ARMY TM 9-6115-753-10

AIR FORCE TO 35C2-3-535-1

MARINE CORPS TM 09244C/09245C-OI
NAVY TM 7610-LL-L1A-0030
TECHNICAL MANUAL

OPERATOR’S MANUAL

FOR

GENERATOR SET, SKID MOUNTED

60KW ADVANCED MEDIUM MOBILE POWER SOURCES
(AMMPS)
MEP-1070 50/60 Hz
(NSN: 6115-01-561-7788) (EIC: N/A)
MEP-1071 400 Hz
(NSN: 6115-01-561-7895) (EIC: N/A)

DISTRIBUTION STATEMENT A — Approved for public release; distribution is unlimited.

HEADQUARTERS, DEPARTMENTS OF THE ARMY,

AIR FORCE, NAVY, AND HEADQUARTERS,
US MARINE CORPS
15 FEBRUARY 2011
PCN 184 092455 00
 TM 9-6115-753-10

WARNING SUMMARY

FIRST AID
For First Aid information, refer to Field Manual (FM) 4-25.11.

5 SAFETY STEPS TO FOLLOW IF SOMEONE IS THE VICTIM OF ELECTRICAL SHOCK:

Do not try to pull or grab the individual.

If possible, turn off the electrical power.

If you cannot turn off the electrical power, pull, push, or lift the person to safety using a dry
wooden pole, dry rope, or some other insulating material.

Send for help as soon as possible.

After the injured person is free of contact with the source of electrical shock, move the person a
short distance away. Immediately start artificial respiration if necessary.

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The Warning Summary summarizes critical safety and hazardous material warnings that must be understood and
applied during operation and maintenance of the Advanced Medium Mobile Power Sources (AMMPS) generator
sets.

x These warnings are important.

x Study and understand all warnings.

x These warnings can save your life and the lives of personnel with whom you work.

x Some general warnings found in the Warning Summary will not be repeated within the Technical Manual
(TM).

x Specific warnings will be listed above the task or paragraph to which they apply.
Operation and maintenance of the AMMPS generator set contains many possibilities for injury or death to
personnel. Be sure to be familiar with general first aid procedures as references in FM 4-25.11, First Aid.

WARNING ICONS

The following icons are used in conjunction with warnings so that you do not miss important information. They
are not meant to be a substitute for reading the warnings, but they provide a graphic description of the danger.

EAR PROTECTION — Headphones over ears shows that noise level will harm ears.

ELECTRICAL — Electrical wire to arm with electricity symbol running through human
body shows that life-threatening shock hazard is present.

ELECTRICAL — Electrical wire to hand with electricity symbol running through hand
shows that shock hazard is present.

FLYING PARTICLES — Objects striking person shows that the material presents a
danger to life or health.

HEAVY OBJECT — Human figure stooping over heavy object shows physical injury
potential from improper lifting technique.

HIGH PRESSURE — Human hand being penetrated by high pressure shows system
pressures present a danger to life or limb.

HOT AREA — Hand over object radiating heat shows that part is hot and can burn.

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MOVING PARTS — Human figure with an arm caught between the gears shows that the
larger moving parts of the equipment present a danger to life or limb.

MOVING PARTS — Hand with fingers caught between gears shows that the smaller
moving parts of the equipment present a danger to life or limb.

WARNING DESCRIPTIONS

WARNING

Electrical

x High voltage is produced when generator set is in operation. Never attempt to start the generator
set unless it is properly grounded. Do not ground yourself in standing water. Never attempt to
connect or disconnect load cables while the generator sets are running. Failure to comply may
cause injury or death to personnel.

x Ensure generator sets are shut down and output terminal board has no voltage prior to making
any connections for operation or moving a generator set that has been operating. Operating
generator sets always contain the risk of electrocution. Failure to comply may cause injury or
death to personnel

x Ensure generator sets are shut down and output terminal board has no voltage prior to making
any connections for parallel operation or moving a generator set that has been operating in
parallel. Operating generator sets always contain the risk of electrocution. Failure to comply may
cause injury or death to personnel.

x Direct Current (DC) voltages are present at generator set electrical components even with
generator set shut down. Avoid shorting any positive with ground/negative. Do not ground
yourself in standing water. Failure to comply may cause injury or death to personnel and damage
to equipment.

x Generator set must be completely shut down prior to washing. Electrocution is possible. Failure to
comply may cause injury or death to personnel.

x Do not start generator set until all internal components are completely dry. Electrocution is
possible. Failure to comply may cause injury or death to personnel.

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WARNING

Electrical — Continued.

x North Atlantic Treaty Organization (NATO) slave receptacle is electrically live at all times and is
not protected by a fuse. Disconnecting main DC circuit breaker does not ensure the circuit is
dead. This circuit is only dead when the batteries are fully disconnected. Disconnect both
batteries before performing maintenance on the slave receptacle. Failure to comply may cause
injury or death to personnel.

x Power is available to the GFCI convenience receptacle only when the main contactor is closed.
Avoid accidental contact. Electrocution is possible. Failure to comply may cause injury or death to
personnel.

x High voltage is produced when this generator set is in operation. Do not contact output cables
when operating this generator set. Failure to comply may cause injury or death to personnel.

x High voltage is produced when generator set is in operation. Do not connect to a load that is not
protected with appropriate safety devices. Do not connect from output terminal board to output
terminal board unless directed by higher command. Never attempt to start the generator set
unless it is properly grounded. Do not ground yourself in standing water. Never attempt to
connect or disconnect load cables while the generator set is running. Do not contact output
cables when operating this generator set. Make sure that the connection between generator set
and load is completely deenergized (safety device opens circuit) prior to disconnecting load
cables or performing maintenance on the output terminal board. Failure to comply may cause
injury or death to personnel.

x High-voltage power is available when the main contactor is closed. Avoid accidental contact with
live components. Ensure load cables are properly connected and the output box door is shut
before closing main contactor. Ensure that personnel working with/on loads connected to the
generator set are aware that main contactor is about to be closed before closing main contactor.
Failure to comply may cause injury or death to personnel.

x Shut down generator sets before performing inspection of load cables. Failure to comply may
cause injury or death to personnel by electrocution.

x High voltage is produced when this generator set is in operation. Ensure engine control and
DEAD CRANK switches are set to OFF, negative battery cable is disconnected, and unit is
completely shut down and free of any power source before attempting any troubleshooting or
maintenance on unit. Failure to comply may cause injury or death to personnel.

x Generator set operator is permitted to make connections to output terminal board only.
Connections to load distribution points or to equipment beyond the output terminal board shall
only be made by properly trained and authorized personnel. Failure to comply may cause injury
or death to personnel.

x High-voltage power is available when the main contactor is closed. Avoid accidental contact with
live components. Ensure load cables are properly connected and the load cable door is shut
before closing main contactor. Ensure that personnel working with/on loads connected to the
generator set are aware that main contactor is about to be closed before closing main contactor.
Failure to comply may cause injury or death to personnel.

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WARNING

Electrical — Continued.

x Do not remove the bonding jumper between GND and N unless the weapon system requires an
underground system. Refer to applicable weapon system TM for specific guidance on power and
connection requirements. Failure to comply may cause injury or death to personnel.

x Ensure the frequency of any device powered by the GFCI convenience receptacle matches the
frequency of the generator set. Failure to comply may cause injury or death to personnel.

WARNING

Heat

x When operating, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow engine to cool before checks, services, and maintenance. Wear
gloves and additional protective clothing as required. Failure to comply may cause injury or death
to personnel.

x When operating, muffler has hot metal surfaces that will burn flesh on contact. Shut down
generator set and allow muffler to cool before performing maintenance. Wear gloves and
additional protective clothing as required. Failure to comply may cause injury or death to
personnel.

x Top and housing panels can get very hot. Allow panels to cool down before performing
maintenance. Wear gloves and additional protective clothing as required. Failure to comply may
cause injury or death to personnel.

x Wear heat-resistant gloves and avoid contacting hot metal surfaces with hands and exposed skin
after components have been heated. Wear additional protective clothing as required. Failure to
comply may cause injury or death to personnel.

x When operating, turbocharger has hot metal surfaces that will burn flesh on contact. Shut down
generator set and allow heater to cool before performing maintenance. Wear gloves and
additional protective clothing as required. Failure to comply may cause injury or death to
personnel.

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WARNING

Jewelry/Clothing

x Metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry and do not wear loose clothing when working on equipment. Failure to comply
may cause injury or death to personnel.

x While inspecting the operation of the generator set, do not inadvertently reach into the generator
set. Failure to comply may cause injury or death to personnel.

WARNING

Lifting
Comply with all lifting requirements. Observe the decals on equipment and parts that identify the
weight and determine if assistance is needed. Maximum lift is 37 lb (16.8 kg) for one person, 74
lb (33.6 kg) for two persons, and 101 lb (45.8 kg) for three persons. Failure to comply may cause
injury or death to personnel.

HAZARDOUS MATERIALS ICONS

BIOLOGICAL — Abstract symbol bug shows that material may contain bacteria or viruses
that present a danger to life or health.

CHEMICAL — Drops of liquid on hand shows that material will cause burns or irritation to
human skin or tissue.

CRYOGENIC — Hand in block of ice shows that material is extremely cold and can injure
human skin or tissue.

EXPLOSION — Rapidly expanding symbol shows that material may explode if subjected
to high temperature, source of ignition, or high pressure.

EYE PROTECTION — Person with goggles shows that material will injure the eyes.

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 TM 9-6115-753-10

FIRE — Flame shows that material may ignite and cause burns.

POISON — Skull and crossbones show that material is poisonous or is a danger to life.

RADIATION — Three circular wedges show that material emits radioactive energy and
can injure human tissue.

VAPOR — Human figure in a cloud shows that material vapors present a danger to life or
health.

HAZARDOUS MATERIALS WARNING DESCRIPTIONS

There is a potential risk that soldiers and other users may be exposed to chemical substances and diesel
engine exhaust during the operation, maintenance, and repair of the AMMPS generator sets.
Potential sources of chemical substances include fuels, oils, lubricants, paints, cleaners/solvents, engine
coolant fluids, cold start fluid, fire extinguishing agents, battery acid/chemicals, and miscellaneous
chemicals used during the setup/operation/maintenance and sustainment throughout the life-cycle of the
AMMPS generator sets.

WARNING

This manual describes physical and chemical processes that may require the use of chemicals,
solvents, paints, and/or other commercially available material. Users of the manual should obtain
the Material Safety Data Sheets (MSDS), Occupational Safety and Health Act (OSHA) Form 20,
or the equivalent from the manufacturers or suppliers of materials to be used. Failure to comply
with all procedures, recommendations, warnings and cautions for safe use, handling, storage,
and disposal of these materials may result in serious injury or death to personnel.

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 TM 9-6115-753-10

WARNING

Batteries

x Batteries give off combustible gas. Do not smoke or use open flame when performing
maintenance. Failure to comply may cause injury or death to personnel and damage to
equipment.

x Battery acid can cause burns to skin and cause eye injury. Wear safety goggles and chemical
gloves and avoid acid splash while working on the batteries. Failure to comply may cause injury
or death to personnel.

WARNING

Cold

In extremely cold weather, skin can stick to metal. Avoid contacting metal items with bare skin in
extremely cold weather. Failure to comply may cause injury or death to personnel.

WARNING

Exhaust

x Hot exhaust gases can ignite combustible materials. Allow room for safe discharge of hot gases.
Failure to comply may cause injury or death to personnel.

x Exhaust discharge contains deadly gases, including carbon monoxide. Exhaust gases are most
dangerous in places with poor ventilation. Do not operate generator set in an enclosed area
unless exhaust discharge is properly vented. Failure to comply may cause injury or death to
personnel.

x Exhaust gases are most dangerous in places with poor ventilation. The best defense against
exhaust gas poisoning is very good ventilation. To protect yourself and others, always obey the
following rules:
ƒ Do not run engine indoors unless you have very good ventilation.
ƒ Do not idle engine for a long time unless there is very good ventilation.
ƒ Be alert at all times. Check for smell of exhaust fumes.
ƒ Failure to comply may cause injury or death to personnel.

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WARNING

Exhaust — Continued.

x Exhaust gas poisoning causes dizziness, headache, loss of muscle control, sleepiness, coma,
and death. If anyone shows signs of exhaust gas poisoning, get all personnel clear of AMMPS.
Make sure they have lots of fresh air. Keep them warm, calm, and inactive. Get medical help. If
anyone stops breathing, give artificial respiration. Failure to comply may cause injury or death to
personnel.

WARNING

Eye

Flying debris or material may enter eyes or strike the face. Wear appropriate eye/face protection
while performing maintenance tasks. Failure to comply may cause injury or death to personnel.

WARNING

Fuel

x Fuels used in the generator set are combustible. Do not smoke or use open fire when performing
maintenance. Fire and possible explosion may result. Failure to comply may cause injury or death
to personnel and damage to equipment.

x Hot engine surfaces from engine and generator circuitry are possible sources of ignition. When
refueling during unit operation with Diesel Fuel (DF)-1, DF-2, Jet Propulsion Fuel (JP) 5, or JP8,
avoid fuel splash and fuel spill. Do not smoke or use open flame when performing refueling.
Remember Preventive Maintenance Checks and Services (PMCS) are still required. Flames and
possible explosion may result. Failure to comply may cause injury or death to personnel.

x Fuel is combustible and toxic to eyes, skin, and respiratory tract. Skin and eye protection are
required when working in contact with fuel. Avoid repeated or prolonged contact. Provide
adequate ventilation. Operators are to wash exposed skin and change soaked clothing promptly if
exposed to fuel. Failure to comply may cause injury or death to personnel.

x Fuels used in the generator set are combustible. Ensure fuel source grounding strap is connected
to unit fuel fill grounding stud (fuel fill static ground). When filling the fuel tank, maintain metal-to-
metal contact between filler nozzle and fuel tank opening to eliminate Electrostatic Discharge
(ESD). Fire and possible explosion can result. Failure to comply may cause injury or death to
personnel.

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WARNING

Fuel — Continued.

x Do not operate generator set if any fuel leaks are present. Fuel is combustible. Always perform
PMCS before operation. Failure to comply may cause injury or death to personnel.

WARNING

High Temperature/Pressure

x Hot coolant can burn. If the radiator cap is hot to the touch, it is too hot to open. Allow the coolant
to cool before opening the radiator cap. Wear gloves, additional protective clothing, and goggles
as required. Contact with high-pressure steam and/or liquids can cause burns and scalding.
Failure to comply may cause injury or death to personnel.

x Cooling system operates at high temperature and pressure. Contact with high-pressure steam
and/or liquids can cause burns and scalding. Shut down generator set and allow system to cool
before performing checks, services, and maintenance. Wear gloves, additional protective
clothing, and goggles as required. Contact with high-pressure steam and/or liquids can cause
burns and scalding. Failure to comply may cause injury or death to personnel.

x Engine coolant is toxic to eyes and poisonous if ingested. Eye protection is required when
working with engine coolant. Avoid repeated or prolonged contact. Failure to comply may cause
injury or death to personnel.

x Cooling system operates at high temperature and pressure. Contact with high-pressure steam
and/or liquids can cause burns and scalding. Do not open radiator cap unless coolant
temperature is below 100°F (38°C). Failure to comply may cause injury or death to personnel.

WARNING

Noise

Hearing protection required during maintenance or repair with engine running. Failure to comply
can cause hearing loss.

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LIST OF EFFECTIVE PAGES/WORK PACKAGES

NOTE: Zero in the "Change No." column indicates an original page or work package.
Date of issue for the original manual is:

Original 15 February 2011

TOTAL NUMBER OF PAGES FOR FRONT MATTER AND REAR MATTER IS 40 AND TOTAL
NUMBER OF WORK PACKAGES IS 21, CONSISTING OF THE FOLLOWING:

Page / WP No. Change No. Page/WP No. Change No.

Front cover 0 WP 0010 (22 pgs) 0
Blank 0 WP 0011 (6 pgs) 0
Warning summary (8 pgs) 0 Chp 4 title page 0
i–x 0 Chp 4 index 0
Chp 1 title page 0 WP 0012 (4 pgs) 0
Chp 1 index 0 WP 0013 (24 pgs) 0
WP 0001 (8 pgs) 0 WP 0014 (4 pgs) 0
WP 0002 (14 pgs) 0 WP 0015 (10 pgs) 0
WP 0003 (10 pgs) 0 WP 0016 (6 pgs) 0
Chp 2 title page 0 WP 0017 (6 pgs) 0
Chp 2 index 0 Chp 5 title page 0
WP 0004 (22 pgs) 0 Chp 5 index 0
WP 0005 (56 pgs) 0 WP 0018 (2 pgs) 0
WP 0006 (22 pgs) 0 WP 0019 (4 pgs) 0
WP 0007 (8 pgs) 0 WP 0020 (2 pgs) 0
WP 0008 (4 pgs) 0 WP 0021 (2 pgs) 0
Chp 3 title page 0 Glossary-1 – Glossary-2 0
Chp 3 index 0 INDEX-1 – INDEX-4 0
WP 0009 (4 pgs) 0 Inside back cover 0
Back cover 0

A/B blank USA

 ARMY TM 9-6115-753-10
AIR FORCE TO 35C2-3-535-1
MARINE CORPS TM 09244C/09245C-OI
NAVY TM 7610-LL-L1A-0030

HEADQUARTERS,
DEPARTMENTS OF THE ARMY, AIR FORCE,
NAVY, AND HEADQUARTERS, US MARINE CORPS
WASHINGTON, D.C., 15 FEBRUARY 2011

TECHNICAL MANUAL
OPERATOR’S MANUAL
FOR
GENERATOR SET, SKID MOUNTED
60KW ADVANCED MEDIUM MOBILE POWER SOURCES (AMMPS)
MEP-1070 50/60 Hz
(NSN: 6115-01-561-7788) (EIC: N/A)
MEP-1071 400 Hz
(NSN: 6115-01-561-7895) (EIC: N/A)

REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS

You can help improve this manual. If you find any mistakes or if you know of a way to improve the procedures,
please let us know. Reports, as applicable by the requiring service, should be submitted as follows:

(a) (A) Army — Mail your letter or DA Form 2028 (Recommended Changes to Publications and Blank
Forms) located in the back of this manual, directly to: Commander, U.S. Army CECOM Life
Cycle Management Command (LCMC) and Fort Monmouth, ATTN: AMSEL-LC-LEO-E-CM,
Fort Monmouth, NJ 07703-5006. You may also send in your recommended changes via
electronic mail or by fax. Our fax number is 732-532-1556, DSN 992-1556. Our e-mail address
is MONM-AMSELLEOPUBSCHG@conus.army.mil. Our online web address for entering and
submitting DA Form 2028s is http://edm.monmouth.army.mil/pubs/2028.html.

(b) (MC) Marine Corps — Submit notice of discrepancies or suggested changes on a NAVMC 10772.
The NAVMC may be submitted via the Internet using URL: http://192.156.19.109/ar/mcefs.nsf.
Once the form is completed click on file in the tool bar at top of screen, scroll to "Send" and
select "Page by email", and enter SMB.LOG.Tech.Pubs.fct@usmc.mil, this will come in to the
Pubs Sections mailbox. This method of submittal does not require a Common Access Card
(CAC) to access the form. The https://pubs.ala.usmc.mil/front.htm URL will allow access to the
Albany Publications web site where the form can be filled out and be submitted by electronic
mail to mbmatcommarlogbases@logcom.usmc.mil. A paper copy NAVMC 10772 can be
mailed in an envelope addressed to Commander, Marine Corps Systems Command (LOG/TP),
814 Radford Blvd, Suite 20343, Albany, GA 31704-0343. Problems or questions regarding the
NAVMC 10772 program should be reported by calling DSN 567-7628, DSN 567-6439 or DSN
567-5017.

(c) (N) Navy — By letter directly to Commander, Space and Naval Warfare Systems Command,
ATTN: SPAWAR 8122, Washington, DC 20363-5100.

(d) (F) Air Force — By Air Force AFTO Form 22 TM Change Recommendation and Reply in
accordance with paragraph 6-5, Section VI, TO 00-5-1 directly to prime ALC/MST.

A reply will be furnished to you.

DISTRIBUTION STATEMENT A –– Approved for public release; distribution is unlimited.

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TABLE OF CONTENTS

WP Sequence No.
Page No.
How To Use This Manual

Chapter 1 — General Information, Description, And Theory Of Operation

General Information ................................................................................................................................ WP 0001

Scope ............................................................................................................................................ WP 0001-1
Table 1. Model Numbers and Equipment Names ......................................................................... WP 0001-1
Figure 1. Skid-Mounted 60 kW AMMPS Generator Set ............................................................... WP 0001-1
Maintenance Forms, Records, and Reports ................................................................................. WP 0001-2
Reporting Equipment Improvement Recommendation (EIR) ....................................................... WP 0001-2
Corrosion Prevention and Control (CPC)...................................................................................... WP 0001-2
Ozone-Depleting Substances ....................................................................................................... WP 0001-3
Destruction of Army Materiel to Prevent Enemy Use ................................................................... WP 0001-3
Destruction of Marine Corps Materiel to Prevent Enemy Use ...................................................... WP 0001-3
Table 2. Demolition Priority Levels ............................................................................................... WP 0001-4
Preparation for Storage or Shipment ............................................................................................WP 0001-4
Warranty Information..................................................................................................................... WP 0001-4
List of Abbreviations/Acronyms..................................................................................................... WP 0001-4
Safety, Care, and, Handling .......................................................................................................... WP 0001-8
Equipment Description And Data ........................................................................................................... WP 0002
Equipment Characteristics, Capabilities, and Features ................................................................ WP 0002-1
Location and Description of Major Components ........................................................................... WP 0002-1
Figure 1. AMMPS 60 kW Generator Set with Doors Closed ........................................................ WP 0002-1
Housing ......................................................................................................................................... WP 0002-1
Figure 2. Rear- and Right-Side View with Doors Open ................................................................ WP 0002-2
Figure 3. Front- and Left-Side View with Door Open.................................................................... WP 0002-3
DCS............................................................................................................................................... WP 0002-3
Skid Assembly............................................................................................................................... WP 0002-4
Figure 4. Skid ................................................................................................................................ WP 0002-4
Engine Assembly .......................................................................................................................... WP 0002-4
Figure 5. Engine Components — Left Side .................................................................................. WP 0002-5
Figure 6. Engine Components — Right Side ................................................................................ WP 0002-6
Figure 7. Systems Components — Right Side ............................................................................. WP 0002-7
Figure 8. Systems Components — Left Side................................................................................ WP 0002-8
Figure 9. 24-VDC Electrical and AC Generator Components — Right Side ................................ WP 0002-9
Figure 10. Output Box Components — Right Side ..................................................................... WP 0002-10
AC Generator .............................................................................................................................. WP 0002-11
Output Box Assembly.................................................................................................................. WP 0002-11
Differences Between Models ...................................................................................................... WP 0002-11
Equipment Data .......................................................................................................................... WP 0002-11
Table 1. Equipment Data ............................................................................................................ WP 0002-11
Theory Of Operation ............................................................................................................................... WP 0003
Scope ............................................................................................................................................ WP 0003-1
Operation....................................................................................................................................... WP 0003-1
DCS............................................................................................................................................... WP 0003-1

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WP Sequence No.
Page No.

Figure 1. AMMPS Control Overview ............................................................................................. WP 0003-2

Technical Principles of Operation ................................................................................................. WP 0003-2
Figure 2. Engine Starting System ................................................................................................. WP 0003-3
Figure 3. Fuel System ................................................................................................................... WP 0003-4
Figure 4. Engine Cooling System ................................................................................................. WP 0003-5
Figure 5. Engine Lubrication System ............................................................................................WP 0003-6
Figure 6. Air Intake and Exhaust System...................................................................................... WP 0003-7
Figure 7. Output Supply System ................................................................................................... WP 0003-9

Chapter 2 — Operator Instructions

Descriptions And Use Of Operator Controls And Indicators .................................................................. WP 0004

Introduction ................................................................................................................................... WP 0004-1
DCS............................................................................................................................................... WP 0004-1
Figure 1. Screen Navigation ......................................................................................................... WP 0004-1
Table 1. Screen Navigation........................................................................................................... WP 0004-2
Figure 2. Generator Set DCS Control Panel................................................................................. WP 0004-3
Table 2. Generator Set DCS Control Panel.................................................................................. WP 0004-3
Figure 3. DCS Control Panel ........................................................................................................ WP 0004-4
Table 3. DCS Control Panel.......................................................................................................... WP 0004-4
Figure 4. Dead Crank Switch ........................................................................................................ WP 0004-5
Table 4. Dead Crank Switch ......................................................................................................... WP 0004-5
Figure 5. Engine Control Switch ................................................................................................... WP 0004-6
Table 5. Engine Control Switch..................................................................................................... WP 0004-6
Figure 6. Main DC Circuit Breaker ................................................................................................ WP 0004-7
Table 6. Main DC Circuit Breaker ................................................................................................. WP 0004-7
Figure 7. Voltage Selection Board ................................................................................................ WP 0004-8
Table 7. Voltage Selection Board ................................................................................................. WP 0004-8
Figure 8. Main Display Screen (Showing 3-Phase Configuration) ............................................... WP 0004-9
Table 8. Main Display Screen ....................................................................................................... WP 0004-9
Figure 9. [Adjustments] Screen 1 — Select Parameter .............................................................. WP 0004-13
Table 9. [Adjustments] Screen 1 — Select Parameter ............................................................... WP 0004-13
Figure 10. [Adjustments] Screen 1 — Adjust .............................................................................. WP 0004-14
Table 10. [Adjustments] Screen 1 — Adjust ............................................................................... WP 0004-14
Figure 11. [Adjustments] Screen 2 — Select Parameter ............................................................ WP 0004-15
Table 11. [Adjustments] Screen 2 Display — Select Parameter ................................................ WP 0004-15
Figure 12. [Adjustments] Screen 2 — Adjust .............................................................................. WP 0004-16
Table 12. [Adjustments] Screen 2 — Adjust ............................................................................... WP 0004-17
Figure 13. [Parallel Adj] Screen .................................................................................................. WP 0004-18
Table 13. [Parallel Adj] Screen ................................................................................................... WP 0004-18
Figure 14. First [Maintenance] Screen........................................................................................ WP 0004-19
Table 14. First [Maintenance] Screen ......................................................................................... WP 0004-19
Figure 15. [Maintenance Items] Screen ...................................................................................... WP 0004-20
Table 15. [Maintenance Items] Screen ....................................................................................... WP 0004-20
Figure 16. [Maintenance Actions] Screen ................................................................................... WP 0004-21
Table 16. [Maintenance Actions] Screen .................................................................................... WP 0004-21
Figure 17. Generator Hour Meter................................................................................................WP 0004-22
Table 17. Generator Hour Meter.................................................................................................WP 0004-22
Operation Under Usual Conditions......................................................................................................... WP 0005
Siting Requirements...................................................................................................................... WP 0005-2
Assembly and Preparation for Use ...............................................................................................WP 0005-3
Screen Navigation......................................................................................................................... WP 0005-3
Figure 1. Screen Navigation ......................................................................................................... WP 0005-3

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WP Sequence No.
Page No.

Installation of Ground Rod ............................................................................................................ WP 0005-4

Figure 2. Grounding Connections ................................................................................................. WP 0005-4
Figure 3. Install Ground Rod With Slide Hammer......................................................................... WP 0005-6
Figure 4. Install Ground Rod With Sledge Hammer ..................................................................... WP 0005-7
Removal of Ground Rod ............................................................................................................... WP 0005-9
Installation of Auxiliary Fuel Lines............................................................................................... WP 0005-10
Figure 5. Auxiliary Fuel Supply Connections .............................................................................. WP 0005-10
Installation of Load Cables.......................................................................................................... WP 0005-11
Figure 6. Installation of Load and Ground Cables ...................................................................... WP 0005-11
Table 1. Load Terminal — Voltage Selection Board................................................................... WP 0005-12
Figure 7. Ground and Output Cable Attachment Detail .............................................................. WP 0005-12
Initial Adjustments ....................................................................................................................... WP 0005-13
Figure 8. Configure Voltage Selection Board.............................................................................. WP 0005-14
Operating Procedures ................................................................................................................. WP 0005-15
Starting Procedure ...................................................................................................................... WP 0005-15
Figure 9. Main DC Circuit Breaker and DEAD CRANK SWITCH ............................................... WP 0005-16
Figure 10. DCS Panel ................................................................................................................. WP 0005-17
Figure 11. Main Screen Message 1 ............................................................................................ WP 0005-18
Table 2. Delay to Crank Messages............................................................................................. WP 0005-19
Figure 12. Main Screen Message 2 ............................................................................................ WP 0005-19
Figure 13. Operator Main Screen ............................................................................................... WP 0005-20
Adjust Generator Set................................................................................................................... WP 0005-21
Figure 14. Main Screen Showing Adjustments — Location........................................................ WP 0005-21
Figure 15. [Adjustments] Screen 1 — Select Option .................................................................. WP 0005-22
Figure 16. [Adjustments] Screen 1 — Set Configuration ............................................................ WP 0005-23
Figure 17. [Adjustments] Screen 2 — Select Parameter ............................................................ WP 0005-24
Figure 18. [Adjustment] Screen 2 — Set Configuration.............................................................. WP 0005-25
Monitoring Generator Set Operational Status............................................................................. WP 0005-26
Figure 19. Main Control Screen Status Indicators 120/208 V 3 Phase ...................................... WP 0005-26
Table 3. Screen Indicator Parameters ........................................................................................ WP 0005-26
Figure 20. Select Maintenance Screen....................................................................................... WP 0005-28
Figure 21. First Maintenance Screen.......................................................................................... WP 0005-29
Figure 22. Maintenance Item Display ......................................................................................... WP 0005-30
Figure 23. Next Items Display ..................................................................................................... WP 0005-31
Operation with Remote Monitoring ............................................................................................. WP 0005-31
Figure 24. Operator Display Panel — Remote Connection ........................................................ WP 0005-32
Figure 25. Remote PC — Connection ........................................................................................ WP 0005-33
Figure 26. Remote PC Display ...................................................................................................WP 0005-34
Stopping Procedure .................................................................................................................... WP 0005-36
Figure 27. Stopping Procedure ................................................................................................... WP 0005-36
Decals and Instruction Plates...................................................................................................... WP 0005-37
Figure 28. Decals and Instructions Plates, Right-Side — Model 1070/1071.............................. WP 0005-37
Table 4. Decals and Instructions Plates, Right-Side — Model 1070/1071 ................................. WP 0005-37
Figure 29. Decals and Instructions Plates, Rear — Model 1070/1071....................................... WP 0005-38
Table 5. Decals and Instructions Plates, Rear — Model 1070/1071 .......................................... WP 0005-38
Figure 30. Decals and Instructions Plates, Top and Inside — Model 1070/1071....................... WP 0005-39
Table 6. Decals and Instructions Plates, Top and Inside — Model 1070/1071 .......................... WP 0005-39
Figure 31. Decals and Instructions Plates, Front — Model 1070/1071 ...................................... WP 0005-40
Table 7. Decals and Instructions Plates, Front — Model 1070/1071 ......................................... WP 0005-40
Figure 32. Decals and Instructions Plates, Left-Side — Model 1070/1071 ................................ WP 0005-41
Table 8. Decals and Instructions Plates, Left-Side — Model 1070/1071 ................................... WP 0005-41
Figure 33. Plate, Identification — Model 1070 ............................................................................ WP 0005-42
Figure 34. Plate, Identification — Model 1071 ............................................................................ WP 0005-42

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WP Sequence No.
Page No.

Figure 35. Label, Lifting and Tie Down — Model 1070/1071...................................................... WP 0005-43
Figure 36. Plate, IUID Identification — Model 1070.................................................................... WP 0005-43
Figure 37. Plate, IUID Identification — Model 1071.................................................................... WP 0005-44
Figure 38. Name Plate, Identification — Model 1070 ................................................................. WP 0005-44
Figure 39. Name Plate, Identification — Model 1071 ................................................................. WP 0005-45
Figure 40. Plate, System Capacity — Model 1070/1071 ............................................................ WP 0005-45
Figure 41. Plate, Set Rating — Model 1070 ............................................................................... WP 0005-46
Figure 42. Plate, Set Rating — Model 1071 ............................................................................... WP 0005-46
Figure 43. Label, Fuel — Model 1070/1071................................................................................ WP 0005-47
Figure 44. Label, Convenience — Model 1070 .......................................................................... WP 0005-47
Figure 45. Label, Convenience — Model 1071 .......................................................................... WP 0005-47
Figure 46. Label, Fuel Diagram — Model 1070/1071................................................................. WP 0005-48
Figure 47. Label, Operating Instructions — Model 1070/1071 ................................................................. WP 0005-49
Figure 48. Label, First Fuel Filter — Model 1070/1071 .............................................................. WP 0005-49
Figure 49. Label, Diagram, Wiring — Model 1070/1071............................................................. WP 0005-50
Figure 50. Plate, Battery Connection — Model 1070/1071 ........................................................ WP 0005-51
Figure 51. Label, Caution, Voltage Connection — Model 1070/1071 ........................................ WP 0005-51
Figure 52. Label, Grounding Stud — Model 1070/1071 ............................................................. WP 0005-52
Figure 53. Label, Schematic, Wiring — Model 1070 .................................................................. WP 0005-53
Figure 54. Label, Slave Receptacle — Model 1071 ................................................................... WP 0005-53
Figure 55. Label, Dead Crank — Model 1070/1071 ................................................................... WP 0005-54
Preparation for Movement .......................................................................................................... WP 0005-54
Parallel Operations ................................................................................................................................. WP 0006
Parallel Operations........................................................................................................................ WP 0006-1
Connecting Generator Sets Parallel Cables (PP Configuration) .................................................. WP 0006-2
Figure 1. Storage Box and Cable — Location .............................................................................. WP 0006-3
Figure 2. DCS Panel — Parallel Setup ......................................................................................... WP 0006-3
Parallel Operation With Switch Box (Two Like Sets) .................................................................... WP 0006-4
Figure 3. Switch Box Paralleling Receptacle ................................................................................ WP 0006-5
Figure 4. Main Display Screen — Parallel Mode .......................................................................... WP 0006-6
Parallel Operation Without Switch Box (Two Or More Like Sets)................................................. WP 0006-8
Adjusting Parallel Operations...................................................................................................... WP 0006-11
Figure 5. Parallel Adjustment Screen, A ..................................................................................... WP 0006-11
Figure 6. Parallel Adjustment Screen, B. .................................................................................... WP 0006-13
Figure 7. Parallel Adjustment Screen, C..................................................................................... WP 0006-15
Figure 8. Parallel Adjustment Screen, D..................................................................................... WP 0006-16
Figure 9. Parallel Adjustment Screen, E ..................................................................................... WP 0006-18
Figure 10. Parallel Adjustment Screen, F ................................................................................... WP 0006-19
Soft Removal From Parallel Operation With [Unload] Soft Key.................................................. WP 0006-19
Figure 11. Soft Unload Key......................................................................................................... WP 0006-20
Removal From Parallel Operation With UNIT PARALLEL Switch.............................................. WP 0006-21
Figure 12. DCS Panel, Remove From Parallel ........................................................................... WP 0006-21
Operation Under Unusual Conditions..................................................................................................... WP 0007
Operation in Extreme Cold -25°F (-31°C) ..................................................................................... WP 0007-2
Operation in Extreme Heat Above 120°F (49°C) .......................................................................... WP 0007-2
Operation in Dusty or Sandy Areas .............................................................................................. WP 0007-2
Operation in Rainy or Humid Conditions.......................................................................................WP 0007-3
Operation in Salt Water Areas ...................................................................................................... WP 0007-3
Operation in High Altitudes ........................................................................................................... WP 0007-4
Operation Using BATTLESHORT Switch ..................................................................................... WP 0007-5
Figure 1. DCS Panel ..................................................................................................................... WP 0007-5
Operation While in Contaminated Areas....................................................................................... WP 0007-6
Use of Ground Fault Circuit Interrupter (GFCI) Convenience Receptacle ................................... WP 0007-7

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WP Sequence No.
Page No.

Figure 2. GFCI Convenience Receptacle ..................................................................................... WP 0007-7

Emergency.............................................................................................................................................. WP 0008
NATO Slave Receptacle Start Operation...................................................................................... WP 0008-1
Figure 1. NATO Slave Receptacle................................................................................................ WP 0008-2
Emergency Stopping..................................................................................................................... WP 0008-3
Figure 2. DCS Panel ..................................................................................................................... WP 0008-3
Operation Using BATTLESHORT Switch ..................................................................................... WP 0008-4

Chapter 3 — Troubleshooting Procedures

Troubleshooting Index ........................................................................................................................... WP 0009

General Troubleshooting Information ...........................................................................................WP 0009-1
Malfunction/Symptom Index.......................................................................................................... WP 0009-1
Troubleshooting Procedures ................................................................................................................. WP 0010
Table 1. Voltage Parameters ...................................................................................................... WP 0010-11
Table 2. Frequency Parameters ................................................................................................. WP 0010-12
DCS Fault And Warning Codes And Descriptions ................................................................................. WP 0011
DCS Fault and Warning Codes and Descriptions......................................................................... WP 0011-1
Table 1. DCS Fault and Warning Codes and Descriptions........................................................... WP 0011-1

Chapter 4 — Operator Maintenance Instructions

PMCS Introduction.................................................................................................................................. WP 0012

Introduction ................................................................................................................................... WP 0012-1
General.......................................................................................................................................... WP 0012-1
Explanation of the Columns Found in PMCS Table ..................................................................... WP 0012-1
Corrosion Prevention and Control (CPC)...................................................................................... WP 0012-1
Inspection ...................................................................................................................................... WP 0012-2
Cleaning and Lubrication .............................................................................................................. WP 0012-3
Fluid Leakage................................................................................................................................ WP 0012-3
PMCS ..................................................................................................................................................... WP 0013
Figure 1. Rear View ...................................................................................................................... WP 0013-2
Figure 2. Right-Side View ............................................................................................................. WP 0013-3
Figure 3. Front View...................................................................................................................... WP 0013-4
Figure 4. Left-Side View................................................................................................................ WP 0013-5
Table 1. PMCS for the 60 kW AMMPS Generator Set ................................................................. WP 0013-5
Service Air Cleaner................................................................................................................................. WP 0014
Inspect Air Filter Restriction Indicator ........................................................................................... WP 0014-1
Figure 1. Air Cleaner — Location.................................................................................................. WP 0014-1
Figure 2. Air Cleaner/Air Filter Restriction Indicator and Dust Ejector Valve................................ WP 0014-2
Remove Air Cleaner Filter Element ..............................................................................................WP 0014-3
Figure 3. Air Cleaner Assembly .................................................................................................... WP 0014-3
Install Air Cleaner Filter Element .................................................................................................. WP 0014-4
Clean Air Cleaner Dust Ejector Valve ...........................................................................................WP 0014-4
Service Cooling System ......................................................................................................................... WP 0015
Check Coolant Level ..................................................................................................................... WP 0015-2
Figure 1. Coolant Overflow Bottle — Location.............................................................................. WP 0015-2
Figure 2. Coolant Recovery Assembly.......................................................................................... WP 0015-3
Figure 3. Coolant Level ................................................................................................................. WP 0015-4
Fill Coolant Overflow Bottle........................................................................................................... WP 0015-5
Figure 4. Radiator Fill — Exterior.................................................................................................. WP 0015-5
Figure 5. Radiator Fill — Interior................................................................................................... WP 0015-6
Figure 6. Pressure Relief Valve .................................................................................................... WP 0015-7

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WP Sequence No.
Page No.

Inspect Radiator Hoses, Interconnecting Tubes, and Clamps ..................................................... WP 0015-9

Figure 7. Cooling System Hoses, Interconnecting Tubes, and Clamps — Left Side ................... WP 0015-9
Figure 8. Cooling System Hoses, Interconnecting Tubes, and Clamps — Right Side............... WP 0015-10
Service Fuel System............................................................................................................................... WP 0016
Check Fuel Level .......................................................................................................................... WP 0016-1
Figure 1. Fuel Fill — Location ....................................................................................................... WP 0016-2
Figure 2. Fuel Filler ....................................................................................................................... WP 0016-3
Fill Fuel Tank................................................................................................................................. WP 0016-3
Service Fuel Filter/Water Separator.............................................................................................. WP 0016-4
Figure 3. Fuel Filter/Water Separator ........................................................................................... WP 0016-4
Service Engine Oil .................................................................................................................................. WP 0017
Check Oil Level of Engine Not In-Service..................................................................................... WP 0017-1
Figure 1. Oil Service Detail — Right Side .....................................................................................WP 0017-2
Check Oil Level of Operating Engine............................................................................................ WP 0017-3
Collect Engine Oil Sample ............................................................................................................ WP 0017-4
Add Engine Oil .............................................................................................................................. WP 0017-5
Figure 2. Oil Service Detail — Left Side ....................................................................................... WP 0017-6

Chapter 5 — Supporting Information

References ............................................................................................................................................. WP 0018

Scope ............................................................................................................................................ WP 0018-1
Field Manuals................................................................................................................................ WP 0018-1
Forms ............................................................................................................................................ WP 0018-1
Technical Manuals ........................................................................................................................ WP 0018-2
Miscellaneous Documents ............................................................................................................ WP 0018-2
Components of End Item (COEI) And Basic Issue Items (BII)............................................................... WP 0019
Scope ............................................................................................................................................ WP 0019-1
General ......................................................................................................................................... WP 0019-1
Explanation of Columns in the COEI List and BII List................................................................... WP 0019-1
Table 1. Components of End Item (COEI) .................................................................................... WP 0019-2
Figure 1. Basic Issue Items (BII)................................................................................................... WP 0019-2
Table 2. Basic Issue Items (BII) .................................................................................................... WP 0019-3
Additional Authorization List (AAL) ......................................................................................................... WP 0020
Scope ............................................................................................................................................ WP 0020-1
General ......................................................................................................................................... WP 0020-1
Explanation of Columns in the AAL .............................................................................................. WP 0020-1
Table 1. Additional Authorizations List (AAL) ............................................................................... WP 0020-1
Expendable And Durable Items List ....................................................................................................... WP 0021
Scope ............................................................................................................................................ WP 0021-1
Explanation of Columns in the Expendable/Durable Items List.................................................... WP 0021-1
Table 1. Expendable and Durable Items....................................................................................... WP 0021-1

Glossary
Alphabetical Index

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HOW TO USE THIS MANUAL

This manual contains operator instructions for the AMMPS 60 kilowatt (kW) generator sets, Mobile Electric Power
(MEP)-1070 (50/60 Hertz (Hz)) and MEP-1071 (400 Hz).
This operator’s manual is part of a family of manuals that includes a field and sustainment maintenance manual
with Repair Parts and Special Tools List (RPSTL) (TM 9-6115-753-24&P), an operator and field maintainer
manual with Repair Parts and Special Tools List for Power Units (PU) and Power Plants (PP) (TM 9-6115-759-
13&P), and a National Maintenance Work Requirement (NMWR) Maintenance Manual (NMWR 9-6115-753).

NOTE
Throughout the family of manuals, directional orientation in relation to the generator set is
described from the point of view of the operator facing the operator’s controls looking out over the
generator set. From this perspective, the end of the generator set containing the operator’s
controls will be referred to as the rear of the generator set.

Manual Overview

This operator’s manual provides operating procedures, troubleshooting, PMCS, maintenance, and supporting
information required to operate and maintain the AMMPS 60 kW generator sets. Listed below are some of the
features included in this TM to help locate and use the provided information.

WORK PACKAGES (WPs)

This TM has been organized using the WP concept. Each chapter contains a series of WPs rather than sections
and paragraphs. Each WP is designed to stand alone as a complete information module. If you keep the
section(s) of this TM in a loose-leaf binder, you will be able to remove just the WP needed to complete a specific
task.
Each WP is numbered using a four-digit number beginning with WP 0001. WPs are numbered sequentially
throughout the TM (e.g. WP 0022, WP 0023, etc.). The Table of Contents lists each chapter and WP title, as well
as all figures and tables contained within each WP. Figures and tables are numbered sequentially within each
WP.
The WP number is located at the top right of each page. It is also located at the bottom of the page with the WP
page number included (0001-1 would be page 1 of the General Information WP (WP 0001, General Information).
Each WP starts on a right-hand page. This is done so you can remove a single WP from the paper TM if needed
for a task. Blank pages are assigned a number, but it appears on the preceding or following page. For example, if
page 0001-10 of a WP is blank, page 0001-9 will have the number 0001-9/10 blank; or if page 0001-1 of a WP is
blank, page 0001-2 will have the number 0001-1 blank/2.
Each WP containing step-by-step maintenance or troubleshooting procedures will end with the words END OF
TASK, and each WP ends with the statement END OF WORK PACKAGE. Think of each WP as a small, stand-
alone TM.
Typographical conventions are as follows:
[Unload] indicates a soft key or switch.
[Previous] + [Next] indicates two simultaneous key presses.
[ + ] [ - ] indicates two sequential key presses.

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 TM 9-6115-753-10

References to equipment placarding or data and description plates (WP 0005, Operation Under Usual Conditions)
are printed as they appear on the equipment whenever possible. On-screen text is shown in brackets in the
manual (i.e. [Ready to Crank]).

Warnings, Cautions, and Notes Definitions

Warning, caution, and note headings, chapter titles, and paragraph headings are printed in bold type. Multiple
warning, caution, or note paragraphs may appear above a procedure, task, or step with one warning, caution, or
note heading. Prior to starting a WP, all warnings included in the WP should be reviewed, understood, and
followed. Review the materials/parts in the initial setup of the WP for any hazardous materials used during
maintenance of the equipment. Then refer to the detailed warnings for hazardous materials in the Warning
Summary. Make sure to read all warnings within referenced WP that are required to complete tasks.

WARNING
Warning highlights an essential operating or maintenance procedure, practice, condition,
statement, etc. which, if not strictly observed, could result in injury to, or death of, personnel or
long term health hazards.

CAUTION
Caution highlights an essential operating or maintenance procedure, practice, condition,
statement, etc., which, if not strictly observed, could result in damage to, or destruction of,
equipment or loss of mission effectiveness.

NOTE
Note highlights an essential operating or maintenance procedure, condition, or statement.

