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TM 5-6115-440-10

TECHNICAL MANUAL

OPERATOR’S MAINTENANCE

MANUAL

GENERATOR SET,

7.5 KW, 28V, DC, GED

AIR COOLED, 2 WHEEL MTD

PNEUMATIC TIRES

JOHN R. HOLLIN6SWORTH

MODEL JHGV7.5A

FSN 6115-074-6396

HEADQUARTERS DEPARTMENT OF THE ARMY

FEBRUARY 1971

This copy is a reprint which includes current

pages from Changes 1 through 3.



W A R N I N GT a k e p a r t i c u l a r h e e d t o s p e c i f i c c a u t i o n s a n d w a r n i n g st h r o u g h o u t t h i s m a n u a l .

HIGH VOLTAGEi s used in the opera t ion of th i s equ ipment .

DEATHor severe burns may resu l t i f pe rsonne l fa i l to observe sa fe typ r e c a u t i o n s . D o n o t o p e r a t e t h i s g e n e r a t o r s e t u n t i l t h eground terminal stud has been connected to a suitable ground.

D i s c o n n e c t t h e b a t t e r y g r o u n d c a b l e b e f o r e r e m o v i n g a n d

sys tem. Before making load connec t ions , be sure the genera tori n s t a l l i n g c o m p o n e n t s o n e n g i n e o r i n e l e c t r i c a l c o n t r o l p a n e l

s e t s a r e n o t o p e r a t i n g a n d l o a d c o n t r o l s w i t c h i s i n t h e O F Fp o s i t i o n . O n g a s o l i n e e n g i n e d r i v e n g e n e r a t o r s e t u t i l i z i n g

m a g n e t o s , s e t m a g n e t o s w i t c h t o O F F o r S T O P p o s i t i o n .

D o n o t a t t e m p t t o c h a n g e l o a d c o n n e c t s w h e n g e n e r a t o r i sr u n n i n g .

Before se rv ic ing any par t o f a genera tor se t , make sure un i t i sc o m p l e t e l y d e - e n e r g i z e d .

DANGEROUS GASESare genera ted as a resu l t o f opera t ing of th i s equ ipment .

DEATHor severe in jury may resu l t i f pe rsonne l fa i l to observe sa fe typ r e c a u t i o n s . U t i l i z e e x t r e m e c a u t i o n , d o n o t s m o k e , o r u s e

e r a t e e x p l o s i v e g a s d u r i n g c h a r g i n g . A l w a y s m a i n t a i n m e t a lopen f lame in v ic in i ty when se rv ic ing ba t te r ies . Ba t te r ies gen-

t o m e t a l c o n t a c t w h e n f i l l i n g t h e f u e l t a n k . D o n o t s m o k e o ru s e o p e n f l a m e i n v i c i n i t y w h e n f i l l i n g t h e f u e l t a n k .

D o n o t a t t e m p t t o f i l l f u e l t a n k w h e n g e n e r a t o r i s r u n n i n g .

Do no t opera te genera tor se t s in inc losed a rea un less exhaus tgases a re p roper ly ven ted to the ou ts ide . Exhaus t d i schargeconta ins noxious and dead ly fumes . Use ex t reme care , shoulda s e l e n i u m r e c t i f i e r m a l f u n c t i o n , t o a v o i d i n h a l a t i o n o f p o i s -o n o u s f u m e s . I f g e n e r a t o r s e t i s s h u t - d o w n b y t h e o p e r a t i o no f a s a f e t y d e v i c e , d o n o t a t t e m p t t o o p e r a t e u n i t u n t i l t h ecause has been de te rmined and e l imina ted .



