TM-9-6115-660-13P Power Plant Diesel Engine Driven 1-Ton Trailer Mounted (With Racks) 3Kw 60 Hz AN/MJQ-42 Manual

Section I. GENERAL INFORMATION - TM-9-6115-660-13P_25
Figure 1-2. Features of PU-798 and PU-799.
Table 1-1. Nomenclature Cross-Reference List
Section II. EQUIPMENT DESCRIPTION
Figure 1-3. Location of Major Components, AN/MJQ- 37 and AN/MJQ-38.
Table 1-2. Description of Major Components, AN/MJQ-7 And AN/MJQ-38
Table 1-3. Description of Major Components, PU-798, PU-798A, PU-799 and PU-799A
Section III. PRINCIPLES OF OPERATION - TM-9-6115-660-13P_32
CHAPTER 2 OPERATING INSTRUCTIONS
Section I. DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS - TM-9-6115-660-13P_35
Table 2-1. Description of Switch Box Controls and lndicators
Section II. OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES
2-2.4.3 Routine Inspections
2-2.6 Operation of Power Plant/Power Unit with Minor Leaks.
Figure 2-2. Power Plant Operator PMCS Routing Diagram (Typical).
Figure 2-3. Power Unit Operator PMCS Routing Diagram (PU-798 and PU-799).
Figure 2-3. 1. Power Unit Operator PMCS Routing Diagram (PU-798A and PU-799A).
Table 2-2. Operator Preventive Maintenance Checks and Services - TM-9-6115-660-13P_43
Operator Preventive Maintenance Checks and Services - continued - TM-9-6115-660-13P_44
Operator Preventive Maintenance Checks and Services - continued - TM-9-6115-660-13P_45
Operator Preventive Maintenance Checks and Services - continued - TM-9-6115-660-13P_46
Operator Preventive Maintenance Checks and Services - continued - TM-9-6115-660-13P_47
Operator Preventive Maintenance Checks and Services - continued - TM-9-6115-660-13P_48
Operator Preventive Maintenance Checks and Services - continued - TM-9-6115-660-13P_49
Operator Preventive Maintenance Checks and Services - continued - TM-9-6115-660-13P_50
Operator Preventive Maintenance Checks and Services - continued - TM-9-6115-660-13P_51
Operator Preventive Maintenance Checks and Services - continued - TM-9-6115-660-13P_52
Operator Preventive Maintenance Checks and Services - continued - TM-9-6115-660-13P_53
Operator Preventive Maintenance Checks and Services - continued - TM-9-6115-660-13P_54
Operator Preventive Maintenance Checks and Services - continued - TM-9-6115-660-13P_55
Operator Preventive Maintenance Checks and Services - continued - TM-9-6115-660-13P_56
Operator Preventive Maintenance Checks and Services - continued - TM-9-6115-660-13P_57
Operator Preventive Maintenance Checks and Services - continued - TM-9-6115-660-13P_58
Operator Preventive Maintenance Checks and Services - continued - TM-9-6115-660-13P_59
Operator Preventive Maintenance Checks and Services - continued - TM-9-6115-660-13P_60
Operator Preventive Maintenance Checks and Services - continued - TM-9-6115-660-13P_61
Section III. OPERATION UNDER USUAL CONDITIONS - TM-9-6115-660-13P_62
2-3.2.2 External Fuel Line Connection
2-3.3 Grounding of Generator Set
The terminal lug
Figure 2-7. Power Plant and Power Unit Ground Connections.
2-3.4 Connecting Load.
Figure 2-8. Switch Box Load Cable Connections.
2-4 INITIAL ADJUSTMENTS, CHECKS, AND SELF TEST. - TM-9-6115-660-13P_69
2-5.3.2 Load Transfer.
2-5.3.3 Stopping Generator Set.
2-6 IDENTIFICATION AND INFORMATION PLATES.
Figure 2-12. PU-798 Identification/Transportation Data Plate.
2-6.5 Power Plant Instruction Plate
Figure 2-14. 1. PU-798A Shipping Data/identification Plate.
Figure 2-14.3. PU-798A and PU-799A Trailer Chassis Identification Plate.
