TM-9-6115-662-13P Power Unit Diesel Engine Driven 1 Ton Trailer Mounted 5 Kw 60 Hz PU-797 Manual

Section I. GENERAL INFORMATION - TM-9-6115-662-13P_29
Figure 1-2. Roadside Front Three Quarter View.
1-6 NOMENCLATURE CROSS-REFERENCE LIST
Section Il. EQUIPMENT DESCRIPTION
1-10 LOCATION AND DESCRIPTION OF MAJOR COMPONENTS.
Figure 1-3. Location of Major Components, Power Unit or Power Plant
1-11 DIFFERENCES BETWEEN MODELS
Section Ill. PRINCIPLES OF OPERATION
CHAPTER 2 OPERATING INSTRUCTIONS
Section I. DESCRIPTION AND USE OF OPERATORS CONTROLS AND INDICATORS
Table 2-1. Description of Switch Box Controls and Indicators - TM-9-6115-662-13P_40
Section Il. OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES
Dry cleaning solvent
2-2.6   Operation of Power Unit/Power Plant with Minor Leaks
Figure 2-2. Operator PMCS Routing Diagram (sheet 1of 2).
Figure 2-2. Operator PMCS Routing Diagram (sheet 2).
Table 2-2. Operator   Preventive Maintenenance Checks and Services for AN/MJQ-40, PU-803, and PU-804
Operator Preventive Maintenance Checks and Services for AN/MJQ-40, PU-803, and PU-804 - continued - TM-9-6115-662-13P_47
Operator Preventive Maintenance Checks and Services for AN/MJQ-40, PU-803, and PU-804 - continued - TM-9-6115-662-13P_48
Operator Preventive Maintenance Checks and Services for AN/MJQ-40, PU-803, and PU-804 - continued - TM-9-6115-662-13P_49
Operator Preventive Maintenance Checks and Services for AN/MJQ-40, PU-803, and PU-804 - continued - TM-9-6115-662-13P_50
Operator Preventive Maintenance Checks and Services for AN/MJQ-40, PU-803, and PU-804 - continued - TM-9-6115-662-13P_51
Operator Preventive Maintenance Checks and Services for AN/MJQ-40, PU-803, and PU-804 - continued - TM-9-6115-662-13P_52
Operator Preventive Maintenance Checks and Services for AN/MJQ-40, PU-803, and PU-804 - continued - TM-9-6115-662-13P_53
Operator Preventive Maintenance Checks and Services for AN/MJQ-40, PU-803, and PU-804 - continued - TM-9-6115-662-13P_54
Operator Preventive Maintenance Checks and Services for AN/MJQ-40, PU-803, and PU-804 - continued - TM-9-6115-662-13P_55
Operator Preventive Maintenance Checks and Services for AN/MJQ-40, PU-803, and PU-804 - continued - TM-9-6115-662-13P_56
Operator Preventive Maintenance Checks and Services for AN/MJQ-40, PU-803, and PU-804 - continued - TM-9-6115-662-13P_57
Operator Preventive Maintenance Checks and Services for AN/MJQ-40, PU-803, and PU-804 - continued - TM-9-6115-662-13P_58
Operator Preventive Maintenance Checks and Services for AN/MJQ-40, PU-803, and PU-804 - continued - TM-9-6115-662-13P_59
Operator Preventive Maintenance Checks and Services for AN/MJQ-40, PU-803, and PU-804 - continued - TM-9-6115-662-13P_60
Operator Preventive Maintenance Checks and Services for AN/MJQ-40, PU-803, and PU-804 - continued - TM-9-6115-662-13P_61
Operator Preventive Maintenance Checks and Services for AN/MJQ-40, PU-803, and PU-804 - continued - TM-9-6115-662-13P_62
Operator Preventive Maintenance Checks and Services for AN/MJQ-40, PU-803, and PU-804 - continued - TM-9-6115-662-13P_63
Operator Preventive Maintenance Checks and Services for AN/MJQ-40, PU-803, and PU-804 - continued - TM-9-6115-662-13P_64
Section III. OPERATION UNDER USUAL CONDITIONS - TM-9-6115-662-13P_65
Figure 2-3. Power Plant Unit A and Unit B Installation.