Changes i n f orce: C1, C2 and C3

TM 5- 6115- 440- 10

C3Change HEADQUARTERS

DEPARTMENT OF THE ARMY No. 3 WASHI NGTON, D. C. , 4 Nov 1986

Operator’ s Mai ntenance Manual

GENERATOR SET, 7. 5 KW, 28 V, DC,GED, AI R COOLED

2 WHEEL MTD, PNEUMATI C TI RES(J OHN R. HOLLI NGSWORTH MODEL

J HGV 7. 5A) NSN 6115- 00- 074- 6396

TM 5- 6115- 440- 10, February 1971, i schanged as f ol l ows:

- 3. Paragraph 3- 3. Add the f ol -l owi ng NOTE between the l ast l i ne of step b. and the f i rst l i ne of step c.

NOTE

Leakage def i ni t i ons f or PMCS shal l becl assi f i ed as fol l ows:

1



TM 5- 6115- 440- 10C 3

Cl ass I Seepaqe of f l ui d (as i ndi cat -ed by wetness or di scol orat i on) notgreat enough to f orm drops.

Cl ass I I Leakage of f l ui d greatenough to form drops but not enough

cause drops to dri p f rom i tem bei ngchecked/ i nspect ed.

Cl ass I I I Leakage of f l ui d greatenough to f orm drops that f al l f romi tem bei ng checked/ i nspected.

CAUTI ON

t o

the

Equi pment operat i on i s al l owabl e wi thmi nor l eakages ( Cl ass I or II). Of course, you must consi der the f l ui d ca-paci ty i n the i tem/ system bei ng check-ed/ i nspected. When i n doubt , not i f yyour supervi sor.

When operat i ng wi th Cl ass I or Cl ass I Il eaks, conti nue to check f l ui d l evel sas requi red i n your PMCS.

2



TM 5- 6115- 440- 10C 3

Page 3-5. Tabl e 3- 1 NOTE i s supersededto read as f ol l ows:

NOTE

Vi sual l y i nspect, concurrentl y wi th the

dai l y checks and servi ces, f or evi denceof Cl ass I I I oi l or f uel l eakage.

Page 3- 6. Tabl e 3- 2. Fi rst l i ne i schanged to read as f ol l ows: Fuel l i nes.I nspect f or Cl ass I I I l eakage and l ooseconnect i ons.

3



TM 5-6115-440-10C 3

By Order of the Secretary of the Army:

JOHN A. WICKHAM, JR.General, United States Army

Chief of Staff

Official:

R. L. DILWORTH Brigadier General, United States Army

The Adjutant General

DISTRIBUTION: To be di st r i but ed i n accor dance wi t h

DA For m 12- 25A, Oper at or Mai nt enancer equi r ement s f or Gener at or Set , GasDr i ven, 2 Wheel Mount ed, 28V, DC, 7. 5KW( J HGV7. 5A) .

4



TM 5-6115-440-10C1

C HANGE H E A D Q U A RT E R SDEPARTMENT OF THE ARMY

No. 1 WASHINGTON, DC, 27 September 1973

Operator’s Maintenance Manual

GENERATOR SET, 7.5 KW, 28V, DC, GED,AIR COOLED, 2 WHEEL MTD, PNEU-MATIC TIRES (JOHN R. HOLLINGS-WORTH MODEL JHGV7.5A) FSN 6115-074-6396

T M 5 - 6 11 5 - 4 4 0 - 1 0 , 2 F e b r u a r y 1 9 7 1 , i s c h a n g e d a s

f o l l o w s :

Page 1-1. Paragraphs 1 -1 and 1 -3 a re superseded as

f o l l o w s :

1-1. ScopeThis ma nua l is for y our use in opera t ing a nd ma in-t a ining th e genera t or set , J ohn R. Hollingsw ort hModel J H G V7.5A.

