ARMY TM 9-6115-671-14 

AIR FORCE TO 35C2-3-446-32 

MARINE CORPS TM 9249A/09246A-14 

TECHNICAL MANUAL 

OPERATOR, UNIT, DIRECT SUPPORT 

AND GENERAL SUPPORT 

MAINTENANCE MANUAL

GENERATOR SET, 

SKID MOUNTED, TACTICAL QUIET

 30 KW, 50/60 AND 400 HZ 

MEP-805B (50/60 HZ) (NSN 6115-01-461-9335) EIC: GGU

MEP-815B (400 HZ) (NSN 6115-01-462-0290) EIC: GGV

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 092491 00 

HOW TO USE THIS MANUAL 

 PAGE viii

EQUIPMENT DESCRIPTION 

 AND DATA PAGE 1-4 

PRINCIPLES OF OPERATION 

 PAGE 1-17 

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 PAGE 5-2

DIRECT SUPPORT 

MAINTENANCE PAGE 5-14

GENERAL SUPPORT 

 MAINTENANCE PAGE 6-1

TM 9-6115-671-14 

A (B blank) USA

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NOTE: The portion of the text affected by the changes is indicated by a vertical line in the 

outer margins of the page. Changes to illustrations are indicated by miniature 

pointing hands. Changes to wiring diagrams are indicated by shaded areas. 

Dates of issue for original and changed pages are: 

Original........ 0............1 July 2000 

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ARMY TM 9-6115-671-14 

AIR FORCE TO 35C2-3-446-32 

MARINE CORPS TM 09249A/09246A-14 

a

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. 
ARMY TM 9-6115-671-14 

AIR FORCE TO 35C2-3-446-32 

MARINE CORPS TM 09249A/09246A-14 

b 

__________ 

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. 
ARMY TM 9-6115-671-14 

AIR FORCE TO 35C2-3-446-32 

MARINE CORPS TM 09249A/09246A-14 

c

__________ 

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. 
ARMY TM 9-6115-671-14 

AIR FORCE TO 35C2-3-446-32 

MARINE CORPS TM 09249A/09246A-14 

d 

__________ 

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. 
ARMY TM 9-6115-671-14 

AIR FORCE TO 35C2-3-446-32 

MARINE CORPS TM 09249A/09246A-14 

e

_________ 

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. 
ARMY TM 9-6115-671-14 

AIR FORCE TO 35C2-3-446-32 

MARINE CORPS TM 09249A/09246A-14 

f 

__________ 

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.
ARMY TM 9-6115-671-14 

AIR FORCE TO 35C2-3-446-32 

MARINE CORPS TM 09249A/0246A-14 

i

Technical Manual

No. 9-6115-671-14 

Technical Order 

No. 35C2-3-446-32 

Technical Manual 

No. 09249A/0246A-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, 

30 KW, 50/60 AND 400 HZ 

MEP-805B (50/60 HZ) (NSN 6115-01-461-9335) (EIC:GGU) 

MEP-815B (400 HZ) (NSN 6115-01-462-0290) (EIC:GGV) 

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

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 2028-2 located in the back of this manual direct to: 

Commander, U.S. Army Communications and Electronics Command (CECOM), ATTN: AMSELLC-LEO-D-CS-CFO, Fort Monmouth, New Jersey 07703-5000. You may also submit your 

recommended changes by E-mail directly to CFO@CECOM2.Monmouth. For Air Force, mail AFTO 

Form 22 directly to Commander, Sacramento Air Logistics Center, ATTN: TILBA, McClellan AFB, 

CA 95652-5990 (AFMC). For Marine Corps, mail NAVMC Form 10772 directly to Commander, 

Marine Corps Logistics Bases (CODE 850), Albany, GA 31704-5000. A reply will be furnished to 

you. 
ARMY TM 9-6115-671-14 

AIR FORCE TO 35C2-3-446-32 

MARINE CORPS TM 09249A/09246A-14 

ii 

TABLE OF CONTENTS 

Page 

How To Use This Manual.............................................................................................................................................ix 

Chapter 1 Introduction 

 Section I General Information.........................................................................................................1-1 

 1.1 Scope ...............................................................................................................................1-1 

 1.2 Limited Applicability.......................................................................................................1-1 

 1.3 Maintenance Forms and Records.....................................................................................1-1 

 1.4 Reporting of Errors ..........................................................................................................1-1 

 1.5 Preparation for Storage or Shipment................................................................................1-3 

 1.6 Quality Assurance............................................................................................................1-3 

 1.7 Reporting Equipment Improvement Recommendation (EIR)..........................................1-3 

 1.8 List of Abbreviations .......................................................................................................1-3 

 1.9 Levels of Maintenance.....................................................................................................1-4 

 1.10 Corrosion Prevention and Control ...................................................................................1-4 

 1.11 Destruction of Army Materiel to Prevent Enemy Use......................................................1-4 

 Section II Equipment Description and Data .....................................................................................1-4 

 1.12 General.............................................................................................................................1-4 

 1.13 Tabulated/Illustrated Data................................................................................................1-4 

 1.14 Differences Between Models .........................................................................................1-15 

 Section III Principles of Operation ..................................................................................................1-17 

 1.15 Introduction....................................................................................................................1-17 

 1.16 Principles of Operation ..................................................................................................1-17 

 1.17 Location and Description of Major Components...........................................................1-36 

Chapter 2 Operating Instructions 

 Section I Description and Use of Operator Controls and Indicators ...............................................2-1 

 2.1 General.............................................................................................................................2-1 

 2.2 DCS Controls and Indicators ...........................................................................................2-1

 2.3 Computer Interface Module (CIM) Display Screen Controls and Indicators...................2-4 

 2.4 Diagnostic Controls and Indicators..................................................................................2-8 

 Section II Preventative Maintenance Checks and Services (PMCS) ..............................................2-14 

 2.5 General...........................................................................................................................2-14 

 2.6 PMCS Procedures..........................................................................................................2-14 

 Section III Operation Under Usual Conditions................................................................................2-21 

 2.7 General...........................................................................................................................2-21 

 2.8 Generator Set Installation ..............................................................................................2-21 

 2.9 Assembly and Preparation for Use.................................................................................2-24 

 2.10 Initial Adjustments, Checks, and Self-Test ....................................................................2-27 

 2.11 Operating Procedure ......................................................................................................2-30 

 2.12 Parallel Unit Operation (Load Sharing) .........................................................................2-33 

 2.13 Remote Operation..........................................................................................................2-36 

 2.14 Preparation for Movement .............................................................................................2-39 

 Section IV Operation Under Unusual Conditions............................................................................2-41 

 2.15 Operation in Extreme Cold Weather Below -25° F (-31° C) .........................................2-41 

 2.16 Operation in Extreme Heat Above 120° F (48.8° C) .....................................................2-42 

 2.17 Operation in Dusty or Sandy Areas................................................................................2-42 

 2.18 Operation Under Rainy or Humid Conditions ...............................................................2-43 

 2.19 Operation in Salt Water Areas .......................................................................................2-43

 2.20 Operation at High Altitudes ...........................................................................................2-44 

 2.21 NATO SLAVE RECEPTACLE Start Operation ...........................................................2-44 
ARMY TM 9-6115-671-14 

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MARINE CORPS TM 09249A/0246A-14 

iii

TABLE OF CONTENTS (continued) 

Page 

 2.22 Emergency Stopping......................................................................................................2-44 

 2.23 Operation Using Battle Short Switch.............................................................................2-44 

 2.24 Nuclear, Biological, and Chemical (NBC) Decontamination Procedures......................2-45 

 2.25 Operation While Contaminated .....................................................................................2-46 

 2.26 Operation in a High Altitude Electromagnetic Pulse (HAEMP) Environment ..............2-46 

Chapter 3 Operator Maintenance Instructions 

 Section I Lubrication Procedures....................................................................................................3-1 

 3.1 Operator Lubrication Instructions....................................................................................3-1 

 Section II Troubleshooting...............................................................................................................3-1 

 3.2 General.............................................................................................................................3-1 

 Symptom Index................................................................................................................3-1 

 Section III Operator Maintenance Procedures.................................................................................3-18 

 3.3 Generator Set Inspection and Service ............................................................................3-18 

Chapter 4 Unit Maintenance Instructions 

Section I Inspecting and Servicing the Equipment..........................................................................4-1 

 4.1 Inspecting and Servicing the Equipment..........................................................................4-1 

Section II Repair Parts; Tools; Test, Measurement and Diagnostic 

 Equipment (TMDE); and Support Equipment .................................................................4-6 

 4.2 Introduction......................................................................................................................4-6 

 Section III Lubrication Procedures....................................................................................................4-6 

 4.3 Unit Lubrication Instructions ...........................................................................................4-6 

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

 4.4 PMCS Procedures............................................................................................................4-7 

 Section V Troubleshooting.............................................................................................................4-10 

 4.5 General...........................................................................................................................4-10 

 Symptom Index..............................................................................................................4-10 

 Section VI Unit Maintenance Procedures ........................................................................................4-49 

 4.6 Maintenance of DC Electrical System ...........................................................................4-49 

 4.7 Maintenance of Housing ................................................................................................4-57 

 4.8 Maintenance of DCS Control Box Assembly ................................................................4-77 

 4.9 Maintenance of Air Intake and Exhaust System ..........................................................4-141 

 4.10 Maintenance of Engine Cooling System ......................................................................4-152 

 4.11 Maintenance of Fuel System........................................................................................4-170 

 4.12 Maintenance of Output Box Assembly ........................................................................4-183 

 4.13 Maintenance of Engine Accessories ............................................................................4-194 

 4.14 Maintenance of Lubrication System.............................................................................4-204 

 Section VII Preparation for Shipment and Storage .........................................................................4-207

 4.15 Preparation for Shipment and Storage .........................................................................4-207 

4.16 CIM Configuration Switch...........................................................................................4-208 

 

Chapter 5 Direct Support Maintenance Instructions 

Section I Repair Parts; Tools; Test, Measurement and Diagnostic Equipment (TMDE); and Support 

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

 5.1 Introduction......................................................................................................................5-1 

 Section II Lubrication Procedures....................................................................................................5-1 

 5.2 Direct Support Lubrication Instructions...........................................................................5-1 

 Section III Troubleshooting...............................................................................................................5-2 

 5.3 General.............................................................................................................................5-2 
ARMY TM 9-6115-671-14 

AIR FORCE TO 35C2-3-446-32 

MARINE CORPS TM 09249A/09246A-14 

iv 

TABLE OF CONTENTS (continued) 

Page 

 Symptom Index................................................................................................................5-2 

 Section IV Direct Support Maintenance Procedures........................................................................5-14 

 5.4 Removal and Installation of Major Components ...........................................................5-14 

 5.5 Maintenance of DCS Control Box Assembly ................................................................5-23 

 5.6 Maintenance of Cooling System ....................................................................................5-25 

 5.7 Maintenance of Fuel System..........................................................................................5-25 

 5.8 Maintenance of Output Box Assembly ..........................................................................5-29 

 5.9 Maintenance of Engine Accessories ..............................................................................5-43 

 5.10 Maintenance of Generator Assembly.............................................................................5-46 

 5.11 Maintenance of Skid Base .............................................................................................5-61 

 

Chapter 6 General Support Maintenance Instructions......................................................................6-1 

Appendix A References.......................................................................................................................A-1 

Appendix B Maintenance Allocation Chart (MAC) 

 Section I Introduction.....................................................................................................................B-1 

 Section II Maintenance Allocation Chart (MAC)............................................................................B-4 

 Section III Tools and Test Equipment for MEP-805B and 815B ...................................................B-13 

 Section IV Remarks ........................................................................................................................B-13 

Appendix C Components of End Item (COEI) and Basic Issue Items (BII) List 

Section I Introduction.....................................................................................................................C-1 

 Section II Components of End Item ................................................................................................C-1 

 Section III Basic Issue Items ............................................................................................................C-1 

Appendix D Additional Authorization List (AAL) 

 Section I Introduction.....................................................................................................................D-1 

 Section II Additional Authorization List .........................................................................................D-1 

Appendix E Expendable and Durable Items List 

 Section I Introduction..................................................................................................................... E-1 

 Section II Expendable and Durable Items List ................................................................................ E-1 

Appendix F Operator’s Lubrication Instructions ................................................................................ F-1 

Appendix G Illustrated List of Manufactured Items............................................................................G-1 

Appendix H Torque Limits 

 Section I Introduction.....................................................................................................................H-1 

 Section II Torque Limits .................................................................................................................H-1 

Appendix I Mandatory Replacement Parts 

 Section I Introduction...................................................................................................................... I-1 

 Section II Mandatory Replacement Parts ......................................................................................... I-1 

Index....................................................................................................................................................................Index-1 
ARMY TM 9-6115-671-14 

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MARINE CORPS TM 09249A/0246A-14 

v

TABLE OF CONTENTS (continued) 

 Page 

Fold-outs 

 Schematic ................................................................................................................................................. FO-1 

 Wiring Diagram........................................................................................................................................ FO-3 

 Wire Harness, CIM Interface and Control Box ........................................................................................ FO-7 

LIST OF ILLUSTRATIONS 

Figure Page 

1-1 30 kW Tactical Quiet Generator Set ............................................................................................................1-2 

1-2 Locations of Data Plates and Access Panels (Front and Right Side)............................................................1-7 

1-3 Locations of Data Plates and Access Panels (Rear and Left Side) ...............................................................1-8 

1-4 Operating Instruction Plate, MEP-805B.......................................................................................................1-9 

1-5 Operating Instruction Plate, MEP-815B.....................................................................................................1-10 

1-6 Identification Plate, MEP-805B and MEP-815B .......................................................................................1-11 

1-7 Set Rating Identification Plate, MEP-805B and MEP-815B......................................................................1-11 

1-8 Voltage Connection Caution Plate..............................................................................................................1-12 

1-9 Grounding Stud Plate .................................................................................................................................1-12 

1-10 NATO SLAVE RECEPTACLE Plate........................................................................................................1-12 

1-11 PARALLELING RECEPTACLE Plate......................................................................................................1-12 

1-12 CONVENIENCE RECEPTACLE Plate, MEP-805B and MEP-815B.......................................................1-12 

1-13 EXTERNAL FUEL SUPPLY Plate ...........................................................................................................1-12 

1-14 Battery Connection Instruction Plate..........................................................................................................1-13 

1-15 Lifting and Tiedown Diagram Plate ...........................................................................................................1-13 

1-16 FUEL SYSTEM DIAGRAM Plate ............................................................................................................1-14 

1-17 Generator Identification Plate (located on generator), MEP-805B and MEP-815B...................................1-14 

1-18 COMMUNICATION RECEPTACLE Plate ..............................................................................................1-14 

1-19 Fault System Flow Diagram .......................................................................................................................1-18 

1-20 Governor Control System Flow Diagram ...................................................................................................1-20 

1-21 Voltage Regulation System Flow Diagram.................................................................................................1-21 

1-22 Fuel System Flow Diagram ........................................................................................................................1-22 

1-23 Generator Set Cooling System Flow Diagram............................................................................................1-24 

1-24 Engine Cooling System Flow Diagram.......................................................................................................1-26 

1-25 Lubrication System Flow Diagram.............................................................................................................1-27 

1-26 Engine Air Intake and Exhaust System Flow Diagram...............................................................................1-28 

1-27 Output Supply System Flow Diagram ........................................................................................................1-30 

1-28 Brushless Generator Schematic ..................................................................................................................1-32 

1-29 Engine Starting System Flow Diagram.......................................................................................................1-34 

1-30 30 kW Generator Set Components .............................................................................................................1-37 

2-1 DCS Controls and Indicators........................................................................................................................2-2 

2-2 CIM Display Screen Controls and Indicators..............................................................................................2-5 

2-3 Diagnostic Controls and Indicators ..............................................................................................................2-9 

2-4 Base Mounting Measurements ...................................................................................................................2-22 

2-5 Minimum Enclosure Clearance Measurements ..........................................................................................2-23 

2-6 Grounding Connections..............................................................................................................................2-25 

2-7 Installation of Load Cables.........................................................................................................................2-27 

2-8 Generator Set Controls ...............................................................................................................................2-28 

2-9 CIM Display Screen Controls and Indicators............................................................................................2-32 

2-10 Parallel Operation Setup.............................................................................................................................2-34 

2-11 Remote PC Display Modes.........................................................................................................................2-40 

2-12 Remote PC Setup........................................................................................................................................2-41 
ARMY TM 9-6115-671-14 

AIR FORCE TO 35C2-3-446-32 

MARINE CORPS TM 09249A/09246A-14 

vi 

LIST OF ILLUSTRATIONS (continued) 

Figure Page 

2-13 NATO Slave Receptacle.............................................................................................................................2-45 

3-1 Air Cleaner Element Replacement .............................................................................................................3-21 

3-2 Crankcase Breather Filter Assembly ..........................................................................................................3-23 

3-3 Coolant Recovery (Overflow) Bottle..........................................................................................................3-25 

3-4 Fuel Tank Filler Neck.................................................................................................................................3-27 

3-5 Fuel Filter/Water Separator ........................................................................................................................3-30 

3-6 Dipstick and Oil Fill Cap............................................................................................................................3-31 

4-1 Fuel Drain Valve and Oil Drain ...................................................................................................................4-4 

4-2 Dipstick and Oil Fill Cap..............................................................................................................................4-6 

4-3 Batteries and Cables ...................................................................................................................................4-51 

4-4 NATO SLAVE RECEPTACLE and Cables ..............................................................................................4-52 

4-5 Generator Set Access Doors.......................................................................................................................4-58 

4-6 DCS Control Box Top Panel......................................................................................................................4-61 

4-7 Top Housing Section..................................................................................................................................4-64 

4-8 Front Housing Section................................................................................................................................4-69 

4-9 Rear Housing Section.................................................................................................................................4-74 

4-10 DCS Control Box Assembly.......................................................................................................................4-78 

4-11 DCS Control Panel Lights DS1 Through DS3 and NETWORK FAILURE Light DS5.............................4-81 

4-12 Time Meter and Switches...........................................................................................................................4-84 

4-13 DCS Control Panel Components ................................................................................................................4-91 

4-14 CIM and Receptacles................................................................................................................................4-100 

4-15 DCS Control Box Back Panel Components .............................................................................................4-108 

4-16 DCS Control Box Floor Components.......................................................................................................4-119 

4-17 Diode Identification..................................................................................................................................4-123 

4-18 DCS Control Box Panels..........................................................................................................................4-137 

4-19 Muffler and Exhaust Pipe.........................................................................................................................4-143 

4-20 Air Cleaner Assembly...............................................................................................................................4-145 

4-21 Crankcase Breather Filter Assembly ........................................................................................................4-150 

4-22 Cooling System ........................................................................................................................................4-153 

4-23 Fan Guards ..............................................................................................................................................4-157 

4-24 Fan Belt ....................................................................................................................................................4-165 

4-25 Coolant Recovery System.........................................................................................................................4-169 

4-26 Fuel Tank Filler Neck and Low Pressure Fuel System.............................................................................4-171 

4-27 Ether Start System ....................................................................................................................................4-179 

4-28 Output Box Assembly ..............................................................................................................................4-185 

4-29 Load Output Terminal Board Assembly...................................................................................................4-192 

4-30 Engine Switches and Senders ...................................................................................................................4-195 

4-31 Battery Current Transducer ......................................................................................................................4-203 

4-32 Oil Drain Valve ........................................................................................................................................4-206 

5-1 Engine and Generator Assembly ................................................................................................................5-18 

5-2 Fuel Tank....................................................................................................................................................5-28 

5-3 Output Box Assembly ................................................................................................................................5-31 

5-4 Output Box Components ............................................................................................................................5-37 

5-5 Testing Current Transformer......................................................................................................................5-38 

5-6 Testing Droop Current Transformer...........................................................................................................5-39 

5-7 Electric Actuator.........................................................................................................................................5-44 

5-8 Generator Assembly Removal....................................................................................................................5-48 

5-9 Generator Assembly ...................................................................................................................................5-50 

5-10 End Bell Removal ......................................................................................................................................5-51 
ARMY TM 9-6115-671-14 

AIR FORCE TO 35C2-3-446-32 

MARINE CORPS TM 09249A/0246A-14 

vii

LIST OF ILLUSTRATIONS (continued) 

Figure Page 

5-11 Rectifier Assembly .....................................................................................................................................5-55 

5-12 Rotor Assembly Lifting Device (Typical) ..................................................................................................5-60 

5-13 Skid Base....................................................................................................................................................5-63 

G-1 Cable Assembly, AC Power (P/Ns 88-22126-1 through 88-22126-7).........................................................G-2 

G-2 Cable Assembly, Battery (P/N 88-22178) ...................................................................................................G-3 

G-3 Cable Assembly, Battery (P/N 88-22127) ...................................................................................................G-4 

G-4 Cable Assembly, Battery (P/N 88-22181) ...................................................................................................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 Holder, Control Panel (P/N 88-22120)........................................................................................................G-8 

G-8 Hose Assembly (P/N 88-20191-6) ..............................................................................................................G-9 

G-9 Insulation, Panel, Top (P/N 88-22582) .....................................................................................................G-10 

G-10 Insulation, Baffle (P/N 88-22592).............................................................................................................G-11 

G-11 Insulation, Panel, Top (P/N 88-22593) .....................................................................................................G-12 

G-12 Insulation, Top, Center (P/N 88-22584)....................................................................................................G-13 

G-13 Insulation, Top, Rear (P/N 88-22585).......................................................................................................G-14 

G-14 Insulation, Front Housing (P/N 88-22591)................................................................................................G-15 

G-15 Insulation, Top, Front (P/N 88-22586)......................................................................................................G-16 

G-16 Insulation, Top, Center (P/N 88-22587)....................................................................................................G-17 

G-17 Insulation, Top, Center (P/N 88-22588)....................................................................................................G-18 

G-18 Insulation, Top, Front (P/N 88-22583)......................................................................................................G-19 

G-19 Pump Assembly, Fuel (P/N 88-22546)......................................................................................................G-20 

G-20 Solenoid Assembly (P/N 88-22553)..........................................................................................................G-21 

G-21 Switch Assembly (P/N 88-22548) .............................................................................................................G-22 

G-22 Wire, Varistor (P/Ns 88-20305-1 through 88-20305-3 and 88-20305-5)..................................................G-23 

LIST OF TABLES 

Table Page 

1-1 Tabulated Data .............................................................................................................................................1-5 

1-2 Performance Characteristics.......................................................................................................................1-15 

2-1 DCS Controls and Indicators........................................................................................................................2-3 

2-2 CIM Display Screen Controls and Indicators...............................................................................................2-6 

2-3 Faults ............................................................................................................................................................2-7 

2-4 Diagnostic Controls and Indicators ............................................................................................................2-11 

2-5 Operator Preventive Maintenance Checks and Services (PMCS) ..............................................................2-16 

2-6 Load Terminal and AC Reconnection Board Selection..............................................................................2-26 

2-7 Fuel.............................................................................................................................................................2-42 

3-1 Operator Troubleshooting ............................................................................................................................3-2 

3-2 Coolant .......................................................................................................................................................3-26 

3-3 Diesel Fuel..................................................................................................................................................3-28 

3-4 Quick Reference General Inspection ..........................................................................................................3-32 

4-1 Coolant .........................................................................................................................................................4-3 

4-2 Fuel...............................................................................................................................................................4-5 

4-3 Unit Preventive Maintenance Checks and Services (PMCS) .......................................................................4-8 
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LIST OF TABLES (continued) 

Table Page 

4-4 Unit Troubleshooting .................................................................................................................................4-12 

5-1 Direct Support Troubleshooting...................................................................................................................5-3 

5-2 Generator Resistance Values at 25° C (77° F)............................................................................................5-56 

G-1 Metric Conversion.....................................................................................................................................G-24 

H-1 Torque Limits for Dry Fasteners .................................................................................................................H-1 

H-2 Effect of Lubrication on Torque..................................................................................................................H-2 

H-3 Torque Limits for Dry Fasteners (Metric) ...................................................................................................H-3 
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HOW TO USE THIS MANUAL 

In this manual (TM 9-6115-671-14) 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. 

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HOW TO USE THIS MANUAL (continued) 

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. 

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. 
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CHAPTER 1 

INTRODUCTION 

SECTION I. GENERAL INFORMATION 

1.1 SCOPE. 

1.1.1 Type of Manual.

This manual contains Unit, Direct Support, and General Support maintenance instructions for the Tactical 

Quiet (TQ), 30 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 Equipment Name

MEP-805B Generator Set, 

 Skid Mounted, 

 Tactical Quiet 

 30 kW 50/60 Hz 

MEP-815B Generator Set, 

 Skid Mounted, 

 Tactical Quiet 

 30 kW 400 Hz 

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). 
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FIGURE 1-1. 30 kW TACTICAL QUIET GENERATOR SET 
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(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-G28554 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 30 kW Generator needs improvement, let us know. Send us an EIR. You, the user, are the only one 

who can tell us what you don’t like about your equipment. Let us know why you don’t like the design or 

performance. Put it on an 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 Army Oil Analysis Program 

 CIM Computer Interface Module 

 DCS Digital Control System 

 DS2 Decontaminating Solution Number 2 

 PC Personal Computer 

 PPE Personal Protection Equipment 

 STB Supertropical Bleach 

 TQ Tactical Quiet 
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1.9 LEVELS OF MAINTENANCE. 

1.9.1 (A) Army users shall refer to the Maintenance Allocation Chart (MAC) for tasks and levels of maintenance 

to be performed. 

1.9.2 (MC) Marine Corps users shall refer to the Source, Maintenance and Recoverability (SMR) Codes for 

maintenance to be performed. 

1.10 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. 

SECTION II. EQUIPMENT DESCRIPTION AND DATA 

1.12 GENERAL. 

The generator set, models MEP-805B and MEP-815B (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, cooling system, excitation system, governing system, fuel 

system, 24 VDC starting system, DCS, and fault system. 

1.13 TABULATED/ILLUSTRATED DATA. 

1.13.1 For a list of Tabulated Data, refer to Table 1-1. 

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 data plates are located at the back of this manual 

as fold-outs. 
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TABLE 1-1. TABULATED DATA 

 MEP-805B MEP-815B 

1. Generator Set: 

 a. National Stock Number 6115-01-461-9335 6115-01-462-0290 

 b. Overall Length 79.7 in. (202.5 cm) 79.7 in. (202.5 cm) 

 c. Overall Width 35.7 in. (90.8 cm) 35.7 in. (90.8 cm) 

 d. Overall Height 55 in. (139.7 cm) 55 in. (139.7 cm) 

 e. Dry Weight (less Basic Issue Items List) 2732 lb. (1239.2 kg) 2732 lb. (1239.2 kg) 

 f. Wet Weight 2931 lb. (1329.5 kg) 2931 lb. (1329.5 kg) 

2. Engine: 

 a. Manufacturer John Deere John Deere 

 b. Model 4045TF151 4045TF151 

 c. Type Four cylinder, four cycle, Four cylinder, four cycle, 

 Turbocharged diesel turbocharged diesel 

 d. Displacement 239 cu. in. (3.9 liters) 239 cu. in. (3.9 liters) 

 e. Altitude Degradation, 3.5% per 1000 ft. (305 m) 3.5% per 1000 ft. (305 m) 

 4000 ft. (1220 m) to 

 8000 ft. (2440 m) 

 f. Firing Order 1, 3, 4, 2 1, 3, 4, 2 

 g. Cold Weather Starting Aid System Use 40°F (4°C) or below 40°F (4°C) or below 

 h. Valve Tappet Clearance Adjustment: 

 Hot or Cold (Intake) 0.014 in. (0.35 mm) 0.014 in. (0.35 mm) 

 Hot or Cold (Exhaust) 0.018 in. (0.45 mm) 0.018 in. (0.45 mm) 

3. Cooling System: 

 a. Type Pressurized radiator and Pressurized radiator and 

 Pump pump 

 b. Capacity 15.5 qts. (14.7 liters) 15.5 qts. (14.7 liters) 

 c. Normal Operating Temperature 170-200°F (77-93°C) 170-200°F (77-93°C) 

 d. Temperature Indicating System 24 VDC 24 VDC 

 Voltage Rating 

4. Lubricating System: 

 a. Type Full flow, circulating pressure Full flow, circulating pressure 

 b. Oil Pump Type Positive displacement gear Positive displacement gear 

 c. Normal Operating Pressure 25-60 psi (172-414 kPa) 25-60 psi (172-414 kPa) 

 d. Oil Filter Type Full flow, spin-on Full flow, spin-on 

 replacement element replacement element 

 e. Capacity 15 qts. (14.2 liters) 15 qts. (14.2 liters) 

 f. Pressure Indicating System Voltage 24 VDC 24 VDC 

 Rating 

5. Fuel System: 

 a. Type of Fuel DF-1, DF-2, DF-A, DF-1, DF-2, DF-A, 

 JP5, JP8 JP5, JP8 

 b. Fuel Tank Capacity 23 gal. (87.05 liters) 23 gal. (87.05 liters) 

 c. Fuel Consumption Rate 2.60 gal. (9.8 liters) per 2.75 gal. (10.4 liters) per 

 Hour hour 

 d. Auxiliary Fuel Pump: 

 (1) Voltage Rating 24 VDC 24 VDC 

 (2) Delivery Pressure 5.0-6.5 psi 5.0-6.5 psi 

 (34.5-65.5 kPa) (max.) (34.5-65.5 kPa) (max.) 

 e. Injection Fuel Pump 

 (1) Manufacturer Stanadyne Stanadyne 

 (2) Model DB4429-5281 DB4429-5281 
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TABLE 1-1. TABULATED DATA (continued) 

 MEP-805B MEP-815B 

 

5. Fuel System (continued); 

 f. Electric Actuator 

 

 (1) Manufacturer Governors of America Governors of America 

 (2) Model ADC100-24 ADC100-24 

6. Engine Starting System: 

 a. Batteries Two 12 volt, connected in Two 12 volt, connected in 

 series series 

 b. Starter: 

 (1) Manufacturer Denso Denso 

 (2) Model RE 40595 RE 40595 

 (3) Voltage Rating 24 VDC 24 VDC 

 (4) Drive Type Gear reduction Gear reduction 

 c. Battery Charging Alternator: 

 (1) Manufacturer Bosch Bosch 

 (2) Model 9 120 060 039 9 120 060 039 

 (3) Rating 42 amps at 24 VDC 42 amps at 24 VDC 

 (4) Protective Fuse 30 amps 30 amps 

7. AC Generator: 

 a. Manufacturer Marathon Electric Marathon Electric 

 b. Type Rotating field, synchronous Rotating field, synchronous 

 c. Load Capacity 30 kW 30 kW 

 d. Model 88-21007 88-21008 

 e. Current Ratings: 

 (1) 120/208 volt connection 60 Hz: 104 amps 104 amps 

 50 Hz: 86 amps 

 (2) 240/416 volt connection 60 Hz: 52 amps 52 amps 

 50 Hz: 43 amps 

 f. Power Factor 0.8 0.8 

 g. Cooling Fan cooled Fan cooled 

 h. Drive Type Direct coupling Direct coupling 

 i. Duty Classification Continuous Continuous 

8. Digital Control System: 

 a. DCS Load Sharing Synchronizer: 

 (1) Manufacturer Governors of America Governors of America 

 (2) Model LSS100 LSS400 

 b. DCS Speed Control Unit: 

 (1) Manufacturer Governors of America Governors of America 

 (2) Model ESD5551 ESD5551 

 c. I/O Interface Module 

 (1) Manufacturer Governors of America Governors of America 

 (2) Model TCM100 TCM400 

 d. Backplane Module 

 (1) Manufacturer Governors of America Governors of America 

 (2) Model TCM102 TCM102 

 e. Automatic Voltage Regulator 

 (1) Manufacturer Governors of America Governors of America 

 (2) Model AVR100 AVR400 
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FIGURE 1-2. LOCATIONS OF DATA PLATES AND ACCESS DOORS (FRONT AND RIGHT SIDE) 
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FIGURE 1-3. LOCATIONS OF DATA PLATES AND ACCESS DOORS (REAR AND LEFT SIDE) 
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FIGURE 1-4. OPERATING INSTRUCTION PLATE, MEP-805B 
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FIGURE 1-5. OPERATING INSTRUCTION PLATE, MEP-815B 
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FIGURE 1-6. IDENTIFICATION PLATE, MEP-805B AND MEP-815B 

FIGURE 1-7. SET RATING IDENTIFICATION PLATE, MEP-805B AND MEP-815B 
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FIGURE 1-8. VOLTAGE 

CONNECTION CAUTION PLATE 

FIGURE 1-9. GROUNDING STUD PLATE 

FIGURE 1-10. NATO SLAVE 

RECEPTACLE 

FIGURE 1-11. PARALLELING 

RECEPTACLE PLATE 

FIGURE 1-12. CONVENIENCE 

RECEPTACLE PLATE, 

MEP-805B AND MEP-815B 

FIGURE 1-13. EXTERNAL FUEL 

SUPPLY PLATE 
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FIGURE 1-14. BATTERY CONNECTION INSTRUCTION PLATE 

FIGURE 1-15. LIFTING AND TIEDOWN DIAGRAM PLATE 
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FIGURE 1-16. FUEL SYSTEM DIAGRAM PLATE 

FIGURE 1-17. GENERATOR IDENTIFICATION PLATE (LOCATED ON GENERATOR), 

MEP-805B AND MEP-815B 

R EC EP TAC LE

FIGURE 1-18. COMMUNICATION RECEPTACLE PLATE 
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1.14 DIFFERENCES BETWEEN MODELS. 

1.14.1 The differences between generator set models covered in this manual are as follows: 

a. Model MEP-805B is equipped with a 50/60 Hz AC generator and three DCS modules which may 

not be used on the MEP-815B (see Table 1-1). 

b. Model MEP-815B is equipped with a 400 Hz AC generator and three DCS modules which may 

not be used on the MEP-805B (see Table 1-1). 

1.14.2 Performance characteristics for the two models are shown in Table 1-2. 

TABLE 1-2. PERFORMANCE CHARACTERISTICS 

 MEP-805B MEP-815B 

1. Voltage: 

 a. Voltage wave form deviation factor 5% (max.) 5% (max.) 

 Singe voltage harmonics 2% (max.) 2% (max.) 

 b. Voltage unbalance 5% of rated voltage (max.) 5% of rated voltage (max.) 

 c. Phase balance voltage 1% of rated voltage (max.) 1% of rated voltage (max.) 

 d. Voltage modulation 1% (max.) 1% (max.) 

 e. Voltage regulation 1% (max.) 1% (max.) 

 f. Short-term stability (30 seconds) 1% of rated voltage 1% of rated voltage 

 g. Long-term stability (4 hours) 2% of rated voltage 2% of rated voltage 

 h. Voltage drift (60°F [16°C] in 8-hour ±1% (max.) ±1% (max.) 

 period) 

 i. Dip and rise for rated load 15% of rated voltage (max.) 12% of rated voltage (max.) 

 Recovery time 0.5 seconds 0.5 seconds 

 j. Dip for low power factor load 30% of no-load voltage 25% of no-load voltage 

 (max.) (max.) 

 Recovery time 0.7 seconds 95% of no-load 0.7 seconds 95% of no-load 

 voltage Voltage 

 k. Adjustment range VAC 50 Hz 400 Hz 

 120/208V connection 190-213V 195-229V 

 240/416V connection 380-426V 395-458V 

 60 Hz 

 120/208V connection 197-240V 

 240/416V connection 395-480V 

2. Frequency: 

 a. Regulation 0.25% of rated frequency 0.25% of rated frequency 

 b. Short-term steady-state stability 0.5% of rated frequency 0.5% of rated frequency 

 (30 seconds) 

 c. Long-term steady-state stability 1% of rated frequency 1% of rated frequency 

 (4 hours) 

 d. Frequency drift (60°F [16°C] in 8 hour 0.5% (max.) 0.5% (max.) 

 period) 

 e. Undershoot with application of load 4% of rated frequency (max.) 1.5% of rated frequency (max.) 

 Recovery time 2 seconds 1 second 

 f. Overshoot with application of load 4% of rated frequency (max.) 1.5% of rated frequency (max.) 

 Recovery time 2 seconds 1 second 

 g. Adjustment range 48-52 Hz, not below 45 Hz 390-420 Hz, not below 370 

 for 50 Hz operation Hz or above 430 Hz 

 58-62 Hz, not above 65 Hz 

 for 60 Hz operation 
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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 PRINCIPLES OF OPERATION. 

1.16.1 Digital Control System (DCS). 

1.16.1.1 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) 

1.16.1.2 In the event that the computer operating software is lost or operating incorrectly, the software must be 

restored. Procedures are provided for TQG remote software restoration in Paragraph 2.13.2. 

1.16.1.3 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. 

1.16.1.4 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. 

 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 Fault System. 

1.16.2.1 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. 
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FIGURE 1-19. FAULT SYSTEM FLOW DIAGRAM 
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1-18 

1.16.2.2 The Fault System consists of the CIM, I/O interface module, fuel level sender, oil pressure sender, 

coolant temperature sender, and BATTLE SHORT switch. 

1.16.2.3 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. 

1.16.2.4 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. 

1.16.2.5 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. 

1.16.2.6 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. 

1.16.3 Governor Control System. 

1.16.3.1 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. 

1.16.3.2 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). 

1.16.3.3 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. 

1.16.4 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 Fuel System. 

1.16.5.1 The Fuel System (Figure 1-22) includes a primary subsystem and an auxiliary subsystem. 

1.16.5.2 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. 
ARMY TM 9-6115-671-14 

AIR FORCE TO 35C2-3-446-32 

MARINE CORPS TM 09249A/09246A-14 

1-19

FIGURE 1-20. GOVERNOR CONTROL SYSTEM FLOW DIAGRAM 
ARMY TM 9-6115-671-14 

AIR FORCE TO 35C2-3-446-32 

MARINE CORPS TM 09249A/09246A-14A 

1-20 

FIGURE 1-21. VOLTAGE REGULATION SYSTEM FLOW DIAGRAM 
ARMY TM 9-6115-671-14 

AIR FORCE TO 35C2-3-446-32 

MARINE CORPS TM 09249A/09246A-14 

1-21

FIGURE 1-22. FUEL SYSTEM FLOW DIAGRAM 
ARMY TM 9-6115-671-14 

AIR FORCE TO 35C2-3-446-32 

MARINE CORPS TM 09249A/09246A-14A 

1-22 

1.16.5.3 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. 

1.16.5.4 The auxiliary subsystem consists of an auxiliary fuel supply, fuel lines, fittings, and an auxiliary fuel 

pump. 

1.16.5.5 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. 

1.16.5.6 The 24 VDC control circuits provide control and power for indicators, fault system, DCS, and auxiliary 

fuel pump. 

1.16.6 Mechanical System. 

1.16.6.1 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. 

1.16.6.2 The mechanical system consists of the housing, insulation, air baffles, and skid base. 

1.16.6.3 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. 

1.16.6.4 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. 

1.16.7 Generator Set Cooling System. 

1.16.7.1 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. 

1.16.7.2 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. 
ARMY TM 9-6115-671-14 

AIR FORCE TO 35C2-3-446-32 

MARINE CORPS TM 09249A/09246A-14 

1-23

FIGURE 1-23. GENERATOR SET COOLING SYSTEM FLOW DIAGRAM
ARMY TM 9-6115-671-14 

AIR FORCE TO 35C2-3-446-32 

MARINE CORPS TM 09249A/09246A-14A 

1-24 

1.16.8 Engine Cooling System. 

1.16.8.1 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). 

1.16.8.2 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. 

1.16.8.3 The DCS, in conjunction with the fault system, provides automatic shutdown in the event coolant 

temperature exceeds 230 ± 5°F (110 ± 3°C). The CIM display screen COOLANT TEMP indicator 

indicates the engine coolant temperature from 100°F to 250°F (38°C to 121°C). 

1.16.8.4 The water pump also circulates coolant through the engine oil cooler to cool the engine oil. 

1.16.9 Lubrication System. 

1.16.9.1 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. 

1.16.9.2 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). 

1.16.10 Engine Air Intake and Exhaust System. 

1.16.10.1 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. 

1.16.10.2 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. 
ARMY TM 9-6115-671-14 

AIR FORCE TO 35C2-3-446-32 

MARINE CORPS TM 09249A/09246A-14 

1-25

FIGURE 1-24. ENGINE COOLING SYSTEM FLOW DIAGRAM 
ARMY TM 9-6115-671-14 

AIR FORCE TO 35C2-3-446-32 

MARINE CORPS TM 09249A/09246A-14A 

1-26 

FIGURE 1-25. LUBRICATION SYSTEM FLOW DIAGRAM 
ARMY TM 9-6115-671-14 

AIR FORCE TO 35C2-3-446-32 

MARINE CORPS TM 09249A/09246A-14 

1-27

FIGURE 1-26. ENGINE AIR INTAKE AND EXHAUST SYSTEM FLOW DIAGRAM 
ARMY TM 9-6115-671-14 

AIR FORCE TO 35C2-3-446-32 

MARINE CORPS TM 09249A/09246A-14A 

1-28 

1.16.10.3 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. 

1.16.10.4 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. 

1.16.10.5 An ether supply system is provided to improve engine starting when outside ambient air temperature is 

below 40°F (4°C). 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. 

1.16.10.6 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. 

1.16.11 Output Supply System. 

1.16.11.1 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. 

1.16.11.2 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 

AMMETER indicates rated current in amps required by 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. 

1.16.11.3 The AC generator also provides 120 VAC power to the CONVENIENCE RECEPTACLE through the 

GROUND FAULT CIRCUIT INTERRUPTER. 
ARMY TM 9-6115-671-14 

AIR FORCE TO 35C2-3-446-32 

MARINE CORPS TM 09249A/09246A-14 

1-29

FIGURE 1-27. OUTPUT SUPPLY SYSTEM FLOW DIAGRAM 
ARMY TM 9-6115-671-14 

AIR FORCE TO 35C2-3-446-32 

MARINE CORPS TM 09249A/09246A-14A 

1-30 

1.16.12 Generator Assembly. 

1.16.12.1 General. Revolving field type generators have a DC field revolving within a stationary AC winding 

called the stator. See brushless 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. 

1.16.12.3 Brushless Exciter. The brushless exciter consists of an armature with a three-phase AC winding and 

rotating rectifier assembly within a stationary field. 

 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. 

1.16.12.5 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. 

1.16.12.6 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. 
ARMY TM 9-6115-671-14 

AIR FORCE TO 35C2-3-446-32 

MARINE CORPS TM 09249A/09246A-14 

1-31

FIGURE 1-28. BRUSHLESS GENERATOR SCHEMATIC 
ARMY TM 9-6115-671-14 

AIR FORCE TO 35C2-3-446-32 

MARINE CORPS TM 09249A/09246A-14A 

1-32 

1.16.12.8 Bearing. The generator rotor assembly is suspended on shielded, factory lubricated ball bearings. 

They are greased for life and do not require lubrication. 

1.16.12.9 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. 

1.16.13 Generator Set Controls. 

1.16.13.1 Engine Starting System. 

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. 

1.16.13.1.2 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 -60 amps to +60 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. 
ARMY TM 9-6115-671-14 

AIR FORCE TO 35C2-3-446-32 

MARINE CORPS TM 09249A/09246A-14 

1-33

FIGURE 1-29. ENGINE STARTING SYSTEM FLOW DIAGRAM 
ARMY TM 9-6115-671-14 

AIR FORCE TO 35C2-3-446-32 

MARINE CORPS TM 09249A/09246A-14A 

1-34 

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. 

1.16.13.3 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. 

1.16.13.4 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. 

1.16.13.5 Shutdown. 

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. 

1.16.13.5.3 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 deenergizing 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. 
ARMY TM 9-6115-671-14 

AIR FORCE TO 35C2-3-446-32 

MARINE CORPS TM 09249A/09246A-14 

1-35

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. 

1.17.2 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. 

1.17.3 CONVENIENCE RECEPTACLE (3). The CONVENIENCE RECEPTACLE is a 120VAC receptacle 

use to operate small plug-in type equipment. 

1.17.4 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. 

1.17.5 Computer Interface Module (CIM) (5). The CIM is located in the DCS control box and contains 

controls and indicators for operating the generator set. 

1.17.6 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. 

1.17.7 AC Generator (7). The AC generator is a single bearing, drip-proof, synchronous, brushless, three 

phase, air-cooled generator. The generator is coupled directly to the rear of the diesel engine. 

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. 

1.17.9 Fuel Tank (9). The 23 gallon (87.05 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. 

1.17.10 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. 

1.17.11 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. 

1.17.12 Radiator (12). The radiator is located at the front of the generator set. It acts as a heat exchanger for 

engine coolant. 

1.17.13 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. 

1.17.14 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. 
ARMY TM 9-6115-671-14 

AIR FORCE TO 35C2-3-446-32 

MARINE CORPS TM 09249A/09246A-14A 

1-36 

FIGURE 1-30. 30 KW GENERATOR SET COMPONENTS (SHEET 1 OF 2) 
ARMY TM 9-6115-671-14 

AIR FORCE TO 35C2-3-446-32 

MARINE CORPS TM 09249A/09246A-14 

1-37

FIGURE 1-30. 30 KW GENERATOR SET COMPONENTS (SHEET 2 OF 2)

ARMY TM 9-6115-671-14 

AIR FORCE TO 35C2-3-446-32 

MARINE CORPS TM 09249A/09246A-14 

1-39/1-40 BLANK 

1.17.15 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. 

1.17.16 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. 

1.17.17 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. 

1.17.18 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. 

1.17.19 Oil Filter (19). The oil filter is located in the engine compartment on the left side. The filter removes 

impurities from engine oil. 

1.17.20 Engine (20). The generator is powered by a four 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. 

1.17.21 Battery Charging Alternator (21). 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. 

1.17.22 Dipstick (22). The dipstick is located in the engine compartment on the left side. The dipstick shows 

the level of oil in the engine drain pan. 

1.17.23 Starter (23). 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. 

1.17.24 Crankcase Breather Filter Assembly (24). 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. 

1.17.25 Fuel Filter/Water Separator (25). 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. 

1.17.26 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. 

1.17.27 Voltage Reconnection Terminal Board (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. 
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CHAPTER 2 

OPERATING INSTRUCTIONS 

CHAPTER INDEX 

SECTION I DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS .......................2-1 

SECTION II PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)...................................2-14 

SECTION III OPERATION UNDER USUAL CONDITIONS.........................................................................2-21 

SECTION IV 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. 
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FIGURE 2-1. DCS CONTROLS AND INDICATORS 
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TABLE 2-1. DCS CONTROLS AND INDICATORS 

KEY CONTROL OR INDICATOR FUNCTION 

1 ELAPSED TIME Meter Indicates total engine operating hours. 

2 Panel Lights Illuminate DCS control panel. 

3 EMERGENCY STOP Switch Shuts down generator set when activated. Removes electrical 

power to governor controller and stops engine from operating. 

4 PANEL LIGHTS Switch Activates and deactivates panel lights. 

5 NETWORK FAILURE Indicator 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. 

6 BATTLE SHORT Switch Bypasses protective devices on generator set. Set will continue 

to operate until overvoltage occurs or fuel is exhausted. 

7 ETHER START Switch When held in ON position momentarily during engine cranking, 

activates ether cold weather starting system for starting engine 

at temperatures below 40°F (4°C). 

8 ENGINE CONTROL Switch 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. 

9 FREQUENCY ADJUST Switch 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. 

10 AC CIRCUIT INTERRUPT Switch Opens and closes AC Circuit Interrupt Relay. Used during 

parallel operation. 

11 VOLTAGE ADJUST Switch Momentary-action toggle switch. Adjusts voltage output of 

generator set. Works in both directions to increase and 

decrease output voltage. 

12 FAULT RESET Switch Resets (turns off) fault indicators displayed on Computer 

Interface Module display screen. Will re-energize governor 

power. 

13 MASTER CONTROL Switch 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. 

14 GROUND FAULT CIRCUIT 

INTERRUPTER TEST Switch 

Tests GROUND FAULT CIRCUIT INTERRUPTER. 

15 GROUND FAULT CIRCUIT 

INTERRUPTER RESET Switch 

Resets GROUND FAULT CIRCUIT INTERRUPTER. 

16 Keypad Up Arrow Pushbutton ↑ Moves cursor on CIM display screen in upward direction until 

released. 

17 Keypad Right Arrow Pushbutton → Moves cursor on CIM display screen to the right until released. 

18 Keypad SELECT Pushbutton When pressed, selects item on CIM display screen indicated by 

cursor. 

19 Keypad Down Arrow Pushbutton ↓ Moves cursor on CIM display screen in downward direction 

until released. 
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TABLE 2-1. DCS CONTROLS AND INDICATORS (continued) 

KEY CONTROL OR INDICATOR FUNCTION 

20 Keypad Left Arrow Pushbutton ← Moves cursor on CIM display screen to the left until released. 

21 DC CONTROL POWER Fuse Provides overcurrent protection for DC circuits. 

22 FREQUENCY SELECT Switch 

(MEP-806B only) 

Allows selection of 50 Hz or 60 Hz. 

23 REACTIVE CURRENT ADJUST 

rheostat 

Adjusts voltage droop when two generator sets are operated in 

parallel. 

24 VOLTAGE SCALE Switch 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. 
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FIGURE 2-2. CIM DISPLAY SCREEN CONTROLS AND INDICATORS 
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TABLE 2-2. CIM DISPLAY SCREEN CONTROLS AND INDICATORS 

KEY CONTROL OR INDICATOR FUNCTION 

1 GEN VOLTAGE indicators Indicates generator output voltage for each of the three phases. 

2 BATTERY VDC indicator Indicates charge status of both generator set DC batteries 

(VDC). 

3 GEN CURRENT indicators Indicates generator output current (amps) for each of the three 

phases. 

4 FAULT INDICATOR display 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. 

5 DELTA VAC gage 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. 

6 MESSAGES display Displays warnings and instructions in the form of operator 

messages related to faults displayed in FAULT INDICATOR 

display. 

7 WATER TEMP virtual meter Indicates generator set cooling system water temperature (°F). 

8 BATTLE SHORT CIRCUIT status 

indicator 

Indicates whether generator set is in battle short mode or not. 

ON indication means battle short circuit is energized. 

9 CONTACTOR POSITION status 

indicator 

Indicates whether contactor is open or closed. 

10 DISPLAY MODE FULL/MAIN 

switch 

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. 

11 SHUTDOWN COMPUTER 

EXIT button 

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. 

12 BATTERY AMPS virtual meter Indicates input current of generator set DC batteries (amps). 

13 OIL PRESSURE virtual meter Indicates engine oil pressure (psi). 

14 BUS VOLTAGE indicators Indicate voltage on output bus. The GEN VOLTAGE and BUS 

VOLTAGE indicators must match within five volts, each phase, 

to perform paralleling operation. 

15 VOLTAGE gage Indicates generator set voltage output (VAC). 

16 FREQ gage Indicates generator set frequency output (Hz). 

17 POWER gage Indicates generator set power output (kW). 

18 FUEL LEVEL gage Indicates amount of fuel in fuel tank (percent remaining). 
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TABLE 2-3. FAULTS 

NOTE: Maintainers can only check faults at their level. 

FAULT MESSAGE # MESSAGE 

CIRCUIT FAILURE - 

FUEL LEVEL 

01 The fuel level signal is lower than the operating range. 

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 - 

FUEL LEVEL 

04 The fuel level signal is higher than the operating range. 

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) 

 06 The coolant temperature is higher than the operating range. 

Check coolant level. Check coolant temperature sensor and circuit. 

(Para. 4.13.2) 

WARNING - COOLANT 

TEMP 

07 Coolant temperature is abnormally high. 

Check coolant level. Verify coolant system lineup. (Para. 3.3.5) 

SHUTDOWN - COOLANT 

TEMP 

08 Coolant temperature is abnormally high. 

Check coolant level. Verify coolant system lineup. (Para. 3.3.5) 

 

CIRCUIT FAILURE - OIL 

PRESSURE 

09 The oil pressure signal is lower than the operating range. 

Check oil pressure. Check oil pressure sensor and circuit.(Para. 

4.13.1) 

 10 The oil pressure signal is higher than the operating range. 

Check oil pressure. check oil pressure sensor and circuit.(Para. 

4.13.1) 

WARNING - LOW OIL 11 Oil pressure is abnormally low. 

Check oil. Verify lubricating system lineup. (Para. 3.3.8) 

SHUTDOWN - LOW OIL 12 Oil pressure is abnormally low. 

Check oil. Verify lubricating system lineup. (Para. 3.3.8) 

 

WARNING - 

OVERVOLTAGE 

13 Generator voltage is abnormally high. 

Adjust VOLTAGE ADJUST switch. (Para. 2.11.1 j) 

SHUTDOWN - 

OVERVOLTAGE 

14 Generator voltage is abnormally high. 

Adjust VOLTAGE ADJUST switch. (Para. 2.11.1 j) 

 

WARNING - OVERSPEED 15 Generator frequency is abnormally high. 

Adjust FREQUENCY ADJUST switch. (Para. 2.11.1 j) 

SHUTDOWN - 

OVERSPEED 

16 Generator frequency is abnormally high. 

Adjust FREQUENCY ADJUST switch. (Para. 2.11.1 j) 

 

WARNING - 

UNDERVOLTAGE 

17 Generator voltage is abnormally low. 

Adjust VOLTAGE ADJUST switch. (Para. 2.11.1 j) 

CONTACTOR TRIP - 

UNDERVOLTAGE 

18 Generator voltage is abnormally low. 

Adjust VOLTAGE ADJUST switch. (Para. 2.11.1 j) 

 

WARNING - OVERLOAD 19 System load is abnormally high. 

Reduce load to within generator set ratings. (Para. 2.11.1 n and o) 
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TABLE 2-3. FAULTS (continued) 

FAULT MESSAGE # MESSAGE 

CONTACTOR TRIP - 

OVERLOAD 

20 System load is abnormally high. 

Reduce load to within generator set ratings. (Para. 2.12) 

 

CONTACTOR TRIP - 

REVERSE POWER 

21 Load share device sensed reverse power conditions. 

Verify load share device setpoints are correct. 

 

CONTACTOR TRIP - 

SHORT CIRCUIT 

22 System load was abnormally high. 

Reduce load to within generator set ratings. 

 

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. 
 2-9

FIGURE 2-3. DIAGNOSTIC CONTROLS AND INDICATORS (SHEET 1 OF 2) 
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FIGURE 2-3. DIAGNOSTIC CONTROLS AND INDICATORS (SHEET 2 OF 2) 
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TABLE 2-4. DIAGNOSTIC CONTROLS AND INDICATORS 

KEY CONTROL OR INDICATOR FUNCTION 

DCS LOAD SHARING SYNCHRONIZER 

1 L1 indicator (green LED) 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. 

2 L2 indicator (green LED) 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. 

3 REVERSE POWER (red LED) 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). 

4 GEN indicator (green LED) 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. 

5 BUS indicator (green LED) 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. 

6 SYNCH ENABLED indicator 

(green LED) 

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. 

7 PARALLEL ENABLE indicator 

(green LED) 

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. 

8 SYNCHRONIZED indicator 

(green LED) 

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. 

9 DC POWER indicator (green 

LED) 

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). 
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TABLE 2-4. DIAGNOSTIC CONTROLS AND INDICATORS (continued) 

KEY CONTROL OR INDICATOR FUNCTION 

SPEED CONTROL UNIT 

10 OVERSPEED indicator (red LED) 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. 

11 ACTUATOR indicator (green 

LED) 

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. 

12 SPEED SENSOR indicator (green 

LED) 

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. 

13 OVERSPEED RESET pushbutton 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. 

14 OVERSPEED TEST pushbutton 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. 

15 DC POWER indicator (green 

LED) 

This indicator is normally lit when the engine is operating. It 

indicates the internal DC power in the module is operating. 

16 CRANK TERMINATION (green 

LED) 

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. 

BACKPLANE MODULE 

17 LED 16 (red) indicator (not assigned) 

18 LED 15 (red) indicator (not assigned) 

19 LED 14 (red) indicator Fault indication. If indicator is lit, indicates a fault has 

occurred. If off, indicates normal running condition. 
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TABLE 2-4. DIAGNOSTIC CONTROLS AND INDICATORS (continued) 

KEY CONTROL OR INDICATOR FUNCTION 

BACKPLANE MODULE (continued) 

20 LED 13 (red) indicator Short circuit indication. If indicator is lit, indicates a short 

circuit condition affecting generator set output has been 

detected. 

21 LED 12 (green) (not assigned) 

22 LED 11 (green) 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. 

23 LED 10 (green) 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. 

24 LED 9 (green) 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. 

25 LED 8 (red) (not assigned) 

26 LED 7 (red) 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. 

27 LED 6 (red) Emergency stop. If indicator is lit, indicates the 

EMERGENCY STOP switch has been activated. If not lit, 

indicates normal running condition. 

28 LED 5 (red) 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. 

29 LED 4 (green) (not assigned) 

30 LED 3 (green) 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. 

31 LED 2 (green) (not assigned) 

32 LED 1 (green) If indicator is lit, fuel pump is operating. If not lit, fuel pump is 

not operating. 

AUTOMATIC VOLTAGE REGULATOR 

33 AC SENSING (green LED) This indicator is normally lit, indicating the AC sensor is 

sending the proper signal to this module. 

34 DC SUPPLY indicator (green 

LED) 

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. 

35 FIELD VOLTAGE (green LED) This indicator is normally lit. It indicates field voltage is 

present, which means the generator is developing AC power. 
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TABLE 2-4. DIAGNOSTIC CONTROLS AND INDICATORS (continued) 

KEY CONTROL OR INDICATOR FUNCTION 

I/O INTERFACE MODULE 

36 HEARTBEAT (green LED) 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. 

37 DIP Switch Assembly (8 positions) 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) 

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 Before Operation. Always keep in mind the CAUTIONS and WARNINGS. Perform Before (B) PMCS. 

2.5.2 During Operation. Always keep in mind the CAUTIONS and WARNINGS. Perform During (D) PMCS. 

2.5.3 After Operation. Perform After (A) PMCS. 

2.5.4 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). 

2.6 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. 

2.6.2 Purpose of Service Intervals. The interval column of the PMCS table indicates when to perform a certain 

check or service. 

2.6.3 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. 
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Class II. Leakage of fluid great enough to form drops, but not enough to cause drops to drip from item 

being checked/inspected. 

Class III. 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. 

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. 

2.6.6 Reporting and Correcting Deficiencies. If the generator set does not perform as required, refer to Chapter 

3, Operator Troubleshooting, to diagnose the problem. 

2.6.7 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. 
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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 D-DURING A-AFTER 

Interval 

Item 

No. B D A 

Item to 

be inspected 

Procedures 

Check for and have 

repaired or adjusted 

as necessary 

Equipment is 

not ready/ 

available if: 

 GENERATOR SET 

 

1 • • • Housing Check door, panels, hinges, and latches 

for damaged, loose or corroded items. 

Inspect air intake and exhaust grilles for 

debris. 

Cannot secure doors. 

Cannot clear debris. 

 

2 • Identification Plates Check to ensure identification plates are 

secure. 

 

3 • • Skid Base Inspect skid base for cracks or corrosion. Skid base is cracked 

or shows signs of 

structural damage. 

 

4 • • 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) 
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B-BEFORE D-DURING A-AFTER 

Interval 

Item 

No. B D A 

Item to 

be inspected 

Procedures 

Check for and have 

repaired or adjusted 

as necessary 

Equipment is 

not ready/ 

available if: 

 ENGINE 

COMPARTMENT 

 

 

5 • • • Engine Assembly Check for loose, damaged, or missing 

hardware and wires. 

Any loose, damaged 

or missing hardware 

or wires. 

 

6 • • • 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 9-2815-259-24. 

Any fuel leaks or 

damaged, loose, or 

missing parts. 