Figure 2-4. Typical Ground Rod Installations.
Figure 2-5. Ground Rod, Grounding Strap, and Slide Hammer.
2-3.4 Connecting Load and/or Paralleling Cables
Figure 2-6 Connecting Power Plant.
Figure 2-7. Fuel Container Adapter.
2-4 INITIAL ADJUSTMENTS, CHECKS, AND SELF TEST. - TM-9-6115-662-13P_72
2-5.3.2   Operating Generator Sets in Parallel.
Figure 2-8. Power Plant Operation.
d. Refer to paragraph 2-5.3.1
2-5.3.3 Removal from Parallel  Operation
c. On operating generator set
Figure 2-9. Load Transfer Operation.
Figure 2-11. PU-804 Identification/Transportation Data Plates.
2-6.2 PU-804 Identification Transportation Data Plate.
POWER PLANT OPERATING PROCEDURES
2-7 PREPARATION FOR MOVEMENT. - TM-9-6115-662-13P_82
Figure 2-15. Disconnection of Power Plant.
2-7.3 Disconnect Ground Cable
Figure 2-16. Ground Rod Removal.
2-7.4 Disconnect External Fuel Source
Section IV. OPERATION UNDER UNUSUAL CONDITIONS
CHAPTER 3 OPERATOR   MAINTENANCE
Section I. OPERATOR LUBRICATION
Section   Il.   TROUBLESHOOTING
Section Ill. MAINTENANCE PROCEDURES
Figure 3-1. Unit A STATUS Indicator Lamp Fails to Light With Generator Set Running.
Figure 3-2. Unit B STATUS Indicator Lamp Fails to Light With Generator Set Running.
Figure 3-3. ON LINE Indicator Lamp Fails to Light When ON/OFF Switch is Placed to ON Position.
Figure3-4. Unit Fails to Parallel Through Switch Box
3-4 Indicator LAMP AND/OR LENS REPLACEMENT
Figure 3-5. Indicator Lamps and P1 Connector Maintenance
CHAPTER 4 UNIT MAINTENANCE
Section I. REPAIR PARTS SPECIAL TOOLS; TEST, MEASUREMENT, AND DIAGNOSTIC EQUIPMENT (TMDE); AND SUPPORT EQUIPMENT
Section Il. SERVICE UPON RECEIPT - TM-9-6115-662-13P_100
Figure 4-2. Unpacking Power Unit.
4-5 lNSTALLATION INSTRUCTIONS
4-5.2.1 ASSEMBLY OF POWER PLANT.
Figure 4-2A. Installation Instructions
4-6 PRELIMINARY SERVICING AND ADJUSTMENT OF EQUIPMENT. - TM-9-6115-662-13P_105
Section Ill. UNIT LUBRICATION
Section IV. UNIT PREVENTIVE MAINTENANCE CHECKS AND SERVICES
Figure 4-3. Unit PMCS Routing Diagram.
Table 4-1. Unit Preventive Maintenance Checks and Services for AN/MJQ-40, PU-803, and PU-804.
Section V. TROUBLESHOOTING
Figure 4-4. Indicator Lamp Is Good But Does Not Light
Figure 4-5. Unit A Has No Power.
Figure 4-6. Unit B Has No Power.
Figure 4-7. Power Is Absent At All Switch Box Load Terminals.
Figure 4-8. Cables Are Connected Properly, But Unit Fails to Parallel Through Switch Box.
Section VI. MAINTENANCE PROCEDURES
Table 4-2. Cable Assembly W19.
4-12 SWITCH BOX ASSEMBLY MAINTENANCE.
