TM 9-6115-672-14

ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 TECHNICAL MANUAL
OPERATOR, UNIT, DIRECT SUPPORT HOW TO USE THIS MANUAL AND GENERAL SUPPORT PAGE ix MAINTENANCE MANUAL EQUIPMENT DESCRIPTION
AND DATA PAGE 1-4 PRINCIPLES OF OPERATION PAGE 1-16 CONTROLS AND INDICATORS PAGE 2-1 OPERATOR PMCS PAGE 2-14 OPERATOR TROUBLESHOOTING PAGE 3-1 OPERATOR MAINTENANCE PAGE 3-18 UNIT TROUBLESHOOTING PAGE 4-10 UNIT MAINTENANCE PAGE 4-49 DIRECT SUPPORT TROUBLESHOOTING DIRECT SUPPORT MAINTENANCE
PAGE 5-2
PAGE 5-14
GENERATOR SET, SKID MOUNTED, TACTICAL QUIET

60 KW, 50/60 AND 400 HZ MEP-806B (50/60 HZ) (NSN 6115-01-462-0291) EIC: GGW MEP-816B (400 HZ) (NSN 6115-01-462-0292) EIC: GGX
GENERAL SUPPORT MAINTENANCE
PAGE 6-1
DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited.
DEPARTMENTS OF THE ARMY, AND THE AIR FORCE AND HEADQUARTERS, MARINE CORPS 1 July 2000
PCN 182 092443 00
TM 9-6115-672-14
LIST OF EFFECTIVE PAGES
INSERT LATEST CHANGED PAGES, DESTROY SUPERSEDED PAGES NOTE: The portion of the text affected by the changes is indicated by a vertical line in the outer margins of the page. Changes to illustrations are indicated by miniature pointing hands. Changes to wiring diagrams are indicated by shaded areas.
Dates of issue for original and changed pages is: Original........ 0............01 July 2000
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USA
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14
WARNING PAGES __________ WARNING High voltage is produced when this generator set is in operation. Make sure unit is completely shut down and free of any power source before attempting any repair or maintenance on the unit. Failure to comply can cause injury or death to personnel. __________ WARNING High voltage is produced when the generator set is in operation. Never attempt to start the generator set unless it is properly grounded. Failure to comply can cause injury or death to personnel. __________ WARNING High voltage is produced when the generator set is in operation. Never attempt to connect or disconnect load cables while the generator set is running. Failure to comply can cause injury or death to personnel. __________ WARNING DC voltages are present at generator set electrical components even with generator set shut down. Avoid shorting any positive with ground/negative. Failure to comply can cause injury to personnel and damage to equipment. __________ WARNING Metal jewelry can conduct electricity. Remove metal jewelry when working on electrical system or components. Failure to comply can cause injury or death to personnel by electrocution. __________ WARNING Diesel fuel is flammable and toxic to eyes, skin, and respiratory tract. Skin and eye protection are required when working in contact with diesel fuel, and avoid repeated or prolonged contact. Provide adequate ventilation. Failure to comply can cause injury or death to personnel.
__________ WARNING Fuels used in the generator set are flammable. When filling the fuel tank, maintain metal-to-metal contact between filler nozzle and fuel tank opening to eliminate static electrical discharge. Failure to comply can result in flames and possible explosion and can cause injury or death to personnel and damage to the generator set. __________ WARNING Fuels used in the generator set are flammable. Do not smoke or use open flames when performing maintenance. Failure to comply can result in flames and possible explosion and can cause injury or death to personnel and damage to the generator set. __________ WARNING CARC paint is a health hazard. Wear protective eyewear, mask and gloves when sanding CARC painted surfaces. Failure to comply can cause personal injury. __________ WARNING Dry cleaning solvent is flammable and toxic to eyes, skin, and respiratory tract. Skin and eye protection are required when working in contact with dry cleaning solvent. Avoid repeated or prolonged contact. Work in ventilated area only. Failure to comply can cause injury or death to personnel. __________ WARNING Exhaust discharge contains deadly gases including carbon monoxide. Do not operate generator set in an enclosed area unless exhaust discharge is properly vented outside. Failure to comply can cause injury or death to personnel. __________ WARNING Batteries give off a flammable gas. Do not smoke or use open flame when performing maintenance. Failure to comply can cause injury or death to personnel and equipment damage due to flames and explosion.
__________ WARNING Hot engine surfaces and sparks from the engine and generator circuitry are possible sources of ignition. When hot refueling with DF-1, DF-2, DF-A, JP5 or JP8, avoid fuel splash and fuel spill. Do not smoke or use open flame when performing refueling. Failure to comply can result in flames and possible explosion and can cause injury or death to personnel and damage to the generator set. __________ WARNING Hot exhaust gases can ignite flammable materials. Allow room for safe discharge of hot gases and sparks. Failure to comply can cause injury or death to personnel. __________ WARNING If necessary to move a generator set which has been operating in parallel with another generator set, shut down both generator sets prior to removing load cables or ground. Failure to comply can cause injury or death to personnel by electrocution.
__________ WARNING Engine exhaust is hot. When it is required to extend exhaust pipe through flammable material (i.e., wall), shield the extension pipe to protect personnel from burns and prevent fire hazard. Failure to comply can cause injury to personnel, damage to equipment, and fire.
__________ WARNING Prior to making any connections for parallel operation or moving a generator set which has been operating in parallel, ensure there is no input to the load output terminal board and the generator sets are shut down. Failure to comply can cause injury or death to personnel by electrocution.
__________ WARNING Cooling system operates at high temperature and pressure. Contact with high pressure steam and/or liquids can result in burns and scalding. Shut down generator set, and allow system to cool before performing checks, services, and maintenance. Failure to comply can cause injury to personnel. __________ WARNING Cooling system operates at high temperatures. Hot coolant is under high pressure and can spray when cooling system is opened. Shut down generator set and allow to cool before servicing radiator. Failure to comply can cause damage to equipment and injury to personnel. __________ WARNING In extreme cold weather, skin can stick to metal. Avoid contacting metal items with bare skin in extreme cold weather. Failure to comply can cause injury to personnel. __________ WARNING Battery acid can cause burns to unprotected skin. Wear protective gloves and safety goggles. Failure to comply can cause injury to personnel. __________ WARNING Cleaning with compressed air can cause flying particles. When using compressed air, wear protective glasses and use clean, low pressure air, less than 30 psi (206.8 kPa). Failure to comply can cause eye injury. __________ WARNING Exhaust system can get very hot. Allow system to cool before performing maintenance. Failure to comply can cause severe burns and injury to personnel. __________ WARNING If not wrapped, hot exhaust pipe can cause burns. Wrap exhaust pipe with protective material. Failure to comply can cause severe injury to personnel.
_________ WARNING Lifting batteries from the battery tray can cause back strain. Ensure proper lifting techniques are used when lifting batteries. Failure to comply can cause personal injury. _________ WARNING Top housing panels can get very hot. Allow panels to cool down before performing maintenance. Failure to comply can result in severe burns to personnel. __________ WARNING Operating the generator set with any access door open exposes personnel to a high noise level. Hearing protection must be worn when operating or working near the generator set with any access door open. Failure to comply can cause hearing damage to personnel. __________ WARNING Breathing ether fumes can cause fainting. Do not manually discharge or deliberately inhale ether. Failure to comply can cause injury to personnel. __________ WARNING Operating the generator set with restricted air flow for cooling can cause the generator set to overheat. Keep all access door inlet panels clear to ensure maximum air flow for engine and generator cooling. Failure to comply can result in poor engine performance and possible overheating and automatic shutdown. __________ WARNING Generator is heavy. Obtain assistance when moving generator with hoist. Failure to comply can cause injury to personnel.
__________ WARNING When disconnecting or removing batteries, disconnect the negative lead that connects directly to the grounding stud first. Disconnect the negative end of the interconnection cable next. When installing batteries, reverse the connection sequence. Failure to comply can cause serious personal injury. FOR FIRST AID, REFER TO FM 21-11.
Technical Manual No. 9-6115-672-14 Technical Order No. 35C2-3-444-32 Technical Manual No. 09244A/09245A-14
DEPARTMENTS OF THE ARMY AND THE AIR FORCE, AND HEADQUARTERS, MARINE CORPS WASHINGTON, DC, 1 July 2000
OPERATOR, UNIT, DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE MANUAL FOR GENERATOR, SKID MOUNTED, TACTICAL QUIET, 60 KW, 50/60 AND 400 HZ
MEP-806B (50/60 HZ) (NSN 6115-01-462-0291) (EIC:GGW) MEP-816B (400 HZ) (NSN 6115-01-462-0292) (EIC:GGX)
REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS You can help improve this manual. If you find any mistakes, or if you know of a way to improve the procedures, please let us know. Mail your letter, DA Form 2028 (Recommended Changes to Publications and Blank Forms) or DA Form 2028-2 located in back of this manual directly to: Commander, US Army Communications-Electronics Command and Fort Monmouth, ATTN: AMSEL-LC-LEO-D-CS-CFO, Fort Monmouth, New Jersey 07703-5006. The fax number is 732532-1413, DSN 992-1413. You may also e-mail your recommendations to [email protected] For Air Force, submit AFTO Form 22 (Technical Order System Publication Improvement Report and Reply) in accordance with paragraph 6-5, Section VI, TO 00-5-1. Forward direct to prime ALC/MST. Marine Corps units, submit NAVMC 10772 (Recommended Changes to Technical Publications) to: Commanding General, Marine Corps Logistics Base (Code 850), Albany, Georgia 317045000. In any case, we will send you a reply.
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 TABLE OF CONTENTS Chapter\ Section Page How To Use This Manual.............................................................................................................................................ix Chapter 1 Section I 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11 Section II 1.12 1.13 1.14 Section III 1.15 1.16 1.17 Chapter 2 Section I 2.1 2.2 2.3 2.4 Section II 2.5 2.6 Section III 2.7 2.8 2.9 2.10 2.11 2.12 2.13 2.14 Section IV 2.15 2.16 2.17 2.18 2.19 2.20 2.21 Introduction General Information.........................................................................................................1-1 Scope ...............................................................................................................................1-1 Limited Applicability.......................................................................................................1-1 Maintenance Forms and Records .....................................................................................1-1 Reporting of Errors ..........................................................................................................1-1 Preparation for Storage or Shipment................................................................................1-3 Quality Assurance ............................................................................................................1-3 Reporting Equipment Improvement Recommendation (EIR) ..........................................1-3 List of Abbreviations .......................................................................................................1-3 Levels of Maintenance .....................................................................................................1-4 Corrosion Prevention Control ..........................................................................................1-4 Destruction of Army Materiel to Prevent Enemy Use......................................................1-4 Equipment Description and Data .....................................................................................1-4 General.............................................................................................................................1-4 Tabulated/Illustrated Data................................................................................................1-4 Differences Between Models .........................................................................................1-15 Principles of Operation ..................................................................................................1-16 Introduction....................................................................................................................1-16 Principles of Operation ..................................................................................................1-16 Location and Description of Major Components...........................................................1-35 Operating Instructions Description and Use of Operator Controls and Indicators ...............................................2-1 General.............................................................................................................................2-1 DCS Controls and Indicators ...........................................................................................2-1 Computer Interface Module (CIM) Display Screen Controls and Indicators...................2-4 Diagnostic Controls and Indicators..................................................................................2-8 Preventative Maintenance Checks and Services (PMCS) ..............................................2-14 General...........................................................................................................................2-14 PMCS Procedures..........................................................................................................2-14 Operation Under Usual Conditions................................................................................2-21 General...........................................................................................................................2-21 Generator Set Installation ..............................................................................................2-21 Assembly and Preparation for Use.................................................................................2-24 Initial Adjustments, Checks, and Self-Test ....................................................................2-27 Operating Procedure ......................................................................................................2-30 Parallel Unit Operation (Load Sharing) .........................................................................2-33 Remote Operation ..........................................................................................................2-36 Preparation for Movement .............................................................................................2-39 Operation Under Unusual Conditions............................................................................2-41 Operation in Extreme Cold Weather Below -25 F (-31 C) .........................................2-41 Operation in Extreme Heat Above 120 F (48.8 C) .....................................................2-42 Operation in Dusty or Sandy Areas................................................................................2-42 Operation Under Rainy or Humid Conditions ...............................................................2-43 Operation in Salt Water Areas .......................................................................................2-43 Operation at High Altitudes ...........................................................................................2-44 NATO SLAVE RECEPTACLE Start Operation ...........................................................2-44
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ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 TABLE OF CONTENTS (continued) Chapter\ Section 2.22 2.23 2.24 2.25 2.26 Chapter 3 Section I 3.1 Section II 3.2 Section III 3.3 Chapter 4 Section I 4.1 Section II 4.2 Section III 4.3 Section IV 4.4 Section V 4.5 Section VI 4.6 4.7 4.8 4.9 4.10 4.11 4.12 4.13 4.14 Section VII 4.15 4.16 Chapter 5 Section I 5.1 Section II 5.2 Page Emergency Stopping ......................................................................................................2-44 Operation Using Battle Short Switch .............................................................................2-44 Nuclear, Biological, and Chemical (NBC) Decontamination Procedures......................2-45 Operation While Contaminated .....................................................................................2-46 Operation in a High Altitude Electromagnetic Pulse (HAEMP) Environment ..............2-46 Operator Maintenance Instructions Lubrication Procedures ....................................................................................................3-1 Operator Lubrication Instructions....................................................................................3-1 Troubleshooting...............................................................................................................3-1 General.............................................................................................................................3-1 Symptom Index................................................................................................................3-1 Operator Maintenance Procedures.................................................................................3-18 Generator Set Inspection and Service ............................................................................3-18 Unit Maintenance Instructions Inspecting and Servicing the Equipment..........................................................................4-1 Inspecting and Servicing the Equipment..........................................................................4-1 Repair Parts; Tools; Test, Measurement and Diagnostic Equipment (TMDE); and Support Equipment .................................................................4-6 Introduction......................................................................................................................4-6 Lubrication Procedures ....................................................................................................4-6 Unit Lubrication Instructions ...........................................................................................4-6 Unit Preventive Maintenance Checks and Services (PMCS) ...........................................4-7 PMCS Procedures............................................................................................................4-7 Troubleshooting.............................................................................................................4-10 General...........................................................................................................................4-10 Symptom Index..............................................................................................................4-10 Unit Maintenance Procedures ........................................................................................4-49 Maintenance of DC Electrical System ...........................................................................4-49 Maintenance of Housing ................................................................................................4-56 Maintenance of DCS Control Box Assembly ................................................................4-78 Maintenance of Air Intake and Exhaust System ..........................................................4-142 Maintenance of Engine Cooling System ......................................................................4-151 Maintenance of Fuel System........................................................................................4-170 Maintenance of Output Box Assembly ........................................................................4-184 Maintenance of Engine Accessories ............................................................................4-195 Maintenance of Lubrication System.............................................................................4-205 Preparation for Shipment and Storage .........................................................................4-206 Preparation for Shipment and Storage .........................................................................4-206 CIM Configuration Switch...........................................................................................4-208 Direct Support Maintenance Instructions Repair Parts; Tools; Test, Measurement and Diagnostic Equipment (TMDE); and Support Equipment........................................................................................................................5-1 Introduction......................................................................................................................5-1 Lubrication Procedures ....................................................................................................5-1 Direct Support Lubrication Instructions...........................................................................5-1
iii
TABLE OF CONTENTS (continued) Chapter\ Section Section III 5.3 Section IV 5.4 5.5 5.6 5.7 5.8 5.9 5.10 5.11 Page Troubleshooting...............................................................................................................5-2 General.............................................................................................................................5-2 Symptom Index................................................................................................................5-2 Direct Support Maintenance Procedures........................................................................5-14 Removal and Installation of Major Components ...........................................................5-14 Maintenance of DCS Control Box Assembly ................................................................5-22 Maintenance of Cooling System ....................................................................................5-24 Maintenance of Fuel System..........................................................................................5-25 Maintenance of Output Box Assembly ..........................................................................5-28 Maintenance of Engine Accessories ..............................................................................5-41 Maintenance of Generator Assembly.............................................................................5-43 Maintenance of Skid Base .............................................................................................5-59
Chapter 6 Appendix A Appendix B Section I Section II Section III Section IV Appendix C Section I Section II Section III Appendix D Section I Section II Appendix E Section I Section II Appendix F Appendix G Appendix H Section I Section II Appendix I Section I Section II
General Support Maintenance Instructions ......................................................................6-1 References.......................................................................................................................A-1 Maintenance Allocation Chart (MAC) Introduction.....................................................................................................................B-1 Maintenance Allocation Chart (MAC)............................................................................B-4 Tools and Test Equipment for MEP-806B and 816B ...................................................B-13 Remarks ........................................................................................................................B-13 Components of End Item (COEI) and Basic Issue Items (BII) List Introduction.....................................................................................................................C-1 Components of End Item ................................................................................................C-1 Basic Issue Items ............................................................................................................C-2 Additional Authorization List (AAL) Introduction.....................................................................................................................D-1 Additional Authorization List .........................................................................................D-1 Expendable and Durable Items List Introduction..................................................................................................................... E-1 Expendable and Durable Items List ................................................................................ E-1 Operators Lubrication Instructions ................................................................................ F-1 Illustrated List of Manufactured Items............................................................................G-1 Torque Limits Introduction.....................................................................................................................H-1 Torque Limits .................................................................................................................H-1 Mandatory Replacement Parts Introduction...................................................................................................................... I-1 Mandatory Replacement Parts ......................................................................................... I-1
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ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 TABLE OF CONTENTS (continued) Chapter\ Section Page Index ....................................................................................................................................................................Index-1 Fold-outs Schematic ................................................................................................................................................. FO-1 Wiring Diagram........................................................................................................................................ FO-3
LIST OF ILLUSTRATIONS Figure 1-1 1-2 1-3 1-4 1-5 1-6 1-7 1-8 1-9 1-10 1-11 1-12 1-13 1-14 1-15 1-16 1-17 1-18 1-19 1-20 1-21 1-22 1-23 1-24 1-25 1-26 1-27 1-28 1-29 1-30 2-1 2-2 2-3 2-4 2-5 2-6 2-7 2-8 2-9 2-10 2-11 2-12 Page 60 Kw Tactical Quiet Generator Set.............................................................................................................1-2 Locations of Data Plates and Access Doors (Front and Right Side).............................................................1-7 Locations of Data Plates and Access Doors (Rear and Left Side)................................................................1-8 Operating Instruction Plate, MEP-806B.......................................................................................................1-9 Operating Instruction Plate, MEP-816B.....................................................................................................1-10 Identification Plate, MEP-806B and MEP-816B .......................................................................................1-11 Set Rating Identification Plate, MEP-806B and MEP-816B ......................................................................1-11 Voltage Connection Caution Plate..............................................................................................................1-12 Grounding Stud Plate .................................................................................................................................1-12 NATO SLAVE RECEPTACLE Plate ........................................................................................................1-12 PARALLELING RECEPTACLE Plate......................................................................................................1-12 CONVENIENCE RECEPTACLE Plate, MEP-806B and MEP-816B.......................................................1-12 EXTERNAL FUEL SUPPLY Plate ...........................................................................................................1-12 Battery Connection Instruction Plate..........................................................................................................1-13 Lifting and Tiedown Diagram Plate ...........................................................................................................1-13 FUEL SYSTEM DIAGRAM Plate ............................................................................................................1-14 Generator Identification Plate (located on generator), MEP-806B and MEP-816B...................................1-14 COMMUNICATION PORT ......................................................................................................................1-14 Fault System Flow Diagram .......................................................................................................................1-18 Governor Control System Flow Diagram ...................................................................................................1-19 Voltage Regulation System Flow Diagram.................................................................................................1-21 Fuel System Flow Diagram ........................................................................................................................1-22 Generator Set Cooling System Flow Diagram............................................................................................1-24 Engine Cooling System Flow Diagram.......................................................................................................1-25 Lubrication System Flow Diagram.............................................................................................................1-26 Engine Air Intake and Exhaust System Flow Diagram...............................................................................1-28 Output Supply System Flow Diagram ........................................................................................................1-30 Brushless Generator Schematic ..................................................................................................................1-31 Engine Starting System Flow Diagram.......................................................................................................1-33 60 kW Generator Set Components .............................................................................................................1-36 DCS Controls and Indicators........................................................................................................................2-2 CIM Display Screen Controls and Indicators ..............................................................................................2-5 Diagnostic Controls and Indicators ..............................................................................................................2-9 Base Mounting Measurements ...................................................................................................................2-22 Minimum Enclosure Clearance Measurements ..........................................................................................2-23 Grounding Connections..............................................................................................................................2-25 Installation of Load Cables.........................................................................................................................2-27 Generator Set Controls ...............................................................................................................................2-28 CIM Display Screen Controls and Indicators ............................................................................................2-32 Parallel Operation Setup.............................................................................................................................2-34 Remote PC Display Modes.........................................................................................................................2-40 Remote PC Setup........................................................................................................................................2-41
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 LIST OF ILLUSTRATIONS (continued) Figure 2-13 3-1 3-2 3-3 3-4 3-5 3-6 4-1 4-2 4-3 4-4 4-5 4-6 4-7 4-8 4-9 4-10 4-11 4-12 4-13 4-14 4-15 4-16 4-17 4-18 4-19 4-20 4-21 4-22 4-23 4-24 4-25 4-26 4-27 4-28 4-29 4-30 4-31 4-32 5-1 5-2 5-3 5-4 5-5 5-6 5-7 5-8 5-9 Page NATO SLAVE RECEPTACLE .................................................................................................................2-45 Air Cleaner Element Replacement .............................................................................................................3-21 Crankcase Breather Filter Assembly ..........................................................................................................3-23 Coolant Recovery (Overflow) Bottle..........................................................................................................3-25 Fuel Tank Filler Neck.................................................................................................................................3-27 Fuel Filter/Water Separator ........................................................................................................................3-30 Dipstick and Oil Fill Cap............................................................................................................................3-31 Fuel Drain Valve and Oil Drain ...................................................................................................................4-4 Dipstick and Oil Fill Cap..............................................................................................................................4-6 Batteries and Cables ...................................................................................................................................4-51 NATO SLAVE RECEPTACLE and Cables ..............................................................................................4-52 Generator Set Access Doors.......................................................................................................................4-58 DCS Control Box Top Panel ......................................................................................................................4-61 Top Housing Section ..................................................................................................................................4-64 Front Housing Section................................................................................................................................4-69 Rear Housing Section .................................................................................................................................4-75 DCS Control Box Assembly.......................................................................................................................4-82 DCS Control Panel Lights DS1 Through DS3 and NETWORK FAILURE Light DS5.............................4-83 Time Meter and Switches ...........................................................................................................................4-85 DCS Control Panel Components ................................................................................................................4-92 CIM and Receptacles................................................................................................................................4-102 DCS Control Box Back Panel Components .............................................................................................4-109 DCS Control Box Floor Components.......................................................................................................4-120 Diode Identification..................................................................................................................................4-124 DCS Control Box Panels ..........................................................................................................................4-137 Muffler and Exhaust Pipe .........................................................................................................................4-143 Air Cleaner Assembly...............................................................................................................................4-145 Crankcase Breather Filter Assembly ........................................................................................................4-152 Cooling System ........................................................................................................................................4-153 Fan Guards ..............................................................................................................................................4-157 Coolant Recovery System.........................................................................................................................4-165 Fan Belt ....................................................................................................................................................4-169 Fuel Tank Filler Neck and Low Pressure Fuel System.............................................................................4-172 Ether Start System ....................................................................................................................................4-180 Output Box Assembly ..............................................................................................................................4-185 Load Output Terminal Board Assembly...................................................................................................4-192 Engine Switches and Senders ...................................................................................................................4-196 Battery Current Transducer ......................................................................................................................4-204 Oil Drain Valve ........................................................................................................................................4-207 Engine and Generator Assembly ................................................................................................................5-21 Fuel Tank....................................................................................................................................................5-27 Output Box Assembly ................................................................................................................................5-30 Output Box Components ............................................................................................................................5-36 Testing Current Transformer ......................................................................................................................5-37 Testing Droop Current Transformer...........................................................................................................5-38 Electric Actuator.........................................................................................................................................5-42 Generator Assembly Removal ....................................................................................................................5-46 Generator Assembly ...................................................................................................................................5-48
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Figure 5-10 5-11 5-12 5-13 G-1 G-2 G-3 G-4 G-5 G-6 G-7 G-8 G-9 G-10 G-11 G-12 G-13 G-14 G-15 G-16 G-17 G-18 G-19 G-20 G-21 G-22 G-23 G-24 G-25 G-26 G-27 G-28 G-29 G-30 G-31 G-32 G-33 G-34 G-35
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 LIST OF ILLUSTRATIONS (continued) Page End Bell Removal ......................................................................................................................................5-49 Rectifier Assembly .....................................................................................................................................5-52 Rotor Assembly Lifting Device (Typical) ..................................................................................................5-57 Skid Base....................................................................................................................................................5-60 Cable Assembly, AC Power (P/Ns 88-22128-1 through 88-22128-7).........................................................G-2 Cable Assembly, Battery (P/N 88-22206) ...................................................................................................G-3 Cable Assembly, Battery (P/N 88-22127) ...................................................................................................G-4 Cable Assembly, Battery (P/N 88-22208) ...................................................................................................G-5 Cable Assembly, Battery (P/N 88-22179) ...................................................................................................G-6 Cable Assembly, Battery (P/N 88-22207) ...................................................................................................G-7 Capacitor Assembly, EMI (P/N 88-22758) .................................................................................................G-8 Cord, Load Wrench (P/N 88-22469) ...........................................................................................................G-9 Diode Assembly (P/N 88-22418-2) ...........................................................................................................G-10 Holder, Control Panel (P/N 88-22120)......................................................................................................G-11 Hose Assembly (P/N 88-20191-7) ............................................................................................................G-12 Insulation, Air Baffle (P/N 88-22616).......................................................................................................G-13 Insulation, Baffle (P/N 88-22769) .............................................................................................................G-14 Insulation, Door (P/N 88-22610)...............................................................................................................G-15 Insulation, Baffle (P/N 88-22615) .............................................................................................................G-16 Insulation, Baffle (P/N 88-22612) .............................................................................................................G-17 Insulation, Door (P/N 88-22601)...............................................................................................................G-18 Insulation, Floor Duct (P/N 88-22599) .....................................................................................................G-19 Insulation, Duct Floor (P/N 88-22600) .....................................................................................................G-20 Insulation, Baffle (P/N 88-22592) .............................................................................................................G-21 Insulation, Panel, Right (P/N 88-22614) ...................................................................................................G-22 Insulation, Rear Panel (P/N 88-22598) .....................................................................................................G-23 Insulation, Rear, Left Side (P/N 88-22637)...............................................................................................G-24 Insulation, Top Front (P/N 88-22602).......................................................................................................G-25 Insulation, Door (P/N 88-22609)...............................................................................................................G-26 Insulation, Door (P/N 88-22770)...............................................................................................................G-27 Insulation, Center, Right Side (P/N 88-22603) .........................................................................................G-28 Insulation, Center, Front (P/N 88-22604)..................................................................................................G-29 Insulation, Top Center (P/N 88-22605).....................................................................................................G-30 Insulation, Panel, Top (P/N 88-22611) .....................................................................................................G-31 Insulation, Housing, Front (P/N 88-22596)...............................................................................................G-32 Pump Assembly, Fuel (P/N 88-22546)......................................................................................................G-33 Solenoid Assembly (P/N 88-22553)..........................................................................................................G-34 Switch Assembly (P/N 88-22549) .............................................................................................................G-35 Wire, Varistor (P/N 88-20305-6 and 88-20305-9) ....................................................................................G-36 LIST OF TABLES
Table 1-1 1-2 2-1 2-2 2-3 2-4
Page Tabulated Data .............................................................................................................................................1-4 Performance Characteristics .......................................................................................................................1-15 DCS Controls and Indicators........................................................................................................................2-3 CIM Display Screen Controls and Indicators ...............................................................................................2-6 Faults ............................................................................................................................................................2-7 Diagnostic Controls and Indicators ............................................................................................................2-11
vii
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 LIST OF TABLES (continued) Table 2-5 2-6 2-7 3-1 3-2 3-3 3-4 4-1 4-2 4-3 4-4 5-1 5-2 G-1 H-1 H-2 H-3 Page Operator Preventive Maintenance Checks and Services (PMCS) ..............................................................2-16 Load Terminal and AC Reconnection Board Selection..............................................................................2-26 Fuel.............................................................................................................................................................2-42 Operator Troubleshooting ............................................................................................................................3-2 Coolant .......................................................................................................................................................3-26 Diesel Fuel..................................................................................................................................................3-28 Quick Reference General Inspection ..........................................................................................................3-32 Coolant .........................................................................................................................................................4-3 Fuel...............................................................................................................................................................4-5 Unit Preventive Maintenance Checks and Services (PMCS) .......................................................................4-8 Unit Troubleshooting .................................................................................................................................4-12 Direct Support Troubleshooting ...................................................................................................................5-3 Generator Resistance Values at 25 C (77 F)............................................................................................5-53 Metric Conversion.....................................................................................................................................G-37 Torque Limits for Dry Fasteners .................................................................................................................H-1 Effect of Lubrication on Torque..................................................................................................................H-2 Torque Limits for Dry Fasteners (Metric) ...................................................................................................H-3
viii
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 HOW TO USE THIS MANUAL In this manual (TM 9-6115-672-14) paragraphs are underlined and sections and chapters appear in capital letters. The location of additional material that must be referenced is clearly marked. Illustrations in this text are located as close as possible to their references. Chapter 1 INTRODUCTION. Contains general information, equipment description and data, and principles of operation for the generator set. Chapter 2 OPERATING INSTRUCTIONS. Contains description and use of operator controls and indicators, Preventive Maintenance Checks and Services (PMCS), procedures for inspecting and servicing the generator set, and instructions for operating the generator set under usual and unusual conditions. Chapter 3 OPERATOR MAINTENANCE INSTRUCTIONS. Contains troubleshooting procedures used to recognize and correct operator level generator set malfunctions, and all maintenance procedures authorized to be performed on the generator set at the operator level. Chapter 4 UNIT MAINTENANCE INSTRUCTIONS. Contains troubleshooting procedures used to recognize and correct generator set malfunctions at the unit level, and all maintenance procedures authorized to be performed on the generator set at the unit level. Chapter 5 DIRECT SUPPORT MAINTENANCE INSTRUCTIONS. Contains direct support level troubleshooting procedures used to recognize and correct generator set malfunctions at the direct support level, and all maintenance procedures authorized to be performed on the generator set at the direct support level. Chapter 6 GENERAL SUPPORT MAINTENANCE INSTRUCTIONS. There are no general support level maintenance tasks for the generator set. APPENDICES. Appendix A lists publications referenced in this manual and should be used in conjunction with this manual. Appendix B is the Maintenance Allocation Chart (MAC) which designates all maintenance and repair functions authorized to be performed at the different maintenance levels. Appendix C lists the Components of End Item (COEI) and Basic Issue Items (BII). Appendix D lists items authorized for use with the generator set, but not issued with it or supported by generator set engineering drawings. Appendix E is the Expendable/Durable Supplies and Materials List (EDSML) which lists all expendable/durable supplies and materials required in performing the maintenance procedures presented in this manual. Appendix F contains lubrication procedures for the generator set at the operator level. Appendix G lists all parts that require fabrication or assembly for the maintenance of the generator set. Materials and procedures required are included. Appendix H provides torque limits for fasteners used in maintenance of the generator set. Appendix I lists parts that must be replaced when maintenance tasks require their removal.
ix
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 HOW TO USE THIS MANUAL (continued)
Index. The index contains key technical manual subjects arranged in alphabetical order. To find information on a specific subject (i.e., Time Meter), use the index to locate specific paragraph.
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 CHAPTER 1 INTRODUCTION SECTION I. GENERAL INFORMATION 1.1 1.1.1 SCOPE. Type of Manual. This manual contains Unit, Direct Support, and General Support maintenance instructions for the Tactical Quiet (TQ), 60 kW 50/60 and 400 Hz Generator Sets (Figure 1-1), herein referred to as generator sets. Included are descriptions of major components and their functions in relation to other components. 1.1.2 Model Numbers and Equipment Names Model Number MEP-806B Equipment Name Generator Set, Skid Mounted, Tactical Quiet 60 kW 50/60 Hz Generator Set, Skid Mounted, Tactical Quiet 60 kW 400 Hz
MEP-816B
1.2
LIMITED APPLICABILITY. Some portions of this publication are not applicable to all services. These portions are prefixed to indicate the service(s) to which they pertain: (A) for Army, (F) for Air force, and (MC) for Marine Corps. Portions not prefixed are applicable to all services.
1.3
MAINTENANCE FORMS AND RECORDS. (A) Maintenance forms and records used by Army Personnel are prescribed by DA PAM 738-750. (F) Maintenance forms and records used by Air Force personnel are prescribed in AFI 21-101, AFI 37-160 and the applicable TO 00-20 Series Technical Orders. (MC) Maintenance forms and records used by Marine Corps personnel are prescribed by TM 4700-15/1.
1.4
REPORTING OF ERRORS. Reporting of errors, omissions, and recommendations for the improvement of this publication by the individual user is encouraged. Reports should be submitted as follows: (A) Army Mail your letter, DA Form 2028 (Recommended Changes to Publications and Blank Forms), or DA Form 2028-2 located in the back of this manual direct to: Commander, U.S. Army Communications and Electronics Command (CECOM), Customer Feedback Office, ATTN: AMSEL-LC-LEO-D-CS-CFO, Fort Monmouth, New Jersey 07703-5008 (F) Air Force AFTO Form 22 in accordance with TO-00-5-1. Mail directly to Commander, Sacramento Air Logistics Center, ATTN: TILBA, McClellan AFB, CA 95652-5990 (AFMC).
1-1
FIGURE 1-1. 60 kW TACTICAL QUIET GENERATOR SET 1-2
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 (MC) Marine Corps by NAVMC form 10772 directly to Commanding General Marine Corps Logistics Base (Code 850), Albany, GA 31704-5000. 1.5 PREPARATION FOR STORAGE OR SHIPMENT. Refer to TB 740-97-2/TO 35-1-4 for procedures to place the generator set into storage. Refer to MIL-G-28554 for procedures on preparing the generator set for shipment. 1.6. QUALITY ASSURANCE (QA). Where applicable, Quality Assurance (QA) requirements have been incorporated into the technical manual. When required, each procedure, paragraph or step in this manual requiring quality assurance is highlighted by the designation "(QA)". 1.7 REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATION (EIR). If your 60 kW Generator needs improvement, let us know. Send us an EIR. You, the user, are the only one who can tell us what you dont like about your equipment. Let us know why you dont like the design or performance. Put it on a SF 368 (Product Quality Deficiency Report). Mail it to us at the address below. We will send you a reply. Commander U.S. Army Communications and Electronics Command (CECOM) Customer Feedback Office ATTN: AMSEL-LC-LEO-D-CS-CFO Fort Monmouth, New Jersey 07703-5008 1.7.1 (AF) USAF Deficiency Reporting and Investigating System, TO 00-35D-54, Appendix A procedures will be used for electronic submission. Submit mailed forms to: SMALC/LHCABD 5029 Dudley Boulevard McClellan AFB, CA 95652-1095 1.7.2 (MC) Quality Deficiency Reports (QDR) shall be submitted on SF 368 in accordance with MCO 4855.10. Submissions may also be made using NAVMC Form 10772. Submit directly to: Commander Marine Corps Logistics Bases (Code 856) Albany, GA 31704-5000 A reply will be furnished to you. 1.8 LIST OF ABBREVIATIONS. AOAP CIM DCS DS2 PC PPE STB TQ Army Oil Analysis Program Computer Interface Module Digital Control System Decontaminating Solution Number 2 Personal Computer Personal Protection Equipment Supertropical Bleach Tactical Quiet
1-3
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 1.9 1.9.1 LEVELS OF MAINTENANCE. (A) Army users shall refer to the Maintenance Allocation Chart (MAC) for tasks and levels of maintenance to be performed. (MC) Marine Corps users shall refer to the Source, Maintenance and Recoverability (SMR) Codes for maintenance to be performed. CORROSION PREVENTION AND CONTROL. Refer to Corrosion and Corrosion Prevention: Metals, MIL-HDBK-729. 1.11 DESTRUCTION OF ARMY MATERIEL TO PREVENT ENEMY USE. Destruction of the generator set to prevent enemy use shall be in accordance with TM 750-244-3.
1.9.2
1.10
SECTION II. EQUIPMENT DESCRIPTION AND DATA 1.12 GENERAL. The generator set, models MEP-806B and MEP-816B (Figure 1-1) are fully enclosed, self-contained, skidmounted, portable units. They are equipped with controls, instruments, and accessories necessary for operation as single units or in parallel with another unit of the same class and mode. The generator sets include a diesel engine, brushless generator, excitation system, speed governing system, fuel system, 24 VDC starting system, DCS, and fault system. 1.13 1.13.1 TABULATED/ILLUSTRATED DATA. For a list of Tabulated Data, refer to Table 1-1. TABLE 1-1. TABULATED DATA (Continued) MEP-806B 1. Generator Set: a. National Stock Number b. Overall Length c. Overall Width d. Overall Height e. Dry Weight (less Basic Issue Items List) f. Wet Weight Engine: a. Manufacturer b. Model c. Type d. e. Displacement Altitude Degradation, 4000 ft. (1220 m) to 8000 ft. (2440 m) 6115-01-462-0291 87.0 in. (221.0 cm) 35.7 in. (90.8 cm) 59.0 in. (142.2 cm) 3556.0 lb. (1613.0 kg) 3992.0 lb. (1810.8 kg) John Deere 6068TF151 Six cylinder, four cycle, Turbocharged diesel 359 cu. In. (5.9 liters) 3.5% per 1000 ft. (305 m) MEP-816B 6115-01-462-0292 87.0 in. (221.0 cm) 35.7 in. (90.8 cm) 59.0 in. (142.2 cm) 3603.0 lb. (1635.7 kg) 4042.0 lb. (1883.5 kg) John Deere 6068TF151 Six cylinder, four cycle, turbocharged diesel 359 cu. in. (5.9 liters) 3.5% per 1000 ft. (305 m)
2.
f. Firing Order 2. Engine (Continued): g. 1-4 Cold Weather Starting Aid System Use
1, 5, 3, 6, 2, 4
1, 5, 3, 6, 2, 4
40F (4C) or below
40F (4C) or below
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 TABLE 1-1. TABULATED DATA (Continued) MEP-806B Valve Tappet Clearance Adjustment: Hot or Cold (Intake) Hot or Cold (Exhaust) Cooling System: a. Type Capacity Normal Operating Temperature Temperature Indicating System Voltage Rating Lubricating System: a. Type b. Oil Pump Type c. Normal Operating Pressure d. Oil Filter Type e. f. 5. Capacity Pressure Indicating System Voltage Rating Fuel System: a. Type of Fuel b. c. d. Fuel Tank Capacity Fuel Consumption Rate Auxiliary Fuel Pump: (1) Voltage Rating (2) Delivery Pressure Injection Pump (1) Manufacturer (2) Model Electric Actuator (1) Manufacturer (2) Model b. c. d. h. 0.014 in. (0.35 mm) 0.018 in. (0.45 mm) Pressurized radiator and Pump 20.5 qts. (19.4 liters) 170-200F (77-93C) 24 VDC MEP-816B 0.014 in. (0.35 mm) 0.018 in. (0.45 mm) Pressurized radiator and pump 20.5 qts. (19.4 liters) 170-200F (77-93C) 24 VDC
3.
4.
Full flow, circulating pressure Positive displacement gear 25-60 psi (172-414 kPa) Full flow, spin-on Replacement element 18 qts. (17 liters) 24 VDC
Full flow, circulating pressure Positive displacement gear 25-60 psi (172-414 kPa) Full flow, spin-on replacement element 18 qts. (17 liters) 24 VDC
DF-1, DF-2, DF-A, JP5, JP8 43.0 gal. (162.7 liters) 5.06 gal. (19.20 liters) per hour 24 VDC 5.0-6.5 psi (34.5-65.5 kPa) (max.) Stanadyne DB4269-5278
DF-1, DF-2, DF-A, JP5, JP8 43.0 gal. (162.7 liters) 5.37 gal. (20.30 liters) per hour 24 VDC 5.0-6.5 psi (34.5-65.5 kPa) (max.) Stanadyne DB4269-5278
e.
f.
Governors of America ADC100-24
Governors of America ADC100-24
6.
Engine Starting System: a. Batteries b. Starter: (1) Manufacturer (2) Model (3) Voltage Rating (4) Drive Type
Two 12 volt, connected in Series Denso RE 40595 24 VDC Gear reduction
Two 12 volt, connected in series Denso RE 40595 24 VDC Gear reduction
1-5
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 TABLE 1-1. TABULATED DATE (Continued) MEP-806B 6. Engine Starting System (Continued) c. Battery Charging Alternator: (1) Manufacturer (2) Model (3) Rating (4) Protective Fuse AC Generator: a. Manufacturer b. Type c. Load Capacity d. Model e. Current Ratings: (1) 120/208 volt connection (2) 240/416 volt connection f. g. h. i. 8. Power Factor Cooling Drive Type Duty Classification MEP-816B
Bosch 9 120 060 039 42 amps at 24 VDC 30 amps
Bosch 9 120 060 039 42 amps at 24 VDC 30 amps
7.
Marathon Electric Rotating field, synchronous 60 Kw 88-21009 60 Hz: 208 amps 50 Hz: 173 amps 60 Hz: 104 amps 50 Hz: 86 amps 0.8 Fan cooled Direct coupling Continuous
Marathon Electric Rotating field, synchronous 60 kW 88-21010 208 amps 104 amps 0.8 Fan cooled Direct coupling Continuous
Governing System: a. DCS Load Sharing Synchronizer: (1) Manufacturer (2) Model b. DCS Speed Control Unit: (1) Manufacturer (2) Model c. I/O Interface Module (1) Manufacturer (2) Model d. Backplane Module (1) Manufacturer (2) Model e. Automatic Voltage Regulator (1) Manufacturer (2) Model
Governors of America LSS100 Governors of America ESD5551 Governors of America TCM100 Governors of America TCM102 Governors of America AVR100
Governors of America LSS400 Governors of America ESD5551 Governors of America TCM400 Governors of America TCM102 Governors of America AVR100
1.13.2
DATA PLATES. There are data plates at various locations on the generator set to provide instructions, cautions, and identification. Figures 1-2 through 1-18 show the location and contents of each plate on the generator set. The wiring diagram and schematic diagram plates are located at the back of this manual as fold-outs.
1-6
FIGURE 1-2. LOCATION OF DATA PLATES AND ACCESS DOORS (FRONT AND RIGHT SIDE)
1-7
FIGURE 1-3. LOCATIONS OF DATA PLATES AND ACCESS DOORS (REAR AND LEFT SIDE)
1-8
FIGURE 1-4. OPERATING INSTRUCTION PLATE, MEP-806B 1-9
FIGURE 1-5. OPERATING INSTRUCTION PLATE, MEP-816B 1-10
FIGURE 1-6. IDENTIFICATION PLATE, MEP-806B AND MEP-816B
FIGURE 1-7. SET RATING IDENTIFICATION PLATE, MEP-806B AND MEP-816B
1-11
FIGURE 1-8. VOLTAGE CONNECTION CAUTION PLATE
FIGURE 1-9. GROUNDING STUD PLATE
FIGURE 1-10. NATO SLAVE RECEPTACLE PLATE
FIGURE 1-11. PARALLELING RECEPTACLE PLATE
FIGURE 1-12. CONVENIENCE RECEPTACLE PLATE, MEP-806B AND MEP-816B
FIGURE 1-13. EXTERNAL FUEL SUPPLY PLATE
1-12
FIGURE 1-14. BATTERY CONNECTION INSTRUCTION PLATE
FIGURE 1-15. LIFTING AND TIEDOWN DIAGRAM PLATE
1-13
FIGURE 1-16. FUEL SYSTEM DIAGRAM PLATE
FIGURE 1-17. GENERATOR IDENTIFICATION PLATE (LOCATED ON GENERATOR), MEP-806B AND MEP-816B
R EC EP TAC LE
FIGURE 1-18. COMMUNICATION RECEPTACLE PLATE
1-14
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 1.14 1.14.1 DIFFERENCES BETWEEN MODELS. The differences between generator set models covered in this manual are as follows: a. Model MEP-806B is equipped with a 50/60 Hz AC generator and three DCS modules which may not be used on the MEP-816B (see Table 1-1). Model MEP-816B is equipped with a 400 Hz AC generator and three DCS modules which may not be used on the MEP-806B (see Table 1-1).
b.
1.14.2
Performance characteristics for the two models are shown in Table 1-2.
TABLE 1-2. PERFORMANCE CHARACTERISTICS MEP-806B 1. Voltage: a. Voltage wave form deviation factor Singe voltage harmonics b. Voltage unbalance c. Phase balance voltage d. Voltage modulation e. Voltage regulation f. Short-term stability (30 seconds) g. Long-term stability (4 hours) h. Voltage drift (60F [16C] in 8-hour period) i. Dip and rise for rated load Recovery time j. Dip for low power factor load Recovery time k. Adjustment range VAC 120/208V connection 240/416V connection 5% (max.) 2% (max.) 5% of rated voltage (max.) 1% of rated voltage (max.) 1% (max.) 1% (max.) 1% of rated voltage 2% of rated voltage 1% (max.) 15% of rated voltage (max.) 0.5 seconds 30% of no-load voltage (max.) 0.7 seconds 95% of no-load Voltage 50 Hz 190-213V 380-426V 60 Hz 197-240V 395-480V 0.25% of rated frequency 0.5% of rated frequency 1% of rated frequency 0.5% (max.) 4% of rated frequency (max.) 2 seconds MEP-816B 5% (max.) 2% (max.) 5% of rated voltage (max.) 1% of rated voltage (max.) 1% (max.) 1% (max.) 1% of rated voltage 2% of rated voltage 1% (max.) 12% of rated voltage (max.) 0.5 seconds 25% of no-load voltage (max.) 0.7 seconds 95% of no-load voltage 400 Hz 195-229V 395-458V
2.
120/208V connection 240/416V connection Frequency: a. Regulation b. Short-term steady-state stability (30 seconds) c. Long-term steady-state stability (4 hours) d. Frequency drift (60F [16C] in 8 hour period) e. Undershoot with application of load Recovery time
0.25% of rated frequency 0.5% of rated frequency 1% of rated frequency 0.5% (max.) 1.5% of rated frequency (max.) 1 second
1-15
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 TABLE 1-2. PERFORMANCE CHARACTERISTICS (continued) MEP-806B 2. Frequency (continued): f. Overshoot with application of load Recovery time Adjustment range 4% of rated frequency (max.) 2 seconds 48-52 Hz, not below 45 Hz for 50 Hz operation 58-62 Hz, not above 65 Hz for 60 Hz operation SECTION III. PRINCIPLES OF OPERATION 1.15 INTRODUCTION. This section contains functional descriptions of the generator set. How the controls and indicators interact with the system is explained as well as the location and description of major components. 1.16 1.16.1 1.16.1.1 PRINCIPLES OF OPERATION. Digital Control System (DCS). The DCS is a closed-loop system providing the operator with real-time system status information and control. It includes automatic shutdown features if critical components fail to protect the generator set from damage and to prevent damaging output power and voltage levels. It includes a digital computer using software to process inputs from the generator set and from the operator. The DCS accepts operator commands to adjust various generator set parameters such as frequency and voltage. The DCS also facilitates operating two or more generator sets in parallel. The DCS can be operated at the generator set or from a remote location using an IBM-compatible personal computer (PC) In the event that the computer operating software is lost or operating incorrectly, the software must be restored. Procedures are provided for restoring the CIM software locally in Paragraph 5.12 and TQG remote software restoration is found in Paragraph 2.13.2. Eight major components or modules are included in the DCS: The DCS speed control unit, automatic voltage regulator, load sharing synchronizer, I/O interface module, backplane module, electric actuator, computer interface module (CIM), and keypad assembly. The DCS provides multiple, integrated functions as the controller of the fault, governor, and voltage regulation systems, as described below. The CIM is the primary operator interface with the DCS. It is a self-contained IBM compatible computer with an AMD 486 processor running the Windows CE operating system. An internally lit Liquid Crystal Display (LCD) screen provides the operator with status displays and control capability. A cursor symbol on the display is controlled by the keypad assembly, which is a set of four arrow keys and a SELECT key to enter commands. The load sharing synchronizer is used when paralleling the generator set to a main bus or to another generator set. This module provides signals to the DCS speed control unit to adjust engine speed settings to maintain a match between the outputs of the two generator sets. The I/O interface module controls and interfaces with all the other components in the DCS. For example, it receives inputs from engine sensors and converts them for use by the CIM. Most of the DCS signals, including control panel inputs, are routed through this module. The status of the I/O interface module is indicated by a green HEARTBEAT light emitting diode (LED) which blinks at a rate of approximately two times per second to indicate the module is operational. MEP-816B 1.5% of rated frequency (max.) 1 second 390-420 Hz, not below 370 Hz or above 430 Hz
g.
1.16.1.2
1.16.1.3
1.16.1.4
1-16
The backplane module is an installation point for three DCS modules and for the main electrical connectors from the AC generator. It connects the front panel switches and these DCS modules with the I/O interface module. This module simplifies the wiring inside the DCS control box by placing many interconnections onto one circuit board assembly. This module also includes diagnostic indicators for the DCS. The other DCS modules are discussed in paragraphs below. 1.16.2 1.16.2.1 Fault System. The Fault System (Figure 1-19) protects the generator set and any connected load against the potential faults described below and provides an indication of any incurred fault. The following summary of the Fault System will assist in understanding the operation of other generator set systems. Additional details relating to specific protection devices are provided in the descriptions of the respective systems. The Fault System consists of the CIM, I/O interface module, fuel level sender, oil pressure sender, coolant temperature sender, and BATTLE SHORT switch. Inappropriate signals received from the senders by the I/O interface module will cause the CIM to display the fault, and a message describing the condition causing the fault, on the CIM display screen. Depending on the nature of the fault, the generator set will shut down or the operator will be warned that action must be taken to avoid shutdown. Activation of the fault system will cause two events to occur. The AC interrupter relay will open and CONTACTOR POSITION status indicator on CIM display screen will indicate OPEN. Although it is possible for more than one fault to occur at one time during operation, and for more than one fault to be displayed on the CIM display screen at a time, only the first fault to occur will cause a message to appear in the MESSAGES display area of the CIM display screen. Once the condition addressed in that message has been corrected by the operator, the operator will activate the FAULT RESET switch, and the next message will be displayed. After the generator set engine has been started, the BATTLE SHORT switch may be used to override all potential faults except engine overspeed and short circuit. Governor Control System. The governor control system (Figure 1-20) includes the DCS speed control unit, electric actuator, DCS load sharing synchronizer, magnetic pickup, fuel injection pump, and FREQUENCY SELECT switch. The electric actuator controls the output of the fuel injection pump in response to the electrical input from the DCS speed control unit. The DCS provides a signal representing the desired engine speed/generator frequency to the DCS speed control unit. A signal representative of the actual engine speed/generator frequency is sent to the DCS speed control unit by the magnetic pickup. Any change in engine speed from that selected by the operator, as sensed by the magnetic pickup, causes the DCS speed control unit to increase or decrease fuel injection pump output to maintain the desired speed. Generator set frequency and power output are indicated on the CIM display screen. The FREQUENCY SELECT switch is used to set the generator for 50 hertz or 60 hertz operating frequencies (MEP-805B only). Twenty-four VDC power is supplied to the DCS speed control unit through the governor control power relay. The governor control power relay is controlled by the fault system. The DCS speed control units of two generator sets operating in parallel are interconnected by the paralleling cable.
1.16.2.2
1.16.2.3
1.16.2.4
1.16.2.5
1.16.2.6
1.16.3 1.16.3.1
1.16.3.2
1.16.3.3
1-17
FIGURE 1-19. FAULT SYSTEM FLOW DIAGRAM
1-18
FIGURE 1-20. GOVERNOR CONTROL SYSTEM FLOW DIAGRAM
1-19
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 1.16.4 Voltage Regulation System. The Voltage Regulation System (Figure 1-21) consists of the automatic voltage regulator and power potential transformer. The automatic voltage regulator senses and controls generator output voltage which is operator adjustable within the design limits by use of the VOLTAGE ADJUST switch. The power potential transformer provides operating power to the automatic voltage regulator module. Generator output voltage is indicated on the CIM display screen. 1.16.5 1.16.5.1 1.16.5.2 Fuel System. The Fuel System (Figure 1-22) includes a primary subsystem and an auxiliary subsystem. The primary subsystem consists of fuel lines, fittings, fuel tank, fuel level sender, transfer pump, fuel filter/water separator, injection pump, DCS speed control unit, and injectors. The injection pump includes a 24 VDC fuel shutoff valve. The injection pump output is controlled by the DCS speed control unit and electric actuator. The DCS speed control unit is energized whenever the ENGINE CONTROL switch is in the START position or either of the two RUN positions. With the engine cranking or running, fuel is drawn from the fuel tank by the transfer pump. After reaching the transfer pump, fuel passes through a fuel filter/water separator where water and small impurities are removed. The fuel then goes to the injection pump. With the governor system energized, the fuel is metered, pressurized and pushed through the injectors by the injection pump. Fuel is sprayed by the injectors into the diesel engine combustion chambers where it is mixed with air and ignited. Fuel that is not used by the injectors is returned to the fuel tank by an excess fuel return line. Power is removed from the DCS speed control unit, and the fuel is shut off whenever the ENGINE CONTROL switch is set to the OFF position. The DCS speed control unit is also de-energized by the fault system, paragraph 1.14.2. The CIM display screen FUEL LEVEL indicator displays the fuel level of the fuel tank from E (empty) to F (full) expressed as percent remaining. The auxiliary subsystem consists of an auxiliary fuel supply, fuel lines, fittings, and an auxiliary fuel pump. When the ENGINE CONTROL switch is set on PRIME & RUN AUX FUEL, it actuates the auxiliary fuel pump and transfers fuel from the auxiliary fuel supply to the fuel tank. The CIM shuts off the auxiliary fuel pump when the fuel tank is full and reactivates the pump as the level drops. The 24 VDC control circuits provide control and power for indicators, fault system, DCS, and auxiliary fuel pump. Mechanical System. The mechanical system provides protection from the elements, structural integrity, transportability, noise suppression, and the cooling system for the generator set. The generator set cooling system is described separately below. The mechanical system consists of the housing, insulation, air baffles, and skid base. The generator set housing is insulated to provide "tactical quiet" noise suppression which makes detection of the generator set by it's audio signature more difficult under battle conditions. Air baffles allow for airflow to cool the generator set with as little impact as possible to the generator set's noise output.
1.16.5.3
1.16.5.4 1.16.5.5
1.16.5.6
1.16.6 1.16.6.1
1.16.6.2 1.16.6.3
1-20
FIGURE 1-21. VOLTAGE REGULATION SYSTEM FLOW DIAGRAM
1-21
FIGURE 1-22. FUEL SYSTEM FLOW DIAGRAM
1-22
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 1.16.6.4 The skid base provides a stable base for the generator set during operation and transport, and allows the generator set to be moved by forklift or mounted on a trailer. Generator Set Cooling System. The Generator Set Cooling System (Figure 1-23) includes air intake and exhaust grilles, baffles, and ducting within the generator set housing and the engine driven radiator cooling fan. The air intake grilles are located in panels on both sides of the generator set housing. The air exhaust grille is located in the housing top panel. Air is drawn in through the air intake grilles and forced through the engine coolant radiator and out of the generator set through the exhaust grille by the radiator cooling fan. Most of the cooling air flows externally past the generator assembly and engine. Some cooling air is circulated internally through the generator assembly by a generator fan which is an integral part of the AC generator assembly. Baffles, ducting, and sound absorbing material are used to control the air flow through the generator set and to reduce sound transmission through the grilles. Engine Cooling System. The Engine Cooling System (Figure 1-24) consists of a radiator, hoses, thermostat, coolant temperature sender, CIM display screen COOLANT TEMP indicator, water pump, oil cooler, cooling fan, and cooling jackets (part of engine). The water pump forces coolant through passages (cooling jackets) in the engine block and cylinder head where the coolant absorbs heat from the engine. When the engine reaches normal operating temperature, the thermostat opens and the heated coolant flows through the upper radiator hose assembly into the radiator. The cooling fan circulates air through the radiator where the coolant temperature is reduced. The DCS, in conjunction with the fault system, provides automatic shutdown in the event coolant temperature exceeds 230 5F (110 3C). The CIM display screen COOLANT TEMP indicator indicates the engine coolant temperature from 100F to 250F (38C to 121C). The water pump also circulates coolant through the engine oil cooler to cool the engine oil. Lubrication System. The Engine Lubrication System (Figure 1-25) consists of an oil pan, dipstick, pump, oil cooler, oil sample valve, oil pressure sender, CIM display screen OIL PRESSURE indicator, oil drain valve, and filter.
1.16.7 1.16.7.1
1.16.7.2
1.16.8 1.16.8.1
1.16.8.2
1.16.8.3
1.16.8.4 1.16.9 1.16.9.1
1-23
INTAKE GRILLES
EXHAUST GRILLE
FIGURE 1-23. GENERATOR SET COOLING SYSTEM FLOW DIAGRAM
1-24
FIGURE 1-24. ENGINE COOLING SYSTEM FLOW DIAGRAM
1-25
FIGURE 1-25. LUBRICATION SYSTEM FLOW DIAGRAM
1-26
1.16.9.2
The oil pan is a reservoir for engine lubricating oil. The dipstick indicates oil level in the pan. The oil level can be checked during engine operation. One side of the dipstick is used for checking oil level while the engine is running and the other side is used while the engine is shut down. The pump draws oil from the oil pan through a screen which removes large impurities. The oil then passes through tubes in the oil cooler. Engine coolant from the engine cooling system is circulated around the tubes to cool the oil. From the cooler, oil passes through a spin-on type filter where small impurities are removed. From the filter, oil is distributed to the engine and turbocharger moving parts and then returns to the oil pan. The oil pressure sender located in the engine block senses oil pressure. Oil pressure is displayed on the CIM display screen OIL PRESSURE indicator. An Army Oil Analysis Program (AOAP) sample valve located in the block allows oil samples to be taken while the engine is operating. The DCS automatically shuts off the engine if oil pressure drops below 15 3 psi (103.4 20.7 kPa). Engine Air Intake and Exhaust System. The Engine Air Intake and Exhaust System (Figure 1-26) consists of an air cleaner assembly, intake manifold, ether supply tank, ether solenoid valve, ETHER START switch, exhaust manifold, turbocharger, muffler, and crankcase breather filter. The air cleaner assembly includes a dust collector, filter element, restriction indicator, and dust evacuator valve. Air is drawn into the dust collector and passes through the filter element. Airborne dirt is removed and trapped in the dust collector and filter element. Some dust can be removed from the dust collector by pinching the evacuator valve. The restriction indicator indicates when the filter should be serviced. Filtered air is drawn out of the filter through air intake tubes into the turbocharger where it is compressed and forced into the engine. Engine exhaust gases are expelled into the exhaust manifold and ported to the turbine of the turbocharger. The turbine drives the turbocharger compressor which compresses the intake air. Exhaust gases discharged by the turbocharger are channeled into the muffler that deadens the sound of the exhaust gases. Gases pass from the muffler through the muffler outlet and are vented upward from the generator set housing. A cover, which is held open by the pressure of the exhaust gases during operation, closes over the exhaust port to prevent rain, water, or other foreign matter from entering the exhaust port when the set is not in use. The cover is easily removed for connection of an exhaust pipe for indoor operation. Combustion gases which enter the crankcase are filtered through the crankcase breather filter to remove oil droplets and are then recycled through the intake manifold. An ether supply system is provided to improve engine starting when outside ambient air temperature is below 40F (4C). The ether system includes an ether supply tank, ether solenoid valve, ETHER switch, and piping from the solenoid valve to the intake manifold. The ether system is activated by turning the ENGINE CONTROL switch to START and momentarily holding the ETHER switch in the ON position while continuing to crank engine. Air in the engine crankcase is drawn out the right side of the engine through a rubber hose and into the crankcase breather filter assembly. There the air swirls around, leaving oil particles in the removable filter, and leaves through a second rubber hose. The air then passes through this output hose into the engine air cleaner assembly output hose. That is, the filtered air from the crankcase enters the engine intake air flow downstream of the intake air filter. Engine intake air flow is then compressed with the turbocharger, enabling filtered crankcase air to be recycled into the engine intake air and used in the combustion process of the engine.
1.16.10 1.16.10.1
1.16.10.2
1.16.10.3
1.16.10.4
1.16.10.5
1.16.10.6
1-27
FIGURE 1-26. ENGINE AIR INTAKE AND EXHAUST SYSTEM FLOW DIAGRAM
1-28
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 1.16.11 1.16.11.1 Output Supply System. The Output Supply System (Figure 1-27) consists of the AC generator, ground fault circuit interrupter, CONVENIENCE RECEPTACLE, current transformer, voltage reconnection terminal board, AC circuit interrupter, load output terminals, AC CIRCUIT INTERRUPT switch, load sharing synchronizer, automatic voltage regulator, CIM display screen FREQ gage, VOLTAGE gage, and POWER gage. Power created by the generator is supplied through the current transformer, voltage reconnection terminal board, and AC circuit interrupter to the load output terminals. The voltage reconnection terminal board allows configuration of the generator set for 120/208 volt connections or 240/416 volt connections. The AC CIRCUIT INTERRUPT switch closes and opens the AC circuit interrupter. This enables or interrupts power flow between the voltage reconnection terminal board and load output terminals. The voltage regulation system (paragraph 1.14.4) senses generator output voltage and provides a control signal to the generator exciter to maintain the desired generator output voltage. Generator output frequency is controlled by the governor control system (paragraph 1.14.3) and is read on the CIM display screen FREQ gage (Hz). The current transformer provides a reduced current signal to the DCS and CIM display screen GEN CURRENT indicators (amps AC). The CIM display POWER gage (kW) provides an indication of the power being used by the load. The GEN CURRENT indicators indicate percent of rated current being supplied to the load. The AC circuit interrupter will open and disconnect the load whenever any of the following faults occur: reverse power, undervoltage, overload, overspeed, low oil pressure, high water temperature, or short circuit. The AC generator also provides 120 VAC power to the CONVENIENCE RECEPTACLE through the GROUND FAULT CIRCUIT INTERRUPTER. Generator Assembly. General. Revolving field type generators have a DC field revolving within a stationary AC winding called the stator. See generator schematic, Figure 1-28. AC power is distributed from the generator through leads connected to the stator windings. There are no sliding contacts between the AC winding and the load, therefore, great amounts of power may be drawn from this generator. To energize the field, DC excitation must be applied to the generator field coils. The excitation current is supplied from a brushless exciter mounted on the generator shaft. The brushless exciter is actually an AC generator with its output rectified through a full wave bridge circuit. This type of brushless exciter will provide the necessary excitation current. The generator set field flash circuit, activated during each engine start, applies voltage to the exciter stator to begin the voltage build-up process to energize the generator field. The generator output voltage is controlled by controlling the alternating field current. This is accomplished by regulating the exciter field coil voltage. The exciter field coil voltage is regulated with a solid state type automatic voltage regulator. 1.16.12.2 Damper Bars. Damper bars are inserted through the field laminations and welded at the end to a solid copper plate. The damper windings provide stable parallel operation, reduce damping current losses, and limit the increase of third harmonic voltage with increase in load. Brushless Exciter. The brushless exciter consists of an armature with a three-phase AC winding and rotating rectifier assembly within a stationary field.
1.16.11.2
1.16.11.3
1.16.12 1.16.12.1
1.16.12.3
1-29
FIGURE 1-27. OUTPUT SUPPLY SYSTEM FLOW DIAGRAM
1-30
FIGURE 1-28. BRUSHLESS GENERATOR SCHEMATIC
1-31
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 The stationary exciter field assembly is mounted in the main generator frame. The exciter armature is press fit and keyed onto the shaft assembly. The rotating rectifier assembly slides over the bearing end of the generator rotor shaft and is secured with bolts and washers to an adapter hub which is shrunk on the generator shaft. 1.16.12.4 Rotating Rectifier Bridge. The rotating rectifier bridge consists of rectifying diodes mounted on a brass heat sink which is in turn mounted on an insulating ring. The entire assembly bolts to the adapter on the generator shaft. Therefore, the rotating rectifier assembly will rotate with the exciter armature eliminating the need for any sliding contacts between the exciter output and the alternator field. Exciter Field. The exciter field on the high frequency exciter consists of laminated segments of high carbon steel which are fitted together to make up the field poles. The field coils are placed into the slots of the field poles. Exciter Field Coil Voltage Source. Field coil DC voltage is obtained by rectifying the voltage from a phase to neutral line of the generator output, or other appropriate terminal, to provide the needed voltage reference. The rectifier bridge is an integral part of the static regulator. The static regulator senses a change in the generator output and automatically regulates current flow in the exciter field coil circuit to increase or decrease the exciter field strength. An external adjust rheostat sized to be compatible with the regulator is used to provide adjustment to the regulator sensing circuit. 1.16.12.7 Balance. The rotor assembly is precision balanced to a high degree of static and dynamic balance. Balance is achieved with the balance lugs on the field pole tips. The balance will remain dynamically stable at speed in excess of the design frequencies. Bearing. The generator rotor assembly is suspended on shielded, factory lubricated ball bearings. They are greased for life and do not require lubrication. Stator Assembly. The stator assembly consists of laminations of steel mounted in a rolled steel frame. Random wound stator coils are fitted into the insulated slots. Generator Set Controls. Engine Starting System.
1.16.12.5
1.16.12.6
1.16.12.8
1.16.12.9
1.16.13 1.16.13.1
1.16.13.1.1 Engine starting is accomplished primarily with two 12 volt batteries, connected in series to provide 24 VDC power, and a starter (Figure 1-29). The starter includes a cranking motor and a solenoid. To permit engine starting, the DC CONTROL POWER circuit breaker must be pushed in, the DEAD CRANK switch must be in the NORMAL position, and the BATTLE SHORT switch must be in the OFF position. In addition, any ENGINE SHUTDOWN fault previously registered on the CIM display screen must have been corrected by activating the FAULT RESET switch. When the ENGINE CONTROL switch is then placed in the START position, the starting circuits supply 24 VDC power to the starter. As the engine accelerates to approximately 900 RPM, the DCS speed control unit disconnects power from the starter.
1-32
DC CONTROL POWER FUSE
FIGURE 1-29. ENGINE STARTING SYSTEM FLOW DIAGRAM
1-33
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 1.16.13.1.2 When the ENGINE CONTROL switch is first moved to the START position, the control modules are energized. The Engine Starting System includes three control circuits. One starting control circuit energizes the K2 relay through closed switch contacts of the crank disconnect relay. The second starting control circuit signals the I/O interface module. With the K2 relay energized, power passes from the batteries through closed contacts of the K2 relay to energize the starter solenoid. With the starter solenoid energized, power passes from the starter solenoid to the cranking motor. The cranking motor then cranks the engine. Engine speed is sensed by the magnetic pickup which sends a signal to the DCS speed control unit. As the engine accelerates to approximately 900 RPM, the signal from the magnetic pickup causes the crank disconnect switch to open the crank disconnect relay. The open contacts break the circuit to the cranking relay and stop engine cranking. The third control circuit causes the field flash relay to be energized. When the ENGINE CONTROL switch is moved to one of the two RUN positions, all starting control circuits are de-energized. The other generator set control and instrument circuits remain energized. 1.16.13.1.3 The engine may be cranked without starting by use of the DEAD CRANK switch. With the DEAD CRANK switch in the CRANK position, the K2 relay coil is energized to initiate engine cranking without energizing any other starting or control functions. 1.16.13.1.4 The generator set can be started without batteries by connecting an external 24 VDC power source to the NATO/SLAVE RECEPTACLE. The generator set can also supply power to another set through the NATO/SLAVE RECEPTACLE. 1.16.13.1.5 The batteries are charged by the battery charging alternator which is belt driven by the engine. The CIM display screen BATTERY CHARGE ammeter indicates the charge/discharge rate of the batteries, from -10 amps to +20 amps. A sensor provides a DC voltage signal, which is directly proportional to the actual battery current flow, to the BATTERY CHARGE ammeter. Normal operating indication on the BATTERY CHARGE ammeter depends on the state of the charge in the batteries. A low charge, which may exist immediately after engine starting, will cause a high reading (indication toward CHARGE area). When the charge in the batteries has been restored, the indicator moves near zero. The battery charging system is protected from reverse polarity in the battery connections by a diode. 1.16.13.2 Field Flash. This circuit provides current to the exciter field windings which sets up an electromagnetic field. The field current is necessary for the set to generate sufficient voltage for the automatic voltage regulator to begin controlling the output voltage of the generator set. The field flash circuit is maintained until the ENGINE CONTROL switch is released from the START position. Operation. Placing the ENGINE CONTROL switch in the PRIME & RUN AUX FUEL positions keeps the DCS speed control unit energized, and fuel will be supplied to the fuel injection pump as long as no fault condition exists. During operation, the operator should periodically check the CIM display screen to ensure readings are in normal operating ranges. The VOLTAGE ADJUST and FREQUENCY ADJUST switches are adjusted as required to maintain desired frequency and voltage output. Applying the Load. The load is applied by placing the AC CIRCUIT INTERRUPT switch in the CLOSED position. This is a momentary contact switch that returns to the neutral, or center, position. The AC circuit interrupter is energized by this momentary contact and a holding circuit keeps it closed, bringing the load on line. Shutdown.
1.16.13.3
1.16.13.4
1.16.13.5
1.16.13.5.1 The AC circuit interrupter is disengaged by placing the AC CIRCUIT INTERRUPT switch in the OPEN position. This is a momentary contact switch which will break the AC circuit interrupter holding circuit and then return to the neutral, or center, position, disconnecting the load from the line. 1.16.13.5.2 The generator set should remain running for five minutes after disconnecting the load. During this five minute interval, oil circulates through the turbocharger, cooling it enough to be shut down.
1-34
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 1.16.13.5.3 When the ENGINE CONTROL switch is placed in the OFF position, all power is removed from the governor control circuit and the engine will stop. 1.16.13.5.4 The EMERGENCY STOP switch will remove power from the governor control circuit by de-energizing circuitry in the DCS. This will cause the engine to shut down. The EMERGENCY STOP switch will not be used as an alternative for routine shutdown procedures. When the generator set is stopped using the EMERGENCY STOP switch, some circuits remain energized causing a drain on the batteries until the ENGINE CONTROL switch is placed in the OFF position. 1.16.13.6 Paralleling.
1.16.13.6.1 The generator set is capable of being operated in parallel with one other set of the same model number. This capability is provided by the PARALLELING RECEPTACLE, paralleling cable, and the load sharing synchronizer. 1.16.13.6.2 The paralleling cable is used to interconnect the governor and automatic voltage regulator paralleling circuits of the two sets. Voltage and frequency of the two generator sets are synchronized by the DCS load sharing synchronizer. The permissive paralleling relay monitors the voltage phase relationship and prevents the AC circuit interrupter from closing when the units are not properly synchronized. 1.17 LOCATION AND DESCRIPTION OF MAJOR COMPONENTS. NOTE All locations (Figure 1-30) referenced herein are given facing the control box side (rear) of the generator set. 1.17.1 COMMUNICATION RECEPTACLE (1). The COMMUNICATION RECEPTACLE is used to connect a remote PC to the DCS control box to facilitate remote operation and monitoring of the generator set. PARALLELING RECEPTACLE (2). The PARALLELING RECEPTACLE is used to connect the paralleling cable between two generator sets of the same size and mode to operate in parallel. CONVENIENCE RECEPTACLE (3). The CONVENIENCE RECEPTACLE is a 120VAC receptacle used to operate small plug-in type equipment. DCS Control Panel Assembly (4). The DCS control panel is located at the rear of the generator set and contains the CIM, switches, and connectors used to control and monitor generator set operation. Computer Interface Module (CIM) (5). The CIM is located in the DCS control panel assembly and contains controls and indicators for operating the generator set. Air Cleaner Assembly (6). The air cleaner assembly is located on the left side behind the AIR CLEANER ACCESS door. It consists of a dry-type, disposable paper filter and canister. The air cleaner assembly features a dust collector which traps large dust particles. The air cleaner assembly has a restriction indicator which will pop up during operation when the air cleaner requires servicing. AC Generator (7). The AC generator is a single bearing, drip-proof, synchronous, brushless, three phase, aircooled generator. The generator is coupled directly to the rear of the diesel engine.
1.17.2
1.17.3
1.17.4
1.17.5
1.17.6
1.17.7
1-35
FIGURE 1-30. 60 KW GENERATOR SET COMPONENTS (SHEET 1 OF 2)
1-36
FIGURE 1-30. 60 KW GENERATOR SET COMPONENTS (SHEET 2 OF 2)
1-37
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 1.17.8 Fuel Drain Valve (8). The fuel drain valve is located on the left side of the skid base. It allows personnel to drain the fuel tank for maintenance. Dipstick (9). The dipstick is located in the engine compartment on the left side. The dipstick shows the level of oil in the engine drain pan. DEAD CRANK Switch (10). The DEAD CRANK switch is located in the engine compartment on the left side. The switch allows the engine to be turned over without starting for maintenance purposes. Muffler (11). The muffler and exhaust tubing are connected to the turbocharger on the engine. The exhaust exits from the top of the generator set housing. Gases are exhausted upward. Radiator (12). The radiator is located at the front of the generator set. It acts as a heat exchanger for engine coolant. Fan Belt (13). The fan belt is located in the engine compartment on the front of the engine. The belt drives the fan, water pump, and battery charging alternator. Oil Drain Valve (14). the oil drain valve is located at the front of the skid base. It allows personnel to drain engine oil for maintenance. Batteries (15). Two batteries are located at the front of the generator set. The batteries are maintenance free, 12 volt type. After starting, the generator set is capable of operating with batteries removed. A diode, located behind the control panel, protects the generator set if the batteries are incorrectly connected. Skid Base (16). The skid base supports the generator set. It has fork lift access openings and cross members for short distance movement. The skid base has provisions in the bottom for installation of the generator set on a trailer. NATO SLAVE RECEPTACLE (17). The NATO SLAVE RECEPTACLE is located on the right side (front) of the generator set. It is a NATO receptacle used for remote battery connection. Water Pump (18). The water pump is located on the front of the engine. The pump circulates engine coolant through the engine block and the radiator. Battery Charging Alternator (19). The battery charging alternator is located on the right side of the engine. It is capable of maintaining the batteries in a state of full charge in addition to providing the required 24 VDC control power. Oil Filter (20). The oil filter is located in the engine compartment on the left side. The filter removes impurities from engine oil. Fuel Tank (21). The 43 gallon (162.7 liter) fuel tank is located in the front of the generator set below the engine and between the skid base members. The fuel tank has sufficient capacity to enable the generator set to operate for at least 8 hours without refueling. Starter (22). The starter is located on the left side of the engine. The electric cranking motor mechanically engages the engine flywheel in order to start the diesel engine. Crankcase Breather Filter Assembly (23). The crankcase breather filter assembly is located in the engine compartment on the right side. The filter element removes oil particles and contaminants from air as it passes from the crankcase to engine air intake.
1.17.9
1.17.10
1.17.11
1.17.12
1.17.13
1.17.14
1.17.15
1.17.16
1.17.17
1.17.18
1.17.19
1.17.20
1.17.21
1.17.22
1.17.23
1-38
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 1.17.24 Fuel Filter/Water Separator (24). The fuel filter/water separator is located in the engine compartment on the right side. The element removes impurities and water from the diesel fuel. Engine (25). The generator is powered by a six cylinder, four cycle, fuel injected, turbocharged, liquid-cooled diesel engine which occupies the front half of the generator set. The engine is also equipped with a fuel filter/water separator, oil filter, and air cleaner assembly. Protection devices automatically stop the engine during conditions of high coolant temperature, low oil pressure, no fuel, overspeed, and overvoltage. Load Output Terminal Board (26). The load output terminal board is located on the right side (rear) of the generator set. Four AC output terminals are located on the board. The are marked L1, L2, L3, and L0. A fifth terminal, marked GND, is located next to the output terminals and serves as equipment ground for the generator set. A removable, solid copper bar is connected between the L0 and GND terminals. Voltage Reconnection Terminal Board TB1 (27). The voltage reconnection terminal board is located on the right side (rear) of the generator set. The board allows reconfiguration from 120/208 to 240/416 VAC output.
1.17.25
1.17.26
1.17.27
1-39/1-40 BLANK
THIS PAGE INTENTIONALLY LEFT BLANK
1-40
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 CHAPTER 2 OPERATING INSTRUCTIONS
CHAPTER INDEX
SECTION I SECTION II SECTION III SECTION IV
DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS .......................2-1 PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)...................................2-14 OPERATION UNDER USUAL CONDITIONS .........................................................................2-21 OPERATION UNDER UNUSUAL CONDITIONS ...................................................................2-41
SECTION I. DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS.
2.1
GENERAL. This section describes and illustrates generator set controls and indicators to ensure proper operation of generator set.
2.2
DCS CONTROLS AND INDICATORS. The Digital Control System (DCS) contains most of the operating controls for the generator set. Figure 2-1 shows the DCS control panel assembly layout. Table 2-1 describes each control and indicator.
2-1
FIGURE 2-1. DCS CONTROLS AND INDICATORS
2-2
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 TABLE 2-1. DCS CONTROLS AND INDICATORS KEY 1 2 3 4 5 CONTROL OR INDICATOR ELAPSED TIME Meter Panel Lights EMERGENCY STOP Switch PANEL LIGHTS Switch NETWORK FAILURE Indicator FUNCTION Indicates total engine operating hours. Illuminate DCS control panel. Shuts down generator set when activated. Removes electrical power to governor controller and stops engine from operating. Activates and deactivates panel lights. When illuminated indicates a failure between Computer Interface Module and Input/Output Module. Generator set will not continue to operate, and capability to monitor its operation and to make adjustments will be degraded or lost. Bypasses protective devices on generator set. Set will continue to operate until overvoltage occurs or fuel is exhausted. When held in ON position momentarily during engine cranking, activates ether cold weather starting system for starting engine at temperatures below 40F (4C). Four position switch: OFF de-energizes all circuits except panel lights and power to CIM. PRIME & RUN AUX FUEL energizes generator set run circuits with auxiliary fuel pump operating. PRIME & RUN energizes generator set run circuits with auxiliary fuel pump de-energized. START energizes engine starter and flashes generator field. Momentary-action toggle switch. Adjusts frequency output of generator set for each activation of the switch. Works in both directions to increase and decrease output frequency. Opens and closes AC Circuit Interrupt Relay. Used during parallel operation. Momentary-action toggle switch. Adjusts voltage output of generator set. Works in both directions to increase and decrease output voltage. Resets (turns off) fault indicators displayed on Computer Interface Module display screen. Will re-energize governor power. When placed in ON position, provides battery power to DCS. Should be first switch activated on panel. Generator set cannot be started unless switch is activated. Tests GROUND FAULT CIRCUIT INTERRUPTER. Resets GROUND FAULT CIRCUIT INTERRUPTER. Moves cursor on CIM display screen in upward direction until released. Moves cursor on CIM display screen to the right until released. When pressed, selects item on CIM display screen indicated by cursor. Moves cursor on CIM display screen in downward direction until released.
6 7
BATTLE SHORT Switch ETHER START Switch
ENGINE CONTROL Switch
FREQUENCY ADJUST Switch
10 11
AC CIRCUIT INTERRUPT Switch VOLTAGE ADJUST Switch
12
FAULT RESET Switch
13
MASTER CONTROL Switch
14 15 16 17 18 19
GROUND FAULT CIRCUIT INTERRUPTER TEST Switch GROUND FAULT CIRCUIT INTERRUPTER RESET Switch Keypad Up Arrow Pushbutton Keypad Right Arrow Pushbutton Keypad SELECT Pushbutton Keypad Down Arrow Pushbutton
2-3
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 TABLE 2-1. DCS CONTROLS AND INDICATORS (continued) KEY 20 21 22 23 24 CONTROL OR INDICATOR Keypad Left Arrow Pushbutton DC CONTROL POWER Fuse FREQUENCY SELECT Switch (MEP-806B only) REACTIVE CURRENT ADJUST rheostat VOLTAGE SCALE Switch FUNCTION Moves cursor on CIM display screen to the left until released. Provides overcurrent protection for DC circuits. Allows selection of 50 Hz or 60 Hz. Adjusts voltage droop when two generator sets are operated in parallel. Reports configuration of output voltage connection selected on voltage reconnection terminal board.
2.3
COMPUTER INTERFACE MODULE (CIM) DISPLAY SCREEN CONTROLS AND INDICATORS. The Computer Interface Module (CIM) Display Screen displays most of the indicators for the generator set. Figure 2-2 shows the CIM display screen layout. Table 2-2 describes each control and indicator. Table 2-3 describes faults that may be displayed in the FAULT INDICATOR section of the CIM display screen and related operator messages that may be displayed in the MESSAGES section.
2-4
FIGURE 2-2. CIM DISPLAY SCREEN CONTROLS AND INDICATORS 2-5
TABLE 2-2. CIM DISPLAY SCREEN CONTROLS AND INDICATORS KEY 1 2 3 4 CONTROL OR INDICATOR GEN VOLTAGE indicators BATTERY VDC indicator GEN CURRENT indicators FAULT INDICATOR display FUNCTION Indicates generator output voltage for each of the three phases. Indicates charge status of both generator set DC batteries (VDC). Indicates generator output current (amps) for each of the three phases. Displays fault indications as they occur. Specific warnings and instructions related to a fault are displayed simultaneously in the MESSAGES display. See Table 2-3 for the list of possible faults. Indicates generator set output voltage versus bus voltage. Used prior to operating in parallel with another unit. Used to monitor system prior to parallel operation to ensure generator and bus voltage are balanced within 5 volts before closing contactor to bus. Displays warnings and instructions in the form of operator messages related to faults displayed in FAULT INDICATOR display. Indicates generator set cooling system water temperature (F). Indicates whether generator set is in battle short mode or not. ON indication means battle short circuit is energized. Indicates whether contactor is open or closed. When FULL/MAIN button is selected with the keypad, CIM display screen toggles between FULL and MAIN modes and button changes to show name of mode currently displayed. When EXIT button is selected with the keypad, the DCS software shuts down so the CIM can be safely deactivated. This will also shut down the generator set if it is running. Indicates input current of generator set DC batteries (amps). Indicates engine oil pressure (psi). Indicate voltage on output bus. The GEN VOLTAGE and BUS VOLTAGE indicators must match within five volts, each phase, to perform paralleling operation. Indicates generator set voltage output (VAC). Indicates generator set frequency output (Hz). Indicates generator set power output (kW). Indicates amount of fuel in fuel tank (percent remaining).
DELTA VAC gage
MESSAGES display
7 8 9 10
WATER TEMP virtual meter BATTLE SHORT CIRCUIT status indicator CONTACTOR POSITION status indicator DISPLAY MODE FULL/MAIN switch SHUTDOWN COMPUTER EXIT button BATTERY AMPS virtual meter OIL PRESSURE virtual meter BUS VOLTAGE indicators
11
12 13 14
15 16 17 18
VOLTAGE gage FREQ gage POWER gage FUEL LEVEL gage
2-6
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 TABLE 2-3. FAULTS NOTE: Maintainers can only check faults at their level. FAULT MESSAGE # MESSAGE CIRCUIT FAILURE 01 The fuel level signal is lower than the operating range. FUEL LEVEL Check fuel level. Check fuel sensor and circuit. (Para. 4.11.5) SHUTDOWN - LOW FUEL 02 Fuel level is abnormally low. Check fuel level. Verify fuel system lineup. WARNING - LOW FUEL 03 Fuel level is abnormally low. Check fuel level. Verify fuel system lineup. CIRCUIT FAILURE 04 The fuel level signal is higher than the operating range. FUEL LEVEL Check fuel level. Check fuel sensor and circuit. (Para. 4.11.5) CIRCUIT FAILURE COOLANT TEMP 05 The coolant temperature signal is lower than the operating range. Check coolant level. Check coolant temperature sensor and circuit. (Para. 4.13.2) The coolant temperature is higher than the operating range. Check coolant level. Check coolant temperature sensor and circuit. (Para. 4.13.2) Coolant temperature is abnormally high. Check coolant level. Verify coolant system lineup. (Para. 3.3.5) Coolant temperature is abnormally high. Check coolant level. Verify coolant system lineup. (Para. 3.3.5) The oil pressure signal is lower than the operating range. Check oil pressure. Check oil pressure sensor and circuit.(Para. 4.13.1) The oil pressure signal is higher than the operating range. Check oil pressure. check oil pressure sensor and circuit.(Para. 4.13.1) Oil pressure is abnormally low. Check oil. Verify lubricating system lineup. (Para. 3.3.8) Oil pressure is abnormally low. Check oil. Verify lubricating system lineup. (Para. 3.3.8) Generator voltage is abnormally high. Adjust VOLTAGE ADJUST switch. (Para. 2.11.1 j) Generator voltage is abnormally high. Adjust VOLTAGE ADJUST switch. (Para. 2.11.1 j) Generator frequency is abnormally high. Adjust FREQUENCY ADJUST switch. (Para. 2.11.1 j) Generator frequency is abnormally high. Adjust FREQUENCY ADJUST switch. (Para. 2.11.1 j) Generator voltage is abnormally low. Adjust VOLTAGE ADJUST switch. (Para. 2.11.1 j) Generator voltage is abnormally low. Adjust VOLTAGE ADJUST switch. (Para. 2.11.1 j) System load is abnormally high. Reduce load to within generator set ratings. (Para. 2.11.1 n and o)
06
WARNING - COOLANT TEMP SHUTDOWN - COOLANT TEMP CIRCUIT FAILURE - OIL PRESSURE
07 08
09
10
WARNING - LOW OIL SHUTDOWN - LOW OIL
11 12
WARNING OVERVOLTAGE SHUTDOWN OVERVOLTAGE WARNING - OVERSPEED SHUTDOWN OVERSPEED WARNING UNDERVOLTAGE CONTACTOR TRIP UNDERVOLTAGE WARNING - OVERLOAD
13 14
15 16
17 18
19
2-7
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 TABLE 2-3. FAULTS (continued) FAULT CONTACTOR TRIP OVERLOAD CONTACTOR TRIP REVERSE POWER CONTACTOR TRIP SHORT CIRCUIT MESSAGE # 20 MESSAGE System load is abnormally high. Reduce load to within generator set ratings. (Para. 2.12) Load share device sensed reverse power conditions. Verify load share device setpoints are correct. System load was abnormally high. Reduce load to within generator set ratings.
21
22
2.4
DIAGNOSTIC CONTROLS AND INDICATORS. The DCS load sharing synchronizer, DCS speed control unit, automatic voltage regulator, backplane module, and I/O interface module are equipped with indicators used as diagnostic tools in troubleshooting. Some of the DCS modules also include controls that are set at installation and may need to be adjusted during troubleshooting. Figure 2-3 shows the locations of the controls and indicators on the DCS modules. Table 2-4 describes each control and indicator.
2-8
FIGURE 2-3. DIAGNOSTIC CONTROLS AND INDICATORS (SHEET 1 OF 2)
2-9
FIGURE 2-3. DIAGNOSTIC CONTROLS AND INDICATORS (SHEET 2 OF 2)
2-10
TABLE 2-4. DIAGNOSTIC CONTROLS AND INDICATORS KEY CONTROL OR INDICATOR DCS LOAD SHARING SYNCHRONIZER 1 L1 indicator (green LED) FUNCTION This indicator is lit when the load sharing control is making transition from zero power output up to a power output in a load sharing (paralleling) condition. Normally, this LED is lit only during the load sharing (paralleling) period. This indicator is lit only when zero power from the generator set is reached before the breaker is opened. It indicates when the I/O interface module is calling for the generator to go to zero power output before the generator breaker is opened automatically by the I/O interface module. This indicator is lit when a reverse power situation exists. The I/O interface module has been notified to remove the generator set from service (open the breaker). This indicator is normally lit when the generator set is operating (engine is running). When lit, the LED indicates the module is receiving AC power from the generator. This indicator is normally lit only when the generator set is running and the main breaker is closed. It is also lit when another generator set is connected to the main breaker and its breaker is closed. When lit, the LED indicates AC power is being received from the bus (the output of the generator set main breaker) into the module. The indicator is not lit if the bus has failed, and when this module is not being used. This indicator is lit only when the I/O interface module requests synchronizing the output power of the generator set with a second generator set and the paralleling cable has been connected between the two sets. In addition, the AC CIRCUIT INTERRUPT switch on the primary set has been previously moved to the CLOSED position. This indicator is lit only during the synchronizing period. This indicator will be lit when the I/O interface module has closed the main breaker. That is, the I/O interface module has commanded the DCS load sharing synchronizer to close the connection with the paralleling cable and begin parallel operation of the two generator sets. This indicator will be lit when the generator is in synch with the bus. When this LED is lit, the DCS load sharing synchronizer has signaled the I/O interface module that paralleling may occur. This indicator is normally lit only when the generator set is operating (engine is running). It is off at all other times. When lit, the LED indicates the internal DC supply of the module is operating (i.e., the module is receiving DC power from the generator set, and the module is properly converting the power into its own operating voltage(s).
L2 indicator (green LED)
REVERSE POWER (red LED)
GEN indicator (green LED)
BUS indicator (green LED)
SYNCH ENABLED indicator (green LED)
PARALLEL ENABLE indicator (green LED)
SYNCHRONIZED indicator (green LED)
DC POWER indicator (green LED)
2-11
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 TABLE 2-4. DIAGNOSTIC CONTROLS AND INDICATORS (continued) KEY CONTROL OR INDICATOR SPEED CONTROL UNIT 10 OVERSPEED indicator (red LED) FUNCTION This indicator is normally off, even when the generator set is operating. When the LED is lit, an engine overspeed condition has occurred (the flywheel RPM sensor has sent the speed control unit a value which is defined as out-of-tolerance). The indicator will remain lit until either of two events has occurred: (1) The OVERSPEED RESET pushbutton has been manually activated, or (2) the generator set (engine) has been stopped and the DC power is reset. This indicator is normally lit when the electric actuator (on the injection fuel pump) has power applied to it. The LED will be lit when the engine is operating or when the engine is being cranked (started). If the indicator is off while the engine is operating, it can mean: (1) the electric actuator has failed, (2) the connection between the actuator and the module has failed, or (3) the module has malfunctioned or failed. This indicator is normally lit when the engine is operating. The indicator lit/off function is directly related to the signal from the speed sensor connected to the flywheel. If the indicator is off, but the engine is operating, this indicates the engine RPM signal is not being received. This can be caused by sensor failure or by a failure in the connection to the sensor. If the OVERSPEED indicator is lit and the engine has stopped, this switch may be used to attempt to reset the overspeed protection system. If the OVERSPEED indicator turns off when the switch is activated, the protection system is reset, and the engine may be restarted. (The conclusion is that no problem exists with engine speed.) If after restarting the OVERSPEED indicator comes on again and the engine stops, there is a problem with engine speed control. This switch is used to test one of the protective systems of the generator set: engine overspeed protection. Pressing this switch while the engine is running at rated speed will activate the overspeed protection system, thereby stopping the engine. This indicator is normally lit when the engine is operating. It indicates the internal DC power in the module is operating. This indicator is normally lit when the engine is operating. When the engine is being started, the indicator will remain off until engine speed exceeds 400 RPM and the cranking relay returns to its normal (non-energized) state. If the indicator remains off and the engine starter continues operation, this is an indication of a failure in the starter assembly or of the cranking relay.
11
ACTUATOR indicator (green LED)
12
SPEED SENSOR indicator (green LED)
13
OVERSPEED RESET pushbutton
14
OVERSPEED TEST pushbutton
15 16
DC POWER indicator (green LED) CRANK TERMINATION (green LED)
BACKPLANE MODULE 17 LED 16 (red) indicator 18 LED 15 (red) indicator 19 LED 14 (red) indicator
(not assigned) (not assigned) Fault indication. If indicator is lit, indicates a fault has occurred. If off, indicates normal running condition.
2-12
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 TABLE 2-4. DIAGNOSTIC CONTROLS AND INDICATORS (continued) KEY CONTROL OR INDICATOR BACKPLANE MODULE (continued) 20 LED 13 (red) indicator FUNCTION Short circuit indication. If indicator is lit, indicates a short circuit condition affecting generator set output has been detected. (not assigned) Remote display connection. Indicator blinks on and off when remote display is properly connected. If not lit, indicates no remote display connection has been made. Data validity from remote display. Indicator blinks on and off to indicate remote data is being received properly. If not lit, remote data is not being received properly. If not lit, can also indicate no remote display function has been connected. Status of the main generator power bus. If indicator is lit, the bus is energized (voltage is present), and voltage is available for paralleling operation. If not lit, indicates the generator set is operating in a stand-alone mode. (not assigned) Network failure. If indicator is lit, indicates the CIM is not communicating with the I/O interface module. If not lit, indicates the CIM is communicating properly. Emergency stop. If indicator is lit, indicates the EMERGENCY STOP switch has been activated. If not lit, indicates normal running condition. CMOS voltage. If indicator is lit, indicates voltage necessary for CMOS device operation is too low. If not lit, CMOS device voltage source is sufficient. (not assigned) Heartbeat. If indicator is blinking on and off, indicates proper operation of this module. If not lit, indicates module has no power applied or has failed. (not assigned) If indicator is lit, fuel pump is operating. If not lit, fuel pump is not operating.
21 22
LED 12 (green) LED 11 (green)
23
LED 10 (green)
24
LED 9 (green)
25 26
LED 8 (red) LED 7 (red)
27
LED 6 (red)
28
LED 5 (red)
29 30
31 32
AUTOMATIC VOLTAGE REGULATOR 33 34 AC SENSING (green LED) DC SUPPLY indicator (green LED) This indicator is normally lit, indicating the AC sensor is sending the proper signal to this module. This indicator is normally lit, indicating that the module's internal DC supply is operating. The source for input power to this module is the AC output of the generator set. Therefore, the indicator will not be lit until the generator set is providing power output to a load. This indicator is normally lit. It indicates field voltage is present, which means the generator is developing AC power.
35
FIELD VOLTAGE (green LED)
2-13
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 TABLE 2-4. DIAGNOSTIC CONTROLS AND INDICATORS (continued) KEY CONTROL OR INDICATOR I/O INTERFACE MODULE 36 HEARTBEAT (green LED) FUNCTION This indicator is normally blinking on and off when DC power has been applied to the module. It is also normally blinking when the generator set is operating (engine running) and the module is functioning properly. If the indicator is either steadystate lit or steady-state off, but the CIM has been turned on and the engine is operating, this is an indication that there is a problem in the I/O interface module. These switches define the configuration of the generator set for the CIM. The generator set configuration is defined in two ways: its output power (kW) rating and its frequency rating. These switches must be set to a specified configuration prior to the module's use in the generator set. Unless these switches are properly set (and remain so), the generator set can experience a malfunction. For the MEP-806B, all switches are set to OFF. For the MEP-816B, Switch 5 is set to ON and all the other switches to OFF. (Ref Figure 4-31)
37
DIP Switch Assembly (8 positions)
SECTION II. PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) 2.5 GENERAL. To ensure the generator set is ready for operation at all times, it must be inspected so that defects can be discovered and corrected before they result in serious damage or failure. 2.5.1 2.5.2 2.5.3 2.5.4 Before Operation. Always keep in mind the CAUTIONS and WARNINGS. Perform Before (B) PMCS. During Operation. Always keep in mind the CAUTIONS and WARNINGS. Perform During (D) PMCS. After Operation. Perform After (A) PMCS. If the Equipment Fails. If the equipment does not perform as required, refer to Chapter 3, Section II under Troubleshooting for possible problems. The Symptom Index is provided as a guide for troubleshooting procedures. Report any malfunctions or failures on DA Form 2404 (refer to DA PAM 738-750). PMCS Procedures. NOTE For general location of items to be inspected in Table 2-5, refer to Figures 1-30 and 2-1. 2.6.1 Purpose of PMCS Table. PMCS, Table 2-5, lists inspections and care of equipment required to keep the generator set in good operating condition. Purpose of Service Intervals. The interval column of the PMCS table indicates when to perform a certain check or service. Special Instructions. The following guidelines are provided to help classify leaks observed while performing PMCS. Class I. Seepage of fluid (as indicated by wetness or discoloration) not great enough to form drops.
2.6
2.6.2 2.6.3
2-14
Class II.
Leakage of fluid great enough to form drops, but not enough to cause drops to drip from item being checked/inspected. Leakage of fluid great enough to form drops that fall from the item being checked/inspected. CAUTION Equipment operation is allowable with minor oil and coolant leakage (Class I or II). When operating with Class I or II leaks, continue to check fluid levels as required in PMCS. All leaks should be reported to the next higher level of maintenance. Failure to comply can cause damage to equipment.
Class III.
2.6.4
Procedures Column. The procedures column of the PMCS table tells how to perform required checks and services. If required tools are not available, or if a procedure indicates, complete DA Form 2404 and submit it to the next higher level of maintenance. NOTE The terms "ready/available" and "mission capable" refer to the same status. The generator set is on hand and able to perform combat missions. Refer to DA PAM 738-750.
2.6.5
"Equipment is not ready/available if" Column. This column tells when and why the generator set cannot be used. Reporting and Correcting Deficiencies. If the generator set does not perform as required, refer to Chapter 3, Operator Troubleshooting, to diagnose the problem. Removal of Assemblies/Equipment to Perform PMCS. There is no requirement to remove assemblies/equipment prior to performing PMCS. NOTE If generator set must be kept in continuous operation, check and service only those items which can be checked and serviced without disturbing operation. Perform complete checks and services when the generator set can be shut down. NOTE The generator set can be operated continuously at any load from no load up to and including rated load. However, at light loads an oily residue (unburned fuel oil) may occasionally be noticed in the exhaust system outlet and around connection joints in the exhaust system. This residue is caused by the inability of the fuel injection system to consistently meter the small amount of fuel required to operate at these low load levels and is not a defect in the fuel system. The oily residue could affect engine performance and create a cosmetic problem on and around the generator set. Operation at rated load will burn off this oily residue. The length of time required at rated load depends on the amount of residue. This oily residue can be prevented by increasing the electrical load on the set.
2.6.6
2.6.7
2-15
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 TABLE 2-5. OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) CAUTION Engine oil and filter must be changed at a hardtime - 100 hours on initial break-in. Failure to change oil and filter may void warranty. B-BEFORE Interval Item No. B D A Item to be inspected GENERATOR SET 1 Housing Check door, panels, hinges, and latches for damaged, loose or corroded items. Inspect air intake and exhaust grilles for debris. Check to ensure identification plates are secure. Inspect skid base for cracks or corrosion. Skid base is cracked or shows signs of structural damage. Cannot secure doors. Cannot clear debris. D-DURING Procedures Check for and have repaired or adjusted as necessary A-AFTER Equipment is not ready/ available if:
Identification Plates
Skid Base
Insulating/Materials
Ensure that insulating materials are free of damage, not missing, and not touching moving or exhaust system parts. __________ WARNING Operating the generator set with any access door open exposes personnel to high noise level. Hearing protection must be worn when operating or working near the generator set with any access door open. Failure to comply can cause hearing damage to personnel. __________ WARNING
Fuels in the generator set are flammable. Do not smoke or use open flame when performing maintenance Failure to comply can result in flames and possible explosion and can cause injury or death to personnel and damage to the generator set. TABLE 2-5. OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) (continued)
2-16
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 B-BEFORE Interval Item No. B D A Item to be inspected ENGINE COMPARTMENT 5 Engine Assembly Check for loose, damaged, or missing hardware and wires. Any loose, damaged or missing hardware or wires. Any fuel leaks or damaged, loose, or missing parts. D-DURING Procedures Check for and have repaired or adjusted as necessary A-AFTER Equipment is not ready/ available if:
Fuel System
Inspect fuel system for leaks and damaged, loose, or missing parts. Check fuel lines fuel injection pump and fuel injectors for cracks, leaks or evidence of damage. See TM 9-2815-260-24. Inspect fuel filter/water separator for leaks, proper mounting, cracks, damage, and missing parts (Refer to Figure 1-30, sheet 2). Drain water from fuel filter/water separator (Refer to paragraph 3.3.7). CAUTION Catch in suitable container.
Fuel Filter/Water Separator
Any fuel leaks.
Fuel filter/water separator not drained.
Ether Start System
Check for deteriorated, loose, or missing parts; loose tubing; and missing or damaged bottle gasket (Refer to Figure 4-26).
Any deteriorated, loose, or missing parts; loose tubing; and missing or damaged bottle gasket. Oil leaks at Class III. Damaged, loose, or missing parts. Oil level is low, and dipstick reads add. Engine oil shows signs of contamination.
Lubrication System
Inspect lubrication system for leaks and damaged, loose, or missing parts.
Check engine oil level.
Check engine oil for contamination (oil color is milky, bubbles, foreign material in oil, etc.).
2-17
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 TABLE 2-5. OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) (continued) B-BEFORE Item No. B Interval D A Item to be inspected D-DURING Procedures Check for and have repaired or adjusted as necessary __________ WARNING Cooling system operates at high temperature and pressure. Contact with high pressure steam and/or liquids can result in burns and scalding. Shut down generator set, and allow system to cool before performing checks, services, and maintenance. Failure to comply can cause injury to personnel. COOLING SYSTEM 10 Radiator Check radiator for leaks, damage, or missing parts. Class III leaks. Radiator cap is missing. Class III leaks. Cooling fan is damaged or loose. A-AFTER Equipment is not ready/ available if:
11 12
Hoses Cooling Fan
Check hose for leaks or cracks. Check fan for damage or looseness.
Check for unusual noise being emitted from fan area. Fan Belts Inspect belts for cracks, fraying, or looseness. Check overflow bottle for leaks and missing parts. Check overflow bottle coolant level. Broken belt(s).
13
14
Overflow Bottle
Class III leaks.
Coolant level is below COLD line.
EXHAUST/ INTAKE SYSTEM 15 Exhaust System Check muffler for leaks and exhaust system for corrosion and damaged or missing parts. Muffler or exhaust system damaged or leaking excessively.
2-18
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 TABLE 2-5. OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) (continued) B-BEFORE Interval Item No. 16 B D A Item to be inspected Air Cleaner Assembly D-DURING A-AFTER Equipment is not ready/ available if: Piping connections are loose. Clogged element is indicated.
Procedures Check for and have repaired or adjusted as necessary Inspect air cleaner assembly and piping for loose or damaged connections. Check restriction indicator for indication of clogged air cleaner element (Refer to Figure 3-1).
ELECTRICAL SYSTEM __________ WARNING DC voltages are present at generator set electrical components even with generator set shut down. Avoid shorting any positive terminal with ground/negative. Failure to comply can cause injury to personnel and damage to equipment.. __________ WARNING Batteries give off a flammable gas. Do not smoke or use open flame when performing maintenance. Failure to comply can cause injury or death to personnel and equipment damage due to flames and explosion. __________ WARNING Battery acid can cause burns to unprotected skin. Avoid contact with battery acid. Failure to comply can cause injury to personnel. 17 Batteries Inspect electrolyte level (wet cell batteries only). Inspect cables and connectors for corrosion and loose, damaged, or missing parts. Electrolyte level is below battery plates. Battery cables are loose, damaged, or missing.
18
Battery Cables
2-19
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 TABLE 2-5. OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) (continued) B-BEFORE Interval Item No. B D A Item to be inspected D-DURING Procedures Check for and have Repaired or adjusted as necessary __________ WARNING High voltage is produced when this generator set is in operation. Make sure unit is completely shut down and free of any power source before attempting any repair or maintenance on the unit. Failure to comply can cause injury or death to personnel. 19 Output Box Assembly Load Output Terminal Board Check for loose or damaged wiring or cables (Figure 1-2). Check output terminals for damaged or missing hardware (26, Figure 1-30 sheet 2) Loose or damaged wiring or cables. Damaged or missing hardware. A-AFTER Equipment is not ready/ available if:
20
DCS CONTROL BOX ASSEMBLY 21 Controls and Indicators Check all controls and indicators for damaged or missing parts. Ensure relays are securely plugged in. Ensure all indicators are operating properly. Control Box Wiring Harness Parallel Operation Cable Check for loose or damaged wiring. Controls or indicators with damaged or missing parts. CIM inoperative.
22
Loose or damaged wires.
23
If required for generator set operation, inspect parallel operation cable for damage.
2-20
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 TABLE 2-5. OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) (continued) B-BEFORE Interval Item No. B D A Item to be inspected D-DURING Procedures Check for and have repaired or adjusted as necessary __________ WARNING High voltage is produced when the generator set is in operation. Never attempt to start the generator set unless it is properly grounded. Failure to comply can cause injury or death to personnel. 24 Ground Rod Cable and Connection Inspect ground rod and cable for loose connections, breaks, damage, and corrosion. Visual inspection only. Cable is missing or damaged. A-AFTER Equipment is not ready/ available if:
SECTION III. OPERATION UNDER USUAL CONDITIONS 2.7 GENERAL. This section provides information and guidance for generator set operation under normal conditions. Refer to FM 20-31. 2.8 2.8.1 GENERATOR SET INSTALLATION. General. __________ WARNING Exhaust discharge contains deadly gases including carbon monoxide. Do not operate generator set in an enclosed area unless exhaust discharge is properly vented outside. Failure to comply can cause injury or death to personnel. a. b. c. 2.8.2 Ensure that installation site is as level as possible. Provide adequate ventilation to prevent recirculation of hot air exhausted from generator set. Refer to Figure 2-4 for base mounting measurements.
Outdoor Installation. a. Make use of natural protective barriers. FIGURE 2-4. BASE MOUNTING MEASUREMENTS
2-21
b.
Allow space on all sides for service and maintenance. Refer to Figure 2-5 for minimum clearance measurements. Ensure soil is firm and well drained. Use planks or other material for support in areas where soil will not support the generator set.
c. d. 2.8.3
Indoor Installation. __________ WARNING Exhaust discharge contains deadly gases including carbon monoxide. Do not operate generator set in an enclosed area unless exhaust discharge is properly vented outside. Failure to comply can cause injury or death to personnel. CAUTION Never position generator set with air inlets near a wall or other object that interferes with cooling air circulation. Failure to comply can cause damage to equipment. a. b. Provide ducts and vents to outside of building if good supply of cooling air is not available. Make air intake and outlet openings in building same size or larger than those on the generator set.
2-22
FIGURE 2-5. MINIMUM ENCLOSURE CLEARANCE MEASUREMENTS
2-23
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 NOTE Make exhaust pipe extension as short and straight as possible, with only one 90 degree bend if needed. NOTE Ensure that inside diameter of exhaust pipe extension is as large or larger than generator exhaust pipe. c. Install a gas-tight metal pipe from exhaust pipe of generator set to outside of building. __________ WARNING Hot exhaust gases can ignite flammable materials. Allow room for safe discharge of hot gases and sparks. Failure to comply can cause injury or death to personnel. d. Provide for harmless discharge of hot gases and sparks. Do not direct exhaust into area containing flammable materials. _________ WARNING Engine exhaust is hot. When it is required to extend exhaust pipe through flammable material (i.e., wall), shield the extension pipe to protect personnel from burns and prevent fire hazard. Failure to comply can cause injury to personnel, damage to equipment, and fire. e. f. g. Shield exhaust pipe with fireproof material at point where it passes through a flammable wall. Wrap exhaust pipe in heat insulating material. Allow space on all sides of generator set for service and maintenance. Refer to Figure 2-5 for minimum clearance measurements.
2.9
ASSEMBLY AND PREPARATION FOR USE. __________ WARNING High voltage is produced when the generator set is in operation. Never attempt to start the generator set unless it is properly grounded. Failure to comply can cause injury or death to personnel.
2.9.1
Installation of Grounding Rod. a. b. Open Load Terminal access door (Figure 1-2). Insert ground cable (2, Figure 2-6) through load terminal access boot and into GND terminal (5) on load output terminal board. Tighten terminal nut.
2-24
FIGURE 2-6. GROUNDING CONNECTIONS
2-25
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 c. Remove grounding rod from inside generator set by removing top left bolts from left side of generator (Figure 1-3). Replace bolt after removing ground rod. Connect coupling (6) to pointed ground rod section (1), and install driving stud (4) in coupling. Make sure driving stud seats on ground rod section. Drive ground rod section (1) into ground until coupling is just above surface. Remove driving stud (4) from coupling (6), and install another ground rod section (1) in coupling. Install another coupling (6) on ground rod section (1). Install driving stud (4) in coupling, and drive ground rod down until new coupling is just above surface. Repeat steps f and g until ground rod has been driven eight feet or deeper, providing an effective ground. Connect clamp (3) and ground cable (2) to ground rod. Tighten clamp screw.
d.
e. f. g.
h.
i. 2.9.2
Installation of Load Cables. __________ WARNING High voltage is produced when the generator set is in operation. Never attempt to connect or disconnect load cables while the generator set is running. Failure to comply can cause injury or death to personnel. a. Shut down generator set, paragraph 2.11.2. CAUTION When using single phase connections, balance loads between terminals. Do not connect all loads between one terminal and L0. Failure to observe this caution can result in damage to equipment. b. Select required output terminals from Table 2-6. TABLE 2-6. LOAD TERMINAL AND AC RECONNECTION BOARD SELECTION RECONNECTION BOARD POSITION 120/208 TERMINALS VOLTAGE READING
L1, L2, L3, N 3 Phase (Single phase loads can be served using any terminal to N)
240/416
L1, L2, L3, N 3 Phase (Single phase loads can be served using any terminal to N)
L1-N 120 volts L2-N 120 volts L3-N120 volts L1-L2 208 volts L2-L3 208 volts L3-L1 208 volts L1-N 240 volts L2-N 240 volts L3-N 240 volts L1-L2 416 volts L2-L3 416 volts L3-L1 416 volts
2-26
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 c. d. e. Open Load Terminal access door (Figure 1-2). Using insulated wrench (1, Figure 2-7), loosen terminal nuts (2) on terminals selected in step b. Insert load cables through load terminal access boot and into terminal studs (3). Tighten terminal nuts (2). Secure insulated wrench (1) in bracket beside output load terminal board, and close terminal board access door.
f.
2.10 2.10.1 2.10.2
INITIAL ADJUSTMENTS, CHECKS, AND SELF-TEST. Preparation. Perform all BEFORE (B) PMCS. Refer to Table 2-5. Initial Adjustments and Checks. a. b. Open left side engine compartment doors (Figure 1-3). Place DEAD CRANK switch (1, Figure 2-8) in NORMAL position.
FIGURE 2-7. INSTALLATION OF LOAD CABLES
2-27
FIGURE 2-8. GENERATOR SET CONTROLS
2-28
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 c. d. e. f. g. Close engine compartment doors. Release DCS control panel by turning two fasteners, and lower DCS control panel slowly. Ensure FREQUENCY SELECT switch (10) is in required position. Ensure VOLTAGE SELECTION switch (9) is set to match voltage requirements. Raise and secure DCS control panel with two fasteners. NOTE If software fails to boot properly, notify next higher level of maintenance.
h.
Place MASTER CONTROL switch (12) in ON position. While DCS software is loading and running its diagnostics on CIM, perform steps i through m. Open output box access door (Figure 1-2). Ensure voltage reconnection terminal board (27, Figure 1-30) is positioned to match voltage requirements. If voltage reconnection board must be changed, notify next higher level of maintenance. Close output box access door. Ensure EMERGENCY STOP switch (2, Figure 2-8) is pulled out.
i. j.
k. l.
m. Ensure BATTLE SHORT switch (4) is in OFF position. n. Ensure NETWORK FAILURE indicator (3) on DCS control panel goes out when DCS software has finished loading and is displayed on CIM display screen as shown in Figure 2-2. If NETWORK FAILURE indicator is still illuminated, use keypad to exit software, place MASTER CONTROL switch (12) in OFF position and panel light switch (16) is in off position, and notify next higher level of maintenance.
2.10.3
Self Test. a. b. Place ENGINE CONTROL switch (6) in PRIME & RUN position. Hold FAULT RESET switch (14) in ON position for two seconds. Release switch. FAULT INDICATOR and MESSAGES portions of CIM display screen should be blank unless a fault condition still exists. Use arrow buttons on keypad to move cursor to DISPLAY MODE portion of CIM display screen. Use SELECT button to alternately click MAIN / FULL button to ensure MAIN screen and FULL screen display properly. Push PRESS TO TEST pushbutton on NETWORK FAILURE INDICATOR (3). Ensure indicator light illuminates. When pushbutton is released, indicator light should go out.
c.
d.
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ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 2.11 OPERATING PROCEDURE. __________ WARNING Exhaust discharge contains deadly gases including carbon monoxide. Do not operate generator set in an enclosed area unless exhaust discharge is properly vented outside. Failure to comply can cause injury or death to personnel. NOTE If generator set is to be operated in parallel with another unit, refer to paragraph 2.12. 2.11.1 Start Generator Set. __________ WARNING High voltage is produced when the generator set is in operation. Never attempt to start the generator set unless it is properly grounded. Failure to comply can cause injury or death to personnel. __________ WARNING Operating the generator set with any access door open exposes personnel to high noise level and can cause hearing damage. Hearing protection must be worn when operating or working near the generator set with any access door open. Failure to comply can cause hearing damage to personnel. a. b. Perform initial adjustments, checks, and self test, paragraph 2.10. Ensure CIM display screen is in MAIN mode (Figure 2-9). If necessary, use keypad arrow buttons to move cursor to DISPLAY MODE. Use SELECT button to click FULL/MAIN button to access MAIN mode screen. Hold FAULT RESET switch (14, Figure 2-8) in ON position for two seconds. Release switch. CAUTION Do not crank engine in excess of 15 seconds at a time. Allow starter to cool at least 15 seconds between attempted starts. Failure to comply can cause damage to equipment. NOTE If engine is not started within 25 seconds after FAULT RESET switch is operated, reset condition will time out and have to be reset again before starting the engine. NOTE At temperatures below 40F (4C) it may be necessary to use the cold weather starting aid (See step d).
c.
2-30
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 d. In cold weather conditions, while performing step e, momentarily hold ETHER START switch (5) to ON position and release. Repeat as necessary until engine accelerates to governed speed. Hold ENGINE CONTROL switch (6) in START position (for 2 seconds) and observe CIM display screen until oil pressure reaches at least 25 psi (172 kPa), voltage has increased to its approximate rated value, and engine has reached stable operating speed. Release ENGINE CONTROL switch (6) to PRIME & RUN position. If operating with an auxiliary fuel source, rotate ENGINE CONTROL switch (6) to PRIME & RUN AUX FUEL position. Check WATER TEMP (170-200F [11-93C]) and OIL PRESSURE (25-60 psi [172-414 kPa]) meters on CIM display screen for normal readings. Use keypad arrow buttons to move cursor to DISPLAY MODE on CIM display screen. Use SELECT button to click FULL / MAIN button to toggle between full and main mode screens. Access FULL mode screen. NOTE Warm up engine without load for five minutes. (If necessary, load can be applied immediately.) Use VOLTAGE ADJUST switch (8) and FREQUENCY ADJUST switch (7) to adjust values for voltage and frequency until required values are displayed on VOLTAGE and FREQUENCY gages on CIM display screen. If required reading cannot be obtained, shut down generator set (paragraph 2.11.2), and notify next higher level of maintenance. Press TEST pushbutton on GROUND FAULT CIRCUIT INTERRUPTER (13). Ensure RESET pushbutton is in in position. Hold AC CIRCUIT INTERRUPT switch (15) in CLOSED position until CONTACTOR POSITION on CIM display screen reads CLOSED.
e.
f. g.
h.
i.
j.
k.
l.
m. With CIM display in Main Display Mode, ensure VOLTAGE (15) and FREQUENCY (16) gages (Figure 2-9) still indicate rated values. Adjust if necessary. n. With CIM display in Full mode screen, if more than rated load is indicated on GEN CURRENT indicator (3) (Figure 2-9) for any phase, reduce load. With CIM Display in Main Mode, observe POWER gage (17) (Figure 2-9) on CIM display screen. If indication is more than 60KW, reduce load. Perform all DURING (D) PMCS requirements in accordance with Table 2-5.
o.
p. 2.11.2
Shut Down Generator Set. a. Hold AC CIRCUIT INTERRUPT switch (15, Figure 2-8) in OPEN position until CONTACTOR POSITION on CIM display screen reads OPEN. Allow generator set to operate five minutes with no load applied. Place ENGINE CONTROL switch (6) in OFF position.
b. c.
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NOTE REFER TO PAGE 2-6 FOR LEGEND
FIGURE 2-9. CIM DISPLAY SCREEN CONTROLS AND INDICATORS
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ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 d. Perform all AFTER (A) PMCS requirements in accordance with Table 2-5. NOTE If software fails to boot properly, notify next higher level of maintenance. e. Use keypad arrow buttons to move cursor to SHUTDOWN COMPUTER on CIM display screen. Use SELECT button to click on EXIT button to exit the DCS software. When CIM display screen displays message that it is safe to turn off the computer, place MASTER CONTROL switch (12) in OFF position. Turn off panel lights. Place DEAD CRANK switch (1) in OFF position.
f.
g. 2.12
PARALLEL UNIT OPERATION (LOAD SHARING). CAUTION Ensure generator sets are the same size and mode before attempting parallel operation.
2.12.1
General. The following method of parallel operation is used to share the load between two generator sets. Refer to Figures 2-1 and 2-2 for location of operator controls and indicators mentioned below and Figure 210 for proper paralleling configuration. Pre-Operation. __________ WARNING Prior to making any connections for parallel operation or moving a generator set which has been operating in parallel, ensure there is no input to the load output terminal board and the generator sets are shut down. Failure to comply can cause injury or death to personnel by electrocution. a. Ensure load requirement is equal or below the combined rated capacity of the two generator sets. __________ WARNING High voltage is produced when the generator set is in operation. Never attempt to start the generator set unless it is properly grounded. Failure to comply can cause injury or death to personnel. b. Determine voltage requirements of load and position voltage reconnection terminal boards of the two generator sets to the required voltage connection. Ensure FREQUENCY SELECT switches (10, Figure 2-8) on both generators are positioned for the same frequency requirements (50 Hz or 60 Hz). Identify one generator set as No. 1 and the other as No. 2. Open BATTERY ACCESS door (Figure 1-2).
2.12.2
c. d.
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FIGURE 2-10. PARALLEL OPERATION SETUP
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ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 e. f. Remove paralleling cable from storage box, and close BATTERY ACCESS door (Figure 1-2). Connect paralleling cable between the two generators sets. Connect the generator sets to the load observing proper phase sequence. Check connections with phase rotation meter (Appendix B). CAUTION Do not close the AC CIRCUIT INTERRUPT switch on either of the generator sets, nor close the load contactor at load, until specifically directed to do so. Closing any of these devices at any other time may severely damage one or both of the generator sets. 2.12.3 Operation. a. b. Start each generator set. Refer to paragraph 2.11.1. Use keypad arrow buttons to move cursor to DISPLAY MODE on CIM display screen. If necessary, use SELECT button to access FULL mode screen. Use VOLTAGE ADJUST switch (8, Figure 2-8) to obtain the same voltage indication on each set. Use FREQUENCY ADJUST switch (7) to obtain approximately the same frequency indication on both sets. Observe CONTACTOR POSITION on CIM display screen to ensure load contactor at load is open. Momentarily hold AC CIRCUIT INTERRUPT switch (15) on generator set No. 1 in CLOSED position until CONTACTOR POSITION reads CLOSED. CAUTION Check CONTACTOR POSITION indication on CIM display screen to ensure load contactor at load is OPEN before attempting to place generators on the line. Failure to comply can cause damage to generator sets. f. Momentarily hold AC CIRCUIT INTERRUPT switch (15) on generator set No. 2 in CLOSED position until CONTACTOR POSITION on CIM display screen reads CLOSED. NOTE The generator sets are now operating in parallel with no load. g. h. i. Check that POWER gage on CIM display screen indicates approximately zero. Close the load contactor at the load. Check that GEN CURRENT indicators (Figure 2-11) on CIM display screens of both generator sets display approximately the same amperage. If not, adjust VOLTAGE ADJUST switch (8, Figure 2-8) up or down to achieve proper reading. Compare POWER Meter readings from CIM display screens on both generator sets. If readings are not within 10 percent, remove from parallel operation at once (paragraph 2.12.4) and notify next higher level of maintenance.
c. d.
e.
j.
2-35
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 2.12.4 Remove from Parallel Operation. __________ WARNING If necessary to move a generator set which has been operating in parallel with another generator set, shut down remaining generator set connected to the load prior to removing load cables or ground. Failure to comply can cause injury or death to personnel by electrocution. CAUTION Prior to removal of one generator set from parallel operation, make sure load does not exceed full load rating of generator set remaining on the line. Failure to comply can cause damage to generator set still on line. a. Momentarily hold AC CIRCUIT INTERRUPT switch (15, Figure 2-8) in OPEN position until CONTACTOR POSITION on CIM display screen reads OPEN. Shut down generator set, paragraph 2.11.2.
b. 2.13 2.13.1
REMOTE OPERATION. Description and Operating Instructions. a. The DCS provides the ability to control and monitor the generator set from a remote location using an IBM-compatible personal computer (PC). Minimum requirements for that computer are: a 486 processor, RS485 serial card, 3.5" Floppy Drive and /or CD ROM drive, Windows 95 operating system, and a mouse. (Note: Multiple RS 485 serial cards are available to use. Recommend an internally installed RS 485 card be used for desktop PCs and a PCMCIA card be used for laptop computers). Remote instrument monitoring allows the operator to observe metering and protective device status. To start and run the generator set the operator must follow the operating procedures described in paragraph 2.11. When connected, the remote display functions are independent of the onboard CIM display. That is, the remote display includes the same controls and indicators as the CIM display (Figure 2-2), but with added controls as indicated in step c below. Switching modes on the remote display screen does not affect the screen mode displayed on the CIM. Additional switching controls on the remote screen allow the operator to control four functions of the remote PC and generator set from the remote location. The SHUTDOWN COMPUTER EXIT button (1, Figure 2-11) is used to shut down the remote operation shutdown and return control of the generator set to the DCS onboard controls. The DISPLAY MODE FULL/MAIN button (2, Figure 2-11) allows the operator to toggle between display modes on the remote computer like the same button does on the CIM display screen. The BATTLESHORT SEL. SW. ON/OFF button (3, Figure.2-11) allows the remote operator to remotely activate and deactivate the generator set's battle short function. The ENGINE CONTROL RUN/STOP button (4, Figure 2-11) allows the operator to stop the generator set engine from the remote PC. A cable links the remote PC to the generator set via the COMMUNICATION RECEPTACLE (J3) (1, Figure 1-30). COMMUNICATION RECEPTACLE (J3) internally connects to (J21) (Figure 2-3), of the I/O interface module via generator set wiring. COMMUNICATION RECEPTACLE (J3) is a nine pin environmentally sealed connector. One end of the remote cable hooks to COMMUNICATION RECEPTACLE (J3), the other end terminates at the RS485 serial card installed in the remote PC.
b.
c.
d.
2-36
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 User needs to follow the specific installation instructions for the 485 serial card that is being used. Refer to Figure 2-12 for information concerning the remote PC setup and pin configurations. e. Special-purpose software (included in the CD called "30/60kW Tactical Quiet Generator CIM Software") is provided with the generator set for use at the remote site to process digital signals between the remote PC and the DCS. This software must be installed on an IBM-compatible PC as described in step a above. Setup of the software is described in paragraph 2.13.2.
2.13.2
TQG Remote Software Installation. a. b. Set up computer in accordance with your computer's instruction manual. Turn on computer. Refer to computer's instruction manual. Wait for computer to boot into Windows 95. The generator set comes with a CD labeled "30/60kW Tactical Quiet Generator CIM Software". If the computer has a CD ROM drive then use procedures d (1) through d (7) below. If the computer only has a 3.5 inch floppy drive then floppy disks need to be prepared using instructions provided in paragraphs e (1) through e (11) below followed by the procedures in paragraphs f (1) through f (7). below. CD ROM Procedures - Insert the CD in the CD ROM drive of computer, refer to computer instruction manual. (1). Left click mouse on Windows 95 START button in the lower left corner of the screen. The START menu will pop up on the screen. (2). Left click mouse on RUN from the START menu. The RUN window will appear. (3). Type the following: d:\remop\setup (Note: 'd:' represents the drive letter of the CD ROM drive. This may not be the same drive letter for all computers. Refer to computer instruction manual to identify the correct drive letter and use that letter in place of 'd') (4). Left click on OK button. At this point the setup wizard will guide you through the installation. (5). To start remote data display software left click mouse on START button in the lower left corner of the screen. The START menu will pop up on the screen. (6). Select PROGRAMS, then left click the "Remote Data Display" icon. (Note: If the message "Error: Communication Failed" comes up on the screen, click OK. This error may come up because the PC is not connected to the CIM). (7). To exit out of this screen, move cursor to EXIT button and left click the mouse. e. Floppy disk preparation. (Note: Any computer that meets the minimum requirements in para. 2.13.1.a above (except for the RS485 serial card which is not required), and has both a 3.5" floppy drive and CD ROM drive can be used for these procedures). (1). Set up computer in accordance with your computer's instruction manual. (2). Turn on computer. Refer to computer's instruction manual. Wait for computer to boot.
c.
d.
2-37
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 (3). Insert the CD labeled " 30/60kW Tactical Quiet Generator CIM Software" in the CD ROM drive of computer, refer to computer instruction manual. (4). Insert a blank, formatted 3.5" floppy disk in the 3.5" floppy drive of computer, refer to computer instruction manual. (5). Left click mouse on START button in the lower left corner of the screen. The START menu will pop up on the screen. (6). Select PROGRAMS, then left click the "MS-DOS Command Prompt" icon. (7). Type in d: (Note: 'd:' represents the drive letter of the CD ROM drive. This may not be the same drive letter for all computers. Refer to computer instruction manual to identify the correct drive letter and use that letter in place of 'd'). Press [ENTER]. (8). After 'D:>\' comes up on screen type in cd batch. Press [ENTER]. (Note: There are three (3) possible ways to make floppy disks. The following paragraphs describe the 3 options). (a) To make only one disk type in the command create[SPACE]# where # represents the number of the disk to be made i.e. "create 2" makes a copy of disk #2. (b) If more than one disk needs to be made type in the command create[SPACE]#[SPACE]#[SPACE]# where # represents the number of the disk that is to be made, ie. To make disks 1, 3, &5 type in "create 1 3 5". (c) To make all eight (8) disks at one time simply type in the command makeall. (9). At next prompt (D:\BATCH>) type in the command from (8) above that is applicable to the number of disks that are to be made, i.e. "create 1", "create 3 4 5" or "makeall". The names of the eight (8) disks are as follows: Disk 1 - Generator Software Remote Operator. Disk 1 of 2 Disk 2 - Generator Software Remote Operator. Disk 2 of 2 Disk 3 - Generator Software Operator Log. Disk 1 of 2 Disk 4 - Generator Software Operator Log. Disk 2 of 2 Disk 5 - Generator Software CIM Network Link. Disk 1 of 1 Disk 6 - Generator Software Windows CE. Disk 1 of 2 Disk 7 - Generator Software Windows CE. Disk 2 of 2 Disk 8 - Generator Software Digital Controls. Disk 1 of 1 (10). Press [ENTER] key. When the copy is complete the screen will prompt you to insert a blank floppy disk. Label each disk as shown above -i.e. "Generator Software Remote Operator. Disk 2 of 2". (11). When copying of the required disks is complete, press [ENTER] and type in exit to return to Windows screen. Remove floppy disk and CD. f. Floppy Disk procedures. Insert 3.5" floppy disk labeled "Generator Software Remote Operator. Disk 1 of 2", in 3.5" floppy drive of computer, refer to computer instruction manual. (1). Left click mouse on Windows 95 START button in the lower left corner of the screen. The START menu will pop up on the screen. (2). Left click mouse on RUN from the START menu. The RUN window will appear.
2-38
(3). Type the following: a:\setup (4). Left click on OK button. At this point the setup wizard will guide you through the installation. When prompted hit "Next" and complete requested information. Keep hitting "Next" until prompted to insert Disk 2. Insert 3.5" floppy disk labeled "Generator Software Remote Operator. Disk 2 of 2", in 3.5" floppy drive of computer. (5). To start remote data display software, left click mouse on Windows 95 START button in the lower left corner of the screen. The START menu will pop up on the screen. (6). Select Programs, then left click the "Remote Data Display" icon. (Note: If the message "Error: Communication Failed" comes up on the screen, click OK. This error may come up because the PC is not connected to the CIM). (7). To exit out of this screen, move cursor to EXIT button and left click the mouse. g. Left click on OK button. At this point the setup wizard will guide you through the installation. When prompted Install 3.5" Floppy Disk labeled TQG Remote Software Disk 2 of 2, in 3.5" Floppy drive of computer. To start remote data display software, Left click mouse on Windows 95 START button in the lower left corner of the screen. The START menu will pop up on the screen. Select Programs, the left Click the "Remote Data Display" icon.
h.
i. 2.14
PREPARATION FOR MOVEMENT. a. Shut down generator set, paragraph 2.11.2. If generator set is operating in parallel, refer to paragraph 2.12.4. Disconnect load cables (Figure 2-7). Disconnect paralleling cable, if used, and store in storage box inside BATTERY ACCESS door (Figure 1-2). When using auxiliary fuel line, disconnect line, drain excess fuel from line, and store line in storage box inside BATTERY ACCESS door (Figure 1-2). Disconnect ground cable, and remove ground rods. Store ground rods in holding brackets located inside generator set housing, below engine compartment access doors (*) . Store ground cable, couplings, clamp, and driving stud in storage box inside BATTERY ACCESS door. Secure all generator set access doors and panels. For assembly and preparation for use, refer to paragraph 2.9.
b. c.
d.
e.
f. g.
2-39
FIGURE 2-11. REMOTE PC DISPLAY MODES
2-40
FIGURE 2-12. REMOTE PC SETUP
SECTION IV. OPERATION UNDER UNUSUAL CONDITIONS 2.15 OPERATION IN EXTREME COLD WEATHER BELOW -25 F (-31 C). The generator set operates in ambient temperatures as low as -25F (-31C) without special winterization equipment. To ensure satisfactory operation under extreme cold weather the following steps must be taken: __________ WARNING
2-41
In extreme cold weather, skin can stick to metal. Avoid contacting metal items with bare skin in extreme cold weather. Failure to comply can cause injury to personnel. a. b. c. Keep generator set and surrounding area as free of ice and snow as practical. Keep fuel tank full to protect against moisture, condensation, and accumulation of water. Ensure proper grade diesel fuel is used. Refer to Table 2-7. TABLE 2-7. FUEL AMBIENT TEMPERATURE +20F TO 120F (-6C TO +49C) 0F TO +20F (-17C TO -6C) -25F TO 0F (-32C TO -17C) -25F TO 0F (-32C TO -17C) DIESEL FUEL VV-F-800 GRADE DF-2, JP5, OR JP8 VV-F-800 GRADE DF-1, JP5, OR JP8 VV-F-800 GRADE DF-1 VV-F-800 GRADE DF-A
d. e. 2.16
Keep batteries free from corrosion and in a well charged condition. Ensure proper oil is used. See Appendix F.
OPERATION IN EXTREME HEAT ABOVE 120 F (48.8 C). a. b. c. d. e. Check vents and radiator air passages frequently for obstructions. Check coolant temperature indicator frequently for any indication of overheating. Allow sufficient space for fuel expansion when filling fuel tank. Keep generator clean and free of dirt. Clean obstructions from generator intake and outlet screens. Clean external surface of engine when generator set is not operating.
2.17
OPERATION IN DUSTY OR SANDY AREAS. a. If possible, provide a shelter for generator set. Use available natural barriers to shield generator set from blowing dust and sand. Wet down dusty and sandy surfaces areas around generator set frequently if water is available. Keep all access doors closed as much as possible to prevent entry of dust and sand into housing assembly. Wipe dust and sand frequently from the generator set external surface and components. Wash exterior surfaces frequently with clean water when generator set is not operating.
b. c.
d.
2-42
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 e. f. Service engine air cleaner assembly frequently to compensate for intake of additional dust or sand. Drain sediment frequently from fuel filter/water separator. When servicing fuel tank, be careful to prevent dust or sand from entering fuel tank. Change engine oil and oil filter frequently. Store oil and fuel in dust-free containers. Ensure generator set ground connections are free of dust and sand, and connections are tight before starting the unit.
g. h. i.
2.18
OPERATION UNDER RAINY OR HUMID CONDITIONS. CAUTION Failure to remove waterproof material before operating generator set could result in damage to equipment. a. If possible, provide a shelter for generator set. Cover generator set with canvas or other waterproof material when it is not being operated. Provide adequate drainage to prevent water from accumulating on operation site. Keep all generator set access doors closed, as much as possible, to prevent entry of water into housing assembly. Drain water frequently from fuel filter/water separator. __________ WARNING DC voltages are present at generator set electrical components even with generator set shut down. Avoid shorting any positive terminal with ground/negative. Failure to comply can cause injury to personnel and damage to equipment. e. f. Remove moisture from generator set components before and after each operating period. Keep fuel tank full to protect against moisture, condensation, and accumulation of water.
b. c.
d.
2.19
OPERATION IN SALT WATER AREAS. CAUTION Failure to remove waterproof material before operating generator set could result in damage to equipment. a. If possible, provide a shelter for the generator set. Locate generator set so radiator faces into prevailing winds. Use natural barriers or, if possible, construct a barrier to protect generator set from salt water. Cover generator set with canvas or other waterproof material when it is not being operated. Keep all generator set access doors closed, as much as possible, to prevent entry of salt water into housing assembly.
b.
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ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 c. d. 2.20 Wash exterior surfaces frequently with clean water when generator set is not operating. Check wiring connections for corrosion and wire insulation for signs of deterioration.
OPERATION AT HIGH ALTITUDES. The generator set will operate at elevations up to 4000 feet (1219.1 meters) above sea level without special adjustment or reduction in load. At elevations greater than 4000 feet, the kilowatt rating is reduced approximately 3.5 percent for each additional 1000 feet (304.8 meters).
2.21 2.21.1
NATO SLAVE RECEPTACLE START OPERATION. General. The NATO SLAVE RECEPTACLE (Figure 2-13) can be used to start the generator set when batteries are discharged. NATO/Slave Emergency Starting Procedure. a. Connect one end of NATO/SLAVE RECEPTACLE cable to fully charged 24 VDC system and other end to discharged generator set's NATO/SLAVE RECEPTACLE (Figure 2-13). Start discharged generator set, paragraph 2.11.1. Remove NATO/SLAVE RECEPTACLE cable after generator set starts. NOTE The generator set cannot be restarted without resetting the EMERGENCY STOP pushbutton and turning ENGINE CONTROL switch to OFF position.
2.21.2
b. c.
2.22 EMERGENCY STOPPING. Depressing the EMERGENCY STOP pushbutton (2, Figure 2-8) will stop the generator set.
2.23
OPERATION USING BATTLE SHORT SWITCH. CAUTION Continued operation using the BATTLE SHORT switch can result in damage to the generator set. NOTE If any emergency situation requires continued operation of the generator set, the BATTLE SHORT switch is used to override all protection devices except the overspeed, short circuit devices, and EMERGENCY STOP function. NOTE BATTLE SHORT switch must be in OFF position to start generator set.
2-44
FIGURE 2-13. NATO SLAVE RECEPTACLE a. b. Start generator set, paragraph 2.11.1. Lift cover on BATTLE SHORT switch (4, Figure 2-8), and place switch in ON position to operate generator set under these emergency conditions.
2.24
NUCLEAR, BIOLOGICAL, AND CHEMICAL (NBC) DECONTAMINATION PROCEDURES. Refer to FM 3-5, NBC Decontamination, for information on decontamination procedures. Specific procedures for the generator set are as follows: a. Control panel indicator sealing gaskets, rubber sleeves, rope draw cords at output terminal access ports, control panel door gaskets, access door gaskets, rubber tubing and belts within the engine compartment, coverings for electrical conduits, external water drain tubing, and retaining cords for NATO SLAVE RECEPTACLE covers will absorb and retain chemical agents. Replacement of these items is the recommended method of decontamination.
2-45
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 b. Lubricants, fuel, coolant, and battery fluid may be present on external surfaces of the generator set or its components due to leaks or normal operation. These fluids will absorb NBC agents. The preferred method of decontamination is removal of these fluids using conventional decontamination methods in accordance with FM 3-5. Continued decontamination of external generator set surfaces with supertropical bleach (STB)/decontaminating solution number 2 (DS2) will degrade clear plastic indicator coverings to a point where reading indicators will become impossible. This problem will become more evident for soldiers wearing protective masks. Therefore, the use of STB or DS2 decontaminates in these areas should be minimized. Indicators and the CIM display screen should be decontaminated with warm soapy water. External surfaces of the control panel assembly that are marked with painted or stamped lettering will not withstand repeated decontamination with STB or DS2 without degradation of this lettering. The recommended method of decontamination for these areas is warm soapy water. Areas that will entrap contaminants, making efficient decontamination extremely difficult, include the following: space behind knobs and switches on the control panel, exposed heads of screws, areas adjacent to and behind exposed wiring conduits, hinged areas of access doors, spaces behind externally mounted equipment specification data plates, areas around external oil drain valve, retaining chains for external receptacle covers, areas behind external receptacle covers, access door locking mechanisms, recessed walls for access door handles, fuel caps, load output terminal board access door, NATO SLAVE RECEPTACLE, frequency adjustment controls, areas around tie-down/lifting rings, crevices around access doors, external screens covering ventilation areas, and areas adjacent to the external fuel drain valve. Replacement of these items, if available, is the preferred method of decontamination. Conventional decontamination methods should be used on these areas, while stressing the importance of thoroughness and the probability of some degree of continuing contact and vapor hazard. In an NBC contaminated environment, the generator set should be operated with all access doors closed to reduce the effects of contamination. The use of overhead shelters or chemical protective covers is recommended as an additional means of protection against contamination in accordance with FM 3-5. When using covers, care should be taken to provide adequate space for air flow and exhaust. For additional NBC information, refer to FM 3-3 and FM 3-4.
c.
d.
e.
f.
g.
h. 2.25
OPERATION WHILE CONTAMINATED. The generator will operate in a normal manner when exposed to nuclear, biological, or chemical (NBC) contamination. It is capable of being operated by personnel wearing NBC clothing without special tools or support equipment. Refer to FM 3-3, FM 3-4, and FM 3-5. OPERATION IN A HIGH ALTITUDE ELECTROMAGNETIC PULSE (HAEMP) ENVIRONMENT. a. Hold AC CIRCUIT INTERRUPTER switch (15, Figure 2-8) in open position until CONTACTOR POSITION on CIM display screen reads OPEN. Place ENGINE CONTROL SWITCH (6) in OFF position. Place MASTER SWITCH (12) in OFF position and wait approximately 10 seconds. Restart and operate generator set in accordance with applicable normal procedures (refer to para 2.11).
2.26
b. c. d.
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ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 CHAPTER 3 OPERATOR MAINTENANCE INSTRUCTIONS
CHAPTER INDEX SECTION I SECTION II SECTION III LUBRICATION PROCEDURES..................................................................................................3-1 TROUBLESHOOTING.................................................................................................................3-1 OPERATOR MAINTENANCE PROCEDURES........................................................................3-18
SECTION I. LUBRICATION PROCEDURES 3.1 OPERATOR LUBRICATION INSTRUCTIONS. Refer to Appendix F. SECTION II. TROUBLESHOOTING 3.2 GENERAL. This section contains troubleshooting information for locating and correcting operating troubles which may develop in the generator set. Each malfunction for an individual component unit or system is followed by a list of tests or inspections which will help to determine probable causes and corrective actions to take. Perform the tests/inspections in the order listed. Table 3-1 is provided for operator troubleshooting. A symptom index is provided for quick identification and location of possible trouble. Table 3-1 cannot list all malfunctions that may occur, nor all tests or inspections and corrective actions. If a malfunction is not listed, or is not corrected by listed corrective actions, notify your supervisor. SYMPTOM INDEX Page Engine Fails to Crank .................................................................................................................................................3-2 Engine Cranks, But Fails To Start ..............................................................................................................................3-3 Engine Starts, But Stops When Engine Control Switch Is Released From Start.........................................................3-4 Engine Stops Suddenly ...............................................................................................................................................3-5 Engine Runs Erratically or Stalls Frequently..............................................................................................................3-5 Engine Knocks............................................................................................................................................................3-6 Engine Does Not Develop Full Power........................................................................................................................3-7 Engine Exhaust Smokes..............................................................................................................................................3-8 Engine Oil Pressure Low ............................................................................................................................................3-9 Engine Overheating ..................................................................................................................................................3-10 Generator Set Fails to Parallel Correctly ..................................................................................................................3-11 CIM Display Screen Does Not Display and Backlight Does Not Light....................................................................3-13 CIM Display Screen BATTERY VDC Indicator Shows Excessive Charging After Prolonged Operation ..............3-14 CIM Display Screen VOLTAGE Gage Fluctuates ...................................................................................................3-15 CIM Display Screen FREQ Gage Fluctuates............................................................................................................3-16 CIM Display Screen does not respond to keypad input test......................................................................................3-17
3-1
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 TABLE 3-1. OPERATOR TROUBLESHOOTING
ENGINE FAILS TO CRANK

