User manual | TM-5-6115-586-34

TM 5-6115-586-34
DEPARTMENT OF THE ARMY TECHNICAL MANUAL
TECHNICAL MANUAL
DIRECT SUPPORT AND GENERAL SUPPORT
MAINTENANCE MANUAL
POWER PLANT, UTILITY, GAS
TURBINE ENGINE DRIVEN
(LIBBY WELDING CO. MODEL LPU-71)
FSN 6115-165-3842
This copy is a reprint which includes current pages from Changes 1
HEADQUARTERS, DEPARTMENT OF THE ARMY
JUNE 1972
WARNING
Take particular heed to specific warnings and cautions throughout this manual.
HIGH VOLTAGE
is used in the operation of this equipment.
DEATH
or severe burns may result if personnel fail to observe safety precautions. Do not operate this
equipment until the ground terminal has been connected to a suitable ground. Disconnect
the battery negative cable before removing or installing components in any electrical pane or
system.
Before servicing or repairing any part of the power plant, be sure that it is not connected to
another power plant that is operating. Do not service the power plant while it is connected for
standby operation Ground the ignition plug or ignition unit before removal by grounding the
high tension lead contact spring to the ignition immediately upon removal of the lead.
HIGH SPEED ROTATION AND HIGH FREQUENCY NOISE
are present during operation of this equipment.
DEATH
or severe injury or loss of hearing may result if personnel fail to observe safety precautions.
During unit starting, operation, or testing stand clear of the sides of the engine. Extreme care
must be exercised to prevent debris or other foreign material from entering the air inlet.
Turbine or compressor failure induced by foreign material entering the unit may be
sufficiently violent to cause severe damage to internal components with possible danger to
personnel in the immediate area. Operators working ii the area of equipment generating high
frequency noises will be required to wear ear plugs to prevent permanent damage to hearing.
Safety or medical officer will provide examination requirements an, federal stock number for
ear plugs and ear protectors.
DANGEROUS GASES AND EXTREME HEAT
are generated as a result of operating this equipment.
DEATH
or severe injury may occur if personnel fail to observe safety precautions. Stay clear of
exhaust opening during operation of the power plant. Allow exhaust and heat exchanger
components to cool before al tempting maintenance on or near them. Extreme exhaust heat
is generated by the gas turbine engine Do not operate power plant in enclosed area unless
adequate ventilation of exhaust gases is provided Exhaust discharge contains noxious and
deadly fumes. Do not smoke or use open flame in vicinity when servicing batteries. Batteries
generate explosive gas during charging. Some solvents used for cleaning of components
during repair are toxic and shall be used only in well ventilated areas. Observe specific
warnings in this manual
LIQUIDS AND GASES UNDER PRESSURE
are generated as a result of operation of this equipment.
INJURY
may result if personnel fail to observe safety precautions. Keep hands and other exposed
areas of the body away from any malfunction of plumbing in refrigeration system, hot water
system, bleed air system, and lubrication system. Wear protective gloves and other clothing
when handling heater components or servicing refrigeration as directed by specific warnings
in this manual.
TM 5-6115-586-34
C1
CHANGE
HEADQUARTERS
DEPARTMENT OF THE ARMY
WASHINGTON, DC 2 August 1974
No. 1
Direct Support and General Support Maintenance Manual
POWER PLANT, UTILITY; GAS TURBINE ENGINE
DRIVEN (LIBBY WELDING CO. MODEL LPU-71)
FSN 6115-937-0929 (NON-WINTERIZED)
FSN 6115-134-0825 (WINTERIZED)
TM 5-6115-586-34, 15 June 1972, is changed as follows:
The title is changed as shown above.
Page 2 of cover: Add to Warnings:
Cleaning solvent, PD-680, used for cleaning, is POTENTIALLY DANGEROUS CHEMICAL. Do not
use near open flame. Flash point of solvent is 100°- 138°F. (38°- 59°C.).
Page 1-1, paragraph 1-3, lines 5 through 8 are changed to: Commander, US Army Troop Support Command,
ATTN: AMSTS-MPP, 4300 Goodfellow Boulevard, St. Louis, MO 63120.
By Order of the Secretary of the Army:
Official:
VERNE L. BOWERS
Major General, United States Army
The Adjutant General
Distribution:
To be distributed in accordance with DA Form 12-25A (qty rqr block No.
Maintenance requirements for MUST System.
CREIGHTON W. ABRAMS
General, United States Army
Chief of Staff
639) Direct and General Support
TM 5-6115-586-34
TECHNICAL MANUAL
HEADQUARTERS
DEPARTMENT OF THE ARMY
WASHINGTON, D.C., 15 June 1972.
No. 5-6115-586-34
DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE MANUAL
POWER PLANT, UTILITY: GAS TURBINE ENGINE DRIVEN
LIBBY WELDING CO. MODEL LPU-71
FSN 6115-165-3842
Paragraph
Page
CHAPTER
Section
1
I.
II.
INTRODUCTION
General ..................................................................................
Description and data ..............................................................
1-1
1-4
1-1
1-4
CHAPTER
2.
Section
I.
II.
III.
IV.
DIRECT SUPPORT AND GENERAL SUPPORT
MAINTENANCE INSTRUCTIONS
Repair parts, Special Tools, and equipment............................
Troubleshooting .....................................................................
General Maintenance ............................................................
Removal and Installation of Major Components and Auxiliaries
2-1
2-3
2-5
2-10
2-1
2-3
2-11
2-21
CHAPTER
Section
3.
I.
II.
III.
IV.
V.
REPAIR OF ENGINE
Engine Electrical and Plumbing Installation ...........................
Engine Accessories ................................................................
Dual Pad Accessory Drive Assembly .....................................
Accessory Gearcase Assembly...............................................
Compressor and Turbine Assembly .......................................
3-1
3-4
3-9
3-15
3-21
3-1
3-15
3-24
3-30
3-34
CHAPTEI
4.
REPAIR OF SKID ASSEMBLY ..............................................
4-1
4-1
CHAPTER
Section
5.
I.
II.
REPAIR OF ELECTRICAL COMPONENTS
Power Plant Electrical Installation...........................................
Engine and Skid Electrical Installation ...................................
5-1
5-32
5-1
5-60
CHAPTER
Section
6.
I.
II.
III.
IV.
V.
REPAIR OF CONDITIONED AIR COOLING SYSTEM
Tube Assemblies and Plumbing Fittings ................................
Compressors, Condensers and Evaporators ..........................
Receivers ...............................................................................
Motor Driven Tube Axial Fan (Recirculating) .........................
Motor Driven Tube Axial Fan (Condenser)..............................
6-1
6-3
6-7
6-8
6-9
6-1
6-13
6-16
6-19
6-25
CHAPTER
7.
REPAIR OF BLEED AIR AND EXHAUST
HEATING INSTALLATION ............................................
7-1
7-1
CHAPTER
Section
8.
I.
II.
III.
REPAIR OF WATER SYSTEM PLUMBING INSTALLATION
Tube Assemblies, Fittings, and Manual Valves.......................
Surge Tank and Pressure Switch............................................
Hot Water Tank, Thermostatic Switch, and Relief Valves ......
8-1
8-5
8-9
8-1
8-1
8-2
CHAPTER
9.
REPAIR OF ENCLOSURE ASSEMBLY ................................
9-1
9-1
CHAPTER
Section
10.
I.
II.
III.
IV.
V.
VI.
REPAIR OF ACCESSORY COMPONENTS
General Information................................................................
Compressed Air and Vacuum System Accessory Components
Water System Accessory Components...................................
External Fuel Filter Assembly: ...............................................
Electrical Cable Accessory Components.................................
Conditioned Air System Accessory Components ...................
10-1
10-2
10-5
10-7
10-12
10-19
10-1
10-1
10-5
10-7
10-9
10-9
APPENDIX
INDEX
A.
REFERENCES.......................................................................
..................................................................................
i
A-1
I-1
TM 5-6115-586-34
LIST OF ILLUSTRATIONS
Figure
2-1.
2-2.
2-3.
2-4.
2-5.
2-5.
2-5.
2-6.
3-1.
3-2.
3-3.
3-4.
3-4.
3-4.
3-4.
3-4.
3-5.
3-6.
3-7.
3-8.
3-9.
3-10.
3-11.
3-12.
3-12.
3-13.
3-14.
3-15.
3-16.
3-17.
3-18.
3-19.
3-20.
3-21.
3-22.
3-23.
3-24.
3-25.
4-1.
4-2.
4-3.
4-4.
4-5.
4-6.
4-7.
4-8.
5-1.
5-2.
5-3.
5-4.
5-5.
5-6.
5-7.
3-8.
3-9.
5-10.
3-11.
3-12.
5-13.
3-14.
5-15.
5-16.
3-17.
3-18.
5-19.
Title
Refrigeration service unit ...........................................................................................................
Refrigeration service unit panel details .......................................................................................
Service unit connected to power plant ........................................................................................
Refrigeration service unit internal details.....................................................................................
Removal of engine and skid assembly (sheet 1 of 3) ..................................................................
Removal of engine and skid assembly (sheet 2 of 3) ..................................................................
Removal of engine and skid assembly (sheet 3 of 3) ..................................................................
Removal of gas turbine engine....................................................................................................
Gas turbine engine wire harness installation................................................................................
Gas turbine engine wire harness assembly..................................................................................
Gas turbine engine wire harness diagram and wire identification chart .......................................
Engine and skid plumbing installation (sheet 1 of 5) ...................................................................
Engine and skid plumbing installation (sheet 2 of 5) ...................................................................
Engine and skid plumbing installation (sheet 3 of 5) ...................................................................
Engine and skid plumbing installation (sheet 4 of 5) ....................................................................
Engine and skid plumbing installation (sheet 5 of 5) ....................................................................
Starter clutch assembly...............................................................................................................
Pawls installed in spider .............................................................................................................
Using clutch torquing holder and torque wrench adapter to check clutch slip torque ....................
Fuel control assembly .................................................................................................................
Fuel atomizer assembly .............................................................................................................
Oil temperature regulator valve...................................................................................................
Test set-up for oil temperature regulator .....................................................................................
Gas turbine engine assembly (sheet 1 of 2) ................................................................................
Gas turbine engine assembly (sheet 2 of 2).................................................................................
Dual pad accessory drive assembly ............................................................................................
Inspection of retainer...................................................................................................................
Inspection of seal ........................................................................................................................
Determining shim requirements for input seal assembly .............................................................
Accessory gearcase assembly ....................................................................................................
Installation of seal .......................................................................................................................
Installation of seal ......................................................................................................................
Inspection of torus ......................................................................................................................
Inspection of torus ......................................................................................................................
Inspection of liner .......................................................................................................................
Inspection of nozzle ....................................................................................................................
Repair of turbine plenum ............................................................................................................
Repair of torus ...........................................................................................................................
Fuel boost pump, exploded view .................................................................................................
Air inlet duct assembly, exploded view........................................................................................
Air inlet plenum assembly, upper, exploded view ........................................................................
Air inlet plenum assembly, lower, exploded view.........................................................................
Heat shield assembly, upper, exploded view ...............................................................................
Heat shield assembly, lower, exploded view................................................................................
Engine skid assembly, exploded view ........................................................................................
Engine skid sub-assembly, exploded view ..................................................................................
DC power branched wire harness assembly ................................................................................
Power plant dc power branched wire harness assembly ..............................................................
DC power branched wire harness assembly ................................................................................
Water system wire harness assembly..........................................................................................
Water system branched wire harness assembly ..........................................................................
Water pumps wire harness assembly ..........................................................................................
Air conditioning system branched wire harness assembly ...........................................................
Air conditioning system wire harness assembly ..........................................................................
Recirculating fans wire harness assembly ...................................................................................
Recirculating fans wire harness assembly ..................................................................................
Recirculating fans wire harness assembly ..................................................................................
400 Hz auxiliary power wire harness assembly............................................................................
Anti-ice thermostat wire harness assembly .................................................................................
Condenser fans wire harness assembly ......................................................................................
Condenser fans wire harness assembly ......................................................................................
Remote power output wire harness assembly..............................................................................
Compressor wire harness assembly ............................................................................................
Compressors wire harness assembly...........................................................................................
Compressors wire harness assembly...........................................................................................
ii
Page
2-6
2-7
2-9
2-10
2-22
2-23
2-24
2-26
3-2
3-3
3-4
3-6
3-8
3-10
3-12
3-14
3-16
3-18
3-19
3-20
3-22
3-23
3-24
3-25
3-26
3-27
3-28
3-29
3-30
3-31
3-32
3-33
3-35
3-36
3-37
3-38
3-40
3-41
4-2
4-4
4-6
4-7
4-9
4-10
4-12
4-14
5-2
5-4
5-5
5-6
5-7
5-8
5-9
5-11
5-13
5-14
5-15
5-16
5-17
5-18
5-20
5-22
5-24
5-25
5-25
Figure
5-20.
5-21.
5-22.
5-23.
5-24.
5-25.
5-26.
5-27.
5-28.
5-29.
5-30.
5-31.
5-32.
5-33.
5-34.
5-35.
5-36.
5-37.
5-38.
5-30.
5-40.
5-41.
5-42.
5-43.
5-44.
5-45.
5-46.
5-47.
5-48.
5-40.
6-1.
6-1.
6-1.
6-1.
6-1.
6-1.
6-2.
6-3.
6-4.
6-5,.
6-6.
6-7.
6-8.
6-9.
6-10.
6-11.
6-12.
6-13 .
6-14.
6-15.
6-16.
6-17 .
6-18.
6-19.
6-20.
6-21.
6-22.
7-1.
7-1.
7-1.
9-1.
9-1.
9-1.
9-1.
9-1.
9-1.
9-1.
TM 5-6115-586-34
Title
Page
Compressor and exhaust fans wire harness assembly ................................................................
5-27
AC power wire harness assembly ...............................................................................................
5-28
Temperature sensors wire harness assembly .............................................................................
5-30
Temperature sensors wire harness assembly .............................................................................
5-32
Battery wire harness assembly ....................................................................................................
5-34
Heat valves wire harness assembly ............................................................................................
5-35
Air conditioning power wire harness assembly ............................................................................
5-37
DC power wire harness assembly................................................................................................
5-38
Compressors wire harness assembly...........................................................................................
5-39
Remote fans wire harness assembly ...........................................................................................
5-40
Condenser fans wire harness assembly ......................................................................................
5-41
Recirculating fans wire harness assembly ...................................................................................
5-42
Remove power wire harness assembly........................................................................................
5-43
Auxiliary power tray assembly ....................................................................................................
5-45
400 Hz auxiliary power wire harness assembly............................................................................
5-47
400 Hz auxiliary output 1 wire harness assembly ........................................................................
5-48
400 Hz auxiliary output 2 wire harness assembly ........................................................................
5-49
Water heater wire harness assembly ..........................................................................................
5-50
Receptacle panel wire harness assembly ...................................................................................
5-51
60 Hz output wire harness assembly. ..........................................................................................
5-52
400 Hz output wire harness assembly ........................................................................................
5-53
400 Hz output wire harness assembly ........................................................................................
5-54
DC Standby wire harness assembly ...........................................................................................
5-55
Slave receptacle cable assembly ...............................................................................................
5-55
60 Hz output wire harness assembly ..........................................................................................
5-56
Air conditioning and heat control panel wire harness assembly ...................................................
5-58
Electrical leads ...........................................................................................................................
5-59
Engine skid power plant wire harness assembly .........................................................................
5-61
Power wire harness assembly .....................................................................................................
5-63
Battery wire harness assembly ....................................................................................................
5-64
Conditioned air cooling system (sheet 1 of 6) .............................................................................
6-2
Conditioned air cooling system (sheet 2 of 6) .............................................................................
6-4
Conditioned air cooling system (sheet 3 of 6) .............................................................................
6-6
Conditioned air cooling system (sheet 4 of 6) .............................................................................
6-8
Conditioned air cooling system (sheet 5 of 6) .............................................................................
6-10
Conditioned air cooling system (sheet 6 of 6) .............................................................................
6-12
Thermostatic switch assembly inspection requirements ..............................................................
6-14
Refrigerant leakage test setup ....................................................................................................
6-14
Refrigerant leakage test setup ....................................................................................................
6-16
Liquid refrigerant receiver ..........................................................................................................
6-17
Refrigerant leakage test setup ....................................................................................................
6-18
Tube axial motor driven fan .......................................................................................................
6-20
Holding fixture torque wrench......................................................................................................
6-21
Schematic wiring diagram ..........................................................................................................
6-22
End bell inspection requirements.................................................................................................
6-22
Rotor assembly inspection requirements ....................................................................................
6-23
Fan housing assembly inspection requirements ..........................................................................
6-23
Bearing installation .....................................................................................................................
6-24
End play measurement ...............................................................................................................
6-25
Tube axial motor driven fan .......................................................................................................
6-26
Holding fixture torque wrench .....................................................................................................
6-27
Schematic wiring diagram ..........................................................................................................
6-28
End bell inspection requirements.................................................................................................
6-28
Rotor assembly inspection requirements ....................................................................................
6-29
Fan housing assembly inspection requirements ..........................................................................
6-29
Bearing installation .....................................................................................................................
6-30
End play measurement ...............................................................................................................
6-31
Bleed air and exhaust heating installation (sheet 1 of 3) .............................................................
7-2
Bleed air and exhaust heating installation (sheet 2 of 3) .............................................................
7-4
Bleed air and exhaust heating installation (sheet 3 of 3) .............................................................
7-6
Enclosure assembly (sheet 1 of 10) ............................................................................................
9-2
Enclosure assembly (sheet-2 of 10) ............................................................................................
9-4
Enclosure assembly (sheet 3 of 10) ............................................................................................
9-6
Enclosure assembly (sheet 4 of 10) ............................................................................................
9-8
Enclosure assembly (sheet 5 of 10) ............................................................................................
9-10
Enclosure assembly (sheet 6 of 10).: ..........................................................................................
9-12
Enclosure assembly (sheet 7 of 10) ............................................................................................
9-13
iii
TM 5-6115-586-34
Figure
9-1.
9-1.
9-1.
9-2.
9-2.
9-2.
9-2.
9-2.
9-2.
9-2.
9-2.
9-2.
10-1.
10-2.
10-3.
10-4.
10-5.
10-6.
FO-1
FO-2.
Title
Enclosure assembly (sheet 8 or 10) ............................................................................................
Enclosure assembly (sheet 9 of 10) ............................................................................................
Enclosure assembly (sheet 10 of 10) ..........................................................................................
Shell assembly (sheet 1 of 9) .....................................................................................................
Shell assembly (sheet 2 of 9) .....................................................................................................
Shell assembly (sheet 3 of 9) .....................................................................................................
Shell assembly (sheet 4 of 9) .....................................................................................................
Shell assembly (sheet 5 of 9) .....................................................................................................
Shell assembly (sheet 6 of 9) .....................................................................................................
Shell assembly (sheet 7 of 9) .....................................................................................................
Shell assembly (sheet 8 of 9) .....................................................................................................
Shell assembly (sheet 9 of 9) .....................................................................................................
Inflation and deflation ejector assembly ......................................................................................
Box and valve manifold assembly ..............................................................................................
Compressed air hose assembly and vacuum hose assembly .....................................................
Water system accessory components ........................................................................................
External fuel filter assembly .......................................................................................................
Conditioned air system accessory components ..........................................................................
Control panel wire harness assembly .........................................................................................
Engine skid wire harness assembly ............................................................................................
iv
Page
9-14
9-15
9-16
9-17
9-18
9-20
9-22
9-24
9-26
9-28
9-30
9-32
10-2
10-4
10-5
10-6
10-8
10-10
FO-1
FO-2
TM 5-6115-586-34
CHAPTER 1
INTRODUCTION
Section I. GENERAL
1-1. Scope
a. This manual contains instructions for the use of direct support and general support maintenance personnel
maintaining the power plant, utility, gas turbine engine driven, Libby Model LPU-71, Type A, as allocated by the
Maintenance Allocation Chart. It provides information on the maintenance of the equipment which is beyond the scope
of the tools, equipment, personnel or supplies normally available to operator and organizational level maintenance
personnel.
b. Appendix A contains a list of publications applicable to this manual.
1-2. Forms and Records
Maintenance forms and records and reports which are to be used by maintenance personnel at all maintenance levels
are listed in and prescribed by TM 38-750.
1-3. Reporting of Errors
Report of errors, omissions, and recommendations for improving this publication by the individual user is encouraged.
Reports should be submitted on DA Form 2028 Recommended Changes to Publications, and forwarded direct to the
Commanding General, U. S. Army Mobility Equipment Command, ATTN: AMSME-MP, 4300 Goodfellow Boulevard,
St. Louis, Mo. 63120.
Section II. DESCRIPTION AND DATA
Voltage ................................... 27.5 vdc
1-4. Description
Current ................................... 50 amps (max)
A description of the power plant, its major components and
Speed...................................... 18,000
to
systems, and its accessory components is provided in TM 525,000 rpm
6115-586-12. Detailed description of specific components
Rated *load test:
and assemblies is contained in the repair instruction chapters
Voltage ................................... 27.5 vdc
in this manual.
Current ................................... 135 amps (max)
1-5. Differences Between Models
Torque .................................... 300
ounceThis manual covers only Libby Welding Company Power
inches
Plant Model LPU-71. There are no differences between units
Speed ..................................... 4500 to 5500
of this model.
rpm
1-6. Tabulated Data
a. General. This paragraph provides tabulated data in
d. Starter Assembly Repair and Replacement
addition to that supplied in TM 5-6115586-12. This additional
Standards.
data is provided for the use of direct support and general
support maintenance personnel.
Armature end play ....................... 0.008 to 0.010
inch
b. Gas Turbine Engine Classification and Rating.
Shaft seal leakage ....................... 10 cubic inches
Acceleration time (start to
per hour (max)
governed speed) ..................... 60 seconds (max)
Special repair compounds and materials:
Compressor type ......................... Two-stage centrifugal
Remove minor nicks,
Inlet air temperature .................... 130°F (54°C) (max)
scratches or burrs ................... Abrasive paper
Combustion chanber type ............ Single reverse flow tube
(Federal
Igniter plug type .......................... Air gap
........................................... Specification PReduction gearing ....................... Spur
P-101, No.
Starter motor duty cycle ............... One minute on, one
........................................... 600 Grit)
........................................... minute off or five starts
Outside motor finish removal Abrasive Paper
........................................... in ten minutes
(Federal
Output shaft speed ...................... 6000 rpm
Specification
P-PTurbine wheel speed (full load) 40,700 +/- 100 rpm
101, No.320 Grit)
Governor type ............................. Knife-edge centrifugal
Refinish motor exterior Primer (Cati-Coat
Exhaust gas temperature (full
No.E42GP15 and
load continuous operations . 1225°F (663°C)
Catalyst V77KP15)
Operating oil pressure . ................ 90 +/- 10 psig
then one coat of
Electrical system ......................... 24 vdc
enamel (Cati-Coat
c. Starter Assembly Classification and Rating.
No.F55BP15 and
Catalyst V66KP15,
Horsepower ................................. 1.5 (rated)
SherwinWilliams Co.,
Operating voltage ........................ 24 vdc (rated)
Cleveland, Ohio, or
Direction of rotation
equivalent; no known
(viewing end of shaft) ............. Counterclockwise
government
Weight ......................................... 14.9 lb (approx)
specification)
No load overspeed test:
1-1
TM 5-6115-586-34
Seal nameplate ..................
Zinc chromate primer
(Military Specification MIL
P-8585)
Special assembly compounds and materials:
Lubricate plates,
rings, retainer ................. Lubricating oil (Military
Specification MIL-L-7808)
e. Starter Assembly Nut and Bolt Torque Data.
Starter clutch slip torque ..... 135 to 145 inch-pounds
f. Fuel Control Assembly Classification and
Rating.
Governor type .................... Isochronous
Pump type .......................... Gear
Lubrication ......................... Fuel
Acceleration limiter valve
cracking pressure .......... 44 to 46 psi
g. Fuel Control Repair and Replacement
Standards.
Leakage allowable .............. None
Special repair compounds and
materials:
Magnetic particle inspect,
shaft, gearshaft .............. Military Specification MIL-I6868
Repair minor nicks,
scratches or burrs
in non-critical areas ........ Abrasive paper (Federal
Specification P-P-101, No.
600 Grit) or fine stone
(Federal Specification AF-3JB)
h. Fuel Control Unit Nut and Bolt Torque Data.
Screw to secure cover to
housing .......................... 40 to 60 inch-pounds
Nut to secure fitting to
housing .......................... 100 to 110 inch-pounds
i. Fuel Shutoff Solenoid Valve Classification and
Rating.
Valve actuator .................... Electromagnet
Normal valve position ......... Closed
Operating pressure ............. 0 to 1000 psig
Operating voltage ............... 11 to 30 vdc
Operating current ............... 1.0 amp (max) at 28 vdc
Drop out voltage ................. 4 vdc (mini
Flow .................................. 500 phr (pounds per hour)
(max)
Pressure drop across valve
at 120 phr (pounds per
hour) flow ...................... 4 psig (max)
Weight ............................... 0.3 lb
j. Fuel Shutoff Solenoid Valve Repair and
Replacement Standards.
Valve leakage at 300 psig
fluid pressure ................. 0.5 cc (cubic centimeters) per
Valve leakage at 1000 psighour (max)
fluid pressure ................. 1.0 cc per hour (max)
Operating voltage at 100 -.3
psig fluid pressure ......... 7.2 vdc (min)
Operating voltage at 300 +/- 3
psig fluid pressure ......... 9.0 vdc (min)
k. Ignition Unit Classification and Rating.
Type. .................................. High voltage, capacitor
discharge
Enclosure............................ Hermetically sealed
1-2
Operating input voltage .....
10 to 30 vdc
Input current ......................
4.5 amperes (max)
Output voltage ...................
18,000 vdc (nom)
Stored energy ....................
4.3 joules per spark
Weight ..............................
3.5 lb
l. Ignition Unit 'Repair and Replacement
Standards.
Spark rate at 10 volts inputOne spark per second (mini
m. Low Oil Pressure Switch Classification and
Rating.
Two single pole double throw
Switch type ........................
switches with no internal
ground
Actuator .............................
Adjustable diaphragm
Current capacity ................
4 amperes at 14 to 29 vdc
Proof pressure ...................
.250 psig
Operating pressure:
Actuation ......................
65 psig
Deactuation (decreasing
pressure) ......................
55-3 psig
n. Dual Pad Gearcase Repair and Replacement
Standards.
Magnetic particle inspect nuts Military Specification MIL-I6868
Special repair compounds and materials:
Remove burrs, scratches,
nicks .............................
Abrasive cloth (Federal
Specification P-C-451 or PC-458)
Treat aluminum parts after
corrosion removal .........
Turco Prepaint (Turco
Products, Inc., Los Angeles,
California, or equivalent;
no known government
specification) or Brush
Alodine (American Chemical
Paint Co., Ambler, Penn.or
equivalent; no known
Reanodize aluminum parts
Military Specification MIL-Aas required ...................
8625
Strip paint .....................
Kestrip "E" (Kelite Products,
Los Angeles, California, or
equivalent; no known
government specification)
Prime parts to be painted Primer (Military Specification
MIL-P-8585)
Paint parts ....................
Black enamel (Military
Specification MIL-E-5557,
Type II)
Special assembly compounds and
materials:
Coat sealing bore of retainer Cement (Glyptal, No. 1276,
General Electric Co.,
Schenectady, New York, or
equivalent; no known
government specification)
o. Dual Pad Accessory Torque Values.
Nut to gearshaft .................
145 to 15 inch-pounds
Nut to gearshaft .................
145 to 155 inch-pounds
Nut to gearshaft .................
145 to 155 inch-pounds
p. Accessory Gearcase Repair and Replacement
Standards
Magnetic particle inspect, jaw Military Specification MIL-I6868
TM 5-6115-586-34
Special assembly compounds and materials
Lubricate packing8agaskets
at installation ................. Petrolatum (Federal
Specification VV-P-236)
q. Accessory Gearcase Nut and Bolt Torque
Values.
Screws securing retainer .... 15 to 20 inch-pounds
r. 400 Hz Generator Repair and Replacement
Standards.
Rated voltage (line to
neutral) .......................... 120 vac
Rated voltage (line to line) . 208 vac
Rated load ......................... 100 CFM @10" H2 0 cooling
air 120 kva
Power factor ....................... 0.8
Phase ................................. Three
Frequency .......................... 400 Hz
Rated speed ....................... 5700 rpm
Maximum speed for regulation 7000 rpm
Overspeed ......................... 7500 rpm
Rotation (viewing drive end) . Counterclockwise
Bolt circle diameter ............ 10.0 in.
Drive spline ........................ 24 teeth, 20/30 pitch, 30
degrees pressure angle
Weight ............................... 135 lbs max
s. 60 Hz Generator Repair and Replacement
Standards.
Rated voltage (line to
neutral ........................... 120 vac
Rated voltage (line to line) . 240 vac
Rated load ......................... 12.5 kva
Power factor ....................... 0.8
Phase ................................. Single
Frequency .......................... 60 Hz
Rated speed ....................... 3600 rpm
Maximum speed for regulation 3600 rpm
Overspeed ......................... 4000 rpm
Rotation (viewing drive end) Counterclockwise
Bolt circle diameter ............ 10.0 in.
Drive spline ........................ 24 teeth, 20/30 pitch, 30
degrees pressure angle
Weight (max) ..................... 118 lbs. max.
t. Air Conditioning Compressor Replacement
Standards.
Type .............................. Two-stage centrifugal compressor, electric motordriven
Operating voltage ............... Three phase 115/ 200 vac at
400 Hz
Rated operating current ...... 60 amp
Maximum operating current . 75 amp
Locked rotor current ........... 350 amp
Rated output ...................... 25-hp at 23,300 rpm
Weight ............................... 35 lb (approx)
Special testing compounds and materials:
Testing refrigerant and oil Refrigerant 114 (Fed Spec BBF-1421) and dry oil (88520KV oil, Bray Oil Co., Los
Angeles, Calif., or
equivalent)
u. Recirculating Fans Repair and Replacement
Standards.
Fan rotation ........................ Counterclockwise viewing fan
wheel end of fan
Duty cycle .......................... Continuous
Operating current after 10
minutes of operation ...... 6 amperes per phase
1-3
Operating voltage ..............
115/200 vac, 400 Hz, 3
phase
Operating speed after 10
minutes of operation with
unobstructed airflow ......
5700 rpm (min)
Thermal protector trip time
with rotor locked ...........
30 seconds (max)
Thermal protector reset time
after trip ........................
30 seconds (max)
Electrical connections to connector:
Pin D (white) .................
Neutral
Pin A (black ..................
Phase 1
Pin B (red) ....................
Phase 2
Pin C (green) ................
Phase 3
Weight ..............................
17.15 lb (approx)
Special Repair Compounds and Materials:
Remove minor scratches and
nicks on impeller ...........
Abrasive paper (Federal
Specification P-P-101, No.
400 grit)
Touch up anodic coating on
reworked impeller .........
Anodic Coating (Military
Specification MIL-A-8625,
Type I)
Remove defective finish on:
Rotor, end bell ..............
Abrasive cloth (Federal
Specification P-C-451, No.
320 grit)
Refinish:
Rotor ............................
Enamel and Catalyst (CatiCoat, No. F55BP; and
Catalyst VV66KP17,
Sherwin-Williams Co.,
Cleveland, Ohio or
equivalent; no known
government specification)
Coat unpainted surfaces of:
Rotor ............................
Lubricant (DC5 Lube, Dow
Corning Corp., Midland,
Michigan, or equivalent; no
known government
specification)
Remove cement deposits ..
Methyl-Ethyl-Ketone (Federal
Specification TT-M-261)
Special assembly compounds and materials:
Apply compound to threads
of rotor shaft .................
Anti seize (Federal
Specification JAN-A-669)
Solder electrical connections Solder (Federal Specification
QQ-S-571, Type SN60WRAP2)
Coat threads of screws with
sealant ......................... . Sealant (Military Specification
MIL-S-22473, Class 10)
After assembly paint:
end of rotor, hex hole
One coat of primer (Cati-Coat
in shaft and nut .............
E42GP15 and Catalyst
V66K-P15 SherwinWilliams Co., Cleveland,
Ohio or equivalent; no
known government
specification) air dry for 15
to 30 minutes and bake at
1500 to 175¢F (66°to
79C ).
TM 5-6115-586-34
v. Condenser Fans Repair and Replacement
Standards.
Fan rotation ........................ Counterclockwise viewing fan
wheel end of fan
Duty cycle .......................... Continuous
Operating current after 10
minutes of operation ...... 15 amperes per phase
Operating voltage ............... 115/200 vac, 400 Hz, 3
phase
Operating speed after 10
minutes of operation with
unobstructed airflow ....... 3800 rpm (min)
Thermal protector trip time
with rotor locked ............ 30 seconds (max)
Thermal protector reset
time after trip ................. 30 seconds (max)
Electrical connections to connector:
Pin D (white) .................. Neutral
Pin A (green) ................. Phase 1
Pin B (red) ..................... Phase 2
Pin C (black) ................. Phase 3
Pin E ............................. Not used
Weight ............................... 58.0 lb (approx)
Special repair compounds and materials:
Remove minor scratches and
nicks on:
impeller .......................... Abrasive paper (Federal
Specification P-P-101, No.
400 grit)
Touch up anodic coating on
reworked impeller .......... Anodic Coating Military
Specification MIL-A-8625,
Type 1)
w. Condenser Replacement Standards.
Type .................................. Refrigerant gas to air
Special cleaning compounds and materials:
Kerosene ....................... Federal Specification VV-K211
Trichlorethylene ............. Military Specification MILT-7003
x. Evaporator Replacement Standards.
Type .................................. Air to refrigerant gas
Special cleaning compound and materials:
Kerosene ....................... Federal Specification V V-K211
Trichlorethylene ............. Military Specification MIL-T7003
y. Receiver Repair and Replacement Standards:
Capacity ............................. 30 lb. refrigerant
Working pressure ............... 110 psig (nom)
Working pressure ................ 165 psig (max)
Weight ............................... 3.8 lb.(approx)
Special cleaning compounds and materials:
1-4
Federal Specification VV-K211
Trichlorethylene ................. Military Specification MIL-T7003
Special repair compounds and materials:
Brazing alloy ................. Military Specification MIL-B20148
Welding ......................... Military Specification MIL-W6858
Primer ........................... (Cati-Coat No. 42GP15,
Sherwin Williams Co.,
Cleveland, Ohio or
equivalent; no known
government specification)
Enamel .......................... Military Specification MIL-E5558 Type II
Catalyst .............................. (Cati-Coat No. V66KP15,
Sherwin-Williams Co.,
Cleveland, Ohio or
equivalent; no known
government specification)
z. Cold Water Pump Replacement Standards
Power ............................ 190 Watts (nom)
270 Watts (max)
Voltage .......................... 115/200 vac, 400 Hz, 3
Phase
Flowrate ........................ 9 gpm
Pressure rise ................. 30 psi (nom)
25 psi (min)
Length ........................... 6.9 Inches
Width ............................ 4.38 Inches
Weight .......................... 4.63 lb
Speed ............................ 11,500 rpm
Duty rating ..................... Continuous
aa. Hot Water Pump Replacement Standards.
Power ............................ 190 Watts (nom)
270 Watts (maxi
Voltage .......................... 200 vac, 400 Hz, 3 Phase
Flow rate ....................... 6 gpm
Pressure rise ................. 23 psi (nom)
22 psi (im)
Length ........................... 7.55 in. (Electrical connector
extends approximately 0.50
in. beyond motor pump)
Diameter ....................... 2.50 in. (Discharge nozzle
extends 0.50 in. beyond
motor pump
Weight .......................... 2.6 lb maximum
Speed ............................ 11,500 rpm
Duty rating ..................... Continuous
ab. Repair and Replacement Standards. Table 1I lists
manufacturer's sizes, tolerances, desired clearances, and
maximum allowable wear and clearances.
Kerosene .......................
TM 5-6115-586-34
Table 1-1. Repair and Replacement Standards
Component
Manufacturer's dimensions
and tolerances in inches
Maximum
Fan, recirculating (fig. 6-7)
Rotor (26) diameter of stack assembly
Rotor (26) shaft bearing surfaces
End bell (23, 24) bearing bore
Impeller (20), bore
Rotor (26) in stator (28)
Bearing (25) in end bell (23, 24)
Bearing (25) on rotor (26) shaft
2.975
0.6691
1.5750
0.6693
Minimum
Maximum
0.026
0.0009
Loose fit
of 0.0002
Loose fit
of 0.0007
0.065
5.972
0.7875
1.8510
1.8510
0.7879
Impeller (22), on rotor (24) shaft
Clearance gap between end bell (16) and
end of rotor (24), shaft
ac. Engine Electrical System Schematic. See TM 5-6115-586-12.
ad. Power Plant Electrical System Schematic. See TM 5-6115-586-12.
ae. Instrument Panel Wiring Diagram. See TM 5-6115-586-12.
af. Engine and Skid Wiring Diagram. See TM 56115-586-12.
ag. Water System Wiring Diagram. See TM 56115-526-12.
1-5
Maximum
allowable
wear and
clearance
0.000
0.0004
0 0000
0.024
0.0002
Press fit
of 0.0003
Press fit
of 0.0001
0.055
5.970
0.7872
1.8505
1.8505
0.7874
Minimum
2.976
0.6694
1.5754
0.6698
Impeller (20) on rotor shaft (26)
Clearance gap between end bell (23, 24)
and end of rotor (26) shaft
Fan, condenser (fig. 6-15)
Rotor (241 diameter of stack assembly
Rotor (24) shaft bearing surfaces
End bell (16), bearing bore
Housing (25), bearing bore
Impeller (22) bore
Rotor (24) in stator (27)
Bearing (23) in end bell (16) or housing
(25), bore
Bearing (23) on rotor (24) shaft
Desired clearance
0.000
0.0004
0.0000
0.0000
0.0000
0.0280
0.0001
0.0315
0.0006
Press fit
of 0.0002
Press fit
of 0.0001
0.80
Loose fit
of 0.0003
Loose fit
of 0.0007
0.84
TM 5-6115-586-34
CHAPTER 2
DIRECT SUPPORT AND GENERAL SUPPORTMAINTENANCE INSTRUCTIONS
Section I. REPAIR PARTS, SPECIAL TOOLS AND EQUIPMENT
2-1. Special Tools and Equipment
The special tools and equipment required to perform direct support and general support maintenance on the power plant
are listed in table 2-1 below and in the Maintenance Allocation chart, Appendix B of TM 5-6115-586-12. Paragraph
references and illustrations indicating the use of special tools and equipment are listed in table 2-1.
2-2. Maintenance Repair Parts.
Repair parts, special tools, test and support equipment are listed and illustrated in TM, 5-6115586-34P.
Table 2-1. Special Tools and Equipment
Item
FSN or
part number
References
Stand, portable, gas turbine engine
4910-758-6189
2-12b
Analyzer, engine, gas turbine
4920-778-6091
2-4a
Cable assembly, special purpose, electrical,
branched
Wrench, spanner
4940-182-4499
2-4a
5120-793-0701
3-17,3-19
Adapter, wrench
5120-608-6794
3-17,3-19
Sling, beam type, adjustable
Mount, gas turbine engine
1730-115-3189
1730-015-8005
2-12b
2-12b
Mount, gas turbine engine
1730-015-8002
2-12b
Adapter, maintenance stand
4920-118-0346
2-12b
Dolly set, utility package, transporting
285186-1-1 (99193)
Wrench, spanner
Driver, seal
5120-320-9613
5120-525-8557
3-23,3-25
3-17,3-19
Driver, seal
5120-733-7113
3-17,3-19
Puller, mechanical seal
Screwdriver and wrench assembly
Adapter, fuel atomizer
5120-608-8239
5120-668-6122
4920-924-1196
3-17,3-19
3-6
3-7e
Service kit, refrigeration
4130-400-2150
Fixture, end play measuring
905128-1-1 (99193)
2-1 thru
2-4
6-14,6-22
2-4b, 6-5b,
6-6b, 6-7e
6-8d, 6-9d
Wrench, torque, holding fixture
5120-178-0057
6-8
6-8
Fixture, bearing press
272166 (99193)
6-13,6-21
6-8,6-9
Wrench, torque, holding fixture
5120-178-0070
6-16
6-9
Holder, clutch torquing
Adapter, torque wrench
Plate, end seal
4920-336-0648
5120-608-4756
268129(99193)
3-7
3-7
6-3
3-5f
3-5f
6-5
2-1
Use
Support gas turbine during assembly,
disassembly, and functional testing.
Monitor operation of the gas turbine
engine.
Connect analyzer to electrical harness of
the gas turbine engine.
Removal and installation of accessory
output shaft nut.
Hold output shaft during removal or
installation of output shaft nut.
Lifting gas turbine unit.
Adapt one side mount of the gas turbine
unit to the maintenance stand.
Adapt one side mount of the gas turbine
unit to the maintenance stand.
Support accessory end of gas turbine
unit in maintenance stand.
Transport power plant to and from
various locations.
Removal or installation of tailpipe.
Installation of output shaft seal in
retainer.
Installation of oil pump drive shaft seal in
accessory case.
Removal of oil pump drive shaft seal.
Adjusting fuel control unit.
Adapt fuel atomizer to tester during
testing.
Service and check refrigeration system.
Measure end play in armature of motor
driven fan.
Hold impeller of motor-driven fan while
impeller shaft nut is tightened.
Holds and aligns fan rotor shaft while
pressing bearing onto shaft.
Hold motor-driven fan shaft while
tightening shaft nut.
Adjustment of starter clutch torque.
Adjustment of starter clutch torque.
Seal inlet ports of refrigerant condenser
during leakage tests.
TM 5-6115-586-34
Table 2-1. Special Tools and Equipment-Continued
Item
FSN or
part number
References
Plate, end seal
905137-1(99193)
6-3
6-5
Plate, Adapter flange
268128(99193)
6-4
6-6
Plate, end seal
268129-1(99193)
6-6
6-7
Wire twister, plier
5120-305-2306
2-9a
2-2
Use
Seal inlet to refrigerant condenser
during leakage tests.
Seal port of evaporator during leakage
tests.
Seal inlet and outlet of refrigerant
receiver during leakage tests.
Facilitate lock wiring of various fasteners
and electrical connectors.
TM 5-6115-586-34
Section II. TROUBLESHOOTING
2-3. General
a. This section provides information useful in diagnosing and correcting' unsatisfactory operation or failure of the
power plant and its components. Malfunctions which may occur are listed in table 22. Each malfunction stated is
followed by a list of probable causes of the trouble. The corrective action recommended is described opposite the
probable cause.
b. Information concerning the use of special test equipment as an aid to troubleshooting is provided in paragraph 24 of this section.
Table 2-2. Troubleshooting
Malfunction
1. Fuel boost pump motor assembly
fails to operate (batteries
charged)
Probable Cause
a. Defective fuel boost pump motor
assembly.
Defective starter motor clutch.
a. Check that 24 VDC is present at
fuel boost pump connector P35.
If 24 VDC is present, repair or
replace pump (para 4-4); if
voltage is not present, continue to
step b.
b. Test wire harness assemblies (para
5-3, 5-26, 5-24, 5-33, and 5-34).
Repair or replace clutch (para 3-5).
No-fuel relay (K44) defective.
Replace relay K44 (para 5-33).
a. Low oil or depleted fuel supply.
a. Service power plant as required.
