOLTAGE LEVEL
RESISTOR, GOV
SYNCHRONIZING RELAY
FREQ SELECTOR SWITCH
AUTO/TRIP/MAN SWITCH
VOLTMETER SWITCH
AMMETER SWITCH
VOLTAGE SELECTOR SWITCH' BUS/GEN
PREHEAT SELECTDR SWITCH
ISOCHRONOUS OR DROOP
70.
71.
72.
737475-
S120
S301
TB
TBM
TB101
TB107
76.
7778.
7980.
81.
T101,102
T103
VR101
81GU
81GU
27/59G
VOLTAGE SELECT CONTROL BUSS POWER
THERMOSTAT, PREHEAT
TERMINAL BOARDS
TERMINAL BOARD
VOLTAGE RECONNECTION BOARD
RESISTOR NETWORK CURRENT
SUMMATION-OVERLOAD SHORT
CIRCUIT RELAY ASSY
POWER XFMR PARALLEL
PHASE SHIFT XFMR
VOLTAGE REGULATOR
UNDER FREQ RELAY
OVER FREQ RELAY
OVER/UNDER VOLTAGE RELAY
NOTES
1. REMOVE JUMPERS FROM TB3-11 & TB3-12, TB4-1 &
TB4-2, TB4-2 & TB4-3 TB4-3 a TB4-4, IN CONTROL
BOX, WHEN REMOTE CONTROL BOX IS INSTALLED IN
SYSTEM.
2. INTERPRET DWG PER DOD-STD-100.
3. FOR A.C. SCHEMATIC DIAGRAM SEE DWG 76-11243.
FO-4 AC Wiring Diagram (Sheet 1 of 4)
FP-23/(FP-24 blank)
TM 5-6115-593-12
TO 35C2-3-463-1
FO-4 AC Wiring Diagram (Sheet 2 of 4)
FP-25 / (FP-26 blank)
TM 5-6115-593-12
TO 35C2-3-463-1
FO-4 AC Wiring Diagram (Sheet 3 of 4)
FP-27 / (FP-28 blank)
TM 5-6115-593-12
TO 35C2-3-463-1
FO-4 AC Wiring Diagram (Sheet 4 of 4)
FP-29 / (FP-30 blank)
TM 5-6115-593-12
TO 35C2-3-463-1
FO-5 AC / DC Control Box (Sheet 1 of 4)
FP-31 / (FP 32 blank)
TM 5-6115-593-12
TO 35C2-3-463-1
FO-5 AC / DC Control Box (Sheet 2 of 4)
FP-33 / (FP - 34 blank)
TM 5-6115-593-12
TO 35C2-3-463-1
FO-5 AC / DC Control Box (Sheet 3 of 4)
FP-35 / (FP-36 blank)
TM 5-6115-593-12
TO 35C2-3-463-1
FO-5 AC / DC Control Box (Sheet 4 of 4)
FP-37/(FP-38 blank)
TM 5-6115-593-12
TO 35C2-3-463-1
FO-6 External Power Box Wiring Diagram (Sheet 1 of 3)
FP-39/(FP-40 blank)
TM 5-6115-593-12
TO 35C2-3-463-1
FO-6 External Power Box Wiring Diagram (Sheet 2 of 3)
FP-41/(FP-42 blank)
TM 5-6115-593-12
TO 35C2-3-463-1
FO-6 External Power Box Wiring Diagram (Sheet 3 of 3)
FP-43/(FP-44 blank)
TM 5-6115-593-12
TO 35C2-3-463-1
FO-7 Unit Control Box Wiring Diagram (Sheet 1 of 4)
FP-45/(FP-46 blank)
TM 5-6115-593-12
TO 35C2-3-463-1
FO-7 Unit Control Box Wiring Diagram (Sheet 2 of 4)
FP-47/(FP-48 blank)
TM 5-6115-593-12
TO 35C2-3-463-1
FO-7. Unit Control Box Wiring Diagram (Sheet 3 of 4)
FP-49/(FP-50 blank)
TM 5-6115-593-12
TO 35C2-3-463-1
FO-7. Unit Control Box Wiring Diagram (Sheet 4 of 4)
FP-51/(FP-52 blank)
TM 5-6115-593-12
TO 35C2-3-463-1
FO-8. Remote Control Module Schematic
FP-53/(FP-54 blank)
TM 5-6115-593-12
TO 35C2-3-463-1
FO-9. Remote Control Module Wiring Diagram (Sheet 1 of 2)
FP-55/(FP-56 blank)
TM 5-6115-593-12
TO 35C2-3-463-1
FO-9. Remote Control Module Wiring Diagram (Sheet 2 of 2)
FP-57/(FP-58 blank)
TM 5-6115-593-12
TO 35C2-3-463-1
FO-10. Generator Reconnection Box Wiring Diagram
FP-59/(FP-60 blank)
TM 5-6115-593-12
TO35C2-3-463-1
FO-11. Engine Accessories Wiring Diagram (Sheet 1 of 2)
FP-61/(FP-62 blank)
TM 5-6115-593-12
TO35C2-3-463-1
FO-11. Engine Accessories Wiring Diagram (Sheet 2of 2)
FP-63/(FP-64 blank)
TM 5-6115-593-12
TO35C2-3-463-1
FO-12. Automatic Control Module AC Schematic (Sheet 1 of 2)
FP-65/(FP-66 blank)
TM 5-6115-593-12
TO35C2-3-463-1
FO-12. Automatic Control Module AC Schematic (Sheet 2 of 2)
FP-67/(FP-68 blank)
TM 5-6115-593-12
TO35C2-3-463-1
FO-13. Automatic Control Module Wiring Diagram(Sheet 1 of 3)
FP-69/(FP-70 blank)
TM 5-6115-593-12
TO35C2-3-463-1
FO-13. Automatic Control Module Wiring Diagram(Sheet 2 of 3)
FP-71/(FP-72 blank)
TM 5-6115-593-12
TO 35C2-3-463-1
FO-13. Automatic Control Module Wiring Diagram (Sheet 3 of 3)
FP-73/(FP-74 blank)
TM 5-6115-593-12
TO 35C2-3-463-1
