PU-181_PGC-1_engine_generator_serv_user_TM11-943_1951.pdf

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1、 TO 16-35 PU 181-5 DEPARTMENT OF THE ARMY TECHNICAL MANUAL ENGI / E .I GE ElATOR ; PU-18 PGC-1 DEPARTMENT OF THE ARMY APRIL 1951 I I: DEPARTMENT OF THE ARMY TECHNICAL MANUAL TM 11-943 ENGINE GENERATOR PU -181 /PGC-1. DEPARTMENT OF THE ARMY United States Government Printing Office Washington: 1951 AP

2、RIL 1951 DEPARTMENT OF THE ARMY vV ASI-IINGTON 25, D. c., 9 April 1951 TM 11-943 is published for the information and oui lance of all concerned. AG 412.5 (2 Apr 51) BY ORDER Ol! TIIE SE RETAHY oF THE An IY : 0FF1CIAL: J. LAWTON COLLINS EDWARD F. WITSELL Oldef of Staff, United tate A1nvy Major Gener

3、al, USA The Adjtttant General DrsTRIDUTION : ii Tech Svc (2) except 11 (65); Arm AFF Bel (ea Svc Test Sec) (1); AFF (5); AA Cornel (2); OS Maj Cornel (5); Base Cornel (5); MDW (5); Log Comel (5); A (20); CHQ (2); FC (2); Sch (2) except 11 (25); Gen Dep (2) ; Dep 11 (20) except Sig S c, Gen Dep (10)

4、; Tng Div (2); PE (10), OSD (2); Lab 11 (5); 4th Two (2) copies to each of the following T/ O 5-316; 6-50; 6-200; 6-200-1; 6-225; 6-226; 6-235; 6-236; 6-416; 8-590; 10-22; 11-15N; 11-18N; 11-95; 11-97; 11-107; 11-127; 11-500; CA, CB, CC, CD; 11-557; 11-587; 11-592; 11-597; 55-12; SPECIAL DISTRIBUTIO

5、N. For explanation of distribution formula, see SR 310-90-1. CONTENTS CHAPTER 1. INTRODUCTION Paragraphs Paoe Section l. General_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ 1- 2 1 II. Description an l daLa_ _ _ 3-6 2 CHAPTER 2. OPERATING INSTRUCTIONS ection f. Service upon rcc

6、eipl. or equipment_ 7-14, 7 !f. ConLrols_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ 15 16 III. Op raLion under u. ual conditions _ 16-21 17 IV. Operation under unusual conditions _ 22-24 20 CHAPTER 3. MAINTENANCE INSTRUCTIONS Section I. OrganiaLional Loot.-25-27 23 II. Lubric

7、aLion and preservation _ _ _ 28-35 24 III. Preventive maintenance _ _ _ _ 36-47 28 IV. Troullc .-h.ooLing _ 48-53 39 CHAPTER 4. FIELD MAINTENANCE Section I . GeneraL _ _ _ 54-55 4 7 II. Cleaning and stripping _ _ 56-57 47 III. Disassembly _ _ _ _ 58-65 50 IV. leaning, inspection, and repair _ _ 66-8

8、3 62 V. Reas.ernbly _ _ _ 84-90 74 VI. Adju irnents _ 91-95 83 1 TII. Final testing _ _ _ _ _ 96-99 87 VIII. Refinishing and rustproofing _ 100-102 88 I X. Suppression _ 103-104 89 CHAPTER 5. SHIPMENT AND LIMITED STORAGE AND DEMOLITION TO PREVENT ENEMY USE Section I . Shipment and limited storage_ _

9、 105 II. Demolition to prevent enemy use _ 1.06-107 APPENDIX I. REFERENCES _ -_ - 11. TABLE OF STANDARD NUTS, BOLTS, SCREWS, AND WASHERS _ - INDEX_ - 91 91 93 97 99 Ill SAFETY NOTICE 1. Sufficient and proper ventilation must be provided if the power unit is operated in a confined space. Exhaust gase