 

7 • • Fuel Filter/Water 

Separator 

Inspect fuel filter/water separator for 

leaks, proper mounting, cracks, damage, 

and missing parts (Refer to Figure 1-30, 

sheet 2). 

Any fuel leaks. 

 

 Drain water from fuel filter/water 

separator (Refer to paragraph 3.3.7). 

Fuel filter/water 

separator not drained. 

 

CAUTION

Catch in suitable container. 

8 • 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. 

 

9 • • • Lubrication System Inspect lubrication system for leaks and 

damaged, loose, or missing parts. 

Oil leaks at Class III. 

Damaged, loose, or 

missing parts. 

 

 Check engine oil level. Oil level is low, and 

dipstick reads add. 

 Check engine oil for contamination (oil 

color is milky, bubbles, foreign material 

in oil, etc.). 

Engine oil shows 

signs of 

contamination. 

 
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TABLE 2-5. OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) 

(continued) 

B-BEFORE D-DURING A-AFTER 

Item Interval 

No. 

B D A 

Item to 

be inspected 

Procedures 

Check for and have 

repaired or adjusted 

as necessary 

Equipment is 

not ready/ 

available if: 

 __________ 

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. 

 

11 • • Hoses Check hose for leaks or cracks. Class III leaks. 

 

12 • Cooling Fan Check fan for damage or looseness. Cooling fan is 

damaged or loose. 

 

 • Check for unusual noise being emitted 

from fan area. 

 

13 • • Fan Belts Inspect belts for cracks, fraying, or 

looseness. 

Broken belt(s). 

 

14 • • • Overflow Bottle Check overflow bottle for leaks and 

missing parts. 

Class III leaks. 

 

• • Check overflow bottle coolant level. 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. 
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TABLE 2-5. OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) 

(continued) 

B-BEFORE D-DURING A-AFTER 

Interval 

Item 

No. B D A 

Item to 

be inspected 

Procedures 

Check for and have 

repaired or adjusted 

as necessary 

Equipment is 

not ready/ 

available if: 

16 • Air Cleaner 

Assembly 

Inspect air cleaner assembly and piping 

for loose or damaged connections. 

Piping connections 

are loose. 

 

 Check restriction indicator for indication 

of clogged air cleaner element (Refer to 

Figure 3-1). 

Clogged element is 

indicated. 

 

 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). 

Electrolyte level is 

below battery plates. 

 

18 • Battery Cables Inspect cables and connectors for 

corrosion and loose, damaged, or 

missing parts. 

Battery cables are 

loose, damaged, or 

missing. 
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TABLE 2-5. OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) 

(continued) 

B-BEFORE D-DURING A-AFTER 

Interval 

Item 

No. B D A 

Item to 

be inspected 

Procedures 

Check for and have 

Repaired or adjusted 

as necessary 

Equipment is 

not ready/ 

available if: 

 __________ 

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 

Check for loose or damaged wiring or 

cables (Figure 1-2). 

Loose or damaged 

wiring or cables. 

 

20 • Load Output 

Terminal Board 

Check output terminals for damaged or 

missing hardware (26, Figure 1-30 sheet 

2) 

Damaged or missing 

hardware. 

 

 DCS CONTROL 

BOX ASSEMBLY 

 

21 • • Controls and 

Indicators 

Check all controls and indicators for 

damaged or missing parts. Ensure relays 

are securely plugged in. 

Controls or indicators 

with damaged or 

missing parts. 

 

 • Ensure all indicators are operating 

properly. 

CIM inoperative. 

 

22 • Control Box Wiring 

Harness 

Check for loose or damaged wiring. Loose or damaged 

wires. 

 

23 • Parallel Operation 

Cable 

If required for generator set operation, 

inspect parallel operation cable for 

damage. 

 

 
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TABLE 2-5. OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) 

(continued) 

B-BEFORE D-DURING A-AFTER 

Interval 

Item 

No. B D A 

Item to 

be inspected 

Procedures 

Check for and have 

repaired or adjusted 

as necessary 

Equipment is 

not ready/ 

available if: 

 __________ 

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. 

 

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 GENERATOR SET INSTALLATION. 

2.8.1 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. Ensure that installation site is as level as possible. 

b. Provide adequate ventilation to prevent recirculation of hot air exhausted from generator set. 

c. Refer to Figure 2-4 for base mounting measurements. 

2.8.2 Outdoor Installation. 

a. Make use of natural protective barriers. 

FIGURE 2-4. BASE MOUNTING MEASUREMENTS 
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b. Allow space on all sides for service and maintenance. Refer to Figure 2-5 for minimum clearance 

measurements. 

c. Ensure soil is firm and well drained. 

d. Use planks or other material for support in areas where soil will not support the generator set. 

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. Provide ducts and vents to outside of building if good supply of cooling air is not available. 

b. Make air intake and outlet openings in building same size or larger than those on the generator set. 
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FIGURE 2-5. MINIMUM ENCLOSURE CLEARANCE MEASUREMENTS 
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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. Shield exhaust pipe with fireproof material at point where it passes through a flammable wall. 

f. Wrap exhaust pipe in heat insulating material. 

g. 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. Open Load Terminal access door (Figure 1-2). 

b. 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. 
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FIGURE 2-6. GROUNDING CONNECTIONS 
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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. 

d. 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. 

e. Drive ground rod section (1) into ground until coupling is just above surface. 

f. Remove driving stud (4) from coupling (6), and install another ground rod section (1) in coupling. 

g. 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. 

h. Repeat steps f and g until ground rod has been driven eight feet or deeper, providing an effective 

ground. 

i. Connect clamp (3) and ground cable (2) to ground rod. Tighten clamp screw. 

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 

TERMINALS VOLTAGE READING 

120/208 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 

240/416 L1, L2, L3, N 

3 Phase 

(Single phase loads can be served 

using any terminal to N) 

L1-N 240 volts 

L2-N 240 volts 

L3-N 240 volts 

L1-L2 416 volts 

L2-L3 416 volts 

L3-L1 416 volts 
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c. Open Load Terminal access door (Figure 1-2). 

d. Using insulated wrench (1, Figure 2-7), loosen terminal nuts (2) on terminals selected in step b. 

e. Insert load cables through load terminal access boot and into terminal studs (3). Tighten terminal nuts 

(2). 

f. Secure insulated wrench (1) in bracket beside output load terminal board, and close terminal board 

access door. 

2.10 INITIAL ADJUSTMENTS, CHECKS, AND SELF-TEST. 

2.10.1 Preparation. Perform all BEFORE (B) PMCS. Refer to Table 2-5. 

2.10.2 Initial Adjustments and Checks. 

a. Open left side engine compartment doors (Figure 1-3). 

b. Place DEAD CRANK switch (1, Figure 2-8) in NORMAL position. 

FIGURE 2-7. INSTALLATION OF LOAD CABLES
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FIGURE 2-8. GENERATOR SET CONTROLS 

c. Close engine compartment doors. 
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d. Release DCS control panel by turning two fasteners, and lower DCS control panel slowly. 

e. Ensure FREQUENCY SELECT switch (10) is in required position. 

f. Ensure VOLTAGE SELECTION switch (9) is set to match voltage requirements. 

g. 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. 

i. Open output box access door (Figure 1-2). 

j. 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. 

k. Close output box access door. 

l. Ensure EMERGENCY STOP switch (2, Figure 2-8) is pulled out. 

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. Place ENGINE CONTROL switch (6) in PRIME & RUN position. 

b. 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. 

c. 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. 

d. Push PRESS TO TEST pushbutton on NETWORK FAILURE INDICATOR (3). Ensure indicator 

light illuminates. When pushbutton is released, indicator light should go out. 
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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. Perform initial adjustments, checks, and self test, paragraph 2.10. 

b. 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. 

c. 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 40°F (4°C) it may be necessary to use the cold weather 

starting aid (See step d). 
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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. 

e. 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. 

f. Release ENGINE CONTROL switch (6) to PRIME & RUN position. 

g. If operating with an auxiliary fuel source, rotate ENGINE CONTROL switch (6) to PRIME & RUN 

AUX FUEL position. 

h. Check WATER TEMP (170-200°F [11-93°C]) and OIL PRESSURE (25-60 psi [172-414 kPa]) meters 

on CIM display screen for normal readings. 

i. 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.) 

j. 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. 

k. Press TEST pushbutton on GROUND FAULT CIRCUIT INTERRUPTER (13). Ensure RESET 

pushbutton is in in position. 

l. Hold AC CIRCUIT INTERRUPT switch (15) in CLOSED position until CONTACTOR POSITION 

on CIM display screen reads CLOSED. 

 

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. 

o. With CIM Display in Main Mode, observe POWER gage (17) (Figure 2-9) on CIM display screen. If 

indication is more than 30KW, reduce load. 

p. Perform all DURING (D) PMCS requirements in accordance with Table 2-5. 

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. 

b. Allow generator set to operate five minutes with no load applied. 

c. Place ENGINE CONTROL switch (6) in OFF position. 
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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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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. 

f. 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. 

g. Place DEAD CRANK switch (1) in OFF position. 

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 2-

10 for proper paralleling configuration. 

2.12.2 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). 

c. Identify one generator set as No. 1 and the other as No. 2. 

d. Open BATTERY ACCESS door (Figure 1-2). 
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FIGURE 2-10. PARALLEL OPERATION SETUP 
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e. Remove paralleling cable from storage box, and close BATTERY ACCESS door (Figure 1-2). 

f. 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. Start each generator set. Refer to paragraph 2.11.1. 

b. Use keypad arrow buttons to move cursor to DISPLAY MODE on CIM display screen. If necessary, 

use SELECT button to access FULL mode screen. 

c. Use VOLTAGE ADJUST switch (8, Figure 2-8) to obtain the same voltage indication on each set. 

d. 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. 

e. 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. Check that POWER gage on CIM display screen indicates approximately zero. 

h. Close the load contactor at the load. 

i. 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. 

j. 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. 
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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. 

b. Shut down generator set, paragraph 2.11.2. 

2.13 REMOTE OPERATION. 

2.13.1 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). 

b. 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. 

c. 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. 

d. 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. 
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 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. Set up computer in accordance with your computer's instruction manual. 

b. Turn on computer. Refer to computer's instruction manual. Wait for computer to boot into Windows 

95. 

c. 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. 

d. 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. 
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(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. 
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(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. 

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. 

b. Disconnect load cables (Figure 2-7). 

c. Disconnect paralleling cable, if used, and store in storage box inside BATTERY ACCESS door (Figure 

1-2). 

d. 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). 

e. 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. 

f. Secure all generator set access doors and panels. 

g. For assembly and preparation for use, refer to paragraph 2.9. 
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FIGURE 2-11. REMOTE PC DISPLAY MODES 
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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 -25°F (-31°C) without special winterization 

equipment. To ensure satisfactory operation under extreme cold weather the following steps must be taken: 

__________ 

WARNING

FIGURE 2-12. REMOTE PC SETUP 
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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. Keep generator set and surrounding area as free of ice and snow as practical. 

b. Keep fuel tank full to protect against moisture, condensation, and accumulation of water. 

c. Ensure proper grade diesel fuel is used. Refer to Table 2-7. 

TABLE 2-7. FUEL 

AMBIENT TEMPERATURE DIESEL FUEL 

+20°F TO 120°F 

(-6°C TO +49°C) 

VV-F-800 GRADE DF-2, JP5, OR JP8 

0°F TO +20°F 

(-17°C TO -6°C) 

VV-F-800 GRADE DF-1, JP5, OR JP8 

-25°F TO 0°F 

(-32°C TO -17°C) 

VV-F-800 

GRADE DF-1 

-25°F TO 0°F 

(-32°C TO -17°C) 

VV-F-800 

GRADE DF-A 

d. Keep batteries free from corrosion and in a well charged condition. 

e. Ensure proper oil is used. See Appendix F. 

2.16 OPERATION IN EXTREME HEAT ABOVE 120° F (48.8° C). 

a. Check vents and radiator air passages frequently for obstructions. 

b. Check coolant temperature indicator frequently for any indication of overheating. 

c. Allow sufficient space for fuel expansion when filling fuel tank. 

d. Keep generator clean and free of dirt. Clean obstructions from generator intake and outlet screens. 

e. 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. 

b. Wet down dusty and sandy surfaces areas around generator set frequently if water is available. 

c. Keep all access doors closed as much as possible to prevent entry of dust and sand into housing 

assembly. 

d. 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. 
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e. Service engine air cleaner assembly frequently to compensate for intake of additional dust or sand. 

f. Drain sediment frequently from fuel filter/water separator. When servicing fuel tank, be careful to 

prevent dust or sand from entering fuel tank. 

g. Change engine oil and oil filter frequently. 

h. Store oil and fuel in dust-free containers. 

i. Ensure generator set ground connections are free of dust and sand, and connections are tight before 

starting the unit. 

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. 

b. Provide adequate drainage to prevent water from accumulating on operation site. 

c. Keep all generator set access doors closed, as much as possible, to prevent entry of water into housing 

assembly. 

d. 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. Remove moisture from generator set components before and after each operating period. 

f. Keep fuel tank full to protect against moisture, condensation, and accumulation of water. 

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. 

b. Keep all generator set access doors closed, as much as possible, to prevent entry of salt water into 

housing assembly. 
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c. Wash exterior surfaces frequently with clean water when generator set is not operating. 

d. Check wiring connections for corrosion and wire insulation for signs of deterioration. 

2.20 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 NATO SLAVE RECEPTACLE START OPERATION. 

2.21.1 General. The NATO SLAVE RECEPTACLE (Figure 2-13) can be used to start the generator set when 

batteries are discharged. 

2.21.2 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). 

b. Start discharged generator set, paragraph 2.11.1. 

c. 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. 

2.22 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. 
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a. Start generator set, paragraph 2.11.1. 

b. 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. 

FIGURE 2-13. NATO SLAVE RECEPTACLE 
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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. 

c. 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. 

d. External surfaces of the control panel assembly that are marked with painted or stamped lettering will 

not withstand repeated decontamination with STB or DS2 without degradation of this lettering. The 

recommended method of decontamination for these areas is warm soapy water. 

e. Areas that will entrap contaminants, making efficient decontamination extremely difficult, include the 

following: space behind knobs and switches on the control panel, exposed heads 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. 

f. In an NBC contaminated environment, the generator set should be operated with all access doors 

closed to reduce the effects of contamination. 

g. The use of overhead shelters or chemical protective covers 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. 

h. For additional NBC information, refer to FM 3-3 and FM 3-4. 

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. 

2.26 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. 

b. Place ENGINE CONTROL SWITCH (6) in OFF position. 

c. Place MASTER SWITCH (12) in OFF position and wait approximately 10 seconds. 

d. Restart and operate generator set in accordance with applicable normal procedures (refer to para 2.11). 
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CHAPTER 2 

OPERATING INSTRUCTIONS 

CHAPTER INDEX 

SECTION I DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS .......................2-1 

SECTION II PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)...................................2-14 

SECTION III OPERATION UNDER USUAL CONDITIONS.........................................................................2-21 

SECTION IV 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. 
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FIGURE 2-1. DCS CONTROLS AND INDICATORS 
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TABLE 2-1. DCS CONTROLS AND INDICATORS 

KEY CONTROL OR INDICATOR FUNCTION 

1 ELAPSED TIME Meter Indicates total engine operating hours. 

2 Panel Lights Illuminate DCS control panel. 

3 EMERGENCY STOP Switch Shuts down generator set when activated. Removes electrical 

power to governor controller and stops engine from operating. 

4 PANEL LIGHTS Switch Activates and deactivates panel lights. 

5 NETWORK FAILURE Indicator 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. 

6 BATTLE SHORT Switch Bypasses protective devices on generator set. Set will continue 

to operate until overvoltage occurs or fuel is exhausted. 

7 ETHER START Switch When held in ON position momentarily during engine cranking, 

activates ether cold weather starting system for starting engine 

at temperatures below 40°F (4°C). 

8 ENGINE CONTROL Switch 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. 

9 FREQUENCY ADJUST Switch 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. 

10 AC CIRCUIT INTERRUPT Switch Opens and closes AC Circuit Interrupt Relay. Used during 

parallel operation. 

11 VOLTAGE ADJUST Switch Momentary-action toggle switch. Adjusts voltage output of 

generator set. Works in both directions to increase and 

decrease output voltage. 

12 FAULT RESET Switch Resets (turns off) fault indicators displayed on Computer 

Interface Module display screen. Will re-energize governor 

power. 

13 MASTER CONTROL Switch 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. 

14 GROUND FAULT CIRCUIT 

INTERRUPTER TEST Switch 

Tests GROUND FAULT CIRCUIT INTERRUPTER. 

15 GROUND FAULT CIRCUIT 

INTERRUPTER RESET Switch 

Resets GROUND FAULT CIRCUIT INTERRUPTER. 

16 Keypad Up Arrow Pushbutton ↑ Moves cursor on CIM display screen in upward direction until 

released. 

17 Keypad Right Arrow Pushbutton → Moves cursor on CIM display screen to the right until released. 

18 Keypad SELECT Pushbutton When pressed, selects item on CIM display screen indicated by 

cursor. 

19 Keypad Down Arrow Pushbutton ↓ Moves cursor on CIM display screen in downward direction 

until released. 
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TABLE 2-1. DCS CONTROLS AND INDICATORS (continued) 

KEY CONTROL OR INDICATOR FUNCTION 

20 Keypad Left Arrow Pushbutton ← Moves cursor on CIM display screen to the left until released. 

21 DC CONTROL POWER Fuse Provides overcurrent protection for DC circuits. 

22 FREQUENCY SELECT Switch 

(MEP-806B only) 

Allows selection of 50 Hz or 60 Hz. 

23 REACTIVE CURRENT ADJUST 

rheostat 

Adjusts voltage droop when two generator sets are operated in 

parallel. 

24 VOLTAGE SCALE Switch 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. 
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FIGURE 2-2. CIM DISPLAY SCREEN CONTROLS AND INDICATORS 
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TABLE 2-2. CIM DISPLAY SCREEN CONTROLS AND INDICATORS 

KEY CONTROL OR INDICATOR FUNCTION 

1 GEN VOLTAGE indicators Indicates generator output voltage for each of the three phases. 

2 BATTERY VDC indicator Indicates charge status of both generator set DC batteries 

(VDC). 

3 GEN CURRENT indicators Indicates generator output current (amps) for each of the three 

phases. 

4 FAULT INDICATOR display 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. 

5 DELTA VAC gage 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. 

6 MESSAGES display Displays warnings and instructions in the form of operator 

messages related to faults displayed in FAULT INDICATOR 

display. 

7 WATER TEMP virtual meter Indicates generator set cooling system water temperature (°F). 

8 BATTLE SHORT CIRCUIT status 

indicator 

Indicates whether generator set is in battle short mode or not. 

ON indication means battle short circuit is energized. 

9 CONTACTOR POSITION status 

indicator 

Indicates whether contactor is open or closed. 

10 DISPLAY MODE FULL/MAIN 

switch 

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. 

11 SHUTDOWN COMPUTER 

EXIT button 

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. 

12 BATTERY AMPS virtual meter Indicates input current of generator set DC batteries (amps). 

13 OIL PRESSURE virtual meter Indicates engine oil pressure (psi). 

14 BUS VOLTAGE indicators Indicate voltage on output bus. The GEN VOLTAGE and BUS 

VOLTAGE indicators must match within five volts, each phase, 

to perform paralleling operation. 

15 VOLTAGE gage Indicates generator set voltage output (VAC). 

16 FREQ gage Indicates generator set frequency output (Hz). 

17 POWER gage Indicates generator set power output (kW). 

18 FUEL LEVEL gage Indicates amount of fuel in fuel tank (percent remaining). 
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TABLE 2-3. FAULTS 

NOTE: Maintainers can only check faults at their level. 

FAULT MESSAGE # MESSAGE 

CIRCUIT FAILURE - 

FUEL LEVEL 

01 The fuel level signal is lower than the operating range. 

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 - 

FUEL LEVEL 

04 The fuel level signal is higher than the operating range. 

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) 

 06 The coolant temperature is higher than the operating range. 

Check coolant level. Check coolant temperature sensor and circuit. 

(Para. 4.13.2) 

WARNING - COOLANT 

TEMP 

07 Coolant temperature is abnormally high. 

Check coolant level. Verify coolant system lineup. (Para. 3.3.5) 

SHUTDOWN - COOLANT 

TEMP 

08 Coolant temperature is abnormally high. 

Check coolant level. Verify coolant system lineup. (Para. 3.3.5) 

 

CIRCUIT FAILURE - OIL 

PRESSURE 

09 The oil pressure signal is lower than the operating range. 

Check oil pressure. Check oil pressure sensor and circuit.(Para. 

4.13.1) 

 10 The oil pressure signal is higher than the operating range. 

Check oil pressure. check oil pressure sensor and circuit.(Para. 

4.13.1) 

WARNING - LOW OIL 11 Oil pressure is abnormally low. 

Check oil. Verify lubricating system lineup. (Para. 3.3.8) 

SHUTDOWN - LOW OIL 12 Oil pressure is abnormally low. 

Check oil. Verify lubricating system lineup. (Para. 3.3.8) 

 

WARNING - 

OVERVOLTAGE 

13 Generator voltage is abnormally high. 

Adjust VOLTAGE ADJUST switch. (Para. 2.11.1 j) 

SHUTDOWN - 

OVERVOLTAGE 

14 Generator voltage is abnormally high. 

Adjust VOLTAGE ADJUST switch. (Para. 2.11.1 j) 

 

WARNING - OVERSPEED 15 Generator frequency is abnormally high. 

Adjust FREQUENCY ADJUST switch. (Para. 2.11.1 j) 

SHUTDOWN - 

OVERSPEED 

16 Generator frequency is abnormally high. 

Adjust FREQUENCY ADJUST switch. (Para. 2.11.1 j) 

 

WARNING - 

UNDERVOLTAGE 

17 Generator voltage is abnormally low. 

Adjust VOLTAGE ADJUST switch. (Para. 2.11.1 j) 

CONTACTOR TRIP - 

UNDERVOLTAGE 

18 Generator voltage is abnormally low. 

Adjust VOLTAGE ADJUST switch. (Para. 2.11.1 j) 

 

WARNING - OVERLOAD 19 System load is abnormally high. 

Reduce load to within generator set ratings. (Para. 2.11.1 n and o) 
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TABLE 2-3. FAULTS (continued) 

FAULT MESSAGE # MESSAGE 

CONTACTOR TRIP - 

OVERLOAD 

20 System load is abnormally high. 

Reduce load to within generator set ratings. (Para. 2.12) 

 

CONTACTOR TRIP - 

REVERSE POWER 

21 Load share device sensed reverse power conditions. 

Verify load share device setpoints are correct. 

 

CONTACTOR TRIP - 

SHORT CIRCUIT 

22 System load was abnormally high. 

Reduce load to within generator set ratings. 

 

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. 
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FIGURE 2-3. DIAGNOSTIC CONTROLS AND INDICATORS (SHEET 1 OF 2) 
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FIGURE 2-3. DIAGNOSTIC CONTROLS AND INDICATORS (SHEET 2 OF 2) 
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TABLE 2-4. DIAGNOSTIC CONTROLS AND INDICATORS 

KEY CONTROL OR INDICATOR FUNCTION 

DCS LOAD SHARING SYNCHRONIZER 

1 L1 indicator (green LED) 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. 

2 L2 indicator (green LED) 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. 

3 REVERSE POWER (red LED) 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). 

4 GEN indicator (green LED) 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. 

5 BUS indicator (green LED) 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. 

6 SYNCH ENABLED indicator 

(green LED) 

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. 

7 PARALLEL ENABLE indicator 

(green LED) 

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. 

8 SYNCHRONIZED indicator 

(green LED) 

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. 

9 DC POWER indicator (green 

LED) 

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). 
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TABLE 2-4. DIAGNOSTIC CONTROLS AND INDICATORS (continued) 

KEY CONTROL OR INDICATOR FUNCTION 

SPEED CONTROL UNIT 

10 OVERSPEED indicator (red LED) 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. 

11 ACTUATOR indicator (green 

LED) 

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. 

12 SPEED SENSOR indicator (green 

LED) 

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. 

13 OVERSPEED RESET pushbutton 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. 

14 OVERSPEED TEST pushbutton 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. 

15 DC POWER indicator (green 

LED) 

This indicator is normally lit when the engine is operating. It 

indicates the internal DC power in the module is operating. 

16 CRANK TERMINATION (green 

LED) 

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. 

BACKPLANE MODULE 

17 LED 16 (red) indicator (not assigned) 

18 LED 15 (red) indicator (not assigned) 

19 LED 14 (red) indicator Fault indication. If indicator is lit, indicates a fault has 

occurred. If off, indicates normal running condition. 
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TABLE 2-4. DIAGNOSTIC CONTROLS AND INDICATORS (continued) 

KEY CONTROL OR INDICATOR FUNCTION 

BACKPLANE MODULE (continued) 

20 LED 13 (red) indicator Short circuit indication. If indicator is lit, indicates a short 

circuit condition affecting generator set output has been 

detected. 

21 LED 12 (green) (not assigned) 

22 LED 11 (green) 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. 

23 LED 10 (green) 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. 

24 LED 9 (green) 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. 

25 LED 8 (red) (not assigned) 

26 LED 7 (red) 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. 

27 LED 6 (red) Emergency stop. If indicator is lit, indicates the 

EMERGENCY STOP switch has been activated. If not lit, 

indicates normal running condition. 

28 LED 5 (red) 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. 

29 LED 4 (green) (not assigned) 

30 LED 3 (green) 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. 

31 LED 2 (green) (not assigned) 

32 LED 1 (green) If indicator is lit, fuel pump is operating. If not lit, fuel pump is 

not operating. 

AUTOMATIC VOLTAGE REGULATOR 

33 AC SENSING (green LED) This indicator is normally lit, indicating the AC sensor is 

sending the proper signal to this module. 

34 DC SUPPLY indicator (green 

LED) 

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. 

35 FIELD VOLTAGE (green LED) This indicator is normally lit. It indicates field voltage is 

present, which means the generator is developing AC power. 
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TABLE 2-4. DIAGNOSTIC CONTROLS AND INDICATORS (continued) 

KEY CONTROL OR INDICATOR FUNCTION 

I/O INTERFACE MODULE 

36 HEARTBEAT (green LED) 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. 

37 DIP Switch Assembly (8 positions) 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) 

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 Before Operation. Always keep in mind the CAUTIONS and WARNINGS. Perform Before (B) PMCS. 

2.5.2 During Operation. Always keep in mind the CAUTIONS and WARNINGS. Perform During (D) PMCS. 

2.5.3 After Operation. Perform After (A) PMCS. 

2.5.4 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). 

2.6 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. 

2.6.2 Purpose of Service Intervals. The interval column of the PMCS table indicates when to perform a certain 

check or service. 

2.6.3 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. 
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Class II. Leakage of fluid great enough to form drops, but not enough to cause drops to drip from item 

being checked/inspected. 

Class III. 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. 

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. 

2.6.6 Reporting and Correcting Deficiencies. If the generator set does not perform as required, refer to Chapter 

3, Operator Troubleshooting, to diagnose the problem. 

2.6.7 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. 
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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 D-DURING A-AFTER 

Interval 

Item 

No. B D A 

Item to 

be inspected 

Procedures 

Check for and have 

repaired or adjusted 

as necessary 

Equipment is 

not ready/ 

available if: 

 GENERATOR SET 

 

1 • • • Housing Check door, panels, hinges, and latches 

for damaged, loose or corroded items. 

Inspect air intake and exhaust grilles for 

debris. 

Cannot secure doors. 

Cannot clear debris. 

 

2 • Identification Plates Check to ensure identification plates are 

secure. 

 

3 • • Skid Base Inspect skid base for cracks or corrosion. Skid base is cracked 

or shows signs of 

structural damage. 

 

4 • • 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) 
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B-BEFORE D-DURING A-AFTER 

Interval 

Item 

No. B D A 

Item to 

be inspected 

Procedures 

Check for and have 

repaired or adjusted 

as necessary 

Equipment is 

not ready/ 

available if: 

 ENGINE 

COMPARTMENT 

 

 

5 • • • Engine Assembly Check for loose, damaged, or missing 

hardware and wires. 

Any loose, damaged 

or missing hardware 

or wires. 

 

6 • • • 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 9-2815-259-24. 

Any fuel leaks or 

damaged, loose, or 

missing parts. 

 

7 • • Fuel Filter/Water 

Separator 

Inspect fuel filter/water separator for 

leaks, proper mounting, cracks, damage, 

and missing parts (Refer to Figure 1-30, 

sheet 2). 

Any fuel leaks. 

 

 Drain water from fuel filter/water 

separator (Refer to paragraph 3.3.7). 

Fuel filter/water 

separator not drained. 

 

CAUTION

Catch in suitable container. 

8 • 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. 

 

9 • • • Lubrication System Inspect lubrication system for leaks and 

damaged, loose, or missing parts. 

Oil leaks at Class III. 

Damaged, loose, or 

missing parts. 

 

 Check engine oil level. Oil level is low, and 

dipstick reads add. 

 Check engine oil for contamination (oil 

color is milky, bubbles, foreign material 

in oil, etc.). 

Engine oil shows 

signs of 

contamination. 

 
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TABLE 2-5. OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) 

(continued) 

B-BEFORE D-DURING A-AFTER 

Item Interval 

No. 

B D A 

Item to 

be inspected 

Procedures 

Check for and have 

repaired or adjusted 

as necessary 

Equipment is 

not ready/ 

available if: 

 __________ 

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. 

 

11 • • Hoses Check hose for leaks or cracks. Class III leaks. 

 

12 • Cooling Fan Check fan for damage or looseness. Cooling fan is 

damaged or loose. 

 

 • Check for unusual noise being emitted 

from fan area. 

 

13 • • Fan Belts Inspect belts for cracks, fraying, or 

looseness. 

Broken belt(s). 

 

14 • • • Overflow Bottle Check overflow bottle for leaks and 

missing parts. 

Class III leaks. 

 

• • Check overflow bottle coolant level. 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. 
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TABLE 2-5. OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) 

(continued) 

B-BEFORE D-DURING A-AFTER 

Interval 

Item 

No. B D A 

Item to 

be inspected 

Procedures 

Check for and have 

repaired or adjusted 

as necessary 

Equipment is 

not ready/ 

available if: 

16 • Air Cleaner 

Assembly 

Inspect air cleaner assembly and piping 

for loose or damaged connections. 

Piping connections 

are loose. 

 

 Check restriction indicator for indication 

of clogged air cleaner element (Refer to 

Figure 3-1). 

Clogged element is 

indicated. 

 

 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). 

Electrolyte level is 

below battery plates. 

 

18 • Battery Cables Inspect cables and connectors for 

corrosion and loose, damaged, or 

missing parts. 

Battery cables are 

loose, damaged, or 

missing. 
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TABLE 2-5. OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) 

(continued) 

B-BEFORE D-DURING A-AFTER 

Interval 

Item 

No. B D A 

Item to 

be inspected 

Procedures 

Check for and have 

Repaired or adjusted 

as necessary 

Equipment is 

not ready/ 

available if: 

 __________ 

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 

Check for loose or damaged wiring or 

cables (Figure 1-2). 

Loose or damaged 

wiring or cables. 

 

20 • Load Output 

Terminal Board 

Check output terminals for damaged or 

missing hardware (26, Figure 1-30 sheet 

2) 

Damaged or missing 

hardware. 

 

 DCS CONTROL 

BOX ASSEMBLY 

 

21 • • Controls and 

Indicators 

Check all controls and indicators for 

damaged or missing parts. Ensure relays 

are securely plugged in. 

Controls or indicators 

with damaged or 

missing parts. 

 

 • Ensure all indicators are operating 

properly. 

CIM inoperative. 

 

22 • Control Box Wiring 

Harness 

Check for loose or damaged wiring. Loose or damaged 

wires. 

 

23 • Parallel Operation 

Cable 

If required for generator set operation, 

inspect parallel operation cable for 

damage. 

 

 
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TABLE 2-5. OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) 

(continued) 

B-BEFORE D-DURING A-AFTER 

Interval 

Item 

No. B D A 

Item to 

be inspected 

Procedures 

Check for and have 

repaired or adjusted 

as necessary 

Equipment is 

not ready/ 

available if: 

 __________ 

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. 

 

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 GENERATOR SET INSTALLATION. 

2.8.1 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. Ensure that installation site is as level as possible. 

b. Provide adequate ventilation to prevent recirculation of hot air exhausted from generator set. 

c. Refer to Figure 2-4 for base mounting measurements. 

2.8.2 Outdoor Installation. 

a. Make use of natural protective barriers. 

FIGURE 2-4. BASE MOUNTING MEASUREMENTS 
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b. Allow space on all sides for service and maintenance. Refer to Figure 2-5 for minimum clearance 

measurements. 

c. Ensure soil is firm and well drained. 

d. Use planks or other material for support in areas where soil will not support the generator set. 

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. Provide ducts and vents to outside of building if good supply of cooling air is not available. 

b. Make air intake and outlet openings in building same size or larger than those on the generator set. 
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FIGURE 2-5. MINIMUM ENCLOSURE CLEARANCE MEASUREMENTS 
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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. Shield exhaust pipe with fireproof material at point where it passes through a flammable wall. 

f. Wrap exhaust pipe in heat insulating material. 

g. 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. Open Load Terminal access door (Figure 1-2). 

b. 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. 
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FIGURE 2-6. GROUNDING CONNECTIONS 
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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. 

d. 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. 

e. Drive ground rod section (1) into ground until coupling is just above surface. 

f. Remove driving stud (4) from coupling (6), and install another ground rod section (1) in coupling. 

g. 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. 

h. Repeat steps f and g until ground rod has been driven eight feet or deeper, providing an effective 

ground. 

i. Connect clamp (3) and ground cable (2) to ground rod. Tighten clamp screw. 

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 

TERMINALS VOLTAGE READING 

120/208 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 

240/416 L1, L2, L3, N 

3 Phase 

(Single phase loads can be served 

using any terminal to N) 

L1-N 240 volts 

L2-N 240 volts 

L3-N 240 volts 

L1-L2 416 volts 

L2-L3 416 volts 

L3-L1 416 volts 
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c. Open Load Terminal access door (Figure 1-2). 

d. Using insulated wrench (1, Figure 2-7), loosen terminal nuts (2) on terminals selected in step b. 

e. Insert load cables through load terminal access boot and into terminal studs (3). Tighten terminal nuts 

(2). 

f. Secure insulated wrench (1) in bracket beside output load terminal board, and close terminal board 

access door. 

2.10 INITIAL ADJUSTMENTS, CHECKS, AND SELF-TEST. 

2.10.1 Preparation. Perform all BEFORE (B) PMCS. Refer to Table 2-5. 

2.10.2 Initial Adjustments and Checks. 

a. Open left side engine compartment doors (Figure 1-3). 

b. Place DEAD CRANK switch (1, Figure 2-8) in NORMAL position. 

FIGURE 2-7. INSTALLATION OF LOAD CABLES
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FIGURE 2-8. GENERATOR SET CONTROLS 

c. Close engine compartment doors. 
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d. Release DCS control panel by turning two fasteners, and lower DCS control panel slowly. 

e. Ensure FREQUENCY SELECT switch (10) is in required position. 

f. Ensure VOLTAGE SELECTION switch (9) is set to match voltage requirements. 

g. 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. 

i. Open output box access door (Figure 1-2). 

j. 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. 

k. Close output box access door. 

l. Ensure EMERGENCY STOP switch (2, Figure 2-8) is pulled out. 

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. Place ENGINE CONTROL switch (6) in PRIME & RUN position. 

b. 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. 

c. 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. 

d. Push PRESS TO TEST pushbutton on NETWORK FAILURE INDICATOR (3). Ensure indicator 

light illuminates. When pushbutton is released, indicator light should go out. 
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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. Perform initial adjustments, checks, and self test, paragraph 2.10. 

b. 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. 

c. 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 40°F (4°C) it may be necessary to use the cold weather 

starting aid (See step d). 
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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. 

e. 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. 

f. Release ENGINE CONTROL switch (6) to PRIME & RUN position. 

g. If operating with an auxiliary fuel source, rotate ENGINE CONTROL switch (6) to PRIME & RUN 

AUX FUEL position. 

h. Check WATER TEMP (170-200°F [11-93°C]) and OIL PRESSURE (25-60 psi [172-414 kPa]) meters 

on CIM display screen for normal readings. 

i. 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.) 

j. 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. 

k. Press TEST pushbutton on GROUND FAULT CIRCUIT INTERRUPTER (13). Ensure RESET 

pushbutton is in in position. 

l. Hold AC CIRCUIT INTERRUPT switch (15) in CLOSED position until CONTACTOR POSITION 

on CIM display screen reads CLOSED. 

 

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. 

o. With CIM Display in Main Mode, observe POWER gage (17) (Figure 2-9) on CIM display screen. If 

indication is more than 30KW, reduce load. 

p. Perform all DURING (D) PMCS requirements in accordance with Table 2-5. 

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. 

b. Allow generator set to operate five minutes with no load applied. 

c. Place ENGINE CONTROL switch (6) in OFF position. 
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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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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. 

f. 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. 

g. Place DEAD CRANK switch (1) in OFF position. 

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 2-

10 for proper paralleling configuration. 

2.12.2 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). 

c. Identify one generator set as No. 1 and the other as No. 2. 

d. Open BATTERY ACCESS door (Figure 1-2). 
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FIGURE 2-10. PARALLEL OPERATION SETUP 
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e. Remove paralleling cable from storage box, and close BATTERY ACCESS door (Figure 1-2). 

f. 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. Start each generator set. Refer to paragraph 2.11.1. 

b. Use keypad arrow buttons to move cursor to DISPLAY MODE on CIM display screen. If necessary, 

use SELECT button to access FULL mode screen. 

c. Use VOLTAGE ADJUST switch (8, Figure 2-8) to obtain the same voltage indication on each set. 

d. 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. 

e. 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. Check that POWER gage on CIM display screen indicates approximately zero. 

h. Close the load contactor at the load. 

i. 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. 

j. 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. 
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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. 

b. Shut down generator set, paragraph 2.11.2. 

2.13 REMOTE OPERATION. 

2.13.1 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). 

b. 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. 

c. 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. 

d. 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. 
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 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. Set up computer in accordance with your computer's instruction manual. 

b. Turn on computer. Refer to computer's instruction manual. Wait for computer to boot into Windows 

95. 

c. 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. 

d. 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. 
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(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. 
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(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. 

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. 

b. Disconnect load cables (Figure 2-7). 

c. Disconnect paralleling cable, if used, and store in storage box inside BATTERY ACCESS door (Figure 

1-2). 

d. 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). 

e. 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. 

f. Secure all generator set access doors and panels. 

g. For assembly and preparation for use, refer to paragraph 2.9. 
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FIGURE 2-11. REMOTE PC DISPLAY MODES 
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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 -25°F (-31°C) without special winterization 

equipment. To ensure satisfactory operation under extreme cold weather the following steps must be taken: 

__________ 

WARNING

FIGURE 2-12. REMOTE PC SETUP 
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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. Keep generator set and surrounding area as free of ice and snow as practical. 

b. Keep fuel tank full to protect against moisture, condensation, and accumulation of water. 

c. Ensure proper grade diesel fuel is used. Refer to Table 2-7. 

TABLE 2-7. FUEL 

AMBIENT TEMPERATURE DIESEL FUEL 

+20°F TO 120°F 

(-6°C TO +49°C) 

VV-F-800 GRADE DF-2, JP5, OR JP8 

0°F TO +20°F 

(-17°C TO -6°C) 

VV-F-800 GRADE DF-1, JP5, OR JP8 

-25°F TO 0°F 

(-32°C TO -17°C) 

VV-F-800 

GRADE DF-1 

-25°F TO 0°F 

(-32°C TO -17°C) 

VV-F-800 

GRADE DF-A 

d. Keep batteries free from corrosion and in a well charged condition. 

e. Ensure proper oil is used. See Appendix F. 

2.16 OPERATION IN EXTREME HEAT ABOVE 120° F (48.8° C). 

a. Check vents and radiator air passages frequently for obstructions. 

b. Check coolant temperature indicator frequently for any indication of overheating. 

c. Allow sufficient space for fuel expansion when filling fuel tank. 

d. Keep generator clean and free of dirt. Clean obstructions from generator intake and outlet screens. 

e. 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. 

b. Wet down dusty and sandy surfaces areas around generator set frequently if water is available. 

c. Keep all access doors closed as much as possible to prevent entry of dust and sand into housing 

assembly. 

d. 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. 
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e. Service engine air cleaner assembly frequently to compensate for intake of additional dust or sand. 

f. Drain sediment frequently from fuel filter/water separator. When servicing fuel tank, be careful to 

prevent dust or sand from entering fuel tank. 

g. Change engine oil and oil filter frequently. 

h. Store oil and fuel in dust-free containers. 

i. Ensure generator set ground connections are free of dust and sand, and connections are tight before 

starting the unit. 

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. 

b. Provide adequate drainage to prevent water from accumulating on operation site. 

c. Keep all generator set access doors closed, as much as possible, to prevent entry of water into housing 

assembly. 

d. 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. Remove moisture from generator set components before and after each operating period. 

f. Keep fuel tank full to protect against moisture, condensation, and accumulation of water. 

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. 

b. Keep all generator set access doors closed, as much as possible, to prevent entry of salt water into 

housing assembly. 
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2-44 

c. Wash exterior surfaces frequently with clean water when generator set is not operating. 

d. Check wiring connections for corrosion and wire insulation for signs of deterioration. 

2.20 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 NATO SLAVE RECEPTACLE START OPERATION. 

2.21.1 General. The NATO SLAVE RECEPTACLE (Figure 2-13) can be used to start the generator set when 

batteries are discharged. 

2.21.2 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). 

b. Start discharged generator set, paragraph 2.11.1. 

c. 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. 

2.22 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. 
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a. Start generator set, paragraph 2.11.1. 

b. 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. 

FIGURE 2-13. NATO SLAVE RECEPTACLE 
ARMY TM 9-6115-671-14 

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2-46 

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. 

c. 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. 

d. External surfaces of the control panel assembly that are marked with painted or stamped lettering will 

not withstand repeated decontamination with STB or DS2 without degradation of this lettering. The 

recommended method of decontamination for these areas is warm soapy water. 

e. Areas that will entrap contaminants, making efficient decontamination extremely difficult, include the 

following: space behind knobs and switches on the control panel, exposed heads 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. 

f. In an NBC contaminated environment, the generator set should be operated with all access doors 

closed to reduce the effects of contamination. 

g. The use of overhead shelters or chemical protective covers 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. 

h. For additional NBC information, refer to FM 3-3 and FM 3-4. 

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. 

2.26 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. 

b. Place ENGINE CONTROL SWITCH (6) in OFF position. 

c. Place MASTER SWITCH (12) in OFF position and wait approximately 10 seconds. 

d. Restart and operate generator set in accordance with applicable normal procedures (refer to para 2.11). 
ARMY TM 9-6115-671-14 

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MARINE CORPS TM 09249A/09246A-14 

3-1 

CHAPTER 3 

OPERATOR MAINTENANCE INSTRUCTIONS 

CHAPTER INDEX 

SECTION I LUBRICATION PROCEDURES..................................................................................................3-1 

SECTION II TROUBLESHOOTING.................................................................................................................3-1 

SECTION III 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 
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MARINE CORPS TM 09249A/09246A-14 

3-2 

TABLE 3-1. OPERATOR TROUBLESHOOTING 

ENGINE FAILS TO CRANK

Engine fails to crank.

Notify next higher level of

maintenance.
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3-3 

TABLE 3-1. OPERATOR TROUBLESHOOTING (CONTINUED) 

No

 OK 

Not OK OK 

 Not OK 

 Yes 

ENGINE CRANKS BUT FAILS TO START

Engine cranks but fails to start.

Inspect air cleaner 

assembly (see para. 3.3.3).

Is ambient temperature above 

40°F(4°C)?

Pull EMERGENCY 

STOP switch to out 

(deactivated) position.

Service air cleaner 

assembly (see para. 

3.3.3).

Inspect/service fuel filter/water 

separator (see para. 3.3.7).

Use ETHER START switch (7, 

Fig 2-1) to assist in starting 

engine in cold weather, below 

40°F (4°C). Does Engine start ?

Notify next higher 

level of maintenance.

Check FAULT INDICATOR 

on CIM display screen. Is a 

fault displayed? (Fig 2-2)

Activate FAULT RESET Switch 

(12, Fig 2-1) on DCS control 

panel. Does fault clear?

Go to troubleshooting 

section corresponding to 

fault displayed. See 

Symptom Index, page 3-1.

Is EMERGENCY 

STOP switch (3, Fig 

2-1) pushed in?

No

Is speed control unit 

DC POWER LED (15, 

Fig 2-3) lit?

Yes

No

No

Notify next higher 

level of maintenance.

 Yes No

Yes

 No

Activate FAULT RESET Switch 

(12, Fig 2-1) on DCS control 

panel. Does fault clear?

No

Notify next higher 

level of maintenance.
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3-4 

TABLE 3-1. OPERATOR TROUBLESHOOTING (CONTINUED) 

No

OK Not OK

Not OK

Yes 

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.

Check FAULT INDICATOR on CIM display 

screen. Is a fault displayed? (fig.2-2)

Go to troubleshooting 

section corresponding to 

fault displayed. See 

Symptom Index, page 

3-1.

Inspect air cleaner 

assembly 

 (see para.3.3.3).

Inspect/service 

fuel filter/water 

seperator 

(see para.3.3.7).

Service air 

cleaner assembly 

(see para.3.3.3).

Notify next higher 

level of 

maintenance.

Notify next higher 

level of 

maintenance.

OK
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TABLE 3-1. OPERATOR TROUBLESHOOTING (CONTINUED)

Yes No

OK Not OK

OK Not OK

Yes No

ENGINE STOPS SUDDENLY

Engine stops 

suddenly.

Check FAULT INDICATOR on 

CIM display screen. Is a fault 

displayed? (fig.2-2)

Go to troubleshooting section 

corresponding to fault displayed. See 

Symptom Index, page 3-1.

Notify next higher 

level of maintenance.

ENGINE RUNS ERRATICALLY OR STALLS 

FREQUENTLY

Engine runs erratically 

or stalls frequently.

Check FAULT INDICATOR on 

CIM display screen. Is a fault 

displayed? (fig.2-2)

Inspect air cleaner assembly 

(see para.3.3.3).

Go to troubleshooting section 

corresponding to fault displayed. 

See Symptom Index, page 3-1.

Inspect/service fuel 

filter/water separator 

(see para.3.3.7).

Notify next higher level 

of maintenance.

Service air cleaner 

assembly 

 (see para.3.3.3).

Notify next higher level 

of maintenance.
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TABLE 3-1. OPERATOR TROUBLESHOOTING (CONTINUED) 

Not OK

OK

OK

Not OK

Yes No

ENGINE KNOCKS

Engine knocks

Check FAULT INDICATOR on 

CIM display screen. Is a fault 

displayed? (fig.2-2)

Go to troubleshooting section 

corresponding to fault displayed. See 

Symptom Index, page 3-1.

Inspect lubrication 

system (see para.3.3.8).

Check for loose parts or foreign 

objects in the engine compartment.

Service lubrication system 

(see para.3.3.8).

Remove foreign objects 

from compartment.

Notify next higher level of 

maintenance.
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3-7 

TABLE 3-1. OPERATOR TROUBLESHOOTING (CONTINUED) 

Not OK OK

Not OK

OK

OK

Not OK

Yes No

ENGINE DOES NOT DEVELOP FULL POWER

Engine does not 

develop full power.

Check FAULT INDICATOR on 

CIM display screen. Is a fault 

displayed? (fig.2-2)

Go to troubleshooting section 

corresponding to fault displayed. 

See Symptom Index, page 3-1.

Inspect air cleaner 

assembly 

(see para.3.3.3).

Inspect/service fuel filter/water 

separator (see para.3.3.7).

Service air cleaner 

assembly (see para.3.3.3).

Notify next higher level of 

maintenance.

Check to see if exhaust opening 

is free from obstructions.

Remove obstruction 

from exhaust opening.

Notify next higher level 

of maintenance.
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3-8 

TABLE 3-1. OPERATOR TROUBLESHOOTING (CONTINUED) 

Yes 

No Yes 

No

Not OK

Yes No

ENGINE EXHAUST SMOKES

Exhaust smokes.

Check FAULT INDICATOR on 

CIM display screen. Is a fault 

displayed? (fig.2-2)

Go to troubleshooting section 

corresponding to fault displayed. 

See Symptom Index, page 3-1.

Is exhaust smoke 

black or gray?

Smoke is white and goes 

away after a few 

minutes.

Inspect air cleaner 

assembly 

(see para.3.3.3).

Service air 

cleaner assembly 

(see para.3.3.3).

Check for improper 

type of fuel 

(see Table 3-3).

OK

Notify next higher 

level of 

maintenance.

White smoke 

during startup is 

normal.

Notify next 

higher level of 

maintenance.
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3-9 

TABLE 3-1. OPERATOR TROUBLESHOOTING (CONTINUED) 

Not OK

Not OK

No Yes 

OK

Not OK OK

ENGINE OIL PRESSURE LOW

Engine has low oil 

pressure.

Inspect lubrication system 

(see para.3.3.8).

Service lubrication 

system (see para.3.3.8).

Check WATER TEMP 

on CIM display screen. Is 

temperature over 200°F?

Inspect engine cooling 

system (see para.3.3.5).

Notify next higher level 

of maintenance.

Inspect air cleaner 

assembly 

(see para.3.3.3).

Service engine 

cooling system 

(see para.3.3.5)

Notify next 

higher level of 

maintenance.

OK

Service air 

cleaner assembly 

(see para.3.3.3).
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3-10 

TABLE 3-1. OPERATOR TROUBLESHOOTING (CONTINUED) 

Yes No

OK Not OK

No

Not OK

Yes

OK

ENGINE OVERHEATING

Engine 

overheating.

Check FAULT INDICATOR on 

CIM display screen. Is a fault 

displayed? (fig.2-2)

Check WATER TEMP on 

CIM display screen. Is 

temperature over 220°F? 

(fig.2-2)

Inspect engine cooling 

system (see para.3.3.5).

Inspect air cleaner 

assembly 

(see para.3.3.3).

Notify next higher

level of 

maintenance.

Notify next 

higher level of 

maintenance.

Service air 

cleaner assembly 

(see para.3.3.3).

Service engine 

cooling system 

(see para.3.3.5).

Go to troubleshooting 

section corresponding to 

fault displayed. See 

Symptom Index, page 

3-1.
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3-11 

TABLE 3-1. OPERATOR TROUBLESHOOTING (CONTINUED) 

 Not OK

 OK Not OK

 No Yes

 Not OK OK

 OK Not OK

 OK Not OK

 Yes No

GENERATOR SET FAILS TO PARALLEL CORRECTLY

Generator set fails to parallel correctly.

Check FAULT INDICATOR

on CIM display screen. Is a

fault displayed? (Fig 2-2)

Go to troubleshooting section

corresponding to fault displayed.

See Symptom Index, page 3-1.

Check that parallel cable

is connected properly (see

para. 2.12.2).

Connect parallel

cable properly (see

para. 2.12.2).

Check that STATUS/CONTACT

POSITION indicator on both

generator sets reads CLOSED.

(Fig 2-2)

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)

Check that load cables

are installed properly

(see para. 2.9.2).

Install load cables

properly (see para.

2.9.2).

Is generator set a

50/60 Hz unit? (Fig.

1-3)

Check that FREQ gage on

CIM display screen

indicates proper Hz setting.

(Fig. 2-2)

Check that FREQUENCY

SELECT switch (22, Fig 2-1)

is in the same position on both

units.

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.

OK
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3-12 

TABLE 3-1. OPERATOR TROUBLESHOOTING (CONTINUED) 

No Yes

OK Not OK

GENERATOR SET FAILS TO PARALLEL CORRECTLY (CONTINUED)

Continued from

previous page.

Check that both generator

voltage reconnect boards

are set to the same voltage

(Fig. 1-30)

Notify next higher level of

maintenance. Are both generators

adjusted to the same

voltage?

Adjust generator sets to rated

voltage using VOLTAGE

ADJUST switch . (11, Fig 2-1)

Notify next higher level of

maintenance.
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3-13 

TABLE 3-1. OPERATOR TROUBLESHOOTING (CONTINUED) 

OK

Not OK 

OK Not OK

OK

Not OK

Not OK OK

Not OK OK

CIM DISPLAY SCREEN DOES NOT DISPLAY AND BACKLIGHT 

DOES NOT LIGHT

CIM display screen does not display and 

backlight does not light.

Is MASTER CONTROL switch 

ON? 

(13, fig.2-1)

Place MASTER 

CONTROL switch to ON 

position.

Confirm that 

Control Panel is lit.

Inspect engine cooling 

system (see para.3.3.5).

Notify next higher 

level of 

maintenance. Replace fuse. Confirm 

that back light 

illuminates. If fuse blows 

again, notify next higher 

level of maintenance.

Attempt 

dead crank.

Check battery 

connections.

Not OK

Replace battery 

connections 

 (see para.4.6.2).

Connect slave unit. 

Refer to para.2.21.

Notify next higher 

level of 

maintenance.
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3-14 

TABLE 3-1. OPERATOR TROUBLESHOOTING (CONTINUED)

OK

No Yes

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)

Are batteries maintenance 

free type?

Inspect batteries 

(see para.3.3.2).

Notify next higher 

level of maintenance.

Notify next higher 

level of 

maintenance.

Service batteries 

(see para.3.3.2).

Not OK
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TABLE 3-1. OPERATOR TROUBLESHOOTING (CONTINUED) 

OK

OK

Yes No

Not OK

CIM DISPLAY SCREEN VOLTAGE GAGE FLUCTUATES

CIM display screen VOLTAGE gage fluctuates.

Is engine running erratically?

Check FAULT INDICATOR 

on CIM display screen. Is a 

fault displayed? (fig. 2-2)

Notify next higher 

level of maintenance.

Inspect air cleaner 

assembly (see 

para.3.3.3).

Got to troubleshooting 

section corresponding to 

fault displayed. See 

Symptom Index, page 3-1.

Service air 

cleaner assembly 

(see para.3.3.3).

Inspect/service fuel 

filter/water separator 

 (see para.3.3.7).

Notify next higher 

level of maintenance.

Notify next higher 

level of maintenance.

Not OK

No Yes
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TABLE 3-1. OPERATOR TROUBLESHOOTING (CONTINUED)

Yes

OK

OK

Yes No

Not OK

CIM DISPLAY SCREEN FREQ GAGE FLUCTUATES

CIM display screen FREQ gage fluctuates. 

(fig.2-2)

Is engine running erratically?

Check FAULT INDICATOR 

on CIM display screen. Is a 

fault displayed? (fig. 2-2)

Notify next higher 

level of maintenance.

Inspect air cleaner 

assembly (see 

para.3.3.3).

Got to troubleshooting 

section corresponding to 

fault displayed. See 

Symptom Index, page 3-1.

Service air 

cleaner assembly 

(see para.3.3.3).

Inspect/service fuel 

filter/water separator 

 (see para.3.3.7).

Notify next higher 

level of maintenance.

Notify next higher 

level of maintenance.

Not OK

No
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3-17 

TABLE 3-1. OPERATOR TROUBLESHOOTING (CONTINUED)

No

Yes

No Yes

Yes No

CIM DISPLAY SCREEN DOES NOT RESPOND TO KEYPAD 

INPUT TEST

CIM display screen works, but backlight does not light or 

only partially lights.

Toggle FAULT RESET switch (12, fig.2-1) to 

the ON position. Release Fault switch. Does CIM 

display screen respond to keypad input?

Verify DEAD CRANK switch 

(10, fig.1-30) is set to 

NORMAL position.

Start and operate 

generator set normally. 

Refer to para.2.11.1.

Set DEAD CRANK 

switch in NORMAL 

position.

Notify next higher 

level of 

maintenance.

Toggle FAULT RESET switch (12, 

fig.2-1) to 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.

Reboot

Toggle FAULT RESET switch 

(12, fig.2-1) to the ON position. 

Release FAULT switch. Does 

CIM display screen respond to 

keypad input?

Start and operate 

generator set normally. 

Notify next higher Refer to para.2.11.1.

level of 

maintenance.

Yes No

 
ARMY TM 9-6115-671-14 

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MARINE CORPS TM 09249A/09246A-14 

3-18 

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 GENERATOR SET INSPECTION AND SERVICE. 

3.3.1 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. Refer to Table 3-4 for Quick Reference General Inspection. 

 

3.3.2 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) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door at front of generator set (Figure 1-2). 

(3) 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). 
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3-19 

(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) Inspect electrolyte level. 

(6) Perform service procedure, step b below, if required. 

(7) Install battery caps. 

(8) Close BATTERY ACCESS door (Figure 1-2). 

b. Service. 

(1) Shut down generator set, paragraph 2.11.2. 

(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). 

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). 
ARMY TM 9-6115-671-14 

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MARINE CORPS TM 09249A/09246A-14 

3-20 

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) Add distilled water to each battery cell as required. 

(5) Replace battery caps. 

(6) Close BATTERY ACCESS door (Figure 1-2). 

(7) 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) Shut down generator set, paragraph 2.11.2. 

(2) Open AIR CLEANER ACCESS door (9, Figure 3-1) at rear of generator set. 

(3) Inspect air cleaner housing (1) for dents, corrosion, missing hardware, and other damage. 

(4) Close AIR CLEANER ACCESS door (9, Figure 3-1). 

(5) 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. 

(7) Close engine compartment access doors. 

b. Service. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open AIR CLEANER ACCESS door (9, Figure 3-1) at rear of generator set. 
ARMY TM 9-6115-671-14 

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3-21 

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). 

(4) Remove wing nut (6) and filter element (7) from rod (5). If dirty or worn, replace filter element. 

(5) Inspect inside of air cleaner housing (1) for debris and grime. Wipe housing interior with clean, 

lint-free cloth (Item 8, Appendix E). 

(6) Install filter element (7) and wing nut (6) on rod (5). 

(7) Install end cap assembly (4) on rod (5), and tighten wing nut (3) fingertight. 

(8) Close AIR CLEANER ACCESS door (9). 

(9) Open left side engine compartment access doors (Figure 1-3). 
ARMY TM 9-6115-671-14 

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MARINE CORPS TM 09249A/09246A-14 

3-22 

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). 

(11) Close left side engine compartment access doors. 

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) Open right side engine compartment access door (Figure 1-2). 

(3) Inspect sight glass (1, Figure 3-2). If fluid is visible, service crankcase breather filter assembly 

(3), step b below. 

(4) Inspect hoses (2) for cracks, holes, dry rot, and damaged or missing hose clamps. 

(5) Inspect crankcase breather filter assembly (3) for cracks, excessive corrosion, and other damage. 

(6) Close engine compartment access doors. 

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). 
ARMY TM 9-6115-671-14 

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3-23 

FIGURE 3-2 CRANKCASE BREATHER FILTER ASSEMBLY 

(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 (4). 

(4) Close engine compartment access doors. 
ARMY TM 9-6115-671-14 

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MARINE CORPS TM 09249A/09246A-14 

3-24 

3.3.5 Engine Cooling System. 

a. Inspection. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open both right and left sets of 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 use caution can cause injury or death 

to personnel. 

(3) Check radiator for dirt, leaves, insects and other blockage inhibiting air flow. 

(4) Check radiator and hoses for leaks, loose connections, loose mountings, corrosion, chafing, and 

missing parts. 

(5) Check coolant level on coolant recovery (overflow) bottle (1, Figure 3-3). 

(6) Close engine access doors. 

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) Shut down generator set, paragraph 2.11.2. 

(2) Open right side engine compartment access doors (Figure 1-2). 

(3) Remove cap (2, Figure 3-3) from coolant recovery (overflow) bottle (1). 

(4) 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. 