TECHNICAL MANUAL CONTENT

A Table of Contents is provided for a quick reference to the chapters and WPs. Become familiar with it in order to
quickly locate the information needed. This TM is divided into the following chapters:
CHAPTER 1 provides general information including characteristics, capabilities, features, and theory of operation
for the AMMPS and its major components. The General Information WP (WP 0001, General Information) contains
a nomenclature cross-reference list, a list of abbreviations and acronyms used in this TM, general information
about this manual, and the related forms and records. Instructions are provided for making equipment
improvement and recommendations. Coverage includes a reference to the manual that contains instructions on
destruction of materiel to prevent enemy use.
CHAPTER 2 provides the detailed instructions for safe operation of the AMMPS. It includes description and use
for AMMPS controls (WP 0004, Description and Use of Operator Controls and Indicators) as well as operations
under usual (WP 0005, Operation Under Usual Conditions) and unusual conditions (WP 0007, Operation Under
Unusual Conditions).
CHAPTER 3 provides an operator troubleshooting malfunction/symptom index (WP 0009, Troubleshooting Index)
and troubleshooting procedures (WP 0010, Troubleshooting Procedures) for AMMPS. Most operator controls and
indicators are contained in a Digital Control System (DCS). All DCS fault and warning codes are listed and
described in Chapter 3 (WP 0011, DCS Fault & Warning Codes and Descriptions). The DCS Fault & Warning
Codes and Descriptions WP provides examples of fault and warning screens exactly as the text will appear on the
DCS display.
CHAPTER 4 provides operator PMCS (WP 0013, PMCS) procedures necessary to service and maintain the
AMMPS 60 kW generator set. Operator maintenance tasks are also provided.
CHAPTER 5 includes supporting information for the AMMPS generator set, which includes a list all the FM, forms,
TM, and miscellaneous publications referenced in the TM (WP 0018, References). Chapter 5 also provides

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Components of End Item (COEI) and Basic Issue Items (BII) lists (WP 0019, COEI and BII Lists) to help inventory
items for safe and efficient operation of the AMMPS. It also contains Additional Authorization List (AAL) (WP
0020, AAL) and a list of expendable and durable items (WP 0021, Expendable and Durable Items List) needed to
operate and maintain the AMMPS generator set.
Appendices and Rear Matter include a Glossary and Department of the Army (DA) Form 2028, Recommended
Changes to Publications and Blank Forms. The Glossary contains the list of terms and definitions which are
uncommon and not identified within the manual or within a standard dictionary. The DA Form 2028 is the
document to be submitted to correct errors found in the manual or to make recommended changes that will
improve the manual.

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 TM 9-6115-753-10

CHAPTER 1

GENERAL INFORMATION, EQUIPMENT DESCRIPTION, AND

THEORY OF OPERATION
FOR
AMMPS 60KW GENERATOR SET
 TM 9-6115-753-10

CHAPTER 1

GENERAL INFORMATION, EQUIPMENT DESCRIPTION, AND THEORY OF OPERATION

WORK PACKAGE INDEX

Title WP Sequence No.
GENERAL INFORMATION.................................................................................................................................. 0001
EQUIPMENT DESCRIPTION AND DATA........................................................................................................... 0002
THEORY OF OPERATION .................................................................................................................................. 0003
 TM 9-6115-753-10 0001

OPERATOR MAINTENANCE
AMMPS 60KW GENERATOR SET
GENERAL INFORMATION

SCOPE

This operator maintenance TM contains instructions for operating and maintaining the AMMPS 60 kW generator
set.

Type of Manual

Operator and crew maintenance.

Model Number(s) and Equipment Name(s)

AMMPS 60 kW 50/60 and 400 hertz (Hz) generator sets, skid mounted (Table 1):

Table 1. Model Numbers and Equipment Names.

MODEL HERTZ NSN
MEP-1070 50/60 6115-01-561-7788
MEP-1071 400 6115-01-561-7895

Purpose of Equipment

The AMMPS 60 kW generator set is designed to provide tactical, quiet Alternating Current (AC) power in a
combat setting. The generator set is designed for ease of transportation, operation, and maintenance. The
Cummins QSB 4.5 Tier III engine supplied with the AMMPS 60 kW generator set eliminates wet stacking
problems.

Figure 1. Skid-Mounted 60 kW AMMPS Generator Set.

0001-1
 TM 9-6115-753-10 0001

MAINTENANCE FORMS, RECORDS, AND REPORTS

(1) (Army). Department of the Army forms and procedures used for equipment maintenance will be those
prescribed by (as applicable) DA PAM 750-8, The Army Maintenance Management System (TAMMS)
Users Manual; DA PAM 738-751, Functional Users Manual for the Army Maintenance Management
System — Aviation (TAMMS-A); or AR 700-138, Army Logistics Readiness and Sustainability.

(2) (Marine Corps). Maintenance forms and records used by Marine Corps personnel are prescribed in TM
4700-15/1.
(3) (Air Force). Maintenance forms and records used by Air Force personnel are prescribed in AFI 21-101
and the applicable TO 00-20, Series of Technical Orders.
(4) (Navy). Navy users should refer to their service peculiar directives to determine applicable maintenance
forms and records to be used.

REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR)

(1) (Army). If your equipment needs improvement, let us know. Send us an EIR. You, the user, are the only one
who can tell us what you don’t like about your equipment. Let us know why you don’t like the design or
performance. If you have Internet access, the easiest and fastest way to report problems or suggestions is to
follow the instructions and links below:
If you have a user’s account, you can submit the PQDR for ALL CECOM (B16) Warranty, EIR, and PQDRs
(including those B16 Aviation related) through the Navy’s Web Product Quality Deficiency Reporting (PQDR) site,
http://www.nslcptsmh.csd.disa.mil/webpqdr/webpqdr.htm. If you do not, either go to EZPQDR,
http://www.nslcptsmh.csd.disa.mil/webpqdr/files/ezpqdr.htm and input your PQDR there, or establish a new
account. New accounts can be established at the following address:
http://www.nslcptsmh.csd.disa.mil/accessforms/uarform.htm.
CECOM (B16) aviation PQDRs will not go to AMCOMs Joint Deficiency Reporting System (JDRS). If AMCOM
should get a CECOM aviation PQDR, they will redirect it to the CECOM PQDR Team.
Use the PQDR for Warranties, EIRs, and PQDRs. There is a block on the PQDR that can be clicked if it is a
Warranty. The originator can still put in the description that they want this investigated as an EIR and then enter
what the issue is.
You may also submit your SF 368 (Product Quality Deficiency Report) via email (MONM-
AMSELLEODCSCFO@CONUS.ARMY.MIL), facsimile (732-532-2929), or regular mail (call 732-532-8843 for the
current mailing address).
We will send you a reply.
(2) (Air Force). Air Force personnel are encouraged to submit EIRs IAW Air Force Regulation (AFR) 900-4.
(3) (Navy). Navy personnel are encouraged to submit EIRs through their local Beneficial Suggestion Program.
(4) (Marine Corps). QDR shall be reported on SF 368 IAW MCO P4855.10, Product Quality Deficiency Report
Manual. Submit to Commanding General, Marine Corps Logistics Base (Code 850), Albany, Georgia 31704-5000.
A reply will be furnished to you.

CORROSION PREVENTION AND CONTROL (CPC)

Corrosion Prevention and Control (CPC) of Army materiel is a continuing concern. It is important that any
corrosion problems with this item be reported so that the problem can be corrected and improvements can be
made to prevent the problem in future items.
Corrosion specifically occurs with metals. It is an electrochemical process that causes the degradation of metals.
It is commonly caused by exposure to moisture, acids, bases, or salts. An example is the rusting of iron.
Corrosion damage in metals can be seen, depending on the metal, as tarnishing, pitting, fogging, surface residue,
and/or cracking.

0001-2
 TM 9-6115-753-10 0001

Plastics, composites, and rubbers can also degrade. Degradation is caused by thermal (heat), oxidation (oxygen),
solvation (solvents), or photolytic (light, typically Ultraviolet (UV)) processes. The most common exposures are
excessive heat or light. Damage from these processes will appear as cracking, softening, swelling, and/or
breaking. SF 368, Product Quality Deficiency Report, should be submitted to the address specified in DA PAM
750-8, The Army Maintenance Management System (TAMMS) Users Manual.
For aircraft TMs, this information shall include a reference to TM 1-1500-344-23, volumes 1 through 4 (Cleaning
and Corrosion Control).

OZONE-DEPLETING SUBSTANCES (ODS)

The use of Class 1 Ozone-Depleting Substances (ODS) for new acquisitions has been curtailed by Section 326 of
the National Defense Authorization Act of Fiscal Year 1993 (Public Law 102, 484) and related Army policy. ODS
are listed in Title VI of the Clean Air Act. For systems procured and fielded prior to the effectiveness of the above
law (June 1993) that use a Class 1 ODS, a listing of those substances required to operate and maintain the
system shall be included in the TM. This requirement applies to any system procured or fielded after June 1993
that requires the use of a Class 1 ODS, where the use of the ODS has been properly documented and waived.
The procuring activity will provide a list of Class 1 ODS on request.

DESTRUCTION OF ARMY MATERIEL TO PREVENT ENEMY USE

Destruction of Army electronics materiel to prevent enemy use shall be IAW TM 750-244-2.
Destruction of Air Force materiel to prevent enemy use shall be IAW AFI 33-201.
Destruction of Navy material to prevent enemy use shall be IAW Navy direction.
Destruction of Marine Corps materiel to prevent enemy use shall be IAW MC direction.

DEMOLITION OF MARINE CORPS MATERIEL TO PREVENT ENEMY USE

Demolition to Render the Generator Set Inoperative

1. When capture or abandonment of the generator set to an enemy is imminent, the responsible unit
commander must make the decision to either destroy or render the equipment inoperative.
2. Based on this decision, orders are issued which cover the desired extent of destruction.
a. Operators should be thoroughly familiar with all methods of destruction without referencing any particular
manual.
b. Demolition of the generator set can be accomplished by explosives, fire, or tools such as a sledge
hammer, pick, or ax. Demolition can also be accomplished by misuse.
3. The method used will depend on the time available and the availability of these materials in the vicinity of the
generator set.
4. Demolition by mechanical means:
a. Use hammer, pick, ax, or any other available tool to destroy vital engine and control parts.
b. Control box, fuel injection lines, and the radiator should be smashed, engine and control box wires pulled
and cut, and any other external engine components (fuel filter, alternator) should be damaged enough to
make them inoperable.
5. Demolition by misuse:
a. Drain diesel generator crankcase oil.
b. Block diesel generator engine air supply ports.
c. Start diesel generator engine and allow it to operate until it fails.

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 TM 9-6115-753-10 0001

d. Pour sand, dirt, or other available abrasive compound in all exposed surfaces and access ports of the
diesel engine and generator.
e. Drain engine coolant.
6. Demolition by burning: Complete as much mechanical damage as possible, and then saturate unit with
combustible fuel and ignite.
7. Demolition by explosives: Place explosive charges in priority order (Table 2).

Table 2. Demolition Priority Levels.

EXPLOSIVE CHARGE
PRIORITY LEVEL COMPONENT
REQUIRED
1 Generator Engine 1 pound (lb)
2 Control Box 1 lb
3 Generator Housing 1 lb
4 Housing/Structure 2 lb

PREPARATION FOR STORAGE OR SHIPMENT

Administrative storage of equipment issued to and used by Army activities will have Preventive Maintenance
Checks and Services (PMCS) performed before storing. When removing the equipment from administrative
storage, the PMCS checks should be performed to assure operational readiness.

WARRANTY INFORMATION

The AMMPS 60 kW generator set is warranted for 1800 hours (hr) of operation or 36 months, whichever occurs
first. The warranty starts on the date the equipment has been accepted in the “Wide Area Work Flow” system.
This warranty includes repair or replacement of any items that prove to be nonconforming and/or defective within
the warranty period. Report all defects to your supervisor, who will take appropriate action.

LIST OF ABBREVIATIONS/ACRONYMS

Acronyms and abbreviations used in this TM are provided and defined below.
Abbreviation/Acronym Definition

- Negative
% Percent
+ Positive
± Plus or minus
Ÿ Up
ź Down
Ż Left
Ź Right
°C Degrees Celsius
°F Degrees Fahrenheit

A After
AAC Ampere Alternating Current
AAL Additional Authorization List
AC Alternating Current
ADC Amperes Direct Current
AFI Air Force Instruction
AFR Air Force Regulation
AFTO Air Force Technical Order
AH Ampere Hour

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Abbreviation/Acronym Definition

AMMPS Advanced Medium Mobile Power Sources

Amp Ampere
AM – VM Ampere Meter – Voltage Meter
AOAP Army Oil Analysis Program
AR Army Regulation
AUX Auxiliary
AVR Automatic Voltage Regulation

B Before
Batt curr Battery Current
BII Basic Issue Items

C Crew (level of maintenance)

CAGEC Commercial and Government Entity Code
CARC Chemical Agent Resistant Coating
CBRN Chemical, Biological, Radiological, and Nuclear
CCV Close Crankcase Ventilation
CECOM LCMC Communications-Electronics Command Life Cycle Management Command
cm Centimeter
COEI Components of End Item
CPC Corrosion Prevention and Control
CPG Cummins Power Generation
CTA Common Table of Allowances

D Depot (level of maintenance)

D During
DA Department of the Army
DC Direct Current
DCS Digital Control System
DF Diesel Fuel
DI Direct Injection
DoD Department of Defense
DS2 Decontamination Solution number 2

E Empty
ea. Each
ECM Electronic Control Module
EIR Equipment Improvement Recommendation
e-mail Electronic mail
ESC Equipment Service Criteria
ESD Electrostatic Discharge
E-Stop Emergency Stop

F Field (level of maintenance)

F Full
FM Field Manual
ft Feet

gal Gallon
Genset Generator Set
GFCI Ground Fault Circuit Interrupter
GFI Ground Fault Interrupter
Glw plg Glow Plug
GPH Gallons Per Hour

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Abbreviation/Acronym Definition

Gov Governor

H Below Depot (level of maintenance)

hr Hour
Hz Hertz

IAW In Accordance With

IBM International Business Machine
ID Identification
in Inch
in3 Cubic inches
IUID Individual Unit Identification

JDRS Joint Deficiency Reporting System

JP Jet Propulsion Fuel
JTA Joint Table of Allowances

kg Kilogram
kPa KiloPascal
kVAR Kilovolt-Ampere Reactive
kW Kilowatt

L Liter
lb Pound
L/Hr Liters Per Hour
LCD Liquid Crystal Display
L-L Line-to-Line
L-N Line-to-Neutral
LRU Line Replaceable Unit

m Meter
mA MilliAmpere
Max Maximum
MCO Marine Corps Order
MEP Mobile Electric Power
MG Mobile Generator
min Minute
mm Millimeter
MSDS Material Safety Data Sheets
MTOE Modified Table of Organization and Equipment
MWO Modification Work Order

N/A Not Applicable

NATO North Atlantic Treaty Organization
NBC Nuclear Biological Chemical
NEMA National Electrical Manufacturers Association
NMWR National Maintenance Work Requirement
No. Number
NSN National Stock Number

ODS Ozone Depleting Substances

OEM Original Equipment Manufacture
OSHA Occupational Safety and Health Act
oz Ounce

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Abbreviation/Acronym Definition

PAM Pamphlet
PC Personal Computer
PDA Personal Data Assistant
PMCS Preventive Maintenance Checks and Services
P/N Part Number
PP Power Plant
PQDR Product Quality Deficiency Report
Press Pressure
psi Pounds per square inch
PU Power Unit

QDR Quality Deficiency Report

qt. Quart
Qty. Recm. Quantity Recommended
Qty. Rqr. Quantity Required

rpm Revolutions per minute

RPSTL Repair Parts and Special Tools List

sec Second
SF Standard Form
SOP Standard Operating Procedure
STB Super-Tropical Bleach

TAMMS The Army Maintenance Management System

TAMMS-A The Army Maintenance Management System — Aviation
TBD To Be Determined
TDA Tactical Decision Aid
Temp Temperature
TM Technical Manual
TOE Table of Organization and Equipment
TO Technical Order

U/I Unit of Issue

USB Universal Serial Bus
UV Ultraviolet

V Volt
VAC Volts Alternating Current
VDC Volts Direct Current

WP Work Package
Wtr Winterization

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SAFETY, CARE, AND HANDLING

ESD: The AMMPS 60 kW generator set DCS contains printed circuit boards and control cards requiring special
handling to protect them from ESD when being serviced. The operator does not need to use special handling for
operation of the AMMPS 60 kW generator set.
This TM describes physical and chemical processes that may require the use of chemicals, solvents, paints, or
other commercially available materials. Users of the TM should obtain the Material Safety Data Sheets (MSDS)
(OSHA Form 20 or equivalent) from the manufacturers or suppliers of materials to be used. Users must be
completely familiar with manufacturer/supplier information and adhere to their procedures, recommendations,
warnings, and cautions for safe use, handling, storage, and disposal of these materials.

END OF WORK PACKAGE

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OPERATOR MAINTENANCE
AMMPS 60KW GENERATOR SET
EQUIPMENT DESCRIPTION AND DATA

EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES

The AMMPS 60 kW generator set (Figure 1) is a fully-enclosed, self-contained, skid-mounted mobile unit. The
generator set consists of six major assemblies: engine assembly, internal fuel assembly, external fuel assembly
(not shown), AC generator assembly, Digital Control System (DCS), and output box assembly. An optional
winterization kit is available for installation in cold weather climates.
The AMMPS 60 kW generator set is designed to accommodate the continuing proliferation of electronics
(computers, Personal Data Assistants (PDA), etc.), life support systems, and global communications necessary in
today’s battlefield that require a continuous, uninterrupted flow of electricity to accommodate all tactical situations.

LOCATION AND DESCRIPTION OF MAJOR COMPONENTS

Figure 1. AMMPS 60 kW Generator Set with Doors Closed.

HOUSING

A steel housing consisting of several individual body panels encloses the AMMPS 60 kW generator set and
protects it from the environment. The housing provides acoustical protection, entry access to generator set
assemblies, control of air flow over internal surfaces, and mounting for generator set components.
The steel housing is durable enough so that no damage should occur within normal usage. The housing design
prevents the invasion of wind-driven rain, snow, and sand to the interior of the units through the design and
placement of the louver and a rain cap. The Chemical Agent Resistant Coating (CARC) paint, polyurethane
coating on circuit boards, sealed connectors, and immersion-proof fan motor housing provide additional protection
against moisture and condensation damage.

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Self-supporting hinged doors allow easy interior access for scheduled service and preventive maintenance.
Individual body panels are removable to allow additional access for replacement and service of major
components.

Body Panels

All body panels are connected using corrosion-resistant captive nuts. All seals are interference fit to the housing
panels.

Figure 2. Rear and Right-Side View with Doors Open.

Top Panel (Figure 2, Item 2). The top panel shields components from the elements.

Rear Panel (Figure 2, Item 9). Located at the rear of the generator set, the rear panel contains the DCS access
door (Figure 2, Item 1), DCS (Figure 2, Item 11), rear access door (Figure 2, Item 10), convenience receptacle
(Figure 2, Item 7), entrance for load cables (Figure 2, Item 8), and fuel fill (Figure 2, Item 12).

Right-Side Panel (Figure 2, Item 5). Located on the right side of the generator set, the right-side panel contains
the right-side access door (Figure 2, Item 3) and output box door (Figure 2, Item 6).

Storage Box (Figure 2, Item 4). An accessory box, stenciled Storage Box, has been installed on the inside of the
right-side access door (Figure 2, Item 3) to provide space for the paralleling cable, grounding rod connecting
hardware, and auxiliary fuel line.

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Figure 3. Front and Left-Side View with Door Open.

Front Panel (Figure 3, Item 1). The front panel is located on the front of the generator set and contains the
NATO slave receptacle (Figure 3, Item 5) and the access panel (Figure 3, Item 6).

Left-Side Panel (Figure 3, Item 2). The left-side panel is located on the left side of the generator set and
contains the left-side access door (Figure 3, Item 4).

Document Box (Figure 3, Item 3). An accessory box, stenciled Document Box, has been installed on the inside
of the left-side access door (Figure 3, Item 4) to provide space for the TM.

Identification (ID) Plates. Identification (ID) plates and placards for system safety and operation are attached to
the housing. See WP 0005, Operation Under Usual Conditions for the placement and contents of the identification
and safety placards.

DCS (Figure 2, Item 11)

The DCS is a microprocessor-based control that allows the operator and maintainer to: start/stop the generator
set and regulate fuel source using the engine control switch; stop the generator set in emergencies with the
EMERGENCY STOP switch; operate the contactor using the AC CIRCUIT INTERRUPT switch; adjust voltage,
frequency, gain, panel lights, and other settings using the adjustment screens with the soft keys; clear/reset
generator faults using the FAULT RESET control; operate in parallel with other generator sets using the UNIT
PARALLEL switch; and perform other necessary functions to provide output power.

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The control unit is powered by the generator set 24-VDC system. The controls are fully functional after
approximately 4 seconds (sec) (boot-up time). Once the generator set model, frequency, and voltage
configurations are determined by the DCS programming, the control automatically adjusts the display value limits,
menus, and operational parameters accordingly, reducing potential operator error.
The AMMPS 60 kW generator set provides limited remote operation capabilities through interface with an
International Business Machine (IBM)-compatible Personal Computer (PC). The operational status of the
generator set can be monitored, battleshort conditions can be set and released, and emergency stop can be
executed from up to a 250-foot (ft) (76.2-meter (m)) distance. Loss of signal between the remote monitoring site
and the generator set does not adversely affect the generator set operation.
The DCS display is a colored Liquid Crystal Display (LCD) with a 6.5-inch (in) (165.1-millimeter (mm)), diagonal
viewing area. It provides a combination of switches and LCD soft keys to allow the operator and maintainer to
control the generator set.

SKID ASSEMBLY (Figure 4)

Figure 4. Skid.

The housing sits on a steel skid that extends beyond the housing walls by approximately 0.39 in (10 mm). The
engine and AC generator are directly mounted to the skid with the focus toward the roll inertia axis. This improves
vibration isolation. The skid is equipped with forklift pockets for transportation capability. The skid base has drains
located between the forklift pockets on each side for draining liquids from the generator set.

ENGINE ASSEMBLY

The AMMPS 60 kW generator set uses a Cummins QSB 4.5 Tier III engine. The vertical, water-cooled, four-cycle
Direct Injection (DI) diesel engine utilizes a four-cylinder, turbocharged process. It consists of the cylinder head
and valve cover, crankcase assembly, pistons, main bearing case, and lubrication system. It is mounted to the
skid toward the front panel of the generator set. See Figure 5 and Figure 6 for a breakdown of major engine
components.

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Figure 5. Engine Components — Left Side.

Major Engine Components/Assemblies

Major engine components/assemblies include: cylinder head and valve cover assembly, block assembly,
lubrication system, Engine Control Module (ECM), fuel system, cooling system, DC electrical system, and air
intake and exhaust system.
Cylinder Head (Figure 5, Item 8) and Valve Cover (Figure 5, Item 1) Assembly. The cylinder head assembly is
located on the top of the block assembly (Figure 6, Item 4) and seals the upper ends of the cylinders to provide
compression, protects the portion of the engine where combustion takes place, and houses the valve assembly.
The valve cover is located on top of the cylinder head assembly and protects the valve assembly from
contamination.
Block Assembly (Figure 6, Item 4). The block assembly houses the connecting rods, crankshaft, pistons,
camshaft, and bearings.
Lubrication System. The AMMPS 60 kW generator set lubrication system is compatible with MIL-PRF-21260E
preservative oil. The lubricating oil conforms to MIL-PRF-46167C and MIL-PRF-2104H.
Operators can safely check and add oil to the lubricating system while the generator set is operating or in the off
condition. The lubrication system includes an oil filter (Figure 6, Item 3) with captive cap to permit oil-filling from a
standard 8-qt capacity can and a readily-accessible oil-level bayonet gage (dipstick) (Figure 6, Item 5). The
dipstick is marked to ensure accurate reading of oil levels. See WP 0017, Service Engine Oil for more information.
Oil Drain Assembly (Figure 6, Item 6). The oil drain assembly is located between the oil pan and the unit skid. It
allows the oil to be easily drained into a remote catch basin using a ball valve (Figure 6, Item 1).
Oil Filter (Figure 6, Item 3). The oil filter/oil cooler assembly is located adjacent to the battery-charging alternator
on the exhaust side of the engine. It removes impurities from the lubricating oil utilizing a full-flow, spin-on,
disposable oil filter cartridge.

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Fuel Injection System. Once fuel has passed through the fuel filter/water separator (Figure 8, Item 7), the fuel
passes through the spin-on fuel filter (Figure 5, Item 4). From the spin-on fuel filter (Figure 5, Item 4), the fuel
passes to the fuel injection pump (Figure 5, Item 5). The fuel injection pump (Figure 5, Item 5) sends high-
pressure fuel for each of the engine’s four cylinders into the fuel injector rail (Figure 5, Item 3). From the fuel
injector rail (Figure 5, Item 3), the fuel travels through the valve cover (Figure 5, Item 1) within high-pressure
internal injector lines to the fuel injectors, which are electronically activated to spray the fuel at high pressure into
the cylinder where it is burned.
ECM (Figure 5, Item 7). The ECM receives data from a variety of sensors. The data is processed through an on-
board computer that controls fuel flow and timing to ensure the most efficient use of fuel. The ECM also monitors
the engine for proper performance and alerts the operator and maintainer of developing problems within the
engine.

Figure 6. Engine Components — Right Side.

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Figure 7. Systems Components — Right Side.

Unit Cooling System

Cooling Fans (Figure 8, Item 6). The five cooling fans allow the generator set to operate in all required
operational environments. The 16-in, variable-speed 24-VDC cooling fans optimize radiator location and air flow
paths for improved cooling efficiency. Intake air for the cooling system is drawn by the cooling fans through four
fan shrouds and inlet ducts on the left-side panel. This air passes through the cooling fins of the radiator, charge
air cooler, and fuel cooler, transferring heat from the cooling system to the air flow. The fifth fan is located
internally and forces air downward into the AC generator area of the unit. The warm air is then expelled into the
atmosphere through a grille in the top panel. The cooling system also reduces wear on the battery-charging
alternator belt and water pump. Cold weather operation is also improved by regulating cabinet temperature at or
near ideal operating temperature.
Coolant Circulation System. This system consists of the radiator, charge air cooler, fuel cooler, thermostat,
water pump, winterization kit, and coolant overflow reservoir. It is responsible for keeping the engine at a safe
temperature. See WP 0015, Service Cooling System for further information on maintaining the cooling system.
Coolant Overflow Bottle (Figure 7, Item 1). Mounted to the rear panel at the fuel fill opening, the coolant
overflow bottle is clearly visible for inspection of coolant level. It provides easy access for coolant filling through
the top panel.
Radiator (Figure 7, Item 3). An aluminum radiator acts as a heat exchanger for the coolant. A radiator fill port is
accessible on the top panel. The captive radiator cap prevents loss of coolant.
Charge Air Cooler (Figure 7, Item 2). Co-located with the radiator, the charge air cooler dissipates the heat from
the compressed air exiting the turbocharger into the air flow. The cooling of the intake air improves the efficiency
of the engine.
Fuel Cooler (Figure 8, Item 5). A fuel cooler is located behind the charge air cooler. The fuel cooler is not visible
unless the top panel is removed. Cooling of the fuel prior to injection into the engine improves the efficiency of the
engine.

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Thermostat (Figure 8, Item 1). A thermostat is located inside the housing where the upper radiator hose
connects to the top of the engine. It monitors coolant temperature and adjusts the cooling system accordingly.
Water Pump (Figure 8, Item 8). The water pump circulates the coolant through the block assembly and the
radiator.
Winterization Kit (Figure 7, Item 6). The optional winterization kit is located inside of the right-side panel. The
fuel-fired coolant heater warms coolant in extreme cold conditions between negative (-) 25 degrees Fahrenheit
(°F) and -50°F (-32 degrees Celsius (°C) and -46°C) by utilizing the fuel from the generator set. The winterization
kit automatically activates, depending on the temperature, and features automatic heat regulation. It is controlled
by the DCS, which provides the [READY TO CRANK] indicator when the heater has completed its cycle.

Figure 8. Systems Components — Left Side.

Air Cleaner Assembly (Figure 7, Item 4). The air cleaner assembly, mounted on a bracket attached to the front
and top panels, filters contaminates from the intake air. The air cleaner assembly contains an integrated,
centrifugal precleaner that removes most dust particles prior to entering the air cleaner element. These larger
contaminants are easily ejected from the air cleaner assembly through a squeeze-type fitting. This extends filter
life and reduces maintenance costs and downtime. The air cleaner assembly is fitted with an indicator to show
when the filter capacity is exceeded. The filter element is replaceable (WP 0014, Service Air Cleaner).

Exhaust System

The exhaust manifold (Figure 6, Item 2) is located on the exhaust side of the engine and is accessible through the
right-side door. As exhaust leaves the compression chamber, it is routed through the exhaust manifold into a
single pipe, and then through the turbocharger (Figure 5, Item 2). The turbocharger uses exhaust gases to turn a
turbine which compresses the intake air. The compressed intake air is directed to the cylinders through the intake
manifold and improves the efficiency and power production of the engine. The exhaust gases exit the
turbocharger and through the muffler (Figure 7, Item 5). The bulkhead-mounted muffler silences the exhaust
pulses from the engine and expels exhaust gases through the top panel grille.

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Unit Fuel System

Fuel Fill (Figure 8, Item 3) and Fuel Tank (Figure 8, Item 4). The AMMPS 60 kW generator set is designed to
utilize diesel fuel or an acceptable substitute (Grade Number (No.) 1-d and Grade No. 2-d fuels per A-A-52557)
and includes design adaptations to accommodate the usage of Jet Propulsion (JP)-8. The fuel fill is located on the
rear panel and allows refueling during operation (WP 0016, Service Fuel System). The fuel tank is mounted
directly to the skid assembly behind the rear access door. It is designed for 8 hr of operation at 75 percent (%)
load on JP-8 fuel with the generator set at a 15-degree angle. The tank drain extends down into the skid area
below the rear panel. The main fuel pump transmits lower-pressure fuel from the fuel tank and sends it through an
in-line fuel filter to the fuel filter/water separator (Figure 8, Item 7) .
Fuel Filter/Water Separator (Figure 8, Item 7). The fuel filter/water separator element is spin-on and removes
debris and water particles from fuel before it enters the engine. A water drain cock is on the bottom of the filter
(WP 0018, Service Fuel System).
External Fuel Tank and Auxiliary Connections (Figure 8, Item 2). Connections for auxiliary fuel supply and
return are located in the fuel filler shroud. The auxiliary fuel pump transfers fuel from the auxiliary fuel tank to the
unit fuel tank.

Figure 9. 24-VDC Electrical and AC Generator Components — Right Side.

24-VDC Electrical System

The 24-VDC electrical system uses two 12-volt (V) batteries (Figure 9, Item 5) connected in series. The batteries
are standard commercial size, sealed, maintenance free, and located side-by-side on the right side of the unit.
They are accessed through the right-side door. The batteries are capable of starting the generator set under all
conditions between -50°F (-46°C) and positive (+) 135°F (57°C) ambient temperatures. The starter (Figure 9, Item
1) is located on the exhaust side of the engine above the oil pan. A NATO slave receptacle (Figure 9, Item 4) is
provided, should the unit require jump-starting from another 24-VDC source. In the event the engine needs to be
manually turned, a three-position DEAD CRANK SWITCH is included (WP 0004, Description and Use of Operator
Controls and Indicators). The 24-VDC system is protected by a 50-Ampere (Amp) main DC circuit breaker (Figure
9, Item 3). The main DC circuit breaker is accessed through the right-side door.

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If the temperature is between +21°F and -25°F (-6°C and -32°C), intake air heaters are used to aid in starting. For
temperatures between -25°F and -50°F (-32°C and -46°C), the optional winterization kit (Figure 7, Item 6) is used
as a starting aid. See WP 0005, Operation Under Usual Conditions for more information.
Belt-Driven Battery-Charging Alternator (Figure 9, Item 2). The standard belt-driven battery-charging
alternator recharges the batteries which in turn provide power to the cooling fan, DCS, and engine systems. The
charging system completely charges the batteries during operation within 4 hr of startup. A voltage regulator
(internal to the alternator) controls the voltage output of the belt-driven battery-charging alternator.

Figure 10. Output Box Components — Right Side.

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AC GENERATOR (Figure 9, Item 6)

The AC generator converts the rotating mechanical energy from the engine into electrical energy. The electrical
energy is then distributed from the output box assembly (Figure 10, Item 3) through cables that enter the output
box assembly (Figure 10, Item 3) via a flexible sleeve (Figure 10, Item 4) from field equipment requiring electric
power or a switch box.
The AC generator and voltage control system are drip-proof, guarded machine type and are synchronous and
brushless, as specified in National Electrical Manufacturers Association (NEMA) Standard No. MG, part 33. The
bearings are sealed and permanently lubricated. System leads are identified with permanent marker and are
brought out of the frame through non abrasive bushings and holders in the output terminal board (Figure 10, Item
1). These isolate each lead and hold it securely in place.
When operating in three-phase at rated load and frequency, the AC generator can withstand, without damage,
two consecutive short circuits at the load terminals of 10 sec or less in duration within a 5-min interval at less than
300% of rated output current.

OUTPUT BOX ASSEMBLY (Figure 10, Item 3)

The output box assembly is located on the right body panel and distributes electricity produced by the AC
generator (Figure 9, Item 6) through the output terminal board (Figure 10, Item 1). The output box contains the
output terminal board, individual load terminals (Figure 10, Item 2), and unit relays. All relays are socket-mounted
and secured with a cover. The relay will not move unless the cover is removed.

DIFFERENCES BETWEEN MODELS

The differences between models of generator set covered in this TM are as follows:
Model MEP-1070 is equipped with a 50/60 Hz generator.
Model MEP-1071 is equipped with a 400 Hz generator.

EQUIPMENT DATA

For a list of leading particulars, refer to Table 1.

Table 1. Equipment Data.

GENERATOR SET:
Model Numbers:
60 kW 50/60 Hz MEP-1070
60 kW 400 Hz MEP-1071
NSN:
60 kW 50/60 Hz NSN 6115-01-561-7788
60 kW 400 Hz NSN 6115-01-561-7895
Overall Length:
MEP-1070 82 in (208 cm)
MEP-1071 82 in (208 cm)
Overall Width:
MEP-1070 36 in (91 cm)
MEP-1071 36 in (91 cm)
Overall Height:
MEP-1070 53 in (135 cm)
MEP-1071 53 in (135 cm)
Dry Weights (less BII):
MEP-1070 3500 lb (1588 kg)
MEP-1071 3500 lb (1588 kg)

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Table 1. Equipment Data — Continued.

Wet Weights:
MEP-1070 3690 lb (1674 kg)
MEP-1071 3690 lb (1674 kg)
Engine:
Manufacturer Cummins
Model QSB 4.5 Tier III
Type: Direct Injection (DI), four cylinder, four cycle, vertical,
water cooled
Displacement 275 in3 (4.5 L)
Altitude Degradation, 4000 – 8000 ft (1220 – 2440 3.5% per 1000 ft (305 m)
m)
Firing Order 1-3-4-2
Winterization Kit Use -25°F – -50°F (-32°C – -46°C)
Valve Tappet Clearance Adjustment
Exhaust 0.020 in (0.508 mm)
Intake 0.010 in (0.254 mm)
Cooling System:
Type Pressurized radiator, forced circulation with pump
Capacity 17 qt (16.0 L)
Normal Operating Temperature Range 185°F – 225°F (85°C – 107°C)
Temperature Indicating System Voltage Rating 24 VDC
Lubrication System:
Type Forced lubrication by pump
Oil Pump Type Gear driven
Normal Operating Pressure 42–71 pounds per square inch (psi) (290–490
kiloPascal (kPa))
Oil Filter Type Spin-on cartridge
Lubricating System Capacity 11.5 qt (10.9 L)
Pressure Indicating System Voltage Rating 24 VDC
Fuel System:
Type of Fuel DF-2D (ASTM D975)
Fuel Tank Capacity 34.7 gal (131.35 L)
Fuel Consumption Rate 50/60 Hz: 3.30 Gallons Per Hour (GPH) (12.5 Liters
per Hour (L/Hr))
400 Hz: 3.435 GPH (13.0 L/Hr)
Auxiliary Fuel Pump:
Voltage Rating 24 VDC
Delivery Pressure 6.3 – 9.7 psi (43.4 – 66.9 kPa)
Fuel Level Sensor:
Type Ultrasonic
Current 20 – 200 milliampere (mA) at 10 – 32 VDC
Starting System:
Batteries 2 X 12 VDC (52 AH) in series
Starter:
Manufacturer Denso
Model 4948534
Voltage Rating 24 VDC
Drive Type Integral

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Table 1. Equipment Data — Continued.

Battery-Charging Alternator:
Manufacturer Delco
Models 4993343
Rating 70 Ampere (Amp)
Protective Fuse None
AC Generator:
Manufacturer Cummins
Type UC227C (50/60 Hz) and Marathon 60 kW (400 Hz)
Load Capacity 60 kW
Current Ratings:
120/208 V connection 208 Amp
240/416 V connection 104 Amp
Power Factor 0.8
Cooling Fan cooled
Drive Type Direct coupling
Duty Classification Continuous
Protection Devices:
Low Oil Pressure:
Trip Pressure 10 psi (145 kPa)
Voltage Rating 5 VDC
Current Rating 4 mA
Coolant High Temperature Controller:
Trip Temperature 223°F (106°C)
Voltage Rating 24 VDC
Current Rating 1 mA
Overvoltage:
Trip Point Conditions Not more than 30% of rated voltage.
Trip Point No more than 1.25 sec after trip condition exists.

END OF WORK PACKAGE

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OPERATOR MAINTENANCE
AMMPS 60KW GENERATOR SET
THEORY OF OPERATION

SCOPE

The AMMPS 60 kW generator set consists of two modes as follows:

MODES: I – 50/60 Hz
II – 400 Hz
The AMMPS 60 kW generator set was specifically designed for the best possible performance focusing on areas
such as reliability, maintainability, weight, dimensions, and fuel consumption.

OPERATION

The AMMPS 60 kW generator set is designed for deployment in the battlefield to provide the personnel with the
continuous power generation necessary for today’s fielded electronic devices and various electrical equipment
demands. The AMMPS 60 kW generator set is developed to be fixed (skid mounted) or mobile (trailer mounted)
giving the flexibility of movement. The generator sets are designed to accommodate paralleling of generator sets
as well as additional and back-up power generation.
The housing assembly serves as the protective shell for the generator set. The housing has been designed with
openings for ease of maintenance and additional acoustical protection to further silence the generator set while
operating. The AMMPS 60 kW generator set has enhancements for protection from unusual/harsh weather and to
shield from debris.
The AMMPS 60 kW generator set is powered by a turbocharged Cummins QSB4.5 Tier III 274.607 in3 (4.5 L) DI
diesel engine mounted directly to the skid assembly. This particular engine has a built-in Closed Crankcase
Ventilation (CCV) system. The engine produces mechanical energy and interconnects with the AC generator via a
rotating shaft.
The AC generator is a Cummins Power Generation (CPG) UC227C (Mode I, Model 1070 (50/60 Hz)) or a
Marathon 60 kW (Mode II, Model 1071 (400 Hz)) It is a synchronous, brushless design and was developed
specifically to meet performance requirements. The AC generator receives mechanical energy from the engine
and converts it to electrical energy. The electricity produced by the AC generator is transmitted to the output
terminal board.

DCS

The DCS uses a menu-driven display format to control generator set operations. From the DCS, the operator
and/or maintainer can start the generator set, adjust the output voltage and frequency (Model 1070, Mode I only),
operate the contactor, stop the AC generator, clear faults, and perform other functions necessary to produce
power (Figure 1). The AMMPS 60 kW generator sets also provide limited remote operation capabilities through
interface with an IBM-compatible PC. The operational status of the generator set can be monitored, battleshort
conditions can be set and released, and emergency stops can be executed from up to 250 ft (76.2 m) distance.
The AMMPS 60 kW generator set is capable of self-diagnostics at start up. This prognostics function monitors the
protective system and will provide a warning of impending activation of protective devices. All operational data is
captured every 15 min during operation. Faults and warnings are automatically captured upon operation of
protective devices and stored in a Fault Log. Additionally, all maintenance prompts and actions are automatically
captured and stored in a Maintenance Log.

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Figure 1. AMMPS Control Overview.

TECHNICAL PRINCIPLES OF OPERATION

Engine Starting System (Figure 2)

The engine starting system consists of two 12-V batteries connected in series to produce 24 V of electric power, a
starter, a 24-V battery-charging alternator, a magnetic pickup (for sensing engine speed), and related switches
and relays required for controlling the starting system. For engine cranking, battery power is supplied to the
starter motor through the starter solenoid, which in turn is controlled by the cranking relay. The starter then
engages the engine flywheel, causing the engine to turn over. For engine starting, the DEAD CRANK SWITCH
must be in the NORMAL position, the main DC circuit breaker must be in the ON position, the EMERGENCY
STOP switch must be pulled out, and the engine control switch must be moved to the START position. The
cranking relay is then controlled by a circuit, consisting of the crank disconnect relay and crank disconnect switch.
As the engine accelerates to the preset speed (sensed by the magnetic pickup), the crank disconnect switch
opens and de-energizes the cranking relay to stop and disengage the starter. The starting sequence may also be
stopped by moving the engine control switch to OFF. The engine may be cranked without starting by use of the
DEAD CRANK SWITCH. With the DEAD CRANK SWITCH in the CRANK position, the cranking relay, starter
solenoid, and starter motor are energized without activating any other starting or control functions. In the event
the batteries become discharged, an alternative source of starting power is provided through the NATO slave
receptacle.
The batteries are charged by the battery-charging alternator, which is belt-driven by the engine. The DCS is
powered by the battery-charging alternator when the engine is operating and by the 24-V batteries at start up.
Shown on the DCS display, the [Battery] ammeter indicates the charge/discharge rate of the batteries (from -80
Amps to +80 Amps, in 0.1 Amp increments). Normal operating indication depends on the state of charge in the
batteries. A low charge, such as exists immediately after engine starting, will cause a high reading (needle moves
toward [+] area). When the charge in the batteries has been restored, the indicator moves toward zero.

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Figure 2. Engine Starting System.

Fuel System (Figure 3)

The fuel system consists of piping, fuel tank, fuel filter, 24-VDC fuel pump, fuel filter/water separator, fuel level
sensor, fuel injection pump, and four fuel injectors (one for each cylinder). Fuel is drawn from the fuel tank by the
transfer pump when the engine control switch is in the PRIME & RUN positions. After reaching the transfer pump,
fuel passes through an initial spin-on fuel filter before reaching a fuel filter/water separator where water and small
impurities are removed. The fuel then goes to the injection pumps where it is pressurized and forced into the
injectors. Through the injectors, fuel is sprayed into the combustion chamber at high pressure, where it is mixed
with air and ignited. The fuel that is not used is returned to the fuel tank via an excess fuel return line.
The auxiliary fuel system consists of an external fuel supply, fuel filter pipe, 24-VDC auxiliary fuel pump, and fuel
level switch. The engine control switch, when set to PRIME & RUN AUX FUEL, actuates the auxiliary fuel pump
and transfers fuel from the external fuel supply to the generator fuel tank. The fuel level switch shuts off the
auxiliary fuel pump when the generator fuel tank is full and reactivates the pump as the level drops to 75%. The
[Fuel] indicator on the DCS displays the fuel level of the generator set fuel tank from empty [0] to full [100] in 1%
increments.

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Figure 3. Fuel System.

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Engine Cooling System (Figure 4)

The engine cooling system consists of a radiator, hoses, thermostat, water pump, electric fan, temperature
sensor, and cooling jackets. The water pump forces coolant through passages (cooling jackets) in the engine
block and cylinder head where the coolant absorbs heat from the engine. When the engine reaches normal
operating temperature, the thermostat opens and the heated coolant flows through the upper radiator hose
assembly into the radiator. Air circulates through the radiator, reducing coolant temperature.
A coolant high-temperature logic control provides automatic shutdown in the event that coolant temperature
exceeds 225 plus or minus (±) 5°F (107 ± 3°C). The [Coolant] indicator on the DCS displays coolant temperature
range from 100°F to 260°F (38°C to 127°C).
Cold outside temperatures make starting the engine difficult. To improve engine starting, the generator set has
two starting aids: standard air intake heaters mounted in the intake manifold and an optional winterization kit. The
air intake heaters warm the air in the combustion chamber to assist with ignition when the ambient air
temperature is below +21°F (-6°C). The winterization kit warms the engine coolant and thus the engine block
when the ambient air temperature is between -25°F and -50°F (-32°C and -45.56°C).

Figure 4. Engine Cooling System.

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Engine Lubrication System (Figure 5)

The lubrication system consists of an oil pan, dipstick, oil pump, oil pressure sensor, oil screen, oil cooler and oil
filter. The oil pan is a reservoir for engine lubricating oil. The dipstick indicates oil level in the pan. A pump draws
oil from the pan through a screen removing large impurities. After passing through an oil cooler, the oil flows
through a spin-on type filter where small impurities are removed. From the filter, oil enters the engine and is
distributed to the engine’s internal moving parts.
After passing through the engine, the oil returns to the oil pan. The [Oil] pressure indicator on the DCS shows oil
pressure sensed by the oil pressure sensor in the engine. The engine automatically shuts off if oil pressure drops
to a dangerously low level (in the red area of the DCS oil pressure gage). It is recommended to check the engine
oil when the engine is not operating, but it can be checked while the engine is operating (WP 0017, Service
Engine Oil).

Figure 5. Engine Lubrication System.

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Air Intake and Exhaust System (Figure 6)

The air intake and exhaust system consists of an air cleaner assembly, intake manifold, exhaust manifold,
turbocharger, and muffler. Ambient air is drawn into the air cleaner assembly where it passes through the air
cleaner element.
Airborne dirt is removed and trapped in the element. A restriction indicator, located on the air cleaner assembly
housing, displays red when the air cleaner element should be serviced. Filtered air is drawn out of the air cleaner
assembly into the inlet portion of the turbocharger. The air exits the turbocharger through an additional air intake
tube into the air intake manifold, where it passes into the engine and is mixed with fuel from the injectors.
Engine exhaust gases are expelled into the exhaust manifold. The exhaust manifold channels the gases into the
turbocharger which then compresses the air from the air filter and forces the air into the intake manifold. The
exhaust gases then pass to the muffler to deaden the sound of the exhaust gases. The gases pass from the
muffler outlet and are vented upward from the generator set housing.

Figure 6. Air Intake and Exhaust System.

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Output Supply System (Figure 7)

The output supply system consists of the AC generator, output terminal board, voltage selection board, Automatic
Voltage Regulator (AVR), Ampere Meter – Voltage Meter (AM – VM), AC circuit interrupter relay, and contactor.
Power created by the generator is supplied through the voltage selection board and the contactor to the output
terminals on the output terminal board. For more information on the theory and practice of electrical generation,
refer to FM 5-424, Theater of Operations Electrical Systems.
The voltage selection board allows configuration of the generator set for the following voltage ranges:
120/208 V, 3 phase, 4 wire
240/416 V, 3 phase, 4 wire
The AC CIRCUIT INTERRUPT switch controls the AC circuit interrupter relay. The relay enables or interrupts the
power flow between the voltage selection board and the output terminals by opening and closing the contactor.
The AC circuit interrupter relay also automatically opens the contactor during any of the faults that require a
shutdown. The AVR senses AC voltage output and provides controlled voltage to the AC generator exciter to
maintain the desired AC generator output voltage. [Voltage] and [Current] are indicated on the operator control
screen on the DCS. The [Genset Voltage] panel on the DCS displays the [Voltage] AC output of the unit. The [Bus
Voltage] panel on the DCS displays the [Voltage] AC output at the output terminal board. The [Genset Current]
screen on the DCS displays the output of the unit in amperes.