10、s produced are poisonous, and excessive inhalations may result in sickness or death. 2. Do not service the unit with Oasoline while it is running or if b d a radio transmitter is operating near the engine generator. Av01 spilling fuel on a hot engine. 3. The operator must observe every standard safe

11、ty regulation while operating this engine generator. 4. This equipment generates high voltage which is dangerous to life. Keep clear of all live parts. Never make or change electrical connections while the equipment is running. Severe and possibly fatal shocks may be experienced. Keep tools, oilcans

12、, loose parts, and moisture away from the engine generator and keep the surround- ing area dry. v Figwe 1. Engine Generator PU-161/PGC-1. vi I. Scope CHAPTER I INTRODUCTION Section I. GENERAL a. These instructions are published for the information and guid- ance of the personnel to whom this equipme

13、nt is issued. They con- tain information on the operation and on the organizational and field maintenance of the equipment as well as a discussion of the theory of operation. They apply only to Engine Generator PU-181/PGC-1. b. Appendix I contains a list of available publications applicable to the e

14、quipment. Appendix II contains a table of all standard nuts, bolts, screws, and washers used in the equipment that are not special items, but are a type readily obtainable from commercial sources. 2. Forms and Records The following standard forms will be used for reporting unsatis- factory condition

15、s of equipment, or improper preservation, packaging, packing, marking, loading, stowage, or handling thereof. a. DD Form 6, Report of Damaged or Improper Shipment, will be filled out and forwarded as prescribed in SR 745-45-5. b. DA AGO Form 468, Unsatisfactory Equipment Report, will be filled out a

16、nd forwarded to the Office of the Chief Signal Officer as prescribed in SR 700-45-5. c. AF Form 54, Unsatisfactory Report, will be filled out and for- warded to Commanding General, Air Materiel Command, Wright- Patterson Air Force Base, Dayton, Ohio, as prescribed in SR 700- 45-5 and AFR 65-26. d. T

17、he followin(J forms explained in TM 37-2810, are necessary in b . connection with the operation and maintenance of Signal Corps m- ternal-combustion -engine-driven equipment. (1) DD Form 110, Vehicle and Equipment Operational Record. (2) WD AGO Form 460 Preventive Maintenance Roster. ( 3) D A A GO F

18、orm 464, Preventive Maintenance and Technical Inspection Work Sheet for Engineer Equipment. e. Use other forms and records as authorized. K PLUG SHIELD FiguTe 2. Engine Genmato1 PU-181/PGC-1, 1 iUht qumter view. Section II. DESCRIPTION AND DATA 3. General Description a. Engine Generator PU-181/PGC-1

19、 is a compact, lightweight, electric gerterating set which consists of gasoline Engine GE-12-F and a-c (alternating-current) Generator GN-51-C. It is designed to deliver 300 watts ac at 120 or 240 volts, operating at 3,600 rpm (revolutions per minute). b. Engine GE-12-F is a single-cylinder, air-coi

20、led, two-cycle gasoline engine which develops 1.25 horsepower at 3,600 rpm. c. Generator GN-51-C is a single-phase, 60-cycle unit of the revolv- ing-field type. It is coupled to the engine crankshaft by means of a spl.ined, flexible coupiing and fan assembly. d. The complete engine generator is moun

21、ted on four rubber shock mountings in an open tubular frame. The rubber shock mountings serve to absorb vibration when the unit is in operation. e. Case CY-739/PGC-1 is provided as a protective housing for the engine generator unit when it is not operating. This case is con- structed of plywood and

22、reinforced at the corners by metal corner pieces. The upper part of the case fits over the engine generator unit 2 Figl.tre 3. Cctse CY-739/PGC-1. and is fastened to a wooden platform base with four spring latches. There are metal carrying handles on opposite ends of the case to facilitate handling.

