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TM 5-6115-904-15 DEPARTMENT OF THE ARMY TECHNICAL MANUAL OPERATOR, ORGANIZATIONAL, FIELD AND DEPOT MAINTENANCE MANUAL GENERATOR SET, GASOLINE ENGINE: 1.5 KW, AC, 120 V, SINGLE PHASE 60 CYCLE, AIR COOLED; OPEN; TUBULAR FRAME; SHOCK MOUNTED (KOHLER MODEL KK 1.5M25) (LESS ENGINE) FSN 6115-591-§867 y Sos HEADQUARTERS, DEPARTMENT OF THE ARMY 4 OCTOBER 1963 SAFETY PRECAUTIONS. BEFORE OPERATION ‘Do not operate the generator set in an enclosed area unless the exhaust fumes are piped to the outside. Inhalation of exhaust fumes will result in serious illness or death, Do not operate the generator set until the ground terminal stud has been connected to a suitable ground. Electrical faults in the generator set load lines, or equipment can cause death by electrocution from contact with an ungrounded system. When filling the fuel tank, do not smoke or use an open flame in the im- mediate vicinity, Always provide metal-to-metal contact between the con- tainer and the fuel tank. This will prevent a spark from being generated as fuel flows over metallic surfaces. Failure to observe this warning may re- sult in death to personnel. DURING OPERATION Do not perform any electrical maintenance or change load connections while the generator set is operating or connected to an energized line. Fail- ure to observe this safety precaution may result in death by electrocution. Exercise extreme caution when making the voltage regulator relay adjustment. The voltage of this generator set can cause death by electro- cution. AFTER OPERATION When filling the fuel tank, always maintain metal-to-metal contact be- tween the filling apparatus and fuel tank to prevent a spark from being caused by static electricity. Before servicing any part of the generator set, make certain that the engine is stopped. Failure to observe this safety precaution may result in severe electrical shock or death by electrocution. TM 5-6115-304-15, DEPARTMENT OF THE ARMY ‘Tecumtcan, Manvat} HEADQUARTERS, Wasutnoton, D.C., 4 October 1963 No. 5-6115-304-15 OPERATOR, ORGANIZATIONAL, FIELD, AND DEPOT MAINTENANCE MANUAL GENERATOR SET, GASOLINE ENGINE: 1.5 KW, AC, 120 V, SINGLE PHASE, 60 CYCLE, AIR COOLED; OPEN; TUBULAR FRAME; SHOCK MOUNTED (KOHLER MODEL KK 1.5M25) (LESS ENGINE) FSN 6115-591-6867 Cuarrer 1. INTRODUCTION Field expedient repaire.. VII. Radio interference suppression. VIIL Engine accessories. IX. Generator... X. Control box. Cnartex 4. DEMOLITION OF GENERATOR SET TO PREVENT ENEMY USE. 5. SHIPMENT AND LIMITED STORAGE Section I. Shipment within zone of interior. II. Limited storage. Cuarren 6. FIELD AND DEPOT MAINTENANCE INSTRUCTIONS Section I. General. II. Description and data__- ms IIL. Special tools and equipment. IV. Troubleshooting. V. Radio interference suppression. VI. Removal and installation generator and engine vit. vil. Arpencix I. II. MAINTENANCE ALLOCATION. IIL. BASIC ISSUE ITEMS AND MAINTEN 44,45 Inoex. TAGO 622TA—Oetober 1 CHAPTER 1 INTRODUCTION Section |. 1, Scope a, These instructions are published for the use of the personnel to whom the Kohler Model KK 1.5M25 Generator Set is issued. Chapters 1 through 5 provide information on the opera- tion, daily preventive maintenance services, and organizational maintenance of the equipment, accessories, components, and attachments. Chapter 6 provides information for field and. depot maintenance (3d, 4th, and 5th echelons)} This manual also provides descriptions of the main units and their functions in relationship to other components. b. Appendix I contains a list of publications applicable to this manual. Appendix II contains the list of basic issue items authorized the oper- ator of this equipment. The organizational, field, and depot maintenance repair parts and special tool lists are in TM 5-6115-304-25P. ¢. Numbers in parentheses on illustrations indicate quantity. Numbers preceding nomen- clature callouts on illustrations indicate the pre- ferred maintenance sequence. d. The direct reporting by the individual user, of errors, omissions, and recommenda- tions for improving this manual is authorized Section i. 3. Description a. General. The Kohler Model KK 1.5M25 Generator Set (figs. 1 and 2) is a self-contain- ed, skid-mounted, portable unit. It is powered by a 2cylinder, 4-cycle, air cooled, military standard engine (fig. 2) that is directly coupled to a 1.5 kilowatt, alternating current generator (fig. 1). b. Engine. Refer to TM 5-2805-206-14 for a description of the engine. ¢. Generator, The generator (fig. 1) is a 2- pole revolving armature, 120-volt, 60-cycle unit with a voltage regulation system. It is rated at 1.5 kilowatt and is directly coupled to the en- gine (fig. 2). d, Control Box. The control box (fig. 1) con- GENERAL and encouraged. DA Form 2028 (Recommended Changes to DA Technical Manual Parts Lists or Supply Manual 7, 8, or 9) will be used for re- porting these improvements. This form will be completed in triplicate using pencil, pen, or typewriter. The original and one copy will be forwarded direct to the Commanding Officer, U. S. Army Mobility Support Cented, ATTN: SMOMS-MM, P. 0. Box 119, Columbus, Ohio 43216. One information copy will be forwarded to the individual's immediate supervisor (e.g., officer, noncommissioned officer, supervisor, ete.). ¢. Report all equipment improvement recom- mendations as prescribed by TM 38-750. 