2-7 PREPARATION FOR MOVEMENT. - TM-9-6115-660-13P_77
d. Remove slide hammer components
Figure 2-15. Remove Ground Rod.
Figure 2-16. Disconnect Auxiliary Fuel (Typical).
Section IV. OPERATION UNDER UNUSUAL CONDITIONS - TM-9-6115-660-13P_81
CHAPTER 3 OPERATOR MAINTENANCE
Section I. OPERATOR LUBRICATION - TM-9-6115-660-13P_84
Section II. TROUBLESHOOTING - TM-9-6115-660-13P_85
Figure 3-1. ON Indicator Lamp Fails To Light With Generator Set Running.
Figure 3-2. ON-LINE Indicator Light Lamp Fails To Light When ON/OFF Switch is Placed In ON Position.
Figure 3-3. SYNCHRONIZING Indicator lamps Fail To Light When TRANSFER Switch Is Operated
Figure 3-4. With All Indicator Lamps Working Properly, Load Will Not Transfer. - TM-9-6115-660-13P_89
Figure 3-5. SYNCHRONIZING lndicator Lamps Fail To Operate ln Unison When Transfer Switch Is Operated
Section III. MAINTENANCE PROCEDURES
CHAPTER 4 UNIT MAINTENANCE - TM-9-6115-660-13P_93
Section VII - TM-9-6115-660-13P_94
Section I. REPAIR PARTS; SPECIAL TOOLS; TEST, MEASUREMENT, AND DIAGNOSTIC EQUIPMENT (TMDE); AND SUPPORT EQUIPMENT - TM-9-6115-660-13P_95
Section II. SERVICE UPON RECEIPT
4-5 INSTALLATION INSTRUCTIONS
4-5.2.3 Assembly of Power Units.
4-6 PRELIMINARY SERVICING AND ADJUSTMENT OF EQUIPMENT. - TM-9-6115-660-13P_99
Figure 4-2. Installation of Ground Wire.
Section III. UNIT LUBRICATION - TM-9-6115-660-13P_101
Section IV. UNIT PREVENTIVE MAINTENANCE CHECKS AND SERVICES - TM-9-6115-660-13P_102
Figure 4-4. Unit PMCS Routing Diagram.
Table 4-1. Unit Preventive Maintenance Checks and Services - TM-9-6115-660-13P_104
Section V. TROUBLESHOOTING - TM-9-6115-660-13P_105
Figure 4-5. ON lndicator Lamp Serviceable But Fails To Light With Generator Set Running
Figure 4-6. ON-LINE Indicator Lamp Serviceable But Fails To Light When ON/OFF Switch Is Placed In ON Position.
Figure 4-7. SYNCHRONIZING Indicator Lamps Fail To Light When TRANSFER Switch Is Operated
Figure 4-8. No Power To Load With ON-LINE Indicator Lamp On.
Figure 4-9. All Indicator Lamps Working Properly But Load Will Not Transfer.
Section VI. MAINTENANCE PROCEDURES.
Figure 4-10. Power Cable Connections to Switch Box Contactors
Figure 4-11. Disconnect Power Cable from Generator Set. - TM-9-6115-660-13P_113
Figure 4-12. Disconnect Power Cable From Switch Box Terminals.
INSTALLATION - TM-9-6115-660-13P_115
2. Insert terminal lug - TM-9-6115-660-13P_116
4-13 SWITCH BOX MAINTENANCE
Figure 4-13. Switch Box Repair.
INSTALLATION - TM-9-6115-660-13P_119
4-14 INDICATOR LIGHT ASSEMBLY MAINTENANCE.
Table 4-2. Indicator Light Assembly Test Points
4-15 SYNCHRONIZING LIGHT MAINTENANCE
TEST - TM-9-6115-660-13P_123
4-16 TOGGLE SWITCH MAINTENANCE. - TM-9-6115-660-13P_124
Figure 4-16. Toggle Switch
4-17 SWITCH BOX LOAD TERMINAL MAINTENANCE
Figure 4-17. Switch Box Load Terminal Maintenance (sheet 1 of 2). - TM-9-6115-660-13P_127
Figure 4-17. Switch Box Load Terminal Maintenance (sheet 2).