23、 A compartment for tools and spare parts is pro- vided in the top of the case. This compartment has a wooden door with a sliding catch which gives access to the tools and spare parts. f. Bag CW-191/ PGC-1 is provided to protect the engine generator unit when it is not operating and when it is not ho

24、used in Case CY-739/ PGC-1. This bag is of waterproof material and completely covers the equipment. When not in use, Bag CW-191/PGG-1 is stowed inside of Case CY-739/ PGC-1, directly above the door to the tool and space parts compartment. Bag CW-191/PGC-1 must be removed from the equipment before th

25、e engine generator unit is plac.ed in Case CY-739/PGC-1. Carrying handles are placed on oppos:te ends of the bag and there are also two rows of metal rings, on oppos1te sides, to facilitate handling. g. The complete weiOht of EnOine Generator PU-181/PGC-1, Case b b CY-739/PGC-1, and Bag CW-191/PGC-1

26、, with the fuel tank empty, is approximately 98 pounds. 3 4. Purpose and Use Engine Generator PU-181/PGC-1 is intended as a source of power for Signal Corps Teletypewriter Set AN/PGC-1. It may also be used to furnish power for other equipment requiring power within its rated capacity. l,igtwe 4. Bag

27、 OW-191/PGG-1. 5. Major Parts and Assemblies (figs. 5 to 9) a. ENGINE. Engine GE-12-F is a single-cylinder, two-cycle, air- cooled unit with a 2-inch bore, a 11/2-inch stroke and a piston dis- placement of 4.72 cubic inches. It is designed to operate satisfactoril on gasolines with an octane rating

28、as low as 72 and will run approxi- mately 71;2 hours at full-load on a single fillino of the fuel tank. The f t: uel tank capacity is 1 gallon. b. GENERATOR. Generator GN-51- C has a two-winding stator (sta- tionary member) and is designed to generate 60-cycle single-phase, ac, 4 TM343-5 I Fiutwe 5.

29、 Engine Genemto1 PU-181/PG0-1, mounted on wooden plattorm base. 120 or 240 volts, at 3,600 rpm. Within the stator is the rotating field which consists of a cylindrical permanent magnet mounted on the gen- erator shaft. No brushes or slip rings are used. , (1) The generator output is 300 watts at 100

30、 percent power fac- tor. When connected for 120 volts, the voltage output with- out load is approximately 128 volts, while at full-load of 300 watts, the voltage output is approximately 112 volts. The electric governor on the engine causes the engine speed to increase with increasing generator load,

31、 so that from no-load to full-load the voltage output is held between these two values. (2) When connected for 240 volts, the voltage output will vary approximately between 256 and 224 volts from no-load to full- load. (3) A single, 20-ampere, twist-lock receptacle and three bind- ino-posts are loca

32、ted in the outer end casting of the generator. To of these posts are for output, while the other, which is marked( is for a o-round connection. (Do not use pliers on b these posts.) Note. Do not use output posts except in cases of emergency where no connecting plug is available. 5 1 - c. MAGNETO. Ig

33、nition is supplied by a high-tension flywheel-type magneto. This consists of a rotor (moving member) which is a part of the engine flywheel and a stator plate (stationary member) mounted directly on the engine crankcase. d. CARBURETOR. The carburetor is of the float feed type. Fuel is supplied to it

34、 directly from the gasoline tank through the fuel line. e. Am CLEANER. The air cleaner is of the replaceable cartridge type. Its function is to prevent the air which enters the carburetor from drawing dust and dirt into the engine. f. GovERNOR. The governor is of the electric solenoid type and is ac

35、tuated by generator voltage. The solenoid is mounted on the car- buretor, and the plunger or armature is connected to the carburetot throttle shaft by a link and lever arrangement. Ac tapped from a portion of the generator indings passes through a dry-type rectifiel F igme 6. Oase 01-739 jPG0-1, top