(see TM 5-6115-586-12.)
b. Clean, repair, or replace fuel filters
(para 3-3, 10-8 through 10-12).
c. Repair or replace fuel control
assembly (para 3-6).
d. Replace fuel solenoid (para 3-6).
e. Replace oil pressure sequencing
switch. (see TM 5-6115-586-12).
f. Clean or replace screen (para 3-7).
a. Tighten or repair control air line
fittings (para 3-3).
b. Repair fuel control pump (para 36).
c. Repair fuel atomizer (para 3-71.
b. Defective wire harness assembly.
2. Starter motor runs but does not
rotate engine.
3. Engine stops motoring when
master switch is released from
START to RUN position.
4. Engine motors but combustion
does not occur.
b. Fuel filter clogged or defective.
c.
5. Engine starts but will not accelerate to governed speed or
accelerates too slowly.
6. Engine lacks ability to carry load.
Fuel control assembly failed.
d. Fuel solenoid failed.
e. Oil pressure sequencing switch
failed.
f. Fuel atomizer screen obstructed.
a. Control air lines leaking.
b. Fuel control pump assembly
failed.
c. Fuel atomizer flow divider sticking
closed.
d. Acceleration limiter supply orifice
plugged.
a. Fuel filter partially clogged.
b. Control air lines leaking.
c.
Fuel control failed.
7. Oil leaks from vent orifice of dual
pad gear box.
Gearbox has positive pressure
because of pump failure.
8. 60 Hz frequency meter out of
limits.
9. DC ammeter out of limits.
10. DC ammeter does not indicate.
Defective meter.
11. Exhaust gas temperature meter
does not indicate.
12. 60 Hz ammeter does not indicate
on either leg.
13. 60 Hz ammeter does not indicate
on one leg.
Corrective Action
Improper adjustment.
a. Damaged shunt.
b. Meter open.
a. Open exhaust gas temperature
thermocouple.
b. Open meter.
Defective meter.
Open current transformer.
2-3
d. Remove and clean orificed fitting
(para 3-6).
a. Replace filter elements as required
(para 3-3, 10-8 through 10-12).
b. Tighten control air lines fittings
(para 3-3).
c. Repair or replace fuel control (para
3-6).
Replace pump assembly on dual pad
gear box (para 3-11 through 313).
Test meter and if faulty, replace
meter (para 5-26).
Center zero adjustment (para 5-26).
a. Replace shunt (para 5-35).
b. Replace ammeter (para 5-26).
a. Replace thermocouple (see TM 56115-586-12).
b. Replace exhaust gas temperature
meter. (see TM 5-6115-586-12).
Replace 60 Hz ammeter (para 5-26).
Replace current transformer (para 5.
26).
TM 5-6115-586-34
Table 2-2. Troubleshooting-Continued
Malfunction
14. 60 Hz voltmeter out of limits.
15. 400 Hz frequency meter out of
limits. (True frequency
established with test instrument.)
16. 400 Hz ammeter out of limits.
17. 400 Hz ammeter does not indicate.
Probable Cause
Meter out of adjustment.
a. Meter out of adjustment.
b. Faulty frequency discrimination
circuit.
Meter out of adjustment.
a. Open current transformer.
b. Defective meter.
18. 400 Hz voltmeter out of limits.
Meter out of adjustment.
19. Heating system does not operate. a. Load control valve does not have
Fans run but load control valve
sufficient pneumatic supply.
does not open.
b. Lockout relay (K42A or K42B)
failed.
20. Heat valves do not control. Load a. Dummy plug (P93) removed.
control valve operates
satisfactorily.
b. Temperature sensors (RT1, RT2,
RT5, or RT6) failed.
c. Temperature controllers (S19 or
S20) failed.
d. Heat system flow control selectors
(S35) or (S36) failed.
21. One or both cooled air systems
a. Mode select switch (S16) failed.
will not actuate from panel. Main
contactor operation satisfactory. b. System select switch (S15) failed.
22. Condenser fans do not operate.
23. Condenser fans operate but
compressor does not energize.
c. Lockout relay (K42A or 42B
failed).
a. Condenser air discharge door
switches (S27 and S28) are
locked open or have failed.
b. Condenser fan contactors (K23
and K24) have failed.
c. Circuit breakers (CB13 and
CB17) failed.
a. Compressor delay relays (K17 and
K18) failed.
b. Compressor contactors (K19 or
K20) failed.
c. Compressor circuit breakers
(CB14 and CB18) failed.
d. Condenser fan interlock switches
(S33 and S34) do not close.
e. Compressor overtemperature
switches (TS7 and TS8) open.
f. Compressor overpressure switches
(S17 and S18) open.
24. Condenser fans and compressors a. Temperature sensors (RT3, RT4)
operate but system does not
failed.
control. (Ambient temperature is b. Air conditioning temperature
between 60°and 90°F.)
controllers (S20 and S21) failed.
c. Remote temperature relav (K40)
failed.
d. Anti-ice relay (K41) failed.
e. Anti-ice sensors (TS10 and TS11)
failed.
2-4
Corrective Action
Adjust meter (para 5-26).
a. Adjust meter (para 5-26).
b. Replace 400 Hz protective panel
(para p-33).
Adjust meter (para 5-26).
a. Replace current transformer (para
5-33).
b. Replace 400 Hz ammeter (para 526).
Adjust meter (para 5-26).
a. Tighten fittings; check for
damaged tubes or fittings; check
for obstructions in supply fittings
(para 3-3).
b. Replace relay (K42A or K42B).
(see TM 5-6115-586-12.)
a. Install plug (P93).
(see TM 56115-586-12.)
b. Replace defective sensor.(see TM
5-6115-586-12.)
c. Replace switches (S19 or S20).(see
TM 5-6115-586-12.)
d. Replace selectors (S35 or S36).
(see TM 5-6115-586-12.)
a. Replace switch (S16).(see TM 56115-586-12).
b. Replace switch (S15).(see TM 56115-586-12.)
c. Replace relays (K42A or K42B).
(see TM 5-6115-586-12.)
a. Unlock switches or replace
switch (S27 or S28).(see TM 56115-586-12.)
b. Replace contactors (K23 or K24).
(see TM 5-6115-586-12.)
c. Replace circuit breakers (CB13 or
CB17). (see TM 5-6115-58612.)
a. Replace relays (K17 or K18).(see
TM 5-6115-586-12.)
b. Replace contactors (K19 or K20).
(see TM 5-6115-586-12.)
c. Replace circuit breakers (CB14
and CB18). (see TM 5-6115586-12.)
d. Adjust attitude of switches (S33 or
S34) or replace if defective. (see
TM 5-6115-586-12.)
e. Cool compressor or replace
defective thermal switch (TS7 or
TS8) (para 6-4).
f. Check refrigeration system for over
pressurization. Replace switches
(S17 and S18) if defective (para
6-2).
a. Replace defective temperature
sensor (para 5-23).
b. Replace switches (S20 or S21).
(see TM 5-6115-586-12.)
c. Replace relay (K40).(see TM 56115-586-12.)
d. Replace relay (K41).(see TM 56115-586-12.)
e. Replace thermal sensors (TS10 or
TS11) (para 5-14).
TM 5-6115-586-34
Table 2-2. Troubleshooting-Continued
Malfunction
25.
Refrigeration system operates but
does not meet cooling performance requirement. System
power draw is less than normal.
(Discharge conditioned air must
be mixed for accurate temperature measurement.)
26.
Refrigeration system operates but
does not meet cooling performance requirement. System
power draw is normal.
27.
Refrigeration system meets
cooling performance requirements but has excessive
power draw.
28.
Hot or cold water pump panel
switches (CB11 or CB12) trip
and will not hold reset. (Voltage
to pumps is satisfactory.
29.
Cold water pump (B14) does not
have supply voltage. (Main
contactor operation satisfactory).
Hot water pump (B15) does not
have supply voltage. (Cold water
pump operating and pressure at
(S11) exceeds 10 psig.)
30.
31.
Flow control valve does not open.
K14 does not have supply
voltage.
32.
Hot water temperature is out of
limits.
Probable Cause
Corrective Action
System low on refrigerant. (Low
The refrigerant level should be above
refrigerant level will be indicated
the lower receiver sight glass
if the conditioned air discharge
when operating system. Check
(from a single part) is highly
and repair refrigerant leaks,
stratafied, i.e., top half may be at
recharge system (para 2-4b.).
near ambient temperature and a
thermal pulse is noted at the
expansion valve.)
a. Refrigeration, de-icing, or com- a. Compare corresponding tubing
pressor bypass valves are not
temperature with both systems
functioning properly.
operating and replace defective
valve (para.6-2).
b. Expansion valve defective.
b. Replace expansion valve. (see TM
5-6115-586-12.)
c. Exhaust gas entering condenser c. This can occur if unit is operating
fan inlet.
under roof. Relocate unit or duct
exhaust gases.
a. Refrigeration system is overa. Reduce refrigerant charge (para 2charged. (Cooling performance
4b).
will also deteriorate with a
Substantial overcharge, (4
pounds or more excess.)
b. Excessive compressor drag.
b. Replace defective compressor
(para 6-4).
a. Pumps (B14 or B15) are seized. a. Repeat reset several times.
Rotation may be imparied by
deposits in pump. Free or replace
pumps (B14 or B15). (see TM 56115-586-12.)
b. Pump motor failed.
b. Replace pumps (B14 or B15). (see
TM 5-6115-586-12).
Defective cold water pump panel
Replace pump panel switch (CB12).
switch (CB12).
(see TM 5-6115-586-12.)
a. Defective low pressure water
switch (S11).
b. Defective hot water pump panel
switch (CB11).
c. Defective hot water pump contactor (K15).
a. Hot water pressure switch (S11)
open.
a. Test and if faulty, replace switch
(S11) (para 8-6, 8-7).
b. Replace switch (CB11).(see TM
5-6115-586-12.)
c. Replace contactor (K15).(see TM
5-6115-586-12.)
a. Check for sufficient pressure to
close switch (S11). Replace
defective switch (S11) (para 8-6,
8-7).
b. Hot water temperature switch
b. Check that water temperature is
(S12) open.
low enough for switch (S12) or
replace if defective (para 8-11).
a. Hot water temperature switch
a. Adjust switch (S12) (clockwise to
(S12) is not properly adjusted.
Decrease water temperature)
(para 8-11).
b. Defective hot water temperature b. Replace switch (S12) (para 8-11).
switch (S12).
c. Defective flow control valve
c. Isolate by opening main contactor
(K14).
(K10), if exhaust gases continue
to flow from water boiler exhaust
port, replace flow control valve
(K14). (see TM 5-6115-586-12).
2-4. Use of Special Troubleshooting Equipment
a. Gas Turbine Engine Analyzer. The gas turbine engine analyzer provides electrical, hydraulic and pneumatic test
systems with their associated controls and instruments for functional testing of the gas turbine engine and malfunctioning
components. A portable multimeter and a portable fuel pressure gauge are provided for use in
2-5
TM 5-6115-586-34
troubleshooting checks at various components on the
engine. A Special Purpose Electrical Branched Cable
Assembly and Analyzer Hose Kit are used to connect the
test systems of the analyzer to the engine. Refer to TM
5-6115-586-12 for instructions on connecting the gas
turbine engine analyzer to the power plant and the
procedures to follow for performing static checks and
functional tests.
(1) One leak detector.
(2) One oil servicing unit.
/3) One oil quantity test unit.
(4) One sling psychrometer.
(5) One refrigeration service wrench.
(6) One 3/4 inch vacuum hose, 10 feet long.
(7) One 3/4 inch vacuum hose, 20 feet long.
(8) One 3/8 inch charging hose, 3 feet long.
(9) One 3/8 inch charging hose, 8 feet long.
(10) Two ¼ inch charging hoses, 12 feet long.
(11) One main power cable, 20 feet long.
(12) One power output cable, 20 feet long.
(13) Four ¼ inch flare seal brass plugs.
(14) Six/8 inch flare seal brass plugs.
(15) Two 3/8 x 3/8 inch unions.
(16) Two 38 x 1/4 inch unions.
(17) One 3/8 inch cylinder adapter fitting.
(18) One cylinder adapter fitting.
(19) One ¼ inch knurled fitting.
(20) One 3/8 inch knurled fitting.
(21) Vacuum hose quick disconnects.
b. Refrigeration System Service Unit.
The
refrigeration system service unit (fig. 2-1 and 2-2) is
designed specifically for servicing refrigeration systems
using refrigerant R114 (Fed. Spec. BB-F1421). The unit
provides servicing functions for refrigeration system
evacuation, dehydration and leak detection; addition of
lubricant to refrigeration system; addition of refrigerant to
the refrigeration system; and testing the refrigeration
system. The instruments and controls are accessible
behind a hinged, removable door, with the electrical and
fluid schematics and operating instructions on the back of
the door. The accessories, stored in the removable door
of the unit, include:
Figure 2-1. Refrigeration service unit.
2-6
TM 5-6115-586-34
Figure 2-2. Refrigeration service unit panel details.
(a) Leak-detector. The leak detector, housed
in a shock-resistant vinyl case, consists of a control unit, a
probe, a six foot long, hose, and a six foot long power
cord. To operate the leak-detector, refer to figure 2-2 and
proceed as follows.
2. Crack purge valve to purge air from gauge
assembly. When gauge and hose assembly are purged,
tighten fitting F 1 and open purge valve fully.
3. If refrigeration system components are
below 75° F (24° C) apply heat to refrigerant in power
plant receiver and condenser to obtain 15
1. Remove cap from bulkhead fitting F1 on
refrigeration service unit panel. Loosely connect one end
of hose assembly to service unit bulkhead fitting Fl.
Securely connect other end of hose assembly to purge
valve located at power plant condenser outlet.
2-7
TM 5-6115-586-34
psig minimum pressure reading on gauge GA1. If
pressure does not increase to 15 psig minimum charge
refrigeration system (para (c) below).
Do not attempt to operate the leakdetector at voltages other than
those specified on the rating plate
since damage to the detector may
result.
4. If gauge GAI indicates 15 psig, or more,
proceed with leak check as outlined in steps 5 through 10.
Note
Screw is for shipping and storage
purposes.
Replace screw after
using detector.
5. Remove screw from cap on reference leak
and allow 15 minutes (minimum) for leak rate to stabilize.
Caution
Do not place probe in a stream of
refrigerant and do not blow
cigarette smoke into the probe
since either will drastically shorten
element life.
Note
Variations in line voltage may
cause erratic operation of the leak
detector resulting in reactions
similar to those for atmospheric
contamination. If voltage variation
is suspected, utilize a voltage
stabilizing device. Note. If the air
flow ball does not rise, tap the
probe tip lightly to make sure ball is
not sticking. If ball still does not
rise, replace detector.
6. Connect power cord to power supply outlet
on service unit.
Note
Contamination of the testing area
may cause erratic operation of the
leak-detector. Contamination can
occur when the leak in the
refrigeration system is very large
and where there is little or no
ventilation in the testing area.
Contamination may also occur
where excessive amounts of
refrigerant gases are used. The
leak-detector cannot differentiate
between
atmospheric
contamination and a possible leak.
Also, in a highly contaminated area,
the flash rate will be unstable, and
it will be impossible to adjust the
balance control.
Under these
conditions leak detection would not
be possible.
A contaminated
condition can be greatly reduced
by ventilating the area or isolating
the area to be checked.
7. Check for sufficient air flow by pointing tip
of probe downward and observing air flow ball in probe. If
air flow is correct, air flow ball will rise and float above tip
of probe.
8. Place sensitivity switch in either HIGH or
LOW position.
9. Adjust flashing rate of lamp in probe by
rotating balance control knob until lamp just ceases to
flash.
10. Hold probe as closely as possible to the
area being checked and move tip of probe approximately
one inch per second along seams or joints suspected of
leaking. When a leak is located, the lamp in probe will
flash as long as probe is held at the leak.
Warning
Do not use leak detector in an
explosive
or
combustible
atmosphere. Ambient atmosphere
is drawn through the probe and
over the element which operates at
approximately 1800° F (982° C).
The resulting combination of high
temperature and an explosive or
combustible
atmosphere
may
cause an explosion resulting in
severe injury or death to personnel
and damage to equipment.
(b) Evacuation procedure. To evacuate the power
plant refrigeration system, refer to figure 2-3 and 2-4 and
proceed as follows:
1. Open service valve on power plant
refrigerant receiver and compressor suction purge valve
on compressor, allowing liquid refrigerant to vent from
system.
2. When venting stops, attach vacuum hose
(ten feet in length) to bulkhead fitting F5 on service unit
and to valve on power plant refrigerant receiver as shown
in figure 2-3.
Caution
2-8
TM 5-6115-586-34
Figure 2-3. service unit connected to power plant.
200 microns of Mercury absolute
cannot be obtained or held for two
hours, leakage in refrigeration
system is indicated. Check for leak
(para (a) above 1.
3. Attach vacuum hose (20 feet in length) to
fitting F4 on service unit and to power plant compressor
suction purge valve.
4. Open valve V4 on service unit.
5. Open gas ballast valve (fig. 2-4) on top of
vacuum pump on service unit.
7.
Operate vacuum pump and evacuate
refrigeration system to a pressure of 200 microns
Mercury, absolute, as indicated on vacuum gauge GA4.
Maintain pressure of 200 microns, or less, for a minimum
of two hours.
6. Place power switch on service unit (fig. 22) in ON position and place heater vacuum pump switch
on service unit in VAC PUMP position.
8.
Close service valve on power plant
refrigerant receiver and close compressor suction purge
valve on power plant compressor.
Note
Close valve V4 on service unit to
obtain accurate measurement of
pressure in refrigeration system on
vacuum gauge GA4. If pressure of
2-9
TM 5-6115-586-34
Figure 2-4. Refrigeration service unit internal details.
connection at service valve and
repeat
the
purge
procedure
outlined above.
4 Tap service valve on power plant receiver
to dislodge any air pockets.
9. Place heater vacuum pump switch on
service unit in OFF position. Place power switch on
service unit in down position. Close gas ballast valve (fig.
2-4) on top of vacuum pump on service unit. Close valve
V4 (fig. 2-2) on service unit. Remove vacuum hoses
from power plant refrigeration system connecting points
and from service unit.
5 Fill beaker with oil, Military Specification
MIL-L-6085A, enough to charge system and enough left
over to prevent entrance of air into charging hose.
(c) Refrigeration system charging procedure. To
charge the power plant refrigeration system, first
evacuate the system as described in paragraph (b) above.
When system has been properly evacuated, refer to
figure 2-2 and proceed as follows:
6 Crack
service
valve
on
power
plant
receiver.
7 Charge
system
Specification MIL-L-6085A.
1 Loosely connect oil charging hose (part. of
refrigeration system service unit) to service valve on
power plant refrigerant receiver.
8 Close
service
with
valve
on
oil,
power
Military
plant
receiver.
2 Fill beaker (part of refrigeration system
service unit) with oil, -Mil Spec MIL-L-6085A, enough to
purge all air from oil charging hose.
9 Remove oil charge hose from power plant
service valve.
10 Place heater vacuum switch on service unit
in HEATER position and place power switch to ON
position.
3 Tighten oil charging hose fitting at service
valve on power plant refrigerant receiver while oil is
bleeding from connection.
11 Allow service unit refrigerant reservoir
heater to stabilize pressure at 70 10 psig
Note
If any air bubbles are observed in
oil in the oil charging hose, loosen
2-10
TM 5-6115-586-34
as indicated on refrigerant pressure gauge GA3 on
service unit.
3. Crack service valve and flow 100 cc refrigerantoil
mixture
into oil-quantity-check beaker (part of
refrigeration system service unit). Close service valve.
12. Loosely connect refrigerant charging hose to
service valve on power plant refrigerant receiver and to
fitting F6 on service unit.
4. Place beaker in a warm place and allow
refrigerant to boil off.
5. Quantity of oil remaining in
refrigerant has boiled off shall be one cc.
13. Check valve V6 on service unit and allow
refrigerant to purge all air from charging hose. Tighten
hose connection at service valve while liquid refrigerant is
purging from connection.
beaker
after
(e) Operation to add oil to refrigeration system. To
add oil to the power plant refrigeration system, refer to
figure 2-2 and proceed as follows.
14. Fully open valve V6 and fully open service valve.
Charge system with refrigerant.
1. Connect oil charging hose to the power plant
compressor suction purge valve.
15. Close valve V6 on service unit and service valve
on power plant receiver. Remove charging hose and
replace protective caps. Check service valve for leakage
(para (a)) above.
2. Operate refrigeration system as described in TM
5-6115-586-12 for fifteen minutes to thoroughly mix the
refrigerant and oil.
d. Checking oil quantity in refrigeration system. To
check the oil quantity in the power plant refrigeration
system refer to figure 2-2 and proceed as follows:
3. Purge oil charge line and add oil to the system as
described in paragraph (c), steps 1 through 9 above.
(f) Operation to remove oil from refrigeration system.
If quantity of oil in refrigeration system is too great, refer
to figure 2-2 and proceed as follows.
1. Operate refrigeration system according to
operating procedure as described in TM 5-6115586-12 for
fifteen minutes to thoroughly mix the refrigerant with the
oil.
1. Operate refrigeration system as described in TM
5-6115-586-12 for fifteen minutes to thoroughly mix the
refrigerant with the oil.
2. Connect refrigerant charging hose to service
valve on power plant refrigerant receiver.
2. Shut off refrigeration system and evacuate
system. (para (b) above. ).
3. Charge system (para (c) above), omitting oil
charging procedure, steps 1 through 9.
Warning
Do not hold oil-quantity check
beaker without gloves or cloth to
protect hands from cold refrigerant.
4. Recheck oil level, (para (d)above), and add oil, if
necessary (para (e) above).
Section III. GENERAL MAINTENANCE
2-5. Power Plant Test Instructions
a. General. The following test instructions are provided to test the operation of the power plant as a unit both
as an initial test to indicate the extent of repairs required and as a final test to establish serviceability of the power plant
following repairs.
b. Test Connections. Standard instrumentation shall be provided to measure all data shown on the data
sheet. All instrumentation shall have been calibrated. Standard instrumentation required is listed in table 2-3. Test setup services required is listed in table 2-4. Record all test data during testing.
c. Precautions During Testing. Shut down the power plant immediately if any of the operating limits are
exceeded or if any malfunction occurs that might result in further damage to components if testing was continued.
Determine the cause and take corrective action before proceeding with tests. Power plant operating limits are provided
in tables 2-5 and 2-6.
2-11
TM 5-6115-586-34
Table 2-3. Standard Instrumentation
Item
(1) I-C Brown
(2) C-A Brown
(3) Temperature bulb
(4) Vibration pickup (2)
(5) Frequency meter
(6) Wattmeter
(7) Voltmeter (3)
(8) Ammeters (4)
(9) Phase rotation tester
(10) VOM
(11) Current transformers
(a) 400 Hz (3)
(b) 60 Hz (2)
(12) Analyzer, engine gas
turbine
(13) Cable, special purpose
(14) Refrigeration system
service unit
Range
Remarks
0 to 600°F
0 to 2000°F
0 to 300°F
0 to 1 mil
0 to 500 Hz
0 to 150 kw
(a) 0 to 300 volts, ac, 400 Hz
(b) 0 to 300 volts, ac, 60 Hz
(c) 0 to 30 volts, de
(a) 0 to 700 amperes, ac, 400 Hz
(b) 0 to 125 amperes, ac, 60 Hz
(c) 30-0-30 amperes, dc
Enclosure inlet temperature.
Turbine discharge temperature.
Oil temperature.
Engine accessory and turbine section pickups.
Generator speed.
Generator output.
Generator output*.
Generator output **
Battery voltage.
Generator output, 3-phase.
Generator output, 1-phase.
Battery charger output.
Variable
Indicating device (volt-ohmmeter).
600/5 (turns ratio)
400/5 (turns ratio)
Generator output.
Generator output.
Special equipment (table 2-1).
Special equipment (table 2-1).
Special equipment (table 2-1).
* Three line-to-line and three line-to-neutral readings required.
* *One line-to-line and two line-to-neutral readings required.
Table 2-4. Test Setup Services
Item
(1) Electrical power dc.
(2) Fuel
Range
Remarks
External 24 vdc, or two 12 vdc in
series, 6TN type witch standard
battery posts, independent of
electrical system, and a
laboratory battery equivalent to
set battery.
MIL-T-5624, Grade JP-4 or JP-5
(3) Lubricant
(4) Load banks
MIL-L-7808
(a) 150 kw, 120/208 vac, 3-phase,
4-wire, 400 Hz with adjustable
power factor.
(b) 16 kw, 120/240 vac, singlephase, 2-wire 60 Hz with adjustable power factor.
(5) DC power supply,
Power supply of 24 vdc: 0 to 50 ohm,
reostats, switches, and
50 watt rheostats SPDT switches
miscellaneous wiring.
with 5 ampere contacts.
(6) (a) 400 Hz power cable (5- Capable of carrying 30 kw, 4-wire,
wire) (3)
three-phase continuous power.
(b) 60 Hz power cable (4- Capable of carrying 10 kw, 3-wire,
wire)
single phase continous power.
(c) 400 Hz power cable (4- Capable of carrying 15 kw, 3-phase
wire) (2)
continous power.
(7) DC stand-by power cable
15 ampere capability.
(8) Shunt
(9) Switches (2)
50 ampere, 50 mv type.
10 ampere, SPDT
2-12
Required to operate the starter motor, relays,
and ignition circuit.
Filtered and supplied at 140°0F
(60°C)
(maximum) to the fuel inlet of the unit.
Synthetic base lubricating oil.
To apply electrical load to the 400 Hz
generator to check the overload sensor.
To apply electrical load to the 60 Hz generator
to check the overload sensor.
To supply external field excitation to 400 H-.
generators to simulate overvoltage, and
undervoltage.
To apply external load to the power plant
through the 400 Hz power output receptacle.
To apply external load to the unit through the
60 Hz power output receptacle.
To apply external load to the unit through the
400 Hz remote power output receptacle.
To supply stand-by start signal to the power
plant.
To check the accuracy of the dc ammeter.
To simulate remote temperature sensor.
TM 5-6115-586-34
Table 2-5. Power Plant Operating Limits (Gas Turbine Engine)
Type
Limit
Tolerance
(1) Leakage
(a) Fuel
One drop per minute
(b) Oil
(2) Acceleration time
(3) Temperatures:
(a) Turbine
One drop per 15 minute period Maximum
60 seconds
Maximum
(b) Turbine
(4) Oil consumption
(5) Starter motor duty cycle
Maximum
1300°F (705°C)
Absolute
maximum
1225°F (663°C)
Maximum
0.25 lb/hr
Maximum
One minute on one minute off Maximum
or 5 starts in 10 minutes.
Remarks
From accessory drain only. Fuel leakage from
plenum drain is permitted only after a false
start or blowout.
From accessory drain.
Starting after 5 psig oil pressure is attained.
Caution: This temperature must not be
exceeded at any time under any operating
circumstances.
Maximum allowable temperature for continous
operation.
Under all operating conditions.
Cool the starter before repeating duty cycle. Do
not exceed 28,000 rpm turbine speed with
the starter energized.
(6) Turbine Wheel Speeds
(a) Continuous operation
(b) Continuous operation
(c) Absolute maximum
(d) 10-second operation
40,700 rpm
41,600 rpm
44,500 rpm
42,500 rpm
±100 rpm
Maximum
Full-load condition.
No-load condition.
Maximum
Do not operate at a speed in excess of 42,500
rpm for longer than 10 seconds.
(7) Vibration:
(a) Accessory pickup
0.6 mil at any frequency
Maximum
Maximum peak vibrations greater than the
limits shown may occur at certain critical
turbine wheel speeds from 17.000 to 23,000
rpm.
Caution: Do not operate the unit continuously at any speed where vibration
exceeds these limits.
At any frequency.
(b) Turbine end pickup.
0.4 mils
d. Preliminary Test Procedure.
(1) Check that instrumentation calibration is current.
(2) Remove all accessory components from stowage compartments. Visually check at this time for loose or
damaged lines, fittings, and wire harnesses.
(3) Secure all access doors that are not normally to be open or removed during testing.
(4) Connect instrumentation called out in table 2-3.
(5) Check that oil tank is filled with oil.
(6) The unit shall be stopped and started in accordance with operating instructions on the control panel.
(7) Record turbine engine and two air conditioner hourmeter readings when power plant is installed in test
setup.
(8) Prime fuel and oil as follows:
(a) Remove electrical connector 'from the oil pressure fuel sequencing switch.
(b) Disconnect fuel boost pump connector and connect to a 24 vdc lamp. Acutate master switch to RUN,
lamp shall not glow. Actuate master switch momentarily to START, lamp shall glow. If the preceding tests check
correctly, reconnect fuel boost pump connector.
2-13
TM 5-6115-586-34
Table 2-6. Power Plant Operating Limits (Electrical System)
Limit
Type
(1) Frequency Regulation:
No-load to full-load.
(2) Voltage Regulation:
Line-to-neutral.
400-Hz
60 Hz
Tolerance
390 Hz
410
58.5 Hz
61.5
Maximum
Maximum
120 volts
120 vac
Rms± 1.2
At balanced loads under all ambient operating
conditions. Line side of main contactor.
120 kva
120 volts
208 volts
400 Hz
12.5 kva
120 vac
240 vac
60 Hz
Nominal
At 0.8 power factor.
Refer to nameplate rating.
Refer to nameplate rating.
See Item (1).
90kw
0kw
30kw
(0.8 pf)
10kw
10 kw
10)kw
(0.8 pf)
Approx
Approx
Approx
At all specified operating conditions.
12.5 kw each output. Mode sw in OFF or
VENT.
30 kw each output. Environmental system
locked out.
(3) Specified
Outputs:
Rated power output
Line-to-neutral
Line-to-line
Frequency
{4) System Electrical Output:
(a) Rated continuous performance.
(b) Rated continuous external power through the
output receptacle.
(c) 400 Hz remote output
Generator
25 kw
Approx
(d) 400 Hz auxiliary output
60 kw
Approx
(5) Undervoltage Trip:
Average line-to-neutral
voltage
90 volts
90 vac
(6) Overvoltage Trip:
Average line-to-neutral
voltage
129 vac
135 vac
129 vac
135 vac
seconds
(7) Overspeed Switch:
AC system frequency
(8) Underfrequency Switch:
AC system frequency
(9) Battery Charger:
(a) Charging rate
(b) Voltage range
(10) Overload Protection
(Gen.):
110 percent load
(11) Overload Protection (400
Hz Output Receptacle)
Single or three-phase
12) Overload Protection (400
Hz Remote Output)
10 to 30
(13) Overload Protection (400
Hz auxiliary output
receptacle):
3-phase
Remarks
At all specified operating conditions.
Relay has nominal actuation time of 4.5
seconds
No trip.
0.5 to 10
Step input above 120 vac base voltage.
420 Hz
440 Hz
Minimum
Maximum
Centrifugal switch will shut down the turbine
and de-energize the ac system.
370 Hz
378 Hz
Minimum
Maximum
Protective panel will de-energize the ac system
and open line contactor.
30 amps dc
28 vdc
Peak rate
0.5v,±0
Charging system is completely automatic.
Maximum at any charge rate.
No trip (367
amps load
current)
No trip (58
amps load
current)
225 amp at
calibrated
temperature
Overload sensor will trip the output contactor
in 10 to 70 seconds at 77°F.(25°C).
95 amps each
output (190
amp total) at
calibrated
temperature
Overload sensor will trip remote output
contactor in 10 to 70 seconds at 77°F.
(25°C).
225 amps at
calibrated
temperature
at either
out put
receptacle.
Overload sensor will trip the output contactor
in 10 to 70 seconds at 77°F. (25°C)
2-14
TM 5-6115-586-34
Caution
Do not exceed starter motor duty
cycle specified in item (5) of table 25.
(a) The 400hz power output receptacles J7 and
J8, located on the power output panel. The phase
rotation shall be LI, L2, L3, N: A,B,C,D and E. Pin E is
equipment ground.
(c) Motor gas turbine engine by means of
starter until oil pressure gauge on test panel registers
pressure.
(b) Disconnect power plug from each of the airconditioning compressors and check phase rotation. The
phase rotation shall be LI, L2, L3, N: A, B, C and D.
(d) Reconnect
pressure switch.
(4) Check generator terminal connections at 60
Hz output panel, J5 60 Hz output receptacle and J6 60 Hz
output receptacle. The connection sequence shall be TI,
T2, T3: B, D, C and E is equipment ground and A is
emergency 24 vdc, output; T3 is neutral.
Voltage
indication shall be 240 volts B to D and 120 volts B to C
and D to C.
electrical
connector
to
oil
(e) Check unit for fuel and oil leaks
immediately after this operation. If leakage is apparent,
correct the difficulty.
e. Instrument Panel Checks.
(1) Close the dc circuit breakers and check the
following items for proper operation as specified.
(5) Check
accuracy
of
the
following
instruments on power plant instrument panel against
calibrated test instruments. Using external adjust screw,
adjust each master to correspond to associated laboratory
meter. Reject and replace any meter that cannot be
adjusted within specified limits.
(a) Check panel light for proper operation.
Panel light shall come on when switch is actuated in ON
position.
(b) With air intake door in open position, check
fuel boost pump for proper operation. Set MASTER
switch in STOP position. Actuate fuel boost pump by
throwing FUEL BOOST switch to ON position. Pump
shall run. Set the MASTER SWITCH in RUN position.
Fuel boost pump shall stop.
(a) Using the voltage-adjust potentiometer on
the voltage regulator, set C-N voltage at 120 volts (red
line). Record C-N voltage indicated on test meter. Error
shall not exceed +/-2 volts. Check A-N and B-N voltage.
(c) With MASTER switch in RUN position,
check PRESS-TO-TEST indicator lights. Pressing in on
each light shall cause it to glow. This test indicates only
that light bulb is functional and not the condition of its
associated circuit. Replace faulty light bulbs.
(b) Using the voltage-adjust potentiometer on
voltage regulator, set TI-T3 voltage at 120 volts (red line).
Record TI-T3 voltage indicated on test meter. Error shall
not exceed +/- 2 volts. Check T2T3 voltage. T2-T3
voltage shall be 120 -'2 volts. TI-T3 voltage shall be 120
+/-2 volts. Check TiT2 voltage. TI-T2 voltage shall be
equal to the sum of T I-T3 and T2-T3 voltage (240 +/- 4
volts).
Note
In order to check compressor trip
lights and remote trip light, unit
must be operating, 400 Hz main
contactor switch must be in CLOSE
position and mode-select switch in
OFF position.
(c) Using a variable-load 0. 8 PF load bank,
set up 100 percent readings on instrument panel 60 Hz
ammeter. Test each leg individually. Record amperage
indicated on test meter for leg being tested. Error shall
not exceed +/-3 percent. The 100 percent load is equal to
52 amperes per leg when a 120 volt load is applied.
(d) Using a variable load 0. 8 PF load bank,
set tp 100 percent readings on instrument panel 400 Hz
ammeter.
Test each phase individually.
Record
amperage indicated on the test meter for the phase being
tested. Error shall not exceed +/-3 percent. The 100
percent load is equal to 333 amperes per phase.
(d) Check for proper operation of start interlock
of 60 Hz load contactor switch and 400 Hz main contactor
switch. Actuate 60 Hz load contactor switch to CLOSE
position. Actuate MASTER switch to START. The power
plant shall not start. Actuate 60 Hz load contactor switch
to OPEN. Repeat this procedure with 400 Hz contactor
switch.
(e) Regulate engine speed to 390 Hz, 400 Hz
and 410 Hz as indicated by the instrument panel 400 Hz
frequency meter.
For each of these settings, log
frequency reading. Error shall be within +/-2. 5 Hz.
(e) Check for proper operation of battery
charger and ready-to-load light. Close battery charger
circuit breaker. Start power plant. Readyto-load light
shall glow at 95 percent governed speed. Battery charger
shall come on when 400 Hz generator voltage builds up.
Generator shall reach full voltage at approximately 70
percent governed speed.
(f) With 400Hz generator operating at 400 Hz,
60 Hz meter should read 60 Hz. Error shall be within 1
Hz.
(g) Remove positive lead from unit battery
charger and connect test shunt (50A) in series. Record
instrument panel meter reading and test meter reading.
Error shall not exceed three amperes.
(2) Run power plant for three minutes at noload
governed speed to allow for stabilization and transients.
(3) Check for phase rotation of 400 Hz system
at the following locations.
2-15
TM 5-6115-586-34
and 392
seconds.
(h) lnstall thermocouple in boss provided on
engine tailpipe section. Cheek tailpipe temperature circuit
by using the Brown indicator and unit thermocouple.
Adjust so that unit thermocouple reads within +/- 25° F
(14°C) of indicator reading.
f. Electrical System Checks.
system checks as follows:
(4) Check air-intake door interlock switch as
follows.
(a) Attempt a start with air-intake door closed.
Unit shall not start.
Perform electrical
(b) While operating, press intake door interlock
switch and hold momentarily. Unit shall shut down.
(1) Operate unit in the following sequence at
steadv-state loads at zero. 100, zero, 50 and 100 percent
rated loads of 0.8 PF. Perform test on both 60 Hz
generator and 400 Hz generator. Log on each data sheet
voltage, frequency and percent load it each load point for
each phase of the 400 Hz generator and for each leg and
L-L of the 60 Hz generator.
(2) Perform voltage regulation check
load application and removal) as follows.
to 408 Hz for 400 Hz system within three
(5) With unit operating and 400 Hz main
contactor switch in OPEN position, actuate 400 Hz output
contactor switch to CLOSE-RESET and release. Using a
volt-ohmeter, set on 300 vac scale, check voltage at J7
and J8, 400 Hz output receptacle and across pins A,B,C
and E. There shall be no voltage indicated.
(6) With 400 Hz main contactor switch in
OPEN position and air-conditioning control circuit breaker
pushed in, rotate ac mode select switch to VENY COOL
AND HEAT. In the VENT, COOL AND HEAT Modes,
there shall be no power, ac or dc, applied to airconditioning system. No fan or compressor shall start nor
shall load control or heating flow-control valves open in
the HEAT mode.
(step
Note
The 10 kw, 60 Hz load can be
applied directly through output
receptacles. To apply 90 kw. 400
Hz loads. attach extra power loads
to terminal board on the air
conditioning panel. Apply 30 kw to
power output and 60 kw to terminal
board connection.
(7) Perform emergency dc output and standby
receptacle output check as follows:
(a) Using a volt-ohmmeter, set at 50 vdc,
check across pin A (+ ) of J5 and J6, 60 Hz output
receptacle and pin D (-) of J7 and J8, 400 Hz output
receptacle and also across pin 1 (+ ) and pin 2 (-) of J 1
dc standby receptacle. This test can be made while
performing 400 Hz output overload sensor trip test, or by
placing 400 Hz output contactor switch in center position
with 400 Hz main contactor closed. When 400 Hz output
contactor trips, there should be a 24 vdc indication
between J5-A and J7-D, J6-A and J8-D and J1-1 and J12.
(a) Apply a step load of 10 kw at 0. 8 PF to 0it)
Hz generator. Allow voltage to stabilize, then remove 10
kw load.
(b) Using a 90 kw at 0. 8 PF load, repeat
paragraph f. step (2), (a) above for 400 Hz generator.
(3) Unit shall meet the following electrical
requirements.
(b) With same meter connection as in (a)
above and when performing underfrequency trip check or
any of the other protective device checks that trip 400 Hz
generator, check for voltage indication. Each check point
shall indicate 24 vdc.
(a) Voltage variation shall not exceed 2. 5
percent from no-load to full-load as set throughout entire
load range and -1 percent at any fixed load.
(b) Upon application or removal of rated load
I10 kw at 0. 8 PF), voltage shall not vary sufficiently to
cause generator protective panel to trip generator off the
line.
(c) With same meter connections as in (a) and
(b) above and when performing any of the protective
device checks that trip 60 Hz generator, observe meters
for voltage indication. When 60 Hz contactor trips, there
shall be 24 vdc showing on meter attached to pin A of J5
or J6.
(c) Upon application or removal of 90 kw at 0.
8 PF, voltage shall not vary sufficiently to cause
protective panel to trip generator off the line.
(d) Frequency shall remain within limits of +/- 2
percent for (0' Liz system and 392 to 408 Hz for 400 Hz
system for all steady-state load conditions.
(8) Place all circuit breakers and switches in
normal position for starting and proceed as follows.
(a) Close air-intake door. Reconnect 24 vdc to
J 1. Unit shall not start. Disconnect 24 vdc from J1.
(e) Transient-frequency limits for sudden
application or removal of 10 kw at 0. 8 PF shall be within
4+/- 3 percent for 60 Hz system. Transient-frequency
limits for sudden application or removal of 80 kw at 0. 8
PF shall be 390 to 410 Hz for the 400 Hz system.
(b) Open air-intake door. Reconnect 24 vdc to
J1. Unit shall start. At 95 percent governed speed, 24
vdc signal from J1 shall cease and all contactors shall
close. The 60 Hz and 400 Hz power shall be available at
output receptacles. With a volt-ohmmeter set at 300 vac,
check pins B and C of J5 and J6 and pins C and D of J7
and J8.
(f) Transient-frequency shall return to and
remain within the range of 58 to 62 Hz for 60 Hz system
2-16
(c) After unit reaches governed
speed, actuate switches as indicated below in the
sequence as listed.
Master switch to RUN.
400 Hz output contactor switch to RESET-CLOSE.
60 Hz load contactor switch to CLOSE.
400 Hz main contactor to CLOSE.
Unit shall continue to run from unit battery and load
contactor shall stay closed without interruption of power.
(9) Check unit capability for achieving
successful starts with the following battery arrangement.
Note.
Ascertain unit has started from unit battery
before performing this test. Disconnect battery within
the unit. External battery must have a full charge with
25.5 vdc minimum.
(a) Connect dc battery cable to
external battery, with reverse polarity to power output
panel receptacle. Reverse polarity light shall glow.
With battery still connected with reverse polarity,
attempt to start unit. Unit shall not start.
(b) Connect dc battery cable to
external battery with correct polarity. Reverse polarity
light shall not glow and unit shall start.
(c) Connect an external 24 Vdc
battery to power-out panel receptacle with unit battery
connected. Start unit. External battery voltage must be
one volt higher than unit battery.
(10) With unit operating, actuate 400 Hz
main contactor switch to CLOSE and 400 Hz output
switch to RESET-CLOSE. Push in 400 Hz convenience
receptacle circuit breaker. Using a volt-ohmmeter set at
300 vac, check for voltage at each of the two outlets.
Meter shall indicate approximately 120 volts L-N.
(11) With unit operating, actuate 60 Hz load
contactor switch to CLOSE. Push in 60 Hz convenience
receptacle circuit breaker. Using a voltohmmeter set at
30.0 vac, check for voltage at each of the two outlets.
Meter shall indicate approximately 120 volts L-N at each
outlet.
(12) Connect a zero to 30 vdc voltmeter
across battery terminals.
Observe panel 30-0-30
ampere ammeter and log indicated readings on data
sheet.
Log voltage when battery charger is fully
charging (30 amperes) and when battery charger is
supplying the unit's rated use. The panel 30-0-30
ammeter shall indicate approximately zero amperes.
Battery charger is completely automatic and is current
limited.
Charging current shall be limited to 30
amperes. Battery charger output voltage shall not
exceed 28 volts when carrying full charge or minimum
charge rate. Adjust voltage as required. With correct
voltage set, adjust current boost and taper charge on KR battery charger to maximum cycle time.