(5) Install cap (2) on coolant recover (overflow) bottle (1). 

(6) Close engine compartment access doors. 
ARMY TM 9-6115-671-14 

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MARINE CORPS TM 09249A/09246A-14 

3-25 

FIGURE 3-3. COOLANT RECOVERY (OVERFLOW) BOTTLE 
ARMY TM 9-6115-671-14 

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MARINE CORPS TM 09249A/09246A-14 

3-26 

TABLE 3-2. COOLANT 

AMBIENT TEMPERATURE RADIATOR COOLANT RATIO 

+40° F to +120° F 

(+4° C to 49° C) 

Water: MIL-A-53009 

Inhibitor, 

Corrosion 

35:1 

-25° F to +120° F 

(-32° C to 49° C) 

ANTIFREEZE, MULTI ENGINE TYPE 

Commercial Item Description (CID) A-A-52624 

Type IP, Ethylene Glycol Base 

N/A 

-25° F to +120° F 

(-32° C to 49° C) 

MIL-A-11755 

Antifreeze 

Not Applicable 

Use Full Strength 

3.3.6 Fuel Tank. 

a. Inspection. 

(1) Start up generator set, paragraph 2.11.1. 

(2) Place ENGINE CONTROL switch (8, Figure 2-1) on control panel in PRIME & RUN or 

PRIME & RUN AUX FUEL position. 

(3) If CIM display screen is not in MAIN mode (Figure 2-2), use keypad arrow buttons to move 

cursor to DISPLAY MODE (10, Figure 2-2). Press SELECT button (18, Figure 2-1) to click 

MAIN button to access MAIN mode screen. 

(4) Check FUEL LEVEL gage (18, Figure 2-2) on CIM display screen for level of fuel in the fuel 

tank. 

(5) 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) Remove fuel cap (1, Figure 3-4) from filler neck (2) on left side of generator set housing. 

(7) Check fuel strainer in filler tube (3) for dirt and other foreign material. 

(8) Install fuel cap (1) on filler neck (2). 
ARMY TM 9-6115-671-14 

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3-27 

FIGURE 3-4. FUEL TANK FILLER NECK 
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3-28 

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) Remove fuel cap (1, Figure 3-4) from filler neck (2) on left side of generator set housing. 

(3) 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 23 gallons (87.05 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 

(-7° C to +49° C) 

VV-F-800 Grade DF-2 

JP5, JP8 

0° F to +20° F 

(-17° C to +7° C) 

VV-F-800 Grade DF-1 

JP5, JP8 

-25° F to 0° F 

(-32° C to -17° C) 

VV-F-800 Grade DF-1 

-25° F to 0° F 

(-32° C to -17° C) 

VV-F-800 Grade DF-A 

(5) Install fuel cap (1) on filler neck (2). 

3.3.7 Fuel Filter/Water Separator. 
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3-29 

a. Inspection. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open right side engine compartment access doors (Figure 1-2). 

(3) Inspect fuel filter/water separator assembly for proper mounting, cracks, dents, leaks, loose fuel 

lines, and missing parts. 

(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, Figure 3-5) and air vent (1) on fuel filter/water separator. Allow water and 

sediment to drain into a suitable container. 

(4) Close drain cock (2) and air vent (1). 

(5) Close engine compartment access doors. 

3.3.8 Lubrication. 

a. Inspection. 

(1) Start up generator set, paragraph 2.11.1. Allow engine to warm up. 

(2) Check for a LOW OIL or OIL PRESSURE fault displayed in the FAULT INDICATOR portion 

of the CIM display panel. 

(3) Shut down generator set, paragraph 2.11.2. 

(4) Open both right and left sets of engine compartment access doors (Figures 1-2 and 1-3). 

(5) Inspect engine for oil leaks, damage, and missing parts. 
ARMY TM 9-6115-671-14 

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MARINE CORPS TM 09249A/09246A-14 

3-30 

FIGURE 3-5. FUEL FILTER/WATER SEPARATOR 
ARMY TM 9-6115-671-14 

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3-31 

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. 

(7) Close engine compartment access doors. 

b. Service. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open left side engine compartment access doors (Figure 1-2). 

(3) Remove oil filler cap (1, Figure 3-6) from oil filler neck. 

(4) Add oil to engine crankcase. Refer to Appendix F. 

(5) Install oil filler cap (1) on oil filler neck. 

(6) Close engine compartment doors. 

FIGURE 3-6. DIPSTICK AND OIL FILL CAP 
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3-32 

TABLE 3-4. QUICK REFERENCE GENERAL INSPECTION 

COMPONENT/ASSEMBLY INSPECTION TASK 

DC ELECTRICAL SYSTEM 

 BATTERY AND SLAVE RECEPTACLE CABLES (9, Figure 4-3) 

 NATO SLAVE RECEPTACLE (17, Figure 1-30) 

Inspect for signs of physical 

damage. Inspect for loose or 

frayed cables. 

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) 

Inspect for signs of physical 

damage such as dents, cracks, 

loose paint and corrosion. 

Ensure all housing data plates are 

present and legible. 

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) 

Inspect for signs of physical 

damage including cracked or 

broken components. Ensure all 

DCS data plates are present and 

legible. 

AIR INTAKE AND EXHAUST SYSTEM 

 MUFFLER AND EXHAUST PIPE (11, Figure 1-30) 

Inspect for signs of physical 

damage such as cracks and 

excessive corrosion. 

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) 

Inspect for signs of physical 

damage including cracked or 

broken components. Visually 

check hoses for bulges, cracks, 

and signs of dry rot. 

FUEL SYSTEM 

 LOW PRESSURE FUEL LINES AND FITTINGS (10, 11 Figure 4-25) 

 ETHER CYLINDER ASSEMBLY (Figure 4-26) 

Inspect for signs of physical 

damage. Visually check lines for 

signs of leakage. 

OUTPUT BOX ASSEMBLY 

 TRANSFORMERS (10, 11 Figure 4-27) 

 OUTPUT BOX PANELS (6, Figure 5-3) 

Inspect for signs of physical 

damage. 

ENGINE ACCESSORIES 

 SENDERS (Figure 4-29) 

 DEAD CRANK SWITCH (10, Figure 1-30) 

 OIL DRAIN VALVE (14, Figure 1-30) 

Inspect for signs of physical 

damage. Ensure oil drain valve 

shows no signs of leakage. 

GENERATOR ASSEMBLY (Figure 5-1) Inspect for signs of physical 

damage. 

ENGINE ASSEMBLY (Figure 5-1) Inspect for signs of physical 

damage. 

SKID BASE (16, Figure 1-30) Inspect for signs of physical 

damage such as dents, cracks, 

loose paint and corrosion. 
ARMY TM 9-6115-671-14 

AIR FORCE TO 35C2-3-446-32 

MARINE CORPS TM 09249A/09246A-14 

4-1 

CHAPTER 4 

UNIT MAINTENANCE INSTRUCTIONS 

CHAPTER INDEX 

SECTION I INSPECTING AND SERVICING THE EQUIPMENT................................................................4-1 

SECTION II REPAIR PARTS; TOOLS; TEST, MEASUREMENT AND DIAGNOSTIC 

 EQUIPMENT (TMDE); AND SUPPORT EQUIPMENT ............................................................4-6 

SECTION III LUBRICATION PROCEDURES..................................................................................................4-6 

SECTION IV UNIT PREVENTIVE MAINTENANCE CHECKS AND SERVICES.........................................4-7 

SECTION V TROUBLESHOOTING...............................................................................................................4-10 

SECTION VI UNIT MAINTENANCE PROCEDURES ...................................................................................4-49 

SECTION VII PREPARATION FOR SHIPMENT AND STORAGE..............................................................4-207 

SECTION I. INSPECTING AND SERVICING THE EQUIPMENT 

4.1 INSPECTING AND SERVICING THE EQUIPMENT. 

4.1.1 Inspection. 

a. Unpack and inventory all end item components for serviceability. 

b. Check that all packing materials have been removed. 

c. Check generator set identification plate for proper identification. 

d. Inspect generator set exterior for shipping damage. 

e. Open BATTERY ACCESS (Figure 1-2), and inspect batteries for damage. 

f. Check battery cables for proper polarity connects, damage, and loose connections. 
ARMY TM 9-6115-671-14 

AIR FORCE TO 35C2-3-446-32 

MARINE CORPS TM 09249A/09246A-14 

4-2 

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. If applicable, remove battery caps. 

h. Check battery electrolyte level, and install battery caps. 

i. Loosen fasteners, lower control panel, and check electrical components for damage or loose connections. 

j. Raise control panel, and secure fasteners. 

k. Check air cleaner assembly for external damage and exhaust opening for obstruction. 

l. 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. 

NOTE 

Dipstick is marked indicating oil level may be checked and oil added when engine is 

running or stopped. Make sure the correct side of the dipstick is checked. 

o. Check oil level. As required, drain preservative from engine and fill with proper lubricating oil, paragraph 

4.1.2. 

p. Unpack grounding rod from inside left engine access door (Figure 1-3) and parallel cable and auxiliary fuel 

hose from storage box. Inspect each item for damage and accountability. 

q. Stow grounding rod, parallel cable, and auxiliary fuel hose in storage box, and close engine compartment 

and BATTERY ACCESS doors . 

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. 

b. 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) Remove radiator cap. 

(2) Check that radiator drain valve is closed. 
ARMY TM 9-6115-671-14 

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4-3 

(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 

RADIATOR 

COOLANT RATIO 

+40°F TO +120°F 

(4°C TO 49°C) 

WATER: MIL-A-53009 

INHIBITOR, CORROSION 

35:1 

-25°F TO +120°F 

(-32°C TO +49°C) 

ANTIFREEZE, MULTI ENGINE TYPE 

Commercial Item Description (CID) A-A-52624 

Type IP, Ethylene Glycol Base 

N/A 

-25°F TO +120°F 

(-32°C TO +49°C) 

MIL-A-11755 

ANTIFREEZE 

N/A 

(4) Remove cap from overflow bottle. 

(5) Fill overflow bottle to COLD level mark. 

(6) Install caps on overflow bottle and radiator. 

(7) 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). 
ARMY TM 9-6115-671-14 

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4-4 

FIGURE 4-1. FUEL DRAIN VALVE AND OIL DRAIN 
ARMY TM 9-6115-671-14 

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4-5 

__________ 

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 DIESEL FUEL 

+20°F TO 120°F 

(-6°C TO +49°C) 

VV-F-800 GRADE DF-2, JP5, OR JP8 

0°F TO +20°F 

(-17°C TO -6°C) 

VV-F-800 GRADE DF-1, JP5, OR JP8 

-25°F TO 0°F 

(-32°C TO -17°C) 

VV-F-800 

GRADE DF-1 

-25°F TO 0°F 

(-32°C TO -17°C) 

VV-F-800 

GRADE DF-A 

(4) Install fuel tank filler cap. 

d. Lubrication. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Place suitable container under OIL DRAIN (2, Figure 4-1), and remove plug. 

(3) Open BATTERY ACCESS door (Figure 1-2), and open oil drain valve. Drain oil. 

(4) Close oil drain valve, and close BATTERY ACCESS door. Install plug in OIL DRAIN (2). 

(5) Remove oil fill cap (1, Figure.4-2). 

NOTE 

Dipstick is marked indicating oil level may be checked and oil added when engine is 

running or stopped. Make sure the correct side of the dipstick is checked. 

(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). 

(7) Install oil fill cap (1). 
ARMY TM 9-6115-671-14 

AIR FORCE TO 35C2-3-446-32 

MARINE CORPS TM 09249A/09246A-14 

4-6 

FIGURE 4-2. DIPSTICK AND OIL FILL CAP 

SECTION II. REPAIR PARTS; TOOLS; TEST, MEASUREMENT 

AND DIAGNOSTIC EQUIPMENT (TMDE); AND SUPPORT EQUIPMENT 

4.2 INTRODUCTION. 

4.2.1 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. 

4.2.2 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 9-2815-259-24. 

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. 
ARMY TM 9-6115-671-14 

AIR FORCE TO 35C2-3-446-32 

MARINE CORPS TM 09249A/09246A-14 

4-7 

SECTION IV. UNIT PREVENTIVE MAINTENANCE CHECKS AND SERVICES 

4.4 PMCS PROCEDURES. 

4.4.1 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. 

4.4.2 Purpose of PMCS Table. The PMCS table lists inspections and care required to keep the generator set in good 

operating condition. 

4.4.3 Purpose of Service Intervals. The interval column of the PMCS tells when to perform a certain check or 

service. 

4.4.4 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. 

4.4.6 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: 

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 
ARMY TM 9-6115-671-14 

AIR FORCE TO 35C2-3-446-32 

MARINE CORPS TM 09249A/09246A-14 

4-8 

TABLE 4-3. UNIT PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) 

M - Monthly Q - Quarterly S - Semi-annually A - Annually B - Biannually H - Hours 

Item Interval 

No. M Q S A B H 

Item to be 

inspected 

Procedures 

Check for and have repaired or 

adjusted as necessary 

Equipment is 

not ready/ 

available if: 

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 

NOTE: Oil filter should be 

changed with lube oil change. 

Refer to TM 9-2815-259-24. 

 

1 • 300 Engine lube oil Drain engine lube oil. Add 

proper lube oil per Appendix F. 

 

2 • Fuel filter/ 

water separator 

Change fuel filter/water 

separator. Refer to TM 9-2815-

259-24. 

 

3 • 300 Cooling 

system 

Drain coolant, and flush cooling 

system. Add proper coolant. 

Refer to paragraph 4.10.1. 

 

4 • 1500 Radiator cap Inspect radiator cap for 

corrosion, torn or deteriorated 

seal, and obvious damage. 

Radiator cap 

or seal is 

damaged. 

 

5 • Batteries Remove batteries. Refer to 

paragraph 4.6.3. Clean batteries, 

cable terminals, and battery 

posts. Test batteries for state of 

charge. 

Batteries will 

not hold 

charge. 

 

6 • 1500 Air cleaner 

assembly 

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. 

 

7 • 750 Air cleaner 

tubing and 

breather 

Remove, clean, and inspect 

tubing and breather hose. Refer 

to paragraph 4.9.5. 
ARMY TM 9-6115-671-14 

AIR FORCE TO 35C2-3-446-32 

MARINE CORPS TM 09249A/09246A-14 

4-9 

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 Interval 

No. M Q S A B H 

Item to be 

inspected 

Procedures 

Check for and have repaired or 

adjusted as necessary 

Equipment is 

not ready/ 

available if: 

 

8 300 Crankcase 

Breather Filter 

Assembly 

Inspect and service. Refer to 

paragraph 4.9.6. 

9 • 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. 

Loose, 

missing, or 

damaged 

hardware or 

insulation. 

 

10 • Radiator and 

interior of 

generator set 

Clean radiator exterior surfaces. 

Refer to paragraph 4.10.7. 

 

11 • Wiring 

harnesses 

Check wiring harnesses for 

breaks and loose connections. 

Repair and tighten wiring 

harnesses as necessary. 

Wiring 

harnesses are 

damaged or 

connections 

are loose. 

 

12 • Muffler Check muffler for leaks, 

restriction, and accumulation of 

carbon. Replace or clean as 

required. Refer to paragraph 

4.9.1. 

Muffler leaks, 

is restricted, or 

has excessive 

carbon 

accumulation. 

 

NOTE 

If the auxiliary fuel system is used as the primary fuel source, the auxiliary fuel 

filter must be replaced semi-annually. 

 

13 • 500 Auxiliary fuel 

filter 

Check for proper operation using 

the auxiliary system as primary 

source. Refer to paragraph 

4.11.2. 

 

NOTE 

Refer to TM9-2815-259-24 for engine preventive maintenance checks and services. 
ARMY TM 9-6115-671-14 

AIR FORCE TO 35C2-3-446-32 

MARINE CORPS TM 09249A/09246A-14 

4-10 

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 
ARMY TM 9-6115-671-14 

AIR FORCE TO 35C2-3-446-32 

MARINE CORPS TM 09249A/09246A-14 

4-11 

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 
ARMY TM 9-6115-671-14 

AIR FORCE TO 35C2-3-446-32 

MARINE CORPS TM 09249A/09246A-14 

4-12 

TABLE 4-4. UNIT TROUBLESHOOTING 

Not OK

OK

OK

No Yes 

ENGINE FAILS TO CRANK

Engine fails to 

crank.

Check FAULT INDICATOR on 

CIM display screen. Is a fault 

displayed?

Go to troubleshooting section 

corresponding to fault 

displayed. See Symptom 

Index, page 4-10.

Check for loose or 

corroded battery cable 

terminals or battery posts.

Inspect batteries 

 (see para.4.6.3).

Clean and tighten 

battery cable terminals 

and battery posts.

Replace batteries 

(see para.4.6.3).

Continued on 

next page.

Not OK
ARMY TM 9-6115-671-14 

AIR FORCE TO 35C2-3-446-32 

MARINE CORPS TM 09249A/09246A-14 

4-13 

TABLE 4-4. UNIT TROUBLESHOOTING (CONTINUED) 

Not OK OK

OK No

OK

No Yes 

ENGINE FAILS TO CRANK (CONTINUED)

Continued from previous page.

Test for battery voltage at input of 

ENGINE CONTROL switch 

 (see para.4.8.5). Is voltage present?

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?

Check wires from TB4 to 

S1-3. Refer to Wiring 

Diagram FO-3.

Test diode CR1 

(see para.4.8.29).

Replace diode CR1 

(see para.4.8.29).

Repair or replace 

defective wires or 

connections.

Not OK

Not OK

Replace ENGINE 

CONTROL switch 

 (see para.4.8.5).

Test start relay 

(see para.4.8.34).

Continued on 

next page. Replace start relay 

 (see para.4.8.34).

Yes
ARMY TM 9-6115-671-14 

AIR FORCE TO 35C2-3-446-32 

MARINE CORPS TM 09249A/09246A-14 

4-14 

 TABLE 4-4. UNIT TROUBLESHOOTING (CONTINUED) 

 OK Not OK 

 Not OK OK 

 OK Not OK 

 OK Not OK 

ENGINE FAILS TO CRANK (CONTINUED) 

Test cranking relay 

(see para. 4.12.7).

Replace cranking relay 

(see para. 4.12.7).

Check starting circuit 

for breaks or loose 

connections. Refer to 

Schematic, FO-1.

Test starter solenoid. 

Refer to 

TM 9-2815-259-24.

Repair or replace 

defective wires or 

connections.

Replace starting motor. 

Refer to TM 9-2815-259-24.

Test starting motor. 

Refer to 

TM 9-2815-259-24.

Replace starter 

solenoid, Refer to 

TM 9-2815-259-24.

Notify next higher level 

of maintenance.

Continued from previous page.
ARMY TM 9-6115-671-14 

AIR FORCE TO 35C2-3-446-32 

MARINE CORPS TM 09249A/09246A-14 

4-15 

TABLE 4-4. UNIT TROUBLESHOOTING (CONTINUED) 

 OK

 OK

Not OK 

OK 

OK

OK

Not OK

Yes

 No

 Not OK

OK

Notify next higher level 

of maintenance.

 No

Not OK 

 Not OK

 No

ENGINE CRANKS, BUT FAILS TO START

Engine cranks, but fails to start.

Pull EMERGENCY 

STOP switch out.

Check FAULT 

INDICATOR on 

CIM display screen. 

Is a fault displayed?

Go to troubleshooting 

section corresponding to 

fault displayed. See 

Symptom Index, page 4-10.

Check EMERGENCY 

STOP switch.(3, Fig 

2-1) Is it pressed in?

Check Speed Control Unit DC 

POWER LED.(15 Fig 2-3) Is it lit?

Check I/O interface module 

(Fig 2-3) for 24VDC at 

connector P25 pin 9. See 

Wiring Diagram, FO-3.

No

Check the I/O interface 

module (Fig 2-3) for 

24VDC at connector P25 

pin 8. Refer to Wiring 

Diagram, FO-3.

Check EMERGENCY 

STOP switch circuit for 

broken wires or connections. 

See Schematic, FO-1.

Repair broken 

wires and 

connections as 

necessary.

Replace I/O interface 

module (see para. 

4.8.25).

Check Speed Control 

Unit connections. See 

Wiring Diagram, FO-3.

Replace DCS speed 

control unit (see para. 

4.8.22).

Replace backplane 

module (see para. 

4.8.24).

Does SPEED SENSOR 

LED (12, Fig 2-3) on Speed 

Control Unit illuminate 

during cranking?

Inspect magnetic pickup 

(see para. 4.13.3). Are 

there broken wires or 

loose connections?

Repair or replace wires. 

See Wiring Diagram, 

FO-3.

Replace magnetic 

pickup (see para. 

4.13.3).

Repeat Starting procedure 

(Para 2.11.1).

Test Emergency 

Stop Switch 

(3, fig 2-1) 

Ref Para 4.8.14.

Replace Emergency 

Stop Switch (3, fig 

2-1) Ref Para 

4.8.14.

Yes

Yes

Yes

Continued on next page

Yes

Notify next higher level of 

maintenance.

No
ARMY TM 9-6115-671-14 

AIR FORCE TO 35C2-3-446-32 

MARINE CORPS TM 09249A/09246A-14 

4-16 

TABLE 4-4. UNIT TROUBLESHOOTING (CONTINUED) 

 OK 

 OK 

Yes

 Not OK 

 Not OK 

 Not OK OK 

 Not OK 

Check for clogged or 

defective fuel filter/water 

separator. Refer to 

TM 9-2815-259-24.

 OK 

ENGINE CRANKS, BUT FAILS TO START (CONTINUED)

Replace fuel filter/ 

water separator. 

Refer to TM 

9-2815-259-24.

Check for defective 

fuel supply pump. 

Refer to TM 

9-2815-259-24.

Notify next higher 

level of maintenance.

Replace fuel supply 

pump. Refer to 

TM 9-2815-259-24.

Continued from previous page.

Check Actuator LED (11, Fig 2-3). Is 

it lit during cranking ?

Yes

Is Overspeed LED 

(10,Fig.2-3) lit ?

No

Replace Speed Control 

Module 

(see Para 4.8.22).

No

Push RESET BUTTON 

on overspeed module 

(13, Fig.2-3). Repeat 

starting procedure.

Check for contaminated fuel. (see 

para.3.3.6) or incorrect grade of 

fuel (Table 3-3).

Using fuel drain valve, (figure 4-1), drain fuel into 

suitable container. Replace fuel filter and fuel/water 

separator. Refer to TM 9-2815-259-24. Service fuel 

tank (see para. 3.3.6). Bleed fuel lines. Refer to TM 

9-2815-259-24.

Check for evidence of air 

bubbles or fuel line blockage.

Unblock or replace fuel 

lines as necessary (see 

para.4.11.1). Ensure fuel 

lines are tight. Bleed fuel 

lines. Refer to TM 

9-2815-259-24.

Check for 

blocked exhaust 

pipe or muffler 

(see para.4.9.1).

 OK 

Unblock exhaust 

pipe or replace 

muffler (see 

para.4.9.1).

 Not OK Not OK 
ARMY TM 9-6115-671-14 

AIR FORCE TO 35C2-3-446-32 

MARINE CORPS TM 09249A/09246A-14 

4-17 

TABLE 4-4. UNIT TROUBLESHOOTING (CONTINUED) 

 

OK 

No

 Not OK 

No

OK

 

OK 

Not OK 

 Yes No 

 Not OK 

 Not OK 

 Not OK 

 OK 

 OK 

 Not OK OK 

Yes 

ENGINE FAILS TO START IN COLD WEATHER

Engine fails to start in 

cold weather.

Check CIM display screen 

BATTERY VDC indicator for 

low or no battery charge.

Inspect batteries (see para. 

4.6.3). Service or replace 

batteries as necessary.

Inspect ether cylinder 

(see para. 4.11.7).

Inspect ether 

solenoid valve 

(see para 4.11.8).

Check FAULT INDICATOR 

on CIM display screen. Is a 

fault displayed?

Go to troubleshooting section 

corresponding to fault displayed. 

See Symptom Index, page 4-10.

Check for proper lube oil 

type (Appendix F).

Drain oil, and replace oil filter. 

Refill with proper oil type. 

Refer to para. 4.1.2. 

Refer to Appendix F.

Check for proper grade of 

fuel (Table 3-3).

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.

Is ether cylinder 

installed?

Install ether 

cylinder 

(see para. 4.11.7).

Test Ether Solenoid 

Relay (16, Fig 4-26) 

 Ref Para 4.11.9

Replace ether cylinder 

(see para. 4.11.7).

Replace ether 

solenoid valve 

(see para 4.11.8).

Test ETHER 

START switch 

(see para. 4.8.6).

Replace ETHER 

START switch 

 (see para. 4.8.6).

Replace Ether Solenoid 

Relay (16, Fig 4-26). 

Ref Para 4.11.9

Notify next higher 

level of 

maintenance.

Perform cold weather starting 

procedure. Ref Para 2.11.1. 

Does Engine Start ?

Not OK 
ARMY TM 9-6115-671-14 

AIR FORCE TO 35C2-3-446-32 

MARINE CORPS TM 09249A/09246A-14 

4-18 

TABLE 4-4. UNIT TROUBLESHOOTING (CONTINUED) 

 No 

 OK Not OK 

 No Yes 

 No 

 Yes 

ENGINE STOPS SUDDENLY

Engine stops suddenly.

Check FAULT 

INDICATOR on CIM 

display screen. Is a fault 

displayed? (Fig 2-2)

Go to troubleshooting section 

corresponding to fault displayed. 

See Symptom Index, page 4-10.

Bleed fuel lines. Refer to TM 

9-2815-259-24. Is there 

evidence of air bubbles or fuel 

line blockage?

Check for defective fuel 

supply pump. Refer to 

TM 9-2815-259-24.

Unblock or replace fuel lines as 

necessary (see para. 4.11.1). 

 Bleed and tighten fuel lines. 

Refer to TM 9-2815-259-24.

Notify next higher 

level of maintenance.

Replace fuel supply 

pump. Refer to TM 

9-2815-259-24.

Change fuel filter/ 

water separator 

 (para. 4.11.10). 

Does Engine Start?
ARMY TM 9-6115-671-14 

AIR FORCE TO 35C2-3-446-32 

MARINE CORPS TM 09249A/09246A-14 

4-19 

TABLE 4-4. UNIT TROUBLESHOOTING (CONTINUED) 

 No 

 Not OK OK 

Not OK OK 

 No 

 Yes No 

ENGINE RUNS ERRATICALLY OR STALLS FREQUENTLY

Engine runs erratically or 

stalls frequently.

Check FAULT 

INDICATOR on 

CIM display screen. 

Is a fault displayed? 

(Fig 2-2)

Go to troubleshooting section 

corresponding to fault displayed. 

See Symptom Index, page 4-10. Bleed fuel lines. Refer to 

TM 9-2815-259-24. Is 

there evidence of air 

bubbles or fuel line 

blockage?

Inspect exhaust 

pipe and muffler 

(see para. 4.9.1).

Unblock exhaust pipe or 

replace muffler (see 

para. 4.9.1).

Check for contaminated 

fuel (see para. 3.3.6) or 

incorrect grade of fuel 

(Table 3-3).

Replace fuel filter/ water separator. 

Refer to TM 9-2815-259-24. 

Drain fuel into suitable container. 

Service fuel tank (see para. 3.3.6). 

Bleed fuel lines. Refer to TM 

9-2815-259-24.

Notify next higher 

level of maintenance.

Change fuel filter/ water separator 

 (para. 4.11.10). 

Does Engine Start?

 Yes 

Unblock or replace fuel lines as 

necessary (see para. 4.11.1). Bleed 

and tighten fuel lines. 

Refer to TM 9-2815-259-24.
ARMY TM 9-6115-671-14 

AIR FORCE TO 35C2-3-446-32 

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4-20 

TABLE 4-4. UNIT TROUBLESHOOTING (CONTINUED) 

Not OK 

Not OK OK 

 No

Not OK OK 

OK 

Yes No 

ENGINE DOES NOT DEVELOP FULL POWER

Engine does not develop full power.

Inspect fuel filter/ 

water separator (see 

para. 3.3.7).

Check for contaminated fuel 

(see para. 3.3.6) or incorrect 

grade of fuel (Table 3-3).

Replace fuel filter/ 

water separator. Refer 

to TM 9-2815-259-24.

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 9-2815-259-24.

Check FAULT INDICATOR 

on CIM display screen. Is a 

fault displayed? (Fig. 2-2)

Go to troubleshooting section 

corresponding to fault 

displayed. See Symptom 

Index, page 4-10.

Bleed fuel lines. Refer to 

TM 9-2815-259-24. Is there 

evidence of air bubbles or 

fuel line obstruction?

Inspect muffler and 

exhaust pipe 

(see para. 4.9.1.).

Unblock or replace fuel lines as 

necessary (see para. 4.11.1). 

 Bleed and tighten fuel lines. 

Refer to TM 9-2815-259-24.

 Yes

Notify next 

higher level of 

maintenance.

Unblock exhaust pipe 

or replace muffler 

(see para. 4.9.1).
ARMY TM 9-6115-671-14 

AIR FORCE TO 35C2-3-446-32 

MARINE CORPS TM 09249A/09246A-14 

4-21 

TABLE 4-4. UNIT TROUBLESHOOTING (CONTINUED) 

 Not OK 

 Yes No 

ABNORMAL ENGINE NOISE

Abnormal engine noise.

Check FAULT INDICATOR 

on CIM display screen. Is a 

fault displayed? (Fig 2-2)

Go to troubleshooting 

section corresponding to 

fault displayed. See 

Symptom Index, page 4-10.

Check for contaminated 

fuel (see para.3.3.6) or 

incorrect grade of fuel 

(Table 3-3).

Replace fuel filter/water 

separator. Refer to TM 

9-2815-259-24. Drain fuel into 

suitable container. Service fuel 

tank (see para.3.3.6). Bleed fuel 

lines. Refer to TM 

9-2815-259-24.

Notify next higher 

level of maintenance.

OK 
ARMY TM 9-6115-671-14 

AIR FORCE TO 35C2-3-446-32 

MARINE CORPS TM 09249A/09246A-14 

4-22 

TABLE 4-4. UNIT TROUBLESHOOTING (CONTINUED) 

OK 

 No Yes 

BLACK OR GRAY EXHAUST SMOKE

Black or gray exhaust 

smoke.

Check FAULT INDICATOR 

on CIM display screen. Is a 

fault displayed? (Fig 2-2)

Go to troubleshooting 

section corresponding to 

fault displayed. See 

Symptom Index, page 4-10.

Check for contaminated 

fuel (see para.3.3.6) or 

incorrect grade of fuel 

(Table 3-3).

Replace fuel filter/water 

separator. Refer to TM 

9-2815-259-24. Drain fuel 

into suitable container. 

Service fuel tank (see 

para.3.3.6). Bleed fuel lines. 

Refer to TM 9-2815-259-24.

Not OK 

Notify next higher 

level of maintenance.
ARMY TM 9-6115-671-14 

AIR FORCE TO 35C2-3-446-32 

MARINE CORPS TM 09249A/09246A-14 

4-23 

TABLE 4-4. UNIT TROUBLESHOOTING (CONTINUED) 

 OK 

 No Yes 

BLUE OR WHITE EXHAUST SMOKE

Blue or white exhaust smoke.

Check for excessive 

engine oil level.

Drain oil into suitable container to 

obtain proper level. Refer to Figure 

4-1 for location of oil drain valve.

Check FAULT INDICATOR 

on CIM display screen. Is a 

fault displayed? (Fig. 2-2)

Go to troubleshooting section 

corresponding to fault displayed. 

See Symptom Index, page 4-10.

Check for contaminated 

fuel (see para. 3.3.6) or 

incorrect grade of fuel 

(Table 3-3)

Not OK

Replace air 

filter (see para 

4.9.4).

Check air filter 

(see para. 3.3.3).

OK

Not OK

Check for defective 

thermostat(s). Refer 

to TM 9-2815-259-24.

Replace fuel filter/water separator. 

Refer to TM 9-2815-259-24. Drain fuel 

into suitable container. Service fuel tank 

(see para. 3.3.6). Bleed fuel lines. Refer 

to TM 9-2815-259-24.

OK Not OK

Replace defective 

thermostat(s). Refer to TM 

9-2815-259-24.

Notify next higher 

level of maintenance.

Not OK OK

TABLE 4-4. UNIT TROUBLESHOOTING (CONTINUED) 
ARMY TM 9-6115-671-14 

AIR FORCE TO 35C2-3-446-32 

MARINE CORPS TM 09249A/09246A-14 

4-24 

Not OK OK

Not OK OK

Not OK OK

OK Not OK

Not OK OK

CIM DISPLAY SCREEN DOES NOT DISPLAY 

AND BACKLIGHT DOES NOT LIGHT

CIM display screen does not display and 

backlight does not light.

Check for loose or 

corroded battery cable 

terminals or battery posts.

Check that batteries are 

installed correctly 

 (see para.4.6.3).

Clean and tighten battery 

cable terminals and battery 

posts (see para.4.6.3).

Install batteries 

correctly 

(see para.4.6.3).

Test DC CONTROL 

POWER fuse (see 

para.4.8.26).

Replace DC 

CONTROL POWER 

fuse (see para.4.8.26).

Test diode CR1 

(see para.4.8.29).

Replace diode CR1 

(see para.4.8.29).

OK Not OK

Test MASTER 

CONTROL switch 

(see para.4.8.9).

Replace MASTER 

CONTROL switch 

(see para.4.8.9).

Check CIM wiring harness 

for breaks or loose 

connections 

 (see para.4.8.38).

Replace CIM wiring 

harness 

 (see para.4.8.38).

Replace CIM 

 (see para.4.8.16).

TABLE 4-4. UNIT TROUBLESHOOTING (CONTINUED) 
ARMY TM 9-6115-671-14 

AIR FORCE TO 35C2-3-446-32 

MARINE CORPS TM 09249A/09246A-14 

4-25 

Not OK 

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. 

Test PANEL LIGHTS switch 

 (see para. 4.8.12). 

Inspect CIM wiring 

harness 

(see para. 4.8.38). 

Replace PANEL 

LIGHTS switch 

(see para. 4.8.12). 

OK 

Not OK OK 

Replace CIM wiring harness 

 (see para. 4.8.38). Check for voltage at wiring 

harness. 

Replace CIM 

(see para. 

4.8.16). 

Repair/replace CIM 

wiring harness. 

(see para. 4.8.38). 

 OK 

 Not OK 
ARMY TM 9-6115-671-14 

AIR FORCE TO 35C2-3-446-32 

MARINE CORPS TM 09249A/09246A-14 

4-26 

TABLE 4-4. UNIT TROUBLESHOOTING (CONTINUED) 

Not OK

CIM DISPLAY SCREEN BATTERY VDC INDICATOR 

SHOWS LOW OR NO VOLTS

CIM display screen BATTERY VDC 

indicator shows low or no volts.

Inspect fan belt 

(see para. 4.10.9).

Adjust or replace fan 

belt (para. 4.10.9).

Check for loose or 

broken wires. Refer to 

Schematic, FO-1.

Repair or replace loose 

or broken wires. Refer 

to Schematic, FO-1.

Check Battery Charging 

Alternator. 

Refer to TM 

9-2815-259-24.

OK

OK

Not OK

Notify next higher 

level of maintenance.

OK

Replace Battery 

Charging Alternator.

Not OK
ARMY TM 9-6115-671-14 

AIR FORCE TO 35C2-3-446-32 

MARINE CORPS TM 09249A/09246A-14 

4-27 

TABLE 4-4. UNIT TROUBLESHOOTING (CONTINUED) 

Not OK OK

CIM DOES NOT RESPOND TO KEYPAD COMMANDS OR 

UPDATE DISPLAY

CIM does not respond to keypad 

commands or update display.

Is NETWORK FAILURE 

light lit?

Inspect and test CIM 

wiring harness 

(see para.4.8.38).

Inspect keypad 

assembly 

(see para.4.8.17).

No Yes

Replace keypad assembly 

(see para.4.8.17).

Replace CIM . 

(see para.4.8.16).

Not OK OK

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.
ARMY TM 9-6115-671-14 

AIR FORCE TO 35C2-3-446-32 

MARINE CORPS TM 09249A/09246A-14 

4-28 

TABLE 4-4. UNIT TROUBLESHOOTING (CONTINUED) 

Not OK OK 

Not OK 

 OK 

 OK 

 OK Not OK

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.

Inspect fan belt 

(see para. 4.10.9).

Adjust or replace fan 

belt (see para. 4.10.9). Test Battery Current 

Transducer (see para. 4.13.5).

Replace Battery 

Current Transducer 

(see para. 4.13.5).

Test alternator. 

Refer to TM 

9-2815-259-24.

Replace alternator. 

Refer to TM 

9-2815-259-24.

Not OK

Check for breaks or loose 

connections or corroded 

terminals in charging 

circuit. Refer to 

Schematic, FO-1

Repair charging 

circuit. Refer to 

Schematic, FO-1.

Is HEARTBEAT LED 

on I/O interface module 

blinking? See para. 

4.8.25.

Replace I/O 

interface module 

(see para. 4.8.25).

No

Notify next 

higher level of 

maintenance.

Yes
ARMY TM 9-6115-671-14 

AIR FORCE TO 35C2-3-446-32 

MARINE CORPS TM 09249A/09246A-14 

4-29 

TABLE 4-4. UNIT TROUBLESHOOTING (CONTINUED) 

 OK Not OK 

 OK 

No Yes 

 OK 

 Not OK 

 OK Not OK 

 Not OK 

CIM DISPLAY SCREEN BATTERY AMPS INDICATOR SHOWS 

EXCESSIVE CHARGING AFTER PROLONGED OPERATION

CIM display screen BATTERY AMPS indicator 

shows excessive charging after prolonged operation.

Inspect/service batteries BT1 

and BT2 (see para. 4.6.3).

Replace batteries 

 (see para. 4.6.3).

Test alternator. Refer 

to TM 9-2815-259-24.

Check for short in 

charging circuit. Refer 

to Schematic, FO-1.

Replace alternator. Refer 

to TM 9-2815-259-24.

Is HEARTBEAT indicator on I/O 

interface module blinking? 

(see para. 4.8.25)

Repair charging 

circuit. Refer to 

Schematic, FO-1.

Test Battery Current Transducer 

(see para. 4.13.5).

Notify next higher level of 

maintenance.

Replace Battery Current Transducer 

(refer to para. 4.13.5).

Replace I/O interface 

module 

(see para. 4.8.25).
ARMY TM 9-6115-671-14 

AIR FORCE TO 35C2-3-446-32 

MARINE CORPS TM 09249A/09246A-14 

4-30 

TABLE 4-4. UNIT TROUBLESHOOTING (CONTINUED) 

CIM DISPLAY SCREEN GENERATOR VOLTAGE GAGE FLUCTUATES

CIM display screen GENERATOR VOLTAGE gage fluctuates.

Notify next higher 

level of maintenance.

Check FAULT INDICATOR on CIM 

display screen. Is a fault displayed? 

(Fig. 2-2)

Go to troubleshooting section 

corresponding to fault displayed. 

See symptom Index, page 4-10.

Check voltage at AC circuit 

interrupter. Is voltage fluctuating? 

Refer to para.4.12.6.

Replace automatic voltage 

regulator 

(see para. 4.8.23).

Check for loose electrical 

connections. Refer to 

Schematic, FO-1.

Notify next higher 

level of maintenance.

Check automatic voltage 

regulator. Are any or all LEDs 

pulsing with voltage fluctuations?

Replace backplane 

module (see para. 4.8.24).

Tighten electrical 

connections.

Is HEARTBEAT LED on 

I/O interface module 

blinking?

Test VOLTAGE ADJUST 

switch (see para. 4.8.10).

Replace VOLTAGE 

ADJUST switch 

(see para. 4.8.10).

Not OK OK

No Yes

Not OK OK

No

Yes

Yes No

No Yes

TABLE 4-4. UNIT TROUBLESHOOTING (CONTINUED) 
ARMY TM 9-6115-671-14 

AIR FORCE TO 35C2-3-446-32 

MARINE CORPS TM 09249A/09246A-14 

4-31 

 Yes 

CIM DISPLAY SCREEN FREQ GAGE FLUCTUATES

CIM display screen FREQ gage 

fluctuates.

Check FAULT INDICATOR on 

CIM display screen. Is a fault 

displayed? (4, Figure 2-9)

Go to troubleshooting section 

corresponding to fault 

displayed. See Symptom 

Index, page 4-10.

Is Engine speed 

fluctuating?

No

Is HEARTBEAT LED on I/O 

interface module blinking?

Check speed control 

unit LED indicators. 

Are the SPEED 

SENSOR, 

ACTUATOR, and 

DC POWER LEDs 

fluctuating?

No

Yes

Yes

Continued on next page

No

Check Speed control unit. Is DC 

POWER LED lit and steady, and 

ACTUATOR and SPEED 

SENSOR LEDs fluctuating?

Yes

Yes

Replace speed control 

unit.

No

Continued on next page

Replace I/O interface 

module (see para. 4.8.25).

Replace CIM. (see para. 

4.8.16).

No

Notify next higher 

level of maintenance.

Not OK
ARMY TM 9-6115-671-14 

AIR FORCE TO 35C2-3-446-32 

MARINE CORPS TM 09249A/09246A-14 

4-32 

TABLE 4-4. UNIT TROUBLESHOOTING (CONTINUED) 

 Not OK 

 Not OK OK 

CIM DISPLAY SCREEN FREQ GAGE FLUCTUATES (CONTINUED)

Check for blocked exhaust 

pipe or muffler 

(see para. 4.9.1).

Unblock or replace fuel 

lines as necessary (see 

para. 4.11.1). Ensure fuel 

lines are tight. Bleed fuel 

lines. Refer to TM 

9-2815-259-24. 

Replace DCS speed control 

unit (see para. 4.8.22).

Check for contaminated 

fuel (see para. 3.3.5) or 

incorrect grade of fuel 

(Table 3-3).

Using fuel drain valve, (Figure 

4-1), drain fuel into suitable 

container. Replace fuel filter and 

fuel filter/water separator. Refer 

to TM 9-2815-259-24. Service 

fuel tank (see para. 3.3.6). Bleed 

fuel lines. Refer to TM 

9-2815-259-24.

Check for evidence of air 

bubbles or fuel line blockage.

Continued from previous page.

Unblock exhaust pipe or 

replace muffler 

(see para. 4.9.1).

 OK 

 OK Not OK 

 Not OK 

Notify next higher level of 

maintenance.
ARMY TM 9-6115-671-14 

AIR FORCE TO 35C2-3-446-32 

MARINE CORPS TM 09249A/09246A-14 

4-33 

TABLE 4-4. UNIT TROUBLESHOOTING (CONTINUED) 

HIGH OIL CONSUMPTION

High oil consumption.

Notify next higher 

maintenance level.

Inspect air cleaner assembly 

(see para. 4.9.2).

Drain oil and replace oil filter. Refer to 

TM 9-2815-259-24. Refill with proper 

lube oil type. Refer to Appendix F.

Check for engine 

oil leaks.

Check for improper 

lube oil. Refer to 

Appendix F.

Unblock or replace air 

cleaner assembly 

components as required 

(see para. 4.9.2).

Notify next higher 

maintenance level.

 Not OK 

Inspect/service 

crankcase breather 

assembly (refer to 

para. 4.9.6).

 OK 

 OK 

 Not OK 

 Not OK OK 

 Not OK 
ARMY TM 9-6115-671-14 

AIR FORCE TO 35C2-3-446-32 

MARINE CORPS TM 09249A/09246A-14 

4-34 

TABLE 4-4. UNIT TROUBLESHOOTING (CONTINUED) 

 Not OK 

OK 

OK 

Not OK 

 No Yes 

ENGINE MISFIRING

Engine misfiring.

Check FAULT INDICATOR 

on CIM display screen. Is a 

fault displayed?

Check for contaminated fuel 

(see para. 3.3.6) or incorrect 

grade of fuel (Table 3-3).

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 9-2815-259-24. 

 Service fuel tank (see para. 

3.3.6). Bleed fuel lines. 

Refer to TM 9-2815-259-24.

Not OK 

Check for air blockage in 

fuel lines.

OK 

Unclog/Bleed fuel 

lines. Check for blocked 

exhaust or muffler. 

(see para. 4.9.1).

Unblock or 

replace muffler 

(see para. 4.9.1).

Inspect air cleaner assembly 

(see para. 4.9.4).

Unblock air 

cleaner assembly 

(see para. 4.9.4).

Notify next 

higher level of 

maintenance.

OK 

Not OK 
ARMY TM 9-6115-671-14 

AIR FORCE TO 35C2-3-446-32 

MARINE CORPS TM 09249A/09246A-14 

4-35 

TABLE 4-4. UNIT TROUBLESHOOTING (CONTINUED) 

Not OK

CIM DISPLAY SCREEN WATER TEMP METER 

INDICATES COOLANT TEMPERATURE TOO LOW

CIM display screen WATER TEMP meter 

indicates coolant temperature too low.

Test coolant 

temperature sender 

(see para. 4.13.2).

Replace coolant 

temperature sender 

(see para. 4.13.2).

Inspect thermostat. 

Refer to TM 

9-2815-259-24.

Replace thermostat. 

Refer to TM 

9-2815-259-24.

Notify next 

higher level of 

maintenance.

OK

OK

Not OK

TABLE 4-4. UNIT TROUBLESHOOTING (CONTINUED) 
ARMY TM 9-6115-671-14 

AIR FORCE TO 35C2-3-446-32 

MARINE CORPS TM 09249A/09246A-14 

4-36 

Not OK

Not OK

Yes

EXCESSIVE FUEL CONSUMPTION

Excessive fuel consumption.

Check FAULT INDICATOR on

CIM display screen. Is a fault 

displayed?

Go to troubleshooting section 

corresponding to fault 

displayed. See Symptom 

Index, page 4-10.

Inspect air cleaner 

assembly 

(see para.4.9.2).

Check for leaks in fuel 

system 

(see para.4.11.1).

Unblock or replace air 

cleaner assembly components 

as required (see para.4.9.2).

Repair low pressure fuel 

lines and fittings as 

required (see para.4.11.1).

Check for contaminated 

oil. Refer to TM 

9-2815-259-24.

Drain oil and replace oil filter. 

Refer to TM 9-2815-259-24. 

Refill with proper lube oil 

type. Refer to Appendix F.

Notify next higher 

level of maintenance.

No

OK Not OK

OK

OK
ARMY TM 9-6115-671-14 

AIR FORCE TO 35C2-3-446-32 

MARINE CORPS TM 09249A/09246A-14 

4-37 

TABLE 4-4. UNIT TROUBLESHOOTING (CONTINUED) 

Not OK

COOLANT IN CRANKCASE OR OIL IN COOLANT

Coolant in crankcase or oil in coolant.

Check for defective oil cooler. 

Refer to TM 9-2815-259-24.

Replace oil cooler. 

Refer to TM 

9-2815-259-24.

Notify next higher 

level of maintenance.

OK

Not OK

ENGINE VIBRATING

Engine vibrating.

Inspect fan 

(see para.4.10.8).

Replace fan 

(see para.4.10.8) Notify next higher 

level of maintenance.

OK
ARMY TM 9-6115-671-14 

AIR FORCE TO 35C2-3-446-32 

MARINE CORPS TM 09249A/09246A-14 

4-38 

TABLE 4-4 UNIT TROUBLESHOOTING (CONTINUED) 

Not OK 

Not OK 

 OK

Not OK 

 OK 

No 

 OK

Yes 

 OK 

Not OK

No

Not OK 

Not OK 

OK Not OK OK 

Yes No 

CIM DISPLAY SCREEN VOLTAGE GAGE 

DOES NOT INDICATE VOLTAGE

CIM display screen VOLTAGE 

gage does not indicate voltage.

Check ribbon cables 

between I/O and 

Backplane.

Repair or replace wires 

as needed. (See 

schematic F01)

Check voltage regulator 

LEDs with generator set 

running. Are they all lit?

Check for output voltage 

at AC circuit interrupter. 

Is it set for rated voltage?

Is CIM screen being 

updated?

Troubleshoot voltage 

regulator circuit for broken 

wires or loose connections. 

Refer to Schematic, FO-1.

Check Field Flash circuit 

wires. (see schematic 

F01)

Repair or replace broken 

wires or loose connections. 

Refer to Wiring Diagram, 

FO-3.

Troubleshoot voltage regulator 

circuit for broken wires or loose 

connections. Refer to schematic 

FO-1.

Are any phases on the CIM display 

screen indicating voltage ? 

Troubleshoot circuit from P5 to K1 

(refer to schematic FO-1).

Refer to Symptom 

Index " CIM does not 

respond to key pad or 

update display".

Inspect and test Field 

flash relay K23. (Ref 

Para. 4.8.34)

Inspect and test 

Resistor R6 (see Para 

4.8.36).

Is HEARTBEAT indicator on 

I/O interface module blinking? 

(see para. 4.8.25).

Test Backplane 

(see Para 4.8.24).

Replace I/O module 

(see Para. 4.8.25).

Yes

OK 

Replace Field flash relay 

K23. (Ref Para. 4.8.34)

OK 

Replace Resistor R6 

(see Para 4.8.36).

Not OK 

Inspect and Test 

Diodes CR7 & CR8 

(see Para 4.8.29).

OK 

Replace Diodes CR7 

& CR8 (see Para 

4.8.29).

Test Auto. Voltage 

Regulator(see Para 

4.8.23).

Replace Backplane 

(see para. 4.8.24).

Replace Voltage 

Regulator(see Para 4.8.23).

 OK

Notify next higher 

level maintanance.

Replace ribbon cables 

between I/O and 

Backplane.

Not OK

Not OK
ARMY TM 9-6115-671-14 

AIR FORCE TO 35C2-3-446-32 

MARINE CORPS TM 09249A/09246A-14 

4-39 

TABLE 4-4. UNIT TROUBLESHOOTING (CONTINUED) 

OK Not OK

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.

Adjust FREQUENCY ADJUST to 

lower frequency. Does the FREQ 

gage respond?

Check for breaks or loose 

connections in AC circuit. 

Refer to Schematic, FO-1.

Adjust FREQUENCY 

ADJUST switch to 

desired value.

Repair charging 

circuit. Refer to 

Schematic, FO-1.

Is HEARTBEAT LED 

on I/O interface 

module blinking?

Yes No

Notify next higher 

level of maintenance.

Replace I/O interface 

module 

(see para.4.8.25).

No Yes
ARMY TM 9-6115-671-14 

AIR FORCE TO 35C2-3-446-32 

MARINE CORPS TM 09249A/09246A-14 

4-40 

TABLE 4-4. UNIT TROUBLESHOOTING (CONTINUED) 

Not OK OK

No Yes

OK Not OK

FAULT INDICATOR DISPLAYS CIRCUIT 

FAILURE - FUEL LEVEL

FAULT INDICATOR displays CIRCUIT 

FAILURE - FUEL LEVEL.

Test fuel level system electrical circuit 

for breaks or loose connections. Refer 

to Schematic, FO-1.

Test fuel level sender 

(see para.4.11.5).

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.

Replace defective 

fuel level sender 

(see para.4.11.5).

Check for breaks or loose 

connections in DC electrical 

circuit. Refer to Schematic, 

FO-1.

Is HEARTBEAT LED 

on I/O interface module 

blinking?

Repair charging circuit. 

Refer to Schematic, 

FO-1.

Not OK OK

Notify next higher level 

of maintenance.

Replace I/O interface 

module (see para.4.8.25).
ARMY TM 9-6115-671-14 

AIR FORCE TO 35C2-3-446-32 

MARINE CORPS TM 09249A/09246A-14 

4-41 

TABLE 4-4. UNIT TROUBLESHOOTING (CONTINUED) 

 Not OK 

FAULT INDICATOR DISPLAYS CIRCUIT FAILURE - OIL 

PRESSURE (LOW) OR OIL PRESSURE (HIGH)

FAULT INDICATOR displays CIRCUIT 

FAILURE - OIL PRESSURE (Low) or OIL 

PRESSURE (High).

Check for improper lube oil 

type. Refer to Appendix F.

Drain oil and replace oil filter. 

Refer to TM 9-2815-259-24. 

Refill with proper lube oil type. 

Refer to Appendix F.

Not OK

OK

Test oil pressure sensor 

circuit for breaks or loose 

connections. Refer to 

Schematic, FO-1.

Not OK

Repair or replace defective 

wires or connectors. Refer 

to Wiring Diagram, FO-3.

Test oil pressure sender 

 (see para. 4.13.1).

Replace oil pressure sender 

(see para. 4.13.1).

Test oil pressure electrical circuit 

for breaks or loose connections. 

Refer to Schematic, FO-1.

Repair or replace defective wires 

or connectors. Refer to wiring 

Diagram, FO-3.

Is HEARTBEAT LED on I/O 

interface module blinking?

Not OK

Notify next higher level of 

maintenance.

Replace I/O interface 

module (see para.4.8.25).

No Yes

OK

OK
ARMY TM 9-6115-671-14 

AIR FORCE TO 35C2-3-446-32 

MARINE CORPS TM 09249A/09246A-14 

4-42 

TABLE 4-4. UNIT TROUBLESHOOTING (CONTINUED) 

OK

 Not OK 

FAULT INDICATOR DISPLAYS CIRCUIT 

FAILURE - COOLANT TEMP

FAULT INDICATOR displays 

CIRCUIT FAILURE - COOLANT 

TEMP.

Test coolant temperature 

electrical circuit for breaks 

or loose connectors. 

Schematic, FO-1.

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

Test coolant 

temperature sender 

(see para. 4.13.2).

OK

Not OK

Check for breaks or loose 

connections in Fault Reset 

switch circuit. Refer to 

Schematic, FO-1.

Replace coolant 

temperature sender 

(see para. 4.13.2).

Check Ribbon 

cables for breaks 

or damage.

OK Not OK

Test Fault Reset 

switch (12, Fig 2-1) 

Ref Para. 4.8.8.

Replace Fault Reset 

switch (12, Fig 2-1) 

Ref Para. 4.8.8.

Not OK

Is HEARTBEAT 

LED on I/O 

interface module 

(see para. 4.8.25) 

blinking?

OK

Replace I/O 

interface module 

(see para. 4.8.25).

Not OK

OK

Replace damaged or 

defective ribbon cable.

 Not OK

Test Backplane. 

 Ref Para. 

4.8.24.

OK

Replace Backplane 

Ref Para. 4.8.24.

Notify next higher 

level of 

maintenance.

Not OK

OK

OK
ARMY TM 9-6115-671-14 

AIR FORCE TO 35C2-3-446-32 

MARINE CORPS TM 09249A/09246A-14 

4-43 

TABLE 4-4. UNIT TROUBLESHOOTING (CONTINUED) 

Replace automatic voltage 

regulator (see para. 4.8.23). 

 Is fault cleared?

Not OK

Not OK OK

FAULT INDICATOR DISPLAYS WARNING - 

OVERVOLTAGE OR SHUTDOWN - OVERVOLTAGE

FAULT INDICATOR displays WARNING - 

OVERVOLTAGE or SHUTDOWN - OVERVOLTAGE.

Check for defective or loose 

connections on voltage adjust 

switch. Refer to Wiring 

Diagram, FO-3.

Repair or replace defective 

or loose connections. Refer to 

Wiring Diagram, FO-3.

Test VOLTAGE ADJUST 

switch (see para. 4.8.10).

Replace VOLTAGE 

ADJUST switch 

(see para. 4.8.10).

Troubleshoot voltage regulator 

circuit for breaks or loose 

connections. Refer to 

 Schematic, FO-1. 

OK

Repair or replace defective or 

loose connections. Refer to 

Wiring Diagram, FO-3. 

Is fault cleared?

OK Not OK

Notify next higher level of 

maintenance.

No No
ARMY TM 9-6115-671-14 

AIR FORCE TO 35C2-3-446-32 

MARINE CORPS TM 09249A/09246A-14 

4-44 

TABLE 4-4. UNIT TROUBLESHOOTING (CONTINUED) 

 OK 

 Not OK 

 Not OK 

 Not OK 

 OK Not OK 

 Not OK 

 OK 

 OK 

 OK 

 Not OK 

 Not OK 

 Not OK 

 Not OK 

 OK 

 OK 

OK 

 Not OK 

Not OK 

CIRCUIT INTERRUPTER WILL NOT CLOSE

Circuit interrupter will not close.

Check Fault Indicator on CIM. 

Is a fault indicated?

Go to troubleshooting section 

corresponding to fault displayed. 

 See Symptom Index Page 4-10.

Yes 

Check for 24 VDC at term.1 

of Circuit Interrupter 

switch, (10, fig 2-1).

No 

Check for 24 VDC at 

term.2 of Battle Short 

switch, (6, Fig 2-1).

Check wire 181D16 for 

continuity, loose 

connections or damage.

Hold circuit Interrupter 

switch (10, Fig 2-1) in the 

closed position and check 

for 24VDC at term.2.

Check for 24VDC at 

TB4-1.

Repair 

wire.

 OK 

Check wire 181C16 

for continuity, loose 

connections or 

damage.

OK 

Repair 

wire.

OK 

Refer to 

Schematic, 

FO-1.

Replace Circuit 

Interrupter 

switch (10, Fig 

2-1). See Para. 

4.8.7

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).

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).

Replace I/O interface 

module, see Para. 4.8.25.

Check wire number 199A16 

for continuity, loose 

connections or damage.

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.

Check wire number 

185A16 for continuity, 

loose connections or 

damage.

See next page. Repair wire.
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TABLE 4-4. UNIT TROUBLESHOOTING (CONTINUED) 

Not OK 

Not OK 

 OK 

 OK 

Not OK 

 OK 

 OK 

OK 

 OK 

 OK 

 Not OK 

 Not OK 

 OK 

Not OK 

Not OK 

Not OK 

 OK 

Yes 

CIRCUIT INTERRUPTER WILL NOT CLOSE Continued

Is the K1 Aux Relay K17 

actuating? 

Check for 24 VDC 

at term. 7 of K17. 

Hold Circuit Interrupter 

switch (10, Fig 2-1) in the 

closed position and check 

for 24VDC at K17-4. 

Check for 24 

VDC at term.7 

of K19. 

Not OK 

Replace K17 Aux relay. 

see Para 4.8.34. 

Repair wire. Hold Circuit 

Interrupter switch 

(10, Fig 2-1) in the 

closed position and 

check for 24VDC at 

J24 pin 9 of the 

backplane module. 

Check for 24VDC at 

Relay K1terminal X. 

Check wire number 

224A16 for contiuity, loose 

connections or damage. 

Repair wire. 

Test Diode CR-3 

(see Para 4.8.29). 

Replace Diode 

CR-3 (see Para 

4.8.29). 

No 

Replace K1Aux 

relay K17 (see 

para 4.8.34). 

Test K1Aux relay 

K17 Coil(see 

para 4.8.25). 

Not OK 

Not OK 

Check wire 

231B16 from 

K19-7 to TB4-2 

for continuity. 

Not OK 

Check wire 

231C16 from 

K19-7 to K17-7 

for continuity. 

Check for 

continuity between 

K1-Y and ground. 

Check wire 100K16 

between K1-Y and 

TB7-6 for 

continuity. 

Repair wire. 

Release Circuit Interrupter 

switch and Check for 

continuity between Backplane 

connector P6-N and K1-X. 

Check wire 

number 185L16 

for contiuity, 

loose connections 

or damage. 

Check for continuity between 

Backplane connector J6-N 

and J24-9. 

Replace Backplane 

module see Para. 4.8.24. 

Not OK 

Continued from previous page. 

OK 

Repair 

wire. 

 OK 

Notify next higher level 

of maintenance. 

Not OK 

 OK 

Not OK 
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TABLE 4-4. UNIT TROUBLESHOOTING (CONTINUED) 

Not OK

 Not OK 

 Not OK 

OK

Not OK 

No Yes 

CIRCUIT INTERRUPTER WILL NOT OPEN

Circuit interrupter will 

not open.