4-18 LOAD TERMINAL COVER MAINTENANCE.
Figure 4-18. Loud Terminal Cover.
4-19 ACCESSORY BOX MAINTENANCE. - TM-9-6115-660-13P_131
Figure 4-20. Repair Accessory Box.
4-20 FIRE EXTINGUISHER BRACKET MAINTENANCE - TM-9-6115-660-13P_133
4-21 TRAILER LIFTING RING MAINTENANCE
4-22 DATA PLATE AND REFLECTOR MAINTENANCE.
Figure 4-22. Identification/Transport on Data Plate and Reflector Replacement.
4-23 AN/MJQ-37, ANIMJQ-38, PU-798, AND PU-799 TRAILER PLATFORM MAINTENANCE.
4-24 PU-789 AND PU-799 FENDER MAINTENANCE.
Figure 4-24. PU-798 and PU-799 Fender Replacement.
INSTALLATION - TM-9-6115-660-13P_140
4-25 AN/MJQ-37 AND AN/MJQ-38 FENDER MAINTENANCE.
Figure 4-25. AN/MJQ-37 and AN/MJQ-38 Fender Replacement.
INSTALLATION - TM-9-6115-660-13P_143
4-26 1 TON TRAILER REAR LEVELING-SUPPORT JACK MAINTENANCE
Figure 4-26. Rear Leveling-Support Jack Replacement; 1 Ton Trailer.
Figure 4-27. Rear Leveling-Support Jack Repair; 1 Ton Trailer.
Figure 4-28. PU-798A and PU-799A Ground Stud Replacement.
Section VII. ADMINISTRATIVE STORAGE - TM-9-6115-660-13P_148
Section IV. OPERATION UNDER UNUSUAL CONDITIONS - TM-9-6115-660-13P_149
Section I. OPERATOR LUBRICATION - TM-9-6115-660-13P_150
Section II. TROUBLESHOOTING - TM-9-6115-660-13P_151
CHAPTER 5 DIRECT SUPPORT MAINTENANCE INSTRUCTIONS
Section I. REPAIR PARTS; SPECIAL TOOLS; TEST, MEASUREMENT, AND DIAGNOSTIC EQUIPMENT (TMDE); AND SUPPORT EQUIPMENT - TM-9-6115-660-13P_153
Section II. TROUBLESHOOTING - TM-9-6115-660-13P_154
Figure 5-1. ON Indicator Lamp Assembly Tests Good, But On Indicator Lamp Fails To Light With Generator Set Running.
Figure 5-2. ON-LINE Indicator Lamp Assembly And ON/OFF Switch Serviceable, But ON-LINE Indicator Lamp Fails To Light When ON/OFF Switch Is Placed In ON Position.
Figure 5-3. SYNCHRONIZlNGING lndicator Lamps And Transfer Switch Serviceable, But SYNCHRONlZlNG Indicator Lamps Fail To Lamps Fail To Light When TRANSFER Switch is Closed And Then Released
Figure 5-4. All Indicator Lamps Working Property, But Load Will Not Transfer.
Section III. MAINTENANCE PROCEDURES - TM-9-6115-660-13P_159
Figure 5-5. Power/Load Cable Removal. - TM-9-6115-660-13P_160
Figure -6. Removing Generator Set Mounting Hardware.
INSTALLATION - TM-9-6115-660-13P_162
Figure 5-7. Switch Box Components.
5-7 ELECTRICAL LEADS W3 - W8 MAINTENANCE
Figure 5-8. Switch Box Lead Connections.
5-8 SWITCH BOX HARNESS W9 MAINTENANCE
Figure 5-9. Switch Box Relay Board Assembly
Table 5-1. Switch Box Harness Wire List
Figure 5-10. Disconnet Swifch Box Harness W9 From Contactor.
Figure 5-11. Switch Box Load Terminals.
INSTALLATION - TM-9-6115-660-13P_171
5-9 RELAY BOARD HARNESS W11 MAINTENANCE.
Figure 5-13. Relay Board Harness Assembly W11 Removal.
5-10 OUTPUT CONNECTOR HARNESS W10 MAINTENANCE.