Turn
adjustment counterclockwise.
(13) With unit operating, actuate 400 Hz
main contactor switch to CLOSE and 400 Hz output
switch to RESET-CLOSE. Push in water line heating
circuit breaker CB6. Using a voltohmmeter set at 300
vac, check for voltage at each of the two water line
heater receptacles J72 and J73 (pin C to pin D). Meter
shall indicate approximately 120 volts, L-N, at each
receptacle.
(14) With unit operating and mode-select
switch in OFF position, actuate 400 Hz main contactor
switch to CLOSE position and proceed as follows.
(a) Actuate remote operation switch to
OPERATE-RESET. Check phase rotation at each of
the remote output receptacles. Phase sequence shall
be L1, L2, L3, N: A, B, C, E and D is +24 vdc. Voltage
shall be 120 volts L-N and 24 vdc from pin D and
ground.
(b) Rotate mode-select switch to
VENT position. Vent fans, as set on the vent-select
switch, shall run. Voltage at remote receptacles shall be
the same as in paragraph f. step ( 14), (a)above.
(c) Rotate mode-select switch to
HEAT and COOL. No voltage shall be available at the
remote output receptacles.
(d) Where two units are available at
test site, attach a 400 Hz auxiliary power output cable to
remote power-output receptacle on operating unit to
remote input on non-operating unit. Actuate remote
operation switch on operating unit to OPERATERESET, then actuate remote-operation switch on nonoperating unit. Vent fans on non-operating unit shall
operate as if unit were operating. Check vent fan
operation through each output.
(e) When two units are not available,
remote input can be checked as follows:
1.
Connect a 400 Hz auxiliary
power output cable between test box and remote input
receptacle.
2.
Place
400
Hz
main
contactor switch in OPEN position.
3.
Actuate
remote
switch
located on test box by placing it in ON position.
4.
Actuate
the
remote
operation switch located on control panel to OPERATERESET.
5.
Place mode-select switch to
VENT.
6.
Rotate vent-system-select
switch to each position and check for proper operation of
vent fans.
7.
Rotate mode-select switch
to HEAT, COOL and OFF. Vent fans shall not operate.
(15) With unit operating and mode-select
switch in OFF position, actuate 400 Hz main contactor
switch to CLOSE position and proceed as follows.
(a) Actuate Output 1 400 Hz auxiliary
operation switch to OPERATE-RESET. Check phase
rotation at Output 1 receptacle (J101).
2-17
and the auxiliary switch in the OFF position, rotate the
mode-select switch to VENT. Actuate the auxiliary
switch to OPERATE-RESET. The vent fans should
continue to operate and voltage should be present at the
auxiliary output receptacles.
(i)
Repeat paragraph f, step (15),
(f),above, except rotate mode-select switch to HEAT.
Complete heating system shall be de-energized (shut
off) and voltage shall be present at auxiliary on output
receptacles.
(j)
Repeat paragraph f, step (15),
(f),above, except rotate mode-select switch to COOL.
Complete air-conditioning system shall be deenergized
(shut-off) and voltage shall be present at auxiliary
output receptacles.
g.
Protective Device Checks. The following
checks are to be performed to ensure proper functioning
of electrical system protective circuits.
(1) While reading 400 Hz generator
frequency on a frequency meter, slowly reduce turbine
speed until meter reads 370 Hz by manually bypassing
fuel.
Then perform test with the EMERGENCY
OPERATION switch closed and determine that under
frequency device will not trip 400 Hz generator off the
line. Generator shall be tripped off the line when
frequency drops to 374 ± 4 Hz with EMERGENCY
OPERATION switch open.
(2) Observe and record exact speed
reading as indicated by frequency meter.
Then,
operating at no-load, slowly increase turbine speed by
means of governor adjustment screw until overspeed
protective-device actuates. Do not exceed 44,500 rpm.
Use fuel bypass to perform this test. Overspeed
protective device must shut down unit between
generator frequencies of 420 and 440 Hz. Repeat test
with EMERGENCY OPERATION switch closed and
ascertain that switch does not render overspeed switch
inoperative.
Readjust speed to original frequency
reading.
(3) Both generators shall be operated at
no-load and rated speed while performing the following
tests. Ascertain that load contactors are in CLOSED
position. Refer to paragraph g, step (7) below.
(a) Remove connector from voltage
regulator of system being checked. Connect voltage
regulator connector to test box. Adjust rheostat until
base voltage of 120 volts L-N on each generator is set
up.
(b) Monitor generator voltage on the
load side of contactors to determine voltage at which
protective panel energizes the GCR and trips load
contactors.
(c) Adjust generator voltage to 128
volts L-N for 30 seconds. Reset to 120 volts L-N.
Adjust voltage to 135 volts L-N. Do not exceed 30
seconds.
Phase sequence shall be L1, L2, L3, N: A, B, C, D with
E as the equipment ground. Voltage shall be 120 volts
line-to-neutral and 208 volts line-to-line.
(b) With Output 1 400 Hz auxiliary
power actuated, the voltage at Output 1 receptacle shall
remain the same as noted above and there shall be no
power, ac or de, applied to the no. 1 conditioned air
system under the following operating conditions.
1.
Mode select switch in HEAT
position as heat system select switch is rotated to
positions 1, 2 and 1 and 2 (no. 2 heated air system shall
operate in position 2 or position 1 and 2).
2.
Mode select switch in
COOL position as air conditioning system select switch
is rotated to positions 1. 2, and 1 and 2 (no. 2 cooled
air system shall operate in position 2 or position 1 and
2).
(c) Place output I auxiliary operation
switch in OFF position and actuate output 2 auxiliary
operation switch to OPERATE-RESET. Check phase
rotation at output 2 receptacle (J102). Phase sequence
shall be L1, L2, L3, N: A, B, C, D with E as equipment
ground. Voltage shall be 120 volts line-to-neutral and
208 volts line-to-line.
(d) With output 2 400 Hz auxiliary
power actuated, the voltage output at output 2
receptacle shall remain the same as noted above and
there shall be no power, ac or dc, applied to the no. 2
conditioned air system under the following operating
conditions:
1.
Mode select switch in HEAT
position as heat system select switch is rotated to
positions 1, 2, and I and 2 (no. 1 heated air system shall
operate in position 1 or position 1 and 2).
2.
Mode select switch in
COOL position as air conditioning system is rotated to
positions 1, 2, and 1 and 2 (no. 1 cooled air system
shall operate in position 1 or position 1 and 2).
(e) With both No. 1 and No. 2 400
Hz auxiliary operation switches actuated to OPERATERESET position, required voltage shall be present at
both Output 1 and Output 2 receptacles and no power
shall be applied to either conditioned air system in any
HEAT or COOL mode.
(f)
Actuate remote operation switch
to OPERATE-RESET. No voltage shall be present at
either of the remote output receptacles (J74 and J75).
(g) With 400 Hz main contactor
closed and remote operation switch, mode-select switch
and auxiliary operation switches in OFF position,
actuate remote operation switch to OPERATE-RESET.
Voltages shall be present at remote output receptacles.
Actuate auxiliary operation switch to OPERATE RESET.
Voltage shall not be present at remote output
receptacles but shall be present at auxiliary output
receptacles.
(h) With the remote operation switch
2-18
(7) When performing one of the protective
panel trip functions in 60 Hz generating system, actuate
control switch to RESET position and hold it there until
reset control trips and remains tripped and ac system
becomes de-energized. Remove simulated fault and
again actuate control. Repeat this procedure for 400 Hz
generating system. Reset control shall reset only once
after actuation and shall then trip and remain tripped as
long as the fault exists and control-switch is hold in
RESET position.
Upon removal of the fault and
reactuation of control, the system shall return to normal
operation.
(8) Low oil pressure shutdown check can
be performed at completion of any test that requires
operation of turbine engine. Disconnect plug from low
oil pressure switch. Turbine engine shall shut down.
Reconnect plug to low oil pressure switch. This test
checks continuity of electrical circuit only. This is no
indication of switch setting or operation.
(9) Check 400 Hz remote output overload
sensor by applying a three-phase balanced 95 ampere
load to each of the remote output receptacles. Overload
sensor shall trip at approximately 190 amperes total
within 10 to 70 seconds at calibrated temperature.
Remote output contactor shall not be reset unless reset
with remote operation switch. Remote trip light shall
glow when remote output contactor trips.
(10) Check 400 Hz auxiliary output overload
sensors by applying a three-phase balanced 225
ampere load to each of the auxiliary output receptacles,
individually. With overload applied, overload sensors
shall trip at approximately 225 amperes within 10 to 70
seconds, at calibrated temperature, without loss of
power to the other auxiliary output receptacle. The 400
Hz auxiliary trip lights shall glow. Tripped output
contactor shall not reset unless reset with 400 Hz
auxiliary operation switch. Acutation of 400 Hz auxiliary
switches to OPERATE-RESET shall reset tripped
contactor without loss of power to output receptacle.
Perform for each output. A delay in resetting of
contactor will be required to allow overload sensors to
cool down.
(11) Check the transient voltage (motor
starting load) as follows.
(a) With 400 Hz generator operating
at no-load, suddenly apply a 240 volts, two per unit, 0.4
power factor load on 60 Hz generating system or start a
120 volts, two horsepower motor. Do not hold two per
unit load on longer than 15 seconds. Voltage shall not
dip sufficiently low to cause the protective panel to trip
generator off the line within the limits of undervoltage
trip.
(b) With 60 Hz generator operating
at no-load and 400 Hz system operating at a steadystate
(d) Immediately after contactors trip,
decrease voltage to 120 volts L-N.
(e) Reset generator control relay.
Check under voltage protective device by lowering
voltage to 92 volts for 30 seconds. Readjust to 120
volts L-N. Decrease to 90 volts L-N. The under voltage
protective device trips generator control relay and deenergizes load contactors.
(f)
The
40U
Hz
overvoltage
protective device shall provide a trip signal on the 400
Hz generator when three phase average voltage
increases to 135 volts and remains thus from 0.5 to 10
seconds. No trip at 128 volts. The 60 Hz overvoltage
increases to 135 volts and remains there from 0.5 to 10
seconds. No trip at 128 volts.
(g) The 400 Hz undervoltage device
shall provide a trip signal on 400 Hz generator when
three phase average voltages decrease to 90 volts and
remain there for 4.5 seconds, minimum. The 60 Hz
undervoltage device shall provide a trip signal when
lowest leg voltage decreases to 90 volts and remains
there for 4.5 seconds minimum. No trip at 92 volts.
(4) Apply 110 percent or rated three phase
balanced load to 400 Hz generator and 110 percent of
rated single-phase, three-wire, balanced load to 60 Hz
generator. Repeat this procedure with 150 percent
balanced load. Refer to paragraph g, step (7) below.
Line contactor shall open at calibrated temperature
within the 30 to 120 seconds at 150 percent. Contactor
shall not trip at 110 percent (operate for five minutes).
The total air-conditioning system will have to be
operating and external loads will have to be attached to
power cable through output connector. The 60 Hz
power can be taken from output receptacle. Obtain
meter readings of generator voltage and current.
Caution: Do not exceed 45 kw on the external
400 Hz output connector.
Note.
To apply loads required for this
test for 400 Hz generator, extra leads will have to be
attached to terminal board on air-conditioning panel.
(5) Apply a three-phase balanced 115
ampere load to each of the 400 Hz output power
receptacles. Overload sensor shall trip at approximately
225 amperes within 10 to 70 seconds at calibrated
temperature. The 400 Hz output contactor shall not
reset unless reset with contactor switch. The 400 Hz
output trip light shall glow when 400 Hz output contactor
trips.
(6) When performing the protective
devices check herein, observe contactor trip indicator
lights on unit control panel. Lights shall glow each time
400 Hz main contactor or 60 Hz load contactor trips.
Actuation of corresponding contactor switch to its reset
position shall extinguish indicator lamp.
2-19
b.
To aid inspection, a table of repair and
replacement standards is provided in table 1-1. This
table specifies maximum clearance and desired
clearance. It may be necessary or economical to
replace parts prior to their reaching maximum wear
limits.
Factors such as hours of operation and
remaining useable life of the component will be
considered in replacement.
c.
When visual inspection of parts is not
sufficient to determine their serviceability, refer to
testing procedures included in the repair instructions.
2-8. General Repair and Replacement Instructions
a.
All forgings and castings that will not
withstand specified torque values shall be repaired by
installing helical inserts or replaced.
b.
Hardware items such as screws, washers,
and nuts shall be replaced if missing or found to be
damaged in any manner that might impair efficiency.
Self-locking nuts, used extensively in this equipment,
shall be replaced if there is any damage that might
impede the self-locking feature..
c.
Loose or damaged rivets shall be replaced.
d.
Do not use mire brush, sand blast, or other
highly abrasive procedures to remove rust or corrosion
from machined surfaces unless specific instructions are
provided for their use in repair instructions. Use crocus
cloth. (Fed Spec P-C-458) for ferrous surfaces and
aluminum oxide abrasive cloth (Fed Spec P-C-451) to
smooth out scores, burrs. rough spots, and galling from
machined surfaces unless otherwise directed. The
finish of the repaired part must be approximately that of
the original finish and the repair and replacement
standards in table 1-1 shall be consulted for parts with
critical dimensions and tolerances.
e.
Damaged threads may be repaired with a
thread chaser or by chasing on a lathe. If threads can
not be restored to satisfactory condition so as not to
impare the efficiency of threaded fastening, the part
shall be replaced.
f.
Painted surfaces to be refinished will be
treated and printed in accordance with MIL-T-704, type
A prior to refinishing. Exterior surfaces of the power
plant shall be )painted with paint in accordance with
MIL-T-704, type A, Lusterless. Also refer to TM 9-213.
2-9. General Reassembly Instructions
a.
Attaching hardware and electrical connectors
shall where applicable be lockwired in accordance with
MS35540 using new lockwire MS2095C20, when
reinstalled.
b.
All tubing shall be reinstalled so that it does
not make direct contact with other surfaces of the power
plant. Use clamps to support tube and hose
three-phase load of 30().0 .kw at 0.8 power factor, apply
the additional surge (starting) current demand of the
total air-conditioning system. Voltage shall not dip
sufficiently low to cause protective panel to trip
generator off the line within limits of the undervoltage
trip.
(12) Generator protective devices shall not
trip generator and load contactor off the line while
undergoing voltage regulation and frequency check and
air-intake door interlock switch check. During air-intake
door interlock test, the protective device will trip 60 Hz
generator if overload time is exceeded.
h.
Air-conditioning
Systems.
Perform
operational checks in accordance with TM 5-6115-58612.
i.
Heating System.
Perform
operational
checks in accordance with TM 5-6115-586-12.
j.
Hot and Cold Water System.
Perform
operational checks in accordance with TM 5-6115-58612.
k.
Bleed-Air System.
Perform operational
check in accordance with TM 5-6115-586-12.
l.
Vacuum System. Perform operational check
in accordance with TM 5-6115-586-12.
2-6. General Disassembly Instructions
a.
Make sure that all wiring, wire harness
connectors, and tubing are disconnected and will not be
subject to damage before removal of major assemblies
and their components.
b.
Be certain to drain fuel, oil, and water from
reservoirs before attempting to remove them from their
associated tubing and fittings.
c.
Remove all shims where used. Keep shims
together and identify them as to location for correct
reassembly. Keep shims clean and flat until they are
reinstalled.
d.
If a part offers unexpected resistance to
removal, check that all attaching hardware has been
removed and that other parts are not interfering with
removal before exerting force.
e.
Do not disassemble riveted or interferencefitted parts unless repair is necessary.
2-7. General Cleaning and Inspection Instructions.
a.
Prior to inspection, all parts should be
cleaned at least to the extent necessary to determine
the condition of the part. All-metal parts may be
cleaned with a dry-cleaning solvent (Fed Spec P-D-680
or equivalent) or may be steam cleaned. Never use any
petroleum base solvent for cleaning electrical parts as
these solvents will damage electrical insulation and
dissolve electrical varnishes. Special cleaning solvents
for electrical parts are Trichlorethylene (Military
Specification MIL-T-700) and Naptha (Military
Specification MIL-N-15178).
Any special cleaning
procedures for other components are also specified in
applicable paragraphs.
2-20
assemblies and prevent contact. The high frequency
vibration of the power plant may cause rapid wear and
damage leading to early failure of these parts if they are
incorrectly installed.
Section IV. REMOVAL AND INSTALLATION OF MAJOR
COMPONENTS AND AUXILIARIES
system electrical components panel, auxiliary power
tray, receptacle panel assembly, four condenser fans,
and four recirculating fans. Refer to paragraph 2-13 for
removal and installation instructions regarding the
auxiliary power tray. Refer to TM 5-6115-586-12 for
instructions regarding removal and installation of the
remaining major components.
2-11. Removal and Installation of Engine and Skid
Assembly
a.
Removal.
(1) Remove the gas turbine engine access
panel (2, fig. 2-5, sheet 1 of 3) by loosening stud
fasteners (1).
2-10. General
a.
The primary component of the power plant is
the engine and skid assembly which is made up of the
following major components: a pneumatic and shaft
power gas turbine engine, a 10 kw 60 Hz generator, a 90
kw 400 Hz generator, a lower electric power chassis
assembly, an upper electric power chassis assembly,
and a skid assembly. The engine and skid assembly
may be removed from the power plant as a unit to
facilitate removal of the engine. Removal of major
components other than the engine may be
accomplished without removing the engine and skid,
assembly if desired.
b.
The other major components of the power
plant are the instrument panel assembly, conditioned air
2-21
1.
2.
3.
4.
5
6.
7.
8.
9.
Stud fastener
Gas turbine engine access panel
Screws
Washer
Engine combustor access panel
Screw
Washer
Fuel and oil components access panel
Battery access and storage compartment door
Figure 2-5. Removal of engine and skid assembly (sheet 1 of 3)
10.
11.
12.
13.
14.
13.
16.
17.
18.
19.
20.
21.
22.
Clamp
Generator cooling air discharge hose
Clamp
Cooling fan inlet air duct
Engine air inlet duct
Nut
Washer
Bolt
Grounding wire
Clamp
Tube
Gasket
Clamp
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
2-22
Clamp
Duct assembly
Gasket
Clamp
Hose assembly
Clamp
Venturi tube assembly
Bolt
Washer
Compartment divider panel
Bolt
Washer
Figure 2-5. Removal of engine and skid assembly (sheet 2 of 3)
2-23
35.
36.
37.
38.
Jackscrew
Engine and skid assembly
34 inch pipes
Platform
Figure 2-5. Removal of engine and skid assembly (sheet 3 of 3)
(2) Remove screws (3) and washers (4)
and remove the engine combustor access panel (5).
Note.
Tag or otherwise identify harness connectors
as removed to aid at installation.
(3) Disconnect wiring harness connectors
P 12, P13, and P14 from instrument panel. Remove
screws 16) and washers (7) and remove the fuel and oil
components access panel (8).
(4) Open battery access and storage
compartment door (9).
(5) Loosen clamps (10, fig. 2-5, sheet 2 of
3), remove generator cooling air discharge hose (11)
and clamps (10).
2-24
and skid assembly. Turn jackscrews (35) to lower skid
assembly to pipes (37).
(17) Position platform (38) in front of the
enclosure and adjacent to the power plant enclosure
frame. Roll skid assembly out of enclosure, positioning
pipes (37) from the enclosure to the platform (38) so
that an even rolling motion is maintained.
(18) Turn jackscrews down to raise engine
and skid assembly. Remove pipes (37) and turn
jackscrews to lower skid assembly to platform.
b.
Installation. Install engine and skid assembly
with all attached components in reverse order of
removal procedure using figure 2-5 as a guide. Perform
power plant test procedures described in paragraph 2-5
after engine and skid assembly installation to ensure
proper power plant performance.
2-12. Removal and Installation of Engine and Skid
Assembly Major Components
a.
Generators. Refer to TM 5-6115-586-12 for
removal and installation instructions for the 400 Hz
generator and the 60 Hz generator.
b.
Gas Turbine Engine.
(1) Removal.
(a) Refer to TM 5-6115-586-12 and
remove the 400 Hz generator and the 60 Hz generator.
Note.
Tag or otherwise identify harness connectors
and wires as removed to aid at installation.
(b) Remove
wiring
harness
connectors as required and feasible to accomplish
engine removal. Remove clamps to allow removal of
harness with engine.
Note.
Tag or otherwise identify hose and tube
assemblies as removed to aid at installation.
(c) Loosen or remove hose and tube
assemblies as required and feasible to accomplish
engine removal. Refer to paragraph 3-3 as an aid to
identifying and removing tube assemblies.
(d) Loosen four clamps (1, fig. 2-6)
and support (2). Remove the tee and duct (3) and
support (2) as an assembly. Remove ducts (4) and oil
temperature regulator (5).
(6) Loosen clamp (12), separate cooling
fan inlet air duct (13) from engine air inlet duct (14) and
remove clamp (12).
(7) Unlatch four suitcase type clamps
holding engine air inlet duct (14) to engine air inlet
plenum and remove engine air inlet duct (14).
(8) Disconnect five harness connectors
located near top of divider panel between engine
compartment battery access and storage compartment,
connectors (P49, P50, P51, P52 and P106). Disconnect
one harness connector (P38) located on top of engine
compartment.
Disconnect one harness connector
located near bottom of divider panel between engine
compartment and battery access and storage
compartment (connector P64).
(9) Remove nut (15), washer (16), and bolt
(17) to disconnect grounding wire (18) from enclosure
frame.
(10) Loosen clamp (19) at compressed air
discharge flange. Disconnect tube (20), remove gasket
(21) and clamp (19).
(11) Remove clamp (22) at turbine exhaust
flange.
(12) Loosen clamp (23) at bleed-air load
control valve, separate duct assembly (24) from load
control valve and remove gasket (25) and clamp (23).
(13) Loosen clamps (26), remove hose
assembly (27) and clamps (26). Loosen clamp (28),
remove venturi tube assembly (29) and clamp (28).
Remove bolts (30), washers (31) and compartment
divider panel (32).
(14) Drain oil tank and then remove oil tank
drain hose from bottom of oil tank and from enclosure
frame fitting. Remove drain tube from the spill drain
below the oil filler cap.
(15) Remove bolts (33) and washers (34)
from skid assembly mounts.
(16) Install jackscrews (35, fig. 2-5, sheet 3
of 3) and turn down to raise the engine and skid
assembly (36) approximately one inch above the
enclosure frame. Place four 3/4 inch pipes (37), or
equivalent, across the enclosure frame under the engine
2-25
Figure 2-6. Removal of gas turbine engine.
2-26
KEY to figure 2-6.
1.
Clamps
2.
Support
3.
Tee and duct
4.
Duct
5.
Oil temperature regulator
6.
Bolt
7.
Washer
8.
Ignition unit
9.
10.
11.
12.
13.
14.
15.
16.
17.
Bolt
Washer
Upper heat shield
Inlet air plenum
Bolt
Washer
Spacer
Gas turbine engine
Skid assembly
assemblies to prevent damage during removal. Install
engine in gas turbine engine portable stand, using
maintenance stand adapters.
Remove beam type
adjustable sling.
(2) Installation.
(a) Install gas turbine engine in
reverse order of removal procedures, using figure 2-6 as
a guide.
(b) Refer to TM 5-6115-586-12 and
install the generators.
c.
Upper Electric Power Chassis Assembly.
Refer to TM 5-6115-586-12.
d.
Lower Electric Power Chassis Assembly.
Refer to TM 5-6115-586-12.
2-13. Removal and Installation of Auxiliary Power
Tray Assembly
a.
Removal.
(1) Disconnect four wire harness leads
(wire numbers X200AG4N, X200AH8N, X200AJ4N, and
X200AK8N) from the ground terminal E3 (located on the
receptacle panel).
(2) Disconnect connector (P103) from rear
of auxiliary power tray assembly.
(3) Remove four screws and washers that
attach the front panel to the enclosure and seven screws
and washers that attach the tray to the enclosure.
Remove the auxiliary power tray assembly.
b.
Installation. Install the auxiliary power tray
assembly by reversing the removal procedure.
Warning. Do not remove ignition unit or ignition
lead without grounding. The high tension ignition
lead must be grounded as soon as it is removed
from the igniter plug. Ground by touching the
contact spring in the lead to the igniter.
(e) Remove four bolts (6) and
washers (7), and remove ignition unit (8) from upper
heat shield (11).
Note.
Keep ignition lead and ignition unit with gas
turbine engine.
(f)
Remove bolts (9), washers (10),
and upper heat shield (11).
(g) Unlatch inlet air plenum (12) top
half, and remove from bottom half.
Note.
Tag or otherwise identify harness connector
and wires as removed to aid at installation.
(h) Attach beam type adjustable sling
with overhead hoist of at least 2000 lb. capacity.
Remove bolts (13), washers (14), spacers (15) and three
mounts and lift engine (16) from skid assembly (17).
Guide wiring harness assembly and hose and tube
2-27
CHAPTER 3
REPAIR OF ENGINE
Section I. ENGINE ELECTRICAL AND PLUMBING INSTALLATION
leads, note location of clamps and routing of harness,
and location of lockwire as an aid at installation.
b.
Removal. Remove gas turbine engine wire
harness assembly according to sequence of index
numbers 1 through 14 assigned to figure 3-1.
c.
Disassembly. After inspection and testing,
disassemble the wire harness only as required for repair
or replacement using the sequence of index numbers 1
through 15 assigned to figure 3-2 and figure 3-3 as
guides.
d.
Cleaning and Inspection.
(1) Clean harness assembly with lint-free
cloth or soft bristle brush.
(2) Visually inspect harness assembly
wiring for wire breaks, frayed or burned insulation,
chafing or other evidence of damage.
3-1. General
This section includes instructions for repair of the engine
wire harness assembly, hose assemblies, tube
assemblies and fittings. Refer to TM 5-6115-586-12 for
schematics of the electrical, fuel, bleedair and
lubrication systems as an aid to troubleshooting and
repair. Refer to TM 5-6115-586-12 for a description of
these components.
3-2. Gas Turbine Engine Branched Wire Harness
Assembly
a.
General. The gas turbine engine branched
wire harness assembly is a multiple lead wiring harness
for engine electrical components and control circuits.
All circuits for the engine are connected to the power
plant electrical system through connector J36. Before
the wire harness assembly is removed, tag electrical
3-1
Figure 3-1.
Gas turbine engine wire harness installation.
3-2
KEY to figure 3-1.
1.
Nut
2.
Washer
3.
Clamp
4.
Clamp
5.
Bolt
6.
Clamp
7.
Clamp
8.
9.
10.
11.
12.
13.
14.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
Clamp
Terminal board
Washer
Washer
Lockwire
Screw
Terminal board cover
Fuel solenoid connector
Hourmeter terminals
Hourmeter circuit breaker terminals
Terminal board
Ground terminal
Ignition coil connector
Load control valve connector
Flow control valve connector
Thermocouple terminals
Low oil pressure switch connector
Oil pressure sequencing switch connector
Tachometer generator connector
Oil temperature bulb connector
Centrifugal switch connector
Power plant electrical system connector
Figure 3-2. Gas turbine engine wire harness assembly.
3-3
Figure 3-3. Gas turbine engine wire harness diagram and wire identification chart.
3-4
(8) Tie wires at all junctions and at all
other places as required with cable tie strap.
g.
Reassembly. Assemble harness assembly in
reverse order of disassembly.
h.
Installation.
(1) Install harness in reverse order of
removal procedure, using figure 3-1 as a guide and
observe the following.
(2) Remove all paint from starter flange
before attaching harness ground wire. Use starter motor
attaching nut to attach harness ground wire to starter
flange.
(3) Lockwire (terminal board, cover)
according to Military Standard MS33540.
3-3. Plumbing Installation
a.
General. The engine and skid plumbing
installation provides interconnection of fuel, lubrication,
and bleed air system components.
The hose
assemblies consist of metallic-braid-protected hoses
with permanently secured end fittings. Support clamps
hold the tube and hose assemblies in place and prevent
them from directly contacting the skid where they would
be subject to early failure due to vibration. Tag the hose
and tube assemblies before removal, and note location
of clamps and routing of plumbing as an aid at
installation.
b.
Removal.
Remove hose and tube and
plumbing fittings according to sequence of index
numbers 1 through 193 assigned to figure 3-4.
(3) Inspect
connectors
for
crossed,
stripped or peened threads and for bent, broken, or
otherwise damaged pins.
e.
Test.
Refer to figure 3-3 and check
individual wires for continuity using a multimeter.
f.
Repair and Replacement.
(1) Replace any part that does not meet
inspection requirements and is damaged beyond simple
repair. Solder all connectors except thermocouple
terminals according to Military Specification MIL-S-6872
using solder in accordance with Federal Specification
QQ-S-571, Composition Sn60.
(2) Solder
thermocouple
terminal
according to Military Specification MIL-S-6872 using
solder in accordance with Federal Specification QQ-S561, Class 5.
(3) If wire (22, fig. 3-3), or wire (23)
require replacement, use wire in accordance with
Military Specification MIL-W-5846B, Type II, Class A.
(4) If wires (25, 26, 27, or 29, fig. 3-3)
require replacement, use wire in accordance with
Military Specification MIL-W-25038, Size 18.
(5) All other wire to be in accordance with
Military Standard MS27110-18.
(6) Identify all leads with wire number in
accordance with figure 3-3.
(7) If connector and terminal location
markers are damaged or missing, apply new markers.
3-5
1.
2.
3.
4.
5.
6.
Tube assy
Tube assy
Elbow
Elbow
Coupling nut
O-ring
7.
8.
9.
10.
11.
12.
Nut
Flat washer
Bolt
Loop clamp
Bracket
Tube assy
13.
14.
15.
16.
17.
18.
Nut
Flat washer
Bolt
Loop clamp
Loop clamp
Loop clamp
Figure 3-4. Engine and skid plumbing installation. (sheet 1 of 5)
3-6
3-7
Figure 3-4. Engine and skid plumbing installation. (sheet 2 of 5)
3-8
KEY to figure 3-4-Continued:
19. Tube assy
20. Tube assy
21. Tube assy
22. Fluid passage bolt
23. Packing
24. Connector
25. Tube assy
26. Union
27. 0-ring
28. Tube assy
29. Union
30. Reducer
31. 0-ring
32. Cross fitting
33. Tube assy
34. Reducer
35. Tube assy
36. Nipple
37. Packing
38. Tube assy
30). Tee
40. Elbow
41. Nut
42. Packing
43.
44.
45.
46.
47.
48.
40.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
64.
65.
66.
67.
3-9
Tube assy
Tube cap
Tee
Coupling nut
O-ring
Tube assy
Tube assy
Tube assy
Tube cross
Fluid passage bolt
Packing
Connector
Oil pump plug
Packing
Tube
Reducer
Packing
Tube assy
Elbow
Elbow
Coupling nut
O-ring
Fluid passage bolt
Packing
Connector
Figure 3-4. Engine and skid plumbing installation. (sheet 3 of 5)
3-10
KEY to figure 3-4-Continued:
68. Tube assy
69. Elbow
70. Tube cap
71. Tee
72. Coupling nut
73. 0-ring
74. Tube assy
75. Tube cap
76. Nut
77. Union
78. Tube assy
79. Tee
80. Tube assy
81. Elbow
82. Coupling nut
83. 0-ring
84. Tube assy
85. Tube cap
86. Tee
87. Nut
88. 0-ring
89. Tube assy
90. Elbow assy
91. Coupling nut
92. O-ring
93. Tee
94. Lockwire
95. Plug/bleeder-ring
96.
97.
98.
99.
100.
101.
102.
103.
104.
105.
106.
107.
108.
109.
110.
111.
112.
113.
114.
115.
116.
117
118.
119.
120.
121.
122.
123.
3-11
0-ring
Hose assy
Elbow
Nut
O-ring
Tube assy
Tube assy
Nut
Nut
Reducer
0-ring
Tube assy
Elbow
Nut
Plug/bleeder
O-ring
Tube assy
Elbow
Nut
O-ring
Tube assy
Elbow
Nut
O-ring
Tube assy
Reducer
Bushing
O-ring
Figure 3-4. Engine and skid plumbing installation. (sheet 4 of 5)
3-12
KEY to figure 3-4-Continued:
124. Tube assy
125. Union
126. O-ring
127. Nut
128. Flat washer
129. Bolt
130. Loop clamp
131. Loop clamp
132. Bolt
133. Tube assy
134. Tube assy
135. Fitting
136. Tube assy
137. Tube assy
138. Elbow
139. Elbow
140. Nut
141. 0-ring
142. Tube assy
143.
144.
145.
146.
147.
148.
149.
150.
151.
152.
153.
154.
155.
156.
157.
158.
159.
160.
161.
3-13
Elbow
Nut
0-ring
Tube assy
Union
Elbow
Elbow
Nut
0-ring
Tube assy
Elbow
Tube assy
Union
Elbow
Elbow
O-ring
Fluid passage bolt
Packing
Elbow
Figure 3-4. Engine and skid plumbing installation. (sheet 5 of 5)
3-14
KEY to figure 3-4-Continued:
162. Cap
163. Nut
164. Flat washer
165. Elbow
166. Tube assy
167. Tee
168. Nut
169. O-ring
170. Tube assy
171. Union
172. O-ring
173. Union
174. Nut
175. Flat washer
176. Bolt
177. Loop clamp
178.
179.
180.
181.
182.
183.
184.
185.
186.
187.
188.
189.
190.
191.
192.
193.
Bracket
Flat washer
Bolt
Loop clamp
Hose assy
Elbow
Hose assy
Elbow
Nut
O-ring
Fluid passage bolt
Packing
Elbow
Tube assy
Relief valve
O-ring
leakage. Inspect connection nuts and sleeves on tube
for loose sleeves or damage to nuts. If damaged,
replace tube.
(5) Inspect plumbing fittings for cracks or
clogged passages.
Clean clogged passages and
replace cracked fittings.
(6) Replace all gaskets and packings at
each overhaul regardless of condition.
d.
Installation.
Install hose and tube and
plumbing fittings in reverse order of removal procedures
of paragraph b. above.
c.
Cleaning, Inspection and Repair.
(1) Clean hose and tube and plumbing
fittings with an approved cleaning solvent and dry
thoroughly with filtered compressed air.
(2) Inspect all threaded parts for stripped,
crossed, or peened threads. If threads are damaged
beyond simple repair, replace part.
(3) Inspect hose for cracks, breaks,
chafing and damage to hose interior. If damaged,
replace hose assembly.
(4) Inspect tube for kinks, bends, cracks,
or other damage which might restrict flow or result in
Section II. ENGINE ACCESSORIES
b.
Removal. Refer to TM 5-6115-586-12 and
remove the starter assembly according to the
instructions provided.
c.
Disassembly of Clutch Assembly. Refer to
figure 3-5 and disassemble the starter clutch assembly
as follows:
(1) Do not remove screws (2) or
nameplate (3) from the starter assembly (1) unless
replacement of the ,nameplate is required after
inspection.
(2) Note and record the position of the
pawls (6) and spider (7) as an aid at reassembly.
Support starter assembly (1) on the workbench and
straighten the end of the spring (8) so that ring (4) and
assembled pawls and spider may be removed. Remove
pins (5) to disassemble pawls (6) from spider (7).
3-4. General
This section provides instructions for repair and
replacement allocated to direct support and general
support maintenance for engine accessory components.
The components included in this section are the starter
assembly, fuel control assembly, fuel atomizer
assembly, and oil temperature regulator valve. Refer to
TM 5-6115-586-12 for repair instructions on other
accessory components.
3-5. Starter Assembly
a.
General. The starter is a 24 VDC high
torque motor with a pawl and clutch mechanism
installed to absorb initial shock of starter rotation.
Repair instructions for the starter clutch assembly and
for replacement of brushes are provided in this
paragraph. If repair of the motor is necessary, refer to
depot maintenance.
3-15
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Starter assembly
Screw
Nameplate
Ring
Pin
Pawl
Spider
Spring
Ring
Washer
Ring
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
Plate
Ring
Plate
Ring
Plate
Retainer
Plate
Spring
Pin
Housing
Motor, engine starter
Figure 3-5. Starter clutch assembly.
(4) Inspect pin holes in spider (7) for wear.
Hole diameter shall be 0.1245 inch to 0.1255 inch.
(5) Inspect rings (11, 13, 15), retainer (17)
and housing (21) for wear, nicks, burrs, grooves, galling,
corrosion, or other damage. Ring (11) shall have a flat
finish of AA64 or better, rings (13, 15) shall have a finish
of AA32, or better. Sides of rings (13, 15) shall be
parallel within 0.002 inch TIR (total indicator reading).
Retainer (17) shall have a flange thickness of 0.075 inch
(minimum), faces of flange shall be parallel within 0.002
inch TIR, and flange surface shall have 'a finish of
AA32, or better. Wear in grooves of housing (21) shall
not exceed 0.010 inch (maximum).
(6) Inspect plates (12, 14, 16, 18) for
galling or other damage. Replace plates (12, 14, 16, 18)
if breaks in bonding material are observed.
(7) Inspect all threaded parts for stripped,
crossed, or peened threads, or foreign particles
imbedded in threads.
(8) Perform magnetic particle inspection
on pin (5), pawl (6), spider (7), rings (11, 13, 15),
retainer (17) and housing (21) in accordance with
Military Specification MIL-I-6868.
(3) Remove spring (8). Remove ring (9),
washer (10), and ring(11).
(4) Remove plate (12), ring (13), plate
(14), ring (15), plate (16), retainer (17), plate (18), and
spring (19).
(5) Remove pin (20) and then remove
housing (21) from motor (22).
d.
Cleaning and Inspection of Clutch Assembly.
(1) Clean all disassembled starter clutch
assembly components with a dry cleaning solvent (Fed
Spec P-D-680) and dry with filtered compressed air.
Note.
Dimensional checks are not necessary in
steps (2) through (5) unless parts show visible evidence
of wear or other damage.
(2) Check pins (5, fig. 3-5) for damage to
wearing surface. Outside diameter of wear surface shall
be 0.1223 inch (minimum).
(3) Inspect pawls (6) for nicks, flats, or
other damage on wearing surface of engaging end.
Replace pawls (6) if flats, nicks, or other damage is
observed.
3-16
(18) on top of spring (19) with smooth (unbounded) side
next to concave side of spring.
(3) Install plate ( 16) on retainer (17).
Install ring (15) on plate (16) align internal spline teeth of
ring (15) with external spline teeth of retainer.
(4) Install plate (14) on retainer (17).
Install ring (131 after aligning teeth.
(5) Install plate (12) over retainer (17) with
rough (bonded) side next to ring (13).
Note.
Do not install ring (9) at this time.
(6) Install ring (11 over retainer (17) with
smooth (unslotted) side next to plate (12). Install
washer (10) over retainer.
(7) Insert pawls (6i) in spider (7), align
holes and insert pins (5).
(8) Install assembled parts (5, 6, 7) inside
retainer (7) with pawls (6) protruding through slots in
retainer and with spring hole in spider clockwise 90
degrees to spring hole in wall retainer, as viewed from
flange end of retainer. See figure 3-6, items 1-6, for
proper installation of pawls in the spider.
Note.
Make sure that spring holds pawls in the
retracted position. If not, reverse pawls in spider.
(9) Inspect nameplate (2) for legibility.
e.
Repair and Replacement of Clutch
Assembly.
(1) Remove any minor nicks, scratches,
burrs or mild corrosion from clutch components with fine
abrasive paper (Fed Spec P-P-101, No. 600 grit). Parts
shall meet applicable inspection dimensions after repair.
After repair, clean parts thoroughly.
(2) Replace spring (8, fig. 3-5).
(3) If nameplate (2) is defective, apply zinc
chromate primer (Mil Spec MIL P-8585) to screws (1)
and install new nameplate before primer dries.
(4) Replace all other damaged or
excessively worn parts. If threads are damaged beyond
simple repair, replace part.
f.
Reassembly of Clutch Assembly.
(1) Apply light film of oil (Military
Specification MIL-L-7808) to both sides of plates (14,
16, fig. 3-5), rings (13, 15) and flared end of retainer
(17).
(2) Insert spring (19) in bottom of housing
(21) with convex side toward starter motor. Install plate
3-17
ME-5-6115-434-35/3-13
1.
2.
3.
Housing
Pawl
Pin
4.
5.
6.
Spider
Ring
Spring
Figure 3-6. Pawls installed in spider.
(11) Insert assembled parts (4 through 8,
and 10, 12 through 17) in housing (21) after aligning
tangs on plates and rings with the two long slots on
housing. Screw ring (11) loosely into housing, holding
up washer (10) to perform this operation.
Note.
Install ring (9) after ring (11) has been
adjusted to give proper slip torque as described below.
(12) Install starter (1, fig. 3-5) in clutch
torquing holder (special tool; see table 2-1) to prevent
rotation of starter armature assembly (fig. 3-7).
(9) Install ring (4, fig. 3-5) inside retainer
(17) to secure assembled parts (5, 6, 7). Install new
spring (8) on bottom side of spider (7) with long flared
end through spring hole in spider and short flared end,
through spring hole in retainer.
Caution: Spring (8) shall not be bent in
toward center or out toward periphery of spider (7).
(10) Bend protruding end of spring (8) to
approximately 45 degrees.
3-18
g. Removal of Starter Brushes.
(1) Remove the clamp and, insulator strip
from the starter motor end cap.
(2) Remove six screws, six lockwashers, and
six flat washers from each of the four brush springs and
eight brush assemblies.
h. Inspection, Replacement, and Installation of
Starter Brushes.
Note
A repair kit shall always be
utilized instead of replacement of
individual parts.
(1) Discard all brush assemblies and replace
with new brush assemblies from repair kit.
(2) Discard insulator and replace with new
insulator from repair kit.
(3) The
repair
kit
contains
partial
replacements for other parts. Inspect the other parts
and replace any damaged or defective parts with those
supplied in the kit.
(4) Install the brush components by reversing
removal procedure.
i. Bench Test and Brush Run-In.
Provide a
source of DC power capable of producing 16 VDC at
approximately 50 amps. With no load on the starter,
run-in the brushes until they are seated on at least 80
percent of their contact area. Be sure rotation of the
starter motor is counter-clockwise when viewing the
starter from the shaft end.
j. Installation. Refer to TM 5-6115-586-12 and
install the starter assembly.
Figure 3-7. Using clutch torquing holder and torque
wrench adapter to check clutch slip torque.
(13) Raise washer (10, fig. 3-5) so that tangs
are not engaged in slot of ring (11) or housing (21).
(14) Turn in ring (11) by wedging a screwdriver
between radial slots in ring and clutch housing and
rotating screwdriver clockwise until top surface of ring is
secure against plates. Spray light film of oil (Military
Specification MIL-L7808) on parts in retainer (17).
Note
It is necessary to hold washer (10)
away from ring (11) to prevent
tang catching in slots when
adjusting torque.
Caution
Check movement of pawls (6) in
spider (7) to be sure they pivot
freely and do not bind or stick. It
is imperative that pawl action is
free and unimpeded through
entire stroke.
If pawls bind,
adjust spring (8) and check for
extraneous material in spider.
(15) Insert torque wrench adapter (special tool;
see table 2-1) into retainer (17) engaging pawls (6) and
attach suitable torque wrench to socket (fig. 3-7). Slip
torque required to turn retainer (17, fig. 3-5) clockwise
shall be within 135 to 145 inch-pounds, as indicated on
torque wrench dial. If slip torque is not within specified
limits, tighten or loosen ring (11) as required.
