SERVICING THE GENERATOR Before the set is operated, it must be serviced. We will use the 60-kW generator set as an example for discussing the servicing of the set after you receive it.

As you read this discussion, refer to figure 3-1 for locating fill and drain points and drain valves.

Batteries All 5-kW through 750-kW generator sets are furnished with dry-charged batteries less the electrolyte. Battery electrolyte must be requisitioned separately.

You must be cautious when installing, activating, or maintaining batteries. Before we discuss connecting WARNING Do not smoke or use an open flame in the vicinity of batteries when servicing them. Batteries generate hydrogen a highly explosive gas. When removing batteries, always remove both negative cables before removing the positive cables (fig. 3-2).

Battery electrolyte contains sulfuric acid and can cause severe burns. It is highly toxic to the skin, eyes, and respiratory tract. Skin, eyes, and face (chemical splash goggles, face shields) and respiratory protection are required. Whenever electrolyte comes into contact with the body, the eyes, or the clothing, you must rinse immediately with clean water, remove contaminated clothing, and then go to sickbay or the medical clinic for a thorough examination. The 60-kW generator set is equipped with two 12- volt, 100-ampere-hour batteries. The batteries are located under the radiator (fig. 3-1, view A) on aroll-out tray (fig. 3-3). They are connected in series to supply 24 volts dc for starting the generator set and operating direct current components. Two slave receptacles (fig. 3-2), connected in parallel, permit easy connection to the batteries to supply or obtain battery power. As we and servicing batteries, let's look at a few safety points you must know about.

Figure 3-2.- Battery cable connections and slave receptacles.

discuss activating the batteries, refer to steps 1 through 3 (following) and figure 3-3. 1.400

1.Open the battery compartment door and secure it to the radiator grille with the door holder. SPECIFIC GRAVITY DESIRED USING 1.835 SPECIFIC USING 1.400 SPECIFIC GRAVITY ACID GRAVITY ACID PARTS OF PARTS OF PARTS OFPARTS OF WATER A C I D WATER ACID

2. Depress the button on top of the quick-release pins, lift up the pins, and pull the roll-out tray assembly out.

3. Remove the filler caps. When you have electrolyte of the correct specific gravity, do not dilute it, but fill the battery cells to the cell slots.

When you prepare your own electrolyte, consult a mixing chart (table 3-1). In this case, use the specific gravity value recommended in the instruction manual.

Table 3-1.- Electrolyte Mixing Chart

The temperature of the electrolyte when placed in the cells should be between 60 F and 90 F. IT SHOULD NEVER EXCEED 90 F.

A chemical reaction occurs when you add electrolyte to the battery, thereby causing the battery to heat. Cool it artificially (cooling fans) or allow it to stand at least 1 hour before placing it in service.

WARNING Be sure to add the acid to the water s-l-o-w-l-y, stirring constantly and thoroughly.

Figure 3-3.- Battery compartment.

You will notice at the end of the cooling period that the level of the electrolyte has dropped because of the electrolyte soaking into the plates and separators. Before placing the battery in service, restore the electrolyte to its proper level. Remove any electrolyte spilled on the battery, using a cloth dampened with a solution of bicarbonate of soda and water.

Although you can place the battery in service 1 hour after filling it with electrolyte, do so only in an emergency. If at all possible, give the battery an initial light charge.

After the battery has been charged, connect the battery into the starting system of the prime mover, as shown in figure 3-2. Always connect the negative cable last.

4. Push in the roll-out tray assembly and install the quick-release pins (fig. 3-3).