Table 5-3. Output Connector Harness Continuity Check
Figure 5-14. Output Connector Harness.
5-11 RELAYS K3-K6 MAINTENANCE
TEST - TM-9-6115-660-13P_178
5-12 PERMISSIVE PARALLELING RELAY MAINTENANCE. - TM-9-6115-660-13P_179
REMOVAL - TM-9-6115-660-13P_180
5-13 CONTACTORS K1 AND K2 MAINTENANCE.
Figure 5-18. Replace Contactor.
Table 5-5. Contactor Operation
5-14 RESISTORS R1-R3 MAINTENANCE
Figure 5-19. Resistors, Capacitors, and Diodes.
5-15 CAPACITORS C1-C4 MAINTENANCE.
5-16 DIODES CR1-CR4 MAINTENANCE.
5-16.1 PU-798A AND PU-799A FLOOR AND FENDER MAINTENANCE
Figure 5-20. PU-798A and PU-799A Floor Replacement.
Figure 5-21. PU-798A and PU-799A Fender Replacement.
5-17 AN/MJQ-37, AN/MJQ-38, PU-798, AND PU-799 TRAILER FENDER REPAIR.
Figure 5-22. Replace AN/MiQ-37 and AN/IMJQ-38 Generator Mounting Rails.
5-19 PU-798 AND PU-799 GENERATOR MOUNTING RAIL MAINTENANCE
5-20 PU-798A AND PU-799A GENERATOR MOUNTING RAIL MAINTENANCE
Figure 5-24. PU-798A and PU-799A Generator Mounting Rail Replacement.
5-21 HIGH MOBILITY TRAILER REAR LEVELING-SUPPORT JACK MAINTENANCE.
Figure 5-25. Rear Leveling-Support Jack Replacement; High Mobility Trailer
APPENDIX A REFERENCES - TM-9-6115-660-13P_198
A-7 MILITARY STANDARDS
A-9 LUBRICATION ORDERS
APPENDIX B MAINTENANCE ALLOCATION CHART - TM-9-6115-660-13P_202
B-3 EXPLANATION OF COLUMNS IN THE MAC - TM-9-6115-660-13P_203
B-4 EXPLANATION OF COLUMNS IN TOOL AND TEST EQUIPMENT REQUIREMENTS - TM-9-6115-660-13P_204
Section II. MAINTENANCE ALLOCATION CHART - TM-9-6115-660-13P_205
MAINTENANCE ALLOCATION CHART (continued)
Section III. TOOL AND TEST EQUIPMENT REQUIREMENTS - TM-9-6115-660-13P_207
Section IV. REMARKS - TM-9-6115-660-13P_208
APPENDIX C COMPONENTS OF END ITEM (COEI) AND BASIC ISSUE ITEMS (Bll) LISTS - TM-9-6115-660-13P_209
SECTION II. COMPONENTS OF END ITEM - TM-9-6115-660-13P_210
SECTION III. BASIC ISSUE ITEMS
APPENDIX D ADDITIONAL AUTHORIZATION UST
APPENDIX E EXPENDABLE AND DURABLE ITEMS LIST - TM-9-6115-660-13P_215
SECTION II. EXPENDABLE AND DURABLE ITEMS LIST - TM-9-6115-660-13P_216
APPENDIX F UNIT AND DIRECT SUPPORT MAINTENANCE REPAIR PARTS AND SPECIAL TOOLS LIST - TM-9-6115-660-13P_217
F-3.2 SMR CODE - TM-9-6115-660-13P_218
F-3.2.2 Maintenance Code - TM-9-6115-660-13P_219
F-3.2.3 Recoverability Code. - TM-9-6115-660-13P_220
F-4 EXPLANATION OF COLUMNS
F-5 SPECIAL INFORMATION
F-6 HOW to LOCATE REPAIR PARTS - TM-9-6115-660-13P_223
Figure F-1. Generator Set Installation
DESCRIPTION AND USABLE ON CODE - TM-9-6115-660-13P_227
Figure F-1. Generator Set Installation.