Check Fault Indicator on 

CIM. Is a fault 

indicated?

Hold Circuit Interrupter 

switch, (10, Fig 2-1)in the 

open position and Check 

for 24 VDC at term. 3.

Go to troubleshooting section 

corresponding to fault displayed. 

See symptom index Page 4-10.

Check for 24 

VDC at term. 2 

of Battle Short 

switch, (6, Fig 

2-1).

Check wire 181D16 for 

continuity, loose 

connections or damage.

OK

Check for Repair wire.

24VDC at 

TB4-1.

Check wire 181C16 for 

continuity, loose 

connections or damage.

Repair wire.

Not OK

Remove top cover of control 

box. See Para 4.7.2. 

Hold Circuit Interrupter switch 

(10, Fig 2-1) in the open 

position and check for 24VDC 

on J25 pin 11of I/O interface 

module (Ref Fig 2-3).

Check wire number 130A16 

for contiuity, loose connections 

or damage. Repair wire.

Hold Circuit Interrupter 

switch (10, Fig 2-1) in the 

open position and check 

for 24VDC on J25 pin 6 of 

I/O interface module (Ref 

Fig 2-3).

Replace I/O 

interface module, 

see Para 4.8.25.

OK

 Test K17,(K1 aux relay) 

(28, Fig 4-16) see Para 

4.8.34.

Replace K17,(K1 

aux relay) (28, Fig 

4-16) see Para 

4.8.34.

Test wiring in 

K17,(K1 aux 

relay) (28, Fig 

4-16) for 

contiuity, loose 

connections or 

damage. see 

schematic FO1.

Replace or 

repair wiring 

as needed.

OK

OK

Not OK

Not OK

Not OK Not OK OK

Refer to Schematic, 

FO-1.

Not OK 

OK

OK

Continued on 

next page.

OK
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TABLE 4-4. UNIT TROUBLESHOOTING (CONTINUED) 

OK 

 Not OK 

CIRCUIT INTERRUPTER WILL NOT OPEN Continued

Repair wire 

Replace wire 185L16 

Not OK 

Check wire between 

Backplane connector P6-N 

and K1-X for continuity, 

loose connections or 

damage. Not OK Test Circuit 

Interrupter K1 see 

Para 4.12.6 

Replace Circuit 

Interrupter K1 

see Para 4.12.6 

OK 

Replace 

Backplane 

Module see Para 

4.8.24 

Test wiring in K1 

aux relay Aux 

Contacts for 

continuity, loose 

connections or 

damage. see 

schematic FO1 

Test Circuit Interrupter 

Relay K1 Terminal X for 

24VDC. 

OK 

 Not OK 

Notify next higher 

level of maintenance. 

Notify next higher level 

of maintenance. 

OK 

Continued from 

previous page. 

Not OK 
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TABLE 4-4. UNIT TROUBLESHOOTING (CONTINUED) 

 Not OK 

 OK 

 OK 

CIM DISPLAY SCREEN DOES NOT RESPOND TO KEYPAD INPUT

CIM dispaly screen does not 

respond to keypad input.

Check keyboard power supply (PS-1) 

for 24VDC. Refer to para. 4.6.5.

Check PS-1 for 5VDC 

Check for 24VDC at TB4. Refer output.

to Schematic, FO-1.

 Not OK 

Check wiring between TB4 and 

PS-1. Refer to Schematic, FO-1.

OK 

Repair wiring.

Not OK 

Check for approx 

24VDC at J24-6.

Not OK 

Trace wiring back to Dead 

Crank switch. Refer to 

Schematic, FO-1.

Not OK 

Replace keypad.

Check wiring to 

J24-6 at TB4.

Replace PS-1.

Not OK 

 OK 
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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. 

4.6.2 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) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door and right side engine compartment access doors . 
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(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 4-

4. 

(4) Close BATTERY ACCESS and engine compartment access doors. 

b. Removal. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door and right side engine compartment access doors . 

(3) Disconnect negative battery cable from battery (1, Figure 4-3). 

(4) Tag and remove applicable cable assembly as shown in Figure 4-3 or 4-4. 

c. Service. 

(1) Remove terminal covers (2, Figure 4-3) from battery posts as required. 

(2) Clean terminals (3, Figure 4-3 or 4-4), battery posts, and terminal lugs (4, 5, 6, and 7, Figure 

4-3). 

(3) Install terminal covers (2), if removed. 

d. Repair. 

NOTE 

If cable cannot be repaired, refer to Appendix G to fabricate a replacement. 

(1) Remove nuts (8, Figure 4-3) and terminal lugs (4, 5, 6, or 7) from terminals (3) as required. 

(2) Cut heat shrink tubing, and remove broken or damaged terminal (3, Figure 4-3 or 4-4) from cable 

assembly. 

(3) Slide new heat shrink tubing over cable end. 

(4) Install terminal (3) on cable end as described in Appendix G. 

(5) Position heat shrink tubing over terminal (3) and cable end, and shrink tubing with heat gun. 

(6) Install terminal lugs (4, 5, 6, or 7, Figure 4-3) and nuts (8). 

e. Installation. 

(1) Install applicable cable assembly as shown in Figure 4-3. 

(2) Connect negative battery cable to battery (1, Figure 4-3). 

(3) Close BATTERY ACCESS and engine compartment access doors. 
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FIGURE 4-3. BATTERIES AND CABLES 
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FIGURE 4-4. NATO SLAVE RECEPTACLE AND CABLES 
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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. 

b. 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) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2). 

(3) Disconnect negative battery cable terminal lug (4, figure 4-3) from battery (9). 

(4) Disconnect interconnect battery cable terminal lug (6) first, then lug (5) from batteries (1 and 9). 

(5) Disconnect positive cable battery lug (7) from battery (1). 

(6) 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) Using care, remove batteries (1 and 9) from battery tray (14). 

(8) Place Battery and Adapter (15) on a flat surface. 

(9) Using flat tipped screwdriver, push down on adapter (15) locking tab, and remove battery by sliding 

horizontally from the adapter. 
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c. Inspection. 

(1) Remove batteries, step b. 

(2) Inspect batteries (1 and 9, Figure 4-3) for cracked cases; broken, burned, or corroded posts; missing 

parts; and other damage. 

(3) Install batteries, step e. 

d. Service. 

(1) Remove terminal covers (2, Figure 4-3) from batteries (1 and 9). 

(2) Clean terminal lugs (4, 5, 6, and 7) and battery posts. 

(3) 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. 

(2) 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. 

(3) Apply general purpose grease (Item 10, Appendix E) to battery posts and terminal lugs (4, 5, 6, and 

7). 

(4) Secure batteries (1and 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) Connect positive battery cable terminal lug (7) to battery (9). 

(6) Connect interconnect battery cable terminal lug (5) first, then leg (6) to batteries (1 and 9). 

(7) Connect negative battery cable terminal lug (4) to battery (9). 

(8) Close BATTERY ACCESS door. 

4.6.4 NATO SLAVE RECEPTACLE. 

a. Inspection. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2). 
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(3) Inspect NATO SLAVE RECEPTACLE (7, Figure 4-4) for loose connections, corrosion, missing 

hardware, and other damage. 

(4) Close BATTERY ACCESS door. 

b. Removal. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable . 

(3) 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). 

(4) Remove cover (4) from NATO SLAVE RECEPTACLE (7). 

(5) Remove nuts (5), bolts (6), NATO SLAVE RECEPTACLE (7) and gasket (17) from generator set. 

(6) Remove nut (8), bolt (9), and cover (4) from generator set. 

c. Installation. 

(1) Install cap (4, Figure 4-4), with bolt (9), and nut (8) on NATO SLAVE RECEPTACLE (7). 

(2) Position NATO SLAVE RECEPTACLE (7) and gasket (17) in generator set with negative terminal 

up. 

(3) Install NATO SLAVE RECEPTACLE (7) and gasket (17), with bolts (6), and nuts (5) on generator 

set. 

(4) Install cap (4) on NATO SLAVE RECEPTACLE (7). 

(5) Install terminals (3), wire (18), lockwashers (2), and bolts (1) on NATO SLAVE RECEPTACLE 

(7). 

(6) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

4.6.5 Keypad Power Supply PS1. 

a. Inspection.

(1) Shut down generator set, paragraph 2.11.2. 

(2) Remove CIM (see paragraph 4.8.16) from the DCS control box assembly. 

(3) Inspect keypad power supply (44, Figure 4-18) mounting surfaces and terminal screws for damage. 

Ensure screws are secure. 

(4) Check for evidence of burned or damaged components on surface of keypad power supply. 

(5) Install CIM (see paragraph 4.8.16). 
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b. Testing.

(1) Shut down generator set, paragraph 2.11.2. 

(2) Remove CIM (see paragraph 4.8.16) from the DCS control box assembly. 

(3) Connect negative battery cable to battery and close battery access door. 

(4) Switch master control switch (12, Figure 2-8) to ON. 

(5) 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. 

(6) If indications are other than between 12VDC and 24 VDC, replace master control switch, paragraph 

4.8.9. 

(7) Place positive lead of multimeter on terminal 3 and negative lead on terminal 4. Multimeter should 

read 5VDC. 

(8) If indications are less than 5VDC, replace keypad power supply (44, Figure 4-18). 

(9) Close battery access door and disconnect negative battery cable. 

(10) Install CIM (refer to paragraph 4.8.16). 

c. Replacement.

(1) Shut down generator set, paragraph 2.11.2. 

(2) Remove CIM (see paragraph 4.8.16) from the DCS control box assembly. 

(3) Tag and disconnect keypad power supply (44, Figure 4-18) electrical leads. 

(4) Remove mounting screws (46), standoffs (45), and key pad power supply (44) from air baffle (30). 

(5) Align new key pad power supply (44) to standoffs (45) and install screws (46). 

(6) Connect electrical leads to key pad power supply (44) and remove tags. 

(7) Install the CIM (see paragraph 4.8.16). 

(8) Connect negative battery lead and close battery compartment door. 
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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. 

4.7.1 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) Shut down generator set, paragraph 2.11.2. 

(2) Open left side engine compartment access doors (Figure 1-3). 

(3) Remove nuts (1, Figure 4-5), lockwashers (2), washers (3), bolts (4), and hinges (5), with door (6) 

attached, from generator set housing. 

(4) Remove nuts (7), lockwashers (8), washers (9), bolts (10), and hinges (5) from door (6). 

(5) Remove locknuts (11), bolts (12), and document box (13) from door (6). 

(6) Drill out rivets (14), and remove fuel system diagram data plate (15) from document box (13). 

(7) Remove locknuts (16), bolts (17), and bracket (18) with holding rod (19) from door (6). 

(8) Remove locknuts (20), bolts (21), and bracket (22) from door (6). 

NOTE 

Note position of latches before removal for reference during installation. 

(9) Remove locknuts (23), screws (24), and latches (25) from door (6). 
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. 

FIGURE 4-5. GENERATOR SET ACCESS DOORS
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b. Inspection. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Inspect access doors, hinges, latches, baffles, and storage boxes for loose and missing hardware, 

cracks, dents, and loose paint, or corrosion. 

(3) Inspect data plates for readability and loose or missing rivets. 

 

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) Remove light corrosion with fine grit abrasive paper (Item 16, Appendix E). 

(3) 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) Apply industrial sealant (Item 18, Appendix E) to top two corners of access door. 

(5) Replace damaged or unreadable data plates. 

(6) Replace loose or missing rivets. 

d. Installation. 

(1) Position latches (25, Figure 4-5) on door (6) as noted during removal. Secure latches to door with 

screws (24), and locknuts (23). 

(2) Install bracket (22), bolts (21), and locknuts (20) on door (6). 

(3) Install bracket (18), holding rod (19), bolts (17), and locknuts (16) on door (6). 

(4) Install fuel system diagram data plate (15) on document box (13) with rivets (14). 

(5) Install document box (13), bolts (12), and locknuts (11) on door (6). 

(6) Install hinges (5), bolts (10), washers (9), lockwashers (8), and nuts (7) on door (6). 
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(7) Position door (6) on generator set housing, and install hinges (5), bolts (4), washers (3), lockwashers 

(2), and nuts (1). 

(8) Close engine compartment access doors. 

4.7.2 DCS Control Box Top Panel. 

a. Removal. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. Refer to 

paragraphs 4.6.2 and 4.6.3. 

(3) Remove DCS control box door (Figure 1-3). Refer to paragraph 4.7.1. 

(4) Release DCS control panel (4, Figure 1-30) by turning two fasteners, and lower panel slowly. 

(5) 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) Carefully separate top panel (4) from generator. Remove control box top panel. 

(8) Remove nuts (7), lockwashers (8), washers (9), and bolts (10) from DCS control box assembly. 

(9) Remove locknuts (12), bolts (13), door ring retainer (14), and door ring (15) from top panel (4). 

(10) Remove old sealant from door ring retainer (14). 
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FIGURE 4-6. DCS CONTROL BOX TOP PANEL 
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b. Inspection. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) 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) Repair all dents and cracks, and remove loose paint. 

(2) Remove light corrosion with fine grit abrasive paper (Item 16, Appendix E). 

(3) 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 4-

6). Position door ring (15) and door ring retainer on top panel (4), and install bolts (13) and 

locknuts (12). 

(2) Install stiffener (11), bolts (10), washers (9), lockwashers (8), and nuts (7) on DCS control box 

assembly. 

(3) Install top panel (4) on control box with bolts (6) and locknuts (5). 

(4) Install washers (3), lockwashers (2), and bolts (1) on top panel (4). 

(6) Raise and secure DCS control panel with two fasteners. 

(7) Install DCS control box door. Refer to paragraph 4.7.1. 

(8) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

4.7.3 Top Housing Section. 

a. Removal. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable . 

(3) Remove DCS control box top, paragraph 4.7.2. 

_________ 
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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 (12). 

(5) Remove bolts (6 and 9), lockwashers (7 and 10), washers (8 and 11), and top housing panel (12) 

from generator set. 

(6) Disconnect radiator fill hose and overflow hose from radiator fill panel (13), and remove panel from 

generator set. 

(7) Remove bolts (14), lockwashers (15), washers (16), and roof stiffener assembly (17) from side 

panels (35 and 36). 

(8) Remove muffler. Refer to paragraph 4.9.1. 

(9) Remove locknuts (18), bolts (19), and air duct channels (20 and 21) from floor panel (37). 

(10) Remove locknuts (22 and 24), bolts (23 and 25), and duct panel (26) from floor panel (37) and side 

panels (35 and 36). 

(11) Remove locknuts (27) and bolts (28) from side panels (35 and 36). 

(12) Remove bolts (29), lockwashers (30), and washers (31) from side panels (35 and 36). 

(13) Remove bolts (32), lockwashers (33), and washers (34) from front panel (40). 

(14) Remove side panels (35 and 36) with floor panel (37) from generator set. 

(15) Remove locknuts (38), bolts (39), and front panel (40) from floor panel (37). 

(16) Remove locknuts (41), bolts (42), and support (43) from front panel (40). 

(17) Remove locknuts (44), bolts (45), and side panels (35 and 36) from floor panel (37). 

(18) Remove locknut (46), bolt (47), and bracket (48) from angle (51). 

(19) Open output box access door (Figure 1-2), and remove locknuts (49), bolts (50), and angle (51) 

from generator set. 

(20) Remove clip halves (52) and insulation (53 through 63) from top panel (12). 

(21) Remove clip halves (64) and insulation (65 and 66) from side panels (35 and 36). 
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FIGURE 4-7. TOP HOUSING SECTION (SHEET 1 OF 3) 
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FIGURE 4-7. TOP HOUSING SECTION (SHEET 2 OF 3) 
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FIGURE 4-7. TOP HOUSING SECTION (SHEET 3 OF 3) 

b. Inspection. 

(1) Remove top housing section, step a above. 

(2) Inspect all top housing section panels for dents, cracks, loose paint, and corrosion. 

(3) Inspect cage nuts (67 through 75, Figure 4-7) for cracking or stripped threads. 

(4) Inspect insulation (53 through 63, 65, and 66) for damage and missing clip halves (52, 64, 76, and 

78) and push-on nuts (77 and 79). 

(5) Inspect seal (80) and door seals (81 and 82) for tears, looseness, and deterioration. 

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. 
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(2) Remove light corrosion with fine grit abrasive paper (Item 16, Appendix E). 

(3) Repaint surfaces in accordance with TM 43-0139. 

(4) Replace cage nuts (67 through 75, Figure 4-7) that are stripped or cracked. 

(5) Replace damaged insulation (53 through 63, 65, and 66). 

(6) Replace missing or damaged clip halves (52, 64, 76, and 78) and push-on nuts (77 and 79). 

(7) Replace damaged seal (80) or door seals (81 and 82). Refer to Appendix E. 

d. Installation. 

(1) Install insulation (65 and 66, Figure 4-7) on side panels (35 and 36) with clip halves (64). 

(2) Install insulation (53 through 63) on top panel (12) with clip halves (52). 

(3) Install angle (51) on generator set with bolts (50) and locknuts (49). Close output box access door. 

(4) Install bracket (48), bolt (47), and locknut (46) on angle (51). 

(5) Install side panels (35 and 36), bolts (45), and locknuts (44) on floor panel (37). 

(6) Install support (43), bolts (42), and locknuts (41) on front panel (40). 

(7) Install front panel (40), bolts (39), and locknuts (38) on floor panel (37). 

(8) Position side panels (35 and 36) with floor panel (37) on generator set. 

(9) Secure front panel (40) to generator set with washers (34), lockwashers (33), and bolts (32). 

(10) Secure side panels (35 and 36) to generator set with washers (31), lockwashers (30), and bolts (29). 

(11) Secure side panels (35 and 36) to generator set with bolts (28) and locknuts (27). 

(12) Install duct panel (26), bolts (23 and 25), and locknuts (22 and 24) on floor panel (37) and side 

panels (35 and 36). 

(13) Install air duct channels (20 and 21), bolts (19), and locknuts (18) on floor panel (37). 

(14) Install muffler. Refer to paragraph 4.9.1. 

(15) Install roof stiffener assembly (17), washers (16), lockwashers (15), and bolts (14) on side panels 

(35 and 36). 

(16) Position radiator fill panel (13) on generator set, and connect radiator fill hose and overflow hose to 

panel. 

(17) Install top housing panel (12), washers (8 and 11), lockwashers (7 and 10), and bolts (6 and 9) on 

generator set. 

(18) Install exhaust cover (5), mount (4), washers (3), lockwashers (2), and bolts (1) on top housing 

panel (12). 
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(19) Install DCS control box top panel, paragraph 4.7.2. 

(20) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

4.7.4 Front Housing Section. 

a. Removal. 

(1) Shut down generator set, paragraph 2.11.2. 

(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. 

(3) Remove engine compartment access doors. Refer to paragraph 4.7.1. 

(4) Remove top housing section, paragraph 4.7.3. 

(5) Remove bolts (1, Figure 4-8) and ground rod sections (2) from brackets (56). 

(6) Remove nuts (3), lockwashers (4), washers (5), and bolts (6) from door sills (22 and 23) and front 

housing (14). 

(7) Remove nuts (7), lockwashers (8), washers (9), and bolts (10) from front housing (14) and skid 

base. 

(8) Remove bolts (11), lockwashers (12), washers, (13) and front housing (14) from skid base. 

(9) Remove nuts (15), lockwashers (16), washers (17), and bolts (18), from doors sills (22 and 23) and 

generator set. 

(10) Remove bolts (19), lockwashers (20), washers (21), and door sills (22 and 23) from skid base. 

(11) Remove clip halves (24) and insulation (25) from front housing (14). 

(12) Remove locknuts (26) and bolts (27) from air deflector (31) and front housing (14). 

(13) Remove bolts (28), lockwashers (29), washers (30), and air deflector (31) from front housing (14). 

(14) Remove bolts (32), lockwashers (33), washers (34), and radiator panels (35 and 36) from front 

housing (14). 

(15) Remove locknuts (37), bolts (38), and supports (39 and 40) from radiator panels (35 and 36). 

(16) Remove bolts (41), lockwashers (42), washers (43), and panel (44) from front housing (14). 

(17) Remove locknuts (45), bolts (46), and support (47) from panel (44). 
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FIGURE 4-8. FRONT HOUSING SECTION (SHEET 1 OF 2) 
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FIGURE 4-8. FRONT HOUSING SECTION (SHEET 2 OF 2) 

(18) Remove locknuts (48), bolts (49), and support channel (50) from front housing (14). 

(19) Remove locknuts (51), bolts (52), and SLAVE RECEPTACLE box (53) from front housing (14). 

(20) Remove locknuts (54), bolts (55), and brackets (56) from door sill (22) and front housing (14). 

b. Inspection. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Inspect all front housing section panels for dents, cracks, loose paint, corrosion, and other damage. 

(3) Inspect cage nuts (57 through 62, Figure 4-8) for cracking or stripped threads. 

(4) Inspect insulation (25) for damage and missing clip halves (24 and 63) and push-on nuts (64). 

(5) Inspect seals (65 through 67) for tears, looseness, and deterioration. 

(6) Inspect identification plates (68, 70, and 72) for readability and loose or missing rivets (69, 71, and 

73). 
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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) Repair all dents and cracks, and remove loose paint. 

(2) Remove light corrosion with fine grit abrasive paper (Item 16, Appendix E). 

(3) Repaint surfaces in accordance with TM 43-0139. 

(4) Replace stripped or cracked cage nuts (57 through 62, Figure 4-8). 

(5) Replace damaged insulation (25) and missing or damaged clip halves (24 and 63) or push-on nuts 

(64). 

(6) Replace damaged seals (65 through 67). Refer to Table E. 

(7) Replace damaged or unreadable identification plates (68, 70, and 72). 

(8) Replace loose or missing rivets (69, 71, and 73). 

d. Installation. 

(1) Install brackets (56, Figure 4-8), bolts (55), and locknuts (54) on front housing (14) and door sill 

(22). 

(2) Install SLAVE RECEPTACLE box (53), bolts (52), and locknuts (51) on front housing (14). 

(3) Install support channel (50), bolts (49), and locknuts (48) on front housing (14). 

(4) Install support (47), bolts (46), and locknuts (45) on panel (44). 

(5) Install panel (44), washers (43), lockwashers (42), and bolts (41) on front housing (14). 

(6) Install supports (39 and 40), bolts (38), and locknuts (37) on radiator panels (35 and 36). 

(7) Install radiator panels (35 and 36), washers (34), lockwashers (33), and bolts (32) on front housing 

(14). 

(8) Install air deflector (31), washers (30), lockwashers (29), and bolts (28) on front housing (14). 

(9) Secure air deflector (31) to front housing (14) with bolts (27) and locknuts (26). 

(10) Install insulation (25) on front housing (14) with panel clips (24), clip halves (63), and push-on nuts 

(64). 

(11) Install door sills (22 and 23), washers (21), lockwashers (20), and bolts (19) on skid base. 

(12) Secure door sills (22 and 23) to generator set with bolts (18), washers (17), lockwashers (16), and 

nuts (15). 
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(13) Install front housing (14), washers (13), lockwashers (12), and bolts (11) on skid base. 

(14) Secure front housing (14) to skid base with bolts (10), washers (9), lockwashers (8), and nuts (7). 

(15) Install bolts (6), washers (5), lockwashers (4), and nuts (3) on front housing (14) and door sills (22 

and 23). 

(16) Position ground rod sections (2) in brackets (56), and install bolts (1). 

(17) Install top housing section, paragraph 4.7.3. 

(18) Install engine compartment access doors. Refer to paragraph 4.7.1. 

(19) Install BATTERY ACCESS door. Refer to paragraph 4.7.1. 

(20) Install NATO SLAVE RECEPTACLE, paragraph 4.6.4, and batteries, paragraph 4.6.3. 

4.7.5 Rear Housing Section. 

a. Removal. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Remove DCS control box assembly, paragraph 4.8.1. 

(3) Remove air cleaner assembly, paragraph 4.9.2. 

(4) Remove 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. 

(5) Remove fuel tank filler neck, paragraph 4.11.3. 

(6) Remove auxiliary fuel pump, paragraph 4.11.2. 

(7) Remove ether solenoid valve, paragraph 4.11.8. 

(8) Remove top housing panel. Refer to paragraph 4.7.3. 

(9) Remove output box. Refer to paragraph 5.8. 

(10) Remove nuts (1, Figure 4-9), lockwashers (2), washers (3), and bolts (4) from rear panel (8) and 

skid base. 

(11) Remove bolts (5), lockwashers (6), washers (7), and rear panel (8) from corner post (40) and left 

side rear panel (19). 

(12) Remove locknuts (9), bolts (10), and load terminal access box (11) from rear panel (8). 

(13) Remove nuts (12), lockwashers (13), washers (14), and bolts (15), from left side rear panel (19) and 

engine compartment door sill (61). 

(14) Remove bolts (16), lockwashers (17), washers (18), and left side rear panel (19) from skid base. 
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(15) Remove locknuts (20), bolts (21), and air baffle (22) from left side rear panel (19). 

(16) Remove clip halves (23) and insulation (24) from air baffle (22). 

(17) Remove locknuts (25), bolts (26), and filler neck panel (27) from left side rear panel (19). 

(18) Remove locknuts (30), bolts (31), and output box sill (32) from corner post (40) and panel (50). 

(19) Remove locknuts (33) and bolts (34) from door sill (39), corner post (40), and panel (50). 

(20) Remove nuts (35), lockwashers (36), washers (37), bolts (38), door sill (39), and corner post (40) 

from skid base. Scrape sealant from mating surfaces of corner post and output box top. 

(21) Remove nuts (43), lockwashers (44), washers (45), and bolts (46) from panel (50). 

(22) Remove bolts (47), lockwashers (48), washers (49), and panel (50) from skid base. Scrape sealant 

from mating surfaces of panel and output box top. 

b. Inspection. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Inspect rear housing section panels for dents, cracks, loose paint, corrosion, and other damage. 

(3) Inspect cage nuts (51 through 54, Figure 4-9) for cracking or stripped threads. 

(4) Inspect insulation (24), clip halves (23,55), and push-on nuts (56) for damage or missing pieces. 

(5) Inspect output box EMI seals (57) for tears, looseness, and deterioration. 

(6) Inspect door seals (58 through 61) for tears, looseness, and deterioration. 

(7) Inspect data plates (63 and 65) for readability and loose or missing rivets (62 and 64). 
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FIGURE 4-9. REAR HOUSING SECTION (SHEET 1 OF 2) 
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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. 

(2) Remove light corrosion with fine grit abrasive paper (Item 16, Appendix E). 

(3) Repaint surfaces in accordance with TM 43-0139. 

(4) Replace stripped or cracked cage nuts (51 through 54, Figure 4-9). 

(5) Replace damaged insulation (24) and missing or damaged clip halves (23 and 55) or push-on nuts 

(56). 

(6) Replace damaged door seals (58 through 61) attach with adhesive (1, Appendix E). 

(7) Using adhesive (1, Appendix E), replace loose or damaged EMI seals (57). Ensure closed side of 

seal faces outward. 
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(8) Replace damaged or unreadable data plates (63 and 65) and loose or missing rivets (62 and 64). 

d. Installation. 

(1) Install panel (50, Figure 4-9), washers (49), lockwashers (48), and bolts (47) on skid base. 

(2) Secure panel (50) with bolts (46), washers (45), lockwashers (44), and nuts (43). 

(3) Install corner post (40), door sill (39), bolts (38), washers (37), lockwashers (36), and nuts (35) on 

skid base. 

(4) Apply industrial sealant (18, Appendix E) to edges and cracks at mating surfaces of corner post 

(40), panel (50), and control box top. 

(5) Secure door sill (39) to corner post (40) and panel (50) with bolts (34) and locknuts (33). 

(6) Install output box sill (32), bolts (31), and locknuts (30) on corner post (40) and panel (50). 

(7) Install filler neck panel (27), bolts (26), and locknuts (25) on left side rear panel (19). 

(8) Install insulation (24) on air baffle (22) with clip halves (23). 

(9) Install air baffle (22), bolts (21), and locknuts (20) on left side rear panel (19). 

(10) Secure left side rear panel (19) to skid base with bolts (16), lockwashers (17), and washers (18). 

(11) Secure left side rear panel (19) and engine compartment door sill (61) with bolts (15), washers (14), 

lockwashers (13), and nuts (12). 

(12) Install load terminal access box (11), bolts (10), and locknuts (9) on rear panel (8). 

(13) Install rear panel (8), washers (7), lockwashers (6), and bolts (5) on corner post (40) and left side 

rear panel (19). 

(14) Secure rear panel (8) to skid base with bolts (4), washers (3), lockwashers (2), and nuts (1). 

(15) Install output box. Refer to paragraph 5.8. 

(16) Install top housing panel. Refer to paragraph 4.7.3. 

(17) Install ether solenoid valve, paragraph 4.11.8. 

(18) Install auxiliary fuel pump, paragraph 4.11.2. 

(19) Install fuel tank filler neck, paragraph 4.11.3. 

(20) 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. 

(21) Install air cleaner assembly, paragraph 4.9.2. 

(23) Install DCS control box assembly, paragraph 4.8.1. 
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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. 

b. Replacement. 

(1) Drill out rivets, and remove data plate from housing. Refer to paragraph 2.16. 

(2) Install data plate on housing with rivets. 

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. 

4.8.1 DCS Control Box 

a. Inspection. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Inspect DCS control box for cracks, breaks, corrosion, loose paint, and missing parts. 

b. Removal. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable . 

(3) Remove DCS control box top panel, paragraph 4.7.2. 

(4) 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). 

(5) Open output box access door (Figure 1-2). 

(6) Remove locknuts (4, Figure 4-10) and bolts (5) securing DCS control box assembly (12) to 

generator set. 
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FIGURE 4-10. DCS CONTROL BOX 
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. 

(7) Remove bolts (6 and 9), lockwashers (7 and 10), washers (8 and 11). 

(8) 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. 

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). 

(2) Secure DCS control box assembly (12) to generator set with bolts (6 and 9), lockwashers (7 and 10), 

and washers (8 and 11). 

(3) Install bolts (5) and locknuts (4). 

(4) Close output box access door (Figure 1-2). 

(5) Secure DCS control box assembly (12, Figure 4-10) to top of output box assembly with washers (3), 

lockwashers (2), and bolts (1). 

(6) Connect two wiring harness connectors at rear of DCS control box assembly (12). 

(7) Install DCS control box top panel, paragraph 4.7.2. 

(8) Connect negative battery cable to battery, and close BATTERY ACCESS door (Figure 1-2). 

4.8.2 Panel Lights DS1 through DS3. 

a. Inspection. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Remove directional cap (1, Figure 4-11) from panel light housing (5). 

(3) Remove light bulb (2) from panel light housing (5). 

(4) Set multimeter to ohms, and check light bulb for continuity across base and threads. Multimeter 

should indicate continuity. 

(5) If multimeter does not indicate continuity, replace light bulb (2). 

(6) Inspect directional caps (1) for cracks, corrosions, stripped threads, and other damage. 

(7) Release DCS control panel by turning two fasteners, and lower panel slowly. 
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(8) Inspect panel light housings (5) on DCS control panel (6) for cracks, corrosion, stripped threads, 

and other damage. 

(9) Install light bulb (2) in panel light housing (5). 

(10) Install directional cap (1) on panel light housing (5). 

(11) Raise and secure DCS control panel. 

(12) Remove DCS control box top panel, paragraph 4.7.2. 

(13) Inspect panel light housing (5) on DCS control panel frame (7) for cracks, corrosion, stripped 

threads, and other damage. 

(14) Install DCS control box top panel, paragraph 4.7.2. 

b. Repair. 

(1) Remove directional cap (1, Figure 4-11) from panel light housing (5). 

(2) Remove light bulb (2) from panel light housing (5). 

(3) Install light bulb (2) in panel light housing (5). 

(4) Install directional cap (1) in panel light housing (5). 

c. Replacement. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable . 

(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. 

(4) If defective panel light is on DCS control panel frame (7), remove DCS control box top panel, 

paragraph 4.7.2. 

(5) Tag and disconnect panel light housing (5) electrical leads. 

(6) Remove jamnut (3), washer (4), and panel light housing (5) from DCS control panel (6) or DCS 

control panel frame (7). 

(7) Install panel light housing (5), washer (4), and jamnut (3) on DCS control panel frame (7) or DCS 

control panel (6). 

(8) Connect panel light housing (5) electrical leads. Remove tags. 

(9) If removed, install DCS control box top panel, paragraph 4.7.2. 

(10) If lowered, raise and secure DCS control panel. 

(11) Connect negative battery cable to battery, and close BATTERY ACCESS doors. 
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FIGURE 4-11. DCS CONTROL BOX PANEL LIGHTS DS1 THROUGH DS3 

AND NETWORK FAILURE LIGHT DS5
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4.8.3 NETWORK FAILURE Light DS5. 

a. Inspection. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Release DCS control panel by turning two fasteners, and lower panel slowly. 

(3) Inspect light housing (11, Figure 4-11) for cracks, corrosion, evidence of shorting, and other 

damage. 

(4) Raise and secure DCS control panel. 

b. Repair. 

(1) Unscrew to remove press-to-test light (8, Figure 4-11) from light housing (11). 

(2) Screw press-to-test light (8) into light housing (11) to install. 

c. Replacement. 

(1) Shut down generator set, paragraph 2.11.2. 

 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable . 

(3) Release DCS control panel by turning two fasteners, and lower panel slowly. 

(4) Tag and disconnect light housing (11, Figure 4-11) electrical leads. 

(5) Remove press-to-test light (8), jamnut (9), washer (10), and light housing (11) from DCS control 

panel (6). 

(6) Install light housing (11), washer (10), jamnut (9), and press-to-test light (8) on DCS control panel 

(6). 

(7) Tighten jamnuts (9 and 12) to secure light housing (11) to DCS control panel (6). 

(8) Connect light housing (11) electrical leads. Remove tags. 

(9) Raise and secure DCS control panel. 

(10) Connect negative battery cable to battery, and close BATTERY ACCESS doors. 

4.8.4 Time Meter (TOTAL HOURS) M3. 

a. Inspection. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Release DCS control panel by turning two fasteners, and lower DCS control panel slowly. 

(3) Inspect time meter (3, Figure 4-12) for broken lens, cracked housing, and other damage. 
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(4) Raise and secure DCS control panel. 

b. Testing. 

(1) Turn ENGINE CONTROL switch (8, Fig 4-12) to PRIME & RUN position. 

(2) Release DCS control panel by turning two fasteners, and lower DCS control panel slowly. 

(3) Set multimeter for DC volts, and connect across terminals 1 and 2 of time meter (3, Figure 4-12). 

(4) 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. 

(5) Raise and secure DCS control panel. 

(6) Turn Engine Control switch (8, Fig 4-12) to off position. 

c. Replacement. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable . 

(3) Release DCS control panel by turning two fasteners, and lower DCS control panel slowly. 

(4) Tag and disconnect electrical leads from the time meter (3, Figure 4-12). 

(5) Remove nuts (1), screws (2), and time meter (3) from DCS control panel. 

(6) Install time meter (3), screws (2), and nuts (1) on DCS control panel. 

(7) Connect electrical leads to time meter (3), and remove tags. 

(8) Raise and secure DCS control panel with two fasteners. 

(9) Connect negative battery cable to battery, and close BATTERY ACCESS door. 
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FIGURE 4-12. TIME METER AND SWITCHES
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4.8.5 ENGINE CONTROL Switch S1. 

a. Inspection. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Release DCS control panel by turning two fasteners, and lower DCS control panel slowly. 

(3) Inspect ENGINE CONTROL switch (8, Figure 4-12) for loose connections and mounting hardware, 

and other damage. 

(4) Raise and secure DCS control panel with two fasteners. 

b. Testing. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable . 

(3) Release DCS control panel by turning two fasteners, and lower DCS control panel slowly. 

(4) Tag and disconnect ENGINE CONTROL switch (8, Figure 4-12) electrical leads. 

(5) Set multimeter for ohms, and check switch for continuity. Refer to schematic, FO-1, to determine 

circuits made to corresponding switch position. 

(6) Check continuity for all four positions. 

(7) If open circuit is noted at any switch position, switch is unserviceable and must be replaced. 

(8) Connect electrical leads to ENGINE CONTROL switch (8), and remove tags. 

(9) Raise and secure DCS control panel with two fasteners. 

(10) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

c. Replacement. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable . 

(3) Release DCS control panel by turning two fasteners, and lower DCS control panel slowly. 

(4) Remove screw (4, Figure 4-12) and knob (5) from ENGINE CONTROL switch (8). 

(5) Tag and disconnect electrical leads from ENGINE CONTROL switch (8). 

(6) Remove nuts (6), screws (7), and ENGINE CONTROL switch (8) from DCS control panel. 

(7) Install ENGINE CONTROL switch (8), screws (7), and nuts (6) on DCS control panel. 

(8) Connect electrical leads to ENGINE CONTROL switch (8), and remove tags. 
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(9) Install knob (5) and screw (4) on ENGINE CONTROL switch (8). 

(10) Raise and secure DCS control panel with two fasteners. 

(11) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

4.8.6 ETHER START Switch S9. 

a. Inspection. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Release DCS control panel by turning two fasteners, and lower DCS control panel slowly. 

(3) Inspect ETHER START switch (11, Figure 4-12) for loose connections and mounting hardware, and 

other damage. 

(4) Raise and secure DCS control panel with two fasteners. 

b. Testing. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable . 

(3) Release DCS control panel by turning two fasteners, and lower DCS control panel slowly. 

(4) Tag and disconnect electrical leads from ETHER START switch (11, Figure 4-12). 

(5) Set multimeter for ohms, and connect across ETHER START switch (11) terminals. Multimeter 

should indicate open circuit. Refer to Schematic FO-1. 

(6) Hold ETHER START switch (11) in ON position. Multimeter should indicate continuity. 

(7) If indications are not as above, replace ETHER START switch. 

(8) Connect electrical leads to ETHER START switch (11), and remove tags. 

(9) Raise and secure DCS control panel with two fasteners. 

(10) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

c. Replacement. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable . 

(3) Release DCS control panel by turning two fasteners, and lower DCS control panel slowly. 

(4) Tag and disconnect ETHER START switch (11, Figure 4-12) electrical leads. 

(5) Remove jamnut (9) and toothed washer (10) securing ETHER START switch (11) to DCS control 

panel. 
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(6) Remove ETHER START switch (11) and tab washer (12) from DCS control panel. 

(7) Position tab washer (12) and ETHER START switch (11) on DCS control panel. 

(8) Secure ETHER START switch (11) to DCS control panel with toothed washer (10) and jamnut (9). 

(9) Connect electrical leads to ETHER START switch (11), and remove tags. 

(10) Raise and secure DCS control panel with two fasteners. 

(11) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

4.8.7 AC CIRCUIT INTERRUPT Switch S5. 

a. Inspection. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Release DCS control panel by turning two fasteners, and lower DCS control panel slowly. 

(3) Inspect AC CIRCUIT INTERRUPT switch (16, Figure 4-12) for loose connections and mounting 

hardware, and other damage. 

(4) Raise and secure DCS control panel with two fasteners. 

b. Testing. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Release DCS control panel by turning two fasteners, and lower DCS control panel slowly. 

(4) Tag and disconnect electrical leads from AC CIRCUIT INTERRUPT switch (16, Figure 4-12). 

(5) 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. 

 

(6) Place and hold AC CIRCUIT INTERRUPT switch (16) in CLOSED position. 

(7) Check for continuity between terminals 1 and 2. 

(8) Hold AC CIRCUIT INTERRUPT switch (16) in OPEN position. 

(9) Check for continuity between terminals 2 and 3. 

 

(10) If indications are not as above, replace AC CIRCUIT INTERRUPT switch (16). 

(11) Connect electrical leads to AC CIRCUIT INTERRUPT switch (16), and remove tags. 

(12) Raise and secure DCS control panel with two fasteners. 
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(13) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

c. Replacement. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Release DCS control panel by turning two fasteners, and lower DCS control panel slowly. 

(4) Tag and disconnect AC CIRCUIT INTERRUPT switch (16, Figure 4-12) electrical leads. 

(5) Remove jamnut (14) and toothed washer (15) securing AC CIRCUIT INTERRUPT switch (16) to 

DCS control panel. 

(6) Remove AC CIRCUIT INTERRUPT switch (16), and tab washer (17) from DCS control panel. 

(7) Position tab washer (17), and AC CIRCUIT INTERRUPT switch (16) on DCS control panel. 

(8) Secure AC CIRCUIT INTERRUPT switch (16) to DCS control panel with toothed washer (15) and 

jamnut (14). 

(9) Connect electrical leads to AC CIRCUIT INTERRUPT switch (16), and remove tags. 

(10) Raise and secure DCS control panel with two fasteners. 

(11) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

4.8.8 FAULT RESET Switch S4. 

a. Inspection. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Release DCS control panel by turning two fasteners, and lower DCS control panel slowly. 

(3) Inspect FAULT RESET switch (21, Figure 4-12) for loose connections and mounting hardware, and 

other damage. 

(4) Raise and secure DCS control panel with two fasteners. 

b. Testing. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable . 

(3) Release DCS control panel by turning two fasteners, and lower DCS control panel slowly. 

(4) Tag and disconnect electrical leads from FAULT RESET switch (21, Figure 4-12). 

(5) 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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(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. 

(7) If indications are not as above, replace FAULT RESET switch (21). 

(8) Connect electrical leads to FAULT RESET switch (21), and remove tags. 

(9) Raise and secure DCS control panel with two fasteners. 

(10) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

c. Replacement. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Release DCS control panel by turning two fasteners, and lower DCS control panel slowly. 

(4) Tag and disconnect electrical leads from FAULT RESET switch (21, Figure 4-12). 

(5) Remove jamnut (19) and toothed washer (20) securing FAULT RESET switch (21) to DCS control 

panel. 

(6) Remove FAULT RESET switch (21) and tab washer (22), from DCS control panel. 

(7) Position tab washer (22) and FAULT RESET switch (21) on DCS control panel. 

(8) Secure FAULT RESET switch (21) to DCS control panel with toothed washer (20) and jamnut (19). 

(9) Connect electrical leads to FAULT RESET switch (21), and remove tags. 

(10) Raise and secure DCS control panel with two fasteners. 

(11) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

4.8.9 MASTER CONTROL Switch S3. 

a. Inspection. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Release DCS control panel by turning two fasteners, and lower DCS control panel slowly. 

(3) Inspect MASTER CONTROL switch (3, Figure 4-13) for loose connections and mounting 

hardware, and other damage. 

(4) Raise and secure DCS control panel with two fasteners. 

b. Testing. 

(1) Shut down generator set, paragraph 2.11.2. 
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(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable . 

(3) Release DCS control panel by turning two fasteners, and lower DCS control panel slowly. 

(4) Tag and disconnect electrical leads from MASTER CONTROL switch (3, Figure 4-13). 

(5) Set multimeter for ohms, and connect across MASTER CONTROL switch (3) terminals. Refer to 

Schematic FO-1. 

 

(6) Place MASTER CONTROL switch (3) in ON position. Multimeter should indicate continuity on 

terminals 5 and 6. 

(7) Place MASTER CONTROL switch (3) in OFF position. Multimeter should indicate open circuit on 

terminal 5 and 6. 

(8) If indications are not as above, replace MASTER CONTROL switch (3). 

(9) Connect electrical leads to MASTER CONTROL switch (3), and remove tags. 

(10) Raise and secure DCS control panel with two fasteners. 

(11) Connect negative battery cable to battery, and close BATTERY ACCESS door. 
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FIGURE 4-13. DCS CONTROL PANEL COMPONENTS 
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c. Replacement. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable . 

(3) Release DCS control panel by turning two fasteners, and lower DCS control panel slowly. 

(4) Tag and disconnect electrical leads from MASTER CONTROL switch (3, Figure 4-13). 

(5) Remove jamnut (1) and toothed washer (2) securing MASTER CONTROL switch (3) to DCS 

control panel. 

(6) Remove MASTER CONTROL switch (3) and tab washer (4) from DCS control panel. 

(7) Position tab washer (4) and MASTER CONTROL switch (3) on DCS control panel. 

(8) Secure MASTER CONTROL switch (3) to DCS control panel with toothed washer (2) and jamnut 

(1). 

(9) Connect electrical leads to MASTER CONTROL switch (3), and remove tags. 

(10) Raise and secure DCS control panel with two fasteners. 

(11) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

4.8.10 VOLTAGE ADJUST Switch S18. 

a. Inspection. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Release DCS control panel by turning two fasteners, and lower DCS control panel slowly. 

(3) Inspect VOLTAGE ADJUST switch (8, Figure 4-13) for loose connections and mounting hardware, 

and other damage. 

(4) Raise and secure DCS control panel with two fasteners. 

b. Testing. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Release DCS control panel by turning two fasteners, and lower DCS control panel slowly. 

(4) Tag and disconnect electrical leads from VOLTAGE ADJUST switch (8, Figure 4-13). 

(5) 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. 
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(6) Hold VOLTAGE ADJUST switch (8) in UP position. Multimeter should indicate continuity on 

terminals 2 and 3. 

(7) Hold VOLTAGE ADJUST switch (8) in DOWN position. Multimeter should indicate continuity on 

terminals 2 and 1. 

(8) If indications are not as above, replace VOLTAGE ADJUST switch. 

(9) Connect electrical leads to VOLTAGE ADJUST switch (8), and remove tags. 

(10) Raise and secure DCS control panel with two fasteners. 

(11) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

c. Replacement. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable . 

(3) Release DCS control panel by turning two fasteners, and lower DCS control panel slowly. 

(4) Tag and disconnect electrical leads from VOLTAGE ADJUST switch (8, Figure 4-13). 

(5) Remove jamnut (6) and toothed washer (7) securing VOLTAGE ADJUST switch (8) to DCS 

control panel. 

(6) Remove VOLTAGE ADJUST switch (8) and tab washer (9) from DCS control panel. 

(7) Position tab washer (9) and VOLTAGE ADJUST switch (8) on DCS control panel. 

(8) Secure VOLTAGE ADJUST switch (8) to DCS control panel with toothed washer (7) and jamnut 

(6). 

(9) Connect electrical leads to VOLTAGE ADJUST switch (8), and remove tags. 

(10) Raise and secure DCS control panel with two fasteners. 

(11) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

4.8.11 FREQUENCY ADJUST Switch S19. 

a. Inspection. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Release DCS control panel by turning two fasteners, and lower DCS control panel slowly. 

(3) Inspect FREQUENCY ADJUST switch (13, Figure 4-13) for loose connections and mounting 

hardware, and other damage. 

(4) Raise and secure DCS control panel with two fasteners. 

b. Testing. 
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(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Release DCS control panel by turning two fasteners, and lower DCS control panel slowly. 

(4) Tag and disconnect electrical leads from FREQUENCY ADJUST switch (13, Figure 4-13). 

(5) 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. 

(6) Hold FREQUENCY ADJUST switch (13) in UP position. Multimeter should indicate continuity on 

terminals 2 and 3. 

(7) Hold FREQUENCY ADJUST switch (13) in the DOWN position. Multimeter should indicate 

continuity on terminals 2 and 1. 

(8) If indications are not as above, replace FREQUENCY ADJUST switch. 

(9) Connect electrical leads to FREQUENCY ADJUST switch (13), and remove tags. 

(10) Raise and secure DCS control panel with two fasteners. 

(11) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

c. Replacement. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Release DCS control panel by turning two fasteners, and lower DCS control panel slowly. 

(4) Tag and disconnect electrical leads from FREQUENCY ADJUST switch (13, Figure 4-13). 

(5) Remove jamnut (11) and toothed washer (12) securing FREQUENCY ADJUST switch (13) to DCS 

control panel. 

(6) Remove FREQUENCY ADJUST switch (13) and tab washer (14) from DCS control panel. 

(7) Position tab washer (14) and FREQUENCY ADJUST switch (13) on DCS control panel. 

(8) Secure FREQUENCY ADJUST switch (13) to DCS control panel with toothed washer (12) and 

jamnut (11). 

(9) Connect electrical leads to FREQUENCY ADJUST switch (13), and remove tags. 

(10) Raise and secure DCS control panel with two fasteners. 

(11) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

4.8.12 PANEL LIGHTS Switch S2. 
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a. Inspection. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Release DCS control panel by turning two fasteners, and lower DCS control panel slowly. 

(3) Inspect PANEL LIGHTS switch (18, Figure 4-13) for loose connections and mounting hardware, 

and other damage. 

(4) Raise and secure DCS control panel with two fasteners. 

b. Testing. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable . 

(3) Release DCS control panel by turning two fasteners, and lower DCS control panel slowly. 

(4) Tag and disconnect electrical leads from PANEL LIGHTS switch (18, Figure 4-13). 

(5) Set multimeter for ohms, and connect across PANEL LIGHTS switch (18) terminals 5 and 6 and 2 

and 3. Refer to Schematic FO-1. 

 

(6) Place PANEL LIGHTS switch (18) in ON position. Multimeter should indicate continuity between 

terminals 2 and 3, and 5 and 6. 

(7) Place PANEL LIGHTS switch (18) in OFF position. Multimeter should indicate open circuit 

between terminals 2 and 3, and 5 and 6. 

(8) If indications are not as above, replace PANEL LIGHTS switch (18). 

(9) Connect electrical leads to PANEL LIGHTS switch (18), and remove tags. 

(10) Raise and secure DCS control panel with two fasteners. 

(11) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

c. Replacement. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Release DCS control panel by turning two fasteners, and lower DCS control panel slowly. 

(4) Tag and disconnect electrical leads from PANEL LIGHTS switch (18, Figure 4-13). 

(5) Remove jamnut (16) and toothed washer (17) securing PANEL LIGHTS switch (18) to DCS control 

panel. 

(6) Remove PANEL LIGHTS switch (18) and tab washer (19) from DCS control panel. 
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(7) Position tab washer (19) and PANEL LIGHTS switch (18) on DCS control panel. 

(8) Secure PANEL LIGHTS switch (18) to DCS control panel with toothed washer (17) and jamnut 

(16). 

(9) Connect electrical leads to PANEL LIGHTS switch (18), and remove tags. 

(10) Raise and secure DCS control panel with two fasteners. 

(11) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

4.8.13 BATTLE SHORT Switch S7. 

a. Inspection. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Release DCS control panel by turning two fasteners, and lower DCS control panel slowly. 

(3) Inspect BATTLE SHORT switch (24, Figure 4-13) for loose connections and mounting hardware, 

and other damage. 

(4) Raise and secure DCS control panel with two fasteners. 

b. Testing. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Release DCS control panel by turning two fasteners, and lower DCS control panel slowly. 

(4) Tag and disconnect electrical leads from BATTLE SHORT switch (24, Figure 4-13). 

(5) Place BATTLE SHORT switch (24) in ON position. 

(6) 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. 

(7) Place BATTLE SHORT switch (24) in OFF position. 

(8) Check for continuity between terminals 4 and 5, and an open circuit between terminals 2 and 3. 

 

(9) If open circuit is indicated, replace BATTLE SHORT switch (24). 

(10) Connect electrical leads to BATTLE SHORT switch (24), and remove tags. 

(11) Raise and secure DCS control panel with two fasteners. 

(12) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

c. Replacement. 
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(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Release DCS control panel by turning two fasteners, and lower DCS control panel slowly. 

(4) Tag and disconnect electrical leads from BATTLE SHORT switch (24, Figure 4-13). 

(5) Remove jamnut (21), toothed washer (22), and cover (23) securing BATTLE SHORT switch (24) to 

DCS control panel. 

(6) Remove BATTLE SHORT switch (24) and tab washer (25) from DCS control panel. 

(7) Position tab washer (25) and BATTLE SHORT switch (24) on DCS control panel. 

(8) Secure BATTLE SHORT switch (24) to DCS control panel with cover (23), toothed washer (22), 

and jamnut (21). 

(9) Connect electrical leads to BATTLE SHORT switch (24), and remove tags. 

(10) Raise and secure DCS control panel with two fasteners. 

(11) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

4.8.14 EMERGENCY STOP Switch S17. 

a. Inspection. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Release DCS control panel by turning two fasteners, and lower DCS control panel slowly. 

(3) Inspect EMERGENCY STOP switch (29, Figure 4-13) for loose connections and mounting 

hardware, and other damage. 

(4) Raise and secure DCS control panel with two fasteners. 

b. Testing. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Release DCS control panel by turning two fasteners, and lower DCS control panel slowly. 

(4) Tag and disconnect electrical leads from EMERGENCY STOP switch (29, Figure 4-13). 

(5) Ensure EMERGENCY STOP switch (29) is in normal (out) position. 

(6) Set multimeter for ohms, and connect across EMERGENCY STOP switch (29) terminals. 

Multimeter should indicate continuity. 

(7) Push EMERGENCY STOP switch (29) to (in) position. Multimeter should indicate no continuity. 
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(8) If indications are not as above, replace EMERGENCY STOP switch. 

(9) Connect electrical leads to EMERGENCY STOP switch (29), and remove tags. 

(10) Raise and secure DCS control panel with two fasteners. 

(11) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

c. Replacement. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Release DCS control panel by turning two fasteners, and lower DCS control panel slowly. 

(4) Tag and disconnect electrical leads from EMERGENCY STOP switch (29, Figure 4-13). 

(5) Unscrew and remove knob (27) and collar (28) from EMERGENCY STOP switch (29), and remove 

switch from DCS control panel. 

(6) Position EMERGENCY STOP switch (29) on DCS control panel and secure with collar (28) and 

knob (27). 

(7) Connect electrical leads to EMERGENCY STOP switch (29), and remove tags. 

(8) Raise and secure DCS control panel with two fasteners. 

(9) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

4.8.15 GROUND FAULT CIRCUIT INTERRUPTER CB3. 

a. Inspection. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Release DCS control panel by turning two fasteners, and lower DCS control panel slowly. 

(3) Inspect GROUND FAULT CIRCUIT INTERRUPTER (32, Figure 4-13) for cracks, corrosion, 

frayed wires, and other damage. 

(4) Raise and secure DCS control panel with two fasteners. 
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b. Testing. 

(1) Start generator set, paragraph 2.11.1. Operate generator set at rated voltage and frequency. 

(2) 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 4-

14) by inserting multimeter leads into one of the outlets. 

(3) 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). 

(4) If indications are other than the above, replace GROUND FAULT CIRCUIT INTERRUPTER (32, 

Figure 4-13). 

c. Replacement. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable . 

(3) Remove DCS control box top panel, paragraph 4.7.2. 

(4) Tag and disconnect GROUND FAULT CIRCUIT INTERRUPTER (32, Figure 4-13) electrical 

leads from TB5 and CONVENIENCE RECEPTACLE (23, Figure 4-14). 

(5) Remove nuts (30, Figure 4-13), screws (31), and GROUND FAULT CIRCUIT INTERRUPTER 

(32) from DCS control panel. 

(6) Install GROUND FAULT CIRCUIT INTERRUPTER (32), screws (31), and nuts (30) on DCS 

control panel. 

(7) Connect GROUND FAULT CIRCUIT INTERRUPTER (32) electrical leads to CONVENIENCE 

RECEPTACLE (23, Figure 4-14) and TB5. Refer to Schematic FO-1. Remove tags. 

(8) Install DCS control box top panel, paragraph 4.7.2. 

(9) Connect negative battery cable to battery, and close BATTERY ACCESS door. 
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FIGURE 4-14. CIM AND RECEPTACLES 

4.8.16 Computer Interface Module (CIM). 

a. Inspection. 

(1) Shut down Generator set, Paragraph 2.11.2 

(2) Remove DCS control box top panel, paragraph 4.7.2. 

(3) Inspect CIM (3, Figure 4-14) for cracks, corrosion, dents, or other damage. 
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(4) Install DCS control box top panel, paragraph 4.7.2. 

b. Removal. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable . 

(3) 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) Loosen two screws, and disconnect power connector (25, fig 4-14) from CIM. 

(5) 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). 

(7) If necessary, drill out rivet nuts (1) from DCS control panel frame. 

c. Installation. 

(1) If removed, install rivet nuts (1, Figure 4-14) with rivet gun. 

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) While providing adequate support, install CIM (3, Figure 4-14) and bolts (2) on DCS control panel 

frame (4). 

(3) Connect data connector (24) to CIM (3). Tighten two thumbscrews. 
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(4) Connect power connection to CIM (3). Tighten two screws. 

(5) Install DCS control box top panel, paragraph 4.7.2. 

(6) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

4.8.17 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) Shut down generator set, paragraph 2.11.2. 

(2) Remove DCS control box top panel, paragraph 4.7.2. 

(3) Attach ESD wrist strap and connect to ground. 

(4) Inspect keypad assembly (7, Figure 4-14) for sticking or non-responsive buttons, corrosion, loose 

and damaged wires or other damage. 

(5) Disconnect ESD wrist strap from ground, and remove wrist strap. 

(6) Install DCS control box top panel, paragraph 4.7.2. 

b. Replacement. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Remove DCS control box top panel, paragraph 4.7.2. 

(4) Remove CIM. Refer to Paragraph 4.8.16. 

(5) Attach ESD wrist strap and connect to ground. 

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 
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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. 

(7) Disconnect data exchange connector P26 from J26. 

(8) Remove locknuts (5), bolts (6), and keypad assembly (7) from DCS control panel frame (4). 

(9) Install keypad assembly (7), bolts (6), and locknuts (5) on DCS control panel frame (4). 

(10) Connect data exchange connector P26 to J26. 

(11) Connect keypad wires to PS-1 terminals 1 and 2. Remove tags. 

(12) Disconnect ESD wrist strap from ground, and remove wrist strap. 

(13) Install DCS control box top panel, paragraph 4.7.2. 

(14) Install CIM. Refer to Paragraph 4.8.16. 

(15) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

4.8.18 COMMUNICATION RECEPTACLE. 

a. Inspection. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Remove DCS control box top panel, paragraph 4.7.2. 

(3) Inspect COMMUNICATION RECEPTACLE (11, Figure 4-14) for cracks, corrosion, stripped or 

damaged threads, evidence of shorting, and other damage. 

(4) Inspect cap (10) for cracks, corrosion, and broken chain. 

(5) Inspect gasket (12) for tears and deterioration. 

(6) Replace defective parts. 

(7) Install control box top panel, paragraph 4.7.2. 

b. Replacement. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Remove DCS control box top panel, paragraph 4.7.2. 
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(4) Tag and desolder electrical leads from COMMUNICATION RECEPTACLE (11, Figure 4-14) and 

groundwire. Refer to Schematic FO-1. 

(5) Remove locknuts (8), screws (9), cap (10), COMMUNICATION RECEPTACLE (11), and gasket 

(12) from DCS control panel frame (4). 

(6) Install gasket (12), COMMUNICATION RECEPTACLE (11), cap (10), screws (9), and locknuts 

(8) on DCS control panel frame (4). 

(7) Solder electrical leads to COMMUNICATION RECEPTACLE (11) and connect ground wire. 

Refer to Schematic FO-1. Remove tags. 

(8) Install control box top panel, paragraph 4.7.2. 

(9) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

4.8.19 PARALLELING RECEPTACLE J2. 

a. Inspection. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Remove DCS control box top panel, paragraph 4.7.2. 

(3) Inspect PARALLELING RECEPTACLE (16, Figure 4-14) for cracks, corrosion, stripped or 

damaged threads, evidence of shorting, and other damage. 

(4) Inspect cap (15) for cracks, corrosion, and broken chain. 

(5) Inspect gasket (17) for tears and deterioration. 

(6) Replace defective parts. 

(7) Install control box top panel, paragraph 4.7.2. 

b. Replacement. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Remove DCS control box top panel, paragraph 4.7.2. 

(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. 

(5) Remove locknuts (13), screws (14), cap (15), PARALLELING RECEPTACLE (16), and gasket 

(17) from DCS control panel frame (4). 

