The kit can also be used to warm the Generator
Set for initial starting within 5 hours at any ambient
temperature down to -65° F.
Power for operation of the kit may be obtained from
any power source that supplies 205 to 240 volts at
50, 60 or 400 Hz single phase. For electrical win-
terization kit operating instructions refer to Fig.
Troubleshoot the electric winterization kit using table
17-3. Typical malfunctions, the possible causes,
and the necessary corrective action are tabulated.
17-15. Removal and Disassembly.
Refer to Operator and Organizational
Maintenance Manual and remove electric winterization
(1) Refer to Operator and Organizational Main-
tenance Manual and disassemble the electric winteri-
(2) See figure 17-3 and disassemble the cool-
(3) See figure 17-4 and disassemble the electric
winterization control box as follows:
Remove screws (1) and cover (2).
Tag all leads attached to heat sink (14)
Remove nut (5) and screw (6) and remove
Remove (7) thru (15) in sequential order.
Tag and unsolder leads from semicon-
and (13). bracket (16) and grommet (17)
can then be removed.
(f) Remove items (18) thru (39) in sequen-
17-16. Inspection and Repair.
a. Replace all gaskets, seal rings and motor
brushes at each overhaul.
b. Replace all electrical and mechanical parts
that do not meet the requirements specified herein
and in table 17-4.
Reassemble control box and coolant pump and motor
assembly in the reverse order of the numerical se-
quence in figure 17-4 and figure 17-3.
a. Coolant Pump and Motor Assembly Test.
(2) Mount motor and pump assembly on a test
stand and install proper fittings in inlet and outlet
ports. Attach hose line from supply tank to port
(3) Attach discharge line with pressure gauge
and needle valve to port marked OUT and return to
(4) Attach electrical plug to motor receptacle
and plug in to dc power supply.
(5) Turn power switch on and run unit for ap-
proximately 15 minutes on 24 Vdc.
(6) Close valve in outlet line. (Make sure dis-
charge pressure does not exceed a maximum of 30 to
40 psi when closing this valve). Open and close valve
a few times to check consistency of relief valve per-
(7) To check pump for rated flow and pressure,
adjust valve in discharge line until a reading of 2 psi
is obtained on pressure gauge. Using a suitable
timer, check for rated coolant flow of 80 gph (gal-
lons per hour) minimum at 2 psi discharge pressure
(at 68°F. ) Amperage draw must not exceed 3.3
amperes during this test. The drive motor speed
should be approximately 7500 rpm. Observe smooth-
ness of operation of both pump and motor. Seal leak-
age of 1 cc per hour is maximum when pump is opera-
ting at 2 psi discharge.
(8) Turn power supply off, then remove dis-
charge line and fitting from OUT port. Plug this
port and apply 40 psi hydrostatic pressure for 20
minutes to inlet port.
No leakage shall be evident
during this test.
b. Electric Winterization Control Box Components.
Inspect the transformer for
visual damage to lugs, windings, etc. If visual dam-
age is obvious, replace transformer. Open trans-
former primary and secondary windings and check
the winding resistances. The primary resistance
(terminals 1 and 2) shall be 6.77 ohms ± 10 percent.
The secondary (termimls 3 and 5) shall be 0. 108 ohm
± 10 percent.
Apply 230 Vac at 60 Hz winding 1-2
with the secondary open circuit. The exciting current
shall be less than 0. 04 amperes, rms.
Apply 253 Vac
to 1-2. The exciting current shall be less than 0. 065
With the secondary open circuit, ap-
ply 230 Vac to winding 1-2. The voltage across 3 to 4
and 4 to 5 shall be 14.8 volts rms, ± 1 percent. If any
of the above tests are failed, replace the transformer.
(2) Inspect the control relay for visual damage.
If visual damage is obvious, replace relay. Check
relay coil with an ohmmeter. The coil resistance
should be 300 ohms ± 10 percent at, or corrected to,
250 C. Apply 24 Vdc to the coil with a dc power sup-
ply. The two normally open contacts shall close.
Remove the 24 Vdc; the two contacts shall open. If
defective, replace per paragraph 17-15.
(3) Test the four control box diodes per para-
Replace a defective diode,
(4) Replace defective connectors.
(1) After coolant pump has been reassembled,
it must be tested before being reinstalled.