DESCRIPTION AND USABLE ON CODE - TM-9-6115-660-13P_229
Figure F-3. Power Cables
DESCRIPTION AND USABLE ON CODE - TM-9-6115-660-13P_231
Figure F-4. Cable Assembly
DESCRIPTION AND USABLE ON CODES - TM-9-6115-660-13P_233
Figure F-5. Switch Box Installation
DESCRIPTION AND USABLE ON CODES - TM-9-6115-660-13P_235
Figure F-6. Relay Board Harness Assembly (Sheet 1 of 2) - TM-9-6115-660-13P_237
F-6 Wire Parts List (Sheet 2 of 2)
DESCRIPTION AND USABLE ON CODES - TM-9-6115-660-13P_239
DESCRIPTION AND USABLE ON CODES - TM-9-6115-660-13P_240
Figure F-7. Permissive Paralleling Relay
DESCRIPTION AND USABLE ON CODES - TM-9-6115-660-13P_243
Figure F-8. Indicator Lights
DESCRIPTION AND USABLE ON CODES - TM-9-6115-660-13P_245
Figure F-9. Light Assembly
DESCRIPTION AND USABLE ON CODE - TM-9-6115-660-13P_247
Figure F-10. Switches
DESCRIPTION AND USABLE ON CODES - TM-9-6115-660-13P_249
Figure F-11. Load Terminal Cover - TM-9-6115-660-13P_250
DESCRIPTION AND USABLE ON CODES - TM-9-6115-660-13P_251
Figure F-12. Load Terminal
DESCRIPTION AND USABLE ON CODES - TM-9-6115-660-13P_253
Figure F-13. Electrical Leads - TM-9-6115-660-13P_254
DESCRIPTION AND USABLE ON CODES - TM-9-6115-660-13P_255
DESCRIPTION AND USABLE ON CODES - TM-9-6115-660-13P_256
Figure F-14. Output Connector Harness Assembly
DESCRIPTION AND USABLE ON CODES - TM-9-6115-660-13P_259
Figure F-15. Switch Box Harness Assembly (Sheet 1 of 2)
Figure F-15. Switch Box Harness Assembly (Sheet 2 of 2)
DESCRIPTION AND USABLE ON CODES - TM-9-6115-660-13P_263
Figure F-16. Contactor
DESCRIPTION AND USABLE ON CODES - TM-9-6115-660-13P_265
Figure F-17. Resistor R3 - TM-9-6115-660-13P_266
DESCRIPTION AND USABLE ON CODES - TM-9-6115-660-13P_267
Figure F-18. Switch Box Assembly
DESCRIPTION AND USABLE ON CODES - TM-9-6115-660-13P_269
Figure F-19. Accessories.
DESCRIPTION AND USABLE ON CODE - TM-9-6115-660-13P_271
Figure F-20. Accessory Box.
DESCRIPTION AND USABLE ON CODE - TM-9-6115-660-13P_273
Figure F-21. Power Plant Fire Extinguisher, Oil Drain and Ground Wire
DESCRIPTION AND USABLE ON CODES - TM-9-6115-660-13P_275
Figure F-22. Power Unit Fire Extinguisher, Oil Drain and Ground Wire. (Sheet 2 of 2) - TM-9-6115-660-13P_276
Figure F-22. Power Unit Fire Extinguisher, Oil Drain and Ground Wire. (Sheet 2 of 2) - TM-9-6115-660-13P_277
DESCRIPTION AND USABLE ON CODE - TM-9-6115-660-13P_278
DESCRIPTION AND USABLE ON CODE - TM-9-6115-660-13P_279
DESCRIPTION AND USABLE ON CODE - TM-9-6115-660-13P_280
Figure F-23. Platforms (Sheet 1 of 2).
Figure F-23. Platforms (Sheet 2 o 2).