2. Record and Report Forms a. DA Form 2258 (Depreservation Guide of Engineer Equipment). . For other record and report forms applic- able to operator, crew, or organizational main- tenance, refer to TM 38-750. Note: Applicable forms, excluding Standard Form 46 (United States Government Motor Vehicle Opera- tor’s Identification Card), which is carried by the operator, will be kept in a canvas bag mounted on the equipment. DESCRIPTION AND DATA tains the controls, instruments, and electrical components necessary for the operation of the generator set. 4. Identification and Tabulated Data a, Identification. The generator set has five identification and instruction plates. (1) Corps of Engineers plate A. The Corps of Engineers plate A is located on the rear of the fuel tank mounting bracket at the right side of the unit. It specifies the nomenclature, stock num- ber, serial number, manufacturer, model, contract number, date manu- factured, length, width, height, capa- city or pay load, gvw, shipping weight, cube, engine manufacturer, engine ‘AGO 62274 ‘CONTROL Box aecEPTACLE COWVECTOR (2) ‘AGO 62270 SHIPPING OIWENSIONS LENGTH 30 INCHES. Vint 19 INCHES WEIGHT 24 INCHES HEGHT 708 POUNDS Figure 1. Generator set, right rear, model number, engine serial number, and date inspected. This information is listed in the tabulated data. Corps of Engineers plate C. The Corps of Engineers plate C is located below the plate A on the rear of the fuel tank mounting bracket at the right side of the unit. It specifies the nomenclature, make, model, serial number, volts, kilowatts, cycles, dates manufactured, TM number, kilovolt- amperes, revolutions per minute, three-quarter (3) FUEL TANK CAP MSC 6115-204-15/1 view, with shipping dimensions. phase, number of wires, amperes, and power factor. This information is listed in the tabulated data, Generator plate, The generator data plate is located on the right side of the generator housing, beneath the fuel tank. It specifies the manufacturer, model, serial specification number, kilowatts, kilovolt-amperes, volts, am- peres per terminal, battery voltage, phase, cycles, revolutions per minute, power factor and horsepower. This 3 Figure 2. information is listed on the tabulated data. (4) Engine plate. The engine data is lo- cated on the flywheel fan cover at the front of the engine. Refer to TM 5-2805-206-14. (5) Operating instructions plate. The operating instructions plate is located on the outer side of the hinged cover of the control box. b. Tabulated Data. (1) Genera Manufacturer _. -Kohler Co. Model é KK 1.5M25 (2) Corps of Engineers U.S. Army plate A. cea 80x COVER GROUND TERMINAL STUD Sc 6115-304-15/2 Generator set, left front, three-quarter view. Nomenclature ----- Generator Set, Electric GED Stock No. -_.. FSN 615-591-6867 Ser. No. Kohler Co. KK 1,5M25 ~88-AF-47249-07 30 inches -19 inches Height — -24 inches Cap or Pay Load 1.5 KW Gvw. Ship Wt. -. -208 Ib (pounds) Cube 2 1.9 Eng. Mfgr. Continental Motors Corp. Model ________________2 AO16-2 Eng. Ser. No. Date Insp. AGO 622A 12-378"! cape ---1 gal. (gallon) —--1.0 pt (pint) -1/8 qt (quart) (1) Dimensions and weight. Air Cleaner — (4) Engine. For tabulated data on the military standard engine, refer to TM 5-2805-206-14. (5) Generator plate. Manufacturer - base plan. . (10) Wiring diagram. Refer to figure 4 Batt. Volts, for the wiring diagram. AGO 62178 5 ne eae ea-ce-e8 reo 1a Boyan 2 10 uF, 00 ature Ls ST Ime RHE ar, 200 OMNECTOR (CONTROL 80x 7 oRNECTOR (AC OUTPUT) o 5 (VOLTAGE nesuLATOR) use 9113-304-15/4 Figure 4. Wiring diagram. 5. Differences in Models This manual covers only the Kohler Model ences exist for the model covered by this mai KK 1.5M25 Generator Set. No known differ- ual. 6 Aco ea CHAPTER 2 INSTALLATION AND OPERATION INSTRUCTIONS Section |. 6. Unloading Equipment ‘The total weight of the packed generator is approximately 230 pounds. A handtruck, fork- jift, or manpower may be used to unload the unit. Keep the set in the UP position while un- loading. 7. Unpacking Equipment a. General. For domestic shipment, the gen- erator set normally is packed in a wood contain- or. b. Unpacking. (1) Remove the container from the gen- erator set. Caution: Exercise care while un- packing to avoid damaging the gen- erator set. (2) Check the equipment against the packing list. Correct or report discrep- ancies to field maintenance. ¢. Depreservation. Prepare the generator set for inspection and operation as outlined on DA Form 2258 (Depreservation Guide of Engineer Equipment), attached on or near the operation- al controls. 