Section I. GENERAL INFORMATION - TM-9-6115-660-13P_25Figure 1-2. Features of PU-798 and PU-799.Table 1-1. Nomenclature Cross-Reference ListSection II. EQUIPMENT DESCRIPTIONFigure 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-38Table 1-3. Description of Major Components, PU-798, PU-798A, PU-799 and PU-799ASection III. PRINCIPLES OF OPERATION - TM-9-6115-660-13P_32CHAPTER 2 OPERATING INSTRUCTIONSSection I. DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS - TM-9-6115-660-13P_35Table 2-1. Description of Switch Box Controls and lndicatorsSection II. OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES 2-2.4.3 Routine Inspections2-2.6 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_43Operator Preventive Maintenance Checks and Services - continued - TM-9-6115-660-13P_44Operator Preventive Maintenance Checks and Services - continued - TM-9-6115-660-13P_45Operator Preventive Maintenance Checks and Services - continued - TM-9-6115-660-13P_46Operator Preventive Maintenance Checks and Services - continued - TM-9-6115-660-13P_47Operator Preventive Maintenance Checks and Services - continued - TM-9-6115-660-13P_48Operator Preventive Maintenance Checks and Services - continued - TM-9-6115-660-13P_49Operator Preventive Maintenance Checks and Services - continued - TM-9-6115-660-13P_50Operator Preventive Maintenance Checks and Services - continued - TM-9-6115-660-13P_51Operator Preventive Maintenance Checks and Services - continued - TM-9-6115-660-13P_52Operator Preventive Maintenance Checks and Services - continued - TM-9-6115-660-13P_53Operator Preventive Maintenance Checks and Services - continued - TM-9-6115-660-13P_54Operator Preventive Maintenance Checks and Services - continued - TM-9-6115-660-13P_55Operator Preventive Maintenance Checks and Services - continued - TM-9-6115-660-13P_56Operator Preventive Maintenance Checks and Services - continued - TM-9-6115-660-13P_57Operator Preventive Maintenance Checks and Services - continued - TM-9-6115-660-13P_58Operator Preventive Maintenance Checks and Services - continued - TM-9-6115-660-13P_59Operator Preventive Maintenance Checks and Services - continued - TM-9-6115-660-13P_60Operator Preventive Maintenance Checks and Services - continued - TM-9-6115-660-13P_61Section III. OPERATION UNDER USUAL CONDITIONS - TM-9-6115-660-13P_622-3.2.2 External Fuel Line Connection2-3.3 Grounding of Generator SetThe terminal lugFigure 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_692-5.3.2 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 PlateFigure 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_77d. Remove slide hammer componentsFigure 2-15. Remove Ground Rod.Figure 2-16. Disconnect Auxiliary Fuel (Typical).Section IV. OPERATION UNDER UNUSUAL CONDITIONS - TM-9-6115-660-13P_81CHAPTER 3 OPERATOR MAINTENANCESection I. OPERATOR LUBRICATION - TM-9-6115-660-13P_84Section II. TROUBLESHOOTING - TM-9-6115-660-13P_85Figure 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 OperatedFigure 3-4. With All Indicator Lamps Working Properly, Load Will Not Transfer. - TM-9-6115-660-13P_89Figure 3-5. SYNCHRONIZING lndicator Lamps Fail To Operate ln Unison When Transfer Switch Is OperatedSection III. MAINTENANCE PROCEDURESCHAPTER 