(6) Install gasket (17), PARALLELING RECEPTACLE (16), cap (15), screws (14), and locknuts (13) 

on DCS control panel frame (4). 

(7) Connect electrical leads to PARALLELING RECEPTACLE (16) using insertion tool (Appendix B, 

Section III). Remove tags. 
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(8) Install control box top panel, paragraph 4.7.2. 

(9) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

4.8.20 CONVENIENCE RECEPTACLE J1. 

a. Inspection. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Remove DCS control box top panel, paragraph 4.7.2. 

(3) Inspect CONVENIENCE RECEPTACLE (23, Figure 4-14) for cracks, breaks, corrosion, bent 

terminals, and other indications of damage. 

(4) Inspect cover (20) for cracks, corrosion, and damaged springs. 

(5) Replace defective parts. 

(6) Install DCS control box top panel, paragraph 4.7.2. 

b. Testing. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Remove DCS control box top panel, paragraph 4.7.2. 

(3) Remove locknuts (18, Figure 4-14), screws (19), and cover (20) from DCS control panel frame (4). 

(4) Remove locknuts (21), screws (22), and CONVENIENCE RECEPTACLE (23) from DCS control 

panel frame (4). 

(5) Tag and disconnect electrical leads from CONVENIENCE RECEPTACLE (23). 

(6) Set multimeter for ohms, and check for continuity between upper side terminals and lower side 

terminals of each plug outlet. 

(7) Replace CONVENIENCE RECEPTACLE if continuity is not indicated between terminals. 

(8) Connect electrical leads to CONVENIENCE RECEPTACLE (23), and remove tags. 

(9) Install DCS control box top panel, paragraph 4.7.2. 

c. Replacement. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Remove DCS control box top panel, paragraph 4.7.2. 

(4) Remove locknuts (18, Figure 4-14), screws (19), and cover (20) from DCS control panel frame (4). 
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(5) Remove locknuts (21), screws (22), and CONVENIENCE RECEPTACLE (23) from DCS control 

panel frame (4). 

(6) Tag and disconnect electrical leads from CONVENIENCE RECEPTACLE (23). 

(7) Connect electrical leads to CONVENIENCE RECEPTACLE (23). Remove tags. 

(8) Install CONVENIENCE RECEPTACLE (23), screws (22), and locknuts (21) on DCS control panel 

frame (4). 

(9) Install cover (20), screws (19), and locknuts (18) on DCS control panel frame (4). 

(10) Install DCS control box top panel, paragraph 4.7.2. 

(11) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

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) Shut down generator set, paragraph 2.11.2. 

(2) Remove DCS control box top panel, paragraph 4.7.2. 

(3) Attach ESD wrist strap and connect to ground. 

(4) Inspect DCS load sharing synchronizer (5, Figure 4-15) for loose or missing mounting hardware and 

any obvious damage. 

(5) Disconnect ESD wrist strap, and remove wrist strap. 

(6) Install DCS control box top panel, paragraph 4.7.2. 

b. Testing. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Connect negative battery cable to battery and close battery access door. 

(3) Start generator set, paragraph 2.11.1. 

(4) 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. 

(5) Set multimeter to VDC. Connect positive lead to P24-11 and negative lead to P24-10. Refer to 

Schematic FO-1. 
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(6) Multimeter reading at 100% load should be 6 VDC. If not, replace load sharing synchronizer (5). 

(7) Disconnect multimeter leads from P24-11 and P24-10. 

(8) Shut down generator set, paragraph 2.11.2. 

(9) Install DCS control box top panel, paragraph 4.7.2. 

c. Removal. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable . 

(3) Remove DCS control box top panel, paragraph 4.7.2. 

(4) Attach ESD wrist strap and connect to ground. 

(5) 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. 
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FIGURE 4-15. DCS CONTROL BOX BACK PANEL COMPONENTS 
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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. 

(2) 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). 

(3) Disconnect ESD wrist strap, and remove wrist strap. 

(4) Install DCS control box top panel, paragraph 4.7.2. 

(5) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

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) Shut down generator set, paragraph 2.11.2. 

(2) Remove DCS control box top panel, paragraph 4.7.2. 

(3) Attach ESD wrist strap and connect to ground. 

(4) Inspect DCS speed control unit (8, Figure 4-15) for loose or missing mounting hardware and any 

obvious damage. 

(5) Disconnect ESD wrist strap, and remove wrist strap. 

(6) Install DCS control box top panel, paragraph 4.7.2. 

b. Testing. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Remove DCS control box top panel, paragraph 4.7.2. 

(3) Start generator set, paragraph 2.11.1. 
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(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. 

(5) Set multimeter to VDC. Connect positive lead to P24-11 and negative lead to P24-10. 

(6) Multimeter reading at 100% load should be 6 VDC. If not, replace load sharing synchronizer (5, 

Figure 4-15). 

(7) Disconnect multimeter leads from P24-11 and P24-10. 

(8) Shut down generator set, paragraph 2.11.2. 

(9) Install DCS control box top panel, paragraph 4.7.2. 

c. Removal. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Remove DCS control box top panel, paragraph 4.7.2. 

(4) Attach ESD wrist strap and connect to ground. 

(5) 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. 

(2) Secure DCS speed control unit (8) to backplane module (20) with washers (7) and locknuts (6). 

(3) Disconnect ESD wrist strap, and remove wrist strap. 

(4) Install DCS control box top panel, paragraph 4.7.2. 

(5) Connect negative battery cable to battery, and close BATTERY ACCESS door. 
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4.8.23 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) Shut down generator set, paragraph 2.11.2. 

(2) Remove DCS control box top panel, paragraph 4.7.2. 

(3) Attach ESD wrist strap and connect to ground. 

(4) Inspect automatic voltage regulator (11, Figure 4-15) for loose or missing mounting hardware and 

any obvious damage. 

(5) Disconnect ESD wrist strap, and remove wrist strap. 

(6) Install DCS control box top panel, paragraph 4.7.2. 

b. Testing. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Remove DCS control box top panel, paragraph 4.7.2. 

(3) Attach ESD wrist strap and connect to ground. 

(4) Set multimeter to ohms, and connect leads to P9-5 and P9-6. Refer to Wiring Diagram FO-3. 

(5) Measure resistance between P9-5 and P9-6. If resistance is other than 28±3 ohms, test back plane 

module, paragraph 4.7.24. 

(6) Disconnect multimeter leads from P9-5 and P9-6. 

(7) Set multimeter to VDC. Connect positive lead to P9-5 and negative lead to P9-6. 

(8) Disconnect ESD wrist strap, and remove wrist strap. 

(9) 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. 

(10) Release ENGINE CONTROL switch, and disconnect multimeter leads from P9-5 and P9-6. 

(11) Connect positive multimeter lead to J24-1 and negative lead to P24-2. If reading is above 20 VDC, 

replace automatic voltage regulator (11). 

(12) Disconnect multimeter leads from P24-1 and P24-2. 
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(13) 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. 

(14) If measurement recorded in step (9) is above 15 VDC and LEDs checked in step (11) are lit, 

automatic voltage regulator (11) is okay. 

(15) Shut down generator set, paragraph 2.11.2. 

(16) Install DCS control box top panel, paragraph 4.7.2. 

c. Removal. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Remove DCS control box top panel, paragraph 4.7.2. 

(4) Remove CIM. See paragraph 4.8.16. 

(5) Attach ESD wrist strap and connect to ground. 

(6) Remove P24 and P9. Refer to Schematic FO-1. 

(7) Remove locknuts (9, Figure 4-15) and washers (10) securing automatic voltage regulator (11) to 

backplane module (20). 

(8) 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. 

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. 

(2) Secure automatic voltage regulator (11) to backplane module (20) with washers (10) and locknuts 

(9). 

(3) Connect leads to R16 and R17. 

(4) Disconnect ESD wrist strap, and remove wrist strap. 

(5) Install DCS control box top panel, paragraph 4.7.2. 
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(6) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

4.8.24 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) Shut down generator set, paragraph 2.11.2. 

(2) Remove DCS control box top panel, paragraph 4.7.2. 

(3) Remove DCS load sharing synchronizer, paragraph 4.8.21. 

(4) Remove DCS speed control unit, paragraph 4.8.22. 

(5) Remove automatic voltage regulator, paragraph 4.8.23. 

(6) Inspect backplane module (20, Figure 4-15) for damaged or missing connectors and components. 

(7) Install automatic voltage regulator, paragraph 4.8.23. 

(8) Install DCS speed control unit, paragraph 4.8.22. 

(9) Install DCS load sharing synchronizer, paragraph 4.8.21. 

(10) Install DCS control box top panel, paragraph 4.7.2. 

b. Testing. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Remove DCS control box top panel, paragraph 4.7.2. 

(3) Attach ESD wrist strap and connect to ground. 

(4) Set multimeter to VDC. Connect positive lead to P24-6 and negative lead to P24-7. Refer to 

Wiring Diagram FO-3. 

(5) Ensure MASTER CONTROL switch is set to ON. Record VDC reading. 

(6) 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. 

(7) If reading is step (6) is 24 VDC, test DCS control box wiring harness, paragraph 4.8.41. 

(8) Start generator set, paragraph 2.11.1. 
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NOTE

Polarity of signal between J9-8 and J9-11 must be correct. Check wiring polarity at 

current transformer in output box prior to test. 

(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). 

(11) Disconnect multimeter leads from P24-5 and P9-8. 

(12) Shut down generator set, paragraph 2.11.2. 

(13) Install DCS control box top panel, paragraph 4.7.2. 

c. Replacement. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Remove DCS control box top panel, paragraph 4.7.2. 

(3) Remove DCS load sharing synchronizer, paragraph 4.8.21. 

(4) Remove DCS speed control unit, paragraph 4.8.22. 

(5) Remove automatic voltage regulator, paragraph 4.8.23. 

(6) Disconnect wiring harness connectors (12). 

(7) Remove screws (13), lockwashers (14), and washers (15) securing backplane connectors (16) 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). 

(9) Tag and disconnect electrical leads from A1-TB1. Refer to Wiring Diagram FO-1. 

(10) Remove locknuts (18), washers (19), backplane module (20), and standoffs (21) from DCS control 

box rear panel. 
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(11) Install standoffs (21), backplane module (20), washers (19), and locknuts (18) on DCS control box 

rear panel. 

(12) Connect P23 (17) and P8 (33) ribbon cable assemblies to backplane module (20). 

(13) Secure backplane connectors (16) to DCS control box rear panel with washers (15), lockwashers 

(14), and screws (13). 

(14) Connect wiring harness connectors (12). 

(15) Install automatic voltage regulator, paragraph 4.8.23. 

(16) Install DCS speed control unit, paragraph 4.8.22. 

(17) Install DCS load sharing synchronizer, paragraph 4.8.21. 

(18) Install DCS control box top panel, paragraph 4.7.2. 

4.8.25 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. 

a. Inspection

(1) Shut down generator set, paragraph 2.11.2. 

(2) Remove DCS control box top panel, paragraph 4.7.2. 

(3) Attach ESD wrist strap and connect to ground. 

(4) Inspect I/O interface module (25, Figure 4-15) for damaged or missing connectors and components. 

(5) Disconnect ESD wrist strap, and remove wrist strap. 

(6) Install DCS control box top panel, paragraph 4.7.2. 
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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. 

(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) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable . 

(3) Remove DCS control box top panel, paragraph 4.7.2. 

(4) Remove CIM. See paragraph 4.8.16. 

(5) 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) Tag and disconnect electrical connectors P20, P21, P17 and P25. Refer to Schematic FO-1. 

 

(7) Disconnect ribbon cable assemblies P23 (17) and P8 (33) from I/O interface module (25). 

(8) Remove screws (23), lockwashers (24), and I/O interface module (25) from DCS control box rear 

panel. 

(9) Set I/O Interface Module Configuration Switch for the proper Generator Set Application. See 

paragraph 4.16. 

(10) Install I/O interface module (25), lockwashers (24), and screws (23) on DCS control box rear panel. 

(11) Install ribbon cable assemblies P23 (17) and P8 (33), to I/O interface module (25). 

 

(12) Connect electrical connectors P20, P21, P17, and P25 to I/O interface module (25) and remove tags. 

Refer to Schematic FO-1. 

(13) Disconnect ESD wrist strap, and remove wrist strap. 

(14) Install CIM. See paragraph 4.8.16. 
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(15) Install DCS control box top panel, paragraph 4.7.2. 

(16) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

4.8.26 DC CONTROL POWER Fuse. 

a. Inspection. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open DCS control panel. 

(3) Inspect DC CONTROL POWER fuseholder (3, Figure 4-16) for loose connections and mounting 

hardware, cracked housing, and other damage. 

(4) Close DCS control panel. 

b. Testing. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Release DCS Control Panel by turning two quick turn fasteners. 

(3) Remove cap (1, Figure 4-16) and fuse (2) from DC CONTROL POWER fuseholder (3) and remove 

fuse from cap. 

(4) Set multimeter for ohms and connect across fuse ends. If fuse is good, multimeter will indicate 

continuity. 

(5) If indications are not as above, replace fuse with one of identical size and rating. 

(6) Install good fuse (2) into cap and install cap (1) and fuse (2) into fuseholder (3). 

(7) Close DCS CONTROL PANEL and secure with two quick turn fasteners. 

c. Replacement. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Remove DCS Control box top panel, paragraph 4.7.2 

(4) Tag and disconnect electrical leads from DC CONTROL POWER fuseholder (3, Figure 4-16). 

(5) Remove cap (1) and fuse (2) from fuseholder (3). Remove jamnut (24), which secures fuseholder to 

auxiliary control bracket (18) and slide fuseholder thru auxiliary control bracket. 

(6) Install DC CONTROL POWER fuseholder (3, Figure 4-16), and secure with jamnut (24). 

(7) Connect electrical leads to DC CONTROL POWER fuseholder (3), and remove tags. Install cap (1) 

and fuse (2), in fuseholder (3). 
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(8) Install DCS control box top panel, paragraph 4.7.2. 

(9) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

4.8.27 FREQUENCY SELECT Switch S12. 

a. Inspection. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Remove DCS control box top panel, paragraph 4.7.2. 

(3) Inspect FREQUENCY SELECT switch (6, Figure 4-16) for loose connections and mounting 

hardware and other damage. 

(4) Install DCS control box top panel, paragraph 4.7.2. 

b. Testing. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable . 

(3) Remove DCS control box top panel, paragraph 4.7.2. 

(4) Remove FREQUENCY SELECT switch. Refer to paragraph 4.8.27.c. 

(5) Set multimeter for ohms, and connect across switch terminals. 

(6) Place FREQUENCY SELECT switch (6) in UP (60 Hz) position. Multimeter should indicate 

continuity. 

(7) Place FREQUENCY SELECT switch (6) in DOWN (50 Hz) position. Multimeter should indicate 

open circuit. 

(8) If indications are other than above, FREQUENCY SELECT switch (6) is defective and must be 

replaced. 

(9) Install FREQUENCY SELECT switch. Refer to paragraph 4.8.27.c. 

(10) Install DCS control box top panel, paragraph 4.7.2. 

(11) Connect negative battery cable to battery, and close BATTERY ACCESS door. 
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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) 

c. Replacement. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Remove DCS control box top panel, paragraph 4.7.2. 

(4) Tag and disconnect electrical leads from FREQUENCY SELECT switch (6, Figure 4-16). 

(5) Remove jamnut (4), lockwasher (5), and FREQUENCY SELECT switch (6) from auxiliary control 

bracket (18). 

(6) Install FREQUENCY SELECT switch (6, Figure 4-16), lockwasher (5), and jamnut (4) on auxiliary 

control bracket (18). 

(7) Connect electrical leads to FREQUENCY SELECT switch (6), and remove tags. 

(8) Install DCS control box top panel, paragraph 4.7.2. 

(9) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

4.8.28 REACTIVE CURRENT ADJUST Rheostat R5. 
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a. Inspection. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Remove DCS control box top panel, paragraph 4.7.2. 

(3) Inspect REACTIVE CURRENT ADJUST rheostat (8, Figure 4-16) for loose connections and 

mounting hardware, and other damage. 

(4) Install DCS control box top panel, paragraph 4.7.2. 

b. Testing. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Remove DCS control box top panel, paragraph 4.7.2. 

(4) Desolder wires 236A, 236B, and 236C. Refer to wiring diagram FO-3. 

(5) Mark reading of REACTIVE CURRENT ADJUST rheostat (8, Figure 4-16) to reposition at 

conclusion of testing steps. 

(6) Set multimeter for ohms, and connect to wires 236B and 236A. Multimeter reading should be 

between 4.5 and 5.5 ohms. 

(7) 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. 

(8) 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. 

(9) If multimeter readings are other than above, replace REACTIVE CURRENT ADJUST rheostat (8). 

(10) Reposition REACTIVE CURRENT ADJUST rheostat (8) as marked in step (5). 

(11) Solder wires 236A, 236B, and 236C. 

(12) Install DCS control box top panel, paragraph 4.7.2. 

(13) Connect negative battery cable to battery, and close BATTERY ACCESS door. 
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c. Replacement. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Remove DCS control box top panel, paragraph 4.7.2. 

(4) Desolder and tag electrical leads from REACTIVE CURRENT ADJUST rheostat (8, Figure 4-16). 

(5) Mark reading of REACTIVE CURRENT ADJUST rheostat (8) to reposition at installation. 

(6) Remove nuts(7 and 45) and REACTIVE CURRENT ADJUST rheostat (8) from auxiliary control 

bracket. 

(7) Reposition REACTIVE CURRENT ADJUST rheostat (8) as marked in step (5), and secure with 

nuts (7and 45). 

(8) Solder electrical leads to REACTIVE CURRENT ADJUST rheostat (8). Remove tags. 

(9) Install DCS control box top panel, paragraph 4.7.2. 

(10) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

4.8.29 Diode CR1-CR10

a. Inspection. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Remove DCS control box top panel, paragraph 4.7.2. 

(3) Inspect diode (9, Figure 4-16) for cracks, breaks, corrosion, bent terminals, and other damage. 

(4) Install DCS control box top panel, paragraph 4.7.2. 

b. Testing. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable . 

(3) Remove DCS control box top panel, paragraph 4.7.2. 

(4) Tag and remove diode from circuit. Refer to Schematic FO-1. 
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(5) 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. 

FIGURE 4-17. DIODE IDENTIFICATION

(6) 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. 

(7) If any indications are other than above, replace diode. 

(8) Install DCS control box top panel, paragraph 4.7.2. 

(9) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

c. Replacement. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Remove DCS control box top panel, paragraph 4.7.2. 

NOTE 

Soldering applies only to CR1. All other diodes are installed with screws. 

(4) For CR2-CR10, tag and remove diode from unit. Refer to Schematic FO-1. 

(5) Tag and desolder electrical leads from terminals (20, Figure 4-16). 

(6) Desolder diode (9) from terminals (20). 

(7) Solder diode (9) to terminals (20). 

(8) Solder electrical leads to terminals (20). Remove tags. 

(9) Install CR2-CR10 and remove tags. Refer to Schematic FO-1. 

(10) Install DCS control box assembly, paragraph 4.8.1. 
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(11) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

4.8.30 Resistor R1. 

a. Inspection. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Remove DCS control box top panel, paragraph 4.7.2. 

(3) Inspect resistor (10, Figure 4-16) for cracks, breaks, corrosion, bent terminals, and other damage. 

(4) Install DCS control box top panel, paragraph 4.7.2. 

b. Testing. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable . 

(3) Remove DCS control box top panel, paragraph 4.7.2. 

(4) Tag and remove R1 (10, Figure 4-16). 

(5) Set multimeter for ohms, and measure resistance across resistor (10). Multimeter indication should 

be between 1235 and 1365 ohms. 

(6) If any indications are other than above, replace resistor. 

(7) Install R1 and remove tags. 

(8) Install DCS control box top panel, paragraph 4.7.2. 

(9) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

c. Replacement. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable . 

(3) Remove DCS control box top panel, paragraph 4.7.2. 

(4) Tag and desolder electrical leads from resistor (10, Figure 4-16). 

(5) Remove resistor (10) from auxiliary control bracket (18). 

(6) Install resistor (10) to auxiliary control bracket (18). 

(7) Solder electrical leads to resistor (10). Remove tags. 

(8) Install DCS control box top panel, paragraph 4.7.2. 

(9) Connect negative battery cable to battery, and close BATTERY ACCESS door. 
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4.8.31 Resistor R2. 

a. Inspection. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Remove DCS control box top panel, paragraph 4.7.2. 

(3) Inspect resistor (13, Figure 4-16) for cracks, breaks, corrosion, bent terminals, and other damage. 

(4) Install DCS control box top panel, paragraph 4.7.2. 

b. Testing. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Remove DCS control box top panel, paragraph 4.7.2. 

(4) Set multimeter for ohms, and measure resistance across resistor (13, Figure 4-16). Multimeter 

indication should be between 310 and 350 ohms. 

(5) If any indications are other than above, replace resistor. 

(6) Install DCS control box top panel, paragraph 4.7.2. 

(7) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

c. Replacement. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Remove DCS control box top panel, paragraph 4.7.2. 

(4) Tag and desolder electrical leads from resistor (13, Figure 4-16). 

(5) Remove nuts (11), lockwashers (12), resistor (13), sleeving (14), screws (15), and lockwashers (16) 

from auxiliary control bracket (18). 

(6) Install lockwashers (16), screws (15), sleeving (14), resistor (13), lockwashers (12), and nuts (11) 

on auxiliary control bracket (18). 

(7) Solder electrical leads to resistor (13). Remove tags. 

(8) Install DCS control box top panel, paragraph 4.7.2. 

(9) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

4.8.32 Auxiliary Control Bracket. 
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a. Inspection. 

 Inspect auxiliary control bracket (18, Figure 4-16) for dents, cracks, loose paint, and corrosion. 

b. Removal. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Remove DCS control box top panel, paragraph 4.7.2. 

(4) Remove auxiliary control bracket components, paragraphs 4.8.26 through 4.8.31. 

(5) Remove bolts (17, Figure 4-16) and auxiliary control bracket (18) from floor of DCS control box 

assembly. 

(6) Remove screws (19) and terminals (20) from auxiliary control bracket (18). 

c. Repair. 

(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) Repair all dents and cracks, and remove loose paint. 

(3) Remove light corrosion with fine grit abrasive paper (Item 16, Appendix E). 

(4) Repaint surfaces in accordance with TM 43-0139. 

(5) Install components removed in step (1), paragraphs 4.8.26 through 4.8.31. 

d. Installation. 

(1) Install terminals (20, Figure 4-16) and screws (19) on auxiliary control bracket (18). 

(2) Install auxiliary control bracket (18) and bolts (17) on floor of DCS control box assembly. 

(3) Install auxiliary control bracket components, paragraphs 4.8.26 through 4.8.31. 

(4) Install DCS control box top panel, paragraph 4.7.2. 

(5) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

4.8.33 VOLTAGE SELECTION Switch S20. 

a. Inspection. 
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(1) Shut down generator set, paragraph 2.11.2. 

(2) Remove DCS control box top panel, paragraph 4.7.2. 

(3) Inspect VOLTAGE SELECTION switch (23, Figure 4-16) for loose connections and mounting 

hardware and other damage. 

(4) Install DCS control box top panel, paragraph 4.7.2. 

b. Testing. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Remove DCS control box top panel, paragraph 4.7.2. 

(4) Remove jamnut (21), lockwasher (22), and VOLTAGE SELECTION switch (23) from bracket (18). 

(5) Tag and disconnect electrical leads from VOLTAGE SELECTION switch (23, Figure 4-16). 

(6) Set multimeter for ohms, and connect across switch terminals. 

(7) Place VOLTAGE SELECTION switch (23) in UP position. Multimeter should indicate continuity. 

(8) Place VOLTAGE SELECTION switch (23) in DOWN position. Multimeter should indicate open 

loop. 

(9) If indications are other than above, VOLTAGE SELECTION switch (23) is defective and must be 

replaced. 

(10) Connect electrical leads to VOLTAGE SELECTION switch (23). 

(11) Install VOLTAGE SELECTION switch (23, Figure 4-16), lockwasher (22), and jamnut (21) on 

bracket (18). 

(12) Install DCS control box top panel, paragraph 4.7.2. 

(13) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

c. Replacement. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Remove DCS control box top panel, paragraph 4.7.2. 

(4) Tag and disconnect electrical leads from VOLTAGE SELECTION switch (23, Figure 4-16). 

(5) Remove jamnut (21), lockwasher (22), and VOLTAGE SELECTION switch (23) from bracket (18). 
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(6) Install VOLTAGE SELECTION switch (23, Figure 4-16), lockwasher (22), and jamnut (21) on 

bracket (18). 

(7) Connect electrical leads to VOLTAGE SELECTION switch (23), and remove tags. 

(8) Install DCS control box top panel, paragraph 4.7.2. 

(9) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

4.8.34 Relays K15, K17, K19, K22, K23. 

a. Inspection. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Remove DCS control box top panel, paragraph 4.7.2. 

(3) Inspect relay (Figure 4-16) for cracks, loose mounting, and other damage. 

(4) Install DCS control box top panel, paragraph 4.7.2. 

b. Removal. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Remove DCS control box top panel, paragraph 4.7.2. 

(4) Release wire clip (26, Figure 4-16), and remove relay from socket. 

c. Testing. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Remove relay K15, see paragraph 4.8.34.b. 

(3) 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. 

(4) Connect multimeter between terminals A and B, and check for indication of 427.5 to 522.5 ohms. 

(5) 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. 

(6) If indications are other than above, relay is defective and must be replaced. 

(7) Install relay, see paragraph 4.8.34.d. 

d. Installation. 

(1) Install relay (Figure 4-16) in socket, and secure with wire clip (26). 
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(2) Install DCS control box top panel, paragraph 4.7.2. 

(3) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

4.8.35 Resistors R16 and R17. 

a. Inspection. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Remove DCS control box top panel, paragraph 4.7.2. 

(3) Inspect resistors (35 and 36, Figure 4-16) for cracks, loose mounting, and other damage. 

(4) Install DCS control box top panel, paragraph 4.7.2. 

b. Testing. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Remove DCS control box top panel, paragraph 4.7.2. 

(4) Set multimeter for ohms, and measure resistance across resistor R16 (35). Multimeter indication 

should be 50 ohms. 

(5) Set multimeter for ohms, and measure resistance across resistor R17 (36). Multimeter indication 

should be 50 ohms. 

(6) If indications are other than above, one or both resistors is defective and must be replaced. 

(7) Install DCS control box top panel, paragraph 4.7.2. 

(8) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

c. Replacement. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Remove DCS control box top panel, paragraph 4.7.2. 

(4) Remove CIM control box assembly, paragraph 4.8.16. 

(5) Remove air baffle. Refer to paragraph 4.8.41. 

(6) Tag and desolder electrical leads from resistors (35 and 36, Figure 4-16). 

(7) Remove nuts (32), lockwashers (33), screws (34) and resistors (35 and 36) from air baffle (30, 

Figure 4-18) of DCS control box assembly. 
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(8) 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. 

(9) Solder electrical leads to resistors (36 and 35, Figure 4-16). Remove tags. 

(10) Install air baffle, refer to paragraph 4.8.41. 

(11) Install CIM, refer to paragraph 4.8.16. 

(12) Install DCS control box top panel, paragraph 4.7.2. 

(13) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

4.8.36 Resistor R6. 

a. Inspection. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Remove DCS control box top panel, paragraph 4.7.2. 

(3) Inspect resistor (41, Figure 4-16) for cracks, breaks, corrosion, bent terminals, and other damage. 

(4) Install DCS control box top panel, paragraph 4.7.2. 

b. Testing. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Remove DCS control box top panel, paragraph 4.7.2. 

(4) Set multimeter for ohms, and measure resistance across resistor (41, Figure 4-16). Multimeter 

indication should be 40 ohms. 

(5) If any indications are other than above, replace resistor. 

(6) Install DCS control box top panel, paragraph 4.7.2. 

(7) Connect negative battery cable to battery, and close BATTERY ACCESS door. 
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c. Replacement. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Remove DCS control box top panel, paragraph 4.7.2. 

(4) Tag and desolder electrical leads from resistor (41, Figure 4-16). 

(5) Open output box access door (Figure 1-2) to access nuts (37). 

(6) Remove nuts (37), lockwashers (38), screws (39), lockwashers (40), resistor (41), and sleeving (42) 

from floor of DCS control box assembly. 

(7) Install sleeving (42), resistor (41), lockwashers (40), screws (39), lockwashers (38), and nuts (37) 

on floor of DCS control box assembly. 

(8) Close output box access door. 

(9) Solder electrical leads on resistor (41). Remove tags. 

(10) Install DCS control box top panel, paragraph 4.7.2. 

(11) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

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. 

a. Inspection. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Remove DCS control box top panel, paragraph 4.7.2. 

(3) Attach ESD wrist strap and connect to ground. 

(4) Inspect DCS wiring harness (43, Figure 4-16) for burned, bent, corroded, and broken terminals. 

(5) Inspect connectors for cracks, corrosion, stripped threads, bent or broken pins, and obvious damage. 

(6) Inspect wire insulation for burns, deterioration, and chafing. 

(7) Disconnect ESD wrist strap, and remove wrist strap. 

(8) Install DCS control box top panel, paragraph 4.7.2. 

b. Testing. 
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(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Remove DCS control box top panel, paragraph 4.7.2. 

(4) Attach ESD wrist strap and connect to ground. 

(5) 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. 

(6) Disconnect ESD wrist strap, and remove wrist strap. 

(7) Install DCS control box top panel, paragraph 4.7.2. 

(8) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

c. Repair. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Remove DCS control box top panel, paragraph 4.7.2. 

(4) Attach ESD wrist strap and connect to ground. 

(5) Replace damaged terminals, wires, and securing hardware on DCS wiring harness (43, Figure 4-16). 

Refer to Schematic, FO-3. 

(6) Disconnect ESD wrist strap, and remove wrist strap. 

(7) Install DCS control box top panel, paragraph 4.7.2. 

(8) 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. 
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a. Inspection. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Remove DCS control box top panel, paragraph 4.7.2. 

(3) Attach ESD wrist strap and connect to ground. 

(4) Inspect connectors on CIM wiring harness (44, Figure 4-16) for cracks, corrosion, bent or broken 

pins, and obvious damage. 

(5) Inspect ribbon cable insulation for burns, deterioration, chafing, and splitting. 

(6) Disconnect ESD wrist strap, and remove wrist strap. 

(7) Install DCS control box top panel, paragraph 4.7.2. 

b. Removal. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Remove DCS control box top panel, paragraph 4.7.2. 

(4) Remove CIM. Refer to paragraph 4.8.16. 

(5) 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. 

(1) Remove CIM wiring harness, 4.8.38. b. Leave ESD wrist strap on. 

(2) 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. 

(3) Install CIM wiring harness, 4.8.38.d. 
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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. 

(2) Disconnect ESD wrist strap, and remove wrist strap. 

(3) Install CIM, refer to paragraph 4.8.16. 

(4) Install DCS control box top panel, paragraph 4.7.2. 

(5) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

4.8.39 DCS Control Panel Assembly. 

a. Removal. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Release DCS control panel by turning two fasteners, and lower panel. 

(4) Remove components from DCS control panel assembly (6, Figure 4-18). Refer to paragraphs 4.8.2 

through 4.8.15. 

(5) 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). 

(6) Remove locknuts (4), bolts (5), and DCS control panel assembly (6) from hinge (9). 

(7) Remove locknuts (7), bolts (8), and hinge (9) from DCS control panel frame (14). 

b. Inspection. 

Inspect DCS control panel assembly (6, Figure 4-18) for dents, cracks, loose paint, and corrosion. 
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c. Repair. 

(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) Repair all dents and cracks, and remove loose paint. 

(3) Remove light corrosion with fine grit abrasive paper (Item 16, Appendix E). 

(4) Repaint surfaces in accordance with TM 43-0139. 

(5) Install components removed in step (1), paragraphs 4.8.2 through 4.8.15. 

d. Installation. 

(1) Install hinge (9, Figure 4-18), bolts (8), and locknuts (7) on DCS control panel frame (14). 

(2) Install DCS control panel assembly (6), bolts (5), and locknuts (4) on hinge (9). 

(3) 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). 

(4) Install components, paragraphs 4.8.2 through 4.8.15. 

(5) Raise and secure DCS control panel. 

(6) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

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) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Remove DCS control box assembly, paragraph 4.8.1. 

(4) Remove CIM, paragraph 4.8.16. 

(5) Remove keypad assembly, paragraph 4.8.17. 

(6) Remove DCS control panel assembly, paragraph 4.8.39. 
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(7) Remove COMMUNICATION RECEPTACLE, paragraph 4.8.18. Do not disconnect electrical 

leads from COMMUNICATION RECEPTACLE. 

(8) Remove PARALLELING RECEPTACLE, paragraph 4.8.19. Do not disconnect electrical leads 

from PARALLELING RECEPTACLE. 

(9) Remove CONVENIENCE RECEPTACLE, paragraph 4.8.20. 

(10) 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). 

(11) If necessary, drill out rivets (15 and 17, Figure 4-18), and remove data plates (16 and 18). 

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) Remove light corrosion with fine grit abrasive paper (Item 16, Appendix E). 

(3) 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). 

(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). 

(3) Install CONVENIENCE RECEPTACLE, paragraph 4.8.20. 

(4) Install PARALLELING RECEPTACLE, paragraph 4.8.19. 

(5) Install COMMUNICATION RECEPTACLE, paragraph 4.8.18. 

(6) Install DCS control panel assembly, paragraph 4.8.39. 

(7) Install keypad assembly, paragraph 4.8.17. 

(8) Install CIM, paragraph 4.8.16. 

(9) Install DCS control box assembly, paragraph 4.8.1. 

(10) Connect negative battery cable to battery, and close BATTERY ACCESS door. 
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FIGURE 4-18. DCS CONTROL BOX PANELS
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4.8.41 DCS Control Box Side Panels. 

a. Removal. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Remove DCS control box top panel, paragraph 4.7.2. 

(4) Remove locknuts (12, Figure 4-18) and bolts (13) securing side panels (26 and 27) to DCS control 

panel frame (14). 

(5) Open output box access door (Figure 1-2), and remove locknuts (19) and bolts (20) securing side 

panel (27) to generator set. 

(6) Remove bolts (21), lockwashers (22), and washers (23) securing side panels (26 and 27) to 

generator set. 

(7) Remove locknuts (24), bolts (25), and side panels (26 and 27) from DCS control box assembly. 

(8) Remove locknuts (28), bolts (29), and air baffle (30) from side panel (27). 

b. Inspection. 

(1) Inspect DCS control panel frame (14, Figure 4-18) for dents, cracks, loose paint, and corrosion. 

(2) Inspect for missing or damaged cage nuts (31). 

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) Remove light corrosion with fine grit abrasive paper (Item 16, Appendix E). 

(3) Repaint surfaces in accordance with TM 43-0139. 

(4) 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. 

(2) Install side panels (27 and 26), bolts (25), and locknuts (24) on DCS control box assembly. 
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(3) Secure side panels (27 and 26) to generator set with washers (23), lockwashers (22), and bolts (21). 

(4) Secure side panel (27) to generator set with bolts (20) and locknuts (19). Close output box access 

door (Figure 1-2). 

(5) 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). 

(6) Install DCS control box top panel, paragraph 4.7.2. 

(7) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

4.8.46 DCS Control Box Bottom. 

a. Removal. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Remove DCS control box assembly, paragraph 4.8.1. 

(4) Remove control box components, paragraphs 4.8.21 through 4.8.36. 

(5) Remove DCS control panel frame, paragraph 4.8.40. 

(6) Remove DCS control box side panels, paragraph 4.8.41. 

(7) Remove bolts (32, Figure 4-18), lockwashers (33), washers (34), and mounting bracket (35) from 

DCS control box bottom (42). 

(8) Remove locknuts (36), screws (37), and relay track (38) from DCS control box bottom (42). 

(9) Remove locknuts (39), screws (40), and latch plate (41) from DCS control box bottom (42). 

(10) Remove screws (30, Figure 4-15), lockwashers (31), washers (32), and standoffs (21 and 26) from 

DCS control box bottom (42, Figure 4-18). 

b. Inspection. 

(1) Inspect DCS control panel bottom (42, Figure 4-18) for dents, cracks, loose paint, and corrosion. 

(2) Inspect for missing or damaged cage nuts (43). 
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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) Repair all dents and cracks, and remove loose paint. 

(2) Remove light corrosion with fine grit abrasive paper (Item 16, Appendix E). 

(3) Repaint surfaces in accordance with TM 43-0139. 

(4) 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). 

(2) Install latch plate (41), screws (40), and locknuts (39) on DCS control box bottom (42). 

(3) Install relay track (38), screws (37), and locknuts (36) on DCS control box bottom (42). 

(4) Install mounting bracket (35), washers (34), lockwashers (33), and bolts (32) on control box bottom 

(42). 

(5) Install DCS control box side panels, paragraph 4.8.41. 

(6) Install DCS control panel frame, paragraph 4.8.40. 

(7) Install control box components, paragraphs 4.8.21 through 4.8.36. 

(8) Install DCS control box assembly, paragraph 4.8.1. 

(9) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

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. 

b. Replacement. 

(1) Drill out rivets, and remove data plate from DCS control box assembly. Refer to paragraph 1.11.2, 

Figure 1-3. 

(2) Install data plate on housing with rivets. 
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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) Shut down generator set, paragraph 2.11.2. 

(2) Remove top housing panel. Refer to paragraph 4.7.3. 

(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. 

(4) Replace damaged parts, refer to paragraph 4.9.1.b. 

(5) Install top housing panel. Refer to paragraph 4.7.3. 

(6) Close engine compartment access doors. 

b. Replacement. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Remove top housing panel and roof stiffener assembly. Refer to paragraph 4.7.3. 

(4) Remove muffler clamp (1, Figure 4-19) from exhaust pipe (8). 

(5) Remove bands (2) from muffler assembly (3) and supports (7). 

(6) Separate exhaust pipe (8) from muffler assembly (3), and remove muffler assembly from generator 

set. 

(7) Remove bolts (4), lockwashers (5), washers (6), and supports (7) from top section floor panel. 

(8) Loosen V-band clamp (9) at turbocharger outlet. 

(9) Remove exhaust pipe (8) and V-band clamp (9) from turbocharger outlet. 
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(10) Inspect muffler assembly (3, Figure 4-19) and exhaust pipe (8) for cracks, excessive corrosion, 

clogging, and other damage. 

(11) Position V-band clamp (9) and exhaust pipe (8) on turbocharger outlet. Tighten clamp. 

(12) Install supports (7), washers (6), lockwashers (5), and bolts (4) on top section floor panel. 

(13) Install muffler (3) and bands (2) on supports (7). 

(14) Position exhaust pipe (8) on muffler (3), and install muffler clamp (1). 

(15) Install roof stiffener assembly and top housing panel. Refer to paragraph 4.7.3. 

(16) Connect negative battery cable to battery, and close BATTERY ACCESS door. 
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FIGURE 4-19. MUFFLER AND EXHAUST PIPE 
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4.9.2 Air Cleaner Assembly. 

a. Inspection. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Remove DCS control box assembly, paragraph 4.8.1. 

(4) Inspect air cleaner assembly (1, Figure 4-20) and mounting bracket (2) for cracks, dents, blockage, 

debris, and other damage. 

(5) Install DCS control box assembly, paragraph 4.8.1. 

(6) Connect negative cable to battery. Close BATTERY ACCESS door. 

b. Service. 

(1) Remove air cleaner filter element, Paragraph 4.9.4. 

(2) Wipe inside of air cleaner housing (3, Figure 4-20) with cleaning cloth (Item 8, Appendix E). 

(3) Install new air cleaner filter element, Paragraph 4.9.4. 

c. Removal. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Remove DCS control box assembly, paragraph 4.8.1. 

(4) Loosen hose clamp (4, Figure 4-20), and remove elbow (5) from air cleaner housing (3). 

(5) Remove nuts (6), lockwashers (7), washers (8), bolts (9), and air cleaner assembly (1) from 

generator set. 

(6) Remove nuts (10), lockwashers (11), bolts (12), and mounting bracket (2) from air cleaner housing 

(3). 
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FIGURE 4-20. AIR CLEANER ASSEMBLY 
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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). 

(2) Using removed components, install air cleaner assembly (1), bolts (9), washers (8), lockwashers (7), 

and nuts (6) on generator set. 

(3) Position elbow (5) and hose clamp (4) on air cleaner housing (3). Tighten hose clamp. 

(4) Install DCS control box assembly, paragraph 4.8.1. 

(5) Connect negative battery cable to battery. Close BATTERY ACCESS door. 

4.9.3 Restriction Indicator. 

a. Inspection. 

(1) Shut down generator set, paragraph 2.11.2. 

(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) Inspect restriction indicator (13, Figure 4-20) for cracks, stripped threads, or other damage. 

(4) Close engine compartment access doors. 

b. Replacement. 

(1) Shut down generator set, paragraph 2.11.2. 

(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) Remove restriction indicator (13, Figure 4-20) from air cleaner housing (3). 
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(4) Install restriction indicator (13) on air cleaner housing (3). Tighten indicator fingertight. 

(5) Close engine compartment access doors. 

4.9.4 Air Cleaner Filter Element. 

a. Removal. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open AIR CLEANER ACCESS door (Figure 1-3). 

(3) Loosen wing nut (14, Figure 4-20), and remove end cap assembly (15) from rod (16) in air cleaner 

housing (3). 

(4) Remove wing nut (17) and filter element (18) from rod (16). 

b. Inspection. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Remove air cleaner filter element, step a above. 

(3) Inspect filter element (18, Figure 4-20) for debris and damage. Replace as necessary. 

(4) Inspect vacuator valve (19) for clogging and debris. Clear as necessary. 

(5) Wipe inside of air cleaner housing (3) with clean, lint-free cloth (Item 8, Appendix E). 

(6) Install air cleaner filter element, step c below. 

c. Installation. 

(1) Install filter element (18, Figure 4-20) and wing nut (17) on rod (16). 

(2) Install end cap assembly (15) on rod (16). Tighten wing nut (14) fingertight. 

(3) Close AIR CLEANER ACCESS door. 

4.9.5 Air Cleaner Hoses. 

a. Inspection. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open left side engine compartment access doors (Figure 1-3). 

(3) Inspect all hoses and tubing (5, 21, 22, and 23, Figure 4-20) for cracks, tears, and holes. 

(4) Inspect hose clamps (4 and 20) for cracks. 

(5) Replace parts as necessary. 
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(6) Close engine compartment access doors. 

b. Removal. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open left side engine compartment access doors (Figure 1-3). 

(3) Loosen hose clamps (4 and 20, Figure 4-20). 

(4) Remove elbow (5) from air cleaner housing (3) and tube assembly (21). 

(5) Remove tube assembly (21) from breather hose (23) and hump hose (22). 

(6) Remove hump hose (22) from turbocharger. 

(7) Remove breather hose (23) from oil breather outlet on valve cover. 

c. Service. 

(1) Remove air cleaner hoses, step b above. 

(2) Clean hoses and tubing with cleaning cloth (Item 8, Appendix E) and with water. 

(3) 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. 

 

(2) Position hose clamp (4) on hump hose (22), and install hump hose on turbocharger. 

 

(3) Position hose clamp (4) on hump hose (22), and install hump hose on tube assembly (21). 

(4) Position hose clamp (20) on breather hose (23), and install breather hose on tube assembly (21). 

(5) Position hose clamps (4) on elbow (5), and install elbow on air cleaner housing (3) and tube 

assembly (21). 

(6) Tighten hose clamps (4 and 20). 

(7) Close engine compartment access doors. 

4.9.6 Crankcase Breather Filter Assembly. 

a. Inspection. 
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(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) 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. 

(4) 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). 

(5) Inspect crankcase breather filter assembly (18) and bracket (17) for cracks, excessive corrosion, and 

other damage. 

(6) Clean light corrosion from bracket (17) and hose attaching points with fine grit abrasive paper (Item 

16, Appendix E). 

(7) Replace damaged parts. 

(8) Close engine compartment access doors. 

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) Shut down generator set, paragraph 2.11.2. 

(2) Open right side engine compartment access doors (Figure 1-2). 

(3) While supporting housing (4, Figure 4-21), loosen collar (3), and remove housing from head (5). 

(4) Remove o-ring (27), end cap (6), filter (7), and filter holder (8) from head (5). Discard filter. 

(5) Install filter holder handtight (8), new filter (7), and end cap (6) in head (5). 

(6) Position housing (4) on head (5) with sight glass (1) visible, and secure with collar (3) handtight. 

(7) Close engine compartment access doors. 
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FIGURE 4-21. CRANKCASE BREATHER FILTER ASSEMBLY
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c. Test.

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open output control box door, refer to Figure 1-2. 

(3) Test heater by disconnecting wires 351A16 and 350A16 at TB7-B10. 

(4) Measure resistance between heater wire 350A16 (HTR1) and ground. Resistance should be 199-

233 ohms. Replace heater if resistance is out of tolerance. 

(5) Measure resistance between heater wire 351A16 (HTR2) and ground. Resistance should be 370-

432 ohms. Replace heater if resistance is out of tolerance. 

(6) 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. 

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) Open right side engine compartment access doors (Figure 1-2). 

(3) 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. 

(4) Loosen hose clamps (9 and 13), and remove flex hoses (10 and 21) from crankcase filter assembly 

(18). 

(5) 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. 

(6) 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). 

(7) 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). 

e. Installation.
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NOTE 

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). 

(2) Install flex hose (10) to crankcase breather and flex hose (21) to exhaust pipe. 

(3) 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). 

(4) Position bracket (17) on engine air intake pipe (20), and secure bracket to pipe with hose clamps 

(13). 

(5) Connect flex hoses (10 and 21) to adapters (19 and 22), and secure with hose clamps (9 and 13). 

(6) Close engine compartment access doors. 

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) Slowly remove radiator cap (1, Figure 4-22) from filler neck (2). 

(3) Install cooling system pressure tester (Appendix B, Section III) in filler neck (2). 

(4) Open engine compartment access doors (Figures 1-2 and 1-3). 

(5) Pump pressure tester until 8 psi is indicated. Check cooling system for leaks. 
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FIGURE 4-22. COOLING SYSTEM (SHEET 1 OF 2) 
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FIGURE 4-22. COOLING SYSTEM (SHEET 2 OF 2) 

 (6) Install radiator cap (1) on pressure tester, and pump tester until 10±1 psi is indicated. Ensure 

radiator cap releases. 

(7) Release pressure from pressure tester, and remove tester from filler neck (2) and radiator cap (1) 

from tester. 

(8) Install radiator cap (1) on filler neck (2). 

(9) Close engine compartment access doors. 

b. Service. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open left side engine compartment access doors (Figure 1-3). 

(3) Flush or drain cooling system in accordance with Preventive Cleaning procedures contained in TM 

750-254. 

(4) Close engine compartment access doors. 
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4.10.2 Filler Hose and Panel. 

a. Removal. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open engine compartment access doors (Figures 1-2 and 1-3).

(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) Slowly remove radiator cap (1, Figure 4-22) from filler neck (2). 

(5) 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. 

(6) Loosen hose clamps (3), and remove filler hose (4) and hose clamps from radiator and filler neck 

(2). 

(7) Loosen hose clamp (5), and disconnect overflow hose (6) from filler neck (2). 

(8) Remove radiator fill panel (7) and filler neck (2) from generator set. 

(9) Remove locknuts (8), bolts (9), chain (10), and filler neck (2) from radiator fill panel (7). 

b. Inspection. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Remove filler hose and panel, step a above. 

(3) Inspect filler hose (4, Figure 4-22) for cracks, holes, and dry rot. 

(4) Inspect radiator filler panel (7), filler neck (2), and radiator cap (1) for cracks, excessive corrosion, 

and other damage. 

(5) Clean light corrosion from filler hose attaching points with fine grit abrasive paper (Item 16, 

Appendix E). 

(6) Replace damaged parts. 

(7) Install filler hose and panel, step c below. 
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c. Installation. 

(1) Install filler neck (2, Figure 4-22), chain (10), bolts (9), and locknuts (8) on radiator fill panel (7). 

(2) Position radiator fill panel (7) and filler neck (2) in generator set. 

(3) Position overflow hose (6) and hose clamp (5) on filler neck (2). Tighten hose clamp. 

(4) Position filler hose (4) and hose clamps (3) on filler neck (2) and radiator. Tighten hose clamps. 

(5) Close coolant drain valve (33), and add coolant/antifreeze to proper level at the filler neck (2). 

(6) Install radiator cap (1) on filler neck (2). 

(7) Install top housing panel. Refer to paragraph 4.7.3. 

(8) Start generator set, paragraph 2.11.1. Allow unit to reach operating temperature, and check for 

leaks. 

(9) Add coolant/antifreeze to overflow bottle as required, paragraph 3.3.4. 

(10) Close engine compartment access doors. 

4.10.3 Fan Guards. 

CAUTION

Fan shroud must be installed when operating Generator Set. 

a. Removal. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Open right side engine compartment access doors (Figure 1-2). 

(4) Remove bolts (1, Figure 4-23), washers (2), lockwashers (3), and right fan guard (5) from brackets 

(10, and 11). 

(5) Remove bolt (14), lockwasher (13), washer (12), and bracket (9) from engine. 

(6) Remove bolts (14), lockwashers (13), washers (12), and brackets (10 and 11) from shroud. 

(7) Open left side engine compartment access doors (Figure 1-3). 

(8) Remove bolts (1), washers (2), lockwashers (3), and left fan guard (4) from brackets (6, 7, and 8). 

(9) Remove bolt (14), lockwasher (13), washer (12), and bracket (6) from engine. 

(10) Remove bolts (14), lockwashers (13), washers (12), and brackets (7 and 8) from shroud. 
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FIGURE 4-23. FAN GUARDS 
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b. Inspection. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open engine compartment access doors (Figures 1-2 and 1-3). 

(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. 

(4) Replace all damaged and missing components. Tighten all loose attaching hardware. 

(5) If necessary, install new protective edging (15), cut to fit. 

(6) Close engine compartment access doors. 

c. Installation. 

(1) Install brackets (7 and 8, Figure 4-23), washers (12), lockwashers (13), and bolts (14) on shroud. 

(2) Install bracket (6), washer (12), lockwasher (13), and bolt (14) on engine. 

(3) Install left fan guard (4), lockwashers (3), washers (2), bolts (1) on brackets (6, 7, and 8). 

(4) Close left side engine compartment doors. 

(5) Install brackets (10 and 11), washers (12), lockwashers (13), and bolts (14) on shroud. 

(6) Install bracket (9), washer (12), lockwasher (13), and bolt (14) on engine. 

(7) Install right fan guard (5), lockwashers (3), washers (2), bolts (1) on brackets (10 and 11). 

(8) Close right side engine compartment access doors. 

(9) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

4.10.4 Coolant Hoses, Upper

a. Removal. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) 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) Slowly remove radiator cap (1, Figure 4-22) from filler neck (2). 

(5) Remove fan guards, paragraph 4.10.3. 

(6) Open coolant drain valve (33), and drain coolant/antifreeze into suitable container. 

(7) Loosen hose clamps (11). Remove upper coolant hose (49) and hose clamps from radiator (32) and 

copper “T” (47). 

(8) Loosen hose clamps (11). Remove upper coolant hose (12) and hose clamps from copper “T” (47) 

and thermostat housing opening. 

(9) Loosen hose clamp (3). Remove copper “T” (47). 

b. Inspection. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Remove upper coolant hoses, step a above. 

(3) Inspect upper coolant hose (12 and 49, Figure 4-22) for cracks, holes, and rotting. 

(4) Clean light corrosion from upper coolant hose attaching points with fine grit abrasive paper (Item 

16, Appendix, E). 

(5) Install upper coolant hoses, step c below. 

c. Installation. 

(1) Install copper “T” (47) and tighten clamp (3). 

(2) Position upper coolant hose (12, Figure 4-22) and hose clamps (11) on thermostat housing opening 

and copper “T” (47). Tighten hose clamps. 

(3) Position upper coolant hose (49) and hose clamps (11) on copper “T” (47) and radiator (32). 

Tighten Clamps. 

(4) Close coolant drain valve (33), and add coolant/antifreeze to proper level at the filler neck (2). 

(5) Install fan guards, paragraph 4.10.3. 

(6) Install radiator cap (1) on filler neck (2). 

(7) Connect negative battery cable to battery, and close BATTERY ACCESS door. 
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(8) Start generator set, paragraph 2.11.1. Allow unit to reach operating temperature, and check for 

leaks. 

(9) Add coolant/antifreeze to overflow bottle as required. 

(10) Close engine compartment access doors. 

(11) Shutdown generator set. 

4.10.5 Coolant Hose, Lower

a. Removal. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) 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) Slowly remove radiator cap (1, Figure 4-22) from filler neck (2). 

(5) Remove fan guards, paragraph 4.10.3. 

(6) Open coolant drain valve (33), and drain coolant/antifreeze into suitable container. 

(7) Loosen hose clamps (13). Remove lower coolant hose (14) and hose clamps from radiator outlet 

opening and water pump opening. 

b. Inspection. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Remove lower coolant hose, step a above. 

(3) Inspect lower coolant hose (14, Figure 4-22) for cracks, holes, and rotting. 

(4) Clean exterior of lower radiator outlet tube with fine grit abrasive paper (Item 16, Appendix, E). 

(5) Install lower coolant hose, step c below. 

c. Installation. 
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(1) Position lower coolant hose (14, Figure 4-22) and hose clamps (13) on water pump opening and 

radiator outlet opening. Tighten hose clamps. 

(2) Close coolant drain valve (33), and add coolant/antifreeze to proper level at the filler neck (2). 

(3) Install fan guards, paragraph 4.10.3. 

(4) Install radiator cap (1) on filler neck (2). 

(5) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

(6) Start generator set, paragraph 2.11.1. Allow unit to reach operating temperature, and check for 

leaks. 

(7) Add coolant/antifreeze to overflow bottle as required. 

(8) Close engine compartment access doors. 

(9) Shut down generator set. 

4.10.6 Coolant Overflow and Drain Hoses. 

a. Removal. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Open engine compartment access doors (Figures 1-2 and 1-3). 

(4) Open coolant drain valve (33, Figure 4-22), and drain coolant/antifreeze into suitable container. 

(5) Locate overflow or drain hose to be removed as shown in Figure 4-22. 

(6) Disconnect hose at both ends, and remove from generator set. 

b. Inspection. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open engine compartment access doors (Figures 1-2 and 1-3). 

(3) Inspect hoses (15, Figure 4-22) for cracks, holes, and rotting. 

(4) Close engine compartment access doors. 

c. Installation. 

(1) Install overflow or drain hose (15, Figure 4-22) in generator set as removed. 

(2) Close coolant drain valve (33), and add coolant/antifreeze to proper level at the filler neck (2). 

(3) Connect negative battery cable to battery, and close BATTERY ACCESS door. 
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(4) Start generator set, paragraph 2.11.1. Allow unit to reach operating temperature, and check for 

leaks. 

(5) Add coolant/antifreeze to overflow bottle as required. 

(6) Close engine compartment access doors. 

(7) Shut down generator set. 

4.10.7 Radiator. 

a. Removal. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open engine compartment access doors (Figures 1-2 and 1-3). 

(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. 

__________ 

WARNING

DC voltages are present at the generator set electrical components even when 

the generator set is shut down. Avoid shorting any positive with a ground 

negative. Failure to comply can cause injury or death. 

(4) Slowly remove radiator cap (1, Figure 4-22) from filler neck (2). 

(5) Remove fan guards, paragraph 4.10.3. 

(6) Open coolant drain valve (33), and drain coolant/antifreeze into suitable container. 

(7) Remove filler hose and panel, paragraph 4.10.2. 

(8) Remove upper coolant hoses, paragraph 4.10.4. 

(9) Remove lower coolant hose, paragraph 4.10.5. 

(10) Remove bolts (16), lockwashers (17), and washers (18), and allow shroud (19) to rest on fan (40). 

(11) Remove nuts (20), lockwashers (21), bolts (22), washers (23), and support tie-rods (24) from 

bracket on engine. 

(12) Remove bolts (25), lockwashers (26), support tie-rods (24), and spacers (27) from radiator (32). 
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(13) Loosen hose clamp (28), and disconnect drain hose (29) from coolant drain valve (33). 

(14) Remove locknuts (30) and washers (31) securing radiator (32) to radiator support (37). 

(15) Lift radiator (32) up and out of generator housing. 

(16) Remove coolant drain valve (33) from radiator (32). 

(17) If necessary, remove nuts (34), lockwashers (35), bolts (36), and radiator support (37) from 

generator set. 

b. Service. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Remove radiator, step a above. 

(3) Inspect radiator for excessive corrosion and scale. 

(4) 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) Clean dirt particles from radiator core air passages using filtered, compressed air, 30 psi maximum. 

(6) Clean exterior surface of radiator with soap and water. 

(7) Install radiator, step d below. 

c. Repair. 

Reference 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. 

(2) Install coolant drain valve (33) on radiator (32). 

(3) Position radiator (32) on radiator support (37), and install washers (31) and locknuts (30). 

(4) Install shroud (19), washers (18), lockwashers (17), and bolts (16). 

(5) Position hose clamp (28) and drain hose (29) on coolant drain valve (33). Tighten hose clamp. 

(6) Install spacers (27), support tie-rods (24), lockwashers (26), and bolts (25) on radiator (32). 
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(7) Install support tie-rods (24), washers (23), bolts (22), lockwashers (21), and nuts (20) on bracket on 

engine. 

(8) Install lower coolant hose, paragraph 4.10.5. 

(9) Install upper coolant hose, paragraph 4.10.4. 

(10) Install fan guards, paragraph 4.10.3. 

(11) Install top section housing, paragraph 4.7.3. 

(12) Install filler hose and panel, paragraph 4.10.2. 

(13) Close coolant drain valve (33), and add coolant/antifreeze to proper level, paragraph 3.3.4. 

(14) Install radiator cap (1) on filler neck (2). 

(15) Start generator set, paragraph 2.11.1. Allow unit to reach operating temperature, and check for 

leaks. 

(16) Add coolant/antifreeze to overflow bottle as required. 

(17) Close engine compartment access doors. 

4.10.8 Fan. 

a. Removal. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Open engine compartment access doors (Figures 1-2 and 1-3). 

(4) Remove fan guards, paragraph 4.10.3. 

(5) Remove bolts (16, Figure 4-22), lockwashers (17), and washers (18), and allow shroud (19) to rest 

on fan (40). 

(6) Remove bolts (38), lockwashers (39), fan (40), and spacer (41) from engine water pump. 

(7) Remove locknuts (42), screws (43), stiffeners (44), supports (45), and seals (46) from shroud (19). 

 

b. Inspection. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Remove fan, step a above. 

(3) Inspect fan (40, Figure 4-22) and blades for cracks, bends, loose rivets, or other damage. 
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(4) Inspect spacer (41) for cracks or other damage. 

(5) 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) Replace damaged parts. 

(7) 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). 

(2) Position spacer (41), fan (40), and shroud (19) in generator set. 

FIGURE 4-24. FAN BELT 
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(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). 

4.10 .9 Fan Belt

a. Inspection

 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS doors (Figure 1-2). 

(3) Disconnect negative battery cable. 

(4) Open engine compartment access doors (Figures 1-2 and 1-3). 

(5) Remove fan guards, paragraph 4.10.3. 

(6) Inspect fan belt (1, Figure 4-24) for fraying, cracks, oil soaking or other damage. 

(7) Replace fan belt that shows any damage or cannot be adjusted for proper tension. 

(8) Install fan guards, paragraph 4.3.10. 

(9) Close engine compartment access doors. 

(10) Connect negative battery cable to battery and close BATTERY ACCESS doors. 

b. Adjustment. 