Engine fails to crank.
Notify next higher level of maintenance.
3-2
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 TABLE 3-1. OPERATOR TROUBLESHOOTING (CONTINUED)
ENGINE CRANKS BUT FAILS TO START

Engine cranks but fails to start.
Yes
Check FAULT INDICATOR on CIM display screen. Is a fault displayed? (Fig 2-2) No
No
No
Activate FAULT RESET Switch (12, Fig 2-1) on DCS control panel. Does fault clear? Yes Go to troubleshooting section corresponding to fault displayed. See Symptom Index, page 3-1. Is speed control unit DC POWER LED (15, Fig 2-3) lit?
Is EMERGENCY STOP switch (3, Fig 2-1) pushed in?
Yes
No
Pull EMERGENCY STOP switch to out (deactivated) position.
Activate FAULT RESET Switch (12, Fig 2-1) on DCS control panel. Does fault clear? Yes Is ambient temperature above 40F(4C)? No
No
No
Use ETHER START switch (7, Fig 2-1) to assist in starting engine in cold weather, below 40F (4C). Does Engine start ?
Not OK
Inspect air cleaner assembly (see para. 3.3.3).
OK
Service air cleaner assembly (see para. 3.3.3).
Not OK
Inspect/service fuel filter/water separator (see para. 3.3.7).
OK
3-3
ENGINE STARTS BUT STOPS WHEN ENGINE CONTROL SWITCH IS RELEASED FROM START
Engine starts but stops when ENGINE CONTROL switch is released from START position.
Check for proper starting procedure. Hold ENGINE CONTROL switch (8, fig 2-1) in START position until 25 psi (172 kPa) oil pressure is reached, then release switch to PRIME & RUN position.
Yes
Check FAULT INDICATOR on CIM display screen. Is a fault displayed? (fig.2-2)
No
Go to troubleshooting section corresponding to fault displayed. See Symptom Index, page 3-1.
OK
Inspect air cleaner Not OK assembly (see para.3.3.3).
OK
Inspect/service fuel filter/water seperator (see para.3.3.7).
Not OK
Service air cleaner assembly (see para.3.3.3).
3-4
ENGINE STOPS SUDDENLY