4 UNIT MAINTENANCE - TM-9-6115-660-13P_93Section VII - TM-9-6115-660-13P_94Section I. REPAIR PARTS; SPECIAL TOOLS; TEST, MEASUREMENT, AND DIAGNOSTIC EQUIPMENT (TMDE); AND SUPPORT EQUIPMENT - TM-9-6115-660-13P_95Section II. SERVICE UPON RECEIPT4-5 INSTALLATION INSTRUCTIONS4-5.2.3 Assembly of Power Units.4-6 PRELIMINARY SERVICING AND ADJUSTMENT OF EQUIPMENT. - TM-9-6115-660-13P_99Figure 4-2. Installation of Ground Wire.Section III. UNIT LUBRICATION - TM-9-6115-660-13P_101Section IV. UNIT PREVENTIVE MAINTENANCE CHECKS AND SERVICES - TM-9-6115-660-13P_102Figure 4-4. Unit PMCS Routing Diagram.Table 4-1. Unit Preventive Maintenance Checks and Services - TM-9-6115-660-13P_104Section V. TROUBLESHOOTING - TM-9-6115-660-13P_105Figure 4-5. ON lndicator Lamp Serviceable But Fails To Light With Generator Set RunningFigure 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 OperatedFigure 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 ContactorsFigure 4-11. Disconnect Power Cable from Generator Set. - TM-9-6115-660-13P_113Figure 4-12. Disconnect Power Cable From Switch Box Terminals.INSTALLATION - TM-9-6115-660-13P_1152. Insert terminal lug - TM-9-6115-660-13P_1164-13 SWITCH BOX MAINTENANCEFigure 4-13. Switch Box Repair.INSTALLATION - TM-9-6115-660-13P_1194-14 INDICATOR LIGHT ASSEMBLY MAINTENANCE.Table 4-2. Indicator Light Assembly Test Points4-15 SYNCHRONIZING LIGHT MAINTENANCETEST - TM-9-6115-660-13P_1234-16 TOGGLE SWITCH MAINTENANCE. - TM-9-6115-660-13P_124Figure 4-16. Toggle Switch4-17 SWITCH BOX LOAD TERMINAL MAINTENANCEFigure 4-17. Switch Box Load Terminal Maintenance (sheet 1 of 2). - TM-9-6115-660-13P_127Figure 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_131Figure 4-20. Repair Accessory Box.4-20 FIRE EXTINGUISHER BRACKET MAINTENANCE - TM-9-6115-660-13P_1334-21 TRAILER LIFTING RING MAINTENANCE4-22 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_1404-25 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_1434-26 1 TON TRAILER REAR LEVELING-SUPPORT JACK MAINTENANCEFigure 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_148Section IV. OPERATION UNDER UNUSUAL CONDITIONS - TM-9-6115-660-13P_149Section I. OPERATOR LUBRICATION - TM-9-6115-660-13P_150Section II. TROUBLESHOOTING - TM-9-6115-660-13P_151CHAPTER 5 DIRECT SUPPORT MAINTENANCE INSTRUCTIONSSection I. REPAIR PARTS; SPECIAL TOOLS; TEST, MEASUREMENT, AND DIAGNOSTIC EQUIPMENT (TMDE); AND SUPPORT EQUIPMENT - TM-9-6115-660-13P_153Section II. TROUBLESHOOTING - TM-9-6115-660-13P_154Figure 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 ReleasedFigure 5-4. All Indicator Lamps Working Property, But Load Will Not Transfer.Section III. MAINTENANCE PROCEDURES - TM-9-6115-660-13P_159Figure 5-5. Power/Load Cable Removal. - TM-9-6115-660-13P_160Figure -6. Removing Generator Set Mounting Hardware.INSTALLATION - TM-9-6115-660-13P_162Figure 5-7. Switch Box Components.5-7 ELECTRICAL LEADS W3 - W8 MAINTENANCEFigure 5-8. Switch Box Lead Connections.5-8 SWITCH BOX HARNESS W9 MAINTENANCEFigure 5-9. Switch Box Relay Board AssemblyTable 5-1. Switch Box Harness Wire ListFigure 5-10. Disconnet Swifch Box Harness W9 From Contactor.Figure 5-11. Switch Box Load Terminals.INSTALLATION - TM-9-6115-660-13P_1715-9 