(16) Slip clutch 10 revolutions after torque
adjustment, using adapter. Recheck slip torque and
readjust as required.
Continue to slip clutch 10
revolutions and readjust until slip torque remains within
135 to 145 pound-inches after slippage.
(17) Lower washer (10) and insert large tang
where a slot in ring (11) is exactly aligned with a slot on
housing (21).
(18) Install ring (9) over washer (10) so that
gap of ring is opposite large tang of washer, larger hook
is in a slot of ring (11) and remaining length is in inner
groove of ring.
3-6. Fuel Control Assembly
a. General.
The fuel control unit provides
regulated fuel flow to the fuel atomizer assembly in
response to engine acceleration conditions and varying
load conditions. The fuel control assembly consists of a
fuel pump assembly, governor assembly, acceleration
limiter valve, full filter assembly and connections for
pneumatic control, electrical control, fuel inlet, fuel
outlet, fuel bypass, fuel pressure gauge and a fuel seal
drain mainfold.
b. Removal. Refer to TM 5-6115-586-12 for fuel
control assembly removal instructions, c. Disassembly.
Disassemble fuel control assembly according to
sequence of index numbers (1 thru 43) assigned to
figure 3-8, observing the following.
(1) Record location and manner of lockwiring
for aid at assembly.
(2) Do not disassemble any staked, swaged,
or press-fit assemblies unless so instructed or unless
required after inspection. Do not remove identification
plates, decals, studs, passage hole plugs or inserts
unless so instructed or unless required after inspection.
(3) Record location and thickness of shims
and spacers for aid at assembly.
3-19
Note
It is possible all fluids have not
been drained from the fuel control
assembly.
Position assembly
over suitable container to catch
any
remaining
fluid
when
separating major assemblies or
removing parts from cavities that
might contain fluids.
(4) Remove drive shaft (1, fig. 3-8).
(5) Unscrew filter cap (2) and remove
packings (3 and 4) and filter element (5).
Figure 3-8. Fuel control assembly.
3-20
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
KEY to figure 3-8.
1. Drive shaft
2. Filter cap
3. Packing
4. Packing
5. Filter element
6. Nut
7. Washer
8. Fuel solenoid valve
9. Washer
10. Fitting
11. Gasket
12. Packing
13. Plug
14. Gasket
15. Plug
16. Packing
17. Plug
18. Packing
19. Nut
20. Washer
21. Screw
(6) Remove nut (6), washer (7) and remove
fuel solenoid valve (8) with items (9 through 12)
attached. Remove washers (9). Remove fitting (10)
from fuel solenoid valve (8) then remove gasket (11)
and packings (12) from fitting (10).
(7) Remove plug (13) with gasket (14)
attached, then remove gasket (14) from plug (13).
(8) Remove plug (15) with packing (16)
attached, then remove packing (16) from plug (15).
(9) Remove plug (17) with packing (18)
attached, then remove packing (18) from plug (17).
(10) Remove nut (19) and washer (20) from
screw (26) in cover (24) to release compression load of
spring (29).
Note
Nut (25) has left-hand thread.
(11) Remove screws (21) and washers (22)
and remove cover (24). Do not remove pin (23) from
cover unless damage is indicated by inspection.
Remove nut (25), screw (26), packings (27), (28), and
spring (29).
Note
If flyweight assembly is removed,
do not disassemble from the
sleeve and bearing.
(12) Remove nut (30) and washer (31) from
screw (37) in cover (35) to release compression load of
spring (40).
Note
Nut (36) has left-hand thread.
(13) Remove screws (32) and washers (33)
and remove cover (35). Do not remove pin (34) from
cover unless damage is indicated by inspection.
Remove nut (36), screw (37), packings (38, 39), spring
(40) and spacer (41).
(14) Remove diaphragm assembly (42) from
housing assembly (43).
Washer
Pin
Cover
Nut
Adjustment screw
Packing
Packing
Spring
Nut
Washer
Screw
Washer
Pin
Cover
Nut
Adjustment screw
Packing
Packing
Spring
Spacer
Diaphragm assy
Housing assy
Note
Do not disassemble the fuel
control assembly further. Refer
additional
repair
to
depot
maintenance.
d. Cleaning, Inspection and Repair.
(1) Cleaning.
Clean all components of
control unit in an approved solvent, except solenoid
valve. Wipe valve with a lint-free cloth dampened in an
approved solvent such as trichlorethylene.
(2) Inspection.
(a) Visually inspect all parts for obvious
damage, excessive wear, or abnormalities. Inspect
threaded parts for stripped, crossed, or peened threads.
(b) Inspect springs for distortion,
cracks, or other damage.
(c) Check operation of solenoid valve.
Apply Test Fluid (Military Specification MIL-T-5624,
Grade UP-4 or JP-5) to valve inlet at 100±3psig
pressure.
Energize solenoid with 7.2 volts dc
(maximum) at coil temperature of 80°F (27° C). Valve
shall open. Slowly reduce voltage. Valve shall close at
4 volts dc or less.
(d) Increase test fluid pressure to 300±3
psig. Maintain coil temperature at 80° F (27° C) and
energize valve with 9.0 volts de (maximum). Valve
shall open. Slowly reduce voltage. Valve shall close at
4 volts dc or less.
(e) Check leakage of solenoid valve.
Maintain test fluid at 300±3psig pressure and check
valve for maximum leakage of 0.5 cc per hour. Reduce
test fluid pressure to zero and remove valve from test
setup.
(f) Check for insulation breakdown of
coil of solenoid valve (8). Apply 750 volts rms between
case and coil for one minute. No shorting is permitted.
(g) Visually inspect shaft (1) for wear,
crack, nicks, or burrs. Check square end of shaft for
0.180 inch minimum across flats and 0.237 inch
3-21
minimum across corners. Check splined end of shaft for
0.5706 inch minimum measured across two 0.0800 inch
diameter pins set in any two serrations across diameter.
e. Reassembly. Assemble fuel control unit in
reverse order of disassembly while observing the
following.
Note
Refer to paragraph 1-6h for torque
data.
(1) Coat packings with thin film of compound
(Military Specification MIL-C-11796, Class 3) before
installation.
(2) Install diaphragm assembly (42) with
open convolute side facing outward from housing
assembly (43).
(3) Install pin (34) in cover (35). Assemble
nut (36), adjustment screw (37), packing 38), washer
(36) and nut (30) to cover (35).
(4) Install spacer (41) on housing assembly
143) with drain hole oriented 90 degrees clockwise from
limiter valve drain boss and with recess in spacer up.
Install packing (39), spring (40) and cover (35) with
attached parts on housing, exercising care that pin (34)
locates inside spring (40) and cover (35) is oriented as
shown in figure 3-8. Secure parts with washers (33) and
screws (32).
(5) Install flyweight assembly in cage if
removed.
(6) Install pin (23) in cover (24). Assemble
nut (25), adjustment screw (26), packing (27), washer
(20), nut (19) and packing (28) to cover (24).
(7) Install spring (29) and cover (24) with
attached parts on housing assembly (43), exercising
care that pin (23) locates inside spring (29) and that
cover (24) is oriented as shown in figure 3-8. Secure
parts with washers (22) and screws (21). Tighten screws
(21) to a torque of 50 to 60 inchpounds.
(8) Install packing (18) on plug (17). Install
plug (17) with attached packing (18) in housing
assembly (43). Install packing (16) on plug (15). Install
plug (15) with attached packing (16) in housing. Install
gasket (14) on plug (13). Install plug (13) with attached
gasket (14) in housing.
(9) Install gasket (11) on fitting (10) and
install fitting (10) in end of fuel solenoid valve (81,
opposite of keyway in fuel solenoid valve electrical
connector. Install packings (12) and washer (9) on
fitting, then insert fitting through boss on housing
assembly. Secure with washer (7) and nut (6) tightened
to 100 to 110 inch-pounds torque value.
(10) Install filter element (5) over guide in
housing assembly. Install packings (4, 3) and filter cap
(2).
(11) Install drive shaft (1).
f. Installation. Refer to TM 5-6115-586-12 for
instructions regarding installation and adjustment of the
fuel control unit.
3-22 3-7. Fuel Atomizer Assembly
a. General. The fuel atomizer assembly sprays
fuel into the combustion chamber in a pattern that
provides proper combustion. Fuel at low pressures is
metered through a small orifice and ejected in a
somewhat concentrated spray pattern of low volume
flow. At higher inlet fuel pressures, a relief valve opens
and permits a large volume of flow to be ejected through
a layer orifice in a wide-angle spray pattern. The flow
volume is dependent on the fuel pressure at the fuel
atomizer assembly inlet. Repair of the fuel atomizer
assembly consists of cleaning or replacement of the
screen and replacement of the relief valve packing.
Further repairs must be referred to depot maintenance.
b. Removal.
Refer to TM 5-6115-586-12 for
instructions on removal of the fuel atomizer assembly.
c. Disassembly.
(1) Remove screen (1, fig. 3-9) from fuel
atomizer housing (5).
(2) Remove relief valve (2); then remove
packings (3 and 4) from the valve.
Figure 3-9. Fuel atomizer assembly.
d. Cleaning, Inspection, and Replacement.
(1) Clean the screen thoroughly with solvent
and dry the screen with clean, filtered compressed air.
(2) Replace the packings (3 and 4, fig. 3-9).
Replace the screen (1) if it is damaged.
e. Reassembly and Testing. Reassemble the fuel
atomizer assembly by reversing the disassembly
3-22
b. Removal. Refer to TM 5-6115-586-12 for oil
temperature regulator and valve removal instructions.
c. Disassembly.
Refer to figure 3-10 and
disassemble the oil temperature regulator valve (items 1
thru 8) in the numerical sequence shown.
Note
Do not remove modification plate
(2) or name plate (3) unless they
must be replaced.
procedure. Refer to TM 5-6115-586-12 and test the fuel
atomizer assembly according to the instructions
provided.
f. Installation. Refer to TM 5-6115-586-12 and
install the fuel atomizer assembly.
3-8. Oil Temperature Regulator Valve
a. General. The oil temperature regulator valve
maintains oil temperature in the engine lubrication
system within specified limits.
Figure 3-10. Oil temperature regulator valve.
d. Cleaning, Inspection and Replacement.
(1) Clean the parts with dry cleaning solvent
(Fed Spec P-D-680 or equivalent) and dry thoroughly.
(2) Replace the packing (5, fig. 3-10).
(3) Check the modification plate (2) and
nameplate (3) for legibility and secure mounting.
(4) Inspect other parts for damage and
replace defective parts.
e. Reassembly. Reassemble the oil temperature
regulator valve by reversing the disassembly sequence.
f. Installation and Test. Refer to TM 5-6115-58612 and install the valve to the oil temperature regulator;
then test the oil temperature regulator valve as follows:
(1) Test oil temperature regulator, using a
test setup as shown in figure 3-11. Use corrosive
preventative oil (Military Specification MIL-C-8188) at
70°to 30°F (21°to 1.1°C).
(2) Attach pressure line to OIL IN port and
discharge line to OIL OUT port of valve.
(3) Open both shutoff valves and start pump.
(4) Close outlet shutoff valve after all air has
been bled from system. Apply an inlet pressure of 100
psi gauge, close shutoff valve in inlet line and observe
leakage and pressure drop. No leakage or pressure
drop is allowable during a five minute test period.
(5) Drain unit, but do not flush.
3-23
Figure 3-11. Test set-up for oil temperature regulator.
Section III. DUAL PAD ACCESSORY DRIVE ASSEMBLY
maintenance personnel shall be confined to
3-9. General
replacement of seals, oil jets, oil scavenge pump, and
This section contains repair instructions for the dual pad
their associated parts and external mounting studs. If
accessory drive assembly which is mounted to and
the housing is cracked or otherwise defective or the
driven by the accessory gearcase assembly. The 60 Hz
drive gears are defective, the dual pad accessory drive
and 400 Hz generators are in turn mounted to and
assembly shall be replaced by a serviceable assembly
driven by the dual pad accessory drive assembly.
and the defective assembly shall be returned to depot
3-10. Removal
maintenance for overhaul.
a. Removal of Generators.
Refer to TM 56115586-12 and remove the 400 Hz generator and the
60 Hz generator according to the removal instructions
provided.
b. Removal
Assembly.
of
Dual
Pad
Accessory
KEY to figure 3-12.
1. Nut
2. Washer
3. Dual pad accessory drive assy
4. Gasket
5. Shaft
6. Nut
7. Bolt
8. Washer
9. Accessory gearcase assembly
10. Packing
11. Shaft
12. Spring
13. Clamp
14. Screw
Drive
(1) Support the dual pad accessory drive
assembly; remove twelve nuts (1, fig. 3-12, sheet 1 of
2) and washers (2) that secure the dual pad accessory
drive assembly (3) to the accessory gearcase assembly
(9) studs, and separate the dual pad accessory drive
assembly.
(2) Remove the shaft (5) and gasket (4) from
the accessory gearcase assembly (9).
3-11. Disassembly
a. Repair of the dual pad accessory drive
assembly by direct support or general support
3-24
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
Washer
Inlet air plenum
Bolt
Washer
Atomizer
Packing
Bolt
Washer
Igniter
Gasket
Clamp
Combustor cap
Packing
Liner
Figure 3-12. Gas turbine engine assembly. (sheet 1 of 2)
3-25
Figure 3-12. Gas turbine engine assembly. (sheet 2 of 2)
3-26
b. Disassemble the dual pad accessory drive
assembly only as directed in the following instructions.
Note
Remove seals only if replacement
is necessary due to leakage or
damage that might lead to early
failure.
(1) Remove two oil jets (1, fig. 3-13) from
housing assembly (33), then remove packings from oil
jets.
Figure 3-13. Dual pad accessory drive assy.
(2) Remove caps (3 and 4) from tee (5).
(4) Remove screws (9), washers (10), and
retainer (11) with stator of seal (12) and shims (13)
Remove tee from reducer (6), then remove from
installed. Remove rotor of seal (12) from gearshaft.
housing.
(3) Straighten key (8) and using adapter
(5) Using arbor press, press seal (12) from
(special tool; see table 2-1), remove retainer nut (7)
retainer (11) and remove shims (13).
from gearshaft, then remove key (8).
(6) Remove bolts (14), washers (15) and
3-27
(b) Inspect for damaged threads in
tapped ejection holes in retainer mounting flange.
(c) Perform
dimensional
and
parallelism inspections in accordance with figure 3-14.
remove the oil scavenge pump as an assembly (16, 17,
and 18). Discard packing (17). Remove shaft (18) if
inspection proves it to be damaged and it must be
replaced.
(7) Straighten key (20) and using adapter,
remove retainer nut (19) and key (20).
(8) Remove screws (211 and washers (22)
and remove retainer (23) with stator of seal (24)
installed. Remove rotor of seal from gearshaft and use
arbor press to press stator of seal (24) from retainer
(23).
(9) Straighten key (26) and using adapter,
remove nut (25) and key (26) from gear shaft.
(10) Remove screws (27) and washers (28)
and remove retainer (29) with stator of seal (30)
installed. Remove rotor of seal from gearshaft and use
arbor press to press stator of seal from retainer.
(11) Remove lock rings (31) and studs (32)
from housing assembly (33) only if inspection reveals
damage necessitating replacement.
3-12. Cleaning, Inspection and Repair
a. Cleaning and Inspection.
(1) Clean removed parts using dry cleaning
solvent (Fed Spec P-D-680 or equivalent) and a soft
bristle brush to facilitate removal of caked grease.
(2) Inspect all metallic parts for corrosion,
wear, nicks, scratches, burrs and cracks.
(3) Inspect all threaded parts for worn,
crossed. -tripped, or peened threads. Make certain all
threaded parts turn freely on mating parts and do not
bind.
(4) Inspect bearing oil jets (1, fig. 3-13) as
follows:
(a) Check to ensure that oil tube and
restrictor are unobstructed.
(b) Inspect for wear or damage to
nozzle installation or oil inlet tube attachment threads.
(c) Check
security
of
brazed
attachment of restrictor to oil tube and oil tube to oil jet
body. Check diameter of restrictor hole. Restrictor hole
shall be 0.035 to 0.040 inch diameter.
(5) Visually inspect retainers (11, 23, 29) as
follows:
(a) Inspect for physical damage on
exterior surfaces and for scratching, galling, or other
defects on sealing surfaces.
Figure 3-14. Inspection of retainer.
(6) Inspect bearing retainer nuts (7, 19, 25,
fig. 3-13) for damaged threads, distortion of spanner
slots, and for evidence of scratching, galling, scoring, or
binding on mating surfaces.
(7) Inspect seals (12, 24, 30) as follows:
(a) Visually inspect rotor for nicks, cuts,
or scratches.
(b) Visually inspect seal for distortion,
wear, or evidence of operational leakage.
(c) Perform dimensional, parallelism
and finish inspection in accordance with figure 3-15.
3-28
(2) Repair or replace retainers (11, 23, 29,
fig. 3-13) as follows, if defects are noted at inspection
described (para a(5) above)
(a) Repair minor surface defects.
(b) Replace retainer if worn or
damaged beyond simple repair or beyond limits shown
in figure 3-14.
(3) Repair or replace retainer nuts (7, 19, 25,
fig. 3-13), if defects are noted at inspection as follows:
(a) Repair minor surface defects.
(b) Replace retainer nut if threads are
damaged or if spanner slots are mutilated.
(4) If inspection reveals a damaged stud or
insert, the damaged part shall be replaced as follows:
(a) Remove insert by drilling to a depth
equal to the thickness of the lockring with a drill equal in
diameter to that of the serrations between the lockring
and insert. Then remove the insert with an "easy-out"
tool.
(b) Remove stud by milling to a depth
equal to the thickness of the lockring with a hollow mill
equal in outside diameter to that of the root diameter of
the outer serrations less 0.0156 inch, then unthread the
stud.
(5) Replace shaft (18) if gear is damaged or
excessively worn. If the oil scavenge pump (16) is
defective, replace the oil scavenge pump.
(6) Replace all packing.
(7) Replace common hardware and fittings if
threads are stripped or damaged.
3-13. Reassembly
a. Install seal rotor, a part of seal (30, fig. 3-13)
onto gearshaft with chamfer next to bearing. Coat seal
seating bore of retainer (29) with one coat of red Enamel
(Glyptal No. 1201) and allow to dry. Using Arbor press
and Fixture, press seal (30) into retainer (29). Install
key (26) into gearshaft and install retainer nut (25).
Using Adapter, tighten retainer nut to 145 to 155 inchpounds, bend key (26) into retainer nut slot. Install
retainer (29) with seal into housing assembly (33) and
secure with screws (27) and washers (28). Tighten
screws (27) to 40 to 60 inch-pounds.
b. Install seal rotor, a part of seal (24), onto
gearshaft with chamfer next to bearing. Coat seal
seating bore of retainer (23) with one coat of red Enamel
(Glyptal No. 1201) and allow to dry. Using arbor press
and fixture, press seal (24) into retainer (23). Install key
(20) on gearshaft and install retainer nut (19). Tighten
retainer nut (19) to 145 to 155 inch-pounds, bend key
into retainer nut slot. Install retainer (23) with seal (24)
into housing assembly (33) and secure with screws (21)
and washers (22). Tighten screws (21) to 40 to 60 inchpounds.
Figure 3-15. Inspection of seat.
(8) Inspect housing for loose, worn, or
damaged studs and lock rings (32 and 31, fig. 3-13).
(9) Visually inspect assembled housing and
gears for evidence of cracked housing, excessively worn
or damaged bearings or gears, loose and misaligned
parts. If any of these defects are noted, the dual pad
accessory drive assembly must be overhauled at depot
level.
b. Repair and Replacement.
(1) Repair or replace oil jet (1, fig. 3-13) if
defects are noted at inspection, as follows:
(a) Remove obstructions from oil tube
and restrictor by passing a length of 0.030 inch diameter
piano wire through restrictor opening and blowing out
with compressed air.
(b) Repair brazed joining of restrictor in
oil tube or oil tube to body in accordance with
established shop practices.
(c) Replace oil jet if threads are
damaged or if oil tube is dented or collapsed, or if
restrictor hole is damaged or enlarged. Restrictor hole
shall be 0.035 to 0.040 inch diameter.
3-29
as required to obtain a dimension of 0.737 to 0.747 inch.
This is the required thickness of shims (13, fig. 3-13).
d. Install amount of shims (13) determined above,
into retainer (11). Coat seal bore of retainer with one
coat of red Enamel (Glyptal No. 1201) and allow to dry.
Using arbor press and fixture, press seal (12) into
retainer (11).
e. Install rotor of seal (12) onto gearshaft with
chamfer next to bearing. Install key (8) and retainer nut
(7) onto gearshaft. Tighten retainer nut to 145 to 155
inch-pounds torque value., Bend key (8) into slot of
retainer nut. Install retainer ( 11) with seal (12) and
shims (13), assembled, into housing and secure with
screws (9) and washers (10). Tighten screw (9) to 40 to
60 inch-pounds.
f. Install new packing (17) into oil scavenge pump
(16). Install shaft (18) into the oil scavenge pump.
g. Install assembled scavenge pump into housing
and secure with bolts (14) and washers (15). Tighten
bolts (14) to 50 to 70 inch-pounds and lockwire in pairs.
h. Install reducer (6) into housing and install tee (5)
into reducer (6). Install caps (3, 4) onto tee (5).
i. Install packings (2) onto oil jets (1) and install oil
jets into housing assembly. Tighten oil jets to 40 to 60
inch-pounds.
3-14. Installation
a. Installation of Dual Pad Accessory Drive
Assembly.
(1) Install shaft (5, fig. 3-12, Sheet 1 of 2)
and gasket onto gearcase assembly (9).
(2) Install accessory drive (3) onto gearcase
assembly (81) and secure with nuts (1) and washers (2).
Tighten nuts to 100 to 110 inchpounds.
b. Installation of Generators. Refer to TM 56115586-12 for 60 Hz, 400 Hz generator installation
instructions.
c. Determine shim requirements for seal (12) at
input end of gearshaft as follows (fig. 3-16).
(1) Measure depth of retainer and record as
dimension A.
(2) Measure height of lip on retainer and
record as dimension B.
(3) Measure from mounting flange of bearing
retainer to outer race of bearing and record as
dimension C (fig. 3-16).
Figure 3-16. Determining shim requirements for
input seal assembly.
(4) Subtract dimension B from dimension A
and add dimension C to the result. Add shim thickness
Section IV. ACCESSORY GEARCASE ASSEMBLY
3-15. General
3-16. Removal
The accessory gearcase assembly consists of a twoa. Refer to TM 5-6115-586-12 and remove the 400
piece gearcase, a spur gear train, and accessory
Hz and 60 Hz generators.
mounting pads for the starter motor assembly, fuel
b. Refer to paragraph 3-10 band remove the dual
control unit, centrifugal switch assembly, oil pump
pad accessory drive assembly.
assembly, cooling fan assembly, and the dual pad
c. Refer to TM 5-6115-586-12 and remove the
accessory drive assembly that drives the 400 Hz and 60
accessory items: the starter motor assembly, the fuel
Hz generators. The accessory gearcase assembly is
control unit, the centrifugal switch assembly, the oil
driven by the gas turbine engine and the spur gear train
pump assembly, and the cooling fan assembly.
transmits the power to the various accessory items at
d. Remove the accessory gearcase assembly from
proper speed and direction of rotation.
the engine as follows:
3-30
b. Disassemble the accessory gearcase assembly
as follows:
(1) Remove screw (1, fig. 3-17), washer (2)
and nozzle (3) with packing (4).
(2) Remove nut (5) and starter jaw (6).
(3) Remove plug and bleeder (7), gasket (8),
bolts (9) and washers (10), then remove retainer (11)
with packing (12) from housing assy (41).
(4) Remove nuts (13), washers (14) and
retainer (15) with packing (16) from housing assembly.
Remove ring(17) and press seal (18) from retainer (15).
(5) Remove screws (19), washers (20) and
retainer (21) with assembled parts. Press stator of seal
(23) from retainer (21).
Remove packing (22).
(1) Support the accessory gearcase assembly
(9, fig. 3-12, sheet I of 2) and remove the bolts (7) and
washer (8) and the nuts (6) and washers (8) that attach it
to the engine.
Remove the accessory gearcase
assembly (9) and packing (10) from the engine.
(2) Remove the shaft (11) and spring (12)
from the engine.
3-17. Disassembly
a. Repair of the accessory gearcase assembly by
direct support or general support maintenance personnel
is confined to replacement of seals, starter jaw, studs
and inserts, and related parts. If the housing or gear
train are defective, the accessory gearcase assembly
shall be overhauled at depot maintenance facilities.
Figure 3-1 7. Accessory gearcase assembly.
3-31
(6) Remove nut (25), spacer (26), key (27)
rotor of seal (23), shims (24) and washer (28).
(7) Do not remove rings, studs, and inserts
(29 through
40) unless inspection
shows
that
replacement is necessary.
3-18. Cleaning, Inspection, and Repair
a. Cleaning. Degrease parts with dry cleaning
solvent (Fed Spec P-D-680 or equivalent) and dry
thoroughly.
b. Inspection.
(1) Inspect all metallic parts for corrosion,
wear, nicks, cracks, burrs, and scratches.
(2) Inspect all threaded parts for worn,
crossed, stripped, or peened threads. Make certain that
all threaded parts turn freely on their mating parts and
do not bind.
(3) Inspect starter jaw for chips, breaks or
cracks.
(4) Visually inspect housing assembly for
evidence of cracked housing, defective gears or
bearings. If these defects are present, the accessory
gearcase assembly must be overhauled at depot
maintenance facilities.
c. Repair.
(1) Replace packings and defective seals.
(2) Replace defective hardware and other
parts found to be defective by inspection.
(3) If inspection reveals a damaged stud or
insert, the damaged part shall be replaced as follows:
(a) Remove insert by drilling to a depth
equal to the thickness of the lockring with a drill equal in
diameter to that of the serrations between the lockring
and insert. Then remove the insert with an "easy-out"
tool.
(b) Remove stud by milling to a depth
equal to the thickness of the lockring with a hollow mill
equal in outside diameter to that of the root diameter of
the outer serrations less 0.0156 inch, then unthread the
stud.
3-19. Reassembly
Assemble the accessory gearcase assembly by
reversing the disassembly sequence using figure 317 as
a guide and observing the following:
a. When assembling seal (18) into retainer ( 15),
refer to figure 3-18 and assemble as follows:
(1) Using arbor press, press seal (18, fig. 317) into retainer (15) and install ring (17) in retainer (15)
to secure seal (18), then install packing (16) onto
retainer (15).
(2) Install assembled retainer into housing
and secure with washers (14) and nuts (13).
Figure 3-18. Installation of seal.
b. Before assembling retainer (21) and seal (23),
make measurements described in figure 3-19 to
determine amount of shims required for bearing pinch
and seal length, and assemble as follows:
3-32
Figure 3-19. Installation seal.
nut and install nut, tighten to torque value of 145 to 155
inch-pounds. Bend key into slot in nut.
Note
If key slots in retainer nut (25, fig.
3-17) do not align with key (27)
replace retainer nut (25). Do not
add shims.
(1) Install shims (24, 28), determined above,
and install rotor of seal (23), spacer (26) and retainer nut
(25).
(4) Coat mating surfaces of seal (23) with
adhesive. Using driver, install seal into retainer (21).
(5) Install required amount of
packing (22) and assembled retainer (21)
Secure with washers screws (20) and
Tighten to torque value of 15 to 20
(2) Hold gearshaft using adapter.
Using
torque wrench, tighten retainer nut (25) to torque value
of 145 to 155 inch-pounds. Check alignment of key lots
in retainer nut (25) and mark aligned key slot.
(3) Remove retainer nut (25) and install key
(27) on gearshaft. Apply a coat of Loctite to threads of
3-33
shims (24),
into housing.
screws (19).
inch-pounds.
mounting flange with washers (8), bolt (7) and nuts (6).
Tighten nuts (6) and bolts (7) to torque value 75 to 85
inch-pounds.
c. Install packing (4) on nozzle (3) and install
nozzle into housing. Secure nozzle (3) using washers
(2) and bolt (1).
3-20. Installation
a. Refer to figure 3-12, sheet I of 2, and install the
accessory gearcase assembly as follows:
b. Refer to TM 5-6115-586-12 for installation
instructions for the cooling fan assembly, oil pump
assembly, centrifugal switch assembly, fuel control unit,
and starter motor assembly.
(1) Install spring (12) and shaft (11) into
compressor and turbine shaft. Install packing (10) onto
gearcase input flange.
c. Refer to paragraph 3-14 and install the dual pad
accessory drive assembly.
(2) Position gearcase assembly (9) on output
mounting flange studs. Secure gearcase to output
Section V. COMPRESSOR AND TURBINE ASSEMBLY
c. Remove bolts (29), washers (30), and fitting
(31), with packing (32) and spring (34) and packings (36,
37) installed. Remove gasket (39) and packing (33).
d. Remove bolts (40, 41, fig. 3-12, sheet 2 of 2),
washers (42), shims (43, 44) and flange (45). Remove
nuts (46), bolts (47, 48), and washers (49).
e. Remove plenum (50) and gasket (51) and shims
(52). Using wrench (special tool; see table 21), remove
exhaust pipe (53) and gasket (54).
f. Remove nuts (55), washers (56), torus (57),
shims (58), nozzle (59) and shims (60).
g. Do not disassemble the compressor and turbine
assembly (61). Refer repairs to depot maintenance.
3-24. Cleaning, Inspection, and Repair
a. Cleaning. Parts may be cleaned by using an
approved solvent in a dip tank or use of spray in a
positive outside ventilated spray booth.
Vapor
degreasing or soap cleaning solution may also be used
if suitable equipment is available.
Warning
Fumes from spray or vapor are
toxic and shall not be inhaled.
Wear solvent-resistant gloves to
prevent absorption of solvent
through
the
skin.
Fire
precautions shall be observed
and fire fighting equipment shall
be available.
b. Inspection.
(1) Inspect torus (57, fig. 3-12, sheet 2 of 2)
as follows: (fig. 3-20 and 3-21.)
3-21. General
This section contains repair instructions for the air inlet
plenum, the turbine plenum, the combustion liner, the
torus, the exhaust pipe, and the turbine nozzle. These
components with the compressor and turbine assembly,
convert and direct the energy developed in the
combustion area to rotational mechanical energy.
3-22. Removal
a. Refer to Chapter 2 of this manual for
instructions regarding removal of the engine and skid
assembly (para 2-11) and removal of the engine from
the skid (para 2-12).
b. Remove wire harness (para 3-2 b) and plumbing
(para 3-3b) as required to facilitate maintenance.
c. Remove the dual pad accessory drive assembly
(para 3-10 b ) and the accessory gearcase assembly
(para 3-16 c).
3-23. Disassembly
Note
Tag shims as removed and keep
them together so that they will be
properly installed at assembly.
a. Remove clamp (13, fig. 3-12, sheet 1 of 2)
screws (14) and washers (15) and remove inlet air
plenum (16).
b. Remove bolts (17), and washers (18) and
remove atomizer (19) and packing (20). Remove bolts
(21) and washers (22) to remove igniter (23) and gasket
(24). Then remove clamp (25) and remove combustor
cap (26), packing (27) and liner (28).
3-34
Figure 3-20. Inspection of torus.
3-35
Figure 3-21. Inspection of torus.
(a) Check for loose or damaged studs.
(2) Inspect exhaust pipe (53, fig. 3-12, sheet
(b) Check for wear on inside diameter
2 of 2) for cracked welds, and damaged flanges or
of flange (diameter B, fig. 3-21).
structural warpage.
(c) Check for cracks or holes in torus.
(3) Inspect liner (28, fig. 3-12, sheet 1 of 2)
for corrosion or wearing, cracks or other damage as
shown in figure 3-22.
3-36
Figure 3-22. Inspection of liner.
repaired or replaced if damage exceeds the limits shown
(4) Perform fluorescent penetrant inspection
in figure 3-23.
in accordance with Military Specification MIL-L-6866 on
nozzle (59, fig. 3-12, sheet 2 of 2). Nozzle must be
3-37
Figure 3-23. Inspection of nozzle.
3-38
(2) Repair nozzle (131) as follows.
(a) Remove cracks or feathering not
more than 0.060 inch deep on trailing edge of vanes as
shown in figure 3-22. Rework of one or more vanes
may be performed without necessarily reworking all
vanes. When cracks or feathering require removal of
material of more than 0.060 to 0.130 inch deep on
trailing edge of vane, all vanes shall be cut back an
identical amount.
(b) Repair erosion of vane leading edge
that is less than 1/8 inch deep by blending and fairing to
blade contour.
(c) Repair scoring that is less than
0.030 inch deep on shroud by blending to shroud
contour.
(d) Repair damaged or worn stud by
building up with weld using inert gas shielded tungsten
arc and Rene 41 or 718 welding rod.
Grind to
dimensions specified in figure 3-23.
(3) Repair exhaust pipe (53, fig. 3-12, sheet
2 of 2) as follows:
(a) Reweld cracked welds per Military
Specification MIL-W,8611, using N-155 Weld rod.
(b) If threads of bolt holes are damaged
beyond repair, plug weld using N-155 weld rod, drill new
holes through plug weld 0.0211 to 0.219 inch. Counter
sink 115° to 125° by 0.25 to 0.28 inch diameter. Tap
with ¼ by 28 UNF-3B tap. Deburr and inspect.
(4) Repair turbine plenum (50, fig. 3-12,
sheet 2 of 2) as described in figure 3-24.
c. Repair.
(1) Repair liner (28, fig. 3-12, sheet 1 of 2)
as follows:
(a) All cracks are to be repaired by
welding except as noted. Weld in accordance with
Military Specification MIL-W-8611, using N-155 filler rod
conforming to Military Specification MIL-R-5031, class
9.
(b) Weld cracks connecting any two
holes in accordance with Military Specification MILW6858.
(c) Weld any cracks over 1/8 inch long
in accordance with Military Specification MIL-W6858.
(d) Replace liner, if buckling is greater
than 1/8 inch deformation.
(e) Replace liner, if metal thickness is
less than 0.030 inch due to corrosion or wear.
(f) If practical, weld any group of
cracks which could cause breaking away of material in
accordance with Military Specification MIL-W6858,
otherwise replace liner.
(g) Weld any cracks separated by less
than ¼ inch of material in accordance with Military
Specification MIL-W-6858.
(h) Remove and replace damaged
cooling skirts. Weld cooling skirts in accordance with
Military Specification MIL-W-6811, using N-155 filler rod
conforming to Military Specification MIL-R-5031, Class
9.
3-39
Figure 3-24. Repair of turbine plenum.
(a) Repair cracks, such as item 1,
figure 3-25, by stop drilling crack ends to prevent further
progression of crack, then welding per Military
Specification MIL-W-8611 using Inco 62 per AMS5679,
Hasteloy W per AMS5786 or Inco 92A per AMS5676.
All inside flow areas shall be free of excess weld.
(b) Repair cracks in nozzle mating
flange (2, fig. 3-25), by machining to remove cracks.
Material removal, not to exceed two inches in length, is
permissible at one location only.
(5) Repair inlet air plenum (16, fig. 3-12,
sheet 1 of 2) as follows:
(a) Weld repair cracks to Military
Specification MIL-W-8611.
(b) Weld
patches
per
Military
Specification MIL-W-8611. Patches shall be 0.040 inch
minimum thickness and shall overlap the crack a
minimum of 0.050 inch minimum, no patches allowed
inside plenum. Do not overlap patches.
(6) Repair torus (57, fig. 3-12, sheet 2 of 2)
as follows.
Note
Cracks within the forged portion
of torus are not repairable.
Condemn the torus if such
damage is found.
3-40
Figure 3-25. Repair of torus.
3-41
d. Install tube (35) with new packings (36, 37).
Install fitting (31) with spring (34) and new packings (31,
32). Install bolts (29) and washers (30). Tighten bolts
(29) to torque value of 50 to 70 inch-pounds.
e. Set turbine plenum (50) down onto support
assembly and use tool to tighten tail pipe (53). Align
turbine plenum. Remove turbine plenum and install
gasket (51). Reinstall turbine plenum into previously
aligned position. Use feeler gauge to measure gap from
turbine plenum rear flange to tail pipe (53) rear flange.
Subtract 0.015 to 0.025 inch from measurement and
record for later shimming operation.
f. Remove turbine plenum and gasket. Install 2
alignment pins in rear flange of tail pipe, install shims
(52) determined (para 3) above, over alignment pins.
Apply a light coat of petrolatum to both sides of gasket,
reinstall gasket and turbine plenum into previous
orientation. Install flange (45) and shims (43, 44) to rear
face of turbine plenum and on alignment pins.
g. Install bolts (47, 48), washers (49) and nuts (46).
Torque bolts to a value of 50 to 70 inchpounds. Install
bolts (40, 41) and washers (42) into flange (45). Torque
bolts to a value of 90 to 110 inch-pounds.
h. Install liner (28, fig. 3-12, sheet 1 of 2). Install
combustor cap (26) with packing (27).
i. Install igniter (23) and gasket (24) with bolts (21)
and washers (22). Install packing (20) and atomizer (19)
with bolts (17) and washers (18).
j. Install inlet air plenum (16) with screws (14),
washers (15) and clamp (13).
3-26. Installation
a. Install accessory gearcase assembly (para 320a
), dual pad accessory drive assembly (para 314),
plumbing (3-3d) and wiring (3-2 h).
b. Refer to paragraphs 2-12 and 2-11 for
instructions for installation of engine to skid and
installation of engine and skid assembly respectively.
(c) Repair cracks in torus skin (3, fig.
325) by patching.
Remove sufficient material to
eliminate all trace of crack. Patch material shall be Inco
600 and shall be 0.043 inch (minimum). Weld patches
on both the inner and outer skin surfaces per Military
Specification MIL-W-8611, using weld rod as specified
in (1) above. Do not overlap patches. Maintain
minimum overlap of patch on torus skin, as shown in
view A, figure 3-25. Inside flow surfaces and joints shall
be free of excess weld.
Note
Recent versions of the torus
contain
10
studs
only.
Consequently stud repair may be
performed on alternating studs
(20 stud version) and removal, if
desired, of remainder.
(d) If inspection revealed damaged
studs, cut off damaged studs flush with torus surface.
Drill through remainder of old stud. Countersink 118 to
122 degrees by 0.530 inch diameter (maximum ) to
remove tack welds. Install new studs as shown in view
B and plug weld per Military Specification MIL-W-8611,
using Inconel 69 weld rod.
(7) Replace all packings and replace any
hardware found to be stripped or damaged.
(8) Replace all other defective parts.
3-25. Reassembly
Note
Be certain that shims (58, 60, fig.
3-12, sheet 2) are installed exactly
as removed. The determination of
thickness of shims requires
special tools and facilities not
normally available to direct
support and general support
maintenance personnel.
a. Install nozzle (59) and shims (60).
b. Install torus (57) with shims (58). Secure with
nuts (55) and washers (56). Tighten nuts, using wrench,
to torque value of 50 to 70 inch-pounds. Coat threads of
exhaust pipe (53) with high temperature compound.
c. Coat threads of transfer tube (38) with
lubricating compound (Liqui-Moly, Grade NV) and install
with new gasket (39). Tighten tube to torque value of
385 to 440 inch-pounds.
3-42
CHAPTER 4
REPAIR OF SKID ASSEMBLY
d. Installation. Refer to paragraph 3-3 of this
manual for hose and tube assembly installation
instructions.
4-3. Oil Tank Assembly
a. General. The oil tank assembly is mounted on
the skid in a cradle. The oil tank is the oil supply
reservoir for the power unit.
b. Removal. Refer to TM 5-6115.586-12 for oil
tank removal instructions.
c. Cleaning, Inspection and Repair.
(1) Clean oil tank assembly with an approved
solvent, drain thoroughly and dry with filtered
compressed air.
(2) Inspect all threaded areas for stripped,
crossed or peened threads. If threads are damaged
beyond simple repair, replace part.
(3) Inspect tank for punctures, ruptures,
broken welds and looseness of fittings.
(4) Reweld broken welds in accordance with
Military Specification MIL-W-8604.
(5) Pressure test oil tank after repair at 5 psig
controlled pressure for five minutes. No leakage is
allowed.
d. Installation. Refer to TM 5-6115-586-12 for oil
tank installation instructions.
4-4. Fuel Boost Pump
a. General. The fuel boost pump furnishes fuel
under pressure to the engine from the external source.
The fuel boost pump is mounted on a mounting plate on
the skid.
b. Removal. Refer to TM 5-6115-586-12 for fuel
boost pump, removal instructions.
c. Disassembly. Remove the four screws (1, fig.
4-1 ) to remove the pump (2). Remove the four bolts (3)
and washers (4) to remove the stator (5), coupling (6),
and gasket (7) from motor (11). Do not remove
receptacle (10) unless damaged. If damaged, remove
the lockwire (8) and the four screws (9). Unsolder the
electrical wires that connect to the receptacle and
remove damaged receptacle (10).
4-1. General
a. The major components of the skid assembly are
the skid, oil tank, fuel tank, fuel filter, fuel pump, fuel
float tank and plumbing installation.
b. Prior to performing any repair to the above
listed items, remove the major components of the
engine and skid assembly (para 2-12).
c. Refer to Chapter 5 of this manual for repair
instructions on skid assembly electrical wire harnesses.
4-2. Hose and Tube Assemblies and Plumbing
Fittings
a. General. The hose and tube assemblies and
plumbing fittings provide interconnection of pneumatic,
fuel, and oil systems components. The hose assemblies
consist of metallic braid protected hoses with
appropriate end fittings permanently secured to the hose
and metallic braid. The tube assemblies consist of
formed metal tubes with standard fittings to provide
orientation of hose and tube assemblies to the
components.
b. Removal. Refer to paragraph 3-3 of this manual
for hose and tube assemblies removal instructions.
c. Cleaning, Inspection and Repair.
(1) Clean hose and tube assemblies and
plumbing fittings with an approved cleaning solvent and
dry thoroughly with filtered compressed air.
(2) Inspect all threaded parts for stripped,
crossed, or peened threads. If threads are damaged
beyond simple repair, replace the part.
(3) Inspect hose assemblies for cracks,
breaks, chafing and damage to hose interior.
If
damaged, replace hose assembly.
(4) Inspect tube assemblies for kinks, bends,
cracks, or other damage which might restrict flow or
result in leakage. If damaged, replace tube assembly.
(5) Inspect plumbing fittings for cracks or
clogged passages.
Clean clogged passages and
replace cracked fittings.
(6) Replace all gaskets and packings at each
overhaul regardless of condition.
4-1
Figure 4-1. Fuel boost pump, exploded view.
4-2
b. Removal. Refer to TM 5-6115-586-12 for fuel
tank removal instructions.
c. Cleaning, Inspection and Repair.
(1) Flush fuel tank with an approved solvent
and dry with filtered compressed air.
(2) Inspect fuel tank fitting bosses for
crossed, stripped or peened threads.
(3) Inspect for cracks, ruptures or punctures.
(4) Repair bosses using simple repair,
replace tank if damaged beyond simple repair or if
inspection requirements are not met.
4-7. Air Inlet Duct and Screen Assembly
a. General.
(1) The screen assembly prevents large
objects from entering the air inlet duct.
