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Figure 1-2. Schematic wiring diagram.
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TM-5-6115-440-34 Generator Set 7.5 Kw 28V DC GED Air Cooled 2 Wheel Mtd Pnematic Tires Manual
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Section IV. REMOVAL AND INSTALLATION OF MAJOR COMPONENTS
CHAPTER 2
D I R E C T SUPPORT AND GENERAL SUPPORT MAINTENANCE INSTRUCTIONS
Section I. REPAIR PARTS, SPECIAL TOOLS AND EQUIPMENT
2-3. Maintenance Repair Parts
2-1. Tools and Equipment
Tools, equipment, and repair parts issued with or
Repair parts  a n d e q u i p m e n t a r e  listed and
authorized for the generator set are listed in the
illustrated in the repair parts and special tools list
basic issue items list, TM 5-6115-440-10.
covering  d i r e c t s u p p o r t a n d g e n e r a l  support
maintenance for this equipment in TM 5-6115-
2 - 2 . Special Tools and Equipment
440-24P
No special tools or equipment are required for
performing maintenance on the generator set.
Section Il. TROUBLESHOOTING
Table 2-1. Troubleshooting
Probable cause
Corrective action
Malfunction
1. Engine fails to start or starts
a. Magneto switch wiring defective
a . Check wiring and correct as
with difficulty
necessary (para 3-7).
b. Magneto
defective
b. Disassemble and replace defective
parts (para 3-13).
c. Starter generator defective
c. Disassemble and replace defective
parts (para 3-14).
2. Engine lacks power
a. Piston rings worn
a. Replace piston rings (para 3-23).
b. Replace bearings (para 3-22).
b. Damaged bearings
c. If cylinder are worn more than
c. Cylinders worn or scored
0.005 inch oversize, regrind and
fit with oversize pistons and
piston rings (para 3-24).
Disassemble and clean engine
Excessive carbon deposits
3. Engine overheats
components.
4. Engine knocks
a. Clean cylinder heads (para 2-6).
a. Carbon or lead deposits
b. Disassemble and correct trouble
b. Loose or defective connecting
rod shell bearing
(para 3-23).
c. Disassemble and correct trouble
c. Worn or loose piston pin
(para 3-23).
d. Replace valve spring (para 3-28).
d. Valve springs weak or broken
a. Disassemble and replace defective
5. Generator output erratic
a. Voltage regulator defective
parts (para 3-2).
b. Generator defective
b. Disassemble and replace defective
parts (para 3-6).
Section Ill. GENERAL MAINTENANCE
2-4. General
2-6. General Cleaning and Inspection Methods
a. Cleaning.
(Refer to TM 5-6115-440-10 for analysis of
operation).  R e f e r t o T M 5 - 6 1 1 5 - 4 4 0 - 2 0 f o r
(1) Clean all parts in an approved cleaning
organizational  maintenance  instructions.
solvent (eg. FED-P-D-680).
(2) Clean surface and install new gaskets.
2 - 5 . Wiring Harness
b. Inspection.
The electrical circuits in the generator set are
( 1 ) Inspect all parts before installing for
completed by individual wire leads or by leads
cracks, wear, rust or corrosion, deterioration of
laced or enclosed to form a wiring harness. When
electrical wiring or any type damage.
testing, repairing or replacing the individual wires
( 2 ) Inspect all hardware for damage, rust
or harness refer to the wiring diagram (fig. 1-1 and
breaks and damaged threads.
1-2).
2-1

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