Engine stops suddenly.
Yes
No
ENGINE RUNS ERRATICALLY OR STALLS FREQUENTLY

Engine runs erratically or stalls frequently.
Yes
No
OK
Inspect air cleaner assembly (see para.3.3.3).
Not OK
OK
Inspect/service fuel filter/water separator (see para.3.3.7).
Not OK
3-5
ENGINE KNOCKS
Engine knocks
Yes
No
OK
Not OK Inspect lubrication system (see para.3.3.8).
Not OK
Check for loose parts or foreign objects in the engine compartment.
OK
Service lubrication system (see para.3.3.8).
Remove foreign objects from compartment.
3-6
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 TABLE 3-1. OPERATOR TROUBLESHOOTING ( CONTINUED)
ENGINE DOES NOT DEVELOP FULL POWER

Engine does not develop full power.
Yes
No
OK
Not OK
Not OK
OK
Not OK
Check to see if exhaust opening is free from obstructions.
OK
Remove obstruction from exhaust opening.
3-7
ENGINE EXHAUST SMOKES
Exhaust smokes.
Yes
No
No
Is exhaust smoke black or gray?
Yes
Not OK Yes Smoke is white and goes away after a few minutes. No White smoke during startup is normal.
Inspect air cleaner assembly (see para.3.3.3). OK
Check for improper type of fuel (see Table 3-3).
3-8
ENGINE OIL PRESSURE LOW

Engine has low oil pressure.
Not OK
Inspect lubrication system (see para.3.3.8).
OK
Service lubrication system (see para.3.3.8).
No
Check WATER TEMP on CIM display screen. Is temperature over 200F?
Yes
Not OK
Inspect engine cooling system (see para.3.3.5). OK
Service engine cooling system (see para.3.3.5)
Inspect air cleaner assembly (see para.3.3.3). OK
Not OK
Service air cleaner assembly (see para.3.3.3). Notify next higher level of maintenance.
3-9
ENGINE OVERHEATING
Engine overheating.
Yes
No
No
Check WATER TEMP on CIM display screen. Is temperature over 220F? (fig.2-2)
Yes
OK
Inspect engine cooling system (see para.3.3.5).
Not OK
Service engine cooling system (see para.3.3.5). OK Inspect air cleaner assembly (see para.3.3.3). Not OK
3-10
GENERATOR SET FAILS TO PARALLEL CORRECTLY
Generator set fails to parallel correctly.
Yes
Check FAULT INDICATOR on CIM display screen. Is a fault displayed? (Fig 2-2)
No
OK
Check that parallel cable is connected properly (see para. 2.12.2).
Not OK
OK
Check that STATUS/CONTACT POSITION indicator on both generator sets reads CLOSED. (Fig 2-2)
Not OK
Connect parallel cable properly (see para. 2.12.2).
Not OK
Check that load cables are installed properly (see para. 2.9.2).
OK
Momentarily hold AC CIRCUIT INTERRUPTER switch (10, Fig 2-1) on generator set(s) in CLOSED position until STATUS/CONTACT POSITION indicator reads CLOSED. (Fig 2-2) Yes
Install load cables properly (see para. 2.9.2).
No
Is generator set a 50/60 Hz unit? (Fig. 1-3)
OK
Check that FREQUENCY SELECT switch (22, Fig 2-1) is in the same position on both units.
Not OK
Not OK
Check that FREQ gage on CIM display screen indicates proper Hz setting. (Fig. 2-2)
OK
Set FREQUENCY SELECT switch on both generators to the same position.
Use FREQUENCY ADJUST switch (9, Fig. 2-1) to obtain proper Hz setting.
Continued on next page.
3-11
GENERATOR SET FAILS TO PARALLEL CORRECTLY (CONTINUED)
Continued from previous page.
OK
Check that both generator voltage reconnect boards are set to the same voltage (Fig. 1-30)
Not OK
No
Are both generators adjusted to the same voltage?
Yes
Adjust generator sets to rated voltage using VOLTAGE ADJUST switch . (11, Fig 2-1)
3-12
CIM DISPLAY SCREEN DOES NOT DISPLAY AND BACKLIGHT DOES NOT LIGHT
CIM display screen does not display and backlight does not light.
Not OK
Is MASTER CONTROL switch ON? (13, fig.2-1)
OK
Place MASTER CONTROL switch to ON position.
Not OK
Confirm that Control Panel is lit. OK
Not OK
Inspect engine cooling system (see para.3.3.5).
OK
Attempt dead crank. Not OK
OK
Replace fuse. Confirm that back light illuminates. If fuse blows again, notify next higher level of maintenance.
OK
Check battery connections.
Not OK
Connect slave unit. Refer to para.2.21. Not OK
Replace battery connections (see para.4.6.2).
3-13
CIM DISPLAY SCREEN BATTERY VDC INDICATOR SHOWS EXCESSIVE CHARGING AFTER PROLONGED OPERATION
CIM display screen BATTERY VDC indicator shows excessive charging after prolonged operation. (fig.2-2)
No
Are batteries maintenance free type?
Yes
Inspect batteries (see para.3.3.2). Not OK
OK
Service batteries (see para.3.3.2).
3-14
CIM DISPLAY SCREEN VOLTAGE GAGE FLUCTUATES
CIM display screen VOLTAGE gage fluctuates.
No
Is engine running erratically?
Yes
Yes
Check FAULT INDICATOR on CIM display screen. Is a fault displayed? (fig. 2-2)
No
Got to troubleshooting section corresponding to fault displayed. See Symptom Index, page 3-1.
OK
Not OK
Not OK
OK
3-15
CIM DISPLAY SCREEN FREQ GAGE FLUCTUATES
CIM display screen FREQ gage fluctuates. (fig.2-2)
No
Is engine running erratically?
Yes
Yes
Check FAULT INDICATOR on CIM display screen. Is a fault displayed? (fig. 2-2)
No
Got to troubleshooting section corresponding to fault displayed. See Symptom Index, page 3-1.
OK
Not OK
Not OK
OK
3-16
CIM DISPLAY SCREEN DOES NOT RESPOND TO KEYPAD INPUT TEST
CIM display screen works, but backlight does not light or only partially lights.
Yes
Toggle FAULT RESET switch (12, fig.2-1) to No the ON position. Release Fault switch. Does CIM display screen respond to keypad input?
Start and operate generator set normally. Refer to para.2.11.1.
Yes
Verify DEAD CRANK switch (10, fig.1-30) is set to NORMAL position.
No
Set DEAD CRANK switch in NORMAL position.
No
Toggle FAULT RESET switch (12, fig.2-1) to the ON position. Release FAULT switch. Does CIM display screen respond to keypad input?
Yes
Reboot
Toggle FAULT RESET switch (12, fig.2-1) to the ON position. Release FAULT switch. Does CIM display screen respond to keypad input? No Notify next higher level of maintenance.
Yes
3-17
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 SECTION III. OPERATOR MAINTENANCE PROCEDURES __________ WARNING Batteries give off a flammable gas. Do not smoke or use open flame when performing maintenance. Failure to comply can cause injury or death to personnel and equipment damage due to flames and explosion. __________ WARNING Battery acid can cause burns to unprotected skin. Wear protective gloves and safety goggles. Failure to comply can cause personal injury. 3.3 3.3.1 GENERATOR SET INSPECTION AND SERVICE. Introduction. a. This section contains operator maintenance procedures. Deficiencies noted during inspection which are beyond the scope of operator level maintenance shall be reported to the next higher level of maintenance. b. 3.3.2 Refer to Table 3-4 for Quick Reference General Inspection.
Batteries BT1 and BT2. __________ WARNING DC voltage is present at generator set electrical components even with generator set shut down. Avoid grounding yourself when in contact with any electrical components. Failure to comply can cause injury or death to personnel. a. Inspection. (1) (2) (3) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door at front of generator set (Figure 1-2). Inspect for damaged battery case, corrosion, or damaged and loose connections on terminal cable. __________ WARNING Batteries give off a flammable gas. Do not smoke or use open flame when performing maintenance. Failure to comply can cause injury or death to personnel and equipment damage due to flames and explosion. NOTE Batteries used in the generator sets may be the maintenance-free type or the type that contains electrolyte. If the batteries in your generator set are maintenance free, skip steps (4) through (7), and go to step (8).
3-18
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 (4) Remove battery caps (located on top of electrolyte type batteries). CAUTION Electrolyte level must cover battery plates in all cells. Failure to comply can cause damage to battery. NOTE Electrolyte level should be at bottom of each cap cylinder. (5) (6) (7) (8) b. Inspect electrolyte level. Perform service procedure, step b below, if required. Install battery caps. Close BATTERY ACCESS door.
Service. (1) (2) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2). __________ WARNING Batteries give off a flammable gas. Do not smoke or use open flame when performing maintenance. Failure to comply can cause injury or death to personnel and equipment damage due to flames and explosion. NOTE Batteries used in the generator sets may be the maintenance-free type or the type that contains electrolyte. If the batteries in your generator set are maintenance free, skip steps (3) through (5) and go to step (6). (3) Remove battery caps (located on top of electrolyte type batteries).
3-19
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 CAUTION Electrolyte level must cover battery plates in all cells. Failure to comply can cause damage to battery. NOTE Electrolyte level should be at bottom of each cap cylinder. (4) (5) (6) (7) Add distilled water to each battery cell as required. Replace battery caps. Close BATTERY ACCESS door (Figure 1-2). If necessary, contact next higher level of maintenance to clean or replace batteries or battery terminals.
3.3.3
Air Cleaner Assembly. a. Inspection. (1) (2) (3) (4) (5) Shut down generator set, paragraph 2.11.2. Open AIR CLEANER ACCESS door at rear of generator set (9, Figure 3-1). Inspect air cleaner housing (1) for dents, corrosion, missing hardware, and other damage. Close AIR CLEANER ACCESS door. Open left side engine compartment access doors (Figure 1-3). NOTE Restriction indicator will pop out displaying a red band when flow through the air cleaner is restricted and requires service. NOTE Restriction indicator is located halfway between the left side engine access door and the rear of the generator set. It may be necessary to use a flashlight to see the indicator. (6) Inspect restriction indicator assembly (2) for indication of restricted air flow through the air cleaner. Close engine compartment access doors.
(7) b.
Service. (1) (2) Shut down generator set, paragraph 2.11.2. Open AIR CLEANER ACCESS door at rear of generator set (9, Figure 1-3).
3-20
FIGURE 3-1. AIR CLEANER ELEMENT REPLACEMENT
(3)
Loosen wing nut (3, Figure 3-1), and remove end cap assembly (4) from rod (5) in air cleaner housing (1). Remove wing nut (6) and filter element (7) from rod (5). If dirty or worn, replace filter element. Inspect inside of air cleaner housing (1) for debris and grime. Wipe housing interior with clean, lint-free cloth (Item 8, Appendix E). Install filter element (7) and wing nut (6) on rod (5). Install end cap assembly (4) on rod (5), and tighten wing nut (3) fingertight. Close AIR CLEANER ACCESS door. Open left side engine compartment access doors (Figure 1-3).
(4) (5)
(6) (7) (8) (9)
3-21
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 NOTE Restriction indicator will pop out displaying a red band when flow through the air cleaner is restricted and requires service. NOTE Restriction indicator is located halfway between the left side engine access door and the rear of the generator set. It may be necessary to use a flashlight to see the indicator. (10) Inspect restriction indicator (2). If the red indicator is visible, reset by pressing the reset button (8). Close left side engine compartment access doors.
(11) 3.3.4
Crankcase Breather Filter Assembly. a. Inspection. (1) Shut down generator set, paragraph 2.11.2. __________ WARNING Exhaust system can get very hot. Allow system to cool before performing maintenance. Failure to comply can cause severe burns and injury to personnel. (2) (3) Open right side engine compartment access door (Figure 1-2). Inspect sight glass (1, Figure 3-2). If fluid is visible, service crankcase breather filter assembly, (3) step b below. Inspect hoses (2) for cracks, holes, dry rot, and damaged or missing hose clamps. Inspect crankcase breather filter assembly (3) for cracks, excessive corrosion, and other damage. Close engine compartment access doors.
(4) (5) (6) b.
Service. (1) Shut down generator set, paragraph 2.11.2. __________ WARNING Exhaust system can get very hot. Allow system to cool before performing maintenance. Failure to comply can cause severe burns and injury to personnel. (2) Open right side engine compartment access doors (Figure 1-2).
3-22
FIGURE 3-2
CRANKCASE BREATHER FILTER ASSEMBLY
3-23
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 (3) Position suitable container under crankcase breather filter assembly (3, Figure 3-2), loosen drain valve (4), and drain fluid into a suitable container . Tighten drain valve. Close engine compartment access doors.
(4) 3.3.5
Engine Cooling System. a. Inspection. (1) (2) Shut down generator set, paragraph 2.11.2. Open both right and left sets of engine compartment access doors (Figure 1-2 and 1-3). __________ WARNING Cooling system operates at high temperature and pressure. Contact with high pressure steam and/or liquids can result in burns and scalding. Shut down generator set, and allow system to cool before performing checks, services, and maintenance. Failure to use caution can cause injury or death to personnel. (3) (4) Check radiator for dirt, leaves, insects and other blockage inhibiting air flow. Check radiator and hoses for leaks, loose connections, loose mountings, corrosion, chafing, and missing parts. Check coolant level on coolant recovery (overflow) bottle (1, Figure 3-3). Close engine access doors.
(5) (6) b.
Service. __________ WARNING Cooling system operates at high temperature and pressure. Contact with high pressure steam and/or liquids can result in burns and scalding. Shut down generator set, and allow system to cool before performing checks, services, and maintenance. Failure to use caution can cause injury or death to personnel. (1) (2) (3) (4) Shut down generator set, paragraph 2.11.2. Open right side engine compartment access doors (Figure 1-2). Remove cap (2, Figure 3-3) from coolant recovery (overflow) bottle (1). Fill coolant recovery (overflow) bottle (1) to HOT line if engine is hot, COLD if engine is cooled down, with proper coolant/antifreeze in accordance with Table 3-2. Install cap (2) on coolant recover (overflow) bottle (1). Close engine compartment access doors.
(5) (6)
3-24
FIGURE 3-3. COOLANT RECOVERY (OVERFLOW) BOTTLE
3-25
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 TABLE 3-2. COOLANT AMBIENT TEMPERATURE +40 F to +120 F (+4 C to 49 C) -25 F to +120 F (-32 C to 49 C) -25 F to +120 F (-32 C to 49 C) 3.3.6 Fuel Tank. a. Inspection. (1) (2) Start up generator set, paragraph 2.11.1. Place ENGINE CONTROL switch on control panel in PRIME & RUN or PRIME & RUN AUX FUEL position. If CIM display screen is not in MAIN mode, use keypad arrow buttons to move cursor to DISPLAY MODE. Press SELECT button to click MAIN button to access MAIN mode screen. Check FUEL LEVEL gage on CIM display screen for level of fuel in the fuel tank. Shut down generator set, paragraph 2.11.2. __________ WARNING Fuels used in the generator set are flammable. Do not smoke or use open flames when performing maintenance. Failure to comply can result in flames and explosion and can cause injury or death to personnel and damage to the generator set. (6) (7) (8) Remove fuel cap (1, Figure 3-4) from filler neck (2) on left side of generator set housing. Check fuel strainer in filler tube (3) for dirt and other foreign material. Install fuel cap (1) on filler neck (2). RADIATOR COOLANT Water: MIL-A-53009 INHIBITOR, CORROSION ANTIFREEZE, MULTI ENGINE TYPE Commercial Item Description (CID) A-A-52624 Type IP, Ethylene Glycol Base MIL-A-11755 ANTIFREEZE RATIO 35:1 N/A
Not Applicable Use Full Strength
(3)
(4) (5)
3-26
FIGURE 3-4. FUEL TANK FILLER NECK
3-27
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 b. Service. NOTE If mission characteristics do not allow shutting down the generator set, it can safely be Hot Refueled, but it is safer to shut down the generator set before refueling. (1) Shut down generator set, paragraph 2.11.2. __________ WARNING Fuels used in the generator set are highly flammable. Do not smoke or use open flames when performing maintenance. Failure to comply can result in flames and explosion and can cause injury or death to personnel and damage to the generator set. __________ WARNING Fuels used in the generator set are flammable. When filling the fuel tank, maintain metal-to-metal contact between filler nozzle and fuel tank opening to eliminate static electrical discharge. Failure to comply can result in flames and explosion and can cause injury or death to personnel and damage to the generator set. (2) (3) Remove fuel cap (1, Figure 3-4) from filler neck (2) on left side of generator set housing. Remove filler tube (3) from filler neck (2), clean strainer as necessary, and reinstall filler tube. CAUTION Using the wrong grade of fuel can damage the generator set engine. Add only specified diesel fuel to the fuel tank. Failure to comply can cause damage to equipment. NOTE Fuel tank holds 43 gallons (162.75 liters) of fuel. (4) Add diesel fuel (see Table 3-3 ) to fuel tank. TABLE 3-3. DIESEL FUEL AMBIENT TEMPERATURE DIESEL FUEL +20 F to +120 F VV-F-800 Grade DF-2 (-7 C to +49 C) JP5, JP8 0 F to +20 F VV-F-800 Grade DF-1 (-17 C to +7 C) JP5, JP8 -25 F to 0 F VV-F-800 Grade DF-1 (-32 C to -17 C) -25 F to 0 F VV-F-800 Grade DF-A (-32 C to -17 C) (5) Install fuel cap (1) on filler neck (2).
3-28
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 3.3.7 Fuel Filter/Water Separator. a. Inspection. (1) (2) (3) Shut down generator set, paragraph 2.11.2. Open right side engine compartment access doors (Figure 1-2). Inspect fuel filter/water separator assembly for proper mounting, cracks, dents, leaks, loose fuel lines, and missing parts. Close engine compartment access doors.
(4) b.
Service. (1) (2) (3) Shut down generator set, paragraph 2.11.2. Open right side engine compartment access doors (Figure 1-2). Open drain cock (2, Figure 3-5) and air vent (1) on fuel filter/water separator. Allow water and sediment to drain into a suitable container. Close drain cock (2) and air vent (1). Close engine compartment access doors.
(4) (5) 3.3.8
Lubrication. a. Inspection. (1) (2) Start up generator set, paragraph 2.11.1. Allow engine to warm up. Check for a LOW OIL or OIL PRESSURE fault displayed in the FAULT INDICATOR portion of the CIM display panel. Shut down generator set, paragraph 2.11.2. Open both right and left sets of engine compartment access doors (Figures 1-2 and 1-3) Inspect engine for oil leaks, damage, and missing parts.
(3) (4) (5)
3-29
FIGURE 3-5. FUEL FILTER/WATER SEPARATOR
3-30
CAUTION Oil dipstick is marked ENGINE OFF on one side and ENGINE ON on the other so crankcase oil can be checked with the engine in either condition. Ensure the appropriate side of the dipstick is used when checking oil level. Failure to comply can cause damage to equipment. (6) Using ENGINE OFF side of dipstick (2, Figure 3-6), check engine crankcase oil level. Refer to Appendix F. Close engine compartment access doors.
(7) b.
Service. (1) (2) (3) (4) (5) (6) Shut down generator set, paragraph 2.11.2. Open left side engine compartment access doors (Figure 1-3). Remove oil filler cap (1, Figure 3-6) from oil filler neck. Add oil to engine crankcase. Refer to Appendix F. Install oil filler cap (1) on oil filler neck. Close engine compartment access doors.
FIGURE 3-6. DIPSTICK AND OIL FILL CAP
3-31
TABLE 3-4. QUICK REFERENCE GENERAL INSPECTION COMPONENT/ASSEMBLY INSPECTION TASK DC ELECTRICAL SYSTEM BATTERY AND SLAVE RECEPTACLE CABLES (9, Inspect for signs of physical damage. Inspect for loose or frayed cables. Figure 4-3) NATO SLAVE RECEPTACLE (17, Figure 1-30) HOUSING ACCESS DOORS (6, Figure 4-5) DCS CONTROL BOX TOP PANEL (4, Figure 1-30) TOP HOUSING SECTION (Figure 4-7) FRONT HOUSING SECTION (Figure 4-8) REAR HOUSING SECTION (Figure 4-9) HOUSING DATA PLATES (Refer to paragraph 2.16) DCS CONTROL BOX ASSEMBLY PANEL LIGHTS (1, Figure 4-11) TIME METER (3, Figure 4-12) SWITCHES (8, Figure 4-8) GROUND FAULT CIRCUIT INTERRUPTER (32, Figure 4-13) KEYPAD ASSEMBLY KP (7, Figure 4-14) CONVENIENCE RECEPTACLE (3, Figure 1-30) AUXILIARY CONTROL BRACKET (17, Figure 4-16) DCS CONTROL BOX WIRING HARNESS (43, Figure 4-16) CIM WIRING HARNESS (44, Figure 4-16) DCS CONTROL PANEL FRAME AND PANELS (14, 26, 27 Figure 4-18) DCS DATA PLATES (Refer to paragraph 2.16) AIR INTAKE AND EXHAUST SYSTEM MUFFLER AND EXHAUST PIPE (11, Figure 1-30) ENGINE COOLING SYSTEM HOSES (12, 14 Figure 4-22) RADIATOR (12, Figure 1-30) FAN GUARDS (22, Figure 4-23) FAN (40, Figure 4-22) FAN BELT (13, Figure 1-30) FUEL SYSTEM LOW PRESSURE FUEL LINES AND FITTINGS (10, 11 Figure 4-25) ETHER CYLINDER ASSEMBLY (Figure 4-26) OUTPUT BOX ASSEMBLY TRANSFORMERS (10, 11 Figure 4-27) OUTPUT BOX PANELS (6, Figure 5-3) ENGINE ACCESSORIES SENDERS (Figure 4-29) DEAD CRANK SWITCH (10, Figure 1-30) OIL DRAIN VALVE (14, Figure 1-30) GENERATOR ASSEMBLY (Figure 5-1) ENGINE ASSEMBLY (Figure 5-1) SKID BASE (16, Figure 1-30) Inspect for signs of physical damage such as dents, cracks, loose paint and corrosion. Ensure all housing data plates are present and legible.
Inspect for signs of physical damage including cracked or broken components. Ensure all DCS data plates are present and legible.
Inspect for signs of physical damage such as cracks and excessive corrosion. Inspect for signs of physical damage including cracked or broken components. Visually check hoses for bulges, cracks, and signs of dry rot.
Inspect for signs of physical damage. Visually check lines for signs of leakage. Inspect for signs of physical damage.
Inspect for signs of physical damage. Ensure oil drain valve shows no signs of leakage. Inspect for signs of physical damage. Inspect for signs of physical damage. Inspect for signs of physical damage such as dents, cracks, loose paint and corrosion .
3-32
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 CHAPTER 4 UNIT MAINTENANCE INSTRUCTIONS
CHAPTER INDEX SECTION I SECTION II INSPECTING AND SERVICING THE EQUIPMENT................................................................4-1 REPAIR PARTS; TOOLS; TEST, MEASUREMENT AND DIAGNOSTIC EQUIPMENT (TMDE); AND SUPPORT EQUIPMENT ............................................................4-6 LUBRICATION PROCEDURES..................................................................................................4-6 UNIT PREVENTIVE MAINTENANCE CHECKS AND SERVICES.........................................4-7 TROUBLESHOOTING...............................................................................................................4-10 UNIT MAINTENANCE PROCEDURES ...................................................................................4-49 PREPARATION FOR SHIPMENT AND STORAGE..............................................................4-206
SECTION III SECTION IV SECTION V SECTION VI SECTION VII
SECTION I. INSPECTING AND SERVICING THE EQUIPMENT
4.1 4.1.1
INSPECTING AND SERVICING THE EQUIPMENT. Inspection. a. b. c. d. e. f. Unpack and inventory all end item components for serviceability. Check that all packing materials have been removed. Check generator set identification plate for proper identification. Inspect generator set exterior for shipping damage. Open BATTERY ACCESS (Figure 1-2), and inspect batteries for damage. Check battery cables for proper polarity connects, damage, and loose connections.
4-1
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 NOTE Batteries used in the generator set may be the maintenance-free type or the type that contains electrolyte. If the batteries in your generator set are maintenance-free, skip steps g and h, and go to step i. g. h. i. j. k. l. If applicable, remove battery caps. Check battery electrolyte level, and install battery caps. Loosen fasteners, lower control panel, and check electrical components for damage or loose connections. Raise control panel, and secure fasteners. Check air cleaner assembly for external damage and exhaust opening for obstruction. Open engine compartment access doors (Figures 1-2 and 1-3).
m. Check fan belt for looseness, and ensure it is not frayed or cracked. n. Inspect generator set for loose or missing mounting hardware or damaged or missing parts. CAUTION Oil dipstick is marked ENGINE OFF on one side and ENGINE ON on the other so crankcase oil can be checked with the engine in either condition. Ensure the appropriate side of the dipstick is used when checking oil level. Failure to comply can cause damage to equipment. o. Check oil level. As required, drain preservative from engine and fill with proper lubricating oil, paragraph 4.1.2. Unpack grounding rod from inside left engine access door (Figure 1-3), parallel cable and auxiliary fuel hose from storage box. Inspect each item for damage and accountability. Stow grounding rod, parallel cable, and auxiliary fuel hose in storage box, and close engine compartment and BATTERY ACCESS doors .
p.
q.
4.1.2
Service. a. Batteries BT1 and BT2. The batteries shipped with new generator sets are maintenance free. If the batteries have been replaced with batteries that require service, refer to paragraph 3.3.2 for instructions. Radiator. _________ WARNING Cooling system operates at high temperature. Hot coolant is under high pressure and can spray when cooling system is opened. Shut down generator set and allow to cool before servicing radiator. Failure to comply can cause damage to equipment and injury to personnel. (1) (2) Remove radiator cap. Check that radiator drain valve is closed.
4-2
(3)
Fill radiator with proper coolant/antifreeze in accordance with Table 4-1. Fill radiator to a level two inches below fill opening. TABLE 4-1. COOLANT
AMBIENT TEMPERATURE +40F TO +120F (4C TO 49C) -25F TO +120F (-32C TO +49C) -25F TO +120F (-32C TO +49C) (4) (5) (6) (7)
RADIATOR COOLANT WATER: MIL-A-53009 INHIBITOR, CORROSION ANTIFREEZE, MULTI ENGINE TYPE Commercial Item Description (CID) A-A-52624 Type IP, Ethylene Glycol Base MIL-A-11755 ANTIFREEZE
RATIO 35:1 N/A
N/A
Remove cap from overflow bottle. Fill overflow bottle to COLD level mark. Install caps on overflow bottle and radiator. After 30 minutes of operation, check coolant/antifreeze level at overflow bottle. Add coolant/antifreeze to overflow bottle as required.
c.
Fuel Tank. __________ WARNING Fuels used in the generator set are flammable. Do not smoke or use open flames when performing maintenance. Failure to comply can result in flames and possible explosion and can cause injury or death to personnel and damage to the generator set. (1) Check that fuel drain valve (1, Figure 4-1) is closed. __________ WARNING Hot engine surfaces and sparks from the engine and generator circuitry are possible sources of ignition. When hot refueling with DF-1, DF-2, DF-A, JP5 or JP8, avoid fuel splash and fuel spill. Do not smoke or use open flame when performing refueling. Failure to comply can result in flames and possible explosion and can cause injury or death to personnel and damage to the generator set. (2) Remove fuel tank filler cap (located on the left side of the generator set housing).
4-3
FIGURE 4-1. FUEL DRAIN VALVE AND OIL DRAIN
4-4
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 __________ WARNING Fuels used in the generator set are flammable. When filling the fuel tank, maintain metal-to-metal contact between filler nozzle and fuel tank opening to eliminate static electrical discharge. Failure to comply can result in flames and possible explosion and can cause injury or death to personnel and damage to the generator set. (3) Fill fuel tank with fuel type in accordance with Table 4-2. Fuel tank capacity is 43 gallons (162.75 liters). TABLE 4-2. FUEL AMBIENT TEMPERATURE +20F TO 120F (-6C TO +49C) 0F TO +20F (-17C TO -6C) -25F TO 0F (-32C TO -17C) -25F TO 0F (-32C TO -17C) (4) d. Install fuel tank filler cap. DIESEL FUEL VV-F-800 GRADE DF-2, JP5, OR JP8 VV-F-800 GRADE DF-1, JP5, OR JP8 VV-F-800 GRADE DF-1 VV-F-800 GRADE DF-A
Lubrication. (1) (2) (3) (4) (5) Shut down generator set, paragraph 2.11.2. Place suitable container under OIL DRAIN (2, Figure 4-1), and remove plug. Open BATTERY ACCESS door (Figure 1-2), and open oil drain valve. Drain oil. Close oil drain valve, and close BATTERY ACCESS door. Install plug in OIL DRAIN (2). Remove oil fill cap (1, Figure.4-2). CAUTION Oil dipstick is marked ENGINE OFF on one side and ENGINE ON on the other so crankcase oil can be checked with the engine in either condition. Ensure the appropriate side of the dipstick is used when checking oil level. Failure to comply can cause damage to equipment. (6) Fill engine with proper engine lubricating oil to FULL mark on dipstick (2). Refer to Appendix F. Lubrication system capacity is 18 quarts (17.03 liters). Install oil fill cap (1).
(7)
4-5
FIGURE 4-2. DIPSTICK AND OIL FILL CAP SECTION II. REPAIR PARTS; TOOLS; TEST, MEASUREMENT AND DIAGNOSTIC EQUIPMENT (TMDE); AND SUPPORT EQUIPMENT . 4.2 4.2.1
INTRODUCTION. Tools and Equipment. There are no special tools or support equipment required to perform unit level of maintenance on the generator set. A list of recommended tools and support equipment required to maintain the generator set is contained in Appendix B, Section III. Maintenance Repair Parts. Repair parts and equipment are listed and illustrated in the Repair Parts and Special Tools List (RPSTL) manual TM 9-6115-672-24P, and TM 9-2815-260-24.
4.2.2
SECTION III. LUBRICATION PROCEDURES 4.3 UNIT LUBRICATION INSTRUCTIONS. Refer to Table 4-3, Preventive Maintenance Checks and Services (PMCS) for unit level lubrication instructions
4-6
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 SECTION IV. UNIT PREVENTIVE MAINTENANCE CHECKS AND SERVICES 4.4 4.4.1 PMCS PROCEDURES. General. To ensure the generator set is ready for operation at all times, it must be inspected so defects can be identified and corrected before they result in serious damage or equipment failure. Purpose of PMCS Table. The PMCS table lists inspections and care required to keep the generator set in good operating condition. Purpose of Service Intervals. The interval column of the PMCS tells when to perform a certain check or service. Procedures Column. The procedures column of the PMCS tells how to perform required checks and services. NOTE The terms "ready/available" and "mission capable" refer to the same status. The generator set is on hand and able to perform combat missions. Refer to DA Pam 738-750. 4.4.5 "Equipment is not ready/available if" Column. This column specifies when and why the generator set cannot be used. Reporting and Correcting Deficiencies. If the generator set does not perform as required, refer to Troubleshooting section to diagnose problems. Report any malfunctions or failures. Mail it to us at the address below. We will send you a reply. a. (A) Use DA Form 2404 , or refer to DA Pam 738-750. Submit mailed forms to:
4.4.2
4.4.3
4.4.4
4.4.6
Commander U.S. Army Communications and Electronics Command (CECOM) Customer Feedback Office ATTN: AMSEL-LC-LEO-D-CS-CFO Fort Monmouth, New Jersey 07703-5008 b. (AF) USAF Deficiency Reporting and Investigating System, TO 00-35D-54, Appendix A procedures will be used for electronic submission. Submit mailed forms to: SMALC/LHCABD 5029 Dudley Boulevard McClellan AFB, CA 95652-1095 c. (MC) Quality Deficiency Reports (QDR) shall be submitted on SF 368 in accordance with MCO 4855.10. Submission may also be made using NAVMC Form 10772. Submit directly to: Commander Marine Corps Logistics Bases (Code 856) Albany, GA 31704-5000
4-7
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 TABLE 4-3. UNIT PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) M - Monthly Item No. Q - Quarterly Interval S A S - Semi-annually Item to be inspected A - Annually B - Biannually H - Hours Equipment is not ready/ available if:
Procedures Check for and have repaired or adjusted as necessary
CAUTION Engine oil and filter must be changed at a hardtime of 100 hours on initial break-in. Failure to change oil and filter may void warranty. 100 First oil change at 100 hours Engine lube oil NOTE: Oil filter should be changed with lube oil change. Refer to TM 9-2815-260-24. Drain engine lube oil. Add proper lube oil per Appendix F. Change fuel filter/water separator. Refer to TM 9-2815260-24. Drain coolant, and flush cooling system. Add proper coolant. Refer to paragraph 4.10.1. Inspect radiator cap for corrosion, torn or deteriorated seal, and obvious damage. Remove batteries. Refer to paragraph 4.6.3. Clean batteries, cable terminals, and battery posts. Test batteries for state of charge. Inspect air cleaner assembly and mounting bracket for cracks, dents, and other damage. Inspect element for clogs and damage. Clean or replace as necessary. Clean housing with clean cloth. Refer to paragraph 4.9.2. Remove, clean, and inspect tubing and breather hose. Refer to paragraph 4.9.5. Radiator cap or seal is damaged. Batteries will not hold charge.
300
Fuel filter/ water separator
300
Cooling system
1500
Radiator cap
Batteries
1500
Air cleaner assembly
750
Air cleaner tubing and breather
4-8
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 TABLE 4-3. UNIT PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) (continued) M - Monthly Q - Quarterly S - Semi-annually A - Annually B - Biannually H - Hours Item No. Interval S A Item to be inspected Procedures Check for and have repaired or adjusted as necessary Inspect and service. Refer to paragraph 4.9.6. Equipment is not ready/ available if:
300
Crankcase Breather Filter Assembly Hardware and sound insulation
Inspect for loose, damaged, or missing hardware and sound insulation. tighten loose hardware. Repair or replace damaged or missing hardware or insulation. Refer to paragraph 4.7. Clean radiator exterior surfaces. Refer to paragraph 4.10.7.
Loose, missing, or damaged hardware or insulation.
10
Radiator and interior of generator set Magnetic pickup
11
Remove, inspect, and clean magnetic pickup. Refer to paragraph 4.13.3. Check wiring harnesses for breaks and loose connections. Repair and tighten wiring harnesses as necessary.
Magnetic pickup is damaged. Wiring harnesses are damaged or connections are loose. Muffler leaks, is restricted, or has excessive carbon accumulation.
12
Wiring harnesses
13
Muffler
Check muffler for leaks, restriction, and accumulation of carbon. Replace or clean as required. Refer to paragraph 4.9.1. NOTE
If the auxiliary fuel system is used as the primary fuel source, the auxiliary fuel filter must be replaced semi-annually. 14 500 Auxiliary fuel filter Check for proper operation using the auxiliary system as primary source. Refer to paragraph 4.11.2.
4-9
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 SECTION V. TROUBLESHOOTING 4.5 GENERAL. This section contains troubleshooting information for locating and correcting operating troubles which may develop in the generator set. Each malfunction for an individual component unit or system is followed by a list of tests or inspections which will help to determine probable causes and corrective actions to take. Perform the tests/inspections in the order listed. Table 4-1 provides unit troubleshooting. This table cannot list all malfunctions that may occur, nor all tests or inspections and corrective actions. If a malfunction is not listed, or is not corrected by listed corrective actions, notify your supervisor. NOTE Before using this table, PMCS and operator level troubleshooting must have been performed. NOTE Refer to paragraph 2.4 for diagnostic controls and indicators. SYMPTOM INDEX Page Engine Fails to Crank ...............................................................................................................................................4-12 Engine Cranks, But Fails To Start ............................................................................................................................4-15 Engine Fails To Start In Cold Weather.....................................................................................................................4-17 Engine Stops Suddenly .............................................................................................................................................4-18 Engine Runs Erratically or Stalls Frequently............................................................................................................4-19 Engine Does Not Develop Full Power......................................................................................................................4-20 Abnormal Engine Noise............................................................................................................................................4-21 Black or Gray Exhaust Smoke ..................................................................................................................................4-22 Blue or White Exhaust Smoke..................................................................................................................................4-23 CIM Display Screen Does Not Display and Backlight Does Not Light....................................................................4-24 CIM Display Screen Works, But Backlight Does Not Light or Only Partially Lights..............................................4-25 CIM Display Screen BATTERY VDC Indicator Shows Low or No charge ............................................................4-26 CIM Does Not Respond To Keypad Commands or Update Display........................................................................4-27 CIM Display Screen BATTERY VDC Indicator Shows No Charge When Batteries Are Low or Discharged ........4-28 CIM Display Screen BATTERY VDC Indicator Shows Excessive Charging After Prolonged Operation ..............4-29 CIM Display Screen VOLTAGE Gage Fluctuates ...................................................................................................4-30 CIM Display Screen FREQ Gage Fluctuates............................................................................................................4-31 High Oil Consumption..............................................................................................................................................4-33 Engine Misfiring .......................................................................................................................................................4-34 CIM Display Screen Indicates WATER TEMP Meter Indicates Coolant Temperature Too Low ...........................4-35 Excessive Fuel Consumption ....................................................................................................................................4-36 Coolant In Crankcase or Oil In Coolant....................................................................................................................4-37 Engine Vibrating.......................................................................................................................................................4-37 CIM Display Screen VOLTAGE Gage Does Not Indicate Voltage .........................................................................4-38 CIM Display Screen VOLTAGE Gage Indicates Voltage, But FREQ Gage Is Off Scale........................................4-39 FAULT INDICATOR Displays CIRCUIT FAILURE - FUEL LEVEL..................................................................4-40 FAULT INDICATOR Displays CIRCUIT FAILURE - OIL PRESSURE (low) or OIL PRESSURE (high) .........4-41 FAULT INDICATOR Displays CIRCUIT FAILURE - COOLANT TEMP ..........................................................4-42 SYMPTOM INDEX Continued
4-10
FAULT INDICATOR Displays WARNING - OVERVOLTAGE or SHUTDOWN -OVERVOLTAGE ..............4-43 CIRCUIT INTERRUPTER will not close................................................................................................................4-44 CIRCUIT INTERRUPTER will not open ................................................................................................................4-46 CIM Display Screen does not respond to keypad input ............................................................................................4-48
4-11
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 TABLE 4-4. UNIT TROUBLESHOOTING
ENGINE FAILS TO CRANK

Engine fails to crank.
No
Check FAULT INDICATOR on CIM display screen. Is a fault displayed?
Yes
Check for loose or corroded battery cable terminals or battery posts. OK
Not OK Clean and tighten battery cable terminals and battery posts. OK
Inspect batteries (see para.4.6.3). Not OK
Replace batteries (see para.4.6.3).
4-12
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 TABLE 4-4. UNIT TROUBLESHOOTING (CONTINUED)
ENGINE FAILS TO CRANK (CONTINUED)
No
Test for battery voltage at input of ENGINE CONTROL switch (see para.4.5). Is voltage present?
Yes
Check wires from TB4 to S1-3. Refer to Wiring Diagram FO-3. Not OK
OK Test ENGINE CONTROL switch output voltage in START position. (see para.4.8.5). Is battery voltage present between output terminal No. 7 and ground? Yes Replace ENGINE CONTROL switch (see para.4.8.5).
Test diode CR1 (see para.4.8.29). Repair or replace defective wires or connections. Not OK
OK
No
Replace diode CR1 (see para.4.8.34).
Not OK
Test start relay OK (see para.4.8.34).
Replace start relay (see para.4.8.34).
4-13
ENGINE FAILS TO CRANK (CONTINUED)
OK
Test cranking relay (see para. 4.12.7).
Not OK
Replace cranking relay (see para. 4.12.7). Check starting circuit Not OK for breaks or loose connections. Refer to Schematic, FO-1.
OK
Not OK
Test starter solenoid. Refer to TM 9-2815-260-24.
OK
Repair or replace defective wires or connections.
Replace starter solenoid, Refer to TM 9-2815-260-24.
OK
Test starting motor. Refer to TM 9-2815-260-24.
Not OK
Replace starting motor. Refer to TM 9-2815-260-24.
4-14
ENGINE CRANKS, BUT FAILS TO START

Engine cranks, but fails to start.
Repeat Starting procedure (Para 2.11.1). OK
No
Yes
Check Speed Control Unit DC POWER LED.(15 Fig 2-3) Is it lit? No
Yes
Does SPEED SENSOR LED (12, Fig 2-3) on Speed Control Unit illuminate during cranking? No
Yes
Continued on next page
Check EMERGENCY STOP switch.(3, Fig 2-1) Is it pressed in? No Check I/O interface module (Fig 2-3) for 24VDC at connector P25 pin 9. See Wiring Diagram, FO-3. Not OK Check EMERGENCY STOP switch circuit for broken wires or connections. See Schematic, FO-1. Not OK
Yes
Pull EMERGENCY STOP switch out. Yes Inspect magnetic pickup (see para. 4.13.3). Are there broken wires or loose connections? No
Repair or replace wires. See Wiring Diagram, FO-3. OK
Replace magnetic pickup (see para. 4.13.3).
OK
Check the I/O interface module (Fig 2-3) for Not OK 24VDC at connector P25 pin 8. Refer to Wiring Diagram, FO-3. OK
Replace I/O interface module (see para. 4.8.25).
Check Speed Control Not OK Unit connections. See Wiring Diagram, FO-3. Test Emergency Stop Switch (3, fig 2-1) Ref Para 4.8.14. OK OK Not OK
Replace DCS speed control unit (see para. 4.8.22).
Repair broken wires and connections as necessary.
Replace backplane module (see para. 4.8.24). Replace Emergency Stop Switch (3, fig 2-1) Ref Para 4.8.14.
4-15
ENGINE CRANKS, BUT FAILS TO START (CONTINUED)

Continued from previous page. Push RESET BUTTON on overspeed module (13, Fig.2-3). Repeat starting procedure.
Yes
Is Overspeed LED (10,Fig.2-3) lit ? No Replace Speed Control Module (see Para 4.8.22).
No
Check Actuator LED (11, Fig 2-3). Is it lit during cranking ? Yes
OK
Check for clogged or defective fuel filter/water separator. Refer to TM 9-2815-260-24.
Not OK
Replace fuel filter/ water separator. Refer to TM 9-2815-260-24.
Not OK
Check for contaminated fuel. (see para.3.3.6) or incorrect grade of fuel (Table 3-3).
OK
OK Using fuel drain valve, (figure 4-1), drain fuel into suitable container. Replace fuel filter and fuel/water separator. Refer to TM 9-2815-260-24. Service fuel tank (see para. 3.3.6). Bleed fuel lines. Refer to TM 9-2815-260-24. Not OK OK Check for blocked exhaust pipe or muffler (see para.4.9.1).
Check for evidence of air bubbles or fuel line blockage. Not OK
OK
Check for defective fuel supply pump. Refer to TM 9-2815-260-24.
Not OK
Not OK
Unblock or replace fuel lines as necessary (see para.4.11.1). Ensure fuel lines are tight. Bleed fuel lines. Refer to TM 9-2815-260-24.
Replace fuel supply pump. Refer to TM 9-2815-260-24.
Unblock exhaust pipe or replace muffler (see para.4.9.1).
4-16
ENGINE FAILS TO START IN COLD WEATHER

Perform cold weather starting No procedure. Ref Para 2.11.1. Does Engine Start ? Check FAULT INDICATOR Yes on CIM display screen. Is a fault displayed? No Go to troubleshooting section corresponding to fault displayed. See Symptom Index, page 4-10. Check for proper lube oil type (Appendix F). Not OK Drain oil, and replace oil filter. Refill with proper oil type. Refer to para. 4.1.2. Refer to Appendix F.
Engine fails to start in cold weather.
Not OK
Check CIM display screen BATTERY VDC indicator for low or no battery charge.
OK
Inspect batteries (see para. 4.6.3). Service or replace batteries as necessary. Not OK
OK
Check for proper grade of fuel (Table 3-3).
OK
Using fuel drain valve (Figure 4-1), drain fuel into suitable container. Service fuel tank (see para. 3.3.6). Bleed fuel lines. Refer to TM 9-2815-259-24. OK
Yes
Is ether cylinder installed?
No
Inspect ether cylinder (see para. 4.11.7).
Not OK
Install ether cylinder (see para. 4.11.7).
Inspect ether Not OK solenoid valve (see para 4.11.8).
Replace ether solenoid valve (see para 4.11.8).
Replace ether cylinder (see para. 4.11.7).
Test ETHER START switch (see para. 4.8.6). OK Test Ether Solenoid Relay (16, Fig 4-26) Ref Para 4.11.9 OK
Not OK
Replace ETHER START switch (see para. 4.8.6).
Not OK
Replace Ether Solenoid Relay (16, Fig 4-26). Ref Para 4.11.9
4-17
ENGINE STOPS SUDDENLY
Engine stops suddenly.
Yes
No
Change fuel filter/ water separator (para. 4.11.9). Does Engine Start? No
Go to troubleshooting section corresponding to fault displayed. See Symptom Index, page 4-10. No Bleed fuel lines. Refer to TM 9-2815-260-24. Is there evidence of air bubbles or fuel line blockage?
Yes
OK
Check for defective fuel supply pump. Refer to TM 9-2815-260-24.
Not OK
Replace fuel supply pump. Refer to TM 9-2815-260-24.
Unblock or replace fuel lines as necessary (see para. 4.11.1). Bleed and tighten fuel lines. Refer to TM 9-2815-260-24.
4-18

Yes
No
Change fuel filter/ water separator (para. 4.11.9). Does Engine Start? No
Go to troubleshooting section corresponding to fault displayed. See Symptom Index, page 4-10. No
Bleed fuel lines. Refer to TM 9-2815-260-24. Is there evidence of air bubbles or fuel line blockage?
Yes
Not OK
Inspect exhaust pipe and muffler (see para. 4.9.1).
OK
Unblock exhaust pipe or replace muffler (see para. 4.9.1). Not OK Check for contaminated fuel (see para. 3.3.6) or OK incorrect grade of fuel (Table 3-3).
Replace fuel filter/ water separator. Refer to TM 9-2815-260-24. Drain fuel into suitable container. Service fuel tank (see para. 3.3.6). Bleed fuel lines. Refer to TM 9-2815-260-24.
4-19
Yes
Check FAULT INDICATOR No on CIM display screen. Is a fault displayed? (Fig. 2-2)
OK
Inspect fuel filter/ water separator (see para. 3.3.7).
Not OK
Not OK
Check for contaminated fuel (see para. 3.3.6) or incorrect grade of fuel (Table 3-3).
OK
Replace fuel filter/ water separator. Refer to TM 9-2815-260-24.
Using fuel drain valve (figure 4-1), drain fuel into suitable container. Service fuel tank (see para. 3.3.6.). Bleed fuel lines. Refer to TM 9-2815-260-24.
No
Bleed fuel lines. Refer to TM 9-2815-260-24. Is there evidence of air bubbles or fuel line obstruction?
Yes
Not OK
Inspect muffler and exhaust pipe (see para. 4.9.1.).
OK
Unblock exhaust pipe or replace muffler (see para. 4.9.1).
4-20
ABNORMAL ENGINE NOISE
Abnormal engine noise.
Yes
No
Not OK
Check for contaminated fuel (see para.3.3.6) or incorrect grade of fuel (Table 33-3).
OK
Replace fuel filter/water separator. Refer to TM 9-2815-260-24. Drain fuel into suitable container. Service fuel tank (see para.3.3.6). Bleed fuel lines. Refer to TM 9-2815-260-24.
4-21
BLACK OR GRAY EXHAUST SMOKE
Black or gray exhaust smoke.
No
Yes
OK
Check for contaminated fuel (see para.3.3.6) or incorrect grade of fuel (Table 33-3).
Not OK
Replace fuel filter/water separator. Refer to TM 9-2815-260-24. Drain fuel into suitable container. Service fuel tank (see para.3.3.6). Bleed fuel lines. Refer to TM 9-2815-260-24.
4-22
BLUE OR WHITE EXHAUST SMOKE
Blue or white exhaust smoke.
No
Check FAULT INDICATOR on CIM display screen. Is a fault displayed? (Fig. 2-2)
Yes
Not OK
Check for excessive engine oil level.
OK
Drain oil into suitable container to obtain proper level. Refer to Figure 4-1 for location of oil drain valve.
Check for contaminated fuel (see para. 3.3.6) or incorrect grade of fuel (Table 3-3)
OK
Check air filter (see para. 3.3.3). Not OK Replace air filter (see para 4.9.4).
OK
Not OK
Not OK
Check for defective thermostat(s). Refer to TM 9-2815-260-24.
OK
Replace fuel filter/water separator. Refer to TM 9-2815-260-24. Drain fuel into suitable container. Service fuel tank (see para. 3.3.6). Bleed fuel lines. Refer to TM 9-2815-260-24.
Replace defective thermostat(s). Refer to TM 9-2815-260-24.
TABLE 4-4. UNIT TROUBLESHOOTING (CONTINUED)
4-23
CIM DISPLAY SCREEN DOES NOT DISPLAY AND BACKLIGHT DOES NOT LIGHT
CIM display screen does not display and backlight does not light.
OK
Check for loose or Not OK corroded battery cable terminals or battery posts.
Not OK
Check that batteries are installed correctly (see para.4.6.3).
OK
Clean and tighten battery cable terminals and battery posts (see para.4.6.3).
Install batteries correctly (see para.4.6.3).
OK
Test DC CONTROL POWER fuse (see para.4.8.26).
Not OK
Not OK
Test diode CR1 (see para.4.8.29).
OK
Replace DC CONTROL POWER fuse (see para.4.8.26).
Replace diode CR1 (see para.4.8.29).
Not OK
Test MASTER CONTROL switch (see para.4.8.9).
OK
Replace MASTER CONTROL switch (see para.4.8.9).
Not OK
Check CIM wiring harness for breaks or loose connections (see para.4.8.38).
OK
Replace CIM wiring harness (see para.4.8.38).
Replace CIM (see para.4.8.16).
4-24
CIM DISPLAY SCREEN WORKS, BUT BACKLIGHT DOES NOT LIGHT OR ONLY PARTIALLY LIGHTS
CIM display screen works, but backlight does not light or only partially lights.
Not OK
Test PANEL LIGHTS switch (see para. 4.8.12).
OK
Not OK Replace PANEL LIGHTS switch (see para. 4.8.12).
Inspect CIM wiring harness (see para. 4.8.38).
OK
Replace CIM wiring harness (see para. 4.8.38).
OK
Check for voltage at wiring harness. NOT OK
Replace CIM (see para. 4.8.16).
Repair/replace CIM wiring harness. (see para. 4.8.38).
4-25
CIM DISPLAY SCREEN BATTERY VDC INDICATOR SHOWS LOW OR NO VOLTS
CIM display screen BATTERY VDC indicator shows low or no volts.
OK
Inspect fan belt (see para. 4.10.9).
Not OK
Check for loose or broken wires. Refer to Schematic, FO-1. Not OK
OK
Adjust or replace fan belt (para. 4.10.9).
Repair or replace loose or broken wires. Refer to Schematic, FO-1.
Check Battery Charging Alternator. Refer to TM 9-2815-260-24.
OK
Not OK
Replace Battery Charging Alternator.
4-26
CIM DOES NOT RESPOND TO KEYPAD COMMANDS OR UPDATE DISPLAY
CIM does not respond to keypad commands or update display.
No
Is NETWORK FAILURE light lit?
Yes
Not OK
Inspect keypad assembly (see para.4.8.17).
OK
Not OK
Inspect and test CIM wiring harness (see para.4.8.38).
OK
Replace keypad assembly (see para.4.8.17).
Replace CIM . (see para.4.8.16).
Replace CIM wiring harness (see para.4.8.38).
Check CIM wiring harness connections at CIM and keypad for proper connection. Refer to Wiring Diagram, FO-1.
4-27
CIM DISPLAY SCREEN BATTERY AMPS INDICATOR SHOWS NO CHARGE WHEN BATTERIES ARE LOW OR DISCHARGED
CIM display screen BATTERY AMPS indicator shows no charge when batteries are low or discharged.
OK
Inspect fan belt (see para. 4.10.9).
Not OK
Not OK
Test Battery Current Transducer (see para. 4.13.5).
OK
Adjust or replace fan belt (see para. 4.10.9).
Replace Battery Current Transducer (see para. 4.13.5).
OK Test alternator. Refer to TM 9-2815-260-24.
Not OK
Check for breaks or loose Not OK connections or corroded terminals in charging circuit. Refer to Schematic, FO-1
OK
Replace alternator. Refer to TM 9-2815-260-24.
Repair charging circuit. Refer to Schematic, FO-1.
Yes
Is HEARTBEAT LED on I/O interface module blinking? See para. 4.8.25.
No
4-28
CIM DISPLAY SCREEN BATTERY AMPS INDICATOR SHOWS EXCESSIVE CHARGING AFTER PROLONGED OPERATION
CIM display screen BATTERY AMPS indicator shows excessive charging after prolonged operation.
OK
Inspect/service batteries BT1 and BT2 (see para. 4.6.3).
Not OK
Replace batteries (see para. 4.6.3).
OK
Test alternator. Refer to TM 9-2815-260-24.
Not OK
Not OK
Check for short in charging circuit. Refer to Schematic, FO-1.
OK
Replace alternator. Refer to TM 9-2815-260-24.
No
Is HEARTBEAT indicator on I/O interface module blinking? (see para. 4.8.25)
Yes
OK
Test Battery Current Transducer (see para. 4.13.5).
Not OK
Replace Battery Current Transducer (refer to para. 4.13.5).
4-29
CIM DISPLAY SCREEN GENERATOR VOLTAGE GAGE FLUCTUATES

CIM display screen GENERATOR VOLTAGE gage fluctuates.
No
Check FAULT INDICATOR on CIM display screen. Is a fault displayed? (Fig. 2-2)
Yes
Yes
Check voltage at AC circuit interrupter. Is voltage fluctuating? Refer to para.4.12.6.
No
Go to troubleshooting section corresponding to fault displayed. See symptom Index, page 4-10.
Yes Check automatic voltage regulator. Are any or all LEDs pulsing with voltage fluctuations? No
Replace automatic voltage regulator (see para. 4.8.23). Check for loose electrical connections. Refer to Schematic, FO-1.
Not OK
OK
Replace backplane module (see para. 4.8.24). No Tighten electrical connections. Is HEARTBEAT LED on I/O interface module blinking? Yes
Not OK Test VOLTAGE ADJUST switch (see para. 4.8.10).
OK
Replace VOLTAGE ADJUST switch (see para. 4.8.10).
4-30
CIM DISPLAY SCREEN FREQ GAGE FLUCTUATES
CIM display screen FREQ gage fluctuates.
Yes
Check FAULT INDICATOR on CIM display screen. Is a fault displayed? (4, Figure 2-9) No
No
Is Engine speed fluctuating? Yes
No
Is HEARTBEAT LED on I/O interface module blinking?
Yes
Check speed control unit LED indicators. Yes Are the SPEED SENSOR, ACTUATOR, and DC POWER LEDs fluctuating?
No
Replace CIM. (see para. 4.8.16). Continued on next page Check Speed control unit. Is DC POWER LED lit and steady, and ACTUATOR and SPEED SENSOR LEDs fluctuating?
Continued on next page
Yes
No
Replace speed control unit.
Not OK
4-31
CIM DISPLAY SCREEN FREQ GAGE FLUCTUATES (CONTINUED)
Not OK
Check for contaminated fuel (see para. 3.3.5) or incorrect grade of fuel (Table 3-3).
OK
Using fuel drain valve, (Figure 4-1), drain fuel into suitable container. Replace fuel filter and fuel filter/water separator. Refer to TM 9-2815-260-24. Service fuel tank (see para. 3.3.6). Bleed fuel lines. Refer to TM 9-2815-260-24.
OK
Check for evidence of air bubbles or fuel line blockage.
Not OK
Not OK
Check for blocked exhaust pipe or muffler (see para. 4.9.1).
OK
Unblock or replace fuel lines as necessary (see para. 4.11.1). Ensure fuel lines are tight. Bleed fuel lines. Refer to TM 9-2815-260-24.
Replace DCS speed control unit (see para. 4.8.22). Unblock exhaust pipe or replace muffler (see para. 4.9.1). Not OK
4-32
HIGH OIL CONSUMPTION
High oil consumption.
Not OK
Inspect air cleaner assembly (see para. 4.9.2).
OK
Unblock or replace air cleaner assembly components as required (see para. 4.9.2).
OK
Check for improper lube oil. Refer to Appendix F.
Not OK
Drain oil and replace oil filter. Refer to TM 9-2815-260-24. Refill with proper lube oil type. Refer to Appendix F. Not OK Check for engine oil leaks. OK
Not OK
Inspect/service crankcase breather assembly (refer to para. 4.9.6).
Notify next higher maintenance level.
Notify next higher maintenance level.
4-33
ENGINE MISFIRING
Engine misfiring.
No
Yes
Check for contaminated fuel (see para. 3.3.6) or incorrect grade of fuel (Table 3-3). Not OK
OK Go to troubleshooting section corresponding to fault displayed. See Symptom Index, page 4-10.
Using fuel drain valve (Fig. 4-1), drain fuel into suitable container. Replace fuel filter and fuel filter/water separator. Refer to TM 9-2815-260-24. Service fuel tank (see para. 3.3.6). Bleed fuel lines. Refer to TM 9-2815-260-24. OK
Check for air blockage in fuel lines. OK
Not OK
Check for blocked exhaust or muffler. (see para. 4.8.1).
Unclog/Bleed fuel lines. Not OK
OK Inspect air cleaner assembly (see para. 4.9.4). Not OK Unblock or replace muffler (see para. 4.9.1).
Unblock air cleaner assembly (see para. 4.9.4).
4-34
CIM DISPLAY SCREEN WATER TEMP METER INDICATES COOLANT TEMPERATURE TOO LOW
CIM display screen WATER TEMP meter indicates coolant temperature too low.
OK
Test coolant temperature sender (see para. 4.13.2).
Not OK
Inspect thermostat. Refer to TM 9-2815-260-24. Not OK
OK
Replace coolant temperature sender (see para. 4.13.2).
Replace thermostat. Refer to TM 9-2815-260-24.
4-35
EXCESSIVE FUEL CONSUMPTION
Excessive fuel consumption.
No
Yes
OK
Not OK
Unblock or replace air cleaner assembly components as required (see para.4.9.2).
OK
Check for leaks in fuel system (see para.4.11.1).
Not OK
Not OK
Check for contaminated oil. Refer to TM 9-2815-260-24.
OK
Repair low pressure fuel lines and fittings as required (see para.4.11.1).
Drain oil and replace oil filter. Refer to TM 9-2815-260-24. Refill with proper lube oil type. Refer to Appendix F.
4-36
COOLANT IN CRANKCASE OR OIL IN COOLANT
Coolant in crankcase or oil in coolant.
OK
Check for defective oil cooler. Refer to TM 9-2815-260-24.
Not OK
Replace oil cooler. Refer to TM 9-2815-260-24.
ENGINE VIBRATING
Engine vibrating.
OK
Inspect fan (see para.4.10.8).
Not OK
Replace fan (see para.4.10.8)
4-37
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 TABLE 4-4 UNIT TROUBLESHOOTING (CONTINUED)
CIM DISPLAY SCREEN VOLTAGE GAGE DOES NOT INDICATE VOLTAGE

CIM display screen VOLTAGE gage does not indicate voltage.
Check voltage regulator Yes LEDs with generator set No running. Are they all lit? Not OK Check for output voltage OK at AC circuit interrupter. Is it set for rated voltage? Not OK Troubleshoot voltage regulator circuit for broken wires or loose connections. Refer to Schematic, FO-1. Not OK OK
Troubleshoot voltage regulator circuit for broken wires or loose connections. Refer to schematic FO-1.
Repair or replace broken wires or loose connections. Refer to Wiring Diagram, FO-3.
Check Field Flash circuit wires. (see schematic F01) OK
Yes Is CIM screen being updated? Are any phases on the CIM display screen indicating voltage ? Troubleshoot circuit from P5 to K1 (refer to schematic FO-1). Not OK Repair or replace wires as needed. (See schematic F01) OK No
Replace Field flash relay K23. (Ref Para. 4.8.35)
Not OK Inspect and test Field flash relay K23. (Ref Para. 4.8.35) OK
OK
Refer to Symptom Index " CIM does not respond to key pad or update display".
OK
Inspect and test Resistor R6 (see Para 4.8.40). Not OK
Check ribbon cables between I/O and Backplane.
Not OK
Replace Resistor R6 (see Para 4.8.40). Inspect and Test Diodes CR7 & CR8 (see Para 4.8.29). Not OK OK Replace Diodes CR7 & CR8 (see Para 4.8.29).
No
Is HEARTBEAT indicator on I/O interface module blinking? (see para. 4.8.25). Yes Test Backplane (see Para 4.8.24). OK
Replace ribbon cables between I/O and Backplane. Test Auto. Voltage Regulator(see Para 4.8.23). OK
Replace I/O module (see Para. 4.8.25). Not OK
Not OK
Replace Backplane (see para. 4.8.24).
Notify next higher level maintanance.
Replace Voltage Regulator(see Para 4.8.23).
4-38
CIM DISPLAY SCREEN VOLTAGE GAGE INDICATES VOLTAGE, BUT FREQ GAGE IS OFF SCALE
CIM display screen VOLTAGE gage indicates voltage, but FREQ gage is off scale.
Yes
Adjust FREQUENCY ADJUST to lower frequency. Does the FREQ gage respond?
No
Adjust FREQUENCY ADJUST switch to desired value.
OK
Check for breaks or loose connections in AC circuit. Refer to Schematic, FO-1.
Not OK
No
Yes
Replace I/O interface module (see para.4.8.25).
4-39
FAULT INDICATOR DISPLAYS CIRCUIT FAILURE - FUEL LEVEL
FAULT INDICATOR displays CIRCUIT FAILURE - FUEL LEVEL.
Not OK
Test fuel level system electrical circuit for breaks or loose connections. Refer to Schematic, FO-1.
OK
Repair or replace defective wires or connections. Refer to Wiring Diagram, FO-1. Hold FAULT RESET switch in ON position for two seconds to clear fault.
OK
Test fuel level sender (see para.4.11.5).
Not OK
No
Yes
Replace defective fuel level sender (see para.4.11.5).
Check for breaks or loose Not OK connections in DC electrical circuit. Refer to Schematic, FO-1.
OK
4-40
FAULT INDICATOR DISPLAYS CIRCUIT FAILURE - OIL PRESSURE (LOW) OR OIL PRESSURE (HIGH)
FAULT INDICATOR displays CIRCUIT FAILURE - OIL PRESSURE (Low) or OIL PRESSURE (High).
Not OK Check for improper lube oil type. Refer to Appendix F.
OK
Drain oil and replace oil filter. Refer to TM 9-2815-260-24. Refill with proper lube oil type. Refer to Appendix F.
OK
Test oil pressure sensor circuit for breaks or loose connections. Refer to Schematic, FO-1.
Not OK
OK
Test oil pressure sender (see para. 4.13.1).
Not OK
Repair or replace defective wires or connectors. Refer to Wiring Diagram, FO-3.
Not OK Test oil pressure electrical circuit for breaks or loose connections. Refer to Schematic, FO-1.
Replace oil pressure sender (see para. 4.13.1).
Repair or replace defective wires or connectors. Refer to wiring Diagram, FO-3.
No
Yes
4-41
FAULT INDICATOR DISPLAYS CIRCUIT FAILURE - COOLANT TEMP

FAULT INDICATOR displays CIRCUIT FAILURE - COOLANT TEMP.
Not OK
Test coolant temperature electrical circuit for breaks or loose connectors. Schematic, FO-1.
OK
OK Repair or replace wires or connectors. Refer to Wiring Diagram, FO-3. Hold FAULT RESET switch in ON position for 2 seconds to clear fault. Did Fault clear? Not OK Check Ribbon cables for breaks or damage. OK OK Not OK Replace coolant temperature sender (see para. 4.13.2).
OK
Test coolant temperature sender (see para. 4.13.2).
Not OK
Check for breaks or loose connections in Fault Reset switch circuit. Refer to Schematic, FO-1. Not OK Test Fault Reset switch (12, Fig 2-1) Ref Para. 4.8.8. Not OK
OK
Is HEARTBEAT LED on I/O interface module (see para. 4.8.25) blinking? Not OK
Replace damaged or defective ribbon cable. OK
Test Backplane. Ref Para. 4.8.24. Not OK
OK
Replace Fault Reset switch (12, Fig 2-1) Ref Para. 4.8.8.
Replace Backplane Ref Para. 4.8.24.
4-42
FAULT INDICATOR DISPLAYS WARNING OVERVOLTAGE OR SHUTDOWN - OVERVOLTAGE
FAULT INDICATOR displays WARNING OVERVOLTAGE or SHUTDOWN - OVERVOLTAGE.
Not OK
Check for defective or loose connections on voltage adjust switch. Refer to Wiring Diagram, FO-3.
OK
Repair or replace defective or loose connections. Refer to Wiring Diagram, FO-3.
OK
Test VOLTAGE ADJUST switch (see para. 4.8.10).
Not OK
OK
Troubleshoot voltage regulator circuit for breaks or loose connections. Refer to Schematic, FO-1.
Not OK
Replace VOLTAGE ADJUST switch (see para. 4.8.10).
Replace automatic voltage regulator (see para. 4.8.23). Is fault cleared? No
Repair or replace defective or loose connections. Refer to Wiring Diagram, FO-3. Is fault cleared? No
4-43
CIRCUIT INTERRUPTER WILL NOT CLOSE

Circuit interrupter will not close. Go to troubleshooting section corresponding to fault displayed. See Symptom Index Page 4-10.
No
Check Fault Indicator on CIM. Is a fault indicated?
Yes
Check for 24 VDC at term.1 of Circuit Interrupter switch, (10, fig 2-1). OK
Not OK
Check for 24 VDC at OK term.2 of Battle Short switch, (6, Fig 2-1).
Check wire 181D16 for continuity, loose connections or damage. OK Not OK Repair wire.
Not OK Hold circuit Interrupter switch (10, Fig 2-1) in the closed position and check for 24VDC at term.2. OK OK
Not OK
Check for 24VDC at TB4-1. Not OK
OK Remove top cover of control box. See Para. 4.7.2. Hold Circuit Interrupter switch (10, Fig 2-1) in the closed position and check for 24VDC on J25 pin 10 of I/O interface module (Ref Fig 2-3). OK OK Hold Circuit Interrupter switch (10, Fig 2-1) in the closed position and check for 24VDC on J25 pin 6 of I/O interface module (Ref Fig 2-3). Not OK Replace I/O interface module, see Para. 4.8.25. OK Replace Circuit Interrupter switch (10, Fig 2-1). See Para. 4.8.7 Not OK Refer to Schematic, FO-1.
Check wire 181C16 for continuity, loose connections or damage. Not OK Repair wire.
Check wire number 199A16 for continuity, loose connections or damage.
Not OK
Repair wire.
Retest Circuit Interrupter switch (10, Fig 2-1) See above.
Hold Circuit Interrupter switch (10, Fig 2-1) in closed position and check for 24VDC at terminal A of K17, (K1 aux relay) 28, Fig 4-16. Not OK
OK
Check wire number 185A16 for continuity, loose connections or damage. OK Not OK
See next page.
Repair wire.
4-44
CIRCUIT INTERRUPTER WILL NOT CLOSE Continued

Yes
Is the K1 Aux Relay K17 actuating? Replace Diode CR-3 (see Para 4.8.29). Check for 24 Not OK VDC at term.7 of K19. OK OK Check wire 231C16 from K19-7 to K17-7 for continuity. Not OK
No
Check for 24 VDC at term. 7 of K17. OK Hold Circuit Interrupter switch (10, Fig 2-1) in the closed position and check for 24VDC at K17-4. OK
Not OK
Not OK
Test Diode CR-3 (see Para 4.8.29).
OK OK
Check wire 231B16 from K19-7 to TB4-2 for continuity. Not OK
Test K1Aux relay K17 Coil(see para 4.8.25). Not OK
Not OK Repair wire. Replace K1Aux relay K17 (see para 4.8.25).
Hold Circuit Interrupter switch (10, Fig 2-1) in the closed position and check for 24VDC at J24 pin 9 of the Not OK backplane module. OK Check for 24VDC at Relay K1terminal X. Not OK OK Check for continuity between K1-Y and ground.
Replace K17 Aux relay. see Para 4.8.35.
Check wire number Not OK 224A16 for contiuity, loose connections or damage.
Repair wire.
Release Circuit Interrupter OK switch and Check for continuity between Backplane connector P6-N and K1-X. OK
Check wire number 185L16 for contiuity, loose connections or damage.
Not OK
Repair wire.
Check wire 100K16 between K1-Y and TB7-6 for continuity. OK
Not OK
Repair wire.
Not OK OK
Check for continuity between Not OK Backplane connector J6-N and J24-9.
Not OK Replace Backplane module see Para. 4.8.24.
4-45
CIRCUIT INTERRUPTER WILL NOT OPEN