(2) The air inlet duct directs air from the
enclosure air inlet to the air inlet plenum assembly.
b. Removal. Refer to paragraph 2-11 of this
manual to remove the air inlet duct and screen
assembly.
c. Disassembly. Do not disassemble the air inlet
duct unless inspection reveals damage. If disassembly
is required, follow sequence of index numbers I through
20 assigned to figure 4-2.
d. Cleaning, Inspection and Repair.
(1) Clean the air inlet duct using an approved
solvent.
(2) Inspect for cracks, tears, holes or dents.
(3) Inspect riveted components for security
and damage.
(4) Inspect
seal
for
security
and
serviceability.
(5) Inspect nut plates for security and
damage.
(6) Inspect screen for broken wires.
d. Cleaning, Inspection and Repair.
(1) Clean fuel boost pump parts using an
approved solvent. Dry with filtered compressed air.
(2) Visually inspect all parts for breakage,
wear, corrosion, or other forms of damage.
(3) Replace parts damaged beyond simple
repair.
(4) If receptacle is damaged, replace with
new receptacle and resolder electrical wiring in
accordance with MIL-S-6872 using solder SN60-WRP2
per Fed Spec QQ-S-571. After reinstalling screws (9),
install new lockwire (8) in accordance with MS33540.
e. Assembly. Assemble the fuel boost pump by
reversing the disassembly sequence given in paragraph
c, above while observing special instructions on
soldering given in paragraph d, (4), above.
f. Installation. Refer to TM 5-6115-586-12 for fuel
boost pump installation instructions.
4-5. Fuel Filter
a. The fuel filter is mounted on an upright bracket
on the skid assembly.
The fuel filter is located
downstream of the skid mounted fuel tank in the fuel
system.
b. Refer to TM 5-6115-586-12 for removal,
disassembly, cleaning, inspection, repair, assembly, and
reinstallation instructions.
4-6. Fuel Tank
a. General. The fuel tank is mounted in a cradle
on the skid. The fuel tank acts as a reservoir and
contains enough fuel to permit unit operation while
switching from one external fuel source to another.
4-3
Figure 4-2. Air inlet duct assembly, exploded view.
4-4
f. Reinstallation.
Refer to paragraph 2-11 to
reinstall the air inlet duct and screen assembly.
4-8. Air Inlet Plenum Assembly
a. General. The air inlet plenum is skid mounted
and directs air to the engine air inlet plenum assembly.
To remove the lower portion, simply remove the
hardware which attaches it to the skid.
b. Disassembly. Do not disassemble the air inlet
plenum unless inspection reveals damage. If damage is
indicated, disassemble by following sequence of index
numbers, 1 through 20, assigned to figure 4-3, and 1
through 18, assigned to figure 4-4
(7) Inspect for screen separation, broken or
cracked laminate.
(8) Replace screen assembly if damaged
beyond simple repair.
(9) Repair cracks using simple shop repair.
(10) Patch holes and tears using simple shop
repair.
(11) Replace loose or damaged rivets.
(12) Replace seals using adhesive.
(13) Replace damaged nut plates.
(14) If air inlet duct is damaged beyond simple
repair, replace the entire assembly.
e. Assembly. Assemble air inlet duct assembly in
reverse order of disassembly procedures given in
paragraph 4-7 c above.
4-5
Figure 4-3. Air inlet plenum assembly, upper, exploded view.
4-6
Figure 4-4. Air inlet plenum assembly, lower, exploded view
4-7
d. Assembly. Assemble air inlet plenum assembly
in reverse order of disassembly procedures
(para 4-8 c. above).
c. Cleaning, Inspection and Repair.
(1) Clean plenum using an approved solvent
and a lint free rag.
e. Reinstallation. Replace the lower portion by
attaching it to the skid with its hardware. Attach
the upper portion as instructed in paragraph 212.
(2) Visually inspect for cracks, holes, or
dents.
(3! Inspect seals for security and abnormal
wear.
4-9. Heat Shield Assembly
(4) Inspect welds for breaks and cracks.
a. General. The heat shield assembly separates
the engine hot section from the plenum inlet
assembly.
(5) Inspect riveted components for security
and damage.
(6) Repair dents by cold working using good
shop practice.
b. Removal. Refer to paragraph 2-12 to remove
the upper portion of the heat shield. To remove
the lower portion, simply remove the hardware
which attaches it to the skid.
(7) Repair cracks using simple shop repair.
(8) Patch hole using simple shop repair.
(9) Replace loose or damaged rivets in
accordance with good shop practice.
c. Disassembly. Do not disassemble the heat
shields unless inspection reveals damage. If
required, disassemble by following the
sequence of index numbers, I through 13,
assigned to figure 4-5 and 1 through 10,
assigned to figure 4-6.
(10) Replace loose or damaged seals using
adhesive.
4-8
Figure 4-5. Heat shield assembly, upper, exploded view.
4-9
Figure 4-6. Heat shield assembly, lower, exploded view.
(11) If heat shields are damaged beyond
d. Cleaning, Inspection and Repair.
simple repair, replace the entire assembly.
e. Assembly. Assemble heat shield assembly in
(1) Clean heat shield using an approved
reverse order of disassembly procedures given
solvent and a stiff bristled brush.
in paragraph 4-9 c. above.
Note
f. Reinstallation. Replace the lower portion by
Do not get solvent on insulation
attaching it to the skid using the hardware that
or seals.
attaches it.
Replace the upper portion as
(2) Inspect for cracks, tears or holes.
instructed in paragraph 2-12.
(3) Inspect bolt, spacers, washers and nuts
securing channels for security of installation.
(4) Inspect
installation.
grommets
for
security
of
(5) Inspect nut plates and all riveted
components for loose rivets or damage to components.
(6) Repair cracks using simple shop repair.
(7) Patch hole or tears using simple shop rep
air.
(8) Tighten loose bolts and
channels.
nuts securing
a. General. The skid assembly mounts the engine,
oil tank, fuel boost pump, fuel filter, fuel tank
and brackets supporting these units.
b. Disassembly.
Do not disassemble skid
assembly unless inspection reveals damage. If
required, follow sequence of index numbers, 1
through 19 assigned to figure 4-7 and I through
11, assigned to figure 4-8 for disassembly.
c. Cleaning, Inspection and Repair.
(9) Replace damaged grommets.
(10) Replace loose or damaged
replace damaged riveted components.
4-10. Skid Assembly
rivets and
(1) Clean skid and component parts with an
approved solvent.
Dry thoroughly with filtered
compressed air
.
(2) Inspect brackets for cracks and breaks.
(3) Inspect brackets for
serviceability of cushioning material.
security
(4) Inspect supports for cracks and breaks.
Inspect support (18, fig.
4-7) for security and
serviceability of cushioning material.
and
4-11
TM 55-1930-209-14&P-4
Figure 4-7. Engine skid assembly.
4-12
(7) If skid parts are damaged beyond simple
repair, replace the entire skid.
(5) Inspect the skid for cracked, broken or
bent components, security and serviceability of nut
plates and screws.
d. Assembly. Assemble skid assembly in reverse
order of disassembly procedures (para 410 b. above).
(6) Inspect pads and spacer for damage or
abnormal wear.
4-13
TM 55-1930-209-14&P-4
Figure 4-8. Engine skid sub-assembly, exploded view.
4-14
CHAPTER 5
REPAIR OF ELECTRICAL COMPONENTS
Section I. POWER PLANT ELECTRICAL INSTALLATION
operating or from any other
5-1. General
electrical power source. Failure
a The power plant electrical installation includes
to observe this warning may lead
all wire harness assemblies (except those located on the
to serious injury or death to
engine and skid), the instrument panel, the conditioned
personnel.
air electrical components panel, the auxiliary power tray,
the receptacle panel assembly, and the conditioned air
5-2. DC Power Branched Wire Harness Assembly
temperature control panel. These components control
(13217E4147)
and deliver power for the 400 Hz and 60 Hz AC
electrical systems and the DC electrical system.
a. Removal.
Refer to figure 5-1; tag and
disconnect the DC power branched wire harness
b. Paragraphs 5-2 through 5-25 contain repair
assembly as follows: (1) Remove the terminal board
instructions for the interconnecting wire harness
cover from terminal board (TB2) located on the inboard
assemblies. The panel wire harness assemblies are
wall of the No. I system condenser compartment.
included in repair instructions for the panel where they
are located. Repair instructions for all single wire
electrical leads used in the unit are provided in
paragraph 5-31.
(1) Remove three nuts, screws, and washers
and remove the terminal board.
(2) Remove
lockwire
and
disconnect
connector P38 (engine skid wire harness). Remove
connector J38 from the floor of No. 1 system condenser
compartment by removing four nuts and screws and
eight washers.
c. Wiring diagrams for the wire harness and panel
assemblies included in this section are provided in TM
5-6115-586-12. Refer to the wiring diagrams as an aid
to testing, repair, and installation. Wire run charts are
provided in this section for individual wire harness
assemblies. Wires are identified in accordance with
MIL-W5088.
Refer also to TM 5-6115-586-12 for
schematics of the electrical system.
(3) Disconnect wires to switches (S27 and
S33). Remove lockwires and disconnect the eight "plugtype" wire harness connectors.
(4) Remove six wire harness clamps, noting
the position of the clamps and routing of the wire
harness.
Warning
Before maintenance is performed
on any electrical component, the
power plant shall be shut down
and shall be disconnected from
another power plant that is
(5) Remove the wire harness.
5-1
TM 55-1930-209-14&P-4
Figure 5-1. DC power branched wire harness assembly.
5-2
Catalyst 501A, Dow Corning Corp., Midland, Michigan,
or equivalent).
b. Disassembly.
After inspection and testing,
disassemble the wire harness only as required for repair
or replacement.
(4) If self-clinching cable straps are removed
to facilitate repairs, install new cable straps at five inch
intervals and all cable breakouts.
c. Cleaning and Inspection.
f. Installation. Install the wire harness assembly
in reverse order of removal procedure. After installing
connectors, safety wire in accordance with' MS33540
using lockwire MS20995C20.
(1) Clean wire harness with a clean, lint-free
cloth moistened with approved solvent and dry
thoroughly.
(2) Inspect for damaged or loose connector
pins, terminals, and terminal board studs. Check for any
evidence of burned areas indicating shorts. Inspect
wiring for damaged insulation and loose connections.
Inspect connectors for damaged or stripped threads.
5-3. Power Plant DC Power Branched Wire Harness
Assembly 113217E4153)
a. Removal.
Refer to figure 5-2; tag and
disconnect the power plant DC power branched wire
harness assembly as follows:
d. Testing. Refer to the wire run chart in figure 5-1
and check individual wires for continuity.
(1) Remove the terminal board cover from
terminal board (TB4) and remove the wire harness
electrical leads from the terminal board studs.
e. Repair. Replacement and Reassembly.
(1) Solder connections will be made in
accordance with MIL-S-6872 using solder type
SN60OWRP2 per Fed Spec QQ-S-571.
(2) Remove lockwire and disconnect P52 and
P106, then remove connectors J52 and J106 from the
inboard wall of the battery access and storage
compartment by removing four nuts and screws and
eight washers from each connector.
(2) Replace defective wires with wire in
accordance with MIL-W-5086, Type II. Wire size and
approximate length in inches is provided in figure 5-1.
(3) Remove lockwires and disconnect the
three remaining wire harness connectors. Disconnect
the leads to the air intake door switch (S4).
(3) If replacement of connector J38 is
necessary, remove potting compound and unsolder
electrical
leads.
Solder
electrical
leads
to
replacement connector. Fill connector backshell with
silicone rubber sealing compound (501 RTV and
(4) Remove the four cable clamps, noting the
position of the clamps and routing of the wire harness.
(5) Remove the wire harness.
5-3
Figure 5-2. Power Plant DC power branched wire harness assembly.
b. Disassembly.
After inspection and testing,
d. Testing. Refer to the wire run chart in figure 5-2.
disassemble the wire harness only as required for repair
and check individual wires for continuity.
or replacement.
e. Repair. Replacement and Reassembly.
c. Cleaning and Inspection.
(1) Solder connections will be made in
accordance with MIL-S-6872 using solder type
SN60OWRP2 per Fed Spec QQ-S-571.
(1) Clean wire harness with a clean, lint-free
cloth moistened with approved solvent and dry
thoroughly.
(2) Replace defective wires with wire in
accordance with MIL-W-5086, Type II. Wire size and
approximate length in inches is provided in figure 5-2.
(2) Inspect for damaged or loose connector
pins and terminal lugs. Check for any evidence of
burned areas indicating shorts.
Inspect wiring for
damaged insulation and loose connections. Inspect
connectors for damaged or stripped threads.
(3) If self-clinching cable straps are removed
to facilitate repairs, install new cable straps at two inch
intervals and all cable breakouts.
5-4
a. Removal.
Refer to figure 5-3; tag and
disconnect the DC power branched wire harness
assembly as follows:
f. Installation. Install the wire harness assembly in
reverse order of removal procedure. After installing
connectors, safety wire in accordance with MS33540
using lockwire MS20995C20.
(1) Remove lockwire and disconnect P65;
then remove connector J65 from the floor of the No. 2
system condenser compartment by removing four nuts
and screws and eight washers.
5-4. DC Power Branched Wire Harness Assembly
(13217E4149)
(2) Inspect for damaged or loose connector
pins and terminal lugs. Check for any evidence of
burned areas indicating shorts.
Inspect wiring for
damaged insulation and loose connections. Inspect
connectors for damaged or stripped threads.
(2) Disconnect leads to switches (S28 and
S34).
(3) Remove four cable clamps; note the
position of the clamps and routing of the wire harness.
(4) Remove the wire harness.
d. Testing. Refer to the wire run chart in figure 5-3
and check individual wires for continuity.
b. Disassembly.
After inspection and testing,
disassemble the wire harness only as required for repair
or replacement.
e. Repair. Replacement and Reassembly.
c. Cleaning and Inspection.
(1) Solder connections will be made in
accordance with MIL-S-6872 using solder type
SN60WiRP2 per Fed Spec QQ-S-571.
(1) Clean wire harness with a clean, lint-free
cloth moistened with approved solvent and dry
thoroughly.
(2) Replace defective wires with wire in
accordance with MIL-W-5086, Type II. Wire size and
approximate length in inches in provided in figure 5-3.
5-5
connectors J65 and P65, safety wire in accordance with
MS33540 using lockwire MS20995C20.
(3) If replacement of connector J65 is
necessary, remove potting compound and unsolder
electrical
leads.
Solder
electrical
leads
to
replacement connector. Fill connector backshell with
silicone rubber sealing compound (501 RTV and
Catalyst 501A, Dow Corning Corp., Midland, Michigan,
or equivalent).
a. Removal. Refer to figure 5-4; tag and remove
the water system wire harness assembly by removing
lockwire and disconnecting P41, P42 and PilI; then
remove connectors J41, J42, and J71 by removing four
nuts and screws and eight washers from each.
(4) If self-clinching cable straps are removed
to facilitate repairs, install new cable straps at five inch
intervals and all cable breakouts.
b. Disassembly.
After inspection and testing,
disassemble the wire harness only as required for repair
or replacement.
f. Installation. Install the wire harness assembly in
reverse order of removal procedure. After installing
Figure 5-4. Water system wire harness assembly.
c. Cleaning and Inspection.
e. Repair, Replacement and Reassembly.
(1) Clean wire harness with a clean, lint-free
cloth moistened with approved solvent and dry
thoroughly.
(1) Solder connections will be made in
accordance with MIL-S-6872 using solder type
SN60WRP2 per Fed Spec QQ-S-571.
(2) Check for any evidence of burned areas
indicating shorts. Inspect wiring for damaged insulation
and loose connections. Inspect connectors for damaged
or stripped threads and damaged or loose pins.
(2) Replace defective wires with wire in
accordance with MIL-W-5086, Type II. Wire size and
approximate length in inches is provided in figure 5-4.
(3) If replacement of connectors (J41, J42,
J71) is necessary, remove potting compound and
unsolder electrical leads. Solder electrical leads to
d. Testing. Refer to the wire run chart in figure 5-4
and check individual wires for continuity.
5-6
replacement connector. Fill connector backshell with
silicone rubber sealing compound (.501 RTV and
Catalyst 501A, Dow Corning Corp., Midland, Michigan,
or equivalent).
5-6.
Water System Branched
Assembly (13217E4143)
Wire
Harness
a. Removal.
Refer to figure 5-5; tag and
disconnect the water system branched wire harness
assembly as follows:
(4) If self-clinching cable straps are removed
to facilitate repairs, install new cable straps at two inch
intervals and all cable breakouts.
(1) Disconnect the wire harness electrical
leads from switches (SII and S12) and disconnect the
connector (P71).
f. Installation. Install the wire harness assembly
in reverse order of removal procedure. After installing
the connectors, safety wire in accordance with MS33540
using lockwire MS20995C20.
(2) Remove the cable clamp; note the
position of the clamp and routing of the wire harness.
Remove the wire harness assembly.
Figure 5-5. Water system branched wire harness assembly.
b. Disassembly.
After inspection and testing,
d. Testing. Refer to the wire run chart in figure 5-5
disassemble the wire harness only as required for repair
or replacement.
and check individual wires for continuity.
c. Cleaning and Inspection.
e. Repair, Replacement and Reassembly.
(1) Clean wire harness with a clean, lint-free
cloth moistened with approved solvent and dry
thoroughly.
(1) Solder connections will be made in
accordance with MIL-S-6872 using solder type
SN6(0WRP2 per Fed Spec QQ-S-571.
(2) Inspect for damaged or loose connector
pins and terminal lugs. Check for any evidence of
burned areas indicating shorts. Inspect connectors for
damaged or stripped threads.
(2) Replace defective wires with wire in
accordance with MIL-W-5086, Type II. Wire size and
approximate length in inches is provided in figure 5-5.
(3) If self-clinching cable straps are removed
5-7
a. Removal.
Refer to figure 5-6; tag and
disconnect the water pumps wire harness assembly as
follows: (11 Remove lockwires and disconnect the four
wire harness connectors (P39, P40, P41, and P77).
to facilitate repairs, install new cable straps at three inch
intervals and at all cable breakouts.
f. Installation. Install the wire harness assembly in
reverse order of removal procedure.
5-7. Water Pumps
(13217E4142)
Wire
Harness
(2) Remove the four cable clamps, noting
their location and routing of the wire harness and
remove the wire harness.
Assembly
Figure 5-6. Water pumps wire harness assembly.
b. Disassembly.
After inspection and testing,
disassemble the wire harness only as required for repair
or replacement.
(2) Replace defective wires with wire in
accordance with MIL-W-5086, Type II. Wire size and
approximate length in inches is provided in figure 5-6.
c. Cleaning and Inspection.
(3) If replacement of connectors P39 and P40
is necessary, remove potting compound and unsolder
electrical leads. Solder electrical leads to replacement
connector. Fill connector potting boot with insulating
compound, Type C per MIL-I-16923.
(1) Clean wire harness with a clean, lint-free
cloth moistened with approved solvent and dry
thoroughly.
(2) Inspect for damaged or loose connector
pins. Check for any evidence of burned areas indicating
shorts. Inspect connectors for damaged or stripped
threads.
(4) If self-clinching cable straps are removed
to facilitate repairs, install new cable straps at two inch
intervals and at all cable breakouts.
d. Testing. Refer to the wire run chart in figure 5-6
and check individual wires for continuity.
f. Installation. Install the wire harness assembly in
reverse order of removal procedure. After installing
connectors, safety wire in accordance with MS33540
using lockwire MS20995C20.
e. Repair, Replacement and Reassembly.
(1) Solder connections will be made in
accordance with MIL-S-6872 using solder type
SN60WRP2 per Fed Spec QQ-S-571.
5-8
(4) Remove eleven cable clamps; note
position of clamps and routing of wire harness. Remove
wire harness.
5-8.
Air Conditioning System Branched Wire
Harness Assembly (13217E4146)
a. Removal.
Refer to figure 5-7; tag and
disconnect the air conditioning system branched wire
harness assembly as follows:
b. Disassembly.
After inspection and testing,
disassemble the wire harness only as required for repair
or replacement.
(1) Remove the terminal board cover from
terminal board (TB8); then remove three nuts and
screws to remove the terminal board.
c. Cleaning and Inspection.
(2) To remove connector J67, remove
lockwire and disconnect P67, then remove four nuts and
screws and eight washers to remove connector J67.
(1) Clean wire harness with a clean, lint-free
cloth moistened with approved solvent and dry
thoroughly.
(3) Remove lockwires and disconnect the
remaining seven connectors.
(2) Inspect for damaged or loose connector
pins, terminal lugs, and terminal board studs. Check for
any evidence of burned areas indicating shorts. Inspect
connectors for damaged or stripped threads.
Figure 5-7. Air conditioning branched wire harness assembly.
5-9
f.
Installation. Install the wire harness
assembly in reverse order of removal procedure. After
installing connectors. Safety wire in accordance with
MS33540 using lockwire MS20995C20.
d. Testing. Refer to the wire run chart in figure 5-7
and check individual wires for continuity.
e. Repair, Replacement and Reassembly.
5-9.
Air Conditioning System
Assembly (13217E4145)
(1) Solder connections will be made in
accordance with MIL-S-6872 using solder type
SN60OWRP2 per Fed Spec QQ-S-571.
'Wire Harness
a. Removal.
Refer to figure 5-8;
tag and
disconnect the air conditioning system wire harness
assembly as follows: (1) Remove the terminal board
cover from terminal board (TB91. Remove three nuts,
screws, and washers and remove the terminal board.
(2) Replace defective wires with wire in
accordance with MIL-W-5086, Type II. Wire size and
approximate length in inches is provided in figure 5-7.
(3) If self-clinching cable straps are removed
to facilitate repairs, install new cable straps at three inch
intervals and at all cable breakouts.
5-10
Figure 5-8. Air conditioning system wire harness assembly.
5-11
(2) Replace defective wires with wire in
accordance with MIL-W-5086, Type II. Wire size and
approximate length in inches is provided in figure 5-8.
(2) Remove connectors J94 and J99 by
removing lockwire from P99 and disconnecting P94
and P99; then remove J94 and J99 by removing four
nuts and screws and eight washers from each.
(3) Remove lockwires
remaining seven connectors.
and
(3) If self-clinching cable straps are removed
to vacilitate repairs, install new cable straps at three
inch intervals and at all cable breakouts.
disconnect
(4) Diode assemblies (CR21 and CR22) may
be repaired if diode checks good but wire, terminal
lugs, or insulation is defective. Replace defective wires
with wire Type E, MIL-W-16878 / 4, size E20. After
crimping the splice for the wire to the diode lead, solder
the splice in accordance with MIL-S-6872 with solder
Type SN60WRP2 per Fed Spec QQ-S-57 1. Install
insulation sleeving with new self-clinching cable straps.
(4) Remove six cable clamps; note position
of clamps and routing of the wire harness. Remove the
wire harness.
b. Disassembly. After inspection and testing,
disassemble the wire harness only as required for
repair or replacement.
f. Installation. Install the wire harness assembly
in reverse order of removal procedure. After installing
connectors, safety wire in accordance( with MS33540
using lockwire MS20995C20.
c. Cleaning and Inspection.
(1) Clean wire harness with a clean, lint-free
cloth moistened with approved solvent and dry
thoroughly.
5-10. Recirculating Fans Wire Harness Assembly
(13217E4165)
(2) Inspect for damaged or loose connector
pins, terminal lugs, and terminal board studs. Check
for any evidence of burned areas indicating shorts.
Inspect connectors for damaged or stripped threads.
a. Removal.
Refer to figure 5-9; tag and
disconnect the recirculating fans wire harness
assembly as follows:
(1) Remove connectors J22 and J23 by
removing lockwire and disconnecting P22 and P23;
then removing four nuts and screws, and eight washers
to remove J22 and J23.
d. Testing. Refer to the wire run chart in figure 5-8
and check individual wires for continuity. Check diodes
CR21 and CR22 for shorts or open with an ohmmeter.
(2) Remove
connector P92.
e. Repair, Replacement and Reassembly.
lockwire
and
disconnect
(3) Remove five cable clamps.
Note
position of cable clamps and routing of wire harness
and remove the wire harness.
(1) Solder connections will be made in
accordance with MIL-S-6872 using solder type
SN60OWRP2 per Fed Spec QQ-S-571.
5-12
Figure 5-9. Recirculating fans wire harness assembly.
b. Disassembly. After inspection and testing,
disassemble the wire harness only as required for
repair or replacement.
(1) Solder connections will be made in
accordance with MIL-S-6872 using solder type
SN60OWRP2 per Fed Spec QQ-S-571.
(2) Replace defective wires with wire in
accordance with MIL-W-5086, Type II. Wire size and
approximate length in inches is provided in figure 5-9.
c. Cleaning and Inspection.
(3) If self-clinching cable straps are removed
to facilitate repairs, install new cable straps at five inch
intervals and at all cable breakouts.
(1) Clean wire harness with a clean, lint-free
cloth moistened with approved cleaning solvent and
dry thoroughly.
(2) Inspect for damaged or loose connector
pins.
Check for any evidence of burned areas
indicating shorts. Inspect connectors for damaged or
stripped threads.
f. Installation. Install the wire harness assembly
in reverse order of removal procedure. After installing
connectors, safety wire in accordance with MS33540
using lockwire MS20995C20.
d. Testing. Refer to the wire run chart in figure 5-9
and check individual wires for continuity.
5-11. Recirculating Fans Wire Harness Assembly
(13217E4141)
e. Repair, Replacement and Reassembly.
a. Removal. Refer to figure 5-10; tag and remove
the recirculating fans wire harness
5-13
assembly by removing lockwire and mating connectors
and remove four nuts, four screws and eight washers
from each connector (J20, J21 and J92).
Remove lockwire, disconnect connector P34, and
remove the wire harness assembly.
b. Disassembly.
After inspection and testing,
disassemble the wire harness only as required for repair
or replacement.
(2) Replace defective wires with wire in
accordance with MIL-W-5086, Type II. Wire size and
approximate length in inches is provided in figure 5-10.
(3) If self-clinching cable straps are removed
to facilitate repairs, install new cable straps at two inch
intervals and at all cable breakouts.
c. Cleaning and Inspection.
(1) Clean wire harness with a clean, lint-free
cloth moistened with approved solvent and dry
thoroughly.
f. Installation. Install the wire harness assembly
in reverse order of removal procedure.
(2) Inspect for damaged or loose connector
pins. Check for any evidence of burned areas indicating
shorts. Inspect connectors for damaged or stripped
threads.
After installing connectors, safety wire to the attaching
hardware in accordance with MS33540 using lockwire
MS20995C20.
5-12. Recirculating Fans Wire Harness Assembly
(13217E4148)
d. Testing. Refer to the wire run chart in figure 510 and check individual wires for continuity.
a. Removal.
Refer to figure 5-11; tag and
disconnect the recirculating fans wire harness as
follows: Figure 5-10. Recirculating fans wire harness
assembly.
e. Repair, Replacement and Reassembly.
(1) Solder connections will be made in
accordance with MIL-S-6872 using solder Type
SN6OWRP2 per Fed Spec QQ-S-571.
5-14
(1) Remove connector J34 by removing the lockwire and disconnecting mating connector P34. Then remove
four nuts, four screws and eight washers to remove J34.
(2) Remove lockwire and disconnect connector P56.
(3) Remove two cable clamps. Note position of the cable clamps and routing of the wire harness and remove
the wire harness.
Figure 5-11. Recirculating fans wire harness assembly.
b. Disassembly.
After inspection and testing,
disassemble the wire harness only as required for repair
or replacement.
(1) Solder connections will be made in
accordance with MIL-S-6872 using solder Type
SN60WRP2 per Fed Spec QQ-S-571.
(2) Replace defective wires with wire in
accordance with MIL-W-5086, Type II. Wire size and
approximate length in inches is provided in figure 5-11.
c. Cleaning and Inspection.
(3) If self-clinching cable straps are removed
to facilitate repairs, install new cable straps at three inch
intervals.
(1) Clean wire harness with a clean, lint-free
cloth moistened with approved solvent and dry
thoroughly.
(2) Inspect for damaged or loose connector
pins. Check for any evidence of burned areas indicating
shorts. Inspect connectors for damaged or stripped
threads.
f. Installation. Install the wire harness assembly
in reverse order of removal procedure. After installing
connectors,, safety wire in accordance with MS33540
using lockwire MS20995C20.
d. Testing. Refer to the wire run chart in figure 511 and check individual wires for continuity.
5-13.
400 Hz Auxiliary Power Wire Harness
Assembly (13217E4131)
e. Repair, Replacement and Reassembly.
a. Removal.
Refer to figure 5-12; tag and
disconnect the 400 Hz auxiliary power wire harness
assembly by removing the electrical leads from switch
(S37) and terminal board (TB3).
5-15
Figure 5-12. 400 Hz auxiliary power wire harness assembly.
(2) If self-clinching cable straps are removed
b. Disassembly.
After inspection and testing,
to facilitate repairs, install new cable straps at three inch
disassemble the wire harness only as required for repair
intervals and at all cable breakouts.
or replacement.
f. Installation. Install the wire harness assembly in
reverse order of removal procedure.
c. Cleaning and Inspection.
5-14. Anti-Ice Thermostat Wire Harness Assembly
(13217E4133)
(1) Clean wire harness with a clean, lint-free
cloth moistened with approved solvent and dry
thoroughly.
a. Removal. Refer to figure 5-13; tag and remove
the anti-ice thermostat wire harness assembly as
follows:
(2) Inspect for damaged or loose terminal
lugs, damaged or cut wire insulation. Check for any
evidence of burned areas indicating shorts.
(1) Remove the thermostats (TS10 and TSI I
from their mounting brackets by removing two nuts and
screws and four washers from each.
d. Testing. Refer to the wire run chart in figure 512 and check individual wires for continuity.
(2) Disconnect
remove the wire harness.
e. Repair, Replacement and Reassembly.
the
connector
(P99)
and
b. Disassembly.
After inspection and testing,
disassemble the wire harness only as required for repair
or replacement.
(1) Replace defective wires with wire in
accordance with MIL-W-5086, Type II. Wire size and
approximate length in inches is provided in figure 5-12.
5-16
Figure 5-13. Anti-ice thermostat wire harness assembly.
(1) If thermostat fails the test in step d above,
c. Cleaning and Inspection.
or connector must be replaced, remove the thermostat
by removing self-clinching cable straps and unsoldering
(1) Clean wire harness with a clean, lint-free
leads from the connector (P99). Cut leads of new
cloth moistened with approved solvent and dry
thermostat to length (fig. 5-13 for approximate lengths).
thoroughly.
(2) Solder leads of thermostat(s) in
(2) Inspect for damaged or loose connector
accordance with MIL-S-6872 using solder type
pins. Check for any evidence of burned areas indicating
SN60WRP2 per Fed Spec QQ-S-571.
shorts. Inspect connectors for damaged or stripped
(3) Install new cable straps at three inch
threads.
intervals and at cable breakouts.
f. Installation. Install the wire harness assembly in
reverse order of removal procedure.
d. Testing.
The thermostats operate through
SPST contacts. TSIO contacts are terminated across
pins A and B of connector P99; TSII contacts are
terminated across pins C and D (fig. 513). Use an
ohmmeter to check that circuits across these pins open
and close at the following ambient temperatures: Open
at 38°F ± 5°F on decreasing temperature and close
at 470°F + 5°on increasing temperature.
5-15. Condenser Fans Wire Harness Assembly
113217E4151)
a. Removal.
Refer to figure 5-14; tag and
disconnect the condenser fans wire harness assembly
by removing lockwires, disconnecting connectors P16,
P17, P43, and P44, then removing four nuts, four
screws, and eight washers from each connector (J16,
J17, J43, and J44).
e. Repair, Replacement and Reassembly.
5-17
Figure 5-14. Condenser fans wire harness assembly.
b. Disassembly.
After inspection and testing,
(2) Inspect for damaged or loose connector
pins, and damaged wires. Check for any evidence of
disassemble the wire harness only as required for repair
burned areas indicating shorts. Inspect connectors for
or replacement.
damaged or stripped threads.
c. Cleaning and Inspection.
d. Testing. Refer to the wire run chart in figure 514 and check individual wires for continuity.
(1) Clean wire harness with a clean, lint-free
cloth moistened with approved solvent and dry
thoroughly.
5-18
f. Installation. Install the wire harness assembly in
reverse order of removal procedure. After installing
connectors, safety wire in accordance with MS33540
using lockwire MS20995C20.
e. Repair, Replacement and Reassembly.
(1) Solder connections will be made in
accordance with MIL-S-6872 using solder Type
SN60OWRP2 per Fed Spec QQ-S-571.
5-16. Condenser Fans Wire Harness Assembly
(13217E4150)
(2) Replace defective wires with wire in
accordance with MIL-W-5086, Type II. Wire size and
approximate length in inches is provided in figure 5-14.
a. Removal.
Refer to figure 5-15.
disconnect the condenser fans wire
assembly as follows:
(3) If replacement of connector J43 is
necessary, remove potting compound and unsolder
electrical leads. Solder
electrical
leads to
replacement connector. Fill connector backshell with
silicone rubber sealing compound (501 RTV and
Catalyst 501A, Dow Corning Corp., Midland, Michigan,
or equivalent).
tag and
harness
(1) Remove lockwire and connectors P18 and
P19; then remove four nuts, eight washers, and four
screws from each connector J18 and J19.
(2) Disconnect connector P44. Remove the
wire harness.
(4) If self-clinching cable straps are removed
to facilitate repairs, install new cable straps at three inch
intervals and at all cable breakouts.
b. Disassembly.
After inspection and testing,
disassemble the wire harness only as required for repair
or replacement.
5-19
Figure 5-15. Condenser fans wire harness assembly.
c. Cleaning and Inspection.
d. Testing. Refer to the wire run chart in figure
515 and check individual wires for continuity.
(1) Clean wire harness with a clean, lint-free
cloth moistened with an approved solvent and dry
thoroughly.
e. Repair. Replacement and Reassembly.
(2) Inspect for damaged or loose connector
pins and damaged wires. Check for any evidence of
burned areas indicating shorts. Inspect connectors for
damaged or stripped threads.
(1) Solder connections will be made in
accordance with MIL-S-6872 using solder Type
SN)OWRP2 per Fed Spec QQ-S-571.
(2) Replace defective wires with wire in
accordance with MIL-W-5086,Type II. Wire size and
5-20
a. Removal.
Refer to figure 5-16; tag and
disconnect the remote power output wire harness
assembly as follows:
approximate length in inches is provided in figure 5-15.
(3) If self-clinching cable straps are removed
to facilitate repairs, install new cable straps at three inch
intervals and at all cable breakouts.
(1) Remove lockwire and connectors PII,
P74, and P75; then remove nuts, washers and screws
from connectors J 1, J74, and J75. Remove wire lead
connections to capacitors (C19, C20, C21, C22, C23,
C24) near J74 and J75.
f. Installation. Install the wire harness assembly in
reverse order of removal procedure. After installing
connectors, safety wire in accordance with MS35540
using lockwire MS20995C20.
5-17.
Remote Power
Assembly (13217E4156)
Output
Wire
(2) Remove wire lead connections to terminal
boards (TB4, TB7).
(3) Disconnect connectors P70 and P76.
Remove the wire harness.
Harness
5-21
Figure 5-16. Remote power output wire harness assembly.
(3) If self-clinching cable straps are removed
to facilitate repairs, install new cable straps at five inch
intervals and at all cable breakouts.
b. Disassembly.
After inspection and testing,
disassemble the wire harness only as required for repair
or replacement.
f. Installation. Install the wire harness assembly in
reverse order of removal procedure. After installing
connectors, safety wire in accordance with MS35540
using lockwire MS20995C20.
5-18.
Compressor Wire Harness Assembly
(13217E4157)
a. Removal.
Refer to figure 5-17; tag and
disconnect the compressor wire harness assembly by
removing lockwire and disconnecting the four
connectors (P46, P48, P97, and P98).
c. Cleaning and Inspection.
(1) Clean wire harness with a clean, lint-free
cloth moistened with an approved solvent and dry
thoroughly.
(2) Inspect for damaged or loose connector
pins, damaged wires, and loose or damaged terminal
lugs. Check for any evidence of burned areas indicating
shorts. Inspect connectors for damaged or stripped
threads.
d. Testing. Refer to the wire run chart in figure
516 and check individual wires for continuity.
b. Disassembly.
After inspection and testing,
disassemble the wire harness only as required for repair
or replacement.
e. Repair, Replacement and Reassembly.
c. Cleaning and Inspection.
(1) Solder connections will be made in
accordance with MIL-S-6872 using solder Type
SN60WRP2 per Fed Spec QQ-S-571.
(1) Clean wire harness with a clean, lint-free
cloth moistened with an approved solvent and dry
thoroughly.
(2) Replace defective wires with wire in
accordance with MIL-W-5086, Type II. Wire size and
approximate length in inches is provided in figure 5-16.
5-23
Figure 5-17. Compressor wire harness assembly.
(2) Inspect for damaged or loose connector
connector backshell as new connector is assembled to
pins and damaged wires. Check for any evidence of
the wire harness.
burned areas indicating shorts. Inspect connectors for
(4) If self-clinching cable straps are removed
damaged or stripped threads.
to facilitate repairs, install new cable straps at five inch
intervals and at all cable breakouts.
d. Testing. Refer to the wire run chart in figure
517 and check individual wires for continuity.
f. Installation. Install the wire harness assembly in
reverse order of removal procedure. After installing
e. Repair, Replacement and Reassembly.
connector, safety wire in accordance with MS35540
(1) Solder connections will be made in
using lockwire MS20995C20.
accordance with MIL-S-6872 using solder Type
5-19.
Compressors Wire Harness Assemblies
SN60OWRP2 per Fed Spec QQ-S-571.
(13217E3796 and 13217E41551
(2) Replace defective wires with wire in
a. Removal. Refer to figure 5-18 or 5-19 as
accordance with MIL-W-5086, Type II. Wire size and
applicable: tag and disconnect the compressors ,wire
approximate length in inches is provided in figure 5-17.
harness assembly as follows: (I) Remove lockwire and
disconnect con
(3) If replacement of connectors P97 and P98
is necessary, install sleeving over exposed threads of
5-24
nectors (P45 and P46 for 13217E3796 assembly or P47
and P48 for 13217E4155 assembly).
attach the two connectors (J45, J46 and J47, J4,lt for
each assembly and remove the wire harness.
(2) Remove nuts, washers, and screws that
Figure 5-18. Compressors wire harness assembly.
Figure 5-19. Compressors wire harness assembly.
5-25
and approximate length in inches is provided in figure 518 and 5-19.
b. Disassembly.
After inspection and testing,
disassemble the wire harnesses only as required for
repair or replacement.
(3) If replacement of connector J45 or J47 is
necessary. remove potting compound and unsolder
electrical leads. Fill connector backshell with silicone
rubber sealing compound (510 RTV and Catalyst 501A.
Dow Corning Corp., Midland, Michigan, or equivalent) at
reassembly.
c. Cleaning and Inspection.
(1) Clean wire harness with a clean. lint-free
cloth moistened with an approved solvent and dry
thoroughly.
(4) If self-clinching cable straps are removed
to facilitate repairs, install new cable straps at five inch
intervals and at all cable breakouts.
(2) Inspect for damaged or loose connector
pins. damaged wires. and loose or damaged terminal
lugs. Check for any evidence of burned areas indicating
shorts. Inspect connectors for damaged or stripped
threads.
f. Installation. Install the wire harness assemblies
in reverse order of removal procedure. After installing
connectors. safety wire in accordance with MS35540
using lockwire MS20995C20.
d. Testing. Refer to the wire run chart in figure
518 or 5-19 as applicable and check individual wires for
continuity.
5-20. Compressor and Exhaust Fans Wire Harness
Assembly 113217E4152)
e. Repair, Replacement and Reassembly.
a. Removal.
Refer to figure 5-20; tag and
disconnect the compressor and exhaust fans wire
harness assembly as follows.
(1) Solder connections will be made in
accordance
with MIL-S-6872
using solder Type
SN60OWRP2 per Fed Spec QQ-S-571.
(2) Replace defective wires with wire in
accordance with MIL-W-5086, Type II. Wire size
5-26
Figure 5-20. Compressor and exhaust fans wire harness assembly.
b. Disassembly.
After inspection and testing,
(1) Disconnect wire lead assemblies to
terminal board TB7.
disassemble the wire harness only as required for repair
or replacement.
(2) Remove cable clamp.
c. Cleaning and Inspection.
(3) Remove lockwire, disconnect connectors
P43, P45, P47, P53, P54, and P55 and remove the wire
(1) Clean wire harness with a clean, lint-free
harness.
cloth moistened with an approved solvent and dry
thoroughly.
5-27
(2) Inspect for damaged or loose connector
pins, damaged wires, and loose or damaged terminal
lugs. Check for any evidence of burned areas indicating
shorts. Inspect connectors for damaged or stripped
threads.
d. Testing. Refer to the wire run chart in figure 52f) and check individual wires for continuity.
e. Repair, Replacement and Reassembly.
(1) Solder connections will be made in
accordance with
MIL-S-6872
using solder Type
SN60(!WRP2 per Fed Spec QQ-S-571.
(2) Replace defective wires with wire in
accordance with MIL-W-5086, Type II. Wire size and
approximate length in inches is provided in figure 5-2 0.
(3) If self-clinching cable straps are removed
to) facilitate repairs, install new cable straps at two :,;l'
internals and at all cable breakouts.
f. Installation. Install the wire harness assembly in
reverse order of removal procedure. After installing
connector, safety wire in accordance with MS35540
using lockwire MS20995C20.
5-21.
AC Power Wire Harness Assembly
(13217E4158)
a. Removal.
Refer to figure 5-21; tag and
disconnect the AC power wire harness assembly as
follows:
(1} Remove terminal board covers from
terminal boards (TB3 and TB7) and disconnect wire
leads to the boards.
(2) Remove lockwire; disconnect connectors
P49, P50, and P51; remove nuts, washers, and screws
that attach connectors J49, J50, and J51; remove wire
harness.
Figure 5-21. AC power wire harness assembly.
5-28
electrical leads. Fill connector backshell with silicone
rubber sealing compound (501 RTV and Catalyst 501A,
Dow Corning Corp., Midland, Michigan, or equivalent) at
reassembly.
b. Disassembly.
After inspection and testing,
disassemble the wire harness only as required for repair
or replacement.
c. Cleaning and Inspection.
(4) If self-clinching cable straps are removed
to facilitate repairs, install new cable straps at three inch
intervals and at all cable breakouts.
(1) Clean wire harness with a clean, lint-free
cloth moistened with an approved solvent and dry
thoroughly.
f. Installation. Install the wire harness assembly in
reverse order of removal procedure. After installing
connector, safety wire in accordance with MS35540
using lockwire MS20995C20.
5-22. Temperature Sensors Wire Harness Assembly
(13217E4159)
a. Removal.
Refer to figure 5-22; tag and
disconnect the temperature sensors wire harness
assembly as follows.
(2) Inspect for damaged or loose connector
pins, damaged wires, and loose or damaged terminal
lugs. Check for any evidence of burned areas indicating
shorts. Inspect connectors for damaged or stripped
threads.
d. Testing. Refer to the wire run chart in figure 521 and check individual wires for continuity.
e. Repair, Replacement and Reassembly.
(1) Solder connections will be made in
accordance with MIL-S-6872 using solder Type
SN60WRP2 per Fed Spec QQ-S-571.
(1) Remove lockwire; disconnect connector
P86; then remove nuts, lockwashers, and screws that
attach connector J86.