INSTALLATION - TM-9-6115-662-13P_119
Figure 4-9. Switch Box Assembly Maintenance.
4-13 LOAD TERMINAL WRENCH ASSEMBLY MAINTENANCE
REPAIR - TM-9-6115-662-13P_122
Figure 4-11. Clamping Catch Replacement
Figure 4-12. Switch replacement
INSTALLATION - TM-9-6115-662-13P_125
4-16 INDICATOR LIGHT MAINTENANCE.
Figure 4-13. Indicator Light Replacement.
4-17 SWITCH BOX LOAD TERMINAL MAINTENANCE.
REPAIR - TM-9-6115-662-13P_129
Figure 4-14. Switch Box Load Terminal Maintenance
Figure 4-15. Switch Box Loud Terminal Repair.
4-18 REAR STEPS MAINTENANCE.
Figure 4-16. Rear Step Replacement.
4-19 ACCESSORY BOX MAINTENANCE.
4-20 STRAP ASSEMBLY MAINTENANCE.
4-21 FENDER MAINTENANCE
Figure 4-19. Fender Replacement
4-22 FRONT STEPS MAINTENANCE.
Figure 4-20. Front Step Replacement.
4-23 FRONT PLATFORM MAINTENANCE.
REMOVAL - TM-9-6115-662-13P_141
Figure 4-21. Front Platform Replacement.
4-24 FIRE EXTINGUISHER BRACKET MAINTENANCE
Section VII. ADMINISTRATIVE STORAGE - TM-9-6115-662-13P_144
CHAPTER 5 DIRECT SUPPORT MAINTENANCE - TM-9-6115-662-13P_146
Section I. REPAIR PARTS; SPECIAL TOOLS TEST, MEASUREMENT, AND DIAGNOSTIC EQUIPMENT (TMDE); AND SUPPORT EQUIPMENT
Section Il. TROUBLESHOOTING
Figure 5-1. Unit A STATUS Lamp Does Not Light With Generator Set AC CIRCUIT INTERRUPTER Switch Closed
Figure 5-2. Unit A Has No Input Power to K1.
Figure 5-3. Unit A Has No Output Power from K1
Figure 5-4. Unit A Has Output Power from K1 But No Output at One or More Load Terminals.
Figure 5-5. Unit B STATUS Lamp Does Not Light With Generator Set AC CIRCUIT lNTERRUPTER Switch Closed
Figure 5-6. Unit B Has No Input Power to K2.
Figure 5-7. Unit B Has No Output Power from K2.
Figure 5-8. Unit B Has Output Power from K2 But No Output at One or More Load Terminals.
Figure 5-9. Power Cable W19 and Parallelling Cables are Good, but Unit Fails to Parallel Through Switch Box.
Section III. MAINTENANCE PROCEDURES
Figure 5-10. Generator Set Removal
5-7 SWITCH BOX ASSEMBLY MAINTENANCE.
Figure 5-11. Switch Box Assembly Test.
Table 5-1. Wiring Harness W20.
Table 5-2. Wiring Harness W9.
Table 5-5. Wiring Harness W18.
Table 5-7. Input Power Leads.
(3) Connect power supply
Figure 5-12. Contactor Test Points.
5-8 CONTROL PANEL ASSEMBLY MAINTENANCE.
Figure 5-13. Control Panel, Wiring Harnesses, and Wiring Leads Maintenance.
5-9 WIRING HARNESS MAINTENANCE
5-10 ELECTRICAL LEADS MAINTENANCE
5-11 BUS BAR MAINTENANCE
Figure 5-14. Bus Bar Maintenance
5-12 CONTACTOR   MAINTENANCE
REMOVAL - TM-9-6115-662-13P_175
Figure 5-15.    Contactor Maintenance
5-13 21/2 TON TRAILER FUEL DRAIN ASSEMBLY MAINTENANCE
Figure 5-16. Fuel Drain Assembly Replacement.