Circuit interrupter will not open.
No
Check Fault Indicator on Yes CIM. Is a fault indicated? Check for 24 VDC at term. 2 of Battle Short switch, (6, Fig 2-1).
Go to troubleshooting section corresponding to fault displayed. See symptom index Page 4-10.
Hold Circuit Interrupter switch, (10, Fig 2-1)in the open position and Check for 24 VDC at term. 3. OK
Not OK
OK
Check wire 181D16 for continuity, loose connections or damage. OK Not OK
Not OK
Remove top cover of control box. See Para 4.7.2. Hold Circuit Interrupter switch Not OK (10, Fig 2-1) in the open position and check for 24VDC on J25 pin 11of I/O interface module (Ref Fig 2-3). OK
Check for 24VDC at TB4-1. Not OK
Repair wire. OK
Refer to Schematic, FO-1.
Check wire 181C16 for Not OK continuity, loose connections or damage.
OK Check wire number 130A16 Not OK for contiuity, loose connections or damage. Test K17,(K1 aux relay) (28, Fig 4-16) see Para 4.8.35. Not OK Replace K17,(K1 aux relay) (28, Fig 4-16) see Para 4.8.35. OK OK
Repair wire.
Repair wire.
Hold Circuit Interrupter switch (10, Fig 2-1) in the open position and check Not OK for 24VDC on J25 pin 6 of I/O interface module (Ref Fig 2-3). OK
Replace I/O interface module, see Para 4.8.25.
Test wiring in K17,(K1 aux relay) (28, Fig Not OK 4-16) for contiuity, loose connections or damage. see schematic FO1. Replace or repair wiring as needed.
4-46
CIRCUIT INTERRUPTER WILL NOT OPEN Continued
Not OK
Test Circuit Interrupter Relay K1 Terminal X for 24VDC.
OK
Test Circuit Interrupter K1 see Para 4.12.6 OK
Not OK
Check wire between Backplane connector P6-N and K1-X for continuity, loose connections or damage. OK
Not OK
Replace wire 185L16
Test wiring in K1 aux relay Aux Contacts for continuity, loose connections or damage. see schematic FO1 Not OK
Replace Circuit Interrupter K1 see Para 4.12.6 OK
Replace Backplane Module see Para 4.8.24
Not OK
Repair wire
4-47
CIM DISPLAY SCREEN DOES NOT RESPOND TO KEYPAD INPUT
CIM dispaly screen does not respond to keypad input.
Not OK
Check keyboard power supply (PS-1) OK for 24VDC. Refer to para. 4.6.5.
Check for 24VDC at TB4. Refer to Schematic, FO-1. OK
Not OK
Check PS-1 for 5VDC Not OK output. OK
Replace keypad. Check wiring between TB4 and PS-1. Refer to Schematic, FO-1. Not OK Check for approx 24VDC at J24-6. Not OK OK Check wiring to J24-6 at TB4. Not OK
Repair wiring.
Trace wiring back to Dead Crank switch. Refer to Schematic, FO-1.
Replace PS-1.
4-48
SECTION VI. UNIT MAINTENANCE PROCEDURES
4.6
MAINTENANCE OF DC ELECTRICAL SYSTEM. __________ WARNING When disconnecting or removing batteries, disconnect the negative lead that connects directly to the grounding stud first. Disconnect the negative end of the interconnection cable next. When installing batteries, reverse the connection sequence. Failure to comply can cause serious personal injury.
4.6.1
Introduction. This section contains unit maintenance procedures for the DC electrical system. Deficiencies noted during inspection or repair which are beyond the scope of unit maintenance shall be reported to the next higher level of maintenance. Battery and SLAVE RECEPTACLE Cables. __________ WARNING Batteries give off a flammable gas. Do not smoke or use open flame when performing maintenance. Failure to comply can cause injury or death to personnel and equipment damage due to flames and explosion. __________ WARNING Battery acid can cause burns to unprotected skin. Wear protective gloves and safety goggles. Failure to comply can cause personal injury. __________ WARNING DC voltages are present at generator set electrical components even with generator shut down. Avoid shorting any positive terminal with ground/negative. Failure to comply can cause injury to personnel and damage to equipment. __________ WARNING Metal jewelry can conduct electricity. Remove metal jewelry when working on electrical system or components. Failure to comply can cause injury or death to personnel by electrocution. NOTE This procedure is typical for the positive, negative, and interconnect battery cables, and the positive and negative NATO SLAVE RECEPTACLE cables. a. Inspection. (1) (2) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door and right side engine compartment access doors (Figure 1-2).
4.6.2
4-49
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 (3) Inspect battery and SLAVE RECEPTACLE cable assemblies for security, cracked insulation, broken, burned, or corroded terminals, missing parts, and other damage. Refer to Figures 4-3 and 44. Close BATTERY ACCESS and engine compartment access doors.
(4) b.
Removal. (1) (2) (3) (4) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2) and right side engine compartment access doors. Disconnect negative battery cable from battery (9, Figure 4-3). Tag and remove applicable cable assembly as shown in Figure 4-3 or 4-4.
c.
Service. (1) (2) (3) Remove terminal covers (2, Figure 4-3) from battery posts as required. Clean terminals (3, Figure 4-3 or 4-4), battery posts, and terminal lugs (4, 5, 6, and 7, Figure 4-3). Install terminal covers (2), if removed.
d.
Repair. NOTE If cable cannot be repaired, refer to Appendix G to fabricate a replacement. (1) (2) Remove nuts (8, Figure 4-3) and terminal lugs (4, 5, 6, or 7) from terminals (3) as required. Cut heat shrink tubing, and remove broken or damaged terminal (3, Figure 4-3 or 4-4) from cable assembly. Slide new heat shrink tubing over cable end. Install terminal (3) on cable end as described in Appendix G. Position heat shrink tubing over terminal (3) and cable end, and shrink tubing with heat gun. Install terminal lugs (4, 5, 6, or 7, Figure 4-3) and nuts (8).
(3) (4) (5) (6) e.
Installation. (1) (2) (3) Install applicable cable assembly as shown in Figure 4-3. Remove tags. Connect negative battery cable to battery (1, Figure 4-3). Close BATTERY ACCESS and engine compartment access doors.
4-50
FIGURE 4-3. BATTERIES AND CABLES
4-51
FIGURE 4-4. NATO SLAVE RECEPTACLE AND CABLES
4-52
4.6.3
Batteries BT1 and BT2. a. Testing. The batteries installed in this generator set are maintenance free. There is no electrolyte testing required. If you have old batteries, see Appendix A. Removal. __________ WARNING When disconnecting or removing batteries, disconnect the negative lead that connects directly to the grounding stud first. Disconnect the negative end of the interconnection cable next. When installing batteries, reverse the connection sequence. Failure to comply can cause serious personal injury. __________ WARNING Battery acid can cause burns to unprotected skin. Wear protective gloves and safety goggles. Failure to comply can cause personal injury. __________ WARNING Metal jewelry can conduct electricity. Remove metal jewelry when working on electrical system or components. Failure to comply can cause injury or death to personnel by electrocution. (1) (2) (3) (4) (5) (6) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2). Disconnect negative battery cable terminal lug (4, figure 4-3) from battery (9). Disconnect interconnect battery cable terminal lug (6) first, then lug (5) from batteries (1 and 9). Disconnect positive cable battery lug (7) from battery (1). Remove nuts (10), washers (11), battery holddown assembly (12), and battery holddown rods (13) securing batteries (1 and 9) to battery tray (14). _________ WARNING Lifting batteries from the battery tray can cause back strain. Ensure proper lifting techniques are used when lifting batteries. Failure to comply can cause personal injury. (7) (8) (9) Using care, remove batteries (1 and 9) from battery tray (14). Place Battery and Adapter (15) on a flat surface. Using flat tipped screwdriver, push down on adapter (15) locking tab, and remove battery by sliding horizontally from the adapter.
b.
4-53
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 c. Inspection. (1) (2) Remove batteries, step b. Inspect batteries (1 and 9, Figure 4-3) for cracked cases; broken, burned, or corroded posts; missing parts; and other damage. Install batteries, step e.
(3) d.
Service. (1) (2) (3) Remove terminal covers (2, Figure 4-3) from batteries (1 and 9). Clean terminal lugs (4, 5, 6, and 7) and battery posts. Install terminal covers (2) on batteries (1 and 9).
e.
Installation. (1) Slide battery horizontally into battery adapter (15) with negative battery post first, until adapter lock snaps into the lock position. Position batteries (1 and 9, Figure 4-3) in battery tray (14) with positive post toward the generator set. Ensure batteries are serviced and fully charged. Apply general purpose grease (Item 10, Appendix E) to battery posts and terminal lugs (4, 5, 6, and 7). Secure batteries (1 and 9) to battery tray with battery holddown rods (13), battery holddown assembly (12), washers (11), and nuts (10). CAUTION Interconnect battery cable terminals are marked with positive and negative. Ensure the cable is installed properly. Failure to comply can cause damage to equipment. (5) (6) (7) (8) Connect positive battery cable terminal lug (7) to battery (9). Connect interconnect battery cable terminal lug (5) first, then leg (6) to batteries (1 and 9). Connect negative battery cable terminal lug (4) to battery (9). Close BATTERY ACCESS door.
(2)
(3)
(4)
4.6.4
NATO SLAVE RECEPTACLE. a. Inspection. (1) (2) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2).
4-54
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 (3) Inspect NATO SLAVE RECEPTACLE (7, Figure 4-4) for loose connections, corrosion, missing hardware, and other damage. Close BATTERY ACCESS door.
(4) b.
Removal. (1) (2) (3) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Tag battery and NATO SLAVE RECEPTACLE cables. Remove bolts (1, Figure 4-4), lockwashers (2), wire (18) and terminals (3) from NATO SLAVE RECEPTACLE (7). Remove cap (4) from NATO SLAVE RECEPTACLE (7). Remove nuts (5), bolts (6), NATO SLAVE RECEPTACLE (7) and gasket (17) from generator set. Remove nut (8), bolt (9), and cap (4) from NATO SLAVE RECEPTACLE (7).
(4) (5) (6) c.
Installation. (1) (2) Install cap (4, Figure 4-4), with bolt (9), and nut (8) on NATO SLAVE RECEPTACLE (7). Position NATO SLAVE RECEPTACLE (7) and gasket (17) in generator set with negative terminal up. Install NATO SLAVE RECEPTACLE (7) and gasket (17), with bolts (6), and nuts (5) on generator set. Install cap (4) on NATO SLAVE RECEPTACLE (7). Install terminals (3), wire (18), lockwashers (2), and bolts (1) on NATO SLAVE RECEPTACLE (7). Connect negative battery cable to battery, and close BATTERY ACCESS door.
(3)
(4) (5)
(6) 4.6.5
Keypad Power Supply PS1. a. Inspection. (1) (2) (3) Shut down generator set, paragraph 2.11.2. Remove CIM (see paragraph 4.8.16) from the DCS control box assembly. Inspect keypad power supply (44, Figure 4-18) mounting surfaces and terminal screws for damage. Ensure screws are secure. Check for evidence of burned or damaged components on surface of keypad power supply. Install CIM (see paragraph 4.8.16).
(4) (5)
4-55
b.
Testing. (1) (2) (3) (4) (5) Shut down generator set, paragraph 2.11.2. Remove CIM (see paragraph 4.8.16) from the DCS control box assembly. Connect negative battery cable to battery and close battery access door. Switch master control switch (12, Figure 2-8) to ON. Set multimeter to volts DC and place positive lead of multimeter on terminal 1 and the negative lead on terminal 2. On PS1 multimeter should read between 12VDC and 24VDC. If indications are other than between 12VDC and 24 VDC, replace master control switch, paragraph 4.8.9. Place positive lead of multimeter on terminal 3 and negative lead on terminal 4. Multimeter should read 5VDC. If indications are less than 5VDC, replace keypad power supply (44, Figure 4-18). Close battery access door and disconnect negative battery cable. Install CIM (refer to paragraph 4.8.16).
(6)
(7)
(8) (9) (10) c.
Replacement. (1) (2) (3) (4) (5) (6) (7) (8) Shut down generator set, paragraph 2.11.2. Remove CIM (see paragraph 4.8.16) from the DCS control box assembly. Tag and disconnect keypad power supply (44, Figure 4-18) electrical leads. Remove mounting screws (46), standoffs (45), and key pad power supply (44) from air baffle (30). Align new key pad power supply (44) to standoffs (45) and install screws (46). Connect electrical leads to key pad power supply (44) and remove tags. Install the CIM (see paragraph 4.8.16). Connect negative battery lead and close battery compartment door.
4.7
MAINTENANCE OF HOUSING __________ WARNING When disconnecting or removing batteries, disconnect the negative lead that connects directly to the grounding stud first. Disconnect the negative end of the interconnection cable next. When installing batteries, reverse the connection sequence. Failure to comply can cause serious personal injury.
4-56
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 4.7.1 Access Doors. NOTE This procedure is written for the left rear engine access door, but is typical for all access doors, hinges, latches, storage boxes, and data plates. NOTE When removing and installation BATTERY ACCESS door, note position of spacers for door hold open mechanism. a. Removal. (1) (2) (3) Shut down generator set, paragraph 2.11.2. Open left side engine compartment access doors (Figure 1-3). Remove nuts (1, Figure 4-5), lockwashers (2), washers (3), bolts (4), and hinges (5), with door (6) attached, from generator set housing. Remove nuts (7), lockwashers (8), washers (9), bolts (10), and hinges (5) from door (6). Remove locknuts (11), bolts (12), and document box (13) from door (6). Drill out rivets (19), and remove wiring diagram data plate (20) from air baffle (13). Remove locknuts (23), bolts (24), and bracket (25) with holding rod (26) from door (6). Remove locknuts (27), bolts (28), and bracket (29) from door (6). NOTE Note position of latches before removal for reference during installation. (9) b. Remove locknuts (30), screws (31), and latches (32) from door (6).
(4) (5) (6) (7) (8)
Inspection. (1) (2) Shut down generator set, paragraph 2.11.2. Inspect access doors, hinges, latches, baffles, and storage boxes for loose and missing hardware, cracks, dents, and loose paint. Inspect data plates for readability and loose or missing rivets.
(3)
4-57
FIGURE 4-5. GENERATOR SET ACCESS DOORS
4-58
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 c. Repair. __________ WARNING CARC paint is a health hazard. Wear protective eyewear, mask and gloves when sanding CARC painted surfaces. Failure to comply can cause personal injury. (1) (2) (3) Repair all dents and cracks, and remove loose paint. Remove light corrosion with fine grit abrasive paper (Item 16, Appendix E). Repaint surfaces in accordance with TM 43-0139. NOTE Step (4) applies to all access doors except the load terminal access door . NOTE Sealant is applied to all four corners of the output box access door. (4) (5) (6) d. Apply industrial sealant (Item 18, Appendix E) to top two corners of access door. Replace damaged or unreadable data plates. Replace loose or missing rivets.
Installation. (1) Position latches (32, Figure 4-5) on door (6) as noted during removal. Secure latches to door with screws (31), and locknuts (30). Install bracket (29), bolts (28), and locknuts (27) on door (6). Install bracket (25), holding rod (26), bolts (24), and locknuts (23) on door (6). Install wiring diagram data plate (20) on air baffle (13) with rivets (19). Install air baffle (13), bolts (12), and locknuts (11) on door (6). Install hinges (5), bolts (10), washers (9), lockwashers (8), and nuts (7) on door (6). Position door (6) on generator set housing, and install hinges (5), bolts (4), washers (3), lockwashers (2), and nuts (1). Close engine compartment access doors.
(2) (3) (4) (5) (6) (7)
(8)
4-59
4.7.2
DCS Control Box Top Panel. a. Removal. (1) (2) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Refer to paragraphs 4.6.2 and 4.6.3. Remove DCS control box door (Figure 1-3). Refer to paragraph 4.7.1. Release DCS control panel (4, Figure 1-30) by turning two fasteners, and lower panel slowly. Remove bolts (1, Figure 4-6), lockwashers (2), and washers (3) from top panel (4). NOTE For ease of access in step 6, remove the CIM. Refer to paragraph 4.8.16.b. (6) Remove locknuts (5) and bolts (6) from top panel (4). Close DCS control panel (4, Figure 1-30). CAUTION The top panel is attached to the generator set housing with a silicone sealant to prevent water from entering the control box. Care must be taken not to bend or scratch the top panel when separating it from the housing. Failure to comply can cause damage to equipment. (7) (8) (9) (10) Carefully separate top panel (4) from generator. Remove control box top panel. Remove nuts (7), lockwashers (8), washers (9), and bolts (10) from DCS control box assembly. Remove locknuts (12), bolts (13), door ring retainer (14), and door ring (15) from top panel (4). Remove old sealant from door ring retainer (14).
(3) (4) (5)
4-60
FIGURE 4-6. DCS CONTROL BOX TOP PANEL
4-61
b.
Inspection. (1) (2) (3) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Inspect top panel (4, Figure 4-6) for dents, cracks, loose paint, corrosion, and missing mounting hardware.
c.
Repair. __________ WARNING CARC paint is a health hazard. Wear protective eyewear, mask and gloves when sanding CARC painted surfaces. Failure to comply can cause personal injury. (1) (2) (3) Repair all dents and cracks, and remove loose paint. Remove light corrosion with fine grit abrasive paper (Item 16, Appendix E). Repaint surfaces in accordance with TM 43-0139.
d.
Installation. (1) Apply tear drop gasket (Item 18, Appendix E) to mating surface of door ring retainer (14, Figure 46). Position door ring (15) and door ring retainer on top panel (4), and install bolts (13) and locknuts (12). Install stiffener (11), bolts (10), washers (9), lockwashers (8), and nuts (7) on DCS control box assembly. Install top panel (4) on control box with bolts (6) and locknuts (5). Install washers (3), lockwashers (2), and bolts (1) on top panel (4). Raise and secure DCS control panel with two fasteners. Install DCS control box door. Refer to paragraph 4.7.1. Connect negative battery cable to battery, and close BATTERY ACCESS door.
(2)
(3) (4) (5) (6) (7)
4.7.3 Top Housing Section. a. Removal. (1) (2) (3) Shut down generator set, paragraph 2.12.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Remove DCS control box top panel, paragraph 4.7.2. __________
4-62
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 WARNING Top housing panels can get very hot. Allow panels to cool down before performing maintenance. Failure to comply can result in severe burns to personnel. (4) Remove bolts (1, Figure 4-7), lockwashers (2), washers (3), mount (4), and exhaust cover (5) from top housing panel. Remove bolts (6 and 9), lockwashers (7 and 10), washers (8 and 11), and top housing panel (12) from generator set. Disconnect radiator fill hose and overflow hose from radiator fill panel (13), and remove panel (13) from generator set. Remove bolts (14), lockwashers (15), washers (16), and roof stiffener assembly (17, Figure 4-7, sheet 2) from side panels (33 and 34). Remove muffler, paragraph 4.9.1. Remove bolts (18), lockwashers 19), washers (20), and air duct channels (21 and 22) from floor panel (35). Remove locknuts (23 and 25), bolts (24 and 26), and duct panel (27) from floor panel (35) and side panels (33 and 34). Remove locknuts (28) and bolts (29) from side panels (33 and 34).
(5)
(6)
(7)
(8) (9)
(10)
(11)
4-63
FIGURE 4-7. TOP HOUSING SECTION (SHEET 1 OF 3)
4-64
4-65
(12) 13) (14) (15) (16) (17) (18)
Remove bolts (30), lockwashers (31), and washers (32) from front panel (38). Remove side panels (33 and 34) with floor panel (35) from generator set. Remove locknuts (36), bolts (37), and front panel (38) from floor panel (35). Remove locknuts (39), bolts (40), and support (41) from front panel (38). Remove locknuts (42), bolts (43), and side panels (33 and 34) from floor panel (35). Remove locknut (44), bolt (45), and bracket (46) from angle (49). Open output box access door (Figure 1-2), and remove locknuts (47), bolts (48), and angle (49) from generator set. Remove clip halves (50) and insulation (51 through 61) from top panel (12). Remove clip halves (62) and insulation (63 and 64) from side panels (33 and 34).
(19) (20)
4-66
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 (21) Remove panel clips (65) and insulation (66 and 67) from floor panel (35).
b.
Inspection. (1) (2) (3) (4) Remove top housing section, step a above. Inspect all top housing section panels for dents, cracks, loose paint, and corrosion. Inspect cage nuts (68 through 75, Figure 4-7) for cracking or stripped threads. Inspect insulation (51 through 61, 63, 64, 66 and 67) for damage and missing clip halves (50, 62, 76 and 78), push-on nuts (77 and 79), and panel clips (65) as applicable. Inspect seal (80) and door seals (81 and 82) for tears, looseness, and deterioration.
(5) c. Repair.
__________ WARNING CARC paint is a health hazard. Wear protective eyewear, mask and gloves when sanding CARC painted surfaces. Failure to comply can cause personal injury. (1) (2) (3) (4) (5) (6) Repair all dents and cracks, and remove loose paint. Remove light corrosion with fine grit abrasive paper (Item 16, Appendix E). Repaint surfaces in accordance with TM 43-0139. Replace cage nuts (68 through 75, Figure 4-7) that are stripped or cracked. Replace damaged insulation (51 through 61, 63, 64, 66 and 67). Replace missing or damaged clip halves (50, 62, 76 and 78), push-on nuts (77 and 79), and panel clips (65). Replace damaged seal (80) or door seals (81 and 82). Refer to Appendix E.
(7) d.
Installation. (1) (2) (3) (4) (5) (6) Install insulation (66 and 67, Figure 4-7) on floor panel (35) with panel clips (65). Install insulation (63 and 64) on side panels (33 and 34) with clip halves (62). Install insulation (51 through 61) on top panel (12) with clip halves (50). Install angle (49) on generator set with bolts (48) and locknuts (47). Close output box access door. Install bracket (46), bolt (45), and locknut (44) on angle (49). Install side panels (33 and 34), bolts (43), and locknuts (42) on floor panel (35).
4-67
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 (7) (8) (9) (10) (11) (12) Install support (41), bolts (40), and locknuts (39) on front panel (38). Install front panel (38), bolts (37), and locknuts (36) on floor panel (35). Position side panels (33 and 34) with floor panel (35) on generator set. Secure front panel (38) to generator set with washers (32), lockwashers (31), and bolts (30). Secure side panels (33 and 34) to generator set with bolts (29) and locknuts (28). Install duct panel (27), bolts (24 and 26), and locknuts (23 and 25) on floor panel (35) and side panels (33 and 34). Install air duct channels (21 and 22), washers (20), lockwashers (19), and bolts (18) on floor panel (35). Install muffler, paragraph 4.9.1. Install roof stiffener (17), washers (16), lockwashers (15), and bolts (14) on side panels (33 and 34). Position radiator fill panel (13) on generator set, and connect radiator fill hose and overflow hose to panel. Install top housing panel (12), washers (8 and 11), lockwashers (7 and 10), and bolts (6 and 9) on generator set. Install exhaust cover (5), mount (4), washers (3), lockwashers (2), and bolts (1) on top housing panel (12). Install DCS control box top panel, paragraph 4.7.2. Connect negative battery cable to battery, and close BATTERY ACCESS door.
(13)
(14) (15) (16)
(17)
(18)
(19) (20) 4.7.4
Front Housing Section. a. Removal. (1) (2) Shut down generator set, paragraph 2.11.2. Remove BATTERY ACCESS door. Refer to paragraph 4.7.1. Remove batteries, paragraph 4.6.3, and NATO SLAVE RECEPTACLE, paragraph 4.6.4. Remove engine compartment access doors. Refer to paragraph 4.7.1. Remove top housing section, paragraph 4.7.3. Remove bolts (1, figure 4-8) and ground rod sections (2) from brackets (56). Remove nuts (3), lockwashers (4), washers (5), and bolts (6) from door sills (22 and 23) and front housing (14).
(3) (4) (5) (6)
4-68
FIGURE 4-8. FRONT HOUSING SECTION (SHEET 1 OF 2)
4-69
FIGURE 4-8. FRONT HOUSING SECTION (SHEET 2 OF 2)
(7)
Remove nuts (7), lockwashers (8), washers (9), and bolts (10) from front housing (14) and skid base. Remove bolts (11), lockwashers (12), washers (13), and front housing (14) from skid base. Remove nuts (15), lockwashers (16), washers (17), and bolts (18) from door sills (22 and 23) and generator set. Remove bolts (19), lockwashers (20), washers (21), and door sills (22 and 23) from skid base. Remove clip halves (24) and insulation (25) from front housing (14). Remove locknuts (26) and bolts (27) from air deflector (31) and front housing (14). Remove bolts (28), lockwashers (29), washers (30), and air deflector (31) from front housing (14). Remove bolts (32), lockwashers (33), washers (34), and radiator panels (35 and 36) from front housing (14). Remove locknuts (37), bolts (38), and supports (39 and 40) from radiator panels (35 and 36). Remove bolts (41), lockwashers (42), washers (43), and panel (44) from front housing (14).
(8) (9)
(10) (11) (12) (13) (14)
(15) (16)
4-70
(17) (18) (19) (20) b.
Remove locknuts (45), bolts (46), and support (47) from panel (44). Remove locknuts (48), bolts (49), and support channel (50) from front housing (14). Remove locknuts (51), bolts (52), and SLAVE RECEPTACLE box (53) from front housing (14). Remove locknuts (54), bolts (55), and brackets (56) from door sill (22) and front housing (14).
Inspection. (1) (2) Shut down generator set, paragraph 2.12.2. Inspect all front housing section panels for dents, cracks, loose paint, corrosion, and other damage.
(3) (4) (5) (6)
Inspect cage nuts (57 through 62, Figure 4-8) for cracking or stripped threads. Inspect insulation (25) for damage and missing clip halves (24 and 63) and push-on nuts (64). Inspect seals (65 through 67) for tears, looseness and deterioration. Inspect identification plates (68, 70 and 72) for readability and loose or missing rivets (69, 71 and 73).
c.
Repair. __________ WARNING CARC paint is a health hazard. Wear protective eyewear, mask and gloves when sanding CARC painted surfaces. Failure to comply can cause personal injury. (1) Repair all dents and cracks, and remove loose paint. (2) (3) (4) (5) Remove light corrosion with fine grit abrasive paper (Item 16, Appendix E). Repaint surfaces in accordance with TM 43-0139. Replace stripped or cracked cage nuts (57 through 62, Figure 4-8). Replace damaged insulation (25) and missing or damaged clip halves (24 and 63) or push-on nuts (64). Replace damaged seals (65 through 67). Refer to Table E. Replace damaged or unreadable identification plates (68, 70 and 72). Replace loose or missing rivets (69, 71 and 73).
(6) (7) (8) d.
Installation. (1) Install brackets (56, Figure 4-8), bolts (55), and locknuts (54) on front housing (14) and door sill (22).
4-71
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 (2) (3) (4) (5) (6) (7) Install SLAVE RECEPTACLE box (53), bolts (52), and locknuts (51) on front housing (14). Install support channel (50), bolts (49), and locknuts (48) on front housing (14). Install support (47), bolts (46), and locknuts (45) on panel (44). Install panel (44), washers (43), lockwashers (42), and bolts (41) on front housing (14). Install supports (39 and 40), bolts (38), and locknuts (37) on radiator panels (35 and 36). Install radiator panels (35 and 36), washers (34), lockwashers (33), and bolts (32) on front housing (14). Install air deflector (31), washers (30), lockwashers (29), and bolts (28) on front housing (14). Secure air deflector (31) to front housing (14) with bolts (27) and locknuts (26). Install insulation (25) on front housing (14) with panel clips (24), clip halves (63), and push-on nuts (64). Install door sills (22 and 23), washers (21), lockwashers (20), and bolts (19) on skid base. Secure door sills (22 and 23) to generator set with bolts (18), washers (17), lockwashers (16), and nuts (15). Install front housing (14), washers (13), lockwashers (12), and bolts (11) on skid base. Secure front housing (14) to skid base with bolts (10), washers (9), lockwashers (8), and nuts (7). Install bolts (6), washers (5), lockwashers (4), and nuts (3) on front housing (14) and door sills (22 and 23). Position ground rod sections (2) in brackets (56), and install bolts (l). Install top housing section, paragraph 4.6.3. Install engine compartment access doors. Refer to paragraph 4.6.1. Install BATTERY ACCESS door. Refer to paragraph 4.6.1. Install NATO SLAVE RECEPTACLE, paragraph 4.5.4, and batteries, paragraph 4.5.3.
(8) (9) (10)
(11) (12)
(13) (14) (15)
(16) (17) (18) (19) (20)
4.7.5
Rear Housing Section. a. Removal. (1) (2) (3) Shut down generator set, paragraph 2.11.2. Remove DCS control box assembly, paragraph 4.8.1. Remove air cleaner assembly, paragraph 4.9.2.
4-72
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 (4) Remove output box access door, load terminal board access door, rear engine compartment access doors, and air cleaner access doors. Refer to paragraph 4.7.1. Remove fuel tank filler neck, paragraph 4.11.3. Remove auxiliary fuel pump, paragraph 4.11.2. Remove ether solenoid valve, paragraph 4.11.8. Remove top housing panel. Refer to paragraph 4.7.3. Remove output box. Refer to paragraph 5.8. Remove nuts (1, Figure 4-9), lockwashers (2), washers (3), and bolts (4) from rear panel (8) and skid base. Remove bolts (5), lockwashers (6), washers (7), and rear panel (8) from corner post (54) and left side rear panel (25). Remove locknuts (11), bolts (12), and load terminal access box (13) from rear panel (8). Remove clip halves (76) and insulation (10) from rear panel (8). Remove nuts (14), lockwashers (15), washers (16), and bolts (17) from left side rear panel (25) and engine compartment door seal (90). Remove nut (18), lockwasher (19), washer (20), and bolt (21) from left side rear panel (25). Remove bolts (22), lockwashers (23), washers (24), and left side rear panel (25) from skid base. Remove locknuts (26), bolts (27), and air baffle (28) from left side rear panel (25). Remove clip halves (29) and insulation (30) from air baffle (28). Remove locknuts (31), bolts (32), and support bracket (33) from left side rear panel (25). Remove locknuts (34), bolts (35), and filler neck panel (36) from left side rear panel (25). Remove locknuts (37), bolts (38), and document box top (39) from left side rear panel (25). Remove clip halves (40) and insulation (41) from left side rear panel (25). Remove locknuts (44), bolts (45), and output box sill (46) from corner post (54) and panel (64). Remove locknuts (47) and bolts (48) from door sill (53), corner post (54) and panel (64). Remove nuts (49), lockwashers (50), washers (51), bolts (52), door sill (53), and corner post (54) from skid base. Scrape sealant from mating surfaces of corner post and output box top. Remove nuts (57), lockwashers (58), and washers (59), and bolts (60) from panel (64). Remove bolts (61), lockwashers (62), washers (63), and panel (64) from skid base. Scrape sealant from mating surfaces of panel and output box top.
(5) (6) (7) (8) (9) (10)
(11)
(12) (13) (14)
(15) (16) (17) (18) (19) (20) (21) (22) (22) (23) (24)
(25) (26)
4-73
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 (27) (28) (29) Remove locknuts (65), bolts (66), and air baffle (67) from panel (64). Remove clip halves (68) and insulation (69) from air baffle (67). Remove clip halves (70) and insulation (71) from panel (64).
b.
Inspection. (1) (2) (3) (4) Shut down generator set, paragraph 2.12.2. Inspect rear housing section panels for dents, cracks, loose paint, corrosion, and other damage. Inspect cage nuts (72 through 76, Figure 4-9) for cracking or stripped threads. Inspect insulation (10,30,41,69,71), clip halves (9,29,40,68,70,76,78,80,82,84), and push-on nuts (77,79,81,83,85) for damage or missing pieces. Inspect output box EMI seals (86) for tears, looseness, and deterioration. Inspect door seals (87,88,89,90) for tears, looseness, and deterioration. Inspect data plates (92 and 94) for readability and loose or missing rivets (91 and 93).
(5) (6) (7)
4-74
FIGURE 4-9. REAR HOUSING SECTION (SHEET 1 OF 2)
4-75
FIGURE 4-9. REAR HOUSING SECTION (SHEET 2 OF 2)
c.
Repair. __________ WARNING CARC paint is a health hazard. Wear protective eyewear, mask and gloves when sanding CARC painted surfaces. Failure to comply can cause personal injury.
(1)
Repair all dents and cracks, and remove loose paint.
4-76
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 (2) (3) (4) (5) Remove light corrosion with fine grit abrasive paper (Item 16, Appendix E). Repaint surfaces in accordance with TM 43-0139. Replace stripped or cracked cage nuts (72 through 76, Figure 4-9). Replace damaged insulation (10,30,41,69,71) and missing or damaged clip halves (9,29,40,68,70,76,78,80,82,84) or push-on nuts (77,79,81,83,85). Replace damaged door seals (87 through 90) attach with adhesive (1, Appendix E). Using adhesive (1, Appendix E), replace loose or damaged EMI seals (86). Ensure closed side of seal faces outward. Replace damaged or unreadable data plates (92 and 94) and loose or missing rivets (91 and 93).
(6) (7)
(8) d.
Installation. (1) (2) (3) (4) (5) (6) Install insulation (71) and clip halves (70) to panel (64). Install insulation (69) and clip halves (68) to air baffle (67). Install air baffle (67), bolts (66), and locknuts (65) to panel (64). Install panel (64) to skid base using bolts (61), lockwashers (62), and washers (63). Install bolts (60), washers (59), lockwashers (58), and nuts (57) to panel (64). Install corner post (54), door sill (53) on skid base using bolts (52), washers (51), lockwashers (50), and nuts (49). Apply industrial sealant (18, Appendix E) to edges and cracks at mating surfaces of corner post (54), panel (64), and control box top. Secure door sill (53) to corner post (54) and panel (64) with bolts (48) and locknuts (47). Install output box sill (46), bolts (45), and locknuts (44) on corner post (54) and panel (64). Install insulation (41) and clip halves (40) to left side rear panel (25). Install document box top (39), bolts (38) and locknuts (37) to left side rear panel (25). Install filler neck panel (36), bolts (35), and locknuts (34) on left side rear panel (25). Install support bracket (33), bolts (32), and locknuts (31) to left side rear panel (25). Install insulation (30) on air baffle (28) with clip halves (29). Install air baffle (28), bolts (27), and locknuts (26) on left side rear panel (25). Secure left side rear panel (25) to skid base with bolts (22), lockwashers (23), and washers (24). Install bolt (21), washer (20), lockwasher (19), and nut (18) to left side rear panel (25).
(7)
(8) (9) (10) (11) (12) (13) (14) (15) (16) (17)
4-77
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 (18) Secure left side rear panel (25) and engine compartment door seal (90) with bolts (17), washers (16), lockwashers (15), and nuts (14). Install insulation (10) and clip halves (76) to rear panel (8). Install load terminal access box (13), bolts (12), and locknuts (11) on rear panel (8). Install washers (7), lockwashers (6), and bolts (5) on rear panel (8), corner post (54), and left side rear panel (25). Secure rear panel (8) to skid base with bolts (4), washers (3), lockwashers (2), and nuts (1). Install output box. Refer to paragraph 5.8 Install top housing panel. Refer to paragraph 4.7.3. Install ether solenoid valve, paragraph 4.11.8. Install auxiliary fuel pump, paragraph 4.11.2. Install fuel tank filler neck, paragraph 4.11.3. Install output box access door, load terminal board access door, rear engine compartment access doors, and air cleaner access door. Refer to paragraph 4.7.1. Install air cleaner assembly, paragraph 4.7.2. Install DCS control box assembly, paragraph 4.8.1.
(19) (20) (21)
(22) (23) (24) (25) (26) (27) (28)
(29) (30) 4.7.6
Housing Data Plates. a. Inspection. Inspect data plates for readability and loose or missing rivets. Refer to paragraph 2.16 for locations of data plates on housing. Replacement. (1) (2) Drill out rivets, and remove data plate from housing. Refer to paragraph 2.16. Install data plate on housing with rivets.
b.
4.8
MAINTENANCE OF DCS CONTROL BOX ASSEMBLY __________ WARNING When disconnecting or removing batteries, disconnect the negative lead that connects directly to the grounding stud first. Disconnect the negative end of the interconnection cable next. When installing batteries, reverse the connection sequence. Failure to comply can cause serious personal injury. __________ WARNING Electronic components of the DCS and CIM are static sensitive. Ensure that no static discharge occurs when you come in contact with those components. Failure to comply can cause damage to electronic components.
4-78
4.8.1
DCS Control Box . a. Inspection. (1) (2) b. Shut down generator set, paragraph 2.11.2. Inspect DCS control box for cracks, breaks, corrosion, loose paint, and missing parts.
Removal. (1) (2) (3) (4) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Remove DCS control box top panel, paragraph 4.7.2. Remove bolts (1, Figure 4-10), lockwashers (2), and washers (3) securing DCS control box assembly (12) to top of output box assembly (Figure 5-3). Open output box access door (Figure 1-2). Remove locknuts (4, Figure 4-10) and bolts (5) securing DCS control box assembly (12) to generator set. Remove bolts (6 and 9), lockwashers (7 and 10), and washers (8 and 11). Slide DCS control box forward, disconnect two wiring harness connectors at rear of DCS control box assembly (12, Figure 4-10) and remove DCS control box assembly (12) from generator set.
(5) (6)
(7) (8)
c.
Repair Repair DCS control box assembly by replacing damaged terminals, damaged or missing mounting hardware, and damaged or defective components. Refer to paragraphs 4.8.2 through 4.8.43.
d.
Installation. (1) Install DCS control box assembly (12) to generator set by sliding DCS control box backward, and connecting two wiring harness connectors at rear of DCS control box assembly (12, Figure 4-10). Secure DCS control box assembly (12) to generator set with bolts (6 and 9), lockwashers (7 and 10), and washers (8 and 11). Install bolts (5) and locknuts (4). Close output box access door (Figure 1-2). Secure DCS control box assembly (12, Figure 4-10) to top of output box assembly with washers (3), lockwashers (2), and bolts (1). Connect two wiring harness connectors at rear of DCS control box assembly (12). Install DCS control box top panel, paragraph 4.7.2.
(2)
(3) (4) (5)
(6) (7)
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ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 (8) Connect negative battery cable to battery, and close BATTERY ACCESS door (Figure 1-2).
4.8.2 Panel Lights DS1 through DS3. a. (1) (2) (3) (4) Inspection. Shut down generator set, paragraph 2.11.2. Remove directional cap (1, Figure 4-11) from panel light housing (5). Remove light bulb (2) from panel light housing (5). Set multimeter to ohms, and check light bulb for continuity across base and threads. Multimeter should indicate continuity. If multimeter does not indicate continuity, replace light bulb (2). Inspect directional caps (1) for cracks, corrosions, stripped threads, and other damage. Release DCS control panel by turning two fasteners, and lower panel slowly. Inspect panel light housings (5) on DCS control panel (6) for cracks, corrosion, stripped threads, and other damage. Install light bulb (2) in panel light housing (5). Install directional cap (1) on panel light housing (5). Raise and secure DCS control panel. Remove DCS control box top panel, paragraph 4.7.2. Inspect panel light housing (5) on DCS control panel frame (7) for cracks, corrosion, stripped threads, and other damage. Install DCS control box top panel, paragraph 4.7.2.
(5) (6) (7) (8)
(9) (10) (11) (12) (13)
(14) b.
Repair. (1) (2) (3) (4) Remove directional cap (1, Figure 4-11) from panel light housing (5). Remove light bulb (2) from panel light housing (5). Install light bulb (2) in panel light housing (5). Install directional cap (1) in panel light housing (5).
c.
Replacement. (1) (2) Shut down generator set, paragraph 2.11.2.
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
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(3)
If defective panel light is on DCS control panel (6, Figure 4-11), release DCS control panel by turning two fasteners, and lower panel slowly. If defective panel light is on DCS control panel frame (7), remove DCS control box top panel, paragraph 4.7.2. Tag and disconnect panel light housing (5) electrical leads. Remove jamnut (3), washer (4), and panel light housing (5) from DCS control panel (6) or DCS control panel frame (7). Install panel light housing (5), washer (4), and jamnut (3) on DCS control panel frame (7) or DCS control panel (6). Connect panel light housing (5) electrical leads. Remove tags. If removed, install DCS control box top panel, paragraph 4.7.2. If lowered, raise and secure DCS control panel. Connect negative battery cable to battery, and close BATTERY ACCESS doors.
(4)
(5) (6)
(7)
(8) (9) (10) (11)
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FIGURE 4-10. DCS CONTROL BOX ASSEMBLY
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FIGURE 4-11. DCS CONTROL BOX PANEL LIGHTS DS1 THROUGH DS3 AND NETWORK FAILURE LIGHT DS5
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ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 4.8.3 NETWORK FAILURE Light DS5. a. Inspection. (1) (2) (3) Shut down generator set, paragraph 2.11.2. Release DCS control panel by turning two fasteners, and lower panel slowly. Inspect light housing (11, Figure 4-11) for cracks, corrosion, evidence of shorting, and other damage. Raise and secure DCS control panel.
(4) b.
Repair. (1) (2) Unscrew to remove press-to-test light (8, Figure 4-11) from light housing (11). Screw press-to-test light (8) into light housing (11) to install.
c.
Replacement. (1) (2) (3) (4) (5) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Release DCS control panel by turning two fasteners, and lower panel slowly. Tag and disconnect light housing (11, Figure 4-11) electrical leads. Remove press-to-test light (8), jamnut (9), washer (10), and light housing (11) from DCS control panel (6). Install light housing (11), washer (10), jamnut (9), and press-to-test light (8) on DCS control panel (6). Tighten jamnuts (9 and 12) to secure light housing (11) to DCS control panel (6). Connect light housing (11) electrical leads. Remove tags. Raise and secure DCS control panel. Connect negative battery cable to battery, and close BATTERY ACCESS doors.
(6)
(7) (8) (9) (10) 4.8.4
Time Meter (TOTAL HOURS) M3. a. Inspection. (1) (2) (3) Shut down generator set, paragraph 2.11.2. Release DCS control panel by turning two fasteners, and lower DCS control panel slowly. Inspect time meter (3, Figure 4-12) for broken lens, cracked housing, and other damage.
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FIGURE 4-12. TIME METER AND SWITCHES
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(4) b.
Raise and secure DCS control panel.
Testing. (1) Turn ENGINE CONTROL switch (8, Fig 4-12) to PRIME & RUN position
(2) (3) (4)
Release DCS control panel by turning two fasteners, and lower DCS control panel slowly. Set multimeter for DC volts, and connect across terminals 1 and 2 of time meter (3, Figure 4-12). If 24 VDC is present, watch for indicator movement. In approximately six minutes, time meter (3) should move 1/10 hour. If time meter does not operate properly, meter is defective and must be replaced. Raise and secure DCS control panel. Turn Engine Control switch (8, Fig 4-12) to off position.
(5) (6) c.
Replacement. (1) (2) (3) (4) (5) (6) (7) (8) (9) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Release DCS control panel by turning two fasteners, and lower DCS control panel slowly. Tag and disconnect electrical leads from the time meter (3, Figure 4-12). Remove nuts (1), screws (2), and time meter (3) from DCS control panel. Install time meter (3), screws (2), and nuts (1) on DCS control panel. Connect electrical leads to time meter (3), and remove tags. Raise and secure DCS control panel with two fasteners. Connect negative battery cable to battery, and close BATTERY ACCESS door.
4.8.5
ENGINE CONTROL Switch S1. a. Inspection. (1) (2) (3) Shut down generator set, paragraph 2.11.2. Release DCS control panel by turning two fasteners, and lower DCS control panel slowly. Inspect ENGINE CONTROL switch (8, Figure 4-12) for loose connections and mounting hardware, and other damage. Raise and secure DCS control panel with two fasteners.
(4)
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b.
Testing. (1) (2) (3) (4) (5) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Release DCS control panel by turning two fasteners, and lower DCS control panel slowly. Tag and disconnect ENGINE CONTROL switch (8, Figure 4-12) electrical leads. Set multimeter for ohms, and check switch for continuity. Refer to Schematic, FO-1, to determine circuits made to corresponding switch position. Check continuity for all four positions. If open circuit is noted at any switch position, switch is unserviceable and must be replaced. Connect electrical leads to ENGINE CONTROL switch (8), and remove tags. Raise and secure DCS control panel with two fasteners. Connect negative battery cable to battery, and close BATTERY ACCESS door.
(6) (7) (8) (9) (10) c.
Replacement. (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Release DCS control panel by turning two fasteners, and lower DCS control panel slowly. Remove screw (4, Figure 4-12) and knob (5) from ENGINE CONTROL switch (8). Tag and disconnect electrical leads from ENGINE CONTROL switch (8). Remove nuts (6), screws (7), and ENGINE CONTROL switch (8) from DCS control panel. Install ENGINE CONTROL switch (8), screws (7), and nuts (6) on DCS control panel. Connect electrical leads to ENGINE CONTROL switch (8), and remove tags. Install knob (5) and screw (4) on ENGINE CONTROL switch (8). Raise and secure DCS control panel with two fasteners. Connect negative battery cable to battery, and close BATTERY ACCESS door.
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4.8.6
ETHER START Switch S9. a. Inspection. (1) (2) (3) Shut down generator set, paragraph 2.11.2. Release DCS control panel by turning two fasteners, and lower DCS control panel slowly. Inspect ETHER START switch (11, Figure 4-12) for loose connections and mounting hardware, and other damage. Raise and secure DCS control panel with two fasteners.
(4) b.
Testing. (1) (2) (3) (4) (5) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Release DCS control panel by turning two fasteners, and lower DCS control panel slowly. Tag and disconnect electrical leads from ETHER START switch (11, Figure 4-12). Set multimeter for ohms, and connect across ETHER START switch (11) terminals. Multimeter should indicate open circuit. Refer to Schematic FO-1. Hold ETHER START switch (11) in ON position. Multimeter should indicate continuity. If indications are not as above, replace ETHER START switch. Connect electrical leads to ETHER START switch (11), and remove tags. Raise and secure DCS control panel with two fasteners. Connect negative battery cable to battery, and close BATTERY ACCESS door.
(6) (7) (8) (9) (10) c.
Replacement. (1) (2) (3) (4) (5) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Release DCS control panel by turning two fasteners, and lower DCS control panel slowly. Tag and disconnect ETHER START switch (11, Figure 4-12) electrical leads. Remove jamnut (9) and toothed washer (10) securing ETHER START switch (11) to DCS control panel. Remove ETHER START switch (11) and tab washer (12) from DCS control panel. Position tab washer (12) and ETHER START switch (11) on DCS control panel.
(6) (7)
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(8) (9) (10) (11) 4.8.7
Secure ETHER START switch (11) to DCS control panel with toothed washer (10) and jamnut (9). Connect electrical leads to ETHER START switch (11), and remove tags. Raise and secure DCS control panel with two fasteners. Connect negative battery cable to battery, and close BATTERY ACCESS door.
AC CIRCUIT INTERRUPT Switch S5. a. Inspection. (1) (2) (3) Shut down generator set, paragraph 2.11.2. Release DCS control panel by turning two fasteners, and lower DCS control panel slowly. Inspect AC CIRCUIT INTERRUPT switch (16, Figure 4-12) for loose connections and mounting hardware, and other damage. Raise and secure DCS control panel with two fasteners.
(4) b.
Testing. (1) (2) (3) (4) (5) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Release DCS control panel by turning two fasteners, and lower DCS control panel slowly. Tag and disconnect electrical leads from AC CIRCUIT INTERRUPT switch (16, Figure 4-12). Set multimeter for ohms and check for open circuits between terminals 1 and 2, terminals 2 and 3, and terminals 1 and 3. Refer to Schematic FO-1. Place and hold AC CIRCUIT INTERRUPT switch (16) in CLOSED position. Check for continuity between terminals 1 and 2. Hold AC CIRCUIT INTERRUPT switch (16) in OPEN position. Check for continuity between terminals 2 and 3. If indications are not as above, replace AC CIRCUIT INTERRUPT switch (16). Connect electrical leads to AC CIRCUIT INTERRUPT switch (16), and remove tags. Raise and secure DCS control panel with two fasteners. Connect negative battery cable to battery, and close BATTERY ACCESS door.
(6) (7) (8) (9) (10) (11) (12) (13)
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c.
Replacement. (1) (2) (3) (4) (5) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Release DCS control panel by turning two fasteners, and lower DCS control panel slowly. Tag and disconnect AC CIRCUIT INTERRUPT switch (16, Figure 4-12) electrical leads. Remove jamnut (14) and toothed washer (15) securing AC CIRCUIT INTERRUPT switch (16) to DCS control panel. Remove AC CIRCUIT INTERRUPT switch (16), and tab washer (17) from DCS control panel. Position tab washer (17), and AC CIRCUIT INTERRUPT switch (16) on DCS control panel. Secure AC CIRCUIT INTERRUPT switch (16) to DCS control panel with toothed washer (15) and jamnut (14). Connect electrical leads to AC CIRCUIT INTERRUPT switch (16), and remove tags. Raise and secure DCS control panel with two fasteners. Connect negative battery cable to battery, and close BATTERY ACCESS door.
(6) (7) (8)
(9) (10) (11) 4.8.8
FAULT RESET Switch S4. a. Inspection. (1) (2) (3) Shut down generator set, paragraph 2.11.2. Release DCS control panel by turning two fasteners, and lower DCS control panel slowly. Inspect FAULT RESET switch (21, Figure 4-12) for loose connections and mounting hardware, and other damage. Raise and secure DCS control panel with two fasteners.
(4) b.
Testing. (1) (2) (3) (4) (5) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Release DCS control panel by turning two fasteners, and lower DCS control panel slowly. Tag and disconnect electrical leads from FAULT RESET switch (21, Figure 4-12). Set multimeter for ohms, and connect across FAULT RESET switch (21) terminals 2 and 3. Multimeter should indicate continuity. Refer to Schematic FO-1.
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ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 (6) Hold FAULT RESET switch (21) in ON position. Multimeter should indicate continuity between terminals 1 and 2 and an open circuit between terminals 2 and 3. If indications are not as above, replace FAULT RESET switch (21). Connect electrical leads to FAULT RESET switch (21), and remove tags. Raise and secure DCS control panel with two fasteners. Connect negative battery cable to battery, and close BATTERY ACCESS door.
(7) (8) (9) (10) c.
Replacement. (1) (2) (3) (4) (5) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Release DCS control panel by turning two fasteners, and lower DCS control panel slowly. Tag and disconnect electrical leads from FAULT RESET switch (21, Figure 4-12). Remove jamnut (19) and toothed washer (20) securing FAULT RESET switch (21) to DCS control panel. Remove FAULT RESET switch (21) and tab washer (22), from DCS control panel. Position tab washer (22) and FAULT RESET switch (21) on DCS control panel. Secure FAULT RESET switch (21) to DCS control panel with toothed washer (20) and jamnut (19). Connect electrical leads to FAULT RESET switch (21), and remove tags. Raise and secure DCS control panel with two fasteners. Connect negative battery cable to battery, and close BATTERY ACCESS door.
(6) (7) (8) (9) (10) (11) 4.8.9
MASTER CONTROL Switch S3. a. Inspection. (1) (2) (3) Shut down generator set, paragraph 2.11.2. Release DCS control panel by turning two fasteners, and lower DCS control panel slowly. Inspect MASTER CONTROL switch (3, Figure 4-13) for loose connections and mounting hardware, and other damage. Raise and secure DCS control panel with two fasteners.
(4)
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FIGURE 4-13. DCS CONTROL PANEL COMPONENTS
4-92
b.
Testing. (1) (2) (3) (4) (5) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Release DCS control panel by turning two fasteners, and lower DCS control panel slowly Tag and disconnect from electrical leads of MASTER CONTROL switch (3, Figure 4-13). Set multimeter for ohms, and connect across MASTER CONTROL switch (3). Refer to Schematic FO-1. Place MASTER CONTROL switch (3) in ON position. Multimeter should indicate continuity on terminals 5 and 6. Place MASTER CONTROL switch (3) in OFF position. Multimeter should indicate open circuit on terminal 5 and 6. If indications are not as above, replace MASTER CONTROL switch (3). Connect electrical leads to MASTER CONTROL switch (3), and remove tags. Raise and secure DCS control panel with two fasteners. Connect negative battery cable to battery, and close BATTERY ACCESS door.
(6)
(7)
(8) (9) (10) (11) c.
Replacement. (1) (2) (3) (4) (5) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Release DCS control panel by turning two fasteners, and lower DCS control panel slowly. Tag and disconnect electrical leads from MASTER CONTROL switch (3, Figure 4-13). Remove jamnut (1) and toothed washer (2) securing MASTER CONTROL switch (3) to DCS control panel. Remove MASTER CONTROL switch (3) and tab washer (4) from DCS control panel. Position tab washer (4) and MASTER CONTROL switch (3) on DCS control panel. Secure MASTER CONTROL switch (3) to DCS control panel with toothed washer (2) and jamnut (1). Connect electrical leads to MASTER CONTROL switch (3), and remove tags. Raise and secure DCS control panel with two fasteners. Connect negative battery cable to battery, and close BATTERY ACCESS door.
(6) (7) (8)
(9) (10) (11)
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ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 4.8.10 VOLTAGE ADJUST Switch S18. a. Inspection. (1) (2) (3) Shut down generator set, paragraph 2.11.2. Release DCS control panel by turning two fasteners, and lower DCS control panel slowly. Inspect VOLTAGE ADJUST switch (8, Figure 4-13) for loose connections and mounting hardware, and other damage. Raise and secure DCS control panel with two fasteners.
(4) b.
Testing. (1) (2) (3) (4) (5) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Release DCS control panel by turning two fasteners, and lower DCS control panel slowly. Tag and disconnect electrical leads from VOLTAGE ADJUST switch (8, Figure 4-13). Set multimeter for ohms, and connect across VOLTAGE ADJUST switch (8) terminals. Multimeter should indicate open circuit between terminals 1 and 2, 2 and 3, and 1 and 3. Refer to Schematic FO-1. Hold VOLTAGE ADJUST switch (8) in UP position. Multimeter should indicate continuity on terminals 2 and 3. Hold VOLTAGE ADJUST switch (8) in DOWN position. Multimeter should indicate continuity on terminals 2 and 1. If indications are not as above, replace VOLTAGE ADJUST switch. Connect electrical leads to VOLTAGE ADJUST switch (8), and remove tags. Raise and secure DCS control panel with two fasteners. Connect negative battery cable to battery, and close BATTERY ACCESS door.
(6)
(7)
(8) (9) (10) (11) c.
Replacement. (1) (2) (3) (4) (5) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Release DCS control panel by turning two fasteners, and lower DCS control panel slowly. Tag and disconnect electrical leads from VOLTAGE ADJUST switch (8, Figure 4-13). Remove jamnut (6) and toothed washer (7) securing VOLTAGE ADJUST switch (8) to DCS control panel.
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ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 (6) (7) (8) Remove VOLTAGE ADJUST switch (8) and tab washer (9) from DCS control panel. Position tab washer (9) and VOLTAGE ADJUST switch (8) on DCS control panel. Secure VOLTAGE ADJUST switch (8) to DCS control panel with toothed washer (7) and jamnut (6). Connect electrical leads to VOLTAGE ADJUST switch (8), and remove tags. Raise and secure DCS control panel with two fasteners. Connect negative battery cable to battery, and close BATTERY ACCESS door.
(9) (10) (11) 4.8.11
FREQUENCY ADJUST Switch S19. a. Inspection. (1) (2) (3) Shut down generator set, paragraph 2.11.2. Release DCS control panel by turning two fasteners, and lower DCS control panel slowly. Inspect FREQUENCY ADJUST switch (13, Figure 4-13) for loose connections and mounting hardware, and other damage. Raise and secure DCS control panel with two fasteners.
(4) b.
Testing. (1) (2) (3) (4) (5) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Release DCS control panel by turning two fasteners, and lower DCS control panel slowly. Tag and disconnect electrical leads from FREQUENCY ADJUST switch (13, Figure 4-13). Set multimeter for ohms, and connect across FREQUENCY ADJUST switch (13) terminals. Multimeter should indicate open circuit between terminals 1 and 2, 2 and 3, and 1 and 3. Refer to Schematic FO-1. Hold FREQUENCY ADJUST switch (13) in UP position. Multimeter should indicate continuity on terminals 2 and 3. Hold FREQUENCY ADJUST switch (13) in the DOWN position. Multimeter should indicate continuity on terminals 2 and 1. If indications are not as above, replace FREQUENCY ADJUST switch. Connect electrical leads to FREQUENCY ADJUST switch (13), and remove tags. Raise and secure DCS control panel with two fasteners. Connect negative battery cable to battery, and close BATTERY ACCESS door.
(6)
(7)
(8) (9) (10) (11)
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ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 c. Replacement. (1) (2) (3) (4) (5) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Release DCS control panel by turning two fasteners, and lower DCS control panel slowly. Tag and disconnect electrical leads from FREQUENCY ADJUST switch (13, Figure 4-13). Remove jamnut (11) and toothed washer (12) securing FREQUENCY ADJUST switch (13) to DCS control panel. Remove FREQUENCY ADJUST switch (13) and tab washer (14) from DCS control panel. Position tab washer (14) and FREQUENCY ADJUST switch (13) on DCS control panel. Secure FREQUENCY ADJUST switch (13) to DCS control panel with toothed washer (12) and jamnut (11). Connect electrical leads to FREQUENCY ADJUST switch (13), and remove tags. Raise and secure DCS control panel with two fasteners. Connect negative battery cable to battery, and close BATTERY ACCESS door.
(6) (7) (8)
(9) (10) (11) 4.8.12
PANEL LIGHTS Switch S2. a. Inspection. (1) (2) (3) Shut down generator set, paragraph 2.11.2. Release DCS control panel by turning two fasteners, and lower DCS control panel slowly. Inspect PANEL LIGHTS switch (18, Figure 4-13) for loose connections and mounting hardware, and other damage. Raise and secure DCS control panel with two fasteners.
(4) b.
Testing. (1) (2) (3) (4) (5) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Release DCS control panel by turning two fasteners, and lower DCS control panel slowly. Tag and disconnect electrical leads from PANEL LIGHTS switch (18, Figure 4-13). Set multimeter for ohms, and connect across PANEL LIGHTS switch (18) terminals 5 and 6 and 2 and 3. Refer to Schematic FO-1. Place PANEL LIGHTS switch (18) in ON position. Multimeter should indicate continuity between terminals 2 and 3, and 5 and 6.
(6)
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(7)
Place PANEL LIGHTS switch (18) in OFF position. Multimeter should indicate open circuit between terminals 2 and 3, and 5 and 6. If indications are not as above, replace PANEL LIGHTS switch (18). Connect electrical leads to PANEL LIGHTS switch (18), and remove tags. Raise and secure DCS control panel with two fasteners. Connect negative battery cable to battery, and close BATTERY ACCESS door.
(8) (9) (10) (11)
c.
Replacement. (1) (2) (3) (4) (5) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Release DCS control panel by turning two fasteners, and lower DCS control panel slowly. Tag and disconnect electrical leads from PANEL LIGHTS switch (18, Figure 4-13). Remove jamnut (16) and toothed washer (17) securing PANEL LIGHTS switch (18) to DCS control panel. Remove PANEL LIGHTS switch (18) and tab washer (19) from DCS control panel. Position tab washer (19) and PANEL LIGHTS switch (18) on DCS control panel. Secure PANEL LIGHTS switch (18) to DCS control panel with toothed washer (17) and jamnut (16). Connect electrical leads to PANEL LIGHTS switch (18), and remove tags. Raise and secure DCS control panel with two fasteners. Connect negative battery cable to battery, and close BATTERY ACCESS door.
(6) (7) (8)
(9) (10) (11)
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ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 4.8.13 BATTLE SHORT Switch S7. a. Inspection. (1) (2) (3) Shut down generator set, paragraph 2.11.2. Release DCS control panel by turning two fasteners, and lower DCS control panel slowly. Inspect BATTLE SHORT switch (24, Figure 4-13) for loose connections and mounting hardware, and other damage. Raise and secure DCS control panel with two fasteners.
(4) b.
Testing. (1) (2) (3) (4) (5) (6) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Release DCS control panel by turning two fasteners, and lower DCS control panel slowly. Tag and disconnect electrical leads from BATTLE SHORT switch (24, Figure 4-13). Place BATTLE SHORT switch (24) in ON position. Set multimeter for ohms, and check for continuity between terminals 2 and 3, and an open circuit between terminals 4 and 5. Refer to Schematic FO-1. Place BATTLE SHORT switch (24) in OFF position. Check for continuity between terminals 4 and 5, and an open circuit between terminals 2 and 3. If open circuit is indicated, replace BATTLE SHORT switch (24). Connect electrical leads to BATTLE SHORT switch (24), and remove tags. Raise and secure DCS control panel with two fasteners. Connect negative battery cable to battery, and close BATTERY ACCESS door.
(7) (8) (9) (10) (11) (12) c.
Replacement. (1) (2) (3) (4) (5) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Release DCS control panel by turning two fasteners, and lower DCS control panel slowly. Tag and disconnect electrical leads from BATTLE SHORT switch (24, Figure 4-13). Remove jamnut (21), toothed washer (22), and cover (23) securing BATTLE SHORT switch (24) to DCS control panel. Remove BATTLE SHORT switch (24) and tab washer (25) from DCS control panel.
(6)
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(7) (8)
Position tab washer (25) and BATTLE SHORT switch (24) on DCS control panel. Secure BATTLE SHORT switch (24) to DCS control panel with cover (23), toothed washer (22), and jamnut (21). Connect electrical leads to BATTLE SHORT switch (24), and remove tags. Raise and secure DCS control panel with two fasteners. Connect negative battery cable to battery, and close BATTERY ACCESS door.
(9) (10) (11) 4.8.14
EMERGENCY STOP Switch S17. a. Inspection. (1) (2) (3) Shut down generator set, paragraph 2.11.2. Release DCS control panel by turning two fasteners, and lower DCS control panel slowly. Inspect EMERGENCY STOP switch (29, Figure 4-13) for loose connections and mounting hardware, and other damage. Raise and secure DCS control panel with two fasteners.
(4) b.
Testing. (1) (2) (3) (4) (5) (6) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Release DCS control panel by turning two fasteners, and lower DCS control panel slowly. Tag and disconnect electrical leads from EMERGENCY STOP switch (29, Figure 4-13). Ensure EMERGENCY STOP switch (29) is in normal (out) position. Set multimeter for ohms, and connect across EMERGENCY STOP switch (29) terminals. Multimeter should indicate continuity. Push EMERGENCY STOP switch (29) to (in) position. Multimeter should indicate no continuity. If indications are not as above, replace EMERGENCY STOP switch (29). Connect electrical leads to EMERGENCY STOP switch (29), and remove tags. Raise and secure DCS control panel with two fasteners. Connect negative battery cable to battery, and close BATTERY ACCESS door.
(7) (8) (9) (10) (11)
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ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 c. Replacement. (1) (2) (3) (4) (5) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Release DCS control panel by turning two fasteners, and lower DCS control panel slowly. Tag and disconnect electrical leads from EMERGENCY STOP switch (29, Figure 4-13). Unscrew and remove knob (27) and collar (28) from EMERGENCY STOP switch (29), and remove switch from DCS control panel. Position EMERGENCY STOP switch (29) on DCS control panel and secure with collar (28) and knob (27). Connect electrical leads to EMERGENCY STOP switch (29), and remove tags. Raise and secure DCS control panel with two fasteners. Connect negative battery cable to battery, and close BATTERY ACCESS door.
(6)
(7) (8) (9) 4.8.15
GROUND FAULT CIRCUIT INTERRUPTER CB3. a. Inspection. (1) (2) (3) Shut down generator set, paragraph 2.11.2. Release DCS control panel by turning two fasteners, and lower DCS control panel slowly. Inspect GROUND FAULT CIRCUIT INTERRUPTER (32, Figure 4-13) for cracks, corrosion, frayed wires, and other damage. Raise and secure DCS control panel with two fasteners.
(4) b.
Testing. (1) (2) Start generator set, paragraph 2.11.1. Operate generator set at rated voltage and frequency. Set multimeter for AC volts, press TEST button on GROUND FAULT CIRCUIT INTERRUPTER (32, Figure 4-13), and check for zero voltage at the CONVENIENCE RECEPTACLE (23, Figure 414) by inserting multimeter leads into one of the outlets. Press RESET button on GROUND FAULT CIRCUIT INTERRUPTER (32, Figure 4-13), and use multimeter to check for 120 VAC at the CONVENIENCE RECEPTACLE (23, Figure 4-14). If indications are other than the above, replace GROUND FAULT CIRCUIT INTERRUPTER (32, Figure 4-13).
(3)
(4)
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ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 c. Replacement. (1) (2) (3) (4) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Remove DCS control box top panel, paragraph 4.7.2. Tag and disconnect GROUND FAULT CIRCUIT INTERRUPTER (32, Figure 4-13) electrical leads from TB5 and CONVENIENCE RECEPTACLE (23, Figure 4-14). Remove nuts (30, Figure 4-13), screws (31), and GROUND FAULT CIRCUIT INTERRUPTER (32) from DCS control panel. Install GROUND FAULT CIRCUIT INTERRUPTER (32), screws (31), and nuts (30) on DCS control panel. Connect GROUND FAULT CIRCUIT INTERRUPTER (32) electrical leads to CONVENIENCE RECEPTACLE (23, Figure 4-14) and TB5. Refer to Schematic FO-1. Remove tags. Install DCS control box top panel, paragraph 4.7.2. Connect negative battery cable to battery, and close BATTERY ACCESS door.
(5)
(6)
(7)
(8) (9)
4-101
FIGURE 4-14. CIM AND RECEPTACLES
4-102
4.8.16
Computer Interface Module (CIM). a. Inspection. (1) (2) (3) (4) b. Shut down Generator set, Paragraph 2.11.2 Remove DCS control box top panel, paragraph 4.7.2. Inspect CIM (3, Figure 4-14) for cracks, corrosion, dents, or other damage. Install DCS control box top panel, paragraph 4.7.2.
Removal. (1) (2) (3) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Remove DCS control box top panel, paragraph 4.7.2. CAUTION CIM has two multi-pin electrical connectors. Pins can be damaged or broken if connectors are pulled from or inserted in CIM sockets at an angle. Use care when connecting or disconnecting wiring harnesses from CIM. Failure to comply can cause damage to equipment and malfunction of the CIM. NOTE CIM has two connectors from the CIM wiring harness. The smaller connector provides power to the CIM. The large connector is for data exchange. Both connectors are secured in place with fasteners. (4) (5) Loosen two screws, and disconnect power connector (25, fig 4-14) from CIM. Loosen two thumbscrews, and disconnect data connector (24) from CIM. CAUTION CIM is mounted in DCS control panel frame suspended by mounting hardware. If mounting hardware is removed without support being provided for the CIM, the CIM and frame may be damaged. Have an assistant support CIM during removal. Failure to comply can cause damage to equipment. (6) While providing adequate support for CIM, remove bolts (2) and CIM (3) from DCS control panel frame (4). If necessary, drill out rivet nuts (1) from DCS control panel frame.
(7) c.
Installation. (1) If removed, install rivet nuts (1, Figure 4-14) with rivet gun.
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ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 CAUTION CIM mounts in DCS control panel frame suspended by mounting hardware. Have an assistant support the CIM during installation. Failure to comply can cause damage to equipment. (2) (3) (4) (5) (6) 4.8.17 While providing adequate support, install CIM (3) and bolts (2) on DCS control panel frame (4). Connect data connector (24) to CIM (3). Tighten two thumbscrews. Connect power connection to CIM (3). Tighten two screws. Install DCS control box top panel, paragraph 4.7.2. Connect negative battery cable to battery, and close BATTERY ACCESS door.
Keypad Assembly KP. CAUTION Electronic components containing printed circuit boards are extremely sensitive to electrostatic discharge (ESD). Wear an ESD wrist strap connected to ground whenever coming in contact with ESD-sensitive components. Failure to comply can cause severe damage to equipment. a. Inspection. (1) (2) (3) (4) Shut down generator set, paragraph 2.11.2. Remove DCS control box top panel, paragraph 4.7.2. Attach ESD wrist strap and connect to ground. Inspect keypad assembly (7, Figure 4-14) for sticking or non-responsive buttons, corrosion, loose and damaged wires or other damage. Disconnect ESD wrist strap from ground, and remove wrist strap. Install DCS control box top panel, paragraph 4.7.2.
(5) (6) b.
Replacement. (1) (2) (3) (4) (5) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Remove DCS control box top panel, paragraph 4.7.2. Remove CIM. Refer to Paragraph 4.8.16. Attach ESD wrist strap and connect to ground.
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CAUTION Keypad assembly has two electrical connectors. Pins can be damaged or broken if connectors are pulled from or inserted at an angle. Use care when connecting or disconnecting wiring harnesses from keypad assembly. Failure to comply can cause damage to equipment. NOTE Keypad assembly has two electrical connectors. One multi-pin serial connector on a wire harness from the keypad provides data exchange and connects to the CIM wiring harness. One single-contact push-on connector on the DCS wiring harness provides power and connects directly to the keypad assembly. (6) Remove two ground straps from keypad assembly (7, Figure 4-14). Tag and disconnect keypad wires from PS-1, terminals 1 and 2. Refer to Schematic FO-1. Disconnect data exchange connector P26 from J26. Remove locknuts (5), bolts (6), and keypad assembly (7) from DCS control panel frame (4). Install keypad assembly (7), bolts (6), and locknuts (5) on DCS control panel frame (4). Connect data exchange connector P26 to J26. Connect keypad wires to PS-1 terminals 1 and 2. Remove tags.. Disconnect ESD wrist strap from ground, and remove wrist strap. Install DCS control box top panel, paragraph 4.7.2. Install CIM. Refer to Paragraph 4.8.16. Connect negative battery cable to battery, and close BATTERY ACCESS door.
(7) (8) (9) (10) (11) (12) (13) (14) (15) 4.8.18
COMMUNICATION RECEPTACLE. a. Inspection. (1) (2) (3) Shut down generator set, paragraph 2.11.2. Remove DCS control box top panel, paragraph 4.7.2. Inspect COMMUNICATION RECEPTACLE (11, Figure 4-14) for cracks, corrosion, stripped or damaged threads, evidence of shorting, and other damage. Inspect cap (10) for cracks, corrosion, and broken chain. Inspect gasket (12) for tears and deterioration. Replace defective parts.
(4) (5) (6)
4-105
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 (7) b. Install control box top panel, paragraph 4.7.2.
Replacement. (1) (2) (3) (4) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Remove DCS control box top panel, paragraph 4.7.2. Tag and desolder electrical leads from COMMUNICATION RECEPTACLE (11, Figure 4-14) and groundwire. Refer to Schematic FO-1. Remove locknuts (8), screws (9), cap (10), COMMUNICATION RECEPTACLE (11), and gasket (12) from DCS control panel frame (4). Install gasket (12), COMMUNICATION RECEPTACLE (11), cap (10), screws (9), and locknuts (8) on DCS control panel frame (4). Solder electrical leads to COMMUNICATION RECEPTACLE (11) and connect ground wire. Refer to Schematic FO-1. Remove tags. Install control box top panel, paragraph 4.7.2. Connect negative battery cable to battery, and close BATTERY ACCESS door.
(5)
(6)
(7)
(8) (9) 4.8.19
PARALLELING RECEPTACLE J2. a. Inspection. (1) (2) (3) Shut down generator set, paragraph 2.11.2. Remove DCS control box top panel, paragraph 4.7.2. Inspect PARALLELING RECEPTACLE (16, Figure 4-14) for cracks, corrosion, stripped or damaged threads, evidence of shorting, and other damage. Inspect cap (15) for cracks, corrosion, and broken chain. Inspect gasket (17) for tears and deterioration. Replace defective parts. Install control box top panel, paragraph 4.7.2.
(4) (5) (6) (7) b.
Replacement. (1) (2) (3) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Remove DCS control box top panel, paragraph 4.7.2.
4-106
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 (4) Tag and disconnect electrical leads from PARALLELING RECEPTACLE (16, Figure 4-14) by inserting removal tool (Appendix B, Section III) into pins of connector. Remove locknuts (13), screws (14), cap (15), PARALLELING RECEPTACLE (16), and gasket (17) from DCS control panel frame (4). Install gasket (17), PARALLELING RECEPTACLE (16), cap (15), screws (14), and locknuts (13) on DCS control panel frame (4). Connect electrical leads to PARALLELING RECEPTACLE (16) using insertion tool (Appendix B, Section III). Remove tags. Install control box top panel, paragraph 4.7.2. Connect negative battery cable to battery, and close BATTERY ACCESS door.
(5)
(6)
(7)
(8) (9) 4.8.20
CONVENIENCE RECEPTACLE J1. a. Inspection. (1) (2) (3) Shut down generator set, paragraph 2.11.2. Remove DCS control box top panel, paragraph 4.7.2. Inspect CONVENIENCE RECEPTACLE (23, Figure 4-14) for cracks, breaks, corrosion, bent terminals, and other indications of damage. Inspect cover (20) for cracks, corrosion, and damaged springs. Replace defective parts. Install DCS control box top panel, paragraph 4.7.2.
(4) (5) (6) b.
Testing. (1) (2) (3) (4) Shut down generator set, paragraph 2.11.2. Remove DCS control box top panel, paragraph 4.7.2. Remove locknuts (18, Figure 4-14), screws (19), and cover (20) from DCS control panel frame (4). Remove locknuts (21), screws (22), and CONVENIENCE RECEPTACLE (23) from DCS control panel frame (4). Tag and disconnect electrical leads from CONVENIENCE RECEPTACLE (23). Set multimeter for ohms, and check for continuity between upper side terminals and lower side terminals of each plug outlet. Replace CONVENIENCE RECEPTACLE if continuity is not indicated between terminals. Connect electrical leads to CONVENIENCE RECEPTACLE (23), and remove tags. Install DCS control box top panel, paragraph 4.7.2.
(5) (6)
(7) (8) (9)
4-107
c.
Replacement. (1) (2) (3) (4) (5) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Remove DCS control box top panel, paragraph 4.7.2. Remove locknuts (18, Figure 4-14), screws (19), and cover (20) from DCS control panel frame (4). Remove locknuts (21), screws (22), and CONVENIENCE RECEPTACLE (23) from DCS control panel frame (4). Tag and disconnect electrical leads from CONVENIENCE RECEPTACLE (23). Connect electrical leads to CONVENIENCE RECEPTACLE (23). Remove tags. Install CONVENIENCE RECEPTACLE (23), screws (22), and locknuts (21) on DCS control panel frame (4). Install cover (20), screws (19), and locknuts (18) on DCS control panel frame (4). Install DCS control box top panel, paragraph 4.7.2. Connect negative battery cable to battery, and close BATTERY ACCESS door.
(6) (7) (8)
(9) (10) (11) 4.8.21
DCS Load Sharing Synchronizer A2. CAUTION Electronic components containing printed circuit boards are extremely sensitive to electrostatic discharge (ESD). Wear an ESD wrist strap connected to ground whenever coming in contact with ESD-sensitive components. Failure to comply can cause severe damage to equipment. a. Inspection. (1) (2) (3) (4) Shut down generator set, paragraph 2.11.2. Remove DCS control box top panel, paragraph 4.7.2. Attach ESD wrist strap and connect to ground. Inspect DCS load sharing synchronizer (5, Figure 4-15) for loose or missing mounting hardware and any obvious damage. Disconnect ESD wrist strap, and remove wrist strap. Install DCS control box top panel, paragraph 4.7.2.
(5) (6)
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FIGURE 4-15. DCS CONTROL BOX BACK PANEL COMPONENTS
4-109
b.
Testing. (1) (2) (3) (4) Shut down generator set, paragraph 2.11.2. Connect negative battery cable to battery and close battery access door. Start generator set, paragraph 2.11.1. Close contactor. Ensure the CONTACT POSITION status indicator on CIM reads CLOSED. On load sharing synchronizer (5, Figure 4-15) check that PARALLEL ENABLE LED is lit. If PARALLEL ENABLE LED is not lit, replace load sharing synchronizer. Set multimeter to VDC. Connect positive lead to P24-11 and negative lead to P24-10. Refer to Schematic FO-1. Multimeter reading at 100% load should be 6 VDC. If not, replace load sharing synchronizer (5). Disconnect multimeter leads from P24-11 and P24-10. Shut down generator set, paragraph 2.11.2. Install DCS control box top panel, paragraph 4.7.2.
(5)
(6) (7) (8) (9) c.
Removal. (1) (2) (3) (4) (5) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Remove DCS control box top panel, paragraph 4.7.2. Attach ESD wrist strap and connect to ground. Remove locknuts (1, Figure 4-15), screws (3), washers (2), and lockwashers (4) securing DCS load sharing synchronizer (5) to DCS control box rear panel. CAUTION DCS load sharing synchronizer is connected to backplane module by a multipin electrical connector. Use care to pull DCS load sharing synchronizer straight out from backplane module to avoid damage to electrical connector. Failure to comply can cause damage to equipment. (6) Carefully remove DCS load sharing synchronizer (5) from backplane module (20) by pulling straight out.
4-110
d.
Installation. CAUTION DCS load sharing synchronizer is connected to backplane module by a multipin electrical connector. Use care to push DCS load sharing synchronizer straight onto backplane module to avoid damage to electrical connector. Failure to comply can cause damage to equipment. (1) Carefully align DCS load sharing synchronizer (5, Figure 4-15) with electrical connector on backplane module (20), and press module connector into backplane connector. Secure DCS load sharing synchronizer (5) to DCS control box rear panel and backplane module (20) with lockwashers (4), washers (2), screws (3), and locknuts (1). Disconnect ESD wrist strap, and remove wrist strap. Install DCS control box top panel, paragraph 4.7.2. Connect negative battery cable to battery, and close BATTERY ACCESS door.
(2)
(3) (4) (5) 4.8.22
DCS Speed Control Unit A3. CAUTION Electronic components containing printed circuit boards are extremely sensitive to electrostatic discharge (ESD). Wear an ESD wrist strap connected to ground whenever coming in contact with ESD-sensitive components. Failure to comply can cause severe damage to equipment. a. Inspection. (1) (2) (3) (4) Shut down generator set, paragraph 2.11.2. Remove DCS control box top panel, paragraph 4.7.2. Attach ESD wrist strap and connect to ground. Inspect DCS speed control unit (8, Figure 4-15) for loose or missing mounting hardware and any obvious damage. Disconnect ESD wrist strap, and remove wrist strap. Install DCS control box top panel, paragraph 4.7.2.
(5) (6) b.
Testing. (1) (2) (3) Shut down generator set, paragraph 2.11.2. Remove DCS control box top panel, paragraph 4.7.2. Start generator set, paragraph 2.11.1.
4-111
(4)
Ensure the CONTACT POSITION status indicator reads CLOSED. Check that PARALLEL ENABLE LED is lit. If PARALLEL ENABLE LED is not lit, replace load sharing synchronizer. Set multimeter to VDC. Connect positive lead to P24-11 and negative lead to P24-10. Multimeter reading at 100% load should be 6 VDC. If not, replace load sharing synchronizer (5, Figure 4-15). Disconnect multimeter leads from P24-11 and P24-10. Shut down generator set, paragraph 2.11.2. Install DCS control box top panel, paragraph 4.7.2.
(5) (6)
(7) (8) (9) c.
Removal. (1) (2) (3) (4) (5) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Remove DCS control box top panel, paragraph 4.7.2. Attach ESD wrist strap and connect to ground. Remove locknuts (6, Figure 4-15) and washers (7) securing DCS speed control unit (8) to backplane module (20). CAUTION DCS speed control unit is connected to backplane module by a multi-pin electrical connector. Use care to pull DCS speed control unit straight out from backplane module to avoid damage to electrical connector. Failure to comply can cause damage to equipment. (6) Carefully remove DCS speed control unit (8) from backplane module (20) by pulling straight out.
d.
Installation. CAUTION DCS load sharing synchronizer is connected to backplane module by a multipin electrical connector. Use care to push DCS load sharing synchronizer straight onto backplane module to avoid damage to electrical connector. Failure to comply can cause damage to equipment. (1) Carefully align DCS speed control unit (8, Figure 4-15) with electrical connector on backplane module (20), and press module connector into backplane connector. Secure DCS speed control unit (8) to backplane module (20) with washers (7) and locknuts (6). Disconnect ESD wrist strap, and remove wrist strap. Install DCS control box top panel, paragraph 4.7.2.
(2) (3) (4)
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ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 (5) 4.8.23 Connect negative battery cable to battery, and close BATTERY ACCESS door.
Automatic Voltage Regulator A4. CAUTION Electronic components containing printed circuit boards are extremely sensitive to electrostatic discharge (ESD). Wear an ESD wrist strap connected to ground whenever coming in contact with ESD-sensitive components. Failure to comply can cause severe damage to equipment. a. Inspection. (1) (2) (3) (4) Shut down generator set, paragraph 2.11.2. Remove DCS control box top panel, paragraph 4.7.2. Attach ESD wrist strap and connect to ground. Inspect automatic voltage regulator (11, Figure 4-15) for loose or missing mounting hardware and any obvious damage. Disconnect ESD wrist strap, and remove wrist strap. Install DCS control box top panel, paragraph 4.7.2.
(5) (6) b.
Testing. (1) (2) (3) (4) (5) Shut down generator set, paragraph 2.11.2. Remove DCS control box top panel, paragraph 4.7.2. Attach ESD wrist strap and connect to ground. Set multimeter to ohms, and connect leads to P9-5 and P9-6. Refer to Wiring Diagram FO-3. Measure resistance between P9-5 and P9-6. If resistance is other than 283 ohms, test back plane module, paragraph 4.7.24. Disconnect multimeter leads from P9-5 and P9-6. Set multimeter to VDC. Connect positive lead to P9-5 and negative lead to P9-6. Disconnect ESD wrist strap, and remove wrist strap. Hold ENGINE CONTROL switch in START position and start generator set. Record VDC reading. Reading should be approximately 8 VDC. If not, test the field flash relay K23 using the procedure described in paragraph 4.8.34. Release ENGINE CONTROL switch, and disconnect multimeter leads from P9-5 and P9-6. Connect positive multimeter lead to J24-1 and negative lead to P24-2. If reading is above 20 VDC, replace automatic voltage regulator (11).
(6) (7) (8) (9)
(10) (11)
4-113
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 (12) (13) Disconnect multimeter leads from P24-1 and P24-2. Check DC SUPPLY, AC SENSING, and FIELD VOLTAGE LEDs on automatic voltage regulator (11, Figure 4-15). If LEDs are not lit, test backplane module, paragraph 4.8.24. If measurement recorded in step (9) is above 15 VDC and LEDs checked in step (11) are lit, automatic voltage regulator (11) is okay. Shut down generator set, paragraph 2.11.2. Install DCS control box top panel, paragraph 4.7.2.
(14)
(15) (16) c.
Removal. (1) (2) (3) (4) (5) (6) (7) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Remove DCS control box top panel, paragraph 4.7.2. Remove CIM. See paragraph 4.8.16. Attach ESD wrist strap and connect to ground. Remove P24 and P9. Refer to Schematic FO-1. Remove locknuts (9, Figure 4-15) and washers (10) securing automatic voltage regulator (11) to backplane module (20). Disconnect leads from R16 and R17. CAUTION Automatic voltage regulator is connected to backplane module by a multi-pin electrical connector. Use care to pull automatic voltage regulator straight out from backplane module to avoid damage to electrical connector. Failure to comply can cause damage to equipment. (9) Carefully remove automatic voltage regulator (11) from backplane module (20) by pulling straight out.
(8)
d.
Installation. (1) Carefully align automatic voltage regulator (11, Figure 4-15) with electrical connector on backplane module (20), and press module connector into backplane connector. Secure automatic voltage regulator (11) to backplane module (20) with washers (10) and locknuts (9). Connect leads to R16 and R17. Disconnect ESD wrist strap, and remove wrist strap. Install DCS control box top panel, paragraph 4.7.2.
(2)
(3) (4) (5)
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(6) 4.8.24
Connect negative battery cable to battery, and close BATTERY ACCESS door.
Backplane Module A1. CAUTION Electronic components containing printed circuit boards are extremely sensitive to electrostatic discharge (ESD). Wear an ESD wrist strap connected to ground whenever coming in contact with ESD-sensitive components. Failure to comply can cause severe damage to equipment. a. Inspection. (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) b. Shut down generator set, paragraph 2.11.2. Remove DCS control box top panel, paragraph 4.7.2. Remove DCS load sharing synchronizer, paragraph 4.8.21. Remove DCS speed control unit, paragraph 4.8.22. Remove automatic voltage regulator, paragraph 4.8.23. Inspect backplane module (20, Figure 4-15) for damaged or missing connectors and components. Install automatic voltage regulator, paragraph 4.8.23. Install DCS speed control unit, paragraph 4.8.22. Install DCS load sharing synchronizer, paragraph 4.8.21. Install DCS control box top panel, paragraph 4.7.2.
Testing. (1) (2) (3) (4) Shut down generator set, paragraph 2.11.2. Remove DCS control box top panel, paragraph 4.7.2. Attach ESD wrist strap and connect to ground. Set multimeter to VDC. Connect positive lead to P24-6 and negative lead to P24-7. Refer to Wiring Diagram FO-3. Ensure MASTER CONTROL switch is set to ON. Record VDC reading. If reading in step (5) is not approximately 24 VDC, connect positive multimeter lead to P5-R and negative lead to P5-c. Record VDC reading. Refer to Schematic FO-1. If reading in step (6) is 24 VDC, test DCS control box wiring harness, paragraph 4.8.37. Disconnect ESD wrist strap, and remove wrist strap.
(5) (6)
(7) (8)
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ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 (9) Start generator set, paragraph 2.11.1.
NOTE Polarity of signal between P9-8 and P9-11 must be correct. Check wiring polarity at current transformer in output box prior to test. Refer to Schematic FO-1. (10) Connect multimeter leads to P24-5 and P9-8. At full load, reading should be approximately 4 VAC. At no load, the reading should be approximately 0 VAC. If either of these readings are different, replace backplane module (20). Disconnect multimeter leads from P24-5 and P9-8. Shut down generator set, paragraph 2.11.2. Install DCS control box top panel, paragraph 4.7.2.
(11) (12) (13) c.
Replacement. (1) (2) (3) (4) (5) (6) (7) Shut down generator set, paragraph 2.11.2. Remove DCS control box, paragraph 4.8.1. Remove DCS load sharing synchronizer, paragraph 4.8.21. Remove DCS speed control unit, paragraph 4.8.22. Remove automatic voltage regulator, paragraph 4.8.23. Disconnect wiring harness connectors (12). Remove screws (13), lockwashers (14), and washers (15) securing backplane connectors (16) and gasket (22) to DCS control box rear panel. CAUTION Backplane module is connected to the CIM wiring harness by multi-pin electrical connectors. Use care when disconnecting and connecting the wiring harness to the backplane module. Failure to comply can cause damage to equipment. (8) Disconnect P23 ribbon cable assembly (17) and P8 ribbon cable assembly (33) from backplane module (20). Tag and disconnect electrical leads from A1-TB1. Refer to Wiring Diagram FO-1. Remove locknuts (18), washers (19), backplane module (20), and standoffs (21) from DCS control box rear panel. Install standoffs (21), backplane module (20), washers (19), and locknuts (18) on DCS control box rear panel. Connect P23 (17) and P8 (33) ribbon cable assemblies to backplane module (20).
(9) (10)
(11)
(12)
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(13)
Secure gasket (22) and backplane connectors (16) to DCS control box rear panel with washers (15), lockwashers (14), and screws (13). Connect wiring harness connectors (12). Install automatic voltage regulator, paragraph 4.8.23. Install DCS speed control unit, paragraph 4.8.22. Install DCS load sharing synchronizer, paragraph 4.8.21. Install DCS control box top panel, paragraph 4.7.2. I/O Interface Module A5. CAUTION Electronic components containing printed circuit boards are extremely sensitive to electrostatic discharge (ESD). Wear an ESD wrist strap connected to ground whenever coming in contact with ESD-sensitive components. Failure to comply can cause severe damage to equipment.
(14) (15) (16) (17) (18) 4.8.25
a.
Inspection (1) (2) (3) (4) (5) (6) Shut down generator set, paragraph 2.11.2. Remove DCS control box top panel, paragraph 4.7.2. Attach ESD wrist strap and connect to ground. Inspect I/O interface module (25, Figure 4-15) for damaged or missing connectors and components. Disconnect ESD wrist strap, and remove wrist strap. Install DCS control box top panel, paragraph 4.7.2.
b.
Testing NOTE There is no indication that the I/O Module has failed in its installed location, other than the HEARTBEAT indicator (36) Figure 2-3, is off when DC Power is applied to the Module, or the indicator remains continuously on at any time.
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(1)
The heartbeat Indicator (36) Figure 2-3, is normally ON blinking when DC power is applied to the module. It is also normally ON blinking when the Generator set is operating (engine is running ) and the I/O Module is functioning properly. If the indicator is either steady state ON or steady state OFF, with the CIM on and the engine running, this indicates there is a problem in the I/O module, and it should be replaced.
c.
Replacement (1) (2) (3) (4) (5) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Remove DCS control box top panel, paragraph 4.7.2. Remove CIM. See paragraph 4.8.16. Attach ESD wrist strap and connect to ground. CAUTION I/O interface module is connected to the CIM and DCS wiring harnesses module by multi-pin electrical connectors. Use care when disconnecting and connecting the wiring harness to the I/O interface module. Failure to comply can cause damage to equipment. (6) (7) (8) Tag and disconnect electrical connectors P20, P21, P17 and P25. Refer to Schematic FO-1. Disconnect ribbon cable assemblies P23 (17) and P8 (33) from I/O interface module (25). Remove screws (23), lockwashers (24), and I/O interface module (25) from DCS control box rear panel. Set I/O Interface Module Configuration Switch for the proper Generator Set Application. See paragraph 4.16. Install I/O interface module (25), lockwashers (24), and screws (23) on DCS control box rear panel. Install ribbon cable assemblies P23 (17) and P8 (33), to I/O interface module (25). Connect electrical connectors P20, P21, P17, and P25 to I/O interface module (25) and remove tags. Refer to Schematic FO-1. Disconnect ESD wrist strap, and remove wrist strap. Install CIM. See paragraph 4.8.16. Install DCS control box top panel, paragraph 4.7.2. Connect negative battery cable to battery, and close BATTERY ACCESS door.
(9)
(10) (11) (12)
(13) (14) (15) (16)
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4.8.26
DC CONTROL POWER Fuse. a. Inspection. (1) (2) (3) Shut down generator set, paragraph 2.11.2. Open DCS control panel. Inspect DC CONTROL POWER Fuseholder (3, Figure 4-16) for loose connections and mounting hardware, cracked housing, and other damage. Close DCS control panel.
(4) b.
Testing. (1) (2) (3) Shut down generator set, paragraph 2.11.2. Release DCS Control Panel by turning two quick turn fasteners. Remove cap (1, Figure 4-16) and fuse (2) from DC CONTROL POWER fuseholder (3) and remove fuse from cap. Set multimeter for ohms and connect across fuse ends. If fuse is good, multimeter will indicate continuity. If indications are not as above, replace fuse with one of identical size and rating. Install good fuse (2) into cap and install cap (1) and fuse (2) into fuseholder (3). Close DCS Control Panel and secure with two quick turn fasteners.
(4)
(5) (6) (7)
c.
Replacement. (1) (2) (3) (4) (5) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Remove DCS Control box top panel, paragraph 4.7.2. Tag and disconnect electrical leads from DC CONTROL POWER fuseholder (3, Figure 4-16). Remove cap (1) and fuse (2) from fuseholder (3). Remove jamnut (24), which secures fuseholder to auxiliary control bracket (18) and slide fuseholder through auxiliary control bracket. Install DC CONTROL POWER fuseholder (3, Figure 4-16), and secure with jamnut(24). Connect electrical leads to DC CONTROL POWER fuseholder (3), and remove tags. Install cap (1) and fuse (2), in fuseholder (3).
(6) (7)
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FIGURE 4-16. DCS CONTROL BOX FLOOR COMPONENTS (SHEET 1 OF 2)
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FIGURE 4-16. DCS CONTROL BOX FLOOR COMPONENTS (SHEET 2 OF 2) (8) (9) 4.8.27 Install DCS control box top panel, paragraph 4.7.2. Connect negative battery cable to battery, and close BATTERY ACCESS door.
FREQUENCY SELECT Switch S12 . a. Inspection. (1) (2) (3) Shut down generator set, paragraph 2.11.2. Remove DCS control box top panel, paragraph 4.7.2. Inspect FREQUENCY SELECT switch (6, Figure 4-16) for loose connections and mounting hardware and other damage. Install DCS control box top panel, paragraph 4.7.2.
(4) b.
Testing. (1) (2) (3) (4) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Remove DCS control box top panel, paragraph 4.7.2. Remove FREQUENCY SELECT switch. Refer to paragraph 4.8.27.c.
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ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 (5) (6) Set multimeter for ohms, and connect across switch terminals. Place FREQUENCY SELECT switch (6) in UP (60 Hz) position. Multimeter should indicate continuity. Place FREQUENCY SELECT switch (6) in DOWN (50 Hz) position. Multimeter should indicate open circuit. If indications are other than above, FREQUENCY SELECT switch (6) is defective and must be replaced. Install FREQUENCY SELECT switch. Refer to paragraph 4.8.27.c. Install DCS control box top panel, paragraph 4.7.2. Connect negative battery cable to battery, and close BATTERY ACCESS door.
(7)
(8)
(9) (10) (11) c.
Replacement. (1) (2) (3) (4) (5) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Remove DCS control box top panel, paragraph 4.7.2. Tag and disconnect electrical leads from FREQUENCY SELECT switch (6, Figure 4-16). Remove jamnut (4), lockwasher (5), and FREQUENCY SELECT switch (6) from auxiliary control bracket (18). Install FREQUENCY SELECT switch (6, Figure 4-16), lockwasher (5), and jamnut (4) on auxiliary control bracket (18). Connect electrical leads to FREQUENCY SELECT switch (6), and remove tags. Install DCS control box top panel, paragraph 4.7.2. Connect negative battery cable to battery, and close BATTERY ACCESS door.
(6)
(7) (8) (9)
4.8.28
REACTIVE CURRENT ADJUST Rheostat R5. a. Inspection. (1) (2) (3) Shut down generator set, paragraph 2.11.2. Remove DCS control box top panel, paragraph 4.7.2. Inspect REACTIVE CURRENT ADJUST rheostat (8, Figure 4-16) for loose connections and mounting hardware, and other damage. Install DCS control box top panel, paragraph 4.7.2.
(4) b.
Testing.
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(1) (2) (3) (4) (5)
Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Remove DCS control box top panel, paragraph 4.7.2. Desolder: Reference Para.5.5.2. (4). Mark reading of REACTIVE CURRENT ADJUST rheostat (8, Figure 4-16) to reposition at conclusion of testing steps. Set multimeter for ohms, and connect to wires 236B and 236A. Multimeter reading should be between 4.5 and 5.5 ohms. Connect multimeter to wires 236A and 236C, and turn REACTIVE CURRENT ADJUST rheostat (8) to full clockwise position. Multimeter reading should be approximately 0 ohms. Turn REACTIVE CURRENT ADJUST rheostat slowly to full counterclockwise position, and observe multimeter. Multimeter reading should evenly increase up to between 4.5 and 5.5 ohms. Connect multimeter to wires 236B and 236C, and turn REACTIVE CURRENT ADJUST rheostat (8) to full clockwise position. Multimeter reading should be between 4.5 and 5.5 ohms. Turn REACTIVE CURRENT ADJUST rheostat slowly to full counterclockwise position, and observe multimeter. Multimeter reading should evenly decrease to approximately 0 ohms. If multimeter readings are other than above, replace REACTIVE CURRENT ADJUST rheostat (8). Reposition REACTIVE CURRENT ADJUST rheostat (8) as marked in step (5). Solder : Reference Para.5.5.2.(11). Install DCS control box top panel, paragraph 4.7.2. Connect negative battery cable to battery, and close BATTERY ACCESS door.
(6)
(7)
(8)
(9) (10) (11) (12) (13) c.
Replacement. (1) (2) (3) (4) (5) (6) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Remove DCS control box top panel, paragraph 4.7.2. Desolder and tag electrical leads from REACTIVE CURRENT ADJUST rheostat (8, Figure 4-16). Mark reading of REACTIVE CURRENT ADJUST rheostat (8) to reposition at installation. Remove nuts(7 and 45) and REACTIVE CURRENT ADJUST rheostat (8) from auxiliary control bracket. Reposition REACTIVE CURRENT ADJUST rheostat (8) as marked in step (5), and secure with nuts (7and 45). Solder electrical leads to REACTIVE CURRENT ADJUST rheostat (8). Remove tags.
(7)
(8)
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(9) (10) 4.8.29
Install DCS control box top panel, paragraph 4.7.2. Connect negative battery cable to battery, and close BATTERY ACCESS door.
Diode CR1-CR10 a. Inspection.
(1) (2) (3) (4) b.
Shut down generator set, paragraph 2.11.2. Remove DCS control box top panel, paragraph 4.7.2. Inspect diode (9, Figure 4-16) for cracks, breaks, corrosion, bent terminals, and other damage. Install DCS control box top panel, paragraph 4.7.2.
Testing. (1) (2) (3) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Remove DCS control box top panel, paragraph 4.7.2.
FIGURE 4-17. DIODE IDENTIFICATION
(4) (5)
Tag and remove diode from circuit. Refer to Schematic FO-1. Connect positive lead of multimeter to cathode side and negative lead to anode side of diode (9, Figure 4-16). Refer to Figure 4-17. Multimeter should indicate open loop for diode. Reverse multimeter leads so positive lead is connected to anode and negative lead is connected to cathode side of diode. Multimeter should indicate continuity for diode. If any indications are other than above, replace diode. Install DCS control box top panel, paragraph 4.7.2.
(6)
(7) (8)
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(9) c.
Replacement. (1) (2) (3) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Remove DCS control box top panel, paragraph 4.7.2. NOTE Soldering applies only to CR1. All other diodes are installed with screws.
(4) (5) (6) (7) (8) (9) (10) (11) 4.8.30
For CR2-CR10, tag and remove diode from unit. Refer to Schematic FO-1. Tag and desolder electrical leads from terminals (20, Figure 4-16). Desolder diode (9) from terminals (20). Solder diode (9) to terminals (20). Solder electrical leads to terminals (20). Remove tags. Install CR2-CR10 and remove tags. Refer to Schematic FO-1. Install DCS control box assembly, paragraph 4.8.1. Connect negative battery cable to battery, and close BATTERY ACCESS door.
Resistor R1. a. Inspection. (1) (2) (3) (4) b. Shut down generator set, paragraph 2.11.2. Remove DCS control box top panel, paragraph 4.7.2. Inspect resistor (10, Figure 4-16) for cracks, breaks, corrosion, bent terminals, and other damage. Install DCS control box top panel, paragraph 4.7.2.
Testing. (1) (2) (3) (4) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Remove DCS control box top panel, paragraph 4.7.2. Tag and remove R1 (10, Figure 4-16).
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(5)
Set multimeter for ohms, and measure resistance across resistor (10). Multimeter indication should be between 1235 and 1365 ohms. If any indications are other than above, replace resistor. Install R1 and remove tags. Install DCS control box top panel, paragraph 4.7.2. Connect negative battery cable to battery, and close BATTERY ACCESS door.
(6) (7) (8) (9) c.
Replacement. (1) (2) (3) (4) (5) (6) (7) (8) (9) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Remove DCS control box top panel, paragraph 4.7.2. Tag and desolder electrical leads from resistor (10, Figure 4-16) Remove resistor (10) from auxiliary control bracket (18). Install resistor (10) to auxiliary control bracket (18). Solder electrical leads to resistor (10). Remove tags. Install DCS control box top panel, paragraph 4.7.2. Connect negative battery cable to battery, and close BATTERY ACCESS door.
4.8.31
Resistor R2. a. Inspection. (1) (2) (3) (4) b. Shut down generator set, paragraph 2.11.2. Remove DCS control box top panel, paragraph 4.7.2. Inspect resistor (13, Figure 4-16) for cracks, breaks, corrosion, bent terminals, and other damage. Install DCS control box top panel, paragraph 4.7.2.
Testing. (1) (2) (3) (4) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Remove DCS control box top panel, paragraph 4.7.2. Set multimeter for ohms, and measure resistance across resistor (13, Figure 4-16). Multimeter indication should be between 310 and 350 ohms.
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(7) (8) (9)
If any indications are other than above, replace resistor. Install DCS control box top panel, paragraph 4.7.2. Connect negative battery cable to battery, and close BATTERY ACCESS door.
c.
Replacement. (1) (2) (3) (4) (5) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Remove DCS control box top panel, paragraph 4.7.2. Tag and desolder electrical leads from resistor (13, Figure 4-16). Remove nuts (11), lockwashers (12), resistor (13), sleeving (14), screws (15), and lockwashers (16) from auxiliary control bracket (18). Install lockwashers (16), screws (15), sleeving (14), resistor (13), lockwashers (12), and nuts (11) on auxiliary control bracket (18). Solder electrical leads to resistor (13). Remove tags. Install DCS control box top panel, paragraph 4.7.2. Connect negative battery cable to battery, and close BATTERY ACCESS door.
(6)
(7) (8) (9)
4.8.32
Auxiliary Control Bracket. a. Inspection. Inspect auxiliary control bracket (18, Figure 4-16) for dents, cracks, loose paint, and corrosion. b. Removal. (1) (2) (3) (4) (5) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Remove DCS control box top panel, paragraph 4.7.2. Remove auxiliary control bracket components, paragraphs 4.8.26 through 4.8.31. Remove bolts (17, Figure 4-16) and auxiliary control bracket (18) from floor of DCS control box assembly. Remove screws (19) and terminals (20) from auxiliary control bracket (18).
(6) c.
Repair.
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ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 (1) As necessary, remove components from auxiliary control bracket (18, Figure 4-16), paragraphs 4.8.26 through 4.8.31. _________ WARNING CARC paint is a health hazard. Wear protective eyewear, mask and gloves when sanding CARC painted surfaces. Failure to comply can cause personal injury. (2) (3) (4) (5) d. Repair all dents and cracks, and remove loose paint. Remove light corrosion with fine grit abrasive paper (Item 16, Appendix E). Repaint surfaces in accordance with TM 43-0139. Install components removed in step (1), paragraphs 4.8.26 through 4.8.31.
Installation. (1) (2) (3) (4) (5) Install terminals (20, Figure 4-16) and screws (19) on auxiliary control bracket (18). Install auxiliary control bracket (18) and bolts (17) on floor of DCS control box assembly. Install auxiliary control bracket components, paragraphs 4.8.26 through 4.8.31. Install DCS control box top panel, paragraph 4.7.2. Connect negative battery cable to battery, and close BATTERY ACCESS door.
4.8.33
VOLTAGE SELECTION Switch S20. a. Inspection. (1) (2) (3) Shut down generator set, paragraph 2.11.2. Remove DCS control box top panel, paragraph 4.7.2. Inspect VOLTAGE SELECTION switch (23, Figure 4-16) for loose connections and mounting hardware and other damage. Install DCS control box top panel, paragraph 4.7.2.
(4) b.
Testing. (1) (2) (3) (4) (5) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Remove DCS control box top panel, paragraph 4.7.2. Remove jamnut (21), lockwasher (22), and VOLTAGE SELECTION switch (23) from bracket (18). Tag and disconnect electrical leads from VOLTAGE SELECTION switch (23, Figure 4-16).
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ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 (6) (7) (8) Set multimeter for ohms, and connect across switch terminals. Place VOLTAGE SELECTION switch (23) in UP position. Multimeter should indicate continuity. Place VOLTAGE SELECTION switch (23) in DOWN position. Multimeter should indicate open loop. If indications are other than above, VOLTAGE SELECTION switch (23) is defective and must be replaced. Connect electrical leads to VOLTAGE SELECTION switch (23). Install VOLTAGE SELECTION switch (23, Figure 4-16), lockwasher (22), and jamnut (21) on bracket (18). Install DCS control box top panel, paragraph 4.7.2. Connect negative battery cable to battery, and close BATTERY ACCESS door.
(9)
(10) (11)
(12) (13) c.
Replacement. (1) (2) (3) (4) (5) (6) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Remove DCS control box top panel, paragraph 4.7.2. Tag and disconnect electrical leads from VOLTAGE SELECTION switch (23, Figure 4-16). Remove jamnut (21), lockwasher (22), and VOLTAGE SELECTION switch (23) from bracket (18). Install VOLTAGE SELECTION switch (23, Figure 4-16), lockwasher (22), and jamnut (21) on bracket (18). Connect electrical leads to VOLTAGE SELECTION switch (23), and remove tags. Install DCS control box top panel, paragraph 4.7.2. Connect negative battery cable to battery, and close BATTERY ACCESS door.
(7) (8) (9) 4.8.34
Relays K15, K17, K19, K22, K23. a. Inspection. (1) (2) (3) (4) b. Shut down generator set, paragraph 2.11.2. Remove DCS control box top panel, paragraph 4.7.2. Inspect relay (Figure 4-16) for cracks, loose mounting, and other damage. Install DCS control box top panel, paragraph 4.7.2.
Removal.
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ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 (1) (2) (3) (4) c. Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Remove DCS control box top panel, paragraph 4.7.2. Release wire clip (26, Figure 4-16), and remove relay from socket.
Testing. (1) (2) (3) Shut down generator set, paragraph 2.11.2. Remove relay K15, see paragraph 4.8.34.b. Set multimeter for ohms, and check for open circuits between terminals 7 and 4, 8 and 5, and 9 and 6. Check for closed circuits between terminals 7 and 1, 8 and 2, and 9 and 3. Connect multimeter between terminals A and B, and check for indication of 427.5 to 522.5 ohms. Apply battery voltage across terminals A and B. Using multimeter, check for open circuits between terminals 7 and 1, 8 and 2, and 9 and 3. Check for closed circuits between terminals 7 and 4, 8 and 5, and 9 and 6. Refer to Wiring Diagram FO-3. If indications are other than above, relay is defective and must be replaced. Install relay, see paragraph 4.8.34.d.