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Figure 7. Output Supply System.

END OF WORK PACKAGE

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 TM 9-6115-753-10

CHAPTER 2

OPERATOR INSTRUCTIONS
FOR
AMMPS 60KW GENERATOR SET
 TM 9-6115-753-10

CHAPTER 2

OPERATOR INSTRUCTIONS

WORK PACKAGE INDEX

Title WP Sequence No.
DESCRIPTIONS AND USE OF OPERATOR CONTROLS AND INDICATORS................................................. 0004
OPERATION UNDER USUAL CONDITIONS ..................................................................................................... 0005
PARALLEL OPERATION..................................................................................................................................... 0006
OPERATION UNDER UNUSUAL CONDITIONS ................................................................................................ 0007
EMERGENCY ...................................................................................................................................................... 0008
 TM 9-6115-753-10 0004

OPERATOR MAINTENANCE
AMMPS 60KW GENERATOR SET
DESCRIPTIONS AND USE OF OPERATOR CONTROLS AND INDICATORS

INTRODUCTION

Each table in this WP lists a key, control/indicator, and its associated function (Tables 1 – 17).

DCS

The DCS (Figure 1) is a microprocessor-based control that allows the operator and maintainer to start/stop the
generator set, operate the generator contactor, switch box contactor (if present), adjust voltage and frequency,
clear/reset generator faults, and perform other necessary functions to provide power. It is mounted in the upper-
right corner of the generator set rear panel. A self-supporting hinged door provides access to the control panel.
The DCS manages display and control functions through two internal electronic circuit boards: one board
manages the control panel and control functions for generator set output, and the second board manages the
interface between the engine/AC generator and the control panel.
The control panel is mounted to the forward face of the DCS. The control panel features a combination of
mechanical switches and a LCD with soft keys.

Figure 1. Screen Navigation.

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Table 1. Screen Navigation.

KEY CONTROL/INDICATOR FUNCTION
Main screen Default screen. Displays after system power up
and during operation to show unit
configuration and operating status.
[Adjustments] screen 1 Center soft key [Adjustments] from Used to adjust the voltage,
main screen. generator set hours, time and date,
temperature/pressure units of
measure, winterization kit test
command, and display screen(s)
brightness. The function heading
will be highlighted with a movable
cursor upon activation of this
screen.
[Adjustments] screen 2 This screen is reached by pressing Used to [Select] and [Adjust] the
[ŻPrevious] + [NextŹ] [Frequency], [Adjust Governor],
simultaneously for 2 sec from and [Automatic Voltage Regulator]
[Adjustments] screen 1. (AVR) [Gain], [Reset] [Governor]
and [AVR Gain], and display
[Genset Running Time].
Parallel adjustments screen This screen is reached by pressing Used to monitor [Total KVAR] and
[Parallel Adj] soft key on [Total KW], to adjust [KW Gain],
[Adjustments] screen 2. [KW Offset], [KVAR Gain] and
[KVAR Offset] and to return to
default settings by pushing keys to
[Reset Gains] and [Reset Offsets].
[Maintenance] screen Not to be used by the operator. Should the maintenance screen be
accidentally selected, press the
[Exit] key to return to the main
screen.

The LCD screen for the AMMPS 60 kW generator set displays five screens (Table 1) (Figure 1). Soft keys
mounted under the display screen allow navigation between the display screens.
Each screen has an [Exit] soft key that will redirect the user back to the main screen at any time. Additionally, the
[Adjustments] screen 1 and [Maintenance] screen automatically redirect the operator to the main screen if idle for
5 min. The [Adjustments] screen 2 and [Parallel Adj.] screen redirects the operator to the main screen when idle
for 2 min.

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Figure 2. Generator Set DCS Control Panel.

Table 2. Generator Set DCS Control Panel.

KEY CONTROL/INDICATOR FUNCTION
1 DCS with LCD screen Contains function controls and displays various menus to the operator
on the colored LCD screen with adjustable backlighting.

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Figure 3. DCS Control Panel.

Table 3. DCS Control Panel.

KEY CONTROL/INDICATOR FUNCTION
1 PANEL LIGHTS Push switch. Turns on and off the built-in panel lighting.
2 LCD screen Displays various menus, diagnostics, and functional information to the
operator. There is a 4-sec delay at start up. The delay increases as
ambient temperature decreases.
3 EMERGENCY STOP Push-pull switch. Rapidly shuts down the unit. This control is used for
emergencies and safety lockout only.
4 FAULT RESET Push switch. Clears fault and warning messages after they have been
corrected.
5 Engine control switch Rotary switch. Controls start and stop of engine and fuel source logic.
When first turned on, activates the control panel and main controller
boards (Figure 5).
6 Soft keys Touch-control switches. Used to control the display, navigate from
screen to screen, and make adjustments (Figure 7).
7 BATTLESHORT Toggle switch. Overrides faults and warnings when ON that would
normally result in an automatic shutdown (WP 0007, Operation Under
Unusual Conditions). Remains OFF during normal operation.

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Table 3. Main Display Screen — Continued.

KEY CONTROL FUNCTION
8 UNIT Push switch. Places AC generator in unit or parallel mode. Parallel logic
splits the load between two or more generator sets.
PARALLEL
Enables DCS load share logic, allowing parallel operation.
[PARALLEL]
Disables load share logic.
[UNIT]
9 AC CIRCUIT INTERRUPT Push switch. Controls the operation of the generator contactor, which
allows the generator set to be connected or disconnected to the load.

Figure 4. DEAD CRANK SWITCH.

Table 4. DEAD CRANK SWITCH.

KEY CONTROL FUNCTION
1 CRANK Three-position toggle switch. Disables power to the fuel pump,
allowing engine to crank but not start.
2 NORMAL Three-position toggle switch. Enables power to fuel pump and starter.
3 OFF Three-position toggle switch. Interrupts all power to starter.

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Figure 5. Engine Control Switch.

Table 5. Engine Control Switch.

KEY CONTROL/INDICATOR FUNCTION
1 OFF Stops generator set when operating. Disables primary fuel pump and
auxiliary fuel system pump. Turns off DCS after 10-min delay.
2 PRIME & RUN Select when using an auxiliary fuel source. Energizes auxiliary fuel
system pump and primary fuel pump. Enables winterization kit in cold
AUX FUEL
environments. Generator remains operating if selected during
operation.
3 PRIME & RUN Select when using unit fuel tank as primary fuel source. Enables
primary fuel pump. Disables auxiliary fuel system pump. Enables
winterization kit in cold environments. Generator set remains operating
if selected during operation.
4 START Spring-loaded when placed in START position to crank engine.
Enables auxiliary fuel system pump logic and primary fuel pump logic.
When the generator set is attempting to start, the DCS provides
automatic field flashing of the excitation system before the AVR is
enabled.
If the switch is held in the START position for a minimum of 1 sec, low
oil pressure protective fault is bypassed.
Enables winterization kit when conditions warrant. Enables and
operates air intake heater.

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Figure 6. Main DC Circuit Breaker.

Table 6. Main DC Circuit Breaker.

KEY CONTROL/INDICATOR FUNCTION
1 OFF/TRIP Indicates circuit breaker is open and no current can pass or the 24-VDC
system has shorted.
2 ON Circuit is closed and current can pass through the 24-VDC system.
3 RESET ĺ Indicates direction to turn switch to restore circuit.

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Figure 7. Voltage Selection Board.

Table 7. Voltage Selection Board.

KEY CONTROL/INDICATOR FUNCTION
1 120/208-V 3 Phase Generator set configured for 120/208-V three-phase load.
2 240/416-V 3 Phase Generator set configured for 240/416-V three-phase load.

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Figure 8. Main Display Screen (Showing 3-Phase Configuration).

Table 8. Main Display Screen.

KEY CONTROL/INDICATOR FUNCTION
1 [Fault XXX:] Displays when fault condition exists. Fault codes and descriptions
are found in WP 0011, DCS Fault & Warning Codes and
Descriptions.
2 [Power] [kW] Indicates total load of the unit in kilowatts.
3 [Freq] [Hz] Indicates the output frequency in hertz.
4 [Genset Mode:] Displays the operational readiness and status of the unit:
[Ready] Engine ready to start.
[Not Ready to Crank] Engine not ready to start.
[Rated Voltage and Frequency] Unit operating at specified output.
[Powering Down] Unit stopped. After unit is shut down, DCS will remain illuminated
for 10 min.
[Delay to Crank—Wtr Kit xx min] Winterization kit activated; xx min until engine is ready to start.
[Delay to Crank—Glw Plg xx Glow plugs (Glw Plg) activated; xx sec until engine is ready to
sec] start.
[Start-up Status: Ready] Engine is ready to start.

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Table 8. Main Display Screen — Continued.

KEY CONTROL/INDICATOR FUNCTION
4 [Not Available] Winterization kit nonresponsive or not installed.
[Running] Engine successfully started and operational.
[Unknown] Communication not established between display control board and
main control board interface.
5 [Fuel] Indicates fuel level as percentage of total available fuel:
Green Fuel level satisfactory.
Yellow Fuel level low, in warning area.
Red Fuel level very low; fault indicated.
6 [Configuration:] Displays capacity in kW, generator [Phase], Voltage (V), and [Hz])
settings:
Load (in kW)
[—kW]
Phase:
[—Phase]
[3 Phase]—Three Phase
[—V] Voltage:
[120 V], [120/240 V], or [120/208 V]
[—Hz] Frequency:
[50], [60], or [400] Hz
7 [Battery] [Vdc] Indicates battery voltage in [Vdc].
Green Voltage level satisfactory.
Yellow Voltage level low, in warning area.
Red Voltage level very low, fault indicated.
8 [Battery] [Adc] Indicates charge level of the batteries in [Adc]:
Green Amperage satisfactory.
Yellow Amperage low, in warning area.
Red Amperage very low; fault indicated.
9 [Oil] [PSI]/[kPa] Indicates engine oil pressure during operation. Can display metric
or standard units of measure:
Oil pressure satisfactory.
Green
Oil pressure low, in warning area.
Yellow
Oil pressure very low; fault indicated.
Red

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Table 8. Main Display Screen — Continued.

KEY CONTROL/INDICATOR FUNCTION
10 [Hours] Displays total operating time of the generator set.
11 Date, Time Displays current date (YYYY-MM-DD) and time (HH:MM:SS).
12 [Coolant] [F]/[C] Indicates engine coolant temperature when operating. Can display
metric or standard units of measure:
Green Coolant temperature satisfactory.
Yellow Coolant temperature high, in warning area.
Red Coolant temperature very high; fault indicated.
13 [Genset Current] [Aac] Indicates generator set output in amperes by line.
14 [Maintenance] Soft key designator. See Key 17 for all possible display options.
15 [Bus Voltage L-L] [Vac] Indicates voltage generated at the output terminal board from
Line-to-Line (L-L).
Indicates voltage generated at the output terminal board from
[Bus Voltage L-N] [Vac]
Line-to-Neutral (L-N).
16 [Genset Voltage L-L] [Vac] Displays the L-L voltage for each phase simultaneously from the
generator set to the generator [Contactor] output bus.
Displays the L-N voltage for each phase simultaneously from the
[Genset Voltage L-N] [Vac]
generator set to the generator [Contactor] output bus.
17 Soft Key Function(s) Five soft keys display screen-specific functions. Control panel
display screen indicates the current soft key function above each
push-button switch. Each soft key has a dedicated label and
function relative to each screen. When the function for a soft key is
not available or invalid, all of the foreground attributes of the soft
key label will be 50% gray in color.
[About] Displays the software versions that are installed for both the main
controller and the display controller.
[L-N] or [L-L] Toggles the voltage displays L-N or L-L. Function is suppressed in
single phase.
[Unload] Unloads generator set during parallel operation. Function is
suppressed when in [UNIT] mode or without load.
[Adjustments] Changes the display context to the first adjustments screen
(Figure 9).
[Aux Disable] or [Aux Enable] Disables or enables auxiliary fuel pump control. Function not
available when engine control switch is not in PRIME & RUN AUX
FUEL position.
[Maintenance] Changes the display context to the first maintenance screen.
[Select] Selects highlighted parameter for adjustment.

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Table 8. Main Display Screen — Continued.

KEY CONTROL/INDICATOR FUNCTION
17 [Ż Previous] Moves the highlighted parameter one item to the left (if the
leftmost parameter is highlighted, wraps to the rightmost).
[Next Ź] Moves the highlighted parameter one item to the right (if the
rightmost parameter is highlighted, wraps to the leftmost).
[Exit] Returns to the main screen.
[Cancel] Cancels adjustment(s) made and restores previously-selected
value. Cursor remains at the selected parameter.
[Accept] Accepts new parameter value.
[+] Moves new parameter value to the next higher step.
[-] Moves new parameter value to the next lower step.
[ŻPrevious]+[NextŹ] When pressed simultaneously for 2 sec moves to [Adjustment]
screen 2 from [Adjustment] screen 1.
18 [Battleshort] Indicates position of the Battleshort switch.
[Active] Battleshort operational. Unit will only stop on EMERGENCY
STOP, short circuit, or overspeed fault.
[Inactive]
Battleshort not operational. All fault functions enabled.
19 [Mode] Indicates generator set configuration (unit or parallel).
[Unit] Operating as a PU.
[Parallel] Operating as a PP with one or more other generators.
20 [Switchbox] Displays status of connection between units when operating in
parallel:
Not connected.
[Open]
Connected.
[Closed]
21 [Contactor] Indicates position of contactor.
[OPEN] Power not supplied to load.
[CLOSED] Power supplied to load.
22 [Warning XXX:] This line displays only when the unit is in a pre-failure condition or
has a defect (WP 0011, DCS Fault & Warning Codes and
Descriptions).

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Figure 9. [Adjustments] Screen 1 — Select Parameter.

Table 9. [Adjustments] Screen 1 — Select Parameter.

KEY CONTROL/INDICATOR FUNCTION
1 [Voltage] Allows the selection of output voltage which will be input to the AVR.
2 [Backlight] Allows the adjustment of operator display backlight illumination level (three
levels available).
3 [Units] Selects standard or metric units of measure.
4 [Real Time Clock] Adjusts date and time.
5 [Selection Hint: – – – ] Indicates available options for current screen: [ŻPrevious], [NextŹ],
[Select], and [Exit].
6 Soft keys Shows active keys and their function (Table 8, Key 17) for this screen.
7 [Winterization Kit Test] Activates the winterization test protocol when selected. Press [Select] to
activate.

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 TM 9-6115-753-10 0004

Figure 10. [Adjustments] Screen 1 — Adjust.

Table 10. [Adjustments] Screen 1 — Adjust.

KEY CONTROL/INDICATOR FUNCTION
1 [Voltage] Adjusts voltage output. Press [Select] to activate.
2 [XXX Vac] Displays the voltage value selected for output. Adjust with [ + ] and [ - ]
keys in 1 VAC increments. Press [Accept] to confirm. Press [Cancel] to
reset adjustment.
3 [Backlight] Adjusts backlight illumination. Three levels are available. Press [Select]
to activate.
4 [High] Displays the level of illumination. Adjust with [ + ] and [ - ] keys. Moves
one increment per adjustment. Press [Accept] to confirm. Press
[Medium]
[Cancel] to reset adjustment.
[Low]
5 [Units] Selects standard or metric units of measure for coolant temperature
and oil pressure. Highlight desired parameter and then press [Select] to
activate.
6 [Real Time Clock] Highlight with the cursor to adjust the time (HH:MM:SS) and date
(YYYY-MM-DD). Press [Select] to activate.
7 [°F, PSI] or [°C, kPa] Selects standard or metric units of measure for display. Adjust with [ + ]
and [ - ] keys. Press [Accept] to confirm. Press [Cancel] to reset
adjustment.
8 [Real Time Clock] Segments Displays current time (HH:MM:SS) and date (YYYY-MM-DD). Adjust
with [ + ] and [ - ] keys. Moves one significant increment per
adjustment. Press [Accept] to confirm. Press [Cancel] to reset
adjustment.

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Table 10. [Adjustments] Screen 1 — Adjust — Continued.

KEY CONTROL/INDICATOR FUNCTION
9 [Select Tip: XXXXX] Verbiage showing available options for current screen such as: [ + ],
[ - ], [Accept], [Cancel], and [Exit] keys and a description of their
functions. Varies with screen being displayed.
10 Soft keys Shows active keys and their function (Table 8, Key 17) for this screen.
11 [Winterization Kit Test] Activates the winterization test protocol when selected. Press [Accept]
to activate.

Figure 11. [Adjustments] Screen 2 — Select Parameter.

Table 11. [Adjustments] Screen 2 Display — Select Parameter.

KEY CONTROL/INDICATOR FUNCTION
1 [Frequency Select] Highlight with cursor to select 50 Hz or 60 Hz frequency on Mode I
units. This function is suppressed in Mode 2, 400 Hz units. Press
[Select] soft key to activate.
2 [Frequency Adjust] Highlight with cursor to adjust frequency of electrical output in 1 Hz
increments. Press [Select] soft key to activate.
3 [Governor Gain] Highlight with cursor to adjust engine speed governor setting (the
allowable percentage of engine speed under/over revolutions per
minute (rpm) setting). Press [Select] soft key to activate.
4 [AVR Gain] Adjusts AVR gain (the allowable percentage of generator voltage
under/over setting).

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Table 11. [Adjustments] Screen 2 Display — Select Parameter — Continued.

KEY CONTROL/INDICATOR FUNCTION
5 [Gov/AVR Gain Reset] Allows the reset of governor and AVR gain settings to the default
settings.
6 [Select Tip: xxxxxx ] Verbiage showing available options for current screen such as:
[ŻPrevious], [NextŹ], [Select], and [Cancel] keys and a description of
their functions. Varies with screen being displayed.
7 Soft key indicators Shows the active keys and their function (Table 8, Key 17) in this
screen.
8 [Parallel Adj] Toggles to parallel adjustment screen (WP 0006, Parallel Operation).
9 [Genset Running Time] Adjust and/or resets hours of desired unit operation expressed in hours.
Set to match hours displayed on generator hour meter (Figure 13).

Figure 12. [Adjustments] Screen 2 — Adjust.

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Table 12. [Adjustments] Screen 2 — Adjust.

KEY CONTROL/INDICATOR FUNCTION
1 [Frequency Select] Highlight with cursor to select 50 Hz or 60 Hz frequency on Mode I
units. Press [Select] soft key to activate. Function is suppressed on
Mode II units.
2 Frequency select indicator Displays frequency number requested for output in hertz: 50 Hz or 60
Hz. Adjust with [ + ] and [ - ] keys. Press [Accept] to confirm.
Press [Cancel] to reset adjustment.
3 [Frequency Adjust] Adjusts frequency in 1 Hz increments. Highlight with cursor to select.
Press [Select] soft key to activate.
4 Frequency adjust indicator Displays frequency number requested for output in hertz (50 Hz or 60
Hz) and allows for increase or decrease in 1 Hz increments. Adjust with
[ + ] and [ - ] keys. Press [Accept] to confirm. Press [Cancel] to reset
adjustment.
5 [Governor Gain] Highlight with cursor to adjust engine speed governor setting. Press
[Select] to activate.
6 Governor Gain Indicator Displays requested percentage of engine speed over/under default
setting. Adjust with [ + ] and [ - ] keys. Press [Accept] to confirm. Press
[Cancel] to reset adjustment.
7 [AVR Gain] Highlight with cursor to adjust the allowable percentage
increase/decrease of output voltage through the AVR. Press [Select] to
activate.
8 AVR Gain Indicator Displays requested percentage of voltage over/under from default
setting. Adjust with [ + ] and [ - ] keys. Press [Accept] to confirm. Press
[Cancel] to reset adjustment.
9 [Gov/AVR Gain Reset] Highlight with cursor to activate the reset of governor and AVR gain to
default settings. Press [Select] to activate.
10 Gov/AVR Gain Reset Allows the reset of governor and AVR gain settings to the default
Indicator settings. Activate reset with [ + ] or [ - ] keys. Press [Accept] to confirm.
Press [Cancel] to reset adjustment.
Settings revert to default.
11 [Adjust Tip ] Explains use of available soft keys such as: [ + ] and [ - ] keys, [Accept],
[Cancel], and [Exit]. Varies with screen displayed.
12 Soft Key Indicators Shows the active keys and their function (Table 8, Key 17) in this
screen.
13 Genset Running Time Displays generator set preset operating hours to five places left of the
Indicator decimal point and one place to the right of the decimal point. Adjust
with [ + ] and [ - ] keys. Press [Accept] to confirm. Press [Cancel] to
reset adjustment.
14 [Genset Running Time] Adjusts and/or resets hours of desired unit operation expressed in
hours. Press [Select] to activate. Should match hour meter in Figure 13.

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 TM 9-6115-753-10 0004

Figure 13. [Parallel Adj] Screen.

Table 13. [Parallel Adj] Screen.

KEY CONTROL/INDICATOR FUNCTION
1 [KW Gain] Adjusts the kilowatt gain values in the DCS AVR control logic.
2 [KW Offset] Adjusts the kilowatt offset values in the DCS AVR control logic.
3 [KVAR Gain] Adjusts the kilovolt-ampere reactive gain values in the DCS AVR
control logic.
4 [KVAR Offset] Adjusts the kilovolt-ampere reactive offset values in the DCS AVR
control logic.
5 [Reset Gains] Returns gain value to initial setting in the DCS AVR control logic.
6 [Reset Offset] Returns offset value to initial setting in the DCS AVR control logic.
7 [Select Tip: xxxxxx] Verbiage showing available options for current screen such as:
[ŻPrevious], [NextŹ], [Select], and [Cancel] keys and a description of
their functions. Varies with screen being displayed.
8 [Genset Adj] Toggles display to [Adjustments] screen 2.
9 [Total KVAR] Displays kilovolt-ampere reactive variance in load sharing between
generator sets as a positive or negative number. The value is used for
adjustment purposes.
10 [Total KW] Displays kilowatt variance in load sharing between generator sets as a
positive or negative number. The value is used for adjustment
purposes.

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 TM 9-6115-753-10 0004

Figure 14. First [Maintenance] Screen.

Table 14. First [Maintenance] Screen.

KEY CONTROL/INDICATOR FUNCTION
1 [Fault XXX:] This line displays most recent unacknowledged fault condition. Fault
codes and descriptions are found in WP 0011, DCS Fault & Warning
Codes and Descriptions.
2 [Warning XXX:] This line displays most recent unacknowledged [Warning] (pre-failure
condition) or defect. Warning codes and descriptions are found in WP
0011, DCS Fault & Warning Codes and Descriptions.
3 Incident display Displays fault or warning code number, date, time, and description of
the most recent fault or warning.
4 Description display Describes fault or warning in detail. Verifies sensor function.
5 [Maint Items] Toggles display to next display screen when soft key pushed.
6 [Next] Toggles display to following fault or warning when soft key pushed.
7 [Previous] Toggles display to prior fault or warning when soft key pushed.
Suppressed when displaying first fault or warning.
8 [Warnings] Changes display to most recent unacknowledged warning when soft
key pressed. Text changes to [Faults] when [Warnings] are displayed.
9 [Active] Display Describes whether [Faults] or [Warnings] are being displayed.
10 [Genset Mode:] Displays the operational readiness and status of the unit.

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Figure 15. [Maintenance Items] Screen.

Table 15. [Maintenance Items] Screen.

KEY CONTROL/INDICATOR FUNCTION
1 Status Display Shows display parameter of this screen.
2 [Maintenance Items] Display Shows maintenance item in need of action by date and time the item(s)
passed into active status (hour interval for scheduled maintenance
achieved or passed) or next item due in numerical sequence if the item
is not active.
3 [Tip] Display Shows actions required to resolve maintenance items.
4 [Maint Actions] Toggles display to next display screen when soft key pushed.
5 [Next] Toggles display to following item when soft key pushed.
6 [Previous] Toggles display to prior item when soft key pushed. Suppressed when
displaying first [Maintenance Item].
7 [Faults] Toggles to display prior [Fault] screen when soft key pushed.

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 TM 9-6115-753-10 0004

Figure 16. [Maintenance Actions] Screen.

Table 16. [Maintenance Actions] Screen.

KEY CONTROL/INDICATOR FUNCTION
1 [Tip] Display Shows actions required to resolve maintenance items. Actions taken
are stored in the maintenance log. Items dismissed or deferred will
recur as [Active Maintenance Items].
2 [Cancel] Returns display to previous screen without saving any actions selected.
3 [Completed] Saves the date and time of the maintenance action was performed in
the maintenance log.
4 [Defer] Reschedules the maintenance item until a later date.
5 [Dismiss] Permanently deletes the maintenance action. Do not select this option.

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Figure 17. Generator Hour Meter.

Table 17. Generator Hour Meter.

KEY CONTROL/INDICATOR FUNCTION
1 Generator set hour meter Records hours operated by prime mover/generator.

END OF WORK PACKAGE

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 TM 9-6115-753-10 0005

OPERATOR MAINTENANCE
AMMPS 60KW GENERATOR SET
OPERATION UNDER USUAL CONDITIONS

INITIAL SETUP:

Test Equipment References

Not Applicable FM 11-487-4
Tools and Special Tools WP 0004, Description and Use of Operator Controls
and Indicators
Not Applicable
WP 0007, Operation Under Unusual Conditions
Materials/Parts
WP 0010, Troubleshooting Procedures
Nut, lock (13) (TM 9-6115-753-24&P)
WP 0011, DCS Fault and Warning Codes and
Cable, remote control, 04-21227/(44940) (1) (WP
Descriptions
0020, Additional Authorization List (AAL))
WP 0013, PMCS
Personnel Required
Equipment Conditions
Operator (1)
Engine control switch OFF
Assistant (1)

OPERATION UNDER USUAL CONDITIONS

WARNING

x DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Do not ground yourself in standing water.
Failure to comply may cause injury or death to personnel and damage to equipment.

x Exhaust discharge contains deadly gases, including carbon monoxide. Exhaust gases are most
dangerous in places with poor ventilation. Do not operate generator set in an enclosed area
unless exhaust discharge is properly vented. Failure to comply may cause injury or death to
personnel.

x Hot exhaust gases can ignite combustible materials. Allow room for safe discharge of hot gases.
Failure to comply may cause injury or death to personnel.

x Exhaust gases are most dangerous in places with poor ventilation. The best defense against
exhaust gas poisoning is very good ventilation. To protect yourself and others, always obey the
following rules:
ƒ Do not run engine indoors unless you have very good ventilation.
ƒ Do not idle engine for a long time unless there is very good ventilation.
ƒ Be alert at all times. Check for smell of exhaust fumes.
ƒ Failure to comply may cause injury or death to personnel.

0005-1
 TM 9-6115-753-10 0005

WARNING

x Exhaust gas poisoning causes dizziness, headache, loss of muscle control, sleepiness, coma,
and death. If anyone shows signs of exhaust gas poisoning, get all personnel clear of AMMPS.
Make sure they have lots of fresh air. Keep them warm, calm, and inactive. Get medical help. If
anyone stops breathing, give artificial respiration. Failure to comply may cause injury or death to
personnel.

x When operating, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow engine to cool before checks, services, and maintenance. Wear
gloves and additional protective clothing as required. Failure to comply may cause injury or death
to personnel.

x High voltage is produced when generator set is in operation. Never attempt to start the generator
set unless it is properly grounded. Do not ground yourself in standing water. Never attempt to
connect or disconnect load cables while the generator sets are running. Failure to comply may
cause injury or death to personnel.

x Metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry and do not wear loose clothing when working on equipment. Failure to comply
may cause injury or death to personnel.

SITING REQUIREMENTS

1. Select the site that provides the following features:

a. Ample space for maneuvering vehicles used to move generator set(s) or trailer-mounted generator set(s).
(1) The 60 kW AMMPS dimensions are 82.0 x 36.0 in (208.3 x 91.4 cm).
(2) Allow for the dimensions and turning radius of the towing vehicle.
b. Firm, reasonably level (less than 15 degree slope on all axes), well-drained terrain that is not adjacent to
low areas where exhaust fumes might collect.
c. Space on all sides for service and maintenance.
d. Generator set(s) positioned as far away as possible from occupied mobile shelters, vehicle cabs, and
building ventilation system air intakes and/or other openings or duct the exhaust to a safe location.
e. Adequate ventilation to prevent recirculation of hot air exhausted from generator set.
f. Adequate open-air ventilation and exhaust exposure controls when the AMMPS is positioned in protected
fighting positions or revetments (barriers/walls/embankments).
g. Adequate open-air ventilation and proper placement of exhaust when AMMPS is mounted on a flatbed
truck chassis or used on a system in occupied shelters.
2. Make use of natural protective barriers.
3. Modify location as required.
a. Level an area larger than the footprint of the unit if a sufficiently level area is unavailable naturally.
(1) The 60 kW AMMPS 50/60 Hz dimensions are 82.0 x 36.0 in (208.3 x 91.4 cm).
(2) The 60 kW AMMPS 400 Hz dimensions are 82.0 x 36.0 in (208.3 x 91.4 cm).
b. Remove combustible materials within 36 in (91.44 cm) of all sides of generator set.
4. Ensure the following conditions are met if using an enclosure:
a. Meet minimum enclosure requirements of 36 in (91.44 cm) from all sides.

0005-2
 TM 9-6115-753-10 0005

b. Install proper exhaust pipe extensions, ducts and vents to outside or use dilution ventilation or local
exhaust ventilation when the AMMPS is operated in an enclosure or building to exhaust gas.
c. Make air inlet and outlet openings in enclosure same size as or larger than those on the generator set.
5. Do not direct exhaust into area containing combustible materials.

END OF TASK

ASSEMBLY AND PREPARATION FOR USE

Screen Navigation

Figure 1. Screen Navigation.

Screen Navigation. The LCD screen for the AMMPS 60 kW generator set displays five screens (Figure 1). The
Main Screen appears as the default screen, and the other four screens are shown as requested. Soft keys
mounted under the display screen allow navigation between the display screens.

Main Screen. The default screen. Displays after system power up and during operation.

[Adjustments] Screen 1. Used to adjust the voltage, generator set hours, time and date, temperature/pressure
units of measure, and display screen brightness. The function heading will be highlighted with a movable cursor
upon activation of this screen.

0005-3
 TM 9-6115-753-10 0005

[Adjustments] Screen 2. Used to adjust the [Frequency], [Governor Gain], Automatic Voltage Regulator [AVR
Gain], [Gov/AVR Gain Reset], and [Genset Running Time]. This screen is reached by pressing [Ż Previous] and
[Next Ź] simultaneously for 2 sec.

Parallel [Adjustments] Screen. Used to monitor [Total KVAR] and [Total KW], to adjust [KW Gain], [KW Offset],
[KVAR Gain], and [KVAR Offset] and to return default settings by pushing keys to [Reset Gains] and [Reset
Offsets]. This screen is reached by pressing [Parallel Adj] soft key on [Adjustments] screen 2.

[Maintenance] Screen. Not to be utilized by the operator except for information gathering. Should the
[Maintenance] screen be accidentally selected, press the [Exit] key to return to the main screen.

Each screen has an [Exit] soft key that redirects the user back to the main screen at any time. Additionally, the
[Adjustments] screen 1 and [Maintenance] screen automatically redirect the operator to the main screen if idle for
5 min. The [Adjustments] screen 2 redirects the operator to the main screen when idle for 2 min.

END OF TASK

Installation of Ground Rod

Figure 2. Grounding Connections.

1. Open output box door (Figure 6, Item 5).

2. Thread ground cable (Figure 2, Item 7) into output box through flexible sleeve (Figure 2, Item 6).
3. Lift protective cover (Figure 6, Item 2) from output terminal board (Figure 6, Item 4).

0005-4
 TM 9-6115-753-10 0005

WARNING
Do not remove the bonding jumper between GND and N unless the weapon system requires an
underground system. Refer to applicable weapon system TM for specific guidance on power and
connection requirements. Failure to comply may cause injury or death to personnel.
4. Ensure the bonding jumper (neutral busbar) (Figure 2, Item 5) is securely fastened between N and ground.
5. Loosen terminal (Figure 2, Item 4) nut using provided terminal nut wrench (Figure 6, Item 6) located inside
output box door (Figure 6, Item 5).
6. Insert ground cable (Figure 7, Item 2) through slot (Figure 7, Item 3) on terminal marked GND.
7. Tighten terminal nut (Figure 7, Item 1) using terminal nut wrench (Figure 6, Item 6).

NOTE
Three sections of ground rod and three couplings are provided with the AMMPS 60 kW generator
set in a rack inside the left door. Desired ground rod depth is 8 ft (2.44 m) or more. Make every
attempt possible to obtain this depth or coverage of the ground rods.

Two tools can be used to drive the ground rod into the ground: a slide hammer assembly (Figure
3) and a sledge hammer (Figure 4). The slide hammer assembly provides the safest and easiest
method of driving the ground rod and should be used unless it is unavailable. Use of the slide
hammer is described in steps 8 and 9. Use of the sledge hammer is described in step 10.
8. Install ground rod (Figure 2, Item 1) using slide hammer (Figure 3, Item 7) assembly.
a. Install impact disk (Figure 3, Item 3) on slide hammer rod (Figure 3, Item 1).
b. Tighten impact disk (Figure 3, Item 3) to end of threads on slide hammer rod (Figure 3, Item 1).
c. Install lock washer and nut (Figure3, Item 4).
d. Tighten lock washer and nut (Figure 3, Item 4) securely against impact disk (Figure 3, Item 3).
e. Remove nut (Figure 3, Item 2), if installed.

NOTE
Ground rod (Figure 2, Item 1) must be installed within 5 feet (ft) (1.52 meter (m)) of flexible sleeve
(Figure 2, Item 6). Ground cable (Figure 2, Item 7) is 6 ft (1.83 m) in length.

For additional grounding information, consult FM 11-487-4, Installation Practices: Grounding,

Bonding, and Shielding.
f. Position slide hammer (Figure 3, Item 7) on slide hammer rod (Figure 3, Item 1).
g. Install nut (Figure 3, Item 2) and tighten to end of threads on slide hammer rod (Figure 3, Item 1).
h. Install ground rod coupling (Figure 3, Item 6) to ground rod (Figure 3, Item 5) and screw slide hammer
into coupling (Figure 3, Item 6).
i. Ensure slide hammer rod (Figure 3, Item 1) seats on ground rod (Figure 3, Item 5).
j. Drive ground rod (Figure 3, Item 5) into ground until coupling (Figure 3, Item 6) is just above surface.
k. Remove slide hammer (Figure 3, Item 7) and install another section of ground rod (Figure 3, Item 5).
l. Install another coupling (Figure 3, Item 6) to ground rod (Figure 3, Item 5) and screw slide hammer rod
(Figure 3, Item 1) into coupling (Figure 3, Item 6).
m. Drive ground rod (Figure 3, Item 5) down until new coupling (Figure 3, Item 6) is just above ground
surface.

0005-5
 TM 9-6115-753-10 0005

Figure 3. Install Ground Rod With Slide Hammer.

NOTE
Avoid driving the third or final ground rod coupling too close to ground level. Allow enough
clearance to easily attach the grounding cable (Figure 2, Item 7).
n. Repeat steps 8k – m until ground rod has been driven 8 ft (2.44 m) or deeper, providing an effective
ground.

CAUTION
Excessive tightening of the clamp screw (Figure 2, Item 3) can sever copper conductors and
weaken the connection to ground. Tighten the clamp (Figure 2, Item 2) only as much as will
prevent the ground cable from being pulled from the clamp (Figure 2, Item 2) by hand. Failure to
comply will cause damage to equipment.

NOTE
Notify field maintenance for step 8o.
o. Connect clamp (Figure 2, Item 2) and ground cable (Figure 2, Item 7) to ground rod (Figure 2, Item 1) and
tighten clamp screw (Figure 2, Item 3) just enough to prevent the cable from being pulled from the clamp
(Figure 2, Item 2) and then tighten 3/4-turn more.
9. Disassemble slide hammer.
a. Remove nut (Figure 3, Item 2) from end of slide hammer rod (Figure 3, Item 1) and retain.
b. Remove slide hammer (Figure 3, Item 7) from slide hammer rod (Figure 3, Item 1).

0005-6
 TM 9-6115-753-10 0005

c. Thread nut (Figure 3, Item 2) on end of slide hammer rod (Figure 3, Item 1) to prevent loss.

Figure 4. Install Ground Rod With Sledge Hammer.

NOTE
Two tools can be used to drive the ground rod into the ground: a slide hammer assembly (Figure
3) and a sledge hammer (Figure 4). If the slide hammer assembly is unavailable, use the sledge
hammer as described in step 10.
10. Install ground rod (Figure 4, Item 7) using sledge hammer (Figure 4, Item 1) if slide hammer (Figure 3, Item 7)
is not available.

NOTE
Ground rod (Figure 4, Item 7) must be installed within 5 ft (1.52 m) of PU ground terminal (Figure
2, Item 4). Ground cable (Figure 2, Item 7) is 6 ft (1.83 m) in length.
a. Connect coupling (Figure 4, Item 6) to first section of ground rod (Figure 4, Item 7).
b. Screw driving stud (Figure 4, Item 2) into coupling (Figure 4, Item 3).

0005-7
 TM 9-6115-753-10 0005

CAUTION
Ensure that driving stud (Figure 4, Item 2) seats completely on couplings (Figure 4, Items 3 and
6) as shown. Failure to comply will cause damage to equipment.

NOTE
The driving stud (Figure 4, Item 2) is illustrated in Figure 4 as it would appear after being attached
to the second coupling (Figure 4, Item 3) after completing step 10e.
c. Drive first section of ground rod (Figure 4, Item 7) into ground until coupling (Figure 4, Item 6) is just
above surface.
d. Remove driving stud (Figure 4, Item 2) and install second section of ground rod (Figure 4, Item 5) to first
coupling (Figure 4, Item 6).
e. Install second coupling (Figure 4, Item 3) and driving stud (Figure 4, Item 2) to second section of ground
rod (Figure 4, Item 5).
f. Drive second section of ground rod (Figure 4, Item 5) down until second coupling (Figure 4, Item 3) is just
above the surface.

NOTE
Avoid driving the ground rod driving stud and coupling too close to ground level on last section of
rod. Allow enough clearance to easily attach the grounding cable.
g. Repeat steps 10a – f until ground rod assembly has been driven 8 ft (2.44 m) or deeper.

CAUTION
Excessive tightening of the clamp screw (Figure 2, Item 3) can sever copper conductors and
weaken the connection to ground. Tighten the clamp (Figure 2, Item 2) only as much as will
prevent the ground cable from being pulled from the clamp (Figure 2, Item 2) by hand. Failure to
comply will cause damage to equipment.

NOTE
Notify field maintenance for steps 10h.
h. Connect clamp (Figure 4, Item 4) and ground cable (Figure 2, Item 7) to ground rod (Figure 4, Item 5) and
tighten clamp (Figure 4, Item 4) just enough to prevent the cable from being pulled from the clamp (Figure
4, Item 4) and then tighten 3/4-turn more.
11. Ensure all grounding connections are secure.
12. Lower protective cover (Figure 6, Item 2) over output terminal board (Figure 6, Item 4).
13. Secure output box door (Figure 6, Item 5).

END OF TASK

0005-8
 TM 9-6115-753-10 0005

Removal of Ground Rod

NOTE
Removing ground rod (Figure 2, Item 1) requires the reverse action of the slide hammer (Figure
3, Item 7). The slide hammer will be installed with the slide hammer (Figure 3, Item 7) between
the end of the grounding rod (Figure 2, Item 1) and the impact disk (Figure 3, Item 3) so that the
slide hammer (Figure 3, Item 7) strikes the impact disk (Figure 3, Item 3) with an upward stroke.
1. Loosen clamp screw (Figure 2, Item 3) and remove ground cable (Figure 2, Item 7) and clamp (Figure 2, Item
2) from ground rod (Figure 2, Item 1).
2. Install impact disk (Figure 3, Item 3) on slide hammer rod (Figure 3, Item 1).
3. Tighten impact disk (Figure 3, Item 3) to end of threads on slide hammer rod (Figure 3, Item 1).
4. Install lock washer and nut (Figure 3, Item 4).
5. Tighten lock washer and nut (Figure 3, Item 4) securely against impact disk (Figure 3, Item 3).
6. Remove nut (Figure 3, Item 2), if installed.
7. Position slide hammer (Figure 3, Item 7) on slide hammer rod (Figure 3, Item 1) under impact disk (Figure 3,
Item 3).
8. Install nut (Figure 3, Item 2) and thread to top of slide hammer rod (Figure 3, Item 1) thread.
9. Screw slide hammer rod (Figure 3, Item 1) into end of coupling (Figure 3, Item 6).
10. Tighten nut (Figure 3, Item 2) until it meets coupling (Figure 3, Item 6).
11. Ensure slide hammer rod (Figure 3, Item 1) seats on ground rod (Figure 3, Item 5).
12. Strike impact disk (Figure 3, Item 3) with slide hammer (Figure 3, Item 7) using an upward motion.
13. Remove ground rod (Figure 3, Item 5) section and coupling (Figure 3, Item 6) just above surface.
14. Install slide hammer rod (Figure 3, Item 1) into end of next section of ground rod (Figure 3, Item 5) and repeat
steps 10 – 13.
15. Install slide hammer rod (Figure 3, Item 1) into end of third section of ground rod (Figure 3, Item 5) and repeat
steps 10 – 13 until ground rod is removed.
16. Disassemble slide hammer (Figure 3, Item 7).
17. Inspect three sections of ground rod (Figure 2, Item 1) for damage and replace as required.
18. Store ground rods (Figure 2, Item 1) in generator set.

END OF TASK

0005-9
 TM 9-6115-753-10 0005

Installation of Auxiliary Fuel Lines

NOTE
This task only applies if directed by higher command to utilize an auxiliary fuel source.

Figure 5. Auxiliary Fuel Supply Connections.

1. Locate connection to auxiliary fuel supply.

a. Connect auxiliary fuel supply inline (Figure 5, Item 1) to fuel shroud inlet fitting (Figure 5, Item 5).
b. Connect auxiliary fuel supply return line (Figure 5, Item 2) to fuel shroud vent fitting (Figure 5, Item 4).
c. Check connections for leaks. Notify field maintenance if any are found.
d. Attach grounding strap (static ground) from auxiliary fuel source to grounding stud (static ground) (Figure
5, Item 3).
2. Turn engine control switch (Figure 10, Item 6) to PRIME & RUN AUX FUEL (Figure 10, Item 7).
3. Allow fuel pump to complete priming of fuel injection pump and filling fuel tank. Listen for audible fuel pump
operations.
4. Check for leaks and notify field maintenance if any are found.
5. Turn engine control switch (Figure 10, Item 6) to OFF.

END OF TASK

0005-10
 TM 9-6115-753-10 0005

Installation of Load Cables

WARNING
Generator set operator is permitted to make connections to output terminal board only.
Connections to load distribution points or equipment beyond the output box shall only be made by
properly trained and authorized personnel. Failure to comply may cause injury or death to
personnel.
1. Secure load information from higher command.

Figure 6. Installation of Load and Ground Cables.

CAUTION
Do not connect the load cables to the convenience receptacle. Failure to comply may cause
damage to equipment.

NOTE
Trailer-mounted PP generator sets are wired directly to the trailer-mounted switchbox or directly
to a cable for connection to a separate output bus. Steps 2 through 13 are not required for trailer-
mounted PP generator sets.
2. Select required output terminals (Figure 6, Item 3) from Table 1.

0005-11
 TM 9-6115-753-10 0005

Table 1. Load Terminal — Voltage Selection Board.

SELECTION OUTPUT VOLTAGE CURRENT
BOARD POSITION TERMINALS READING READING TERMINAL
208 V (L1-L2) L1
120/208-V 3 PH L1, L2, L3, N 208 V (L2-L3) L2
208 V (L3-L1) L3
416 V (L1-L2) L1
240/416-V 3 PH L1, L2, L3, N 416 V (L2-L3) L2
416 V (L3-L1) L3

Figure 7. Ground and Output Cable Attachment Detail.

3. Open output box door (Figure 6, Item 5).

4. Lift protective cover (Figure 6, Item 2) from output terminal board (Figure 6, Item 4).
5. Remove terminal nut wrench (Figure 6, Item 6) from brackets on the inside of output box door (Figure 6, Item
5).
6. Loosen terminal nuts (Figure 7, Item 1) (shown removed for clarity) using terminal nut wrench (Figure 6, Item
6) on terminals selected from Table 1 in step 2.
7. Insert ends of load cables (Figure 6, Item 1) through flexible sleeve (Figure 2, Item 6).
8. Insert ends of load cables (Figure 6, Item 1) into slots (Figure 7, Item 3) of output terminals (Figure 6, Item 3)
selected in step 2 from Table 1.
9. Tighten terminal nuts (Figure 6, Item 7 and Figure 7, Item 1).
10. Check ground cable (Figure 2, Item 7) connection to terminal (Figure 6, Item 3). Tighten as necessary.
11. Secure terminal nut wrench (Figure 6, Item 6) on the brackets inside of the output box door (Figure 6, Item 5).

0005-12
 TM 9-6115-753-10 0005

12. Lower protective cover (Figure 6, Item 2) over output terminal board (Figure 6, Item 4).
13. Secure output box door (Figure 6, Item 5).

END OF TASK

INITIAL ADJUSTMENTS

1. Perform all Before PMCS procedures in IAW operator PMCS (WP 0013, PMCS).
2. Place voltage selection moveable board (Figure 8, Item 5) into position for output required by higher
command.

WARNING

x High voltage is produced when generator set is in operation. Never attempt to start the generator
set unless it is properly grounded. Do not ground yourself in standing water. Never attempt to
connect or disconnect load cables while the generator set is operating. Failure to comply may
cause injury or death to personnel.

x High voltage is produced when this generator set is in operation. Do not contact output cables
when operating this generator set. Failure to comply may cause injury or death to personnel.
a. Secure load information from higher command.
b. Open output box door (Figure 6, Item 5).

0005-13
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Figure 8. Configure Voltage Selection Board.

0005-14
 TM 9-6115-753-10 0005

NOTE
120/208 V output is set by locating the voltage selection moveable board (Figure 8, Item 5) to the
left-side position with an arrow pointing to 120/208 (Figure 8, Item 3) on the voltage selection
stationary board (Figure 8, Item 2). 240/416 V output is set by locating the voltage selection
moveable board (Figure 8, Item 5) to the right-side position with an arrow pointing to 240/416
(Figure 8, Item 1) on the voltage selection stationary board (Figure 8, Item 2).
It is not necessary to complete steps d through l if voltage selection board is positioned as
required.
c. Note current position of voltage selection moveable board (Figure 8, Item 5).
d. Remove four cap screws (Figure 8, Item 7) from protective cover (Figure 8, Item 6). Notify field
maintenance if assistance is required for this step and remaining steps.
e. Remove protective cover (Figure 8, Item 6).
f. Inspect protective cover (Figure 8, Item 6) for damage. Notify field maintenance if replacement is
required.
g. Remove 13 lock nuts (Figure 8, Item 4) from voltage selection stationary board (Figure 8, Item 2). Discard
13 lock nuts (Figure 8, Item 4).
h. Place voltage selection moveable board (Figure 8, Item 5) in position required by higher command.
i. Install voltage selection moveable board (Figure 8, Item 5) with 13 new lock nuts (Figure 8, Item 4).
Tighten finger tight.
j. Tighten 13 lock nuts (Figure 8, Item 4).
k. Install protective cover (Figure 8, Item 6) with four cap screws (Figure 8, Item 7).
l. Close output box door (Figure 6, Item 5).
3. Adjust [Frequency] to output frequency required. See Adjust Generator Set task.
4. Connect load cables as required IAW Table 1.