8. Inspecting and Servicing Equipment Note: Make sure equipment is completely deproces- sed before servicing. Make sure preservatives have been removed from all components. a, Inspection. (1) Perform the daily preventive main- tenance services prescribed in para- graph 30 and the quarterly preventive maintenance services as outlined in paragraph 31. (2) Make a thorough visual inspection of the generator set for loose or missing mounting hardware, damage, or miss- ing parts. Inspect the fuel lines for cracks or leaks. Correct or report de- ficiencies to field maintenance. (3) For inspection of the engine, refer to TM 5-2805-206-14. AGO 227A SERVICE UPON RECEIPT OF EQUIPMENT b, Servicing. (1) Lubrication. The generator is equip- ped with sealed bearings and requires no lubrication. For lubrication of the engine, refer to TM 5-2805-206-14. (2) Fuel system. (a) Service the fuel strainer (TM 5-2805-206-14). (b) Remove the fuel tank cap (fig. 1), refer to the maintenance and opera- ting supplies, and fill the fuel tank with the proper grade of fuel. Warning: When filling the fuel tank, always maintain metal-to- metal contact between the filling apparatus and fuel tank to prevent a spark from being caused by stat- ic electricity. Warning: Do not fill the fuel tank while the engine is in opera- tion. Gasoline spilled on a hot en- gine may explode. 9. Installation or Setting-up Instructions a. General. The generator set should be in- stalled on a level site, clear of obstacles, and with ample ventilation. b. Installation. When preparing for a per- manent installation, construct the base outlined by figure 3. Select a site where there will be suf- ficient space on all sides for servicing and oper- ation of the unit. For temporary installation, move the generator set as close to the worksite as practical. Avoid, if possible, dusty or sandy locations. Use boards or other material for a base in areas where ground is soft. ¢. Indoor Installation. Keep the area well ventilated at all times so that the generator set will receive a maximum supply of air. Install a gastight exhaust line to pipe the exhaust gases to the outside. Use as few bends in the line as possible. Provide metal shields for the exhaust lines where they pass through flammable walls. Wrap the exhaust lines with asbestos if there is any danger of anyone touching them. Warning: Do not operate the generator set in an enclosed area unless the exhaust gases are piped to the outside. Inhalation of exhaust, fumes will result in serious illness or death. d. Grounding. The generator set must be grounded prior to operation. The ground can be, in order of preference, an underground metal- lie water piping system, a driven metal rod, or a buried metal plate. A ground rod must have a minimum diameter of % inch if solid or 34 inch if pipe, and must be driven to a minimum depth of 8 feet. A ground plate must have a minimum area of 9 square feet and be buried at a mini- mum depth of 4 feet. The ground lead must be No. 6 AWG (American Wire Gage) copper wire and be bolted or clamped to the rod, plate, or piping system. Connect the other end of the ground lead to the generator set ground termi- nal stud (fig. 2). Warning: Do not operate the generator set until the ground terminal stud has been con- Section Il. 10. Dismantling for Movement a, Preparation for Movement. (1) Stop the generator set (par. 16). (2) Disconnect the load lines and ground lead (par. 9). (8) Remove the exhaust pipe extension (par. 9), if used. (4) Open the drain valve located under the fuel tank and drain the fuel into a suitable container. (5) Refer to the basic issue items list and make sure that all items listed are on or with the equipment. Section Ill. 12. General This section describes, locates, illustrates, and furnishes the operator, crew, or organiza- tional maintenance personnel sufficient infor- mation about the various controls and instru- ments for proper operation of the generator set, nected to a suitable ground. Electrical faults in the generator set, lead lines, or equipment can cause death by electrocution from contact with an ungrounded system. e. Leveling. Set up the unit as level as pos- sible. Keep the unit as level as possible during operation. f. Load Connections. (1) Loosen the nuts on the load terminal studs (fig. 1). (2) Insert the stripped end of the load line into the terminal stud and tighten the nut. Warning: Do not install or change the load cables while the generator set is operating. The voltage genera- ted by this equipment can cause death by electrocution. Note: The receptacles (fig. 1) may be used in lieu of the load terminal studs. MOVEMENT TO A NEW WORKSITE (6) Remove all anchoring devices, b. Handling the Generator Set. (1) Movement within the immediate area, If the generator set is to be moved only a short distance, it may be car- ried or towed to the new worksite. (2) Movement from the immediate area or over rough terrain. Use a hand- truck or forklift and move the genera- tor to the new worksite. 11. Reinstallation Afer Movement Refer to paragraph 9 for reinstallation in- structions after movement to a new worksite. CONTROLS AND INSTRUMENTS 13. Controls and Instruments Refer to figure 5 for the purpose, normal readings, and location of all controls and instru- ments, AGO 62274, VOLIVETER. NORWAL READING 120 VOLTS RNEOSTAT. k0,US 0 A. ANMETER, LOAD SWITCH, VOLTMETER, AND RHEDSTAT HOKE LEVER. wsc 615-304-155 © Figure 5. Controls and instruments. AGO 62278 9 FUEL thw == 0. FUEL SMUTOFF VALVE FUEL GAGE INDICATES. FUEL_LEVEL E. FUEL GAGE vse 6115-304.15'5 @ Figure $—Continued. Section IV. OPERATION OF EQUIPMENT 14. General a. The instructions in this section are pub- lished for the information and guidance of the personnel responsible for operation of the gen- erator set. b. The operator must know how to perform every operation of which the generator set is capable. This section gives instructions on starting and stopping the engine, and operating details of the generator set. Since nearly every job presents a different problem, the operator may have to vary given procedures to fit the individual job. Warning: Do not perform any electrical maintenance or change load connections while the generator set is operating or connected to an energized line. Failure to observe this safe- ty precaution may result in severe electrical shock or death by electrocution. 