NOTE 

Run engine for 5 minutes if belt is cold. If belt is hot, let cool for 10 to 15 minutes. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Open engine compartment access doors (Figures 1-2 and 1-3). 

(4) Remove fan guards, paragraph 4.10.3. 

(5) Check fan belt (1, Figure 4-24) for 1/2 inch (1.27 cm) deflection between alternator pulley (2) and 

fan pulley (6). 

(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) Apply outward pressure to alternator front frame until belt tension is correct. 
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(8) Tighten alternator mounting bolt (4) and nut (5). 

(9) Install fan guards, paragraph 4.10.3. 

(10) Close engine compartment access doors. 

(11) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

c. Replacement. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Open engine compartment access doors (Figures 1-2 and 1-3). 

(4) Remove fan guards, paragraph 4.10.3. 

(5) Loosen alternator mounting bolt (4, Figure 4-24) and nut (5). 

(6) Pivot alternator to relieve tension on fan belt (1), and remove belt from alternator pulley (2), 

crankshaft pulley (3), and fan pulley (6). 

(7) Slip fan belt (1) over fan (40, Figure 4-22), and remove fan belt from generator set. 

(8) Slip new fan belt (1, Figure 4-24) over fan (40, Figure 4-22). 

(9) Install new fan belt (1, Figure 4-24) onto alternator pulley (2), crankshaft pulley (3), and fan pulley 

(6). 

(10) Adjust tension on fan belt (1), step b above. 

(11) Install fan guards, paragraph 4.10.3. 

(12) Close engine compartment access doors. 

(13) Connect negative battery cable to battery, and close BATTERY ACCESS door. 
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4.10.10 Coolant Recovery System. 

a. Inspection. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open left side engine compartment access doors (Figure 1-2). 

(3) Inspect coolant recovery system components for cracks, holes, or other damage. 

(4) Replace damaged parts. 

(5) Close engine compartment access doors. 

b. Removal. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open left 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 (3, Figure 4-25). Disconnect hose (4) from overflow bottle (5), and drain 

coolant into suitable container. 

(4) Loosen hose clamp (1), and disconnect hose (2) from overflow bottle (5). 

(5) Remove overflow bottle (5) from wire holder (10). 

(6) Remove nuts (6), lockwashers (7), washers, (8), bolts (9), and wire holder (10) from mounting 

bracket (13). 

(7) Remove bolts (12), lockwashers (11), and mounting bracket (13) from engine. 

c. Installation. 

(1) Install mounting bracket (13, Figure 4-25), lockwashers (11), and bolts (12) on engine. 

(2) Install wire holder (10), washers (8), bolts (9), lockwashers (7), and nuts (6) on mounting bracket 

(13). 

(3) Install overflow bottle (5) in wire holder (10). 

(4) Position hose clamps (1 and 3) and hoses (2 and 4) on overflow bottle (5). Tighten hose clamps. 

(5) Fill overflow bottle (5) with coolant to the COLD level. Refer to Table 3-2 for proper coolant. 
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(6) Start generator set, paragraph 2.11.1. Check for leaks, and run until normal operating temperature is 

reached. 

(7) Add coolant to HOT level of overflow bottle (5). 

(8) Close engine compartment access doors. 

FIGURE 4-25. COOLANT RECOVERY SYSTEM 
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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) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Open engine compartment access doors (Figures 1-2 and 1-3). 

(4) 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. 

(2) Disconnect fuel line at both ends, and remove any clamps. 

(3) Remove fuel line or fitting from generator set. 

(4) Cover or cap all openings. 

(5) Remove any caps, and position fuel line or fitting in generator set. 

(6) Install any clamps as removed, and connect fuel line at both ends. Tighten clamps. 

(7) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

(8) Start generator set, paragraph 2.11.1. Check for fuel leaks. 

(9) Shut down generator set, paragraph 2.11.2. 

(10) Close engine compartment access doors. 

4.11.2 Auxiliary Fuel Pump E1. 

a. Inspection. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open left side engine compartment access doors (Figure 1-3). 
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FIGURE 4-26. FUEL TANK FILLER NECK AND LOW PRESSURE FUEL SYSTEM (SHEET 1 OF 2) 
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FIGURE 4-26. FUEL TANK FILLER NECK AND LOW PRESSURE FUEL SYSTEM (SHEET 2 OF 2) 

(3) Inspect auxiliary fuel pump (11, Figure 4-26) for leaks, cracks, missing hardware, loose 

connections, and other damage. 

(4) Close engine compartment access doors. 

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) Connect generator set to auxiliary fuel supply. 

(3) Open left side engine compartment access doors (Figure 1-3). 

(4) Disconnect auxiliary fuel pump outlet line (5, Figure 4-26) at fuel tank fitting, and place 

disconnected end in measuring container. 

(5) Move generator set ENGINE CONTROL switch to PRIME & RUN AUX FUEL position for one 

minute, and return ENGINE CONTROL switch to OFF position. 

(6) Measuring container should collect at least 36 ounces (1.06 liters) of fuel. Properly dispose of fuel. 

(7) Replace auxiliary fuel pump (11) if delivery amount is less than above. 

(8) Connect auxiliary fuel pump outlet line (5) at fuel tank fitting. 
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(9) Disconnect generator set from auxiliary fuel supply. 

(10) Close engine compartment access doors. 

c. Replacement. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Open left side engine compartment access doors (Figure 1-3). 

(4) Tag and disconnect auxiliary fuel pump (11, Figure 4-26) electrical connector. 

(5) 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. 

(6) Remove fuel strainer (4) from auxiliary fuel pump (11). 

(7) Disconnect auxiliary fuel outlet line (5) from elbow (12). 

(8) Remove nuts (6), lockwashers (7), bolts (8), washers (9), cap and chain assembly (10), and auxiliary 

fuel pump (11) from filler neck panel. 

(9) Remove elbow (12) from auxiliary fuel pump (11). 

(10) If necessary, remove locknut (13) and fitting (14) from filler neck panel. 

(11) If removed, install fitting (14) and locknut (13) on filler neck panel. 

(12) Install elbow (12) on auxiliary fuel pump (11). 

(13) Install auxiliary fuel pump (11), chain assembly (10), washers (9), bolts (8), lockwashers (7), and 

nuts (6) on filler neck panel. 

(14) Connect auxiliary fuel outlet line (5) on elbow (12). 

(15) Install fuel strainer (4) on auxiliary fuel pump (11). 

(16) Remove caps from fuel inlet hose (2), and position hose clamps (1) on fuel inlet hose. Connect fuel 

inlet hose to fitting (3), fitting (3) to fitting (14), and fuel inlet hose to fuel strainer (4). Tighten 

hose clamps. 

(17) Connect auxiliary fuel pump (11) electrical connector. Remove tags. 

(18) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

(19) Move generator set ENGINE CONTROL switch to PRIME AND RUN AUX FUEL position, and 

check for fuel leaks. 

(20) Return ENGINE CONTROL switch to OFF position. 

(21) Close engine compartment access doors. 
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4.11.3 Fuel Tank Filler Neck. 

a. Removal. 

(1) Shut down generator set, paragraph 2.11.2. 

(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) Remove cap (28, Figure 4-26), open fuel drain valve (30), and drain fuel into a suitable container. 

(4) Open left side engine compartment access doors (Figure 1-3). 

(5) Remove filler neck tube and cap assembly (15) from filler neck (24). 

(6) Loosen hose clamp (16), and disconnect hose (17) from connector (18). 

(7) Remove connector (18) from reducer (21). 

(8) Remove seal nut (19), washer (20), and reducer (21) from side of filler neck (24). 

(9) Remove locknuts (22) and bolts (23) securing filler neck (24) to filler neck panel. 

(10) Loosen hose clamps (25 and 26). Remove filler neck (24), fuel fill hose (27), and hose clamps from 

generator set. 

b. Inspection. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Remove fuel tank filler neck, step a above. 

(3) Inspect fuel fill hose (27, Figure 4-26) for cracking, wear, or other damage. 

(4) Inspect filler neck (24) for corrosion, cracking, or other damage. 

(5) Inspect filler neck tube and cap assembly (15) for damage. 

(6) Replace damaged parts. 

(7) Install fuel tank filler neck, step c below. 
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c. Installation. 

(1) Position fuel fill hose (27, Figure 4-26), clamps (25 and 26), and filler neck (24) on fuel tank. 

(2) Secure filler neck (24) to filler neck panel with bolts (23) and locknuts (22). 

(3) Tighten hose clamps (25 and 26). 

(4) Install reducer (21), washer (20), and seal nut (19) on side of filler neck (24). 

(5) Install connector (18) on reducer (21). 

(6) Position hose clamp (16) on hose (17). Connect hose to connector (18), and tighten hose clamp. 

(7) Install filler neck tube and cap assembly (15) in filler neck (24). 

(8) Close engine compartment access doors. 

(9) Close fuel drain valve (30), install cap (28), and service fuel tank. Refer to Table 4-2 for proper 

fuel. 

(10) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

4.11.4 Fuel Drain Valve. 

 Replacement. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Open left side engine compartment access doors (Figure 1-3). 

(4) Remove cap (28, Figure 4-26) from adapter (29). 

__________ 

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) Open fuel drain valve (30), and drain fuel into a suitable container. 

(6) Remove adapter (29) from fuel drain valve (30), and fuel drain valve from elbow (31). 

(7) If necessary, remove elbow (31) and connector (32) from fuel tank fitting. 

(8) If removed, install connector (32) and elbow (31) on fuel tank fitting. 

(9) Install fuel drain valve (30) on elbow (31), and adapter (29) on fuel drain valve. 
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(10) Ensure fuel drain valve (30) is closed, and service fuel tank. Refer to Table 4-2 for proper fuel. 

(11) Check fuel drain valve (30) and fitting for leakage. 

(12) Install cap (28) on adapter (29). 

(13) Close engine compartment access doors. 

(14) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

4.11.5 Fuel Level Sender MT5. 

a. Inspection. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open right side engine compartment access doors (Figure 1-2). 

(3) Inspect fuel level sender (39, Figure 4-26) for loose connections and mounting, and other damage. 

(4) Close engine compartment access doors. 

b. Removal. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), disconnect negative battery cable from battery. 

(3) Open right side engine compartment access doors (Figure 1-3). 

(4) Remove nut (33, Figure 4-26) and electrical lead (34) from fuel level sender (39). Tag lead. 

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 (35), lockwashers (36), washers (37), electrical lead (38), fuel level sender (39), and 

gasket (40) from generator set fuel tank. Tag lead. 

(6) Cover opening in fuel tank. 

c. Testing. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Remove fuel level sender, step b above. 

(3) Position fuel level sender in vertical position, similar to position as installed in fuel tank. 

(4) Set multimeter for ohms. Connect positive lead to fuel level sender terminal and negative lead to 

fuel level sender ground. 
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(5) With fuel level sender arm resting freely in what would be an empty position, multimeter should 

indicate between 216 and 264 ohms. 

(6) Move fuel level sender arm up to what would be a full position. Multimeter should indicate 

between 29.7 and 36.3 ohms. 

(7) Replace fuel level sender if indications are not as above. 

(8) Install fuel level sender, step d below. 

d. Installation. 

(1) Remove cover from fuel tank opening. 

(2) Thoroughly clean mating surfaces for new gasket (40, 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. 

(3) Position fuel level sender (39) in fuel tank. Ensure float is in same position as removed. 

(4) Remove tag from electrical lead (38), and secure fuel level sender (39) and lead to fuel tank with 

washers (37), lockwashers (36), and bolts (35). 

 

(5) Remove tag, and install electrical lead (34) on fuel level sender (39). 

(6) Close engine compartment access doors. 

(7) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

4.11.6 Fuel Pickup. 

a. Removal. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), disconnect negative battery cable from battery. 

(3) Open right side engine compartment access doors (Figure 1-2). 

(4) Disconnect hose (41, Figure 4-26) from adapter (47). 

NOTE

Mark position of fuel pickup before removing. 

(5) Remove screws (42), lockwashers (43), washers (44), fuel pickup (45), and gasket (46) from fuel 

tank. 

(6) Remove adapter (47) from fuel pickup (45). 

(7) Cover opening in fuel tank. 

b. Inspection. 
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(1) Shut down generator set, paragraph 2.11.2. 

(2) Remove fuel pickup, step a above. 

(3) Inspect fuel pickup for clogs, stripped threads, and other damage. 

(4) Replace damaged parts. 

(5) Install fuel pickup, step c below. 

c. Installation. 

(1) Remove cover from fuel tank opening. 

(2) Thoroughly clean mating surfaces for new gasket (46, 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. 

(3) Install adapter (47) on fuel pickup (45). 

(4) Install fuel pickup (45), washers (44), lockwashers (43), and screws (42) on fuel tank. 

(5) Connect hose (41) to adapter (47). 

(6) Close engine compartment access doors. 

(7) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

4.11.7 Ether Cylinder Assembly. 

a. Removal. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open right side engine compartment access doors (Figure 1-2). 

(3) Loosen wingnut (1, Figure 4-27), and unscrew ether cylinder (2) from ether solenoid valve (3). 

(4) Install cap (4) on ether solenoid valve (3). 

(5) Remove nuts (5), lockwashers (6), washers (7), cylinder bracket assembly (8), and bolts (9) from 

generator set housing. 

b. Inspection. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open right side engine compartment access doors (Figure 1-2). 
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FIGURE 4-27. ETHER START SYSTEM
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NOTE

Cylinder bracket assembly is located on the inside wall of the generator housing and 

cannot be adequately inspected when installed. 

(3) Remove ether cylinder, step a above. 

(4) Inspect cylinder bracket assembly (8, Figure 4-27) for cracks, corrosion, stripped or damaged 

threads, and other damage. 

(5) Shake ether cylinder, and listen for liquid. If there is little or no sound of liquid in cylinder, replace 

cylinder. 

(6) Install ether cylinder assembly, step c below. 

c. Installation. 

(1) Install bolts (9, Figure 4-27), cylinder bracket assembly (8), washers (7), lockwashers (6), and nuts 

(5) on generator set housing. 

(2) Remove cap (4) from ether solenoid valve (3). 

(3) Insert ether cylinder (2) through cylinder bracket assembly (8), and screw cylinder into ether 

solenoid valve (3). 

(4) Close clamp of cylinder bracket assembly (8), and tighten wingnut (1). 

(5) Close engine compartment access doors. 

4.11.8 Ether Solenoid Valve L6. 

a. Removal. 

(1) Shut down generator set, paragraph 2.11.2. 

__________ 

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) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Open right side engine compartment access doors (Figure 1-2). 

(4) Tag and disconnect electrical leads from ether solenoid valve (3, Figure 4-27). 

(5) Disconnect tube assembly (10) from adapter (19) and spray nozzle (11). 

(6) Loosen wingnut (1), and unscrew ether cylinder (2) from ether solenoid valve (3). 

(7) Install cap (4) on ether solenoid valve (3). 
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(8) Remove nuts (12), lockwashers (13), washers (14), relay (16), and bolts (15) from generator set 

housing. 

(9) Remove bolts (17) from bracket (18) and remove solenoid (3) from bracket. 

(10) Remove adapter (19) from solenoid (3). 

(11) Remove spray nozzle (11) from engine intake manifold. 

(12) Close engine compartment doors. 

b. Inspection. 

(1) Remove ether solenoid valve, step a above. 

(2) Inspect ether solenoid valve (3, Figure 4-27) for cracks, corrosion, damaged threads, and other 

damage. 

 

(3) Inspect tube assembly (10) for cracks, breaks, pinching, damaged threads, and other damage. 

(4) Inspect spray nozzle (11) for cracks, corrosion, clogging, and other damage. 

(5) Replace any defective parts. 

(6) Install ether solenoid valve, step c below. 

c. Installation. 

(1) Open right side engine compartment access doors (Figure 1-2). 

(2) Install spray nozzle (11, Figure 4-27) on engine intake manifold. 

(3) Install adapter (19) into solenoid (3). 

(4) Install solenoid (3) to bracket (18) with bolts (17). 

(5) Install relay (16), bolts (15), washers (14), lockwashers (13), and bolts (12) on generator set 

housing. 

(6) Remove cap (4) from ether solenoid valve (3). 

(7) Insert ether cylinder (2) through cylinder bracket assembly (8), and screw cylinder into ether 

solenoid valve (3). 

(8) Close clamp of cylinder bracket assembly (8), and tighten wingnut (1). 

(9) Connect tube assembly (10) to adapter (19) and spray nozzle (11). 

(10) Connect electrical leads to ether solenoid valve (3). Remove tags. 

(11) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

(12) Close engine compartment access doors. 
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4.11.9 Ether Solenoid Relay. 

a. Inspection. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open right side engine compartment access doors (Figure 1-2). 

(3) Inspect ether solenoid relay (16, Figure 4-27) for cracks, loose mounting and other damage. 

(4) Replace damaged parts. 

(5) Close engine compartment access doors. 

b. Removal.

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open battery access door (Figure 1-2) and disconnect negative battery cable. 

(3) Open right side engine access doors. 

(4) Tag and disconnect electrical wires from ether solenoid relay (16). 

(5) Remove nut (12), lockwasher (13), washer (14), bolt (15), and ether solenoid relay (16). 

c. Testing.

(1) Shut down generator set, paragraph 2.11.2. 

(2) Tag and disconnect electrical leads to the ether solenoid relay (16, Figure 4-27) and remove from 

generator set. 

(3) Set multimeter for ohms, and connect leads between terminals 85 and 86, and check for an 

indication of 288 to 352 ohms. 

(4) If indications are other than above, relay is defective and must be replaced. 

(5) Attach electrical leads to ether solenoid relay K24 (16) and remove tags. 

d. Installation.

(1) Install ether solenoid relay (16, Figure 4-27) with bolts (15), washers (14), lockwashers (13), and 

nuts (12). 

(2) Attach electrical leads to ether solenoid relay (16) and remove tags. 

(3) Connect negative battery cable to battery, and close battery access door (Figure 1-2) and right side 

engine access doors (Figure 1-2). 

4.11.10 Fuel Filter/Water Separator.

a. Inspection.
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(1) Shut down Generator set , Paragraph 2.11.2 

(2) Open right side engine compartment access doors (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 door. 

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) and Air Vent (1, Fig 3-5), and drain water and sediment into suitable 

container. 

(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 9-2815-259-24, Paragraph 3.12.2. 

d. Installation.

 (1) Refer to Engine Manual 9-2815-259-24, 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) Shut down generator set, paragraph 2.11.2. 

 (2) Open battery access door (Figure 1-2) and disconnect negative cable. 

(3) Open output box access door (Figure 1-2). 

(4) Inspect protective cover (3, Figure 4-28) and moveable terminal board (6) for cracks, breaks, 

corrosion, and other damage. 

(5) Replace defective parts. 
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(6) Connect negative battery cable to battery and close battery access door. 

(7) Close output box access door. 

b. Removal. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Open output box access door (Figure 1-2). 

(4) Remove locknuts (1, Figure 4-28), washers (2), and protective cover (3) from standoffs (4). 

(5) Remove locknuts (5) and moveable terminal board (6) from terminal studs (7). 

c. Installation. 

(1) Install moveable terminal board (6, Figure 4-28) and locknuts (5) on terminal studs (7). 

(2) Install protective cover (3), washers (2), and locknuts (1) on standoffs (4). 

(3) Close output box access door. 

(4) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

4.12.2 Output Box Wiring Harness. 

a. Inspection. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open output box access door (Figure 1-2). 

(3) Inspect wiring harness (8, Figure 4-28) for burned, bent, corroded, and broken terminals. 

(4) Inspect connectors for cracks, corrosion, stripped threads, bent or broken pins, and obvious damage. 

(5) Inspect wire insulation for burns, deterioration, and chafing. 

(6) Close output box access door. 
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FIGURE 4-28. OUTPUT BOX ASSEMBLY 
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b. Testing. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Open output box and engine compartment access doors (Figures 1-2 and 1-3). 

(4) 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. 

(5) Close output box and engine compartment access doors. 

(6) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

c. Repair. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Open applicable access doors (Figures 1-2 and 1-3). 

(4) Replace damaged terminals and securing hardware. 

(5) Close access doors. 

(6) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

4.12.3 Current Transformer CT1, CT2, CT3. 

a. Inspection. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open output box access door (Figure 1-2). 

(3) Inspect current transformer (9, Figure 4-28) for security, cracked housing, broken or stripped 

terminals, and loose or missing hardware. 

(4) Close output box access door. 

b. Testing. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Open output box access door (Figure 1-2). 

(4) Tag and disconnect electrical leads from current transformer (9, Figure 4-28) secondary terminals 

A1, A2, B1, B2, C1 and C2. 
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(5) Set multimeter for ohms, and check for continuity between secondary terminals A1 and A2, B1 and 

B2, and C1 and C2. 

(6) If continuity is not present, current transformer is defective. Notify next higher level of 

maintenance. 

(7) If continuity is present, connect electrical leads to secondary terminals A1, A2, B1, B2, C1, and C2. 

Remove tags. 

(8) Close output box access door. 

(9) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

4.12.4 Droop Current Transformer CT5. 

 a. Inspection.

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open output box access door (Figure 1-2). 

(3) Inspect droop current transformer (10, Figure 4-28) for security, cracked housing, broken wire 

terminals, and loose or missing hardware. If testing or replacement is required, notify next higher 

level of maintenance. 

(4) Close output box access door. 

4.12.5 Power Potential Transformer T1. 

a. Inspection. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open output box access door (Figure 1-2). 

(3) Inspect potential power transformer (11, Figure 4-28) for security, cracked housing, broken wire 

terminals, and loose or missing hardware. If testing or replacement is required, notify next higher 

level of maintenance. 

(4) Close output box access door. 
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4.12.6 AC Circuit Interrupter K1. 

a. Inspection. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open output box access door (Figure 1-2). 

(3) Inspect AC circuit interrupter (17, Figure 4-28) for security, cracked housing, broken wire terminals, 

and loose or missing hardware. 

(4) Close output box access door. 

b. Testing. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Open output box access door (Figure 1-2). 

(4) Set multimeter for ohms, and check for open circuits between AC circuit interrupter (17, Figure 4-

28) terminals A1 and A2, B1 and B2, C1 and C2, and 11 and 12. 

(5) Connect jumper wire from cranking relay (20) terminal A1 to AC circuit interrupter (17) terminal X. 

(6) Connect negative battery cable to battery. 

(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. 

(8) Disconnect negative battery cable. 

(9) Replace AC circuit interrupter if indications are other than as specified above. 

(10) If replacement is not necessary, remove jumper wire from terminal A1 of cranking relay (20) to 

terminal X of AC circuit interrupter (17). 

(11) Close output box access door. 

(12) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

c. Replacement. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Open output box and load terminal board access doors (Figure 1-2). 

(4) Remove rear panel. Refer to paragraph 4.7.5. 

(5) Remove screws (12, Figure 4-28), washers (13), and cover (14) from AC circuit interrupter (17). 
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(6) Tag and disconnect electrical leads from AC circuit interrupter (17). 

(7) Remove locknuts (15), screws (16), and AC circuit interrupter (17) from output box. 

(8) Install AC circuit interrupter (17, Figure 4-28), screws (16), and locknuts (15) on output box. 

(9) Connect electrical leads to AC circuit interrupter (17). Remove tags. 

(10) Install cover (14), washers (13), and screws (12) on AC circuit interrupter (17). 

(11) Install rear panel. Refer to paragraph 4.7.5. 

(12) Close output box and load terminal board access doors. 

(13) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

4.12.7 Cranking Relay K2. 

a. Inspection. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open output box access door (Figure 1-2). 

(3) Inspect cranking relay (20, Figure 4-28) for security, cracked housing, broken wire terminals, and 

loose or missing hardware. 

(4) Close output box access door. 

b. Testing. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Open output box access door (Figure 1-2). 

(4) Tag and disconnect wires from terminals X1, X2, and A2 of cranking relay (20, Figure 4-28). 

(5) Connect a jumper wire between terminals A1 and X1 of cranking relay (20). 

(6) Connect negative battery cable to battery. 

(7) Connect X2 wires disconnected in step 4 to cranking relay (20) terminal X2. Listen for audible 

actuation. 

(8) 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. 

(9) If cranking relay (20) is not defective, disconnect negative battery cable. 

(10) Remove jumper wire from cranking relay (20). 
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(11) Connect wires to terminals X1 and A2 of cranking relay (20). Remove tags. 

(12) Close output box access door. 

(13) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

c. Replacement. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Open output box and right side engine compartment access doors (Figure 1-2). 

(4) Tag and disconnect electrical leads from cranking relay (20, Figure 4-28). 

(5) Remove locknuts (18), screws (19), and cranking relay (20) from output box. 

(6) Install cranking relay (20), screws (19), and locknuts (18) on output box. 

(7) Connect electrical leads to cranking relay (20). Remove tags. 

(8) Close output box and right side engine compartment access doors. 

(9) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

4.12.8 Load Output Terminal Board TB2. 

a. Removal. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Open load terminal board access door (Figure 1-2), and disconnect load output cables L1, L2, L3, 

and N from load output terminal board. 

(4) Remove rear housing panel. Refer to paragraph 4.7.5. 

(5) Remove locknut (1, Figure 4-29), bolt (2), and lockwashers (3) securing ground strap (20) to skid 

base. 

(6) Remove bolts (4), lockwashers (5), and washers (6) securing load output terminal board (11) to 

supports (34 and 35). 

(7) Remove locknuts (7), brass washers (8), electrical leads (9), and varistor leads (10) from load 

terminals (14). Tag leads. 

(8) Remove terminal load board (11) from generator set. 

(9) Remove jamnuts (12), brass washers (13), and load terminals (14) from load output terminal board 

(11). 
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(10) Remove locknuts (15), washers (16), and bus bar (17) from terminal studs (21 and 26). 

(11) Remove locknut (18), lockwasher (19), ground strap (20), and terminal stud (21) from load output 

terminal board (11). 

(12) Remove locknut (22), washer (23), ground bus bar (24), EMI filter (25), and terminal stud (26) from 

load output terminal board (11). 

(13) Disconnect varistor leads (10) from varistors (29). 

(14) Remove locknuts (27), bolts (28), varistors (29), EMI filters (30), and ground plane bar (31) from 

load output terminal board (11). 

(15) Remove locknuts (32), bolts (33), and terminal board supports (34 and 35) from generator set. 

(16) Remove locknuts (36), bolts (37), cord (38), insulated wrench (39), and bracket (40) from terminal 

board support (34). 

b. Inspection. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open load output terminal board access door (Figure 1-2). 

(3) Inspect load output terminal board (11, Figure 4-29) for cracks, corrosion, and obvious damage. 

(4) Inspect load terminals (14) for stripped threads or other obvious damage. 

(5) Inspect varistor leads (10) for damaged insulation and loose terminals. 

(6) Inspect and test varistors (29) as follows: 

(a) Inspect varistors (29) for obvious external damage. 

(b) Remove varistors, refer to paragraph 4.12.8.a. 

(c) Set multimeter for ohms, and test each varistor by connecting multimeter to varistor terminals 

1 and 2. Note multimeter indication. 

(d) Reverse multimeter leads, and note multimeter indication. 

(e) Multimeter indications should be infinite in both directions. 

(f) If indications are other than above, varistors (29) are defective and must be replaced. 

(g) Install varistors, refer to 4.12.8.d. 
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FIGURE 4-29. LOAD OUTPUT TERMINAL BOARD ASSEMBLY (SHEET 1 OF 2) 
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FIGURE 4-29. LOAD OUTPUT TERMINAL BOARD ASSEMBLY (SHEET 2 OF 2) 

(7) Inspect cage nuts (41) for cracking or stripped threads. 

(8) Replace damaged and defective parts. 

(9) Close load output terminal board access door. 

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). 

(2) 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). 

(4) Connect varistor leads (10) to varistors (29). 

(5) Install terminal stud (26), EMI filter (25), ground bus bar (24), washer (23), and locknut (22). 

(6) Install terminal stud (21), ground strap (20), lockwasher (19), and locknut (18) on load output 

terminal board (11). Do not tighten locknut. 
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(7) Install bus bar (17), washers (16), and locknuts (15) on terminal studs (21 and 26). 

(8) Install load terminals (14), brass washers (13), and jamnuts (12) on load output terminal board (11). 

(9) Position load output terminal board (11) in generator set. 

(10) Install varistor leads (10), electrical leads (9), brass washers (8), and locknuts (7) on load terminals 

(14). Remove tags. 

(11) Secure load output terminal board (11) to terminal board supports (34 and 35) with washers (6), 

lockwashers (5), and bolts (4). 

(12) Apply a thin coat of antiseize compound (6, Appendix E) to skid base at ground strap mating 

surface. 

(13) Secure ground strap (20) to skid base with lockwashers (3), bolt (2), and locknut (1). Tighten 

locknut (18). 

(14) Install rear housing panel. Refer to paragraph 4.7.5. 

(15) Connect load output cables L1, L2, L3, and N to load output terminal board assembly, and close 

load terminal board access door. 

(16) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

4.13 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. 

4.13.1 Oil Pressure Sender MT7. 

a. Testing. 

(1) Start generator set, paragraph 2.11.1. 

(2) Open left side engine compartment access doors (Figure 1-3). 

(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. 

(4) Shut down generator set, paragraph 2.11.2. 

(5) If indications are not as above, replace oil pressure sender (1), refer to paragraph 4.13.1. b and d. 
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FIGURE 4-30. ENGINE SWITCHES AND SENDERS
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b. Removal. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Open left side engine compartment access doors (Figure 1-3). 

(4) Disconnect electrical plug connector from oil pressure sender (1, Figure 4-30). 

(5) Remove oil pressure sender (1) from adapter (10). 

c. Service. 

(1) Shut down generator set, paragraph 2.11.2. 

(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. 

__________ 

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 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). 

(4) Inspect oil pressure sender for cracked casing, stripped or damaged threads, corrosion, or other 

damage. 

(5) Replace oil pressure sender if damaged. 

(6) Install oil pressure sender, refer to paragraph 4.13.1.d. 

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. 
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(1) Apply sealing compound (Item 22, Appendix E) to threads of oil pressure sender (1, Figure 4-30), 

and install switch on adapter (10). 

(2) Connect electrical plug connector to oil pressure sender (1). Remove tags. 

(3) Close engine compartment access doors. 

(4) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

4.13.2 Coolant Temperature Sender MT6. 

a. Testing. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Open left side engine compartment access doors (Figure 1-3). 

(4) Remove dead crank switch plate, refer to paragraph 4.14.4. 

(5) Disconnect electrical plug connector from coolant temperature sender (2, Figure 4-30) by 

unscrewing retaining ring. 

(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 70°F, ohm range is 108-111ohms. For each +10°F, add two ohms to either end of range. For 

each -10°F, subtract two ohms. 

Example: 

At 80°F range, should equal 110-113 ohms. 

At 60°F, range should equal 106-109 ohms. 

(7) Connect negative battery cable to battery. 

(8) Start up generator set, paragraph 2.11.1. 

(9) Allow engine to operate while observing multimeter. Ohms indication should decrease as 

temperature rises. 

(10) Shut down generator set, paragraph 2.11.2. 

(11) Disconnect negative battery cable. 

(12) If indications are not as above, replace coolant temperature sender (2). Refer to paragraph 4.13.2. 

b. 

(13) If coolant temperature sender (2) meets above requirements, connect electrical plug connector to 

sender by tightening retaining ring. 

(14) Close engine compartment access doors. 

(15) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

b. Removal. 
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(1) Shut down generator set, paragraph 2.11.2. 

(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) Slowly remove radiator cap (1, Figure 4-22) from filler neck (2). 

(4) 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. 

(5) Close engine block drain valve (3). 

(6) Disconnect electrical plug connector from coolant temperature sender (2). 

(7) Remove coolant temperature sender (2) from engine head. 

c. Service. 

(1) Shut down generator set, paragraph 2.11.2. 

(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). 

(4) Inspect coolant temperature sender for cracked casing, stripped or damaged threads, corrosion, or 

other damage. 

(5) Replace coolant temperature sender if damaged. 

(6) Install coolant temperature sender, 4.13.2.d. 

d. Installation. 
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(1) Apply sealing compound (Item 22, Appendix E) to threads of coolant temperature sender (2, Figure 

4-30), and install switch on engine block. 

(2) Connect electrical plug connector to coolant temperature sender (2). 

(3) Add coolant/antifreeze to proper level at the filler neck (2, Figure 4-22). 

(4) Install radiator cap (1) on filler neck (2). 

(5) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

(6) Start generator set, paragraph 2.11.1. Allow unit to reach operating temperature, and check for 

leaks. 

(7) Add coolant/antifreeze to overflow bottle as required. 

(8) Close engine compartment access doors. 

4.13.3 Magnetic Pickup MPU. 

a. Removal. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Open left side engine compartment access doors (Figure 1-3). 

(4) Disconnect electrical plug connector from magnetic pickup (4, Figure 4-30). 

(5) Loosen locknut (5), and remove magnetic pickup (4) from flywheel housing. 

b. Service. 

(1) Shut down generator set, paragraph 2.11.2. 

(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. 
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__________ 

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). 

(4) Inspect magnetic pickup for cracked casing, stripped or damaged threads, corrosion, and bent or 

broken connector pins. 

(5) Replace magnetic pickup if damaged. 

(6). Install magnetic pickup, 4.13.3.c. 

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). 

(2) Connect electrical plug connector to magnetic pickup (4). Remove tags. 

(3) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

(4) Adjust magnetic pickup (4), 4.13.3.d. 

(5) Close engine compartment access doors. 

d. Testing. 

(1) Disconnect P13 from receptacle J13 at magnetic pickup. Refer to FO-1. 

(2) Set multimeter for VAC, and connect multimeter positive lead to terminal B of P13 and negative 

lead to terminal A. 

(3) 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. 

(4) If indications are not as above, replace magnetic pickup. Refer to paragraph 4.13.3. 
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4.13.4 DEAD CRANK Switch S10. 

a. Testing. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Open left side engine compartment access doors (Figure 1-3). 

(4) Remove DEAD CRANK switch from plate. Refer to paragraph 4.13.4.b. 

(5) Tag and disconnect electrical leads from DEAD CRANK switch (9, Figure 4-30). 

(6) Set multimeter for ohms and with switch in NORMAL position, check for continuity between 

contacts 2 and 3. 

(7) Move switch to CRANK position, and check for continuity between contacts 1 and 2. 

(8) If DEAD CRANK switch (9) fails continuity checks, replace switch. 

(9) If DEAD CRANK switch (9) meets above requirements, connect electrical leads to switch. 

(10) Attach DEAD CRANK switch to plate. Refer to paragraph 4.13.4.b. 

(11) Close engine compartment access doors. 

(12) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

b. Replacement. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Open left side engine compartment access doors(Figure 1-3). 

(4) Remove nut (6), lockwasher (7), key washer (8), and DEAD CRANK switch (9) from DEAD 

CRANK bracket (11). 

(5) Tag and disconnect electrical leads from DEAD CRANK switch (9, Figure 4-30). 

(6) Connect electrical leads to DEAD CRANK switch (9). Remove tags. 

(7) Attach DEAD CRANK switch (9), key washer (8), lockwasher (7), and nut (6) to DEAD CRANK 

bracket (11). 

(8) Close engine compartment doors. 

(9) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

4.13.5 Battery Current Transducer BCT.
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 a. Inspection.

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open right side engine compartment access door, (Figure 1-2). 

(3) Verify that BCT (1, Figure 4-31) housing is not damaged and is securely mounted to its bracket. 

(4) Check plug P1 (2) and wires for broken or chaffed wires. 

(5) Close right side engine compartment access door, (Figure 1-2). 

 b. Testing.

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open battery access door, (Figure 1-2). Disconnect negative battery cable. 

(3) Disconnect P1 (2) from J1 (3) at the battery current transducer. Refer to Schematic FO-1. 

(4) Apply 12VDC at P1 (2) positive DC to red wire, and negative DC to black wire. 

(5) 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. 

(6) If multimeter indicates value other than above, replace Battery Current Transducer (1). 

c. Replacement.

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open battery access door, (Figure 1-2). Disconnect negative battery cable. 

(3) Open right side engine compartment access door, (Figure 1-2). 

(4) Disconnect P1 (2) from J1 (3) at the battery current transducer. 

(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). 

(6) Cut ring terminal (8) from wire number 310A16 and feed wire through the top of the battery current 

transducer (1). 

(7) Tag and remove wire number 145C16 from the positive post of battery number one. 

(8) Cut ring terminal from wire number145C16 and feed the wire through the top of the battery current 

transducer (1). 

(9) Remove the bolts (9), washer (10) and nuts (11) on the battery current transducer. 
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FIGURE 4-31. BATTERY CURRENT TRANSDUCER 
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(10) Place new battery current transducer on bracket (12). Verify that holes line up with mounting 

bracket (12). 

(11) Attach battery current transducer (1) to bracket (12) with bolts (9), washer (10) and nuts (11). 

(12) Feed wire number 310A16 through the battery current transducer. 

(13) Strip 1/4 " of insulation from the end of wire 310A16. 

(14) Crimp ring terminal (8) to the end of wire 310A16. 

(15) Attach wire number 310A16 to the positive post of the alternator with isolating washer (7), terminal 

washer (6), washer (5) and nut (4). 

(16) Feed wire number 145C16 through the top of the battery current transducer (1) and route to the 

battery compartment. 

(17) Strip 1/4 " of insulation from the end of wire 145C16. 

(18) Crimp ring terminal to the end of wire 145C6. 

(19) Attach wire number 145C16 to the positive post of battery number one. Refer to Schematic FO-1. 

(20) Reconnect negative cable to battery. 

(21) Close battery access door, (Figure 1-2). 

(22) Close right side engine compartment access door, (Figure 1-2). 

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) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS and right side engine compartment access doors (Figure 1-2). 

(3) Inspect oil drain line for cracks, holes, loose or missing hardware, or other damage. 

(4) Close BATTERY ACCESS and right side engine compartment access doors. 
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b. Replacement. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Open right side engine compartment access doors (Figure 1-2). 

(4) Remove plug (1, Figure 4-32), open drain valve (4), and drain engine oil into suitable container. 

(5) Loosen hose clamps (2), and remove oil drain hose from adapters (3 and 7). 

(6) Remove adapter (3) from drain valve (4). 

(7) Remove drain valve (4) from pipe fitting (5). 

(8) Remove pipe fitting (5) from skid base fitting (6). 

(9) 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. 

(10) Apply sealing compound (Item 22, Appendix E) to pipe threads of adapters (3 and 7). Install 

adapter on drain valve (4). 

(11) Position hose clamp (2) on oil drain hose. Connect hose to adapters (3 and 7), and tighten hose 

clamp. 

(12) Apply sealing compound (Item 22, Appendix E) to threads of plug (1). Install plug on skid base 

fitting (6). 

(13) Service lubrication system, paragraph 3.3.8. 

(14) Check engine oil drain line and valve for leakage. 

(15) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

(16) Close engine compartment access doors. 
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4-206 

FIGURE 4-32. OIL DRAIN VALVE
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SECTION VII. PREPARATION FOR SHIPMENT AND STORAGE 

4.15 PREPARATION FOR SHIPMENT AND STORAGE. 

4.15.1 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. 
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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 module’s 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 WHAT CONFIGURATION IS CONTROLLED BY THESE SWITCHES 

1- 4 Power rating (30, 60 KW) 

5 Frequency (50/60 or 400 Hz) 

6-8 Not assigned. 

The switch positions applicable to the 30 KW TQG sets are as follows: 

Input/Output Module, Model TCM100:

SWITCH 1 2 3 4 5 6 7 8 GEN SET TYPE 

Setting off off off off off off off off 30 KW, 50/60 Hz MEP-805B 

Input/Output Module, Model TCM400:

SWITCH 1 2 3 4 5 6 7 8 GEN SET TYPE 

Setting off off off off on off off off 30 KW, 400 Hz MEP-815B 
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5-1 

CHAPTER 5 

DIRECT SUPPORT MAINTENANCE INSTRUCTIONS 

CHAPTER INDEX 

SECTION I REPAIR PARTS, TOOLS, TEST, MEASUREMENT AND DIAGNOSTIC 

 (TMDE, AND SUPPORT EQUIPMENT......................................................................................5-1 

SECTION II LUBRICATION PROCEDURES..................................................................................................5-1 

SECTION III TROUBLESHOOTING.................................................................................................................5-2 

SECTION IV DIRECT SUPPORT MAINTENANCE PROCEDURES............................................................5-14 

NOTE 

Procedures may require CD-ROM. See Appendix C. 

SECTION I. REPAIR PARTS; TOOLS; TEST, MEASUREMENT 

AND DIAGNOSTIC (TMDE); AND SUPPORT EQUIPMENT 

5.1 INTRODUCTION. 

5.1.1 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. 

5.1.2 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. 

5.1.3. Fabrication of Tools and Equipment. No requirement exists for fabrication of tools and equipment for 

maintenance of the generator set. 

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. 
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5-2 

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
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5-3 

TABLE 5-1. DIRECT SUPPORT TROUBLESHOOTING 

Not OK

ENGINE CRANKS BUT FAILS TO START

Engine cranks but fails to start.

Verify fuel injection

pump timing. Refer to TM

9-2815-259-24.

Adjust fuel injection pump

timing. Refer to TM

9-2815-259-24. Test electric actuator

(see para 5.9.1).

OK

Refer to TM

9-2815-259-24.

OK

Replace electric

actuator

(para 5.9.1).

Not OK
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TABLE 5-1. DIRECT SUPPORT TROUBLESHOOTING (CONTINUED) 

ENGINE RUNS ERRATICALLY OR STALLS FREQUENTLY

Engine runs erratically or

stalls frequently.

Refer to TM

9-2815-259-24.

 OK Not OK 

 Not OK OK 

ENGINE DOES NOT DEVELOP FULL POWER

Engine does not 

develop full power.

Test fuel injection 

nozzles. Refer to TM 

9-2815-259-24.

Replace fuel injection 

nozzles. Refer to TM 

9-2815-259-24.

Refer to TM 

9-2815-259-24.

Test actuator A6 

(see para. 5.9.1).

Replace actuator A6 

(see para. 5.9.1).
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5-5 

TABLE 5-1. DIRECT SUPPORT TROUBLESHOOTING (CONTINUED) 

 Not OK OK

 Not OK OK

ABNORMAL ENGINE NOISE

Abnormal engine noise.

Visually check for split or

cracked rubber on engine

mounts. Refer to figure 5-1.

Replace engine mounts

(see para. 5.4.2). Check your

drive disc bolts

(Eng to Gen).

Refer to TM

9-2815-259-24.

Tighten drive disc bolts

(Eng to Gen).
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5-6 

TABLE 5-1. DIRECT SUPPORT TROUBLESHOOTING (CONTINUED) 

BLACK OR GRAY EXHAUST SMOKE

Black or gray

exhaust smoke.

Refer to TM

9-2815-259-24.

BLACK OR WHITE EXHAUST SMOKE

Black or White

exhaust smoke.

Refer to TM

9-2815-259-24.
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5-7 

TABLE 5-1. DIRECT SUPPORT TROUBLESHOOTING (CONTINUED) 

ENGINE MISFIRING

Engine misfiring. 

Refer to TM 

9-2815-259-24. 

Coolant in crankcase 

or oil in coolant. 

 Refer to TM 

9-2815-259-24. 

COOLANT IN CRANKCASE OR OIL IN COOLANT
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5-8 

TABLE 5-1. DIRECT SUPPORT TROUBLESHOOTING (CONTINUED) 

 Not OK

 OK Not OK

 OK

GENERATOR SET FAILS TO GENERATE

SUFFICIENT VOLTAGE

Generator set fails to generate

sufficient voltage.

Check for low engine

speed. Refer to

TM 9-2815-259-24.

Refer to TM

9-2815-259-24.

Test generator main

stator (see para. 5.10.7).

Replace defective components.

Test power potential

transformer (see para. 5.8.6).

Replace power potential

transformer (see para.

5.8.6).

 Not OK
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5-9 

TABLE 5-1. DIRECT SUPPORT TROUBLESHOOTING (CONTINUED) 

 Not OK

 OK Not OK

 Not OK OK

GENERATOR SET OUTPUT FLUCTUATES

Generator set output fluctuates.

Check for irregular

engine speed. Refer to

TM 9-2815-259-24.

Refer to TM

9-2815-259-24.

Test generator

 (see para. 5.10).

Replace defective

component.

Check for loose

terminations or load

connections.

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).
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5-10 

TABLE 5-1. DIRECT SUPPORT TROUBLESHOOTING (CONTINUED) 

 OK 

 Not OK 

 OK Not OK 

GENERATOR NOISY WHEN RUNNING

Generator noisy when running.

Check for loose mounting 

hardware between 

generator and engine 

(see para. 5.4.2).

Tighten engine/ generator 

mounting hardware 

 (see para. 5.4.2).

Remove end bell (see para. 

5.10.2). Check main bearing 

for leaks, rough operation, and 

other signs of damage.

Replace main bearing 

(see para. 5.10.2).

Inspect generator 

assembly (see para. 5.10.)

Replace components as 

required.

 Not OK 
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TABLE 5-1. DIRECT SUPPORT TROUBLESHOOTING (CONTINUED) 

ENGINE OIL PRESSURE LOW

Engine oil pressure low. 

Refer to TM 

9-2815-259-24. 

ENGINE OIL PRESSURE HIGH

Refer to TM 

9-2815-259-24. 

Engine oil pressure high. 
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TABLE 5-1. DIRECT SUPPORT TROUBLESHOOTING (CONTINUED) 

FAULT INDICATOR DISPLAYS WARNING - UNDERVOLTAGE

OR CONTACTOR TRIP - UNDERVOLTAGE

FAULT INDICATOR displays WARNING -

UNDERVOLTAGE or CONTACTOR TRIP -

UNDERVOLTAGE.

Check for low engine

speed. Refer to TM

9-2815-259-24.

Repair engine. Refer to

TM 9-2815-259-24.

Not OK

Test potential transformer

(see para. 5.8.6)

Replace potential transformer

(see para 5.8.6).

OK

Not OK

Test generator main

stator (see para. 5.10.7).

OK

Replace components

(see para 5.10.7).

Not OK
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TABLE 5-1. DIRECT SUPPORT TROUBLESHOOTING (CONTINUED) 

FAULT INDICATOR DISPLAYS

SHUTDOWN - OVERSPEED

FAULT INDICATOR displays

SHUTDOWN - OVERSPEED

Test electric actuator

(see para. 5.9.1).

Replace electric actuator

(see para. 5.9.1).

Not OK

Refer to TM

9-2815-259-24.

OK
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5-14 

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) Shut down generator set, paragraph 2.11.2. 

(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. 
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(4) Totally drain radiator and coolant bottle, refer to paragraph 4.10. 

(5) Remove DSC control box, refer to paragraph 4.7.2. 

(6) Remove top housing section, refer to paragraph 4.7.3. 

(7) 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) Disconnect radiator drain hose (paragraph 4.10.7). 

(9) Disconnect engine coolant drain hose at engine petcock (Figure 4-22). 

(10) Disconnect coolant overflow bottle drain line and remove bracket from engine. 

(11) Disconnect fuel water separator drain line. 

NOTE 

Ensure the tie straps are removed as required. 

(12) Remove dead crank switch (save all washers) (paragraph 4.13.4). 

(13) Tag and disconnect fuel float switch (paragraph 4.11.5). 

(14) Tag and disconnect oil pressure sender (4.13.1). 

(15) Unplug electric actuator, P10. 

(16) Unplug magnetic pickup, P12. 

(17) Unplug auxiliary fuel pump, P13. 

(18) Disconnect fuel rail return line and cap (Figure 4-25). 

(19) Disconnect auxiliary pump output line and cap (Figure 4-25). 

(20) Loosen hose clamp (Figure 4-25, 25) from fuel collar fill hose (27). 

(21) Disconnect battery charging alternator output wire. Remove battery charging alternator current 

sensor bracket from alternator. 
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(22) Tag and disconnect crankcase ventilation hose heater wires (4). 

(23) Tag and disconnect wiring harness wires at battery. 

(24) Disconnect ether tube. 

(25) Tag and disconnect wiring harness from ether injection solenoid and relay. 

(26) Tag and disconnect wires to starter, including the ground wires. 

(27) Disconnect fuel line to engine mechanical fuel pump. 

(28) Disconnect fuel vent line at fuel filler neck from t-connection above starter. 

(29) 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). 

(31) Disconnect rotor exciter wires, F1 and F2 from TB8. 

(32) Remove rear generator housing section (paragraph 4.7.5). 

(33) Pull main alternator output wires, T1 through T12, and rotor exciter wires, F1 and F2 through 

hole in bottom of output box. 

(34) Disconnect main output terminal board ground strap from skid. 

(35) Remove right and left side generator housing panels as complete assemblies. 

(36) Remove locknuts (1, Figure 5-1), washers (2), snubbing washers (3), washers (5), bolts (4), and 

engine supports (22) from skid base. 

(37) Remove locknuts (6), washers (7), snubbing washers (10), Belleville washers (9) and bolts (8) 

from generator and skid base. 

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. 

(38) Attach lifting harness to engine and generator lifting points. Raise engine and generator 

assembly from skid base. 

(39) Remove shock mounts (18) from generator mounting points on skid base. 

(40) Remove bolt (45), lockwasher (46), and rear engine lifting bracket (47) from engine. 

(41) Remove bolts (42), lockwashers (43), and front engine lifting bracket (44) from engine. 
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(42) Remove nuts (11), washers (12), plates (16), angles (17), washers (14), nuts (15), and bolts (13) 

from generator. 

(43) Remove bolts (19), lockwashers (20), washers (21), and engine supports (22) from engine. 

(44) Remove bolts (23), lockwashers (24), washers (25), and rear engine supports (26). 

(45) Remove locknuts (27), washers (28), bolts (29) and engine mounts (30) from skid base. 

b. Installation. 

(1) Install engine mounts (30, Figure 5-1), bolts (29), washers (28), and locknuts (27) on skid base. 

(2) Install rear engine supports (26), washers (25), lockwashers (24), and bolts (23) on engine. 

(3) Install engine supports (22), washers (21), lockwashers (20), and bolts (19) on engine. Torque 

bolts to 120 ft-lb (162.6 Nm). 

(4) Position shock mounts (18) at generator mounting points on skid base. 

(5) Install angles (17), plates (16), nuts (15), washers (14), bolts (13), washers (12), and nuts (11) 

on generator. 

(6) Install front engine lifting bracket (44), lockwashers (43), and bolts (42). 

(7) Install rear engine lifting bracket (47), lockwashers (46), and bolts (45). 

CAUTION

Rated capacity of overhead hoist should be at least 2000 lbs (907 kg). Arrange lifting device to 

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.

(8) Attach lifting harness to engine and generator lifting points. Raise engine and generator 

assembly from maintenance stand or fixture. 

(9) Position engine and generator assembly on skid base with mounting holes and brackets aligned. 

(10) Cut cable ties from generator power leads (48). 
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FIGURE 5-1. ENGINE AND GENERATOR ASSEMBLY (SHEET 1 OF 2) 

FIGURE 5-1. ENGINE AND GENERATOR ASSEMBLY (SHEET 2 OF 2) 
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(11) Secure generator to skid base with snubbing washers (10), Belleville washers (9), bolts (8), 

washers (7), and locknuts (6). Torque bolts to 210 ft-lb (284.9 Nm). 

(12) Secure engine supports (22) to skid base with washers (5), bolts (4), snubbing washers (3), 

washers (2), and locknuts (1). Torque locknuts to 75 ft-lb (101.7 Nm). 

(13) Adjust nuts (11 and 15) to obtain 0.5 in. minimum clearance between ends of bolts (13) and skid 

base. Torque bolts to 150 ft-lb (203 Nm). 

(14) Install right and left side generator housing panels as complete assemblies. 

(15) Connect main output terminal board ground strap to skid. 

(16) Pull main alternator output wires, T1 through T12, and rotor exciter wires, F1 and F2 through 

hole in bottom of output box. 

(17) Install rear generator housing section (paragraph 4.7.5). 

(18) Connect rotor exciter wires, F1 and F2 to TB8. 

(19) Install main alternator output wires, T1 through T12, to current Transformer (CT1) and droop 

current transformer (CT5). 

(20) Connect main alternator output wires, T1 through T12, to voltage reconnection switch. 

(21) Connect fuel vent line at fuel filler neck to t-connection above starter. 

(22) Connect fuel line to engine mechanical fuel pump. 

(23) Connect wires to starter, including the ground wires. Remove tags. 

(24) Connect wiring harness to ether injection solenoid and relay. Remove tag. 
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5-20 

(25) Connect ether tube. 

(26) Connect wiring harness wires at battery. Remove tags. 

(27) Connect crankcase ventilation hose heater wires (4). Remove tags. 

(28) Connect battery charging alternator output wire. Install battery charging alternator current 

sensor bracket to alternator. 

(29) Tighten hose clamp (Figure 4-25, 25) to fuel collar fill hose (27). 

(30) Connect auxiliary pump output line and cap (Figure 4-25). 

(31) Connect fuel rail return line and cap (Figure 4-25). 

(32) Plug in auxiliary fuel pump, P13. 

(33) Plug in magnetic pickup, P12. 

(34) Plug in electric actuator, P10. 

(35) Connect oil pressure sender (4.13.1). Remove tag. 

(36) Connect fuel float switch (paragraph 4.11.5). Remove tag. 

(37) Install dead crank switch and saved washers (paragraph 4.13.4). 

(38) Connect fuel water separator drain line. 

(39) Connect coolant overflow bottle drain line and install bracket to engine. 

(40) Connect engine coolant drain hose at engine petcock (Figure 4-22). 

(41) Connect radiator drain hose (paragraph 4.10.7). 

(42) Install air filter assembly, refer to paragraph 4.9.2. 

(43) Install top housing section, refer to paragraph 4.7.3. 

(44) Install DSC control box, refer to paragraph 4.7.2. 

(45) Service engine lubrication system, paragraph 3.3.7. 

(46) Service coolant system, paragraph 3.3.4. 

(47) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

(48) Start generator set, paragraph 2.11.1. Check for proper operation. 
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5-21 

5.4.3 Engine/Generator Disassembly. 

NOTE 

Refer to engine manual TM 9-2815-259-24 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) Remove governor actuator (if replacing the engine). 

(2) Remove temperature sender. 

(3) Remove oil pressure sensor. 

(4) Remove engine coolant drain cock. 

(5) Remove speed sensor and bushing. 

(6) Remove dead crank switch bracket. 

(7) Remove engine legs on bell housing. 

(8) Remove cable on fuel injector pump and bracket. 

(9) Remove bracket for fan guards. 

(10) Remove radiator and brackets. 

(11) Remove breather, breather hoses, heaters and insulation. 

(12) Remove ether injector. 

(13) Remove oil drain from oil pan. 

(14) Remove fan blade and extension hub. 

(15) Remove bracket clamp bolts. 

(16) Remove fuel pump fittings. 

(17) Remove oil sampling valves. 

b. 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. 
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c. Removal. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Remove engine and generator assembly, paragraph 5.4.2. 

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. 

(4) Attach lifting harness to overhead hoist and generator lifting eye. Take up slack on harness. 

(5) Remove nuts (31, Figure 5-1), lockwashers (32), screws (33), washers (34), and band cover (35) 

from generator case. 

(6) Scribe mark on generator drive disc and engine flywheel for alignment of bolts during 

installation. 

(7) Remove bolts (36), lockwashers (37), and washers (38) securing generator drive disc to engine 

flywheel. 

(8) Remove bolts (39), lockwashers (40), and washers (41) securing generator to engine flywheel 

housing. 

(9) Lift generator slowly from engine. Ensure engine flywheel and generator separate smoothly, 

avoiding any undue stress. 

(10) Remove bolts (42), lockwashers (43), and front engine lifting bracket (44) from engine. 

(11) Remove bolt (45), lockwasher (46), and rear engine lifting bracket (47) from engine. 

d. Installation. 

(1) Install rear engine lifting bracket (47, Figure 5-1), lockwasher (46), and bolt (45) on engine. 

(2) Install front engine lifting bracket (44), lockwashers (43), and bolts (42) 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) Attach lifting harness to overhead hoist and generator lifting eye. Take up slack on harness. 

(4) Position generator to mount onto engine. Ensure generator drive disc (22, Figure 5-9) is aligned 

with engine flywheel. Partially install three bolts (39), lockwashers (40), and washers (41) into 

generator housing. Note scribe mark made at removal. 

(5) Secure generator drive disc (22) to engine flywheel with washers (38), lockwashers (37), and 

bolts (36). Torque bolts to 25 ft-lb (33.9 Nm). 
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(6) Secure generator to engine flywheel housing with washers (41), lockwashers (40), and bolts 

(39). Torque bolts to 25 ft-lb (33.9 Nm). 

(7) Install band cover (35), washers (34), screws (33), lockwashers (32), and nuts (31) on generator 

case. 

(8) Detach lifting device from generator lifting eye. 

(9) Install engine and generator assembly, paragraph 5.4.2. 

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) Shut down generator set, paragraph 2.11.2. 

(2) Remove DCS control box top panel, paragraph 4.7.2. 

(3) Attach ESD wrist strap and connect to ground. 

(4) Inspect DCS wiring harness for burned, bent, corroded, and broken terminals. Refer to Figure 4-

16. 

(5) Inspect connectors for cracks, corrosion, stripped threads, bent or broken pins, and obvious 

damage. 

(6) Inspect wire insulation for burns, deterioration, and chafing. 

(7) Disconnect ESD wrist strap, and remove wrist strap. 

(8) Install DCS control box top panel, paragraph 4.7.2.d. 

b. Testing. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Remove DCS control box top panel, paragraph 4.7.2.a. 
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(4) Attach ESD wrist strap and connect to ground. 

(5) Set multimeter for ohms, and test individual wires of DCS wiring harness for continuity. Refer 

to wiring diagram, FO-3, for wire identification. 

(6) Disconnect ESD wrist strap, and remove wrist strap. 

(7) Install DCS control box top panel, paragraph 4.7.2.d. 

(8) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

c. Replacement. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Remove DCS control box top panel, paragraph 4.7.2.a. 

(4) Attach ESD wrist strap and connect to ground. 

(5) 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. 

(6) 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. 

(7) Disconnect ESD wrist strap, and remove wrist strap. 

(8) Install DCS control box top panel, paragraph 4.7.2.d. 

(9) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

5.5.2 Resistor R1. 

a. Replacement. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Remove DCS control box top panel, paragraph 4.7.2. 

(4) Remove sleeving (14), tag and desolder electrical leads from resistor (10, Figure 4-16). Refer to 

Schematic FO-1. 

(5) Remove resistor (10) from auxiliary control bracket (18). 

(6) Install resistor (10) to auxiliary control bracket (18). 

(7) Install sleeving (14) and solder electrical leads to resistor (10). Remove tags. 

(8) Install DCS control box top panel, paragraph 4.7.2. 

(9) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

5.5.3 Resistor R2
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a. Replacement. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Remove DCS control box top panel, paragraph 4.7.2. 

(4) Tag and desolder electrical leads from resistor (13, Figure 4-16). 

(5) Remove nuts (11), lockwashers (12), resistor (13), sleeving (14), screws (15), and lockwashers 

(16) from auxiliary control bracket (18). 

(6) Install lockwashers (16), screws (15), sleeving (14), resistor (13), lockwashers (12), and nuts 

(11) on auxiliary control bracket (18). 

(7) Solder electrical leads to resistor (13). Remove tags. 

(8) Install DCS control box top panel, paragraph 4.7.2. 

(9) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

5.6 MAINTENANCE OF COOLING SYSTEM. 

5.6.1 Radiator. 

 Repair radiator in accordance with TM 750-254. 

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) Shut down generator set, paragraph 2.11.2. 

(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 fuel drain valve assembly. 
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(3) Remove cap (28), Figure 4-25), open fuel drain valve (30), and drain fuel into a suitable 

container. 

