TM 9-6115-624-BD
Section VI. HARDWARE, MECHANICAL LINKAGES, CABLES AND PULLEYS
3-14. General. Various elements of hardware and linkages are used throughout generators to transfer the control actions
from the control panel to the components being controlled. Damage can occur to the mounting hardware or the rods,
cables and levers in the mechanical linkage systems. Pins can become lost, linkages can bend or break which will
disable or hamper the generator operation. This section will give various procedures that may be used to repair or
restore needed functions.
3-15. Mismatched Threads, Forcing. The proper bolts may not always be available to make repairs. Mismatched bolts
can be used to make BDAR repairs but care must be taken so as not to break bolts by forcing them too far. Coarse
threaded bolts may be used in holes with fine threads. Forced threads will not hold as much stress as standard threads
but will provide a limited operational capability.
3-16. Thread Clean-Up. Damaged threads decrease the load bearing capability of bolts. Damaged threads can be
repaired or cleaned up using a thread file or a triangular shaped file. The threads must be cleaned to remove any dirt or
metal particles which might cause further damage to threaded holes. Use a wire brush and a nail or scribe to remove
stuck metal particles. Damaged threads must have burrs removed. Cross-threaded bolts must have the torn metal
removed where they connect between threads. Turning a hardened steel nut onto the bolt can help realign damaged
threads.
3-17. Hardware Mounting. Brackets and components can be connected or mounted without proper bolts. An iron rod or
stud can be inserted through the connecting holes and peened over on each side. The mushroomed ends will keep the
components together. A stud can be screwed into a threaded hole and a nut used to hold the component. If the proper
size nut is not available, use a nut larger than the stud threads and peen the stud end to hold the nut in place. Linkages
can also be connected by inserting a rod or bolt and peening the ends to keep it from dropping out of position.
3-18. Push/Pull Rod, Damaged. Mechanical linkage rods can bend or break from explosive shock, impact or binding
components. Rods can be repaired or improvised to regain usage of the system involved. The cause of breakage must
be determined and corrected. Rods or shafts that are bent must be straightened. Place the rod/shaft on a hard flat
surface and hit with a hammer to bend it straight. Broken rods/shafts can be splinted using scrap metal.
a.
Limitations.
Possible degraded output
b.
Personnel/time Required.
1-2 soldiers/1.0-2.0 hours
c.
Materials/tools.
Welding equipment
Drill
Hacksaw (item 1, appx 1)
Plate stock
d.
Procedural Steps.
(1)
Option 1: Welding equipment available.
(a)
Determine if damaged rod is made of steel or aluminum alloy.
(b)
Measure rod length between connecting points.
3-9
