TM   5-6115-584-12 NAVFAC   P-8-622-12 TO-35C2-3-456-1 CHAPTER  4 ORGANIZATIONAL MAINTENANCE Section I. SERVICE UPON RECEIPT OF MATERIAL 4-1.  INSPECTING  AND  SERVICING  GENERATOR SET. a. Unloading Equipment. (1)  The  dry  weight  of  the  engine  Generator  Set  is 960 pounds. A crane, fork lift, or similar lifting device or fabricated skids must be used to unload the equipment. The equipment must be kept in the UP position while unloading. Do not use a lifting device with a capacity of less than 1500 pounds. Do not allow the crated Genera- tor  Set  to  swing  while  it  is  suspended.  Failure  to observe this warning may result in serious injury or death to personnel. b.   Unpacking. (1)  Before  unpacking,  move  the  engine  Generator Set as near as possible to the location where it will be oper- ated. Exercise care in the use of bars, hammers, and simi- lar tools while uncrating the unit to avoid damaging the equipment. (2) Remove the top and then the sides of the crate (figure  4-1). (3)  Remove  barrier  bag,  dessicant  bags,  and  ship- ping material from engine Generator Set. (4)   Disconnect   engine   Generator   Set   from   crate skid  by  removing  carriage  bolts,  nuts,  washers,  and  lift engine Generator Set off skid. c. Service  and  Inspection. (1) Prepare the engine Generator Set for inspection and servicing as outlined in the following paragraphs. For Army users, refer to D Form 2258. (2) Make a thorough visual inspection of the entire Generator Set for loose or missing hardware or damaged or missing parts. Report all damaged or missing parts on DD Form 6. (3)  Inspect  all  air  cleaner  connections  for  tightness and  damage. (3.1) On ASK equipped generators, inspect ASK for damage. Check that exhaust plenum is clear of debris. (4) Check engine intake and exhaust systems (figure 1-2) to make certain they are unobstructed by foreign mate- rial. (5) Check that main fuel tank drain cock (figure 1-2) is  closed. (6)   Remove   all   preservative   material   except   for preservatives  crankcase  oil. Do not smoke or use an open flame in the vicinity when filling fuel tank. Hot refueling of generators while they are operating poses a safety hazard and should not be attempted. Hot engine surfaces and sparks produced from the engine and generator circuitry are possible sources of ignition. Severe injury or death to personnel and damage to the equipment may result. NOTE On generators equipped with acoustic suppression kit (ASK), route auxiliary fuel line under rear flap on skid to auxiliary fuel pump. (7) Fill fuel tank with appropriate fuel and set MAS- TER SWITCH (figure 2-3) to RUN position to connect main fuel tank to electrical fuel pumps. If an auxiliry source of fuel is to be used in operating the engine Generator Set, connect fuel hose to AUXILIARY FUEL, CONNECTION and set MASTER SWITCH to RUN AUX FUEL position. (8)  Batteries  are  shipped  in  a  dry  state.  If  batteries are hermetically sealed, destroy sealing device inside each cell by tapping with a blunt instrument. Remove all sealing particles.  Battery  electrolyte  must  be  requisitioned  sepa- rately. To activate the battery, remove all caps and fill bat- tery  cells  with  electrolyte.  Electrolyte  level  should  be  3/.8 inch above top of plates for each cell. Make sure vent holes in caps are open, and replace caps. Connect batteries as shown in figure 4-16. NOTE The  electrolyte  level  must  be  rechecked  approxi- mately 30 minutes after initial filling as the plates and separators will absorb the solution, thus result- ing in a low level. If the battery is not to be used within 12 hours after initial filling, it should be put on a charger and brought up, to the correct specific gravity.  Test  batteries  as  described  in  paragraph 4-25c, for the ambient temperature in effect. Do not smoke or use an open flame in the vicinity when servicing batteries. Batteries generate hydro- gen, a highly explosive gas. Electrolyte contains sul- phuric acid and can cause severe burns. Handle it with care. If the solution comes in contact with the body,   eyes   or   clothing,   rinse   immediately   with clean  water.  Avoid  spilling  electrolyte  on  ainted surfaces. Change  9 4 - 1