TM 5-6115-593-12 TO 35C2-3-463-1 Section V.  OPERATOR/CREW MAINTENANCE 3-6. GENERAL.      Instructions   in   this   section   are provided  to  assist  the  operator/crew  in  maintaining  the generator set. If during inspections defective components are noted, refer to higher level maintenance for replacement or repair. 3-7. MAINTENANCE OF BATTERIES AND RELATED ITEMS. a. Inspection (1)   Inspect cables and connectors for corrosion and looseness. (2)   Inspect   batteries   for   damage   or   cracked cases. b. Service.  Service at intervals shown in table 3-2. (1)   Check  electrolyte  level  of  batteries.    If  low, fill  with  distilled  water  to  3/8  inch  (9.5  mm) above plates.  Refer to next higher level of maintenance. (2) Apply grease to cable connectors to prevent corrosion.  If connectors are corroded, clean prior    to    applying    grease.        (3)    Replace batteries when cracked.  Refer to next higher level of maintenance. (4)   Tighten  loose  cable  connectors.    Refer  to next higher level of maintenance. 3-8. MAINTENANCE OF MUFFLER AND EXHAUST. WARNING Be certain that the exhaust is not fed back into the  system,  or  back  into  the  immediate  area  of working personnel.  Exhaust may be injurious to the  health  of  personnel.    Inspect  the  mufflers and exhaust system as follows (see figure 4-11): a. Inspect mufflers for looseness, rust, and damage. b. Inspect metal hoses for rust and dents. c. Inspect  entire  exhaust  system  for  evidence  of leaks, particularly around gasket areas. d. Inspect  weather  cap  for  proper  operation.    Cap must open and close freely. e. Inspect entire assembly for loose nuts and bolts. 3-9  MAINTENANCE    OF    EXTERNAL    POWER    BOX ASSEMBLY.    See  figure  4-12  and  inspect  receptacles, circuit     breakers,     switches,     and     plate     and     sleeve assembly    for    loose    mounting    and    loose    electrical connections. 3-10. MAINTENANCE   OF   AC-DC   CONTROL   BOX ASSEMBLY.  Inspect the AC-DC Control Box Assembly as follows (see figure 4-17): a. Inspect circuit breaker, switches, potentiometer, and DC amp shunt for cracks, breaks, corroded terminals and loose electrical connections. b.   Inspect receptacles and shorting plug for damaged threads, bent, loose or missing pins. c. Inspect wiring for defective insulation. 3-11. MAINTENANCE OF CONTROL CUBICLE.  See figures 4-20 and 4-22 and proceed as follows: a. Inspection. (1)   Inspect     transformers,     switches,     and     circuit breakers for cracks, breaks, corroded terminals, and loose electrical connections. (2)   Inspect gauges and instruments for damage. (3)   Inspect lamps for loose electrical connections. (4)   Inspect receptacles for damaged threads, bent, loose, or missing pins.  Inspect telephone jack for loose mounting. 3-10