(4) (5)
(6) (7) d.
Installation. (1) (2) (3) Install relay (Figure 4-16) in socket, and secure with wire clip (26). Install DCS control box top panel, paragraph 4.7.2. Connect negative battery cable to battery, and close BATTERY ACCESS door.
4.8.35
Resistors R16 and R17. a. Inspection. (1) (2) (3) (4) b. Shut down generator set, paragraph 2.11.2. Remove DCS control box top panel, paragraph 4.7.2. Inspect resistors (35 and 36, Figure 4-16) for cracks, loose mounting, and other damage. Install DCS control box top panel, paragraph 4.7.2.
Testing. (1) (2) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable.
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ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 (3) (4) Remove DCS control box top panel, paragraph 4.7.2. Set multimeter for ohms, and measure resistance across resistor R16 (35). Multimeter indication should be 50 ohms. Set multimeter for ohms, and measure resistance across resistor R17 (36). Multimeter indication should be 50 ohms. If indications are other than above, one or both resistors is defective and must be replaced. Install DCS control box top panel, paragraph 4.7.2. Connect negative battery cable to battery, and close BATTERY ACCESS door.
(5)
(6) (7) (8) c.
Replacement. (1) (2) (3) (4) (5) (6) (7) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Remove DCS control box top panel, paragraph 4.7.2. Remove CIM control box assembly, paragraph 4.8.16. Remove air baffle. Refer to paragraph 4.8.41. Tag and desolder electrical leads from resistors (35 and 36, Figure 4-16). Remove nuts (32), lockwashers (33), screws (34) and resistors (35 and 36) from air baffle (30, Figure 4-18) of DCS control box assembly. Install resistors (36 and 35, Figure 4-16), screws (34), lockwashers (33), and nuts (32) on air baffle (30, Figure 4-18) of DCS control box assembly. Solder electrical leads to resistors (36 and 35, Figure 4-16). Remove tags. Install air baffle, refer to paragraph 4.8.41. Install CIM, refer to paragraph 4.8.16. Install DCS control box top panel, paragraph 4.7.2. Connect negative battery cable to battery, and close BATTERY ACCESS door.
(8)
(9) (10) (11) (12) (13) 4.8.36
Resistor R6. a. Inspection. (1) (2) (3) Shut down generator set, paragraph 2.11.2. Remove DCS control box top panel, paragraph 4.7.2. Inspect resistor (41, Figure 4-16) for cracks, breaks, corrosion, bent terminals, and other damage.
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ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 (4) b. Install DCS control box top panel, paragraph 4.7.2.
Testing. (1) (2) (3) (4) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Remove DCS control box top panel, paragraph 4.7.2. Set multimeter for ohms, and measure resistance across resistor (41, Figure 4-16). Multimeter indication should be 40 ohms. If any indications are other than above, replace resistor. Install DCS control box top panel, paragraph 4.7.2. Connect negative battery cable to battery, and close BATTERY ACCESS door.
(7) (8) (9) c.
Replacement. (1) (2) (3) (4) (5) (6) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Remove DCS control box top panel, paragraph 4.7.2. Tag and desolder electrical leads from resistor (41, Figure 4-16). Open output box access door (Figure 1-2) to access nuts (37). Remove nuts (37), lockwashers (38), screws (39), lockwashers (40), resistor (41), and sleeving (42) from floor of DCS control box assembly. Install sleeving (42), resistor (41), lockwashers (40), screws (39), lockwashers (38), and nuts (37) on floor of DCS control box assembly. Close output box access door. Solder electrical leads on resistor (41). Remove tags. Install DCS control box top panel, paragraph 4.7.2. Connect negative battery cable to battery, and close BATTERY ACCESS door.
(7)
(8) (9) (10) (11) 4.8.37
DCS Control Box Wiring Harness. CAUTION Electronic components containing printed circuit boards are extremely sensitive to electrostatic discharge (ESD). Wear an ESD wrist strap connected to ground whenever coming in contact with ESD-sensitive components. Failure to comply can cause severe damage to equipment.
4-132
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 a. Inspection. (1) (2) (3) (4) (5) (6) (7) (8) b. Shut down generator set, paragraph 2.11.2. Remove DCS control box top panel, paragraph 4.7.2. Attach ESD wrist strap and connect to ground. Inspect DCS wiring harness (43, Figure 4-16) for burned, bent, corroded, and broken terminals. Inspect connectors for cracks, corrosion, stripped threads, bent or broken pins, and obvious damage. Inspect wire insulation for burns, deterioration, and chafing. Disconnect ESD wrist strap, and remove wrist strap. Install DCS control box top panel, paragraph 4.7.2.
Testing. (1) (2) (3) (4) (5) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Remove DCS control box top panel, paragraph 4.7.2. Attach ESD wrist strap and connect to ground. Set multimeter for ohms, and test individual wires of DCS wiring harness (43, Figure 4-16) for continuity. Refer to wiring diagram, FO-3, for wire identification. If continuity is not found, perform step c below to repair wiring harness. Notify higher level of maintenance if it is necessary to replace wiring harness. Disconnect ESD wrist strap, and remove wrist strap. Install DCS control box top panel, paragraph 4.7.2. Connect negative battery cable to battery, and close BATTERY ACCESS door.
(6) (7) (8) c.
Repair. (1) (2) (3) (4) (5) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Remove DCS control box top panel, paragraph 4.7.2. Attach ESD wrist strap and connect to ground. Replace damaged terminals, wires, and securing hardware on DCS wiring harness (43, Figure 4-16). Refer to Schematic, FO-3. Disconnect ESD wrist strap, and remove wrist strap.
(6)
4-133
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 (7) (8) Install DCS control box top panel, paragraph 4.7.2. Connect negative battery cable to battery, and close BATTERY ACCESS door.
4.8.38
CIM Wiring Harness. CAUTION Electronic components containing printed circuit boards are extremely sensitive to electrostatic discharge (ESD). Wear an ESD wrist strap connected to ground whenever coming in contact with ESD-sensitive components. Failure to comply can cause severe damage to equipment. a. Inspection. (1) (2) (3) (4) Shut down generator set, paragraph 2.11.2. Remove DCS control box top panel, paragraph 4.7.2. Attach ESD wrist strap and connect to ground. Inspect connectors on CIM wiring harness (44, Figure 4-16) for cracks, corrosion, bent or broken pins, and obvious damage. Inspect ribbon cable insulation for burns, deterioration, chafing, and splitting. Disconnect ESD wrist strap, and remove wrist strap. Install DCS control box top panel, paragraph 4.7.2.
(5) (6) (7) b.
Removal. (1) (2) (3) (4) (5) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Remove DCS control box top panel, paragraph 4.7.2. Remove CIM. Refer to paragraph 4.8.16. Attach ESD wrist strap and connect to ground. CAUTION CIM wiring harness has multi-pin electrical connectors. Pins can be damaged or broken if connectors are pulled from or inserted into sockets at an angle. Use care when connecting or disconnecting wiring harness to components. Failure to comply can cause damage to equipment and malfunction of the CIM. (6) Carefully disconnect CIM wiring harness connectors from components, and remove CIM wiring harness (44, Figure 4-16) from DCS control box assembly.
c.
Testing.
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(1) (2)
Remove CIM wiring harness, 4.8.38. b. Leave ESD wrist strap on. Set multimeter for ohms, and test individual wires of CIM wiring harness (44, Figure 4-16) for continuity by testing pin-to-pin at wiring harness connectors. Refer to Wire Harness FO-7. If continuity is not indicated, replace wiring harness. Install CIM wiring harness, 4.8.38.d.
(3) d.
Installation. CAUTION CIM wiring harness has multi-pin electrical connectors. Pins can be damaged or broken if connectors are pulled from or inserted into sockets at an angle. Use care when connecting or disconnecting wiring harness to components. Failure to comply can cause damage to equipment and malfunction of the CIM. (1) Position CIM wiring harness (44, Figure 4-16) in DCS control box assembly. Carefully connect wiring harness connectors to components. Disconnect ESD wrist strap, and remove wrist strap. Install CIM, refer to paragraph 4.8.16. Install DCS control box top panel, paragraph 4.7.2. Connect negative battery cable to battery, and close BATTERY ACCESS door.
(2) (3) (4) (5) 4.8.39
DCS Control Panel Assembly. a. Removal. (1) (2) (3) (4) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Release DCS control panel by turning two fasteners, and lower panel. Remove components from DCS control panel assembly (6, Figure 4-18). Refer to paragraphs 4.8.2 through 4.8.15. Remove locknut (1), screw (2), and panel holder (3) from DCS control panel assembly (6 ). Remove hook on panel holder from hole in DCS control panel frame (14). Remove locknuts (4), bolts (5), and DCS control panel assembly (6) from hinge (9). Remove locknuts (7), bolts (8), and hinge (9) from DCS control panel frame (14).
(5)
(6) (7) b.
Inspection. Inspect DCS control panel assembly (6, Figure 4-18) for dents, cracks, loose paint, and corrosion.
c.
Repair.
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(1)
As necessary, remove components from DCS control panel assembly (6), paragraphs 4.8.2 through 4.8.15. _________ WARNING CARC paint is a health hazard. Wear protective eyewear, mask and gloves when sanding CARC painted surfaces. Failure to comply can cause personal injury.
(2) (3) (4) (5) d.
Repair all dents and cracks, and remove loose paint. Remove light corrosion with fine grit abrasive paper (Item 16, Appendix E). Repaint surfaces in accordance with TM 43-0139. Install components removed in step (1), paragraphs 4.8.2 through 4.8.15.
Installation. (1) (2) (3) Install hinge (9, Figure 4-18), bolts (8), and locknuts (7) on DCS control panel frame (14). Install DCS control panel assembly (6), bolts (5), and locknuts (4) on hinge (9). Install hook on panel holder (3) in hole in DCS control panel frame (14). Install panel holder (3), screw (2), and locknut (1) on DCS control panel assembly (6). Install components, paragraphs 4.8.2 through 4.8.15. Raise and secure DCS control panel. Connect negative battery cable to battery, and close BATTERY ACCESS door.
(4) (5) (6)
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FIGURE 4-18. DCS CONTROL BOX PANELS
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ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 4.8.40 DCS Control Panel Frame. a. Inspection. Inspect DCS control panel frame (14, Figure 4-18) for dents, cracks, loose paint, and corrosion. b. Removal. (1) (2) (3) (4) (5) (6) (7) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Remove DCS control box assembly, paragraph 4.8.1. Remove CIM, paragraph 4.8.16 Remove keypad assembly, paragraph 4.8.17. Remove DCS control panel assembly, paragraph 4.8.39. Remove COMMUNICATION RECEPTACLE, paragraph 4.8.18. Do not disconnect electrical leads from COMMUNICATION RECEPTACLE. Remove PARALLELING RECEPTACLE, paragraph 4.8.19. Do not disconnect electrical leads from PARALLELING RECEPTACLE. Remove CONVENIENCE RECEPTACLE, paragraph 4.8.20. Remove locknuts (10 and 12, Figure 4-18), bolts (11 and 13), and DCS control panel frame (14) from DCS control box assembly (Figure 4-10). If necessary, drill out rivets (15 and 17, Figure 4-18), and remove data plates (16 and 18).
(8)
(9) (10)
(11) c.
Repair. __________ WARNING CARC paint is a health hazard. Wear protective eyewear, mask and gloves when sanding CARC painted surfaces. Failure to comply can cause personal injury. (1) (2) (3) Repair all dents and cracks, and remove loose paint. Remove light corrosion with fine grit abrasive paper (Item 16, Appendix E). Repaint surfaces in accordance with TM 43-0139.
d.
Installation. (1) If removed, install data plates (16 and 18, Figure 4-18) on DCS control panel (14) with rivets (15 and 17).
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ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 (2) Apply continuous bead, approximately .12 inch in diameter, of sealant (Item 18, Appendix E) to mating surfaces of DCS control panel frame (14), DCS control box bottom (42), and side panels (26 and 27). Immediately install DCS control panel frame (14), bolts (13 and 11), and locknuts (12 and 10) on DCS control box assembly (Figure 4-10). Install CONVENIENCE RECEPTACLE, paragraph 4.8.20. Install PARALLELING RECEPTACLE, paragraph 4.8.19. Install COMMUNICATION RECEPTACLE, paragraph 4.8.18. Install DCS control panel assembly, paragraph 4.8.39. Install keypad assembly, paragraph 4.8.17. Install CIM, paragraph 4.8.16. Install DCS control box assembly, paragraph 4.8.1. Connect negative battery cable to battery, and close BATTERY ACCESS door.
(3) (4) (5) (6) (7) (8) (9) (10) 4.8.41
DCS Control Box Side Panels. a. Removal. (1) (2) (3) (4) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Remove DCS control box top panel, paragraph 4.7.2. Remove locknuts (12, Figure 4-18) and bolts (13) securing side panels (26 and 27) to DCS control panel frame (14). Open output box access door (Figure 1-2), and remove locknuts (19) and bolts (20) securing side panel (27) to generator set. Remove bolts (21), lockwashers (22), and washers (23) securing side panels (26 and 27) to generator set. Remove locknuts (24), bolts (25), and side panels (26 and 27) from DCS control box assembly. Remove locknuts (28), bolts (29), and air baffle (30) from side panel (27).
(5)
(6)
(7) (8) b.
Inspection. (1) (2) Inspect DCS control panel frame (14, Figure 4-18) for dents, cracks, loose paint, and corrosion. Inspect for missing or damaged cage nuts (31).
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c.
Repair. __________ WARNING CARC paint is a health hazard. Wear protective eyewear, mask and gloves when sanding CARC painted surfaces. Failure to comply can cause personal injury. (1) (2) (3) (4) Repair all dents and cracks, and remove loose paint. Remove light corrosion with fine grit abrasive paper (Item 16, Appendix E). Repaint surfaces in accordance with TM 43-0139. Replace missing or damaged cage nuts (31).
d.
Installation. (1) Apply continuous bead, approximately .12 inch in diameter, of sealant (Item 18, Appendix E) to mating surfaces of air baffle (30, Figure 4-18) and side panel (27). Immediately install air baffle (30), bolts (29), and locknuts (28) on side panel. Install side panels (27 and 26), bolts (25), and locknuts (24) on DCS control box assembly. Secure side panels (27 and 26) to generator set with washers (23), lockwashers (22), and bolts (21). Secure side panel (27) to generator set with bolts (20) and locknuts (19). Close output box access door (Figure 1-2). Apply continuous bead, approximately .12 inch in diameter, of sealant (Item 18, Appendix E) to mating surfaces of side panels (27 and 26, Figure 4-18). Immediately secure side panels (26 and 27) to DCS control panel frame (14) with bolts (13) and locknuts (12). Install DCS control box top panel, paragraph 4.7.2. Connect negative battery cable to battery, and close BATTERY ACCESS door.
(2) (3) (4)
(5)
(6) (7) 4.8.42
DCS Control Box Bottom. a. Removal. (1) (2) (3) (4) (5) (6) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Remove DCS control box assembly, paragraph 4.8.1. Remove control box components, paragraphs 4.8.21 through 4.8.36. Remove DCS control panel frame, paragraph 4.8.40. Remove DCS control box side panels, paragraph 4.8.41.
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ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 (7) Remove bolts (32, Figure 4-18), lockwashers (33), washers (34), and mounting bracket (35) from DCS control box bottom (42). Remove locknuts (36), screws (37), and relay track (38) from DCS control box bottom (42). Remove locknuts (39), screws (40), and latch plate (41) from DCS control box bottom (42). Remove screws (30, Figure 4-15), lockwashers (31), washers (32), and standoffs (21 and 26) from DCS control box bottom (42, Figure 4-18).
(8) (9) (10)
b.
Inspection. (1) (2) Inspect DCS control panel bottom (42, Figure 4-18) for dents, cracks, loose paint, and corrosion. Inspect for missing or damaged cage nuts (43).
c.
Repair. __________ WARNING CARC paint is a health hazard. Wear protective eyewear, mask and gloves when sanding CARC painted surfaces. Failure to comply can cause personal injury. (1) (2) (3) (4) Repair all dents and cracks, and remove loose paint. Remove light corrosion with fine grit abrasive paper (Item 16, Appendix E). Repaint surfaces in accordance with TM 43-0139. Replace missing or damaged cage nuts (43).
d.
Installation. (1) Install standoffs (21 and 26, Figure 4-15), washers (32), lockwashers (31), and screws (30) on DCS control box bottom (42, Figure 4-18). Install latch plate (41), screws (40), and locknuts (39) on DCS control box bottom (42). Install relay track (38), screws (37), and locknuts (36) on DCS control box bottom (42). Install mounting bracket (35), washers (34), lockwashers (33), and bolts (32) on control box bottom (42). Install DCS control box side panels, paragraph 4.8.41. Install DCS control panel frame, paragraph 4.8.40. Install control box components, paragraphs 4.8.21 through 4.8.36. Install DCS control box assembly, paragraph 4.8.1. Connect negative battery cable to battery, and close BATTERY ACCESS door.
(2) (3) (4)
(5) (6) (7) (8) (9)
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ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 4.8.43 DCS Data Plates. a. Inspection. Inspect data plates for readability and loose or missing rivets. Refer to paragraph 1.11.2, Figure 1-3, for locations of data plates on DCS control box assembly. Replacement. (1) Drill out rivets, and remove data plate from DCS control box assembly. Refer to paragraph 1.11.2, Figure 1-3. Install data plate on housing with rivets.
b.
(2) 4.9
MAINTENANCE OF AIR INTAKE AND EXHAUST SYSTEM. __________ WARNING When disconnecting or removing batteries, disconnect the negative lead that connects directly to the grounding stud first. Disconnect the negative end of the interconnection cable next. When installing batteries, reverse the connection sequence. Failure to comply can cause serious personal injury.
4.9.1
Muffler and Exhaust Pipe. __________ WARNING Exhaust system can get very hot. Allow system to cool before performing maintenance. Failure to comply can cause severe burns and injury to personnel. a. Inspection. (1) (2) (3) Shut down generator set, paragraph 2.11.2. Remove top housing panel. Refer to paragraph 4.7.3. Open engine compartment access doors (Figures 1-2 and 1-3). Inspect muffler assembly (3, Figure 4-19) and exhaust pipe (8) for cracks, excessive corrosion, clogging, and other damage. Replace damaged parts, refer to paragraph 4.9.1.b. Install top housing panel. Refer to paragraph 4.7.3. Close engine compartment access doors.
(4) (5) (6) b.
Replacement. (1) (2) (3) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Remove top housing panel and roof stiffener assembly. Refer to paragraph 4.7.3.
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FIGURE 4-19. MUFFLER AND EXHAUST PIPE
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ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 (4) (5) (6) Remove muffler clamp (1, Figure 4-19) from exhaust pipe (8). Remove bands (2) from muffler assembly (3) and supports (7). Separate exhaust pipe (8) from muffler assembly (3), and remove muffler assembly from generator set. Remove boltss (4), lockwashers (5), washers (6), and supports (7) from top section floor panel. Loosen V-band clamp (9) at turbocharger outlet. Remove exhaust pipe (8) and V-band clamp (9) from turbocharger outlet. Inspect muffler assembly (3, Figure 4-19) and exhaust pipe (8) for cracks, excessive corrosion, clogging, and other damage. Position V-band clamp (9) and exhaust pipe (8) on turbocharger outlet. Tighten clamp. Install supports (7), washers (6), lockwashers (5), and boltss (4) on top section floor panel. Install muffler (3) and bands (2) on supports (7). Position exhaust pipe (8) on muffler (3), and install muffler clamp (1). Install roof stiffener assembly and top housing panel. Refer to paragraph 4.7.3. Connect negative battery cable to battery, and close BATTERY ACCESS door.
(7) (8) (9) (10)
(11) (12) (13) (14) (15) (16) 4.9.2
Air Cleaner Assembly. a. Inspection. (1) (2) (3) (4) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Remove DCS control box assembly, paragraph 4.8.1. Inspect air cleaner assembly (1, Figure 4-20) and mounting bracket (2) for cracks, dents, blockage, debris, and other damage. Install DCS control box assembly, paragraph 4.8.1. Connect negative cable to battery. Close BATTERY ACCESS door.
(5) (6) b.
Service. (1) (2) (3) Remove air cleaner filter element, Paragraph 4.9.4. Wipe inside of air cleaner housing (3, Figure 4-20) with cleaning cloth (Item 8, Appendix E). Install new air cleaner filter element, Paragraph 4.9.4.
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FIGURE 4-20. AIR CLEANER ASSEMBLY
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ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 c. Removal. (1) (2) (3) (4) (5) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door, and disconnect negative battery cable. Remove DCS control box assembly, paragraph 4.8.1. Loosen hose clamp (4, Figure 4-20), and remove elbow (5) from air cleaner housing (3). Remove nuts (6), lockwashers (7), washers (8), bolts (9), and air cleaner assembly (1) from generator set. Remove nuts (10), lockwashers (11), bolts (12), and mounting bracket (2) from air cleaner housing (3).
(6)
d.
Installation. (1) Using removed components, install mounting bracket (2, Figure 4-20), bolts (12), lockwashers (11), and nuts (10) on air cleaner housing (3). Using removed components, install air cleaner assembly (1), bolts (9), washers (8), lockwashers (7), and nuts (6) on generator set. Position elbow (5) and hose clamp (4) on air cleaner housing (3). Tighten hose clamp. Install DCS control box assembly, paragraph 4.8.1. Connect negative battery cable to battery. Close BATTERY ACCESS door.
(2)
(3) (4) (5) 4.9.3
Restriction Indicator. a. Inspection. (1) (2) Shut down generator set, paragraph 2.11.2. Open left side engine compartment access doors (Figure 1-3). __________ WARNING Exhaust system can get very hot. Allow system to cool before performing maintenance. Failure to comply can cause severe burns and injury to personnel. NOTE Restriction indicator is located halfway between the left side engine access door and the rear of the generator set. It may be necessary to use a flashlight to see the indicator. (3) (4) Inspect restriction indicator (13, Figure 4-20) for cracks, stripped threads, or other damage. Close engine compartment access doors.
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b.
Replacement. (1) (2) Shut down generator set, paragraph 2.11.2. Open left side engine compartment access doors (Figure 1-3). NOTE Restriction indicator is located halfway between the left side engine access door and the rear of the generator set. It may be necessary to use a flashlight to see the indicator. (3) (4) (5) Remove restriction indicator (13, Figure 4-20) from air cleaner housing (3). Install restriction indicator (13) on air cleaner housing (3). Tighten indicator fingertight. Close engine compartment access doors.
4.9.4
Air Cleaner Filter Element. a. Removal. (1) (2) (3) Shut down generator set, paragraph 2.11.2. Open AIR CLEANER ACCESS door (Figure 1-3). Loosen wing nut (14, Figure 4-20), and remove end cap assembly (15) from rod (16) in air cleaner housing (3). Remove wing nut (17) and filter element (18) from rod (16).
(4) b.
Inspection. (1) (2) (3) (4) (5) (6) Shut down generator set, paragraph 2.11.2. Remove air cleaner filter element, step a above. Inspect filter element (18, Figure 4-20) for debris and damage. Replace as necessary. Inspect vacuator valve (19) for clogging and debris. Clear as necessary. Wipe inside of air cleaner housing (3) with clean, lint-free cloth (Item 8, Appendix E). Install air cleaner filter element, step c below.
c.
Installation. (1) (2) (3) Install filter element (18, Figure 4-20) and wing nut (17) on rod (16). Install end cap assembly (15) on rod (16). Tighten wing nut (14) fingertight. Close AIR CLEANER ACCESS door.
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ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 4.9.5 Air Cleaner Hoses. a. Inspection. (1) (2) (3) (4) (5) (6) b. Shut down generator set, paragraph 2.11.2. Open left side engine compartment access doors (Figure 1-3). Inspect all hoses and tubing (5, 21, 22, and 23, Figure 4-20) for cracks, tears, and holes. Inspect hose clamps (4 and 20) for cracks. Replace parts as necessary. Close engine compartment access doors.
Removal. (1) (2) (3) (4) (5) (6) (7) Shut down generator set, paragraph 2.11.2. Open left side engine compartment access doors (Figure 1-3). Loosen hose clamps (4 and 20, Figure 4-20). Remove elbow (5) from air cleaner housing (3) and tube assembly (21). Remove tube assembly (21) from breather hose (23) and hump hose (22). Remove hump hose (22) from turbocharger. Remove breather hose (23) from oil breather outlet on valve cover.
c.
Service. (1) (2) (3) Remove air cleaner hoses, step b above. Clean hoses and tubing with cleaning cloth (Item 8, Appendix E) and with water. Install air cleaner hoses, step d below.
d.
Installation. (1) Position hose clamp (20, Figure 4-20) on breather hose (23), and install breather hose on oil breather. Position hose clamp (4) on hump hose (22), and install hump hose on turbocharger. Position hose clamp (4) on hump hose (22), and install hump hose on tube assembly (21). Position hose clamp (20) on breather hose (23), and install breather hose on tube assembly (21). Position hose clamps (4) on elbow (5), and install elbow on air cleaner housing (3) and tube assembly (21).
(2) (3) (4) (5)
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ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 (6) (7) Tighten hose clamps (4 and 20). Close engine compartment access doors.
4.9.6
Crankcase Breather Filter Assembly. a. Inspection. (1) Shut down generator set, paragraph 2.11.2. __________ WARNING Exhaust system can get very hot. Allow system to cool before performing maintenance. Failure to comply can cause severe burns and injury to personnel. (2) (3) Open right side engine compartment access doors (Figure 1-2). Inspect sight glass (1, Figure 4-21). If fluid is visible, drain by positioning suitable container under crankcase breather filter assembly (18) and loosening drain valve (2). Tighten drain valve when complete. Properly dispose of fluid. Inspect flex hoses (10 and 21), heater tape (11 and 12), and insulation (14) for cracks, holes, dry rot, and damaged or missing hose clamps (9 and 13). Inspect crankcase breather filter assembly (18) and bracket (17) for cracks, excessive corrosion, and other damage. Clean light corrosion from bracket (17) and hose attaching points with fine grit abrasive paper (Item 16, Appendix E). Replace damaged parts. Close engine compartment access doors.
(4)
(5)
(6)
(7) (8) b.
Service. __________ WARNING Exhaust system can get very hot. Allow system to cool before performing maintenance. Failure to comply can cause severe burns and injury to personnel. (1) (2) (3) (4) (5) Shut down generator set, paragraph 2.11.2. Open right side engine compartment access doors (Figure 1-2). While supporting housing (4, Figure 4-21), loosen collar (3), and remove housing from head (5). Remove o-ring (27), end cap (6), filter (7), and filter holder (8) from head (5). Discard filter. Install filter holder (8), new filter (7), and end cap (6) in head (5).
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ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 (6) (7) c. Test. (1) (2) (3) (4) Shut down generator set, paragraph 2.11.2. Open output control box door, refer to Figure 1-2. Test heater by disconnecting wires 351A16 and 350A16 at TB7-B10. Measure resistance between heater wire 350A16 (HTR1) and ground. Resistance should be 199233 ohms. Replace heater if resistance is out of tolerance. Measure resistance between heater wire 351A16 (HTR2) and ground. Resistance should be 370432 ohms. Replace heater if resistance is out of tolerance. Disconnect heater thermostat at terminals TB7-A8 and TB7-A10 and remove from generator set. Test heater thermostat by checking continuity. Thermostat switch should open at temperatures above 20 F. Expose thermostat to temperature below 15 F. Thermostat should close and have continuity. Replace if defective. Position housing (4) on head (5) with sight glass (1) visible, and secure with collar (3). Close engine compartment access doors.
(5)
(6)
d.
Removal. (1) Shut down generator set, paragraph 2.11.2. __________ WARNING Exhaust system can get very hot. Allow system to cool before performing maintenance. Failure to comply can cause severe burns and injury to personnel. (2) (3) Open right side engine compartment access doors (Figure 1-2). Peel back insulation (14, Figure 4-21) as required to expose heater tapes (11 and 12). Unwind heater tapes from assembly and remove from generator set. Loosen hose clamps (9 and 13), and remove flex hoses (10 and 21) from crankcase filter assembly (18). While supporting crankcase filter assembly (18), remove screws (15), lockwashers (16), from bracket (17). Note position of arrow on head of assembly in relation to the bracket for installation later. Remove crankcase filter assembly (18) from generator set. As required, remove flex hose (10) from crankcase breather and flex hose (21) from exhaust pipe. Remove bracket (17) from engine air intake pipe (20). As required, remove nipple (26), elbow (25), nipple (24) elbow (23) and adapter (22) from head (5) of crankcase breather filter (18). On other side of head (5), remove adapter (19).
(4)
(5)
(6)
(7)
e.
Installation. NOTE
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ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 In step (1), apply sealing compound (Item 22, Appendix E) to pipe threads of components as they are installed. (1) Install nipple (26), elbow (25), nipple (24) elbow (23) and adapter (22) to head (5) of crankcase breather filter (18). On other side of head (5), install adapter (19) to crankcase breather filter (18). Install flex hose (10) to crankcase breather and flex hose (21) to exhaust pipe. Position bracket (17) on crankcase breather filter assembly (18) with arrow aligned as noted in step (5), and secure with lockwashers (16) and screws (15). Position bracket (17) on engine air intake pipe (20), and secure bracket to pipe with hose clamps (13). Connect flex hoses (10 and 21) to adapters (19 and 22), and secure with hose clamps (9 and 13). Close engine compartment access doors.
(2) (3)
(4)
(5) (6) 4.10
MAINTENANCE OF ENGINE COOLING SYSTEM. __________ WARNING When disconnecting or removing batteries, disconnect the negative lead that connects directly to the grounding stud first. Disconnect the negative end of the interconnection cable next. When installing batteries, reverse the connection sequence. Failure to comply can cause serious personal injury.
4.10.1
Engine Cooling System. a. Testing. (1) Shut down generator set, paragraph 2.11.2. __________ WARNING Cooling system operates at high temperature and pressure. Contact with high pressure steam and/or liquids can result in burns and scalding. Shut down generator set, and allow system to cool before performing checks, services, and maintenance. Failure to comply can cause injury to personnel. (2) (3) (4) Slowly remove radiator cap (1, Figure 4-22) from filler neck (2). Install cooling system pressure tester (Appendix B, Section III) in filler neck (2). Open engine compartment access doors (Figures 1-2 and 1-3).
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FIGURE 4-21 CRANKCASE BREATHER FILTER ASSEMBLY
4-152
FIGURE 4-22. COOLING SYSTEM (SHEET 1 OF 2)
4-153
FIGURE 4-22. COOLING SYSTEM (SHEET 2 OF 2) (5) (6) Pump pressure tester until 8 psi is indicated. Check cooling system for leaks. Install radiator cap (1) on pressure tester, and pump tester until 101 psi is indicated. Ensure radiator cap releases. Release pressure from pressure tester, and remove tester from filler neck (2) and radiator cap (1) from tester. Install radiator cap (1) on filler neck (2). Close engine compartment access doors.
(7)
(8) (9) b.
Service. (1) (2) (3) Shut down generator set, paragraph 2.11.2. Open left side engine compartment access doors (Figure 1-3). Flush or drain cooling system in accordance with Preventive Cleaning procedures contained in TM 750-254. Close engine compartment access doors.
(4) 4.10.2
Filler Hose and Panel.
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a.
Removal. (1) (2) (3) Shut down generator set, paragraph 2.11.2. Open engine compartment access doors (Figures 1-2 and 1-3). Remove top housing panel. Refer to paragraph 4.7.3. __________ WARNING Cooling system operates at high temperature and pressure. Contact with high pressure steam and/or liquids can result in burns and scalding. Shut down generator set, and allow system to cool down before performing checks, services, and maintenance. Failure to comply can cause injury to personnel. (4) (5) Slowly remove radiator cap (1, Figure 4-22) from filler neck (2). Open coolant drain valve (33), and drain coolant/antifreeze into suitable container to a level below filler hose (4) connection at radiator. Properly dispose of fluid. Loosen hose clamps (3), and remove filler hose (4) and hose clamps from radiator and filler neck (2). Loosen hose clamp (5), and disconnect overflow hose (6) from filler neck (2). Remove radiator fill panel (7) and filler neck (2) from generator set. Remove locknuts (8), bolts (9), chain (10), and filler neck (2) from radiator fill panel (7).
(6)
(7) (8) (9) b.
Inspection. (1) (2) (3) (4) Shut down generator set, paragraph 2.11.2. Remove filler hose and panel, step a above. Inspect filler hose (4, Figure 4-22) for cracks, holes, and dry rot. Inspect radiator fill panel (7), filler neck (2), and radiator cap (1) for cracks, excessive corrosion, and other damage. Clean light corrosion from filler hose attaching points with fine grit abrasive paper (Item 16, Appendix E). Replace damaged parts. Install filler hose and panel, step c below.
(5)
(6) (7) c.
Installation. (1) (2) Install filler neck (2, Figure 4-22), chain (10), bolts (9), and locknuts (8) on radiator fill panel (7). Position radiator fill panel (7) and filler neck (2) in generator set.
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ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 (3) (4) (5) (6) (7) (8) Position overflow hose (6) and hose clamp (5) on filler neck (2). Tighten hose clamp. Position filler hose (4) and hose clamps (3) on filler neck (2) and radiator. Tighten hose clamps. Close coolant drain valve (33), and add coolant/antifreeze to proper level at the filler neck (2). Install radiator cap (1) on filler neck (2). Install top housing panel. Refer to paragraph 4.7.3. Start generator set, paragraph 2.11.1. Allow unit to reach operating temperature, and check for leaks. Add coolant/antifreeze to overflow bottle as required, paragraph 3.3.4. Close engine compartment access doors.
(9) (10) 4.10.3
Fan Guards. CAUTION Fan shroud must be installed when operating Generator Set. a. Removal. (1) (2) (3) (4) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Open right side engine compartment access doors (Figure 1-2). Remove bolts (1, Figure 4-23), washers (2), lockwashers (3), and right fan guard (5) from brackets (10, and 11). Remove bolt (14), lockwasher (13), washer (12), and bracket (9) from engine. Remove bolts (14), lockwashers (13), washers (12), and brackets (10 and 11) from shroud. Open left side engine compartment access doors (Figure 1-3). Remove bolts (1), washers (2), lockwashers (3), and left fan guard (4) from brackets (6, 7, and 8). Remove bolt (14), lockwasher (13), washer (12), and bracket (6) from engine. Remove bolts (14), lockwashers (13), washers (12), and brackets (7 and 8) from shroud.
(5) (6) (7) (8) (9) (10)
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FIGURE 4-23. FAN GUARDS
4-157
b.
Inspection.
(1) (2) (3)
Shut down generator set, paragraph 2.11.2. Open engine compartment access doors (Figures 1-2 and 1-3). Inspect fan guards (4 and 5, Figure 4-23), brackets (6, 7, 8, 9, 10 and 11), and attaching hardware for damage, corrosion, and loose or missing hardware. Replace all damaged and missing components. Tighten all loose attaching hardware. If necessary, install new protective edging (15), cut to fit. Close engine compartment access doors.
(4) (5) (6) c.
Installation. (1) (2) (3) (4) (5) (6) (7) (8) (9) Install brackets (7 and 8, Figure 4-23), washers (12), lockwashers (13), and bolts (14) on shroud. Install bracket (6), washer (12), lockwasher (13), and bolt (14) on engine. Install left fan guard (4), lockwashers (3), washers (2), bolts (1) on brackets (6, 7, and 8). Close left side engine compartment doors. Install brackets (10 and 11), washers (12), lockwashers (13), and bolts (14) on shroud. Install bracket (9), washer (12), lockwasher (13), and bolt (14) on engine. Install right fan guard (5), lockwashers (3), washers (2), bolts (1) on brackets (10 and 11). Close right side engine compartment access doors. Connect negative battery cable to battery, and close BATTERY ACCESS door.
4.10.4
Coolant Hoses, Upper a. Removal. (1) (2) (3) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Open engine compartment access doors (Figures 1-2 and 1-3).
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__________ WARNING Cooling system operates at high temperature and pressure. Contact with high pressure steam and/or liquids can result in burns and scalding. Shut down generator set, and allow system to cool down before performing checks, services, and maintenance. Failure to comply can cause injury to personnel. (4) (5) (6) (7) Slowly remove radiator cap (1, Figure 4-22) from filler neck (2). Remove fan guards, paragraph 4.10.3. Open coolant drain valve (33), and drain coolant/antifreeze into suitable container. Loosen hose clamps (11). Remove upper coolant hose (49) and hose clamps from radiator (32) and copper T (47). Loosen hose clamps (11). Remove upper coolant hose (12) and hose clamps from copper T (47) and thermostat housing opening. Loosen hose clamp (3). Remove copper T (47).
(8)
(9) b.
Inspection. (1) (2) (3) (4) Shut down generator set, paragraph 2.11.2. Remove upper coolant hoses, step a above. Inspect upper coolant hose (12 and 49, Figure 4-22) for cracks, holes, and rotting. Clean light corrosion from upper coolant hose attaching points with fine grit abrasive paper (Item 16, Appendix, E). Install upper coolant hoses, step c below.
(5) c.
Installation. (1) (2) Install copper T (47) and tighten clamp (3). Position upper coolant hose (12, Figure 4-22) and hose clamps (11) on thermostat housing opening and copper T (47). Tighten hose clamps. Position upper coolant hose (49) and hose clamps (11) on copper T (47) and radiator (32). Tighten Clamps. Close coolant drain valve (33), and add coolant/antifreeze to proper level at the filler neck (2). Install fan guards, paragraph 4.10.3. Install radiator cap (1) on filler neck (2). Connect negative battery cable to battery, and close BATTERY ACCESS door.
(3)
(4) (5) (6) (7)
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ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 (8) Start generator set, paragraph 2.11.1. Allow unit to reach operating temperature, and check for leaks. Add coolant/antifreeze to overflow bottle as required. Close engine compartment access doors. Shutdown generator set.
(9) (10) (11)
4.10.5
Coolant Hose, Lower a. Removal. (1) (2) (3) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Open engine compartment access doors (Figures 1-2 and 1-3). _________ WARNING Cooling system operates at high temperature and pressure. Contact with high pressure steam and/or liquids can result in burns and scalding. Shut down generator set, and allow system to cool before performing checks, services, and maintenance. Failure to comply can cause injury to personnel. (4) (5) (6) (7) Slowly remove radiator cap (1, Figure 4-22) from filler neck (2). Remove fan guards, paragraph 4.10.3. Open coolant drain valve (33), and drain coolant/antifreeze into suitable container. Loosen hose clamps (13). Remove lower coolant hose (14) and hose clamps from radiator outlet opening and water pump opening.
b.
Inspection. (1) (2) (3) (4) (5) Shut down generator set, paragraph 2.11.2. Remove lower coolant hose, step a above. Inspect lower coolant hose (14, Figure 4-22) for cracks, holes, and rotting. Clean exterior of lower radiator outlet tube with fine grit abrasive paper (Item 16, Appendix, E). Install lower coolant hose, step c below.
c.
Installation. (1) Position lower coolant hose (14, Figure 4-22) and hose clamps (13) on water pump opening and radiator outlet opening. Tighten hose clamps. Close coolant drain valve (33), and add coolant/antifreeze to proper level at the filler neck (2).
(2)
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(3) (4) (5) (6)
Install fan guards, paragraph 4.10.3. Install radiator cap (1) on filler neck (2). Connect negative battery cable to battery, and close BATTERY ACCESS door. Start generator set, paragraph 2.11.1. Allow unit to reach operating temperature, and check for leaks. Add coolant/antifreeze to overflow bottle as required. Close engine compartment access doors. Shut down generator set.
(7) (8) (9) 4.10.6
Coolant Overflow and Drain Hoses. a. Removal. (1) (2) (3) (4) (5) (6) b. Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Open engine compartment access doors (Figures 1-2 and 1-3). Open coolant drain valve (33, Figure 4-22), and drain coolant/antifreeze into suitable container. Locate overflow or drain hose to be removed as shown in Figure 4-22. Disconnect hose at both ends, and remove from generator set.
Inspection. (1) (2) (3) (4) Shut down generator set, paragraph 2.11.2. Open engine compartment access doors (Figures 1-2 and 1-3). Inspect hoses (15, Figure 4-22) for cracks, holes, and rotting. Close engine compartment access doors.
c.
Installation. (1) (2) (3) (4) Install overflow or drain hose (15, Figure 4-22) in generator set as removed. Close coolant drain valve (33), and add coolant/antifreeze to proper level at the filler neck (2). Connect negative battery cable to battery, and close BATTERY ACCESS door. Start generator set, paragraph 2.11.1. Allow unit to reach operating temperature, and check for leaks. Add coolant/antifreeze to overflow bottle as required.
(5)
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(6) (7) 4.10.7 Radiator. a.
Close engine compartment access doors. Shut down generator set.
Removal. (1) (2) (3) Shut down generator set, paragraph 2.11.2. Open engine compartment access doors (Figures 1-2 and 1-3). Remove top housing section, paragraph 4.7.3. __________ WARNING Cooling system operates at high temperature and pressure. Contact with high pressure steam and/or liquids can result in burns and scalding. Shut down generator set, and allow system to cool before performing checks, services, and maintenance. Failure to comply can cause injury to personnel. (4) (5) (6) (7) (8) (9) (10) (11) Slowly remove radiator cap (1, Figure 4-22) from filler neck (2). Remove fan guards, paragraph 4.10.3. Open coolant drain valve (33), and drain coolant/antifreeze into suitable container. Remove filler hose and panel, paragraph 4.10.2. Remove upper coolant hoses, paragraph 4.10.4. Remove lower coolant hose, paragraph 4.10.5. Remove bolts (16), lockwashers (17), and washers (18), and allow shroud (19) to rest on fan (40). Remove nuts (20), lockwashers (21), bolts (22), washers (23), and support tie-rods (24) from bracket on engine. Remove bolts (25), lockwashers (26), support tie-rods (24), and spacers (27) from radiator (32). Loosen hose clamp (28), and disconnect drain hose (29) from coolant drain valve (33). Remove locknuts (30) and washers (31) securing radiator (32) to radiator support (37). Lift radiator (32) up and out of generator housing. Remove coolant drain valve (33) from radiator (32). If necessary, remove nuts (34), lockwashers (35), bolts (36), and radiator support (37) from generator set.
(12) (13) (14) (15) (16) (17)
b.
Service.
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ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 (1) (2) (3) (4) Shut down generator set, paragraph 2.11.2. Remove radiator, step a above. Inspect radiator for excessive corrosion and scale. Check inside of radiator for corrosion and scale. __________ WARNING Cleaning with compressed air can cause flying particles. When using compressed air, wear protective glasses and use clean, low pressure air, less than 30 psi (206.8 kPa). Failure to comply can cause eye injury. (5) (6) (7) c. Clean dirt particles from radiator core air passages using filtered, compressed air, 30 psi maximum. Clean exterior surface of radiator with soap and water. Install radiator, step d below.
Repair. For repair, refer to paragraph 5.6.1.
d.
Installation. (1) If removed, install radiator support (37, Figure 4-22), bolts (36), lockwashers (35), and nuts (34) on generator set. Install coolant drain valve (33) on radiator (32). Position radiator (32) on radiator support (37), and install washers (31) and locknuts (30). Install shroud (19), washers (18), lockwashers (17), and bolts (16). Position hose clamp (28) and drain hose (29) on coolant drain valve (33). Tighten hose clamp. Install spacers (27), support tie-rods (24), lockwashers (26), and bolts (25) on radiator (32). Install support tie-rods (24), washers (23), bolts (22), lockwashers (21), and nuts (20) on bracket on engine. Install lower coolant hose, paragraph 4.10.5. Install upper coolant hoses, paragraph 4.10.4. Install filler hose and panel, paragraph 4.10.2. Install fan guards, paragraph 4.10.3. Install top section housing, paragraph 4.7.3. Close coolant drain valve (33), and add coolant/antifreeze to proper level, paragraph 3.3.4.
(2) (3) (4) (5) (6) (7)
(8) (9) (10) (11) (12) (13)
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ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 (14) (15) Install radiator cap (1) on filler neck (2). Start generator set, paragraph 2.11.1. Allow unit to reach operating temperature, and check for leaks. Add coolant/antifreeze to overflow bottle as required. Close engine compartment access doors.
(16) (17) 4.10.8 Fan. a.
Removal. (1) (2) (3) (4) (5) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Open engine compartment access doors (Figures 1-2 and 1-3). Remove fan guards, paragraph 4.10.3. Remove bolts (16, Figure 4-22), lockwashers (17), and washers (18), and allow shroud (19) to rest on fan (40). Remove bolts (38), lockwashers (39), fan (40), and spacer (41) from engine water pump. Remove locknuts (42), screws (43), stiffeners (44), supports (45), and seals (46) from shroud (19).
(6) (7) b.
Inspection. (1) (2) (3) (4) (5) Shut down generator set, paragraph 2.11.2. Remove fan, step a above. Inspect fan (40, Figure 4-22) and blades for cracks, bends, loose rivets, or other damage. Inspect spacer (41) for cracks or other damage. Inspect seals (46), supports (45), and stiffeners (44) for damage. NOTE If installing new seals, screw holes need to be match drilled at assembly. (6) (7) Replace damaged parts. Install fan, step c below
c.
Installation. (1) Install seals (46, Figure 4-22), supports (45), stiffeners (44), screws (43), and locknuts (42) on Shroud (19). Position Spacer (41), fan (40), and shroud (19) in generator set.
(2)
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FIGURE 4-24. FAN BELT
(3)
Secure fan (40) and spacer (41) to engine water pump with lockwashers (39) and bolts (38). Torque bolts to 24 ft-lb (32 Nm). Install shroud (19), washers (18), lockwashers (17), and bolts (16). Install fan guards, paragraph 4.10.3. Connect negative battery cable to battery, and close BATTERY ACCESS door.
(4) (5) (6) 4.10.9 a.
Fan Belt. Inspection. (1) (2) (3) (4) (5) (6) (7) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2). Disconnect negative battery cable. Open engine compartment access doors (Figures 1-2 and 1-3). Remove fan guards, paragraph 4.10.3 Inspect fan belt (1, Figure 4-24) for fraying, cracks, oil soaking or other damage. Replace fan belt that shows any damage or cannot be adjusted for proper tension.
4-165
(8) (9) (10) b.
Install fan guards, paragraph 4.3.10 Close engine compartment access doors. Connect negative battery cable to battery and close BATTERY ACCESS doors.
Adjustment. NOTE Run engine for 5 minutes if belt is cold. If belt is hot, let cool for 10 to 15 minutes. (1) (2) (3) (4) (5) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Open engine compartment access doors (Figures 1-2 and 1-3). Remove fan guards, paragraph 4.10.3. Check fan belt (1, Figure 4-24) for 1/2 inch (1.27 cm) deflection between alternator pulley (2) and fan pulley (6). If fan belt needs adjustment, loosen alternator mounting bolt (4) and nut (5). CAUTION Do not pry against alternator rear frame. Failure to comply can cause damage to alternator or mounting brackets. (7) (8) (9) (10) (11) Apply outward pressure to alternator front frame until belt tension is correct. Tighten alternator mounting bolt (4) and nut (5). Install fan guards, paragraph 4.10.3. Close engine compartment access doors. Connect negative battery cable to battery, and close BATTERY ACCESS door.
(6)
c.
Replacement. (1) (2) (3) (4) (5) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Open engine compartment access doors (Figures 1-2 and 1-3). Remove fan guards, paragraph 4.10.3. Loosen alternator mounting bolt (4, Figure 4-24) and nut (5).
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ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 (6) Pivot alternator to relieve tension on fan belt (1), and remove belt from alternator pulley (2), crankshaft pulley (3), and fan pulley (6). Slip fan belt (1) over fan (40, Figure 4-22), and remove fan belt from generator set. Slip fan belt (1, Figure 4-24) over fan (40, Figure 4-22). Install fan belt (1, Figure 4-24) onto from alternator pulley (2), crankshaft pulley (3), and fan pulley (6). Adjust tension on fan belt (1), step b above. Install fan guards, paragraph 4.10.3. Close engine compartment access doors. Connect negative battery cable to battery, and close BATTERY ACCESS door.
(7) (8) (9)
(10) (11) (12) (13)
4.10.10 Coolant Recovery System. a. Inspection. (1) (2) (3) (4) (5) b. Shut down generator set, paragraph 2.11.2. Open right side engine compartment access doors (Figure 1-2). Inspect coolant recovery system components for cracks, holes, or other damage. Replace damaged parts. Close engine compartment access doors.
Removal. (1) (2) Shut down generator set, paragraph 2.11.2. Open right side engine compartment access doors (Figure 1-2). __________ WARNING Cooling system operates at high temperature and pressure. Contact with high pressure steam and/or liquids can result in burns and scalding. Shut down generator set, and allow system to cool before performing checks, services, and maintenance. Failure to comply can cause injury to personnel. (3) Loosen hose clamp (1, Figure 4-25). Disconnect hose (2) from overflow bottle (5), and drain coolant into suitable container. Loosen hose clamp (3), and disconnect hose (4) from overflow bottle (5). Remove overflow bottle (5) from wire holder (11). Remove nuts (6), lockwashers (7), washers (8), washers (10), bolts (9), and wire holder (11) from mounting bracket (14).
(4) (5) (6)
4-167
(7)
Remove bolts (12), washers (13), and mounting bracket (14) from engine.
4-168
FIGURE 4-25. COOLANT RECOVERY SYSTEM c. Installation.
4-169
(1) (2)
Install mounting bracket (14, Figure 4-25), washers (13), and bolts (12) on engine. Install wire holder (11), bolts (9), washers (10), washers (8), lockwashers (7), and nuts (6) on mounting bracket (14). Install overflow bottle (5) in wire holder (11). Position hose clamps (1 and 3) and hoses (2 and 4) on overflow bottle (5). Tighten hose clamps. Fill overflow bottle (5) with coolant to the COLD level. Refer to Table 3-2 for proper coolant. Start generator set, paragraph 2.11.1. Check for leaks, and run until normal operating temperature is reached. Add coolant to HOT level of overflow bottle (5). Close engine compartment access doors.
(3) (4) (5) (6)
(7) (8)
4.11
MAINTENANCE OF FUEL SYSTEM. __________ WARNING When disconnecting or removing batteries, disconnect the negative lead that connects directly to the grounding stud first. Disconnect the negative end of the interconnection cable next. When installing batteries, reverse the connection sequence. Failure to comply can cause serious personal injury.
4.11.1
Low Pressure Fuel Lines and Fittings. a. Inspection. (1) (2) (3) (4) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable . Open engine compartment access doors (Figures 1-2 and 1-3). Inspect fuel lines and fittings for damage or leaking condition. Damaged components must be replaced. Identify components. Refer to Figure 4-26.
b.
Replacement. (1) Inspect low pressure lines and fittings. Identify damaged components found during inspection. Damaged lines and fittings must be replaced. Refer to Figure 4-26. Disconnect fuel line at both ends, and remove any clamps. Remove fuel line or fitting from generator set. Cover or cap all openings.
(2) (3) (4)
4-170
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 (5) (6) (7) (8) (9) (10) 4.11.2 Remove any caps, and position fuel line or fitting in generator set. Install any clamps as removed, and connect fuel line at both ends. Tighten clamps. Connect negative battery cable to battery, and close BATTERY ACCESS door. Start generator set, paragraph 2.11.1. Check for fuel leaks. Shut down generator set, paragraph 2.11.2. Close engine compartment access doors.
Auxiliary Fuel Pump E1. a. Inspection. (1) (2) (3) Shut down generator set, paragraph 2.11.2. Open left side engine compartment access doors (Figure 1-3). Inspect auxiliary fuel pump (11, Figure 4-26) for leaks, cracks, missing hardware, loose connections, and other damage. Close engine compartment access doors.
(4) b.
Testing. (1) Shut down generator set, paragraph 2.11.2. NOTE Ensure auxiliary fuel supply is no more than 6 feet (1.83 m) below generator set. (2) (3) (4) Connect generator set to auxiliary fuel supply. Open left side engine compartment access doors (Figure 1-3). Disconnect auxiliary fuel pump outlet line (5, Figure 4-26) at fuel tank fitting, and place disconnected end in measuring container. Move generator set ENGINE CONTROL switch to PRIME & RUN AUX FUEL position for one minute, and return ENGINE CONTROL switch to OFF position. Measuring container should collect at least 36 ounces (1.06 liters) of fuel. Properly dispose of fuel. Replace auxiliary fuel pump (11) if delivery amount is less than above. Connect auxiliary fuel pump outlet line (5) at fuel tank fitting. Disconnect generator set from auxiliary fuel supply. Close engine compartment access doors.
(5)
(6) (7) (8) (9) (10)
4-171
FIGURE 4-26. FUEL TANK FILLER NECK AND LOW PRESSURE FUEL SYSTEM (SHEET 1 OF 2)
4-172
FIGURE 4-26. FUEL TANK FILLER NECK AND LOW PRESSURE FUEL SYSTEM (SHEET 2 OF 2)
c.
Replacement. (1) (2) (3) (4) (5) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Open left side engine compartment access doors (Figure 1-3). Tag and disconnect auxiliary fuel pump (11, Figure 4-26) electrical connector. Loosen hose clamps (1). Disconnect fuel inlet hose (2) from fuel strainer (4), fitting (3) from fitting (14), and fuel inlet hose from fitting (3). Cap fuel inlet hose. Remove fuel strainer (4) from auxiliary fuel pump (11). Disconnect auxiliary fuel outlet line (5) from elbow (12). Remove nuts (6), lockwashers (7), bolts (8), washers (9), cap and chain assembly (10), and auxiliary fuel pump (11) from filler neck panel. Remove elbow (12) from auxiliary fuel pump (11). If necessary, remove locknut (13) and fitting (14) from filler neck panel.
(6) (7) (8)
(9) (10)
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ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 (11) (12) (13) If removed, install fitting (14) and locknut (13) on filler neck panel. Install elbow (12) on auxiliary fuel pump (11). Install auxiliary fuel pump (11), chain assembly (10), washers (9), bolts (8), lockwashers (7), and nuts (6) on filler neck panel. Connect auxiliary fuel outlet line (5) on elbow (12). Install fuel strainer (4) on auxiliary fuel pump (11). Remove caps from fuel inlet hose (2), and position hose clamps (1) on fuel inlet hose. Connect fuel inlet hose to fitting (3) to fitting (14), and fuel inlet hose (2) to fuel strainer (4). Tighten hose clamps. Connect auxiliary fuel pump (11) electrical connector. Remove tags. Connect negative battery cable to battery, and close BATTERY ACCESS door. Move generator set ENGINE CONTROL switch to PRIME AND RUN AUX FUEL position, and check for fuel leaks. Return ENGINE CONTROL switch to OFF position. Close engine compartment access doors.
(14) (15) (16)
(17) (18) (19)
(20) (21) 4.11.3
Fuel Tank Filler Neck. a. Removal. (1) (2) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. __________ WARNING Diesel fuel is flammable and toxic to eyes, skin, and respiratory tract. Skin and eye protection are required when working in contact with diesel fuel, and avoid repeated or prolonged contact. Failure to comply can cause injury or death to personnel. (3) (4) (5) (6) (7) (8) (9) Remove cap (28, Figure 4-26), open fuel drain valve (30), and drain fuel into a suitable container. Open left side engine compartment access doors (Figure 1-3). Remove filler neck tube and cap assembly (15) from filler neck (24). Loosen hose clamp (16), and disconnect hose (17) from connector (18). Remove connector (18) from reducer (21). Remove seal nut (19), washer (20), and reducer (21) from side of filler neck (24). Remove locknuts (22) and bolts (23) securing filler neck (24) to filler neck panel.
4-174
(10)
Loosen hose clamps (25 and 26). Remove filler neck (24), fuel fill hose (27), and hose clamps from generator set.
b.
Inspection. (1) (2) (3) (4) (5) (6) (7) Shut down generator set, paragraph 2.11.2. Remove fuel tank filler neck, step a above. Inspect fuel fill hose (27, Figure 4-26) for cracking, wear, or other damage. Inspect filler neck (24) for corrosion, cracking, or other damage. Inspect filler neck tube and cap assembly (15) for damage. Replace damaged parts. Install fuel tank filler neck, step c below.
c.
Installation. (1) (2) (3) (4) (5) (6) (7) (8) (9) Position fuel fill hose (27, Figure 4-26), clamps (25 and 26), and filler neck (24) on fuel tank. Secure filler neck (24) to filler neck panel with bolts (23) and locknuts (22). Tighten hose clamps (25 and 26). Install reducer (21), washer (20), and seal nut (19) on side of filler neck (24). Install connector (18) on reducer (21). Position hose clamp (16) on hose (17). Connect hose to connector (18), and tighten hose clamp. Install filler neck tube and cap assembly (15) in filler neck (24). Close engine compartment access doors. Close fuel drain valve (30), install cap (28), and service fuel tank. Refer to Table 4-2 for proper fuel. Connect negative battery cable to battery, and close BATTERY ACCESS door.
(10) 4.11.4
Fuel Drain Valve. Replacement. (1) (2) (3) (4) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Open left side engine compartment access doors (Figure 1-3). Remove cap (28, Figure 4-26) from adapter (29).
4-175
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 __________ WARNING Diesel fuel is flammable and toxic to eyes, skin, and respiratory tract. Skin and eye protection are required when working in contact with diesel fuel, and avoid repeated or prolonged contact. Failure to comply can cause injury or death to personnel. (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) 4.11.5 Open fuel drain valve (30), and drain fuel into a suitable container. Remove adapter (29) from fuel drain valve (30), and fuel drain valve from elbow (31). If necessary, remove elbow (31) and connector (32) from fuel tank fitting. If removed, install connector (32) and elbow (31) on fuel tank fitting. Install fuel drain valve (30) on elbow (31), and adapter (29) on fuel drain valve. Ensure fuel drain valve (30) is closed, and service fuel tank. Refer to Table 4-2 for proper fuel. Check fuel drain valve (30) and fitting for leakage. Install cap (28) on adapter (29). Close engine compartment access doors. Connect negative battery cable to battery, and close BATTERY ACCESS door.
Fuel Level Sender MT5. a. Inspection. (1) (2) (3) (4) b. Shut down generator set, paragraph 2.11.2. Open right side engine compartment access doors (Figure 1-2). Inspect fuel level sender (41, Figure 4-26) for loose connections and mounting, and other damage. Close engine compartment access doors.
Removal. (1) (2) (3) (4) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable from battery. Open right side engine compartment access doors (Figure 1-2). Remove nut (33, Figure 4-26), lockwasher (34), washer (35), and electrical lead (36) from fuel level sender (41). Tag lead.
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ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 NOTE Mark position of float when removing sender. Float must be in same position when installed to ensure clearance with fuel tank. (5) Remove screws (37), lockwashers (38), washers (39), electrical lead (40), fuel level sender (41), and gasket (42) from generator set fuel tank. Tag lead. Cover opening in fuel tank.
(6) c.
Testing. (1) (2) (3) (4) Shut down generator set, paragraph 2.11.2. Remove fuel level sender, step b above. Position fuel level sender in vertical position, similar to position as installed in fuel tank. Set multimeter for ohms. Connect positive lead to fuel level sender terminal and negative lead to fuel level sender ground. With fuel level sender arm resting freely in what would be an empty position, multimeter should indicate between 216 and 264 ohms. Move fuel level sender arm up to what would be a full position. Multimeter should indicate between 29.7 and 36.3 ohms. Replace fuel level sender if indications are not as above. Install fuel level sender, step d below.
(5)
(6)
(7) (8) d.
Installation. (1) (2) Remove cover from fuel tank opening. Thoroughly clean mating surfaces for new gasket (42, Figure 4-26). Ensure no foreign material enters fuel tank. Apply sealant (Item 21, Appendix E) to both sides of gasket. Position gasket on fuel tank. Position fuel level sender (41) in fuel tank. Ensure float is in same position as removed. Remove tag from electrical lead (40), and secure fuel level sender (41) and lead to fuel tank with washers (39), lockwashers (38), and screws (37). Remove tag, and install electrical lead (36), washers (35), and lockwashers (34) on fuel level sender (41). Close engine compartment access doors. Connect negative battery cable to battery, and close BATTERY ACCESS door.
(3) (4)
(5)
(6) (7)
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ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 4.11.6 Fuel Pickup. a. Removal. (1) (2) (3) (4) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable from battery. Open right side engine compartment access doors (Figure 1-2). Disconnect hose (50, Figure 4-26) from elbow (56). NOTE Mark position of fuel pickup before removing. (5) Remove screws (51), lockwashers (52), washers (53), fuel pickup (54), and gasket (55) from fuel tank. Remove elbow (56) from fuel pickup (54). Cover opening in fuel tank.
(6) (7) b.
Inspection. (1) (2) (3) (4) (5) Shut down generator set, paragraph 2.11.2. Remove fuel pickup, step a above. Inspect fuel pickup for clogs, stripped threads, and other damage. Replace damaged parts. Install fuel pickup, step c below.
c.
Installation. (1) (2) Remove cover from fuel tank opening. Thoroughly clean mating surfaces for new gasket (55, Figure 4-26). Ensure no foreign material enters fuel tank. Apply sealant (Item 21, Appendix E) to both sides of gasket. Position gasket on fuel tank. Install elbow (56) on fuel pickup (54). Install fuel pickup (54), washers (53), lockwashers (52), and screws (51) on fuel tank. Connect hose (50) to elbow (56). Close engine compartment access doors. Connect negative battery cable to battery, and close BATTERY ACCESS door.
(3) (4) (5) (6) (7)
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ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 4.11.7 Ether Cylinder Assembly. a. Removal. (1) (2) (3) (4) (5) Shut down generator set, paragraph 2.11.2. Open right side engine compartment access doors (Figure 1-2). Loosen wingnut (1, Figure 4-27), and unscrew ether cylinder (2) from ether solenoid valve (3). Install cap (4) on ether solenoid valve (3). Remove nuts (5), lockwashers (6), washers (7), cylinder bracket assembly (8), and bolts (9) from generator set housing.
b.
Inspection. (1) (2) Shut down generator set, paragraph 2.11.2. Open right side engine compartment access doors (Figure 1-2). NOTE Cylinder bracket assembly is located on the inside wall of the generator housing and cannot be adequately inspected when installed. (3) (4) Remove ether cylinder, step a above. Inspect cylinder bracket assembly (8, Figure 4-27) for cracks, corrosion, stripped or damaged threads, and other damage. Shake ether cylinder, and listen for liquid. If there is little or no sound of liquid in cylinder, replace cylinder. Install ether cylinder assembly, step c below.
(5)
(6) c.
Installation. (1) Install bolts (9, Figure 4-27), cylinder bracket assembly (8), washers (7), lockwashers (6), and nuts (5) on generator set housing. Remove cap (4) from ether solenoid valve (3). Insert ether cylinder (2) through cylinder bracket assembly (8), and screw cylinder into ether solenoid valve (3). Close clamp of cylinder bracket assembly (8), and tighten wingnut (1). Close engine compartment access doors.
(2) (3)
(4) (5)
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FIGURE 4-27. ETHER START SYSTEM
4.11.8
Ether Solenoid Valve L6. a. Removal. (1) Shut down generator set, paragraph 2.11.2.
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__________ WARNING DC voltages are present at generator set electrical components even with generator shut down. Avoid shorting any positive terminal with ground/negative. Failure to comply can cause injury to personnel and damage to equipment. (2) (3) (4) (5) (6) (7) (8) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Open left side engine compartment access doors (Figure 1-2). Tag and disconnect electrical leads from either solenoid valve (3, Figure 4-27). Disconnect tube assembly (10) from adapter (19) and spray nozzle (11). Loosen wingnut (1), and unscrew ether cylinder (2) from ether solenoid valve (3). Install cap (4) on ether solenoid valve (3). Remove nuts (12), lockwashers (13), washers (14), relay (16), and bolts (15) from generator set housing. Remove bolts (17) from bracket (18) and remove solenoid (3) from bracket. Remove adapter (19) from solenoid (3). Remove spray nozzle (11) from engine intake manifold. Close engine compartment doors.
(9) (10) (11) (12)
b.
Inspection. (1) (2) Remove ether solenoid valve, step a above. Inspect ether solenoid valve (3, Figure 4-27) for cracks, corrosion, damaged threads, and other damage. Inspect tube assembly (10) for cracks, breaks, pinching, damaged threads, and other damage. Inspect spray nozzle (11) for cracks, corrosion, clogging, and other damage. Replace any defective parts. Install ether solenoid valve, step c below.
(3) (4) (5) (6)
c.
Installation.
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ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 __________ WARNING DC voltages are present at generator set electrical components even with generator shut down. Avoid shorting any positive terminal with ground/negative. Failure to comply can cause injury to personnel and damage to equipment.
(1) (2) (3) (4) (5)
Open left side engine compartment access doors (Figure 1-2). Install spray nozzle (11, Figure 4-27) on engine intake manifold. Install adapter (19) into solenoid (3). Install solenoid (3) to bracket (18) with bolts (17). Install relay (16), bolts (15), washers (14), lockwashers (13), and bolts (12) on generator set housing. Remove cap (4) from ether solenoid valve (3). Insert ether cylinder (2) through cylinder bracket assembly (8), and screw cylinder into ether solenoid valve (3). Close clamp of cylinder bracket assembly (8), and tighten wingnut (1). Connect tube assembly (10) to adapter (19) and spray nozzle (11). Connect electrical leads to ether solenoid valve (3). Remove tags. Connect negative battery cable to battery, and close BATTERY ACCESS door. Close engine compartment access doors.
(6) (7)
(8) (9) (10) (11) (12) 4.11.9
Ether Solenoid Relay. a. Inspection. (1) (2) (3) (4) (5) Shut down generator set, paragraph 2.11.2. Open right side engine compartment access doors (Figure 1-2). Inspect ether solenoid relay (16, Figure 4-27) for cracks, loose mounting and other damage. Replace damaged parts. Close engine compartment access doors.
b.
Removal.
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ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 (1) (2) (3) (4) (5) c. Shut down generator set, paragraph 2.11.2. Open battery access door (Figure 1-2) and disconnect negative battery cable. Open right side engine access doors. Tag and disconnect electrical wires from ether solenoid relay (16). Remove nut (12), lockwasher (13), washer (14), bolt (15), and ether solenoid relay (16).
Testing. (1) (2) Shut down generator set, paragraph 2.11.2. Tag and disconnect electrical leads to the ether solenoid relay (16, Figure 4-27) and remove from generator set. Set multimeter for ohms, and connect leads between terminals 85 and 86, and check for an indication of 288 to 352 ohms. If indications are other than above, relay is defective and must be replaced. Attach electrical leads to ether solenoid relay K24 (16) and remove tags.
(3)
(4) (5) d.
Installation. (1) Install ether solenoid relay (16, Figure 4-27) with bolts (15), washers (14), lockwashers (13), and nuts (12). Attach electrical leads to ether solenoid relay (16) and remove tags. Connect negative battery cable to battery, and close battery access door (Figure 1-2) and right side engine access doors (Figure 1-2).
(2) (3)
4.11.10 Fuel Filter/Water Separator. a. Inspection. (1) Shut down generator set, paragraph 2.11.2 (2) Open left side engine compartment access door (Figure 1-3). (3) Inspect fuel filter/water separator assembly (25, Fig 1-30) for proper mounting, physical damage, leaks, and loose fuel lines. (4) Close engine compartment access doors. b. Service. (1) Shut down generator set, paragraph 2.11.2. (2) Open right side engine compartment access doors (Figure 1-2). (3) Open drain cock (2, Fig 3-5).
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(4) Close drain cock (2, Fig. 3-5) and air vent (1, Fig. 3-5). (5) Close engine compartment access doors. c. Removal. (1) Refer to engine manual 9-6115-672-24, Paragraph 3.12.2. d. Installation. (1) Refer to engine manual 9-6115-672-24, Paragraph 3.12.2. 4.12. MAINTENANCE OF OUTPUT BOX ASSEMBLY. __________ WARNING When disconnecting or removing batteries, disconnect the negative lead that connects directly to the grounding stud first. Disconnect the negative end of the interconnection cable next. When installing batteries, reverse the connection sequence. Failure to comply can cause serious personal injury. 4.12.1 Voltage Reconnection Terminal Board TB1. a. Inspection. (1) (2) (3) (4) Shut down generator set, paragraph 2.11.2. Open battery access door (Figure 1-2) and disconnect negative cable. Open output box access door (Figure 1-2). Inspect protective cover (3, figure 4-28) and moveable terminal board (6) for cracks, breaks, corrosion, and other damage. Replace defective parts. Connect negative battery cable to battery and close battery access door. Close output box access door.
(5) (6) (7) b.
Removal. (1) Shut down generator
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FIGURE 4-28. OUTPUT BOX ASSEMBLY
4-185
(2) (3) (4) (5) c.
Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Open output box access door (Figure 1-2). Remove locknuts (1, Figure 4-28), washers (2), and protective cover (3) from standoffs (4). Remove locknuts (5) and moveable terminal board (6) from terminal studs (7).
Installation. (1) (2) (3) (4) Install moveable terminal board (6, Figure 4-28) and locknuts (5) on terminal studs (7). Install protective cover (3), washers (2), and locknuts (1) on standoffs (4). Close output box access door. Connect negative battery cable to battery, and close BATTERY ACCESS door.
4.12.2
Output Box Wiring Harness. a. Inspection. (1) (2) (3) (4) (5) (6) b. Shut down generator set, paragraph 2.11.2. Open output box access door (Figure 1-2). Inspect wiring harness (8, Figure 4-28) for burned, bent, corroded, and broken terminals. Inspect connectors for cracks, corrosion, stripped threads, bent or broken pins, and obvious damage. Inspect wire insulation for burns, deterioration, and chafing. Close output box access door.
Testing. (1) (2) (3) (4) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Open output box and engine compartment access doors (Figures 1-2 and 1-3). Set multimeter for ohms, and test individual wires of wiring harness (8, Figure 4-28) for continuity. Refer to wiring diagram, FO-3, for wire identification. Close output box and engine compartment access doors. Connect negative battery cable to battery, and close BATTERY ACCESS door.
(5) (6)
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c.
Repair. (1) (2) (3) (4) (5) (6) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Open applicable access doors (Figures 1-2 and 1-3). Replace damaged terminals and securing hardware. Close access doors. Connect negative battery cable to battery, and close BATTERY ACCESS door.
4.12.3
Current Transformer CT1, CT2, CT3. a. Inspection. (1) (2) (3) Shut down generator set, paragraph 2.11.2. Open output box access door (Figure 1-2). Inspect current transformer (9, Figure 4-28) for security, cracked housing, broken or stripped terminals, and loose or missing hardware. Close output box access door.
(4) b.
Testing. (1) (2) (3) (4) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Open output box access door (Figure 1-2). Tag and disconnect electrical leads from current transformer (9, Figure 4-28) secondary terminals A1, A2, B1, B2, C1 and C2. Set multimeter for ohms, and check for continuity between secondary terminals A1 and A2, B1 and B2, and C1 and C2. If continuity is not present, current transformer is defective. Notify next higher level of maintenance. If continuity is present, connect electrical leads to secondary terminals A1, A2, B1, B2, C1, and C2. Remove tags. Close output box access door. Connect negative battery cable to battery, and close BATTERY ACCESS door.
(5)
(6)
(7)
(8) (9)
4.12.4
Droop Current Transformer CT5.
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Inspection. (1) (2) (3) Shut down generator set, paragraph 2.11.2. Open output box access door (Figure 1-2). Inspect droop current transformer (10, Figure 4-28) for security, cracked housing, broken wire terminals, and loose or missing hardware. If testing or replacement are required, notify next higher level of maintenance. Close output box access door.
(4) 4.12.5
Power Potential Transformer T1. Inspection. (1) (2) (3) Shut down generator set, paragraph 2.11.2. Open output box access door (Figure 1-2). Inspect potential power transformer (11, Figure 4-28) for security, cracked housing, broken wire terminals, and loose or missing hardware. If testing or replacement are required, notify next higher level of maintenance. Close output box access door.
(4) 4.12.6
AC Circuit Interrupter K1. a. Inspection. (1) (2) (3) Shut down generator set, paragraph 2.11.2. Open output box access door (Figure 1-2). Inspect AC circuit interrupter (17, Figure 4-28) for security, cracked housing, broken wire terminals, and loose or missing hardware. Close output box access door.
(4) b.
Testing. (1) (2) (3) (4) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Open output box access door. Set multimeter for ohms, and check for open circuits between AC circuit interrupter (17, Figure 428) terminals A1 and A2, B1 and B2, C1 and C2, and 11 and 12. Connect jumper wire from cranking relay (20) terminal A1 to AC circuit interrupter (17) terminal X. Connect negative battery cable to battery.
(5) (6)
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(7)
Check for closed circuits (continuity) between AC circuit interrupter (17) terminals A1 and A2, B1 and B2, C1 and C2, and 11 and 12. Disconnect negative battery cable. Replace AC circuit interrupter if indications are other than as specified above. If replacement is not necessary, remove jumper wire from terminal A1 of cranking relay (20) to terminal X of AC circuit interrupter (17). Close output box access door. Connect negative battery cable to battery, and close BATTERY ACCESS door.
(8) (9) (10)
(11) (12) c.
Replacement. (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Open output box and load terminal board access doors (Figure 1-2). Remove rear panel. Refer to paragraph 4.7.5. Remove screws (12, Figure 4-28), washers (13), and cover (14) from AC circuit interrupter (17). Tag and disconnect electrical leads from AC circuit interrupter (17). Remove locknuts (15), screws (16), and AC circuit interrupter (17) from output box. Install AC circuit interrupter (17, Figure 4-28), screws (16), and locknuts (15) on output box. Connect electrical leads to AC circuit interrupter (17). Remove tags. Install cover (14), washers (13), and screws (12) on AC circuit interrupter (17). Install rear panel. Refer to paragraph 4.7.5. Close output box and load terminal board access doors. Connect negative battery cable to battery, and close BATTERY ACCESS door.
4.12.7
Cranking Relay K2. a. Inspection. (1) (2) (3) Shut down generator set, paragraph 2.11.2. Open output box access door (Figure 1-2). Inspect cranking relay (20, Figure 4-28) for security, cracked housing, broken wire terminals, and loose or missing hardware.
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ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 (4) b. Close output box access door.
Testing. (1) (2) (3) (4) (5) (6) (7) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Open output box access door (Figure 1-2). Tag and disconnect wires from terminals X1, X2, and A2 of cranking relay (20, Figure 4-28). Connect a jumper wire between terminals A1 and X1 of cranking relay (20). Connect negative battery cable to battery. Connect X2 wires disconnected in step 4 to cranking relay (20) terminal X2. Listen for audible actuation. Set multimeter for ohms, and check for continuity between terminals A1 and A2 of cranking relay (20). If no continuity is indicated, cranking relay is defective. Notify next higher level of maintenance. If cranking relay (20) is not defective, disconnect negative battery cable. Remove jumper wire from cranking relay (20). Connect wires to terminals X1 and A2 of cranking relay (20). Remove tags. Close output box access door. Connect negative battery cable to battery, and close BATTERY ACCESS door.
(8)
(9) (10) (11) (12) (13) c.
Replacement. (1) (2) (3) (4) (5) (6) (7) (8) (9) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Open output box and right side engine compartment access doors (Figure 1-2). Tag and disconnect electrical leads from cranking relay (20, Figure 4-28). Remove locknuts (18), screws (19), and cranking relay (20) from output box. Install cranking relay (20), screws (19), and locknuts (18) on output box. Connect electrical leads to cranking relay (20). Remove tags. Close output box and right side engine compartment access doors. Connect negative battery cable to battery, and close BATTERY ACCESS door.
4.12.8
Load Output Terminal Board TB2.
4-190
a.
Removal. (1) (2) (3) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Open load terminal board access door (Figure 1-2), and disconnect load output cables L1, L2, L3, and N from load output terminal board. Remove rear housing panel. Refer to paragraph 4.7.5. Remove locknut (1, Figure 4-29), bolt (2), and lockwashers (3) securing ground strap (20) to skid base. Remove bolts (4), lockwashers (5), and washers (6) securing load output terminal board (11) to supports (34 and 35). Remove locknuts (7), brass washers (8), electrical leads (9), and varistor leads (10) from load terminals (14). Tag leads. Remove terminal load board (11) from generator set. Remove jamnuts (12), brass washers (13), and load terminals (14) from load output terminal board (11). Remove locknuts (15), washers (16), and bus bar (17) from terminal studs (21 and 26). Remove locknut (18), lockwasher (19), ground strap (20), and terminal stud (21) from load output terminal board (11). Remove locknut (22), washer (23), ground bus bar (24), EMI filter (25), and terminal stud (26) from load output terminal board (11). Disconnect varistor leads (10) from varistors (29). Remove locknuts (27), bolts (28), varistors (29), EMI filters (30), and ground plane bar (31) from load output terminal board (11). Remove locknuts (32), bolts (33), and terminal board supports (34 and 35) from generator set. Remove locknuts (36), bolts (37), cord (38), insulated wrench (39), and bracket (40) from terminal board support (34).
(4) (5)
(6)
(7)
(8) (9)
(10) (11)
(12)
(13) (14)
(15) (16)
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FIGURE 4-29. LOAD OUTPUT TERMINAL BOARD ASSEMBLY (SHEET 1 OF 2)
4-192
FIGURE 4-29. LOAD OUTPUT TERMINAL BOARD ASSEMBLY (SHEET 2 OF 2)
b.
Inspection. (1) (2) (3) (4) (5) (6) Shut down generator set, paragraph 2.11.2. Open load output terminal board access door (Figure 1-2). Inspect load output terminal board (11, Figure 4-29) for cracks, corrosion, and obvious damage. Inspect load terminals (14) for stripped threads or other obvious damage. Inspect varistor leads (10) for damaged insulation and loose terminals. Inspect and test varistors (29) as follows: (a) (b) (c) Inspect varistors (29) for obvious external damage. Remove varistors, refer to paragraph 4.12.8.a. Set multimeter for ohms, and test each varistor by connecting multimeter to varistor terminals 1 and 2. Note multimeter indication. Reverse multimeter leads, and note multimeter indication. Multimeter indications should be infinite in both directions. If indications are other than above, varistors (29) are defective and must be replaced. Install varistors, refer to 4.12.8.d.
(d) (e) (f) (g) (7) (8) (9)
Inspect cage nuts (41) for cracking or stripped threads. Replace damaged and defective parts. Close load output terminal board access door.
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c.
Repair. Repair load output terminal board assembly by replacing damaged or defective wires, load terminals, EMI filters, and varistors.
d.
Installation. (1) Install bracket (40, Figure 4-29), insulated wrench (39), cord (38), bolts (37), and locknuts (36) on terminal board support (34). Install terminal board supports (34 and 35), bolts (33), and locknuts (32) on generator set. NOTE Position EMI filters to align with mounting holes for load terminals L1, L2, and L3 respectively. (3) Install ground plane bar (31), EMI filters (30), varistors (29), bolts (28), and locknuts (27) on load output terminal board (11). Connect varistor leads (10) to varistors (29). Install terminal stud (26), EMI filter (25), ground bus bar (24), washer (23), and locknut (22). Install terminal stud (21), ground strap (20), lockwasher (19), and locknut (18) on load output terminal board (11). Do not tighten locknut. Install bus bar (17), washers (16), and locknuts (15) on terminal studs (21 and 26). Install load terminals (14), brass washers (13), and jamnuts (12) on load output terminal board (11). Position load output terminal board (11) in generator set. Install varistor leads (10), electrical leads (9), brass washers (8), and locknuts (7) on load terminals (14). Remove tags. Secure load output terminal board (11) to terminal board supports (34 and 35) with washers (6), lockwashers (5), and bolts (4). Apply a thin coat of antiseize compound (6, Appendix E) to skid base at ground strap mating surface. Secure ground strap (20) to skid base with lockwashers (3), bolt (2), and locknut (1). Tighten locknut (18). Install rear housing panel. Refer to paragraph 4.7.5. Connect load output cables L1, L2, L3, and N to load output terminal board assembly, and close load terminal board access door. Connect negative battery cable to battery, and close BATTERY ACCESS door.
(2)
(4) (5) (6)
(7) (8) (9) (10)
(11)
(12)
(13)
(14) (15)
(16) 4.13
MAINTENANCE OF ENGINE ACCESSORIES.
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ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 __________ WARNING When disconnecting or removing batteries, disconnect the negative lead that connects directly to the grounding stud first. Disconnect the negative end of the interconnection cable next. When installing batteries, reverse the connection sequence. Failure to comply can cause serious personal injury. 4.13.1 Oil Pressure Sender MT7. a. Testing. (1) (2) (3) Start generator set, paragraph 2.11.1. Open left side engine compartment access doors (Figure 1-3). Set multimeter to VDC. Place positive lead of multimeter on the black wire lead of the oil pressure sender connector, and the negative lead to ground. Readings shall be between 1 and 5 VDC. Shut down generator set, paragraph 2.11.2. If indications are not as above, replace oil pressure sender (1), refer to paragraph 4.13.1. b and d.
(4) (5) b.
Removal. (1) (2) (3) (4) (5) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Open left side engine compartment access doors (Figure 1-3). Disconnect electrical plug connector from oil pressure sender (1, Figure 4-30). Remove oil pressure sender (1) from adapter (10).
c.
Service. (1) (2) Shut down generator set, paragraph 2.11.2. Remove oil pressure sender, refer to paragraph 4.13.1.b. __________ WARNING Cleaning with compressed air can cause flying particles. When using compressed air, wear protective glasses and use clean, low pressure air, less than 30 psi (206.8 kPa). Failure to comply can cause eye injury.
4-195
FIGURE 4-30. ENGINE SWITCHES AND SENDERS
4-196
__________ WARNING Dry cleaning solvent is flammable and toxic to eyes, skin, and respiratory tract. Skin and eyeprotection are required when working in contact with dry cleaning solvent. Avoid repeated or prolonged contact. Work in ventilated area only. Failure to comply can cause injury or death to personnel.
(3)
Clean oil pressure sender with dry, filtered compressed air, and wipe with a clean, lint-free cloth (Item 8, Appendix E) lightly moistened with dry cleaning solvent (Item 20, Appendix E). Inspect oil pressure sender for cracked casing, stripped or damaged threads, corrosion, or other damage. Replace oil pressure sender if damaged. Install oil pressure sender, refer to paragraph 4.13.1.d.
(4)
(5) (6) d.
Installation. CAUTION Use care not to introduce pipe thread sealing compound into the pressure orifice in the end of the oil pressure sender. Sealing compound in the pressure orifice can cause the oil pressure sender to malfunction and result in damage to equipment. (1) Apply sealing compound (Item 22, Appendix E) to threads of oil pressure sender (1, Figure 4-30), and install switch on adapter (10). Connect electrical plug connector to oil pressure sender (1). Remove tags. Close engine compartment access doors. Connect negative battery cable to battery, and close BATTERY ACCESS door.
(2) (3) (4) 4.13.2
Coolant Temperature Sender MT6. a. Testing. (1) (2) (3) (4) (5) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Open left side engine compartment access doors (Figure 1-3). Remove dead crank switch plate, refer to paragraph 4.14.4. Disconnect electrical plug connector from coolant temperature sender (2, Figure 4-30) by unscrewing retaining ring.
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ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 (6) Set multimeter for ohms, and connect positive lead to temperature sender terminal and negative lead to pin 4. Multimeter should indicate as follows: At 70F, ohm range is 108-111ohms. For each +10F, add two ohms to either end of range. For each -10F, subtract two ohms. Example: At 80F range, should equal 110-113 ohms. At 60F, range should equal 106-109 ohms. Connect negative battery cable to battery. Start up generator set, paragraph 2.11.1. Allow engine to operate while observing multimeter. Ohms indication should decrease as temperature rises. Shut down generator set, paragraph 2.11.2. Disconnect negative battery cable. If indications are not as above, replace coolant temperature sender (2). Refer to paragraph 4.13.2. b d. If coolant temperature sender (2) meets above requirements, connect electrical plug connector to sender by tightening retaining ring. Close engine compartment access doors. Connect negative battery cable to battery, and close BATTERY ACCESS door.
(7) (8) (9)
(10) (11) (12)
(13)
(14) (15) b.
Removal. (1) (2) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. __________ WARNING Cooling system operates at high temperature and pressure. Contact with high pressure steam and/or liquids can result in burns and scalding. Shut down generator set, and allow system to cool before performing checks, services, and maintenance. Failure to comply can cause injury or death to personnel. (3) (4) Slowly remove radiator cap (1, Figure 4-22) from filler neck (2). Open left side engine compartment access doors (Figure 1-3), open engine block drain valve (3, Figure 4-30), and drain coolant into suitable container. Close engine block drain valve (3). Disconnect electrical plug connector from coolant temperature sender (2). Remove coolant temperature sender (2) from engine head.
(5) (6) (7) c.
Service.
4-198
(1) (2)
Shut down generator set, paragraph 2.11.2. Remove coolant temperature sender, refer to paragraph 4.13.2. b. __________ WARNING Cleaning with compressed air can cause flying particles. When using compressed air, wear protective glasses and use clean, low pressure air, less than 30 psi (206.8 kPa). Failure to comply can cause eye injury. __________ WARNING Dry cleaning solvent is flammable and toxic to eyes, skin, and respiratory tract. Skin and eye protection are required when working in contact with dry cleaning solvent. Avoid repeated or prolonged contact. Work in ventilated area only. Failure to comply can cause injury or death to personnel.
(3)
Clean coolant temperature sender with dry, filtered compressed air, and wipe with a clean, lint-free cloth (Item 8, Appendix E) lightly moistened with dry cleaning solvent (Item 20, Appendix E). Inspect coolant temperature sender for cracked casing, stripped or damaged threads, corrosion, or other damage. Replace coolant temperature sender if damaged. Install coolant temperature sender, 4.13.2.d.
(4)
(5) (6) d.
Installation. (1) Apply sealing compound (Item 22, Appendix E) to threads of coolant temperature sender (2, Figure 4-30), and install switch on engine block. Connect electrical plug connector to coolant temperature sender (2). Add coolant/antifreeze to proper level at the filler neck (2, Figure 4-22). Install radiator cap (1) on filler neck (2). Connect negative battery cable to battery, and close BATTERY ACCESS door. Start generator set, paragraph 2.11.1. Allow unit to reach operating temperature, and check for leaks. Add coolant/antifreeze to overflow bottle as required. Close engine compartment access doors.
(2) (3) (4) (5) (6)
(7) (8)
4-199
4.13.3
Magnetic Pickup MPU. a. Removal. (1) (2) (3) (4) (5) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Open left side engine compartment access doors (Figure 1-3). Disconnect electrical plug connector from magnetic pickup (4, Figure 4-30). Loosen locknut (5), and remove magnetic pickup (4) from flywheel housing.
b.
Service. (1) (2) Shut down generator set, paragraph 2.11.2. Remove magnetic pickup, refer to paragraph 4.13.3.a. __________ WARNING
Cleaning with compressed air can cause flying particles. When using compressed air, wear protective glasses and use clean, low pressure air, less than 30 psi (206.8 kPa). Failure to comply can cause eye injury. __________ WARNING Dry cleaning solvent is flammable and toxic to eyes, skin, and respiratory tract. Skin and eye protection is required when working in contact with dry cleaning solvent. Avoid repeated or prolonged contact. Work in ventilated area only. Failure to comply can cause injury or death to personnel. (3) Clean magnetic pickup with dry, filtered compressed air, and wipe with a clean, lint-free cloth (Item 8, Appendix E) lightly moistened with dry cleaning solvent (Item 20, Appendix E). Inspect magnetic pickup for cracked casing, stripped or damaged threads, corrosion, and bent or broken connector pins. Replace magnetic pickup if damaged. Install magnetic pickup, 4.13.3.c.
(4)
(5) (6). c.
Installation. (1) Screw magnetic pickup (4, Figure 4-30) into flywheel housing until pickup bottoms out on flywheel. Back magnetic pickup out 1 1/2 turns. Tighten locknut (5). Connect electrical plug connector to magnetic pickup (4). Remove tags.
(2)
4-200
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 (3) (4) (5) d. Connect negative battery cable to battery, and close BATTERY ACCESS door. Adjust magnetic pickup (4), 4.13.3.d. Close engine compartment access doors.
Testing. (1) (2) Disconnect P13 from receptacle J13 at magnetic pickup. Refer to FO-1. Set multimeter for VAC, and connect multimeter positive lead to terminal B of P13 and negative lead to terminal A. Set MASTER CONTROL switch to ON and crank engine with DEAD CRANK switch. Observe multimeter. Indication should be between 1.0 and 1.5 VAC. If indications are not as above, replace magnetic pickup. Refer to paragraph 4.13.3.
(3)
(4) 4.13.4
DEAD CRANK Switch S10. a. Testing. (1) (2) (3) (4) (5) (6) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Open left side engine compartment access doors (Figure 1-3). Remove DEAD CRANK switch from plate. Refer to paragraph 4.13.4.b. Tag and disconnect electrical leads from DEAD CRANK switch (9, Figure 4-30). Set multimeter for ohms and with switch in NORMAL position, check for continuity between contacts 2 and 3. Move switch to CRANK position, and check for continuity between contacts 1 and 2. If DEAD CRANK switch (9) fails continuity checks, replace switch. If DEAD CRANK switch (9) meets above requirements, connect electrical leads to switch. Attach DEAD CRANK switch to plate. Refer to paragraph 4.13.4.b. Close engine compartment access doors. Connect negative battery cable to battery, and close BATTERY ACCESS door.
(7) (8) (9) (10) (11) (12) b.
Replacement. (1) (2) (3) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Open left side engine compartment access doors(Figure 1-3).
4-201
(4)
Remove nut (6), lockwasher (7), key washer (8), and DEAD CRANK switch (9) from DEAD CRANK bracket (11). Tag and disconnect electrical leads from DEAD CRANK switch (9, Figure 4-30). Connect electrical leads to DEAD CRANK switch (9). Remove tags. Attach DEAD CRANK switch (9), key washer (8), lockwasher (7), and nut (6) to DEAD CRANK bracket (11). Close engine compartment doors. Connect negative battery cable to battery, and close BATTERY ACCESS door.
(5) (6) (7)
(8) (9)
4.13.5 Battery Current Transducer BCT. a. Inspection. (1) (2) (3) (4) (5) b. Testing. (1) (2) (3) (4) (5) Shut down generator set, paragraph 2.11.2. Open battery access door, (Figure 1-2). Disconnect negative battery cable. Disconnect P1 (2) from J1 (3) at the battery current transducer. Refer to Schematic FO-1. Apply 12VDC at P1 (2) positive DC to red wire, and negative DC to black wire. Set multimeter to VDC and place positive test lead to green wire on P1(2). Place negative test lead to black wire P1. Multimeter should indicate 5.9 VDC - 6.1 VDC. If multimeter indicates value other than above, replace Battery Current Transducer (1). Shut down generator set, paragraph 2.11.2. Open right side engine compartment access door, (Figure 1-2). Verify that BCT (1, Figure 4-31) housing is not damaged and is securely mounted to its bracket. Check plug P1 (2) and wires for broken or chaffed wires. Close right side engine compartment access door, (Figure 1-2).
(6) c.
Replacement. (1) (2) (3) (4) Shut down generator set, paragraph 2.11.2. Open battery access door, (Figure 1-2). Disconnect negative battery cable. Open right side engine compartment access door, (Figure 1-2). Disconnect P1 (2) from J1 (3) at the battery current transducer.
4-202
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 (5) Tag and remove wire number 310A16 (FO-1) from positive post of alternator by removing nut (4), washer (5), terminal washer (6) and isolating washer (7). Cut ring terminal (8) from wire number 310A16 and feed wire through the top of the battery current transducer (1). Tag and remove wire number 145C16 from the positive post of battery number one. Cut ring terminal from wire number145C16 and feed the wire through the top of the battery current transducer (x). Remove the bolts (9), washer (10) and nuts (11) on the battery current transducer. Place new battery current transducer on bracket (12). Verify that holes line up with mounting bracket (12). Attach battery current transducer (1) to bracket (12) with bolts (9), washer (10) and nuts (11). Feed wire number 310A16 through the battery current transducer. Strip 1/4 " of insulation from the end of wire 310A16. Crimp ring terminal (8) to the end of wire 310A16. Attach wire number 310A16 to the positive post of the alternator with isolating washer (7), terminal washer (6), washer (5) and nut (4). Feed wire number 145C16 through the top of the battery current transducer (1) and route to the battery compartment. Strip 1/4 " of insulation from the end of wire 145C16. Crimp ring terminal to the end of wire 145C6. Attach wire number 145C16 to the positive post of battery number one. Refer to Schematic FO-1. Reconnect negative cable to battery. Close battery access door, (Figure 1-2). Close right side engine compartment access door, (Figure 1-2).
(6)
(7) (8)
(9) (10)
(11) (12) (13) (14) (15)
(16)
(17) (18) (19) (20) (21) (22)
4-203
FIGURE 4-31. BATTERY CURRENT TRANSDUCER
4-204
4.14
MAINTENANCE OF LUBRICATION SYSTEM. __________ WARNING When disconnecting or removing batteries, disconnect the negative lead that connects directly to the grounding stud first. Disconnect the negative end of the interconnection cable next. When installing batteries, reverse the connection sequence. Failure to comply can cause serious personal injury.
4.14.1
Oil Drain Valve. a. Inspection. (1) (2) (3) (4) b. Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS and right side engine compartment access doors (Figure 1-2). Inspect oil drain line for cracks, holes, loose or missing hardware, or other damage. Close BATTERY ACCESS and right side engine compartment access doors.
Replacement. (1) (2) (3) (4) (5) (6) (7) (8) (9) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Open right side engine compartment access doors (Figure 1-2). Remove plug (1, Figure 4-32), open drain valve (4), and drain engine oil into suitable container. Loosen hose clamps (2), and remove oil drain hose from adapters (3 and 7). Remove adapter (3) from drain valve (4). Remove drain valve (4) from pipe fitting (5). Remove pipe fitting (5) from skid base fitting (6). Apply sealing compound (Item 22, Appendix E) to threads of pipe fitting (5, Figure 4-32). Install pipe fitting (5) on skid base fitting (6), and drain valve (4) on pipe fitting. Apply sealing compound (Item 22, Appendix E) to pipe threads of adapters (3 and 7 ). Install adapter (3) on drain valve (4). Position hose clamps (2) on oil drain hose. Connect hose to adapters (3 and 7), and tighten hose clamp. Apply sealing compound (Item 22, Appendix E) to threads of plug (1). Install plug on skid base fitting (6). Service lubrication system, paragraph 3.3.8.
(10)
(11)
(12)
(13)
4-205
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 (14) (15) (16) Check engine oil drain line and valve for leakage. Connect negative battery cable to battery, and close BATTERY ACCESS door. Close engine compartment access doors.
SECTION VII. PREPARATION FOR SHIPMENT AND STORAGE
4.15 4.15.1
PREPARATION FOR SHIPMENT AND STORAGE. Preservation. Preserve generator set in accordance with levels A, B, or C of MIL-G-28554. Preserve generator set cooling systems in accordance with method II of MIL-G-28554 or the antifreeze and winter procedure of MIL-E-10062.
4.15.2
Packing. Pack generator sets in accordance with levels A, B, or C of MIL-G-28554.
4.15.3
Marking. Mark for shipment or storage in accordance with MIL-STD-129.
4.15.4
Use of Corrosion-Preventive Compounds, Moisture Barriers, and Desiccant Materials. Refer to corrosion and Corrosion Prevention/Metal, MIL-HDBK-729.
4.15.5
Special Instructions for Administrative Storage. Placement of equipment in administrative storage should be for short periods of time when a shortage of maintenance effort exists. Items should be in mission readiness within 24 hours or within the time factors as determined by the directing authority. During the storage period, appropriate maintenance records shall be kept. Before placing the equipment in administrative storage, current preventive maintenance checks and services should be completed, shortcomings and deficiencies should be corrected, and all Modification Work Orders (MWO) should be applied. Inside storage is preferred for items selected for administrative storage. If inside storage is not available, trucks, vans, conex containers, and other containers may be used.
4.15.6
General Storage. For storage information refer to TB 740-97-2.
4-206
FIGURE 4-32. OIL DRAIN VALVE
4-207
4.16
CIM CONFIGURATION SWITCH An eight position DIP Switch illustrated below is located beneath a protective plastic cover on the front of the Computer Interface Module. This switch defines the configuration of the generator set for the Computer Interface Module. The generator set configuration is defined in two ways: Output power (KW) rating, and Frequency rating. This switch must be set to a specific configuration corresponding to the table below prior to the modules use in the generator set. Unless this switch is properly configured, the generator set can experience a malfunction.
Configuration Switches Description: There are eight rocker-type switches in one switch assembly, which is accessible from the front of the module. Each switch is numbered left to right when viewing the module from the front. Each may be placed in either a up (on) or down (off) position, which correspond to a logical 1 or 0 configuration. SWITCH NUMBER 1- 4 5 6-8 WHAT CONFIGURATION IS CONTROLLED BY THESE SWITCHES Power rating (30, 60 KW) Frequency (50/60 or 400 Hz) Not assigned.
The switch positions applicable to the 60 KW TQG sets are as follows: Input/Output Module, Model TCM100: SWITCH Setting 1 off 2 on 3 off 4 off 5 off 6 off 7 off 8 off GEN SET TYPE 60 KW, 50/60 Hz MEP-806B
Input/Output Module, Model TCM400: SWITCH Setting 1 off 2 on 3 off 4 off 5 on 6 off 7 off 8 off GEN SET TYPE 60 KW, 400 Hz MEP-816B
4-208
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 CHAPTER 5 DIRECT SUPPORT MAINTENANCE INSTRUCTIONS
CHAPTER INDEX
SECTION I
REPAIR PARTS, TOOLS, TEST, MEASUREMENT AND DIAGNOSTIC (TMDE, AND SUPPORT EQUIPMENT......................................................................................5-1 LUBRICATION PROCEDURES..................................................................................................5-1 TROUBLESHOOTING.................................................................................................................5-2 DIRECT SUPPORT MAINTENANCE PROCEDURES............................................................5-14
SECTION II SECTION III SECTION IV
NOTE Procedures may require CD-ROM. See Appendix C.
SECTION I. REPAIR PARTS; TOOLS; TEST, MEASUREMENT AND DIAGNOSTIC (TMDE); AND SUPPORT EQUIPMENT 5.1 5.1.1 INTRODUCTION. Maintenance Repair Parts. Repair parts and equipment are listed and illustrated in the Repair Parts and Special Tools List (RPSTL) manual TM 9-6115-671-24P. Tools and Equipment. There are no special tools or support equipment required to perform direct support level of maintenance on the generator set. A list of recommended tools and support equipment required to maintain the generator set is contained in Appendix B, Section III. Fabrication of Tools and Equipment. No requirement exists for fabrication of tools and equipment for maintenance of the generator set.
5.1.2
5.1.3.
SECTION II. LUBRICATION PROCEDURES
5.2
DIRECT SUPPORT LUBRICATION INSTRUCTIONS. There are no special lubrication instructions required to perform direct support level of maintenance. Refer to LO 9-6115-644-12 for generator set lubrication requirements.
5-1
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 SECTION III. TROUBLESHOOTING 5.3 GENERAL. This section contains troubleshooting information for locating and correcting operating troubles which may develop in the generator set. Each malfunction for an individual component unit or system is followed by a list of tests or inspections which will help to determine probable causes and corrective actions to take. Perform the tests/inspections in the order listed. Table 5-1 is provided for direct support troubleshooting. This table cannot list all malfunctions that may occur, nor all tests or inspections and corrective actions. If a malfunction is not listed, or is not corrected by listed corrective actions, notify your supervisor. NOTE Before using this table, PMCS and lower level troubleshooting must be performed. NOTE Refer to paragraph 2.4 for diagnostic controls and indicators.
SYMPTOM INDEX Page Engine Cranks, But Fails To Start ..............................................................................................................................5-3 Engine Runs Erratically or Stalls Frequently..............................................................................................................5-4 Engine Does Not Develop Full Power........................................................................................................................5-4 Abnormal Engine Noise..............................................................................................................................................5-5 Black or Gray Exhaust Smoke ....................................................................................................................................5-6 Blue or White Exhaust Smoke....................................................................................................................................5-6 Engine Misfiring .........................................................................................................................................................5-7 Coolant In Crankcase or Oil In Coolant......................................................................................................................5-7 Generator Set Fails To Generate Sufficient Voltage...................................................................................................5-8 Generator Set Output Fluctuates.................................................................................................................................5-9 Generator Noisy When Running...............................................................................................................................5-10 Engine Oil Pressure Low ..........................................................................................................................................5-11 Engine Oil Pressure High .........................................................................................................................................5-11 FAULT INDICATOR Displays WARNING - UNDERVOLTAGE or CONTACTOR TRIP UNDERVOLTAGE...........................................................................................................................................5-12 FAULT INDICATOR Displays SHUTDOWN - OVERSPEED..............................................................................5-13
5-2
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 TABLE 5-1. DIRECT SUPPORT TROUBLESHOOTING
ENGINE CRANKS BUT FAILS TO START