(2) Replace defective wires with wire in
accordance with MIL-W-5086, Type II. Wire size and
approximate length in inches is provided in figure 5-21.
(2) Disconnect wire leads at temperature
sensors (RT5, RT6, RT7, and RT8).
(3) If replacement of connector J50
necessary, remove potting compound and unsolder
(3) Remove seven loop-type cable clamps
and remove the wire harness.
is
5-29
Figure 5-22. Temperature sensors wire harness assembly.
b. Disassembly.
After inspection and testing,
disassemble the wire harness only as required for repair
or replacement.
d. Testing. Refer to the wire run chart in figure 522 and check individual wires for continuity.
e. Repair, Replacement and Reassembly.
c. Cleaning and Inspection.
(1) Solder connections will be made in
accordance with MIL-S-6872 using solder Type
SN60WRP2 per Fed Spec QQ-S-571.
(1) Clean wire harness with a clean, lint-free
cloth moistened with an approved solvent and dry
thoroughly.
(2) Replace defective wires with wire in
accordance with MIL-W-5086, Type II. Wire size and
approximate length in inches is provided in figure 5-22.
(2) Inspect for damaged or loose connector
pins, damaged wires, and loose or damaged terminal
lugs. Check for any evidence of burned areas indicating
shorts. Inspect connector for damaged or stripped
threads.
(3) If self-clinching cable straps are removed
Figure 5-22.
Temperature sensors wire harness
assembly.
5-30
to facilitate repairs, install new cable straps at five inch
intervals and at all cable breakouts.
disconnect the temperature sensors wire harness
assembly as follows:
(1) Remove
lockwires
and
disconnect
connectors P85 and P93; then remove nuts, washers
and screws that attach connectors J85 and J93.
f. Installation. Install the wire harness assembly in
reverse order of removal procedure. After installing
connector, safety wire in accordance with MS35540
using lockwire MS20995C20.
5-23.
Temperature
Sensors
Assembly (13217E4160)
Wire
(2) Disconnect wire leads to temperature
sensors (RT1, RT2, RT3, and RT4). Remove sensors
from mounts by removing nuts, washers and screws.
Harness
(3) Remove seven loop-type cable clamps
and remove wire harness.
a. Removal. Refer to figure 5-23; tag and
5-31
Figure 5-23. Temperature sensors wire harness assembly.
and approximate length in inches is provided in figure 523.
b. Disassembly.
After inspection and testing,
disassemble the wire harness only as required for repair
or replacement.
(3) Replace defective or inoperative sensors.
c. Cleaning and Inspection.
(4) If self-clinching cable straps are removed
to facilitate repairs, install new cable straps at five inch
intervals and at all cable breakouts.
(1) Clean wire harness with a clean, lint-free
cloth moistened with an approved solvent and dry
thoroughly.
f. Installation. Install the wire harness assembly in
reverse order of removal procedure. After installing
connector, attach safety wire in accordance with
MS35540 using lockwire MS20995C20.
5-24. Battery Wire Harness Assembly (13217E4168)
a. Removal.
Refer to figure 5-24; tag and
disconnect the battery wire harness assembly as follows:
(2) Inspect for damaged or loose connector
pins, damaged wires, and loose or damaged terminal
lugs. Check for any evidence of burned areas indicating
shorts. Inspect connectors for damaged or stripped
threads.
d. Testing. Refer to the wire run chart in figure 523 and check individual wires for continuity.
(1) Remove the battery clamps. Observe
polarity of leads for correct installation after repair.
e. Repair, Replacement and Reassembly.
(1) Solder connections will be made in
accordance with MIL-S-6872 using solder Type
SN60OWRP2 per Fed Spec QQ-S-571.
(2) Replace defective wires with wire in
accordance with MIL-W-5086, Type II. Wire size
5-33
Figure 5-24. Battery wire harness assembly.
(2) Disconnect wire leads to ground terminal
El and to connector J2.
(3) Disconnect connector P64 and remove
nuts, washers, and screws that attach connector J64.
Then remove the wire harness.
b. Disassembly.
After inspection and testing,
disassemble the wire harness only as required for repair
or replacement.
c. Cleaning and Inspection.
(1) Clean wire harness with a clean, lint-free
cloth moistened with an approved solvent and dry
thoroughly.
(2) Inspect for damaged or loose connector
pins, damaged wires, and loose or damaged terminal
lugs and battery clamps. Check for any evidence of
burned areas indicating shorts. Inspect connector for
damaged or stripped threads.
d. Testing. Refer to the wire run chart in figure
524 and check individual wires for continuity.
e. Repair, Replacement and Reassembly
(1) Solder connections will be made in
accordance with MIL-S-6872 using solder Type
SN60OWRP2 per Fed Spec QQ-S-571.
(2) Replace defective wires with wire in
accordance with MIL-W-5086, Type II. Wire size and
approximate length in inches is provided in figure 5-24.
(3) If replacement of connector J64 is
necessary, remove potting compound and unsolder
electrical leads. Fill connector backshell with silicone
rubber sealing compound (501 RTV and Catalyst 501A,
Dow Corning Corp., Midland, Michigan, or equivalent) at
reassembly.
(4) If self-clinching cable straps are removed
to facilitate repairs, install new cable straps at five inch
intervals and at all cable breakouts.
f. Installation. Install the wire harness assembly in
reverse order of removal procedure. After installing
connector, safety wire in accordance with MS35540
using lockwire MS20995C20.
5-25. Heat Valves Wire Harness Assembly
(13217D4163)
a. Removal.
Refer to figure 5-25; tag and
disconnect the heat valves wire harness assembly as
follows:
(1) Remove
lockwire
and
disconnect
connector P89; then remove nuts, washers, and screws
that attach connector J89.
(2) Remove
connectors P90, P91.
lockwire
and
disconnect
(3) Remove five loop-type cable clamps and
remove the wire harness.
Figure 5-25. Heat valves wire harness assembly.
5-35
by defective current transformers. Both 60 Hz and 1400 Hz
ammeters read full scale for 100 ma. Check alumel-chromel
leads, resistor, and exhaust gas thermocouple at the engine
before replacement of the exhaust gas temperature indicator.
b. Disassembly. After inspection and testing,
disassemble the wire harness only as required for repair or
replacement.
c. Cleaning and Inspection.
(1) Clean wire harness with a clean, lint-free cloth
moistened with an approved solvent and dry thoroughly.
(4) Test switches and relays by. continuity check.
Refer to the power plant schematic and wiring diagram in TM
5-6155-586-12 for switch and relay contact arrangement.
(2) Inspect for damaged or loose connector pins
and damaged wires. Check for any evidence of burned areas
indicating shorts. Inspect connectors for damaged or stripped
threads.
(5) Replace all parts that are damaged beyond
simple repair and all parts that are proven defective by
testing.
c. Reassembly and Installation. Refer to TM 56115586-12 for reassembly and installation instructions.
d. Testing. Refer to the wire run chart in figure 525 and
check individual wires for continuity.
5-27. Conditioned Air System
Panel
e. Repair, Replacement and Reassembly.
a. Removal and Disassembly. Refer to TM 56115-58612 for removal and disassembly instructions.
(1) Solder connections will be made in
accordance with MIL-S-6872 using solder Type SN60WRP2
per Fed Spec QQ-S-571.
b. Cleaning and Inspection. Refer to TM 56115-586-12
and perform cleaning and inspection procedures as
instructed.
(2) Replace defective wires with wire in
accordance with MIL-W-5086, Type II.
Wire size and
approximate length in inches is provided in figure 5-25.
c. Testing.
(3) If self-clinching cable straps are removed to
facilitate repairs, install new cable straps at two inch intervals
and at all cable breakouts.
(1)
Test time delay (K17, K18) as follows:
(a) Connect the negative side of a 24 VDC
source to pin E of the relay connector.
f. Installation. Install the wire harness assembly in
reverse order of removal procedure.
After installing
connectors, safety wire in accordance with MS35540 using
lockwire MS20995C20.
(b) Connect +24 VDC to pin C; then check
for closed circuit between pin D and pin H, and an open circuit
between pin D and pin G.
5-26. Instrument Panel Assembly
(c) Connect +24 VDC to pin A (-24 VDC
lead remains at pin E); then check that circuit opens between
pin D and pin H, and closes between pin I) and pin G.
a. Removal, Disassembly, Cleaning and Inspection.
Refer to TM 5-6115-586-12 for these instructions.
(d) Check the time delay by connecting
ohmmeter across pin A and pin F. The ohmmeter should
indicate an open circuit. Connect -24 VDC lead to pin B and
+24 VDC lead to pin D and check the ohmmeter indicates
closing of pin A to pin F circuit within 30 ± 3 seconds for K17
and within 60 ± 6 seconds for K18.
b. Repair, Testing, and Adjustments.
(1) Test and repair the panel wire harness
assembly as follows.
(a) Refer to the wire run chart in figure FO1 (located in back of manual) and check individual wires for
continuity.
(e) If the relay does not operate properly in
any of the above tests, it is defective and must be replaced.
(b) Replace defective wires with wire in
accordance with MIL-W-5086, Type II.
Wire size and
approximate length in inches is provided in figure FO-1.
(2) Test relays K23, K24, K25 and K26 by
applying a source of 24 VDC across the coil (observe polarity:
positive to terminal X 1; negative to terminal X2) and checking
that the three sets of N.O. contacts (L1-T1, L2-T2, and L3T3) close with power applied and that there are no short
circuits between them. Check that circuits open when 24 VDC
source is disconnected.
(c) Solder connections in accordance with
MIL-S-6872 using solder Type SN60WRP2 per Fed Spec QQS-571.
(d) If self-clinching cable straps are
removed to facilitate repairs, install new straps at two inch
intervals and all cable breakouts.
(3) Test relays K19, K20, K27 with 24 VDC
source across the coil (observe polarity, positive to terminal
X1; negative to NEG). Contact arrangement is A1-A2 N.O.,
B1-B2 N.O., CI-C2 N.O., 11-12 N.O. and 12-13 N.C.
(2) Meters may be electrically tested by
comparison with calibrated standard meters. Adjust meters
by turning adjustment screw, located in face of meter, until
meters read the same as the calibrated standard meters. If
synchronization of meters is unobtainable, replace inoperative
meter.
(3) Test ammeters before replacement
incorrect readings during operation may be caused
Electrical Components
as
5-36
(5) Refer to wire run chart in figure and check
continuity of individual wires in. the air conditioning
power wire harness assembly.
(4) Test relay K21 and 24 VDC across the
coil (positive to X1 and negative to X2). Contact
arrangement is: A1-A3 N.O., A2-A3 N.C., T1-L1 N.O.,
T1-L11 N.C., T2-L2 N.O., T2-L12 N.C., T3-L3 N.O., T3L13N.C.
Figure 5-26. Air conditioning power wire harness assembly.
5-37
(6) Refer to wire run chart in figure 5-27 and
check continuity of individual wires in the DC power wire
harness assembly.
Figure 5-27. DC power wire harness assembly.
5-38
(7) Refer to wire run chart in figure 5-28 and
check continuity of individual wires in the two
compressors wire harness assemblies.
Figure 5-28. Compressors wire harness assembly.
5-39
(8) Refer to wire run chart in figure 5-29 and
check continuity of individual wires in the remote fans
wire harness assembly.
Figure 5-29. Remote fans wire harness assembly.
5-40
(9) Refer to wire run chart in figure 5-30 and
check continuity of individual wires in the condenser
fans wire harness assembly.
Figure 5-30. Condenser fans wire harness assembly.
5-41
(10) Refer to wire run chart in figure 5-31 and
check continuity of individual wires in the recirculating
fans wire harness assembly.
Figure 5-31. Recirculating fans wire harness assembly.
5-42
(11) Refer to wire run chart in figure 5-32 and
check continuity of individual wires in the remote power
wire harness assembly.
Figure 5-32. Remote power wire harness assembly.
compressors wire harness assemblies and recirculating fans
wire harness assembly where they shall be installed at two
inch intervals. Cable straps shall also be installed at all cable
breakouts.
d. Repair and Replacement.
(1) Replace all parts that are damaged beyond
simple repair; replace all missing or defective hardware.
Replace damaged nut plates or loose rivets on the panel.
(2)
e. Reassembly and Installation. Refer to TM 56115-58612 for reassembly and installation instructions.
Repair wire harness assemblies as follows:
(a) Disassemble
the
wire
harness
assemblies only as required for repair or replacement.
5-28. Auxiliary Power Tray Assembly
a. Removal. Refer to paragraph 2-13 a of this manual
for removal instructions.
(b) Solder connections shall be made in
accordance with MIL-S-6872 using solder Type SN60WRP2
per Fed Spec QQ-S-571.
b. Disassembly. Refer to figure 5-33 and disassemble
the auxiliary power tray assembly as follows: (I) Disconnect
leads 'of 400 Hz auxiliary power wire harness (4) from relays
K43A and K43B (27). and from thermal relays S37A, S37C,
S38A. and S38C (26).
(c) Replace defective wires with wire in
accordance with MIL-W-5086, Type II.
Wire size and
approximate length in inches is provided in applicable wire run
charts.
(d) If self-clinching cable straps are
removed to facilitate repairs, install new cable straps at three
inch intervals on all wire harness assemblies except
5-43
and 9) from the capacitor mounting brackets (15). Push
insulated sleeving (10) back far enough to disconnect
wire harness leads from the capacitors.
(2) Remove nuts (1), washers (2) and screws
(31 that attach wire harness connector. Carefully pull
disconnected wire harness (4) through grommets (28)
and remove the harness.
(4) Remove nuts (11), washers (12 and 13)
and screws (14) to remove capacitor mounting brackets
(15), wire harnesses (16 and 17) and gaskets (18).
(3) Remove the leads of the 400 Hz auxiliary
wire harnesses (16 and 17) from relays K43A and K43B.
Remove nuts (5), three washers (6), and screw (7) to
remove each of the six capacitors (8
5-44
Figure 5-33. Auxiliary power tray assembly.
5-45
KEY to figure 5-33.
(6) Remove screws (22 and 23) with washers
(24 and 25) to remove six thermal relays (26) and two
armature relays (27) from the panel (29).
1. Nut
2. Washer
3. Screw
4. 400 Hz auxiliary power wire harness
5. Nut
6. Washer
7. Screw
8. Capacitor (C26. C29)
9. Capacitor (C25, C27, C28, C30)
10. Insulated Sleeving
11. Nut
12. Washer
13. Washer
14. Screw
15. Capacitor mounting bracket
16. 400 Hz auxiliary output wire harness
17. 400 Hz auxiliary output wire harness
18. Gasket
19. Bus bar
20. Bus bar
21. Insulated sleeving
22. Screw
23. Screw
24. Washer
25. Washer
26. Thermal relay (S37A, S37B, S37C, S38A,
S38B, S38C}
27. Armature relay (K43A, K43B)
28. Grommet
29. Panel
(7) If replacement is necessary, remove two
grommets (28) from the panel.
c. Cleaning, Inspection and Testing.
(1) Clean electrical components with a clean
rag dampened with solvent approved for electrical
components.
(2) Inspect relays for damaged terminal
studs, cracked cases, signs of overheating or short
circuit.
(3) Test capacitors
capacitor tester, if available.
(4) Inspect gaskets
damage or deterioration.
for
and
leakage
with
grommets
a
for
(5) Inspect wire harness assemblies for dam
aged or loose connector pins and terminal lugs,
damaged wires, any burned areas indicating shorts.
Inspect connectors for damaged or stripped threads.
(6) Refer to the wire run chart in figure 5-34
for 400 Hz auxiliary power wire harness, figure 535 for
400 Hz auxiliary output 1 wire harness, and figure 5-36
for 400 Hz auxiliary output 2 wire harness, and check
individual wires for continuity.
(5) Note connection points, then remove four
bus bars (19) from the thermal relays (26) and six bus
bars (20) that connect thermal relays to armature relays
(27). Do not remove insulation sleeving (21) unless
replacement is required.
d. Repair and Replacement.
(1) Repair wire harness assemblies
follows, disassembling only as necessary.
5-46
as
Figure 5-34. 400 Hz auxiliary power wire harness.
5-47
Figure 5-35. 400 Hz auxiliary output 1 wire harness assembly.
5-48
Figure 5-36. Hz auxiliary output 2 wire harness assembly
f. Installation. Refer to paragraph 2-13 of this
manual for installation instructions.
5-29. Receptacle Panel Assembly
a. Removal and Disassembly. Refer to TM 56115586-12 for instructions regarding removal and
disassembly of receptacle panel assembly.
(a) Solder connections will be made in
accordance with MIL-S-6872 using solder Type
SN60OWRP2 per Fed Spec QQ-S-571.
(b) Replace defective wires with wire in
accordance with MIL-W-5086, Type II. Wire size and
approximate length in inches is provided in wire run
charts (fig. 5-34 through 5-36).
b. Cleaning and Inspection. Refer to TM 561 15586-12 for cleaning and inspection procedures for
receptacle panel assembly components.
(c) If self clinching cable straps are
removed to facilitate repair, replace them with new
cable straps.
c. Testing.
(2) Replace all components found to be dam
aged or defective.
(1) Test capacitors for shorts and leakage
with capacitor tester.
(3) Replace damaged nut plates and loose
rivets on panel. Repair bent panel and capacitor
mounting brackets by simple shop repair.
(2) Refer to wire run chart in figure 5-37 and
test individual wires for continuity in the water heater
wire harness.
e. Reassembly. Reassemble the auxiliary, power
tray assembly by reversing disassembly sequence given
in paragraph 5-28 b. above.
5-49
\
Figure 5-37. Water heater wire harness assembly.
5-50
(3) Refer to wire run chart in figure 5-38 and
test individual wires for continuity in the receptacle
panel wire harness.
Figure 5-38. Receptacle panel wire harness assembly.
5-51
{4) Refer to wire run chart in figure 5-39 and
test individual wires for continuity in 60 Hz output wire
harness assembly (13217E4199).
Figure 5-39. 60 Hz output wire harness assembly.
5-52
(5) Refer to wire run charts in figure 5-40 and 5-41
and test individual wires for continuity in the 400 Hz
output wire harness assemblies (13217E4200 and
13217E4201, respectively).
Figure 5-40. 400 Hz output wire harness assembly.
5-53
Figure 5-41. 400 Hz output wire harness assembly.
5-54
(6) Refer to wire run chart in figure 5-42 and test
individual wires for continuity in the DC standby wire
harness assembly.
Figure 5-42. DC standby wire harness assembly.
(7) Refer to figure 5-43 and check slave
receptacle cable assembly.
Figure 5-43. Slave receptacle cable assembly.
5-55
(8) Refer to wire run chart in figure 5-44 and test
individual wires for continuity in the 60 Hz output wire
harness assembly (13217E4358).
Figure 5-44. 60 Hz output wire harness assembly.
d. Repair and Replacement.
(e) Replace connectors with defective or
(1) Repair wire harness and cable assemblies as
missing covers or any defect which would prevent
follows:
proper weather-seal of connector covers.
(a) Disassemble cable only as necessary for
(2) Replace receptacle covers that do not
provide proper weather-seal.
repair.
(3) Repair bent panel by simple shop repair.
(b) Replace wires found to be defective in
(4) Replace all other components found to be
tests (step f. above) or that were noted to be dam aged
defective through inspection or testing.
during inspection with wire in accordance with MIL-We. Reassembly and Installation. Refer to TM
5086, Type II. Wire size and approximate length in
56115-586-12
for
reassembly
and
installation
inches is provided in the wire run charts in the
instructions.
illustrations referenced for testing.
(c)
Solder connections will be in
5-30. Conditioned Air Temperature Control Panel
accordance with MIL-S-6872 using solder Type
Assembly
SN60WRP2 per Fed Spec QQ-S-571.
a. Removal, Disassembly, Cleaning and Inspection.
(d) If self-clinching cable straps are
Refer to TM 5-6115-586-12 for instructions regarding
removed to facilitate repairs, replace them with new
removal and disassembly of the temperature control
cable straps at same interval and at cable breakouts.
panel, and cleaning and inspection of components.
5-56
temperature control switches. If one system is not
operating properly. interchanging the like switches is a
simple test.
if the same system continues
to
malfunction, the sensor or wiring is defective. If the
opposite system malfunctions instead, the switch is
defective.
b. Testing.
(1) The heat range selector switches are rotary,
2 pole, 4 position, non-shorting switches. An ohmmeter
check of open and closed circuits in each position may
be made to determine if switch is serviceable.
(3) Refer to the wire run chart in figure 5-45 and
test individual wires for continuity for the air conditioning
and heat control panel wire harness assembly. Lamps
are 24 VDC.
(2) The air temperature control switches operate
with the temperature sensors. Incorrect operation may
be due to failure of either the switch or the sensor. As
two conditioned air systems are used, there are two heat
temperature control switches and two cooled air
5-57
Figure 5-45. Air conditioning and heat control panel wire harness assembly.
5-58
(3) Replace all other parts found to be
defective through inspection or testing.
d. Reassembly and installation. Refer to TM 5611
5-586-12 for reassembly and installation instructions.
5-31. Electrical Leads and Jumpers
a.
General.
This paragraph contains repair
instructions for all single wire electrical leads and
jumpers used in the power plant, including the battery
interconnecting lead. The chart in figure 546 lists wire
numbers. terminations, and assembly where the lead is
used. Locate the wire to be repaired in the listing and
then follow the general instructions in this paragraph.
c. Repair and Replacement.
(1) Repair the wire harness assembly as
follows:
(a)
Solder connections will be made in
accordance with MIL-S-6872 using solder Type
SNL'60WRP2 per Fed Spec per QQ-S-571.
(b)
Replace defective wires with wire in
accordance with MIL-W-5086, Type II. Wire size and
approximate length in inches is provided in figure 5-4/i.
(c)
If self-clinching cable straps are
removed to facilitate repairs, install new cable straps at
five inch intervals and at all cable breakouts.
(2) Bent panel may be repaired by simple shop
repair.
Figure 5-46. Electrical leads.
5-59
(3) If lugs on battery electrical lead must be
replaced, unscrew them from adapter and install new
lugs. If adapter must be replaced, solder to wire in
accordance with MIL-S-6872 using solder Type
SN60OWRP2 per Fed Spec QQ-S-571.
d.
Installation.
Reconnect electrical leads in
locations as tagged or utilize termination data in wire run
chart in figure 5-46.
b. Removal and
Disassembly. Tag
and
disconnect electrical lead. Disassemble only for repair.
c. Inspection and Repair.
(1) Inspect electrical lead for damaged or loose
terminals, damaged wire or insulation.
(2) Repair leads by replacing defective wire and
terminals. S' ire size and approximate length in inches
is provided.
Section II. ENGINE AND SKID ELECTRICAL INSTALLATION
Be certain that bushings and mica washers are correctly
installed on diodes at assembly.
5-32. General
The engine and skid electrical installation consists of the
upper electric power chassis assembly, the lower
electric power chassis assembly and interconnecting
wire harness assemblies. There are four wire harness
assemblies in the installation, the engine skid wire
harness on the lower power chassis, the power wire
harness, and the battery wire harness. The engine wire
harness repair instructions are provided in paragraph 32 of this manual. Electrical leads and jumpers are
included in -paragraph 5-31 above.
(b) Solder connections will be made in
accordance with MIL-S-6872 using solder Type
SN60OWRP2 per Fed Spec QQ-S-571.
(c) Replace defective wires with wire in
accordance with MIL-W-5086, Type II. Wire size and
approximate length in inches is provided in figure FO-2.
5-33. Upper Electric Power Chassis Assembly
(d) If self-clinching cable straps are
removed to facilitate repairs, install new cable straps at
reassembly.
a. Removal and Disassembly. Refer to TM 561 11
5-586-12 for instructions regarding removal of the upper
electric power chassis assembly and removal of
components.
(2) Replace damaged nut plates and loose or
missing rivets on chassis. Repair bent chassis by
simple shop repair.
(3) Replace all other parts found to be defective
through inspection or testing. Defective battery charger
and voltage regulators shall be replaced and defective
units sent to depot maintenance facilities for repair.
b. Cleaning, Inspection and Testing. Cleaning,
inspection, and testing instructions are provided in TM
5-6115-586-12. Also refer to figure FO-2 located in
back of manual) for a wire run chart for the engine skid
power unit wire harness as an aid to testing. Test
diodes on wire harness ICR through CR20) with an
ohmmeter; a serviceable diode will indicate a low
resistance in one direction (forward biased! and a
significantly higher resistance when ohmmeter lead
connections are reversed (reverse bias ). A diode that
indicates an open circuit or near the same resistance in
both directions is defective.
d. Reassembly and Installation. Refer to TM
56115-586-12
for
reassembly
and
installation
instructions.
5-34. Lower Electric Power Chassis Assembly
a. Removal and Disassembly. Refer to TM 56115586-12 for removal and disassembly instructions.
c. Repair and Replacement.
b. Cleaning, Inspection and Testing. Cleaning,
inspection, and testing instructions are provided in TM
5-6115-586-12. Also refer to figure 5-47 for a wire run
chart for the engine skid wire harness as an aid to
testing.
(1) Repair the wire harness assembly as follows:
(a) When replacing diodes, use a pair of
pliers or a clip as a "heat sink" to avoid damage to the
new-diode when soldering it to the wire harness lead.
5-60
Figure 5-47. Engine skid power unit wire harness assembly.
5-61
and voltage regulators shall be replaced and defective
units sent to depot maintenance facilities for repair.
d. Reassembly and Installation. Refer to TM 56115-586-12
for reassembly
and
installation
instructions.
c. Repair and Replacement.
(1) Repair the wire harness assembly as follows:
(a) Solder connections will be made in
accordance with MIL-S-6872 using solder Type
SN60OWRP2 per Fed Spec QQ-S-57 1.
(b) Replace defective wires with wire in
accordance with MIL-W-5086, Type II. Wire size and
approximate length in inches is provided in figure 5-4li.
(c)
If self-clinching cable straps are
removed to facilitate repairs, replace with new straps at
same interval and at all cable breakouts.
(2) Replace damaged nut plates and loose or
missing rivets on chassis. Repair bent chassis by
simple shop repair.
(3) Replace all other parts found to be defective
through inspection or testing. Defective battery charger
5-35. Power Wire Harness Assembly
(13217E4001)
a.
Removal.
Refer to figure 5-48; tag and
disconnect the power wire harness assembly as follows:
(1) Disconnect the wire harness leads to GI, KII.
K12, and SI0.
(2) Remove lockwires and disconnect the three
connectors (P49, P50 and P51); then remove the w ire
harness assembly.
5-62
Figure 5-48. Power wire harness assembly
b. Disassembly. After inspection and testing,
d. Testing. Refer to the wire run chart in figure 5-48
disassemble the wire harness only as required for repair
and check individual wires for continuity.
or replacement.
e. Repair, Replacement and Reassembly.
c. Cleaning and Inspection.
(1) Solder connections will be made in
(1) Clean wire harness with a clean, lint-free
accordance with MIL-S-6872 using solder Type
cloth moistened with an approved solvent and dry
SN60WRP2 per Fed Spec QQ-S-571.
thoroughly.
(2) Replace defective wires with wire in
(2) Inspect for damaged or loose connector pins,
accordance with MIL-W-5086, Type II. Wire size and
damaged wires, and loose or damaged terminal lugs.
approximate length in inches is provided in figure 5-48.
Check for any evidence of burned areas indicating
(3) If self-clinching cable straps are removed to
shorts. Inspect connectors for damaged or stripped
facilitate repairs, install new cable straps at same
threads.
intervals and at all cable breakouts.
5-63
disconnect the battery wire harness assembly as follows:
(1) Disconnect wire leads from BI, KI, K16, and
K33.
(2) Remove lockwire; disconnect connector P64
and remove wire harness assembly.
f. Installation. Install the wire harness assembly
in reverse order of removal procedure. After installing
connector, safety wire in accordance with MS35540
using lockwire MS20()995C20.
5-36. Battery Wire Harness Assembly
13217E41.54)
a. Removal. Refer to figure 5-49; tag and
Figure 5-49. Battery wire harness assembly.
e. Repair, Replacement and Reassembly.
(1) Solder connections will be made in
accordance with MIL-S-6872 using solder Type
SN60WRP2 per Fed Spec QQ-S-571.
(2) Replace defective wires with wire in
accordance with MIL-W-5086, Type II. Wire size and
approximate length in inches is provided in figure 5-49.
(3) If self-clinching cable straps are removed to
facilitate repairs, install new cable straps at two inch
intervals and at all cable breakouts.
f. Installation. Install the wire harness assembly in
reverse order of removal procedure. After installing
connector, safety wire in accordance with MS35540
using lockwire M S20()995C20.
b. Disassembly. After inspection and testing,
disassemble the wire harness only as required for repair
or replacement.
c. Cleaning and Inspection.
(1) Clean wire harness with a clean, lint-free
cloth moistened with an approved solvent and dry
thoroughly.
(2) Inspect for damaged or loose connector pins,
damaged wires, and loose or damaged terminal lugs.
Check for any evidence of burned areas indicating
shorts. Inspect connectors for damaged or stripped
threads.
d. Testing. Refer to the wire run chart in figure 5-49
and check individual wires for continuity.
5-64
CHAPTER 6
REPAIR OF CONDITIONED AIR COOLING SYSTEM
Section I. TUBE ASSEMBLIES AND PLUMBING FITTINGS
b. Cleaning, Inspection and Repair.
(1) Clean tube assemblies and fittings with
kerosene and degrease with trichlorethylene IMILT7003) heated to 1600 to 1800 F in a vapor degreaser.
Warning: Trichlorethylene (MIL-T-7003) is toxic
and should be used only in a well ventilated area.
Failure to observe this warning may result in
serious harm or death to personnel.
(2) Inspect flared tube fittings and hardware for
stripped, crossed, peened, or otherwise damaged
threads.
(3) Inspect tube assemblies for cracks, dents,
corrosion, or other obvious damage.
6-1. General
The conditioned air cooling systems consists of two
separate air conditioning refrigeration systems. Each
separate system consists of compressor, evaporator,
condenser, receiver, and tubing interconnecting these
components.
6-2.
Tube Assemblies, Fittings, and Solenoid
Valves
a. Removal. Remove the tube assemblies, fittings,
and valves by following the ascending numerical
sequence, of the index numbers I through 187 assigned
to figure 6-1.
Note. Each tube assembly is independent of the others
and it is not necessary to completely disassemble the system
to repair or replace any one tube assembly. Only the tube
requiring such repair need be removed.
6-1
Figure 6-1. Conditioned air cooling system, exploded view. (sheet 1 of 6)
6-2
Key to figure 6-1.
1. Pressure switch
2. Gasket
3. Tube assembly
4. Union
5. Gasket
6. Nut
7. Flatwasher
8. Bolt
9. Bolt
10. By-pass tube
11. Rubber seal
12. Rubber seal
13. Solenoid valve
14. Tube assembly
15. Grommet
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
Union
Gasket
Nut
Flatwasher
Bolt
Tube assembly
Rubber seal
Nut
Flatwasher
Bolt
Bolt
Tube assembly
Grommet
Rubber seal
Tube assembly
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
6-3
Rubber seal
Rubber seal
Solenoid valve
Cap
Valve
Nut
Flatwasher
Bolt
Tube clamp
Nut
Flatwasher
Bolt
Tube assembly
Grommet
Rubber seal
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
Nut
Flat washer
Bolt
Tube assembly
Rubber seal
Nut
Flat washer
Bolt
Rubber seal
Nut
Flat washer
Bolt
Tube assembly
Rubber seal
Figure 6-1. Conditioned air cooling system, exploded view. (sheet 2 of 6)
6-4
Key to figure 6-1-Continued:
69. Rubber seal
60. Nut
61. Flat washer
62. Bolt
63. Tube assembly
64. Rubber seal
65. Nut
66. Flat washer
67. Bolt
68. Tube assembly
69.
70.
71.
72.
73.
74.
75.
76.
77.
78.
Tube assembly
Nut
Flat washer
Bolt
Tube assembly
Rubber seal
Grommet
Nut
Flat washer
Bolt
79.
80.
81.
82.
83.
84.
85.
86.
87.
88.
6-5
Tube assembly
Rubber seal
Grommet
Cap
Valve
Nut
Flat washer
Bolt
Tube assembly
Rubber seal
89.
90.
91.
92.
93.
94.
95.
0)6.
97.
98.
Tube Assembly
Union
Grommet
Gasket
Nut
Flat washer
Spacer
Bolt
Compressor
Spacer
Figure 6-1. Conditioned air cooling system, exploded view. (sheet 3 of 6)
6-6
Key to figure 6-1-Continued:
99.
Cap
100.
Valve
101.
Nut
102.
Flat washer
103.
Bolt
104.
Tube assembly
105.
106.
107.
108.
109.
110.
111.
Rubber seal
Tube assembly
Union
Gasket
Grommet
Nut
Flat washer
112.
113.
114.
115.
116.
117.
118.
6-7
Spacer
Bolt
Compressor
Spacer
Nut
Flat washer
Bolt
119.
120.
121.
122.
123.
124.
125.
Rubber seal
Tube assembly
Check valve
Nut
Flat washer
Bolt
Solenoid valve
Figure o-1. Conditioned air cooling system, exploded view. (sheet 4 of 6)
6-8
Keyto figure 6-1-Continued:
126.
Nut
127.
Flat washer
128.
Bolt
120.
Brace
130.
Brace
131.
132.
133.
1:34.
135.
136.
Bolt
Bolt
Flat washer
Fan housing
Nut
Flat washer
137.
138.
139.
140.
141.
142.
6-9
Bolt
Tube assembly
Rubber seal
Bolt
Flat washer
Tube assembly
143.
144.
145.
146.
147.
Rubber seal
Bolt
Flat washer
Rubber strip
Evaporator
Figure 6-1. Conditioned air cooling system, exploded view. (sheet 5 of 6)
6-10
KEY to figure 6-1-Continued:
148.
Nut
149.
Flat washer
150.
Bolt
151.
Tube assembly
152.
Rubber seal
153.
Grommet
154.
155.
156.
157.
158.
159.
Nut
Flat washer
Bolt
Tube assembly
Rubber seal
Grommet
160.
161.
162.
163.
164.
165.
6-11
Bolt
Solenoid valve
Tube assembly
Grommet
Dehydrator
Gasket
166.
167.
168.
169.
170.
171.
Nut
Lockwasher
Bolt
Tube assembly
Rubber seal
Grommet
Figure 6-1. Conditioned air cooling system, exploded view. (sheet 6 of 6)
6-12
KEY to figure 6-1-Continued:
172.
Nut
173.
Flat washer
174.
Bolt
175.
Tube assembly
176.
Rubber seal
177.
Cap
178.
Valve
179.
Hose clamp
180.
181.
182.
183.
184.
185.
186.
187.
(4) Replace all rubber seals and gaskets each
time tube assemblies are removed.
(5) Replace valves found to be defective
through troubleshooting and testing.
(6) Replace all other parts damaged beyond
simple repair.
c. Installation. Install the tube assemblies and
fittings by reversing the procedures required to remove
them.
Receiver
Screen
Screw
Flat washer
Bolt
Flat washer
Foam tape
Condenser
Section II. COMPRESSORS, CONDENSER, AND EVAPORATORS
emphasis on sub-paragraph (4)
replacement of seals and gaskets.
6-3. General
No major repairs on the compressors, condensers, and
evaporators shall be performed at this maintenance
level. It, however, is the responsibility of Direct Support
Maintenance to test and replace the condensers and
evaporators as necessary. Also, minor services to the
compressors shall be performed at this level in addition
to replacement of the entire assembly.
6-4. Compressors
a. Removal.
(1) Tag the electrical wire harnesses to facilitate
reinstallation. Disconnect the wire harnesses.
(2) Tag the tube assemblies prior to removal to
facilitate reinstallation.
Disconnect all tubing that
connects to the compressor.
(3) Remove the nuts (93, fig. 6-1, sheet 2 of 6),
washers (94), spacers (95), and bolts (96). Remove the
compressor (97) from the mount and remove the
spacers (98). Remove the other compressor (114, fig.
6-1, sheet 3 of 6) in the same manner.
b. Installation.
(1) Position the spacers (98, figure 6-1, sheet 2
of 6) and the compressor (97) on the mount. After
aligning the holes, insert bolts (96) and washers (94)
through the bottom. Replace the spacers (95) and
secure the compressor using the nuts (93) and washers
(94).
(2) Install the tube assemblies.
which
requires
the
(3) Install all electrical wire harnesses.
c. Service
(1) Refrigerant filter. This filter is located on
the bottom of the compressor motor housing and is
designed to filter the refrigerant entering the
compressor.
The
filter
should
be
replaced
periodically as some foreign material will accumulate
within it. The gaskets must also be replaced each time
the filter is replaced.
(2) Thermostatic switch.
(a) This switch assembly is located in a well
at the lower portion of the motor housing assembly. The
switch assembly consists of a shield, thermostat, and an
electrical connector.
(b) The switch is designed to open (break
the circuitry to the compressor) when the motor housing
reaches 225° ± 15°F (107.2° ± 9.4°C). When the
compressor housing cools down to 165° ± 15°,F (73.9°
± 9.4 C, the switch will close again to allow the
compressor to resume operation.
(c) If the switch should fail to close after the
compressor housing has cooled to the required
temperature, remove the switch and inspect it in
accordance with requirements shown in figure 6-2.
Check also for damage to the pins of the connector.
(d)
Replace a switch found to have
damaged pins.
(e) Replace a switch that does not meet the
requirements shown in figure 6-2.
Note. Prior to installing tube assemblies, observe the
instructions given in paragraph 6-2b for the cleaning,
inspection, and repair of tube assemblies and fittings with the
6-13
Figure 6-2. Thermostatic switch assembly inspection requirements.
6-5. Condensers
a. Removal.
(1) Disconnect the tube assemblies that connect
to the condensers.
(2) Remove the screws (182, fig. 6-1, sheet 6 of
6) and washers (183) at the sides of the condensers.
Remove the bolts (184) and washers (185) at the top of
the condensers. Remove the foam tape (186) and
condensers (187) from the power plant.
b. Testing.
(1) Pressure test condenser as follows:
(a) Attach end seal plates (see Special
Tools, table 2-1) to condenser ports.
(b) Apply compressed air at refrigerant
vapor inlet duct seal, pressurize condenser to 148 ± 2.0
psig, and immerse condenser in water for five minutes.
There must be no leakage indicated by bubbles, or
evidence of permanent deformation of condenser as a
result of pressure applied during test.
(c) Dry condenser as thoroughly as possible
with compressed air, and complete drying by heating in
an oven for at least one hour at 250° F (121.1° C)
maximum.
(2) Test condenser for refrigerant leakage as
follows.
(a) Seal condenser as instructed (para b (1)
(a) ) above.
(b) Connect unit refrigerant inlet to
refrigeration system in service unit (para 2-4 b) as
shown in figure 6-3. Use synthetic rubber tubing in test
setup.
(c) Open valve connecting condenser to
vacuum pump and evacuate condenser for at least 15
minutes at maximum pressure of 0.5 inch of mercury
absolute.
(d) Shut off valve to vacuum pump and
charge condenser by permitting refrigerant gas to flow
into condenser until no more flow occurs.
Figure 6-3. Refrigerant leakage test setup.
6-14
rubber strips (146) from the power plant.
b. Testing.
(1) Pressure test evaporators.
(a) Attach adapter flange plates (see
Special Tools, table 2-1) to evaporator ports.
(b) Apply compressed air at refrigerant inlet
flange, pressurize evaporator to 148 ± 2.0 psi gauge,
and immerse in water for five minutes. There must be
no leakage indicated by complete absence of bubbles,
or evidence of permanent deformation of evaporator as
a result of pressure applied during test.
(c) Dry evaporators as thoroughly as
possible with compressed air and complete drying by
heating in an oven for at least one hour at 250° F
(121.1°C) maximum.
(2) Test evaporator for refrigerant leakage.
(a) Seal evaporator as outlined in paragraph
(1) above.
(b) Connect refrigerant inlet to the
refrigeration system service unit (para 2-4b) as shown in
figure 6-4.
(c) Open valve connecting evaporator to
vacuum pump-and evacuate evaporator for at least 15
minutes at maximum pressure of mercury absolute.
(d) Shut off valve to vacuum pump and
charge evaporator to 60 ± 5 psi with refrigerant.
(e) Shut off source of refrigerant and
pressurize evaporator with nitrogen until mixture of
refrigerant plus nitrogen reaches 100 psi gauge. Shut off
source of nitrogen, close shutoff valve near disconnect
fitting, and separate disconnect fitting. Use leak detector
to check for leakage from evaporator through
disconnect fitting.
(f) Fabricate an air-tight box large enough to
contain evaporator. Locate hole for leak detector probe
on side of air-tight box near the bottom, and seal hole
with tape. Use leak detector to check for residual
refrigerant in bottom of air-tight box. If gas is detected,
blow out with compressed air and recheck with leak
detector. When no refrigerant remains, seal charged
and pressurized evaporator inside air-tight box so that
no refrigerant can escape.
(e) Shut off source of refrigerant gas and
pressurize condenser with nitrogen until mixture of
refrigerant gas plus nitrogen reaches 100 psig. Shut off
source of nitrogen, close shutoff valve near disconnect
fitting, and separate the disconnect fitting. Use leak
detector to check for leakage from condenser through
disconnect fitting.
(f) Fabricate an air-tight box large enough to
contain one unit at a time. Locate hole for leak detector
probe on side of air-tight box near the bottom, and seal
hole with tape. Use leak detector to check for residual
refrigerant gas in bottom of air-tight box. If any is
detected, blow out with compressed air and recheck with
leak detector. When no refrigerant gas remains, seal
charged and pressurized condenser inside air-tight box
so that no refrigerant gas can escape.
(g) After 30 minutes, remove tape, insert
leak detector probe, and check for any refrigerant gas
that has leaked from condenser and settled to bottom of
air-tight box. Remove condenser from box.
(h) If no leakage is detected during either
check, permit refrigerant gas and nitrogen to escape
from condenser.
Note. Remove condenser from test area if there is a
possibility that escaping refrigerant gas may affect other test
in area.
(i) If leakage is detected, release refrigerant
gas and nitrogen from condenser and replace faulty
condenser with a known good one.
c. Installation.
(1) Position the condenser (187, fig. 6-1, sheet
6 of 6) and new tape (186) in the power plant and secure
using the bolts (184), screws (182) and washers (183,
185).
Note.
Observe cleaning, inspection and repair
instructions for tube assemblies given in paragraph 6.2b.
Also, use new foam tape each time condenser is replaced.
(2) Install the tube assemblies. 6-6.
Evaporators
a. Removal.
(1) Disconnect the tube assemblies that connect
to the evaporators.
(2) Remove the bolts (144, fig. 6-1, sheet 4 of
6) and washers (1451 to remove the evaporators (147)
and
Note. Remove evaporator from test area if there is a
possibility that escaping refrigerant may affect other tests in
area.
6-15
Figure 6-4. Refrigerant leakage test setup.
c. Installation.
(1) Position new rubber strips (146, fig. 6-1,
sheet 4 of 6) and evaporators (147) in the power plant
and secure it to the same using bolts (144) and washers
(145).
(g) After 30 minutes, remove tape, insert
leak detector probe, and check for any refrigerant that
has leaked from evaporator and settled to bottom of airtight box. Remove evaporator from air-tight box.
(h) If no leakage is detected, permit
refrigerant and nitrogen to escape from evaporator.
(i) If leakage is detected, release refrigerant
and nitrogen from evaporator and replace faulty
evaporator with a known good one.