(4) Remove engine and generator assembly, paragraph 5.4.2. 

(5) Remove fuel drain valve, paragraph 4.11.4. 

(6) 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. 

(7) Lift fuel tank (7) from skid base. 

(8) Remove fuel level sender, paragraph 4.11.5. 

(9) Remove fuel pickup, paragraph 4.11.6. 

(10) Remove fittings (8) from fitting studs (10) on right side of fuel tank (7). 

(11) Remove fitting (13) from tee (9). 

(12) Remove tee (9) from fitting stud (10) on left side of tank (7). 

(13) Remove fittings studs (10), washers (11), and bushings (12) from fuel tank (7). 

(14) Cover all openings in fuel tank (7). 

b. Inspection. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Remove fuel tank, step 5.7.1a . 

(3) Inspect fuel tank (7, Figure 5-2) for leaks, cracks, missing hardware, and other damage. 

(4) If damage is found, replace fuel tank (7). 

(5) Install fuel tank, step 5.7.1c. 
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c. Installation. 

(1) Uncover openings in fuel tank (7, Figure 5-2). 

(2) Apply sealing compound (Item 22, Appendix E) to threads of fitting studs (10). Install bushings 

(12), washers (11), and fitting studs on fuel tank (7). Torque fitting studs to 40 inch-pounds. 

(3) Apply sealing compound (Item 22, Appendix E) to threads of tee (9). Install tee on fitting stud 

(10) on left side of fuel tank (7). 

(4) Apply sealing compound (Item 22, Appendix E) to threads of fittings (8). Install fittings on 

fitting studs (10) on right side of fuel tank (7). 

(5) Apply sealing compound (Item 22, Appendix E) to threads of fitting (13). Install fitting on tee 

(9) on left side of fuel tank (7). 

(6) Install fuel pickup, paragraph 4.11.6. 

(7) Install fuel level sender, paragraph 4.11.5. 

(8) Position fuel tank (7) in skid base. 

(9) Secure fuel tank (7) to skid base with holddown assemblies (6), washers (5), bolts (4), washers 

(3), lockwashers (2), and bolts (1). 

(10) Install fuel drain valve, paragraph 4.11.4. 

(11) Install engine and generator assembly, paragraph 5.4.2. 

(12) Service fuel tank. Refer to Table 4-1 for proper fuel. 

(13) Connect negative battery cable to battery, and close BATTERY ACCESS door. 
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FIGURE 5-2. FUEL TANK 
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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) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Remove DCS control box assembly, paragraph 4.8.1. 

(4) Remove top housing section, paragraph 4.7.3. 

(5) Remove air cleaner assembly, paragraph 4.9.2. 

(6) Remove output box access door. Refer to paragraph 4.7.1. 

(7) Remove rear housing panel. Refer to paragraph 4.7.5. 

(8) Open left side engine compartment access doors (Figure 1-3). 

(9) Tag and disconnect electrical leads from fuel injection pump (refer to TM 9-2815-259-24), 

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). Disconnect crankcase breather assembly wire 

(refer to paragraph 4.9.6). 

(10) Open right side engine compartment access doors (Figure 1-2). 

(11) Tag and disconnect electrical leads from battery charging alternator, starter, ether solenoid 

valve, fuel level sender (refer to paragraph 4.11.5), and slave cables and battery cables (4.6.2). 

Refer to paragraph 4.11.9 and TM 9-2815-259-24. 

(12) Remove locknuts (1, Figure 5-3), screws (2), and loop clamps (3) from side panel (32) and 

wiring harness (31). 

(13) Remove voltage reconnection terminal board, paragraph 5.8.2. 

(14) 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. 

(15) Unwrap main generator cables from droop current transformer (33) and current transformer (34). 
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(16) Remove screws (7), washers (8), and cover (9) from AC circuit interrupter (35). 

(17) Tag and disconnect output cables from terminals A2, B2, and C2 of AC circuit interrupter (35). 

(18) Tag and disconnect exciter leads F1 and F2 from terminals 1 and 2 of terminal board (29). 

(19) Remove locknuts (10), bolts (11), and output box assembly from generator set. 

b. Installation. 

(1) Install output box assembly on generator set with bolts (11, Figure 5-3) and locknuts (10). 

(2) Connect exciter leads F1 and F2 to terminals 1 and 2 of terminal board (29). Remove tags. 

(3) Connect output cables to terminals A2, B2, and C2 of AC circuit interrupter (35). Remove tags. 

(4) Install cover (9), washers (8), and screws (7) on AC circuit interrupter (35). 

(5) Install main generator cables on current transformer (34) and droop current transformer (33) the 

same number of wraps recorded during removal. 

(6) Install output box top panel (6), bolts (5), and locknuts (4) on output box assembly. 

(7) Install voltage reconnection terminal board, paragraph 5.8.2. 

(8) Install loop clamps (3), screws (2), and locknuts (1) on wiring harness (31) and side panel (32). 

(9) On right side of engine, connect electrical leads from battery charging alternator, starter, ether 

solenoid valve, crankcase breather assembly heater wires, slave cables and battery cables. Refer 

to paragraph 4.11.9 and TM 9-2815-259-24. Remove tags. 

(10) Connect electrical leads to fuel injection pump (refer to TM 9-2815-259-24), 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. 

(11) Install rear housing panel. Refer to paragraph 4.7.5. 

(12) Install output box access door. Refer to paragraph 4.7.1. 

(13) Install air cleaner assembly, paragraph 4.9.2. 

(14) Install top housing section, paragraph 4.7.3. 

(15) Install DCS control box assembly, paragraph 4.8.1. 

(16) Close engine compartment access doors. 

(17) Connect negative battery terminal to battery, and close BATTERY ACCESS door. 
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FIGURE 5-3. OUTPUT BOX ASSEMBLY (SHEET 1 OF 2) 
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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) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Open output box and load terminal board access doors (Figure 1-2). 

(4) Remove locknuts (12, Figure 5-3), washers (13), and protective cover (14) from standoffs (15). 

(5) Remove standoffs (15), washers (16), bolts (17), washers (18), and mounts (19) from rear panel 

(36) and voltage reconnection board (22). 

(6) 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. 

(7) Remove voltage reconnection board (22), with moveable terminal board (24) attached, from rear 

panel (36). 

(8) Remove locknuts (23) and moveable terminal board (24) from terminal studs (26). 

(9) Remove nuts (25) and terminal studs (26) from voltage reconnection board (22). 

(10) Install terminal studs (26) and nuts (25) on voltage reconnection board (22). Torque nuts to 150-

200 in-lb (16.9-22.6 Nm). 

(11) Install moveable terminal board (24) and locknuts (23) on terminal studs (26). 

(12) Position voltage reconnection board (22) and moveable terminal board (24) on rear panel (36). 
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(13) Install capacitors (21), electrical cables, main generator cables, and locknuts (20) on voltage 

reconnection board (22). Remove tags. 

(14) Secure voltage reconnection board (22) to rear panel (36) with mounts (19), washers (18), bolts 

(17), washers (16), and standoffs (15). 

(15) Install protective cover (14), washers (13), and locknuts (12) on standoffs (15). 

(16) Close output box and load terminal board access doors. 

(17) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

5.8.3 Output Box Wiring Harness. 

a. Removal. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Remove DCS control box assembly, paragraph 4.8.1. 

(4) Remove output box top panel, paragraph 5.8.1. 

(5) Open left side engine compartment access doors (Figure 1-3). 

(6) Tag and disconnect crankcase breather assembly heater wires (refer to paragraph 4.9.6) and 

slave and battery cables (refer to paragraph 4.6.2). 

(7) Tag and disconnect electrical leads from fuel injection pump (refer to TM 9-2815-259-24), 

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). 

(8) Open right side engine compartment access doors (Figure 1-2). 

(9) Tag and disconnect electrical leads from battery charging alternator, starter, and ether solenoid 

valve. Refer to paragraph 4.11.9 and TM 9-2815-259-24. 

(10) Open output box access door (Figure 1-2). 

(11) Remove screws (7, Figure 5-3), washers (8), and cover (9) from AC circuit interrupter (35). 

(12) 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). 

(13) Tag and disconnect electrical leads for droop current transformer (33) from terminal board (29). 

(14) Remove locknuts (27), screws (28), and terminal boards (29 and 30) from side panel (32). 

(15) Remove locknuts (1), screws (2), and loop clamps (3) from side panel (32) and wiring harness 

(31). 

(16) Remove wiring harness (31) from output box and generator set. 
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b. Inspection. 

(1) Remove output box wiring harness, step 5.8.3.a above. 

(2) Inspect wiring harness for burned, bent, corroded, and broken terminals. 

(3) Inspect connectors for cracks, corrosion, stripped threads, bent or broken pins, and other 

obvious damage. 

(4) Inspect wire insulation for burns, deterioration, and chafing. 

(5) Install output box wiring harness, step 5.8.3.e below. 

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) Replace damaged cable assemblies, terminals, connectors, sockets, and terminal boards. 

(2) Replace wires with damaged insulation and those that do not indicate continuity. 

e. Installation. 

(1) Position wiring harness (31, Figure 5-3) in output box and generator set. 

(2) Install loops clamps (3), screws (2), and locknuts (1) on wiring harness (31) and side panel (32). 

(3) Install terminal boards (30 and 29), screws (28), and locknuts (27) on side panel (32). 

(4) Connect electrical leads from droop current transformer (33) to terminal board (29). Remove 

tags. 

(5) 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. 

(6) Install cover (9), washers (8), and screws (7) on AC circuit interrupter (35). 

(7) On right side of engine, connect electrical leads from battery charging alternator, starter, and 

ether solenoid valve. Refer to paragraph 4.11.9 and TM 9-2815-259-24. Remove tags. 

(8) Connect crankcase breather assembly heater wires (refer to paragraph 4.9.6) and slave and 

battery cables (refer to paragraph 4.6.2). Remove tags. 
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(9) Connect electrical leads to fuel injection pump (refer to TM 9-2815-259-24), 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. 

(10) Install output box top panel, paragraph 5.8.1. 

(11) Install DCS control box assembly, paragraph 4.8.1. 

(12) Close output box and engine compartment access doors. 

(13) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

5.8.4 Current Transformer CT1, CT2, CT3. 

a. Removal. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Remove DCS control box assembly, paragraph 4.8.1. 

(4) Remove output box top panel, paragraph 5.8.1. 

(5) Open output box and right side engine compartment access doors (Figure 1-2 and 1-3). 

(6) Tag and disconnect electrical leads from current transformer (4, Figure 5-4). 

(7) 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) Unwrap main generator cables from droop current transformer (7) and current transformer (4). 

(9) Remove locknuts (1), screws (2), washers (3), and current transformer (4) from rear panel (33). 

b. Testing. 

(1) Remove current transformer, step 5.8.4.a above. 

(2) 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. 

(3) Set up a test circuit using 10 gauge wire as shown in Figure 5-5. Make 10 passes with wire 

through phase A window. 

(4) Turn on power source and load bank. Adjust load bank until 27.7 amps is indicated on ammeter. 
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(5) Set multimeter for amperes, and connect to secondary terminals A1 and A2. Multimeter 

indication must be 0.9 to 1.1 amps. 

(6) Repeat steps (3) through (5) using phase B window and secondary terminals B1 and B2. 

(7) Repeat steps (3) through (5) using phase C window and secondary terminals C1 and C2. 

(8) Replace current transformer if multimeter indication in any phase is other than stated in step (5). 

(9) Remove current transformer from test circuit. 

(10) Install current transformer, step 5.8.4.c below. 

c. Installation. 

(1) Install current transformer (4, Figure 5-4), washers (3), screws (2), and locknuts (1) on rear 

panel (33). 

(2) Install main generator cables on current transformer (4) and droop current transformer (7) the 

same number of wraps recorded during removal. 

(3) Connect main generator cables T2 and T8 to voltage reconnection board (34). Remove tags. 

(4) Connect electrical leads to current transformer (4). Remove tags. 

(5) Install output box top panel, paragraph 5.8.1. 

(6) Install DCS control box assembly, paragraph 4.8.1. 

(7) Close output box and engine compartment access doors. 

(8) Connect negative battery cable to battery, and close BATTERY ACCESS door. 
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FIGURE 5-4. OUTPUT BOX COMPONENTS
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FIGURE 5-4. OUTPUT BOX COMPONENTS (SHEET 2 OF 2) 

FIGURE 5-5. TESTING CURRENT TRANSFORMER 

5.8.5 Droop Current Transformer CT5. 

a. Removal. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Open output box and right side engine compartment access doors (Figure 1-2). 

(4) 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) Unwrap main generator cables from droop current transformer (7). 

(6) Tag and disconnect droop current transformer (7) electrical leads from terminal board (35). 

(7) Remove locknuts (5), screws (6), and droop current transformer (7) from rear panel (33). 
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b. Testing. 

(1) Remove droop current transformer, step 5.8.5.a above. 

(2) 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. 

(3) 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. 

(4) Turn on power source and load bank. Adjust load bank until 20.8 amps is indicated on AC 

ammeter. 

(5) Set multimeter for AC amperes, and connect to secondary leads 1 and 2. Multimeter indication 

must be 0.9 to 1.1 amps. 

(6) Replace droop current transformer if multimeter indication in any phase is other than stated in 

step (5). 

FIGURE 5-6. TESTING DROOP CURRENT TRANSFORMER

(7) Remove droop current transformer from test circuit. 

(8) Install droop current transformer, step 5.8.5.c below. 

c. Installation. 

(1) Install droop current transformer (7, Figure 5-4), screws (6), and locknuts (5) on rear panel (33). 

(2) Connect droop current transformer (7) electrical leads to terminal board (35). Remove tags. 

(3) Install main generator cables on droop current transformer (7) the same number of wraps 

recorded during removal. 

(4) Connect main generator cables T2 and T8 to voltage reconnection board (34). Remove tags. 

(5) Close output box and engine compartment access doors. 

(6) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

5.8.6 Power Potential Transformer T1. 
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a. Removal. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Remove DCS control box assembly, paragraph 4.8.1. 

(4) Remove output box top panel, paragraph 5.8.1. 

(5) Tag and disconnect electrical leads from power potential transformer (10, Figure 5-4). 

(6) Remove locknuts (8), screws (9), and power potential transformer (10) from rear panel (33). 

b. Testing.

(1) Remove power potential transformer, step 5.8.6.a above. 

(2) Set multimeter for ohms, and take reading between terminals 1 and 2. Reading should be 

between 2.1 and 2.6 ohms. If reading is not within these parameters, the transformer is defective 

and must be replaced. 

(3) Take a reading between terminals 3 and 7. Reading should be between 2.2 and 2.8 ohms. If 

reading is not within these parameters, the transformer is defective and must be replaced. 

(4) Take a reading between terminals 4 and 6. Reading should be between 4.2 and 5.2 ohms. If 

reading is not within these parameters, the transformer is defective and must be replaced. 

(5) Check for an open circuit between terminals 1 and 3, 1 and 4, and 7 and 4. If continuity is 

present between these points, the transformer is defective and must be replaced. 

(6) Turn on power source. Apply 208V RMS/60 Hz to terminals 1 and 2. Check voltage across 

terminals 3 and 7. Reading should be between 139 and 171V RMS. Check voltage across 

terminals 4 and 6. Reading should be between 23 and 29 V RMS. If reading is not within these 

parameters, the transformers is defective and must be replaced. 

(7) Install power potential transformer, step 5.8.6.c below. 

c. Installation. 

(1) Install power potential transformer (10, Figure 5-4), screws (9), and locknuts (8) on rear panel 

(31). 

(2) Connect electrical leads to power potential transformer (10). Remove tags. 

(3) Install output box top panel, paragraph 5.8.1. 

(4) Install DCS control box assembly, paragraph 4.8.1. 

(5) Connect negative battery cable to battery, and close BATTERY ACCESS door. 
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5.8.7 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. 

(2) Inspect grommets (28 and 29), protective edging (30), door seal (31), and EMI seal (32) for 

looseness, tears, deterioration, and other damage. 

b. Removal. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Remove DCS control box assembly, paragraph 4.8.1. 

(4) Remove rear housing panel. Refer to paragraph 4.7.5. 

(5) Remove output box access door. Refer to paragraph 4.7.1. 

(6) Remove air cleaner assembly, paragraph 4.9.2. 

(7) Remove locknuts (11, Figure 5-4), bolts (12), and top panel (13) from output box assembly. 

(8) Remove voltage reconnection terminal board, paragraph 5.8.2. 

(9) Remove droop current transformer, paragraph 5.8.5. 

(10) Remove power potential transformer, paragraph 5.8.6. 

(11) Remove current transformer, paragraph 5.8.4. 

(12) Remove output box wiring harness, paragraph 5.8.3. 

(13) Remove locknuts (14), screws (15), and AC circuit interrupter (16) from rear panel (33). 

(14) Remove locknuts (17), screws (18), and cranking relay (19) from side panel (27). 

(15) Remove locknuts (20), bolts (21), and output box panels (24, 27, and 33) from generator set. 

(16) Remove locknuts (22), bolts (23), and side panel (24) from rear panel (33). 

(17) Remove locknuts (25), bolts (26), and side panel (27) from rear panel (33). 

(18) Remove grommets (28 and 29) from rear panel (33). 
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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) Repair all dents and cracks, and remove loose paint. 

(2) Remove light corrosion with fine grit abrasive paper (Item 16, Appendix E). 

(3) Replace damaged grommets (28 and 29, Figure 5-4) and door seal (31). 

(4) Using adhesive (1, Appendix E), replace damaged protective edging (30). 

(5) Using adhesive (1, Appendix E), replace damaged EMI seal (32). 

(6) Repaint surfaces in accordance with TM 43-0139. 

 

d. Installation. 

(1) Install grommets (28 and 29, Figure 5-4) in real panel (33). 

(2) Install side panel (27), bolts (26), and locknuts (25) on rear panel (33). 

(3) Install side panel (24), bolts (23), and locknuts (22) on rear panel (33). 

(4) Position output box panels (33, 27, and 24) in generator set, and secure with bolts (21) and 

locknuts (20). 

(5) Install cranking relay (19), screws (18), and locknuts (17) on side panel (27). 

(6) Install AC circuit interrupter (16), screws (15), and locknuts (14) on rear panel (33). 

(7) Install output box wiring harness, paragraph 5.8.3. 

(8) Install current transformer, paragraph 5.8.4. 

(9) Install power potential transformer, paragraph 5.8.6. 

(10) Install droop current transformer, paragraph 5.8.5. 

(11) Install voltage reconnection terminal board, paragraph 5.8.2. 

(12) Install output box top panel (13), bolts (12), and locknuts (11) on output box assembly. 

(13) Install air cleaner assembly, paragraph 4.9.2. 

(14) Install output box access door. Refer to paragraph 4.7.1. 

(15) Install rear housing panel. Refer to paragraph 4.7.5. 

(16) Install DCS control box assembly, paragraph 4.8.1. 
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(17) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

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) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Disconnect output box wiring harness from electrical connector (1, Figure 5-7). 

(4) Set multimeter for ohms. Test continuity at contacts within electrical connector (1). Multimeter 

should indicate continuity. 

(5) If multimeter reading is other than above, replace electric actuator (11, Figure 5-8). 

(6) Connect electrical connector (1) to output box wiring harness. 

(7) Connect negative battery cable to battery, and close BATTERY ACCESS door. 
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FIGURE 5-7. ELECTRIC ACTUATOR 
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c. Replacement. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Remove fan guard from left side of generator set. Refer to paragraph 4.10.3. 

(4) Remove dead crank switch plate (10, Figure 4-29). 

(5) Disconnect output box wiring harness from electrical connector (1, Figure 5-7). 

(6) Loosen coupling nut (2), and remove fuel line (3) and seal (4) from elbow (5). 

(7) 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) Remove cap screws (10), electric actuator (11), and gasket (12) from engine. 

(9) Position gasket (12) and electric actuator (11) on engine. Secure with cap screws (10) as noted 

in step (6). 

(10) Install adapter (9), seal (8), adapter (7), seal (6), and elbow (5) on electric actuator (11). 

(11) Position seal (4) and fuel line (3) on elbow (5). Tighten coupling nut (2). 

(12) Connect output box wiring harness to electrical connector (1). 

(13) Install fan guard from left side of generator set. Refer to paragraph 4.10.3. 

(14) Install dead crank switch plate (10, Figure 4-29). 

(15) Connect negative battery cable to battery, and close BATTERY ACCESS door. 
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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. 

5.10.1 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) Shut down generator set, paragraph 2.11.2. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Remove output box assembly, paragraph 5.8.1. 

(4) Remove rear housing section, paragraph 4.7.5. 

(5) Remove load output terminal board, paragraph 4.12.8. 

(6) Remove rear forklift guide. Refer to paragraph 5.11.1. 

(7) Loosen bolts (1, Figure 5-8), and lower engine support brackets (2) to contact skid base. 

(8) Tighten bolts. If necessary, place wooden shims under brackets to ensure contact. 

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. 

(9) Attach lifting harness to overhead hoist and generator lifting eye (27). Take up slack on harness. 

(10) Remove nuts (3), lockwashers (4), screws (5), washers (6), and band cover (7) from generator 

case. 

(11) Remove bolts (8), lockwashers (9), and washers (10) securing generator drive disc (22, Figure 5-

9) to engine flywheel. 

(12) Remove bolts (11), lockwashers (12), and washers (13) securing generator to engine flywheel 

housing. 

(13) Remove locknuts (14), washers (15), bolts (16), Belleville washers (17), and snubbing washers 

(18) securing generator to skid base. 
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(14) Lift generator slowly from skid base. Ensure engine flywheel and generator separate smoothly, 

avoiding any undue stress. 

(15) Remove jamnuts (19), washers (20), bolts (21), washers (22), jamnuts (23), 

plates (24), and angles (25) from generator. 

(16) Remove shock mounts (26) from skid base. 

b. Installation. 

(1) Position shock mounts (26, Figure 5-8) on skid base. 

(2) Install angles (25), plates (24), jamnuts (23), washers (22), bolts (21), washers (20), and jamnuts 

(19) on generator. Do not tighten jamnuts. 

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) Attach lifting harness to overhead hoist and generator lifting eye (27). 

(4) Position generator on skid base with mounting holes aligned to angles (25) and engine flywheel 

housing. 

(5) Secure generator to engine flywheel housing with washers (13), lockwashers (12), and bolts 

(11). Tighten bolts slowly to ensure proper seating of generator case lip in flywheel housing. 

Torque bolts to 25 ft-lb (33.9 Nm). 

(6) Secure generator to skid base with snubbing washers (18), Belleville washers (17), bolts (16), 

washers (15), and locknuts (14). Torque bolts to 210 ft-lb (284.9 Nm). 

(7) Secure generator drive disc to engine flywheel with washers (10), lockwashers (9), and bolts (8). 

Torque bolts to 25 ft-lb (33.9 Nm). 

(8) Install band cover (7), washers (6), screws (5), lockwashers (4), and nuts (3) on generator. 

(9) Adjust jamnuts (19 and 23) on generator mount to obtain 0.5 in. minimum clearance between 

ends of bolts (21) and skid base. Torque nuts to 150 ft-lb (203.4 Nm). 

(10) Detach lifting device from generator lifting eye (27). 

(11) Raise engine support brackets (2) from skid base, and tighten bolts (1). 

(12) Install rear forklift guide. Refer to paragraph 5.11.1. 

(13) Install load terminal board, paragraph 4.12.8. 

(14) Install rear housing section, paragraph 4.7.5. 

(15) Install output box assembly, paragraph 5.8.1. 
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FIGURE 5-8. GENERATOR ASSEMBLY REMOVAL 

(16) Connect negative battery cable to battery, and close BATTERY ACCESS door. 
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(17) Start generator set, paragraph 2.11.1. Check for proper operation. 

5.10.2 End Bell and Main Bearing. 

a. Removal. 

(1) Shut down generator set, paragraph 2.11.2. 

 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Remove rear housing panel. Refer to paragraph 4.7.5. 

(4) Remove bolts (1, Figure 5-9), lockwashers (2), top cover (3), and louvered covers (4) from end 

bell (7). 

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 9-2815-259-24, 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) Remove bolts (5) and lockwashers (6) from end bell (7). 

(6) Install two bolts (5) in back-out holes in end bell flange. Refer to Figure 5-10. 

(7) Loosen lead clamp assembly (33, Figure 5-9) clamping generator leads at side of generator 

housing (11). Ensure wires F1 and F2 are free to slide in and out of generator housing. 

(8) Remove end bell (7), with exciter stator (16) attached, by tightening bolts (5) evenly into back-out 

holes. Remove bolts from back-out holes. 

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. 

(9) Using bearing puller, remove bearing (9) from main rotor shaft (10). Discard bearing. 
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FIGURE 5-9. GENERATOR ASSEMBLY 
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FIGURE 5-10. END BELL REMOVAL

b. 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 (9, Figure 5-9) to expand diameter to fit on main rotor shaft (10). Install new 

bearing (9) on main rotor shaft (10). Ensure bearing is seated squarely against shaft shoulder by 

applying pressure to inner race only. 

(2) Position bearing (9) in end bell (7). 

NOTE 

It may be necessary to use a lifting device to raise and align end ball with 

generator housing. 

(3) Position end bell (7), with exciter stator (16) attached, on generator housing (11) while pulling 

slack of wires F1 and F2 through side of generator housing. Secure end bell with lockwashers 

(6) and bolts (5). Torque bolts to 59-61 in-lb (6.7-7.0 Nm). 

(4) Tighten lead clamp assembly (33) at side of generator housing (11), ensuring generator leads are 

clamped securely. 
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(5) Install louvered cover (4), top cover (3), lockwashers (2), and bolts (1) on end bell (7). 

(6) Install rear housing panel. Refer to paragraph 4.7.5. 

(7) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

5.10.3 Rotating Rectifier. 

a. Testing. 

(1) Shut down generator set, paragraph 2.11.2. Allow generator to cool to ambient temperature. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Remove rear housing panel. Refer to paragraph 4.7.5. 

(4) 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 9-2815-259-24. 

(5) Tag main rotor and diode leads, and remove nuts (1, Figure 5-11), lockwashers (2), and leads 

from terminal bolts (9). 

(6) Tag exciter rotor leads, and remove bolts (3), washers (4), and leads from rectifier mounting 

plate (5). 

(7) Set multimeter for ohms, and connect positive lead to one side and negative lead to other side of 

each diode (6). Record multimeter reading for each diode. 

(8) Repeat step (7) with multimeter leads reversed. 

(9) 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. 

(10) Install exciter rotor leads, washers (4), and bolts (3) on rectifier mounting plate (5). Remove 

tags. 

(11) Install diode and main rotor leads, lockwashers (2), and nuts (1) on terminal bolts (9). 

(12) Install end bell cover plates. Refer to paragraph 5.10.2. 

(13) Install rear housing panel. Refer to paragraph 4.7.5. 

(14) Connect negative battery cable to battery, and close BATTERY ACCESS door. 
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b. Removal. 

(1) Shut down generator set, paragraph 2.11.2. 

 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Remove rear housing panel. Refer to paragraph 4.7.5. 

(4) Remove end bell and main bearing, paragraph 5.10.2. 

(5) Remove nuts (1, Figure 5-11) and lockwashers (2) securing main rotor leads and rotating 

rectifier diode leads to terminal bolts (9). Tag and remove leads. 

(6) Remove bolts (3) and washers (4) securing exciter rotor leads to rotating rectifier plate (5). Tag 

and remove leads. 

(7) Remove bolts (12, Figure 5-9), lockwashers (13), and rotating rectifier (14) from rotor assembly 

(28). 

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. 

(3) Remove rear housing panel. Refer to paragraph 4.7.5. 

(4) 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 9-2815-259-24. 

(5) Unsolder electrical lead from diode (6, Figure 5-11) to be removed. 

(6) Remove nut (7), lockwasher (8), and diode (6) from rotating rectifier plate (5) through access 

hole in end bell. 

(7) Run bead of thermal-electrical contact compound (Item 9, Appendix E) around base of diode (6) 

prior to installing. Do not coat threads. 

(8) Insert diode (6) through generator end bell access hole, and install on rotating rectifier plate (5) 

with lockwasher (8) and nut (7). Torque nut to 28-30 inch-pounds (3.16-3.38 Nm). 

(9) Using soldering iron and solder (Item 19, Appendix E), solder electrical lead to diode (6). 

(10) Install end bell top cover and louvered covers. Refer to paragraph 5.10.2. 
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FIGURE 5-11. RECTIFIER ASSEMBLY 
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(11) Install rear housing panel. Refer to paragraph 4.8.5. 

(12) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

d. Installation. 

(1) Install rotating rectifier (14, Figure 5-9), lockwashers (13), and bolts (12) on rotor assembly 

(28). 

(2) Install exciter rotor leads, washers (4, Figure 5-11), and bolts (3) on rotating rectifier plate (5). 

(3) Install main rotor leads and rotating rectifier diode leads, lockwashers (2), and bolts (1) on 

terminal bolts (9). 

(4) Install end bell and main bearing, paragraph 5.10.2. 

(5) Install rear housing panel. Refer to paragraph 4.7.5. 

(6) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

5.10.4 Exciter Stator. 

a. Inspection.

(1) Shut down generator set, paragraph 2.11.2. Allow generator to cool to ambient temperature. 

 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) 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 chaffing. 

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. 

(2) 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. 

(3) Set multimeter for ohms, and connect between disconnected exciter field leads. Multimeter 

reading should be as shown in Table 5-2. 

(4) Multimeter reading other than in Table 5-2 indicates open or shorted windings, and exciter stator 

must be replaced. 

(5) Connect multimeter between each exciter field lead and generator frame in turn. 

(6) Multimeter reading of less than infinity indicates defective ground insulation, and exciter stator 

must be replaced. 
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TABLE 5-2. GENERATOR RESISTANCE VALUES AT 25° C (77° F) 

 Resistance 

Component MEP-805B MEP-815B 

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 

(7) Connect exciter field leads F1 and F2 to terminals 1 and 2 of terminal board TB8 (Refer to 

Schematic FO-1), and close output box access door. 

(8) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

c. Replacement. 

(1) Shut down generator set, paragraph 2.11.2. 

 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Remove rear housing panel. Refer to paragraph 4.7.5. 

(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. 

(5) 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. 

(6) Remove end bell. Refer to paragraph 5.10.2. 

(7) Remove bolt (15, Figure 5-10) and exciter stator (16) from end bell (7). 

(8) Detach "fish wires" once F1 and F2 leads clear generator housing (11). 

(9) Attach "fish wires" to F1 and F2 leads of exciter stator (16). 

(10) Gently pull on "fish wires" to pull F1 and F2 leads back through generator housing (11). 

Disconnect "fish wires", and position F1 and F2 leads in output box, Figure 1-3. 

(11) Position exciter stator (16) in end bell (7). Secure exciter stator in place with bolt (15). 

(12) Install end bell. Refer to paragraph 5.10.2. 

(13) 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). 

(14) Install rear housing panel. Refer to paragraph 4.7.5. 

(15) Connect negative battery cable to battery, and close BATTERY ACCESS door. 
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5.10.5 Exciter Rotor . 

a. Inspection.

(1) Shut down generator set, paragraph 2.11.2. Allow generator to cool to ambient temperature. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Remove rear housing panel. Refer to paragraph 4.7.5. 

(4) Remove end bell top cover and louvered covers. Refer to paragraph 5.10.2. 

(5) Visually inspect generator assembly for obvious damage. Check exciter leads for broken wires 

and signs of chaffing. 

b. Testing.

(1) Perform inspection per paragraph 5.10.5.a. 

(2) Tag exciter rotor leads, and remove bolts (3, Figure 5-11), lockwashers (4), and leads from 

rotating rectifier plate (5). 

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 9-2815-259-24. 

(3) Connect resistance bridge 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 
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(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 exciter rotor must be replaced. 

Refer to paragraph 5.10.6. 

(5) Set multimeter for ohms, and connect between each exciter rotor lead and rotor shaft in turn. 

(6) Multimeter reading of less than infinity indicates defective ground insulation, and exciter rotor 

must be replaced. Refer to paragraph 5.10.6. 

(7) Install exciter rotor leads, lockwashers (4), and bolts (3) on rotating rectifier plate (5). 

(8) Install end bell top cover and louvered covers. Refer to paragraph 5.10.2. 

(9) Install rear housing panel. Refer to paragraph 4.7.5. 

(10) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

5.10.6 Generator Rotor Assembly. 

a. Testing. 

(1) Shut down generator set, paragraph 2.11.2. Allow generator to cool to ambient temperature. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Remove rear housing panel. Refer to paragraph 4.7.5. 

(4) Remove end bell top cover and louvered covers. Refer to paragraph 5.10.2. 

(5) Remove nuts (1, Figure 5-11) and lockwashers (2) securing main rotor leads to terminal bolts 

(9). 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 9-2815-259-24. 

(6) Set multimeter for ohms, and connect between disconnected main rotor leads. Multimeter 

reading should be as shown in Table 5-2. 

(7) Reading other than in Table 5-2 indicates shorted or open windings, and main rotor must be 

replaced. 

(8) Connect multimeter between each main rotor lead and rotor shaft in turn. 

(9) Multimeter reading of less than infinity indicates defective ground insulation, and main rotor 

must be replaced. 

(10) Install securing main rotor leads and rotating rectifier diode leads, lockwashers (2), and bolts (1) 

on terminal bolt (9). 

(11) Install end bell top cover and louvered covers. Refer to paragraph 5.10.2. 

(12) Install rear housing panel. Refer to paragraph 4.7.5. 

(13) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

b. Removal. 
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(1) Shut down generator set, paragraph 2.11.2. 

(2) Remove generator assembly, paragraph 5.10.1. 

(3) Remove bolts (20, Figure 5-9), washers (21), and drive discs (22) from drive hub (26). 

(4) Remove bolts (23), lockwashers (24), and fan (25) from drive hub (26). 

(5) Attach a suitable rotor lifting device to drive hub (26) and overhead hoist as shown in Figure 5-

12. 

(6) Remove end bell and main bearing. Refer to paragraph 5.10.2. 

(7) 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 (28) and attached components from main stator and generator 

housing (11). 

c. Installation. 

(1) Install rotating rectifier, paragraph 5.10.3. 

(2) 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) Attach suitable rotor lifting device to drive hub (26) and overhead hoist as shown in Figure 5-12. 

(4) Carefully install rotor assembly (28, Figure 5-9) and matched components into main stator and 

generator housing (11). 

(5) Install end bell. Refer to paragraph 5.10.2. Remove rotor lifting device. 

(6) Install fan (25) on drive hub (26) with lockwashers (24) and bolts (23). 
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FIGURE 5-12. ROTOR ASSEMBLY LIFTING DEVICE (TYPICAL) 

NOTE 

Make sure all disc mounting holes at the inner and outer diameter are properly 

aligned. 

(7) Install drive discs (22), washers (21), and bolts (20) on drive hub (26). Torque bolts (20) to 35 

ft-lb (47 Nm). 

(8) Install generator assembly, paragraph 5.10.1. 

5.10.7 Generator Main Stator and Housing, 

a. Testing. 

(1) Shut down generator set, paragraph 2.11.2. Allow generator to cool to ambient temperature. 

(2) Open BATTERY ACCESS door (Figure 1-2), and disconnect negative battery cable. 

(3) Remove rear housing, paragraph 4.7.5. 

(4) Remove voltage reconnection terminal board. Refer to paragraph 5.8.2. 

(5) Tag and disconnect wires from voltage reconnection terminal, paragraph 5.8. 

 

(6) 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. 

(7) All resistance readings should be as shown in Table 5-2. 

(8) If resistance is low, there are shorted windings. If resistance is high, stator windings are open. 

In either case, stator must be replaced. 

(9) Set multimeter for ohms, and connect between each of the ten coil leads from generator clamp 

assembly (3, Figure 5-9) and ground. 
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(10) If multimeter indicates resistance on any connection, stator windings are grounded and stator 

must be replaced. 

(11) Connect wires to voltage reconnection terminal board and remove tags. Refer to paragraph 

5.8.2. 

(12) Install moveable terminal board and protective cover on voltage reconnection terminal board. 

Refer to paragraph 5.8.2. 

(13) Install rear housing, paragraph 4.7.5. 

(14) Connect negative battery cable to battery, and close BATTERY ACCESS door. 

b. Replacement. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Remove generator assembly, paragraph 5.10.1. 

(3) Remove generator rotor assembly, paragraph 5.10.6. 

(4) Install generator rotor assembly, paragraph 5.10.6. 

(5) 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. 

b. Removal. 

(1) Shut down generator set, paragraph 2.11.2. 

(2) Remove engine and generator assembly, paragraph 5.4.2. 

(3) Remove fuel tank, paragraph 5.7.1. 

(4) Remove nuts (1, Figure 5-13), lockwashers (2), bolts (3), washers (4), and forklift guides (5) 

from skid base. 

(5) Remove cable grommets (6 and 7) from skid base. 

c. Repair. 

Repair of skid base will be limited to corrosion control and spot welding minor cracks. If major 
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structural damage has occurred, replace skid base. Repair surfaces in accordance with TM-43-0139. 

d. Installation. 

(1) Install cable grommets (7 and 6, Figure 5-13) in skid base. 

(2) Install forklift guides (5), washers (4), bolts (3), lockwashers (2), and nuts (1) on skid base. 

(3) Install fuel tank, paragraph 5.7.1. 

(4) Install engine and generator assembly, paragraph 5.4.2. 
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FIGURE 5-13. SKID BASE 
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CHAPTER 6 

GENERAL SUPPORT MAINTENANCE INSTRUCTIONS 

NOTE 

There are no general support level maintenance tasks for the generator set. 

Refer to TM 9-2815-259-24 for engine repair at the general support level. 
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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, 

 30 kW, 50/60 and 400 Hz ..................................................................................TM 9-6115-671-24P 

Unit, Direct Support and General support Maintenance Instructions: 

 Diesel Engine, 4 Cylinder ....................................................................................TM 9-2815-259-24 

A.5 MISCELLANEOUS PUBLICATIONS. 

Corrosion and Corrosion Prevention: Metals ........................................................................MIL-HDBK-729

Lubrication Order: Generator Set, Tactical Quiet, 30 kW, 50/60 and 400 Hz ...................LO 9-6115-644-12 

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 

Warranty Technical Bulletin ...............................................................................................TB 9-6115-645-24 
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APPENDIX B 

MAINTENANCE ALLOCATION CHART (MAC) 

SECTION I. INTRODUCTION 

B.1 GENERAL. 

 a. This section provides a general explanation of all maintenance and repair functions authorized at 

various maintenance levels under the standard Army Maintenance System concept. 

 

 b. 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. 

 

 c. Section III lists the tools and test equipment (both special tools and common tool sets) required for 

each maintenance function as referenced from section II. 

 

 d. Section IV contains supplemental instructions and explanatory notes for particular maintenance 

functions. 

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). 

 

 b. Test. To verify serviceability by measuring the mechanical or electrical characteristics of an item and 

comparing those characteristics with prescribed standards. 

 

 c. Service. Operations required periodically to keep an item in proper operating condition, i.e., to clean 

(includes decontamination, when required), preserve, drain, paint, or replenish fuel, lubricants, 

chemical fluids, or gases. 

 

 d. Adjust. To maintain or regulate, within prescribed limits, by bringing into proper position, or by 

setting the operating characteristics to specified parameters. 

 

 e. Align. To adjust specified variable elements of an item to bring about optimum or desired 

performance. 

 

 f. Calibrate. To determine and cause corrections to be made or to be adjusted on instruments or test, 

measuring, and diagnostic equipment used in precision measurement. Consists of comparisons of two 

instruments, one of which is a certified standard of known accuracy, to detect and adjust any 

discrepancy in the accuracy of the instrument being compared. 

 

 g. 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. 
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 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. 

 

 i. 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. 

 

 j. 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. 

 

 k. 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. 

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". 

 

 b. Column 2, Component/Assembly. Column 2 contains the item names of components, assemblies, 

subassemblies, and modules for which maintenance is authorized. 

 

 c. 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). 

 

 d. 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. 
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 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. 

 

f. 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. 

B-4 EXPLANATION OF COLUMNS IN TOOL AND TEST EQUIPMENT REQUIREMENTS, 

SECTION III. 

 a. Column 1, Reference Code. The tool and test equipment reference code correlates with a 

code used in the MAC, Section II, Column 5. 

 

 b. Column 2, Maintenance Level. The lowest level of maintenance authorized to use the tool or 

test equipment. 

 

 c. Column 3, Nomenclature. Name or identification of the tool or test equipment. 

 

 d. Column 4, National Stock Number. The National Stock Number of the tool or test 

equipment. 

 

 e. Column 5, Tool Number. The manufacturer’s part number of the tool or test equipment. 

B.5 EXPLANATION OF COLUMNS IN REMARKS, SECTION IV. 

 a. Column 1, Reference Code. The code recorded in column 6, section II. 

 

 b. 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. 
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B-4 

SECTION II. MAINTANANCE ALLOCATION CHART 

FOR MEP-805B AND 815B (continued) 

(1) 

GROUP 

NUMBER 

(2) 

COMPONENT/ 

ASSEMBLY 

(3) 

MAINTENANCE 

FUNCTION 

(4) 

MAINTENANCE LEVEL 

(5) 

TOOLS AND 

EQUIP 

(6) 

REMARKS 

 C O F H D 

00 GENERATOR SET, 60 KW 

(LESS ENGINE) 

INSPECT 4.3 8.1 2.3 

 TEST .1 6.6 7.6 2,5 

 SERVICE 1.7 2.7 1,2 F 

 ADJUST 2.0 .3 1 

 REPAIR 9.7 3.0 1,2,3,4 

 REMOVE 14.4 22.8 1,2,3 

 INSTALL 14.4 22.8 1,2,3 

 REPLACE 16.1 7.7 1,2 

01 DC ELECTRICAL SYSTEM. INSPECT .3 .3 

 TEST .1 5 

 REPAIR .2 1,2,4 

 SERVICE .1 .3 1,5 F 

 REMOVE .5 1,2,4 

 INSTALL .5 

0101 BATTERIES TEST .1 5 

 REMOVE .2 1 

 INSPECT .1 .1 

 SERVICE .1 .1 1 A,F 

 INSTALL .2 1 

0102 BATTERY AND SLAVE 

RECEPTACLE CABLES. 

INSPECT .1 .1 

 REMOVE .2 1 

 SERVICE .2 1 

 REPAIR .2 2,4 

 INSTALL .2 1 

0103 NATO SLAVE RECEPTACLE. INSPECT .1 .1 

 REMOVE .1 1 

 INSTALL .1 1 

02 HOUSING INSPECT .6 .8 

 REMOVE 4.3 1 

 REPAIR 4.3 1 

 INSTALL 4.3 1 

0201 ACCESS DOORS. REMOVE .5 1 

 REPAIR .5 1 

 INSPECT .1 .1 

 INSTALL .5 1 
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SECTION II. MAINTANANCE ALLOCATION CHART 

FOR MEP-805B AND 815B (continued) 

(1) 

GROUP 

NUMBER 

(2) 

COMPONENT/ 

ASSEMBLY 

(3) 

MAINTENANCE 

FUNCTION 

(4) 

MAINTENANCE LEVEL 

(5) 

TOOLS AND 

EQUIP 

(6) 

REMARKS 

 C O F H D 

202 DCS CONTROL BOX TOP 

PANEL. 

REMOVE .5 1 

 INSPECT 0.1 0.1 

 REPAIR 0.5 1 

 INSTALL 0.5 1 

0203 TOP HOUSING SECTION. REMOVE 1.0 1 

 INSPECT 0.1 0.2 

 REPAIR 1.0 1 

 INSTALL 1.0 1 

0204 FRONT HOUSING SECTION. REMOVE 1.5 1 

 REPAIR 1.0 1 

 INSPECT 0.1 0.2 

 INSTALL 1.5 1 

0205 REAR HOUSING SECTION. REMOVE 2.0 1 

 REPAIR 1.0 1 

 INSPECT 0.1 0.2 

 INSTALL 2.0 1 

0206 HOUSING DATA PLATES INSPECT 0.1 0.1 

 INSTALL 0.3 2 

03 DCS CONTROL BOX 

ASSEMBLY 

REMOVE 0.4 1,6 

 REPAIR 2.7 1,2 C 

 INSPECT 0.2 1.0 .1 

 INSTALL 0.4 1 

 REPLACE 1.0 1.0 1 

 TEST 0.1 1.0 1.0 1,5 

0301 PANEL LIGHTS INSPECT 0.1 0.1 

 REPAIR 0.2 1 C 

 REPLACE 0.3 1 

0302 TIME METER INSPECT 0.1 0.1 

 TEST 0.3 5 

 REPLACE 0.2 1 

0303 SWITCHES INSPECT 0.1 0.1 

 TEST 0.2 5 

 REPLACE 0.2 1 

0304 GROUND FAULT CIRCUIT 

INTERRUPTER 

INSPECT 0.1 0.1 

 TEST 0.1 0.1 5 

 REPLACE 0.5 1 
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SECTION II. MAINTANANCE ALLOCATION CHART 

FOR MEP-805B AND 815B (continued) 

(1) 

GROUP 

NUMBER 

(2) 

COMPONENT/ 

ASSEMBLY 

(3) 

MAINTENANCE 

FUNCTION 

(4) 

MAINTENANCE LEVEL 

(5) 

TOOLS AND 

EQUIP 

(6) 

REMARKS 

 C O F H D 

0305 COMPUTER INTERFACE 

MODULE (CIM). 

INSPECT 0.1 

 REMOVE 0.3 1 

 INSTALL 0.3 1 

0306 KEYPAD ASSEMBLY KP. INSPECT 0.1 0.1 

 REPLACE 0.2 1 E 

0307 COMMUNICATION PORT. INSPECT 0.1 

 REPLACE 0.2 1 

0308 PARALLELING RECEPTACLE INSPECT 0.1 

 REPLACE 0.4 1 

0309 CONVENIENCE 

RECEPTACLE 

INSPECT 0.1 0.1 

 TEST 0.2 5 

 REPLACE 0.5 1 

0310 DCS LOAD SHARING 

SYNCHRONIZER 

INSPECT 0.1 

 REMOVE 0.3 1,6 E 

 INSTALL 0.3 1.6 

 TEST 0.4 

0311 DCS SPEED CONTROL UNIT INSPECT 0.1 

 REMOVE 0.3 1,6 E 

 INSTALL 0.3 1,6 

 TEST 0.4 

0312 AUTOMATIC VOLTAGE 

REGULATOR 

INSPECT 0.1 

 REMOVE 0.3 1,6 E 

 INSTALL 0.3 1,6 

 TEST 0.6 

0313 BACKPLANE MODULE INSPECT 0.1 

 REPLACE 1.0 1,6 E 

 TEST 0.5 

0314 I/O INTERFACE MODULE INSPECT 0.1 

 REPLACE 1.0 1,6 E 

 TEST 0.2 

0315 DC CONTROL POWER 

CIRCUIT BREAKER 

INSPECT 0.1 

 TEST 0.2 5 

 REPLACE 0.5 1 

0316 REACTIVE CURRENT 

ADJUST RHEOSTAT 

INSPECT 0.1 

 TEST 0.2 5 

 REPLACE 0.5 1 
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B-7 

SECTION II. MAINTANANCE ALLOCATION CHART 

FOR MEP-805B AND 815B (continued) 

(1) 

GROUP 

NUMBER 

(2) 

COMPONENT/ 

ASSEMBLY 

(3) 

MAINTENANCE 

FUNCTION 

(4) 

MAINTENANCE LEVEL 

(5) 

TOOLS AND 

EQUIP 

(6) 

REMARKS 

 C O F H D 

317 DIODE INSPECT 0.1 

 TEST 0.2 5 

 REPLACE 0.5 1 

0318 RESISTORS INSPECT 0.1 

 TEST 0.2 5 

 REPLACE 0.5 1 

0319 AUXILIARY CONTROL 

BRACKET. 

INSPECT 0.1 0.1 

 REMOVE 0.2 1 

 REPAIR 0.5 1 D 

 INSTALL 0.5 1 

0320 RELAYS INSPECT 0.1 

 REMOVE 0.2 1 

 TEST 0.3 5 

 INSTALL 0.2 1 

0321 DCS CONTROL BOX WIRING 

HARNESS. 

INSPECT 0.1 0.2 0.1 

 TEST 1.0 1.0 5 E 

 REPAIR 1.0 1 

 REPLACE 8.0 1 

0322 CIM WIRING HARNESS. INSPECT 0.1 0.2 

 TEST 1.0 5 

 REMOVE 0.2 1 E 

 INSTALL 0.2 1 I 

0323 DCS CONTROL PANEL 

FRAME AND PANELS 

REMOVE 1.0 1 

 INSPECT 0.1 0.1 

 REPAIR 1.0 1 

 INSTALL 1.0 1 

0324 DCS DATA PLATES. INSPECT 0.1 0.1 

 REPLACE 0.3 2 

 REPAIR 0.3 

0325 KEYPAD POWER SUPPLY INSPECT 0.2 

 REPLACE 0.4 

 TEST 0.3 

04 AIR INTAKE AND EXHAUST 

SYSTEM. 

INSPECT 0.3 0.9 2 

 SERVICE 0.4 0.4 2 F 

 REPLACE 2.2 1 
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B-8 

SECTION II. MAINTANANCE ALLOCATION CHART 

FOR MEP-805B AND 815B (continued) 

(1) 

GROUP 

NUMBER 

(2) 

COMPONENT/ 

ASSEMBLY 

(3) 

MAINTENANCE 

FUNCTION 

(4) 

MAINTENANCE LEVEL 

(5) 

TOOLS AND 

EQUIP 

(6) 

REMARKS 

 C O F H D 

0401 MUFFLER AND EXHAUST 

PIPE 

INSPECT 0.1 0.5 

 REPLACE 1.5 1 

0402 AIR CLEANER ASSEMBLY REMOVE 1.0 1 

 INSPECT 0.1 0.2 

 SERVICE 0.2 0.2 1 F 

 REPLACE 1.0 1 

0403 CRANKCASE BREATHER 

FILTER ASSEMBLY. 

INSPECT 0.1 0.2 

 SERVICE 0.2 0.2 1 F 

 REPLACE 1.0 1 

05 ENGINE COOLING SYSTEM. INSPECT 0.6 1.0 1 

 TEST 0.5 1 

 SERVICE 0.2 0.5 1 F 

 REMOVE 3.8 

 INSTALL 3.8 

 REPAIR 1.0 

 REPLACE 0.5 1 

0501 HOSES REMOVE 0.5 1 

 INSPECT 0.1 0.4 

 INSTALL 0.5 1 

0502 RADIATOR REMOVE 2.0 1 

 INSPECT 0.1 0.2 

 SERVICE 0.5 1 

 REPAIR 1.0 2 

 INSTALL 2.0 1 

0503 FAN GUARDS. REMOVE 0.5 1 

 INSPECT 0.1 0.1 

 INSTALL 0.5 1 

0504 FAN. REMOVE 1.0 1 

 INSPECT 0.1 0.1 

 INSTALL 1.0 1 

0505 FAN BELT. INSPECT 0.1 0.1 

 ADJUST 0.5 1 

 REPLACE 0.5 1 

0506 COOLANT RECOVERY 

SYSTEM. 

INSPECT 0.1 0.1 

 REMOVE 0.5 1 

 INSTALL 0.5 1 

 SERVICE 0.2 1 F 
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B-9 

SECTION II. MAINTANANCE ALLOCATION CHART 

FOR MEP-805B AND 815B (continued) 

(1) 

GROUP 

NUMBER 

(2) 

COMPONENT/ 

ASSEMBLY 

(3) 

MAINTENANCE 

FUNCTION 

(4) 

MAINTENANCE LEVEL 

(5) 

TOOLS AND 

EQUIP 

(6) 

REMARKS 

 C O F H D 

06 FUEL SYSTEM. INSPECT 0.5 1.0 1 

 INSTALL 2.3 2.5 1,2 

 TEST 1.0 2 

 REMOVE 2.3 2.5 1 

 REPLACE 1.5 1 

 SERVICE 0.8 1 F 

0601 LOW PRESSURE FUEL 

LINES AND FITTINGS. 

INSPECT 0.1 0.2 

 REPLACE 0.5 1 

0602 AUXILIARY FUEL PUMP INSPECT 0.1 

 TEST 0.5 1 

 REPLACE 0.5 1 

0603 FUEL TANK FILLER NECK. REMOVE 0.5 1 

 INSPECT 0.1 

 INSTALL 0.5 1 

0604 FUEL DRAIN VALVE. INSPECT 0.1 

 REPLACE 0.5 1 

0605 FUEL LEVEL SENDER INSPECT 0.1 

 REMOVE 0.2 1 

 TEST 0.3 1,5 

 INSTALL 0.2 1 

0606 FUEL PICKUP. REMOVE 0.5 1 

 INSPECT 0.1 

 INSTALL 0.5 1 

0607 ETHER CYLINDER 

ASSEMBLY. 

REMOVE 0.2 1 

 INSPECT 0.1 0.1 

 INSTALL 0.2 1 

0608 ETHER SOLENOID VALVE REMOVE 0.4 1 

 INSPECT 0.2 

 INSTALL 0.4 1 

0609 FUEL TANK. REMOVE 5.0 2 

 INSPECT 0.2 0.1 0.2 

 SERVICE 0.3 0.2 1 F 

 INSTALL 5.0 2 

0610 FUEL FILTER/WATER 

SEPARATOR. 

INSPECT 0.1 0.1 

 SERVICE 0.5 0.2 1 F 
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B-10 

SECTION II. MAINTANANCE ALLOCATION CHART 

FOR MEP-805B AND 815B (continued) 

(1) 

GROUP 

NUMBER 

(2) 

COMPONENT/ 

ASSEMBLY 

(3) 

MAINTENANCE 

FUNCTION 

(4) 

MAINTENANCE LEVEL 

(5) 

TOOLS AND 

EQUIP 

(6) 

REMARKS 

 C O F H D 

0611 ETHER SOLENOID RELAY INSPECT 0.1 

 REMOVE 0.2 

 TEST 0.2 

 INSTALL 0.2 

07 OUTPUT BOX ASSEMBLY. INSPECT 0.2 1.0 0.6 

 REMOVE 1.2 4.3 1,2 

 INSTALL 1.2 4.3 1,2 

 REPAIR 1.5 2.0 1,2 

 REPLACE 1.0 0.2 1,2 

 TEST 1.6 1.6 1,2 

0701 VOLTAGE RECONNECTION 

TERMINAL BOARD 

INSPECT 0.2 0.2 

 REMOVE 0.4 1,2 

 REPLACE 1.5 1,2 

 INSTALL 0.4 1,2 

0702 OUTPUT BOX WIRING 

HARNESS. 

INSPECT 0.2 0.2 

 REMOVE 2.0 1 

 TEST 0.6 0.6 5 

 REPAIR 0.5 1.0 1,2 

 INSTALL 2.0 1 

0703 TRANSFORMERS INSPECT 0.1 0.1 

 REMOVE 1.3 1 

 TEST 0.4 1.0 5 

 INSTALL 1.3 1 

0704 AC CIRCUIT INTERRUPTER 

RELAY 

INSPECT 0.2 

 TEST 0.3 5 

 REPLACE 1.0 1 

0705 CRANKING RELAY INSPECT 02 

 TEST 0.5 5 

 REPLACE 0.5 1 

0706 OUTPUT BOX PANELS. INSPECT 0.1 0.1 

 REMOVE 1.4 2 

 REPAIR 1.0 1,2 

 INSTALL 1.4 2 

 
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B-11 

SECTION II. MAINTANANCE ALLOCATION CHART 

FOR MEP-805B AND 815B (continued) 

(1) 

GROUP 

NUMBER 

(2) 

COMPONENT/ 

ASSEMBLY 

(3) 

MAINTENANCE 

FUNCTION 

(4) 

MAINTENANCE LEVEL 

(5) 

TOOLS AND 

EQUIP 

(6) 

REMARKS 

 C O F H D 

0707 LOAD OUTPUT TERMINAL 

BOARD TB2. 

REMOVE 1.0 

 INSPECT 0.1 

 REPAIR 1.0 

 INSTALL 1.0 

08 ENGINE ACCESSORIES. INSPECT 0.2 0.1 0.1 

 REPLACE 0.5 0.5 1 

 INSTALL 1.0 1 

 TEST 1.5 0.3 

 REMOVE 1.0 

 SERVICE 1.0 1 

0801 SENDERS INSPECT 0.1 0.1 

 TEST 0.5 5 

 REMOVE 0.5 1 

 SERVICE 0.4 G 

 INSTALL 0.5 1 

0802 MAGNETIC PICKUP MPU. REMOVE 0.4 1 

 SERVICE 0.4 

 INSTALL 0.4 1 

 TEST 0.5 

0803 DEAD CRANK SWITCH INSPECT 0.1 

 TEST 0.5 5 

 REPLACE 0.5 1 

0804 BATTERY CURRENT 

TRANSDUCER 

INSPECT 0.1 

 TEST 0.3 

 REPLACE 1.0 

0805 ELECTRIC ACTUATOR INSPECT 0.1 

 TEST 0.3 5 

 REPLACE 0.5 2 

09 LUBRICATION SYSTEM. INSPECT 0.1 0.2 

 SERVICE 0.2 0.5 2 F 

901 OIL DRAIN VALVE. INSPECT 0.2 

 REPLACE 0.5 2 

10 GENERATOR ASSEMBLY. INSPECT 0.2 1.4 

 REMOVE 9.0 2,3 

 INSTALL 9.0 2,3 

 TEST 5.0 2,5 

 REPLACE 6.0 

 
ARMY TM 9-6115-671-14 

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B-12 

SECTION II. MAINTANANCE ALLOCATION CHART 

FOR MEP-805B AND 815B (continued) 

(1) 

GROUP 

NUMBER 

(2) 

COMPONENT/ 

ASSEMBLY 

(3) 

MAINTENANCE 

FUNCTION 

(4) 

MAINTENANCE LEVEL 

(5) 

TOOLS AND 

EQUIP 

(6) 

REMARKS 

 C O F H D 

1001 END BELL AND MAIN 

BEARING 

REMOVE 2.0 1 

 INSTALL 2.0 1 

1002 ROTATING RECTIFIER TEST 1.0 

 REMOVE 2.5 1 

 INSTALL 2.5 1 

1003 EXCITER STATOR. INSPECT 0.3 

 TEST 0.5 

 REPLACE 4.4 

1004 EXCITER ROTOR INSPECT 0.5 

 TEST 1.0 

1005 GENERATOR ROTOR 

ASSEMBLY. 

INSPECT 0.1 

 TEST 1.0 5 

 REMOVE 3.0 1 

 INSTALL 3.0 1 

1006 GENERATOR MAIN STATOR 

AND HOUSING, 

INSPECT 0.1 

 TEST 1.0 

 REPLACE 10.0 

11 ENGINE ASSEMBLY. INSPECT 0.1 

 REMOVE 4.0 2,3 H 

 INSTALL 4.0 2,3 H 

12 SKID BASE. INSPECT 0.1 0.1 

 REMOVE 6.0 2 

 REPAIR 1.0 2 

 INSTALL 6.0 2 

 
B-13/B-14 BLANK 

SECTION III. TOOLS AND TEST EQUIPMENT 

FOR 

MEP-805B AND MEP-815B 

TOOL OR TEST 

EQUIPMENT 

REF CODE MAINTENANCE 

LEVEL NOMENCLATURE 

NATIONAL 

STOCK NUMBER TOOL NUMBER 

1 O, F TOOL KIT, GENERAL 

MECHANIC’S AUTOMOTIVE 

5180-00-177-7033 SC 5180-90-CL-N26 

(30 October 1986) 

2 O, F SHOP EQUIPMENT, 

AUTOMOTIVE MAINT AND 

REPAIR; ORGANIZATIONAL 

MAINTENANCE, COMMON NO. 