END OF TASK

OPERATING PROCEDURES

Starting Procedure

NOTE
At any time during adjustment or operation, if the DCS display screen becomes dark, pressing
any one of the five soft keys (WP 0004, Description and Use of Operator Controls and Indicators)
will cause the DCS to illuminate.

1. Perform Before PMCS (WP 0013, PMCS).

2. Place DEAD CRANK SWITCH (Figure 9, Item 2) found inside left-side door in NORMAL position.
3. Turn main DC circuit breaker (Figure 9, Item 1) found inside right-side door to ON.

0005-15
 TM 9-6115-753-10 0005

Figure 9. Main DC Circuit Breaker and DEAD CRANK SWITCH.

4. Pull out EMERGENCY STOP (Figure 10, Item 3) on DCS.

0005-16
 TM 9-6115-753-10 0005

Figure 10. DCS Panel.

5. Move engine control switch (Figure 10, Item 6) to PRIME & RUN (Figure 10, Item 4).
6. Allow fuel pump to complete priming of fuel injector pump before proceeding. Listen for fuel pump to stop
operating.

CAUTION
The default starting position for the UNIT PARALLEL switch (Figure 10, Item 10) is [UNIT]. If the
DCS reports the unit is in [PARALLEL], notify field maintenance. Failure to comply will cause
damage to equipment.
7. Ensure voltage selection moveable board (Figure 8, Item 5) located inside the output box is positioned to
match required voltage output.
8. Ensure BATTLESHORT switch (Figure 10, Item 9) is in the OFF position.
9. Push PANEL LIGHTS switch (Figure 10, Item 1) when illumination is required.

0005-17
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NOTE
Under normal operating conditions, the control panel display will take 4 sec or more to establish
contact with the Display and Main Controller Boards. While contact is being established, the
screen display is gray. It will be indicated in the Mode and Status lines as: [Genset Mode:
Unknown] and [Establishing Communications]. The length of time the screen is either blank or
gray depends on ambient temperature. See WP 0007, Operation Under Unusual Conditions for
cold weather operations.

The [DELAY TO START] of the winterization kit can be over-ridden if tactical conditions require
an immediate attempt to start. See steps 10a through 10e.
10. Verify all Before PMCS have been completed IAW Operator PMCS (WP 0013, PMCS) when [Genset Mode:
Ready to Crank] (Figure 11, Item 1) appears on DCS display screen (Figure 10, Item 2). If [Genset Mode:
Ready to Crank] (Figure 11, Item 1) is not displayed, see Table 2. Override [DELAY TO CRANK] as follows:
a. Turn BATTLESHORT switch (Figure 10, Item 9) to ON while engine control switch (Figure 10, Item 6) is
turned to PRIME & RUN (Figure 10, Item 4).
b. Turn BATTLESHORT switch (Figure 10, Item 9) to OFF.
c. Turn engine control switch (Figure 10, Item 6) to START (Figure 10, Item 5).
d. Push FAULT RESET switch (Figure 10, Item 8).
e. Proceed to step 11.

Figure 11. Main Screen Message 1.

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 TM 9-6115-753-10 0005

NOTE
If [Genset Mode: Ready to Crank] (Figure 11, Item 1) does not appear within 15 min of indicated
time, check DCS display screen (Figure 10, Item 2) for winterization kit faults and contact field
maintenance.

The phrase “xx minutes” in table below is substituting for an unknown variable amount of time.

Table 2. Delay to Crank Messages.

MESSAGE(S) ACTION
[Start-up Status: Delay To Crank—Wtr kit xx minutes] Wait at least xx min. [Genset Mode: Ready to
(Figure 12, Item 1) Crank] (Figure 11, Item 1) will appear. See WP
[Winterization kit: Not Ready to Crank] (Figure 12, Item 2) 0010, Troubleshooting Procedures if not
displayed after xx min.
[Start-up Status: Delay To Crank—Glow Plugs xx minutes] Wait at least xx min. [Genset Mode: Ready to
Crank] (Figure 11, Item 1) will appear. See WP
0010, Troubleshooting Procedures if not
displayed after xx min.

Figure 12. Main Screen Message 2.

11. Move engine control switch (Figure 10, Item 6) to START (Figure 10, Item 5).
12. Return engine control switch (Figure 10, Item 6) to PRIME & RUN (Figure 10, Item 4) or PRIME & RUN AUX
FUEL (Figure 10, Item 7), as required.

NOTE
It is recommended to warm up engine without load for 5 min; however, load can be applied
immediately as required.
13. Warm up engine without load for 5 min.

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Figure 13. Operator Main Screen.

14. Check operator main screen for proper phase (Figure 13, Item 1), voltage (Figure 13, Item 2), and frequency
(Figure 13, Item 3). Adjust as necessary. See Adjust Generator Set task.
15. Apply load by pushing AC CIRCUIT INTERRUPT switch (Figure 10, Item 11) on control panel once.
16. Observe main screen display for [Contactor Closed] indication which shows that generator set is now
supplying power to the load.
17. Notify field maintenance if [Contactor Closed] does not display.

END OF TASK

0005-20
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Adjust Generator Set

Figure 14. Main Screen Showing Adjustments — Location.

NOTE
The frequency of Mode 1 generator sets cannot be selected unless the engine control switch is
set to PRIME & RUN (Figure 10, Item 4) or PRIME & RUN AUX FUEL (Figure 10, Item 7).

Push [Cancel] soft key (Figure 16, Item 1) at any time to change incorrect setting(s).
1. Push [Adjustments] soft key (Figure 14, Item 1).

0005-21
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Figure 15. [Adjustments] Screen 1 — Select Option.

NOTE
Selected area will be highlighted on screen.
2. Push [Ż Previous] soft key (Figure 15, Item 1) or [Next Ź] soft key (Figure 15, Item 3) to scroll through
[Adjustments] screen 1 options.
3. Push [Select] soft key (Figure 15, Item 2) to adjust desired option.

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Figure 16. [Adjustments] Screen 1 — Set Configuration.

4. Push [ - ] soft key (Figure 16, Item 4) or [ + ] soft key (Figure 16, Item 3) to adjust setting.
5. Push [Accept] soft key (Figure 16, Item 2) to confirm setting.
6. Push [Cancel] soft key (Figure 16, Item 1) to reject incorrect setting.
7. Repeat steps 2 through 6 as required for additional [Adjustments] screen 1 settings.

NOTE
Two minutes of inactivity will cause [Adjustments] screen 2 to automatically revert to the main
screen. Changes will not be saved.
8. Push [Ż Previous] soft key (Figure 15, Item 1) and [Next Ź] soft key (Figure 15, Item 3) simultaneously for 2
sec to switch from [Adjustments] screen 1 to [Adjustments] screen 2.

0005-23
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Figure 17. [Adjustments] Screen 2 — Select Parameter.

9. Push [Ż Previous] soft key (Figure 17, Item 1) or [Next Ź] soft key (Figure 17, Item 3) to scroll through
[Adjustments] screen 2 options.

NOTE
Selected area will be highlighted on screen.

Notify field maintenance if adjustments to Governor Gain or AVR Gain must be made.
10. Push [Select] soft key (Figure 17, Item 2) to adjust desired option.

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Figure 18. [Adjustments] Screen 2 — Set Configuration.

11. Push [ - ] soft key (Figure 18, Item 4) or [ + ] soft key (Figure 18, Item 3) to adjust setting.
12. Push [Accept] soft key (Figure 18, Item 2) to confirm.
13. Push [Cancel] soft key (Figure 18, Item 1) to reject incorrect setting.
14. Repeat steps 9 – 13 as required for additional [Adjustments] screen 2 settings.

END OF TASK

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Monitoring Generator Set Operational Status

Figure 19. Main Control Screen Status Indicators 120/208 V 3 Phase.

Table 3. Screen Indicator Parameters.

SCREEN INDICATOR UPPER MAXIMUM LIMIT LOWER MINIMUM LIMIT
[Power] 66.0 kW 0 kW
[Frequency] 50 Hz (UOC 98E) 51.5 Hz 48.5 Hz
[Frequency] 60 Hz (UOC 98E) 61.98 Hz 58.2 Hz
[Frequency] 400 Hz (UOC 98F) 412 Hz 388 Hz
[Fuel] 100% 5%
[Battery] 32 V 24 V
[Battery] 90 Amp 0 Amp
[Oil] 60 psi (413.7 kPa) 20 psi (137.9 kPa)
[Coolant] 230°F (104°C) 185°F (85°C)
[Voltage] [120/208 V], [3 Phase], 122/212 V 114/189 V
[50 Hz]
[Voltage] [120/208 V], [3 Phase], 126/240 V 114/205 V
[60 Hz]
[Voltage] [240/416 V], [3 Phase], 264/425 V 216/379 V
[50 Hz]
Voltage] [240/416 V], [3 Phase], 264/479 V 216/394 V
[60 Hz]

1. Perform all During PMCS (WP 0013, PMCS).

2. Monitor the following main control screen status indicators during operation. If outside prescribed limits (Table
3), perform troubleshooting procedures (WP 0010, Troubleshooting Procedures).
a. [Power] (Figure 19, Item 10).
b. [Frequency] (Figure 19, Item 3).

0005-26
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c. [Fuel] (Figure 19, Item 4).

d. [Battery Vdc] Volts (Figure 19, Item 5).
e. [Battery Adc] Amperes (Figure 19, Item 6).

CAUTION
Operating the unit with low oil pressure may cause engine overheating and/or excessive engine
wear. Avoid operating the unit with continued low oil pressure. Failure to comply will cause
damage to equipment.
f. [Oil] (Figure 19, Item 7).

CAUTION
Operating the unit with extreme high or low coolant temperature may cause excessive engine
wear and engine seizing. Do not operate the unit with continued high coolant temperature. Failure
to comply will cause damage to equipment.
g. [Coolant] (Figure 19, Items 8 and 9).

NOTE
Faults and warnings (Figure 19, Items 1 and 2) are preceded by a code number and description.
See WP 0011, DCS Fault and Warning Codes and Descriptions to determine operator
authorization for handling warnings and/or fault codes. Warnings, if not addressed, will usually
lead to faults. Faults normally cause unit to shut down. Attempt to resolve warnings and faults
(WP 0010, Troubleshooting Procedures). Notify field maintenance if unable to resolve a fault or
warning. Faults and warnings are displayed on the illustration for purposes of illustration: fault and
warning parameters are not met on illustration.
3. Monitor status bar for faults and warnings (Figure 19, Items 1 and 2).

NOTE
Step 4 applies to all [Warning] code except [Warning 3661: Active Maintenance Item] and to all
[Fault] codes. Step 5 through step 9 applies only to [Warning 3661: Active Maintenance Item].
4. Troubleshoot the generator set (WP 0010, Troubleshooting Procedures) if [Fault] codes, [Warning] codes, or
parameters other than those set are found.

0005-27
 TM 9-6115-753-10 0005

Figure 20. Select Maintenance Screen.

5. Select [Maintenance] screen if [Warning 3661: Active Maintenance Item] (Figure 20, Item 1) is shown in
[Warning] display line of DCS by pushing [Maintenance] soft key (Figure 20, Item 2).

0005-28
 TM 9-6115-753-10 0005

Figure 21. First Maintenance Screen.

6. Push [Maint Items] soft key (Figure 21, Item 1) to display [Active Maintenance Item] described (Figure 22,
Item 1). Record information displayed.

0005-29
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Figure 22. Maintenance Item Display.

7. Push [Next] soft key (Figure 22, Item 2) to display and record [Next Service Due In xx Hours xxx xxx xxx]
(Figure 23, Items 1 and 2). Record information.

0005-30
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Figure 23. Next Items Display.

8. Repeat step 7 until all service items [xxx xxx xxx] (Figure 23, Item 2) with less than 24 hr listed under [Next
Service Due In xx Hours] (Figure 23, Item 1) have been displayed and recorded.

9. Notify field maintenance of all service items recorded.

END OF TASK

Operation with Remote Monitoring

1. Secure permission for remote monitoring from higher command.

NOTE
The AMMPS 60 kW generator set provides limited remote operation capabilities. The operational
status of generator set can be monitored, battleshort conditions can be set and released, and an
emergency stop can be executed up to a 250-ft (76.2-m) distance. The intent of remote operation
capability is to permit the operator to monitor more than one unit at the same time and to be
sheltered from severe environmental conditions. Loss of signal between remote monitoring site
and generator set does not adversely affect generator set operation. Loss of signal between
remote monitoring site and generator set will release [BATTLESHORT] setting at the generator
set. The remote monitoring system connects to main control board, bypassing screen control
board.
2. Perform all Before PMCS required (WP 0013, PMCS).
3. Start generator set. See Starting Procedure task.
4. Perform all During PMCS required (WP 0013, PMCS).
5. Ensure unit is operating at requested parameters. See Monitoring Generator Set Operational Status task.

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NOTE
This cable and converter do not come with the generator set and must be ordered.
6. Insert remote control cable (Figure 24, Item 2) into REMOTE connector (Figure 24, Item 1) on DCS.

Figure 24. Operator Display Panel — Remote Connection.

7. Connect other end (Figure 25, Item 3) of remote control cable (Figure 25, Item 2) into suitable interface of
IBM-compatible PC (Figure 25, Item 1).
8. Initialize IBM-compatible PC (Figure 25, Item 1).

0005-32
 TM 9-6115-753-10 0005

Figure 25. Remote PC — Connection.

9. Monitor PC display screen for:

a. [Fault] codes (Figure 26, Item 2).
b. [Warning] codes (Figure 26, Item 3).
c. [Genset Mode:] (Figure 26, Item 1).

NOTE
Step 11 applies to all [Warning] code except [Warning 3661: Active Maintenance Item] and to all
[Fault] codes.
10. Troubleshoot at the generator set (WP 0010, Troubleshooting Procedures) if [Fault] codes (Figure 26, Item 2),
[Warning] codes (Figure 26, Item 3), or parameters other than those set are found.
11. Follow steps 5 through 9 of Monitoring Generator Set Operational Status task if [Warning 3661: Active
Maintenance Item] is shown in [Warning] display line of DCS.

0005-33
 TM 9-6115-753-10 0005

Figure 26. Remote PC Display.

12. Monitor PC display screen to ensure AC generator outputs remain within acceptable parameters.
a. [Genset Voltage] Line-to-Line [Lx-Lx] (Figure 26, Item 4) and Line-to-Neutral [Lx-N] (Figure 26, Item 16).
b. [Bus Voltage] [Lx-Lx] (Figure 26, Item 5) and [Lx-N] (Figure 26, Item 15).
c. [Genset Current] Line-to-Line (Figure 26, Item 6).

0005-34
 TM 9-6115-753-10 0005

d. [Genset Frequency] (Figure 26, Item 7).

e. [Bus Frequency] (Figure 26, Item 8).
f. [Power] (Figure 26, Item 9). Troubleshoot generator if parameters not met (WP 0010, Troubleshooting
Procedures).
13. Monitor PC display screen for engine functions.
a. [Fuel Level] (Figure 26, Item 10).
b. [Battery Voltage] (Figure 26, Item 11).
c. [Battery Amps] (Figure 26, Item 12).
d. [Oil Pressure] (Figure 26, Item 13).
e. [Coolant Temperature] (Figure 26, Item 14).
14. Troubleshoot engine if not within required parameters (WP 0010, Troubleshooting Procedures).

NOTE
[Battle Short Command] (Figure 26, Item 19) position will display [OFF] when battleshort is
inactive and [ON] for active. The remote battleshort command is independent of the battleshort
command on the DCS. It is possible to turn on the battleshort from the DCS. In this case, the
[Battle Short] status field (Figure 26, Item 17) will transition to [Active] and the [Battle Short
Command] (Figure 26, Item 19) position will remain in the [OFF] position.
15. Enable or disable battleshort as required by tactical conditions by placing PC cursor over [Battleshort
Command] (Figure 26, Item 19) symbol and clicking mouse or pressing [Enter] on keyboard.

CAUTION
Do not allow the engine to operate with any of the monitored engine functions in the red area of
the monitoring tapes unless specifically required to do so by higher command. Shut down the
generator set using the remote emergency stop function or by utilizing the Stopping Procedure
task. Failure to comply will cause damage to equipment.

NOTE
Both the remote [Emergency Stop] (Figure 26, Item 20) and the EMERGENCY STOP switch
(Figure 10, Item 3) must be [OFF] to restart the engine while the remote monitor is active.
16. Enable or disable [Emergency Stop] (Figure 26, Item 20) as required by faulty engine/AC generator condition
by placing PC cursor over [Emergency Stop] (Figure 26, Item 20) command symbol and clicking mouse or
pressing [Enter] on keyboard. The [Emergency Stop] status display (Figure 26, Item 18) will show either
[Stopped] or [Not Stopped]. The [Emergency Stop] (Figure 26, Item 20) command symbol will display either
[OFF] or [ON].
17. Troubleshoot at generator set if [Emergency Stop] (Figure 26, Item 20) has been activated (WP 0010,
Troubleshooting Procedures).

END OF TASK

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Stopping Procedure

Figure 27. Stopping Procedure.

1. Push AC CIRCUIT INTERRUPT switch (Figure 27, Item 1) to place generator contactor in [CONTACTOR
OPEN] position.

NOTE
The engine can be shut down immediately after the load is removed. It is preferred that a cool
down period of 5 min be allowed before engine shut down.
2. Allow generator set to operate for 5 min with no load applied.
3. Place engine control switch (Figure 27, Item 2) in OFF position.
4. Place DEAD CRANK SWITCH (Figure 9, Item 2) in OFF position.
5. Push in EMERGENCY STOP (Figure 10, Item 3).
6. Turn main DC circuit breaker (Figure 9, Item 1) to OFF/TRIP.
7. Perform all After PMCS (WP 0013, PMCS).

END OF TASK

0005-36
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DECALS AND INSTRUCTIONS PLATES

Identification and instructions plates are mounted on the generators. Figure 28 through Figure 32 show the
location and contents of each plate on each generator. Table 4 through Table 8 identifies the plates illustrated in
Figure 33 through Figure 55.

Figure 28. Decal and Instructions Plates, Right-Side — Model 1070/1071.

Table 4. Decal and Instructions Plates, Right-Side — Model 1070/1071.

ITEM MODE 1070 MODE 1071
NAME
NUMBER FIGURE NUMBER FIGURE NUMBER
1 Plate, Identification Figure 33 Figure 34
2 Label, Lifting and Tie Down Figure 35 Figure 35
3 Plate, Individual Unit Identification (IUID) Figure 36 Figure 37
4 Name Plate, Identification Figure 38 Figure 39
5 Plate, System Capacity Figure 40 Figure 40
6 Plate, Set Rating Figure 41 Figure 42

0005-37
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Figure 29. Decal and Instructions Plates, Rear — Model 1070/1071.

Table 5. Decal and Instructions Plates, Rear — Model 1070/1071.

ITEM MODE 1070 MODE 1071
NAME
NUMBER FIGURE NUMBER FIGURE NUMBER
1 Label, Fuel Figure 43 Figure 43
2 Label, Convenience Figure 44 Figure 45

0005-38
 TM 9-6115-753-10 0005

Figure 30. Decal and Instructions Plates, Top and Inside — Model 1070/1071.

Table 6. Decal and Instructions Plates, Top and Inside — Model 1070/1071.
ITEM MODE 1070 MODE 1071
NAME
NUMBER FIGURE NUMBER FIGURE NUMBER
1 Label, Fuel Diagram Figure 46 Figure 46
2 Label, Operating Instructions Figure 47 Figure 47
3 Label, First Fuel Filter Figure 48 Figure 48
4 Label, Diagram, Wiring Figure 49 Figure 49
5 Label, Battery Connection Figure 50 Figure 50
6 Plate, Identification Generator Figure 53 Figure 54
7 Label, Caution Voltage Connection Figure 51 Figure 51
8 Label, Grounding Stud Figure 52 Figure 52

0005-39
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Figure 31. Decal and Instructions Plates, Front — Model 1070/1071.

Table 7. Decal and Instructions Plates, Front — Model 1070/1071.

ITEM MODE 1070 MODE 1071
NAME
NUMBER FIGURE NUMBER FIGURE NUMBER
1 Label, Schematic, Wiring Figure 53 Figure 53
2 Label, Slave Receptacle Figure 54 Figure 54

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Figure 32. Decal and Instructions Plates, Left-Side — Model 1070/1071.

Table 8. Decal and Instructions Plates, Left-Side — Model 1070/1071.

ITEM MODE 1070 MODE 1071
NAME
NUMBER FIGURE NUMBER FIGURE NUMBER
1 Label, Dead Crank Switch Figure 55 Figure 55

0005-41
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Figure 33. Plate, Identification — Model 1070.

Figure 34. Plate, Identification — Model 1071.

0005-42
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Figure 35. Label, Lifting and Tie Down — Model 1070/1071.

Figure 36. Plate, IUID Identification — Model 1070.

0005-43
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Figure 37. Plate, IUID Identification — Model 1071.

Figure 38. Name Plate, Identification — Model 1070.

0005-44
 TM 9-6115-753-10 0005

Figure 39. Name Plate, Identification — Model 1071.

Figure 40. Plate, System Capacity — Model 1070/1071.

0005-45
 TM 9-6115-753-10 0005

Figure 41. Plate, Set Rating — Model 1070.

Figure 42. Plate, Set Rating — Model 1071.

0005-46
 TM 9-6115-753-10 0005

Figure 43. Label, Fuel — Model 1070/1071.

Figure 44. Label, Convenience — Model 1070.

Figure 45. Label, Convenience — Model 1071.

0005-47
 TM 9-6115-753-10 0005

Figure 46. Label, Fuel Diagram — Model 1070/1071.

0005-48
 TM 9-6115-753-10 0005

Figure 47. Label, Operating Instructions — Model 1070/1071.

Figure 48. Label, First Fuel Filter — Model 1070/1071.

0005-49
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Figure 49. Label, Diagram, Wiring — Model 1070/1071.

0005-50
 TM 9-6115-753-10 0005

Figure 50. Plate, Battery Connection — Model 1070/1071.

Figure 51. Label, Caution, Voltage Connection — Model 1070/1071.

0005-51
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Figure 52. Label, Grounding Stud — Model 1070/1071.

0005-52
 TM 9-6115-753-10 0005

Figure 53. Label, Schematic, Wiring — Model 1070/1071.

Figure 54. Label, Slave Receptacle — Model 1070/1071.

0005-53
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Figure 55. Label, Dead Crank — Model 1070/1071.

END OF TASK

PREPARATION FOR MOVEMENT

WARNING
Ensure generator sets are shut down and output terminal board has no voltage prior to making
any connections for operation or moving a generator set that has been operating. Operating
generator sets always contain the risk of electrocution. Failure to comply may cause injury or
death to personnel.

NOTE
For initial setup after movement, see Assembly and Preparation for Use task.

Different modes of transportation require various levels of fluid removal. Contact field
maintenance to drain required fluids.
1. Shutdown all generators to be moved. See Stopping Procedure task.
2. Examine DCS main display screens [Bus Voltage] to ensure there is no voltage at output terminal board.
3. Disconnect load cables. See Installation of Load Cables task.
4. Disconnect auxiliary fuel line (if used). Notify field maintenance if assistance is needed.

NOTE
Dispose of excess fuel IAW local SOP.
a. Drain excess fuel from line.
b. Store line in storage box.
5. Disconnect ground cable. Notify field maintenance if assistance is needed. See Installation of Ground Rod
task.
6. Remove ground rods.

0005-54
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7. Store ground rods in storage rack on front panel of generator set inside left-side door.
8. Store cable and couplings in storage box located inside right-side door.
9. Secure all generator set access doors and panels.

END OF TASK

END OF WORK PACKAGE

0005-55/56 blank
 TM 9-6115-753-10 0006

OPERATOR MAINTENANCE
AMMPS 60KW GENERATOR SET
PARALLEL OPERATION

INITIAL SETUP:

Test Equipment References

Not Applicable WP 0004, Description and Use of Operator Controls
and Indicators
Tools and Special Tools
Equipment Condition
Not Applicable
Engine control switch OFF (WP 0005, Operation
Materials/Parts
Under Usual Conditions)
Not Applicable
Personnel Required
Operator (1)

PARALLEL OPERATION

WARNING

x DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Do not ground yourself in standing water.
Failure to comply may cause injury or death to personnel and damage to equipment.

x Ensure generator sets are shut down and output terminal board has no voltage prior to making
any connections for parallel operation or moving a generator set that has been operating in
parallel. Operating generator sets always contain the risk of electrocution. Failure to comply may
cause injury or death to personnel.

x High voltage is produced when generator set is in operation. Do not connect to a load that is not
protected with appropriate safety devices. Do not connect from output terminal board to output
terminal board unless directed by higher command. Never attempt to start the generator set
unless it is properly grounded. Do not ground yourself in standing water. Never attempt to
connect or disconnect load cables while the generator set is operating. Do not contact output
cables when operating this generator set. Make sure that the connection between generator set
and load is completely deenergized (safety device opens circuit) prior to disconnecting load
cables or performing maintenance on the output terminal board. Failure to comply may cause
injury or death to personnel.

x Exhaust discharge contains deadly gases, including carbon monoxide. Exhaust gases are most
dangerous in places with poor ventilation. Do not operate generator set in an enclosed area
unless exhaust discharge is properly vented. Failure to comply may cause injury or death to
personnel.

x When operating, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow engine to cool before checks, services, and maintenance. Wear
gloves and additional protective clothing as required. Failure to comply may cause injury or death
to personnel.

0006-1
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Connecting Generator Sets Parallel Cables (PP Configuration)

WARNING

x High voltage is produced when generator set is in operation. Never attempt to start the generator
set unless it is properly grounded. Do not ground yourself in standing water. Never attempt to
connect or disconnect load cables while the generator sets are operating. Failure to comply may
cause injury or death to personnel.

x High-voltage power is available when the main contactor is closed. Avoid accidental contact with
live components. Ensure load cables are properly connected and the load cable door is shut
before closing main contactor. Ensure that personnel working with/on loads connected to the
generator set are aware that main contactor is about to be closed before closing main contactor.
Failure to comply may cause injury or death to personnel.

x Generator set operator is permitted to make connections to output terminal board only.
Connections to load distribution points or to equipment beyond the output terminal board shall
only be made by properly trained and authorized personnel. Failure to comply may cause injury
or death to personnel.

CAUTION
All generator sets to be operated in parallel must be of the same capacity and selected for the
same voltage and frequency. Failure to comply will cause damage to equipment.

Ensure the load requirement is equal to or less than the combined rated capacity of the two or
more generator sets. Failure to comply will cause damage to equipment.

NOTE
Output requirements will be given to the operator prior to operation.
1. Ensure equipment conditions are met in order presented in initial setup.
2. Secure load information and paralleling requirements from higher authority.

CAUTION
For 50/60 Hz generator sets, ensure that both generator set frequency selections are positioned
for the same load requirements. Failure to match the settings will result in damage to the load
equipment being supplied by the generator set. Failure to comply will cause damage to
equipment.
3. Ensure adjustments are set for the generator sets’ required output (WP 0005, Operation Under Usual
Conditions) of both [Freq] (Figure 4, Item 2) and [Genset Voltage] (either [L-N] or [L-L]) (Figure 4, Item 1).

0006-2
 TM 9-6115-753-10 0006

Figure 1. Storage Box and Cable — Location.

4. Remove paralleling cable (Figure 1, Item 1) from the right-side door storage box (Figure 1, Item 2).

Figure 2. DCS Panel — Parallel Setup.

5. Connect paralleling cable (Figure 1, Item 1) to PARALLEL receptacle (Figure 2, Item 2) on both generator
sets.
0006-3
 TM 9-6115-753-10 0006

CAUTION
Ensure the proper phase-to-phase to neutral orientation (WP 0005, Operation Under Usual
Conditions) is selected when performing the following step. Failure to comply will cause damage
to equipment.

NOTE
Parallel operation can be carried out with either skid- or trailer-mounted power plant generator
sets. Trailer-mounted power plant generator sets are hard wired to a switch box. Skid-mounted
generator sets usually are not hard wired to a common bus. Connect output cables to the load if
skid mounted, or from the switch box if trailer mounted, to the load in the voltage and frequency
configuration as directed by higher command.
6. Connect the load to generator sets (WP 0005, Operation Under Usual Conditions) as instructed.

END OF TASK

Parallel Operation with Switch Box (Two Like Sets)

CAUTION
When generator sets are configured for parallel operation the amperage capacity of
interconnecting cables and switch box(es) must be of sufficient capacity to safely distribute the
combined amperage of the generator sets connected together in parallel. Failure to comply may
cause damage to equipment.
1. Connect generator sets (units A and B or more) parallel cables in PP configuration for both units to be
operated together as a PP. See Connecting Generator Sets Parallel Cables (PP Configuration) task.
2. Make output cable connections between generator sets (units A and B or more) and switch boxes if
necessary.

CAUTION
During examination of connectors and connector parts, note the position of alignment mating
surfaces to ensure that when connectors are assembled to plugs they are in correct orientation.
Failure to comply may cause damage to equipment.

NOTE
Step 3 and step 4 are required only if generator switch box cables were disconnected and
removed following a previous period of operation.
3. Remove dust cap(s) from switch box contactor cable(s) (Figure 3, Item 3) and examine for evidence of foreign
material, signs of corrosion, and damaged and/or missing connector parts.

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 TM 9-6115-753-10 0006

Figure 3. Switch Box Paralleling Receptacle.

4. Notify field maintenance if there is any evidence of foreign material, signs of corrosion, and damaged and/or
missing connector parts.
5. Connect switch box contactor cable(s) (Figure 3, Item 3) to SWITCH BOX CONTACTOR RECEPTACLE(s)
(Figure 3, Item 1) located in convenience receptacle compartment (Figure 3, Item 2).

NOTE
The first generator set to be placed on-line in a power plant with switch box configuration should
be the unit that is hardwired to the switch box and is designated unit A.

The DCS does not enable the AC CIRCUIT INTERRUPT switch (Figure 2, Item 1) or the UNIT
PARALLEL switch (Figure 2, Item 4) until the generator set has reached [Rated Voltage and
Frequency] as shown on the status line of the DCS main display.
6. Start unit A only (WP 0005, Operation Under Usual Conditions).

0006-5
 TM 9-6115-753-10 0006

NOTE
The DCS panel may briefly display an initializing screen with all data grayed out before the main
display screen appears.

Figure 4. Main Display Screen — Parallel Mode.

7. Ensure [Genset Voltage] (either [L-N] or [L-L]) (Figure 4, Item 1) and [Freq] (Figure 4, Item 2) are at required
values as indicated on the DCS main display screen (Figure 4).
a. Select correct parameters, if necessary (WP 0005, Operation Under Usual Conditions).
b. Select [Adjustments] soft key (Figure 4, Item 3) and adjust as required (WP 0005, Operation Under Usual
Conditions).

CAUTION
If [Running — Synchronized] does not display, do not proceed to step 9. Notify field maintenance
of problem. Failure to comply will cause damage to equipment.

NOTE
Immediately following step 8, [Genset Mode] line of DCS will first display [Running —
Synchronizing]. After a brief delay, [Running — Synchronized] should display.
8. Push UNIT PARALLEL switch (Figure 2, Item 4) until [Parallel] mode (Figure 4, Item 4) and [Switchbox]
(Figure 4, Item 5) [Closed] message is displayed on unit A.

0006-6
 TM 9-6115-753-10 0006

CAUTION
If [Running — Load Share] or [Contactor Closed] does not display immediately following step 9,
contact field maintenance for direction on continuing operation. Failure to comply may cause
damage to equipment.

NOTE
Immediately following step 9, [Genset Mode] line of DCS should display [Running — Load Share].
The [Contactor] display (Figure 4, Item 6) of the DCS should display [Closed].
9. Push and hold AC CIRCUIT INTERRUPT switch (Figure 2, Item 1) until DCS [Genset Mode] changes to
[Running — Load Share].
10. Start second generator set (unit B) (WP 0005, Operation Under Usual Conditions).

NOTE
The DCS display may briefly display an initializing screen with all data grayed out before the main
screen appears.
11. Ensure [Genset Voltage] (either [L-N] or [L-L]) (Figure 4, Item 1) and [Freq] (Figure 4, Item 2) are at required
values as indicated on the DCS main display screen.
a. Select correct parameters, if necessary (WP 0005, Operation Under Usual Conditions).
b. Select [Adjustments] soft key (Figure 4, Item 3) and adjust as required (WP 0005, Operation Under
Usual Conditions).

CAUTION
If [Running — Synchronized] does not display immediately following step 12, do not proceed to
step 13. Notify field maintenance of problem. Failure to comply will cause damage to equipment.

NOTE
Immediately following step 12, [Genset Mode] line of DCS will first display [Running —
Synchronizing]. After a brief delay, [Running — Synchronized] should display.
12. Push UNIT PARALLEL switch (Figure 2, Item 4) until [Parallel] mode (Figure 4, Item 4) and [Switchbox]
(Figure 4, Item 5) [Closed] message is displayed on unit B.

0006-7
 TM 9-6115-753-10 0006

CAUTION
If [Running — Load Share] or [Contactor Closed] does not display immediately following step 13,
contact field maintenance for direction on continuing operation. Failure to comply may cause
damage to equipment.

NOTE
Immediately following step 13, [Genset Mode] line of DCS should display [Running — Load
Share]. The [Contactor] display of the DCS should display [Closed]. If [Running — Load Share] or
[Contactor Closed] does not display, notify field maintenance.
13. Push and hold AC CIRCUIT INTERRUPT switch (Figure 2, Item 1) until DCS [Genset Mode] changes to
[Running — Load Share].

END OF TASK

Parallel Operation Without Switch Box (Two Or More Like Sets)

1. Connect generator sets’ parallel cables in PP configuration. See Connecting Generator Sets Parallel Cables
(PP Configuration) task for all generator sets to be operated together as a PP.

CAUTION
When generators are operated in parallel without a switch box, pay careful attention to the
settings of each generator set and to the phase-to-phase connection of the load cables. Ensure
the combined capacity of the units is sufficient to carry the required load. Failure to comply will
cause damage to equipment.

NOTE
Designation of unit A or B, etc., is variable and dependant on the order they are placed on line
when used in PP configuration without a switch box.
2. Start generator set unit A (WP 0005, Operation Under Usual Conditions).
3. Ensure [Genset Voltage] (either [L-N] or [L-L]) (Figure 4, Item 1) and [Freq] (Figure 4, Item 2) are at required
values as indicated on the DCS main display screen.
a. Select correct parameters, if necessary (WP 0005, Operation Under Usual Conditions).
b. Select [Adjustments] soft key (Figure 4, Item 3) and adjust as required.

0006-8
 TM 9-6115-753-10 0006

CAUTION
If [Running — Synchronized] does not display immediately following step 4, do not proceed to
step 5. Notify field maintenance of problem. Failure to comply will cause damage to equipment.

NOTE
The following sequence occurs after executing step 4. The generator automatically attempts to
close switch box contactor to detect the condition of the output bus. Because this is the first
generator on the output bus and the output bus is deenergized and there is not a switch box, the
DCS will first display in the [Genset Mode] line of DCS [Running — Synchronizing]. After a brief
delay, [Running — Synchronized] should display.
4. Push UNIT PARALLEL switch (Figure 2, Item 4) until [Parallel] mode (Figure 4, Item 4) and [Switchbox]
(Figure 4, Item 5) [Open] message is displayed on unit A.

CAUTION
If [Running — Load Share] or [Contactor Closed] does not display immediately following step 5,
contact field maintenance for direction on continuing operation. Failure to comply may cause
damage to equipment.

NOTE
Immediately following step 5, [Genset Mode] line of DCS should display [Running — Load Share].
The [Contactor] display of the DCS should display [Closed].

After step 5, having found no switch box in this configuration, the DCS will issue a warning to the
user: [Warning 3658: Switch Box Fail to Close]. Operation will not be stopped, allowing the
operator to verify that the operation should continue. This warning cannot be cleared until the
generator set has been shut down. Before generator set is to be restarted, push FAULT RESET
(Figure 2, Item 2) to clear the warning. At this point the entire load is being carried by unit A.
5. Push and hold AC CIRCUIT INTERRUPT switch (Figure 2, Item 1) until DCS [Genset Mode] changes to
[Running — Load Share].
6. Start second generator set (unit B) (WP 0005, Operation Under Usual Conditions).
7. Ensure [Genset Voltage] (either [L-N] or [L-L]) (Figure 4, Item 1) and [Freq] (Figure 4, Item 2) are at required
values as indicated on the DCS main display screen.
a. Select correct parameters, if necessary (WP 0005, Operation Under Usual Conditions).
b. Select [Adjustments] soft key (Figure 4, Item 3) and adjust as required (WP 0005, Operation Under Usual
Conditions).

0006-9
 TM 9-6115-753-10 0006

CAUTION
Step 8 must be completed before step 9 for each generator set placed in parallel. Failure to
comply will cause damage to equipment.

If [Running — Synchronized] does not display immediately following step 8, do not proceed to
step 9. Notify field maintenance of problem. Failure to comply will cause damage to equipment.

NOTE
There is no switchbox in this configuration. The DCS will detect the condition of the bus directly.
The generator set automatically attempts to close switch box contactor to detect the condition of
the output bus. Since generator set unit A is already on the bus, generator set unit B will begin
the synchronization sequence. The DCS will first display in the [Genset Mode] line of DCS
[Running — Synchronizing]. After a brief delay, [Running — Synchronized] should display.
8. Push UNIT PARALLEL switch (Figure 2, Item 4) until [Parallel] mode (Figure 4, Item 4) and [Switchbox]
(Figure 4, Item 5) [Open] message is displayed on unit B.

CAUTION
If [Running — Load Share] or [Contactor Closed] does not display immediately following step 9,
contact field maintenance for direction on continuing operation. Failure to comply may cause
damage to equipment.

NOTE
Immediately following step 9, [Genset Mode] line of DCS should display [Running — Load Share].
The [Contactor] display of the DCS should display [Closed].

After step 9, having found no switch box in this configuration, the DCS will issue a warning to the
user: [Warning 3658: Switch Box Fail to Close]. Operation will not be stopped, allowing the
operator to verify that the operation should continue. This warning cannot be cleared until the
generator set has been shut down. Before generator set is to be restarted, push FAULT RESET
(Figure 2, Item 2) to clear the warning. At this point, the load is being shared between unit A and
unit B.
9. Push and hold AC CIRCUIT INTERRUPT switch (Figure 2, Item 1) until DCS [Genset Mode] changes to
[Running — Load Share].
10. Repeat steps 6 through 9 for each additional generator set to be operated in parallel.

END OF TASK

0006-10
 TM 9-6115-753-10 0006

Adjusting Parallel Operations

CAUTION
Units operating in parallel should share the output load equally. Any variation from equal load
sharing exceeding 2% should be corrected. Unequal load sharing may cause excessive wear to
the generator set. Failure to comply may cause damage to equipment.

Before the first use of two or more generator sets in a PP configuration, steps 1 through 11
should be completed to insure mechanical balance for parallel operation. Unequal load sharing
may cause excessive wear to the generator set. Repeat these steps when an additional
generator set or replacement generator set is added to the power plant. Failure to comply may
cause damage to equipment.

NOTE
Contact field maintenance to perform adjustments.

All adjustments can be returned to prior setting after change by pushing [Cancel] soft key (Figure
6, Item 7). Pushing [Exit] soft key (Figure 6, Item 4) before accepting changes will return to main
screen and adjustments will not be saved.

Screen navigated to will be highlighted with white background and black type.

Figure 5. Parallel Adjustment Screen, A.

1. Connect all generator sets in power plant configuration with paralleling cables. See Connecting Generator
Sets Parallel Cables (PP Configuration) task.
2. Connect all units to a switch box if available.

0006-11
 TM 9-6115-753-10 0006

3. Start all generator sets (WP 0005, Operation Under Usual Conditions) to be operated in parallel.

NOTE
This operation requires there be no load placed on the bus.
4. Place all generator sets into parallel operation. See Parallel Operation with Switch Box (Two Like Sets task or
Parallel Operation without Switch Box (Two Or More Like Sets) task without load.
5. Monitor all generator sets operating in parallel for [Total KW] (Figure 5, Item 5) in adjust parallel screen.
a. Push [Adjustments] soft key (Figure 4, Item 3) in main display screen (WP 0005, Operation Under Usual
Conditions).
b. Push [ŻPrevious] and [NextŹ] simultaneously for 2 sec to switch from [Adjustments] screen 1 to
[Adjustments] screen 2 (WP 0005, Operation Under Usual Conditions).
c. Push [Parallel Adj] soft key to reach parallel adjustment display screen (WP 0004, Description and Use of
Operator Controls and Indicators) from [Adjustments] screen 2.

NOTE
If a zero value is shown for [Total KW] (Figure 5, Item 5), the generator sets are in balance and
no adjustments are necessary.
d. Record [Total KW] (Figure 5, Item 5) on all generators.
6. Adjust [KW Offset] (Figure 5, Item 1) or any generator set showing a value (positive or negative) for [Total
KW] (Figure 5, Item 5).
a. Return to parallel adjustment screen (Steps 5a through 5c).
b. Navigate to [KW Offset] (Figure 5, Item 1) by pushing soft key labeled [NextŹ] (Figure 5, Item 3) until
[KW Offset] (Figure 5, Item 1) is highlighted.
c. Push [Select] soft key (Figure 5, Item 2) to enable adjustments.
d. Adjust the value of [KW Offset] (Figure 5, Item 1) until the average [Total KW] (Figure 5, Item 5) on all
generator sets is zero.

NOTE
A combination of positive and negative adjustments may be made in step 6d. Adjustments on
both sides of the decimal point can be made. It is not necessary in all situations to make such
adjustments; however, the system requires that you navigate to both the right (Figure 6, Item 2)
and left (Figure 6, Item 1) sides of the decimal point before accepting the changes made utilizing
the [NextŹ] soft key (Figure 5, Item 3) and [Accept] soft key (Figure 8, Item 4) as they appear.
(1) Increase the value of [KW Offset] (Figure 5, Item 1) for any generator set with a positive value for
[Total KW] (Figure 5, Item 5) by pushing the [ + ] soft key (Figure 6, Item 5) or decrease the value of
[KW Offset] (Figure 5, Item 1) for any generator set with a negative value for [Total KW] (Figure 5,
Item 5) by pushing the [ - ] soft key (Figure 6, Item 6).
(2) Shift to the right (Figure 6, Item 2) of the decimal point by selecting [NextŹ] soft key (Figure 5, Item
3) or return to the left (Figure 6, Item 1) of the decimal point by selecting [ŻPrevious] soft key (Figure
7, Item 1), as necessary.
(3) Select [NextŹ] soft key (Figure 5, Item 3) from the farthest right-hand digit (Figure 8, Item 2) when
desired value is attained.
(4) Select [Accept] soft key (Figure 8, Item 4) to commit desired value.

0006-12
 TM 9-6115-753-10 0006

Figure 6. Parallel Adjustment Screen, B.

7. Monitor all generator sets operating in parallel for [Total KVAR] (Figure 5, Item 4) in adjust parallel screen.
a. Push [Adjustments] soft key (Figure 4, Item 3) in main display screen (WP 0005, Operation Under Usual
Conditions).
b. Push [ŻPrevious] and [NextŹ] simultaneously for 2 sec to switch from [Adjustments] screen 1 to
[Adjustments] screen 2 (WP 0005, Operation Under Usual Conditions).
c. Push [Parallel Adj] soft key to reach parallel adjustment display screen (WP 0004, Description and Use of
Operator Controls and Indicators) from [Adjustment] screen 2.

NOTE
If a zero value is shown for [Total KVAR] (Figure 5, Item 4), the generator sets are in balance and
no adjustments are necessary.
d. Record [Total KVAR] (Figure 5, Item 4) on all generators.
8. Adjust [KVAR Offset] (Figure 6, Item 3) for any generator set showing a value (positive or negative) for [Total
KVAR] (Figure 5, Item 4).
a. Return to parallel adjustment screen. See steps 7a through 7c.
b. Navigate to [KVAR Offset] (Figure 6, Item 3) by pushing [NextŹ] soft key (Figure 5, Item 3) until [KVAR
Offset] (Figure 6, Item 3) is highlighted.
c. Push [Select] soft key (Figure 5, Item 2) to enable adjustments.
d. Adjust the value of [KVAR Offset] (Figure 6, Item 3) until the average [Total KVAR] (Figure 5, Item 4) on
all generator sets is zero.

0006-13
 TM 9-6115-753-10 0006

NOTE
A combination of positive and negative adjustments may be made in step 8d. Adjustments on
both sides of the decimal point can be made. It is not necessary in all situations to make such
adjustments. However, the system requires that you navigate to both the right and left sides of
the decimal point before accepting the changes made utilizing the [NextŹ] soft key (Figure 5,
Item 3) and [Accept] soft key (Figure 8, Item 4) as they appear.
(1) Increase the value of [KVAR Offset] (Figure 6, Item 3) for any generator set with a positive value for
[Total KVAR] (Figure 5, Item 4) by pushing the [ + ] soft key (Figure 6, Item 5) or decrease the value
of [KVAR Offset] (Figure 6, Item 3) for any generator set with a negative value for [Total KVAR]
(Figure 5, Item 4) by pushing the [ - ] soft key (Figure 6, Item 6).
(2) Shift to the right (Figure 6, Item 2) decimal points by selecting [NextŹ] soft key (Figure 5, Item 3) or
shift to the left decimal points by selecting [ŻPrevious] soft key (Figure 7, Item 1), as necessary.
(3) Select [NextŹ] soft key (Figure 5, Item 3) from the farthest right-hand digit (Figure 8, Item 2) when
desired value is attained.
(4) Select [Accept] soft key (Figure 8, Item 4) to commit desired value.

CAUTION
The maximum range of adjustment for [KVAR Offset] (Figure 6, Item 3) is ± 5%. If the maximum
[KVAR Offset] (Figure 6, Item 3) has been reached and the generator sets have not reached zero
[Total KVAR] (Figure 5, Item 4), do not apply load and notify field maintenance. Failure to comply
may cause damage to equipment.
9. Push [Reset Offsets] (Figure 7, Item 3) to set both [KW Offset] (Figure 5, Item 1) and [KVAR Offset] (Figure 6,
Item 3) to zero if unable to achieve balance.
a. Navigate to [Reset Offsets] (Figure 7, Item 3) using the [NextŹ] soft key (Figure 5, Item 3).
b. Push [Select] soft key (Figure 5, Item 2).
c. Push [Accept] soft key (Figure 8, Item 4).
d. Offsets are now restored to original values.
e. Notify field maintenance of failure to achieve mechanical balance.
10. Push [EXIT] soft key (Figure 6, Item 4) to return to main screen.
11. Apply load if able to achieve mechanical balance.