Engine cranks but fails to start.
Not OK
Verify fuel injection pump timing. Refer to TM 9-2815-260-24.
OK
Adjust fuel injection pump timing. Refer to TM 9-2815-260-24.
Not OK
Test electric actuator (see para 5.9.1).
OK
Replace electric actuator (para 5.9.1).
Refer to TM 9-2815-260-24.
5-3
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 TABLE 5-1. DIRECT SUPPORT TROUBLESHOOTING (CONTINUED)
Refer to TM 9-2815-260-24.

Not OK
Test fuel injection nozzles. Refer to TM 9-2815-260-24.
OK
Replace fuel injection nozzles. Refer to TM 9-2815-260-24.
OK
Test actuator A6 (see para. 5.8.1).
Not OK
Refer to TM 9-2815-260-24.
Replace actuator A6 (see para. 5.8.1).
5-4
ABNORMAL ENGINE NOISE

Abnormal engine noise.
Not OK
Visually check for split or cracked rubber on engine mounts. Refer to figure 5-1.
OK
Replace engine mounts (see para. 5.4.2).
Not OK
Check your drive disc bolts (Eng to Gen).
OK
Tighten drive disc bolts (Eng to Gen).
Refer to TM 9-2815-260-24.
5-5
BLACK OR GRAY EXHAUST SMOKE
Black or gray exhaust smoke.
Refer to Tm 9-2815-260-24.
BLACK OR WHITE EXHAUST SMOKE
Black or White exhaust smoke.
Refer to TM 9-2815-260-24.
5-6
ENGINE MISFIRING
Engine misfiring.
Refer to Tm 9-2815-260-24.
COOLANT IN CRANKCASE OR OIL IN COOLANT
Coolant in crankcase or oil in coolant.
Refer to TM9-2815-260-24.
5-7
GENERATOR SET FAILS TO GENERATE SUFFICIENT VOLTAGE
Generator set fails to generate sufficient voltage.
Not OK
Check for low engine speed. Refer to TM 9-2815-260-24.
OK
Refer to TM 9-2815-260-24. OK Test power potential transformer (see para. 5.8.6). Not OK
Not OK Test generator main stator (see para. 5.10.7).
Replace power potential transformer (see para. 5.8.6).
Replace defective components.
5-8
GENERATOR SET OUTPUT FLUCTUATES

Generator set output fluctuates.
Not OK
Check for irregular engine speed. Refer to TM 9-2815-260-24.
OK
Refer to TM 9-2815-260-24. OK Check for loose terminations or load connections. Not OK
Test generator (see para. 5.10).
Not OK
Tighten terminations and load connections.
Start generator set (see para. 2.12.1). If output still fluctuates, replace generator assembly (see para. 5.10.1).
Replace defective component.
5-9
GENERATOR NOISY WHEN RUNNING

Generator noisy when running.
OK
Remove end bell (see para. 5.10.2). Check main bearing Not OK for leaks, rough operation, and other signs of damage.
Not OK
Check for loose mounting OK hardware between generator and engine (see para. 5.4.2).
Replace main bearing (see para. 5.10.2).
Tighten engine/ generator mounting hardware (see para. 5.4.2).
Not OK
Inspect generator assembly (see para. 5.10).
Peplace components as required.
5-10
ENGINE OIL PRESSURE LOW
Engine oil pressure low.
Refer to Tm 9-2815-260-24.
ENGINE OIL PRESSURE HIGH
Engine oil pressure high.
Refer to Tm 9-2815-260-24.
5-11
FAULT INDICATOR DISPLAYS WARNING - UNDERVOLTAGE OR CONTACTOR TRIP - UNDERVOLTAGE