36、 section 1emovea 1om bcLSe. where it is converted into de (direct current) and supplied to the sole- noid. This current produces a magnetic pull on the plunger, moving it against the action of a small spring, and thus controls the throttle valve movement which in turn varies the engine speed to obta

37、in sub- stantially constant voltage under generator load variations. g. WooDEN CASE. The wooden case (Case CY-739/PGC-1) is for storage and moving of the unit. It is of plywood reinforced with metal corners. The top is held to the base by four spring catches. The wooden base has four clamps to hold

38、the power unit securely. The base may be used for an operating platform for the power unit when conditions warrant. h. WATERPROOF BAG. A rubberized waterproof bag is packed in the upper inside of the wooden case over the tool and spare parts com- 6 partment door. Unpack the bag with the open end o t

39、he case up. Set the unit in the bag on the padded base and close the edge by fold- ing over and over on creased lines. Seal and strap the bag tightly or waterproof protection. ligwe 7. Bag OW-191/PGC-v, partially open. 6. Tabular Data a. vVmGHTS AND DIMENSIONS. It om Height Width Length Weight (in.)

40、 (in.) (in.) (lb.) Engine Generator PU- 181/PGC- 1 con-12 1%6 14Ys 17Ys - sisting of: 17Ys 37 1 Engine GE-12- F (complete) _ 121%6 13Ys 1 Generator GN-51- C _ - -7Ys 6 6 19 1 basic engine _ _ _ - 4).6 7%6 7% 8% 1 Bag CW-191/PGC- L _ _ 13 14Ys 18 5Ys 1 wooden Case CY-739/PGC- L _ 19%4 16% 19% 28 1 se

41、t tools and materials. 1 set running spare parts. 7 b. PERFORMANCE C uARACTERlSlICS. Approx. I ad Y. load_ - J ad- load- Full load _ - - Amperes 0. 6 1. 26 1. 92 2. 63 Volts 120. 5 119. 5 1J 7. 5 114. 0 WaLts 75 150 225 300 - 1 , stcs llrO appro Check all connections, includ- ing the fuel line shut-

42、off (fig. 13). Periodically tighten all connections. 19 f/1194)-14 Fiunte 14. Testing spatlc pltu. 2 I. Stopping To stop the engine, press the wire level extending from the maO, neto backplate (fig. 10) down until the engine comes to a complee stop. Always close the fuel shut-off valve and fuel tank

43、 air vent when the unit is not in operation. Section IV. OPERATION UNDER UNUSUAL CONDITIONS 22. Operation in Arctic Climates a. GENERAL. Special precautions are necessary to prevent pool: performance or total operational failure of equipment in subzero temperatures. Most Signal Corps equipment can u

44、sed in wintel if difficulties common in low temperatures _are anticipated and pre, cautions taken to prevent them. F01 operatiOn ptroses, place equip, ment in heated rooms whenever possible. Wrp 1t m blankets, wher on the arch, to protect it from winds and freezmg temperature. Th folJowmg problems m

45、ay be encountered : 20 (1) (2) (3) Steel shrinks and becomes brittle in subzero temperatur Nat ural rubber resists cold weather well, but certain s. of synthetic rubber are unreliable and become brittl ypes Canvas freezes and loses its pliability in cold weathe;: (4) Lubricants become stiff causing

46、drag and also causing mov- ing parts to stick. b. CoLD WEATHER TREATlm T AND INsmucnoNs. (1) Cleanliness. Gummy and dirty parts, oil, and grease solidify more readily in extremely cold weather. Clean all parts thoroughly to maintain sluggish-free action. (2) Lub1icarlit . Store fuel and lubricants i

47、n tightly closed con- tainers at all times. Always fill container to avoid air spaces. Condensation form in air spaces and water is deposited at the bottom of the fuel or oilcan. Prevent snow and water from getting into the lubricants and lubrication equipment. (3) Lttb?ication. Service all lubrication points more f