Note.
Observe cleaning, inspection and repair
instructions for tube assemblies given in paragraph 6-2b.
Also, use new rubber strips each time evaporator is replaced.
(2) Install the tube assemblies.
Section III. RECEIVERS
(2) Disassemble in sequence of index numbers I
through 20 assigned to figure 6-5, observing the
following.
(3) Do not remove inserts (8) from cap (10)
unless required after inspection.
c. Cleaning, Inspection and Repair.
(1) Wipe all parts, except receiver (20), with a
clean, dry cloth.
(2) Thoroughly wash interior and exterior of
receiver (20) with kerosene and drain. Degrease with
trichlorethylene heated to 160° to 180°F (71.1°to 82.2°
C).
Warning: Trichlorethylene (MIL-T70031 is toxic,
and should be used only in a well
6-7. General
The receivers are mounted in the refrigerant
compartment.
The receivers discharge refrigerant
received from the condensers.
a. Removal.
(1) Disconnect tube assemblies that directly
connect to the receiver.
(2) Remove clamps (179, fig. 6-1,sheet 6 of 6 )
to remove the receiver (180). Remove the screen
b. Disassembly (fig. 6-5).
(1) Before proceeding with disassembly,
complete pressure test, and refrigerant leakage test
para e) below.
6-16
(7) Check receiver (20) for cracks, dents, and
distortion. Check flange surfaces for burrs.
(8) Check painted surfaces for damage or
deterioration.
(9) Replace all parts that do not pass inspection
and are damaged beyond repair. Replace packings (14,
17) and gaskets (16), at each overhaul.
(10) Replace damaged or inoperative valve (4).
ventilated area. Failure to observe this warning may
result in serious harm or death to personnel.
(3) Check all parts for damage and stripped or
crossed threads.
(4) Check nameplate (2) for damage and
illegibility.
(5) Check valve (4) for damage and freedom of
operation.
(6) Check disks (15) for chips and cracks.
Figure 6-5. Liquid refrigerant receiver, exploded view.
(11) Repair receiver (20) by torch brazing in
accordance with Military Specification MIL-W6858) as
applicable. Remove burrs from flange surfaces and
recut damaged threads.
(12) If insert (8) is damaged, remove and install
new insert 3/4 to 1 3/4 turns below countersink and
break off tang.
6-17
bubbles) and no evidence of permanent deformation of
receiver as a result of pressure applied during test.
Exhaust air and remove unit from test setup.
(d) Dry receiver as thoroughly as possible
with compressed air and complete drying by heating in
an oven for at least one hour at 250° F (12'1.10° C)
maximum.
(2) Test receiver for refrigerant leakage as
follows.
(a) Seal receiver as instructed (para e (1)
(a)) above.
(b) Connect liquid inlet of unit to
refrigeration system service unit as shown in figure
(c) Open valve connecting receiver to
vacuum pump, and evacuate receiver for at least 15
minutes at maximum pressure of 0.5 inch of mercury
absolute.
(13) Touch up defective painted surfaces with
one coat of primer mixed one part primer to one part
catalyst thinner; allow to air dry for at least two hours or
bake for one-half at 150° to 275° F (65.6° to 135° C).
Cover primer coat with one coat of black wrinkle enamel
Military Specification MIL-E-5558 and bake for one hour
at 250°to 300°F (121.1°to 148.9°C).
d.
Assembly.
Assemble in reverse order of
disassembly procedures (para 6-7 b. above).
e. Testing.
(1) Pressure test receiver as follows.
(a) Attach and secure end plate seals (see
Special Tools, table 2-1 to the ports of the receiver.
(b) Remove cap from valve (4, fig. 6-5) and
close valve (4); replace cap.
(c) Apply compressed air at liquid inlet port
seal, pressurize receiver to 165 ± 2.0 psi gauge, and
immerse receiver in water for five minutes. There must
be no leakage (indicated by complete absence of
Figure 6-6. Refrigerant leakage test setup.
(d) Shut off valve to vacuum pump and
charge receiver by permitting refrigerant gas to flow into
receiver until no more flow occurs.
(e) Shut off source of refrigerant gas and
pressurize receiver with nitrogen until mixture of
refrigerant gas plus nitrogen reaches 100 psi gauge.
Shut off source of nitrogen, close the shutoff valve near
the disconnect fitting, and separate the disconnect
fitting. Use leak detector to check for leakage from
receiver through disconnect fitting.
(f) Fabricate an airtight box large enough to
contain one unit at a time. Locate hole for leak detector
probe on side of air-tight box near the bottom, and seal
hole with tape. Use leak detector
6-18
TM 5-6115-586-34
(h) If no leakage is detected by either check, permit
refrigerant gas and nitrogen to. escape from receiver.
(i) If leakage is detected, find approximate area of leak
with leak detector. Use detergent to find exact location,
and
wipe detergent from receiver, and eliminate
leakage, using methods outlined (para c ) above, then
repeat leak detection procedure.
f. Installation.
(1) Position receiver (180, fig. 6-1, sheet 6 of
6) on mount and secure using clamps (179). Replace
screen (181).
(2) Install tube assemblies.
to check for residual refrigerant gas in bottom of air-tight
box. If any is detected, blow out with compressed air
and recheck with leak detector. When no refrigerant gas
remains, seal charged and pressurized receiver inside
air-tight box so that no refrigerant gas can escape.
(g) After 30 minutes, remove tape, insert leak
detector probe, and check for any refrigerant gas that
has leaked from receiver and settled to bottom of airtight box. Remove receiver from air-tight box.
Note
Remove receiver from test area if
there is a possibility that escaping
refrigerant gas may affect other
tests in area.
Section IV. MOTOR DRIVEN TUBE AXIAL FAN (Recirculating)
b. Disassembly.
(1) Disassemble according to sequence of item
numbers I through 30 assigned to figure 6-7 observing
the following.
(2) Do not remove plates (2, 3) or label (4)
unless required after inspection.
(3) Unsolder wires for connector (5). Do not cut
wires.
6-8. General
This motor driven fan essentially consists of a cylindrical
housing assembly, a motor rotor, two end bell
assemblies, a fan impeller, and a thermal protector.
The housing assembly includes a motor stator. The fan
is used to circulate the flow of air through the
environmental system.
a. Removal. Refer to TM 5-6115-586-12 for
recirculating fans removal instructions.
6-19
Figure 6-7. Tube axial motor driven fan, part no. 605370-1-2, exploded view.
6-20
KEY to figure 6-7.
1. Screw
2. Plate
3. Plate
4. Label
5. Connector
6. Bushing
7. Bushing
8. Bushing
9. Screw
10. Washer
11. Disc
12. Disc
13. Disc
14. Nut
15. Screw
16.
17.
18.
I 9.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
(4) Remove screws (9); then remove end bell 123)
with assembled parts attached. Unsolder wires from
thermal protector (16); then remove thermal protector
from end bell (23).
(5) Remove nut (18) using holding fixture torque
wrench (see Special Tools, table 2-1), as shown in figure
6-8.
(Protector
Grommet
Nut
Washer
Impeller
Screw
Plug
End bell
End bell
Bearing
Rotor
Housing assy
Stator
Insert
Housing
Figure 6-8. Holding fixture torque wrench.
(6) Do not remove plugs (22, fig. 6-7) from end
bell (23, 24) unless required after inspection.
(7) Remove rotor (26}) from housing (27); then
remove bearings (25) from rotor (26).
(8) Do not remove stator (28) from housing
(30).
c. Cleaning, Inspection and Repair.
(1) Cleaning.
(a) Check thermal protector (16), rotor (26)
and stator (28) in housing (30) using a soft bristle brush.
Warning
Varnish on stator (28) is soluble in
solvent. Do not allow solvent to
contact stator. Use solvent in a
well-ventilated area.
Avoid
breathing fumes. Keep away from
flame.
(b) Clean exterior surface of housing (30)
with a clean, lintfree cloth moistened with an approved
cleaning solvent and dry thoroughly.
(c) Wash all other parts in dry-cleaning
solvent and dry thoroughly.
(2) Inspection.
(a) Inspect all parts and wiring for damage.
Check bearing surfaces; bearing surfaces must have no
discoloration indicative of overheating.
(b) Inspect all threaded parts for stripping or
cross-threading.
(i) Inspect plates (2, 3) and label (4) for
legibility and for security of attachment.
(d) Inspect connector (5) for loose, bent, or
broken pins and for evidence of arc-over between pins
and shell.
(e) Connect thermal protector (16) to a test
circuit (fig. 6-9) which monitors opening and closing of
the contacts, and check operation at the following
temperatures.
6-21
Figure 6-9. Schematic wiring diagram.
1. With the temperature of thermal
protector at 77°F (25°C), pass a current of 25 amperes
of 115 vac through protector within one minute contacts
must close.
2. Heat thermal protector to 307° to
333°F (152.8°to 166.7°C); contacts must be open.
3. Remove thermal protector from test
circuit.
(f) Inspect end bell (23, 24) in accordance
with requirements shown in figure 6-10. Check plugs
(22, fig. 6-7) in each end bell (23, 24) for security of
attachment and damage.
(g)
Dimensionally inspect the rotor as
illustrated in figure 6-11.
(h)
Inspect housing (30, fig.
6-7) in
accordance with requirements in figure 6-12.
(i) Inspect stator (28, fig. 6-7) for broken
leads. Check the dc resistance of each coil; resistance
of each coil must be 0.50 to 0.62 ohm.
"A" DIAMETER AND "C" SURFACE ESTABLISH
CENTER-LINE.
"B" DIAMETER MUST BE CONCENTRIC WITH "A"
DIAMETER WITHIN 0.001 INCH TOTAL INDICATOR
READING.
A
1.5750
B
4.561
IN.
1.5754
Figure 6-10. End bell inspection requirements.
6-22
IN.
4.562
ME-5-6115-434-35/6-34
Figure 6-12. Fan housing assembly inspection requirements.
6-23
(a) Replace all parts that do not pass
inspection requirements and are damaged beyond
repair.
(b) Replace washer (10, fig. 6-7), grommet
(17), and bearings (25) regardless of condition. Use
bearing press fixture to press bearing (25) onto rotor
(26) shaft, as shown in figure 6-13.
(j) Inspect blades of impeller (20, fig. 6-7)
and outside diameter of hub for nicks, cracks, erosion.
Inspect blade tips and interior of housing (27) for
evidence of scraping.
(3) Repair.
Figure 6-13. Bearing installation.
(c)
Replace rotor if dimensional
sealant (Military Specification MIL-S-22473, class 40)
and install screws while sealant is wet.
requirements are not met.
(4) Install impeller (20) on shaft of rotor (26),
(d) If impeller appears to be damaged or
observing direction of rotation.
Apply anti- seize
faulty, replace. Report damaged impeller to depot
compound (Federal Specification JAN-A- 669) to
maintenance for repair.
threaded shaft of rotor (26); then install washer (19) and
(e) If inserts (29) are defective, remove
nut (18). Tighten nut (18) to 230 to 270 pound-inches
defective insert and install new insert 3/4 to 1 1/2
torque, using holding fixture torque wrench. (fig. 6-8)
pitches below surface of housing (30). Remove tangs.
(5) Install thermal protector (16, fig. 6-7) on
d. Assembly.
end bell (23). Temporarily install end bell (23) on
(1) Assemble in reverse order of removal
housing (27). Measure rotor (26) end play, using end
procedures (para 6-8 b.) observing the following.
play measuring fixture (fig. 6-14). Install discs (11, 12,
(2) Install rotor (26) with bearings (25) into
13, fig. 6-7) as required to obtain shaft end play of
housing assembly (27).
0.055 to 0.065 inch.
(3) Install end bell (24) with plugs (22) and
secure with screws (21). Coat threads of screws with
6-24
Figure 6-14. End play measurement.
Coat E42GP15 mixed equal parts by volume with
(6) Remove end bell (23, fig. 6-7) and connect electrical
Catalyst V66KP15) and air-dry for 15 to 30 minutes;
wiring in accordance with figure 6-9. Make electrical
connections, using solder (Federal specification QQ-Sthen bake at 150° to 175° F (65.6° to 79.4° C) for one
571, Type SN60WRAP2).
hour.
(7) Reinstall end bell (23, fig. 6-7), discs (1, 12, 13) and
e.
Installation.
Refer to TM
6-115-586-12 for
washer (10). Install washer (10) with tang ends against
recirculating fans installation instructions.
bearing outer race.
(8) After assembly, paint end of rotor (26) shaft, hex
hole in shaft, and nut (18) with one coat of primer (Cati-
Section V. MOTOR DRIVEN TUBE AXIAL FAN (CONDENSER)
b. Disassembly.
(1) Disassembly according to sequence of item
numbers I through 30 assigned to exploded view (fig. 615) observing the following.
(2) Do not remove plates (2,3), or label (4)
unless required after inspection, Unsolder -wires from
connector (5).
6-9. General
This motor driven fan consists essentially of a cylindrical
housing assembly, a motor rotor, and end bell assembly,
a fan fairing, and a thermal protector. The housing
assembly includes a motor stator. The fan is used to
force the flow of ambient cooling air through the
condenser of the air- conditioning system.
a. Removal. Refer to TM 5-6115-586-12 for
condenser fans removal instructions.
6-25
Figure 6-15. Tube axial motor driven fan, exploded view.
6-26
KEY to figure 6-15.
1. Screw
16.
2. Plate
17.
3. Plate
18.
4. Label
19.
5. Connector
20.
6. Screw
21.
7. Washer
22.
8. Disc
23.
9. Disc
24.
10. Disc
25.
11. Washer
26.
12. Nut
27.
13. Washer
28. Retainer
14. Screw
29. Insert
15. Protector, thermal 30. Housing
(3) Remove screws (6) and washers (7); then
remove end bell
16) with thermal protector (15)
attached. Unsolder wires from thermal protector; then
remove thermal protector from end bell.
Do not
disassemble end bell (16).
(4) Remove nut (19), using holding fixture
torque wrench as illustrated in figure 6-16.
(5) Remove rotor (24, fig. 6-15) with bearings
(23).
(6) Do not remove stator (27) from housing
(30).
End bell
Clamp
Grommet
Nut
Washer
Fairing
Impeller
Bearing
Rotor
Housing assy
Set screw
Stator
Figure 6-16. Holding fixture torque wrench.
c. Cleaning, Inspection and Repair.
(a) Inspect all parts and wiring for damage.
(1) Cleaning.
Check bearing surfaces; bearing surfaces must have
no discoloration, indicative of overheating.
(a) Clean thermal protector (15), motor rotor
(b) Inspect all threaded parts for stripping or
(24), and motor-stator (27) in fan housing (30), using a
cross-threading.
soft bristle brush.
(c) Inspect plates (2,3) and label (4) for
Warning Varnish on stator (27) is soluble in solvent. Do
not allow solvent to contact stator. Use solvent in well
legibility and for security of attachment.
ventilated area. Avoid breathing fumes. Keep away
(d) Inspect connector (5) for loose, bent.
from flame.
o0 broken pins and for evidence of arc-over between
(b) Clean exterior surfaces of housing (30)
pins and shell.
with a clean, lint-free cloth moistened with dry cleaning
(e) Connect thermal protector (15) to a test
solvent (Federal Specification P-D-680).
circuit as shown in figure 6-17 which monitors opening
(c) Wash all other parts in dry cleaning
and closing of the contacts. and check operation at the
solvent and dry thoroughly.
following temperatures:
(2) Inspection.
6-27
1. Withthe temperature of thermal
protector at (77°F (25° C). pass a current of 60
amperes at 115 vac through protector; contacts must
open between 10 and 20 seconds. Remove current
from protector; within one minute contacts must close.
2. Heat thermal protector 290° to 315°
F (143.3°to 157.2°C); contact must be open.
3. Remove thermal protector from test
circuit.
(f) Inspect end bell (16) in accordance with
figure 6-18.
(g) Inspect fairing (21, fig. 6-15) for cracks
and distortion.
Figure 6-17. Schematic wiring diagram.
B
C
7.8968
2.000
IN.
7.8978
1.8505
IN.
2.002
CENTERLINE IS NORMAL TO 'A" SURFACE AT
CENTER OF " B" DIAMETER.
D
IN.
1.8510
'C" DIAMETER MUST BE CONCENTRIC WITH
CENTER-LINE
WITHIN
0.003
INCH
TOTAL
INDICATOR READING.
"D" DIAMETER MUST BE CONCENTRIC WITH
CENTER- LINE WITHIN 0.001 INCH TOTAL
INDICATOR READING.
Figure 6-18. End bell inspection requirements.
(h) 1)Dimensionally inspect rotor as
(k) Inspect blades of impeller (22. fig. 6illustrated in figure 6-19.
15) and outside diameter of hub for nicks, cracks,
(i) Inspect housing assembly (25, fig. 6-15)
erosion. Inspect blade tips and interior of housing 13()1
for evidence of scraping.
in accordance with figure 6-20.
(j) Inspect stator (27, fig. 6-15) for broken
leads. Check the resistance of each coil (fig. 6-17).
Resistance of each coil must be 0.29 to 0.36 ohm.
6-28
Figure 6-19. Rotor assembly inspection requirements.
Figure 6-20. Fan housing assembly inspection requirements.
6-29
(3) Repair.
(a) Replace all parts that do not pass
inspection and are damaged beyond repair.
(b) Replace washers (11, fig. 6-15),
grommet 118), and bearings (231 regardless of
condition. Use bearing press fixture to install new
bearings (fig. 6-21 .
Figure 6-21. Bearing installation.
(1) Assemble in reverse order of disassemble
(c) If retainer in end bell (16, fig. 6-15)
procedures (para 6-9 b. above) observing the following.
requires replacement, replace complete end bell
(2) Install rotor (24, fig. 6-15) with bearing (23)
assembly.
into housing assembly (25).
(d) If impeller appears to be damaged or
(3) Install impeller (22) on shaft or rotor (24),
faulty, replace. Report damaged impeller to depot
observing direction of rotation.
Apply anti-seize
maintenance for repair.
compound (Specification JAN-A-669) to threaded shaft
(e) Replace
rotor
if dimensional
of rotor (24) before installing nut (19) to 460 to 480
requirements are not met.
pound-inches torque, using holding fixture torque
(f) If finish on outside of end bell (16) or
wrench (fig. 6-16).
housing (25) is defective, protect unpainted areas from
(4) Install thermal protector (15, fig. 6-16) on
sanding residue and new paint. Smooth defective
end
bell
(16). Temporarily install end bell (16) on
areas with abrasive cloth (Federal Specification P-Chousing assembly (25). Measure rotor (24) shaft end
451, No. 320 Grit) and clean thoroughly. Apply one
play, using end play measuring fixture (fig. 6- 22).
coat of primer (Military Specification MIL-P8585) and
Install discs (8, 9, 10, fig. 6-16) as required to obtain a
air-dry for 8 hours or bake for 3/4 hour at 250° F
total rotor (24) shaft end play of 0.080 to 0.084 inch.
(121°C).
(5) Remove end bell (16) and connect elec(g) If inserts (29) are defective, remove
trical wiring in accordance with figure 6-17. Make
defective insert and install new insert 3/4 to :1 1/2
electrical
connections,
using solder
(Federal
pitches below surface of housing (30). Remove tangs.
Specification
QQ-S-571,
Type
SN60-W-RA-P2).
d. Assembly.
6-30
Figure 6-22. End play measurement.
(8) After assembly, paint end of rotor (24) shaft,
hex hole in shaft, and nut (19) with one coat of primer
(Cati-Coat E42GP15, mixed equal parts by volume with
Catalyst V66KP15) and air-dry for 15 to 30 minutes;
then bake at 150°to 175°F (65.°to 79.4°) for one hour.
e. Installation. Refer to TM 5-6115-586-12 for
condenser fans installation instructions.
(6) Coat threads of clamps ( 17, fig. 6-15) with
surface primer to dry.
Coat threads with sealant
(Military Specification MIL-S-224373, Class 10) and
install screws while sealant is wet.
(7)
Tighten screws on clamp (17) inside
housing (25). Install end bell (16), washers (11), and
discs (8, 9, 10), then tighten screws on clamp (17) on
outside of housing assembly (25).
6-31
CHAPTER 7
REPAIR OF BLEED AIR AND EXHAUST HEATING INSTALLATION
b. Removal. Remove ducting, tube and plumbing
fittings only as required and feasible by following the
sequence of index numbers, 1 through 30, assigned to
figure 7-1, sheet I of 3.
c. Cleaning, Repair and Inspection.
(1) Clean ducting, tubes and plumbing fittings
with an approved solvent and thoroughly dry with filtered
compressed air.
(2) Visually inspect ducting for dents, cracks,
damage to mating flanges or other damage.
(3) Inspect tubes for cracks, dents. damaged
threads or other damage.
(4) Replace all parts damaged beyond simple
repair.
d. Installation. Install ducting, tube assemblies and
plumbing fittings in reverse order of removal
procedures.
7-1. General
The bleed air and exhaust heating installation supplies
heated air upon user demand. The installation consists
of an engine mounted unloading air shutoff valve,
ducting, two hot air flow control valves, temperature
sensors and controls mounted on the air conditioning
control panels. The exhaust system portion of this
installation consists of a diffuser, bellows, box, plenum
and stack assembly. A heat exchanger, mounted on the
box next to the stack, is also included in this installation.
Tubing hoses and plumbing fittings provide
interconnection of these components and connection to
the power plant.
7-2. Ducting, Tubing, and Plumbing Fittings
a. General. The ducting, tube assemblies and
plumbing fittings interconnect the heating system
components.
7-1
Figure 7-1. Bleed air and exhaust heating installation, exploded view. (sheet 1 of 3)
7-2
KEY to fig. 7-1.
1. Nut
2. Bolt
3. Flat washer
4. Shielding support
5. Shielding tube
6. Sleeving
7. Coupling-clamp
8.
9.
10.
11.
12.
13.
14.
15.
Metal gasket
Butterfly valve
Nut
Flat washer
Bolt
Washer
Metal tube
Nut
16.
17.
18.
19.
20.
21.
22.
23.
7-3
Plain washer
Bolt
Flexible pipe
Coupling-clamp
Gasket
Gasket
Nut
Plain washer
24.
25.
26.
27.
28.
29.
30.
Bolt
Heat manifold duct
Gasket
Tube assembly
Tee
Nut
Packing
31. Clamp
39. Union
32. Bolt
40. Coupling
33. Flat washer
41. Heat exchanger
34. Muffler
42. Valve
35. Seal
43. Insulation
36. Gasket
44. Bolt
37. Clamp
45. Plain washer
38. Clamp
46. Support
Figure 7-1. Bleed air and exhaust heating installation, exploded view. (sheet 2 of 31
7-4
7-5
Figure 7-1. Bleed air and exhaust heating installation, exploded view. (sheet 3 of 3)
7-6
secure with coupling (40) and clamps (37 and 38).
(4) Position gasket (36) onto exchanger (41),
position seal (35) and slide exhaust (34) in on top of
exchanger (41 ) with gasket (36) and secure with
washers (33) and bolts (32), secure (35) to exhaust 134)
with clamp (31).
(5) Install plumbing connections.
7-4. Exhaust System
The exhaust system consists of a ring assembly
mounted to the enclosure, exhaust box, and a bellows
and diffuser interconnecting the engine exhaust to the
exhaust box.
a. Disassembly.
(1) Loosen and remove clamp (50, fig. 7-1, sheet 3 of
3), remove bolts (52), washers (53, 54) from exhaust
stack (55).
(2) Remove exhaust stack (55) from top of
plenum (75), then remove gaskets (56, 57, 58) from top
of frame (78) and seal (51) from top of exhaust stack
(55).
(3) Remove tube assembly (59) from union (60)
on bottom of frame (78).
(4) Remove water system heat ducting from top
of frame (78).
(5) Remove coupling clamp (79), gasket (80),
bolts (70), washers (71), flange (72) and gasket (73)
from frame (78) inlet.
(6) Remove bellows (83), gaskets (73) and
flange (74) from frame (78).
(7) Remove bolts (81), washers (82), and
diffuser (85) with gasket (84) from frame (78).
(8) Remove bolts (65), washers (66), skin (67),
gasket (68) and channel (69) from frame ( 78).
(9) Lift plenum (75) from frame (78), then
remove insulation (76, 77). Remove nuts (61), washers
(62), bolts (63), and frame (78), then remove spacers
(64).
b. Cleaning, Inspection and Repair.
(1) Clean exhaust system components with an
approved solvent and stiff bristled brush.
(2) Inspect components for cracks, broken
welds or other damage.
(3) Replace any part damaged beyond simple
repair.
(4) Replace gaskets (56, 57, 58, 68, 73), and
seal (51) at each overhaul regardless of condition.
c. Assembly.
(1) Wrap plenum (75,fig. 7-1,sheet 3 of 3) in
insulation (77).
(2) Fill void between plenum (75) and frame
(78) with insulation (76).
(3) Install spacers (64), frame (78), and secure
with bolts (63), washers (62) and nuts (61).
(4) Install channel (69), gasket (68) and skin
(67). Secure with washers (66) and bolts (65).
(5) Install gasket (84) and diffuser (85) and
secure to bellows (83) with washers (82) and bolts (81).
KEY to figure 7-1--Continued:
66. Flat washer
47. Gasket
67. Skin
48. Gasket
68. Gasket
49. Gasket
69. Channel
50. Clamp
70. Bolt
51. Seal
71. Flat washer
52. Bolt
72. Flange
53. Washer
:73. Gasket
54. Washer
74. Flange
55. Exhaust stack
.75. Plenum
56. Gasket
76. Insulation
57 . Gasket
77. Insulation
58. Gasket
78. Frame
59. Tube assembly
79. Coupling clamp
60. Union
80. Gasket
61. Nut
81. Bolt
62. Flat washer
82. Flat washer
63. Bolt
83. Bellows
64. Spacer
84. Gasket
65. Bolt
85. Diffuser
7-3. Heat Exchanger
a. Removal.
(1) Remove clamp (31, fig. 7-1, sheet 2 of 3),
bolts (32), and washers (33), then remove muffler (341,
seal (35) and gasket (36) from exchanger (41).
(2) Loosen and remove clamp (37, 38), upper
coupling (40) and exchanger (41) from outlet flange
of valve (42). Remove tube (27) from union (3:9 1.
(3) Remove lower coupling (40), and valve
(42).
(4) Remove insulation (43) from around support
(46), then remove bolts (44) and washers (45) securing
support (46). Remove support (46) and gaskets (47, 48,
49, fig. 7-1, sheet 3 of 3) from exhaust box.
(5) Discard gaskets (47, 48, 49, 36) and seal
(35) at each overhaul.
b. Cleaning, Inspection and Repair.
(1) Clean all parts with a rag moistened in an
approved cleaning solvent.
(2) Inspect parts for cracks, dents or other
obvious damage.
(3) Inspect all threaded parts for stripped,
crossed, or peened threads.
(4) Repair minor cracks and dents using
simple shop repair practices.
(5) Replace all parts damaged beyond simple
repair.
(6)
Replace gaskets and seals at each
overhaul.
c. Installation.
(1) Install insulation (43, fig. 7-1, sheet 2 of 3),
around support (46). Install gasket (47 through 49) onto
exhaust box, then install support (46) with insulation (43)
onto gaskets (47 through 49) and secure with washers
(45) and bolts (44).
(2) Install valve (42) onto support (46) and
secure with one coupling (40).
(3) Install exchanger (41) onto valve (42) and
7-7
(2) Inspect tube assemblies for kinks, bends,
cracks or other damage which might restrict flow or
result in leakage. Inspect nuts and sleeves on tube
assemblies for loose sleeves or. damage to nuts.
(3) Install handles on manual valves and
operate valve to ensure freedom of moving parts and
absence of binding.
(4) Repair minor damage to tube assemblies
using simple shop repair practices. If tube assemblies
are damaged beyond simple repair practices, replace
the damaged assembly.
(5) Repair any minor damage to manual valves
using simple shop repair. Replace frozen, damaged or
otherwise inoperative valves.
c. Installation. Refer to TM 5-6115-586-12 for
installation procedures.
(6) Position gaskets (73), flange (74) and flange
(7-2); secure with bolts (70) and washers
(7) Install gasket (80) and coupling clamp 179)
onto diffuser (85).
(8) Install tube assembly (59) onto union (60).
then install new seal (51) to top of exhaust stack (55),
and position gasket (56, 57, 58) on top of frame (78).
(9)
Install exhaust stack (55) on top of
previously installed gasket (56, 57, 58) on top of frame
(78) and secure with bolts (52), washers (53, 54).
(10) Install clamp (50) over seal (51) and secure
clamp (50).
7-5. Bleed Air Lines and Fittings
a. Removal. Refer to TM 5-6115-586-12 for
removal procedures.
b. Cleaning, Inspection and Repair.
(1) Clean all parts with an approved cleaning
solvent and dry thoroughly with filtered com- pressed
air.
7-8
CHAPTER 8
REPAIR OF WATER SYSTEM PLUMBING INSTALLATION
Section I. TUBE ASSEMBLIES, FITTINGS, AND MANUAL VALVES
(2) Inspect tube assemblies for cracks, bends
or crimps which might restrict flow or result in leakage.
Inspect connection nuts and sleeves on tube assemblies
for loose sleeves or damage to nuts.
(3) Inspect check valves for crossed, stripped
or peened threads.
(4) Inspect hot and cold water shutoff valves,
hot water return / drain valve, and hot water tank vent
valve for crossed, stripped, or peened threads or other
visible damage. Check valves for ease of operation and
absence of binding.
c. Repair.
(1) Replace all fittings damaged beyond
simple repair of threads.
(2) Replace defective tube assemblies.
(3) Replace check valves if they do not operate
properly or if threads are damaged beyond simple
repair.
(4) Replace leaking or binding valves and
valves with damaged threads.
8-4. Reassembly and Installation
Refer to TM
5-6115-586-12 for instructions on
installation of tube assemblies, fittings, and valves.
8-1. General
This section contains repair instructions for the tube
assemblies and fittings that interconnect water system
components and for the manually operated valves
utilized to control water flow and vent the system.
8-2. Removal and Disassembly
Refer to TM 5-6115-586-12 for instructions regarding
removal of tube assemblies, fittings, and valves.
8-3. Cleaning, Inspection and Repair
a. Cleaning. Clean tube assemblies, fittings and
valves with soft bristle brush and hot, soapy water.
Rinse thoroughly and dry with filtered, compressed air.
Note
Do not use solvent for cleaning as
plumbing must carry potable
water. If necessary, the ends of
tube assemblies may be sealed
and the external surfaces cleaned
with a rag moistened with solvent.
b. Inspection.
(1) Inspect fittings for stripped, crossed or
peened threads. Inspect plumbing fittings for cracks or
clogged passages.
Section II. SURGE TANK AND PRESSURE SWITCH
(1) Inspect threaded areas for crossed,
stripped or peened threads.
(2) Inspect tank for cracks, breaks in welds and
dents. Tank shall not leak when tested at 150 PSIG
minimum.
(3) Inspect switch body for dents, cracks, or
other damage.
(4) Check continuity across switch terminal
posts. Contact arrangement is single pole, double
throw: common to one post should be open and
common to the other post should be closed.
(5) Apply adjustable pressure to pick up area of
switch and check that the closed set of contacts open
and the open set closes at 10-1 PSIG. Contacts should
return to normal positions at 5 PSI differential on
decreasing pressure.
c. Repair.
(1) Repair damaged threads. If threads cannot
be repaired, replace the part.
8-5. General
The surge tank dampens pressure surges in the water
system. It is mounted to a bracket in the water system
compartment by two clamps. The pressure switch,
mounted to fittings at the top of the tank, actuates the
hot water pump contactor (K 15).
8-6. Removal
Refer to TM 5-6115-586-12 for removal instructions.
8-7. Cleaning, Inspection and Repair
a. Cleaning.
Note
Cap openings prior to cleaning
tank externally with solvent. Do
not get solvent inside tank.
(1) Clean external portions of the tank using an
approved solvent and a stiff bristled brush.
(2) Back flush tank with clean hot water.
b. Inspection and Testing.
8-1
(2) Welding repair of corrosion resistant steel
surge tank shall be attempted only by properly certified
welder. (Refer to MIL-T-5021, Class A, Group II).
(3) Replace pressure switch found to be
defective through inspection or testing.
8-8. Installation
Refer to TM 5-6115-586-12 for installation instructions.
Section III. HOT WATER TANK, THERMOSTATIC SWITCH AND RELIEF VALVES
d. Check continuity across terminal posts; circuit
shall be closed.
e. Apply heated water to pick up area of switch; as
heat reaches 160°± 4-5°F, circuit across terminal posts
shall open.
f. Replace switch if damaged beyond simple repair
or if switch fails to meet test requirements.
8-13. Pressure and Temperature Relief Valve
a. Clean relief valve using a cloth dampened in an
approved solvent.
b. Inspect threaded areas for crossed, stripped or
peened threads.
c. Provide a means of controlling and measuring
pressure and temperature of test water.
d. Inspect relief valve for dents, cracks or other
damage.
i. Check relief valve setting; valve shall open at 15
psig.
f. Check temperature relief setting; valve shall start
to open at 200°F and shall be fully open at 210°F.
g. Replace relief valve if damaged beyond simple
repair or if inspection requirements are not met.
8-14. Safety Relief Valve
a. Clean safety relief valve using a cloth dampened
in an approved solvent.
b. Inspect threaded areas for stripped, crossed or
peened threads.
c. Inspect body of valve for dents, cracks or other
damage.
d. Apply air pressure to inlet post of valve and
gradually increase pressure to 100 psig. Valve shall
relieve at 100 ± 5 psig.
e. Replace valve if damaged beyond simple repair
or if test requirements are not met.
8-15. Installation of Components
Refer to TM 5-6115-586-12 for installation instructions.
8-9. General
This section contains repair instructions for the hot water
storage tank, the thermostatic switch and the relief
valve, mounted to the hot water tank fittings, and the
safety relief valve mounted to the heat exchanger
fittings.
8-10. Removal of Components
Refer to TM 5-6115-586-12 for instructions on removal
of the hot water tank, thermostatic switch and relief
valve.
8-11. Hot Water Tank
a. Cleaning and Inspection.
Note
Cap all ports on tank. Do not
allow solvent to get into tank.
(1) Clean tank externally using an approved
cleaning solvent and a stiff bristled brush.
(2) Clean tank internally by back flushing with
clean hot water.
(3) Inspect threaded areas for crossed,
stripped or peened, threads.
(4) Inspect tank for cracks, dents or other dam
age.
b. Repair.
(1) Repair defective threads. If threads
cannot be repaired, replace the tank.
(2) Welding repair of the hot water tank shall be
attempted only by a certified welder (per MIL-T-5021,
Class A, Group II).
8-12. Thermostatic Switch
a. Clean thermostatic switch with a cloth dampened
in an approved solvent.
b. Inspect threaded areas for crossed, stripped or
peened threads.
c. Inspect switch body for dents, cracks or other
damage.
8-2
CHAPTER 9
ENCLOSURE AND SHELL ASSEMBLY
disassemble only those parts
requiring repair or replacement
and those parts necessary to gain
access to the damaged parts.
b. Cleaning. Inspection an Repairs.
(1) Clean components of the enclosure with a
clean cloth dampened in an approved solvent, dry
thoroughly with compressed air.
(2) Inspect doors and panels for cracks, loose
rivets, damaged fasteners and other defects.
(3) Inspect frame assembly and other welded
components for cracks or breaks on welded joints.
Reweld the frame which is aluminum alloy 6061. T4
and T6 QQ-A-200 / 8 and QQ-A-250 / 16 using filler
4043, examine and certify according to military
specification MIL-T-5021.
(4) Repair damaged components using simple
shop repair.
9-1. General
The enclosure and shell assembly contains the
operating components of the power units and systems
and mounts lifting and leveling components.
9-2. Enclosure and Shell Assembly
a. Disassembly.
(1) Do not disassemble the enclosure unless
inspection reveals damage. If required, disassemble the
enclosure assembly by following the sequence of index
numbers 1 through 271 assigned to figure 9-1 .
(2) Do not disassemble the shell assembly
unless inspection reveals damage.
If required,
disassemble the shell assembly by following the
sequence of index numbers 1 through 315 assigned to
figure 9-1.
Note
Do not disassemble the enclosure
or the shell assembly in their
entirety.
Remove
and
9-1
Figure 9-1. Enclosure assembly, exploded view. (sheet 1 of 10)
9-2
KEY to figure 9-1.
1. Nut
2. Plate
3. Bolt
4. Flat washer
5. Ring bolt
6. Bracket
7.
8.
9.
10.
11.
12.
13.
Bracket
Nut
Bolt
Bolt
Flat washer
Bracket
Spacer
14.
15.
16.
17.
18.
19.
20.
9-3
Spacer
Ring bolt
Nut
Bolt
Flat washer
Nut plate
Nut
21.
22.
23.
24.
25.
26.
27.
Bolt
Flat washer
Bracket
Nut
Bolt
Flat washer
Folding step
Figure 9-1. Enclosure assembly, exploded view. (sheet 2 of 10)
9-4
KEY to figure 9-1Continued:
28. Retainer
29. Stud
30. Rivet
31. Rivet
32.
33.
34.
35.
36.
37.
Catch
Tape
Rivet
Receptacle
Rivet
Hinge
38.
39.
40.
41.
42.
43.
9-5
Nut
Flat washer
Bolt
Strike
Flat washer
Bolt
44.
45.
46.
47.
48.
49.
Flat washer
Seal ring
Ring
Bolt
Flat washer
Top plate
50. Bolt
62. Turnlock fastener stud
73. Turnlock fastener stud
51. Flat washer
63. Rivet
74. Turnlock fastener stud
52. Rivet
64. Receptacle
75. Rivet
53, Rivet
65. Rivet
76. Rivet
54. Hinge
66. Nut plate
77. Hinge
55. Retainer
67. Insulation
78. Coupling clamp
56. Turnlock fastener stud
68. Bolt
79. Packing
57. Turnlock fastener stud
69. Bolt
80. Dust cover
58. Rivet
70. Washer
81. Bolt
59. Rivet
71. Retainer
82. Flat washer
60, Hinge
72. Turnlock fastener stud
83. Screen
61. Retainer
84. Air duct
Figure 9-1. Enclosure assembly, exploded view. (sheet 3 of 10)
9-6
9-7
Figure 9-1. Enclosure assembly, exploded view. (sheet 4 of 10)
9-8
KEY to figure 9-1-Continued:
85. Bolt
86. Bolt
87. Flat washer
88. Retainer
89. Turnlock fastener stud
90. Turnlock fastener stud
91.
92.
93.
94.
95.
96.
Turnlock fastener stud
Rivet
Rivet
Hinge
Nut
Flat washer
9-9
97. Machine screw
98. Machine screw
99. Spacer
100. Shield
101. Outlet shield
102. Insulation
103.
104.
105.
106.
107.
108.
109.
Nut
Flat washer
Machine screw
Spacer
Shield
Shield
Insulation
Figure 9-1. Enclosure assembly, exploded view. (sheet 5 of 10)
9-10
KEY to figure 9-1-Continued:
110. Bolt
111. Flat washer
112. Panel
113. Insulation
114. Nut'
115. Flat washer
116. Bolt
117. Bolt
118.
119.
120.
121.
122.
123.
124.
125.
126.
127.
Bracket
Bracket
Brace
Nut
Bolt
Flat washer
Partition
Panel
Nut
Flat washer
128.
129.
130.
131.
132.
133.
134.
135.
136.
137.
9-11
Bolt
Bracket
Pump mount bracket
Bolt
Flat washer
Bolt
Bolt
Flat washer
Bolt
Flat washer
138.
139.
140.
141.
142.
143.
144.
145.
146.
Clip
Base plate
Rivet
Plate nut
Plate nut
Rivet
Plate nut
Rivet
Rivet
Figure 9-1. Enclosure assembly, exploded view. (sheet 6 of 10)
9-12
178.
179.
180.
181.
182.
183.
184.
185.
186.
187.
188.
Wing nut
Flat washer
Eyebolt
Eyebolt
Nut
Flat washer
Bolt
Battery support assy
Nut
Flat washer
Bolt
189.
190.
191.
192.
193.
194.
195.
196.
197.
198.
199.
Rail
Center support
Battery support
Nut
Flat washer
Tie-down fitting
Nut
Flat washer
Screw
Retainer
Retainer
200.
201.
202.
203.
204.
205.
206.
207.
208.
209.
210.
Figure 9-1. Enclosure assembly. exploded view. (sheet 7 of 10)
9-13
Retainer
Retainer
Nut
Bolt
Bracket
Nut
Flat washer
Flange
Bolt
Air inlet tube
Polyurethane foam
211. Nut
212. Flat Washer
213. Bolt
214. Flat washer
215. Mounting plate
216. Spacer
217. Nut
218. Flat washer. Nut
foam
219.
220.
221.
222.
223.
224.
225.
226.
Resilient mount
Screw
Bolt
Flat washer
Plenum case
Grommet
Nut
Flat washer
Figure 9-1. Enclosure assembly, exploded view. (sheet 8 of 10)
9-14
227.
228.
229.
230.
231.
232.
233.
234.
Bolt
Valve bracket
Nut
Flat washer
Bolt
Bracket
Insulation
Polyurethane
235.
236.
237.
238.
239.
240.
241.
242.
Bolt
Bolt
Flat washer
Exhaust panel assy
Exhaust panel door
Retainer
Turnlock fastener stud
Rivet
243.
244.
245.
246.
247.
248.
249.
Insulation
Exhaust panel
Nut
Flat washer
Bolt
Elbow
Turbine access panel
Figure 9-1. Enclosure assembly, exploded view. (sheet 9 of 10)
9-15
250.
251.
252.
253.
254.
255.
256.
257.
Retainer
Stud fastener
Stud fastener
Stud fastener
Stud fastener
Rivet
Handle
Rivet
Figure 9-1. Enclosure assembly, exploded view. (sheet 10 of 10)
9-16
1.
2.
3.
4.
5.
6.
7.
Rivet
Bail handle
Rivet
Top plenum panel
Top compressor panel
Rivet
Rivet
8. Top panel
9. Rivet
10. Left condenser door
11. Right condenser door
12. Nut
Figure 9-2. Shell assembly, exploded view. (sheet 1 of 9)
9-17
13.
14.
15.
16.
17.
18.
19.
Washer
Ball stud
Retainer
Turnlock fastener stud
Rivet
Hinge
Rivet
Figure 9-2. Shell assembly, exploded view. (sheet 2 of 9)
9-18
KEY to figure 9-2-Continued:
20. Rivet
21. Top panel, right
22. Plate spacer
23. Rivet
24. Panel frame
25. Plate spacer
26. Condenser fan support
27. Condenser fan support
28.
29.
30.
31.
32.
33.
34.
35.
36.
Rivet
Rivet
Plate spacer
Condenser door, left front
Nut
Flat washer
Bolt
Flat washer
Tubing
9-19
37.
38.
39.
40.
41.
42.
43.
44.
45.
Rivet
Lock
Rivet
Rivet
Hinge
Rivet
Rivet
Plate spacer
Condenser door, right front
46.
47.
48.
49.
50.
51.
52.
53.
54.
Rivet
Lock
Rivet
Rivet
Hinge
Rivet
Latch retainer
Rivet
Receptacle
Figure 9-2. Shell assembly, exploded view. (sheet 3 of 9)
9-20
KEY to figure 9-2-Continued:
55. Rivet
56. Rivet
57. Turbine air inlet door
58. Screw
59. Tooth lockwasher
60. Rivet
61. Butt hinge
62. Rivet
63. Retainer
64.