DESCRIPTION AND USABLE ON CODES - TM-9-6115-660-13P_283
Figure F-24. Power Plant/Power Unit Trailer Assembly (Sheet 1 of 2)
Figure F-24. Power Plant/Power Unit Trailer Assembly (Sheet 2 of 2) - TM-9-6115-660-13P_285
DESCRIPTION AND USABLE ON CODE - TM-9-6115-660-13P_286
DESCRIPTION AND USABLE ON CODE - TM-9-6115-660-13P_287
Figure F-25. 1 1/2 Ton Trailer, AN/MJQ-36 Fender
DESCRIPTION AND USABLE ON CODES - TM-9-6115-660-13P_289
Figure F-26. One Ton Trailer, Fenders, PU-798, PU-799
DESCRIPTION AND USABLE ON CODES - TM-9-6115-660-13P_291
Figure F-27. High Mobility Trailer, Mounting Rails and Fenders, (PU 798A and PU 799A). (Sheet 1 of 2)
Figure F-27. High Mobility Trailer, Mounting Rails and Fender, (PU 798A and PU799A). (Sheet 2 of 2).
DESCRIPTION AND USABLE ON CODE - TM-9-6115-660-13P_294
DESCRIPTION AND USABLE ON CODE - TM-9-6115-660-13P_295
Figure F-28. Jack Leveling-Support Assembly.
DESCRIPTION AND USABLE ON CODE - TM-9-6115-660-13P_297
Figure F-29. Power Plant/Power Unit Trailer Assembly.
DESCRIPTION AND USABLE ON CODE - TM-9-6115-660-13P_299
DESCRIPTION AND USABLE ON CODES - TM-9-6115-660-13P_300
SECTION IV CROSS- REFERENCE-INDEXES - TM-9-6115-660-13P_304
NATIONAL STOCK NUMBER INDEX - TM-9-6115-660-13P_305
PART NUMBER INDEX - TM-9-6115-660-13P_306
PART NUMBER - TM-9-6115-660-13P_307
PART NUMBER - TM-9-6115-660-13P_308
PART NUMBER - TM-9-6115-660-13P_309
PART NUMBER - TM-9-6115-660-13P_310
PART NUMBER - TM-9-6115-660-13P_311
PART NUMBER - TM-9-6115-660-13P_312
PART NUMBER - TM-9-6115-660-13P_313
FIGURE AND ITEM NUMBER INDEX - TM-9-6115-660-13P_314
FIGURE AND ITEM NUMBER INDEX - TM-9-6115-660-13P_315
FIGURE AND ITEM NUMBER INDEX - TM-9-6115-660-13P_316
FIGURE AND ITEM NUMBER INDEX - TM-9-6115-660-13P_317
FIGURE AND ITEM NUMBER INDEX - TM-9-6115-660-13P_318
FIGURE AND ITEM NUMBER INDEX - TM-9-6115-660-13P_319
FIGURE AND ITEM NUMBER INDEX - TM-9-6115-660-13P_320
FIGURE AND ITEM NUMBER INDEX - TM-9-6115-660-13P_321
APPENDIX G LIST OF MANUFACTURED ITEMS
Figure G-1. Electrical Leads
Figure G-2. Relay Board Harness Assembly W11 (Sheet 1 of 2).
Figure G-2. Relay Board Harness Assembly W11 (Sheet 2). - TM-9-6115-660-13P_325
Figure G-3. SWITCH BOX HARNESS ASSEMBLY W9 (sheet 1 0f 4)
Figure G-3. SWITCH BOX HARNESS ASSEMBLY W9 (sheet 2 0f 4)
Figure G-3. SWITCH BOX HARNESS ASSEMBLY W9 (sheet 3 0f 4)
Figure G-3. SWITCH BOX HARNESS ASSEMBLY W9 (sheet 4 0f 4)
Figure G-4. Output Connector Harness Assembly W10 (Sheet 1 of 2)
Figure G-4. Output Connector Harness Assembly W10 (Sheet 2). - TM-9-6115-660-13P_331
Figure G-5. Cable Assembly W1 and W2 (Sheet 1 of 2).
Figure G-5. Cable Assembly W1 and W2 (Sheet 2).
Figure G-6. Deck Covering.
Figure G-7. Switch Box Gasket.
APPENDIX H TORQUE LIMITS
APPENDIX I MANDATORY REPLACEMENT PARTS - TM-9-6115-660-13P_337
GLOSSARY - TM-9-6115-660-13P_338
Section II. DEFINITION OF UNUSUAL TERMS
Figure FO-1. Power Plant Wiring Diagram
FO-2. Power Plant Schematic - TM-9-6115-660-13P_347

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