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CHAPTER 2 D I R E C T SUPPORT AND GENERAL SUPPORT MAINTENANCE INSTRUCTIONS
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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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Figure 2-1. Engine and starter-generator, removal and installation.
Section IV. REMOVAL AND INSTALLATION OF MAJOR COMPONENTS
2-7. General
(6) Remove two screws (8) fig. 2-2 washers (9)
and throttle and choke mounting bracket (10) from
This section contains instruction for removal and
frame assembly (4).
installation of the engine, starter-generator and
(7) Remove four screws (2) and washers (3)
control box. Repair instructions for these com-
s e c u r i n g tubular frame assembly (4) to base
ponents are contained in Chapter 3.
assembly. Lift frame assembly (with fuel tank and
2 - 8 . Starter-Generator
control box remaining in place) off base assembly.
a. Removal.
(8) Remove drive belts (TM 5-6115-440-20).
(1) Disconnect leads from starter generator
(9) Remove two clamps that secure oil line to
(fig. 1-1).
base assembly.
(2) Remove lock nuts (14, fig. 2-1) and slide
(10) Remove screw, washer and nut which
assembled starter-generator  ( 1 3 ) a n d a d a p t e r
secures the oil drain plug and chain assembly to the
assembly (15) toward the engine.
base assembly (TM 5-6115-440-20).
(3) Remove drive belt from generator sheave
(11) Remove four screws (9,fig.2-1) and lock
( T M  5-6115-440-20).
nuts (8) that secure engine (10) to base assembly
(4) Lift assembled starter-generator (13) and
(28).
adapter assembly (15) off adapter base plate (18).
(12) Lift engine off base assembly with a
(5) Remove six screws (12) and nuts (11) and
crane.
seperate starter-generator from adapter assembly.
b. Installation. Installation procedure for the
b. Installation.
engine is the reverse of the removal procedure.
(1) Installation procedure for the starter.
2 - 1 0 . Control Box
generator is the reverse procedure of removal.
a. Removal.
(2) Adjust the drive belt tension (TM 5-6115-
(1) Remove battery (TM 5-6115-440-10).
440-20).
(2) Disconnect control box leads at generator,
2 - 9 . Engine
ground stud and magneto.
a. Removal.
(3) Disconnect power cables and battery leads
(1) Remove battery (TM 5-6115-440-10).
from rear of control box.
(2) Disconnect control box leads leading to
(4) Open control box door and remove four
generator, ground stud and magneto.
screws and flex nuts that secure control box to shelf
(3) Remove battery leads and power cables
of frame assembly.
from rear of control box.
( 5 ) Lift control box out of shelf of frame
(4) Drain fuel tank and disconnect fuel line
assembly.
leading from fuel tank to fuel selector valve.
b. Installation. Installation procedure for the
(5) Remove fuel line leading from fuel strainer
control box is the reverse of the removal procedure.
to fuel selector valve.
Key to Figure 2-1:
15.
Adapter Assy, Generator
1. Belt, V, Matched set
16.
Nut, lock hex
2. Bushing, taper lock
17.
Screw, cap hex head
3. Sheave, engine
18.
Base plate, adapter
4. Key, engine sheave
19.
Screw, square-head
5. Bushing, taper lock
20.
Nut, hex
6. Sheave, generator
21.
Washer, lock split
7. Key, generator sheave
22.
U-bolt, lifting bar assy
8. Nut, lock hex
23.
Nut, hex
9. Screw, cap hex head
24.
Washer, lock split
10. Engine, gas
25.
Bolt, eye, lifting bar assy
11. Nut, lock hex
26.
Screw hex
12. Screw cap hex head
27.
Bar assy lifting
13. Starter-generator
28.
Base assembly
14. Nut, lock hex
2-2

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