1-1



1-3. Reporting of Equipment Publication Im-provementsThe reporting of errors, omissions, and recommenda-t ions for improving this manual by the individualuser is encouraged. Reports should be submitted onDA Form 2028 (Recommended Changes to Publi-cations) and forward direct to Commander, USArmy Troop Support Command, ATTN: AMSTS-

MP P S t . Louis, MO 63120.Page B - 1. Appendix B is superseded as follows:

1- 2



APPENDIX B

BASIC ISSUE-ITEMS-LIST-AND ITEMSTROOP INSTALLED OR AUTHORIZEDLIST

Section I. INTRODUCTION

B-1. ScopeThis appendix listsfor operation of the

B-2. GeneralThis list is divided

a. Basic Issueapplicable.

b. Items TroopSection III.A list of items in

items required by the operatorgenerator set.

into the following sections: Items List-Section II. Not

installed or Authorized List-

alphabetical sequence, which atthe discretion of the unit commander may accom-pany the generator set. These items are NOT SUB-JECT TO TURN-IN with the generator set whenevacuated.

B-1



B-3. Explanation of Columns

The following provides an explanation of columnsin the tabular list of Basic Issue Items List, SectionII, and Items Troop installed or Authorized List,Section III.

a. Sou r ce, M ai n t en an ce, an d Recover abi l i ty Cod e (s) (SM R): (Not applicable).

b. Federal Stock Number. This column indicatesthe Federal stock number assigned to the item andwill be used for requisitioning purposes.

c. Descr ip t ion . This column indicates the Federalitem name and any additional description of theitem required.

d. U n i t of M ea su r e (U / M ). A two characteralphabetic abbreviation indicating the amount orquantity of the item upon which the allowances arebased, e.g., ft, ea, pr, etc.

e. Quant i ty Furn i shed wi th Equ ipment (BI IL) .(Not applicable).

f. Quan ti ty Au th or i zed (I tem s T r oop I n stal l ed or Author ized) . This column indicates the quantity of

the item authorized to be used with the equipment.

B-2



Sec tion Ill. ITEMS TROOP INSTALLED OR

AUTHORIZED LIST


CREIGHTON W. ABRAMS

Gener al , U ni ted States Ar m y Official: Chi ef of Sta ff

VERNE L. BOWERSM ajor Gener al , U ni ted Stat es Ar m y T he Ad j ut ant Gener al

Distribution:To be distributed in accordance with DA Form

12-25D (Qty Rqr Block No. 717), Operator require-ments for Generator Sets: 7.5 KW, D.C.

B-3



TECHNICALM ANUAL

No. 5-6115-440-10

TM 5-6115-440-10HEADQUARTERS

DEPARTMENT OF THE ARMY

WASHINGTON , D.C., 2 February 1971

OPERATORS MAINTENANCE MANUAL

GENERATOR SET, 7.5KW, 28V DC,

GED AIR COOLED, 2 WHEEL

MTD, PNEUMATIC TIRES

JOHN R. HOLLINGSWORTH

MODEL JHGV7.5A

FSN 6115-074-6396

This manual supersedes, so much of TM 5-6115-440-15, 17 June 1968, including all changes as pertains to Opera-tor’s maintenance.

i



C H A P T E R 1 .

S e c t i o n I .II.

C H A P T E R 2 .


C H A P T E R 3 .


III.

IV.

A P P E N D I X A .

B.

ii

Paragraph PageI N T R O D U C T I O N

General l-l-l-3 1-1

Description and da ta 1-4 , 1-5 1-2

OPERATINGI N S T R U C T I O N S

Operating procedure 2-1 -2-4 2-1- 2-4Operation underunusual condi t ions _2-5- 2-10 2-10 -2- l2

MAINTENANCEI N S T R U C T I O N S

Lubrication 3-1, 3-2 3 - 1 - 3 - 3

Preventive maintenance checks and services 3 - 3 - 3 - 4

Troubleshooting ------- -- 3-4 3-4

Maintenanceprocedure 3-5- - 3 - 7 3-10- -3-14

REFERENCES A-1

B. BASIC ISSUEITEMS LIST

(BILL) B-1



CHAPTER 1

INTRODUCTION

Section I. GENERAL

1-1. Purpose and Scope

This manual is for your use in operating the 7.5 KWgenerator.

1-2. Maintenance Forms and Records

Ma intena nce forms a nd records t ha t y ou a re requiredt o use a re expla ined in TM 38-750.

