Chapter 1. GENERAL INFORMATION
Repair Procedures - TM-9-6115-624-BD0011
BDAR Recommendations and QDR/EIR
Section III. BDAR TASKS AND RESPONSIBILITIES
Organizational Maintenance and Maintenance Teams (MT)
Direct Support/General Support Maintenance Team
Table 1-1. Summary of BDAR Time Guidelines.
Reports
Chapter 2. ASSESSING BATTLEFIELD DAMAGE
Assessment Process
Figure 2-1. Battlefield Damage Assessment.
Assessment Types
Chapter 3. GENERAL REPAIR
Procedural Steps
Gaskets, Engine
Gaskets, Environmental
V-Belt, Missing or Broken
Table 3-1. Adjustable-Link V-Belt Data
Section V. BRACKETS AND WELDMENTS
Figure 3-3. Bracket Broken.
Section VI. HARDWARE, MECHANICAL LINKAGES, CABLES AND PULLEYS
Figure 3-4. Push/Pull Rod Damage Repair with Splint.
Chapter 4. ENGINE
Figure 4-1. Engine Failure Assessment Procedure (Sheet 1 of 2).
Figure 4-1. Engine Failure Assessment Procedure (Sheet 2 of 2).
Section II. ENGINE FAILURE
Air Cleaner, Damaged/Leaking
Figure 4-2. Emergency Filter for Air Intake.
Section V. ENGINE LUBRICATION SYSTEM
Oil Level Low
Chapter 5. FUEL SUPPLY SYSTEM
Figure 5-1. Fuel Supply System Failure Assessment.
Section II. FUEL STORAGE SYSTEMS
Option 2: Plugging Holes, Metal or Fiberglass Tanks.
Figure 5-2. Plugging Holes in Metal or Fiberglass Tank.
Section III. FUEL PUMPS
Figure 5-3. Stopping Leaks in Low Pressure Coupling.
Fuel Line (Low Pressure Rupture)
Figure 5-5. Metal Tubing Cracks Repair.
Figure 5-6. Metal Tubing Holes Repair.
Figure 5-8. Damaged Bends Repair.
Section V. FUEL FILTERS
Chapter 6. COOLING SYSTEM
Figure 6-1. Air Cooling System Failure Assessment.
Figure 6-2. Liquid Cooling System Failure Assessment.
Section III. LIQUID COOLING SYSTEM
Option 1: Repair of Small Hole.
Figure 6-3. Radiator Hole Epoxy Fix.
Figure 6-4. Radiator Core, Puncture Repair.
Figure 6-5. Hose Clamp Repair.
Figure 6-6. Hose, Small Leak.
Figure 6-7. Hose, Large Leak.
Figure 6-8. Reinforce Collapsed Hose.
Figure 6-9. Pipe inserted into Damaged Hose.
Figure 6-10. Substitute Hose as Sleeve.
Chapter 7. DC ELECTRICAL SYSTEM
Figure 7-1. Basic Engine DC Electrical System
Figure 7-2. DC Electrical System Failure Assessment (Sheet 1 of 2)
Figure 7-2. DC Electrical System Failure Assessment (Sheet 2 of 2)
Section II. DC ELECTRICAL COMPONENTS
Fuse or Circuit Breaker Failure
Figure 7-3. Wire Bundle Repair of Wiring Harness.
Figure 7-4. Connector Spliced to Generator Wiring.
Option 1: Solder wire method.
Figure 7-5. Solder Method to Repair Wires.
Option 2: Wire splice method.
Figure 7-6. Splice Method to Repair Same Size Wire.
Option 3: Splicing different size wires.
Figure 7-7. Splicing Various Size Wires.
Cable, Heavy Duty, Damaged
Section IV. ELECTRICAL MOTORS
Starter Solenoid Defective, Delco-Remy Only
Figure 7-10. Starter Solenoid Defective.
Section V. BATTERIES AND BATTERY CABLES
Appendix A. REFERENCES SYSTEM
Appendix B. SPECIAL AND FABRICATED TOOLS
Table B-1. Tools.
Table B-1. Tools.-CONT.
Section III. TEST EQUIPMENT
Figure B-1. Voltage Indicator Made from Light Bulb.
Uncontrolled Amperage
Procedural Steps.
Appendix C. EXPENDABLE/DURABLE SUPPLIES AND MATERIALS
Table C-1. Expendable/Durable Supplies and Materials
Table C-1. Expendable/Durable Supplies and Materials--CONT.
Appendix D. SUBSTITUTE MATERIALS/PARTS
Fuel Blending
Section II. POL SUBSTITUTES
Table D-1. Fuels and Substitute Fuels
Table D-2. Lubrication Substitutes
Table D-3. Generator Application Substitutes.
Table D-3. Generator Application Substitutes
Section III. PARTS COMMONALITY
Table D-4. Parts Commonality (15 thru 200KW DOD STD Diesel Engine Driven Sets).
Table D-6. Parts Commonality ((5KW, 60HZ (MEP-002A), 10KW, 60HZ (MEP-003A). 10KW, 400HZ (MEP-1 12A) DOD STD Diesel Engine Driven Sets)).
Table D-6. Parts Commonality ((5KW, 60HZ (MEP-002A), 10KW, 60HZ (MEP-003A). 10KW, 400HZ (MEP-1 12A) DOD STD Diesel Engine Driven Sets)). (cont)
Appendix E. BDAR TRAINING PROCEDURES
TM-9-6115-624-BD Battlefield Damage Assessment and Repair for Generators Manual
Repair Procedures - TM-9-6115-624-BD0011
BDAR Recommendations and QDR/EIR
Section III. BDAR TASKS AND RESPONSIBILITIES
Organizational Maintenance and Maintenance Teams (MT)
Direct Support/General Support Maintenance Team
Table 1-1. Summary of BDAR Time Guidelines.