0006-14
 TM 9-6115-753-10 0006

Figure 7. Parallel Adjustment Screen, C.

12. Monitor all generator sets operating in parallel for [Power] on main display screen.
13. Adjust [KW Gain] (Figure 8, Item 1) on generator set(s) when [Power] indicator(s) for one or more generator
set(s) fluctuates widely around a nominal average.
a. Push [Adjustments] soft key (Figure 4, Item 3) in main display screen (WP 0005, Operation Under Usual
Conditions).
b. Push [ŻPrevious] and [NextŹ] simultaneously for 2 sec to switch from [Adjustments] screen 1 to
[Adjustments] screen 2 (WP 0005, Operation Under Usual Conditions).
c. Push [Parallel Adj] soft key to reach parallel adjustment display screen (WP 0004, Description and Use of
Operator Controls and Indicators).
d. Navigate to [KW Gain] (Figure 8, Item 1) by pushing [NextŹ] soft key (Figure 5, Item 3) until [KW Gain]
(Figure 8, Item 1) is highlighted.
e. Push [Select] soft key (Figure 5, Item 2) to enable adjustments.
f. Adjust [KW Gain] (Figure 8, Item 1) down by pushing [ - ] soft key (Figure 6, Item 6) by an equal amount
on each generator set until the unstable load sharing conditions are resolved.

NOTE
Do not select [Reset Gains] (Figure 7, Item 2) until both [KW Gain] (Figure 8, Item 1) and [KVAR
Gain] (Figure 8, Item 3) adjustments have been completed and balance has not been achieved.
14. Adjust [KW Gain] (Figure 8, Item 1) on generator set(s) when [Power] averages are stable but respond slowly
when the load on the bus is changed.

0006-15
 TM 9-6115-753-10 0006

a. Push [Adjustments] soft key (Figure 4, Item 3) in main display screen (WP 0005, Operation Under Usual
Conditions).
b. Push [ŻPrevious] and [NextŹ] simultaneously for 2 sec to switch from [Adjustments] screen 1 to
[Adjustments] screen 2 (WP 0005, Operation Under Usual Conditions).
c. Push [Parallel Adj] soft key to reach parallel adjustment display screen (WP 0004, Description and Use of
Operator Controls and Indicators).
d. Navigate to [KW Gain] (Figure 8, Item 1) by pushing [NextŹ] soft key (Figure 5, Item 3) until [KW Gain]
(Figure 8, Item 1) is highlighted.
e. Push [Select] soft key (Figure 5, Item 2) to enable adjustments.
f. Adjust [KW Gain] (Figure 8, Item 1) up by pushing [ + ] soft key (Figure 6, Item 5) by an equal amount on
each generator set until the [Power] load sharing responds more quickly.

Figure 8. Parallel Adjustment Screen, D.

15. Monitor [Total KVAR] (Figure 5, Item 4) approximately every 30 min for variance from average.
a. Push [Adjustments] soft key (Figure 4, Item 3) in main display screen (WP 0005, Operation Under Usual
Conditions).
b. Push [ŻPrevious] and [NextŹ] simultaneously for 2 sec to switch from [Adjustments] screen 1 to
[Adjustments] screen 2 (WP 0005, Operation Under Usual Conditions).
c. Push [Parallel Adj] soft key to reach parallel adjustment display screen (WP 0004, Description and Use of
Operator Controls and Indicators).
d. Record [Total KVAR] (Figure 5, Item 4) on all generators.
e. Compare each generator set [Total KVAR] (Figure 5, Item 4) against average [Total KVAR] (Figure 5,
Item 4).

0006-16
 TM 9-6115-753-10 0006

16. Adjust [KVAR Gain] (Figure 8, Item 3) on generator set(s) when [Total KVAR] (Figure 5, Item 4) indicator(s)
for one or more generator set(s) fluctuates widely around a nominal average.
a. Push [Adjustments] soft key (Figure 4, Item 3) in main display screen (WP 0005, Operation Under Usual
Conditions).
b. Push [ŻPrevious] and [NextŹ] simultaneously for 2 sec to switch from [Adjustments] screen 1 to
[Adjustments] screen 2 (WP 0005, Operation Under Usual Conditions).
c. Push [Parallel Adj] soft key to reach parallel adjustment display screen (WP 0004, Description and Use of
Operator Controls and Indicators).
d. Navigate to [KVAR Gain] (Figure 8, Item 3) by pushing [NextŹ] soft key (Figure 5, Item 3) until [KVAR
Gain] (Figure 8, Item 3) is highlighted.
e. Push [Select] soft key (Figure 5, Item 2) to enable adjustments.
f. Adjust [KVAR Gain] (Figure 8, Item 3) down by pushing [ - ] soft key (Figure 6, Item 6) by an equal
amount on each generator set until the unstable load sharing conditions are resolved.
17. Adjust [KVAR Gain] (Figure 8, Item 3) on generator set(s) when [Total KVAR] (Figure 5, Item 4) averages are
stable but respond slowly when the load on the bus is changed.
a. Push [Adjustments] soft key (Figure 4, Item 3) in main display screen (WP 0005, Operation Under Usual
Conditions).
b. Push [ŻPrevious] and [NextŹ] simultaneously for 2 sec to switch from [Adjustments] screen 1 to
[Adjustments] screen 2 (WP 0005, Operation Under Usual Conditions).
c. Push [Parallel Adj] soft key to reach parallel adjustment display screen (WP 0004, Description and Use of
Operator Controls and Indicators).
d. Navigate to [KVAR Gain] (Figure 8, Item 3) by pushing [NextŹ] soft key (Figure 5, Item 3) until [KVAR
Gain] (Figure 8, Item 3) is highlighted.
e. Push [Select] (Figure 5, Item 2) to enable adjustments.
f. Adjust [KVAR Gain] (Figure 8, Item 3) up by pushing [ + ] soft key (Figure 6, Item 5) by an equal amount
on each generator set until the [Total KVAR] (Figure 5, Item 4) load sharing responds more quickly.

0006-17
 TM 9-6115-753-10 0006

Figure 9. Parallel Adjustment Screen, E.

18. Push [Reset Gains] (Figure 9, Item 1) to set both [KW Gain] (Figure 8, Item 1) and [KVAR Gain] (Figure 8,
Item 3) to zero if unable to achieve balance.
a. Navigate to [Reset Gains] (Figure 9, Item 1) using the [NextŹ] soft key (Figure 9, Item 3).
b. Push [Select] soft key (Figure 9, Item 2) when [Reset] is highlighted. Soft key control label will be
changed to [Accept] soft key (Figure 10, Item 1).
c. Push [Accept] soft key (Figure 8, Item 4).
d. Gain values are now restored to original values.

0006-18
 TM 9-6115-753-10 0006

Figure 10. Parallel Adjustment Screen, F.

19. Push [Exit] soft key (Figure 10, Item 2) to return to main screen.
20. Notify field maintenance if unable to resolve unstable or slow response conditions.

END OF TASK

Soft Removal From Parallel Operation With [Unload] Soft Key

NOTE
Removal with the [unload] soft key (Figure 11, Item 1) is the preferred method of removing
generator sets from parallel operations.
1. Select unit to be removed from parallel operation.

0006-19
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Figure 11. Soft Unload Key.

WARNING
Ensure generator sets are shut down and load board has no voltage prior to making any
connections for parallel operation or moving a generator set that has been operating in parallel.
Operating generator sets always contain the risk of electrocution. Failure to comply may cause
injury or death to personnel.

CAUTION
Ensure generator set(s) remaining on line have sufficient capacity to carry the load required.
Failure to comply will cause damage to equipment.
2. Select and push [Unload] soft key (Figure 11, Item 1).

NOTE
The DCS will automatically ramp down the load and open the output contactor to exit paralleling
when the load has transferred.
3. Monitor main display screen. Mode will change to [Unit] when DCS has exited paralleling mode and
transferred load to remaining generator(s).
4. Shut down generator set (WP 0005, Operation Under Usual Conditions) if required.

END OF TASK

0006-20
 TM 9-6115-753-10 0006

Removal From Parallel Operation With UNIT PARALLEL Switch

NOTE
Removal with the [Unload] soft key (Figure 11, Item 1) is the preferred method of removing
generator sets from parallel operations. Removal with the UNIT PARALLEL switch (Figure 12,
Item 3) is not normally recommended.

Figure 12. DCS Panel, Remove From Parallel.

1. Switch to [UNIT] mode on first unit to be removed from parallel operation by pushing UNIT PARALLEL switch
(Figure 12, Item 3).
2. Push AC CIRCUIT INTERRUPT switch (Figure 12, Item 1) to open contactor.
3. Shut down generator set (WP 0005, Operation Under Usual Conditions).
4. Switch to [UNIT] mode on next unit to be removed from parallel operation by pushing UNIT PARALLEL switch
(Figure 12, Item 3).
5. Push AC CIRCUIT INTERRUPT switch (Figure 12, Item 1) to open contactor.
6. Shut down generator set (WP 0005, Operation Under Usual Conditions).
7. Repeat steps 1 through 3 for all remaining generator sets operating in parallel.
8. Remove paralleling cables from PARALLEL receptacle (Figure 12, Item 2) on all generator sets.
9. Store paralleling cables in generator set storage box located in right-side door.
10. Remove switch box contactor cable (Figure 3, Item 3) from SWITCH BOX CONTROL RECEPTACLE (Figure
3, Item 1) if used.

END OF TASK

END OF WORK PACKAGE

0006-21/22 blank
 TM 9-6115-753-10 0007

OPERATOR MAINTENANCE
AMMPS 60KW GENERATOR SET
OPERATION UNDER UNUSUAL CONDITIONS

INITIAL SETUP:

Test Equipment References

Not Applicable FM 3-4
Tools and Special Tools FM 3-5
Not Applicable FM 31-70
Materials/Parts WP 0005, Operation Under Usual Conditions
Rags, wiping (WP 0021, Expendable and Durable WP 0010, Troubleshooting Procedures
Items List, Item 9)
WP 0014, Service Air Cleaner
Personnel Required
WP 0016, Service Fuel System
Operator (1)
WP 0021, Expendable and Durable Items List
References
Equipment Conditions
FM 3-11.5
Not Applicable
FM 3-3

OPERATION UNDER UNUSUAL CONDITIONS

WARNING

x High voltage is produced when generator set is in operation. Never attempt to start the generator
set unless it is properly grounded. Do not ground yourself in standing water. Never attempt to
connect or disconnect load cables while the generator set is operating. Failure to comply may
cause injury or death to personnel.
x DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Do not ground yourself in standing water.
Failure to comply may cause injury or death to personnel and damage to equipment.

x Do not start generator set until internal components are completely dry. Electrocution is possible.
Failure to comply may cause injury or death to personnel.

x Generator set must be completely shut down prior to washing. Electrocution is possible. Failure to
comply may cause injury or death to personnel.

x Exhaust discharge contains deadly gases, including carbon monoxide. Exhaust gases are most
dangerous in places with poor ventilation. Do not operate generator set in an enclosed area
unless exhaust discharge is properly vented. Failure to comply may cause injury or death to
personnel.

x When operating, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow engine to cool before checks, services, and maintenance. Wear
gloves and additional protective clothing as required. Failure to comply may cause injury or death
to personnel.
0007-1
 TM 9-6115-753-10 0007

UNUSUAL ENVIRONMENT/WEATHER
Operation in Extreme Cold -25°F (-31°C)

NOTE
The generator set operates in ambient temperatures as low as -25°F (-31°C) without special
winterization equipment. To ensure satisfactory operation under extremely cold weather, the
following steps must be taken. For additional general information on cold weather operations,
refer to FM 31-70, Basic Cold Weather Manual.
1. Provide a ventilated shelter for generator set, if possible.
2. Ensure generator set and surrounding area remain as free of ice and snow as possible.

WARNING
In extremely cold weather, skin can stick to metal. Avoid contacting metal items with bare skin in
extremely cold weather. Failure to comply may cause injury or death to personnel.
3. Ensure fuel tank is kept full to protect against moisture, condensation, and accumulation of water.
4. Ensure that proper grade fuel is used (WP 0016, Service Fuel System).
5. Ensure batteries remain free from corrosion and in a well-charged condition.

END OF TASK

Operation in Extreme Heat Above 120°F (49°C)

1. Check vents and radiator air passages frequently for obstructions.

2. Check coolant temperature indicator frequently for indication of overheating.
3. Allow sufficient space for fuel expansion when filling fuel tank.
4. Ensure generator set remains clean and free of dirt.
5. Remove obstructions from generator intake and outlet screens.
6. Remove dirt and debris from external surface of engine when generator set is not operating.

END OF TASK

Operation in Dusty or Sandy Areas

1. Provide a ventilated shelter for generator set, if possible.

2. Use available natural barriers to shield the generator set from blowing dust or sand.

CAUTION
While wetting dusty/sandy areas, protect generator set from water and mud splash. Failure to
comply will cause damage to equipment.
3. Wet dusty and sandy surface areas around generator set frequently if water is available.
4. Prevent entry of dust and sand into housing assembly by keeping all access doors closed as much as
possible.
5. Wipe dust and sand frequently from the generator set external surfaces and components.
6. Wash exterior surfaces frequently with a damp wiping rag when generator set is not operating and is
completely shut down.

0007-2
 TM 9-6115-753-10 0007

7. Service engine air cleaner assembly (WP 0014, Service Air Cleaner) frequently to compensate for intake of
additional dust or sand.
8. Drain sediment frequently from fuel filter/water separator.

CAUTION
When servicing fuel tank, prevent dust or sand from entering. Failure to comply will cause
damage to equipment.
9. Request field maintenance change engine oil and oil filter frequently.
10. Store oil and fuel in dust-free containers.
11. Ensure that generator set ground connections are free of dust and sand, and that connections are tight before
starting the generator set.

END OF TASK

Operation in Rainy or Humid Conditions

1. Provide a ventilated shelter for generator set, if possible.

CAUTION
Failure to remove canvas or waterproof material before operating generator set may result in
damage to equipment. Failure to comply may cause damage to equipment.
2. Cover generator set with canvas or other waterproof material when it is not being operated.
3. Provide adequate drainage to prevent water from accumulating on operation site.
4. Prevent water from entering the housing assembly when operating in rain or high humidity by keeping all
generator set access doors closed.
5. Drain water frequently from fuel filter/water separator.
6. Check wiring connections for corrosion and check wire insulation for signs of deterioration. Contact field
maintenance if any of these conditions exist.

END OF TASK

Operation in Salt Water Areas

1. Provide a ventilated shelter for the generator set, if possible.

2. Locate generator set so that radiator faces into prevailing winds.
3. Use natural barriers or, if possible, construct a barrier to protect generator set from salt water.

CAUTION
Failure to remove canvas or waterproof material before operating generator set may result in
damage to equipment. Failure to comply may cause damage to equipment.
4. Cover generator set with canvas or other waterproof material when it is not being operated.
5. Prevent water from entering the housing assembly when operating in salt-water areas by keeping all
generator set access doors closed.

0007-3
 TM 9-6115-753-10 0007

CAUTION
Protect generator set from water and mud splash while wiping. Failure to comply will cause
damage to equipment.
6. Wash exterior surfaces frequently with a damp wiping rag when generator set is not operating and is
completely shut down.
7. Check wiring connections for corrosion and wire insulation for signs of deterioration daily. Contact field
maintenance if any of these conditions exist.

END OF TASK

Operation in High Altitudes

The generator set will operate at elevations up to 4000 ft (1219.1 m) above sea level without special adjustment
or reduction in load. At elevations greater than 4000 ft (1219.1 m) above sea level, the kilowatt rating is reduced
approximately 3.5% for each additional 1000 ft (304.8 m).

END OF TASK

0007-4
 TM 9-6115-753-10 0007

Operation Using BATTLESHORT Switch

Figure 1. DCS Panel.

1. Engage BATTLESHORT switch (Figure 1, Item 1) only when ordered by higher command.

CAUTION
Continued operation using the BATTLESHORT switch (Figure 1, Item 1) may result in damage to
equipment. Stop using BATTLESHORT immediately when ordered by higher command. Failure
to comply may cause damage to equipment.

NOTE
BATTLESHORT switch (Figure 1, Item 1) must be in OFF position to start generator set.

If any emergency situation requires continued operation of the generator set, the BATTLESHORT
switch (Figure 1, Item 1) is used to override all the safety devices except the short circuit devices,
an overspeed fault, and the emergency stop function.
2. Start generator set if set is not operating (WP 0005, Operation Under Usual Conditions).
3. Lift cover on BATTLESHORT switch (Figure 1, Item 1) and place switch in ON position.
4. Lift cover on BATTLESHORT switch (Figure 1, Item 1) and place switch in OFF position when
BATTLESHORT conditions no longer exist.

END OF TASK

0007-5
 TM 9-6115-753-10 0007

Operation While in Contaminated Areas

The generator set is capable of being operated by personnel wearing Chemical, Biological, Radiological, and
Nuclear (CBRN) protective clothing without special tools or supporting equipment. Refer to FM 3-5, Nuclear
Biological Chemical (NBC) Decontamination for information on decontamination procedures. Specific procedures
for the generator set are the following:
1. Control panel indicators sealing gasket, rubber sleeves, rope draw cords at output load terminal access ports,
control panel door gaskets, access door gaskets, rubber tubing, belts within the engine compartment,
coverings for electrical conduits, external water drain tubing, and retaining cords for slave receptacle covers
will absorb and retain chemical agents. Replacement of these items is the recommended method of
decontamination.
2. Lubricants, fuel, coolant, or battery fluids may be present on the external surfaces of the generator set or
components due to leaks or normal operation. These fluids will absorb CBRN agents. The preferred method
of decontamination is removal of these fluids using conventional decontamination methods IAW FM 3-5, NBC
Decontamination.
3. Indicators should be decontaminated with warm, soapy water. Continued decontamination of external
generator set surfaces with Super-Topical Bleach (STB)/Decontamination Solution number 2 (DS2) will
degrade clear plastic indicator coverings to a point where reading indicators will become impossible. This
problem will become more evident for soldiers wearing protective masks; therefore, the use of STB or DS2
decontamination in these areas should be minimized.
4. The recommended method of decontamination for external surfaces of the control panel is with warm, soapy
water. External surfaces of the DCS panel assembly that are marked with painted or stamped lettering will not
withstand repeated decontamination with STB or DS2 without degradation of the lettering.
5. Replacement of the following items, if available, is the preferred method of decontamination. The areas will
entrap contaminants, making efficient decontamination extremely difficult. Conventional methods of
decontamination, if used, must stress the importance of thoroughness and the probability of some degree of
continuing contact and vapor hazard.
a. Exposed heads of screws.
b. Areas adjacent to and behind exposed wiring conduits.
c. Hinged areas or access doors.
d. Retaining chains for external receptacle covers.
e. Areas around the tie-down/lifting rings, crevices around access doors, external screens covering
ventilation areas, the external oil drain valve, and areas adjacent to the external fuel drain valve.
f. Areas behind knobs and switches on the control panel, externally mounted equipment specification data
plates, external receptacle covers, access doors, access door locking mechanisms, recessed wells for
access door handles, fuel cap, load terminal board, slave receptacles, and frequency adjustment controls.
6. The generator set should be operated with all access doors closed to reduce the effects of contamination if in
a CBRN-contaminated environment.
7. The use of overhead shelters or chemical protective covers is recommended as an additional means of
protection against contamination IAW FM 3-5, NBC Decontamination. If using covers, care should be taken to
provide adequate space for air flow and exhaust.
8. Additional CBRN information can be found at FM 3-3, Chemical and Biological Contamination Avoidance;
and, FM 3-4, NBC Protection. Other services use applicable publications for CBRN In addition to FM 3-11.5,
Multiservice Tactics, Techniques, and Procedures for Chemical, Biological, Radiological, and Nuclear
Decontamination.

END OF TASK

0007-6
 TM 9-6115-753-10 0007

Use of the Ground Fault Circuit Interrupter (GFCI) Convenience Receptacle

Figure 2. GFCI Convenience Receptacle.

NOTE
Ground Fault Circuit Interrupter (GFCI) convenience receptacle reset is located between the
receptacles on the 50/60 Hz generator set. The Ground Fault Interrupter (GFI) reset for the 400
Hz generator set is located on the right side interior panel inside of the rear door. The contactor
must be closed to reset the GFCI convenience receptacle or the GFI.

The 15 Amp circuit breaker reset is located above the receptacles in both the 50/60 and 400 Hz
generator sets.
1. Locate the GFCI convenience receptacle (Figure 2) on the rear panel of the generator set.

0007-7
 TM 9-6115-753-10 0007

WARNING

x Power is available to the convenience receptacle only when the main contactor is closed. Avoid
accidental contact. Electrocution is possible. Failure to comply may cause injury or death to
personnel.

x Ensure the frequency of any device powered by the GFCI convenience receptacle matches the
frequency of the generator set. Failure to comply may cause injury or death to personnel.

CAUTION
The 400 Hz generator set GFCI convenience receptacle may only be used on resistive load
devices drawing less than 15 Amps. Do not use the 400 Hz convenience receptacle for power
tools, computers, or computer-like devices. The 50/60 Hz generator set GFCI convenience
receptacle may be used for any device drawing less than 15 Amps. Failure to comply will cause
damage to equipment.

The maximum power rating for the GFCI convenience receptacle is 15 Amps. Avoid continuous
operation above 15 Amps. Failure to comply may cause damage to equipment.
2. Start the generator set if it is not operating (WP 0005, Operation Under Usual Conditions).
3. Ensure load does not exceed the maximum rating.
4. Reset the GFCI/GFI.
5. Plug appropriate connector into convenience receptacle.

END OF TASK

END OF WORK PACKAGE

0007-8
 XXXXXXXXXXXXXXXX TM 9-6115-753-10 0008

X OPERATOR INSTRUCTIONS

X AMMPS 60KW GENERATOR SET

EMERGENCY

X
INITIAL SETUP:

Test Equipment References

Not Applicable WP 0005, Operation Under Usual Conditions

Not Applicable
Materials/Parts
X
Tools and Special Tools WP 0010, Troubleshooting Procedures
Equipment Conditions
Not Applicable

X
Not Applicable
Personnel Required
Operator (1)

X
NATO SLAVE RECEPTACLE START OPERATION

WARNING

X
High voltage is produced when the generator set is in operation. Never attempt to start the
generator set unless it is properly grounded. Do not ground yourself in standing water. Never
attempt to connect or disconnect load cables while the generator set is operating. Failure to
comply can cause injury or death to personnel.

X
1. Ensure equipment conditions are met in order presented in initial setup.
2. Locate NATO slave receptacle (Figure 1, Item 2) on front-side of generator set.

X
WARNING
NATO slave receptacle is electrically live at all times and is not protected by a fuse.
Disconnecting main DC circuit breaker does not ensure the circuit is dead. This circuit is only
dead when the batteries are fully disconnected. Disconnect both batteries before performing

X
maintenance on the slave receptacle. Failure to comply may cause injury or death to personnel.
3. Ensure 24-VDC power source system is fully charged.

X
X 0008-1

XXXXXXXXXXXXXXXX
X XXXXXXXXXXXXXXX TM 9-6115-753-10 0008

X
X
X
X
X
X
X Figure 1. NATO Slave Receptacle.

4. Remove protective cover (Figure 1, Item 1) from NATO slave receptacle (Figure 1, Item 2).

X
5. Connect one end of NATO slave cable to fully-charged 24-VDC system, and other end to discharged
generator set NATO slave receptacle (Figure 1, Item 2).

NOTE

X The NATO slave receptacle (Figure 1, Item 2) can be used to start generator set when batteries
are discharged.
6. Start fully-charged 24-VDC system.

X
7. Start generator set (WP 0005, Operation Under Usual Conditions).
8. Remove NATO slave cable after generator set starts.

END OF TASK

X
X 0008-2

X XXXXXXXXXXXXXXX
 XXXXXXXXXXXXXXXX TM 9-6115-753-10 0008

X
EMERGENCY STOPPING

X
X
X
X
X
X Figure 2. DCS Panel.

1. Push EMERGENCY STOP (Figure 2, Item 1) if operating parameters exceed those permitted in
Table 3; WP 0005, Operation Under Usual Conditions.

X
2. Resolve problem using troubleshooting procedures (WP 0010, Troubleshooting Procedures).
3. Push FAULT RESET (Figure 2, Item 2) switch to clear fault from DCS.

X
NOTE
To restart the generator set, the following steps must be completed.
4. Pull out EMERGENCY STOP switch (Figure 2, Item 1).

X
5. Turn engine control switch (Figure 2, Item 3) to OFF.
6. Restart generator set (WP 0005, Operation Under Usual Conditions).

END OF TASK

X
X 0008-3

XXXXXXXXXXXXXXXX
X XXXXXXXXXXXXXXX TM 9-6115-753-10 0008

XOPERATION USING BATTLESHORT SWITCH

X
1. Engage BATTLESHORT switch (Figure 2, Item 4) only when ordered by higher command.

CAUTION

X
Continued operation using the BATTLESHORT switch (Figure 2, Item 4) may result in damage to
equipment. Stop using BATTLESHORT switch (Figure 2, Item 4) immediately when ordered by
higher command. Failure to comply may cause damage to equipment.

NOTE

X BATTLESHORT switch (Figure 2, Item 4) must be in OFF position to start generator set.

If any emergency situation requires continued operation of the generator set, the BATTLESHORT

X
switch (Figure 2, Item 4) is used to override all the safety devices except the short circuit devices
and the emergency stop function.
2. Start generator set if set not operating (WP 0005, Operation Under Usual Conditions).
3. Lift cover on BATTLESHORT switch (Figure 2, Item 4) and place switch in ON position.

X
4. Lift cover on BATTLESHORT switch (Figure 2, Item 4) and place switch in OFF position when
BATTLESHORT conditions no longer exist.

END OF TASK

XEND OF WORK PACKAGE

X
X
X
X
X 0008-4

X XXXXXXXXXXXXXXX
 TM 9-6115-753-10

CHAPTER 3

TROUBLESHOOTING PROCEDURES
FOR
AMMPS 60KW GENERATOR SET
 TM 9-6115-753-10

CHAPTER 3

TROUBLESHOOTING PROCEDURES

WORK PACKAGE INDEX

Title WP Sequence No.
TROUBLESHOOTING INDEX ............................................................................................................................. 0009
TROUBLESHOOTING PROCEDURES .............................................................................................................. 0010
DCS FAULT AND WARNING CODES AND DESCRIPTIONS ........................................................................... 0011
 TM 9-6115-753-10 0009

OPERATOR MAINTENANCE
AMMPS 60KW GENERATOR SET
TROUBLESHOOTING INDEX

GENERAL TROUBLESHOOTING INFORMATION

Operator troubleshooting procedures are designed to isolate and correct AMMPS faults and warnings so that
electrical power is provided to end-users with the least possible service interruption. Troubleshooting techniques
apply to all AMMPS components as indicated.
Troubleshooting procedures list the symptoms, malfunctions, and corrective actions required to correct system
faults and warnings. Perform all steps in the order they appear in the WP. Troubleshooting procedures are listed
according to symptom, followed by the malfunction, then any corrective action(s). All necessary references to
procedures/instructions can be found within the Troubleshooting WP (WP 0010, Troubleshooting Procedures).
The DCS constantly monitors the engine sensors for abnormal conditions, such as low oil pressure and high
coolant temperature. If any of these conditions occur, the DCS panel will display a message indicating a fault or
warning code. The system will shut down if a fault is indicated. If a warning is indicated but not addressed, it will
frequently become a fault. If a malfunction or failure occurs during operation or performance check, perform
troubleshooting IAW the Malfunction/Symptom Index and any displayed fault or warning codes (WP 0011, DCS
Fault and Warning Codes and Descriptions).
Do not begin a task until you understand the task.

MALFUNCTION/SYMPTOM INDEX

The malfunction/symptom index is a quick reference for locating troubleshooting procedures. Troubleshooting
procedures are arranged based upon the location of the malfunction (i.e., engine, alternator, or controls) and the
presence of a DCS code.

DCS Fault and Warning Codes

Refer to WP 0011, DCS Fault and Warning Codes and Descriptions for a list of all DCS fault codes.

Indications from Manual Troubleshooting Techniques

Field maintenance is responsible for performing manual troubleshooting techniques, including continuity tests and
voltage checks, maintenance actions that require the use of tools, and DCS function activities other than routine
operator adjustments.

After Corrective Action

After the corrective action is completed, the equipment must be tested to verify that a fault or warning has been
corrected. Locate the malfunction in the troubleshooting procedures and perform the test or inspection. If the
correct response is not obtained, continue to troubleshoot all suspected malfunctions and perform corresponding
corrective actions until the equipment is operational or is replaced with operational equipment.

Specific Troubleshooting Procedures

This TM cannot list all malfunctions that may occur or all tests or inspections and corrective actions. If a
malfunction is not listed or is not corrected by the listed corrective action, notify field maintenance.

0009-1
 TM 9-6115-753-10 0009

Malfunction/Symptom Troubleshooting Procedure WP and Page

1. DCS indicates no power available and no lighted display.........................................................WP 0010, Page 1

a. Battery cables loose, damaged, corroded, or disconnected...............................................WP 0010, Page 1
b. Main DC circuit breaker in OFF/TRIP position....................................................................WP 0010, Page 2
2. Engine fails to crank ..................................................................................................................WP 0010, Page 2
a. Discharged battery ..............................................................................................................WP 0010, Page 2
3. Engine fails to crank or cranks slowly [Fault 1438: Fail To Crank]............................................WP 0010, Page 2
a. Faulty control, speed sensing, or starting systems(s).........................................................WP 0010, Page 2
4. Engine fails to crank [Fault 1434: Remote E-Stop] ...................................................................WP 0010, Page 3
a. Remote EMERGENCY STOP is ON ..................................................................................WP 0010, Page 3
5. Engine fails to crank [Fault 1433: Local E-Stop] .......................................................................WP 0010, Page 3
a. Local EMERGENCY STOP switch pushed in.....................................................................WP 0010, Page 3
6. Engine fails to crank [Warning 1131: Battleshort Active]...........................................................WP 0010, Page 4
a. BATTLESHORT switch ON [Warning 1131: Battleshort Active].........................................WP 0010, Page 4
b. Engine fails to start [Fault 359: Fail to Start] .......................................................................WP 0010, Page 4
7. Engine fails to start [Warning 3663: Winterization Kit Failure to Heat]......................................WP 0010, Page 4
a. Winterization kit/air intake heaters failed to activate [Fault 3663: Winterization
Kit Failure to Heat] ..............................................................................................................WP 0010, Page 4
b. Winterization kit/air intake heaters activated.......................................................................WP 0010, Page 5
8. Engine starts but stops ..............................................................................................................WP 0010, Page 5
a. Fuel tank level is low [Fault 1918: Fuel Level Low] ............................................................WP 0010, Page 5
b. Fuel filter/water separator clogged......................................................................................WP 0010, Page 6
c. Air filter clogged. .................................................................................................................WP 0010, Page 6
d. Fault condition not corrected...............................................................................................WP 0010, Page 6
9. Engine stops suddenly ..............................................................................................................WP 0010, Page 7
a. DCS operator screen displays [Fault 1245: Engine Shutdown]
or [Fault 2661: Engine Shutdown].......................................................................................WP 0010, Page 7
b. DCS operator screen displays [Fault 1445: Short Circuit] ..................................................WP 0010, Page 7
c. DCS operator screen displays [Fault 1472: High Current Shutdown] ................................WP 0010, Page 8
d. DCS operator screen displays [Fault 415: Low Oil Pressure].............................................WP 0010, Page 8
e. DCS operator screen displays [Fault 151: High Coolant Temperature] .............................WP 0010, Page 9
f. Voltage selection board connections were moved or loosened during
generator set operation [Fault 3668: Output Voltage Configuration Bit 0 Changed]
or [Fault 3669: Output Voltage Configuration Bit 1 Changed] ........................................... WP 0010, Page 9
g. DCS operator screen displays [Fault 1448: Underfrequency] ............................................WP 0010, Page 9
h. DCS operator screen displays [Fault 234: Overspeed Shutdown] ...................................WP 0010, Page 10
i. DCS operator screen displays [Fault 1459: Reverse Power] ...........................................WP 0010, Page 10
j. DCS operator screen displays [Fault 1446: High AC Voltage] .........................................WP 0010, Page 10

0009-2
 TM 9-6115-753-10 0009

Malfunction/Symptom Troubleshooting Procedure WP and Page

k. DCS operator screen displays [Fault 1447: Low AC Voltage] ..........................................WP 0010, Page 11
10. AC voltage fluctuation..............................................................................................................WP 0010, Page 11
a. Erratic change in voltage shown on GENSET VOLTAGE indicator .................................WP 0010, Page 11
11. AC frequency fluctuation .........................................................................................................WP 0010, Page 11
a. Erratic change in frequency shown on DCS [FREQ] indicator .........................................WP 0010, Page 11
12. DCS operator screen displays [Warning 143: Pre-Low Oil Pressure].....................................WP 0010, Page 12
a. Engine oil level below normal ...........................................................................................WP 0010, Page 12
b. Improper grade of oil for conditions ..................................................................................WP 0010, Page 12
13. DCS operator screen displays [Warning 146: Pre-High Coolant Temperature]......................WP 0010, Page 12
a. Coolant temperature lower than [Fault] condition but higher than normal........................WP 0010, Page 12
b. Obstructed ventilation and air flow paths ..........................................................................WP 0010, Page 13
14. DCS operator screen displays [Warning 1441: Low Fuel Level].............................................WP 0010, Page 14
a. Fuel level higher than FAULT condition level but lower than normal ...............................WP 0010, Page 14
b. Faulty fuel level sensor .....................................................................................................WP 0010, Page 14
15. DCS operator screen displays [Warning 2936: Fuel Level Sensor High]
or [Warning 2937: Fuel Level Sensor Low].......................................................................WP 0010, Page 14
a. Faulty fuel sensor..............................................................................................................WP 0010, Page 14
16. DCS operator screen displays [Warning 441: Low Battery Voltage], [Warning 1442:
Weak Battery], [Warning 3662: Battery Discharge], or [Warning 3663: Winterization
Kit Failure to Heat] ...................................................................................................................WP 0010, Page 14
a. Battery cables loose, damaged, corroded, or disconnected.............................................WP 0010, Page 15
b. Faulty battery-charging alternator .....................................................................................WP 0010, Page 15
17. DCS operator screen displays [Warning 1444: KW Overload]................................................WP 0010, Page 15
a. Load placed on generator is more than the capacity of the generator .............................WP 0010, Page 15
18. DCS operator screen displays [Warning 1471: Overcurrent] ..................................................WP 0010, Page 15
a. Current above normal but not sufficient to create a FAULT condition..............................WP 0010, Page 15
19. DCS operator screen displays [Warning 1416: Fail To Shutdown] .........................................WP 0010, Page 16
a. Engine failed to shutdown after engine control switch was turned to
OFF position......................................................................................................................WP 0010, Page 16
20. DCS operator screen displays [Warning 1449: Overfrequency] .............................................WP 0010, Page 16
a. Generator set was subjected to a single step large block load removal
that was within the parameters of speed control but sufficient to create
a [Warning 1449: Overfrequency] condition......................................................................WP 0010, Page 16
21. DCS operator screen displays [Warning 3678: Genset Frequency Changed]........................WP 0010, Page 17
a. Frequency changed from parameters selected upon generator startup or
normal operation ...............................................................................................................WP 0010, Page 17

0009-3
 TM 9-6115-753-10 0009

Malfunction/Symptom Troubleshooting Procedure WP and Page

22. DCS operator screen displays [Warning 1417: Power Down Failure].....................................WP 0010, Page 17
a. Processor fault [Warning 1417: Power Down Failure] message appears
for longer than 10 min .......................................................................................................WP 0010, Page 17
23. DCS operator screen displays [Warning 1457: Fail To Synchronize] .....................................WP 0010, Page 17
a. Generator set paralleling parameters improperly selected or greater than
allowed by synchronizing detectors ..................................................................................WP 0010, Page 17
24. DCS operator screen displays [Warning 3658: Switch Box Fail To Close] .............................WP 0010, Page 18
a. Paralleling operations are being conducted without a switch box ....................................WP 0010, Page 18
b. Generator set paralleling parameters improperly selected or greater than
allowed by synchronizing detectors ..................................................................................WP 0010, Page 18
25. Engine exhaust smoking .........................................................................................................WP 0010, Page 19
a. Engine emits white exhaust smoke...................................................................................WP 0010, Page 19
b. Engine emits black exhaust smoke...................................................................................WP 0010, Page 19
c. Engine emits blue exhaust smoke due to oil in combustion chambers ............................WP 0010, Page 20
26. Engine starts but develops lower than rated speed ................................................................WP 0010, Page 20
a. Engine speed is low but not enough to create a fault or warning condition......................WP 0010, Page 20
27. Engine starts at speed but less than rated voltage .................................................................WP 0010, Page 20
a. Automatic voltage regulator system or component(s) subjected to fault condition...........WP 0010, Page 20
28. Power not available at GFCI convenience receptacle.............................................................WP 0010, Page 20
a. GFCI convenience receptacle has been subjected to a ground fault
condition ............................................................................................................................WP 0010, Page 21

END OF WORK PACKAGE

0009-4
 TM 9-6115-753-10 0010

OPERATOR MAINTENANCE
AMMPS 60KW GENERATOR SET
TROUBLESHOOTING PROCEDURES

INITIAL SETUP:

Test Equipment References

Not Applicable WP 0013, PMCS
Tools and Special Tools WP 0014, Service Air Cleaner
Not Applicable WP 0015, Service Cooling System
Materials/Parts WP 0016, Service Fuel System
Not Applicable WP 0017, Service Engine Oil
Personnel Required Equipment Conditions
Operator (1) Engine control switch set to PRIME & RUN AUX
FUEL or PRIME & RUN (WP 0005, Operation
References
Under Usual Conditions)
WP 0011, DCS Fault & Warning Codes and
Descriptions

TROUBLESHOOTING PROCEDURE

NOTE
Always perform PMCS prior to beginning any troubleshooting procedure (WP 0013, PMCS).
Follow all procedures for starting the generator set (WP 0005, Operation Under Usual
Conditions).

Read the entire corrective action sequence before beginning steps to complete corrective action
for a malfunction.

SYMPTOM

DCS indicates no power available and no lighted display.

MALFUNCTION

Battery cables loose, damaged, corroded, or disconnected.

CORRECTIVE ACTION

STEP 1. Push PANEL LIGHTS switch.

STEP 2. Inspect battery cables and connections if symptom continues.
STEP 3. Notify field maintenance if battery cables and/or connections are loose,
damaged, corroded, or disconnected.
STEP 4. If cables and connectors are serviceable and symptom continues, proceed to
next malfunction.

0010-1
 TM 9-6115-753-10 0010

MALFUNCTION

Main DC circuit breaker in OFF/TRIP position.

CORRECTIVE ACTION

STEP 1. Examine circuit breaker to determine if in OFF/TRIP position (WP 0005,

Operation Under Usual Conditions).
STEP 2. If circuit breaker is in OFF/TRIP position, move switch handle to ON position to
RESET circuit breaker.
STEP 3. If circuit breaker returns to OFF/TRIP position after only a single attempt to
move to ON, notify field maintenance.
STEP 4. Push PANEL LIGHTS switch to determine if power has been restored.
STEP 5. Notify field maintenance if DCS still indicates no power available (no lighted
display).
STEP 6. If DCS indicates that power is available (lighted display), turn engine control
switch to START position.
STEP 7. If engine fails to crank, proceed to next symptom.

SYMPTOM

Engine fails to crank.

MALFUNCTION

Discharged battery.

CORRECTIVE ACTION

STEP 1. Examine [Battery] [Vdc] parameter on DCS display.

STEP 2. Notify field maintenance if battery is discharged (indicator is in the red area of DCS
display).
STEP 3. If battery indicates charged (indicator is in the green area of DCS display), push FAULT
RESET switch to clear fault on DCS.
STEP 4. Turn engine control switch to START position.
STEP 5. Attempt to start generator set using NATO slave receptacle (WP 0008, Emergency).
STEP 6. Notify field maintenance if battery indicator remains in the red area on DCS display.

SYMPTOM

Engine fails to crank or cranks slowly [Fault 1438: Fail To Crank].

MALFUNCTION

Faulty control, speed sensing, or starting system(s).

CORRECTIVE ACTION

Notify field maintenance.

0010-2
 TM 9-6115-753-10 0010

NOTE
Symptom applies only if generator set is configured for remote operation. If generator set is not
configured for remote operation, proceed to next symptom.

SYMPTOM

Engine fails to crank [Fault 1434: Remote E-Stop].

MALFUNCTION

Remote EMERGENCY STOP is ON.

CORRECTIVE ACTION

STEP 1. Determine cause if EMERGENCY STOP command was enabled intentionally.

STEP 2. Restore from cause, if possible (WP 0011, DCS Fault and Warning Codes and
Descriptions).
STEP 3. Notify field maintenance if unable to restore from cause.
STEP 4. Disable remote EMERGENCY STOP.
STEP 5. Place PC cursor over EMERGENCY STOP command symbol and click mouse or press
ENTER on keyboard.
STEP 6. If EMERGENCY STOP command was not enabled intentionally, complete the
preceding STEP 4 and STEP 5, and then proceed to STEP 7.
STEP 7. Push FAULT RESET switch at DCS panel to clear [Fault 1433: Remote E-Stop].
STEP 8. Turn engine control switch to START.
STEP 9. If engine fails to crank, proceed to next symptom.

SYMPTOM

Engine fails to crank [Fault 1433: Local E-Stop].

MALFUNCTION

Local EMERGENCY STOP switch pushed in.

CORRECTIVE ACTION

STEP 1. Determine cause if EMERGENCY STOP switch was pushed intentionally.

STEP 2. Restore from cause if possible (WP 0011, DCS Fault and Warning Codes and
Descriptions).
STEP 3. Notify field maintenance if unable to restore from cause.
STEP 4. If EMERGENCY STOP switch was not pushed intentionally, pull EMERGENCY STOP
switch knob out to extended position.
STEP 5. Push FAULT RESET switch at DCS panel to clear [Fault 1433: Local E-Stop].
STEP 6. Turn engine control switch to START.
STEP 7. If engine fails to crank, proceed to next symptom.

0010-3
 TM 9-6115-753-10 0010

SYMPTOM

Engine fails to crank [Warning 1131: Battleshort Active].

MALFUNCTION

BATTLESHORT switch ON [Warning 1131: Battleshort Active].

CORRECTIVE ACTION

STEP 1. Examine BATTLESHORT switch to determine if in ON position.

STEP 2. If BATTLESHORT switch is ON, move switch handle to OFF position.
STEP 3. Push FAULT RESET switch at DCS panel to clear [Warning 1131: Battleshort Active].
STEP 4. Turn engine control switch to START.
STEP 5. If engine fails to crank, notify field maintenance.

MALFUNCTION

Engine fails to start [Fault 359: Fail to Start].

CORRECTIVE ACTION

STEP 1. Perform WP 0016, Service Fuel System.

STEP 2. Push FAULT RESET switch at DCS panel to clear [Fault 359: Fail to Start].
STEP 3. Turn engine control switch to START.
STEP 4. Perform WP 0014, Service Air Cleaner if [Fault 359: Fail to Start] reappears on DCS.
STEP 5. Push FAULT RESET switch at DCS panel to clear [Fault 359: Fail to Start].
STEP 6. Turn engine control switch to START.
STEP 7. Notify field maintenance if [Fault 359: Fail to Start] reappears on DCS display.

SYMPTOM

Engine fails to start [Warning 3663: Winterization Kit Failure to Heat].

MALFUNCTION

Winterization kit/air intake heaters failed to activate [Fault 3663: Winterization Kit Failure to Heat].

NOTE
Air intake heaters report on DCS as [Glw Plg].

CORRECTIVE ACTION

STEP 1. Examine cold weather starting aid status on DCS display.

STEP 2. Turn engine control switch to PRIME & RUN or PRIME & RUN AUX FUEL position if
fuel is being supplied from an auxiliary source.
STEP 3. Observe coolant temperature indicator on DCS display.

0010-4
 TM 9-6115-753-10 0010

STEP 4. When coolant and ambient air temperature are below +20°F (-6°C), [Not Ready To
Crank] message will appear on DCS display.
STEP 5. Wait until [Ready To Crank] message appears after the allotted time has passed, as
indicated on the DCS display.
STEP 6. Turn engine control switch to START position.
STEP 7. If engine fails to start, notify field maintenance.

MALFUNCTION

Winterization kit/air intake heaters activated.

NOTE
Air intake heaters report on DCS as [Glw Plg].

CORRECTIVE ACTION

STEP 1. Examine cold weather starting aid status on DCS display.

STEP 2. Turn engine control switch to PRIME & RUN or PRIME & RUN AUX FUEL position if
fuel is being supplied from an auxiliary source.
STEP 3. Observe coolant temperature indicator on DCS display.
STEP 4. If coolant and ambient temperature are above +20°F (-6°C) and cold start aids are
activated, move main DC circuit breaker to OFF/TRIP position.
STEP 5. Notify field maintenance.

SYMPTOM

Engine starts but stops.

MALFUNCTION

Fuel tank level is low [Fault 1918: Fuel Level Low].

CORRECTIVE ACTION

STEP 1. Examine fuel level indication on DCS display.

STEP 2. If fault status line indicates [Fault 1918: Fuel Level Low] or if fuel indicator is in the
yellow or red area, refill fuel tank (WP 0016, Service Fuel System).
STEP 3. Examine fuel level visually if no level indication appears on DCS display (WP 0016,
Service Fuel System).
STEP 4. If fuel is not visible, refill fuel tank (WP 0016, Service Fuel System).
STEP 5. Examine DCS fault status line for additional fault(s) that is (are) displayed.
STEP 6. Restore from fault(s) if possible (WP 0011, DCS Fault and Warning Codes and
Descriptions).
STEP 7. Notify field maintenance if unable to clear fault.

0010-5
 TM 9-6115-753-10 0010

NOTE
FAULT RESET switch must be pushed to clear each fault code as it is displayed on the DCS
display when more than one FAULT code has been presented.
STEP 8. Turn engine control switch to START position.
STEP 9. If engine starts but stops after START switch has been released, proceed to
next malfunction.

MALFUNCTION

Fuel filter/water separator clogged.

CORRECTIVE ACTION

STEP 1. Service fuel filter/water separator (WP 0016, Service Fuel System).
STEP 2. Turn engine control switch to START position.
STEP 3. If engine starts but stops after START switch has been released, proceed to next
malfunction.

MALFUNCTION

Air filter clogged.