1-3. Recommending Improvements

You can improve this manual by recommending im-provements using DA Form 2028 (RecommendedChanges to Publicat ions) or a let ter, and mail directto Commanding General , Headquar ters , U.S. ArmyMobi l i ty Equipment Command, ATTN: AMSME-MPP, 4300 Goodfellow Blvd., St. Louis, Mo., 63120.A reply will be furnished direct to you.



Se c ti o n Il . DESC RIPTIO N A ND DA TA

1-4. Description

The 7.5KW generator is a self-contained, wheelmounted unit with winterization capabilities. It ispowered by a four cylinder, four cycle air-cooled en-

gine which is coupled to a 28 volt D.C. (Direct Cur-rent) generator ( fig. 1-1 ). If you need a detaileddescription of any component of the generator set,ask your supervisor to se e TM 5-6115-440-20.

1-5. Ta b ulated Da ta

Ta b l e 1 - 1 . Ta b u l a t e d D a t a

Components capacities (approximately)

Fuel tank 6 gal.Engine crankcase 4 qt. + 1 qt. for oil filterAir cleaner 1 qt.

1-2

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http://025659.pdf/



Fig

e11

1 - 3



Fig

e12

1 - 4



CHAPTER 2

OPERATING INSTRUCTIONS

WARNINGI f equ ipment fa i l s to opera te , re fe rtroubleshooting procedure in chapter 3.

Sec tion I. OPERATING PROCEDURES

2-1. Controls and Instruments

to

The purpose of the controls and instruments andtheir normal and maximum readings are illustratedin figure 2-1.

2-2a .

s e t .b.

Pre-Operating Instruc tionsRemove the canvas cover from the generator

Check engine oil level. Level should be even withfull mark.

c. Check battery electrolyte level. Level should be inch above the plates.

2-1



Fig

e21

2 -2



Fig

e21

2 - 3



d. Inspect the drive belts for damaged or cracked belts.

e. Check engine fuel tank level. Level should bewithin within 1½ -from the top.

NOTE

If generator set integral fuel tank is used,

make sure fuel tank cap vent is in openposition.

2-3. Starting

Refer to figures 2-2(1), 2-2(2) and 2-2(3) and startthe generator set.

NOTE

The engine governor will automatically con-trol the engine speed by varying the throttleopening. No manual control is required.

2-4. Stopping

a. Refer to figure 2-3 (1) and 2-3 (2) and stop thegenerator set.

b. For emergency stopping, place magneto groundswitch (on bottom of magneto) in the upward posi-tion.

2-4



Fig

e22

2 - 5



Fig

e22

2 - 6



Fig

e22

2 - 7



Fig

e23

2 - 8



Fig

e23

Fig

e23

2 - 9



Se c t io n I l . O PERA TIO N UNDER UNUSUA L

C O NDITIO NS2-5. Operat ion in Extreme Cold (Below – 25 o F.)

a. Use set with winter izat ion ki t , i f avai lable .b. Before starting winterized set, play blow torch

over exposed engine a rea s concent ra t ing on cra nkcaseand engine block.

c. Place canvas cover over set while operating.Open flaps over exhaust, muffler and engine intake air.

d . Keep fuel tank full at all t imes to prevent mois-t ure cond ensa t ion. K eep fuel t a nk ca p secur ely closed.

e. Use MIL-L-10295 oil, grade OES in the crank-case, for easier staring at temperatures below - 10°F.

f . Allow the engine to run a t a bout full th rot t le(1800 rpm) for a minimum of 10 minutes.

g. In crea se engine speed t o full t hr ot t le (2725 rpm)for 5 minutes before applying the load.

h . Keep bat tery ful ly charged. After adding waterto bat tery, run engine for a t lea st one hour.

2 - 6 . O p e r a t i o n i n E x t r e m e H e a t

a. Check the cooling fins on the cylinder and headfrequently t o be sure they a re clea n a nd n ot da ma ged.

b. If possible, operate at less than full rated load.This w ill minimize da nger of overhea t ing.