10 15. Starting a. Preparation for Starting. Perform the preventive maintenance services as outlined in paragraph 30. b. Starting. Refer to figure 6 and start the engine, 16. Stopping Refer to figure 7 and stop the engine. 17. Generator Set Operation a. General. When the load is connected and the engine is operating, the generator operates at its rated voltage as indicated on the volt- meter. The ammeter should indicate between 0 to 12.5 amperes. If a reading of more than 12.5 amperes is indicated, reduce the load or report the condition to organizational maintenance. The generator set does not have a throttle con- trol and the engine is designed to operate con- AGo 62277 CONTROL 80% LOAD SWITCH 1. OPEN FUEL SHUTOFE VALVE STEP 2. TURN RAEDSTAT KNOB FULLY a ne ! COUNTERCLOCKWISE AND POSITION LOAD Hitch TO OFF STEP 3. CLOSE CHOKE. WRAP STARTER STEP 4 GRADUALLY OPEN CHOKE AS ENGINE OPE ON FLANGE AND PULL RITH ATTAINS OPERATING TEMPERATURE WICK STEADY MOTION WSC 6115-304-15/6 Figure 6. Engine starting instructions. AGO 62274 W CONTROL 80x Load SwiToH STEP 1, TURN RHFOSTAT KNOB FULLY COUNTERCLOCKMISE STEP 2. POSITION LOAD SWITCH TO OFF UNTIL ENGINE STOPS STEP 4. CLOSE THE FUEL SHUTOFF VALVE Figure 7. Engine stopping instructions, tinuously at 3,600 revolutions per minute (full load) in accordance with the governor setting. The operator must observe the generator set, paying particular attention to unusual sounds which indicate malfunction. In such an event, 12 stop the engine (par. 16). Refer to paragraph 42 or report the condition to organizational maintenance. b. Operation. Refer to figure 8 and operate the generator set. AGO e227, START THE ENGINE (PAR. 15) ADJUST RHEDSTAT KNOB UNTIL OL TWETER INDICATES 120 MBLTS S17 OBSERVE. ANWETER AND VOLTHETER FOR NORMAL READINGS. Ws 6115-306-15/8 Figure 8. Generator set operating instructions. 18. Operation in Extreme Cold (Below O°F) a, General, The generator set will function satisfactorily at temperatures down to —65°F, (Fahrenheit). Care should be taken to keep the engine in good operating condition, to assure quick starting in very cold weather. b, Fuel System. Keep the fuel tank as full as possible to prevent condensation. Drain and service the fuel filter more frequently than under normal conditions (TM 5-2805-206-14). e. Blectrical System. (1) Before attempting to start the engine, remove any accmumulation of ice or snow from the spark plug or wiring. Caution: Do not bend or kink wir- ing during cold weather. Electrical wiring becomes brittle with extreme cold. (2) Allow at least « 5-minute stabilization period after starting the engine before applying the load to the generator. d, Lubrication. Lubricate the engine as pre- scribed in TM 5-2805-206-14. AGO 622A. 19. Operation in Extreme Heat a, Indoor Ventilation. If the generator set is operated indoors, allow sufficient space around the equipment for air circulation. b. Cooling Inspect the cooling fins on cylin- der frequently to make sure they are clean. ¢. Generator. Inspect the instruments fre- quently to make sure generator is not over- loaded, Excessive overloading will eause arcing at the brushes, d. Lubrication. Lubricate the engine as pre- scribed in TM 5-2805-206-14. 20. Operation in Dusty or Sandy Areas a, Protection. Shield generator set from dust. Take advantage of natural barriers which offer protection from dust and sand. b. Air Cleaner. Service the air cleaner daily to keep the carburetor free of dirt and sand (TM 5-2805-206-14). c. Lubrication. Lubricate the engine as pre- scribed in TM 5-2805-206-14. Keep lubricants free of dust and sand. 21. Operation Under Rainy or Humid Condi a. General. If the unit is outside and is not operating, place a canvas cover or waterproof cover over the unit during storms. During dry periods, remove the cover. b. Fuel. Keep the fuel tank as full as possible to prevent condensation. Drain and service the fuel filter more frequently than under normal conditions (TM 5-2805-206-14). ¢. Electrical System, Humid conditions can cause corrosion and deterioration of electrical components. Keep electrical components and wiring clean and dry. 22. Operation in Salt Water Areas a. General. Wipe the generator set with a clean cloth dampened with clean, fresh water at frequent intervals. Use care not to contaminate the fuel supply or damage the electrical system with water. b. Lubrication. Use care to keep salt water from entering engine when adding or changing oil. Lubricate more frequently than under nor- mal conditions. Lubricate the engine as pre- scribed in TM 5-2805-206-14. c. Preservation. Paint all exposed nonpolish- ed surfaces. Coat exposed parts of polished steel 13 or other ferrous material with standard issue, rustproofing material, if available or cover parts with a light coat of grease. Refer to TB ENG 60. 