TM  5-6115-332-14 P-8-614-14 TO  35C2-3-424-1 CHAPTER  8 GENERATOR  SET  TEST  AND  INSPECTION  AFTER  REPAIR AND   OVERHAUL Section  I. GENERAL   REQUIREMENTS The   activity   performing   the   repair   or   overhaul   is erator   set   must   perform   those   tests   and   inspections responsible   for   the   performance   of   all   applicable required   by   the   applicable   component   or   system   re- tests    and    inspections    specified    herein.    Activities pair   instruction. performing   maintenance   on   any   portion   of   the   gen- Section  II. lNSPECTION a.  All   material,   repair   parts,   assemblies,   com- ponents,    welding,    refinishing    and    other    workman- ship   shall   be   sampled   in   accordance   with   MIL-STD- 105D   to   assure   compliance   with   standards   estab- lished   in   this   manual. b.  overhaul    inspection    procedures    for    disassem- bled    components    and    subassemblies    are    contained throughout    the    manual    where    applicable.    All    data necessary   to   determine   serviceability   of   each   com- ponent   or   subassembly   such   as   dimensional   data, fits,   tolerances,   and   surface   finish   information   is contained   herein. c.  Used   components   and   repair   parts   recovered as   products   of   disassembly   will   be   examined   100% by   the   activity   performing   the   repair   to   determine serviceability. Section  III. OPERATIONAL   TESTS a.  Using   the   visual   and   operational   check   list (Table   8-1),   visually   inspect   and   operationally   test the   generator   set   for   a   minimum   of   four   hours   as follows: (1)   1/4   hour   warm   up. (2)  1  hour  1/2  load  at  .8  power  factor-. (3)   2-1/4   hours   full   load   at   .8   power   factor. (4)  1/4  hour  125%   load  at  .8  power     factor. (5)   1/4   hour   idle. b.  During   the   test   period,   the   following   oper- ational     checks     will     be     made. (1)   The   proper   operation    of    all    components under   no   load   and   full   capacity   load   conditions. (2)   Proper   function   and   adjustment   of   all   in- struments,    controls    and    gages. ( 3 )      O v e r h e a t i n g , vibration and unusual noises. (4)   Record   voltage,   current,   power,   factor,   fre- quency   and   temperature   readings   at   the   above loads. (5)   Check   operation   of   control   and   protective the   test   run   periods   are   completed   and   the   load gradually   removed,   shut   down   the   unit,   after   the   1/ 4   hour   idle   period. (6)  Oil  and   fuel. CAUTIO N If   during   the   operational   test,   exces- sive  noise  or  vibration  is  observed  or any   overheating   or   malfunctions occur  which  may  cause  damage  to  the equipment,   stop   operation   immedi- ately   until   necessary   repairs   are made. (7)  If   the   malfunction   is   minor   and   will   not damage   the   generator   set,   the   tests   may   continue and   defects   corrected   upon-completion   of   tests. (8)   Inspect    f o r    p r o p e r    f u n c t i o n i n g ,    c o m - ponents   which   have   been   overhauled   or   repaired. (9)  Presence   of   one   or   more   defects   shall   be cause   for   rejection   until   acceptable   repair   has   been made.  If  repair  is  required  to  a  major  component,  re- equipment   while   conducting   the   test   run   and   when peat   the   entire   operational   test. 8  - 1