Reports
Chapter 2. ASSESSING BATTLEFIELD DAMAGE
Assessment Process
Figure 2-1. Battlefield Damage Assessment.
Assessment Types
Chapter 3. GENERAL REPAIR
Procedural Steps
Gaskets, Engine
Gaskets, Environmental
V-Belt, Missing or Broken
Table 3-1. Adjustable-Link V-Belt Data
Section V. BRACKETS AND WELDMENTS
Figure 3-3. Bracket Broken.
Section VI. HARDWARE, MECHANICAL LINKAGES, CABLES AND PULLEYS
Figure 3-4. Push/Pull Rod Damage Repair with Splint.
Chapter 4. ENGINE
Figure 4-1. Engine Failure Assessment Procedure (Sheet 1 of 2).
Figure 4-1. Engine Failure Assessment Procedure (Sheet 2 of 2).
Section II. ENGINE FAILURE
Air Cleaner, Damaged/Leaking
Figure 4-2. Emergency Filter for Air Intake.
Section V. ENGINE LUBRICATION SYSTEM
Oil Level Low
Chapter 5. FUEL SUPPLY SYSTEM
Figure 5-1. Fuel Supply System Failure Assessment.
Section II. FUEL STORAGE SYSTEMS
Option 2: Plugging Holes, Metal or Fiberglass Tanks.
Figure 5-2. Plugging Holes in Metal or Fiberglass Tank.
Section III. FUEL PUMPS
Figure 5-3. Stopping Leaks in Low Pressure Coupling.
Fuel Line (Low Pressure Rupture)
Figure 5-5. Metal Tubing Cracks Repair.
Figure 5-6. Metal Tubing Holes Repair.
Figure 5-8. Damaged Bends Repair.
Section V. FUEL FILTERS
Chapter 6. COOLING SYSTEM
Figure 6-1. Air Cooling System Failure Assessment.
Figure 6-2. Liquid Cooling System Failure Assessment.
Section III. LIQUID COOLING SYSTEM
Option 1: Repair of Small Hole.
Figure 6-3. Radiator Hole Epoxy Fix.
Figure 6-4. Radiator Core, Puncture Repair.
Figure 6-5. Hose Clamp Repair.
Figure 6-6. Hose, Small Leak.
Figure 6-7. Hose, Large Leak.
Figure 6-8. Reinforce Collapsed Hose.
Figure 6-9. Pipe inserted into Damaged Hose.
Figure 6-10. Substitute Hose as Sleeve.
Chapter 7. DC ELECTRICAL SYSTEM
Figure 7-1. Basic Engine DC Electrical System
Figure 7-2. DC Electrical System Failure Assessment (Sheet 1 of 2)
Figure 7-2. DC Electrical System Failure Assessment (Sheet 2 of 2)
Section II. DC ELECTRICAL COMPONENTS
Fuse or Circuit Breaker Failure
Figure 7-3. Wire Bundle Repair of Wiring Harness.
Figure 7-4. Connector Spliced to Generator Wiring.
Option 1: Solder wire method.
Figure 7-5. Solder Method to Repair Wires.
Option 2: Wire splice method.
Figure 7-6. Splice Method to Repair Same Size Wire.
Option 3: Splicing different size wires.
Figure 7-7. Splicing Various Size Wires.
Cable, Heavy Duty, Damaged
Section IV. ELECTRICAL MOTORS
Starter Solenoid Defective, Delco-Remy Only
Figure 7-10. Starter Solenoid Defective.
Section V. BATTERIES AND BATTERY CABLES
Appendix A. REFERENCES SYSTEM
Appendix B. SPECIAL AND FABRICATED TOOLS
Table B-1. Tools.
Table B-1. Tools.-CONT.
Section III. TEST EQUIPMENT
Figure B-1. Voltage Indicator Made from Light Bulb.
Uncontrolled Amperage
Procedural Steps.
Appendix C. EXPENDABLE/DURABLE SUPPLIES AND MATERIALS
Table C-1. Expendable/Durable Supplies and Materials
Table C-1. Expendable/Durable Supplies and Materials--CONT.
Appendix D. SUBSTITUTE MATERIALS/PARTS
Fuel Blending
Section II. POL SUBSTITUTES
Table D-1. Fuels and Substitute Fuels
Table D-2. Lubrication Substitutes
Table D-3. Generator Application Substitutes.
Table D-3. Generator Application Substitutes
Section III. PARTS COMMONALITY
Table D-4. Parts Commonality (15 thru 200KW DOD STD Diesel Engine Driven Sets).
Table D-6. Parts Commonality ((5KW, 60HZ (MEP-002A), 10KW, 60HZ (MEP-003A). 10KW, 400HZ (MEP-1 12A) DOD STD Diesel Engine Driven Sets)).
Table D-6. Parts Commonality ((5KW, 60HZ (MEP-002A), 10KW, 60HZ (MEP-003A). 10KW, 400HZ (MEP-1 12A) DOD STD Diesel Engine Driven Sets)). (cont)
Appendix E. BDAR TRAINING PROCEDURES
TM-9-6115-624-BD Battlefield Damage Assessment and Repair for Generators Manual