23. Operation at High Altitudes The generator set is rated 1.5 kw (kilowatt) at altitudes up to 5,000 feet above sea level 14 without any special adjustments. However, be- cause of thinner air at high altitudes, the car- buretor may require adjustment to provide a leaner fuel-air mixture. (TM 5-2805-206-14). To guard against overheating of the generator set at higher altitudes, provide ample space and ventilation around the set. AGO 627A CHAPTER 3 OPERATOR AND ORGANIZATIONAL MAINTENANCE INSTRUCTIONS Section I. 24. Special Tools and Equipment No special tools or equipment are required by the operator or organizational maintenance personnel for the maintenance of the generator set (less engine). 25. Basic Issue Tools and Equipment Tools and repair parts issued with or author- Section Il. 27. General Lubrication Maintenance a. Generator. Lubrication is not required for the generator. b. Engine. For general lubrication instruc- tions on the engine, refer to TM 5-2805-206-14, Section tl. 29. General To insure that the equipment is ready for op- eration at all times, it must be inspected system- atically, so that defects may be discovered and corrected before they result in serious damage or failure. The necessary preventive mainte- nance services to be performed are listed and de- scribed in paragraphs 30 and 31. The item num- bers indicate the sequence of minimum inspec- tion requirements. Defects discovered during operation of the unit will be noted for future correction, to be made as soon as operation has ceased. Stop operation immediately if a defi- ciency is noted during operation which would damage the equipment if operation were con- tinued. All deficiencies and shortcomings will be recorded, together with the corrective action taken, on DA Form 2404 (Equipment Inspec- tion and Maintenance Worksheet) at the earli- est possible opportunity. 30. Daily Preventive Maintenance Services ‘This paragraph contains an illustrated tabu- ‘AGO 6227 OPERATOR AND ORGANIZATIONAL MAINTENANCE TOOLS AND EQUIPMENT ized for the generator set are listed in the basic issue items list, appendix III. 26. Organizational Maintenance Repair Parts Organizational maintenance repair parts are listed and illustrated in TM 5-6115-304-25P. LUBRICATION 28. Detailed Lubrication Information a. Refer to TM 5-2805-206-14 for detailed lubrication instructions on the engine, b. The generator is equipped with a sealed bearing and requires no lubrication. PREVENTIVE MAINTENANCE SERVICES lated listing of preventive maintenance services which must be performed by the operator. The item numbers are listed consecutively and indi- cate the sequence of minimum requirements. Refer to figure 9 for the daily preventive main- tenance services. 31. Quarterly Preventive Maintenance ices a, This paragraph contains an illustrated tabulated listing of preventive maintenance services which must be performed by organiza- tional maintenance personnel at quarterly inter- vals. A quarterly interval is equal to 8 calendar months, or 250 hours of operation, whichever oceurs first. b, The item numbers are listed consecutively and indicate the sequence of minimum require- ments. Refer to figure 10 for the quarterly pre- ventive maintenance services. PREVENTIVE MAINTENANCE SERVICES TM5-6115-304-15 GENERATOR SET KOHLER MODEL KK. 5W25 GROUND TERMINAL. Check for proper ground. A proper ground wil! consist of a 3/ hollow rod or §/8-inch-dia. solid rod, 9 feet long. The = cable will be No. 6 AWG copper wire, bolted or clamped to the rod and attached to the ground terminal of the generator set. OlL LEVEL GAGE. Add oil as indicated by tevel gage. Reference current 105-2805-206-14. FUEL FILTER. Tighten thumbnut if gasket is leaking. (Clean weekly.) Reference TW5-2805-206-14, par. 55, CONTROLS AND INSTRUMENTS. Inspect for damage and loose mounting. Mith unit operating, check for proper operation. Normal operating readings for instruments are as follows: Yo! tmeter 120 volts Anme ter Indicates applied load not to exceed 12.8 amperes maximum wse 6115-304 1578 (1) Figure 9. Daily preventive maintenance services. AGO 627A NOTE 1. OPERATION. During operation observe for any unusual noise or vibration. wsc 6115-304-15/9 (2) Figure 9—Continued. AGO ez27A 7 PREVENTIVE MAINTENANCE SERVICES QUARTERLY TW5~6115-304-15 GENERATOR SET OIL LEVEL GAGI KOHLER MODEL KKI. 5625 ELECTRICAL CONNECTOR. Clean corroded connector and tighten loose connections. Replace damaged connector. GROUND TERMINAL, Check for proper ground. A proper ground will consist of a 3/4-inel hollow rod or 5/8-inch-dia. solid rod, 9 feet long. The cable will be No. 6 AWG copper wire, bolted or clamped to the rod and attached to the ground terminal of the generator set. SPARK PLUGS, Replace spark plugs that have cracked insulators and burned alectrodes. Clean and set spark plug gaps for 0.024-0.026 inch. Torque spark plugs to 25 to 27 foot-pounds. Replace leads which are frayed or broken. Clean and tighten lead connections. Reference TN5-2605-208-14, CONTACT POINTS. Replace pitted or burned points. Proper gap adjustment is 0.018 inch. (Check adjustment every 500 hours.) Reference