CORRECTIVE ACTION

STEP 1. Service air cleaner element (WP 0014, Service Air Cleaner).
STEP 2. Turn engine control switch to START position.
STEP 3. If engine starts but stops after START switch has been released, proceed to next
malfunction.

NOTE
When generator set was subjected to a fault condition, the FAULT RESET switch was pushed
without the condition being corrected, the generator set was then shut down and would not start
until fault condition was corrected.

FAULT RESET switch must be pushed to clear each fault code as it is displayed on the DCS
when more than one FAULT code has been presented.

MALFUNCTION

Fault condition not corrected.

CORRECTIVE ACTION

STEP 1. Examine fault code that appears on DCS display.

STEP 2. Restore from FAULT if possible (WP 0011, DCS Fault and Warning Codes and
Descriptions), or notify field maintenance if unable to clear fault.
STEP 3. Turn engine control switch to START position.
STEP 4. If engine starts but stops after START switch has been released, notify field
maintenance.
0010-6
 TM 9-6115-753-10 0010

SYMPTOM

Engine stops suddenly.

MALFUNCTION

DCS operator screen displays [Fault 1245: Engine Shutdown] or [Fault 2661: Engine Shutdown].

NOTE
FAULT RESET switch must be pushed to clear each fault code as it is displayed on the DCS
when more than one fault code has been presented.

CORRECTIVE ACTION

STEP 1. Push FAULT RESET switch at DCS panel to clear [Fault 1245: Engine Shutdown].
STEP 2. Examine DCS fault status line for additional fault(s) that is (are) displayed.
STEP 3. Restore from faults if possible (WP 0011, DCS Faults & Warning Codes Descriptions)
or notify field maintenance if unable to clear fault.
STEP 4. Turn engine control switch to START position.
STEP 5. If [Fault 1245: Engine Shutdown] or [Fault 2661: Engine Shutdown] reappears, notify
field maintenance.

MALFUNCTION

DCS operator screen displays [Fault 1445: Short Circuit].

CORRECTIVE ACTION

WARNING
Shut down generator sets before performing inspection of load cables. Failure to comply may
cause injury or death to personnel by electrocution.
STEP 1. Examine external cables and components visually for signs of damage due to
excessive heat.
STEP 2. When the generator set has stopped, open output terminal board access door
to visually examine load connections for signs of damage due to excessive heat
and/or the odor of burned insulation.
STEP 3. Notify field maintenance if there is any sign of damage due to excessive heat.
STEP 4. Push FAULT RESET switch to clear fault on DCS.

CAUTION
Do not attempt to start generator set if there is indication of heat damage. Only restart generator
set on order of higher command or when field maintenance has examined and corrected damage.
Failure to comply will cause damage to equipment.
STEP 5. Turn engine control switch to START position.
STEP 6. If [FAULT 1445: Short Circuit] reappears, notify field maintenance.

0010-7
 TM 9-6115-753-10 0010

MALFUNCTION

DCS operator screen displays [Fault 1472: High Current Shutdown].

CORRECTIVE ACTION

WARNING
Shut down generator sets before performing inspection of load cables. Failure to comply may
cause injury or death to personnel by electrocution.
STEP 1. Visually examine external cables and components for signs of damage due to
excessive heat.
STEP 2. When the generator set has stopped, open output terminal board access door
to visually examine load connections for signs of damage due to excessive heat
and/or the odor of burned insulation.
STEP 3. Notify field maintenance if there is any sign of damage due to excessive heat.
STEP 4. Push FAULT RESET switch to clear fault on DCS.

CAUTION
Do not attempt to start generator set if there is indication of heat damage. Only restart generator
set on order of higher command or when field maintenance has examined and corrected damage.
Failure to comply will cause damage to equipment.
STEP 5. Turn engine control switch to START position.
STEP 6. If generator set is not operating within [Genset Current] parameters, notify field
maintenance.

WARNING
When operating, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow engine to cool before checks, services, and maintenance. Wear
gloves and additional protective clothing as required. Failure to comply may cause injury or death
to personnel.

MALFUNCTION

DCS operator screen displays [Fault 415: Low Oil Pressure].

CORRECTIVE ACTION

STEP 1. Inspect engine oil level (WP 0017, Service Engine Oil).
STEP 2. Add engine oil if necessary (WP 0017, Service Engine Oil).
STEP 3. Push FAULT RESET switch to clear fault on DCS.
STEP 4. Examine [FAULT] status line for additional fault(s) that are displayed.
STEP 5. Restore from fault(s) if possible (WP 0011, DCS Fault and Warning Codes and
Descriptions) or notify field maintenance if unable to clear fault.
STEP 6. Turn engine control switch to START position.
STEP 7. If engine starts but stops after engine control switch has been released, notify field
maintenance.

0010-8
 TM 9-6115-753-10 0010

MALFUNCTION

DCS operator screen displays [Fault 151: High Coolant Temperature].

CORRECTIVE ACTION

WARNING
Cooling system operates at high temperature and pressure. Contact with high-pressure steam
and/or liquids can cause burns and scalding. Shut down generator set and allow system to cool
before performing checks, services, and maintenance. Wear gloves, additional protective
clothing, and goggles as required. Contact with high-pressure steam and/or liquids can cause
burns and scalding. Failure to comply may cause injury or death to personnel.
STEP 1. Visually examine coolant level (WP 0015, Service Cooling System).
STEP 2. Add coolant as required (WP 0015, Service Cooling System).
STEP 3. Push FAULT RESET switch to clear fault on DCS.
STEP 4. Examine coolant temperature on DCS display.
STEP 5. If coolant temperature is in the green area of DCS display, turn engine control
switch to START position.
STEP 6. Proceed to STEP 7 if engine starts, but high coolant temperature [Fault 151:
High Coolant Temperature] reappears.
STEP 7. Inspect ventilation and air flow paths.
STEP 8. Clear ventilation and air flow paths of obstruction(s).
STEP 9. Push FAULT RESET switch to clear fault on DCS display.
STEP 10. Examine coolant temperature on DCS display.
STEP 11. If coolant temperature is in the green area of the DCS display, turn engine
control switch to START position.
STEP 12. If high coolant temperature [Fault 151: High Coolant Temperature] reappears,
notify field maintenance.

MALFUNCTION

Voltage selection board connections were moved or loosened during generator set operation
[Fault 3668: Output Voltage Configuration Bit 0 Changed] or [Fault 3669: Output Voltage
Configuration Bit 1 Changed].

CORRECTIVE ACTION

STEP 1. Examine the position of the voltage selection board to determine that it is
selected for the ordered voltage configuration.
STEP 2. Push FAULT RESET switch to clear fault on DCS display.
STEP 3. Turn engine control switch to START position.
STEP 4. If [Fault 3668: Output Voltage Configuration Bit 0 Changed] or [Fault 3669:
Output Configuration Bit Changed] reappears, notify field maintenance.

MALFUNCTION

DCS operator screen displays [Fault 1448: Underfrequency].

0010-9
 TM 9-6115-753-10 0010

CORRECTIVE ACTION

STEP 1. Push FAULT RESET switch to clear fault on DCS display.

STEP 2. Turn engine control switch to START.
STEP 3. Observe [FREQUENCY] level on DCS display.
STEP 4. If [Fault 1448: Underfrequency] reappears, service fuel filter/water separator
(WP 0016, Service Fuel System).
STEP 5. Push FAULT RESET switch to clear fault on DCS display.
STEP 6. Turn engine control switch to START position.
STEP 7. Observe [FREQUENCY] level on DCS display.
STEP 8. If [Fault 1448: Underfrequency] reappears, notify field maintenance.

MALFUNCTION

DCS operator screen displays [Fault 234: Overspeed Shutdown].

CORRECTIVE ACTION

STEP 1. Push FAULT RESET switch to clear fault on DCS display.

STEP 2. Turn engine control switch to START position.
STEP 3. If [Fault 234: Overspeed Shutdown] reappears, notify field maintenance.

MALFUNCTION

DCS operator screen displays [Fault 1459: Reverse Power].

CORRECTIVE ACTION

STEP 1. Push FAULT RESET switch to clear fault on DCS display.

STEP 2. Examine [Contactor] indication to verify that [Contactor] is [Open].
STEP 3. If [Contactor] does not indicate [Open], push AC CIRCUIT INTERRUPT switch.
STEP 4. Reexamine [Contactor] indication to verify that [Contactor] is [Open].
STEP 5. If [Contactor] does not indicate [Open], notify field maintenance.
STEP 6. If [Contactor] indicates [Open], turn engine control switch to START position.
STEP 7. Examine DCS fault status line for additional fault(s) that is (are) displayed.
STEP 8. Restore from fault(s) if possible (WP 0011, DCS Fault and Warning Codes and
Descriptions), or notify field maintenance if unable to clear fault(s).

MALFUNCTION

DCS operator screen displays [Fault 1446: High AC Voltage].

CORRECTIVE ACTION

STEP 1. Push FAULT RESET switch to clear fault on DCS display.

STEP 2. Turn engine control switch to START position.

0010-10
 TM 9-6115-753-10 0010

STEP 3. Observe [Genset Voltage] on DCS display.

STEP 4. If generator set voltage is more than the maximum voltage listed in Table 1,
notify field maintenance.

MALFUNCTION

DCS operator screen displays [Fault 1447: Low AC Voltage].

CORRECTIVE ACTION

STEP 1. Push FAULT RESET switch to clear fault on DCS display.

STEP 2. Turn engine control switch to START position.
STEP 3. Observe [Genset Voltage] on DCS display.
STEP 4. If generator set voltage is less than or more than the voltage parameters listed
in Table 1, notify field maintenance and request instructions for continuing
operation.

Table 1. Voltage Parameters.

GENERATOR SET VOLTAGE CONFIGURATION MINIMUM – MAXIMUM VOLTAGE
120/208-V 3 Phase 118 – 122 V/205 – 211 V
All
240/416-V 3 Phase 235 – 249-V/408 – 424-V

SYMPTOM

AC voltage fluctuation.

MALFUNCTION

Erratic change in voltage shown on GENSET VOLTAGE indicator.

CORRECTIVE ACTION

STEP 1. Observe generator voltage for a transient condition.

STEP 2. If voltage continues to fluctuate for more than a 30-sec period of time, notify
field maintenance.
STEP 3. If voltage is less than or more than the values indicated in Table 1, notify field
maintenance and request instructions on continued operation.

SYMPTOM

AC frequency fluctuation.

MALFUNCTION

Erratic change in frequency shown on DCS [FREQ] indicator.

0010-11
 TM 9-6115-753-10 0010

CORRECTIVE ACTION

STEP 1. Observe generator frequency for a transient condition.

STEP 2. If frequency continues to fluctuate less than the minimum or more than the
maximum value indicated in Table 2 for more than a 15-sec period of time,
notify field maintenance and request instructions on continued operation.

Table 2. Frequency Parameters.

GENERATOR SET MINIMUM – MAXIMUM FREQUENCY
50 Hz 49.5 – 50.5 Hz
60 Hz 59.5 – 60.5 Hz
400 Hz 399 – 401 Hz

SYMPTOM

DCS operator screen displays [Warning 143: Pre-Low Oil Pressure].

MALFUNCTION

Engine oil level below normal.

CORRECTIVE ACTION

STEP 1. Perform WP 0017, Service Engine Oil.

STEP 2. Push FAULT RESET switch to clear warning on DCS.
STEP 3. If engine was stopped to service engine oil, turn engine control switch to
START position.
STEP 4. If [Warning 143: Pre-Low Oil Pressure] reappears, notify field maintenance.

MALFUNCTION

Improper grade of oil for conditions.

CORRECTIVE ACTION

STEP 1. Perform WP 0017, Service Engine Oil.

STEP 2. Push FAULT RESET switch to clear warning on DCS.
STEP 3. If engine was stopped to service engine oil, turn engine control switch to
START position.
STEP 4. If [Warning 143: Pre-Low Oil Pressure] reappears, notify field maintenance and
request instructions on continued operation.

SYMPTOM

DCS operator screen displays [Warning 146: Pre-High Coolant Temperature].

MALFUNCTION

Coolant temperature lower than [Fault] condition but higher than normal.

0010-12
 TM 9-6115-753-10 0010

CORRECTIVE ACTION

WARNING

x Flying debris or material may enter eyes or strike the face. Wear appropriate eye/face protection
while performing maintenance tasks. Failure to comply may cause injury or death to personnel.

x Hearing protection is required during maintenance or repair with engine running. Failure to
comply can cause hearing loss.

x When operating, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow engine to cool before checks, services, and maintenance. Wear
gloves and additional protective clothing as required. Failure to comply may cause injury or death
to personnel.

CAUTION
Operating generator set with doors open or with panels removed for an extended length of time
will cause engine to overheat. Do not operate generator with doors open or panels removed for
longer than necessary to complete your task. Monitor DCS temperature indicator to prevent
engine overheating. Failure to comply will cause damage to equipment.
STEP 1. Examine DCS panel to determine and note coolant temperature.
STEP 2. Open left-side access door.
STEP 3. Examine coolant overflow bottle visually for coolant level midpoint between
HIGH and LOW level marks (WP 0015, Service Cooling System).
STEP 4. If coolant level is visible, notify field maintenance.
STEP 5. If coolant level is not visible, notify field maintenance and request instructions
on continued operation.
STEP 6. If [Warning 146: Pre-High Coolant Temperature] continues, proceed to next
malfunction.

MALFUNCTION

Obstructed ventilation and air flow paths.

CORRECTIVE ACTION

STEP 1. Inspect ventilation and air flow paths.

STEP 2. Clear ventilation and air flow paths of obstruction(s).
STEP 3. Push FAULT RESET switch to clear warning on DCS.
STEP 4. If [Warning 146: Pre-High Coolant Temperature] continues, notify field
maintenance and request instructions on continued operation.

0010-13
 TM 9-6115-753-10 0010

SYMPTOM

DCS operator screen displays [Warning 1441: Low Fuel Level].

MALFUNCTION

Fuel level higher than FAULT condition level but lower than normal.

CORRECTIVE ACTION

STEP 1. Examine fuel level indication on DCS display.

STEP 2. If fuel level indicator is in the green area on the DCS display or there is no fuel
level indicated, examine fuel level visually (WP 0016, Service Fuel System).
STEP 3. If fuel level is not visible, refill fuel tank (WP 0016, Service Fuel System).
STEP 4. If fuel level is visible, notify field maintenance.
STEP 5. Push FAULT RESET switch to clear [Warning 1441: Low Fuel Level].
STEP 6. If [Warning 1441: Low Fuel Level] reappears, notify field maintenance.

MALFUNCTION

Faulty fuel level sensor.

CORRECTIVE ACTION

STEP 1. Examine fuel level indication on DCS display.

STEP 2. If fuel level indicator is in the green area on the DCS display or there is no fuel
level indicated, examine fuel level visually (WP 0016, Service Fuel System).
STEP 3. If fuel level is not visible, refill fuel tank (WP 0016, Service Fuel System).
STEP 4. If fuel level is visible, notify field maintenance.
STEP 5. Push FAULT RESET switch to clear [Warning 1441: Low Fuel Level].
STEP 6. If [Warning 1441: Low Fuel Level] reappears, notify field maintenance.

SYMPTOM

DCS operator screen displays [Warning 2936: Fuel Level Sensor High] or [Warning 2937: Fuel Level
Sensor Low].

MALFUNCTION

Faulty fuel sensor.

CORRECTIVE ACTION

Notify field maintenance.

SYMPTOM

DCS operator screen displays [Warning 441: Low Battery Voltage], [Warning 1442: Weak Battery],
[Warning 3662: Battery Discharge], or [Warning 3663: Winterization Kit Failure to Heat].

0010-14
 TM 9-6115-753-10 0010

MALFUNCTION

Battery cables loose, damaged, corroded, or disconnected.

CORRECTIVE ACTION

WARNING
Metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry and do not wear loose clothing when working on equipment. Failure to comply
may cause injury or death to personnel.
STEP 1. Inspect battery cables and connections.
STEP 2. If battery cables and/or connections are loose, damaged, corroded, or
disconnected, notify field maintenance.
STEP 3. If cables and connectors are serviceable, proceed to next malfunction.

MALFUNCTION

Faulty battery-charging alternator.

CORRECTIVE ACTION

Notify field maintenance.

SYMPTOM

DCS operator screen displays [Warning 1444: KW Overload].

MALFUNCTION

Load placed on generator is more than the capacity of the generator.

CORRECTIVE ACTION

STEP 1. Observe DCS display for possible transient overload condition.

STEP 2. If overload condition is less than maximum [kW] output, push FAULT RESET
switch to clear [Warning 1444: kW Overload].
STEP 3. If overload condition is greater than 10% of maximum kilowatt, continuously
monitor coolant temperature level and notify field maintenance and request
instructions on continued operation.

SYMPTOM

DCS operator screen displays [Warning 1471: Overcurrent].

MALFUNCTION

Current above normal but not sufficient to create a FAULT condition.

0010-15
 TM 9-6115-753-10 0010

CORRECTIVE ACTION

STEP 1. Observe DCS display for possible transient over current condition.
STEP 2. If over current condition is less than maximum [Genset Current], push FAULT
RESET switch to clear [Warning 1471: Over current].
STEP 3. If over current condition remains near the maximum value of current indicated
on DCS display, continuously monitor coolant temperature level and notify field
maintenance and request instructions on continued operation.

SYMPTOM

DCS operator screen displays [Warning 1416: Fail To Shutdown].

MALFUNCTION

Engine failed to shutdown after engine control switch was turned to OFF position.

CORRECTIVE ACTION

STEP 1. Verify that engine control switch is in OFF position.

STEP 2. If engine control switch is in OFF position, push EMERGENCY STOP switch on
engine control panel.

WARNING

x Flying debris or material may enter eyes or strike the face. Wear appropriate eye/face protection
while performing maintenance tasks. Failure to comply may cause injury or death to personnel.

x Hearing protection is required during maintenance or repair with engine running. Failure to
comply can cause hearing loss.

CAUTION
Operating generator set with doors open or with panels removed for an extended length of time
will cause engine to overheat. Do not operate generator with doors open or panels removed for
longer than necessary to complete your task. Monitor DCS temperature indicator to prevent
engine overheating. Failure to comply will cause damage to equipment.
STEP 3. If engine continues to operate, open right-side door and move DEAD CRANK
SWITCH toggle to OFF position.
STEP 4. If engine continues to operate, notify field maintenance.
STEP 5. If engine stops, notify field maintenance.

SYMPTOM

DCS operator screen displays [Warning 1449: Overfrequency].

MALFUNCTION

Generator set was subjected to a single step large block load removal that was within the
parameters of speed control but sufficient to create a [Warning 1449: Overfrequency] condition.

0010-16
 TM 9-6115-753-10 0010

CORRECTIVE ACTION

STEP 1. Observe DCS display for a possible transient over frequency condition.
STEP 2. If over frequency condition continues, adjust frequency to required value on
DCS panel (WP 0005, Operation Under Usual Conditions).
STEP 3. If over frequency condition continues or if unable to adjust frequency to
required value, notify field maintenance and request instructions on continued
operation.

SYMPTOM

DCS operator screen displays [Warning 3678: Genset Frequency Changed].

MALFUNCTION

Frequency changed from parameters selected upon generator startup or normal operation.
STEP 1. Observe DCS display for a change in selected frequency.
STEP 2. Adjust frequency to required value on DCS panel (WP 0005, Operation Under
Usual Conditions).
STEP 3. If unable to adjust frequency to required value, contact field maintenance and
request instructions on continued operation.

SYMPTOM

DCS operator screen displays: [Warning 1417: Power Down Failure].

MALFUNCTION

Processor fault [Warning 1417: Power Down Failure] message appears for longer than 10 min.

CORRECTIVE ACTION

STEP 1. Move main DC circuit breaker switch handle to OFF/TRIP position.

STEP 2. Return main DC circuit breaker switch handle to RESET/ON position.
STEP 3. Turn engine control switch to PRIME & RUN AUX FUEL or PRIME & RUN to
reboot processor.
STEP 4. Push FAULT RESET switch to clear [Warning 1417: Power Down Failure].
STEP 5. If [Warning 1417: Power Down Failure] reappears, notify field maintenance.

SYMPTOM

DCS operator screen displays [Warning 1457: Fail To Synchronize].

MALFUNCTION

Generator set paralleling parameters improperly selected or greater than allowed by

synchronizing detectors.

0010-17
 TM 9-6115-753-10 0010

CORRECTIVE ACTION

STEP 1. Examine voltage and frequency options on DCS display to determine if they are
selected for required values (WP 0005, Operation Under Usual Conditions).
STEP 2. Examine voltage selection boards on each generator to determine if they are
selected for required values (WP 0005, Operation Under Usual Conditions).
STEP 3. Select voltage and frequency on operating generator sets to match required
parameters (WP 0005, Operation Under Usual Conditions).
STEP 4. Repeat paralleling task (WP 0011, DCS Fault and Warning Codes and
Descriptions).
STEP 5. If [Warning 1457: Fail To Synchronize] reappears, notify field maintenance.

SYMPTOM

DCS operator screen displays [Warning 3658: Switch Box Fail To Close].

MALFUNCTION

Paralleling operations are being conducted without a switch box.

NOTE
This warning cannot be cleared until the generator set has been shut down. Before generator set
is to be restarted, push FAULT RESET to clear the warning.

CORRECTIVE ACTION

STEP 1. Examine output connections to verify the generator sets are not connected
through a switch box.
STEP 2. If generator sets are connected through a switch box proceed to next
malfunction.
STEP 3. Continue operation of generator sets and ignore warning.
STEP 4. Clear warning prior to restart of generator sets.

MALFUNCTION

Generator set paralleling parameters improperly selected or greater than allowed by

synchronizing detectors.

CORRECTIVE ACTION

STEP 1. Examine voltage and frequency options on DCS display to determine if they are
selected for required values (WP 0005, Operation Under Usual Conditions).
STEP 2. Examine voltage selection boards on each generator set to determine if they
are selected for required values (WP 0005, Operation Under Usual Conditions).
STEP 3. Select voltage and frequency on operating generator sets to match required
parameters (WP 0005, Operation Under Usual Conditions).
STEP 4. Repeat paralleling task (WP 0006, Parallel Operation).

0010-18
 TM 9-6115-753-10 0010

STEP 5. If [Warning 3658: Switch Box Fail To Close] reappears, notify field
maintenance.

SYMPTOM

Engine exhaust smoking.

MALFUNCTION

Engine emits white exhaust smoke.

CORRECTIVE ACTION

WARNING

x Flying debris or material may enter eyes or strike the face. Wear appropriate eye/face protection
while performing maintenance tasks. Failure to comply may cause injury or death to personnel.

x Hearing protection is required during maintenance or repair with engine running. Failure to
comply can cause hearing loss.

CAUTION
Operating generator set with doors open or with panels removed for an extended length of time
will cause engine to overheat. Do not operate generator with doors open or panels removed for
longer than necessary to complete your task. Monitor DCS temperature indicator to prevent
engine overheating. Failure to comply will cause damage to equipment.
STEP 1. Inspect for evidence of water in fuel tank.
STEP 2. Inspect fuel filter/water separator for contamination (WP 0016, Service Fuel
System).
STEP 3. If contamination appears, drain fuel filter/water separator (WP 0016, Service
Fuel System).
STEP 4. Turn engine control switch to START position.
STEP 5. If malfunction continues, notify field maintenance and request instructions on
continued operation.

MALFUNCTION

Engine emits black exhaust smoke.

CORRECTIVE ACTION

STEP 1. Examine [GENSET CURRENT] parameters for high load condition.

STEP 2. If [GENSET CURRENT] parameters are within limits, service air cleaner
element (WP 0014, Service Air Cleaner).
STEP 3. Turn engine control switch to START position.
STEP 4. If malfunction continues, notify field maintenance and request instructions on
continued operation.

0010-19
 TM 9-6115-753-10 0010

MALFUNCTION

Engine emits blue exhaust smoke due to oil in combustion chambers.

CORRECTIVE ACTION

Notify field maintenance.

SYMPTOM

Engine starts but develops lower than rated speed.

MALFUNCTION

Engine speed is low but not enough to create a fault or warning condition.

CORRECTIVE ACTION

STEP 1. Examine frequency indicator on DCS display.

STEP 2. If frequency is less than rated, make adjustment (WP 0005, Operation Under
Usual Conditions) to obtain rated frequency.
STEP 3. If unable to obtain rated frequency, service fuel/water separator (WP 0016,
Service Fuel System).
STEP 4. Turn engine control switch to START position.
STEP 5. If symptom continues, service air cleaner element (WP 0014, Service Air
Cleaner).
STEP 6. If symptom continues, notify field maintenance.

SYMPTOM

Engine starts at speed but less than rated voltage.

MALFUNCTION

Automatic voltage regulator system or component(s) subjected to fault condition.

CORRECTIVE ACTION

STEP 1. Examine [GENSET VOLTAGE] on DCS display.

STEP 2. If [GENSET VOLTAGE] is less than rated voltage, make adjustment to obtain
rated voltage (WP 0005, Operation Under Usual Conditions).
STEP 3. If unable to obtain rated voltage, notify field maintenance.

0010-20
 TM 9-6115-753-10 0010

WARNING
Ensure the frequency of any device powered by the GFCI convenience receptacle matches the
frequency of the generator set. Failure to comply may cause injury or death to personnel.

NOTE
Power is available from the GFCI convenience receptacle only when the generator set is
operating and the [CONTACTOR] is [CLOSED].

SYMPTOM

Power not available at GFCI convenience receptacle.

MALFUNCTION

GFCI convenience receptacle has been subjected to a ground fault condition.

CORRECTIVE ACTION

STEP 1. If generator is operating and the [CONTACTOR] is [CLOSED], push RESET

switches located on the face of the GFCI convenience receptacle.
STEP 2. If symptom continues, notify field maintenance.

END OF WORK PACKAGE

0010-21/22 blank
 TM 9-6115-753-10 0011

OPERATOR MAINTENANCE
AMMPS 60KW GENERATOR SET
DCS FAULT AND WARNING CODES AND DESCRIPTIONS

INITIAL SETUP:

Test Equipment References

Not Applicable WP 0005, Operation Under Usual Conditions
Tools and Special Tools WP 0006, Parallel Operation
Not Applicable WP 0010, Troubleshooting Procedures
Materials/Parts WP 0014, Service Air Cleaner
Not Applicable WP 0015, Service Cooling System
Personnel Required WP 0016, Service Fuel System
Not Applicable WP 0017, Service Engine Oil
Equipment Conditions
Not Applicable

DCS FAULT AND WARNING CODES AND DESCRIPTIONS

Table 1 lists the fault and warning code numbers and DCS panel text displayed on the control panel. Fault or
warning codes to be addressed by the operator are listed first followed by the fault or warning codes that must be
addressed by field maintenance personnel. When displayed, the operator is to respond to these codes IAW the
procedures found in this TM. The WP number(s) to be referenced is (are) listed in the Action column. If the initial
response of the operator to terminate the code is ineffective, notify field maintenance.

Table 1. DCS Fault and Warning Codes and Descriptions.

MESSAGE WORD CORRECTIVE ACTION
FAULT CODES TO BE ADDRESSED BY FAULT CODES TO BE ADDRESSED BY OPERATOR
OPERATOR
Fault 151: High Coolant Temperature WP 0015, Service Cooling System;
WP 0010, Troubleshooting Procedures.
Fault 234: Overspeed Shutdown WP 0010, Troubleshooting Procedures.
Fault 359: Fail to Start WP 0016, Service Fuel System;
WP 0010, Troubleshooting Procedures.
Fault 415: Low Oil Pressure WP 0017, Service Engine Oil;
WP 0010, Troubleshooting Procedures.
Fault 1245: Engine Shutdown WP 0010, Troubleshooting Procedures, Engine Stops
Suddenly.
Fault 1433: Local E-Stop WP 0010, Troubleshooting Procedures, Engine fails to
crank.
Fault 1434: Remote E-Stop WP 0010, Troubleshooting procedure, Engine fails to
crank.
Fault 1438: Fail To Crank WP 0010, Troubleshooting Procedure, Engine fails to
crank.
Fault 1445: Short Circuit WP 0005, Operation Under Usual Conditions;
WP 0010, Troubleshooting Procedures.

0011-1
 TM 9-6115-753-10 0011

MESSAGE WORD CORRECTIVE ACTION

FAULT CODES TO BE ADDRESSED BY FAULT CODES TO BE ADDRESSED BY OPERATOR
OPERATOR
Fault 1446: High AC Voltage WP 0010, Troubleshooting Procedure, Generator was
subjected to an overvoltage condition.
Fault 1447: Low AC Voltage WP 0010, Troubleshooting Procedure, Generator was
subjected to an undervoltage condition.
Fault 1448: Underfrequency WP 0014, Service Air Cleaner;
WP 0016, Service Fuel System;
WP 0010, Troubleshooting Procedures.
Fault 1452: Genset Contactor Fail to Close WP 0010, Troubleshooting Procedures.
Fault 1453: Genset Contactor Fail to Open WP 0010, Troubleshooting Procedure.
Fault 1459: Reverse Power WP 0010, Troubleshooting Procedures.
Fault 1472: High Current Shutdown WP 0010, Troubleshooting Procedures.
Fault 1918: Fuel Level Low WP 0016, Service Fuel System;
WP 0010, Troubleshooting Procedures.
Fault 2661: Engine Shutdown WP 0010, Troubleshooting Procedures, Engine stops
suddenly.
Fault 3668: Output Voltage Configuration Bit 0 WP 0010, Troubleshooting Procedures.
Changed
Fault 3669: Output Voltage Configuration Bit 1 WP 0010, Troubleshooting Procedures.
Changed
FAULT CODES TO BE ADDRESSED BY FIELD FAULT CODES TO BE ADDRESSED BY FIELD
MAINTENANCE MAINTENANCE
Fault 111: ECM Failure Contact field maintenance.
Fault 115: Speed Signal Lost Contact field maintenance.
Fault 155: High Intake Manifold Temp Contact field maintenance.
Fault 236: Loss of Speed Sense Contact field maintenance.
Fault 342: Calibration Code Failure Contact field maintenance.
Fault 449: High Fuel Supply Pressure Contact field maintenance.
Fault 781: CAN Data Link Failure Contact field maintenance.
Fault 1461: Loss of Field Contact field maintenance.
Fault 2335: Excitation Fault Contact field maintenance.
Fault 2336 Checksum Fault Contact field maintenance.
Fault 2914: Genset AC Meter Failed Contact field maintenance.
Fault 2972: Field Overload Contact field maintenance.
Fault 3659: Switch Box Fail To Open Contact field maintenance.
Fault 3664: Invalid Genset Configuration Contact field maintenance.
Fault 3665: Invalid Voltage Configuration Contact field maintenance.
Fault 3673: Convenience Receptacle AC Meter Contact field maintenance.
Failed
Fault 3677: Genset Configuration Factory Test Fault Contact field maintenance.
WARNING CODES TO BE ADDRESSED BY WARNING CODES TO BE ADDRESSED BY
OPERATOR OPERATOR
Warning 143: Pre-Low Oil Pressure WP 0017, Service Engine Oil;
WP 0010, Troubleshooting Procedures.
Warning 146: Pre-High Coolant Temperature WP 0015, Service Cooling System;
WP 0010, Troubleshooting Procedures.
Warning 152: Low Coolant Temp WP 0015, Service Cooling System;
WP 0010, Troubleshooting Procedures.
Warning 284: Speed Signal Sensor Low WP 0010, Troubleshooting Procedures.
Warning 334: Coolant Temp Error WP 0015, Service Cooling System;
WP 0010, Troubleshooting Procedures.

0011-2
 TM 9-6115-753-10 0011

MESSAGE WORD CORRECTIVE ACTION

WARNING CODES TO BE ADDRESSED BY WARNING CODES TO BE ADDRESSED BY
OPERATOR OPERATOR
Warning 441: Low Battery Voltage WP 0010, Troubleshooting Procedures.
Warning 1131: Battleshort Active WP 0005, Operation Under Usual Conditions;
WP 0010, Troubleshooting Procedures.
Warning 1246: Unknown Engine Fault WP 0010, Troubleshooting Procedures.
Warning 1416: Fail to Shutdown WP 0010, Troubleshooting Procedures.
Warning 1417: Power Down Failure WP 0010, Troubleshooting Procedures.
Warning 1441: Low Fuel Level WP 0016, Service Fuel System;
WP 0010, Troubleshooting Procedures.
Warning 1442: Weak Battery WP 0010, Troubleshooting Procedures.
Warning 1444: KW Overload WP 0005, Operation Under Usual Conditions;
WP 0010, Troubleshooting Procedures.
Warning 1449: Overfrequency WP 0005, Operation Under Usual Conditions;
WP 0010, Troubleshooting Procedures.
Warning 1457: Fail To Synchronize WP 0010, Troubleshooting Procedures.
Warning 1471: Overcurrent WP 0005, Operation Under Usual Conditions;
WP 0010, Troubleshooting Procedures.
Warning 1845: Water In Fuel Sensor OOR High WP 0016, Service Fuel System;
WP 0010, Troubleshooting Procedures.
Warning 1852: Pre-High Water In Fuel WP 0016, Service Fuel System;
WP 0010, Troubleshooting Procedures.
Warning 1992: High Speed Warning WP 0010, Troubleshooting Procedures.
Warning 2917: Genset Bus Voltage High WP 0010, Troubleshooting Procedures.
Warning 2936: Fuel Level Sensor High WP 0010, Troubleshooting procedures.
Warning 2937: Fuel Level Sensor Low WP 0010 Troubleshooting Procedures.
Warning 3658: Switch Box Fail To Close WP 0010, Troubleshooting Procedures.
Warning 3663: Winterization Kit Failure to Heat WP 0010, Troubleshooting Procedures.
Warning 3678: Genset Frequency Changed WP 0010, Troubleshooting Procedures.
WARNING CODES TO BE ADDRESSED BY FIELD WARNING CODES TO BE ADDRESSED BY FIELD
MAINTENANCE MAINTENANCE
Warning 121: Speed Signal Error Contact field maintenance.
Warning 122: Intake Manifold Pressure Sensor High Contact field maintenance.
Warning 123: Intake Manifold Pressure Sensor Low Contact field maintenance.
Warning 124: High Intake Manifold Pressure Contact field maintenance.
Warning 135: Oil Pressure Sensor High Contact field maintenance.
Warning 141: Oil Pressure Sensor Low Contact field maintenance.
Warning 144: Coolant Temperature Sensor OOR Contact field maintenance.
High
Warning 145: Coolant Temperature Sensor OOR Contact field maintenance.
Low
Warning 153: Intake Manifold Temp Sensor High Contact field maintenance.
Warning 154: Intake Manifold Temp Sensor Low Contact field maintenance.
Warning 221: Ambient Air Pressure Sensor High Contact field maintenance.
Warning 222: Air Pressure Sensor Low Contact field maintenance.
Warning 227: Sensor Supply 2 High Contact field maintenance.
Warning 238 Sensor Supply 3 Low Contact field maintenance.
Warning 239: Sensor Supply 3 High Contact field maintenance.
Warning 271: Fuel Pressure Solenoid Valve Low Contact field maintenance.
Warning 272: Fuel Pressure Solenoid Valve High Contact field maintenance.
Warning 281: Cylinder Pressure Imbalance Contact field maintenance.

0011-3
 TM 9-6115-753-10 0011

MESSAGE WORD CORRECTIVE ACTION

WARNING CODES TO BE ADDRESSED BY FIELD WARNING CODES TO BE ADDRESSED BY FIELD
MAINTENANCE MAINTENANCE
Warning 285: CAN Multiplex PGN Rate Error Contact field maintenance.
Warning 286: CAN Multiplex Calibration Error Contact field maintenance.
Warning 295: Ambient Air Pressure Sensor Error Contact field maintenance.
Warning 311: Injector 1 Solenoid High Current Contact field maintenance.
Warning 313: Injector 3 Solenoid High Current Contact field maintenance.
Warning 315: Injector 2 High Solenoid Current Contact field maintenance.
Warning 319: Real Time Clock Error Contact field maintenance.
Warning 321: Injector 4 High Solenoid Current Contact field maintenance.
Warning 324: Injector Solenoid 3 Low Current Contact field maintenance.
Warning 331: Injector Solenoid 2 Low Current Contact field maintenance.
Warning 332: Injector Solenoid 4 Low Current Contact field maintenance.
Warning 341: ECM Data Lost Contact field maintenance.
Warning 343: ECM Hardware Failure Contact field maintenance.
Warning 351: Injector Power Supply Failure Contact field maintenance.
Warning 352: Sensor Supply 1 Low Contact field maintenance.
Warning 386: Sensor Supply 1 High Contact field maintenance.
Warning 427: CAN Data Link Degraded Contact field maintenance.
Warning 442: High Battery Voltage Contact field maintenance.
Warning 451: Injector Metering 1 Pressure High Contact field maintenance.
Warning 452: Injector Metering 1 Pressure Low Contact field maintenance.
Warning 488: High Intake Manifold 1 Temp Contact field maintenance.
Warning 496: Speed Sensor Supply Voltage Error Contact field maintenance.
Warning 554: APC Pressure Error Contact field maintenance.
Warning 559: Low Injector Metering 1 Pressure Contact field maintenance.
Warning 689: Crankshaft Speed Error Contact field maintenance.
Warning 697: ECM Temp High Contact field maintenance.
Warning 698: ECM Temp Low Contact field maintenance.
Warning 731: Crankshaft Mechanical Misalignment Contact field maintenance.
Warning 757: ECM Data Lost Contact field maintenance.
Warning 782: CAN Data Link Failure Contact field maintenance.
Warning 1117: Power Lost With Ignition On Contact field maintenance.
Warning 1376: Camshaft Speed Error Contact field maintenance.
Warning 1451: Genset/Bus Voltage Mismatch Contact field maintenance.
Warning 1456: Bus Out Of Synchronization Range Contact field maintenance.
Warning 1458: Synchronization Phase Rotation Contact field maintenance.
Mismatch
Warning 1469: Speed/Hz Mismatch Contact field maintenance.
Warning 1689: Real Time Clock Contact field maintenance.
Warning 1846: Water In Fuel Sensor OOR Low Contact field maintenance.
Warning 2111: Coolant Temp 2 Sensor OOR High Contact field maintenance.
Warning 2112: Coolant Temp Sensor OOR Low Contact field maintenance.
Warning 2311: Fuel Injection Control Valve Failure Contact field maintenance.
Warning 2545: Keyswitch Reset Required Contact field maintenance.
Warning 2662: Engine Warning Contact field maintenance.
Warning 2727: J1939 Datalink Error Contact field maintenance.
Warning 2915: Genset Bus AC Meter Failed Contact field maintenance.
Warning 2968: AVR Fault Contact field maintenance.
Warning 3661: Maintenance Item is Active Contact field maintenance.
Warning 3662: Battery Discharge Contact field maintenance.
Warning 3666: Master Control Switch Configuration Contact field maintenance.

0011-4
 TM 9-6115-753-10 0011

MESSAGE WORD CORRECTIVE ACTION

WARNING CODES TO BE ADDRESSED BY FIELD WARNING CODES TO BE ADDRESSED BY FIELD
MAINTENANCE MAINTENANCE
Warning 3667: Voltage Configuration Change Contact field maintenance.
Warning 3671: Low Genset Battery Voltage During Contact field maintenance.
Winterization
Warning 3672: Automatic Field Flash Not Complete Contact field maintenance.
Warning 3674: Genset Configuration Change Contact field maintenance.

END OF WORK PACKAGE

0011-5/6 blank
 TM 9-6115-753-10

CHAPTER 4

MAINTENANCE INSTRUCTIONS
FOR
AMMPS 60KW GENERATOR SET
 TM 9-6115-753-10

CHAPTER 4

MAINTENANCE INSTRUCTIONS

WORK PACKAGE INDEX

Title WP Sequence No.
PMCS INTRODUCTION ...................................................................................................................................... 0012
PMCS ................................................................................................................................................................... 0013
SERVICE AIR CLEANER .................................................................................................................................... 0014
SERVICE COOLING SYSTEM ............................................................................................................................ 0015
SERVICE FUEL SYSTEM ................................................................................................................................... 0016
SERVICE ENGINE OIL........................................................................................................................................ 0017
 TM 9-6115-753-10 0012

OPERATOR MAINTENANCE
AMMPS 60KW GENERATOR SET
PMCS INTRODUCTION

INTRODUCTION

This section contains information that you will need to perform operator PMCS. Steps are included to help you
perform these procedures easily and quickly. PMCS consists of scheduled maintenance items used to make sure
the AMMPS 60 kW generator sets are ready for operation at all times. Inspect the system regularly and carefully
so that you can find, correct, or prevent any defects.

GENERAL

PMCS is performed to keep the equipment in operating condition. The checks are used to find, correct, or report
problems. Pay attention to warning and caution statements. A warning indicates the possibility of injury or death to
personnel. A caution means the equipment could be damaged.
x Before beginning operation of the equipment, perform Before (B) PMCS.
x During operation, perform During (D) PMCS.
x After operation, perform After (A) PMCS.

EXPLANATION OF THE COLUMNS FOUND IN PMCS TABLE

Column (1) – Item No. The item number lists the checks and services in the order they are to be performed. This
column will be used as a source of item for the TM Number Column on DA Form 2404, Equipment Inspection and
Maintenance Worksheet; or DA Form 5988E (electronic version), Equipment Inspection and Maintenance
Worksheet, in recording the result of the PMCS.
Column (2) – Interval. References when the PMCS should be performed.
Column (3) – Item to be checked or serviced. Identifies the portion of the system to be inspected.
Column (4) – Procedure. Provides the procedures for performing the checks.
Column (5) –Equipment Not Ready/Available If. Contains the criteria that will render the system incapable of
performing its primary mission. If the system does not perform as required, refer to Chapter 3, Operator
Troubleshooting Procedures (WP 0009, Troubleshooting Index). If equipment appears to be malfunctioning and
the problem cannot be fixed, immediately report it to your supervisor and report it on DA Form 2404, Equipment
Inspection and Maintenance Worksheet.

CORROSION PREVENTION AND CONTROL (CPC)

Corrosion Prevention and Control (CPC) of Army materiel is a continuing concern. It is important that any
corrosion problems with this item be reported so that the problem can be corrected and improvements can be
made to prevent the problem in future items.

Corrosion specifically occurs with metals. It is an electrochemical process that causes the degradation of metals.
It is commonly caused by exposure to moisture, acids, bases, or salts. An example is the rusting of iron.
Corrosion damage in metals can be seen, depending on the metal, as tarnishing, pitting, fogging, surface residue,
and/or cracking.

0012-1
 TM 9-6115-753-10 0012

Plastics, composites, and rubbers can also degrade. Degradation is caused by thermal (heat), oxidation (oxygen),
solvation (solvents), or photolytic (light, typically Ultraviolet (UV)) processes. The most common exposures are
excessive heat or light. Damage from these processes will appear as cracking, softening, swelling, and/or
breaking. SF 368, Product Quality Deficiency Report, should be submitted to the address specified in DA PAM
750-8, The Army Maintenance Management System (TAMMS) Users Manual.
For aircraft TMs, this information shall include a reference to TM 1-1500-344-23, volumes 1 through 4 (Cleaning
and Corrosion Control).

Rust Definition

Rust is defined as any various scaly or powdery reddish-brown or reddish-yellow materials that form on iron and
iron-coated materials in the presence of moisture, deteriorating as a result of disuse or neglect.

Deterioration Definition

Deterioration is defined as any condition that causes material to be impaired or lessens the quality or value of the
material.

Cracking Definition

Cracking is defined as when material is found to be split or broken, either completely or partially.

INSPECTION

Look for signs of problems or trouble. Most problems can be detected by sight, touch, smell, or sound. Be alert
when around the AMMPS 60 kW generator set.
Inspect to ensure that all components are in good condition. Are they correctly assembled, stowed, or secured?
Are any components worn, corroded, or rusty? Correct any problems found or notify your immediate supervisor.
There are common items on the generator set that should be checked. These include the following:
Bolts, clamps, screws, and nuts: Continuously inspect for looseness. Inspect for chipped paint, bare metal,
rust, and corrosion around bolt and screw heads and nuts. Replace as necessary. Tighten hardware as required.
If tools are required, notify field maintenance.
Welds: Some components of the AMMPS 60 kW generator set are welded. To inspect welds, look for chipped
paint, rust, corrosion, and gaps. When these conditions are found, notify field maintenance.

0012-2
 TM 9-6115-753-10 0012

WARNING
x NATO slave receptacle is electrically live at all times and is not protected by a fuse.
Disconnecting main DC circuit breaker does not ensure the circuit is dead. This circuit is only
dead when the batteries are fully disconnected. Disconnect both batteries before performing
maintenance on the slave receptacle. Failure to comply may cause injury or death to
personnel.

x Metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry and do not wear loose clothing when working on equipment. Failure to
comply may cause injury or death to personnel.

x High voltage is produced when generator set is in operation. Never attempt to start the
generator set unless it is properly grounded. Do not ground yourself in standing water. Never
attempt to connect or disconnect load cables while the generator set is operating. Failure to
comply may cause injury or death to personnel.
Electrical wires, connectors, and harnesses: Tighten loose connections. Inspect for cracked or broken
insulation, bare wires, and broken connectors. If any are found, notify field maintenance.
Hoses and fluid lines: Inspect for wear, damage, and leaks. Ensure clamps and fittings are tight. Wet spots
indicate a leak. A stain by a fitting or connector can also mean a leak. When this is found, notify field
maintenance.

CLEANING AND LUBRICATION

Proper cleaning and lubrication can aid in avoiding possible problems or trouble. Make it a habit to do the
following:

CAUTION

Follow all cleaning and lubrication instructions carefully. Failure to comply may cause damage to
equipment.
Under harsh environmental conditions, conduct PMCS more frequently.
Use only the recommended cleaning solutions and lubricants found in the Expendable and Durable Items List
(WP 0021, Expendable and Durable Items List).
Clean the screen of the DCS using the proper lens paper found in the Expendable and Durable Items List (WP
0021, Expendable and Durable Items List).

Oil Filters

Oil filters shall be serviced/cleaned/changed, as applicable, when:

They are known to be contaminated or clogged,
Service is recommended by AOAP laboratory analysis, or
At prescribed hardtime intervals.

AOAP Sampling Intervals

Engine oil/transmission oil/hydraulic fluids must be sampled at 60 days (Active Army and Reserve NG) as
prescribed by DA PAM 750-8, the Army Maintenance Management Systems (TAMMS) Users Manual. See
Sample Oil Task, Service Engine Oil (WP 0017, Service Engine Oil).

0012-3
 TM 9-6115-753-10 0012

Warranty Hardtime

For equipment under manufacturer's warranty, hardtime oil service intervals shall be followed. Intervals shall be
shortened if lubricants are known to be contaminated or if operation is under adverse conditions (such as longer-
than-usual operating hours, extended idling periods, extreme dust).

