Battery terminals

[LCA078]

Quick question about battery terminals for most currently field generators in the military: Do they use the serviceable terminals that attach to the battery cable with the 3/8" bolt? Or are they like typical automotive cables with the lead terminal molded directly onto the cable. When I look in the AMMPS parts manuals, I don't see serviceable terminals like these.

 

[Scoobyshep]

From what

Quick question about battery terminals for most currently field generators in the military: Do they use the serviceable terminals that attach to the battery cable with the 3/8" bolt? Or are they like typical automotive cables with the lead terminal molded directly onto the cable. When I look in the AMMPS parts manuals, I don't see serviceable terminals like these.

View attachment 957699

I have dealt with i find more factory made connectors for batteries. I routinely abuse my electrical skills and crimp eye lugs on.

 

[LuckeyD]

They use something similar to your picture. The cables have a lug crimped and soldered on the cable end. I would pass out NSNs like 5940-00-549-6581 + and 5940-00-549-6583 - and each gets a PKG of 25 lugs and they used to cost about a dollar a pop, but now they are over $65 for a PKG. They fit everything in a MOPO

 

[Guyfang]

What AMMPS TM are you looking at?

 

[LCA078]

I was looking at the AMMPS TMs uploaded in the TM section:

Mep-1070/1071 ammps 60kw 6115-01-561-7788

MEP-1070/1071 AMMPS 60KW 6115-01-561-7788 (3rd generation generator) TM 9-6115-753-10 TM 9-6115-753-24&P

www.steelsoldiers.com

and

Mep-1050/1051 ammps 15kw 6115-01-561-7634

MEP-1050/1051 AMMPS 15KW 6115-01-561-7634 (3rd generation generator) TM 9-6115-751-10 TM 9-6115-751-24&P

www.steelsoldiers.com

For the 60kW, it doesn't list the replaceable/consumable terminals in the -24P. See the snippet from that TM The 15kW is pretty much the same.


On the other hand, the HMMWV -24P does have the consumable terminals listed. One pn for the positive and another for the negative terminal.


Maybe for the gensets, they just consider the terminals an obvious consumable and don't bother listing it?

 

[LuckeyD]

Was trying to reply. The manuals were being updated with an Engineer Change proposal (ECP). Seems keeping the fused cables on hand was an issue and made for higher rates of inoperability. The change was being proposed 3rd QTR 2022. I retired. MOPOs could get clamps and lugs, but cables took a while. Many were going back to what it used to be as it worked.

 

[Scoobyshep]

on paper fused ends are "maintenance free" in reality they spread the failure to the cable.

short version here is as long as you have a solid low resistance connection, go for it.

 

[LuckeyD]

Actually, if put together correctly, both are fine. You use what you can get your hands on, and put it together right.

 

[Guyfang]

Maybe for the gensets, they just consider the terminals an obvious consumable and don't bother listing it?

There is a list of consumables in the back of the TM. If it were, (and its not) a consumable, it would be there.

 

[LCA078]

After my many years in the service and also growing up on a farm with old equipment, I can safely say that the replaceable terminal clamps are the only way to go. Terminal camps are probably one of the worst treated components out there. Over tightened, beat on, and flat out abused by most operators because when you're changing a battery out, you're probably pissed and in a time of urgency. You're using whatever tools you have on hand too.

I always keep a couple new sets of terminals in my 'go-bag' of tools just to be on the safe side.

 

[2Pbfeet]

After my many years in the service and also growing up on a farm with old equipment, I can safely say that the replaceable terminal clamps are the only way to go. Terminal camps are probably one of the worst treated components out there. Over tightened, beat on, and flat out abused by most operators because when you're changing a battery out, you're probably pissed and in a time of urgency. You're using whatever tools you have on hand too.

I always keep a couple new sets of terminals in my 'go-bag' of tools just to be on the safe side.

Me, too. I also scooped up a hydraulic crimper and large bore adhesive lined heat shrink tubing. I don't mind fixing something once. Twice, annoys me.

Given the vibration, abuse, and battery acid, it seems to me that battery terminals are ripe for issues.

All the best, 2PbFeet

 

[Scoobyshep]

Me, too. I also scooped up a hydraulic crimper and large bore adhesive lined heat shrink tubing. I don't mind fixing something once. Twice, annoys me.

Given the vibration, abuse, and battery acid, it seems to me that battery terminals are ripe for issues.

All the best, 2PbFeet

Me personally, i do something similar, eyelugs pressed on cables, marine heat shrink and on connection points Dielectric grease.

Ask any apprentice or intern ive had they will all say the same shep-ism fix it long enough for me to retire, I dont want to do it twice

 

[LuckeyD]

They are not listed because the engineers did not think about how GIs treated a battery clamp. I asked about this and they reluctantly told me it was never thought of. Part of the ECP. "Industry Standard" they said. I had to point out other items in the inventory. All so they can add to the manual the clamps and lugs with a page in the back on how to make the lugs onto the cables, to connect up a Battery clamp. It got me really upset as we were already doing it to many gen sets in the AMMPS family and I had pictures of MEP REPS in the war zone doing it. They had to concede. I am unable to get my hands on a manual newer than 2016 to say. One of those things I had to endure, and another reason I retired.

 

[Scoobyshep]

They are not listed because the engineers did not think about how GIs treated a battery clamp. I asked about this and they reluctantly told me it was never thought of. Part of the ECP. "Industry Standard" they said. I had to point out other items in the inventory. All so they can add to the manual the clamps and lugs with a page in the back on how to make the lugs onto the cables, to connect up a Battery clamp. It got me really upset as we were already doing it to many gen sets in the AMMPS family and I had pictures of MEP REPS in the war zone doing it. They had to concede. I am unable to get my hands on a manual newer than 2016 to say. One of those things I had to endure, and another reason I retired.

I once asked for a drawing revision for a part we had to modify every installation. I was told it was impossible because its used elsewhere(complete bs, they didnt want to do the paperwork) and included in the email was the phrase " Its robotics not ride, you can do what you want anyway" which is a dangerous thing to tell me verbally, in text form it was one hell of a shield.

 

[LuckeyD]

Now do this with 278 different items of junk. One PM is in one place, another is in in another place, and another is in another, on and on....Real headache
3 fleet managers in different places, and CECOM engineers that really did not want to play with a non educated LAR Master tech until they found out I had more master degrees than most of them. We actually had a PHD working. This lady was Super Cool! Could have been my MOM, but she wasn'T.

 

[LCA078]

They are not listed because the engineers did not think about how GIs treated a battery clamp. I asked about this and they reluctantly told me it was never thought of. Part of the ECP. "Industry Standard" they said. I had to point out other items in the inventory. All so they can add to the manual the clamps and lugs with a page in the back on how to make the lugs onto the cables, to connect up a Battery clamp. It got me really upset as we were already doing it to many gen sets in the AMMPS family and I had pictures of MEP REPS in the war zone doing it. They had to concede. I am unable to get my hands on a manual newer than 2016 to say. One of those things I had to endure, and another reason I retired.

That first sentence says it all. But from the heart of a career Soldier, I do thank you for pushing to improve our equipment we used downrange. Your efforts and also from other folks like you are not unrecognized nor unappreciated. You just may not see it directly from us so thank you.

On a side note about LARs, we were aviation and had all kinds of one-off special equipment that usually was inop or folks forgot how to use. I remember when a LARs rep would visit us downrange to help. It was like a sacred moment when we all gathered and listened to the LAR explain the issue. It was one of the few times I can recall when my guys were actually listening and not arguing with each other about the "right" way to fix something. LOL!