TW5S-2805-206-14, Add oi! as indicated by level gage. Reference current L.0. (05-280 FUEL FILTER. Tighten thumb nut if gasket is leaking. Clean a dirty filter element. Reference TW5-2805-206-14, par. 55. WSC 6115-304-15/10 Figure 10. Quarterly preventive maintenance services. ‘AGO 6227 Tew PAR REF| FUEL TANK, Add fuel as required. Tighten loose mounting. Replace leaking 53 fuel tank. Replace defective cap gasket. Clean cap vent. GENERATOR BRUSHES AND CONTACT RINGS. Check generator for worn or frayed wiring. Smooth or clean,rough or dirty contact rings. Replace brushes if worn to bottom of ‘Y" mark on brushes. GBNTROLS AND INSTRUMENTS. Replace damaged instruments. Tighten loose 13 Mounting. With the unit operating, check for proper operation. Normal operating readings for instruments are as follows; Yol tmeter 120 volts Anme ter Indicates applied load not to exceed 12.5 amperes maximum. NOTE 1. OPERATIONAL TEST, During operation observe for any unusual noise or vibration. ADJUSTMENTS. test. NOTE 2. Wake all necessary adjustments during operational ust 6115-304-15/10 2) Figure 10—Continued. AGO 627A 9 Section IV. OPERATOR'S MAINTENANCE 32. Fuel Filter and Air Cleaner Service the fuel filter and air cleaner as shown by TM 5-2805-206-14. Warning: Before servicing any part of the generator set, make certain that the engine is stopped. Failure to observe this safety pre- caution may result in severe electrical shock or death by electrocution. 33. Fuel Tank Cap and Strainer a, Removal. Refer to figure 11 and remove the fuel tank cap and strainer. b. Cleaning and Inspection (1) Clean the fuel tank cap and strainer with an approved cleaning solvent and dry thoroughly. (2) Inspect the fuel tank cap for breaks or other damage. Inspect the gasket for breaks or signs of deterioration. Make sure the vent in the cap and gasket are open. (8) Inspect the strainer for cracks, breaks, or a plugged screen, (4) Replace a defective fuel tank cap or strainer. c. Installation. Refer to figure 11 and install the fuel tank cap and strainer. Fue TaN oe a Figure 11, Fuel tank cap and strainer, removal and installation. 20 AGO 227A Section V. TROUBLESHOOTING 34. General This section provides information useful in liagnosing and correcting unsatisfactory opera- ‘ion or failure of the generator set and its com- ponents. Each trouble symptom stated is fol- owed by a list of probable causes of the trouble. The possible remedy recommended is described »pposite the probable cause. Any trouble beyond the scope of organizational maintenance shall pe reported to field maintenance, 3d echelon. Refer to TM 5-2805-206-14 for engine trouble- shooting. 35. Generator Fails to Build up Rated Voltage Probable cone Pewite romety Rheostate incorrectly Adjust the rheostat (par. adjusted —_. 17). Brush contact poor Inspect and replace defective brushes or tension spring (par. 68). Engine speed too low -..-Refer to TM 5-2805-206-14 for engine maintenance. 36. Generator Overheats Probable cause Poasible remedy Generator overloaded Reduce the load. Brush pressure excessive Inspect and replace defective brushes or tension spring (par. 58). Section VI. 41. Field Expedient Repairs Operator and organizational maintenance roubles may occur while the generator set is operating in the field where supplies and repair parts are not available and normal corrective action cannot be performed. When this condi- rion exists, the following expedient repairs may may be used in emergencies, upon the decision of the unit commander. Equipment so repaired must be removed from operation as soon as pos- sible and properly repaired before being placed in operation again. Section Vil. 45. General Methods Used to Attain Proper Suppression Essentially, suppression is attained by pro- viding a low-resistance path to ground for stray AGO az2tA Probable cause Possible remedy ‘Vent holes restricted --.-Remove the restriction. Generator dirty Blow dirt and dust from gen- erator. 37. Generator Fails to Supply Load Probab cause Pousti remedy Terminal studs or re- Replace studs or rceptacle ceptacle defective. (pars. 64 and 68). Ammeter defective Replace ammeter (par. 63). Load switch defective Replace switch (par. 65). 38. Generator Voltage Fluctuates Pile remety Reduce the load. Refer to TM5-2805-206-14 for engine maintenance. Probable cause Generator overloaded —. Engine speed fluctuates ‘Brush contact poor --...- Inspect and replace defective brushes or tension springs (par. 68). 39, Generator Brushes Spark Excessively Probable couse Pousible remedy Inspect and replace defective brushes or tension springs (par. 58). Generator overloaded -..- Reduce the load. 40. Generator Noisy Brush contact poor — Pouible remedy * Inspect and replace defective brushes or tension springs (par. 58). ‘Mounting bolts loose -._. Tighten mounting bolts. FIELD EXPEDIENT REPAIRS € 42. Voltmeter Does Not Register Trouble Bepedient remedy ‘Voltmeter shorted or Disconnect and tape the volt- grounded. meter leads separately. 43. Loss of Fuel placed. (par. 50). 