FLUID LEAKAGE

WARNING
Fuel is combustible and toxic to eyes, skin, and respiratory tract. Skin and eye protection are
required when working in contact with fuel. Avoid repeated or prolonged contact. Provide
adequate ventilation. Operators are to wash skin and change clothing promptly if in contact with
fuel. Failure to comply may cause injury or death to personnel.

CAUTION

When operating with Class I or II leaks, continue to check fluid level as required by PMCS. Class
III leaks should be reported to your supervisor immediately. Any Class I, II, or III fuel leak requires
equipment shut down. Failure to comply may cause damage to equipment.
It is necessary to know how fluid leakage affects the status of the AMMPS 60 kW generator set. Following are
types/classes of leakage you need to know to determine the status of the AMMPS 60 kW generator set. Learn
these leakage definitions and remember: when in doubt, notify your supervisor. Equipment operation is allowed
with minor leakage (Class I or II). Consideration must be given to fluid capacity in the item/system being
checked/inspected. When in doubt, notify your supervisor.
Any Class I, II, or III fuel leak requires equipment shut down.
Class III leaks should be reported immediately to your supervisor.
(1) Class I: Seepage of fluid (as indicated by wetness or discoloration) not great enough to form drops.
(2) Class II: Leakage of fluid great enough to form drops but not enough to cause drops to drip from item
being checked/inspected.
(3) Class III: Leakage of fluid great enough to form three drops that fall from item being checked/inspected
within 5 sec.

END OF WORK PACKAGE

0012-4
 TM 9-6115-753-10 0013

OPERATOR MAINTENANCE
AMMPS 60KW GENERATOR SET
PMCS

INITIAL SETUP:

Test Equipment References

Not Applicable WP 0014, Service Air Cleaner
Tools and Special Tools WP 0015, Service Cooling System
Flashlight (WP 0021, Expendable and Durable Items WP 0016, Service Fuel System
List, Item 2)
WP 0017, Service Engine Oil
Materials/Parts
Equipment Conditions
Antifreeze (WP 0021, Item 1)
Engine control switch OFF (WP 0005, Operation
Oil, lubricating (WP 0021, Item 6) Under Usual Conditions)
Rags, wiping (WP 0021, Item 8) Main DC circuit breaker OFF (WP 0005)
Personnel Required DEAD CRANK SWITCH OFF (WP 0005)
Operator (1) Unit cooled, before and after procedures

0013-1
 TM 9-6115-753-10 0013

Figure 1. Rear View.

0013-2
 TM 9-6115-753-10 0013

Figure 2. Right-Side View.

0013-3
 TM 9-6115-753-10 0013

Figure 3. Front View.

0013-4
 TM 9-6115-753-10 0013

Figure 4. Left-Side View.

Table 1. PMCS for the 60 kW AMMPS Generator Set.

ITEM TO BE
ITEM CHECKED OR EQUIPMENT NOT
NO. INTERVAL SERVICED PROCEDURE READY/AVAILABLE IF:

WARNING

x Fuel is combustible and toxic to eyes, skin, and respiratory tract. Skin and eye protection are
required when working in contact with fuel. Avoid repeated or prolonged contact. Provide
adequate ventilation. Operators are to wash skin and change clothing promptly if in contact
with fuel. Failure to comply may cause injury or death to personnel.

x Fuels used in the generator set are combustible. Do not smoke or use open fire when
performing maintenance. Fire and possible explosion may result. Failure to comply may cause
injury or death to personnel and damage to equipment.

x Fuels used in the generator set are combustible. Ensure fuel source grounding strap is
connected to unit fuel fill grounding stud (fuel fill static ground). When filling the fuel tank,
maintain metal-to-metal contact between filler nozzle and fuel tank opening to eliminate ESD.
Fire and possible explosion can result. Failure to comply may cause injury or death to
personnel.

x Do not operate generator set if any fuel leaks are present. Fuel is combustible. Always perform
PMCS before operation. Failure to comply may cause injury or death to personnel.

0013-5
 TM 9-6115-753-10 0013

Table 1. PMCS for the 60 kW AMMPS Generator Set — Continued.

ITEM TO BE
ITEM CHECKED OR EQUIPMENT NOT
NO. INTERVAL SERVICED PROCEDURE READY/AVAILABLE IF:

WARNING

x Power is available to the convenience receptacle when the main contactor is closed. Avoid
accidental contact. Electrocution is possible. Failure to comply may cause injury or death to
personnel.

x Cooling system operates at high temperature and pressure. Contact with high-pressure steam
and/or liquids can cause burns and scalding. Shut down generator set and allow system to
cool before performing checks, services, and maintenance. Wear gloves, additional protective
clothing, and goggles as required. Contact with high-pressure steam and/or liquids can cause
burns and scalding. Failure to comply may cause injury or death to personnel.

x Exhaust discharge contains deadly gases, including carbon monoxide. Exhaust gases are
most dangerous in places with poor ventilation. Do not operate generator set in an enclosed
area unless exhaust discharge is properly vented. Failure to comply may cause injury or death
to personnel.

x NATO slave receptacle is electrically live at all times and is not protected by a fuse.
Disconnecting main DC circuit breaker does not ensure the circuit is dead. This circuit is only
dead when the batteries are fully disconnected. Disconnect both batteries before performing
maintenance on the slave receptacle. Failure to comply may cause injury or death to
personnel.

x Battery acid can cause burns to skin and cause eye injury. Wear safety goggles and chemical
gloves and avoid acid splash while working on the batteries. Failure to comply may cause
injury or death to personnel.

x Batteries give off combustible gas. Do not smoke or use open flame when performing
maintenance. Failure to comply may cause injury or death to personnel and damage to
equipment.

x While inspecting the operation of the generator set, do not inadvertently reach into the
generator set. Failure to comply may cause injury or death to personnel.

x Hearing protection is required during maintenance and repair with engine running. Failure to
comply can cause hearing loss.

x High voltage is produced when generator set is in operation. Never attempt to start the
generator set unless it is properly grounded. Do not ground yourself in standing water. Never
attempt to connect or disconnect load cables while the generator sets are operating. Failure to
comply may cause injury or death to personnel.

x Ensure the frequency of any device powered by the GFCI convenience receptacle matches the
frequency of the generator set. Failure to comply may cause injury or death to personnel.

0013-6
 TM 9-6115-753-10 0013

Table 1. PMCS for the 60 kW AMMPS Generator Set — Continued.

ITEM TO BE
ITEM CHECKED OR EQUIPMENT NOT
NO. INTERVAL SERVICED PROCEDURE READY/AVAILABLE IF:

WARNING

x Engine coolant is toxic to eyes and poisonous if ingested. Eye protection is required when
working with engine coolant. Avoid repeated or prolonged contact. Failure to comply may
cause injury or death to personnel.

x When operating, muffler has hot metal surfaces that will burn flesh on contact. Shut down
generator set and allow muffler to cool before performing maintenance. Wear gloves and
additional protective clothing as required. Failure to comply may cause injury or death to
personnel.

x Metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry and do not wear loose clothing when working on equipment. Failure to
comply may cause injury or death to personnel.

x When operating, generator set engine has hot metal surfaces that will burn flesh on contact.
Shut down generator set and allow generator set engine to cool before checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply
may cause injury or death to personnel.

CAUTION
Operating generator set with doors open or with panels removed for an extended length of time
will cause engine to overheat. Do not operate generator with doors open or panels removed for
longer than necessary to complete your task. Monitor DCS temperature indicator to prevent
engine overheating. Failure to comply will cause damage to equipment.
Rear Panel
1 Before Ground rod, 1. Inspect ground rod and cable Ground rod, clamp, or cable
clamp, and for missing parts or damage, missing or damaged, or
cable loose connection, or corrosion. connection loose.
2. Notify field maintenance of
corroded parts.
2 Before Rear panel 1. Inspect rear panel for damage Rear panel missing or
or corroded parts. punctured.
2. Notify field maintenance of
minor corrosion or damage.
3 Before ID plates and 1. Ensure ID plates and
information information labels are present,
labels secure, and legible. Two are
required (WP 0005, Operation
Under Usual Conditions).
2. Notify field maintenance of
missing, loose, or illegible plates.
4 Before DCS cover 1. Check cover, latch, hinges, and
(Figure 1, Item seals for damage or loose or
3) corroded parts.

0013-7
 TM 9-6115-753-10 0013

Table 1. PMCS for the 60 kW AMMPS Generator Set — Continued.

ITEM TO BE
ITEM CHECKED OR EQUIPMENT NOT
NO. INTERVAL SERVICED PROCEDURE READY/AVAILABLE IF:
2. Secure cover in open position.
3. Notify field maintenance of
damage, loose or corroded parts,
or cover that cannot be secured.
5 Before DCS 1. Inspect for damage and Damaged or missing parts.
missing parts.
2. Notify field maintenance of
defects.
6 Before Convenience 1. Check cover and hinge for Cover will not close.
receptacle damage or loose or corroded
(Figure 1, Item parts.
4)
2. Check receptacles for Receptacles damaged or
damaged or corroded parts. corroded.
3. Notify field maintenance of
defects.
7 Before Flexible sleeve 1. Inspect for tears, loose closure, Separated from rear panel.
or separation from rear panel.
2. Tighten loose ties.
3. Notify field maintenance of
tears.
8 Before Fuel fill (Figure 1. Clean fuel fill (Figure 1, Item 1)
1, Item 1) area of dirt and debris (WP 0016,
Service Fuel System).
2. Inspect the auxiliary fuel Damaged, corroded, or
connections for damage, missing missing parts.
parts, or corrosion.
3. Inspect cap and strainer for Damaged or missing cap.
dirt, wear, and defects. Punctured or missing strainer.
4. Remove dirt on cap or strainer.
5. Inspect chain and gasket for Damaged or missing gasket.
wear.
6. Notify field maintenance of
wear.
7. Inspect grounding stud (fuel fill Grounding stud (fuel fill static
static ground) for damage or ground) missing or corroded.
corrosion.
8. Notify field maintenance of
minor damage to grounding stud
(fuel fill static ground).
9 Before Coolant 1. Ensure coolant level is
overflow bottle between LOW and FULL (WP
(Figure 1, Item 0015, Service Cooling System).
2)
2. Add coolant as necessary (WP
0015, Service Cooling System).
3. Inspect hoses for leaks. Class III leak.
4. Notify field maintenance of
Class I, II, or III leaks.

0013-8
 TM 9-6115-753-10 0013

Table 1. PMCS for the 60 kW AMMPS Generator Set — Continued.

ITEM TO BE
ITEM CHECKED OR EQUIPMENT NOT
NO. INTERVAL SERVICED PROCEDURE READY/AVAILABLE IF:
5. Inspect coolant overflow bottle Cap cracked through,
cap for damage or loose hoses. missing, or missing hoses.
6. Reconnect loose hoses. Unable to resolve loose
hoses.
7. Notify field maintenance of
defects.
10 Before Fuel drain line 1. Inspect for leaks, damage, Any leaks or missing cap.
corrosion, or missing cap.
2. Notify field maintenance of
damage or corroded parts.
11 Before Fuel drain valve 1. Ensure fuel drain valve is in off
position (valve handle
perpendicular to line).
2. Inspect for leaks, damage, or Any leaks.
corroded parts.
3. Notify field maintenance of
damage or corroded parts.
12 Before Rear door 1. Inspect door, hinges, seals, Door cannot be secured.
and latch for damage or loose or
corroded parts.
2. Notify field maintenance of
loose, damaged, or corroded
parts.
Inside Rear Door
13 Before Fuel tank 1. Open rear door.
(Figure 1, Item
5)
2. Inspect fuel tank (Figure 1, Any classification of fuel leak
Item 5) for leaks, damage, or or damaged, loose, or
loose or missing parts. missing parts.
3. Notify field maintenance of
defects.
14 Before Fuel system 1. Inspect for leaks, damage, or Any classification of fuel leak
hoses loose or missing hardware. or damaged, loose, or
missing parts.
2. Notify field maintenance of
defects.
15 Before Fuel pumps and 1. Inspect fuel pumps and fuel Any classification of fuel leak
fuel manifold manifold for leaks or damage. or damage.
2. Notify field maintenance of
defects.
16 Before Electrical 1. Inspect electrical connectors
connections for looseness.
2. Push visibly loose connectors Connector looseness cannot
into place. be resolved.
3. Notify field maintenance of
defects.
4. Close rear door.

0013-9
 TM 9-6115-753-10 0013

Table 1. PMCS for the 60 kW AMMPS Generator Set — Continued.

ITEM TO BE
ITEM CHECKED OR EQUIPMENT NOT
NO. INTERVAL SERVICED PROCEDURE READY/AVAILABLE IF:
Top Panel
17 Before Top panel 1. Inspect top panel for damage Top panel missing or
or corroded parts. punctured.
2. Notify field maintenance of
minor corrosion or damage.
3. Inspect air intake and exhaust
grates for debris.
4. Remove debris from intake and Clogged intake and/or
exhaust grates if present. exhaust grates cannot be
resolved.
18 Before IDs and 1. Ensure label is present,
information secure, and legible. One is
labels required (WP 0005, Operation
Under Usual Conditions).
2. Notify field maintenance of
missing, loose, or illegible plates.
19 Before Coolant 1. Remove coolant overflow bottle
cap.
2. Inspect coolant color for Milky or dirty color.
contamination.
3. Inspect coolant level and add
as required (WP 0015, Service
Cooling System).
4. Replace coolant overflow bottle
cap.
20 Before Radiator, 1. Inspect for leaks. Any Class III coolant leaks.
exterior
2. Notify field maintenance for
corrosion and Class I, II, or III
leaks.
3. Inspect radiator for loose Damaged, loose, or missing
mounting and obstructions in parts (including radiator cap),
cooling fins. or cooling fins obstructed.
4. Notify field maintenance of
defects.
21 Before Radiator, 1. Energize DCS and examine
interior coolant temperature indicator
(WP 0005, Operation Under
Usual Conditions).
2. Do not proceed to step 3
unless coolant temperature is
below 100°F (38°C).
3. Remove radiator cap.
4. Inspect coolant color for Milky or dirty color.
contamination.
5. Inspect coolant level and add
as required (WP 0015, Service
Cooling System).
6. Notify field maintenance of
defects.

0013-10
 TM 9-6115-753-10 0013

Table 1. PMCS for the 60 kW AMMPS Generator Set — Continued.

ITEM TO BE
ITEM CHECKED OR EQUIPMENT NOT
NO. INTERVAL SERVICED PROCEDURE READY/AVAILABLE IF:
22 Before Intercooler 1. Inspect intercooler for loose Greater than 30% of cooling
mounting, damage, and fins obstructed or damaged
obstruction in cooling fins. by puncture.
2. Notify field maintenance of
loose mounting, damage, and
obstruction of cooling fins.
3. Inspect air lines and Air lines punctured or
connections to intercooler for disconnected.
damage, corrosion, and proper
connection.
4. Notify field maintenance of
damage or corrosion.
23 Before Oil coalescer 1. Inspect panel below oil Class III oil leaks.
coalescer for evidence of oil
leaks.
2. Notify field maintenance of
Class I, II or III oil leaks.
24 Before Muffler 1. Inspect muffler for damage, Muffler punctured, damaged,
punctures, or corrosion. or corroded through to
interior.
2. Inspect muffler rain cap for Rain cap missing or
proper operation, damage, or inoperable.
corrosion.
3. Notify field maintenance of
minor corrosion or damage to any
part of muffler.
Right-Side Panel
25 Before Right-side panel 1. Inspect right-side panel for Right-side panel missing or
damage or corroded parts. punctured.
2. Notify field maintenance of
minor corrosion or damage.
26 Before ID plates and 1. Ensure ID plates and
information information labels are present,
labels secure, and legible. Six are
required (WP 0005, Operation
Under Usual Conditions).
2. Notify field maintenance of
missing, loose, or illegible plates.
27 Before Skid base 1. Inspect skid base for cracks Skid base cracked or shows
and corrosion. signs of structural damage.
2. Notify field maintenance of
minor corrosion or damage.
28 Before Output box door 1. Inspect door, hinges, seals, Door cannot be secured.
(Figure 2, Item and latch for damage or loose or
1) corroded parts.
2. Notify field maintenance of
damage or loose or corroded
parts.

0013-11
 TM 9-6115-753-10 0013

Table 1. PMCS for the 60 kW AMMPS Generator Set — Continued.

ITEM TO BE
ITEM CHECKED OR EQUIPMENT NOT
NO. INTERVAL SERVICED PROCEDURE READY/AVAILABLE IF:
29 Before Right-side door 1. Inspect door, hinges, seals, Door cannot be secured.
and latch for damage or loose or
corroded parts.
2. Notify field maintenance of
damage or loose or corroded
parts.
Inside Output Box Door
30 Before Output 1. Open output box door (Figure
connections 2, Item 1).
2. Inspect ground and load cable
connections for tightness to
output load board and by pulling
gently.
3. Tighten as required (WP 0005, Cable cannot be secured.
Operation Under Usual
Conditions).
4. Inspect neutral busbar, Neutral busbar missing or
terminals, and terminal nuts for disconnected.
damage, looseness, or corrosion.
5. Notify field maintenance of
damage, loose, or corroded
terminals, neutral busbar, or
terminal nuts.
31 Before Output terminal 1. Inspect output terminal board Output terminal board
board protective protective cover for cracks, protective cover missing,
cover corroded hinge, or damage. damaged, or punctured.
Missing or damaged hinge or
hinge fasteners.
2. Notify field maintenance of
corroded hinge or minor damage.
32 Before ID plates and 1. Ensure ID plates and
information information labels are present,
labels secure, and legible. Two are
required (WP 0005, Operation
Under Usual Conditions).
2. Notify field maintenance of
missing, loose, or illegible plates.
33 Before Terminal nut 1. Inspect for damage.
wrench
2. Notify field maintenance of
damage or missing terminal nut
wrench.
3. Close output box door (Figure
2, Item 1).
Inside Right-Side Door
34 Before Engine and 1. Open right-side door.
compartment
base
2. Inspect for leaks. Any classification of fuel leak.
Class III oil or coolant leaks.

0013-12
 TM 9-6115-753-10 0013

Table 1. PMCS for the 60 kW AMMPS Generator Set — Continued.

ITEM TO BE
ITEM CHECKED OR EQUIPMENT NOT
NO. INTERVAL SERVICED PROCEDURE READY/AVAILABLE IF:
3. Notify field maintenance of any
Class I, II, or III oil or coolant
leaks.
35 Before Internal exhaust 1. Inspect internal exhaust pipe Any puncture to exhaust pipe.
pipe for damage, corrosion, or
puncture.
2. Inspect exhaust pipe clamps Missing clamp or separated
for looseness or corrosion. exhaust joint.
3. Notify field maintenance of
loose clamp.
36 Before Radiator hoses 1. Inspect radiator hoses and Class III coolant leak, missing
and pipes clamps for leaks, looseness, clamp, or puncture of hoses
(Figure 2, Item damage, corrosion, or puncture. or pipes.
4)
2. Notify field maintenance of any
Class I, II, or III coolant leaks.

WARNING
When operating, turbocharger has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow turbocharger to cool before performing maintenance. Wear
gloves and additional protective clothing as required. Failure to comply may cause injury or
death to personnel.
37 Before Turbocharger 1. Inspect for leaks, corrosion, Any classification of oil leak,
damage, loose fittings, and damaged or missing parts, or
missing parts. loose fittings.
2. Notify field maintenance for
corrosion and Class I, II, or III
leaks.
38 Before Air lines 1. Inspect for punctured, Punctured, collapsed, or
collapsed, or loose connections. disconnected air lines.
2. Notify field maintenance of
loose connections.
39 Before Air filter 1. Check air filter restriction gage. Tripped air flow restriction
restriction gage Replace air cleaner (Figure 4, gage.
Item 1) element and reset
restriction gage as required (WP
0014, Service Air Cleaner).
2. Notify field maintenance of
defects.
40 Before Winterization kit 1. Inspect winterization kit heater Any classification of fuel leak
(if installed) body for leaks. or Class III coolant leak.
2. Inspect winterization kit fuel Any classification of fuel leak
pump and lines for leaks or or missing clamp.
missing or damaged clamps.
3. Inspect winterization kit coolant Class III coolant leak, missing
hoses and clamps for leaks, clamp, or puncture of hoses.
looseness, damage, corrosion, or
puncture.

0013-13
 TM 9-6115-753-10 0013

Table 1. PMCS for the 60 kW AMMPS Generator Set — Continued.

ITEM TO BE
ITEM CHECKED OR EQUIPMENT NOT
NO. INTERVAL SERVICED PROCEDURE READY/AVAILABLE IF:
4. Notify field maintenance of any
Class I, II, or III coolant leaks.

NOTE
Oil lines are located at the oil filter/cooler, the turbocharger, and the fuel injection pump.
41 Before Oil lines and oil 1. Inspect oil lines for leaks. Class III oil leak.
filter (Figure 2,
Item 2)
2. Inspect oil filter (Figure 2, Item Class III oil leak.
2) for leaks.
3. Ensure oil filter (Figure 2, Item
2) tightly seated.
4. Hand tighten oil filter (Figure 2, Oil filter cannot be tightened.
Item 2) if loose.
5. Notify field maintenance of
Class I, II, or III oil leaks.
42 Before Oil level 1. Check oil level (WP 0017,
Service Engine Oil).
2. Add oil as required (WP 0017,
Service Engine Oil).
3. Notify field maintenance of
defects.
43 Before Battery- 1. Inspect for loose wires or Loose wires or cracked
charging cracked housing. housing.
alternator
(Figure 2, Item
3)
2. Notify field maintenance of
defects.
44 Before Batteries 1. Inspect batteries (Figure 2, Cracked or swollen casing.
(Figure 2, Item Item 5) for cracked or swollen
5) and cables casings, corroded terminals,
loose or corroded cables and
connections.
2. Notify field maintenance of
corroded terminals.
45 Before Starter (Figure 1. Inspect starter (Figure 2, Item
2, Item 6) 6) for damage, corrosion, or loose
wiring.
2. Notify field maintenance of
defects.
46 Before AC generator 1. Inspect AC generator for Cracked generator housing,
cracks, breaks, and loose or broken, or missing hardware.
missing hardware or wiring.
2. Inspect AC generator wiring for Loose, broken, or missing
corrosion, breaks, and loose or wiring.
missing wiring.

0013-14
 TM 9-6115-753-10 0013

Table 1. PMCS for the 60 kW AMMPS Generator Set — Continued.

ITEM TO BE
ITEM CHECKED OR EQUIPMENT NOT
NO. INTERVAL SERVICED PROCEDURE READY/AVAILABLE IF:
3. Notify field maintenance of
corrosion.
47 Before Document box 1. Inspect document box for
damage, missing or loose
hardware, or missing contents.
2. Notify field maintenance of
defects noted.
3. Close right-side door.
Front Panel
48 Before Front panel 1. Inspect front panel for damage Front panel missing or
or corroded parts. punctured.
2. Notify field maintenance of
minor corrosion or damage.
49 Before ID plates and 1. Ensure label is present,
information secure, and legible. One is
labels required (WP 0005, Operation
Under Usual Conditions).
2. Notify field maintenance of
missing, loose, or illegible plate.
50 Before NATO slave 1. Inspect for damaged, loose, or Damaged, loose, or corroded
receptacle corroded connections. connections.
(Figure 3, Item
1)
2. Inspect for missing safety cap. Safety cap missing.
3. Notify field maintenance of
defects.
Left-Side Panel
51 Before Left-side panel 1. Inspect left-side panel for Left-side panel missing or
damage or corroded parts. punctured.
2. Notify field maintenance of
minor corrosion or damage.
3. Inspect air intake grate for
debris.
4. Remove debris from intake Clogged intake grate cannot
grate if present. be resolved.
5. Notify field maintenance of
defects.
52 Before Skid base 1. Inspect skid base for cracks Skid base cracked or shows
and corrosion. signs of structural damage.
2. Notify field maintenance of
minor corrosion or damage.
53 Before Oil drain outlet 1. Inspect oil drain outlet (Figure Class III leak.
(Figure 4, Item 4, Item 4) for leaks.
4)
2. Notify field maintenance of
Class I, II, or III leaks.
3. Notify field maintenance of
missing, loose, or cracked oil
drain outlet cap.

0013-15
 TM 9-6115-753-10 0013

Table 1. PMCS for the 60 kW AMMPS Generator Set — Continued.

ITEM TO BE
ITEM CHECKED OR EQUIPMENT NOT
NO. INTERVAL SERVICED PROCEDURE READY/AVAILABLE IF:
54 Before Left-side door 1. Inspect door, hinges, seals, Door cannot be secured.
and latch for damage or loose or
corroded parts.
2. Notify field maintenance of
defects.
Inside Left-Side Door
55 Before Engine and 1. Open left-side door.
compartment
base
2. Inspect for leaks. Any classification of fuel leak.
Class III oil or coolant leaks.
3. Notify field maintenance of any
Class I, II, or III oil or coolant
leaks.
56 Before Oil drain line 1. Ensure oil drain line ball valve
ball valve is in off position (handle
perpendicular to line).
2. Notify field maintenance if oil
drain line ball valve is inoperable.
57 Before Air cleaner 1. Check air cleaner (Figure 4, Damage that restricts air flow.
(Figure 4, Item Item 1) for damage.
1) assembly
2. Open dust ejector valve and
remove dust and particles (WP
0014, Service Air Cleaner).
3. Notify field maintenance of
defects.

NOTE
Oil lines are located at the oil filter/cooler, the turbocharger, and the fuel injection pump.
58 Before Oil lines 1. Inspect oil lines for leaks. Class III oil leak.
2. Notify field maintenance of
Class I, II, or III oil leaks.
59 Before Fuel injector 1. Inspect for leaks, loose Any fuel leak or kinked lines.
pump and lines connections, damage, or kinked
lines.
2. Notify field maintenance of
minor damage.
60 Before Fuel feed lines 1. Inspect for leaks. Any classification of fuel leak.
(Figure 4, Item
2)
2. Notify field maintenance of
defects.
61 Before Fuel filter/water 1. Inspect fuel filter/water Any classification of fuel leak.
separator separator (Figure 4, Item 3) for
(Figure 4, Item leaks, damage, or loose fittings.
3)

0013-16
 TM 9-6115-753-10 0013

Table 1. PMCS for the 60 kW AMMPS Generator Set — Continued.

ITEM TO BE
ITEM CHECKED OR EQUIPMENT NOT
NO. INTERVAL SERVICED PROCEDURE READY/AVAILABLE IF:
2. Notify field maintenance of
loose fittings or damage.
3. Inspect fuel filter
water/separator bowl for water or
contaminants (WP 0016, Service
Fuel System).
4. Drain water and contaminants
from fuel filter/water separator
(Figure 4, Item 3) if present (WP
0016, Service Fuel System).
5. Notify field maintenance of
defects.
62 Before Spin-on fuel 1. Inspect spin-on fuel filter for Any classification of fuel leak.
filter and lines leaks, damage, or loose fittings.
2. Notify field maintenance of
loose fittings or damage.
3. Inspect fuel lines for leaks or Any classification of fuel leak.
loose connections.
4. Notify field maintenance of
loose fittings.
63 Before AC generator 1. Inspect AC generator for Cracked generator housing,
cracks, breaks, and loose or broken, or missing hardware.
missing hardware.
2. Notify field maintenance of
corrosion.
64 Before Radiator hoses 1. Inspect radiator hoses and Class III coolant leak, missing
and pipes clamps for leaks, looseness, clamp, or puncture of hoses
(Figure 2, Item damage, corrosion, or puncture. or pipes.
4)
2. Notify field maintenance of any
Class I, II, or III coolant leaks.
65 Before Oil filler tube 1. Inspect for leaks, damage, or Class III leak or missing cap.
missing cap.
2. Notify field maintenance of any
Class I, II, or III oil leaks.
66 Before Relay panel 1. Inspect (visually only) relay Relay panel (Figure 4, Item 5)
(Figure 4, Item panel (Figure 4, Item 5) for cover punctured or
5) damage and connectors for connectors disconnected.
looseness.
2. Connect loose or disconnected Connectors cannot be
connectors. reconnected.
3. Notify field maintenance of
minor damage and looseness
67 Before Storage box 1. Inspect storage box for
damage, missing or loose
hardware, or missing contents.
2. Notify field maintenance of
defects noted.
3. Close left-side door.

0013-17
 TM 9-6115-753-10 0013

Table 1. PMCS for the 60 kW AMMPS Generator Set — Continued.

ITEM TO BE
ITEM CHECKED OR EQUIPMENT NOT
NO. INTERVAL SERVICED PROCEDURE READY/AVAILABLE IF:
4. Start generator set (WP 0005,
Operation Under Usual
Conditions).
During
Top Panel, Rear Panel, and
Inside Rear Door
68 During DCS 1. Inspect indicators for proper Indicators not operating
operation, erratic display, obvious properly.
improper reporting (example: unit
overheated, coolant temperature
indicates 150°F (65.5°C)).
2. Check battery voltage on DCS Battery voltage is below 16
operator’s main screen (WP VDC.
0005, Operation Under Usual
Conditions).
3. Ensure circuit interrupter is
closed as required.
4. Close as required. Circuit interrupter will not
remain closed.
5. Notify field maintenance of
defects.
69 During Engine 1. Check color of exhaust smoke. Exhaust smoke is black,
white, or blue.
2. Listen for any unusual engine Unusual, severe engine
noises. noises.
3. Notify field maintenance of
defects.
70 During Ground rod and 1. Inspect for arcing, damage, Arcing, damaged, or loose
connections corrosion, and loose connections. connections.
2. Notify field maintenance of
corroded parts.
71 During Convenience 1. Reset GFCI circuit breaker
receptacle (WP 0005, Operation Under
Usual Conditions).
2. Notify field maintenance of
defects.
72 During Rear door 1. Inspect door, hinges, seals, Door cannot be secured.
and latch for damage and loose
or corroded parts.
2. Notify field maintenance of
damage or loose or corroded
parts.

0013-18
 TM 9-6115-753-10 0013

Table 1. PMCS for the 60 kW AMMPS Generator Set — Continued.

ITEM TO BE
ITEM CHECKED OR EQUIPMENT NOT
NO. INTERVAL SERVICED PROCEDURE READY/AVAILABLE IF:

CAUTION
Operating generator set with doors open or with panels removed for an extended length of time
will cause engine to overheat. Do not operate generator with doors open or panels removed for
longer than necessary to complete the task. Monitor DCS temperature indicator to prevent
engine overheating. Failure to comply will cause damage to equipment.
73 During Fuel tank 1. Open rear door.
(Figure 1, Item
5)
2. Inspect fuel tank (Figure 1, Any classification of fuel leak,
Item 5) for leaks or damage or damage, or any loose or
loose or missing parts. missing parts.
3. Notify field maintenance of
defects.
74 During Fuel system 1. Inspect for leaks, damage, or Any classification of fuel leak
hoses loose or missing hardware. or damaged, loose, or
missing parts.
2. Notify field maintenance of
defects.
75 During Fuel pumps and 1. Inspect fuel pumps and fuel Any classification of fuel leak
fuel manifold manifold for leaks or damage. or damage.
2. Notify field maintenance of
defects.
76 During Electrical 1. Inspect electrical connectors Connector loose.
connections for looseness.
2. Notify field maintenance of
defects.
3. Close rear door.
77 During Fuel drain fitting 1. Inspect fuel drain for leaks, Any fuel leak or missing cap.
missing cap, or damage.
2. Notify field maintenance of
defects.
78 During Coolant 1. Inspect for leaks or loose Class III coolant leak or
overflow bottle hoses. missing cap.
(Figure 1, Item
2)
2. Check coolant level (WP 0015,
Service Cooling System).
3. Notify field maintenance of
defects.

0013-19
 TM 9-6115-753-10 0013

Table 1. PMCS for the 60 kW AMMPS Generator Set — Continued.

ITEM TO BE
ITEM CHECKED OR EQUIPMENT NOT
NO. INTERVAL SERVICED PROCEDURE READY/AVAILABLE IF:

CAUTION
Operating generator set with doors open or with panels removed for an extended length of time
will cause engine to overheat. Do not operate generator with doors open or panels removed for
longer than necessary to complete your task. Monitor DCS temperature indicator to prevent
engine overheating. Failure to comply will cause damage to equipment.
Inside Right-Side Door
79 During Engine and 1. Open right-side door.
compartment
base
2. Inspect for leaks. Any classification of fuel leak.
Class III oil or coolant leaks.
3. Notify field maintenance of any
Class I, II, or III oil or coolant
leaks.

NOTE
Oil lines are located at the oil filter/cooler and turbocharger.
80 During Oil lines 1. Inspect oil lines for leaks. Class III oil leak.
2. Notify field maintenance of
Class I, II, or III oil leaks.

NOTE
Dipstick is located inside right-side door.

Check engine oil level each time the fuel tank (Figure 1, Item 5) is filled or once every 8 hr of
continuous operation utilizing an auxiliary fuel source.
81 During Oil level 1. Check oil level (WP 0017,
Service Engine Oil).
2. Add oil as required (WP 0017,
Service Engine Oil).
3. Notify field maintenance of
defects.
82 During AC 1. Inspect for excessive noise Excessive noise and/or
generator set and vibration. vibration.
2. Inspect for external damage, Signs of damage, arcing, or
arcing, and loose connections. loose connections.
3. Notify field maintenance of
defects.
4. Close right-side door.

0013-20
 TM 9-6115-753-10 0013

Table 1. PMCS for the 60 kW AMMPS Generator Set — Continued.

ITEM TO BE
ITEM CHECKED OR EQUIPMENT NOT
NO. INTERVAL SERVICED PROCEDURE READY/AVAILABLE IF:

NOTE
Observe fan operation through grate on left-side panel.
Left-Side Panel and Inside Left-
Side Door
83 During Cooling fans (4) 1. Inspect for obstruction, Damaged or loose fan.
damage, and looseness.
2. Notify field maintenance of
defects.

CAUTION
Operating generator set with doors open or with panels removed for an extended length of time
will cause engine to overheat. Do not operate generator with doors open or panels removed for
longer than necessary to complete your task. Monitor DCS temperature indicator to prevent
engine overheating. Failure to comply will cause damage to equipment.

NOTE
Oil lines are located at the fuel injection pump and the oil drain assembly at the bottom of the
oil pan.
84 During Oil lines 1. Open left-side door.
2. Inspect oil lines for leaks. Class III oil leak.
3. Notify field maintenance of
Class I, II, or III oil leaks.
4. Ensure oil fill cap is tightened Oil fill cap missing.
securely.
5. Notify field maintenance of
defects.
85 During Fuel lines and 1. Inspect fuel lines, fittings, and Any classification of fuel leak.
fuel filter/water fuel filter/water separator (Figure
separator 4, Item 3) for leaks, looseness, or
(Figure 4, Item corrosion.
3)
2. Notify field maintenance of
loose fittings or corrosion.
86 During Spin-on fuel 1. Inspect spin-on fuel filter, Any classification of fuel leak.
filter and lines fittings, and lines for leaks,
looseness, or corrosion.
2. Notify field maintenance of
defects.
87 During AC generator 1. Inspect for excessive noise and Excessive noise and/or
set vibration. vibration.
2. Inspect for external damage, Signs of damage, arcing, or
arcing, and loose connections. loose connections.
3. Notify field maintenance of
defects.
0013-21
 TM 9-6115-753-10 0013

Table 1. PMCS for the 60 kW AMMPS Generator Set — Continued.

ITEM TO BE
ITEM CHECKED OR EQUIPMENT NOT
NO. INTERVAL SERVICED PROCEDURE READY/AVAILABLE IF:
4. Close left-side door.

NOTE
Allow generator set to cool for 15 min before performing after operation PMCS. Perform after
operation PMCS in the sequence indicated, beginning at the rear panel and proceeding
counterclockwise to the left-side panel.
After
88 After Fuel fill (Figure 1. Inspect the auxiliary fuel Damaged, corroded, or
1, Item 1) connections for damage, missing missing parts.
parts, or corrosion.
2. Clean fuel fill (Figure 1, Item 1)
area of dirt and debris (WP 0016,
Service Fuel System).
3. Remove fuel fill cap.
4. Inspect cap and strainer for Damaged or missing cap.
dirt, wear, and defects. Punctured or missing strainer.
5. Inspect chain and gasket for Damaged or missing gasket.
wear.
6. Replace fuel fill cap. Fuel fill cap will not seal.
7. Inspect grounding stud for Grounding stud missing or
damage or corrosion. corroded.
8. Notify field maintenance of
defects.
89 After Fuel tank 1. Refill fuel tank (Figure 1, Item
(Figure 1, Item 5) to capacity (WP 0016, Service
5) Fuel System).
2. Notify field maintenance of
defects.
90 After Coolant 1. Inspect for leaks, cracks, loose Class III coolant leak. Missing
overflow bottle hoses, or missing cap. cap.
(Figure 1, Item
2)
2. Connect loose hoses. Hose cannot be reconnected.
3. Check coolant level (WP 0015,
Service Cooling System).
4. Fill cooling system as required
(WP 0015, Service Cooling
System).
5. Notify field maintenance of
defects.
91 After Output 1. Inspect ground and load cable
connections connections for tightness to
output load board by pulling
gently.
2. Tighten as required (WP 0005,
Operation Under Usual
Conditions).

0013-22
 TM 9-6115-753-10 0013

Table 1. PMCS for the 60 kW AMMPS Generator Set — Continued.

ITEM TO BE
ITEM CHECKED OR EQUIPMENT NOT
NO. INTERVAL SERVICED PROCEDURE READY/AVAILABLE IF:
3. Inspect terminals and terminal Terminal board shows
nuts for indications of arcing or evidence of arcing or high
high temperature. temperature.
4. Notify field maintenance of
defects.
92 After Output terminal 1. Inspect output terminal board Output terminal board
board protective protective cover for indications of protective cover missing,
cover arcing or high temperature. cracked through, or melted.
Missing or damaged hinge or
hinge fasteners.
2. Notify field maintenance of
defects.
93 After Oil drain outlet 1. Inspect oil drain outlet (Figure Class III leak.
(Figure 4, Item 4, Item 4) for leaks.
4)
2. Notify field maintenance of
Class I, II, or III leaks.
3. Notify field maintenance of
missing, loose, or cracked oil
drain outlet cap.
94 After Engine and 1. Inspect for leaks. Any classification of fuel leak.
compartment Class III oil or coolant leaks.
base right-side.
2. Notify field maintenance of any
Class I, II, or III oil or coolant
leaks.

NOTE
Dipstick is located inside right-side door. Oil fill is located inside left-side door.
95 After Oil level 1. Check oil level (WP 0017,
Service Engine Oil).
2. Add oil as required (WP 0017,
Service Engine Oil).
3. Ensure oil fill cap is tightened Oil fill cap missing.
securely.
4. Notify field maintenance of
defects.
96 After Batteries 1. Inspect batteries and cables for Cracked or swollen casing.
(Figure 2, Item cracked or swollen casings or
5) and cables corroded terminals, cables, or
fittings.
2. Notify field maintenance of
defects.
97 After Engine and 1. Inspect for leaks. Any fuel leaks. Class III oil or
compartment coolant leaks.
base left-side.

0013-23
 TM 9-6115-753-10 0013

Table 1. PMCS for the 60 kW AMMPS Generator Set — Continued.

ITEM TO BE
ITEM CHECKED OR EQUIPMENT NOT
NO. INTERVAL SERVICED PROCEDURE READY/AVAILABLE IF:
2. Notify field maintenance of any
Class I, II, or III fuel, oil, or
coolant leaks.
98 After Intake and 1. Clean debris from all intake
exhaust grates and exhaust grates.
2. Notify field maintenance if
clogged grates cannot be
resolved.

END OF WORK PACKAGE

0013-24
 TM 9-6115-753-10 0014

OPERATOR MAINTENANCE
AMMPS 60KW GENERATOR SET
SERVICE AIR CLEANER

INITIAL SETUP:

Test Equipment Personnel Required

Not Applicable Operator (1)
Tools and Special Tools References
Not Applicable Not Applicable
Materials/Parts Equipment Conditions
Element, air cleaner filter (WP 0021, Expendable Engine control switch OFF (WP 0005, Operation
and Durable Items List, Item 2) Under Usual Conditions)
Unit cool

SERVICE AIR CLEANER

Inspect Air Filter Restriction Indicator

WARNING
Flying debris or material may enter eyes or strike the face. Wear appropriate eye/face protection
while performing maintenance tasks. Failure to comply may cause injury or death to personnel.

Figure 1. Air Cleaner — Location.

0014-1
 TM 9-6115-753-10 0014

Figure 2. Air Cleaner/Air Filter Restriction Indicator and Dust Ejector Valve.

1. Ensure equipment conditions are met in order presented in initial setup.

NOTE
Both right- and left-side doors must be opened to allow enough natural light to enter the engine
compartment so that the air filter restriction indicator (Figure 2, Item 1) can be viewed.
2. Open right- and left-side doors and locate air filter (Figure 1).
3. Locate air filter restriction indicator (Figure 2, Item 1) mounted on exit side elbow of air cleaner.
4. Inspect the air filter restriction indicator (Figure 2, Item 1) visually:
a. If no red shows inside the air filter restriction indicator (Figure 2, Item 1), the air filter element is in
serviceable condition.
b. If a red band is visible inside the air filter restriction indicator (Figure 2, Item 1), the air filter element must
be changed.
c. If filter element change is indicated, proceed to Remove Air Cleaner Filter Element task.
5. Close right- and left-side doors.

END OF TASK

0014-2
 TM 9-6115-753-10 0014

Remove Air Cleaner Filter Element

1. Open left- and right-side doors.

Figure 3. Air Cleaner Assembly.

2. Release lever on air cleaner base cover (Figure 3, Item 3) and twist cover counterclockwise until there is
resistance.
3. Pull air cleaner base cover (Figure 3, Item 3) straight down to expose filter element (Figure 3, Item 2) and
remove cover from unit.
4. Inspect unit for damage and replace as required.
5. Turn end of filter element (Figure 3, Item 2) in either direction to disengage seal.
6. Remove filter element (Figure 3, Item 2) gently from air cleaner housing (Figure 3, Item 1) by pulling
downward and discard element.

END OF TASK

0014-3
 TM 9-6115-753-10 0014

Install Air Cleaner Filter Element

1. Remove dirt and debris from air cleaner base cover (Figure 3, Item 3), sealing surfaces, and inside of air
cleaner housing (Figure 3, Item 1).
2. Insert new filter element (Figure 3, Item 2) into air cleaner housing (Figure 3, Item 1) and twist in either
direction to secure.

NOTE
When air cleaner base cover (Figure 3, Item 3) is placed on bottom of air cleaner and turned
clockwise, a click can be heard when the cover is properly secured.
3. Position air cleaner base cover (Figure 3, Item 3) on housing mount and turn clockwise to secure.
4. Reset air filter restriction indicator (Figure 2, Item 1) on air cleaner assembly (Figure 1) by pushing yellow
button on air filter restriction indicator (Figure 2, Item 1).
5. Close left- and right-side door.
6. Ensure that field maintenance personnel have updated any maintenance action items within the DCS
[Maintenance] screen after air filter has been changed.

END OF TASK

Clean Air Cleaner Dust Ejector Valve

1. Open left-side door.

2. Locate air cleaner dust ejector valve (Figure 2, Item 2) on base of air cleaner assembly.
3. Squeeze top and bottom of air cleaner dust ejector valve (Figure 2, Item 2) to open the air cleaner dust
ejector valve (Figure 2, Item 2) and eject any excess dust or dirt that has accumulated inside the air cleaner
housing into a suitable container.
4. Release the air cleaner dust ejector valve (Figure 2, Item 2) to close.
5. Close left-side door.

END OF TASK

END OF WORK PACKAGE

0014-4
 TM 9-6115-753-10 0015

OPERATOR MAINTENANCE
AMMPS 60KW GENERATOR SET
SERVICE COOLING SYSTEM

INITIAL SETUP:

Test Equipment Personnel Required

Not Applicable Operator (1)
Tools and Special Tools References
Flashlight (WP 0021, Expendable and Durable Items Not Applicable
List, Item 3)
Equipment Conditions
Materials/Parts
Engine control switch OFF (WP 0005, Operation
Antifreeze (WP 0021, Item 1) Under Usual Conditions)
Funnel, flexible (WP 0021, Item 5) Unit cool
Rags, wiping (WP 0021, Item 9)
Water, distilled (WP 0021, Item 11)

SERVICE COOLING SYSTEM

WARNING

x High voltage is produced when generator set is in operation. Never attempt to start the generator
set unless it is properly grounded. Do not ground yourself in standing water. Never attempt to
connect or disconnect load cables while the generator set is operating. Failure to comply may
cause injury or death to personnel.

x Hearing protection is required during maintenance or repair with engine running. Failure to
comply can cause hearing loss.

x Cooling system operates at high temperature and pressure. Contact with high-pressure steam
and/or liquids can cause burns and scalding. Do not open radiator cap unless coolant
temperature is below 100°F (38°C). Failure to comply may cause injury or death to personnel.

x Hot coolant can burn. If the radiator cap is hot to the touch, it is too hot to open. Allow the coolant
to cool before opening the radiator cap. Wear gloves, additional protective clothing, and goggles
as required. Contact with high-pressure steam and/or liquids can cause burns and scalding.
Failure to comply may cause injury or death to personnel.

x Cooling system operates at high temperature and pressure. Contact with high-pressure steam
and/or liquids can cause burns and scalding. Shut down generator set and allow system to cool
before performing checks, services, and maintenance. Wear gloves, additional protective
clothing, and goggles as required. Contact with high-pressure steam and/or liquids can cause
burns and scalding. Failure to comply may cause injury or death to personnel.

0015-1
 TM 9-6115-753-10 0015

Check Coolant Level

Figure 1. Coolant Overflow Bottle — Location.

1. Ensure equipment conditions are met in order presented in initial setup.

0015-2
 TM 9-6115-753-10 0015

Figure 2. Coolant Recovery Assembly.

NOTE
Coolant overflow bottle (Figure 2, Item 1) is visible from the outside of the generator set above
the fuel fill area (Figure 3, Item 1).
2. Locate coolant overflow bottle (Figure 1) (Figure 2, Item 1).

0015-3
 TM 9-6115-753-10 0015

Figure 3. Coolant Level.

3. Inspect the level of the coolant in the coolant overflow bottle (Figure 2, Item 1) visually.
a. The coolant level should be between the HIGH (Figure 3, Item 2) and LOW (Figure 3, Item 4) marks of
the coolant overflow bottle (Figure 2, Item 1).
b. Add coolant (Fill Coolant Overflow Bottle task) if the coolant level is below the LOW (Figure 3, Item 4)
level.

END OF TASK

0015-4
 TM 9-6115-753-10 0015

Fill Coolant Overflow Bottle

WARNING
Hot coolant can burn. If the coolant overflow bottle or the radiator cap is hot to the touch, it is too
hot to open. Allow the coolant to cool before opening the coolant overflow bottle or radiator cap.
Wear gloves, additional protective clothing, and goggles as required. Contact with high-pressure
steam and/or liquids can cause burns and scalding. Failure to comply may cause injury or death
to personnel.
1. Remove radiator cap (Figure 4, Item 1) from radiator.