FAULT INDICATOR displays WARNING UNDERVOLTAGE or CONTACTOR TRIP UNDERVOLTAGE.
Not OK
Check for low engine speed. Refer to TM 9-2815-260-24.
OK
Repair engine. Refer to TM 9-2815-260-24.
OK
Test potential transformer (see para. 5.8.6)
Not OK
Test generator main stator (see para. 5.9.8).
Not OK
Replace potential transformer (see para 5.8.6).
Replace components (see para 5.10.7).
5-12
FAULT INDICATOR DISPLAYS SHUTDOWN - OVERSPEED
FAULT INDICATOR displays SHUTDOWN - OVERSPEED
Not OK
Test electric actuator (see para. 5.9.1).
OK
Replace electric actuator (see para. 5.9.1).
Refer to TM 9-2815-260-24.
5-13
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 SECTION IV. DIRECT SUPPORT MAINTENANCE PROCEDURES __________ WARNING Batteries give off a flammable gas. Do not smoke or use open flame when performing maintenance. Failure to comply can cause injury or death to personnel and equipment damage due to flames and explosion. __________ WARNING Battery acid can cause burns to unprotected skin. Wear protective gloves and safety goggles. Failure to comply can cause personal injury. 5.4 REMOVAL AND INSTALLATION OF MAJOR COMPONENTS. __________ WARNING When disconnecting or removing batteries, disconnect the negative lead that connects directly to the grounding stud first. Disconnect the negative end of the interconnection cable next. When installing batteries, reverse the connection sequence. Failure to comply can cause serious personal injury. 5.4.1 General. The engine and generator are bolted together at the engine flywheel and flywheel housing adapter. The engine and generator may be removed as an assembly or separately. The engine and generator assembly is mounted on the skid base at four points. There are also brackets installed on both sides of the engine when removing the generator separately. 5.4.2 Engine and Generator Assembly. __________ WARNING Generator is heavy. Obtain assistance when moving generator with hoist. Failure to comply can cause injury to personnel. a. Removal. (1) (2) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2) and disconnect negative battery cable. CAUTION Engine and oil drain line can be damaged if oil drain line is not disconnected from engine before removing engine from skid base. Engine oil must be drained and drain line disconnected before removing engine from skid base. Failure to comply can cause damage to equipment. (3) Remove oil drain plug, open drain valve, and drain engine oil into a suitable container. Refer to Figure 4-1.
5-14
(4) (5) (6) (7)
Totally drain radiator and coolant bottle, refer to paragraph 4.10. Remove DSC control box, refer to paragraph 4.7.2. Remove top housing section, refer to paragraph 4.7.3. Remove air filter assembly, refer to paragraph 4.9.2. NOTE Disconnect wire ties and wire clamps as needed. Note position of removed wire ties and reinstall after repair is complete. NOTE Note location of wiring harnesses as removed. Tag connectors prior to removal to aid in reconnection.
(8) (9) (10) (11)
Disconnect radiator drain hose (paragraph 4.10.7). Disconnect engine coolant drain hose at engine petcock (Figure 4-22). Disconnect coolant overflow bottle drain line and remove bracket from engine. Disconnect fuel water separator drain line. NOTE Ensure the tie straps are removed as required.
(12) (13) (14) (15) (16) (17) (18) (19) (20) (21)
Remove dead crank switch (save all washers) (paragraph 4.13.4). Tag and disconnect fuel float switch (paragraph 4.11.5). Tag and disconnect oil pressure sender (4.13.1). Unplug electric actuator, P10. Unplug magnetic pickup, P12. Unplug auxiliary fuel pump, P13. Disconnect fuel rail return line and cap (Figure 4-25). Disconnect auxiliary pump output line and cap (Figure 4-25). Loosen hose clamp (Figure 4-25, 25) from fuel collar fill hose (27). Disconnect battery charging alternator output wire. Remove battery charging alternator current sensor bracket from alternator.
5-15
(22) (23) (24) (25) (26) (27) (28) (29)
Tag and disconnect crankcase ventilation hose heater wires (4). Tag and disconnect wiring harness wires at battery. Disconnect ether tube. Tag and disconnect wiring harness from ether injection solenoid and relay. Tag and disconnect wires to starter, including the ground wires. Disconnect fuel line to engine mechanical fuel pump. Disconnect fuel vent line at fuel filler neck from t-connection above starter. Disconnect main alternator output wires, T1 through T12, from voltage reconnection switch. NOTE Note location, number of wraps, direction of wraps and which wires are wrapped through the current transformer (CT1) and droop current transformer (CT5) prior to removal.
(30)
Remove main alternator output wires, T1 through T12, from current Transformer (CT1) and droop current transformer (CT5). Disconnect rotor exciter wires, F1 and F2 from TB8. Remove rear generator housing section (paragraph 4.7.5). Pull main alternator output wires, T1 through T12, and rotor exciter wires, F1 and F2 through hole in bottom of output box. Disconnect main output terminal board ground strap from skid. Remove right and left side generator housing panels as complete assemblies. Remove locknuts (8), washers (9), snubbing washers (10), washers (12), and bolts (11), and engine supports (28) from skid base. Remove locknuts (13), washers (14), snubbing washers (15 and 23), Belleville washers (17) and bolts (16) from generator and skid base. Remove nuts (3), lockwashers (4), washers (6), and bolts (5) from support frame (7). CAUTION Rated capacity of overhead hoist should be at least 2000 lbs (907 kg). Arrange lifting device so that it supports both engine and generator to avoid undue stress on the engine and generator coupling. Failure to comply can cause damage to equipment.
(31) (32) (33)
(34) (35) (36)
(37)
(38)
(39)
Attach lifting harness to engine and generator lifting points. Raise engine and generator assembly from skid base. Remove shock mounts (24) from generator mounting points on skid base.
(40) 5-16
(41)
Remove bolt (52), washer (53), bolt (50), washer (51) and rear engine lifting bracket (54) from engine. Remove bolts (47), lockwashers (48), and front engine lifting bracket (49) from engine. Remove jamnuts (18), washers (19), washers (21), jamnuts (22), and bolts (20) from generator. Remove bolts (25), lockwashers (26), washers (27), and engine supports (28) from engine. Remove locknuts (29), washers (30), bolts (31) and engine mounts (32) from skid base.
(42) (43) (44) (42) b.
Installation. (1) (2) (3) (4) (5) Install engine mounts (32, Figure 5-1), bolts (31), washers (30), and locknuts (29) on skid base. Install engine supports (28), washers (27), lockwashers (26), and bolts (25) on engine. Install bolts (20), jamnuts (22), washers (21), washers (19), and jamnuts (18) on generator. Install front engine lifting bracket (49) lockwashers (48), and bolts (47) to engine. Install rear engine lifting bracket (54), lockwasher (53), bolt (52), washer (51), and bolt (50) to engine. Position shock mounts (24) at generator mounting points on skid base.
(6)
CAUTION Rated capacity of overhead hoist should be at least 2000 lbs (907 kg). Arrange lifting device so that it supports both engine and generator to avoid undue stress on the engine and generator coupling. Failure to comply can cause damage to equipment. (7) Attach lifting harness to engine and generator lifting points. Raise engine and generator assembly from maintenance stand or fixture. Position engine and generator assembly on skid base with mounting holes and brackets aligned. Cut cable ties from generator power leads (55). Secure generator to skid base with snubbing washers (15 and 23), Belleville washers (17), bolts (16), washers (14), and locknuts (13). Torque bolts to 210 ft-lb (284.9 Nm). Secure engine supports (28) to skid base with washers (12), bolts (11), snubbing washers (10), washers (9), and locknuts (8). Torque locknuts to 75 ft-lb (101.7 Nm). Install bolts (5), washers (6), lockwashers (4), nuts (3), and support frame (7). Install right and left side generator housing panels. Connect main output terminal board ground strap to skid base.
(8) (9) (10)
(11)
(12) (13) (14)
5-17
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 (15) Pull main alternator output wires, T1 through T12, and rotor exciter wires, F1 and F2 through hole in bottom of output box. Install rear generator housing section (paragraph 4.7.5). Connect rotor exciter wires, F1 and F2 from TB8. Install main alternator output wires, T1 through T12, from current Transformer (CT1) and droop current transformer (CT5). Connect main alternator output wires, T1 through T12, from voltage reconnection switch. Connect fuel vent line at fuel filler neck from t-connection above starter. Connect fuel line to engine mechanical fuel pump. Connect wires to starter, including the ground wires. Remove tags. Connect wiring harness from ether injection solenoid and relay. Remove tags. Connect ether tube. Connect wiring harness wires at battery. Remove tags. Connect crankcase ventilation hose heater wires (4). Remove tags. Connect battery charging alternator output wire. Install battery charging alternator current sensor bracket to alternator. Tighten hose clamp (Figure 4-25, 25) to fuel collar fill hose (27). Connect auxiliary pump output line and cap (Figure 4-25). Connect fuel rail return line and cap (Figure 4-25). Plug in auxiliary fuel pump, P13. Plug in magnetic pickup, P12. Plug in electric actuator, P10. Connect oil pressure sender (4.13.1). Remove tag. Connect fuel float switch (paragraph 4.11.5). Remove tag. Install dead crank switch (paragraph 4.13.4). Connect fuel water separator drain line. Connect coolant overflow bottle drain line and install bracket to engine. Connect engine coolant drain hose at engine petcock (Figure 4-22). Connect radiator drain hose (paragraph 4.10.7). Install air filter assembly, refer to paragraph 4.9.2.
(16) (17) (18)
(19) (20) (21) (22) (23) (24) (25) (26) (27)
(28) (29) (30) (31) (32) (33) (34) (35) (36) (37) (38) (39) (40) (41) 5-18
(42) (43) (44) (45) (46) (47) 5.4.3
Install top housing section, refer to paragraph 4.7.3. Install DCS control box, refer to paragraph 4.7.2. Service engine lubrication system, paragraph 3.3.7. Service coolant system, paragraph 3.3.4. Connect negative battery cable to battery, and close BATTERY ACCESS door. Start generator set, paragraph 2.11.1. Check for proper operation.
Engine/Generator Disassembly. NOTE Refer to engine manual TM 9-2815-260-24 for information concerning repair of the engine. NOTE When removing generator only, refer to paragraph 5.10. a. Old Component Removal Prior to Installation. The following components may not be supplied with the new engine and must be removed from the old engine. Install on the new engine prior to its installation in the generator set. (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) Remove governor actuator (if replacing the engine). Remove temperature sender. Remove oil pressure sensor. Remove engine coolant drain cock. Remove speed sensor and bushing. Remove dead crank switch bracket. Remove engine legs on bell housing. Remove cable on fuel injector pump and bracket. Remove bracket for fan guards. Remove radiator and brackets. Remove breather, breather hoses, heaters and insulation. Remove ether injector. Remove oil drain from oil pan. Remove fan blade and extension hub. 5-19
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 (15) (16) (17) b. Remove bracket clamp bolts. Remove fuel pump fittings. Remove oil sampling valves.
Compare New and Old Engine. Compare new and old engines. Remove components unique to the old engine and install these on the new engine prior to installation in the generator set.
c.
Installation. (1) Install rear engine lifting bracket (54, Figure 5-1), lockwasher (53), and bolt (52), lockwasher (51), and bolt (50) on engine. Install front engine lifting bracket (49), lockwashers (48), and bolts (47) on engine. __________ WARNING Generator is heavy. Obtain assistance when moving generator with hoist. Failure to comply can cause injury to personnel. CAUTION Generator is heavy. Rated capacity of overhead hoist should be at least 1,000 lb. (454 kg). Failure to comply can cause damage to equipment. (3) (4) Attach lifting harness to overhead hoist and generator lifting eye. Take up slack on harness. Position generator to mount onto engine. Ensure generator drive disc is aligned with engine flywheel. Note scribe mark made at removal. Install bolts (40), lockwashers (41) and washer (42) into flywheel housing. Secure generator to engine flywheel housing with washers (42), lockwashers (41), and bolts (40). Torque bolts to 25 ft-lb (33.9 Nm). Secure generator drive disc to engine flywheel with washers (39) and bolts (38). Torque bolts to 25 ft-lb (33.9 Nm). Install band cover (37), washers (36), screws (35), lockwashers (34), and nuts (33) on generator case. Detach lifting device from generator lifting eye. Install engine and generator assembly, paragraph 5.4.2
(2)
(5)
(6)
(7)
(8) (9)
5-20
FIGURE 5-1. ENGINE AND GENERATOR ASSEMBLY (SHEET 1 OF 2)
5-21
FIGURE 5-1. ENGINE AND GENERATOR ASSEMBLY (SHEET 2 OF 2) 5.5 MAINTENANCE OF DCS CONTROL BOX ASSEMBLY. __________ WARNING When disconnecting or removing batteries, disconnect the negative lead that connects directly to the grounding stud first. Disconnect the negative end of the interconnection cable next. When installing batteries, reverse the connection sequence. Failure to comply can cause serious personal injury. 5.5.1 DCS Control Box Wiring Harness. CAUTION Electronic components containing printed circuit boards are extremely sensitive to electrostatic discharge (ESD). Wear an ESD wrist strap connected to ground whenever coming in contact with ESD-sensitive components. Failure to comply can cause severe damage to equipment. a. Inspection. (1) (2) (3) 5-22 Shut down generator set, paragraph 2.11.2. Remove DCS control box top panel, paragraph 4.7.2. Attach ESD wrist strap and connect to ground.
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 (4) Inspect DCS wiring harness for burned, bent, corroded, and broken terminals. Refer to Figure 4-16. Inspect connectors for cracks, corrosion, stripped threads, bent or broken pins, and obvious damage. Inspect wire insulation for burns, deterioration, and chafing. Disconnect ESD wrist strap, and remove wrist strap. Install DCS control box top panel, paragraph 4.7.2.
(5)
(6) (7) (8) b.
Testing. (1) (2) (3) (4) (5) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Remove DCS control box top panel, paragraph 4.7.2. Attach ESD wrist strap and connect to ground. Set multimeter for ohms, and test individual wires of DCS wiring harness for continuity. Refer to Wiring Diagram FO-3, for wire identification. Disconnect ESD wrist strap, and remove wrist strap. Install DCS control box top panel, paragraph 4.7.2. Connect negative battery cable to battery, and close BATTERY ACCESS door.
(6) (7) (8) c.
Replacement. (1) (2) (3) (4) (5) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Remove DCS control box top panel, paragraph 4.7.2. Attach ESD wrist strap and connect to ground. Disconnect DCS control box wiring harness connectors and terminals from components, and remove wiring harness from DCS control box assembly. Refer to Wiring Diagram FO-3. Position DCS control box wiring harness in DCS control box, and connect wiring harness connectors and terminals to components. Refer to Wiring Diagram FO-3. Disconnect ESD wrist strap, and remove wrist strap. Install DCS control box top panel, paragraph 4.7.2. Connect negative battery cable to battery, and close BATTERY ACCESS door.
(6)
(7) (8) (9)
5.5.2
Resistor R1. 5-23
Replacement. (1) (2) (3) (4) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Remove DCS control box top panel, paragraph 4.7.2. Remove sleeving (14), tag and desolder electrical leads from resistor (10, Figure 4-16). Refer to Schematic FO-1. Remove resistor (10) from auxiliary control bracket (18). Install resistor (10) to auxiliary control bracket (18). Install sleeving (14) and solder electrical leads to resistor (10). Remove tags. Install DCS control box top panel, paragraph 4.7.2. Connect negative battery cable to battery, and close BATTERY ACCESS door.
(5) (6) (7) (8) (9) 5.5.3
Resistor R2 Replacement. (1) (2) (3) (4) (5) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Remove DCS control box top panel, paragraph 4.7.2. Tag and desolder electrical leads from resistor (13, Figure 4-16). Remove nuts (11), lockwashers (12), resistor (13), sleeving (14), screws (15), and lockwashers (16) from auxiliary control bracket (18). Install lockwashers (16), screws (15), sleeving (14), resistor (13), lockwashers (12), and nuts (11) on auxiliary control bracket (18). Solder electrical leads to resistor (13). Remove tags. Install DCS control box top panel, paragraph 4.7.2. Connect negative battery cable to battery, and close BATTERY ACCESS door.
(6)
(7) (8) (9) 5.6 5.6.1
MAINTENANCE OF COOLING SYSTEM. Radiator. Repair radiator in accordance with TM 750-254.
5-24
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 5.7 MAINTENANCE OF FUEL SYSTEM. __________ WARNING When disconnecting or removing batteries, disconnect the negative lead that connects directly to the grounding stud first. Disconnect the negative end of the interconnection cable next. When installing batteries, reverse the connection sequence. Failure to comply can cause serious personal injury. 5.7.1 Fuel Tank. a. Removal. (1) (2) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. __________ WARNING Diesel fuel is flammable and toxic to eyes, skin, and respiratory tract. Skin and eye protection are required when working in contact with diesel fuel, and avoid repeated or prolonged contact. Provide adequate ventilation. Failure to comply can cause injury or death to personnel. NOTE Refer to Figure 1-30 for general location of assembly. (3) Remove cap (28, Figure 4-26), open fuel drain valve (30), and drain fuel into a suitable container. Remove engine and generator assembly, paragraph 5.4.2. Remove fuel drain valve, paragraph 4.11.4. Remove nuts (1, Figure 5-2), lockwashers (2), washers (3), bolts (4), washers (5), and holddown assemblies (6) securing fuel tank (7) to skid base. Remove fuel tank (7) from skid base. Remove fuel level sender, paragraph 4.11.5. Remove fuel pickup, paragraph 4.11.6. Remove fitting (8) from fitting stud (11) on right side of fuel tank (7). Remove fitting (9) from fitting stud (11) on left side of tank (7). Remove tee (10) from fitting stud (11). Remove fittings studs (11), washers (12), and bushings (13) from fuel tank (7). Cover all openings in fuel tank (7).
(4) (5) (6)
(7) (8) (9) (10) (11) (12) (13) (14)
b.
Inspection. 5-25
(1) (2) (3) (4) (5) c.
Shut down generator set, paragraph 2.11.2. Remove fuel tank, refer to paragraph 5.7.1.a. Inspect fuel tank (7, Figure 5-2) for leaks, cracks, missing hardware, and other damage. If damage is found, replace fuel tank (7). Install fuel tank, refer to paragraph 5.7.1.c.
Installation. (1) (2) Uncover openings in fuel tank (7, Figure 5-2). Apply sealing compound (Item 22, Appendix E) to threads of fitting studs (11). Install bushings (13), washers (12), and fitting studs (11) on fuel tank (7). Torque fitting studs (11) to 40 inchpounds. Apply sealing compound (Item 22, Appendix E) to threads of tee (10). Install tee on fitting stud (11) on fuel tank (7). Apply sealing compound (Item 22, Appendix E) to threads of fitting (9). Install tee on fitting stud (11) on left side of fuel tank (7). Apply sealing compound (Item 22, Appendix E) to threads of fitting (8). Install fitting on fitting stud (11) on right side of fuel tank (7). Install fuel pickup, paragraph 4.11.6. Install fuel level sender, paragraph 4.11.5. Position fuel tank (7) in skid base. Secure fuel tank (7) to skid base with holddown assemblies (6), washers (5), bolts (4), washers (3), lockwashers (2), and bolts (1). Install fuel drain valve, paragraph 4.11.4. Install engine and generator assembly, paragraph 5.4.2. Service fuel tank. Refer to Table 4-1 for proper fuel. Connect negative battery cable to battery, and close BATTERY ACCESS door.
(3)
(4)
(5)
(5) (6) (7) (8)
(9) (10) (11) (12)
5-26
FIGURE 5-2. FUEL TANK
5-27
5.8
MAINTENANCE OF OUTPUT BOX ASSEMBLY. __________ WARNING When disconnecting or removing batteries, disconnect the negative lead that connects directly to the grounding stud first. Disconnect the negative end of the interconnection cable next. When installing batteries, reverse the connection sequence. Failure to comply can cause serious personal injury.
5.8.1
Output Box Assembly. a. Removal. (1) (2) (3) (4) (5) (6) (7) (8) (9) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Remove DCS control box assembly, paragraph 4.8.1. Remove top housing section, paragraph 4.7.3. Remove air cleaner assembly, paragraph 4.9.2. Remove output box access door. Refer to paragraph 4.7.1. Remove rear housing panel. Refer to paragraph 4.7.5. Open left side engine compartment access doors (Figure 1-3). Tag and disconnect electrical leads from fuel injection pump (refer to TM 9-2815-260-24), electric actuator (refer to paragraph 5.9.1), DEAD CRANK switch (refer to paragraph 4.13.4), oil pressure sender (refer to paragraph 4.13.1), coolant temperature sender (refer to paragraph 4.13.2), auxiliary fuel pump (refer to paragraph 4.11.2), fuel pickup (refer to paragraph 4.11.6) and magnetic pickup (refer to paragraph 4.13.3). Open right side engine compartment access doors (Figure 1-2). Tag and disconnect electrical leads from battery charging alternator, starter, and ether solenoid valve, fuel level sender (refer to paragraph 4.13.1), crankcase breather assembly heater wires, slave cables and battery cables (4.6.2). Refer to paragraph 4.11.9 and TM 9-2815-260-24. Remove locknuts (1, Figure 5-3), screws (2), and loop clamps (3) from side panel (32) and wiring harness (31). Remove voltage reconnection terminal board, paragraph 5.8.2. Remove locknuts (4), bolts (5), and top panel (6) from output box assembly. NOTE Record number and direction of wraps when removing main generator cables from transformer for installation later.
(10) (11)
(12)
(13) (14)
5-28
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 (15) Unwrap main generator cables from droop current transformer (33) and current transformer (34). Remove screws (7), washers (8), and cover (9) from AC circuit interrupter (35). Tag and disconnect output cables from terminals A2, B2, and C2 of AC circuit interrupter (35). Tag and disconnect exciter leads F1 and F2 from terminals 1 and 2 of terminal board (29). Remove locknuts (10), bolts (11), and output box assembly from generator set.
(16)
(17)
(18)
(19) b.
Installation. (1) Install output box assembly on generator set with bolts (11, Figure 5-3) and locknuts (10). Connect exciter leads F1 and F2 to terminals 1 and 2 of terminal board (29). Remove tags. Connect output cables to terminals A2, B2, and C2 of AC circuit interrupter (35). Remove tags. Install cover (9), washers (8), and screws (7) on AC circuit interrupter (35). Install main generator cables on current transformer (34) and droop current transformer (33) the same number of wraps recorded during removal. Install output box top panel (6), bolts (5), and locknuts (4) on output box assembly. Install voltage reconnection terminal board, paragraph 5.8.2. Install loop clamps (3), screws (2), and locknuts (1) on wiring harness (31) and side panel (32). On right side of engine, connect electrical leads from battery charging alternator, starter, and ether solenoid valve, fuel level sender (refer to paragraph 4.13.1), crankcase breather assembly heater wires, slave cables and battery cables (4.6.2). Refer to paragraph 4.11.9 and TM 9-2815260-24. Remove tags. Connect electrical leads from fuel injection pump (refer to TM 9-2815-260-24), electric actuator (refer to paragraph 5.9.1), DEAD CRANK switch (refer to paragraph 4.13.4), oil pressure sender (refer to paragraph 4.13.1), coolant temperature sender (refer to paragraph 4.13.2), auxiliary fuel pump (refer to paragraph 4.11.2), fuel pickup (refer to paragraph 4.11.6) and magnetic pickup (refer to paragraph 4.13.3). Remove tags.
(2) (3)
(4) (5)
(6) (7) (8) (9)
(10)
(11) Install rear housing panel. Refer to paragraph 4.7.5. (12) (13) (14) (15) Install output box access door. Refer to paragraph 4.7.1. Install air cleaner assembly, paragraph 4.9.2. Install top housing section, paragraph 4.7.3. Install DCS control box assembly, paragraph 4.8.1. 5-29
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 (16) (17) Close engine compartment access doors. Connect negative battery terminal to battery, and close BATTERY ACCESS door.
FIGURE 5-3. OUTPUT BOX ASSEMBLY (SHEET 1 OF 2)
5-30
FIGURE 5-3. OUTPUT BOX ASSEMBLY (SHEET 2 OF 2)
5.8.2
Voltage Reconnection Terminal Board TB1. a. Inspection. Inspect voltage reconnection terminal board (22, Figure 5-3) for cracks, corrosion, stripped threads, bent or broken terminal studs, and other obvious damage. b. Replacement. (1) (2) (3) (4) (5) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Open output box and load terminal board access doors (Figure 1-2). Remove locknuts (12, Figure 5-3), washers (13), and protective cover (14) from standoffs (15). Remove standoffs (15), washers (16), bolts (17), washers (18), and mounts (19) from rear panel (36) and voltage reconnection board (22). Tag electrical cables, main generator cables, and capacitors (21) at voltage reconnection board (22). Remove locknuts (20), cables, and capacitors (21) from voltage reconnection board. Remove voltage reconnection board (22), with moveable terminal board (24) attached, from rear panel (36). Remove locknuts (23) and moveable terminal board (24) from terminal studs (26). Remove nuts (25) and terminal studs (26) from voltage reconnection board (22). Install terminal studs (26) and nuts (25) on voltage reconnection board (22). Torque nuts to 150200 inch-pounds (16.9-22.6 Nm). Install moveable terminal board (24) and locknuts (23) on terminal studs (26). 5-31
(6)
(7)
(8) (9) (10)
(11)
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 (12) (13) Position voltage reconnection board (22) and moveable terminal board (24) on rear panel (36). Install capacitors (21), electrical cables, main generator cables, and locknuts (20) on voltage reconnection board (22). Remove tags. Secure voltage reconnection board (22) to rear panel (36) with mounts (19), washers (18), bolts (17), washers (16), and standoffs (15). Install protective cover (14), washers (13), and locknuts (12) on standoffs (15). Close output box and load terminal board access doors. Connect negative battery cable to battery, and close BATTERY ACCESS door.
(14)
(15) (16) (17) 5.8.3
Output Box Wiring Harness. a. Removal. (1) (2) (3) (4) (5) (6) (7) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Remove DCS control box assembly, paragraph 4.8.1. Remove output box top panel, paragraph 5.8.1. Open left side engine compartment access doors (Figure 1-3). Tag and disconnect crankcase breather assembly heater wires and slave and battery cables. Tag and disconnect electrical leads from fuel injection pump (refer to TM 9-2815-260-24), electric actuator (refer to paragraph 5.10.1), DEAD CRANK switch (refer to paragraph 4.13.4), oil pressure sender (refer to paragraph 4.13.1), coolant temperature sender (refer to paragraph 4.13.2), auxiliary fuel pump (refer to paragraph 4.11.2), fuel pickup (refer to paragraph 4.11.6), fuel level sender (refer to paragraph 4.11.5), and magnetic pickup (refer to paragraph 4.13.3). Open right side engine compartment access doors (Figure 1-2). Tag and disconnect electrical leads from battery charging alternator, starter, and ether solenoid valve. Refer to paragraph 4.11.9 and TM 9-2815-260-24. Open output box access door (Figure 1-2). Remove screws (7, Figure 5-3), washers (8), and cover (9) from AC circuit interrupter (35). Tag and disconnect electrical leads from cranking relay (37), current transformer (34), AC circuit interrupter (35), potential power transformer (38), and voltage reconnection board (22). Tag and disconnect electrical leads for droop current transformer (33) from terminal board (29). Remove locknuts (27), screws (28), and terminal boards (29 and 30) from side panel (32). Remove locknuts (1), screws (2), and loop clamps (3) from side panel (32) and wiring harness (31). Remove wiring harness (31) from output box and generator set.
(8) (9)
(10) (11) (12)
(13) (14) (15) (16) 5-32
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 b. Inspection. (1) (2) (3) Remove output box wiring harness, step a above. Inspect wiring harness for burned, bent, corroded, and broken terminals. Inspect connectors for cracks, corrosion, stripped threads, bent or broken pins, and other obvious damage. Inspect wire insulation for burns, deterioration, and chafing. Install output box wiring harness, 5.8.3.e.
(4) (5) c.
Testing.
Set multimeter for ohms. Check individual wires, connectors, and terminal boards for continuity. Refer to Wiring Diagram FO-3, for wire identification. d. Repair. (1) (2) e. Replace damaged cable assemblies, terminals, connectors, sockets, and terminal boards. Replace wires with damaged insulation and those that do not indicate continuity.
Installation. (1) (2) (3) (4) Position wiring harness (31, Figure 5-3) in output box and generator set. Install loops clamps (3), screws (2), and locknuts (1) on wiring harness (31) and side panel (32). Install terminal boards (30 and 29), screws (28), and locknuts (27) on side panel (32). Connect electrical leads from droop current transformer (33) to terminal board (29). Remove tags. Connect electrical leads to AC circuit interrupter (35), current transformer (34), cranking relay (37), power potential transformer (38), and voltage reconnection board (22). Remove tags. Install cover (9), washers (8), and screws (7) on AC circuit interrupter (35). On right side of engine, connect electrical leads from battery charging alternator, starter, crankcase breather assembly heater wires, slave and battery cables and ether solenoid valve. Refer to paragraph 4.11.9 and TM 9-2815-260-24. Remove tags. Connect electrical leads to fuel injection pump (refer to TM 9-2815-260-24), electric actuator (refer to paragraph 5.10.1), DEAD CRANK switch (refer to paragraph 4.13.4), oil pressure sender (refer to paragraph 4.13.1), coolant temperature sender (refer to paragraph 4.13.2), auxiliary fuel pump (refer to paragraph 4.11.2), fuel pickup (refer to paragraph 4.11.6), fuel level sender (refer to paragraph 4.11.5), and magnetic pickup (refer to paragraph 4.13.3). Remove tags. Install output box top panel, paragraph 5.8.1. Install DCS control box assembly, paragraph 4.8.1. Close output box and engine compartment access doors. 5-33
(5)
(6) (7)
(8)
(9) (10) (11)
(12) 5.8.4
Current Transformer CT1, CT2, CT3. a. Removal. (1) (2) (3) (4) (5) (6) (7) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Remove DCS control box assembly, paragraph 4.8.1. Remove output box top panel, paragraph 5.8.1. Open output box and right side engine compartment access doors (Figure 1-2). Tag and disconnect electrical leads from current transformer (4, Figure 5-4). Tag and disconnect main generator cables T2 and T8 from voltage reconnection board (34). NOTE Record number and direction of wraps when removing main generator cables from transformer for installation later. (8) (9) b. Unwrap main generator cables from droop current transformer (7) and current transformer (4). Remove locknuts (1), screws (2), washers (3), and current transformer (4) from rear panel (33).
Testing. (1) (2) Remove current transformer, refer to paragraph 5.8.4.a. Set multimeter for ohms, and check for continuity between secondary terminals A1 and A2, B1 and B2, and C1 and C2. If continuity is present, continue with test. If continuity is not present, current transformer is defective and must be replaced. Set up a test circuit using 10 gauge wire as shown in Figure 5-5. Make 10 passes with wire through phase A window. Turn on power source and load bank. Adjust load bank until 27.7 amps is indicated on ammeter. Set multimeter for amperes, and connect to secondary terminals A1 and A2. Multimeter indication must be 0.9 to 1.1 amps. Repeat steps (3) through (5) using phase B window and secondary terminals B1 and B2. Repeat steps (3) through (5) using phase C window and secondary terminals C1 and C2.
(3)
(4) (5)
(6) (7)
5-34
(8) (9) (10) c.
Replace current transformer if multimeter indication in any phase is other than stated in step (5). Remove current transformer from test circuit. Install current transformer, refer to paragraph 5.8.4.c.
Installation. (1) Install current transformer (4, Figure 5-4), washers (3), screws (2), and locknuts (1) on rear panel (33). Install main generator cables on current transformer (4) and droop current transformer (7) the same number of wraps recorded during removal. Connect main generator cables T2 and T8 to voltage reconnection board (34). Remove tags. Connect electrical leads to current transformer (4). Remove tags. Install output box top panel, paragraph 5.8.1. Install DCS control box assembly, paragraph 4.8.1. Close output box and engine compartment access doors. Connect negative battery cable to battery, and close BATTERY ACCESS door.
(2)
(3) (4) (5) (6) (7) (8) 5.8.5
Droop Current Transformer CT5. a. Removal. (1) (2) (3) (4) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Open output box and right side engine compartment access doors (Figure 1-2). Tag and disconnect main generator cables T2 and T8 from voltage reconnection board (34, Figure 5-4). NOTE Record number and direction of wraps when removing main generator cables from transformer for installation later. (5) (6) (7) Unwrap main generator cables from droop current transformer (7). Tag and disconnect droop current transformer (7) electrical leads from terminal board (35). Remove locknuts (5), screws (6), and droop current transformer (7) from rear panel (33).
5-35
FIGURE 5-4. OUTPUT BOX COMPONENTS
5-36
FIGURE 5-4. OUTPUT BOX COMPONENTS (SHEET 2 OF 2)
FIGURE 5-5. TESTING CURRENT TRANSFORMER
b.
Testing. (1) (2) Remove droop current transformer, refer to paragraph 5.8.5.a. Set multimeter for ohms, and check for continuity between secondary leads 1 and 2. If continuity is present, continue with test. If continuity is not present, droop current transformer is defective and must be replaced. Set up a test circuit using 10 gauge wire as shown in Figure 5-6. Make 10 passes with wire through window of droop current transformer. Turn on power source and load bank. Adjust load bank until 20.8 amps is indicated on AC ammeter. Set multimeter for AC amperes, and connect to secondary leads 1 and 2. Multimeter indication must be 0.9 to 1.1 amps. Replace droop current transformer if multimeter indication in any phase is other than stated in step (5). 5-37
(3)
(4)
(5)
(6)
FIGURE 5-6. TESTING DROOP CURRENT TRANSFORMER (7) (8) c. Remove droop current transformer from test circuit. Install droop current transformer, refer to paragraph 5.8.5.c.
Installation. (1) (2) (3) Install droop current transformer (7, Figure 5-4), screws (6), and locknuts (5) on rear panel (33). Connect droop current transformer (7) electrical leads to terminal board (35). Remove tags. Install main generator cables on droop current transformer (7) the same number of wraps recorded during removal. Connect main generator cables T2 and T8 to voltage reconnection board (34). Remove tags. Close output box and engine compartment access doors. Connect negative battery cable to battery, and close BATTERY ACCESS door.
(4) (5) (6) 5.8.6
Power Potential Transformer T1. a. Removal. (1) (2) (3) (4) (5) (6) b. Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Remove DCS control box assembly, paragraph 4.8.1. Remove output box top panel, paragraph 5.8.1. Tag and disconnect electrical leads from power potential transformer (10, Figure 5-4). Remove locknuts (8), screws (9), and power potential transformer (10) from rear panel (33).
Installation. (1) Install power potential transformer (10, Figure 5-4), screws (9), and locknuts (8) on rear panel (31). Connect electrical leads to power potential transformer (10). Remove tags.
(2) 5-38
(3) (4) (5) 5.8.7
Install output box top panel, paragraph 5.8.1. Install DCS control box assembly, paragraph 4.8.1. Connect negative battery cable to battery, and close BATTERY ACCESS door.
Output Box Panels. a. Inspection. (1) Inspect output box panels (13, 24, 27, and 33, Figure 5-4) for cracks, dents, loose paint, corrosion, and other damage. Inspect grommets (28 and 29), protective edging (30), door seal (31), and EMI seal (32) for looseness, tears, deterioration, and other damage.
(2)
b.
Removal. (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16) (17) (18) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Remove DCS control box assembly, paragraph 4.8.1. Remove rear housing panel. Refer to paragraph 4.7.5. Remove output box access door. Refer to paragraph 4.7.1. Remove air cleaner assembly, paragraph 4.9.2. Remove locknuts (11, Figure 5-4), bolts (12), and top panel (13) from output box assembly. Remove voltage reconnection terminal board, paragraph 5.8.2. Remove droop current transformer, paragraph 5.8.5. Remove power potential transformer, paragraph 5.8.6. Remove current transformer, paragraph 5.8.4. Remove output box wiring harness, paragraph 5.8.3. Remove locknuts (14), screws (15), and AC circuit interrupter (16) from rear panel (33). Remove locknuts (17), screws (18), and cranking relay (19) from side panel (27). Remove locknuts (20), bolts (21), and output box panels (24, 27, and 33) from generator set. Remove locknuts (22), bolts (23), and side panel (24) from rear panel (33). Remove locknuts (25), bolts (26), and side panel (27) from rear panel (33). Remove grommets (28 and 29) from rear panel (33).
c.
Repair. 5-39
__________ WARNING CARC paint is a health hazard. Wear protective eyewear, mask and gloves when sanding CARC painted surfaces. Failure to comply can cause personal injury. (1) (2) (3) (4) (5) (6) d. Repair all dents and cracks, and remove loose paint. Remove light corrosion with fine grit abrasive paper (Item 16, Appendix E). Replace damaged grommets (28 and 29, Figure 5-4) and door seal (31). Using adhesive (1, Appendix E), replace damaged protective edging (30). Using adhesive (1, Appendix E), replace damaged EMI seal (32). Repaint surfaces in accordance with TM 43-0139.
Installation. (1) (2) (3) (4) Install grommets (28 and 29, Figure 5-4) in real panel (33). Install side panel (27), bolts (26), and locknuts (25) on rear panel (33). Install side panel (24), bolts (23), and locknuts (22) on rear panel (33). Position output box panels (33, 27, and 24) in generator set, and secure with bolts (21) and locknuts (20). Install cranking relay (19), screws (18), and locknuts (17) on side panel (27). Install AC circuit interrupter (16), screws (15), and locknuts (14) on rear panel (33). Install output box wiring harness, paragraph 5.8.3. Install current transformer, paragraph 5.8.4. Install power potential transformer, paragraph 5.8.6. Install droop current transformer, paragraph 5.8.5. Install voltage reconnection terminal board, paragraph 5.8.2. Install output box top panel (13), bolts (12), and locknuts (11) on output box assembly. Install air cleaner assembly, paragraph 4.9.2. Install output box access door. Refer to paragraph 4.7.1. Install rear housing panel. Refer to paragraph 4.7.5. Install DCS control box assembly, paragraph 4.8.1. Connect negative battery cable to battery, and close BATTERY ACCESS door.
(5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16) (17) 5-40
5.9
MAINTENANCE OF ENGINE ACCESSORIES. __________ WARNING When disconnecting or removing batteries, disconnect the negative lead that connects directly to the grounding stud first. Disconnect the negative end of the interconnection cable next. When installing batteries, reverse the connection sequence. Failure to comply can cause serious personal injury.
5.9.1
Electric Actuator A6. a. Inspection. Inspect electric actuator (11, Figure 5-7) for corrosion, dents, missing hardware, and obvious damage. b. Testing. (1) (2) (3) (4) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Disconnect output box wiring harness from electrical connector (1, Figure 5-7). Set multimeter for ohms. Test continuity at contacts within electrical connector (1). Multimeter should indicate continuity. If multimeter reading is other than above, replace electric actuator (11, Figure 5-8). Connect electrical connector (1) to output box wiring harness. Connect negative battery cable to battery, and close BATTERY ACCESS door.
(5) (6) (7)
5-41
FIGURE 5-7. ELECTRIC ACTUATOR
5-42
c.
Replacement. (1) (2) (3) (4) (5) (6) (7) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Remove fan guard from left side of generator set. Refer to paragraph 4.10.3. Remove dead crank switch plate (10, Figure 4-29). Disconnect output box wiring harness from electrical connector (1, Figure 5-7). Loosen coupling nut (2), and remove fuel line (3) and seal (4) from elbow (5). Remove elbow (5), seal (6), adapter (7), seal (8), and adapter (9) from electric actuator (11). NOTE One cap screw is longer than the others. Note position of cap screws for installation later. (8) (9) Remove cap screws (10), electric actuator (11), and gasket (12) from engine. Position gasket (12) and electric actuator (11) on engine. Secure with cap screws (10) as noted in step (6). Install adapter (9), seal (8), adapter (7), seal (6), and elbow (5) on electric actuator (11). Position seal (4) and fuel line (3) on elbow (5). Tighten coupling nut (2). Connect output box wiring harness to electrical connector (1). Install fan guard from left side of generator set. Refer to paragraph 4.10.3. Install dead crank switch plate (10, Figure 4-29). Connect negative battery cable to battery, and close BATTERY ACCESS door.
(10) (11) (12) (13) (14) (15) 5.10
MAINTENANCE OF GENERATOR ASSEMBLY. __________ WARNING When disconnecting or removing batteries, disconnect the negative lead that connects directly to the grounding stud first. Disconnect the negative end of the interconnection cable next. When installing batteries, reverse the connection sequence. Failure to comply can cause serious personal injury.
5-43
5.10.1
Generator Assembly. __________ WARNING High voltage is produced when this generator set is in operation. Make sure unit is completely shut down and free of any power source before attempting any repair or maintenance on the unit. Failure to comply can cause injury or death to personnel. a. Removal. (1) (2) (3) (4) (5) (6) (7) (8) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Remove output box assembly, paragraph 5.8.1. Remove rear housing section, paragraph 4.8.5. Remove load output terminal board, paragraph 4.12.8. Remove rear forklift guide. Refer to paragraph 5.11.1. Loosen nut (31, Figure 5-8), adjust bolt (32) to contact support frame (33) and tighten nut (31). Remove nuts (1, Figure 5-8), lockwashers (2), bolts (3), washers (4), and rear forklift guide (5) from skid base. __________ WARNING Rated capacity of overhead hoist should be at least 1,000 lbs. (454 kg.) Using a hoist with less capacity could result in equipment damage, personal injury or death. (9) (10) Attach lifting harness to overhead hoist and generator lifting eye. Take up slack. Remove nuts (6), lockwashers (7), screws (8), washers (9), and band cover (10) from generator case. Remove bolts (11), and washers (12) securing generator drive disc to engine flywheel. Remove bolts (13), lockwashers (14), and washers (15) securing generator to engine flywheel housing. Remove nuts (16), washers (17), snubbing washers (18), bolts (19) and Belleville washers (20) securing generator to skid base. Lift generator slowly from skid base, ensuring that engine flywheel housing adapter and generator separate smoothly avoiding any undue stress. Remove generator shock mounts (26) from skid base. Remove nuts (21), washers (22), bolts (23), washers (24), nuts (25) from generator mounts.
(11) (12)
(13)
(14)
(15) (16) 5-44
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 b. Installation. (1) (2) Position generator shock mounts (26, Figure 5-8) in skid base. Install bolts (23), nuts (25), washers (24), washers (22) and nuts (21) on generator mounts. __________ WARNING Rated capacity of overhead hoist should be at least 1,000 lbs. (454 kg.) Using a hoist with less capacity could result in equipment damage, personal injury or death. (3) (4) Attach lifting harness to overhead hoist and generator lifting eye. Position generator on skid base aligning mounting holes with mounts and engine flywheel housing. Install bolts (13), washers (14), and lockwashers (15). Tighten bolts (13) slowly to ensure even and proper seating of generator case lip to engine flywheel housing. Torque bolts to 25 lbs.-ft (34 Nm). Install bolts (19), Belleville washers (20), snubbing washers (18), washers (17), and nuts (16) securing generator to skid base. Torque nuts (16) to 210 lbs-ft. (285 Nm). Install bolts (11) and washers (12) securing generator drive disc to engine flywheel. Torque bolts (11) to 35 lbs-ft.(47 Nm). Install screen band (10) on generator case with screws (8), washers (9), lockwashers (7), and nuts (6). Adjust nuts (21) on generator mount, to obtain 0.5 in. (12.7 mm) minimum clearance between ends of bolts (23) and skid base. Torque nuts (21) to 150 lbs.-ft. (203 Nm). Loosen nut (31), adjust bolt (32) until 0.25 in. (6.4 mm) protudes past contact support frame (33). Tighten nut (31). Install rear forklift guide. Refer to paragraph 5.11.1. Install load terminal board, paragraph 4.12.8. Install rear housing section, paragraph 4.8.5. Install output box assembly, paragraph 5.8.1. Connect negative battery cable to battery, and close BATTERY ACCESS door. Start generator set, paragraph 2.11.1. Check for proper operation.
(5)
(6)
(7)
(8)
(9)
(10)
(11) (12) (13) (14) (15) (16)
5-45
FIGURE 5-8. GENERATOR ASSEMBLY REMOVAL 5-46
5.10.2
End Bell and Main Bearing. a. Removal. (1) (2) (3) (4) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Remove rear housing panel. Refer to paragraph 4.7.5. Remove bolts (5, Figure 5-9), lockwashers (6), top cover (7), and louvered covers (12) from end bell (16). CAUTION The end bell supports the main rotor, thus the rotor will drop on the stator once the end bell is removed. Prior to proceeding, bar engine by using center bolt on harmonic balancer, TM 9-2815-260-24, until two main rotor poles are vertical in generator stator. Having the rotor in this position will limit the amount of drop, otherwise damage to rotor and/or stator could occur. (5) Loosen lead clamp assembly (3, Figure 5-9) clamping generator leads at front of generator housing (33). Ensure wires F1 and F2 are free to slide in and out of generator housing. Remove bolts (13) and lockwashers (14) and washer (15) from end bell (16). Remove end bell (16), with exciter stator (22) attached.
(6) (7)
CAUTION If bearing needs to be removed for any reason, always install new bearing. Main bearing is easily damaged when removed from rotor shaft. Failure to install a new bearing can cause damage to equipment. (8) b. Using bearing puller, remove bearing (17) from main rotor shaft (23). Discard bearing.
Installation. CAUTION If bearing needs to be removed for any reason, always install new bearing. Main bearing is easily damaged when removed from rotor shaft. Failure to install a new bearing can cause damage to equipment. (1) Heat new bearing (17, Figure 5-9) to expand diameter to fit on main rotor (23) shaft. Install new bearing (17) on main rotor (23) shaft. Ensure bearing is seated squarely against shaft shoulder by applying pressure to inner race only. Position bearing (17) in end bell (16).
(2)
5-47
FIGURE 5-9. GENERATOR ASSEMBLY 5-48
FIGURE 5-10. END BELL REMOVAL
NOTE It may be necessary to use a lifting device to raise and align end bell with generator. (3) Position end bell (16), with exciter stator (22) attached, on generator housing (33) while pulling slack of wires F1 and F2 through front of generator housing. Secure end bell with washers (15), lockwashers (14) and bolts (13). Torque bolts to 59-61 inch-pounds (6.7-7.0 Nm). Tighten lead clamp assembly (3) at front of generator housing (33), ensuring generator leads are clamped securely. Install louvered cover (12), top cover (7), lockwashers (6), and bolts (5) on end bell (16). Install rear housing panel. Refer to paragraph 4.7.5. Connect negative battery cable to battery, and close BATTERY ACCESS door.
(4)
(5) (7) (8)
5-49
5.10.3
Rotating Rectifier. a. Testing. (1) (2) (3) (4) Shut down generator set, paragraph 2.11.2. Allow generator to cool to ambient temperature. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Remove rear housing panel. Refer to paragraph 4.7.5. Remove end bell cover plates. Refer to paragraph 5.10.2. NOTE It will be necessary to bar (turn) engine in order to position a specific area of the rotating rectifier at one of the end bell access holes. Use center bolt on harmonic balancer to turn engine. Refer to TM 9-2815-260-24. (5) Tag main rotor and diode leads, and remove nuts (1, Figure 5-11), lockwashers (15), and leads from terminal bolts (2). Tag exciter rotor leads, and remove bolts (3), washers (4), and leads from rectifier mounting plate (13). Set multimeter for ohms, and connect positive lead to one side and negative lead to other side of each diode (7). Record multimeter reading for each diode. Repeat step (7) with multimeter leads reversed. Resistance (ohms) readings should show continuity in one direction and no continuity in reversed direction. If readings show continuity or no continuity in both directions, diode is defective and must be replaced. Install exciter rotor leads, washers (4), and bolts (3) on rectifier mounting plate (13). Remove tags. Install diode and main rotor leads, lockwashers (15), and nuts (1) on rotating rectifier terminals. Install end bell cover plates. Refer to paragraph 5.10.2. Install rear housing panel. Refer to paragraph 4.7.5. Connect negative battery cable to battery, and close BATTERY ACCESS door.
(6)
(7)
(8) (9)
(10)
(11) (12) (13) (14) b.
Removal. (1) (2) (3) (4) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Remove rear housing panel. Refer to paragraph 4.7.5. Remove end bell and main bearing, paragraph 5.10.2.
5-50
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 (5) Remove nuts (1, Figure 5-11) and lockwashers (15) securing main rotor leads and rotating rectifier diode leads to terminal bolts (2). Tag and remove leads. Remove bolts (3) and washers (4) securing exciter rotor leads to rotating rectifier plate (13). Tag and remove leads. Remove bolts (18, Figure 5-9), lockwashers (19), and rotating rectifier (20) from rotor assembly (23).
(6)
(7)
c.
Replacement of Rotating Rectifier Diodes. (1) Shut down generator set, paragraph 2.11.2. (2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Remove rear housing panel. Refer to paragraph 4.7.5. Remove end bell top cover and louvered covers. Refer to paragraph 5.10.2. NOTE It will be necessary to bar (turn) engine in order to position a specific area of the rotating rectifier at one of the end bell access holes. Use center bolt on harmonic balancer to turn engine. Refer to TM 9-2815-260-24. (5) (6) Unsolder electrical lead from diode (7, Figure 5-11) to be removed. Remove nut (5), lockwasher (6), and diode (7) from rotating rectifier plate (13) through access hole in end bell. Run bead of thermal-electrical contact compound (Item 9, Appendix E) around base of diode (7) prior to installing. Do not coat threads. Insert diode (7) through generator end bell access hole, and install on rotating rectifier plate (13) with lockwasher (6) and nut (5). Torque nut to 28-30 inch-pounds (3.16-3.38 Nm). Using soldering iron and solder (Item 19, Appendix E), solder electrical lead to diode (7). Install end bell top cover and louvered covers. Refer to paragraph 5.10.2. Install rear housing panel. Refer to paragraph 4.7.5. Connect negative battery cable to battery, and close BATTERY ACCESS door.
(3) (4)
(7)
(8)
(9) (10) (11) (12) d.
Installation. (1) Install rotating rectifier (20, Figure 5-9), lockwashers (19), and bolts (18) on rotor assembly (23). Install exciter rotor leads, washers (4, Figure 5-11), and bolts (3) on rotating rectifier plate (13). Install main rotor leads and rotating rectifier diode leads, lockwashers (15), and nuts (1) on terminal bolts (2). Install end bell and main bearing, paragraph 5.10.2.
(2) (3)
(4)
5-51
FIGURE 5-11. RECTIFIER ASSEMBLY
5-52
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 (5) (6) Install rear housing panel. Refer to paragraph 4.7.5. Connect negative battery cable to battery, and close BATTERY ACCESS door.
5.10.4
Exciter Stator. a. Inspection. (1) (2) (3) Shut down generator set, paragraph 2.11.2. Allow generator to cool to ambient temperature. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Open output box access door (Figure 1-2), visually inspect generator assembly for obvious damage. Check exciter field leads for broken wires and signs of wear.
b.
Testing. (1) Shut down generator set, paragraph 2.11.2. Allow generator to cool to ambient temperature. Inspect Exciter Stator per paragraph 5.10.4 a. Open output box access door (Figure 1-2), and disconnect exciter field leads F1 and F2 from terminals 1 and 2 of terminal board TB8. Refer to Schematic FO-1. Set multimeter for ohms, and connect between disconnected exciter field leads. Multimeter reading should be as shown in Table 5-2. Multimeter reading other than in Table 5-2 indicates open or shorted windings, and exciter stator must be replaced.
(2)
(3)
(4)
TABLE 5-2. GENERATOR RESISTANCE VALUES AT 25 C (77 F) Resistance Component MEP-806B MEP-816B Exciter Stator Between 24.85 & 33.61 ohms Between 24.7301 & 33.4583 ohms Exciter Rotor Between 0.202 & 0.274 ohms Between 0.2082 & 0.2816 ohms Generator Rotor Between 0.52 & 0.70 ohms Between 1.0835 & 1.4659 ohms Generator Stator Between 0.040 & 0.054 ohms Between 0.015 & 0.0202 ohms (5) (6) Connect multimeter between each exciter field lead and generator frame in turn. Multimeter reading of less than infinity indicates defective ground insulation, and exciter stator must be replaced. Connect exciter field leads to terminals 1 and 2 of terminal board TB8 (Refer to Schematic FO1). Close output box access door (Figure 1-2). Connect negative battery cable to battery, and close BATTERY ACCESS door.
(7)
(8) c.
Replacement. (1) (2) (3) Shut down generator set, paragraph 2.11.2. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Remove rear housing panel. Refer to paragraph 4.7.5. 5-53
(4)
Open output box access door (Figure 1-2), and disconnect exciter field leads F1 and F2 from terminals 1 and 2 of terminal board TB8. Refer to Schematic FO-1. Attach pieces of rigid wire with a hook bent into one end of each ("fish wires") to disconnected F1 and F2 leads to aid in installation process. Remove end bell. Refer to paragraph 5.10.2. Remove bolt (21, Figure 5-9) and exciter stator (22) from end bell (16). Detach "fish wires" once F1 and F2 leads clear generator housing (33). Attach "fish wires" to F1 and F2 leads of exciter stator (22). Gently pull on "fish wires" to pull F1 and F2 leads back through generator housing (33). Disconnect "fish wires", and position F1 and F2 leads in output box, Figure 1-3. Position exciter stator (22) in end bell (16). Secure exciter stator in place with bolt (21). Install end bell. Refer to paragraph 5.10.2. Connect exciter field leads F1 and F2 to terminals 1 and 2 of terminal board TB8 (Figure 5-9). Close output box access door (Figure 1-2). Install rear housing panel. Refer to paragraph 4.7.5. Connect negative battery cable to battery, and close BATTERY ACCESS door.
(5)
(6) (7) (8) (9) (10)
(11) (12) (13)
(14) (15) 5.10.5
Exciter Rotor . a. Inspection. (1) (2) (3) (4) (5) Shut down generator set, paragraph 2.11.2. Allow generator to cool to ambient temperature. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Remove rear housing panel. Refer to paragraph 4.7.5. Remove end bell top cover and louvered covers. Refer to paragraph 5.10.2. Visually inspect generator assembly for obvious damage. Check exciter leads for broken wires and signs of wear.
b.
Test. (1) (2) Perform inspection per paragraph 5.10.5.a. Tag exciter rotor leads, and remove bolts (3, Figure 5-11), lockwashers (4), and leads from rotating rectifier plate (14).
5-54
NOTE It will be necessary to bar (turn) engine in order to position a specific area of the rotating rectifier at one end of the end bell access holes. Use center bolt on harmonic balancer. Refer to TM 9-2815-260-24. (3) Connect resistance bridge (ohmmeter) between two exciter rotor leads, and note resistance reading. Continue this procedure until readings are noted for each combination of leads (i.e., 1 and 2, 1 and 3, and 2 and 3). NOTE Ambient temperature must be expressed in C. To convert C to F, use F = C x 9 5 + 32. (a) To determine the resistance values at current ambient temperature, use the following formula: R1 = R25 [1 + 0.00385 (T-25)] Where: R1 = Unknown resistance R25 = Known resistance at 25 C (77 F) T = Current ambient temperature (b) Example for exciter stator leads at 5 C (41 F): R1 = 29.23 [1 + 0.00385 (5-25)] R1 = 29.23 [1 + 0.00385 (-20)] R1 = 29.23 [1 + (-0.077)] R1 = 29.23 [0.923] R1 = 26.98 15% ohms (4) Resistance readings should be as shown in Table 5-2 for each combination of leads. Readings other than in Table 5-2 indicate open or shorted windings, and rotor assembly must be replaced. Refer to paragraph 5.10.6. Set multimeter for ohms, and connect between each exciter rotor lead and rotor shaft in turn. Multimeter reading of less than infinity indicates defective ground insulation, and rotor assembly must be replaced. Refer to paragraph 5.10.6. Install exciter rotor leads, lockwashers (4), and bolts (3) on rotating rectifier plate (14). Install end bell top cover and louvered covers. Refer to paragraph 5.10.2. Install rear housing panel. Refer to paragraph 4.7.5. Connect negative battery cable to battery, and close BATTERY ACCESS door.
(5) (6)
(7) (8) (9) (10)
5-55
5.10.6
Generator Rotor Assembly. a. Testing. (1) (2) (3) (4) (5) Shut down generator set, paragraph 2.11.2. Allow generator to cool to ambient temperature. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Remove rear housing panel. Refer to paragraph 4.7.5. Remove end bell top cover and louvered covers. Refer to paragraph 5.10.2. Remove nuts (1, Figure 5-11) and lockwashers (15) securing main rotor leads to terminal bolts (2). Tag and remove leads. NOTE It will be necessary to bar (turn) engine in order to position a specific area of the rotating rectifier at one end of the end bell access holes. Use center bolt on harmonic balancer. Refer to TM 9-2815-260-24. (6) Set multimeter for ohms, and connect between disconnected main rotor leads. Multimeter reading should be as shown in Table 5-2. Reading other than in Table 5-2 indicates shorted or open windings, and main rotor must be replaced. Connect multimeter between each main rotor lead and rotor shaft in turn. Multimeter reading of less than infinity indicates defective ground insulation, and main rotor must be replaced. Install securing main rotor leads and rotating rectifier diode leads, lockwashers (15), and bolts (1) on terminal bolt (2). Install end bell top cover and louvered covers. Refer to paragraph 5.10.2. Install rear housing panel. Refer to paragraph 4.7.5. Connect negative battery cable to battery, and close BATTERY ACCESS door.
(7)
(8) (9)
(10)
(11) (12) (13)
b. Removal. (1) (2) (3) (4) (5) Shut down generator set, paragraph 2.11.2. Remove generator assembly, paragraph 5.10.1. Remove bolts (24, Figure 5-9), washers (25) and drive discs (26) from drive hub (31). Remove bolts (27), lockwashers (28), and fan (29) from drive hub (31). Attach a suitable rotor lifting device to drive hub (31) and overhead hoist as shown in Figure 512.
5-56
FIGURE 5-12. ROTOR ASSEMBLY LIFTING DEVICE (TYPICAL) (6) (7) Remove end bell and main bearing. Refer to paragraph 5.10.2. Remove rotating rectifier, paragraph 5.10.3. CAUTION Special care should be taken when removing rotor assembly, winding damage could result if rotor is allowed to hit main stator. (8) Carefully remove rotor assembly (23) and attached components from main stator and generator housing (33).
c.
Installation. (1) (2) Install rotating rectifier, paragraph 5.10.3. Install main bearing. Refer to paragraph 5.10.2. CAUTION Special care must be taken installing rotor assembly. Winding damage could result if rotor is allowed to hit main stator. (3) (4) Attach suitable rotor lifting device to drive hub (31) and overhead hoist as shown in Figure 5-12. Carefully install rotor assembly (23, Figure 5-9) and matched components into main stator and generator housing (33). Install end bell. Refer to paragraph 5.10.2. Remove rotor lifting device. Install fan (29) on drive hub (31) with lockwashers (28) and bolts (27).
(5) (6)
5-57
NOTE Make sure all disc mounting holes at the inner and outer diameter are properly aligned. (7) Install drive discs (26), washers (25), and bolts (24) on drive hub (31). Torque bolts (24) to 35 ft-lb (47 Nm). Install generator assembly, paragraph 5.10.1.
(8) 5.10.7
Generator Main Stator and Housing. a. Testing. (1) (2) (3) (4) (5) (6) Shut down generator set, paragraph 2.11.2. Allow generator to cool to ambient temperature. Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Remove rear housing, paragraph 4.7.5. Remove voltage reconnection terminal board. Refer to paragraph 5.8.2. Tag and disconnect wires from voltage reconnection terminal, paragraph 5.8. Connect resistance bridge, and note readings between terminals T1 and T4, T2 and T5, T3 and T6, T7 and T0, T8 and T0, and T9 and T0 of voltage reconnection terminal board. Refer to FO1. All resistance readings should be as shown in Table 5-2. If resistance is low, there are shorted windings. If resistance is high, stator windings are open. In either case, stator must be replaced. Set multimeter for ohms, and connect between each of the ten coil leads from generator clamp assembly (3, Figure 5-9) and ground. If multimeter indicates resistance on any connection, stator windings are grounded and stator must be replaced. Connect wires to voltage reconnection terminal board and remove tage. Refer to paragraph 5.8.2. Install moveable terminal board and protective cover on voltage reconnection terminal board. Refer to paragraph 5.8.2. Install rear housing, paragraph 4.7.5. Connect negative battery cable to battery, and close BATTERY ACCESS door.
(7) (8)
(9)
(10)
(11)
(12)
(13) (14) b.
Replacement. (1) (2) Shut down generator set, paragraph 2.11.2. Remove generator assembly, paragraph 5.10.1.
5-58
(3) (4) (5)
Remove generator rotor assembly, paragraph 5.10.6. Install generator rotor assembly, paragraph 5.10.6. Install generator assembly, paragraph, 5.10.1.
5.11
MAINTENANCE OF SKID BASE. __________ WARNING When disconnecting or removing batteries, disconnect the negative lead that connects directly to the grounding stud first. Disconnect the negative end of the interconnection cable next. When installing batteries, reverse the connection sequence. Failure to comply can cause serious personal injury.
5.11.1
Skid Base. a. Inspection. Inspect skid base for obvious signs of damage such as corrosion and dents. a. Removal. (1) (2) (3) (4) Shut down generator set, paragraph 2.11.2. Remove engine and generator assembly, paragraph 5.4.2. Remove fuel tank, paragraph 5.7.1. Remove nuts (1, Figure 5-13), lockwashers (2), bolts (3), washers (4), and forklift guides (5) from skid base. Remove cable grommets (6 and 7) from skid base.
(5) b.
Repair. Repair of skid base will be limited to corrosion control and spot welding minor cracks. If major structural damage has occurred, replace skid base. Repair surfaces in accordance with TM-430139. Installation. (1) (2) (3) (4) Install cable grommets (7 and 6, Figure 5-13) in skid base. Install forklift guides (5), washers (4), bolts (3), lockwashers (2), and nuts (1) on skid base. Install fuel tank, paragraph 5.7.1. Install engine and generator assembly, paragraph 5.4.2.
c.
5-59
FIGURE 5-13. SKID BASE
5-60
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 CHAPTER 6 GENERAL SUPPORT MAINTENANCE INSTRUCTIONS
NOTE There are no general support level maintenance tasks for the generator set. Refer to TM 9-2815-260-24 for engine repair at the general support level.
6-1/6-2 BLANK
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS XX TM 09244A/09245A-14
6-2
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 APPENDIX A REFERENCES A.1 SCOPE. This appendix lists all forms, field manuals, technical manuals, and miscellaneous publications referenced in this manual. A.2 FORMS. Equipment Inspection and Maintenance Work Sheet ................................................................DA Form 2404 Product Quality Deficiency Report ....................................................................................................... SF 368 Recommended Changes to Publications and Blank Forms........................................................DA Form 2028 Recommended Changes to DA Publications ......................................................................... DA Form 2028-2 A.3 FIELD MANUALS. Electric Power Generation in the Field..............................................................................................FM 20-31 First Aid for Soldiers.........................................................................................................................FM 21-11 NBC Contamination Avoidance ............................................................................................................FM 3-3 NBC Decontamination ..........................................................................................................................FM 3-5 NBC Protection .....................................................................................................................................FM 3-4 Operation and Maintenance of Ordnance Material in Cold Weather (0 F to -65 F).......................FM 9-207 A.4 TECHNICAL MANUALS. Cooling Systems: Tactical Vehicles .............................................................................................TM 750-254 Destruction of Materiel.............................................................................................................. TM 750-244-3 Painting Instruction for Army Materiel .........................................................................................TM 43-0139 Repair Parts and Special Tools List: Generator Set, Tactical Quiet, 60 kW, 50/60 and 400 Hz ..................................................................................TM 9-6115-672-24P Unit, Direct Support and General support Maintenance Instructions: Diesel Engine, 6 Cylinder .................................................................................... TM 9-2815-260-24 A.5 MISCELLANEOUS PUBLICATIONS. Corrosion and Corrosion Prevention: Metals ........................................................................MIL-HDBK-729 Lubrication Order: Generator Set, Tactical Quiet, 60 kW, 50/60 and 400 Hz ...................LO 9-6115-645-12 Marking for Shipment and Storage............................................................................................ MIL-STD-129 Packaging of Generator Set, Mobile Power and Supplemental Equipment................................ MIL-G-28554 Preparation for Shipment and Storage of Engine ........................................................................MIL-E-10062 Preservation of USAMECOM Mechanical Equipment for Shipment and Storage....................... TB 740-97-2 The Army Maintenance Management System (TAMMS)................................................... DA PAM 738-750
A-1/A-2 BLANK
A-2
APPENDIX B MAINTENANCE ALLOCATION CHART (MAC) SECTION I. INTRODUCTION B.1 GENERAL. a. This section provides a general explanation of all maintenance and repair functions authorized at various maintenance levels under the standard Army Maintenance System concept. The Maintenance Allocation Chart (MAC) in section II designates overall authority and responsibility for the performance of maintenance functions on the generator set and its components. The application of the maintenance functions to the generator set or component will be consistent with the capacities and capabilities of the designated maintenance categories. Section III lists the tools and test equipment (both special tools and common tool sets) required for each maintenance function as referenced from section II. Section IV contains supplemental instructions and explanatory notes for particular maintenance functions.
b.
c.
d.
B.2 MAINTENANCE FUNCTIONS. Maintenance Functions are limited to and defined as follows: a. Inspect. To determine the serviceability of an item by comparing its physical, mechanical, and/or electrical characteristics with established standards through examination (i.e., by sight, sound, or feel). Test. To verify serviceability by measuring the mechanical or electrical characteristics of an item and comparing those characteristics with prescribed standards. Service. Operations required periodically to keep an item in proper operating condition, i.e., to clean (includes decontamination, when required), preserve, drain, paint, or replenish fuel, lubricants, chemical fluids, or gases. Adjust. To maintain or regulate, within prescribed limits, by bringing into proper position, or by setting the operating characteristics to specified parameters. Align. To adjust specified variable elements of an item to bring about optimum or desired performance. Calibrate. To determine and cause corrections to be made or to be adjusted on instruments or test, measuring, and diagnostic equipment used in precision measurement. Consists of comparisons of two instruments, one of which is a certified standard of known accuracy, to detect and adjust any discrepancy in the accuracy of the instrument being compared. Remove/Install. To remove and install the same item when required to perform service or other maintenance functions. Install may be the act of emplacing, seating, or fixing into position a spare, repair part, or module (component or assembly) in a manner to allow the proper functioning of an equipment or system.
b.
c.
d.
e.
f.
g.
B-1
h.
Replace. To remove an unserviceable item and install a serviceable counterpart in its place. Replace is authorized by the MAC and assigned as the third position code of the SMR code. Repair. The application of maintenance services, including fault location/troubleshooting, removal/installation, and disassembly/assembly procedures, and maintenance actions to identify troubles and restore serviceability to an item by correcting specific damage, fault, malfunction, or failure in a part, subassembly, module (component or assembly), end item, or system. Overhaul. That maintenance effort (service/action) prescribed to restore an item to a completely serviceable/operational condition as required by maintenance standards in appropriate technical publications (i.e., DMWR). Overhaul is normally the highest degree of maintenance performed by the Army. Overhaul does not normally return an item to like new condition. Rebuild. Consists of those services/actions necessary for the restoration of unserviceable equipment to a like new condition in accordance with original manufacturing standards. Rebuild is the highest degree of material maintenance applied to Army equipment. The rebuild operation includes the act of returning to zero those age measurements (hours/miles, etc.) considered in classifying Army equipment/components.
i.
j.
k.
B.3 EXPLANATION OF COLUMNS IN THE MAC, SECTION II. a. Column 1, Group Number. Column 1 lists functional group code numbers, the purpose of which is to identify maintenance significant components, assemblies, subassemblies, and modules with the next higher assembly. End item group number shall be "00". Column 2, Component/Assembly. Column 2 contains the item names of components, assemblies, subassemblies, and modules for which maintenance is authorized. Column 3, Maintenance Function. Column 3 lists the functions to be performed on the item listed in column 2. (For detailed explanation of these functions, see paragraph B.2). Column 4, Maintenance Level. Column 4 specifies each level of maintenance authorized to perform each function listed in column 3, by the indicating work time required (expressed as man-hours in whole hours and decimals) in the appropriate subcolumn. This work-time figure represents the active time required to perform that maintenance function at the indicated level of maintenance. If the number or complexity of the tasks within the listed maintenance function vary at different maintenance levels, appropriate work time figure will be shown for each level. The work time figure represents the average time required to restore an item (assembly, subassembly, component, module, end item, or system) to a serviceable condition under typical field operating conditions. This time includes preparation time (continuation/follow-on tasks) (including any necessary disassembly/assembly time), troubleshooting/fault location time, and quality assurance time in addition to the time required to perform the specific tasks identified for the maintenance functions authorized in the MAC. The symbol designations for the various maintenance levels are as follows: NOTE When a complete replace or repair task performed at higher level maintenance includes lower level maintenance tasks (equipment condition/follow on tasks), the lower level work time figures in the MAC must be added to the higher level work time shown in the MAC to determine the total to accomplish that maintenance function.
b.
c.
d.
B-2
C..........................................................................................Operator or crew O..........................................................................................Unit Maintenance F ..........................................................................................Direct Support Maintenance L ..........................................................................................Specialized Labor Activity (SRA) H..........................................................................................General Support Maintenance D..........................................................................................Depot Maintenance e. Column 5, Tools and Test Equipment Reference Code. Column 5 specifies, by code, those common tool sets (not individual tools), common TMDE, and special tools, special TMDE, and support equipment required to perform the designated function. Codes are keyed to tools and test equipment in section III. Column 6, Remarks. When applicable, this column contains a letter code, in alphabetic order, which shall be keyed to the remarks contained in section IV. EXPLANATION OF COLUMNS IN TOOL AND TEST EQUIPMENT REQUIREMENTS, SECTION III. a. Column 1, Reference Code. The tool and test equipment reference code correlates with a code used in the MAC, Section II, Column 5. Column 2, Maintenance Level. The lowest level of maintenance authorized to use the tool or test equipment. Column 3, Nomenclature. Name or identification of the tool or test equipment. Column 4, National Stock Number. The National Stock Number of the tool or test equipment. Column 5, Tool Number. The manufacturers part number of the tool or test equipment.
f.
B-4
b.
c. d.
e. B.5
EXPLANATION OF COLUMNS IN REMARKS, SECTION IV. a. b. Column 1, Reference Code. The code recorded in column 6, section II. Column 2, Remarks. This column, along with the related codes, should be used to clarify maintenance and inspection functions by different military occupational specialties involved in maintaining some components.
B-3
SECTION II. MAINTENANCE ALLOCATION CHART FOR MEP-806B AND 816B (continued) (1) GROUP NUMBER (2) COMPONENT/ ASSEMBLY (3) MAINTENANCE FUNCTION C 00 GENERATOR SET, 60 KW (LESS ENGINE) INSPECT TEST SERVICE ADJUST REPAIR REMOVE INSTALL REPLACE 01 DC ELECTRICAL SYSTEM. INSPECT TEST REPAIR SERVICE REMOVE INSTALL 0101 BATTERIES TEST REMOVE INSPECT SERVICE INSTALL 0102 BATTERY AND SLAVE RECEPTACLE CABLES. INSPECT REMOVE SERVICE REPAIR INSTALL 0103 NATO SLAVE RECEPTACLE. INSPECT REMOVE INSTALL 02 HOUSING INSPECT REMOVE REPAIR INSTALL 0201 ACCESS DOORS. REMOVE REPAIR INSPECT INSTALL .1 .6 .1 .1 .1 .1 .1 .3 4.3 .1 1.7 (4) MAINTENANCE LEVEL (5) TOOLS AND EQUIP D (6) REMARKS
O 8.1 6.6 2.7 2.0 9.7 .3
F 2.3 7.6
2,5 1,2 1 1,2,3,4 1,2,3 1,2,3 1,2 5 1,2,4 1,5 1,2,4 5 1 1 1 A,F F F
3.0
14.4 22.8 14.4 22.8 16.1 7.7 .3 .1 .2 .3 .5 .5 .1 .2 .1 .1 .2 .1 .2 .2 .2 .2 .1 .1 .1 .8 4.3 4.3 4.3 .5 .5 .1 .5
1 1 2,4 1 1 1 1 1 1 1 1 1
B-4
SECTION II. MAINTENANCE ALLOCATION CHART FOR MEP-806B AND 816B (continued) (1) GROUP NUMBER (2) COMPONENT/ ASSEMBLY (3) MAINTENANCE FUNCTION C 0202 DCS CONTROL BOX TOP PANEL. REMOVE INSPECT REPAIR INSTALL 0203 TOP HOUSING SECTION. REMOVE INSPECT REPAIR INSTALL 0204 FRONT HOUSING SECTION. REMOVE REPAIR INSPECT INSTALL 0205 REAR HOUSING SECTION. REMOVE REPAIR INSPECT INSTALL 0206 03 HOUSING DATA PLATES DCS CONTROL BOX ASSEMBLY INSPECT INSTALL REMOVE REPAIR INSPECT INSTALL REPLACE TEST 0301 PANEL LIGHTS INSPECT REPAIR REPLACE 0302 TIME METER INSPECT TEST REPLACE 0303 SWITCHES INSPECT TEST REPLACE 0304 GROUND FAULT CIRCUIT INTERRUPTER INSPECT TEST REPLACE 0.1 0.1 0.1 0.1 0.1 0.1 0.2 0.1 0.1 0.1 0.1 0.1 (4) MAINTENANCE LEVEL (5) TOOLS AND EQUIP D 1 (6) REMARKS
O .5 0.1 0.5 0.5 1.0 0.2 1.0 1.0 1.5 1.0 0.2 1.5 2.0 1.0 0.2 2.0 0.1 0.3 0.4 2.7 1.0 0.4 1.0 1.0 0.1 0.2 0.3 0.1 0.3 0.2 0.1 0.2 0.2 0.1 0.1 0.5 .1
1 1 1 1 1 1 1 1 1 1 1 2 1,6 1,2 1 1.0 1.0 1 1,5 1 1 5 1 5 1 C C
5 1
B-5
SECTION II. MAINTENANCE ALLOCATION CHART FOR MEP-806B AND 816B (continued) (1) GROUP NUMBER (2) COMPONENT/ ASSEMBLY (3) MAINTENANCE FUNCTION C 0305 COMPUTER INTERFACE MODULE (CIM). INSPECT REMOVE INSTALL 0306 0307 0308 0309 KEYPAD ASSEMBLY KP. COMMUNICATION PORT. INSPECT REPLACE INSPECT REPLACE PARALLELING RECEPTACLE INSPECT REPLACE CONVENIENCE RECEPTACLE INSPECT TEST REPLACE 0310 DCS LOAD SHARING SYNCHRONIZER INSPECT REMOVE INSTALL TEST 0311 DCS SPEED CONTROL UNIT INSPECT REMOVE INSTALL TEST 0312 AUTOMATIC VOLTAGE REGULATOR INSPECT REMOVE INSTALL TEST 0313 BACKPLANE MODULE INSPECT REPLACE TEST 0314 I/O INTERFACE MODULE INSPECT REPLACE TEST 0315 DC CONTROL POWER CIRCUIT BREAKER INSPECT TEST REPLACE 0316 REACTIVE CURRENT ADJUST RHEOSTAT INSPECT TEST REPLACE 0.1 0.1 (4) MAINTENANCE LEVEL (5) TOOLS AND EQUIP D (6) REMARKS
O 0.1 0.3 0.3 0.1 0.2 0.1 0.2 0.1 0.4 0.1 0.2 0.5 0.1 0.3 0.3 0.4 0.1 0.3 0.3 0.4 0.1 0.3 0.3 0.6 0.1 1.0 0.5 0.1 1.0 0.2 0.1 0.2 0.5 0.1 0.2 0.5
1 1 1 1 1 E
5 1
1,6 1.6
1,6 1,6
1,6 1,6
1,6
1,6
5 1
5 1
B-6
SECTION II. MAINTENANCE ALLOCATION CHART FOR MEP-806B AND 816B (continued) (1) GROUP NUMBER (2) COMPONENT/ ASSEMBLY (3) MAINTENANCE FUNCTION C 0317 DIODE INSPECT TEST REPLACE 0318 RESISTORS INSPECT (4) MAINTENANCE LEVEL (5) TOOLS AND EQUIP D 5 1 (6) REMARKS
O 0.1 0.2 0.5 0.1
TEST REPLACE 0319 AUXILIARY CONTROL BRACKET. INSPECT REMOVE REPAIR INSTALL 0320 RELAYS INSPECT REMOVE TEST INSTALL 0321 DCS CONTROL BOX WIRING INSPECT HARNESS. TEST REPAIR REPLACE 0322 CIM WIRING HARNESS. INSPECT TEST REMOVE INSTALL 0323 DCS CONTROL PANEL FRAME AND PANELS REMOVE INSPECT REPAIR INSTALL 0324 DCS DATA PLATES. INSPECT REPLACE REPAIR 0325 KEYPAD POWER SUPPLY INSPECT REPLACE TEST 04 AIR INTAKE AND EXHAUST SYSTEM. INSPECT SERVICE REPLACE 0.3 0.4 0.1 0.1 0.1 0.1 0.1
0.2 0.5 0.1 0.2 0.5 0.5 0.1 0.2 0.3 0.2 0.2 1.0 1.0 8.0 0.2 1.0 0.2 0.2 1.0 0.1 1.0 1.0 0.1 0.3 0.3 0.2 0.4 0.3 0.9 0.4 2.2 0.1 1.0
5 1
1 1 1 1 5 1 D
5 1 1 5 1 1 1
E I
1 1 2
2 2 1 F
B-7
SECTION II. MAINTENANCE ALLOCATION CHART FOR MEP-806B AND 816B (continued) (1) GROUP NUMBER (2) COMPONENT/ ASSEMBLY (3) MAINTENANCE FUNCTION C 0401 MUFFLER AND EXHAUST PIPE AIR CLEANER ASSEMBLY INSPECT REPLACE 0402 REMOVE INSPECT SERVICE REPLACE 0403 CRANKCASE BREATHER FILTER ASSEMBLY. INSPECT 0.1 0.1 0.2 0.1 (4) MAINTENANCE LEVEL (5) TOOLS AND EQUIP D (6) REMARKS
O 0.5 1.5 1.0 0.2 0.2 1.0 0.2
1 1 1 1 F
SERVICE REPLACE 05 ENGINE COOLING SYSTEM. INSPECT TEST SERVICE REMOVE INSTALL REPAIR REPLACE 0501 HOSES REMOVE INSPECT INSTALL 0502 RADIATOR REMOVE INSPECT SERVICE REPAIR INSTALL 0503 FAN GUARDS. REMOVE INSPECT INSTALL 0504 FAN. REMOVE INSPECT INSTALL 0505 FAN BELT. INSPECT ADJUST REPLACE 0506 COOLANT RECOVERY SYSTEM. INSPECT REMOVE INSTALL SERVICE
0.2 0.6 0.2
0.2 1.0 1.0 0.5 0.5 3.8 3.8 1.0 0.5 0.5
1 1 1 1 1
1 1 1 1 1 1.0 2 1 1 1 1 1 1 1
0.1
0.4 0.5 2.0
0.1
0.2 0.5 2.0 0.5
0.1
0.1 0.5 1.0
0.1 0.1
0.1 1.0 0.1 0.5 0.5
0.1
0.1 0.5 0.5 1 1 1 F
0.2
B-8
SECTION II. MAINTENANCE ALLOCATION CHART FOR MEP-806B AND 816B (continued) (1) GROUP NUMBER (2) COMPONENT/ ASSEMBLY (3) MAINTENANCE FUNCTION C 06 FUEL SYSTEM. INSPECT INSTALL TEST REMOVE REPLACE SERVICE 0601 LOW PRESSURE FUEL LINES AND FITTINGS. INSPECT REPLACE 0602 AUXILIARY FUEL PUMP INSPECT TEST REPLACE 0603 FUEL TANK FILLER NECK. REMOVE INSPECT INSTALL 0604 0605 FUEL DRAIN VALVE. FUEL LEVEL SENDER INSPECT REPLACE INSPECT REMOVE TEST INSTALL 0606 FUEL PICKUP. REMOVE INSPECT INSTALL 0607 ETHER CYLINDER ASSEMBLY. REMOVE INSPECT INSTALL 0608 ETHER SOLENOID VALVE REMOVE INSPECT INSTALL 0609 FUEL TANK. REMOVE INSPECT SERVICE INSTALL 0610 FUEL FILTER/WATER SEPARATOR. INSPECT SERVICE 0.1 0.5 0.1 0.2 1 F 0.2 0.3 0.1 0.2 5.0 0.1 0.8 0.1 0.2 0.5 0.1 0.5 0.5 0.5 0.1 0.5 0.1 0.5 0.1 0.2 0.3 0.2 0.5 0.1 0.5 0.2 0.1 0.2 0.4 0.2 0.4 5.0 0.2 1 2 F 1 2 1 1 1 1 1 1,5 1 1 1 1 1 1 1 1 0.5 (4) MAINTENANCE LEVEL (5) TOOLS AND EQUIP D 1 2.5 2.5 1,2 2 1 1 1 F (6) REMARKS
O 1.0 2.3 1.0 2.3 1.5
B-9
SECTION II. MAINTENANCE ALLOCATION CHART FOR MEP-806B AND 816B (continued) (1) GROUP NUMBER (2) COMPONENT/ ASSEMBLY (3) MAINTENANCE FUNCTION C 0611 ETHER SOLENOID RELAY INSPECT REMOVE TEST INSTALL 07 OUTPUT BOX ASSEMBLY. INSPECT REMOVE INSTALL REPAIR REPLACE TEST 0701 VOLTAGE RECONNECTION TERMINAL BOARD INSPECT 0.2 (4) MAINTENANCE LEVEL (5) TOOLS AND EQUIP D (6) REMARKS
O 0.1 0.2 0.2 0.2 1.0 1.2 1.2 1.5 1.0 1.6 0.2
0.6 4.3 4.3 2.0 0.2 1.6 0.2 1,2 1,2 1,2 1,2 1,2
REMOVE REPLACE INSTALL 0702 OUTPUT BOX WIRING HARNESS. INSPECT REMOVE TEST REPAIR INSTALL 0703 TRANSFORMERS INSPECT REMOVE TEST INSTALL 0704 AC CIRCUIT INTERRUPTER RELAY INSPECT TEST REPLACE 0705 CRANKING RELAY INSPECT TEST REPLACE 0706 OUTPUT BOX PANELS. INSPECT REMOVE REPAIR INSTALL 0.1 0.1
0.4 1.5 0.4 0.2 0.2 2.0 0.6 0.5 0.1 1.3 0.4 0.2 0.3 1.0 02 0.5 0.5 0.1 1.4 1.0 1.4 1.0 1.3 0.6 1.0 2.0
1,2 1,2 1,2
1 5 1,2 1 1 5 1
5 1 5 1 2 1,2 2
B-10
SECTION II. MAINTENANCE ALLOCATION CHART FOR MEP-806B AND 816B (continued) (1) GROUP NUMBER (2) COMPONENT/ ASSEMBLY (3) MAINTENANCE FUNCTION C 0707 LOAD OUTPUT TERMINAL BOARD TB2. REMOVE INSPECT REPAIR INSTALL 08 ENGINE ACCESSORIES. INSPECT REPLACE INSTALL TEST REMOVE SERVICE 0801 SENDERS INSPECT TEST REMOVE SERVICE INSTALL 0802 MAGNETIC PICKUP MPU. REMOVE SERVICE INSTALL TEST 0803 DEAD CRANK SWITCH INSPECT TEST REPLACE 0804 BATTERY CURRENT TRANSDUCER INSPECT TEST REPLACE 0805 ELECTRIC ACTUATOR INSPECT TEST REPLACE 09 901 10 LUBRICATION SYSTEM. OIL DRAIN VALVE. GENERATOR ASSEMBLY. INSPECT SERVICE INSPECT REPLACE INSPECT REMOVE INSTALL TEST REPLACE 0.2 0.1 0.2 0.2 0.5 0.2 0.5 1.4 9.0 9.0 5.0 6.0 2,3 2,3 2,5 H 2 2 F 0.1 0.5 0.5 0.1 0.3 1.0 0.1 0.3 0.5 5 2 5 1 0.1 0.2 (4) MAINTENANCE LEVEL (5) TOOLS AND EQUIP D (6) REMARKS
O 1.0 0.1 1.0 1.0 0.1 0.5 1.0 1.5 1.0 1.0 0.1 0.5 0.5 0.4 0.5 0.4 0.4 0.4 0.5
0.1 0.5 0.3 1 1 1
5 1 G 1 1 1
B-11
SECTION II. MAINTENANCE ALLOCATION CHART FOR MEP-806B AND 816B (continued) (1) GROUP NUMBER 1001 (2) COMPONENT/ ASSEMBLY END BELL AND MAIN BEARING ROTATING RECTIFIER (3) MAINTENANCE FUNCTION C REMOVE INSTALL 1002 TEST REMOVE INSTALL 1003 EXCITER STATOR. INSPECT TEST REPLACE 1004 EXCITER ROTOR INSPECT O F 2.0 2.0 1.0 2.5 2.5 0.3 0.5 4.4 0.5 1 1 H D 1 1 (4) MAINTENANCE LEVEL (5) TOOLS AND EQUIP (6) REMARKS
TEST 1005 GENERATOR ROTOR ASSEMBLY. INSPECT TEST REMOVE INSTALL 1006 GENERATOR MAIN STATOR AND HOUSING, INSPECT TEST REPLACE 11 ENGINE ASSEMBLY. INSPECT REMOVE INSTALL 12 SKID BASE. INSPECT REMOVE REPAIR INSTALL 0.1 0.1 0.1 0.1
1.0
1.0 3.0 3.0
5 1 1
1.0 10.0 4.0 4.0 0.1 6.0 1.0 6.0 2 2 2 2,3 2,3 H H
B-12
SECTION III. TOOLS AND TEST EQUIPMENT FOR MEP-806B AND MEP-816B TOOL OR TEST EQUIPMENT REF CODE 1 2
MAINTENANCE LEVEL O, F O, F
NOMENCLATURE TOOL KIT, GENERAL MECHANICS AUTOMOTIVE SHOP EQUIPMENT, AUTOMOTIVE MAINT AND REPAIR; ORGANIZATIONAL MAINTENANCE, COMMON NO. 1 (LESS POWER) SHOP EQUIPMENT, AUTOMOTIVE MAINT AND REPAIR, FIELD MAINTENANCE, WHEELED VEHICLES, POST CAMP AND STATION, SET A SHOP EQUIPMENT ELECTRICAL REPAIR, SEMI TRAILER MOUNTED MULTIMETER STRAP, WRIST, ELECTROSTATIC DISCHARGE SECTION IV. REMARKS FOR MEP-806B AND MEP-816B
NATIONAL STOCK NUMBER 5180-00-177-7033 4910-00-754-0654
TOOL NUMBER SC 5180-95-N26 (30 October 1986) SC 4910-95-A74 (10 Sept. 1994)
4910-00-348-7696
SC 4910-95-A02 (1 October 1989)
O, F
4940-00-294-9517
SC 4940-95-B05 LIN: T10275 AN/PSM-45A Fluke TL6-60
5 6
O, F O, F
6625-01-265-6000 5920-01-112-9042
REFERENCE CODE A B C D E F Wet-cell batteries only. (Not Used)
REMARKS
Repair is limited to replacement of light bulbs. Repair is limited to replacement of installed items. Use wrist strap when removing or replacing item in order to prevent possible damage to components from electrostatic discharge. Operator service function consists of adding fuel, adding oil, adding coolant to coolant recovery bottle, adding water to wet-cell batteries, replacing air filter element, draining crankcase breather filter, and draining water and sediment from fuel filter/water separator, as appropriate. This service function involves cleaning of senders with a solvent. Refer to TM 9-2815-260-24 (6-cylinder diesel engine manual). This harness is the ribbon cable harness connecting the DCS modules to the CIM.
G H I
B-13/B-14 BLANK
B-14
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 APPENDIX C COMPONENTS OF END ITEM (COEI) AND BASIC ISSUE ITEMS (BII) LIST
SECTION I. INTRODUCTION C.1 SCOPE. This appendix lists components of the end item and basic issue items for the generator set to help inventory the items for safe and efficient operation of the equipment. C.2 GENERAL. The Components of End Item (COEI) and Basic Issue Items (BII) lists are divided into the following sections: a. Section II, Components of End Item. This listing is for information purposes only, and is not authority to requisition replacements. These items are part of the generator set. As part of the end item, these items must be with the end item whenever it is issued or transferred between property accounts. Items of COEI are removed and separately packaged for transportation or shipment only when necessary. Illustrations are furnished to help you find and identify the items. Section III, Basic Issue Items. These essential items are required to place the generator set in operation, operate it, and to do emergency repairs. Although shipped separately packaged, BII must be with the generator set during operation and when it is transferred between property accounts. This list is your authority to request/requisition them for replacement based on authorization of the end item by the TOE/MTOE. Illustrations are furnished to help you find and identify the items.
b.
C.3
EXPLANATION OF COLUMNS. The following provides an explanation of columns found in the tabular listing: a. b. Column (1), Illus Number, gives the identifying number of the item illustrated. Column (2), National Stock Number, identifies the stock number of the item to be used for requisitioning purposes. Column (3), Description and Usable On Code, identifies the Federal item name (in all capital letters) followed by a minimal description when needed. The last line below the description is the Commercial and Government Entity Code (CAGEC) in parentheses and the part number. Column (4), U/I (unit of issue), indicates how the item is issued for the National Stock Number shown in column (2). Column (5), Qty Rqd, indicates the quantity required.
c.
d.
e.
SECTION II. COMPONENTS OF END ITEM NONE
C-1
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 SECTION III. BASIC ISSUE ITEMS (1) Illus Number 1 2 (2) National Stock Number (3) Description Cage and Part Number TECHNICAL MANUAL TM 9-6115-672-14 WARRANTY TECHNICAL BULLETIN TB 9-6115-645-24 GROUNDING ROD W-R-550 AUXILIARY FUEL LINE 69-668 PARALLELING CABLE 88-22209 CIM SOFTWARE 96-23569 (4) Usable On Code U/I EA EA (5) Qty Reqd 1 1
3 4 5 6
5975-00-296-5324 4720-00-021-3320 6150-01-406-9533
EA EA EA EA
1 1 1 1
C-2
1.
Technical Manual
2. Warranty Technical Bulletin
C-3
3. Grounding Rod
4. Auxiliary Fuel Line
C-4
5. Paralleling Cable
6. CIM Software NOTE CD is available from U.S. Army CECOM SEC, ATTN: AMSEL-SE-OP-R, Fort Monmouth, NJ 07703
C-5/C-6 BLANK
C-6
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 APPENDIX D ADDITIONAL AUTHORIZATION LIST (AAL) SECTION I. INTRODUCTION D.1 SCOPE. This appendix lists additional items authorized for the support of the generator set. D.2 GENERAL. This list identifies items that do not have to accompany the generator set and that do not have to be turned in with it. These items are all authorized by CTA, MTOR, TDA, or JTA. D.3 EXPLANATION OF LISTING. National Stock Numbers, descriptions, and quantities are provided to help identify and request the additional items required to support the generator set. The items are listed in alphabetical sequence by item name under the type document (i.e., CTA, MTOR, TDA, or JTA) which authorizes the item(s). SECTION II. ADDITIONAL AUTHORIZATION LIST (2) National Stock Number 4210-00-202-7858 5342-00-066-1235 7240-00-222-3088 7240-00-177-6154 5120-01-013-1676 (3) Description Cage and Part Number FIRE EXTINGUISHER FUEL ADAPTER FUEL CAN FLEXIBLE SPOUT HAMMER, SLIDE (4) Usable On Code U/I EA EA EA EA EA (5) Qty Reqd 1 1 1 1 1
D-1/D-2 BLANK
D-2
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 APPENDIX E EXPENDABLE AND DURABLE ITEMS LIST SECTION I. INTRODUCTION E.1 SCOPE. This appendix lists expendable supplies and materials required to operate and maintain the generator set. These items are authorized by CTA 50-970, Expendable Items (except medical, Class V, repair parts, and heraldic items). E.2 EXPLANATION OF COLUMNS. a. Column (1), Item Number. Number assigned to an entry in the listing for reference within the technical manual to identify the material, i.e. "Use cleaning compound (Item 5, Appendix E)". Column (2), Level. Identifies the lowest level of maintenance requiring the listed item. Column (3), National Stock Number (NSN). Standardized number assigned to an item for the purpose of requisition. Column (4), Description. Federal item name and, if required, description of the item. The last line for each applicable item indicates the Commercial and Government Entity (CAGE) code in parenthesis followed by the part number. Column (5), Unit of Measure (U/M). Measure used in performing actual maintenance function. Measure is expressed by a two character alphabetical abbreviation (i.e., ea, in, pr). If the unit of measure differs from the unit of issue, requisition the lowest unit that will satisfy requirements. SECTION II. EXPENDABLE AND DURABLE ITEMS LIST (1) Item Number 1 2 3 4 5 6 7 8 9 (2) Level O, F O, F O, F O, F O, F O, F O O, F F (3) National Stock Number 8040-00-390-7959 6850-00-181-7929 6850-00-181-7933 6850-00-181-7940 6850-00-174-1806 8030-01-234-2792 2910-00-646-9727 7920-01-338-3329 8030-00-056-8673 (4) Description Adhesive, Seal, EC847 Antifreeze, MIL-A-46153, 1 Gal. Can Antifreeze, MIL-A-46153, 5 Gal. Can Antifreeze, MIL-A-46153, 55 Gal. Can Antifreeze, MIL-A-11755, 1 Gal. Can Antiseize Compound, CP-8, 8 Oz. Can Cartridge, Engine, Ether, MS39254 Cloth, Cleaning, TX-1250 Compound, Thermo, Pentrox A (5) U/M QT GL GL GL GL OZ EA EA OZ
b. c.
d.
e.
E-1
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 SECTION II. EXPENDABLE AND DURABLE ITEMS LIST (continued) (1) Item Number 10 11 12 13 14 15 16 17 18 19 20 21 22 (2) Level O, F O, F O, F O, F O, F O, F O, F O, F O, F O, F O, F O, F O, F (3) National Stock Number 9150-00-663-1770 6850-01-160-3868 9150-00-152-4117 9150-00-189-6727 9150-00-186-6681 9150-00-402-2372 5330-00-543-3600 8030-01-408-9944 8040-00-843-0802 3439-00-974-1873 6850-00-264-9038 8030-00-849-0071 8040-01-359-8441 (4) Description Grease, General Purpose, 630AA, 6 Lb. Can Inhibitor, Corrosion, MIL-A-53009 Lubricating Oil, Engine, MIL-L-2104, 15/40W Lubricating Oil, Engine, BRAYC0421C, 10W Lubricating Oil, Engine, ALIEDC030, 30W Lubricating Oil, Engine, MIL-L-46167, OEA Paper, Abrasive, ALOXGRIT 80 Adhesive, Edge Seal, PES-821-B Sealant, RTV108 Solder, Tin Alloy, SN60WRAP2, 1 Lb. Spool Solvent, Dry Cleaning, P-D-680, 5 Gal. Can Sealing Compound, FORM GASKET 2 Sealing Compound, MIL-S-22473, Grade HVV (5) U/M LB QT QT QT QT QT SH QT OZ LB GL TU OZ
E-2
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-14 MARINE CORPS TM 09244A/09245A-14 APPENDIX F OPERATORS LUBRICATION INSTRUCTIONS
F.1
SCOPE. This appendix lists operator lubrications and instructions for the generator set.
F.2
GENERAL. Intervals (on-condition or hard time) and the related man-hour times are based on normal operation. The man-hour time specified is the time you need to do all the services prescribed for a particular interval. Oncondition (OC) oil sample intervals shall be applied unless changed by the Army Oil Analysis Program (AOAP) laboratory. Change the hard time interval if your lubricants are contaminated or if you are operating the equipment under adverse operating conditions, including longer-than-usual operating hours. The hard time interval may be extended during periods of low activity. If extended, adequate preservation precautions must be taken. Hard time intervals will be applied in the event AOAP laboratory support is not available.
F.3
LUBRICANTS. NOTE Operator level lubrication is limited to adding engine crankcase oil. NOTE For arctic operation, refer to FM 9-207. EXPECTED TEMPERATURES +40F (+4C) 0F (-17C) Above to to +32 (0C) -10F (-23C) -65F (-53C) OE/HDO15/40 or OE/HDO-30 OE-HDO-10 OEA
LUBRICANTS OE/HDO-OIL, Engine Heavy Duty
CAPACITY With Filter 20 quarts (18.92 liters) Without Filter 19 quarts (17.97 liters)
OEA-OIL, Engine, Sub-zero
CAUTION At 100 hours hard time, the oil and filter must be changed or the warranty may be voided.
F-1/F-2 BLANK
F-2
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPSTM 09244A/09245A-14 APPENDIX G ILLUSTRATED LIST OF MANUFACTURED ITEMS
G.1
INTRODUCTION. This appendix includes complete instructions for fabricating or assembling parts as required for these generator sets. NOTE All dimensions are expressed in inches. Refer to Table G-1 for metric conversion. PARTS INDEX
Figure Number Page G-1 Cable Assembly, AC Power (P/N 88-22128-1 through 88-22128-7) ..........................................................G-2 G-2 Cable Assembly, Battery (P/N 88-22206) ...................................................................................................G-3 G-3 Cable Assembly, Battery (P/N 88-22127) ...................................................................................................G-4 G-4 Cable Assembly, Battery (P/N 88-22208) ...................................................................................................G-5 G-5 Cable Assembly, Battery (P/N 88-22179) ...................................................................................................G-6 G-6 Cable Assembly, Battery (P/N 88-22207) ...................................................................................................G-7 G-7 Capacitor Assembly, EMI (P/N 88-22758) .................................................................................................G-8 G-8 Cord, Load Wrench (P/N 88-22469) ...........................................................................................................G-9 G-9 Diode Assembly (P/N 88-22418-2) ...........................................................................................................G-10 G-10 Holder, Control Panel (P/N 88-22120)......................................................................................................G-11 G-11 Hose Assembly (P/N 88-20191-7) ............................................................................................................G-12 G-12 Insulation, Air Baffle (P/N 88-22616).......................................................................................................G-13 G-13 Insulation, Baffle (P/N 88-22769) .............................................................................................................G-14 G-14 Insulation, Door (P/N 88-22610)...............................................................................................................G-15 G-15 Insulation, Baffle (P/N 88-22615) .............................................................................................................G-16 G-16 Insulation, Baffle (P/N 88-22612) .............................................................................................................G-17 G-17 Insulation, Door (P/N 88-22601)...............................................................................................................G-18 G-18 Insulation, Floor Duct (P/N 88-22599) .....................................................................................................G-19 G-19 Insulation, Duct Floor (P/N 88-22600) .....................................................................................................G-20 G-20 Insulation, Baffle (P/N 88-22592) .............................................................................................................G-21 G-21 Insulation, Panel, Right Side (P/N 88-22614) ...........................................................................................G-22 G-22 Insulation, Rear Panel (P/N 88-22598) .....................................................................................................G-23 G-23 Insulation, Rear, Left (P/N 88-22637).......................................................................................................G-24 G-24 Insulation, Top Front (P/N 88-22602).......................................................................................................G-25 G-25 Insulation, Door (P/N 88-22609)...............................................................................................................G-26 G-26 Insulation, Door (P/N 88-22770)...............................................................................................................G-27 G-27 Insulation, Center, Right Side (P/N 88-22603) .........................................................................................G-28 G-28 Insulation, Center, Front (P/N 88-22604)..................................................................................................G-29 G-29 Insulation, Top Center (P/N 88-22605).....................................................................................................G-30 G-30 Insulation, Panel, Top (P/N 88-22611) .....................................................................................................G-31 G-31 Insulation, Housing, Front (P/N 88-22596)...............................................................................................G-32 G-32 Pump Assembly, Fuel (P/N 88-22546)......................................................................................................G-33 G-33 Solenoid Assembly (P/N 88-22553)..........................................................................................................G-34 G-34 Switch Assembly (P/N 88-22549) .............................................................................................................G-35 G-35 Wire, Varistor (P/Ns 88-20305-6 through 88-20305-9) ............................................................................G-36
G-1
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 G.2 ILLUSTRATIONS.
NOTES: 1. 2. Dimensions shown are in inches. Refer to TM 9-6115-672-24P for materials required and length (L) of wire.
PROCEDURES: 1. 2. 3. Cut wire (1) to length indicated. Strip 0.75 inch of insulation from each end of wire (1). Crimp terminal (2) on each end of wire (1).
FIGURE G-1. CABLE ASSEMBLY, AC POWER (P/Ns 88-22128-1 THROUGH 88-22128-7)
G-2
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPSTM 09244A/09245A-14
NOTES: 1. 2. Dimensions shown are in inches. Refer to TM 9-6115-672-24P for materials required.
PROCEDURES: 1. 2. 3. Cut wire (1) to length indicated. Strip 0.75 inch of insulation from each end of wire (1). Position insulation sleeving (2) on center of wire (1). Mark sleeving with wire number "100B0", and shrink to fit. Crimp terminal (3) on each end of wire (1).
4.
FIGURE G-2. CABLE ASSEMBLY, BATTERY (P/N 88-22206)
G-3
PROCEDURES: 1. 2. 3. Cut wire (1) to length indicated. Strip 0.75 inch of insulation from each end of wire (1). Position insulation sleeving (2) on center of wire (1). Mark sleeving with wire number "100A0", and shrink to fit. Mark insulation sleeving (4) with "NEGATIVE", and slide over one end of wire (1). Crimp terminal (3) on each end of wire (1). Position insulation sleeving (4) as shown, and shrink to fit.
4. 5. 6.
G-4
PROCEDURES: 1. 2. 3. Cut wire (1) to length indicated. Strip 0.75 inch of insulation from each end of wire (1). Position insulation sleeving (2) on center of wire (1). Mark sleeving with wire number "165B0", and shrink to fit. Mark insulation sleeving (4) with "POSITIVE", and slide over one end of wire (1). Crimp terminal (3) on each end of wire (1). Position insulation sleeving (4) as shown, and shrink to fit.
4. 5. 6.
G-5
PROCEDURES: 1. 2. 3. Cut wire (1) to length indicated. Strip 0.75 inch of insulation from each end of wire (1). Position insulation sleeving (2) on center of wire (1). Mark sleeving with wire number "218A0", and shrink to fit. Mark one insulation sleeving (4) with "NEGATIVE", the other "POSITIVE", and slide over each end of wire (1). Crimp terminal (3) on each end of wire (1). Position insulation sleeving (4) as shown, and shrink to fit.
4.
5. 6.
G-6
PROCEDURES: 1. 2. 3. Cut wire (1) to length indicated. Strip 0.75 inch of insulation from each end of wire (1). Position insulation sleeving (2) on center of wire (1). Mark sleeving with wire number "165A0", and shrink to fit. Mark insulation sleeving (4) with "POSITIVE", and slide over each end of wire (1). Crimp terminal (3) on each end of wire (1). Position insulation sleeving (4) as shown, and shrink to fit.
4. 5. 6.
G-7
PROCEDURES: 1. 2. 3. Cut each lead of capacitor (1) to obtain dimension shown with terminals (2) installed. Strip 0.75 inch of insulation from each lead of capacitor (1). Crimp and solder terminals (2) on end of each lead.
FIGURE G-7. CAPACITOR ASSEMBLY, EMI (P/N 88-22758)
G-8
PROCEDURES: 1. 2. Cut rope (1) to length indicated. Crimp and terminal (2) on one end of rope (1).
FIGURE G-8. CORD, LOAD WRENCH (P/N 88-22469)
G-9
NOTES: 1. Refer to TM 9-6115-672-24P for materials required.
PROCEDURES: 1. Strip 0.75 inch of insulation sleeving (2) on each lead of diode (1), leaving 0.25 inch of bare wire on each lead. Shrink to fit. Crimp and solder terminals (2) on end of each diode (1) lead.
3.
FIGURE G-9. DIODE ASSEMBLY (P/N 88-22418-2)
G-10
PROCEDURES: 1. 2. 3. 4. 5. Cut rope (1) to length indicated. Slide insulation sleeving (2) over one end of rope (1). Crimp terminal (3) on each end of wire (1). Install hook (4) in one terminal, and close hook end to secure it to terminal. Position insulation sleeving (2) as shown, and shrink to fit.
FIGURE G-10. HOLDER, CONTROL PANEL (P/N 88-22120)
G-11
PROCEDURES: 1. 2. Cut hose (1) to obtain dimension shown with adapters (2) installed. Crimp adapter (2) on each end of hose (1).
FIGURE G-11. HOSE ASSEMBLY (P/N 88-20191-7)
G-12
MATERIALS Description Foam, Sound Absorbing NOTES: 1. 2. Dimensions shown are in inches. Tolerances are 0.1 inch unless otherwise stated. Part Number FF40JM02
PROCEDURES: 1. 2. 3. Cut foam to dimensions shown. Drill holes as shown. Coat edge indicated using sealant (Item 17, Appendix E).
FIGURE G-12. INSULATION, AIR BAFFLE (P/N 88-22616)
G-13
FIGURE G-13. INSULATION, BAFFLE (P/N 88-22769)
G-14
PROCEDURES: 1. 2. Cut foam to dimensions shown. Drill holes as shown.
FIGURE G-14. INSULATION, DOOR (P/N 88-22610)
G-15
G-16
G-17
G-18
FIGURE G-18. INSULATION, FLOOR DUCT (P/N 88-22599)
G-19
FIGURE G-19. INSULATION, DUCT FLOOR (P/N 88-22600)
G-20
G-21
FIGURE G-21. INSULATION, PANEL, RIGHT SIDE (P/N 88-22614)
G-22
FIGURE G-22. INSULATION, REAR PANEL (P/N 88-22598)
G-23
FIGURE G-23. INSULATION, REAR, LEFT SIDE (P/N 88-22637)
G-24
FIGURE G-24. INSULATION, TOP FRONT (P/N 88-22602)
G-25
G-26
ERIALS Description Foam, Sound Absorbing NOTES: 1. 2. Dimensions shown are in inches. Tolerances are 0.1 inch unless otherwise stated. Part Number FF40JM02
G-27
FIGURE G-27. INSULATION, CENTER, RIGHT SIDE (P/N 88-22603)
G-28
FIGURE G-28. INSULATION, CENTER, FRONT (P/N 88-22604)
G-29
FIGURE G-29. INSULATION, TOP CENTER (P/N 88-22605)
G-30
FIGURE G-30. INSULATION, PANEL, TOP (P/N 88-22611)
G-31
FIGURE G-31. INSULATION, HOUSING, FRONT (P/N 88-22596)
G-32
PROCEDURES: 1. 2. 3. 4. 5. Remove and discard terminals supplied with fuel pump (1). Strip 0.125 inch of insulation from end of each fuel pump (1) lead. Crimp pin (2) on end of each lead. Insert pins (2) into housing (3) with red wire in position 1 and black wire in position 2. Mark strap (4) with "P11", and install in position shown.
FIGURE G-32. PUMP ASSEMBLY, FUEL (P/N 88-22546)
G-33
NOTES: 1. 2. Refer to TM 9-6115-672-24P for materials required. Solenoid wiring is not polarity sensitive, so position of terminals is not important.
PROCEDURES: 1. 2. Strip 0.25 inch of insulation from each solenoid (1) lead. Crimp terminal (2) on one lead end and terminal (3) on the other.
FIGURE G-33. SOLENOID ASSEMBLY (P/N 88-22553)
G-34
NOTES: 1. 2. Dimensions are in inches. Refer to TM 9-6115-672-24P for materials required.
PROCEDURES: 1. 2. 3. Strip 0.125 inch of insulation from end of each switch (1) lead. Crimp pin (2) on end of each lead. Insert pins into housing (3) with lead A in position 1, lead B in position 2, lead C in position 3, and lead D in position 4. Mark "P12" on strap (4), and install in position shown.
4.
FIGURE G-34. SWITCH ASSEMBLY (P/N 88-22549)
G-35
PROCEDURES: 1. 2. 3. Cut wire (1) to length indicated. Strip 0.50 inch of insulation from each end of wire (1). Crimp terminal (2) on one end of wire (1) and terminal (3) on other end.
FIGURE G-35. WIRE, VARISTOR (P/NS 88-20305-6 THROUGH 88-20305-9)
G-36
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPSTM 09244A/09245A-14 TABLE G-1. METRIC CONVERSION
Part I. Fractional Equivalent Fractional Inches 1/16 1/8 3/16 1/4 5/16 3/8 7/16 1/2 9/16 5/8 11/16 3/4 13/16 7/8 15/16 1 Decimal Inches .0625 .1250 .1875 .2500 .3125 .3750 .4375 .5000 .5625 .6250 .6875 .7500 .8125 .8750 .9375 1 mm 1.587 3.175 4.762 6.350 7.937 9.525 11.112 12.700 14.287 15.875 17.462 19.050 20.637 22.225 23.812 25.400
Part II. Inches to Centimeters Inches 1 2 3 4 5 6 7 8 9 10 20 30 40 50 60 70 80 90 100 cm 2.540 5.080 7.620 10.160 12.700 15.240 17.780 20.320 22.860 25.400 50.800 76.200 101.600 127.000 152.400 177.800 203.200 228.600 254.000
G-37/G-38 BLANK
THIS PAGE INTENTIONALLY LEFT BLANK.
G-38
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-14 MARINE CORPS TM 09244A/09245A-14 APPENDIX H TORQUE LIMITS SECTION I. INTRODUCTION H.1 SCOPE . Section II lists torque ratings for fasteners used on the generator set. When torque values are called out in the maintenance procedures, whose supersede specified in this appendix. Table H-1 lists torque limits for standard fasteners installed dry. Table H-2 provides formulas for converting the dry torque values to wet. Table H-3 lists torque limits for metric fasteners installed dry.
SECTION II. TORQUE LIMITS TABLE H-1. TORQUE LIMITS FOR DRY FASTENERS
SIZE Diameter in Inches 1/4 1/4 5/16 5/16 3/8 3/8 7/16 7/16 1/2 1/2 9/16 9/16 5/8 5/8 3/4 3/4 7/8 7/8 1 1 Threads Per Inch 20 28 18 24 16 24 14 20 13 20 12 18 11 28 10 26 9 24 8 14 Millimeters 6.350 6.350 7.937 7.937 9.525 9.525 11.112 11.112 12.700 12.700 14.287 14.287 15.875 15.875 19.050 19.050 22.225 22.225 25.400 25.400 SAE GRADE 0-1-2 Foot Newton Pounds Meters 6 8 7 9 12 16 13 18 20 27 22 30 32 43 35 47 47 64 51 69 69 94 75 102 96 130 105 142 155 210 169 229 206 279 225 304 310 420 338 458
TORQUE SAE GRADE 3 Foot Newton Pounds Meters 9 12 10 13 17 23 18 25 30 40 33 44 47 64 51 69 69 93 75 102 103 140 112 152 145 197 158 214 234 317 255 346 372 504 405 550 551 747 601 814
SAE GRADE 5 Foot Newton Pounds Meters 10 14 11 15 19 26 21 28 33 45 36 49 54 73 59 80 78 106 85 115 114 155 124 168 154 209 168 228 257 348 280 380 382 518 416 565 587 796 640 867
See Table H-2 for the effect of lubrication on torque.
H-1
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-14 MARINE CORPS TM 09244A/09245A-14 TABLE H-1. TORQUE LIMITS FOR DRY FASTENERS (continued)
SIZE Diameter in Inches 1/4 1/4 5/16 5/16 3/8 3/8 7/16 7/16 1/2 1/2 9/16 9/16 5/8 5/8 3/4 3/4 7/8 7/8 1 1 Threads Per Inch 20 28 18 24 16 24 14 20 13 20 12 18 11 28 10 26 9 24 8 14 Millimeters 6.350 6.350 7.937 7.937 9.525 9.525 11.112 11.112 12.700 12.700 14.287 14.287 15.875 15.875 19.050 19.050 22.225 22.225 25.400 25.400 SAE GRADE 6 Foot Newton Pounds Meters 13 17 14 18 24 33 26 35 43 58 47 64 69 94 75 102 106 144 116 157 150 203 164 222 209 283 228 309 350 475 382 517 550 746 600 813 825 1119 899 1219
TORQUE SAE GRADE 7 Foot Newton Pounds Meters 13 18 14 19 25 34 27 37 44 60 48 65 71 96 77 105 110 149 120 163 154 209 168 228 215 291 234 318 360 488 392 532 570 773 621 842 840 1139 916 1241
SAE GRADE 8 Foot Newton Pounds Meters 14 19 15 21 29 39 32 43 47 64 51 69 78 106 85 115 119 161 130 176 169 229 184 250 230 312 251 340 380 515 414 562 600 813 654 887 900 1220 981 1330
See Table H-2 for the effect of lubrication on torque.
TABLE H-2. EFFECT OF LUBRICATION ON TORQUE TORQUE RATING IN FOOT-POUNDS 5/16-18 Thread/Inch 1/2-13 Thread/Inch 29 121 19 (66%) 90 (26%) 18 (38%) 87 (28%) 17 (41%) 83 (31%) 16 (45%) 79 (35%) 16 (45%) 79 (35%) 14 (52%) 66 (45%) 13 (55%) 62 (49%)
Lubricant NO LUBE, Steel Plated and cleaned SAE 20 Oil SAE 40 Oil Plated and SAE 30 White Grease White Moly Film Graphite and Oil
Use the above lubrication percentages to calculate the approximate decrease in torque rating for other bolt sizes.
H-2
TABLE H-3. TORQUE LIMITS FOR DRY FASTENERS (METRIC)
Diameter in Millimeters 6 8 10 12 14 16 18 22 24
Coarse Thread Pitch 1.00 1.00 1.25 1.25 1.25 2.00 2.00 2.50 3.00
Inches 0.2362 0.3150 0.3937 0.4624 0.5512 0.6299 0.7087 0.8771 0.9449
Standard 5D Ft-lb Nm 5 10 19 34 55 83 111 182 261 7 14 26 46 75 113 150 247 354
Standard 8G Ft-lb Nm 6 16 31 54 89 132 182 284 419 8 22 42 73 121 179 247 385 568
Standard 10K Ft-lb Nm 8 22 40 70 117 175 236 394 570 11 30 54 95 159 237 320 534 773
Standard 12K Ft-lb Nm 10 27 49 86 137 208 283 464 689 14 37 66 117 186 282 384 629 934
To determine torque rating for a fine thread bolt, increase the above coarse thread ratings by 9%. See Table H-2 for the effect of lubrication on torque.
H-3/H-4 BLANK
H-4
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-14 MARINE CORPS TM 09244A/09245A-14 APPENDIX I MANDATORY REPLACEMENT PARTS SECTION I. INTRODUCTION I.1 SCOPE. Section II of this appendix lists parts that must be replaced if removed during maintenance.
SECTION II. MANDATORY REPLACEMENT PARTS
Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38
Part No. 88-22193 88-22704 88-20563-1 88-20286 5 070118 69-561-1 69-561-2 69-561-3 69-561-4 69-561-6 88-21674-1 88-21674-2 88-21674-3 88-22783 84-4870 88-20568-1 88-20568-2 88-20568-3 88-20568-4 88-20568-5 88-20568-6 88-21930-1 88-21930-3 88-21930-4 MIL-R-6130 69-662-5 69-662-11 69-662-17 69-662-20 69-662-22 69-662-35 69-662-36 69-662-37 69-662-51 69-662-64 69-662-65 88-22705 88-22708
NSN 5305-01-140-9118 (none) (none) 5330-01-366-2836 (none) 5310-00-836-3520 5310-00-063-7360 5310-00-052-3632 5310-00-094-3421 5310-01-012-3595 (none) (none) (none) (none) (none) (none) (none) (none) (none) (none) (none) 5310-01-366-4412 (none) 5310-01-406-1672 9320-01-009-4856 5305-00-224-1092 (none) 5305-00-211-9344 5305-00-036-6972 5305-00-218-4864 5305-00-038-3103 5305-00-036-6902 5305-00-038-3145 5305-00-038-3148 5305-00-191-6226 5305-01-187-5878 (none) (none)
Nomenclature Bolt, Self-Locking, .375-16 x .875 Edging, Rubber Gasket Gasket, Fuel Tank Locknut, Bulkhead, .500-20 UNF Nut and Captive Washer Assembly, 4-40 Nut and Captive Washer Assembly, 6-32 Nut and Captive Washer Assembly, 8-32 Nut and Captive Washer Assembly, 10-24 Nut and Captive Washer Assembly, 10-32 Nut, Cage, 10-32, .064-.105 Grip Nut, Cage, 10-32, .025-.063 Grip Nut, Cage, .25-20, .025-.063 Grip Nut, Push-On Nut, Self-Locking, .750-10 UNC-2B Nut, Self-Locking, .25-20 UNC-2B Nut, Self-Locking, .375-16 UNC-2B Nut, Self-Locking, .375-16 UNC-2B Nut, Self-Locking, .375-16 UNC-3B Nut, Self-Locking, .500-13 UNC-3B Nut, Self-Locking, .625-11 UNC-3B Nut, Self-Locking, .375-16 UNC-2B Nut, Self-Locking, .164-32 UNC-2B Nut, Self-Locking, .190-32 UNF-2B Rubber, Cellular, .75 x 1.00 with PSA Screw and Captive Washer Assy, 4-40 x .50 Screw and Captive Washer Assy, 4-40 x 1.50 Screw and Captive Washer Assy, 6-32 x .31 Screw and Captive Washer Assy, 6-32 x .50 Screw and Captive Washer Assy, 6-32 x .75 Screw and Captive Washer Assy, 8-32 x .50 Screw and Captive Washer Assy, 8-32 x. .62 Screw and Captive Washer Assy, 8-32 x .75 Screw and Captive Washer Assy, 10-24 x .62 Screw and Captive Washer Assy, 10-32 x .50 Screw and Captive Washer Assy, 10-32 x .62 Seal, Door Seal, EMI, Output box Door
Quantity 8 AR 1 3 1 24 52 19 59 402 45 119 35 AR 5 4 2 15 4 2 2 15 22 29 AR 8 4 2 18 6 8 6 2 38 16 6 AR AR
I-1
SECTION II. MANDATORY REPLACEMENT PARTS (continued) Item No. 39 40 41 42 43 44 45 46 47 Part No. 88-22712 88-22792-2 AA55610-62 AA55610-63 AA55610-64 AA55610-65 AA55610-67 AA55610-68 AA55610-69 NSN 5330-01-384-3057 (none) (none) (none) (none) (none) (none) (none) (none) Nomenclature Seal, Shroud, Radiator Washer, Lock, Intl and Ext Tooth, .375 Washer, Lock-Spring, Helical, .219 Washer, Lock-Spring, Helical, .25 Washer, Lock-Spring, Helical, .312 Washer, Lock-Spring, Helical, .375 Washer, Lock-Spring, Helical, .500 Washer, Lock-Spring, Helical, .562 Washer, Lock-Spring, Helical, .625 Quantity AR 3 176 140 13 38 2 1 8
I-2
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 INDEX A AC Circuit Interrupter K1 Inspection ........................................................................................................................................................4-188 Replacement ....................................................................................................................................................4-189 Testing.............................................................................................................................................................4-188 AC CIRCUIT INTERRUPT Switch S5 Inspection ..........................................................................................................................................................4-89 Replacement ......................................................................................................................................................4-90 Testing...............................................................................................................................................................4-89 Access Doors Inspection ..........................................................................................................................................................4-57 Installation.........................................................................................................................................................4-59 Removal ............................................................................................................................................................4-57 Repair ................................................................................................................................................................4-59 Air Cleaner Assembly Inspection .............................................................................................................................................. 3-20, 4-144 Install ..............................................................................................................................................................4-146 Location and Description ..................................................................................................................................1-35 Removal ..........................................................................................................................................................4-146 Service................................................................................................................................................... 3-20, 4-144 Air Cleaner Filter Element Inspection ........................................................................................................................................................4-147 Installation.......................................................................................................................................................4-147 Removal ..........................................................................................................................................................4-147 Air Cleaner Hoses Inspection ........................................................................................................................................................4-148 Installation.......................................................................................................................................................4-148 Removal ..........................................................................................................................................................4-148 Service.............................................................................................................................................................4-148 Air Intake and Exhaust System, Engine ...................................................................................................................1-27 Automatic Voltage Regulator A4 Inspection ........................................................................................................................................................4-113 Installation........................................................................................................................................................ 4114 Removal ..........................................................................................................................................................4-114 Testing.............................................................................................................................................................4-113 Auxiliary Control Bracket Inspection ........................................................................................................................................................4-127 Installation.......................................................................................................................................................4-128 Removal ..........................................................................................................................................................4-127 Repair ..............................................................................................................................................................4-128 Auxiliary Fuel Pump E1 Inspection ........................................................................................................................................................4-171 Replacement ....................................................................................................................................................4-173 Testing.............................................................................................................................................................4-171
Index-1
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS 09244A/09245A-14
B Backplane Module A1 Inspection ....................................................................................................................................................... 4-115 Replacement ................................................................................................................................................... 4-116 Testing ............................................................................................................................................................ 4-115 Batteries BT1 and BT2 Inspection ................................................................................................................................................ 3-18, 4-54 Installation ........................................................................................................................................................ 4-54 Location and Description.................................................................................................................................. 1-38 Removal............................................................................................................................................................ 4-53 Service ..............................................................................................................................................3-19, 4-2, 4-54 Testing .............................................................................................................................................................. 4-53 Battery and SLAVE RECEPTACLE Cables Inspection ......................................................................................................................................................... 4-49 Installation ........................................................................................................................................................ 4-50 Removal............................................................................................................................................................ 4-50 Repair ............................................................................................................................................................... 4-50 Service .............................................................................................................................................................. 4-50 Battery Charging Alternator, Location and Description .......................................................................................... 1-38 Battery Current Transducer Inspection ....................................................................................................................................................... 4-202 Replacement ................................................................................................................................................... 4-202 Testing ............................................................................................................................................................ 4-202 BATTLE SHORT Switch S7 Inspection ......................................................................................................................................................... 4-98 Replacement ..................................................................................................................................................... 4-98 Testing .............................................................................................................................................................. 4-98 C CIM Configuration Switch .................................................................................................................................... 4-208 CIM Wiring Harness Inspection ....................................................................................................................................................... 4-134 Installation ...................................................................................................................................................... 4-135 Removal.......................................................................................................................................................... 4-134 Testing ............................................................................................................................................................ 4-135 COMMUNICATION RECEPTACLE Inspection ....................................................................................................................................................... 4-105 Location and Description.................................................................................................................................. 1-35 Replacement ................................................................................................................................................... 4-106 Computer Interface Module (CIM) Controls and Indicators....................................................................................................................................... 2-4 Inspection ....................................................................................................................................................... 4-103 Installation ...................................................................................................................................................... 4-103 Location and Description.................................................................................................................................. 1-35 Removal.......................................................................................................................................................... 4-103
Index-2
C-(Continued) CONVENIENCE RECEPTACLE J1 Inspection ........................................................................................................................................................4-107 Location and Description ..................................................................................................................................1-35 Replacement ....................................................................................................................................................4-108 Testing.............................................................................................................................................................4-107 Coolant Hose, Lower Inspection ........................................................................................................................................................4-160 Installation.......................................................................................................................................................4-160 Removal ..........................................................................................................................................................4-160 Coolant Hose, Upper Inspection ........................................................................................................................................................4-159 Installation.......................................................................................................................................................4-159 Removal ..........................................................................................................................................................4-158 Coolant Overflow and Drain Hoses Inspection ........................................................................................................................................................4-161 Installation.......................................................................................................................................................4-161 Removal ..........................................................................................................................................................4-161 Coolant Recovery System Inspection ........................................................................................................................................................4-167 Installation.......................................................................................................................................................4-170 Removal ..........................................................................................................................................................4-167 Coolant Temperature Sender MT6 Installation.......................................................................................................................................................4-199 Removal ..........................................................................................................................................................4-198 Service.............................................................................................................................................................4-199 Testing.............................................................................................................................................................4-197 Cooling System, Engine ...........................................................................................................................................1-23 Inspection ..........................................................................................................................................................3-24 Service................................................................................................................................................... 3-24, 4-154 Testing.............................................................................................................................................................4-151 Cooling System, Generator Set ................................................................................................................................1-23 Crankcase Breather Filter Assembly Inspection .............................................................................................................................................. 3-22, 4-149 Install...............................................................................................................................................................4-151 Location and Description ..................................................................................................................................1-38 Removal ..........................................................................................................................................................4-150 Service................................................................................................................................................... 3-22, 4-149 Test..................................................................................................................................................................4-150 Cranking Relay K2 Inspection ........................................................................................................................................................4-189 Replacement ....................................................................................................................................................4-190 Testing.............................................................................................................................................................4-190 Current Transformer CT1, CT2, CT3 Inspection ........................................................................................................................................................4-187 Installation.........................................................................................................................................................5-35 Removal ............................................................................................................................................................5-34 Testing................................................................................................................................................... 4-187, 5-34
Index-3
D DC CONTROL POWER Fuse F1 Inspection ....................................................................................................................................................... 4-119 Replacement ................................................................................................................................................... 4-119 Testing ............................................................................................................................................................ 4-119 DCS Control Box Assembly Inspection ......................................................................................................................................................... 4-79 Installation ........................................................................................................................................................ 4-79 Location and Description.................................................................................................................................. 1-35 Removal............................................................................................................................................................ 4-79 Repair ............................................................................................................................................................... 4-79 DCS Control Box Bottom Inspection ....................................................................................................................................................... 4-141 Installation ...................................................................................................................................................... 4-141 Removal.......................................................................................................................................................... 4-140 Repair ............................................................................................................................................................. 4-141 DCS Control Box Side Panels Inspection ....................................................................................................................................................... 4-139 Installation ...................................................................................................................................................... 4-140 Removal.......................................................................................................................................................... 4-139 Repair ............................................................................................................................................................. 4-140 DCS Control Box Top Panel Inspection ......................................................................................................................................................... 4-62 Installation ........................................................................................................................................................ 4-62 Removal............................................................................................................................................................ 4-60 Repair ............................................................................................................................................................... 4-62 DCS Control Box Wiring Harness Inspection .............................................................................................................................................. 4-133, 5-22 Repair ............................................................................................................................................................. 4-134 Replacement ..................................................................................................................................................... 5-23 Testing ................................................................................................................................................... 4-133, 5-23 DCS Control Panel Assembly Inspection ....................................................................................................................................................... 4-136 Installation ...................................................................................................................................................... 4-136 Removal.......................................................................................................................................................... 4-135 Repair ............................................................................................................................................................. 4-136 DCS Control Panel Frame Inspection ....................................................................................................................................................... 4-138 Installation ...................................................................................................................................................... 4-138 Removal.......................................................................................................................................................... 4-138 Repair ............................................................................................................................................................. 4-138 DCS Controls and Indicators ..................................................................................................................................... 2-1 DCS Load Sharing Synchronizer A2 Inspection ....................................................................................................................................................... 4-108 Installation ...................................................................................................................................................... 4-111 Removal.......................................................................................................................................................... 4-110 Testing ............................................................................................................................................................ 4-110
Index-4
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 D-(Continued) DCS Speed Control Unit A3 Inspection ........................................................................................................................................................4-111 Installation.......................................................................................................................................................4-112 Removal ..........................................................................................................................................................4-112 Testing ....................................................................................................................................................................4-111 Data Plates..................................................................................................................................................................1-6 Data Plates, DCS Inspection ........................................................................................................................................................4-142 Replacement ....................................................................................................................................................4-142 Data Plates, Housing Inspection ..........................................................................................................................................................4-78 Replacement ......................................................................................................................................................4-78 DEAD CRANK Switch S10 Location and Description ..................................................................................................................................1-38 Replacement ....................................................................................................................................................4-201 Testing.............................................................................................................................................................4-201 Diagnostic Controls and Indicators ............................................................................................................................2-8 Digital Control System .............................................................................................................................................1-16 Dipstick, Location and Description ..........................................................................................................................1-38 Diode CR1 CR10 Inspection ........................................................................................................................................................4-124 Replacement ....................................................................................................................................................4-125 Testing.............................................................................................................................................................4-124 Droop Current Transformer CT5 Inspection ........................................................................................................................................................4-188 Installation.........................................................................................................................................................5-38 Removal ............................................................................................................................................................5-35 Testing...............................................................................................................................................................5-37 E Electric Actuator A6 Inspection ..........................................................................................................................................................5-41 Replacement ......................................................................................................................................................5-43 Testing...............................................................................................................................................................5-41 EMERGENCY STOP Switch S17 Inspection ..........................................................................................................................................................4-99 Replacement ....................................................................................................................................................4-100 Testing...............................................................................................................................................................4-99 End Bell and Main Bearing Installation.........................................................................................................................................................5-47 Removal ............................................................................................................................................................5-47 Engine and Generator Assembly Disassembly ......................................................................................................................................................5-19 Installation.........................................................................................................................................................5-17 Removal ............................................................................................................................................................5-14 ENGINE CONTROL Switch S1 Inspection ..........................................................................................................................................................4-86 Replacement ......................................................................................................................................................4-87 Testing...............................................................................................................................................................4-87
Index-5
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS 09244A/09245A-14 E-(Continued) Ether Cylinder Assembly Inspection ....................................................................................................................................................... 4-179 Installation ...................................................................................................................................................... 4-179 Removal.......................................................................................................................................................... 4-179 Ether Solenoid Relay Inspection ....................................................................................................................................................... 4-182 Installation ...................................................................................................................................................... 4-183 Removal.......................................................................................................................................................... 4-183 Testing ............................................................................................................................................................ 4-183 Ether Solenoid Valve L6 Inspection ....................................................................................................................................................... 4-181 Installation ...................................................................................................................................................... 4-182 Removal.......................................................................................................................................................... 4-180 ETHER START Switch S9 Inspection ......................................................................................................................................................... 4-88 Replacement ..................................................................................................................................................... 4-88 Testing .............................................................................................................................................................. 4-88 Exciter Rotor Testing .............................................................................................................................................................. 5-54 Inspection ......................................................................................................................................................... 5-54 Exciter Stator Inspection ......................................................................................................................................................... 5-53 Replacement ..................................................................................................................................................... 5-53 Testing .............................................................................................................................................................. 5-53 F Fan Inspection ....................................................................................................................................................... 4-164 Installation ...................................................................................................................................................... 4-165 Removal.......................................................................................................................................................... 4-164 Fan Belt Adjustment ..................................................................................................................................................... 4-166 Inspection ....................................................................................................................................................... 4-165 Location and Description.................................................................................................................................. 1-38 Replacement ................................................................................................................................................... 4-166 Fan Guards Inspection ....................................................................................................................................................... 4-158 Installation ...................................................................................................................................................... 4-158 Removal.......................................................................................................................................................... 4-156 FAULT RESET Switch S4 Inspection ......................................................................................................................................................... 4-90 Replacement ..................................................................................................................................................... 4-91 Testing .............................................................................................................................................................. 4-90 Fault System ............................................................................................................................................................ 1-17 Filler Hose and Panel Inspection ....................................................................................................................................................... 4-155 Installation ...................................................................................................................................................... 4-155 Removal.......................................................................................................................................................... 4-155
Index-6
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 F-(Continued) FREQUENCY ADJUST Switch S19 Inspection ..........................................................................................................................................................4-95 Replacement ......................................................................................................................................................4-96 Testing...............................................................................................................................................................4-95 FREQUENCY SELECT Switch S12 (MEP-806B only) Inspection ........................................................................................................................................................4-121 Replacement ....................................................................................................................................................4-122 Testing.............................................................................................................................................................4-121 Fuel Drain Valve Location and Description ..................................................................................................................................1-38 Replacement ....................................................................................................................................................4-175 Fuel Filter/Water Separator Inspection .............................................................................................................................................. 3-29, 4-183 Location and Description ..................................................................................................................................1-39 Service................................................................................................................................................... 3-29, 4-183 Removal ..........................................................................................................................................................4-184 Installation.......................................................................................................................................................4-184 Fuel Level Sender MT5 Inspection ........................................................................................................................................................4-176 Installation.......................................................................................................................................................4-177 Removal ..........................................................................................................................................................4-176 Testing.............................................................................................................................................................4-177 Fuel Lines and Fittings, Low Pressure Inspection ........................................................................................................................................................4-170 Replacement ....................................................................................................................................................4-170 Fuel Pickup Inspection ........................................................................................................................................................4-178 Installation.......................................................................................................................................................4-178 Removal ..........................................................................................................................................................4-178 Fuel System ..............................................................................................................................................................1-20 Fuel Tank Inspection ................................................................................................................................................ 3-26, 5-26 Installation.........................................................................................................................................................5-26 Location and Description ..................................................................................................................................1-38 Removal ............................................................................................................................................................5-25 Service....................................................................................................................................................... 3-28, 4-3 Fuel Tank Filler Neck Inspection ........................................................................................................................................................4-175 Installation.......................................................................................................................................................4-175 Removal ..........................................................................................................................................................4-174 G Generator Assembly, AC..........................................................................................................................................1-29 Installation.........................................................................................................................................................5-45 Location and Description ..................................................................................................................................1-35 Removal ............................................................................................................................................................5-44 Generator Set Controls .............................................................................................................................................1-32
Index-7
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS 09244A/09245A-14 G-(Continued) Generator Set Installation Indoor ............................................................................................................................................................... 2-22 Outdoor............................................................................................................................................................. 2-21 Governor Control System ........................................................................................................................................ 1-17 GROUND FAULT CIRCUIT INTERRUPTER CB3 Inspection ....................................................................................................................................................... 4-100 Replacement ................................................................................................................................................... 4-101 Testing ............................................................................................................................................................ 4-100 Grounding Rod, Installation of ................................................................................................................................ 2-24 H Housing Section, Front Installation ........................................................................................................................................................ 4-71 Inspection ......................................................................................................................................................... 4-71 Removal............................................................................................................................................................ 4-68 Repair ............................................................................................................................................................... 4-71 Housing Section, Rear Installation ........................................................................................................................................................ 4-77 Inspection ......................................................................................................................................................... 4-74 Removal............................................................................................................................................................ 4-72 Repair ............................................................................................................................................................... 4-76 Housing Section, Top Inspection ......................................................................................................................................................... 4-67 Installation ........................................................................................................................................................ 4-67 Removal............................................................................................................................................................ 4-62 Repair ............................................................................................................................................................... 4-67 I I/O Interface Module A5 Inspection ....................................................................................................................................................... 4-117 Replacement ................................................................................................................................................... 4-118 Testing ............................................................................................................................................................ 4-117 Initial Adjustments, Checks, and Self-Test.............................................................................................................. 2-27 Inspecting and Servicing the Equipment ................................................................................................................... 4-1 K Keypad Assembly KP Inspection ....................................................................................................................................................... 4-104 Replacement ................................................................................................................................................... 4-104 Keypad Power Supply PS1 Inspection ......................................................................................................................................................... 4-55 Replacement ..................................................................................................................................................... 4-56 Testing .............................................................................................................................................................. 4-56
Index-8
L Load Cables, Installation of......................................................................................................................................2-26 Load Output Terminal Board TB2 Inspection ........................................................................................................................................................4-193 Installation.......................................................................................................................................................4-194 Location and Description ..................................................................................................................................1-39 Removal ..........................................................................................................................................................4-191 Repair ..............................................................................................................................................................4-194 Lubrication System...................................................................................................................................................1-23 Inspection ..........................................................................................................................................................3-29 Service....................................................................................................................................................... 3-31, 4-5 M Magnetic Pickup MPU Installation.......................................................................................................................................................4-200 Removal ..........................................................................................................................................................4-200 Service.............................................................................................................................................................4-200 Testing.............................................................................................................................................................4-201 Main Stator and Housing, Generator Replacement ......................................................................................................................................................5-58 Testing...............................................................................................................................................................5-58 MASTER CONTROL Switch Inspection ..........................................................................................................................................................4-91 Replacement ......................................................................................................................................................4-93 Testing...............................................................................................................................................................4-93 Mechanical System...................................................................................................................................................1-20 Muffler and Exhaust Pipe Inspection ........................................................................................................................................................4-142 Replacement ....................................................................................................................................................4-142 Location and Description ..................................................................................................................................1-38 N NATO SLAVE RECEPTACLE Inspection ..........................................................................................................................................................4-54 Installation.........................................................................................................................................................4-55 Location and Description ..................................................................................................................................1-38 Removal ............................................................................................................................................................4-55 NETWORK FAILURE Light DS5 Inspection ..........................................................................................................................................................4-84 Repair ................................................................................................................................................................4-84 Replacement ......................................................................................................................................................4-84 Nuclear, Biological, and Chemical (NBC) Decontamination...................................................................................2-45 O Oil Drain Valve Inspection ........................................................................................................................................................4-205 Location and Description ..................................................................................................................................1-38 Replacement ....................................................................................................................................................4-205
Index-9
O-(Continued) Oil Filter, Location and Description ........................................................................................................................ 1-38 Oil Pressure Sender MT7 Installation ...................................................................................................................................................... 4-197 Removal.......................................................................................................................................................... 4-195 Service ............................................................................................................................................................ 4-195 Testing ............................................................................................................................................................ 4-195 Operation Under Unusual Conditions Dusty or Sandy Areas ....................................................................................................................................... 2-42 Emergency Stopping......................................................................................................................................... 2-44 Extreme Cold Weather Below -25F (-31C)................................................................................................... 2-41 Extreme Heat Above 120F (48.8C) ............................................................................................................... 2-42 High Altitude Electromagnetic Pulse (HAEMP) Environment ........................................................................ 2-46 High Altitudes .................................................................................................................................................. 2-44 NATO Slave Receptacle Start Operation ......................................................................................................... 2-44 Rainy or Humid Conditions.............................................................................................................................. 2-43 Salt Water Areas............................................................................................................................................... 2-43 Using Battle Short Switch ................................................................................................................................ 2-44 While Contaminated ......................................................................................................................................... 2-46 Output Box Assembly Installation ........................................................................................................................................................ 5-29 Removal............................................................................................................................................................ 5-28 Output Box Panels Inspection ......................................................................................................................................................... 5-39 Installation ........................................................................................................................................................ 5-40 Removal............................................................................................................................................................ 5-39 Repair ............................................................................................................................................................... 5-40 Output Box Wiring Harness Inspection .............................................................................................................................................. 4-186, 5-33 Installation ........................................................................................................................................................ 5-33 Removal............................................................................................................................................................ 5-32 Repair .................................................................................................................................................... 4-187, 5-33 Testing ................................................................................................................................................... 4-186, 5-33 Output Supply System ............................................................................................................................................. 1-29 P Panel Lights DS1 through DS3 Inspection ......................................................................................................................................................... 4-80 Repair ............................................................................................................................................................... 4-80 Replacement ..................................................................................................................................................... 4-81 PANEL LIGHTS Switch S2 Inspection ......................................................................................................................................................... 4-96 Replacement ..................................................................................................................................................... 4-97 Testing .............................................................................................................................................................. 4-96 Parallel Unit Operation ............................................................................................................................................ 2-33 PARALLELING RECEPTACLE J2 Inspection ....................................................................................................................................................... 4-106 Replacement ................................................................................................................................................... 4-106 Location and Description.................................................................................................................................. 1-35
Index-10
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 P-(Continued) Power Potential Transformer T1 Inspection ........................................................................................................................................................4-188 Installation.........................................................................................................................................................5-38 Removal ............................................................................................................................................................5-38 Preparation for Movement........................................................................................................................................2-39 Preparation for Shipment and Storage....................................................................................................................4-206 R Radiator Installation.......................................................................................................................................................4-163 Location and Description ..................................................................................................................................1-38 Removal ..........................................................................................................................................................4-162 Repair ............................................................................................................................................................... 5-24 Service..................................................................................................................................................... 4-2, 4-163 REACTIVE CURRENT ADJUST Rheostat R5 Inspection ........................................................................................................................................................4-122 Replacement ....................................................................................................................................................4-123 Testing.............................................................................................................................................................4-123 Relays K15, K17, K19, K22, K23 Inspection ........................................................................................................................................................4-129 Removal ..........................................................................................................................................................4-130 Testing.............................................................................................................................................................4-130 Installation.......................................................................................................................................................4-130 Remote Operation.....................................................................................................................................................2-36 Resistor R1 Inspection ........................................................................................................................................................4-125 Replacement .......................................................................................................................................... 4-126, 5-24 Testing.............................................................................................................................................................4-125 Resistor R2 Inspection ........................................................................................................................................................4-126 Replacement .......................................................................................................................................... 4-127, 5-24 Testing.............................................................................................................................................................4-126 Resistor R6 Inspection ........................................................................................................................................................4-132 Replacement ....................................................................................................................................................4-132 Testing.............................................................................................................................................................4-132 Resistors R16 and R17 Inspection ........................................................................................................................................................4-130 Replacement ....................................................................................................................................................4-131 Testing.............................................................................................................................................................4-131 Restriction Indicator Inspection ........................................................................................................................................................4-146 Replacement ....................................................................................................................................................4-147 Rotor Assembly, Generator Installation.........................................................................................................................................................5-57 Removal ............................................................................................................................................................5-56 Testing...............................................................................................................................................................5-56
Index-11
ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS 09244A/09245A-14 R-(Continued) Rotating Rectifier Installation ........................................................................................................................................................ 5-51 Removal............................................................................................................................................................ 5-50 Replacement of Rectifier Diodes...................................................................................................................... 5-51 Testing .............................................................................................................................................................. 5-50 S Shut Down Generator Set ........................................................................................................................................ 2-31 Skid Base Inspection ......................................................................................................................................................... 5-59 Installation ........................................................................................................................................................ 5-59 Location and Description.................................................................................................................................. 1-38 Removal............................................................................................................................................................ 5-59 Repair ............................................................................................................................................................... 5-59 Start Generator Set................................................................................................................................................... 2-30 Starter, Location and Description ............................................................................................................................ 1-38 T Time Meter M3 Inspection ......................................................................................................................................................... 4-84 Replacement ..................................................................................................................................................... 4-86 Testing .............................................................................................................................................................. 4-86 V VOLTAGE ADJUST Switch S18 Inspection ......................................................................................................................................................... 4-94 Replacement ..................................................................................................................................................... 4-94 Testing .............................................................................................................................................................. 4-94 Voltage Reconnection Terminal Board TB1 Inspection .............................................................................................................................................. 5-31, 4-184 Installation ...................................................................................................................................................... 4-186 Location and Description.................................................................................................................................. 1-39 Removal.......................................................................................................................................................... 4-184 Replacement ..................................................................................................................................................... 5-31 Voltage Regulation System ..................................................................................................................................... 1-20 Voltage Selection Switch S20 Inspection ....................................................................................................................................................... 4-128 Replacement ................................................................................................................................................... 4-129 Testing ............................................................................................................................................................ 4-128 W Water Pump, Location and Description................................................................................................................... 1-38
Index-12
By Order of the Secretary of the Army: ERIC K. SHINSEKI General, United States Army Chief of Staff
Official:
0016405
By Order of the Secretary of the Marine Corps: RANDALL P. SHOCKEY Director, Program Support Marine Corps Systems Command
By Order of the Secretary of the Air Force: MICHAEL E. RYAN General, United States Air Force Chief of Staff Official: GEORGE T. BABBITT General, United States Air Force Commander, AFMC
DISTRIBUTION: To be distributed in accordance with the initial distribution number (IDN) 256635 requirements for TM 9-6115-672-14.
RECOMMENDED CHANGES TO EQUIPMENT TECHNICAL PUBLICATIONS
SOMETHING WRONG WITH THIS PUBLICATION

