ARMY TM 9-6115-639-13
AIR FORCE TO 35C2-3-386-51
MARINE CORPS TM 10155A-13/1
f. Control Box Assembly. The control box assembly is mounted to the enclosure assembly at the rear of
the generator set. Instruments, controls, and indicators required to operate the generator set are located on the
control box assembly. The control box assembly consists of a control panel (18, Figure 1-2), ground fault
circuit interrupter (13) (60 Hz only), and convenience receptacle (15) (60 Hz only). Internal components
include the governor control module, control logic relays and diodes, voltage surge arrestors, diagnostic test
points, and associated wiring harnesses and electrical connectors.
The control panel (18) portion of the box is hinged to allow access for testing and maintenance. The
control panel contains the following instruments and switches: HOURS meter, FUEL LEVEL gauge,
VOLTAGE meter, LOAD meter, START / RUN / STOP switch, EMERGENCY STOP switch, AUX FUEL
switch, PREHEAT switch, VOLTAGE ADJUST potentiometer, CIRCUIT INTERRUPTER switch, DC
CIRCUIT BREAKER switch, BATTLE SHORT switch, and a fault indicator module. The fault indicator
module contains lights that indicate the following generator set conditions: ENGINE HIGH TEMP, LOW OIL
PRESSURE, NO FUEL, OVERVOLTAGE, OVERLOAD SHORT CIRCUIT, and BATTLE SHORT ON.
Refer to paragraph 2-1, Operator’s Controls and Indicators, for a complete explanation of each instrument and
switch.
g. Output Terminals and Slave Receptacle. The output terminal board and ground terminal are located
on the generator set skid base, just below the control box assembly. A hinged cover (16, Figure 1-2) allows
access to the three load terminals and single ground terminal. An insulated wrench, used for connecting wires to
the terminals, is secured to the rear of the hinged cover. A filter mounted to the back of the load terminals
prevents electro-magnetic interference (EMI). The generator set’s 24VDC slave receptacle is mounted to the
skid base, to the right of the output terminals.
h. Engine / Generator Assembly. The engine / generator assembly (Figure 1-3) consists of a single-
cylinder diesel engine (14), permanent magnet generator (5), and associated electrical, fuel, and oil components.
The engine / generator assembly is mounted to the skid base (8) with vibration mounts (7) to prevent engine
vibration from affecting the operation of other generator set components. A fuel drain plug (9) and oil drain
plug (10) allow maintenance personnel to drain engine fluids.
i.
Engine. The generator set is equipped with a single cylinder, air cooled, direct injection, four-stroke
cycle, diesel engine (14, Figure 1-3). The engine is designed to operate between 3000 and 3600 RPM, with an
output of 6.7 horsepower at 3600 RPM. An electric governor sets the no load speed at 3000 to 3050 RPM.
The engine has self-contained oil lubrication and fuel systems. A mechanical governor (13) is set for
3800 RPM, maximum, and is controlled by an electrical governor for variable speed operation. The engine is
equipped with an air filter (2), muffler (3), 24VDC starter motor (4), manifold heater (15), engine high
temperature switch (6), engine oil low pressure switch (12), and oil fill cap and gauge (11). A rope pull recoil
system (1) permits manual start of the engine without the battery.
Engine cooling is provided by a flywheel fan, which forces air over the cylinder fins and engine
components. The fan is completely guarded to prevent inadvertent contact during operation.
j.
Generator. The permanent magnet generator (5, Figure 1-3) consists of four three-phase isolated AC
output windings. Voltage output is proportional to engine speed (approximately 190VAC at 3kW, 3450 RPM).
The rotating portion of the generator is mounted directly to the engine, on the engine crankshaft extension,
without a bearing. The generator stator is direct mounted to the engine, and uses Class H insulation.
1-8