Figure 4. Radiator Fill — Exterior.

0015-5
 TM 9-6115-753-10 0015

Figure 5. Radiator Fill — Interior.

CAUTION
While filling the coolant, air must be vented from the engine coolant passages. Vent air by
opening pressure relief valve (Figure 6) and pouring coolant slowly into the filler opening. Failure
to comply may cause damage to equipment.
2. Remove coolant overflow bottle filler cap (Figure 2, Item 2 and Figure 3, Item 3) from coolant overflow bottle
(Figure 2, Item 1).

0015-6
 TM 9-6115-753-10 0015

Figure 6. Pressure Relief Valve.

3. Open left-side door.

4. Open relief valve fitting (Figure 6, Item 2) on upper radiator/lower radiator interconnecting tube (Figure 6,
Items 1 and 4) by lifting the relief valve lever (Figure 6, Item 3) 90 degrees from the position shown.

CAUTION
Do not use antifreeze and scale inhibiter at the same time. Failure to comply may cause damage
to equipment.
5. Add coolant until the level reaches the LOW (Figure 3, Item 4) mark on the coolant overflow bottle (Figure 2,
Item 1).

CAUTION
Do not use antifreeze and scale inhibiter at the same time. Failure to comply may cause damage
to equipment.

NOTE
The following steps assume there is no coolant present in the coolant overflow bottle (Figure 2,
Item 1).

Pour coolant slowly into the radiator to allow trapped air to escape.
6. Fill the radiator with approved coolant until the coolant level reaches the narrow opening at the bottom of the
filler neck (Figure 5, Item 1).

0015-7
 TM 9-6115-753-10 0015

7. Inspect for missing, damaged, and/or cracked radiator or coolant overflow bottle filler cap gasket.
8. Contact field maintenance for missing, damaged, and/or cracked radiator or coolant overflow bottle filler cap
and/or gasket.

CAUTION
Be sure to close radiator cap (Figure 4, Item 1) and coolant overflow bottle filler cap (Figure 2,
Item 2 and Figure 3, Item 3) securely to avoid coolant leakage. Engine may overheat if radiator
cap (Figure 4, Item 1) and/or coolant overflow bottle filler cap (Figure 2, Item 2 and Figure 3, Item
3) are loose. Failure to comply may cause damage to equipment.
9. Reinstall radiator cap (Figure 3, Item 1 and Item 2).
10. Reinstall coolant overflow bottle filler cap (Figure 2, Item 2 and Figure 3, Item 3).
11. Return the relief valve lever (Figure 6, Item 3) to original position as shown in Figure 6.
12. Wipe up any spilled coolant and dispose of IAW local SOP.
13. Close left-side door.

CAUTION
Operating generator set with doors open or with panels removed for an extended length of time
will cause engine to overheat. Do not operate generator set with doors open or panels removed
for longer than necessary to complete your task. Monitor DCS temperature indicator to prevent
engine overheating. Failure to comply will cause damage to equipment.
14. Start engine and operate until the engine has reached 195°F (90°C) (WP 0005, Operation Under
Usual Conditions).
15. Shut down engine and allow it to cool.
16. Recheck coolant level. See Check Coolant Level task.
17. Fill as required. See Fill Coolant Overflow Bottle task.

END OF TASK

0015-8
 TM 9-6115-753-10 0015

Inspect Radiator Hoses, Interconnecting Tubes, and Clamps

Figure 7. Cooling System Hoses, Interconnecting Tubes, and Clamps — Left Side.

1. Open right- and left-side doors.

CAUTION
Loss of coolant may be caused by leaks in the cooling system. Visually inspect all cooling system
hoses and clamps, as well as radiator and coolant overflow bottle for signs of coolant leaks.
Operation is permitted with Class I or II leaks present. Notify field maintenance of all leaks. If a
Class III leak is found, do not operate the generator set. Failure to comply may cause damage to
equipment.

NOTE
Upper radiator hose assemblies to be inspected begin at the connection to the radiator at the unit
bulkhead (Figure 7, Item 1) and end at the connection to the thermostat (Figure 7, Item 3) on the
front of the engine.

Lower radiator hose assemblies to be inspected, begin at the connection to the radiator at the unit
bulk head (Figure 7, Item 2) and end at the connection to the water pump (Figure 8, Item 2) on
the front of the engine. The drain hose (Figure 8, Item 3) is part of the lower radiator assemblies.
2. Inspect the upper radiator hose assemblies (Figure 7) through the left-side door visually for damage, wear,
fraying, loose connections, or corrosion to hose clips and clamp bands.

0015-9
 TM 9-6115-753-10 0015

Figure 8. Cooling System Hoses, Interconnecting Tubes, and Clamps — Right Side.

3. Inspect the pressure relief valve assembly (Figure 6) visually for damage, wear, fraying, loose connections, or
corrosion to hose clips and clamp bands.
4. Inspect the lower radiator hose assemblies (Figure 8) through the right-side door visually for damage, wear,
fraying, loose connections, or corrosion to hose clips and clamp bands.

WARNING
Do not operate generator set if any fuel leaks are present. Fuel is combustible. Always perform
PMCS before operation. Failure to comply may cause injury or death to personnel.
5. Inspect winterization kit (Figure 8, Item 1) coolant hoses and fuel hoses visually for damage, wear, fraying,
loose connections, or corrosion to hose clips and clamp bands.

CAUTION
Do not operate the generator set if Class III coolant leaks are present. Failure to comply will
cause damage to equipment.
6. Notify field maintenance of any leaks, damage, or corrosion.
7. Close right- and left-side access doors.

END OF TASK

END OF WORK PACKAGE

0015-10
 TM 9-6115-753-10 0016

OPERATOR MAINTENANCE
AMMPS 60KW GENERATOR SET
SERVICE FUEL SYSTEM

INITIAL SETUP:

Test Equipment Personnel Required

Not Applicable Operator (1)
Tools and Special Tools References
Not Applicable Not Applicable
Materials/Parts Equipment Conditions
Fuel, diesel (WP 0021, Expendable and Durable Not Applicable
Items List, Item 4)
Pan, drip (WP 0021, Item 8)
Rags, wiping (WP 0021, Item 9)

SERVICE FUEL SYSTEM

Check Fuel Level

WARNING

x When operating, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow engine to cool before checks, services, and maintenance. Wear
gloves and additional protective clothing as required. Failure to comply may cause injury or death
to personnel.

x Fuels used in the generator set are combustible. Do not smoke or use open fire when performing
maintenance. Fire and possible explosion may result. Failure to comply may cause injury or death
to personnel and damage to equipment.

x Fuel is combustible and toxic to eyes, skin, and respiratory tract. Skin and eye protection are
required when working in contact with fuel. Avoid repeated or prolonged contact. Provide
adequate ventilation. Operators are to wash skin and change clothing promptly if in contact with
fuel. Failure to comply may cause injury or death to personnel.

x Hot engine surfaces from engine and generator circuitry are possible sources of ignition. When
refueling during unit operation with DF-1, DF-2, JP5, or JP8, avoid fuel splash and fuel spill. Do
not smoke or use open flame when performing refueling. Remember PMCS are still required.
Flames and possible explosion may result. Failure to comply may cause injury or death to
personnel.

x While inspecting the operation of the generator set, do not inadvertently reach into the generator
set. Failure to comply may cause injury or death to personnel.

0016-1
 TM 9-6115-753-10 0016

Figure 1. Fuel Fill — Location.

1. Locate the fuel fill area (Figure 1) on the rear panel of the unit.

NOTE
Refueling is permitted while the generator set is operating.
2. Clean any dirt or debris from the fuel filler cap (Figure 2, Item 2) area.
3. Turn the fuel filler cap (Figure 2, Item 2) counterclockwise to the first detent to relieve any pressure in the fuel
tank.

0016-2
 TM 9-6115-753-10 0016

Figure 2. Fuel Filler.

4. Remove the fuel filler cap (Figure 2, Item 2) from the fuel filler neck (Figure 2, Item 1) by turning
counterclockwise beyond the first detent. Note orientation of fuel filler cap (Figure 2, Item 2) to aid in
installation.

CAUTION
DCS screen shows fuel level as a percentage of capacity and is reported from electronic gage.
Always verify need for fuel visually before adding fuel. Failure to comply may cause damage to
equipment.
5. Observe level of fuel in the fuel filler neck (Figure 2, Item 1). If level is below the indicator plate/fuel filler neck
screen (Figure 2, Item 4) in the fuel filler neck (Figure 2, Item 1), additional fuel is required.
6. Add approved fuel to the tank. See Fill Fuel Tank task.
7. Replace fuel filler cap (Figure 2, Item 2) using orientation noted in step 4. Turn clockwise to second detent.

END OF TASK

Fill Fuel Tank

1. Remove fuel filler cap (Figure 2, Item 2). See Check Fuel Level task.

0016-3
 TM 9-6115-753-10 0016

WARNING
Fuels used in the generator set are combustible. Ensure fuel source grounding strap is connected
to unit fuel fill grounding stud (static ground). When filling the fuel tank, maintain metal-to-metal
contact between filler nozzle and fuel tank opening to eliminate ESD. Fire and possible explosion
can result. Failure to comply may cause injury or death to personnel.
2. Attach grounding strap from fuel source to grounding stud (static ground) on fuel filler neck (Figure 2, Item 3).

NOTE
Refueling while the generator set is operating is permitted.
3. Add approved fuel until the level of fuel is at the indicator plate/fuel filler neck screen (Figure 2, Item 4) in the
fuel filler neck (Figure 2, Item 3).
4. Clean any spilled fuel and dispose of IAW local SOP.
5. Replace fuel filler cap (Figure 2, Item 2). See Check Fuel Level task.
6. Remove grounding strap from grounding stud (static ground) on fuel filler neck (Figure 2, Item 3).

END OF TASK

Service Fuel Filter/Water Separator

Figure 3. Fuel Filter/Water Separator.

0016-4
 TM 9-6115-753-10 0016

CAUTION
Operating generator set with doors open or with panels removed for an extended length of time
will cause engine to overheat. Do not operate generator with doors open or panels removed for
longer than necessary to complete your task. Monitor DCS temperature indicator to prevent
engine overheating. Failure to comply will cause damage to equipment.
1. Turn engine control switch OFF (WP 0005, Operation Under Usual Conditions).
2. Open left-side door.
3. Locate the fuel filter/water separator (Figure 3, Item 1) attached to the front panel inside the left-side door.
4. Place fuel drain hose (Figure 3, Item 4) outside of left-side door.

NOTE
Capture all drained contaminated fuel and dispose IAW local SOP.
5. Place a suitable container beneath fuel drain hose (Figure 3, Item 4) of the fuel filter/water separator (Figure
3, Item 1) located on the interior panel to catch contaminated fuel.

NOTE
To drain the fluid within the fuel filter/water separator (Figure 3, Item 1) at a greater rate of speed
than gravity drain, a pump plunger (Figure 3, Item 2) can be employed to eject the fluid.
6. Turn pump plunger (Figure 3, Item 2) in a counterclockwise direction to loosen pump plunger.
7. Extend pump plunger (Figure 3, Item 2) upward to full height.
8. Open fuel drain valve (Figure 3, Item 3) on the bottom of the fuel filter/water separator (Figure 3, Item 1) to
allow contaminated fuel to drain into the suitable container.
9. Depress pump plunger (Figure 3, Item 2) until at the bottom of stroke to eject fluid in the fuel filter/water
separator (Figure 3, Item 1) into the suitable container.
10. Repeat steps 7 through 9 as required until no contamination is seen in flow.
11. Close the fuel drain valve (Figure 3, Item 3) on the bottom of the fuel filter/water separator (Figure 3, Item 1)
once the drain flow is clean.
12. Turn pump plunger (Figure 3, Item 2) in a clockwise direction until tight.
13. Clean any spilled or contaminated fuel and dispose of IAW local SOP.
14. Start engine and check for leaks and proper operation (WP 0005, Operation Under Usual Conditions).
15. Close left-side door.

END OF TASK

END OF WORK PACKAGE

0016-5/6 blank
 TM 9-6115-753-10 0017

OPERATOR MAINTENANCE
AMMPS 60KW GENERATOR SET
SERVICE ENGINE OIL

INITIAL SETUP:

Test Equipment Personnel Required

Not Applicable Operator (1)
Tools and Special Tools References
Not Applicable TB-43-0211
Materials/Parts Equipment Conditions
Oil, lubricating (WP 0021, Expendable and Durable Not Applicable
Items List, Item 7)
Rags, wiping (WP 0021, Item 9)
Sample bottle, plastic, 3 ounce (oz) (WP 0021, Item
10)

SERVICE ENGINE OIL

WARNING
Wear heat-resistant gloves and avoid contacting hot metal surfaces with hands and exposed skin
after components have been heated. Wear additional protective clothing as required. Failure to
comply may cause injury or death to personnel.

Check Oil Level of Engine Not In-Service

CAUTION
When using an oil of a different make or viscosity from the previous oil, contact field maintenance
to drain oil before servicing engine oil. Never mix two different types of oil. Failure to comply may
cause damage to equipment.

Improper oil level may cause internal engine failure. Oil level too high will raise engine oil
pressure, which may lead to failure of internal engine oil seals. Oil level too low may result in
failure of internal engine compartments due to non-lubrication. Failure to comply may cause
damage to equipment.

Keep all lubricants in closed containers and store in a clean, dry place away from external heat.
Allow no dust, dirt, or other foreign material to mix with the lubricants. Keep all lubrication
equipment clean and ready for use. Failure to comply may cause damage to equipment.

0017-1
 TM 9-6115-753-10 0017

NOTE
Keep all external parts not requiring lubrication free of lubricants. Before lubricating the generator
set, wipe all lubrication points free of dirt and grease. Clean all lubrication points after lubricating
to prevent accumulation of foreign matter.

As shown on the engine oil dipstick (Figure 1, Item 3), two oil level conditions are indicated on the
same engine oil dipstick (Figure 1, Item 3). Ensure that the side of the engine oil dipstick (Figure
1, Item 3) that is used to measure the level of engine oil is the same as the operating status of the
engine that the oil is being measured in.
1. Start engine and operate for approximately 5 min to warm engine oil (WP 0005, Operation Under Usual
Conditions).
2. Turn engine control switch to OFF.

Figure 1. Oil Service Detail — Right Side.

3. Open right-side door and locate the engine oil dipstick (Figure 1, Item 3).
4. Pause for a minimum of 2 min after the engine stops to allow time for oil to drain from the top of the engine
before performing the next step.
5. Pull engine oil dipstick (Figure 1, Item 3) from the engine and wipe clean.
6. Return engine oil dipstick (Figure 1, Item 3) to engine.
7. Pull engine oil dipstick (Figure 1, Item 3) again from engine.
a. Observe and note the level of oil (Figure 1, Item 4) displayed on the engine oil dipstick (Figure 1, Item 3).
b. Level should be between the FULL (Figure 1, Item 6) and ADD (Figure 1, Item 7) marks on the engine oil
dipstick (Figure 1, Item 3).

0017-2
 TM 9-6115-753-10 0017

8. Return engine oil dipstick (Figure 1, Item 3) to engine.

CAUTION
Improper oil level may cause internal engine failure. Oil level too high will raise engine oil
pressure, which may lead to failure of internal engine oil seals. Oil level too low may result in
failure of internal engine compartments due to non-lubrication. Failure to comply may cause
damage to equipment.
9. Contact field maintenance for assistance if oil level is too high.
10. Add approved engine oil if required. See Add Engine Oil task.
11. Wipe up any spilled engine oil and dispose of oil-soaked materials IAW local SOP.
12. Close right-side door.

END OF TASK

Check Oil Level of Operating Engine

WARNING

x Hearing protection is required during maintenance or repair with engine running. Failure to
comply can cause hearing loss.

x Metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry and do not wear loose clothing when working on equipment. Failure to comply
may cause injury or death to personnel.

x Flying debris or material may enter eyes or strike the face. Wear appropriate eye/face protection
while performing maintenance tasks. Failure to comply may cause injury or death to personnel.

CAUTION
Improper oil level may cause internal engine failure. Oil level too high will raise engine oil
pressure, which may lead to failure of internal engine oil seals. Oil level too low may result in
failure of internal engine compartments due to non-lubrication. Failure to comply may cause
damage to equipment.

Operating generator set with doors open or with panels removed for an extended length of time
will cause engine to overheat. Do not operate generator with doors open or panels removed for
longer than necessary to complete your task. Monitor DCS temperature indicator to prevent
engine overheating. Failure to comply will cause damage to equipment.

NOTE
The engine oil level may be checked and oil may be added with the engine operating. Whenever
possible, stop the generator set prior to servicing oil system.

As shown on the engine oil dipstick (Figure 1, Item 3), two oil level conditions are indicated on the
same engine oil dipstick (Figure 1, Item 3). Ensure that the side of the engine oil dipstick (Figure
1, Item 3) that is used to measure the level of engine oil is the same as the operating status of the
engine that the oil is being measured in.
1. Open right-side door and locate engine oil dipstick (Figure 1, Item 3).
2. Pull engine oil dipstick (Figure 1, Item 3) from the engine and wipe clean.
0017-3
 TM 9-6115-753-10 0017

3. Return engine oil dipstick (Figure 1, Item 3) to engine.

4. Pull engine oil dipstick (Figure 1, Item 3) again from the engine.
a. Observe and note the level of oil (Figure 1, Item 5) displayed on the engine oil dipstick (Figure 1, Item 3).
b. Level should be between the FULL (Figure 1, Item 6) and ADD (Figure 1, Item 7) marks on the engine oil
dipstick (Figure 1, Item 3).
5. Return engine oil dipstick (Figure 1, Item 3) to engine.
6. Contact field maintenance for assistance if oil level is too high.
7. Add approved engine oil if required. See Add Engine Oil task.
8. Examine areas adjacent to the oil sample collection valve (Figure 1, Item 1) and spin-on oil filter (Figure 1,
Item 2) visually for evidence of leakage.
9. Contact field maintenance if there is evidence of leakage.
10. Wipe up any spilled engine oil and dispose of oil-soaked materials IAW local SOP.
11. Close right-side door.

END OF TASK

Collect Engine Oil Sample

NOTE
The value of an oil sample is wholly dependent on whether the lubricant has circulated in the
component long enough to accumulate and mix wear metal concentrations uniformly.
1. Perform Check Oil Level of Engine Not In-Service task or Check Oil Level of Operating Engine task to
determine if oil level is adequate to withdraw a sample.
2. Restart generator set if engine was not operating in service.
3. Open right-side door and locate oil sample collection valve (Figure 1, Item 1).
4. Place a wiping rag under the oil sample collection valve (Figure 1, Item 1) outlet to absorb purge oil.

CAUTION
Oil that has been trapped within the oil sample collection valve (Figure 1, Item 1) must be purged
to prevent a false sample. Engine oil of an operating generator set can reach temperatures in
excess of 150°F (65°C) at pressures greater than 80 psi. The time required to open the oil
sample collection valve (Figure 1, Item 1) to clear the oil sample collection valve (Figure 1, Item
1) of possible contaminated oil should be momentary. Keeping the oil sample collection valve
(Figure 1, Item 1) open for an extended period of time will reduce oil level. Failure to comply may
cause damage to equipment.
5. Push toggle valve toward engine to release purge oil, and then release.
6. Wipe valve outlet with a clean wiping rag.
7. Place uncapped oil sample collection bottle under valve outlet.
8. Push toggle valve toward engine and hold until oil is within 1/2 in from sample bottle opening.
9. Cap sample bottle.
10. Wipe up any spilled engine oil and dispose of oil-soaked materials IAW local SOP.
11. Turn engine control switch to OFF position if generator set was started only to retrieve oil sample.

0017-4
 TM 9-6115-753-10 0017

12. Perform Check Oil Level of Engine Not In-Service task or Check Oil Level of Operating Engine task.
13. Record information on oil sample bottle as outlined in TB-43-0211, AOAP.

END OF TASK

Add Engine Oil

CAUTION
Improper oil level may cause internal engine failure. Oil level too high will raise engine oil
pressure, which may lead to failure of internal engine oil seals. Oil level too low may result in
failure of internal engine compartments due to non-lubrication. Failure to comply may cause
damage to equipment.

NOTE
Engine oil level is determined and noted by performing Check Oil Level of Engine Not In-Service
task or Check Oil Level of Operating Engine task.

The engine oil level may be checked and oil may be added with the engine operating. Whenever
possible, stop the generator set prior to servicing oil system.
1. Open left-side door and locate oil filter cap (Figure 2, Item 1).

Figure 2. Oil Service Detail — Left Side.

2. Remove oil filter cap (Figure 2, Item 1).

0017-5
 TM 9-6115-753-10 0017

3. Add additional oil as required to raise the oil level to the FULL (Figure 1, Item 6) mark on the engine
oil dipstick (Figure 1, Item 3).
4. Return oil filter cap (Figure 2, Item 1) to engine.
5. Perform Check Oil Level of Engine Not In-Service task, steps 1 through 13, or Check Oil Level of
Operating Engine task, steps 1 through 11.
6. Close left-side door.

END OF TASK

END OF WORK PACKAGE

0017-6
 TM 9-6115-753-10

CHAPTER 5

SUPPORTING INFORMATION
FOR
AMMPS 60KW GENERATOR SET
 TM 9-6115-753-10

CHAPTER 5

SUPPORTING INFORMATION

WORK PACKAGE INDEX

Title WP Sequence No.
REFERENCES..................................................................................................................................................... 0018
COMPONENTS OF END ITEM (COEI) AND BASIC ISSUE ITEMS (BII) LIST .................................................. 0019
ADDITIONAL AUTHORIZATION LIST (AAL) ...................................................................................................... 0020
EXPENDABLE AND DURABLE ITEMS LIST...................................................................................................... 0021
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 TM 9-6115-753-10 0019

OPERATOR MAINTENANCE
AMMPS 60KW GENERATOR SET
COMPONENTS OF END ITEM (COEI) AND BASIC ISSUE ITEMS (BII) LISTS

INTRODUCTION

Scope

This work package provides COEI and BII lists for the AMMPS 60 kW generator set to help you inventory items
for safe and efficient operation of the equipment.

General

The COEI and BII information is divided into the following lists:
Components of End Item (COEI). This list is for information purposes only and is not authority to requisition
replacements. These items are part of the AMMPS. As part of the end item, these items must be with the end
item whenever it is issued or transferred between property accounts. Items of COEI are removed and separately
packaged for transportation or shipment only when necessary. Illustrations are furnished to help you find and
identify the items.
Basic Issue Item (BII). These essential items are required to place the AMMPS in operation, operate it, and to do
emergency repairs. Although shipped separately packaged, BII must be with the AMMPS during operation and
when it is transferred between property accounts. Listing these items is your authority to request/requisition them
for replacement based on authorization of the end item by the TOE/MTOE. Illustrations are furnished to help you
find and identify the items.

Explanation of Columns in the COEI List and BII List

Column (1) Illus. Number. Gives you the number of the item illustrated.
Column (2) National Stock Number (NSN). Identifies the stock number of the item to be used for requisitioning
purposes.
Column (3) Description, Part Number/(CAGEC). Identifies the Federal item name (in all capital letters) followed by
a minimum description when needed. The stowage location of COEI and BII is also included in this column. The
last line below the description is the part number and the Commercial and Government Entity Code (CAGEC) (in
parentheses).
Column (4) Usable On Code. When applicable, gives you a code if the item you need is not the same for different
models of equipment. These codes are identified below.
Code Used on
98N Model MEP 1070
98P Model MEP 1071
Column (5) U/I. Unit of Issue (U/I) indicates the physical measurement or count of the item as issued per the
National Stock Number shown in column (2).
Column (6) Qty Rqr. Indicates the quantity required.
There are no COEI items for the AMMPs 60 kW skid-mounted generators.

0019-1
 TM 9-6115-753-10 0019

Figure 1. Basic Issue Items (BII) (Sheet 1 of 2).

0019-2
 TM 9-6115-753-10 0019

Figure 1. Basic Issue Items (BII) (Sheet 2 of 2).

Table 2. Basic Issue Items (BII).

(1) (2) (3) (4) (5) (6)
ILLUS. NATIONAL STOCK NUMBER DESCRIPTION, PART USABLE U/I QTY
NUMBER (NSN) NUMBER/(CAGEC) ON CODE RQR
1 6150-01-406-9533 CABLE, PARALLELING Not EA 1
88-22209 Applicable
2 4720-00-021-3320 FUEL LINE, AUXILIARY Not EA 1
69-668 Applicable
3 OIL DRAIN EXTENSION PIPE Not EA 1
Applicable
4 5975-00-296-5324 ROD, GROUNDING, ASSY. Not EA 1
(1) CLAMP Applicable
(2) COUPLING (3)
(3) DRIVING STUD
(4) GROUND CABLE
(5) GROUND ROD (3)
5 TM 9-6115-753-10 Not EA 1
Applicable

END OF WORK PACKAGE

0019-3/4 blank
 TM 9-6115-753-10 0020

OPERATOR MAINTENANCE
AMMPS 60KW GENERATOR SET
ADDITIONAL AUTHORIZATION LIST (AAL)

INTRODUCTION

Scope

This work package lists additional items you are authorized for the support of AMMPS 60 kW generator set.

General

This list identifies items that do not have to accompany the AMMPS generator and that do not have to be turned
in with it. These items are all authorized to you by CTA, MTOE, TDA, or JTA.

Explanation of Columns in the AAL

Column (1) National Stock Number (NSN). Identifies the stock number of the item to be used for requisitioning
purposes.
Column (2) Description, Part Number/(CAGEC). Identifies the Federal item name (in all capital letters) followed by
a minimum description when needed. The last line below the description is the part number and the Commercial
and Government Entity Code (CAGEC) (in parentheses).
Column (3) Usable On Code. When applicable, gives you a code if the item you need is not the same for different
models of equipment. These codes are identified below.
Code Used on
98N Model MEP 1070
98P Model MEP 1071
Column (4) U/I. Unit of Issue (U/I) indicates the physical measurement or count of the item as issued per the
National Stock Number shown in column (1).
Column (5) Qty Recom. Indicates the quantity recommended.

Table 1. Additional Authorization List (AAL).

(1) (2) (3) (4) (5)
NATIONAL STOCK USABLE QTY
NUMBER (NSN) DESCRIPTION, PART NUMBER/(CAGEC) ON CODE U/I RECOM.
CABLE, LOCAL CONTROL, 04-21226/(44940) N/A EA 1
CABLE, REMOTE CONTROL, 04-21227/(44940) N/A EA 1
5120-00-251-4489 HAMMER, HAND, ENGINEERS, DOUBLE, 8# A-A- N/A EA 1
1293/(58536)
5120-01-013-1676 SLIDE HAMMER, GROUND ROD N/A EA 1
13226E7741/(97403)

END OF WORK PACKAGE

0020-1/2 blank
 TM 9-6115-753-10 0021

OPERATOR MAINTENANCE
AMMPS 60KW GENERATOR SET
EXPENDABLE AND DURABLE ITEMS LIST

INTRODUCTION

Scope

This work package lists expendable and durable items that you will need to operate and maintain the AMMPS 60
kW generator set. This list is for information only and is not authority to requisition the listed items. These items
are authorized to you by CTA 50-970, Expendable/Durable Items (Except Medical, Class V, Repair Parts, and
Heraldic Items), CTA 50-909, Field and Garrison Furnishings and Equipment, or CTA 8-10, Army Medical
Department Expendable/Durable Items.

Explanation of Columns in the Expendable/Durable Items List

Column (1) Item No. This number is assigned to the entry in the list and is referenced in the narrative instructions
to identify the item (e.g., Use brake fluid (WP 0098, Item 5)).
Column (2) Level. This column identifies the lowest level of maintenance that requires the listed item (C = Crew).
Column (3) National Stock Number (NSN). This is the NSN assigned to the item which you can use to requisition
it.
Column (4) Item Name, Description, Part Number/(CAGEC). This column provides the other information you need
to identify the item. The last line below the description is the part number and the Commercial and Government
Entity Code (CAGEC) (in parentheses).
Column (5) U/I. Unit of Issue (U/I) code shows the physical measure or count of an item, such as gallon, dozen,
gross, etc.

Table 1. Expendable and Durable Items.

(1) (2) (3) (4) (5)
ITEM NATIONAL STOCK ITEM NAME, DESCRIPTION, PART
NO. LEVEL NUMBER (NSN) NUMBER/(CAGEC) U/I
1 C 6850-00-181-7933 Antifreeze MIL-A-46153 (81349) Bottle
2 C 1660-99-783-4056 Element, air cleaner filter EA
3 C 6230-00-163-1856 Flashlight, 928572/(24617) EA
4 C 9140-00-000-0184 Fuel, diesel AA 52557 Gal
5 C 4940-01-120-6793 Funnel, flexible EA
6 C 9150-00-079-7374 Oil, engine SAE 30 Qt
7 C 9150-00-186-6681 Oil, lubricating MIL-PRF-2104H (81349) Qt
8 C 1615-01-322-0311 Pan, drip 145S1112-26 (77272) EA
9 C 7920-00-140-0869 Rag, wiping 8722-0088 (03950) Box
10 C 8125-01-082-9697 Sample bottle, plastic, 3 ounce (oz) EA
11 C 6810-00-107-1510 Water, distilled O-C-265 (81348) Drum

END OF WORK PACKAGE

0021-1/2 blank
 TM 9-6115-753-10

GLOSSARY

SCOPE

This WP defines all of the terms used in the AMMPS 60 kW generator set TM.
TERM DEFINITION
Adjustment hints indicator Portion of the DCS display which shows functional soft keys to use during
adjustment.
Automatic Voltage Regulator Electrical regulator designed to automatically maintain a constant voltage
(AVR) level. Important component in synchronous generators, it controls the
output voltage of the generator by controlling its excitation.
Exciter The exciter is a device that supplies DC to the field coils of a synchronous
generator, producing the magnetic flux required for inducing output voltage
in the armature coils (stator).
Gain The measure of the ability of a generator to increase the amplitude of
voltage from the input to the output. It is usually defined as the mean ratio
of the signal output of a system to the signal input of the same system.
Ground Fault Protection (GFP) Circuitry designed to protect personnel from line-to-ground fault currents.
Line-to-Line (L-L) Voltage The voltage between any two phases of an AC generator.
Line-to Neutral (L-N) Voltage The voltage between a phase and the common neutral where the three
phases are tied together in a 3-phase, 4-wire, Y-connected generator.
Load factor The ratio of the average load to the generator set power rating.
Offset Ratio of the variation in the point at which two related sine waves cross
zero.
Parallel operation The operation of two or more AC power sources whose output leads are
connected to a common load.
Permanent Magnet Generator A generator whose field is a permanent magnet as opposed to an electro-
(PMG) magnet (wound field).
Power Plant (PP) Two AMMPS generator sets hooked up in parallel with the use of a switch
box.
Power Unit (PU) A single AMMPS generator set.
Switch box Device utilized for joining two AMMPS in parallel for additional electricity
production.
Synchronization Status obtained when an incoming generator set is matched with and in
step to the same frequency, voltage, and phase sequence as the operating
power source in a paralleling application.
Unit A Generator set directly wired to the switch box in a PP. Unit A is the first set
to be placed on line. This is also called generator set A.
Unit B Generator set directly wired to a connecting cable assembly in a PP. Unit B
is the second set to be placed on line. This is also called generator set B.

END OF WORK PACKAGE

Glossary-1/Glossary-2 blank
 TM 9-6115-753-10

ALPHABETICAL INDEX
SUBJECT WP SEQUENCE NO.-PAGE NO.

A
Additional Authorization List (AAL) ....................................................................................................... WP 0020

C
Components of End Item (COEI) and Basic Issue Item (BII) List ......................................................... WP 0019

D
Descriptions and Use of Operator Controls and Indicators .................................................................. WP 0004

DCS Fault and Warning Codes and Descriptions................................................................................. WP 0011

E
Emergency ............................................................................................................................................ WP 0008

NATO Slave Receptacle Start Operation ....................................................................................... WP 0008-1

Emergency Stopping ...................................................................................................................... WP 0008-3
Operation using BATTLESHORT switch ........................................................................................ WP 0008-4

Equipment Description and Data .......................................................................................................... WP 0002

Expendable and Durable Items List ...................................................................................................... WP 0021

G
General Information .............................................................................................................................. WP 0001

O
Operation Under Unusual Conditions ................................................................................................... WP 0007

Operation in Extreme Cold -25°F (-31°C)....................................................................................... WP 0007-2

Operation in Extreme Heat above 120°F (49°C) ............................................................................ WP 0007-2
Operation in Dusty or Sandy Areas ................................................................................................ WP 0007-2
Operation in Rainy or Humid Conditions ........................................................................................ WP 0007-3
Operation in Salt Water Areas........................................................................................................ WP 0007-3
Operation in High Altitudes............................................................................................................. WP 0007-4
Operating Using BATTLESHORT Switch....................................................................................... WP 0007-5
Operation While in Contaminated Areas ........................................................................................ WP 0007-6
Use of Ground Fault Circuit Interrupter (GFCI) Convenience Receptacle ..................................... WP 0007-7

Index-1
 TM 9-6115-753-10

INDEX — Continued.
Operation Under Usual Conditions ....................................................................................................... WP 0005

Siting Requirements ....................................................................................................................... WP 0005-2

Assembly and Preparation for Use................................................................................................. WP 0005-3
Screen Navigation .......................................................................................................................... WP 0005-3
Installation of Ground Rod.............................................................................................................. WP 0005-4
Installation of Auxiliary Fuel Lines ................................................................................................. WP 0005-6
Installation of Load Cables ............................................................................................................. WP 0005-7
Initial Adjustments........................................................................................................................... WP 0005-9
Operating Procedures .................................................................................................................... WP 0005-11
Starting Procedure.......................................................................................................................... WP 0005-11
Adjust Generator Set ...................................................................................................................... WP 0005-17
Monitoring Generator Set Operational Status ................................................................................ WP 0005-22
Operation with Remote Monitoring ................................................................................................. WP 0005-27
Stopping Procedure ........................................................................................................................ WP 0005-32
Decals and Instructions Plates ....................................................................................................... WP 0005-33
Preparation for Movement .............................................................................................................. WP 0005-50

P
Parallel Operation ................................................................................................................................. WP 0006

Connecting Generator Sets Parallel Cables (PP Configuration).................................................... WP 0006-2

Parallel Operation With Switch Box (Two Like Sets)...................................................................... WP 0006-4
Parallel Operation Without Switch Box (Two or More Like Sets) ................................................... WP 0006-8
Adjusting Parallel Operations ......................................................................................................... WP 0006-11
Sort Removal from Parallel Operation With [Unload] Soft Key ...................................................... WP 0006-19
Removal from Parallel Operation with UNIT PARALLEL Switch .................................................. WP 0006-21

PMCS .................................................................................................................................................... WP 0013

PMCS Introduction ................................................................................................................................ WP 0012

R
References ............................................................................................................................................ WP 0018

S
Service Air Cleaner ............................................................................................................................... WP 0014

Inspect Air Filter Restriction Indicator ............................................................................................ WP 0014-1

Remove Air Cleaner Filter Element ................................................................................................ WP 0014-3
Install Air Cleaner Filter Element .................................................................................................... WP 0014-4
Clean Air Cleaner Dust Ejector Valve ............................................................................................ WP 0014-4

Service Cooling System ........................................................................................................................ WP 0015

Check Coolant Level ...................................................................................................................... WP 0015-2

Fill Coolant Overflow Bottle ........................................................................................................... WP 0015-5
Inspect Radiator Hoses, Interconnecting Tubes, and Clamps ....................................................... WP 0015-9

Index-2
 TM 9-6115-753-10

INDEX — Continued.
Service Engine Oil..................................................................................................................................WP 0017

Check Oil Level of Engine Not In-Service .......................................................................................WP 0017-1

Check Oil Level of Operating Engine ..............................................................................................WP 0017-3
Collect Engine Oil Sample...............................................................................................................WP 0017-4
Add Engine Oil.................................................................................................................................WP 0017-5

Service Fuel System ..............................................................................................................................WP 0016

Check Fuel Level .............................................................................................................................WP 0016-1

Fill Fuel Tank ...................................................................................................................................WP 0016-3
Service Fuel Filter/Water Separator ................................................................................................WP 0016-4

T
Theory of Operation ...............................................................................................................................WP 0003

Troubleshooting Index............................................................................................................................WP 0009

Troubleshooting Procedures ..................................................................................................................WP 0010

END OF WORK PACKAGE

Index-3/4 blank
 RECOMMENDED CHANGES TO PUBLICATIONS AND DATE
Use Part II (reverse) for Repair Parts and Special Tool
BLANK FORMS Lists (RPSTL) and Supply Catalogs/Supply Manuals
(SC/SM). 07 01 09
For use of this form, see AR 25-30; the proponent agency is OAASA

TO (Forward to proponent of publication or form) (Include ZIP Code) FROM (Activity and location) (Include ZIP Code)
Commander: US Army CECOM LCMC Jane Q. Doe, SFC
ATTN: AMSEL-LC-LEO-E-CM 1234 Any Street
Fort Monmouth, NJ 07703-5006 Anytown, AL 34565
PART I – ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS
PUBLICATION/FORM NUMBER DATE TITLE
TM 11-1234-567-14 06 01 09 Operator, Field and Sustainment Support Maintenance Manual
for Radio, AN/ABC-123
ITEM PAGE PARA- LINE FIGURE TABLE RECOMMENDED CHANGES AND REASON
GRAPH NO.

1 WP 0005 2 Test or Corrective Action column should identify a different WP number.

PG 3

* Reference to line numbers within the paragraph or subparagraph.

TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON, SIGNATURE
PLUS EXTENSION
Jane Q. Doe, SPC
123-4567
DA FORM 2028, FEB 74 REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED. USAPA V4.01
TO (Forward direct to addressee listed in publication) FROM (Activity and location) (Include ZIP Code) DATE

PART II – REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS
PUBLICATION NUMBER DATE TITLE
TB 9-2590-528-13&P INTERROGATION ARM ASSEMBLY (IAA)

TOTAL NO.
PAGE COLM LINE NATIONAL STOCK REFERENCE FIGURE ITEM OF MAJOR
RECOMMENDED ACTION
NO. NO. NO. NUMBER NO. NO. NO. ITEMS
SUPPORTED

PART III – REMARKS (Any general remarks, recommendations, or suggestions for improvement of publications
and blank forms. Additional blank sheets may be used if more space is needed.)

TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON, SIGNATURE

PLUS EXTENSION
Jane Q. Doe, SPC
123-4567
USAPA V4.01
 RECOMMENDED CHANGES TO PUBLICATIONS DATE
Use Part II (reverse) for Repair Parts and
AND BLANK FORMS Special Tool Lists (RPSTL) and Supply
Catalogs/Supply Manuals (SC/SM).
For use of this form, see AR 25-30; the proponent agency is OAASA

TO (Forward to proponent of publication or form) (Include ZIP Code) FROM (Activity and location) (Include ZIP Code)

PART I – ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS
PUBLICATION/FORM NUMBER DATE TITLE

ITEM PAGE PARA- LINE FIGURE TABLE RECOMMENDED CHANGES AND REASON
GRAPH NO.

* Reference to line numbers within the paragraph or subparagraph.

TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON, SIGNATURE
PLUS EXTENSION

DA FORM 2028, FEB 74 REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED. USAPA V4.01
TO (Forward direct to addressee listed in publication) FROM (Activity and location) (Include ZIP Code) DATE

PART II – REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS
PUBLICATION NUMBER DATE TITLE

TOTAL NO.
PAGE COLM LINE NATIONAL STOCK REFERENCE FIGURE ITEM OF MAJOR RECOMMENDED
NO. NO. NO. NUMBER NO. NO. NO. ITEMS ACTION
SUPPORTED

PART III – REMARKS (Any general remarks, recommendations, or suggestions for improvement of publications
and blank forms. Additional blank sheets may be used if more space is needed.)

TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON, SIGNATURE

PLUS EXTENSION

USAPA V4.01
 RECOMMENDED CHANGES TO PUBLICATIONS DATE
Use Part II (reverse) for Repair Parts and
AND BLANK FORMS Special Tool Lists (RPSTL) and Supply
Catalogs/Supply Manuals (SC/SM).
For use of this form, see AR 25-30; the proponent agency is OAASA

TO (Forward to proponent of publication or form) (Include ZIP Code) FROM (Activity and location) (Include ZIP Code)

PART I – ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS
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TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON, SIGNATURE
PLUS EXTENSION

DA FORM 2028, FEB 74 REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED. USAPA V4.01
TO (Forward direct to addressee listed in publication) FROM (Activity and location) (Include ZIP Code) DATE

PART II – REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS
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USAPA V4.01
 RECOMMENDED CHANGES TO PUBLICATIONS DATE
Use Part II (reverse) for Repair Parts and
AND BLANK FORMS Special Tool Lists (RPSTL) and Supply
Catalogs/Supply Manuals (SC/SM).
For use of this form, see AR 25-30; the proponent agency is OAASA

TO (Forward to proponent of publication or form) (Include ZIP Code) FROM (Activity and location) (Include ZIP Code)

PART I – ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS
PUBLICATION/FORM NUMBER DATE TITLE

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TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON, SIGNATURE
PLUS EXTENSION

DA FORM 2028, FEB 74 REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED. USAPA V4.01
TO (Forward direct to addressee listed in publication) FROM (Activity and location) (Include ZIP Code) DATE

PART II – REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS
PUBLICATION NUMBER DATE TITLE

TOTAL NO.
PAGE COLM LINE NATIONAL STOCK REFERENCE FIGURE ITEM OF MAJOR RECOMMENDED
NO. NO. NO. NUMBER NO. NO. NO. ITEMS ACTION
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PART III – REMARKS (Any general remarks, recommendations, or suggestions for improvement of publications
and blank forms. Additional blank sheets may be used if more space is needed.)

TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON, SIGNATURE

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USAPA V4.01
 TM 9-6115-753-10

By Order of the Secretary of the Army:

GEORGE W. CASEY, JR.

General, United States Army
Chief of Staff
Official:

JOYCE E. MORROW
Administrative Assistant to the
Secretary of the Army
1100301

By Order of the Secretary of the Air Force:

NORTON A. SCHWARTZ
General, USAF
Chief of Staff, USAF
Official:

DONALD J. HOFFMAN
General, USAF
Commander, AFMC

By Order of the Marine Corps:

J.E. CAVE
Product Group Director, PG-15
Ground Transportation Engineer Systems
Marine Corps System Command

By Order of the Secretary of the Navy:

NAVAL FACILITIES ENGINEERING NAVAL FACILITIES EXPEDITIONARY

COMMAND (NAVFAC) LOGISTICS CENTER (NFELC)
CODE EXP 21

Army Distribution: To be distributed IAW the Initial Distribution Number (IDN) 360016
requirements for TM 9-6115-753-10.

Marine Corps Distribution: To be distributed IAW PCN 184 092455 00.

 THE METRIC SYSTEM AND EQUIVALENTS

LINEAR MEASURE SQUARE MEASURE

1 Centimeter = 10 Millimeters = 0.01 Meters = 0.3937 Inches 1 Sq. Centimeter = 100 Sq. Millimeters = 0.155 Sq. Inches
1 Meter = 100 Centimeters = 1000 Millimeters = 39.37 Inches 1 Sq. Meter = 10,000 Sq. Centimeters = 10.76 Sq. Feet
1 Kilometer = 1000 Meters = 0.621 Miles 1 Sq. Kilometer = 1,000 Sq. Meters = 0.386 Sq. Miles
WEIGHTS CUBIC MEASURE

1 Gram = 0.001 Kilograms = 1000 Milligrams = 0.035 Ounces 1 Cu. Centimeter = 1000 Cu. Millimeters = 0.06 Cu. Inches
1 Kilogram = 1000 Grams = 2.2 Lb. 1 Cu. Meter = 1,000,000 Cu. Centimeters = 35.31 Cu. Feet
1 Metric Ton = 1000 Kilograms = 1 Megagram = 1.1 Short Tons
TEMPERATURE
LIQUID MEASURE
5/9 (°F – 32) = °C
1 Milliliter = 0.001 Liters = 0.0338 Fluid Ounces 212° Fahrenheit is equivalent to 100° Celsius
1 Liter = 1000 Milliliters = 33.82 Fluid Ounces 90° Fahrenheit is equivalent to 32.2° Celsius
32° Fahrenheit is equivalent to 0º Celsius
9/5 (°C + 32) = °F

APPROXIMATE CONVERSION FACTORS

TO CHANGE TO MULTIPLY BY
Inches .................................... Centimeters ....................................................2.540
Feet ........................................ Meters ............................................................0.305
Yards ...................................... Meters ............................................................0.914
Miles ....................................... Kilometers ......................................................1.609
Square Inches ........................ Square Centimeters .......................................6.451
Square Feet............................ Square Meters................................................0.093
Square Yards.......................... Square Meters................................................0.836
Square Miles........................... Square Kilometers..........................................2.590
Acres ...................................... Square Hectometers ......................................0.405
Cubic Feet .............................. Cubic Meters ..................................................0.028
Cubic Yards ........................... Cubic Meters ..................................................0.765
Fluid Ounces .......................... Milliliters........................................................29.573
Pints........................................ Liters...............................................................0.473
Quarts..................................... Liters...............................................................0.946
Gallons ................................... Liters...............................................................3.785
Ounces ................................... Grams...........................................................28.349
Pounds ................................... Kilograms .......................................................0.454
Short Tons ............................. Metric Tons ....................................................0.907
Pound-Feet............................. Newton-Meters ...............................................1.356
Pounds per Square Inch......... Kilopascals .....................................................6.895
Miles per Gallon...................... Kilometers per Liter ........................................0.425
Miles per Hour ........................ Kilometers per Hour .......................................1.609
TO CHANGE TO MULTIPLY BY
Centimeters ............................ Inches.............................................................0.394
Meters..................................... Feet ................................................................3.280
Meters..................................... Yards ..............................................................1.094
Kilometers............................... Miles ...............................................................0.621
Square Centimeters................ Square Inches ................................................0.155
Square Meters ....................... Square Feet..................................................10.764
Square Meters ....................... Square Yards .................................................1.196
Square Kilometers ................. Square Miles ..................................................0.386
Square Hectometers............... Acres ..............................................................2.471
Cubic Meters ......................... Cubic Feet ....................................................35.315
Cubic Meters ......................... Cubic Yards....................................................1.308
Milliliters.................................. Fluid Ounces ..................................................0.034
Liters....................................... Pints ...............................................................2.113
Liters....................................... Quarts.............................................................1.057
Liters....................................... Gallons ...........................................................0.264
Grams..................................... Ounces ...........................................................0.035
Kilograms................................ Pounds ...........................................................2.205
Metric Tons............................. Short Tons......................................................1.102
Newton-Meters ...................... Pound-Feet.....................................................0.738
Kilopascals ............................ Pounds per Square Inch.................................0.145
Kilometers per Liter ............... Miles per Gallon .............................................2.354
Kilometers per Hour................ Miles per Hour ................................................0.621
PIN: 086673-000