FROM: (PRINT YOUR UNIT'S COMPLETE
THEN ... JOT DOWN THE INFO ABOUT IT ON THIS FORM. CAREFULLY TEAR IT OUT. FOLD IT AND DROP IT IN THE MAIL.
PUBLICATION
Commander Stateside Army Depot ATTN: AMSTA-US Stateside, N.J. 07703-5007

DATE SENT
10 July 1975
PUBLICATION
PUBLICATION DATE
TM 11-5840-340-12
BE EXACT PIN-POINT WHERE IT PAGE NO PARA GRAPH FIGURE NO TABLE NO
23 Jan 74
Radar Set AN/PRC-
IN THIS SPACE TELL WHAT IS WRONG AND WHAT SHOULD BE DONE ABOUT IT:
2-25
2-28
Recommend that the installation antenna alignment procedure be changed throughout to specify a 20 IFF antenna lag rather than 10. REASON: Experience has shown that with only a 10 lag, the antenna servo system is too sensitive to wind gusting excess of 25 knots, and has a tendency to rapidly accelerate and decelerate as it hunts, causing strain to the drive train. Hunting is minimized by adjusting the lag to 20 degradation of operation.
3-10
3-3
3-1
Item 5, Functional column. Change 2 dB" to 3 dB. REASON: The adjustment procedure for the TRANS POWER FAULT indicator calls for a 3 dB (500 watts) adjustment to light the TRANS POWER FAULT indicator.
5-6
5-8
Add new step f.1 to read, Replace cover plate removed in step e.1, above." REASON: To replace the cover plate. FO-3 Zone C 3. On J1-2, change +24 VDC" to +5 VDC". REASON: This is the output line of the 5 VDC power supply. +24 VDC is the input voltage.
PRINTED NAME, GRADE OR TITLE AND TELEPHONE
SIGN HERE
SSG I. M. DeSpiritof
999-1776
PREVIOUS ARE OBSOLETE P.S. - IF YOUR OUTFIT WANTS TO KNOW ABOUT RECOMMENDATION MAKE A CARBON COPY OF AND GIVE IT TO YOUR
DA 1 JUL 792028-2
FORM
REVERSE OF DA FORM 2028-2
TEAR ALONG DOTTED LINE
FILL IN YOUR UNIT'S ADDRESS FOLD BACK
DEPARTMENT OF THE ARMY
PLEASE AFFIX STAMP POSTAGE REQUIRED

OFFICIAL BUSINESS
Commander U.S. Army Communications-Electronics Command and Fort Monmouth ATTN: AMSEL-LC-LEO-D-CS-CFO Fort Monmouth, New Jersey 07703-5000

OFFICIAL BUSINESS

OFFICIAL BUSINESS

OFFICIAL BUSINESS
PIN: 078167-000

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ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14 TECHNICAL MANUAL

GENERATOR SET, SKID MOUNTED, TACTICAL QUIET

GENERAL SUPPORT MAINTENANCE

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

LIST OF EFFECTIVE PAGES

TOTAL NUMBER OF PAGES IS 500, CONSISTING OF THE FOLLOWING:

* Zero in this column indicates an original page.

ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14

ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14

ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14

ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14

ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14

ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14

ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14

ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14

Table 1-1 1-2 2-1 2-2 2-3 2-4

ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14

FIGURE 1-1. 60 kW TACTICAL QUIET GENERATOR SET 1-2

40F (4C) or below

40F (4C) or below

Governors of America ADC100-24

Governors of America ADC100-24

Two 12 volt, connected in Series Denso RE 40595 24 VDC Gear reduction

Two 12 volt, connected in series Denso RE 40595 24 VDC Gear reduction

Bosch 9 120 060 039 42 amps at 24 VDC 30 amps

Bosch 9 120 060 039 42 amps at 24 VDC 30 amps

ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14

ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14

ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14

FIGURE 1-4. OPERATING INSTRUCTION PLATE, MEP-806B 1-9

ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14

FIGURE 1-5. OPERATING INSTRUCTION PLATE, MEP-816B 1-10

ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14

FIGURE 1-6. IDENTIFICATION PLATE, MEP-806B AND MEP-816B

FIGURE 1-7. SET RATING IDENTIFICATION PLATE, MEP-806B AND MEP-816B

ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14

FIGURE 1-8. VOLTAGE CONNECTION CAUTION PLATE

FIGURE 1-9. GROUNDING STUD PLATE

FIGURE 1-10. NATO SLAVE RECEPTACLE PLATE

FIGURE 1-11. PARALLELING RECEPTACLE PLATE

FIGURE 1-12. CONVENIENCE RECEPTACLE PLATE, MEP-806B AND MEP-816B

FIGURE 1-13. EXTERNAL FUEL SUPPLY PLATE

ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14

FIGURE 1-14. BATTERY CONNECTION INSTRUCTION PLATE

FIGURE 1-15. LIFTING AND TIEDOWN DIAGRAM PLATE

ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14

FIGURE 1-16. FUEL SYSTEM DIAGRAM PLATE

ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14

ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14

FIGURE 1-19. FAULT SYSTEM FLOW DIAGRAM

ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14

FIGURE 1-20. GOVERNOR CONTROL SYSTEM FLOW DIAGRAM

ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14

FIGURE 1-21. VOLTAGE REGULATION SYSTEM FLOW DIAGRAM

ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14

FIGURE 1-22. FUEL SYSTEM FLOW DIAGRAM

1.16.8.4 1.16.9 1.16.9.1

ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14

FIGURE 1-23. GENERATOR SET COOLING SYSTEM FLOW DIAGRAM

ARMY TM 9-6115-672-14 AIR FORCE TO 35C2-3-444-32 MARINE CORPS TM 09244A/09245A-14