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 CheckFigure 5-14. Output Connector Harness.5-11 RELAYS K3-K6 MAINTENANCETEST - TM-9-6115-660-13P_1785-12 PERMISSIVE PARALLELING RELAY MAINTENANCE. - TM-9-6115-660-13P_179REMOVAL - TM-9-6115-660-13P_1805-13 CONTACTORS K1 AND K2 MAINTENANCE.Figure 5-18. Replace Contactor.Table 5-5. Contactor Operation5-14 RESISTORS R1-R3 MAINTENANCEFigure 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 MAINTENANCEFigure 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 MAINTENANCE5-20 PU-798A AND PU-799A GENERATOR MOUNTING RAIL MAINTENANCEFigure 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 TrailerAPPENDIX A REFERENCES - TM-9-6115-660-13P_198A-7 MILITARY STANDARDSA-9 LUBRICATION ORDERSAPPENDIX B MAINTENANCE ALLOCATION CHART - TM-9-6115-660-13P_202B-3 EXPLANATION OF COLUMNS IN THE MAC - TM-9-6115-660-13P_203B-4 EXPLANATION OF COLUMNS IN TOOL AND TEST EQUIPMENT REQUIREMENTS - TM-9-6115-660-13P_204Section II. MAINTENANCE ALLOCATION CHART - TM-9-6115-660-13P_205MAINTENANCE ALLOCATION CHART (continued)Section III. TOOL AND TEST EQUIPMENT REQUIREMENTS - TM-9-6115-660-13P_207Section IV. REMARKS - TM-9-6115-660-13P_208APPENDIX C COMPONENTS OF END ITEM (COEI) AND BASIC ISSUE ITEMS (Bll) LISTS - TM-9-6115-660-13P_209SECTION II. COMPONENTS OF END ITEM - TM-9-6115-660-13P_210SECTION III. BASIC ISSUE ITEMSAPPENDIX D ADDITIONAL AUTHORIZATION USTAPPENDIX E EXPENDABLE AND DURABLE ITEMS LIST - TM-9-6115-660-13P_215SECTION II. EXPENDABLE AND DURABLE ITEMS LIST - TM-9-6115-660-13P_216APPENDIX F UNIT AND DIRECT SUPPORT MAINTENANCE REPAIR PARTS AND SPECIAL TOOLS LIST - TM-9-6115-660-13P_217F-3.2 SMR CODE - TM-9-6115-660-13P_218F-3.2.2 Maintenance Code - TM-9-6115-660-13P_219F-3.2.3 Recoverability Code. - TM-9-6115-660-13P_220F-4 EXPLANATION OF COLUMNS F-5 SPECIAL INFORMATIONF-6 HOW to LOCATE REPAIR PARTS - TM-9-6115-660-13P_223Figure F-1. Generator Set InstallationDESCRIPTION AND USABLE ON CODE - TM-9-6115-660-13P_227Figure F-1. Generator Set Installation.DESCRIPTION AND USABLE ON CODE - TM-9-6115-660-13P_229Figure F-3. Power CablesDESCRIPTION AND USABLE ON CODE - TM-9-6115-660-13P_231Figure F-4. Cable AssemblyDESCRIPTION AND USABLE ON CODES - TM-9-6115-660-13P_233Figure F-5. Switch Box InstallationDESCRIPTION AND USABLE ON CODES - TM-9-6115-660-13P_235Figure F-6. Relay Board Harness Assembly (Sheet 1 of 2) - TM-9-6115-660-13P_237F-6 Wire Parts List (Sheet 2 of 2)DESCRIPTION AND USABLE ON CODES - TM-9-6115-660-13P_239DESCRIPTION AND USABLE ON CODES - TM-9-6115-660-13P_240Figure F-7. Permissive Paralleling RelayDESCRIPTION AND USABLE ON CODES - TM-9-6115-660-13P_243Figure F-8. Indicator LightsDESCRIPTION AND USABLE ON CODES - TM-9-6115-660-13P_245Figure F-9. Light AssemblyDESCRIPTION AND USABLE ON CODE - TM-9-6115-660-13P_247Figure F-10. SwitchesDESCRIPTION AND USABLE ON CODES - TM-9-6115-660-13P_249Figure F-11. Load Terminal Cover - TM-9-6115-660-13P_250DESCRIPTION AND USABLE ON CODES - TM-9-6115-660-13P_251Figure F-12. Load TerminalDESCRIPTION AND USABLE ON CODES - TM-9-6115-660-13P_253Figure F-13. Electrical Leads - TM-9-6115-660-13P_254DESCRIPTION AND USABLE ON CODES - TM-9-6115-660-13P_255DESCRIPTION AND USABLE ON CODES - TM-9-6115-660-13P_256Figure F-14. Output Connector Harness AssemblyDESCRIPTION AND USABLE ON CODES - TM-9-6115-660-13P_259Figure 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_263Figure F-16. ContactorDESCRIPTION AND USABLE ON CODES - TM-9-6115-660-13P_265Figure F-17. Resistor R3 - TM-9-6115-660-13P_266DESCRIPTION AND USABLE ON CODES - TM-9-6115-660-13P_267Figure F-18. Switch Box AssemblyDESCRIPTION AND USABLE ON CODES - TM-9-6115-660-13P_269Figure F-19. Accessories.DESCRIPTION AND USABLE ON CODE - TM-9-6115-660-13P_271Figure F-20. Accessory Box.DESCRIPTION AND USABLE ON CODE - TM-9-6115-660-13P_273Figure F-21. Power Plant Fire Extinguisher, Oil Drain and Ground WireDESCRIPTION AND USABLE ON CODES - TM-9-6115-660-13P_275Figure F-22. Power Unit Fire Extinguisher, Oil Drain and Ground Wire. (Sheet 2 of 2) - TM-9-6115-660-13P_276Figure F-22. Power Unit Fire Extinguisher, Oil Drain and Ground Wire. (Sheet 2 of 2) - TM-9-6115-660-13P_277DESCRIPTION AND USABLE ON CODE - TM-9-6115-660-13P_278DESCRIPTION AND USABLE ON CODE - TM-9-6115-660-13P_279DESCRIPTION AND USABLE ON CODE - TM-9-6115-660-13P_280Figure 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_283Figure 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_285DESCRIPTION AND USABLE ON CODE - TM-9-6115-660-13P_286DESCRIPTION AND USABLE ON CODE - TM-9-6115-660-13P_287Figure F-25. 1 1/2 Ton Trailer, AN/MJQ-36 FenderDESCRIPTION AND USABLE ON CODES - TM-9-6115-660-13P_289Figure F-26. One Ton Trailer, Fenders, PU-798, PU-799DESCRIPTION AND USABLE ON CODES - TM-9-6115-660-13P_291Figure 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_294DESCRIPTION AND USABLE ON CODE - TM-9-6115-660-13P_295Figure F-28. Jack Leveling-Support Assembly.DESCRIPTION AND USABLE ON CODE - TM-9-6115-660-13P_297Figure F-29. Power Plant/Power Unit Trailer Assembly.DESCRIPTION AND USABLE ON CODE - TM-9-6115-660-13P_299DESCRIPTION AND USABLE ON CODES - TM-9-6115-660-13P_300SECTION IV CROSS- REFERENCE-INDEXES - TM-9-6115-660-13P_304NATIONAL STOCK NUMBER INDEX - TM-9-6115-660-13P_305PART NUMBER INDEX - TM-9-6115-660-13P_306PART NUMBER - TM-9-6115-660-13P_307PART NUMBER - TM-9-6115-660-13P_308PART NUMBER - TM-9-6115-660-13P_309PART NUMBER - TM-9-6115-660-13P_310PART NUMBER - TM-9-6115-660-13P_311PART NUMBER - TM-9-6115-660-13P_312PART NUMBER - TM-9-6115-660-13P_313FIGURE AND ITEM NUMBER INDEX - TM-9-6115-660-13P_314FIGURE AND ITEM NUMBER INDEX - TM-9-6115-660-13P_315FIGURE AND ITEM NUMBER INDEX - TM-9-6115-660-13P_316FIGURE AND ITEM NUMBER INDEX - TM-9-6115-660-13P_317FIGURE AND ITEM NUMBER INDEX - TM-9-6115-660-13P_318FIGURE AND ITEM NUMBER INDEX - TM-9-6115-660-13P_319FIGURE AND ITEM NUMBER INDEX - TM-9-6115-660-13P_320FIGURE AND ITEM NUMBER INDEX - TM-9-6115-660-13P_321APPENDIX G LIST OF MANUFACTURED ITEMSFigure G-1. Electrical LeadsFigure 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_325Figure 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_331Figure 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 LIMITSAPPENDIX I MANDATORY REPLACEMENT PARTS - TM-9-6115-660-13P_337GLOSSARY - TM-9-6115-660-13P_338Section II. DEFINITION OF UNUSUAL TERMSFigure FO-1. Power Plant Wiring Diagram FO-2. Power Plant Schematic - TM-9-6115-660-13P_347