1 (LESS POWER) 

4910-00-754-0654 SC 4910-95-A74 

(10 Sept. 1994) 

3 F SHOP EQUIPMENT, 

AUTOMOTIVE MAINT AND 

REPAIR, FIELD MAINTENANCE, 

WHEELED VEHICLES, POST 

CAMP AND STATION, SET A 

4910-00-348-7696 SC 4910-95-A02 

(1 October 1989) 

4 O, F SHOP EQUIPMENT 

ELECTRICAL REPAIR, SEMI 

TRAILER MOUNTED 

4940-00-294-9517 SC 4940-95-B05 

LIN: T10275 

5 O, F MULTIMETER 6625-01-265-6000 AN/PSM-45A 

6 O, F STRAP, WRIST, 

ELECTROSTATIC DISCHARGE 

5920-01-112-9042 Fluke TL6-60 

SECTION IV. REMARKS 

FOR 

MEP-805B AND MEP-815B 

REFERENCE 

CODE 

REMARKS 

A Wet-cell batteries only. 

B (Not Used) 

C Repair is limited to replacement of light bulbs. 

D Repair is limited to replacement of installed items. 

E Use wrist strap when removing or replacing item in order to prevent possible damage to 

components from electrostatic discharge. 

F 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. 

G This service function involves cleaning of senders with a solvent. 

H Refer to TM 9-2815-259-24 (4-cylinder diesel engine manual). 

I This harness is the ribbon cable harness connecting the DCS modules to the CIM. 
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B-14 

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C-1

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. 

b. Section III, Basic Issue Items. These essential items are required to place the generator set in 

operation, operate it, and to do emergency repairs. Although shipped separately packaged, BII must be 

with the generator set during operation and when it is transferred between property accounts. This list 

is your authority to request/requisition them for replacement based on authorization of the end item by 

the TOE/MTOE. Illustrations are furnished to help you find and identify the items. 

C.3 EXPLANATION OF COLUMNS. 

 The following provides an explanation of columns found in the tabular listing: 

a. Column (1), Illus Number, gives the identifying number of the item illustrated. 

b. Column (2), National Stock Number, identifies the stock number of the item to be used for 

requisitioning purposes. 

c. Column (3), Description and Usable On Code, identifies the Federal item name (in all capital letters) 

followed by a minimal description when needed. The last line below the description is the Commercial 

and Government Entity Code (CAGEC) in parentheses and the part number. 

d. Column (4), U/I (unit of issue), indicates how the item is issued for the National Stock Number shown 

in column (2). 

e. Column (5), Qty Rqd, indicates the quantity required. 

SECTION II. COMPONENTS OF END ITEM 

NONE 
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C-2 

SECTION III. BASIC ISSUE ITEMS 

(1) 

Illus 

Number 

(2) 

National Stock Number 

(3) 

Description 

Cage and Part Number 

Usable 

On Code 

(4) 

U/I 

(5) 

Qty 

Reqd 

1 TECHNICAL MANUAL 

 TM 9-6115-671-14 

 EA 1 

2 WARRANTY TECHNICAL 

BULLETIN 

 TB 9-6115-XXX-24 

 EA 1 

3 5975-00-296-5324 GROUNDING ROD 

 W-R-550 

 EA 1 

4 4720-00-021-3320 AUXILIARY FUEL LINE 

69-668 

 EA 1 

5 6150-01-406-9533 PARALLELING CABLE 

88-22209 

 EA 1 

6 CIM SOFTWARE 

96-23569 

 EA 1 
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C-3

1. Technical Manual 

2. Warranty Technical Bulletin 
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C-4 

3. Grounding Rod 

4. Auxiliary Fuel Line 
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C-5/C-6 BLANK 

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 
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D-1/D-2 BLANK 

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 

(3) 

Description 

Cage and Part Number 

Usable 

On Code 

(4) 

U/I 

(5) 

Qty 

Reqd 

4210-00-202-7858 FIRE EXTINGUISHER EA 1 

5342-00-066-1235 FUEL ADAPTER EA 1 

7240-00-222-3088 FUEL CAN EA 1 

7240-00-177-6154 FLEXIBLE SPOUT EA 1 

5120-01-013-1676 HAMMER, SLIDE EA 1 
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D-2 

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E-1

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)". 

b. Column (2), Level. Identifies the lowest level of maintenance requiring the listed item. 

c. Column (3), National Stock Number (NSN). Standardized number assigned to an item for the purpose 

of requisition. 

d. 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. 

e. 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 

(2) 

Level 

(3) 

National Stock 

Number 

(4) 

Description 

(5) 

U/M 

 

1 O, F 8040-00-390-7959 Adhesive, Seal, EC847 QT 

2 O, F 6850-00-181-7929 Antifreeze, MIL-A-46153, 1 Gal. Can GL 

3 O, F 6850-00-181-7933 Antifreeze, MIL-A-46153, 5 Gal. Can GL 

4 O, F 6850-00-181-7940 Antifreeze, MIL-A-46153, 55 Gal. Can GL 

5 O, F 6850-00-174-1806 Antifreeze, MIL-A-11755, 1 Gal. Can GL 

6 O, F 8030-01-234-2792 Antiseize Compound, CP-8, 8 Oz. Can OZ 

7 O 2910-00-646-9727 Cartridge, Engine, Ether, MS39254 EA 

8 O, F 7920-01-338-3329 Cloth, Cleaning, TX-1250 EA 

9 F 8030-00-056-8673 Compound, Thermo, Pentrox A OZ 
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E-2 

SECTION II. EXPENDABLE AND DURABLE ITEMS LIST (continued) 

(1) 

Item 

Number 

(2) 

Level 

(3) 

National Stock 

Number 

(4) 

Description 

(5) 

U/M 

10 O, F 9150-00-663-1770 Grease, General Purpose, 630AA, 6 Lb. Can LB 

 

11 O, F 6850-01-160-3868 Inhibitor, Corrosion, MIL-A-53009 QT 

12 O, F 9150-00-152-4117 Lubricating Oil, Engine, MIL-L-2104, 15/40W QT 

13 O, F 9150-00-189-6727 Lubricating Oil, Engine, BRAYC0421C, 10W QT 

14 O, F 9150-00-186-6681 Lubricating Oil, Engine, ALIEDC030, 30W QT 

15 O, F 9150-00-402-2372 Lubricating Oil, Engine, MIL-L-46167, OEA QT 

16 O, F 5330-00-543-3600 Paper, Abrasive, ALOXGRIT 80 SH 

17 O, F 8030-01-408-9944 Adhesive, Edge Seal, PES-821-B QT 

18 O, F 8040-00-843-0802 Sealant, RTV108 OZ 

19 O, F 3439-00-974-1873 Solder, Tin Alloy, SN60WRAP2, 1 Lb. Spool LB 

20 O, F 6850-00-264-9038 Solvent, Dry Cleaning, P-D-680, 5 Gal. Can GL 

21 O, F 8030-00-849-0071 Sealing Compound, FORM GASKET 2 TU 

22 O, F 8040-01-359-8441 Sealing Compound, MIL-S-22473, Grade HVV OZ 
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F-1/F-2 BLANK 

APPENDIX F 

OPERATOR’S 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 

LUBRICANTS CAPACITY Above 

+32° (0°C) 

+40°F (+4°C) 

to 

-10°F (-23°C) 

0°F (-17°C) 

to 

-65°F (-53°C) 

OE/HDO-OIL, Engine 

Heavy Duty 

With Filter 

14 quarts (13.24 

liters) 

OE/HDO15/40 

or 

 

 OE/HDO-30 OE-HDO-10 OEA 

OEA-OIL, Engine, 

Sub-zero 

Without Filter 

13 quarts (12.30) 

 

CAUTION

At 100 hours hard time, the oil and filter must be changed or the warranty may be voided.
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F-2 

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G-1

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 88-22126-1 through 88-22126-7) ..........................................................G-2 

G-2 Cable Assembly, Battery (P/N 88-22178) ...................................................................................................G-3 

G-3 Cable Assembly, Battery (P/N 88-22127) ...................................................................................................G-4 

G-4 Cable Assembly, Battery (P/N 88-22181) ...................................................................................................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 Holder, Control Panel (P/N 88-22120)........................................................................................................G-8 

G-8 Hose Assembly (P/N 88-20191-6) ..............................................................................................................G-9 

G-9 Insulation, Panel, Top (P/N 88-22582) .....................................................................................................G-10 

G-10 Insulation, Baffle (P/N 88-22592).............................................................................................................G-11 

G-11 Insulation, Panel, Top (P/N 88-22593) .....................................................................................................G-12 

G-12 Insulation, Top, Center (P/N 88-22584)....................................................................................................G-13 

G-13 Insulation, Top, Rear (P/N 88-22585).......................................................................................................G-14 

G-14 Insulation, Front Housing (P/N 88-22591)................................................................................................G-15 

G-15 Insulation, Top, Front (P/N 88-22586)......................................................................................................G-16 

G-16 Insulation, Top, Center (P/N 88-22587)....................................................................................................G-17 

G-17 Insulation, Top, Center (P/N 88-22588)....................................................................................................G-18 

G-18 Insulation, Top, Front (P/N 88-22583)......................................................................................................G-19 

G-19 Pump Assembly, Fuel (P/N 88-22546)......................................................................................................G-20 

G-20 Solenoid Assembly (P/N 88-22553)..........................................................................................................G-21 

G-21 Switch Assembly (P/N 88-22548) .............................................................................................................G-22 

G-22 Wire, Varistor (P/Ns 88-20305-1 through 88-20305-3 and 88-20305-5)..................................................G-23 
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G-2 

G.2 ILLUSTRATIONS. 

NOTES: 

1. Dimensions shown are in inches. 

2. Refer to TM 9-6115-671-24P for materials required and length (L) of wire. 

PROCEDURES: 

1. Cut wire (1) to length indicated. 

2. Strip 0.75 inch of insulation from each end of wire (1). 

3. Crimp terminal (2) on each end of wire (1). 

Figure G-1. Cable Assembly, AC Power (P/Ns 88-22126-1 through 88-22126-7) 
ARMY TM 9-6115-671-14 

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MARINE CORPS TM 09249A/09246A-14 

G-3

NOTES: 

1. Dimensions shown are in inches. 

2. Refer to TM 9-6115-671-24P for materials required. 

PROCEDURES: 

1. Cut wire (1) to length indicated. 

2. Strip 0.75 inch of insulation from each end of wire (1). 

3. Position insulation sleeving (2) on center of wire (1). Mark sleeving with wire number "100B0", and shrink to 

fit. 

4. Crimp terminal (3) on each end of wire (1). 

Figure G-2. Cable Assembly, Battery (P/N 88-22178) 
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MARINE CORPS TM 09249A/09246A-14 

G-4 

NOTES: 

1. Dimensions shown are in inches. 

2. Refer to TM 9-6115-671-24P for materials required. 

PROCEDURES: 

1. Cut wire (1) to length indicated. 

2. Strip 0.75 inch of insulation from each end of wire (1). 

3. Position insulation sleeving (2) on center of wire (1). Mark sleeving with wire number "100A0", and shrink to 

fit. 

4. Mark insulation sleeving (4) with "NEGATIVE", and slide over one end of wire (1). 

5. Crimp terminal (3) on each end of wire (1). 

6. Position insulation sleeving (4) as shown, and shrink to fit. 

Figure G-3. Cable Assembly, Battery (P/N 88-22127) 
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MARINE CORPS TM 09249A/09246A-14 

G-5

NOTES: 

1. Dimensions shown are in inches. 

2. Refer to TM 9-6115-671-24P for materials required. 

PROCEDURES: 

1. Cut wire (1) to length indicated. 

2. Strip 0.75 inch of insulation from each end of wire (1). 

3. Position insulation sleeving (2) on center of wire (1). Mark sleeving with wire number "165B0", and shrink to 

fit. 

4. Mark insulation sleeving (4) with "POSITIVE", and slide over one end of wire (1). 

5. Crimp terminal (3) on each end of wire (1). 

6. Position insulation sleeving (4) as shown, and shrink to fit. 

Figure G-4. Cable Assembly, Battery (P/N 88-22181) 
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G-6 

NOTES: 

1. Dimensions shown are in inches. 

2. Refer to TM 9-6115-671-24P for materials required. 

PROCEDURES: 

1. Cut wire (1) to length indicated. 

2. Strip 0.75 inch of insulation from each end of wire (1). 

3. Position insulation sleeving (2) on center of wire (1). Mark sleeving with wire number "218A0", and shrink to 

fit. 

4. Mark one insulation sleeving (4) with "NEGATIVE", the other "POSITIVE", and slide over each end of wire 

(1). 

5. Crimp terminal (3) on each end of wire (1). 

6. Position insulation sleeving (4) as shown, and shrink to fit. 

Figure G-5. Cable Assembly, Battery (P/N 88-22179) 
ARMY TM 9-6115-671-14 

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MARINE CORPS TM 09249A/09246A-14 

G-7

NOTES: 

1. Dimensions shown are in inches. 

2. Refer to TM 9-6115-671-24P for materials required. 

PROCEDURES: 

1. Cut wire (1) to length indicated. 

2. Strip 0.75 inch of insulation from each end of wire (1). 

3. Position insulation sleeving (2) on center of wire (1). Mark sleeving with wire number "165A0", and shrink to 

fit. 

4. Mark insulation sleeving (4) with "POSITIVE", and slide over each end of wire (1). 

5. Crimp terminal (3) on each end of wire (1). 

6. Position insulation sleeving (4) as shown, and shrink to fit. 

Figure G-6. Cable Assembly, Battery (P/N 88-22207) 
ARMY TM 9-6115-671-14 

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G-8 

NOTES: 

1. Dimensions shown are in inches. 

2. Refer to TM 9-6115-671-24P for materials required. 

PROCEDURES: 

1. Cut rope (1) to length indicated. 

2. Slide insulation sleeving (2) over one end of rope (1). 

3. Crimp terminal (3) on each end of wire (1). 

4. Install hook (4) in one terminal, and close hook end to secure it to terminal. 

5. Position insulation sleeving (2) as shown, and shrink to fit. 

Figure G-7. Holder, Control Panel (P/N 88-22120) 
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G-9

NOTES: 

1. Dimensions shown are in inches. 

2. Refer to TM 9-6115-671-24P for materials required. 

PROCEDURES: 

1. Cut hose (1) to obtain dimension shown with adapters (2) installed. 

2. Crimp adapter (2) on each end of hose (1). 

Figure G-8. Hose Assembly (P/N 88-20191-6) 
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G-10 

MATERIALS 

Description Part Number 

Foam, Sound Absorbing FF40JM02 

NOTES: 

1. Dimensions shown are in inches. 

2. Tolerances are 0.1 inch unless otherwise stated. 

PROCEDURES: 

1. Cut foam to dimensions shown. 

2. Drill holes as shown. 

Figure G-9. Insulation, Panel, Top (P/N 88-22582) 
ARMY TM 9-6115-671-14 

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MARINE CORPS TM 09249A/09246A-14 

G-11

MATERIALS 

Description Part Number 

Foam, Sound Absorbing FF40JM02 

NOTES: 

1. Dimensions shown are in inches. 

2. Tolerances are 0.1 inch unless otherwise stated. 

PROCEDURES: 

1. Cut foam to dimensions shown. 

2. Drill holes as shown. 

3. Coat edge indicated using sealant (Item 17, Appendix E). 

Figure G-10. Insulation, Baffle (P/N 88-22592) 
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G-12 

MATERIALS 

Description Part Number 

Foam, Sound Absorbing FF40JM02 

NOTES: 

1. Dimensions shown are in inches. 

2. Tolerances are 0.1 inch unless otherwise stated. 

PROCEDURES: 

1. Cut foam to dimensions shown. 

2. Drill holes as shown. 

Figure G-11. Insulation, Panel, Top (P/N 88-22593) 
ARMY TM 9-6115-671-14 

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G-13

MATERIALS 

Description Part Number 

Foam, Sound Absorbing FF40JM02 

NOTES: 

1. Dimensions shown are in inches. 

2. Tolerances are 0.1 inch unless otherwise stated. 

PROCEDURES: 

1. Cut foam to dimensions shown. 

2. Drill holes as shown. 

Figure G-12. Insulation, Top, Center (P/N 88-22584) 
ARMY TM 9-6115-671-14 

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G-14 

MATERIALS 

Description Part Number 

Foam, Sound Absorbing FF40JM02 

NOTES: 

1. Dimensions shown are in inches. 

2. Tolerances are 0.1 inch unless otherwise stated. 

PROCEDURES: 

1. Cut foam to dimensions shown. 

2. Drill holes as shown. 

3. Coat indicated edge using sealant (17, Appendix E). 

Figure G-13. Insulation, Top, Rear (P/N 88-22585) 
ARMY TM 9-6115-671-14 

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G-15

MATERIALS 

Description Part Number 

Foam, Sound Absorbing FF40JM02 

NOTES: 

1. Dimensions shown are in inches. 

2. Tolerances are 0.1 inch unless otherwise stated. 

PROCEDURES: 

1. Cut foam to dimensions shown. 

2. Drill holes as shown. 

Figure G-14. Insulation, Front Housing (P/N 88-22591) 
ARMY TM 9-6115-671-14 

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G-16 

MATERIALS 

Description Part Number 

Foam, Sound Absorbing FF40JM02 

NOTES: 

1. Dimensions shown are in inches. 

2. Tolerances are 0.1 inch unless otherwise stated. 

PROCEDURES: 

1. Cut foam to dimensions shown. 

2. Drill holes as shown. 

Figure G-15. Insulation, Top, Front (P/N 88-22586) 
ARMY TM 9-6115-671-14 

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G-17

MATERIALS 

Description Part Number 

Foam, Sound Absorbing FF40JM02 

NOTES: 

1. Dimensions shown are in inches. 

2. Tolerances are 0.1 inch unless otherwise stated. 

PROCEDURES: 

1. Cut foam to dimensions shown. 

2. Drill holes as shown. 

Figure G-16. Insulation, Top, Center (P/N 88-22587) 
ARMY TM 9-6115-671-14 

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G-18 

MATERIALS 

Description Part Number 

Foam, Sound Absorbing FF40JM02 

NOTES: 

1. Dimensions shown are in inches. 

2. Tolerances are 0.1 inch unless otherwise stated. 

PROCEDURES: 

1. Cut foam to dimensions shown. 

2. Drill holes as shown. 

Figure G-17. Insulation, Top, Center (P/N 88-22588) 
ARMY TM 9-6115-671-14 

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G-19

MATERIALS 

Description Part Number 

Foam, Sound Absorbing FF40JM02 

NOTES: 

1. Dimensions shown are in inches. 

2. Tolerances are 0.1 inch unless otherwise stated. 

PROCEDURES: 

1. Cut foam to dimensions shown. 

2. Drill holes as shown. 

Figure G-18. Insulation, Top, Front (P/N 88-22583) 
ARMY TM 9-6115-671-14 

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G-20 

NOTES: 

1. Dimensions shown are in inches. 

2. Refer to TM 9-6115-671-24P for materials required. 

PROCEDURES: 

1. Remove and discard terminals supplied with fuel pump (1). 

2. Strip 0.125 inch of insulation from end of each fuel pump (1) lead. 

3. Crimp pin (2) on end of each lead. 

4. Insert pins (2) into housing (3) with red wire in position 1 and black wire in position 2. 

5. Mark strap (4) with "P11", and install in position shown. 

Figure G-19. Pump Assembly, Fuel (P/N 88-22546) 
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G-21

NOTES: 

1. Refer to TM 9-6115-671-24P for materials required. 

2. Solenoid wiring is not polarity sensitive, so position of terminals is not important. 

PROCEDURES: 

1. Strip 0.25 inch of insulation from each solenoid (1) lead. 

2. Crimp terminal (2) on one lead end and terminal (3) on the other. 

Figure G-20. Solenoid Assembly (P/N 88-22553) 
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G-22 

NOTES: 

1. Dimensions are in inches. 

2. Refer to TM 9-6115-671-24P for materials required. 

PROCEDURES: 

1. Strip 0.125 inch of insulation from end of each switch (1) lead. 

2. Crimp pin (2) on end of each lead. 

3. 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. 

4. Mark "P12" on strap (4), and install in position shown. 

Figure G-21. Switch Assembly (P/N 88-22548) 
ARMY TM 9-6115-671-14 

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G-23

NOTES: 

1. Dimensions shown are in inches. 

2. Refer to TM 9-6115-671-24P for materials required. 

PROCEDURES: 

1. Cut wire (1) to length indicated. 

2. Strip 0.50 inch of insulation from each end of wire (1). 

3. Crimp terminal (2) on one end of wire (1) and terminal (3) on other end. 

Figure G-22. Wire, Varistor (P/Ns 88-20305-1 through 88-20305-3 and 88-20305-5) 
ARMY TM 9-6115-671-14 

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G-24 

TABLE G-1. METRIC CONVERSION 

Part I. Fractional Equivalent 

Fractional Inches Decimal Inches mm 

1/16 .0625 1.587 

1/8 .1250 3.175 

3/16 .1875 4.762 

1/4 .2500 6.350 

5/16 .3125 7.937 

3/8 .3750 9.525 

7/16 .4375 11.112 

1/2 .5000 12.700 

9/16 .5625 14.287 

5/8 .6250 15.875 

11/16 .6875 17.462 

3/4 .7500 19.050 

13/16 .8125 20.637 

7/8 .8750 22.225 

15/16 .9375 23.812 

1 1 25.400 

Part II. Inches to Centimeters 

Inches cm 

1 2.540 

2 5.080 

3 7.620 

4 10.160 

5 12.700 

6 15.240 

7 17.780 

8 20.320 

9 22.860 

10 25.400 

20 50.800 

30 76.200 

40 101.600 

50 127.000 

60 152.400 

70 177.800 

80 203.200 

90 228.600 

100 254.000 
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H-1

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 TORQUE 

SAE GRADE 0-1-2 SAE GRADE 3 SAE GRADE 5 

Diameter in 

Inches 

Threads Per 

Inch 

Millimeters Foot 

Pounds 

Newton 

Meters 

Foot 

Pounds 

Newton 

Meters 

Foot 

Pounds 

Newton 

Meters 

1/4 20 6.350 6 8 9 12 10 14 

1/4 28 6.350 7 9 10 13 11 15 

5/16 18 7.937 12 16 17 23 19 26 

5/16 24 7.937 13 18 18 25 21 28 

3/8 16 9.525 20 27 30 40 33 45 

3/8 24 9.525 22 30 33 44 36 49 

7/16 14 11.112 32 43 47 64 54 73 

7/16 20 11.112 35 47 51 69 59 80 

1/2 13 12.700 47 64 69 93 78 106 

1/2 20 12.700 51 69 75 102 85 115 

9/16 12 14.287 69 94 103 140 114 155 

9/16 18 14.287 75 102 112 152 124 168 

5/8 11 15.875 96 130 145 197 154 209 

5/8 28 15.875 105 142 158 214 168 228 

3/4 10 19.050 155 210 234 317 257 348 

3/4 26 19.050 169 229 255 346 280 380 

7/8 9 22.225 206 279 372 504 382 518 

7/8 24 22.225 225 304 405 550 416 565 

1 8 25.400 310 420 551 747 587 796 

1 14 25.400 338 458 601 814 640 867 

See Table H-2 for the effect of lubrication on torque. 
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H-2 

TABLE H-1. TORQUE LIMITS FOR DRY FASTENERS (CONTINUED) 

 

SIZE TORQUE 

SAE GRADE 6 SAE GRADE 7 SAE GRADE 8 

Diameter in 

Inches 

Threads Per 

Inch 

Millimeters Foot 

Pounds 

Newton 

Meters 

Foot 

Pounds 

Newton 

Meters 

Foot 

Pounds 

Newton 

Meters 

1/4 20 6.350 13 17 13 18 14 19 

1/4 28 6.350 14 18 14 19 15 21 

5/16 18 7.937 24 33 25 34 29 39 

5/16 24 7.937 26 35 27 37 32 43 

3/8 16 9.525 43 58 44 60 47 64 

3/8 24 9.525 47 64 48 65 51 69 

7/16 14 11.112 69 94 71 96 78 106 

7/16 20 11.112 75 102 77 105 85 115 

1/2 13 12.700 106 144 110 149 119 161 

1/2 20 12.700 116 157 120 163 130 176 

9/16 12 14.287 150 203 154 209 169 229 

9/16 18 14.287 164 222 168 228 184 250 

5/8 11 15.875 209 283 215 291 230 312 

5/8 28 15.875 228 309 234 318 251 340 

3/4 10 19.050 350 475 360 488 380 515 

3/4 26 19.050 382 517 392 532 414 562 

7/8 9 22.225 550 746 570 773 600 813 

7/8 24 22.225 600 813 621 842 654 887 

1 8 25.400 825 1119 840 1139 900 1220 

1 14 25.400 899 1219 916 1241 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 

Lubricant 5/16-18 Thread/Inch 1/2-13 Thread/Inch 

NO LUBE, Steel 29 121 

Plated and cleaned 19 (66%) 90 (26%) 

SAE 20 Oil 18 (38%) 87 (28%) 

SAE 40 Oil 17 (41%) 83 (31%) 

Plated and SAE 30 16 (45%) 79 (35%) 

White Grease 16 (45%) 79 (35%) 

White Moly Film 14 (52%) 66 (45%) 

Graphite and Oil 13 (55%) 62 (49%) 

Use the above lubrication percentages to calculate the approximate decrease in torque rating for other bolt sizes. 
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H-3/H-4 BLANK 

TABLE H-3. TORQUE LIMITS FOR DRY FASTENERS (METRIC) 

 

 Standard 5D Standard 8G Standard 10K Standard 12K 

Diameter in 

Millimeters 

Coarse 

Thread Pitch 

Inches Ft-lb Nm Ft-lb Nm Ft-lb Nm Ft-lb Nm 

6 1.00 0.2362 5 7 6 8 8 11 10 14 

8 1.00 0.3150 10 14 16 22 22 30 27 37 

10 1.25 0.3937 19 26 31 42 40 54 49 66 

12 1.25 0.4624 34 46 54 73 70 95 86 117 

14 1.25 0.5512 55 75 89 121 117 159 137 186 

16 2.00 0.6299 83 113 132 179 175 237 208 282 

18 2.00 0.7087 111 150 182 247 236 320 283 384 

22 2.50 0.8771 182 247 284 385 394 534 464 629 

24 3.00 0.9449 261 354 419 568 570 773 689 934 

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. 
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H-4 

THIS PAGE INTENTIONALLY LEFT BLANK 
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I-1

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. Part No. NSN Nomenclature Quantity 

1 88-22193 5305-01-140-9118 Bolt, Self-Locking, .375-16 x .875 8 

2 88-22704 (none) Edging, Rubber AR 

3 88-20563-1 (none) Gasket 1 

4 88-20286 5330-01-366-2836 Gasket, Fuel Tank 3 

5 5 070118 (none) Locknut, Bulkhead, .500-20 UNF 1 

6 69-561-1 5310-00-836-3520 Nut and Captive Washer Assembly, 4-40 24 

7 69-561-2 5310-00-063-7360 Nut and Captive Washer Assembly, 6-32 56 

8 69-561-3 5310-00-052-3632 Nut and Captive Washer Assembly, 8-32 17 

9 69-561-4 5310-00-094-3421 Nut and Captive Washer Assembly, 10-24 59 

10 69-561-6 5310-01-012-3595 Nut and Captive Washer Assembly, 10-32 427 

11 88-21674-1 (none) Nut, Cage, 10-32, .064-.105 Grip 45 

12 88-21674-2 (none) Nut, Cage, 10-32, .025-.063 Grip 104 

13 88-21674-3 (none) Nut, Cage, .25-20, .025-.063 Grip 29 

14 88-22783 (none) Nut, Push-On AR 

15 72-2061-1 5310-00-630-2383 Nut, Self-Locking, .38-16 UNC-2B 13 

16 88-20568-1 (none) Nut, Self-Locking, .25-20 UNC-2B 4 

17 88-20568-2 (none) Nut, Self-Locking, .375-16 UNC-2B 2 

18 88-20568-4 (none) Nut, Self-Locking, .375-16 UNC-3B 8 

19 88-20568-5 (none) Nut, Self-Locking, .500-13 UNC-3B 2 

20 88-20568-6 (none) Nut, Self-Locking, .625-11 UNC-3B 2 

21 88-21930-1 5310-01-366-4412 Nut, Self-Locking, .375-16 UNC-2B 2 

22 88-21930-2 5310-01-365-5788 Nut, Self-Locking, .500-13 UNC-2B 5 

23 88-21930-3 (none) Nut, Self-Locking, .164-32 UNC-2B 20 

24 88-21930-4 5310-01-406-1672 Nut, Self-Locking, .190-32 UNF-2B 30 

25 88-22786 (none) Nut, Self-Locking, Prevailing Torque 15 

26 MIL-R-6130 9320-01-009-4856 Rubber, Cellular, .75 x 1.00 with PSA AR 

27 69-662-5 5305-00-224-1092 Screw and Captive Washer Assy, 4-40 x .50 8 

28 69-662-11 (none) Screw and Captive Washer Assy, 4-40 x 1.50 4 

29 69-662-17 5305-00-211-9344 Screw and Captive Washer Assy, 6-32 x .31 4 

30 69-662-20 5305-00-036-6972 Screw and Captive Washer Assy, 6-32 x .50 18 

31 69-662-22 5305-00-218-4864 Screw and Captive Washer Assy, 6-32 x .75 6 

32 69-662-35 5305-00-038-3103 Screw and Captive Washer Assy, 8-32 x .50 8 

33 69-662-36 5305-00-036-6902 Screw and Captive Washer Assy, 8-32 x. .62 4 

34 69-662-37 5305-00-038-3145 Screw and Captive Washer Assy, 8-32 x .75 2 

35 69-662-51 5305-00-038-3148 Screw and Captive Washer Assy, 10-24 x .62 38 

36 69-662-64 5305-00-191-6226 Screw and Captive Washer Assy, 10-32 x .50 16 

37 69-662-65 5305-01-187-5878 Screw and Captive Washer Assy, 10-32 x .62 6 

38 88-22705 (none) Seal, Door AR 
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I-2 

SECTION II. MANDATORY REPLACEMENT PARTS (continued) 

Item No. Part No. NSN Nomenclature Quantity 

39 88-22708 (none) Seal, EMI, Output Box Door 74.8” 

40 88-22712 5330-01-384-3057 Seal, Shroud, Radiator AR 

41 88-22792-2 (none) Washer, Lock, Intl and Ext Tooth, .375 3 

42 AA55610-62 (none) Washer, Lock-Spring, Helical, .219 152 

43 AA55610-63 (none) Washer, Lock-Spring, Helical, .25 148 

44 AA55610-64 (none) Washer, Lock-Spring, Helical, .312 12 

45 AA55610-65 (none) Washer, Lock-Spring, Helical, .375 54 

46 AA55610-67 (none) Washer, Lock-Spring, Helical, .500 5 

47 AA55610-68 (none) Washer, Lock-Spring, Helical, .562 1 

48 AA55610-69 (none) Washer, Lock-Spring, Helical, .625 4 
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Index-1 

INDEX 

A 

AC Circuit Interrupter K1 

 Inspection ........................................................................................................................................................4-188 

 Replacement ....................................................................................................................................................4-188 

 Testing.............................................................................................................................................................4-188 

AC CIRCUIT INTERRUPT Switch S5 

 Inspection ..........................................................................................................................................................4-87 

 Replacement ......................................................................................................................................................4-87 

 Testing...............................................................................................................................................................4-87 

Access Doors 

 Inspection ..........................................................................................................................................................4-59 

 Installation.........................................................................................................................................................4-59 

 Removal ............................................................................................................................................................4-57 

 Repair ................................................................................................................................................................4-59 

Air Cleaner Assembly 

 Inspection .............................................................................................................................................. 3-22, 4-144 

 Location and Description ..................................................................................................................................1-36 

 Removal ..........................................................................................................................................................4-144 

 Installation.......................................................................................................................................................4-145 

 Service................................................................................................................................................... 3-20, 4-144 

Air Cleaner Filter Element 

 Inspection ........................................................................................................................................................4-147 

 Installation.......................................................................................................................................................4-147 

 Removal ..........................................................................................................................................................4-147 

Air Cleaner Hoses 

 Inspection ........................................................................................................................................................4-147 

 Installation.......................................................................................................................................................4-148 

 Removal ..........................................................................................................................................................4-148 

 Service.............................................................................................................................................................4-148 

Air Intake and Exhaust System, Engine ...................................................................................................................1-23 

Automatic Voltage Regulator A4 

 Inspection ........................................................................................................................................................4-111 

 Installation........................................................................................................................................................4112 

 Removal ..........................................................................................................................................................4-112 

 Testing.............................................................................................................................................................4-111 

Auxiliary Control Bracket 

 Inspection ........................................................................................................................................................4-126 

 Installation.......................................................................................................................................................4-126 

 Removal ..........................................................................................................................................................4-126 

 Repair ..............................................................................................................................................................4-126 

Auxiliary Fuel Pump E1 

 Inspection ........................................................................................................................................................4-170 

 Replacement ....................................................................................................................................................4-173 

 Testing.............................................................................................................................................................4-172 

B 

Backplane Module A1 

 Inspection ........................................................................................................................................................4-113 

 Replacement ....................................................................................................................................................4-114 

 Testing.............................................................................................................................................................4-113 
ARMY TM 9-6115-671-14 

AIR FORCE TO 35C2-3-446-32 

MARINE CORPS TM 09249A/09246A-14 

Index-2

Batteries BT1 and BT2 

 Inspection ................................................................................................................................................ 3-18, 4-54 

 Installation.........................................................................................................................................................4-54 

 Location and Description ..................................................................................................................................1-39 

 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...........................................................................................1-39 

BATTLE SHORT Switch S7 

 Inspection ..........................................................................................................................................................4-96 

 Replacement ......................................................................................................................................................4-97 

 Testing...............................................................................................................................................................4-96 

C 

CIM Wiring Harness 

 Inspection ........................................................................................................................................................4-133 

 Installation.......................................................................................................................................................4-134 

 Removal ..........................................................................................................................................................4-133 

 Testing.............................................................................................................................................................4-133 

COMMUNICATION RECEPTACLE 

 Inspection ........................................................................................................................................................4-103 

 Location and Description ..................................................................................................................................1-36 

 Replacement ....................................................................................................................................................4-103 

Computer Interface Module (CIM) 

 Controls and Indicators........................................................................................................................................2-4 

 Inspection ........................................................................................................................................................4-100 

 Installation.......................................................................................................................................................4-101 

 Location and Description ..................................................................................................................................1-36 

 Removal ..........................................................................................................................................................4-101 

CONVENIENCE RECEPTACLE J1 

 Inspection ........................................................................................................................................................4-105 

 Location and Description ..................................................................................................................................1-36 

 Replacement ....................................................................................................................................................4-105 

 Testing.............................................................................................................................................................4-105 

Coolant Hose, Lower 

 Inspection ........................................................................................................................................................4-160 

 Installation.......................................................................................................................................................4-161 

 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 
ARMY TM 9-6115-671-14 

AIR FORCE TO 35C2-3-446-32 

MARINE CORPS TM 09249A/09246A-14

Index-3 

Coolant Recovery System 

 Inspection ........................................................................................................................................................4-168 

 Installation.......................................................................................................................................................4-168 

 Removal ..........................................................................................................................................................4-168 

Coolant Temperature Sender MT6 

 Installation.......................................................................................................................................................4-199 

 Removal ..........................................................................................................................................................4-198 

 Service.............................................................................................................................................................4-198 

 Testing.............................................................................................................................................................4-197 

Cooling System, Engine ...........................................................................................................................................1-25 

 Inspection ..........................................................................................................................................................3-24 

 Service................................................................................................................................................... 3-24, 4-154 

 Testing.............................................................................................................................................................4-152 

Cooling System, Generator Set.................................................................................................................................1-23 

Crankcase Breather Filter Assembly 

 Inspection .............................................................................................................................................. 3-22, 4-149 

 Install...............................................................................................................................................................4-152 

 Location and Description ..................................................................................................................................1-39 

 Removal ..........................................................................................................................................................4-151 

 Service................................................................................................................................................... 3-22, 4-149 

 Test..................................................................................................................................................................4-152 

Cranking Relay K2 

 Inspection ........................................................................................................................................................4-189 

 Replacement ....................................................................................................................................................4-190 

 Testing.............................................................................................................................................................4-189 

Current Transformer CT1, CT2, CT3 

 Inspection ........................................................................................................................................................4-186 

 Installation.........................................................................................................................................................5-36 

 Removal ............................................................................................................................................................5-35 

 Testing................................................................................................................................................... 4-186, 5-35 

D 

DC CONTROL POWER Fuse F1 

 Inspection ........................................................................................................................................................4-117 

 Replacement ....................................................................................................................................................4-117 

 Testing.............................................................................................................................................................4-117 

DCS Control Box Assembly 

 Inspection ..........................................................................................................................................................4-77 

 Installation.........................................................................................................................................................4-79 

 Location and Description ..................................................................................................................................1-36 

 Removal ............................................................................................................................................................4-77 

 Repair ................................................................................................................................................................4-79 

DCS Control Box Bottom 

 Inspection ........................................................................................................................................................4-139 

 Installation.......................................................................................................................................................4-140 

 Removal ..........................................................................................................................................................4-139 

 Repair ..............................................................................................................................................................4-140 

DCS Control Box Side Panels 

 Inspection ........................................................................................................................................................4-138 

 Installation.......................................................................................................................................................4-138 

 Removal ..........................................................................................................................................................4-138 

 Repair ..............................................................................................................................................................4-138 
ARMY TM 9-6115-671-14 

AIR FORCE TO 35C2-3-446-32 

MARINE CORPS TM 09249A/09246A-14 

Index-4

DCS Control Box Top Panel 

 Inspection ..........................................................................................................................................................4-62 

 Installation.........................................................................................................................................................4-62 

 Removal ............................................................................................................................................................4-60 

 Repair ................................................................................................................................................................4-62 

DCS Control Box Wiring Harness 

 Inspection .............................................................................................................................................. 4-131, 5-23 

 Repair ..............................................................................................................................................................4-132 

 Replacement ......................................................................................................................................................5-24 

 Testing................................................................................................................................................... 4-132, 5-24 

DCS Control Panel Assembly 

 Inspection ........................................................................................................................................................4-134 

 Installation.......................................................................................................................................................4-135 

 Removal ..........................................................................................................................................................4-134 

 Repair ..............................................................................................................................................................4-135 

DCS Control Panel Frame 

 Inspection ........................................................................................................................................................4-135 

 Installation.......................................................................................................................................................4-136 

 Removal ..........................................................................................................................................................4-135 

 Repair ..............................................................................................................................................................4-136 

DCS Controls and Indicators......................................................................................................................................2-1 

DCS Load Sharing Synchronizer A2 

 Inspection ........................................................................................................................................................4-106 

 Installation.......................................................................................................................................................4-109 

 Removal ..........................................................................................................................................................4-107 

 Testing.............................................................................................................................................................4-106 

DCS Speed Control Unit A3 

 Inspection ........................................................................................................................................................4-109 

 Installation.......................................................................................................................................................4-110 

 Removal ..........................................................................................................................................................4-110 

Testing ....................................................................................................................................................................4-109 

Data Plates..................................................................................................................................................................1-4 

Data Plates, DCS 

 Inspection ........................................................................................................................................................4-140 

 Replacement ....................................................................................................................................................4-140 

Data Plates, Housing 

 Inspection ..........................................................................................................................................................4-77 

 Replacement ......................................................................................................................................................4-77 

DEAD CRANK Switch S10 

 Location and Description ..................................................................................................................................1-36 

 Replacement ....................................................................................................................................................4-201 

 Testing.............................................................................................................................................................4-201 

Diagnostic Controls and Indicators.............................................................................................................................2-8 

Digital Control System .............................................................................................................................................1-17 

Dipstick, Location and Description ..........................................................................................................................1-39 

Diode CR1 

 Inspection ........................................................................................................................................................4-122 

 Replacement ....................................................................................................................................................4-123 

 Testing.............................................................................................................................................................4-122 

Droop Current Transformer CT5 

 Inspection ........................................................................................................................................................4-187 

 Installation.........................................................................................................................................................5-39 

 Removal ............................................................................................................................................................5-38 

 Testing...............................................................................................................................................................5-39 
ARMY TM 9-6115-671-14 

AIR FORCE TO 35C2-3-446-32 

MARINE CORPS TM 09249A/09246A-14

Index-5 

E 

Electric Actuator A6 

 Inspection ..........................................................................................................................................................5-43 

 Replacement ......................................................................................................................................................5-45 

 Testing...............................................................................................................................................................5-43 

EMERGENCY STOP Switch S17 

 Inspection ..........................................................................................................................................................4-97 

 Replacement ......................................................................................................................................................4-98 

 Testing...............................................................................................................................................................4-97 

End Bell and Main Bearing 

 Installation.........................................................................................................................................................5-52 

 Removal ............................................................................................................................................................5-49 

Engine and Generator Assembly 

 Installation.........................................................................................................................................................5-17 

 Removal ............................................................................................................................................................5-14 

Engine/Generator Disassembly 

 Installation.........................................................................................................................................................5-22 

 Location and Description ..................................................................................................................................1-39 

 Removal ............................................................................................................................................................5-22 

ENGINE CONTROL Switch S1 

 Inspection ..........................................................................................................................................................4-85 

 Replacement ......................................................................................................................................................4-85 

 Testing...............................................................................................................................................................4-85 

Ether Cylinder Assembly 

 Inspection ........................................................................................................................................................4-178 

 Installation.......................................................................................................................................................4-180 

 Removal ..........................................................................................................................................................4-178 

Ether Solenoid Valve L6 

 Inspection ........................................................................................................................................................4-181 

 Installation.......................................................................................................................................................4-181 

 Removal ..........................................................................................................................................................4-180 

ETHER START Switch S9 

 Inspection ..........................................................................................................................................................4-86 

 Replacement ......................................................................................................................................................4-86 

 Testing...............................................................................................................................................................4-86 

Exciter Rotor Testing................................................................................................................................................5-60 

Exciter Stator 

 Inspection ..........................................................................................................................................................5-55 

 Replacement ......................................................................................................................................................5-56 

 Testing...............................................................................................................................................................5-55 

F 

Fan 

 Inspection ........................................................................................................................................................4-165 

 Installation.......................................................................................................................................................4-166 

 Removal ..........................................................................................................................................................4-164 

Fan Belt 

 Adjustment ......................................................................................................................................................4-166 

 Inspection ........................................................................................................................................................4-166 

 Location and Description ..................................................................................................................................1-36 

 Replacement ....................................................................................................................................................4-167 
ARMY TM 9-6115-671-14 

AIR FORCE TO 35C2-3-446-32 

MARINE CORPS TM 09249A/09246A-14 

Index-6

Fan Guards 

 Inspection ........................................................................................................................................................4-158 

 Installation.......................................................................................................................................................4-158 

 Removal ..........................................................................................................................................................4-156 

FAULT RESET Switch S4 

 Inspection ..........................................................................................................................................................4-88 

 Replacement ......................................................................................................................................................4-89 

 Testing...............................................................................................................................................................4-88 

Fault System .............................................................................................................................................................1-17 

Field Flash Relay K23 

 Inspection ........................................................................................................................................................4-128 

 Installation.......................................................................................................................................................4-129 

 Removal ..........................................................................................................................................................4-128 

 Testing.............................................................................................................................................................4-128 

Filler Hose and Panel 

 Inspection and Cleaning ..................................................................................................................................4-155 

 Installation.......................................................................................................................................................4-156 

 Removal ..........................................................................................................................................................4-155 

FREQUENCY ADJUST Switch S19 

 Inspection ..........................................................................................................................................................4-93 

 Replacement ......................................................................................................................................................4-94 

 Testing...............................................................................................................................................................4-94 

FREQUENCY SELECT Switch S12 (MEP-805B only) 

 Inspection ........................................................................................................................................................4-118 

 Replacement ....................................................................................................................................................4-120 

 Testing.............................................................................................................................................................4-118 

Fuel Drain Valve 

 Location and Description ..................................................................................................................................1-36 

 Replacement ....................................................................................................................................................4-175 

Fuel Filter/Water Separator 

 Inspection .............................................................................................................................................. 3-29, 4-183 

 Install...............................................................................................................................................................4-183 

 Location and Description ..................................................................................................................................1-39 

 Removal ..........................................................................................................................................................4-183 

 Service................................................................................................................................................... 3-29, 4-183 

Fuel Level Sender MT5 

 Inspection ........................................................................................................................................................4-176 

 Installation.......................................................................................................................................................4-177 

 Removal ..........................................................................................................................................................4-176 

 Testing.............................................................................................................................................................4-176 

Fuel Lines and Fittings, Low Pressure 

 Inspection ........................................................................................................................................................4-170 

 Replacement ....................................................................................................................................................4-170 

Fuel Pickup 

 Inspection ........................................................................................................................................................4-178 

 Installation.......................................................................................................................................................4-178 

 Removal ..........................................................................................................................................................4-177 

Fuel System ..............................................................................................................................................................1-19 

Fuel Tank 

 Inspection ................................................................................................................................................ 3-26, 5-26 

 Installation.........................................................................................................................................................5-27 

 Location and Description ..................................................................................................................................1-36 

 Removal ............................................................................................................................................................5-25 

 Service....................................................................................................................................................... 3-28, 4-3 
ARMY TM 9-6115-671-14 

AIR FORCE TO 35C2-3-446-32 

MARINE CORPS TM 09249A/09246A-14

Index-7 

Fuel Tank Filler Neck 

 Inspection ........................................................................................................................................................4-174 

 Installation.......................................................................................................................................................4-175 

 Removal ..........................................................................................................................................................4-174 

Fuel Transfer Pump Level Relay K19 

 Inspection ........................................................................................................................................................4-128 

 Installation.......................................................................................................................................................4-129 

 Removal ..........................................................................................................................................................4-128 

 Testing.............................................................................................................................................................4-128 

G 

Generator Assembly, AC..........................................................................................................................................1-31 

 Installation.........................................................................................................................................................5-47 

 Location and Description ..................................................................................................................................1-36 

 Removal ............................................................................................................................................................5-46 

Generator Set Controls .............................................................................................................................................1-33 

Generator Set Installation 

 Indoor ................................................................................................................................................................2-22 

 Outdoor..............................................................................................................................................................2-21 

Governor Control System.........................................................................................................................................1-19 

GROUND FAULT CIRCUIT INTERRUPTER CB3 

 Inspection ..........................................................................................................................................................4-98 

 Replacement ......................................................................................................................................................4-99 

 Testing...............................................................................................................................................................4-99 

Grounding Rod, Installation of.................................................................................................................................2-24 

H 

Housing Section, Front 

 Inspection ..........................................................................................................................................................4-70 

 Installation.........................................................................................................................................................4-71 

 Removal ............................................................................................................................................................4-68 

 Repair ................................................................................................................................................................4-71 

Housing Section, Rear 

 Inspection ..........................................................................................................................................................4-73 

 Installation.........................................................................................................................................................4-76 

 Removal ............................................................................................................................................................4-72 

 Repair ................................................................................................................................................................4-75 

Housing Section, Top 

 Inspection ..........................................................................................................................................................4-66 

 Installation.........................................................................................................................................................4-67 

 Removal ............................................................................................................................................................4-62 

 Repair ................................................................................................................................................................4-66 

I 

I/O Interface Module A5 

 Inspection ........................................................................................................................................................4-115 

 Replacement ....................................................................................................................................................4-116 

 Testing.............................................................................................................................................................4-116 

Initial Adjustments, Checks, and Self-Test ..............................................................................................................2-27 

Inspecting and Servicing the Equipment ....................................................................................................................4-1 
ARMY TM 9-6115-671-14 

AIR FORCE TO 35C2-3-446-32 

MARINE CORPS TM 09249A/09246A-14 

Index-8

K 

K1 Auxiliary Relay K17 

 Inspection ........................................................................................................................................................4-128 

 Installation.......................................................................................................................................................4-129 

 Removal ..........................................................................................................................................................4-128 

 Testing.............................................................................................................................................................4-128 

Keypad Assembly KP 

 Inspection ........................................................................................................................................................4-102 

 Replacement ....................................................................................................................................................4-102 

L 

Load Cables, Installation of......................................................................................................................................2-26 

Load Output Terminal Board TB2 

 Inspection ........................................................................................................................................................4-191 

 Installation.......................................................................................................................................................4-193 

 Location and Description ..................................................................................................................................1-39 

 Removal ..........................................................................................................................................................4-190 

 Repair ..............................................................................................................................................................4-193 

Load/Unload Relay K22 

 Inspection ........................................................................................................................................................4-128 

 Installation.......................................................................................................................................................4-129 

 Removal ..........................................................................................................................................................4-128 

 Testing.............................................................................................................................................................4-128 

Lubrication System...................................................................................................................................................1-25 

 Inspection ..........................................................................................................................................................3-29 

 Service....................................................................................................................................................... 3-31, 4-5 

M 

Magnetic Pickup MPU 

 Adjustment ......................................................................................................................................................4-200 

 Installation.......................................................................................................................................................4-200 

 Removal ..........................................................................................................................................................4-199 

 Service.............................................................................................................................................................4-199 

Main Stator and Housing, Generator 

 Replacement ......................................................................................................................................................5-61 

 Testing...............................................................................................................................................................5-60 

MASTER CONTROL Switch 

 Inspection ..........................................................................................................................................................4-89 

 Replacement ......................................................................................................................................................4-92 

 Testing...............................................................................................................................................................4-90 

Mechanical System...................................................................................................................................................1-23 

Muffler and Exhaust Pipe 

 Inspection ........................................................................................................................................................4-141 

 Replacement ....................................................................................................................................................4-141 

 Location and Description ..................................................................................................................................1-36 
ARMY TM 9-6115-671-14 

AIR FORCE TO 35C2-3-446-32 

MARINE CORPS TM 09249A/09246A-14

Index-9 

N 

NATO SLAVE RECEPTACLE 

 Inspection ..........................................................................................................................................................4-54 

 Installation.........................................................................................................................................................4-55 

 Location and Description ..................................................................................................................................1-39 

 Removal ............................................................................................................................................................4-55 

NETWORK FAILURE Light DS5 

 Inspection ..........................................................................................................................................................4-82 

 Repair ................................................................................................................................................................4-82 

 Replacement ......................................................................................................................................................4-82 

Nuclear, Biological, and Chemical (NBC) Decontamination...................................................................................2-45 

O 

Oil Drain Valve 

 Inspection ........................................................................................................................................................4-204 

 Location and Description ..................................................................................................................................1-36 

 Replacement ....................................................................................................................................................4-205 

Oil Filter, Location and Description.........................................................................................................................1-39 

Oil Pressure Sender MT7 

 Installation.......................................................................................................................................................4-196 

 Removal ..........................................................................................................................................................4-196 

 Service.............................................................................................................................................................4-196 

 Testing.............................................................................................................................................................4-194 

Operation Under Unusual Conditions 

 Dusty or Sandy Areas........................................................................................................................................2-42 

 Emergency Stopping .........................................................................................................................................2-44 

 Extreme Cold Weather Below -25°F (-31°C)....................................................................................................2-41 

 Extreme Heat Above 120°F (48.8°C)................................................................................................................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.........................................................................................................................................................5-30 

 Removal ............................................................................................................................................................5-29 

Output Box Panels 

 Inspection ..........................................................................................................................................................5-41 

 Installation.........................................................................................................................................................5-42 

 Removal ............................................................................................................................................................5-41 

 Repair ................................................................................................................................................................5-42 

Output Box Wiring Harness 

 Inspection .............................................................................................................................................. 4-184, 5-34 

 Installation.........................................................................................................................................................5-34 

 Removal ............................................................................................................................................................5-33 

 Repair .................................................................................................................................................... 4-186, 5-34 

 Testing................................................................................................................................................... 4-186, 5-34 

Output Supply System ..............................................................................................................................................1-29 
ARMY TM 9-6115-671-14 

AIR FORCE TO 35C2-3-446-32 

MARINE CORPS TM 09249A/09246A-14 

Index-10

P 

Panel Lights DS1 through DS3 

 Inspection ..........................................................................................................................................................4-79 

 Repair ................................................................................................................................................................4-80 

 Replacement ......................................................................................................................................................4-80 

PANEL LIGHTS Switch S2 

 Inspection ..........................................................................................................................................................4-95 

 Replacement ......................................................................................................................................................4-95 

 Testing...............................................................................................................................................................4-95 

Parallel Unit Operation.............................................................................................................................................2-33 

PARALLELING RECEPTACLE J2 

 Inspection ........................................................................................................................................................4-104 

 Replacement ....................................................................................................................................................4-104 

 Location and Description ..................................................................................................................................1-36 

Power Potential Transformer T1 

 Inspection ........................................................................................................................................................4-187 

 Installation.........................................................................................................................................................5-40 

 Removal ............................................................................................................................................................5-40 

 Testing...............................................................................................................................................................5-40 

Preparation for Movement........................................................................................................................................2-39 

Preparation for Shipment and Storage ....................................................................................................................4-207 

R 

Radiator 

 Installation.......................................................................................................................................................4-163 

 Location and Description ..................................................................................................................................1-36 

 Removal ..........................................................................................................................................................4-162 

 Repair ................................................................................................................................................... 4-163, 5-25 

 Service..................................................................................................................................................... 4-2, 4-163 

REACTIVE CURRENT ADJUST Rheostat R5 

 Inspection ........................................................................................................................................................4-121 

 Replacement ....................................................................................................................................................4-122 

 Testing.............................................................................................................................................................4-121 

Remote Operation.....................................................................................................................................................2-36 

Resistor R1 

 Inspection ........................................................................................................................................................4-124 

 Replacement .......................................................................................................................................... 4-124, 5-24 

 Testing.............................................................................................................................................................4-124 

Resistor R2 

 Inspection ........................................................................................................................................................4-125 

 Replacement .......................................................................................................................................... 4-125, 5-25 

 Testing.............................................................................................................................................................4-125 

Resistor R6 

 Inspection ........................................................................................................................................................4-130 

 Replacement ....................................................................................................................................................4-131 

 Testing.............................................................................................................................................................4-130 

Resistors R116 and R17 

 Inspection ........................................................................................................................................................4-129 

 Replacement ....................................................................................................................................................4-129 

 Testing.............................................................................................................................................................4-129 
ARMY TM 9-6115-671-14 

AIR FORCE TO 35C2-3-446-32 

MARINE CORPS TM 09249A/09246A-14

Index-11 

Restriction Indicator 

 Inspection ........................................................................................................................................................4-146 

 Replacement ....................................................................................................................................................4-146 

Rotor Assembly, Generator 

 Installation.........................................................................................................................................................5-59 

 Removal ............................................................................................................................................................5-59 

 Testing...............................................................................................................................................................5-58 

Rotating Rectifier 

 Installation.........................................................................................................................................................5-55 

 Removal ............................................................................................................................................................5-53 

 Replacement of Rectifier Diodes.......................................................................................................................5-53 

 Testing...............................................................................................................................................................5-52 

S 

Shut Down Generator Set .........................................................................................................................................2-31 

Skid Base 

 Inspection ..........................................................................................................................................................5-61 

 Installation.........................................................................................................................................................5-62 

 Location and Description ..................................................................................................................................1-39 

 Removal ............................................................................................................................................................5-61 

 Repair ................................................................................................................................................................5-62 

Start Generator Set....................................................................................................................................................2-30 

Starter, Location and Description .............................................................................................................................1-39 

Start Relay K15 

 Inspection ........................................................................................................................................................4-128 

 Installation.......................................................................................................................................................4-129 

 Removal ..........................................................................................................................................................4-128 

 Testing.............................................................................................................................................................4-128 

T 

Time Meter M3 

 Inspection ..........................................................................................................................................................4-82 

 Replacement ......................................................................................................................................................4-83 

 Testing...............................................................................................................................................................4-83 

V 

VOLTAGE ADJUST Switch S18 

 Inspection ..........................................................................................................................................................4-92 

 Replacement ......................................................................................................................................................4-93 

 Testing...............................................................................................................................................................4-92 

Voltage Reconnection Terminal Board TB1 

 Inspection .............................................................................................................................................. 5-32, 4-183 

 Installation.......................................................................................................................................................4-184 

 Location and Description ..................................................................................................................................1-39 

 Removal ..........................................................................................................................................................4-184 

 Replacement ......................................................................................................................................................5-32 

Voltage Regulation System ......................................................................................................................................1-19 

Voltage Scale Switch 

 Inspection ........................................................................................................................................................4-127 

 Replacement ....................................................................................................................................................4-127 

 Testing.............................................................................................................................................................4-127 
ARMY TM 9-6115-671-14 

AIR FORCE TO 35C2-3-446-32 

MARINE CORPS TM 09249A/09246A-14 

Index-12

W 

Water Pump, Location and Description....................................................................................................................1-39 
RECOMMENDED CHANGES TO EQUIPMENT TECHNICAL PUBLICATIONS

PREVIOUS

ARE OBSOLETE

P.S. - IF YOUR OUTFIT WANTS TO KNOW ABOUT

RECOMMENDATION MAKE A CARBON COPY OF DA 2028-2 AND GIVE IT TO YOUR

FORM

1 JUL 79

BE EXACT PIN-POINT WHERE IT

SOMETHING WRONG

PUBLICATION PUBLICATION DATE PUBLICATION

IN THIS SPACE TELL WHAT IS WRONG

AND WHAT SHOULD BE DONE ABOUT IT:

DATE SENT

FROM: (PRINT YOUR UNIT'S COMPLETE

WITH THIS PUBLICATION

THEN ... JOT DOWN THE INFO

ABOUT IT ON THIS FORM.

CAREFULLY TEAR IT OUT.

FOLD IT AND DROP IT IN THE

MAIL.

PRINTED NAME, GRADE OR TITLE AND TELEPHONE SIGN HERE

PAGE

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TABLE

NO

TM 11-5840-340-12 23 Jan 74 Radar Set AN/PRC10 July 1975

Commander

Stateside Army Depot

ATTN: AMSTA-US

Stateside, N.J. 07703-5007

2-25 2-28

3-10 3-3 3-1

5-85-6

FO-3

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.

Item 5, Functional column. Change “2 dB" to “3 dB”.

REASON: The adjustment procedure for the TRANS POWER

FAULT indicator calls for a 3 dB (500 watts) adjustment to light

the TRANS POWER FAULT indicator.

Add new step f.1 to read, “Replace cover plate removed in

step e.1, above."

REASON: To replace the cover plate.

Zone C 3. On J1-2, change “+24 VDC" to “+5 VDC".

REASON: This is the output line of the 5 VDC power supply.

+24 VDC is the input voltage.

SSG I. M. DeSpiritof 999-1776
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DEPARTMENT OF THE ARMY

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Commander

U.S. Army Communications-Electronics Command

 and Fort Monmouth

ATTN: AMSEL-LC-LEO-D-CS-CFO

Fort Monmouth, New Jersey 07703-5000

PLEASE

AFFIX

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DEPARTMENT OF THE ARMY

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Commander

U.S. Army Communications-Electronics Command

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ATTN: AMSEL-LC-LEO-D-CS-CFO

Fort Monmouth, New Jersey 07703-5000

PLEASE

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REVERSE OF DA FORM 2028-2

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Commander

U.S. Army Communications-Electronics Command

 and Fort Monmouth

ATTN: AMSEL-LC-LEO-D-CS-CFO

Fort Monmouth, New Jersey 07703-5000

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Commander

U.S. Army Communications-Electronics Command

 and Fort Monmouth

ATTN: AMSEL-LC-LEO-D-CS-CFO

Fort Monmouth, New Jersey 07703-5000

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By Order of the Secretary of the Army: 

 ERIC K. SHINSEKI 

 General, United States Army 

 Official: Chief of Staff

 

 0024403 

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 

 

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