2 - 1 0



c. Provide shade to protect the unit from direct raysof the sun.

d. Make sure that cooling air circulation is notrestricted.

2-7. Op erat io n in Dusty o r Sa nd y A rea s

a. Shield the unit from dust. Take advantage of natural barriers which offer protection from blowingsand and dust. When not in operation, install thecanvas generator set cover over the unit.

b. Strain the fuel before adding it to the fuel tank.Make sure pouring vessels are clean.

c. Check air cleaner frequently. Make sure oil inair cleaner is not dirty, as this condition will consider-ably shorten service life.

d. Clean the generator set frequently. Wipe with a

cloth dampened with an approved cleaning solvent.

2-8 . Ope ra t i on Unde r Ra iny o r HumidCondi t ions

a. When the generator set is not in operation, keepit in a sheltered area.

b. Keep fuel tank full at all times to prevent mois-ture condensation.

2 - 9 . O p e r a t i o n i n S a l t Wa t e r A r e a s

a. Avoid contact with salt water to prevent corro-

2-11



sion. If the generator set comes in contact with salt

water, wash with fresh water.b. Paint exposed metallic surfaces if paint has been

chipped off or otherwise removed. Coat exposed fer-rous metal surfaces with a standard issue rustproofingmaterial if available, or cover parts with a light filmof grease.

2 - 1 0 . O p e r a t i o n a t H i g h A l t i t u d e s

a. Engine power output will decrease at a rate of 3½ precent for each 1000-foot increase in elevationabove sea level. The generator output will decreaseaccordingly as engine output decreases.

b. Maintain maximum performance by following

all service instructions carefully. Be sure the oil in theair cleaner is not dirty.

2-12



CHAPTER 3

MAINTENANCE INSTRUCTIONS

Se c tio n I. LUBRIC A TIO N

3-1. General Lubricat ion Ins t ruct ions

This sec t ion conta ins lubr ica t ion ins t ruc t ions whichare supplement to, and not specifically covered in the

opera t or /crew por t ion of lubr ica t ion ins t ru ct ions .

3-2. Detai led Lubricat ion Informat ion

a. General. Keep a l l lubr icants in c losed conta iners

a n d s t o r e i n a c l e a n , d r y p l a c e a w a y f r o m e x t e r n a l

heat . Do not al low any dust , dir t or foreign matter tocome in contact with lubricants.

b. Cleaning. Keep al l external parts that do require

lubr i ca t ion f r ee o f lub r i can t s . Befo re lubr i ca t ing the

equipment, wipe all lubrication points free of dirt and

grease. Clean all lubrication points after lubricating toprevent accumulation of foreign matter.

c. Points of Lubrication. S e r v i c e t h e l u b r i c a t i o n

points at proper intervals as i l lustrated on the lubrica-t ion ins t ruc t ions (Fig. 3- 1).

3-1



Figure 3 1.

3-2



d . OES Oil.

(1) When using grade OES oil in the crankcase(under conditions of extreme cold), check the oil levelfrequently, as oil consumption may increase.

(2) This oil may require changing more fre-quently than usual because contamination by dilutionand sludge formation will increase under cold weatheroperation conditions.

3 - 3 . G e n e r a l

a. To insure that the generator set is ready foroperation at all times, it must be inspected systematic-ally so that defects may be discovered and corrected before they result in serious damage or failure.

b. Item numbers indicate the sequence of minimuminspection requirements. Defects discovered duringoperation of the unit shall be noted for future correc-tion, to be made as soon as operation has ceased. Stopoperation immediately if a deficiency is noticed whichwould damage the equipment if operation were con-

tinued. All deficiencies and shortcomings will be re-corded together with the corrective action taken onDA Form 2404 (Equipment Inspection and Mainte-nance Worksheet) at the earliest possible opportunity.

c. Refer to table 3-1 for Before Operation, During

3-3



Operation, and After Operation, Preventive Mainte-

nance Checks and Services.

d. Refer t o table 3 -2 for, Daily and Weekly, Pre-ventive Maintenance Checks and Services.