44, Ammeter Does Not Register Trewle apediont remedy Ammeter shorted or Disconnect and tape the am- grounded meter leads together (par. 63). RADIO INTERFERENCE SUPPRESSION currents. The methods used include shielding the ignition and high-frequency wires, ground- ing the frame with bonding straps, and using capacitors and resistors. For general informa- a <— seneRaror REMOVE NUT RENOVE GROUND TERMINAL GENERATOR GROUND STRAP A. ENGINE AND GENERATOR GROUND STRAPS. CAPACITOR (2),.0.1 UF, 500-V,AC0t VOLTAGE REGULATOR B. FUEL TANK STREP ©. CAPACITORS Wsc 6115-304-15/12 Figure 12. Radio interference suppression components, location, removal, and installation. 22 AGO 6227 tion on radio interference suppression, see TM 11-483. 46. Interference Suppression Components Figure 12 locates and illustrates the interfer- ence suppression components. 47. Replacement of Suppression Components a, Remove a voltage regulator cover (par. 67). Section VIII. 49. General This section includes maintenance instruc- tions for the fuel hose, drain valve, fuel shutoff valve, fuel filter, fuel gage, fuel tank, muffler ex- NOTE OPEN DRAIN VALVE AND ORAIN FUEL INTO S date = Figure 13. AGO 62278 TURN FUEL SHUTOFF VALVE AND DRAIN VALVE COUNTERCLOCKNISE 10 REMOVE. pe b. Refer to figure 12 and remove and install the radio interference suppression components. 48. Testing of Radio Interference Suppression Components Test the capacitors for leaks and shorts on a capacitor tester ; replace defective capacitors. If test equipment is not available and interference is indicated, isolate the cause of interference by the trial-and-error method of replacing each capacitor in turn until the cause of interference is located and eliminated. ENGINE ACCESSORIES tension and engine vibration dampeners. Refer to TM 5-2805-206-14 for maintenance of en- gine components. SII) WSC 6115-306-15/1395 Fuel hose, drain valve, and fuel shutof’ valve, removal and installation. 23 1 CLOSE FUEL SHUTOFF_ VALVE, Preannnesy /~ 4. TURN FILTER 800) COUNTERCLOCKR] SE AND REMOVE FRON NIPPLE 73. TURN RNURLED NUT COUNTERCLOCKWISE, pa SWING BAIL TO SIDE, AND RENOVE OWL. CASKET, AND BAIL Figure 14. Fuel filter, removal and installation 50. Fuel Hose, Drain Valve and Fuel Shutoff Valve a. Removal. Refer to figure 13 and remove the fuel hose, drain valve, and fuel shutoff valve. b. Cleaning and Inspection. (1) Clean the removed parts with a clean, ary cloth. (2) Inspect the drain valve and fuel shut- off valve for cracks, breaks, or improp- er operation. (8) Inspect the drain hose for cracks, breaks, and signs of leakage or deter- ioration. (4) Replace a defective part. c. Installation. Refer to figure 13 and install the fuel hose, drain valve, and fuel shutoff valve. d. Field Expedient Repair. Tape a cracked fuel hose until the defective hose can be re- placed. 24 51. Fuel Filter a, Removal. Refer to figure 14 and remove the fuel filter. b. Cleaning and Inspection. Refer to TM 5-2805-206-14 and clean and inspect the fuel filter. c. Installation. Refer to figure 14 and install the fuel filter. 52. Fuel Gage a. Removal. Refer to figure 15 and remove the fuel gage. b. Cleaning and Inspection. (1) Clean the fuel gage with a clean, dry cloth. (2) Inspect the sight glass, gaskets, and retainer for cracks or breaks. (8) Inspect the gage for cracks, breaks, bends, and illegibility of markings. (4) Replace a defective part. NOTE: REMOVE RETAINER BY TURNING COUNTERCLOCKWISE, AND REMOVE SASS IND GASKET (2) LIFT - 2 POEL CHGE PRON FULL TAM) REGRET . cs ' WSC_6115-304-15,15) Figure 15, Fuel gage, removal and installation. c. Installation, Refer to figure 15 and install the fuel gage. 53. Fuel Tank a, Removal (1) Refer to figure 16 and remove the fuel tank. (2) Remove the fuel tank cap and strainer (par. 33). (3) Remove the drain valve and fuel shut- off valve (par. 50). (4) Remove the fuel gage (par. 52). AGO 62274, b. Cleaning and Inspection. (1) Clean the fuel tank with an approved cleaning sholvent and dry thoroughly. (2) Inspect the fuel tank for cracks, breaks, dents, and other damage. (3) Replace a defective fuel tank. c. Installation. (1) Install the fuel gage (par. 52). (2) Install the drain valve and fuel shut- off valve (par. 50). (3) Install the fuel tank cap and strainer (par. 33). 25 3. REWOVE NUT (2) OPEN DRAIN VALVE AND DRAIN FUEL FROM TANK IW A SUITABLE CONTAINER Figure 16. Fuel tank, removal and installation. (4) Refer to figure 16 and install the fuel tank. 54. Muffler Extension a. Inspection. Inspect the muffler extension for cracks, breaks, holes, and rusted areas. b. Removal. Refer to figure 17 and remove the muffler extension. c. Installation, Refer to figure 17 and install the muffler extension. 26 55. Engine Vibration Dampeners a. Removal. Refer to figure 18 and remove the engine vibration dampeners. b. Cleaning and Inspection. (1) Clean the vibration dampeners with a clean, dry cloth. (2) Inspect the vibration dampeners for cracks, breaks, and signs of deteriora- tion. AGO «27a (3) Replace a defective vibration dampen- er. tallation. Refer to figure 18 and install e vibration dampeners. RENOVE NUT (2) Insc 6115-304-18/17 Figure 17. Muffler extension, removal and installa~ tion. Section IX. 56. General ‘The generator is a two-pole, revolving arma- ture, alternating shock-mounted on one end and directly coupled to the engine on the other end. ‘The elongated holes and louvers in the endbell cover provide ventilation for the generator. The endbell cover must be removed to gain access to the electrical contact brushes. The voltmeter, ammeter, receptacle, load switch, and the volt- age adjusting rheostat are located on the con- trol box panel. The load terminals are located on the under side of the control box. 57. Endbell Cover a, Removal. Refer to figure 19 and remove the endbell cover. b. Cleaning, Inspection, and Repair. (1) Clean the endbell cover with an ap- proved cleaning solvent and dry thor- oughly. (2) Inspect the cover for cracks, dents, and burs. AGO 62274, SB) Foe), NOTE) REROVE THE OTHER VIBRATION DANPENER IN & Figure 18. SIMILAR RANNER BLOCK THE ENGINE REMOVE NUT. REWOVE SCREW (4) ENGINE viBRATI TANPENER ig SC 6115-304-15/18 removal and Engine vibration dampeners installation GENERATOR Figure 19. 