65.
66.
67.
68.
69.
70.
71.
72.
Turnlock fastener stud
Foam tape
Rivet
Lock
Protective cap
Rivet
Receptacle
Rivet
Rivet
9-21
73.
74.
75.
76.
77.
78.
79.
80.
81.
Hinge
Plate spacer
Rivet
Condenser door, right
Retainer
Turnlock fastener stud
Turnlock fastener stud
Turnlock fastener stud
Rivet
82.
83.
84.
85.
86.
87.
88.
89.
90.
91.
Rivet
Receptacle
Hinge
Rivet
Hinge
Rivet
Latch retainer
Rivet
Plate nut
Plate nut
Figure 9-2. Shell assembly, exploded view. (sheet 4 of 9)
9-22
KEY to figure 9-2-Continued:
92. Rivet
93. Rivet
94. Outer evaporator panel
95. Rivet
96. Rivet
97. Rivet
98. Rivet
99. Partition assembly
100. Nut
101. Flat washer
102. Bolt
103.
104.
105.
106.
107.
108.
109.
110.
111.
112.
113.
Insulation retainer
Insulation
Plenum partition
Rivet
Rivet
Rivet
Rivet
Condenser floor, right
Floor stiffener
Rivet
Power panel frame
9-23
114.
115.
116.
117.
118.
119.
120.
121.
122.
123.
124.
Rivet
Rivet
Rivet
Panel housing
Rivet
Rivet
Receptacle
Bracket
Rivet
Plate nut
Rivet
125.
126.
127.
128.
129.
130.
131.
132.
133.
134.
135.
136.
Plate nut
Rivet
Plate nut
Rivet
Plate nut
Rivet
Plate nut
Rivet
Plate nut
Rivet
Receptacle
Rivet
Figure 9-2. Shell assembly, exploded view. (sheet 5 of 9)
9-24
KEY to figure 9-2-Continued:
137. Rivet
138. Rivet
139. Inlet air door assy
140. Nut
141. Flat washer
142. Screw
143. Spacer
144. Door positioning arm
145. Wing nut
146. Flat washer
147.
148.
149.
150.
151.
152.
153.
154.
155.
156.
157.
Rod
Grommet
Flat washer
Door
Retainer
Turnlock fastener stud
Rivet
Rivet
Rivet
Hinge
Rivet
9-25
158.
159.
160.
161.
162.
163.
164.
165.
166.
167.
168.
Filter holding frame
Rivet
Rivet
Rivet
Retainer
Stud fastener
Rivet
Rivet
Receptacle
Rivet
Rivet
169.
170.
171.
172.
173.
174.
175.
176.
177.
178.
179.
Hinge
Rivet
Rivet
Flange
Rivet
Rivet
Rivet
Plate spacer
Rivet
Rivet
Receptacle
Figure 9-2. Shell assembly, exploded view. (sheet 6 of 9)
9-26
KEY to figure 9-2-Continued:
180. Rivet
181. Rivet
182. Plate spacer
183. Air outlet door
184. Rivet
185.
186.
187.
188.
189.
190.
Hinge
Retainer
Turnlock fastener stud
Rivet
Flange
Rivet
9-27
191.
192.
193.
194.
195.
196.
Rivet
Outlet panel frame
Retainer
Stud fastener
Rivet
Foam tape
197.
198.
199.
200.
201.
202.
Rivet
Receptacle
Rivet
Rivet
Plate nut
Plate nut
Figure 9-2. Shell assembly, exploded view. (sheet 7 of 9)
9-28
KEY to figure 9-2
--Continued: -203. Rivet
204. Left condenser door
205. Retainer
206. Turnlock fastener stud
207. Turnlock fastener stud
208. Turnlock fastener stud
209. Rivet
210. Rivet
211. Receptacle
212. Hinge
213.
214.
215.
216.
217.
218.
219.
220.
221.
222.
223.
Rivet
Hinge
Rivet
Compressor door
Rivet
Lock
Rivet
Rivet
Hinge
Rivet
Exhaust compartment panel
9-29
224.
225.
226.
227.
228.
229.
230.
231.
232.
233.
234.
Rivet
Rivet
Condenser compartment floor
Floor stiffener
Rivet
Rivet
Compressor floor panel
Rivet
Recessed panel
Rivet
Rivet
235.
236.
237.
238.
239.
240.
241.
242.
243.
244.
245.
Evaporator panel
Rivet
Latch retainer
Rivet
Rivet
Receptacle
Rivet
Rivet
Rivet
Plate nut
Plate nut
Figure 9-2. Shell assembly, exploded view. (sheet 8 of 9)
9-30
KEY to figure 9-2-Continued:
246. Rivet
247. Rivet
248. Rivet
249. Rivet
250. Combustor compartment panel
251. Rivet
252. Insulation
253. Rivet
254. Rivet
255. Rivet
256.
257.
258.
259.
260.
261.
262.
263.
264.
265.
Plenum separator support
Air inlet panel
Rivet
Rivet
Rivet
Rivet
Handbook storage rack
Rear compressor panel
Rivet
Condenser panel
9-31
266.
267.
268.
269.
270.
271.
272.
273.
274.
275.
Rivet
Rivet
Rivet
Condenser support assy
Bolt
Flat washer
Condenser support angle
Left condenser support
Rivet
Latch retainer
Figure 9-2. Shell assembly, exploded view. (sheet 9 of 9)
9-32
297.
298.
299.
300.
301.
302.
303.
304.
305.
306.
307.
308.
309.
310.
311.
312.
313.
314.
315.
KEY to figure 9-2-Continued:
276. Rivet
277. Rivet
278. Rivet
279. Lower plenum panel
280. Plenum panel assy
281. Nut
282. Flat washer
283. Bolt
284. Bolt
285. Cover
286. Panel
287. Rivet
288. Engine bulkhead
289. Rivet
290. Nut plate
291. Rivet
292. Rivet
293. Rivet
294. Right condenser support assy
295. Bolt
296. Flat washer
Condenser support angle
Right condenser support
Rivet
Rivet
Rivet
Rear reinforcement plate
Front reinforcement plate
Rivet
Rivet
Rivet
Bottom left panel
Bottom right panel
Rivet
Receptacle plate
Plate nut
Rivet
Rivet
Plate nut
Enclosure frame
(5) If the components of a subassembly are damaged beyond simple shop repair, replace the entire
subassembly.
(6) Repaint frame assembly with primer (Cati-coat 42GP22 and thinner VK66KP46, Sherwin-Williams Co.,
Cleveland, Ohio, or equivalent, no known government specifications) air dry thirty minutes and bake at 150°to 175°F.
for one hour. Apply a finish coat of enamel (Federal specification TT-E-527, Color 3412 (Federal Specification TT-595).
c. Assembly.
(1} Assemble the shell assembly in reverse order of disassembly procedures (para 9-2 a above).
(2) Assemble the enclosure in reverse order of disassembly procedures (para 9-2 a. above).
9-33
CHAPTER 10
REPAIR OF ACCESSORY COMPONENTS
Section I. GENERAL INFORMATION
6115-586-12. A list of the accessory components and
an illustration of each is also included in TM 5-6115586-12; therefore, illustrations are provided in this
chapter only when required as an aid to repair of
specific components.
10-1. General Information
This chapter contains repair instructions for the
accessory components used with the power plant. No
removal or installation instructions are given as these
items are normally installed during setting up of the
power plant and removed for movement to a new
worksite according to instructions provided in TM 5-
Section II. COMPRESSED AIR AND VACUUM SYSTEM ACCESSORY COMPONENTS
10-2. Inflation and Deflation Ejector Assembly
b.
Disassembly.
Refer to figure 10-1 and
disassemble the inflation and deflation ejector assembly
as follows.
(1) Remove nut (1) , ejector assembly support
(2), flat washer (3) and bolt (4) from the ejector
tube (14).
a. General. The inflation and deflation ejector
assembly is used in conjunction with the compressed air
hose assembly to apply inflation air from the power plant
compressed air outlet for the MUST hospital inflatable
elements. Its main components are an ejector tube, a
quick disconnect coupling half, and a support.
10-1
Figure 10-1. Inflation and deflation ejector assembly.
10-2
(4)
Inspect quick disconnect coupling half for
damaged cap, nose piece, or clip. Check that cable
assembly is not damaged, broken or missing.
KEY to figure 10-1.
1.
Nut
2.
Ejector assembly support
3.
Flat washer
4.
Bolt
5.
Quick disconnect coupling half
6.
Cap
7.
Seal
8.
Nose piece
9.
Clip
10. Sleeve
11. Cable assembly
12. Nut
13. Packing
14. Ejector tube
d.
Repair and Replacement.
(1)
Replace parts if threads are damaged
beyond simple repair.
(2)
Repair tube by welding; replace loose
rivets. If ejector tube is damaged beyond simple repair,
replace the tube.
(3)
Replace damaged or missing quick
disconnect coupling half components and replace seal.
(4)
(2)
Loosen nuts (12) and remove the quick
disconnect coupling half (5), nuts (12), and packing (13).
Replace packing (13).
e.
Reassembly. Refer to figure 10-1 and
reassemble the inflation and deflation ejector assembly
by reversing the disassembly sequence.
(3) Disassemble the quick disconnect coupling
half by removing the cap (6) and seal (7) from the nose
piece (8). Leave cable assembly ( 1) and sleeve (10)
attached unless repair is necessary. Remove clip (9) by
sliding it off opposite end of nose piece from the cap.
10-3. Box and Valve Manifold Assembly
a.
General.
The box and valve manifold
assembly connects the inflation and deflation ejector
assembly to the MUST hospital inflatable element. Its
main components are the junction box, the two
regulating valves, and the manifold cap.
c. Cleaning and Inspection
(1)
Clean metal components of the assembly
with solvent and dry thoroughly with compressed air.
(2)
Inspect threaded parts for damaged,
stripped or crossed threads.
b.
Disassembly. Remove screws (1, fig. 10-2)
and washers (2, 3) to remove regulating valve (4).
Remove manifold cap (5) from junction box (6).
(3) Inspect ejector tube for cracks, bends, and
broken welds. Check that wire mesh in the tube is not
torn or clogged. Check for loose rivets.
c.
Cleaning, Inspection, and Testing.
(1)
Clean the metal parts with solvent
and dry thoroughly.
10-3
Figure 10-2. Box and valve manifold assembly.
KEY to figure 10-2.
1.
Screw
4. Regulating valve
2.
Lockwasher
5.
Manifold cap
3.
Flat washer
6.
Junction box
(2)
Inspect the junction box (6. fig. 102) for bends and breaks. loose or missing latches or
rivet nuts.
(3)
Visually inspect the two regulating
valves for damage.
(4)
Test that regulating valves relieve at
1.5 -0.25 PSIG.
d.
Repair and Replacement. Replace all parts
damaged beyond simple repair.
e.
Reassembly.
Reassemble the box and
valve manifold assembly by reversing the disassembly
sequence.
10-4. Compressed Air Hose Assembly and Vacuum
Hose Assembly
a.
General.' The compressed air hose assembly
connects the inflation and deflation ejector assembly
to the power plant compressed air outlet. The vacuum
hose assembly connects the power plant vacuum outlet
to elements of the MUST system that require vacuum
service.
b.
Disassembly.
(1)
Remove the two body and plug
assemblies (fig. 10-3) from the compressed air hose
ends by unscrewing them from the hose coupling nuts.
(2) Remove the body and plug assemblies
from the vacuum hose ends by unscrewing them from
the hose coupling nuts.
Figure 10-3. Compressed air hose assembly and vacuum hose assembly.
c.
Inspection. Inspect both hose assemblies
for any damage that could cause leakage, incorrect or
difficult connection of hose assemblies to fittings.
d.
Repair and Replacement.
defective parts.
Replace all
e.
Reassembly. Reassemble hose assemblies
by reversing disassembly procedure.
Section III. WATER SYSTEM ACCESSORY COMPONENTS
thermostatically-controlled electric heater that is
10-5. Dual Water Hose Assembly
powered from the power plant 400 Hz electrical system.
a.
General. The dual water hose assembly
b.
Disassembly. The dual water hose assembly
connects the hot and cold water outlets of the power
(fig. 10-4) shall be disassembled only as required
plant water system to other elements of the MUST
for repair as determined after inspection and
system.
The two hoses are heated by a
testing.
10-5
Figure 10-4. Water system accessory components.
10-6
c.
assembly delivers water from the source to the power
plant water system inlet.
Both
hose
assemblies
are
heated
by
thermostatically-controlled electric heating elements
powered from the power plant 400 Hz electrical system.
Inspection and Testing.
(1)
Visually inspect the dual water
hose assembly for damage, signs of leakage, stripped or
crossed threads on coupling nuts and electrical
connectors, missing or damage protective cap or plugs.
b.
Disassembly. The water recirculating hose
and' water supply and drain hose assemblies (fig. 10-4)
shall be disassembled only as necessary for repairs
indicated after inspection and testing.
(2)
Test the heater with 400 Hz, 120
VAC. Connector pin arrangement is as follows: pin A:
spare, pin B: spare, pin C: 400 Hz, 120 VAC (phase),
pin D: 400 Hz, 120 VAC (neutral), pin E: ground.
c.
(3)
(1)
Visually inspect the hose assemblies
for damage, signs of leakage, stripped or crossed
threads, missing or damaged plugs or protective caps.
Inspect heated flap of water recirculating hose assembly
for visible damage.
pressure.
d.
Inspection and Testing.
Test for leaks at 100 PSI water
Repair and Replacement.
(1)
Replace. damaged
plugs, connector or protective cap.
or
missing
(2)
Test the heaters with 400 Hz 120
VAC.
Connector pin arrangement is: pin A: spare, pin B:
spare, pin C: 400 Hz, 120 VAC (phase, pin D: 400 Hz,
120 VAC (neutral), pin E: ground.
(2)
If wires are defective in the electrical
cable, one of the spare wires (pin A, pin B) may be
utilized if the remainder of the cable is in good
condition. The connector pin must be jumped to the
new pin connection to obtain power through the mating
connector on the power plant, and the new wire must be
connected to the heating element at the cable splice.
(3)
water pressure.
d.
(3)
If hose assembly is damaged
beyond simple repair and replacement, replace the
entire assembly.
Test for leaks in hoses at 75 PSI
Repair and Replacement.
(1)
Replace damaged
plugs, connector, or protective cap.
10-6. Water Recirculating Hose and Water Supply
and Drain Hose Assemblies
a.
General.
The water recirculating hose
assembly is utilized to recirculating cold water back to
source to prevent freezing in cold weather operation and
for recirculation of hot water back through the power
plant water system. The water supply and drain hose
or
missing
(2)
If wires are defective in the electrical
cable, spare pins A and B may be utilized if remainder
of cable is serviceable. Pins must be jumped for proper
connection to obtain power through mating connection
power plant.
Section IV. EXTERNAL FUEL FILTER ASSEMBLY
a.
Refer to TM 5-6115-586-12 and remove the
10-7. General
two filter elements, gaskets, cases, and retainer rings
The fuel filter assembly delivers and filters fuel from the
according to instructions provided.
external fuel fitting. It consists of a dual element filter
with a selector valve, three hose assemblies for
b.
Unscrew hoses (fig. 10-5) and fittings and
connection to fuel source and one hose assembly with
shutoff valve.
fuel shutoff valve for connection of filters to power plant
fuel inlet.
c.
Remove two nuts, four flat washers, and two
bolts to remove filter head assembly from fuel filter
10-8. Disassembly
bracket.
10-7
Figure 10-5. External fuel filter assembly.
d.
Inspect hoses for cuts, deterioration, splits
10-9. Cleaning and Inspection
or other damage that could cause leakage.
a.
Clean metal parts in an approved cleaning
solvent and dry thoroughly with filtered compressed air.
10-10. Repair and Replacement
b.
Inspect all threaded parts for stripped,
crossed, or peened threads.
a.
Replace filters and gaskets.
c.
Inspect filter cases, valve, retainers, and
filter 10-8 head assembly for cracks, corrosion or other
obvious damage.
b.
Replace all other damaged parts. Replace
entire hose if damaged.
10-8
586-12 for instructions regarding installation of filters
and gaskets.
10-11.
Reassembly
Reassemble the external fuel filter assembly by
reversing disassembly procedure. Refer to TM 56115-
Section V. ELECTRICAL CABLE ACCESSORY COMPONENTS
10-12.
General
b.
Refer to TM 5-6115-586-12 and test
a.
The electrical cable accessory components
individual wires for continuity.
are the 400 Hz electrical power output cable
assembly, the 60 Hz electrical power output cable
c.
Replace the cable assembly if inspection
assembly, the 400 Hz remote power cable assembly,
and / or testing reveals damage or lack of continuity in
DC electrical power standby cable assembly, external
individual wires.
DC electrical power input cable assembly, external
battery DC power cable assembly.
10-16.
DC Electrical Power Standby Cable
b.
Refer to TM 5-6115-586-12 for a description
Assembly
of use of the cable assemblies, illustrations, and wire
a.
Visually inspect the cable assembly for
run charts.
damaged connectors or connector covers, sleeves, or
cables.
c.
This section contains inspection, testing,
and replacement instructions for the cable assemblies.
b.
Refer to TM 5-6115-586-12 and test
individual wires for continuity.
10-13.
400 Hz Electrical Power Output Cable
c.
Replace the cable assembly if inspection
Assembly
and /or testing reveals damage or lack of continuity in
a.
Visually inspect the cable assembly for
individual wires.
damaged connectors or connector covers, sleeves, or
cables.
10-17.
External DC Electrical Power Input Cable
b.
Refer to TM 5-6115-586-12 and test
Assembly
individual wires for continuity.
a.
Visually inspect the cable assembly for
damaged connectors or connector covers, sleeves, or
c.
Replace the cable assembly if inspection
cables.
and/ or testing reveals damage or lack of continuity in
individual wires.
b.
Refer to TM 5-6115-586-12 and test
individual wires for continuity.
10-14.
60 Hz Electrical Power Output Cable
c.
Replace the cable assembly if inspection
Assembly
and /or testing reveals damage or lack of continuity in
a.
Visually inspect the cable assembly for
individual wires.
damaged connectors or connector covers, sleeves, or
cables.
10-18.
External Battery DC Power Cable
b.
Refer to TM 5-6115-586-12 and test
Assembly
individual wires for continuity.
a.
Visually inspect cable assembly for
damaged connector, lugs, adapters, or cable.
c.
Replace the cable assembly if inspection
and / or testing reveals damage or lack of continuity in
b.
Test continuity of the two wires.
individual wires.
c.
Replace the cable assembly if inspection
10-15.
400 Hz Remote Power. Cable Assembly
and / or testing reveals damage or lack of continuity in
individual wires.
a.
Visually inspect the cable assembly for dam
aged connectors or connector covers, sleeves, or
cables.
Section VI. CONDITIONED AIR SYSTEM ACCESSORY COMPONENTS
Visually inspect the two clamps (fig. 10-6) and
10-19.
Coupling Assembly
the flanged coupling for damage and check that
a. Inspection.
the clamps operate satisfactorily.
10-9
Figure 10-6. Conditioned air system accessory components.
b.
Replacement.
flanged coupling.
Replace defective clamps or
10-20. Conditioned Air Duct Assembly
Visually inspect air duct assembly (fig.
10-6) for
obvious damage.
Replace assembly if damaged
beyond simple repair.
10-10
APPENDIX A
REFERENCES
A1.
A2.
A3.
A4.
A5.
A6.
A7.
Fire Protection
TM 5420020010
Hand Portable Fire Extinguishers Approved for
Army Users
Lubrication
C9100IL
Identification List for Fuels, Lubricants, Oils and
Waxes
Lubrication Order
LO 5611558612
Radio Suppression
TM 11483
Maintenance
TM 38750
TM 5611558612
TM 5611558634P
TM
9614020015
TM
5492020015
Radio Interference Suppression
The Army Maintenance Management Systems
Operator and Organizational Maintenance Manual
Direct Supportand General Support Main
tenance Repair Parts and Special Tools List
Operation and Organizational, Field and Depot
Maintenance Storage Batteries, Lead-Acid Type
Operator, Organizational,
Field and Depot
Maintenance Manual, Engine Analyzer, Gas
Turbine
Shipment and Storage
TB 740972
Preservation of USAMEC Mechanical Equipment
for Shipment and Storage
Administrative Storage of Equipment
TM 740901
Radioactive Material
TB 750248 Instructions
for Safe Handling, Maintenance,
Storage, and Disposal of Radioactive Com
modities Managed by U.S. Army Mobility
Equipment Command
Destruction to Prevent Enemy Use
TM 7502443
Procedures for Destruction of Equipment to
Prevent Enemy Use
A-1
INDEX
Paragraph
AC power wire harness assembly (13217E4158) ..............................................................................5-21
Accessory components:
Compressed air and vacuum system:
Box and valve manifold assembly ................................................................................10-3
Compressed air hose assembly and vacuum hose assembly .......................................10-4
Inflation and deflation ejector assembly ........................................................................10-2
Conditioned air system:
Conditioned air duct assembly ....................................................................................10-20
Coupling assembly .....................................................................................................10-19
Electrical Cables:
DC electrical power standby cable assembly ...............................................................10-16
External battery DC power cable assembly .................................................................10-18
External DC electrical power input cable assembly ......................................................10-17
General
...............................................................................................................10-12
400 Hz electrical power output cable assembly ...........................................................10-13
400 Hz remote power cable assembly .........................................................................10-15
60 Hz electrical power output cable assembly .............................................................10-14
External fuel filter assembly:
Cleaning and inspection ..............................................................................................10-9
Disassembly ................................................................................................................10-8
General
................................................................................................................10-7
Reassembly ...............................................................................................................10-11
Repair and replacement...............................................................................................10-10
General information ...............................................................................................................10-1
Water system:
Dual water hose assembly ...........................................................................................10-5
Water recirculating hose and water supply and drain hose assemblies .........................10-6
Accessory gearcase assembly:
Cleaning, inspection and repair ..............................................................................................3-18
Disassembly
................................................................................................................3-17
General
................................................................................................................3-15
Installation
................................................................................................................3-20
Reassembly
3-19 .........................................................................................................3-32
Removal
................................................................................................................3-16
Accessory gearcase nut and bolt torque values ................................................................................1-6q
Accessory gearcase repair and replacement standards ....................................................................1-6p
Air conditioning compressor replacement standards ......................................................................... 1-6t
Air conditioning system branched wire harness assembly (13217E4146) ...........................................5-8
Air conditioning wire harness assembly (13217E41451 .....................................................................5-9
Air inlet duct and screen assembly ....................................................................................................4-7
Air inlet plenum assembly 4-8............................................................................................................4-5
Anti-ice thermostat wire harness assembly (13217E4133) ................................................................5-14
Auxiliary power tray assembly:
Removal and installation of ....................................................................................................2-13
Repair instructions 5-28 .........................................................................................................5-43
Battery wire harness assembly:
(13217E4154 (Skid) ...............................................................................................................5-36
(13217E4168)
................................................................................................................5-24
Bleed air and exhaust heating installation, repair of:
Ducting, tubing and plumbing fittings ......................................................................................7-2
Exhaust system
.................................................................................................................7-4
General
.................................................................................................................7-1
Heat exchanger
.................................................................................................................7-3
Lines and fittings .................................................................................................................7-5
Bleed air lines and fittings 7-5............................................................................................................7-8
Box and valve manifold assembly ....................................................................................................10-3
Cleaning instructions (general)...........................................................................................................2-7
Cold water pump replacement standards .........................................................................................1-6z
Compressed air and vacuum system: (accessory components)
Box and valve manifold assembly ..........................................................................................10-3
Compressed air hose assembly and vacuum hose assembly .................................................10-4
Inflation and deflation ejector assembly .................................................................................10-2
I-1
Page
5-28
10-3
10-5
10-1
10-10
10-9
10-9
10-9
10-9
10-9
'
10-9'
10-9
10-8
10-7
10-7
10-9
10-8
10-1
10-5
10-7
3-32
3-31
3-30
3-34
3-30
1-3
1-2
1-3
5-9
5-10
4-3
5-16
2-27
5-64
5-33
7-1
7-7
7-1
7-7
'7-8
10-3
2-20
1-4
10-3
10-5
10-1
Paragraph
Compressed air hose assembly and vacuum hose assembly ............................................................10-4
Compressor and exhaust fans wire harness assembly (13217E4152) ...............................................5-20
Compressor and turbine assembly:
Cleaning, inspection and repair ..............................................................................................3-24
Disassembly
................................................................................................................3-23
General
................................................................................................................3-21
Installation
................................................................................................................3-26
Reassembly
................................................................................................................3-25
Removal
................................................................................................................3 22
Compressor wire harness assembly (13217E4157) ..........................................................................5-18
Compressors .,
.................................................................................................................6-4
Compressors wire harness assemblies (13217E3796 and 13217E 4155) .........................................5-19
Condenser fans repair and replacement standards ...........................................................................1-6v
Condenser fans wire harness assembly:
(13217E4150)
................................................................................................................5-16
(13217E4151)
................................................................................................................5-15
Condenser replacement standards .................................................................................................. 1-6w
Condensers
.................................................................................................................6-5
Conditioned air cooling system, repair of:
Compressors
.................................................................................................................6-4
Condensers
.................................................................................................................6-5
Evaporators
.................................................................................................................6-6
General (compressors, condensers, evaporators) ...................................................................6-3
General (tube assemblies and plumbing fittings) .....................................................................6-1
Motor driven tube axial fan (condensers) .................................................................................6-9
Motor driven tube axial fan' (recirculating) ...............................................................................6-8
Receivers
.................................................................................................................6-7
Tube assemblies, fittings, and solenoid valves ........................................................................6-2
Conditioned air duct assembly .........................................................................................................10-20
Conditioned air system (accessory components):
Conditioned air duct assembly ..............................................................................................10-20
Coupling assembly ...............................................................................................................10-19
Conditioned air system electrical components panel .........................................................................5-27
Conditioned air temperature control panel assembly ........................................................................5-30
Coupling assembly (accessory component)......................................................................................10-19
DC electrical power standby cable assembly ...................................................................................10-16
DC power branched wire harness assembly:
(13217E4147)
.................................................................................................................5-2
(13217E4149)
.................................................................................................................5-4
Description
.................................................................................................................1-4
Differences between models ..............................................................................................................1-5
Disassembly instructions (general) ....................................................................................................2-6
Dual pad accessory drive assembly:
Cleaning, inspection, and repair .............................................................................................3-12
Disassembly :
................................................................................................................3-11
General
.................................................................................................................3-9
Installation
................................................................................................................3-14
Reassembly
................................................................................................................3-13
Removal
................................................................................................................3-10
Dual pad accessory torque values ....................................................................................................1-6o
Dual pad gearcase repair and replacement standards . .....................................................................1-6n
Dual water hose assembly ...............................................................................................................10-5
Ducting, tubing (bleed air) 72 .............................................................................................................7-1
Electrical cables (accessory components):
DC electrical power standby cable assembly .........................................................................10-16
External battery de power cable assembly ............................................................................10-18
External dc electrical power input cable assembly .................................................................10-17
General
1012 109
400 Hz electrical power output cable assembly .....................................................................10-13
400 Hz remote power cable assembly ...................................................................................10-15
60 Hz electrical power output cable assembly .......................................................................10-14
Electrical leads and jumpers ............................................................................................................5-31
Enclosure and shell assembly ........................................................................................................9-1,9-2
Engine accessories:
Fuel atomizer
.................................................................................................................3-7
Fuel control assembly .............................................................................................................3-6
General
.................................................................................................................3-4
Oil temperature regulator ........................................................................................................3-8
Starter
.................................................................................................................3-5
I-2
Page
10-5
5-26
3-34
3-34
3-34
3-42
3-42
3-34
5-23
6-13
5-24
1-4
5-19
5-17
1-4
6-14
613
6-14
6-15
6-13
6-1
6-25
6-19
6-16
6-1
10-10
10-10
10-9
5-36
5-56
10-9
10-9
5-1
5-5
1-4
1-4
2-20
328
3-24
3-24
3-30
3-29
3-24
1-2
1-2
10-5
10-9
10-9
10-9
10-9
10-9
10-9
5-59
9-1
3-22
3-19
3-15
3-23
3-15
Paragraph
Engine and skid assembly, removal and installation of .....................................................................2-11
Engine and skid electrical installation:
Battery wire harness assembly ...............................................................................................3-6
General
................................................................................................................5-32
Lower electric power chassis assembly ..................................................................................5-34
Power wire harness assembly (13217E4001) ..........................................................................3-5
Upper electric power chassis assembly ..................................................................................5-33
Engine and skid major components, removal and installation of ........................................................2-2
Engine and skid wiring diagram ...................................................................................................... 1-6af
Engine electrical and plumbing installation:
Gas turbine engine branched wire harness assembly ..............................................................3-2
General
.................................................................................................................3-1
Plumbing installation ..............................................................................................................3-3
Engine electrical system schematic .................................................................................................1-6ac
Evaporator replacement standards ...................................................................................................1-6x
Evaporators 66
615
Exhaust system
74 7
External battery dc power cable assembly .......................................................................................10-18
External dc electrical power input cable assembly ...........................................................................10-17
External fuel filter assembly (accessory components):
Cleaning and inspection .........................................................................................................10-9
Disassembly
................................................................................................................10-8
General
................................................................................................................10-7
Reassembly
...............................................................................................................10-11
Repair and replacement ........................................................................................................10-10
Forms and records
.................................................................................................................1-2
Fuel atomizer
.................................................................................................................3-7
Fuel boost pump
.................................................................................................................4-4
Fuel control assembly
.................................................................................................................3-6
Fuel control assembly classification and rating ................................................................................. 1-6f
Fuel control repair and replacement standards .................................................................................1-6g
Fuel control unit nut and bolt torque data ........................................................................................ 1-6 h
Fuel filter
.................................................................................................................4-5
Fuel shutoff solenoid valve classification and rating .......................................................................... 1-6i
Fuel shutoff solenoid valve repair and replacement standards .......................................................... 1-6]
Fuel tank
.................................................................................................................4-6
Gas turbine engine analyzer .............................................................................................................2-4a
Gas turbine engine branched wire harness assembly ........................................................................3-2
Gas turbine engine classification and rating .....................................................................................1-6b
Heat exchanger
.................................................................................................................7-3
Heat shield assembly
.................................................................................................................4-9
Heat valves wire harness assembly (13217E4163) ...........................................................................5-25
Hot water pump replacement standards ..........................................................................................1-6aa
Hot water tank:
Cleaning, inspection and repair...............................................................................................8-11
Installation
................................................................................................................8-15
Removal
................................................................................................................8-10
Ignition unit classification and rating..................................................................................................1-6k
Ignition unit repair and replacement standards .................................................................................16-1
Inflation and deflation ejector assembly ............................................................................................10-2
Inspection instructions (general) ........................................................................................................2-7
Instrument panel assembly ..............................................................................................................5-26
Instrument panel wiring diagram .....................................................................................................1-6ae
Low oil pressure switch classification and rating .............................................................................. 1-6m
Lower electric power chassis assembly .............................................................................................3-4
Maintenance repair parts .................................................................................................................2-2
Motor driven tube axial fan (condenser) .............................................................................................6-9
Motor driven tube axial fan (recirculating) ..........................................................................................6-8
Oil tank assembly
.................................................................................................................4-3
Oil temperature regulator .................................................................................................................3-8
Plumbing installation, engine ............................................................................................................3-3
Power plant electrical installation:
AC power wire harness assembly (13217E4158) ...................................................................5-21
Air conditioning system branched wire harness assembly (13217E4146) ................................5-8
Air conditioning wire harness assembly (13217E4145) ............................................................5-9
I-3
Page
2-21
5-64
5-60
5-60
5-62
5-60
2-25
1-5
3-1
3-1
3-5
1-5
1-4
10-9
10-9
10-8
10-7
10-7
10-9
10-8
1-1
3-22
4-1
3-19
1-2
1-2
1-2
4-3
1-2
1-2
4-3
2-5
3-1
1-1
7-7
4-8
5-35
1-4
8-2
8-2
8-2
1-2
1-2
10-1
2-20
5-36
1-5
1-2
5-6
9-1
6-25
6-19
4-1
3-23
3-15
5-28
5-9
5-10
Paragraph
Power plant electrical installation Continued
Anti-ice thermostat wire harness assembly (13217E4133) .....................................................5-14
Auxiliary power tray assembly ................................................................................................5-28
Battery wire harness assembly (13217E4168) ........................................................................5-24
Compressor and exhaust fans wire harness assembly (13217E4152) ....................................5-20
Compressor wire harness assembly (13217E4157) ................................................................5-18
Compressors wire harness assemblies (13217E3796 and 13217E4155) ................................5-19
Condenser fans wire harness assembly:
(13217E4150) .............................................................................................................5-16
13217E4151) ...............................................................................................................5-15
Conditioned air system electrical components panel .........................................................................5-27
Conditioned air temperature control panel assembly ........................................................................5-30
DC power branched wire harness assembly:
(13217FE41471) .................................................................................................................5-2
(13217E4149)
.................................................................................................................5-4
Electrical leads and jumpers ............................................................................................................5-31
General
.................................................................................................................5-1
Heat valves wire harness assembly (13217E4163) ...........................................................................5-25
Instrument panel assembly ..............................................................................................................5-36
Power unit de power branched wire harness assembly (13217E4153) ...............................................5-3
Receptacle panel assembly ..............................................................................................................5-29
Recirculating fans wire harness assembly:
(13217E4141)
................................................................................................................5-11
(13217E4148)
................................................................................................................5-12
(113217E4165)
................................................................................................................5-10
Remote power output wire harness assembly (13217E4156) ............................................................5-17
Temperature sensors wire harness assembly:
(1321 E4159)
................................................................................................................5-22
(13217E4160)
................................................................................................................5-23
Water pumps wire harness assembly (13217E4142) .........................................................................5-7
Water system branched wire harness assembly (13217E4143) .........................................................5-6
Water system wire harness assembly (13217E4144) ........................................................................5-5
400 Hx auxiliary power wire harness assembly (13217E4131) ..........................................................5-13
Power plant electrical system schematic .........................................................................................1-6ad
Power plant test instructions:
Air conditioning system checks ............................................................................................. 2-5 h
Bleed air system checks ........................................................................................................2-5k
Electrical system checks ........................................................................................................ 2-5f
General
................................................................................................................2-5a
Heating system checks .......................................................................................................... 2-2i
Hot and cold water system checks ......................................................................................... 2-5j
Instrument panel checks ........................................................................................................ 2-5 e
Precautions during testing .....................................................................................................2-5c
Preliminary test procedures ...................................................................................................2-5d
Protective device checks ........................................................................................................2-5g
Test connections .................................................................................................................2-b
Vacuum system checks .........................................................................................................2-51
Power plant dc power branched wire harness assembly ( 13217E4153) ............................................5-3
Power wire harness assembly (13217E4001) ...................................................................................5-35
Pressure and temperature relief valve:
Cleaning, inspection and repair ..............................................................................................8-13
Installation
................................................................................................................8-15
Removal
................................................................................................................8-10
Pressure switch (water)
........................................................................................................... 8-5— 8-8
Reassembly instructions (general) ....................................................................................................2-9
Receiver repair and replacement standards ......................................................................................1-6y
Receivers
.................................................................................................................6-7
Receptacle panel assembly ...............................................................................................................2-9
Recirculating fans repair and replacement standards ........................................................................1-6u
(13217E4141)
................................................................................................................5-11
(13217E4148)
................................................................................................................5-12
(13217E416S )
................................................................................................................5-10
Refrigeration system service unit ......................................................................................................2-4b
Remote power output wire harness assembly (13217E4156) .............................................................1-7
Removal and installation of engine and skid major components:
Gas turbine engine ................................................................................................................2-12
Generators
...............................................................................................................2-12a
Lower electric power chassis assembly..................................................................................2-12d
Upper electric power chassis assembly..................................................................................2-12c
I-4
Page
5-16
5-43
5-33
5-26
5-23
5-24
5-19
5-17
5-36
5-56
7-1
7-7
5-59
5-1
5-35
5-3
5-49
5-13
5-14
5-12
5-21
5-29
5-31
5-8
5-7
5-6
5-15
1-5
2-20
2-20
2-16
2-5
2-20
2-20
2-15
2-11
2-13
2-18
2-11
2-20
5-3
5-62
8-2
8-2
8-2
8-1.8-2
2-20
1-4
6-16
5-49
1-3
5-13
5-14
5-12
2-6
5-21
2-25
2-25
2-27
2-27
Paragraph
Removal and installation of major components and auxiliaries:
Auxiliary power tray assembly ................................................................................................2-13
Engine and skid assembly .....................................................................................................2-11
Engine and skid components .................................................................................................2-12
General
................................................................................................................2-10
Repair and replacement standards ..................................................................................................1-6ab
Repair instructions (general) .............................................................................................................2-8
Replacement instructions (general) ...................................................................................................2-8
Reporting of errors
.................................................................................................................1-3
Safety relief valve:
Cleaning, inspection and repair ..............................................................................................8-14
Installation
................................................................................................................8-15
Removal
................................................................................................................8-10
Scope
.................................................................................................................1-1
Skid assembly, repair of:
Air inlet duct and screen assembly ..........................................................................................4-7
Air inlet plenum assembly .......................................................................................................4-8
Fuel boost pump .................................................................................................................4-4
Fuel filter
.................................................................................................................4-5
Fuel tank
................................................................................................................4-6
General
.................................................................................................................4-1
Heat shield
.................................................................................................................4-9
Hose and tube assemblies and fittings ....................................................................................4-2
Oil tank assembly .................................................................................................................4-3
Skid
................................................................................................................4-10
Special tools and equipment .............................................................................................................2-1
Starter, engine
.................................................................................................................3-5
Starter assembly classification and rating ........................................................................................1-6c
Starter assembly nut and bolt torque data ........................................................................................1-6e
Starter assembly repair and replacement standards .........................................................................1-6d
Surge tank and pressure switch:
Cleaning, inspection and repair ...............................................................................................8-7
General
.................................................................................................................8-5
Installation
.................................................................................................................8-8
Removal
.................................................................................................................8-6
Tabulated data:
Accessory gearcase nut and bolt torque values ......................................................................1-6q
Accessory gearcase repair and replacement standards ..........................................................1-6p
Air conditioning compressor replacement standards .............................................................. 1-6t
Cold water pump replacement standards ...............................................................................1-6z
Condenser fans repair and replacement standards .................................................................1-6v
Condenser replacement standards ........................................................................................ 1-6w
Conditioned air system wiring diagram .................................................................................1-6ah
Dual pad accessory torque values .........................................................................................1-6o
Dual pad gearcase repair and replacement standard ..............................................................1-6n
Engine and skid wiring diagram ............................................................................................ 1-6af
Engine electrical system schematic ......................................................................................1-6ac
Evaporator replacement standards ........................................................................................1-6x
Fuel control assembly classification and rating ...................................................................... 1-6f
Fuel control repair and replacement standards .......................................................................1-6g
Fuel control unit nut and bolt torque data ...............................................................................1-6h
Fuel shutoff solenoid valve classification and rating ............................................................... 1-6i
Fuel shutoff solenoid valve repair and replacement standards ................................................ 1-6i
Gas turbine engine classification and rating ............................................................................1-6b
General
................................................................................................................1-6a
Hot water pump replacement standards ................................................................................1-6aa
Ignition unit classification and rating ......................................................................................1-6k
Ignition unit repair and replacement standards .......................................................................16-1
Instrument panel wiring diagram ...........................................................................................1-6ae
Low oil pressure switch classification and rating ................................................................... 1-6m
Power plant electrical system schematic ...............................................................................1-6ad
Receiver repair and replacement standards ...........................................................................1-6y
Repair and replacement standards .......................................................................................1-6ab
Starter assembly classification and rating ..............................................................................1-6c
Starter assembly nut and bolt torque data ..............................................................................1-6e
Starter assembly repair and replacement standards ...............................................................1-6d
Water system wiring diagram ...............................................................................................1-6ag
I-5
Page
2-27
2-21
2-25
2-21
1-4
2-20
2-20
1-1
8-2
8-2
8-2
1-1
4-3
4-5
4-1
4-3
4-3
4-1
4-8
4-1
4-1
4-10
2-1
3-15
1-1
1-2
1-1
8-1
8-1
8-2
8-1
1-3
1-2
1-3
1-4
1-4
1-4
1-5
1-2
1-2
1-5
1-5
1-4
1-2
1-2
1-2
1-2
1-2
1-1
1-1
1-4
1-2
1-2
1-5
1-2
1-5
1-4
1-4
1-1
1-2
1-1
1-5
Paragraph
Tabulated data Continued
400 Hz generator repair and replacement standards .............................................................. 1-6r
60 Hz generator repair and replacement standards ................................................................1-6s
Temperature sensors wire harness assembly:
(13217E4159)
................................................................................................................5-22
(13217E4160) .
................................................................................................................5-23
Thermostatic switch:
Cleaning, inspection and repair ..............................................................................................8-12
Installation
................................................................................................................8-15
Removal
................................................................................................................8-10
Troubleshooting (general) .................................................................................................................2-3
Troubleshooting equipment, use of:
Gas turbine engine analyzer ..................................................................................................2-4a
Refrigeration system service unit ...........................................................................................2-4b
Upper electric power chassis assembly ............................................................................................5-33
Water pumps wire harness assembly:
(13217E4142)
.................................................................................................................5-7
Water recirculating hose and water supply and drain hose assemblies .............................................10-6
Water system (accessory components):
Dual water hose assembly ......................................................................................................10-5
Water recirculating hose and water supply and drain hose assemblies....................................10-6
Water system branched wire harness assembly:'
(13217E4143)
.................................................................................................................5-6
Water system tube assemblies, fittings and manual valves:
Cleaning, inspection and repair ...............................................................................................8-3
General
.................................................................................................................8-1
Reassembly and installation ...................................................................................................8-4
Removal and disassembly ......................................................................................................8-2
Water system wire harness assembly (13217E4144) ........................................................................5-5
Water system wiring diagram ..........................................................................................................1-6ag
400 Hz auxiliary power wire harness assembly (13217E4131) ...........................................................5-13
400 Hz electrical power output cable assembly ................................................................................10-13
400 Hz generator repair and replacement standards ......................................................................... 1-6r
400 Hz remote power cable assembly .............................................................................................10-15
60 Hz electrical power output cable assembly ..................................................................................10-4
60 Hz generator repair and replacement standards............................................................................1-6s
I-6
Page
1-3
1-3
5-29
5-31
8-2
8-2
8-2
2-3
2-5
2-6
5-60
5-8
10-7
10-5
10-7
8-1
8-1
8-1
8-1
5-6
1-5
10-9
1-3
10-9
10-9
13
By Order of the Secretary of the Army:
Official:
W. C. WESTMORELAND,
General, United States Army,
Chief of Staff.
VERNE L. BOWERS,
Major General, United States Army,
The Adjutant General.
Distribution:
To be distributed in accordance with DA Form 12-25A, (qty rqr block no. 639) Direct and General Support
maintenance requirements for Equipment, Miscellaneous: MUST System.
U.S. GOVERNMENT PRINTING OFFICE: 1991 0 - 281-504 (47441)
Figure FO-1. Control panel wire harness assembly.
FO-1
Figure FO-2. Engine skid wire harness assembly.
FO-2
PIN: 025693-000
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