Sec tion Ill. TROUBLESHOOTING

3-4. General

a. This section contains troubleshooting informa-tion for locating and correcting most of the operatingtroubles which may develop in the generator set.Each malfunction for an individual component, unit,

or system is followed by a list of tests or inspectionswhich will help you to determine probable causes andcorrective action for you to take. You should performthe tests/inspections and corrective action in the orderlisted.

b. This manual cannot list all possible malfunctions

that may occur, or all test, or inspections and correc-tive actions. If a malfunction is not listed (exceptwhen malfunction and cause are obvious), or is notcorrected by listed corrective actions, notify yoursupervisor.

3-4



Ta

e3

1

3 - 5



3 - 6



3 - 9



Section IV. MAINTENANCE PROCEDURES

3-5. Air Cleaner Service

a. Refer to figure 3-2 and service the air cleaner.b. After installation of air cleaner, wipe off any oil

spillage to prevent accumulation of foreign matter.NOTE

When operating under extreme dust or sandycondition wash non-removable element inFED. P-D-680 solvent every three months.

3-6. Cleaning Fuel Strainer

a. D i sassem bl y. Refer to figure 3-3 and disassemblethe fuel strainer as follows:

(1) Shut off the fuel valve.(2) Loosen knurled nut.(3) Swing the wire bail to one side and remove

the glass bowl, gasket, and filter screen.b. Cl ean i ng. Clean the glass bowl and filter screen

with FED-P-D-680 Cleaning solvent.

c. Reassembly.(1) Install a new gasket if old one is not in good

condition.(2) When installing parts, do not tighten knurled

nut excessively.(3) Open fuel valve.

3-10



Figure 3 2

3-11



Figure 3 3.

3 - 7 . B a t t e r y

a. R em o v a l .

(1) Remove two wingnuts, flatwashers, lock-washers, and nuts a battery hold down bolt (fig. 3-4).

(2) Disconnect battery leads from battery.(3) Lift battery out of the frame.

b. I n s t a l l a t i o n .

(1) Check battery electrolyte for correct levelinch above p la te ) .

3–12



Figure 3 4.

(2) Position battery in frame.(3) Connect battery leads.

3-13



(4) Secure battery in place with two battery hold

down bolts, wingnuts, flatwashers, lockwashers andnuts (fig. 3-4).

3-14



APPENDIX A

REFERENCE

A-1. Maintenance

TM 5-6115- Organizational Maintenance

440-20 m a n u a l G e n e r a t o r S e t ,7.5KW, 28V DC, G.E.D.Air Cooled 2 Wheel MTD,Pneumatic Tires (John R.H o l l i n g s w o r t h M o d e lJHGV7.5A) F S N 6 1 1 5 -074-6396.

TM 38-750 T h e Army MaintenanceM a n a g e m e n t S y s t e m

A-2. Lubrication ( TA M M S ) C9100-IL Identification List for Fuels,

L u b r i c a n t s , O i l s a n dWa x e s .

A-1



APPENDIX B

BASIC ISSUE ITEMSFEDERAL STOCK NAME QUANTITY

NUMBER FURNISHEDWITH EQUIPMENT

7510-889-3494 BINDER, LOG BOOKTM 5-6115-440-10

B-1




W. C. WESTMORELAND,General, United States Army,

Official: Chief of Staff.KENNETH G. WICKHAM,

Major General, United States ArmyThe Adjutant General.

Distribution:

To be distributed in accordance with DA Form 12-25,(qty rqr block no. 717) Section IV, Operator ’s maintenancerequirements for Generator Sets, Engine Driven, 7.5 KW,D C.

U.S. GOVERNMENT PRINTING OFFICE : 1991 0 - 281-504 (42337)

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