7 NOTE” TEST TENSION OF BRUSH SPRINGS. ty TENSION SHOULD RE 8 TO 10 OUNCES NOTE: 1F BRUSHES ARE OIL-SOAKED OR HORN TO LESS THAN 1/2 INGH, INSTALL NEW BRUSHES NOTE: REMOVE REMAINING BRUSHES AND SPRINGS INA SIMILAR MANNER. Wsc 6115-304-15 20 Figure 20. Brushes, and springs, removal and installation. (3) Remove all burs and straighten minor c. Installation. Refer to figure 19 and install dents. Replace a defective cover. the endbell cover. 28 AGO @227A NOTE WSC 6115-304-15/21 Figure 21. Generator vibration dampeners, removal and installation. 58, Brushes and Springs a. Removal. (1) Remove the endbell cover (par. 57). (2) Refer to figure 20 and remove the brushes and springs. b. Cleaning and Inspection. (2) Clean brushes with a dry, clean cloth. (2) Clean the springs with an approved cleaning solvent and dry thoroughly. (3) Clean the contact rings with No. 00 sandpaper and a piece of clean canvas. (4) Inspect the brushes for breaks, cracks, chips and frayed leads. Replace a de- AGO 62270 fective brush or one that is worn to less than % inch in length. (5) Inspect the springs for breaks, cracks, and fatigue. (6) Replace a defective spring. c. Installation. (1) Refer to figure 20 and install the brushes and springs. (2) Seat the brushes (TM 5-764). (3) Install the endbell cover (par. 57). 59. Generator Vibration Dampeners a, Removal. Refer to figure 21 and remove the generator vibration dampeners. 29 b. Cleaning and Inspection. (3) Replace a defective vibration damp- (1) Clean the vibration dampeners with a ener. clean, dry cloth. (2) Inspect the vibration dampeners for cracks, breaks, and deterioration. c. Installation. Refer to figure 21 and install the generator vibration dampeners. Section X. CONTROL BOX 60. General capacitors, and current transformer. The control box protects and provides mount- ing for the voltmeter, ammeter, receptacle, load 61. Control Box Assembly switch, rheostat, load terminal studs, voltage a. Removal. Refer to figure 22 and remove regulator relay, heat sink and diodes, resistors, the control box assembly. CONTROL BOX \ REMOVE SCREW (2) SCONNECT ELECTRICAL CABLE a SSC 6115-304-15/22 | Figure 22. Control box assembly, removal and installation. 30 AGO 62278 By { : CONNECTOR gee an Figure 23. b. Installation. Refer to figure 22 and install the control box assembly. 62. Voltmeter a. Removal. Refer to figure 23 and remove the voltmeter. b. Cleaning and Inspection. (1) Clean the voltmeter with a clean, dry cloth. (2) Inspect the voltmeter for missing hardware, cracked or broken glass, or AGO 6227 al A RECEPTACLE Se B _Ieowreot po | WSC 6115-304-15,23 wi re Voltmeter, ammeter, receptable connector, load switch, and rheostat, removal and installation. other damage. (3) Replace a defective voltmeter. c. Installation. Refer to figure 23 and install the voltmeter. d, Field Expedient Repair. Disconnect and tape the voltmeter leads separately. 63. Ammeter a. Removal. Refer to figure 23 and remove the ammeter. au REMOVE SCREW (8). VOLTAGE REGULATOR COVE Figure 24. b. Cleaning and Inspection. (1) Clean the ammeter with a clean, dry cloth. (2) Inspect the ammeter for missing hardware, cracked or broken glass, or other damage. (3) Replace a defective ammeter. c. Installation. Refer to figure 23 and install the ammeter. d. Field Expedient Repair. Disconnect and tape the ammeter leads together. 64. Receptacle Connector a. Removal. Refer to figure 23 and remove the receptacle connector. b. Cleaning and Inspection. (1) Clean the receptacle connector with a clean, dry cloth. (2) Inspect the receptacle connector for cracks, breaks, or other damage. (3) Replace a defective receptacle connec- tor. ¢. Installation, Refer to figure 23 and install the receptacle connector. 32 | mote ag LET? eee: b 3 OTe) LIFT VOLTAGE REGULATOR UP aNo TP FoRNARo. TAG AND DISOOMNECT ELECTRICAL LEADS B. VOLTAGE REGULATOR sc 6119-906-15/24 Voltage regulator, removal and installation. 65. Load Switch a, Removal. Refer to figure 23 and remove the load switch. b. Cleaning and Inspection. (1) Clean the load switch’ with a clean, dry cloth. (2) Inspect the load switch for damaged terminals or improper operation. (3) Replace a defective load switch. c. Installation. Refer to figure 23 and install the load switch. 66. Rheostat a, Removal. Refer to figure 23 and remove the rheostat. b. Cleaning and Inspection. (1) Clean the rheostat with a clean, dry cloth. (2) Inspect the rheostat for cracks, breaks, or worn areas, or other dam- age. (3) Replace a defective rheostat. AGO «227A,