FO-14. Remote Control Module Interconnect Wiring Diagram
FP-75/(FP-76 blank)
TM 5-6115-593-12
TO 35C2-3-463-1
FO-15. Automatic Control Module Interconnect Wiring Diagram
FP-77/(FP-78 blank)
TM 5-6115-593-12
TO 35C2-3-463-1
FO-16. Louver Control Schematic
FP-79/(FP-80 blank)
TM 5-6115-593-12
TO 35C2-3-463-1
FO-17. Louver Control Schematic
FP-81/(FP-82 blank)
TM 5-6115-593-12
TO-35C2-3-463-1
By Order of the Secretaries of the Army and the Air Force:
CARL E. VUONO
General, United States Army
Chief of Staff
Official:
THOMAS F. SIKORA
Brigadier General, United States Army
The Adjutant General
LARRY D. WELCH , General USAF
Chief of Staff
Official:
ALFRED G. HANSEN
General, USAF, Commander, Air Force
Logistics Command
DISTRIBUTION:
To be distributed in accordance with DA Form 12-25E, 0865).
The Metric System and Equivalents
Linear Measure
Liquid Measure
1 centiliter = 10 milliters = .34 fl. ounce
1 deciliter = 10 centiliters = 3.38 fl. ounces
1 liter = 10 deciliters = 33.81 fl. ounces
1 dekaliter = 10 liters = 2.64 gallons
1 hectoliter = 10 dekaliters = 26.42 gallons
1 kiloliter = 10 hectoliters = 264.18 gallons
1 centimeter = 10 millimeters = .39 inch
1 decimeter = 10 centimeters = 3.94 inches
1 meter = 10 decimeters = 39.37 inches
1 dekameter = 10 meters = 32.8 feet
1 hectometer = 10 dekameters = 328.08 feet
1 kilometer = 10 hectometers = 3,280.8 feet
Square Measure
Weights
1 sq. centimeter = 100 sq. millimeters = .155 sq. inch
1 sq. decimeter = 100 sq. centimeters = 15.5 sq. inches
1 sq. meter (centare) = 100 sq. decimeters = 10.76 sq. feet
1 sq. dekameter (are) = 100 sq. meters = 1,076.4 sq. feet
1 sq. hectometer (hectare) = 100 sq. dekameters = 2.47 acres
1 sq. kilometer = 100 sq. hectometers = .386 sq. mile
1 centigram = 10 milligrams = .15 grain
1 decigram = 10 centigrams = 1.54 grains
1 gram = 10 decigram = .035 ounce
1 decagram = 10 grams = .35 ounce
1 hectogram = 10 decagrams = 3.52 ounces
1 kilogram = 10 hectograms = 2.2 pounds
1 quintal = 100 kilograms = 220.46 pounds
1 metric ton = 10 quintals = 1.1 short tons
Cubic Measure
1 cu. centimeter = 1000 cu. millimeters = .06 cu. inch
1 cu. decimeter = 1000 cu. centimeters = 61.02 cu. inches
1 cu. meter = 1000 cu. decimeters = 35.31 cu. feet
Approximate Conversion Factors
To change
To
inches
feet
yards
miles
square inches
square feet
square yards
square miles
acres
cubic feet
cubic yards
fluid ounces
pints
quarts
gallons
ounces
pounds
short tons
pound-feet
pound-inches
Multiply by
centimeters
meters
meters
kilometers
square centimeters
square meters
square meters
square kilometers
square hectometers
cubic meters
cubic meters
milliliters
liters
liters
liters
grams
kilograms
metric tons
Newton-meters
Newton-meters
2.540
.305
.914
1.609
6.451
.093
.836
2.590
.405
.028
.765
29,573
.473
.946
3.785
28.349
.454
.907
1.356
.11296
To change
ounce-inches
centimeters
meters
meters
kilometers
square centimeters
square meters
square meters
square kilometers
square hectometers
cubic meters
cubic meters
milliliters
liters
liters
liters
grams
kilograms
metric tons
To
Newton-meters
inches
feet
yards
miles
square inches
square feet
square yards
square miles
acres
cubic feet
cubic yards
fluid ounces
pints
quarts
gallons
ounces
pounds
short tons
Temperature (Exact)
°F
Fahrenheit
temperature
5/9 (after
subtracting 32)
Celsius
temperature
°C
Multiply by
.007062
.394
3.280
1.094
.621
.155
10.764
1.196
.386
2.471
35.315
1.308
.034
2.113
1.057
.264
.035
2.205
1.102
PIN: 041070-000
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