Section V. BATTERIES AND BATTERY CABLES
Corrosive Battery Electrolyte (Potassium Hydroxide). Wear rubber gloves, apron, and face shield
when handling leaking batteries. If potassium hydroxide is spilled on clothing, or other material,
wash immediately with clean water. If spilled on personnel immediately start flusing the affected
area with clean water. Continue washing until medical assistance arrives.
7-16. General. The batteries store electrical energy to start the engine and to supply energy for accessory systems to
operate without requiring engine operation. The batteries also act as a buffer for the electrical charging system. Without
a battery in the circuit, the charging system will charge at its maximum rate and rapidly burn out. The DOD Generator
Sets were designed to be able to operate without batteries and starting can be accomplished through the use of the slave
receptacle. The battery cables' end terminals must be securely wrapped and taped with electrical insulating materials if
they are not to be secured to the appropriate battery terminals.
7-17. Battery Terminal Post, Broken. Battery terminal posts can be repaired if they are broken. The stub can be built
back up with lead (figure 7-11). If melting facilities or tools are not available a post can be secured with a self-tapping
screw or bolt. The battery should be replaced as soon as possible if the post is only screwed or bolted in place.
Corroded or loose terminals are frequently a cause of starting system failure. See specific TM for corrective action.
Figure 7-11. Battery Terminal Part Repair.
7-18. Battery Cracks. Batteries can become cracked from vibration, impact or freezing. Cracks can be repaired or
sealed until replacements can be obtained. Most epoxies will not shrink and are resistant to acid. Epoxies make a semi-
permanent repair and should be used as a first option.
Section VI. GOVERNOR SYSTEM
7-19. General. The governor system on a generator regulates the engine speed to produce an even output of power.
When the speed fluctuates enough that power output is affected. The governor is not functioning properly. To counter
this, the throttle linkage can be adjusted manually until the engine RPM produces the desired frequency. The output can
be observed with another soldier at the control gauges. Then the linkage can be wired into position with a paper clip or
piece of wire or other binding. This will work where a relatively constant load is applied to the generator. Load changes
will cause RPM changes necessitating throttle adjustment.