APPENDIX A REFERENCES - TM-9-6115-662-13P_180
A-7. MILITARY STANDARDS
A-10. FIELD MANUALS.
APPENDIX B MAINTENANCE ALLOCATION CHART - TM-9-6115-662-13P_184
B-3. EXPLANATION of COLUMNS in the MAC
B-4 EXPLANATION of COLUMNS in TOOL and TEST EQUIPMENT REQUIREMENTS - TM-9-6115-662-13P_186
Section II. MAINTENANCE ALLOCATION CHART - TM-9-6115-662-13P_187
MAINTENANCE ALLOCATION CHART -CONT
SECTION III. TOOL AND TEST EQUIPMENT REQUIREMENTS
Section IV. REMARKS - TM-9-6115-662-13P_190
APPENDIX C COMPONENTS OF END ITEM (COEI) AND BASIC ISSUE ITEMS (Bll) LISTS - TM-9-6115-662-13P_192
SECTION II. COMPONENTS OF END ITEM - TM-9-6115-662-13P_193
SECTION Ill. BASIC ISSUE ITEMS
APPENDIX D ADDITIONAL AUTHORIZATION LIST - TM-9-6115-662-13P_196
SECTION II. ADDITIONAL AUTHORIZED ITEMS LIST
APPENDIX E EXPENDABLE AND DURABLE ITEMS LIST - TM-9-6115-662-13P_198
SECTION II. EXPENDABLE AND DURABLE ITEMS LIST - TM-9-6115-662-13P_199
APPENDIX F UNIT AND DIRECT SUPPORT MAINTENANCE REPAIR PARTS AND SPECIAL TOOLS LIST - TM-9-6115-662-13P_200
F-3.2 SMR CODE - TM-9-6115-662-13P_201
F-3.2.2 Maintenance Code.
F-3.2.2.2 Maintenance Code Fourth Position.
F-4 EXPLANATION OF COLUMNS
F-4.3 FIGURE AND ITEM NUMBER INDEX
F-6 HOW TO LOCATE REPAIR PARTS - TM-9-6115-662-13P_206
Figure F-1. Generator Set Installation
DESCRIPTION AND USABLE ON CODES - TM-9-6115-662-13P_210
Figure F-2. Cable Assembly
DESCRIPTION AND USABLE ON CODES - TM-9-6115-662-13P_212
Figure F-3. Switch Box Assembly
DESCRIPTION AND USABLE ON CODES - TM-9-6115-662-13P_214
DESCRIPTION AND USABLE ON CODES - TM-9-6115-662-13P_215
Figure F-4. Load Terminal Wrench Assembly
DESCRIPTION AND USABLE ON CODES - TM-9-6115-662-13P_218
Figure F-5. Control Panel Assembly
DESCRIPTION AND USABLE ON CODES - TM-9-6115-662-13P_220
Figure F-6. Control Panel Wiring Harness, W20
DESCRIPTION AND USABLE ON CODES - TM-9-6115-662-13P_222
Figure F-7. Lamp Holder
DESCRIPTION AND USABLE ON CODES - TM-9-6115-662-13P_224
Figure F-8. Load Terminals
DESCRIPTION AND USABLE ON CODES - TM-9-6115-662-13P_226
Figure F-9. Wiring Harness, W9
DESCRIPTION AND USABLE ON CODES - TM-9-6115-662-13P_228
Figure F-10. Wiring Harness, W 10
DESCRIPTION AND USABLE ON CODES - TM-9-6115-662-13P_230
Figure F-11. Wiring Harness, W17
DESCRIPTION AND USABLE ON CODES - TM-9-6115-662-13P_232
Figure F-12.
DESCRIPTION AND USABLE ON CODES - TM-9-6115-662-13P_234
Figure F-13. Electrical Lead
DESCRIPTION AND USABLE ON CODES - TM-9-6115-662-13P_236
DESCRIPTION AND USABLE ON CODES - TM-9-6115-662-13P_237
Figure F-14. Bus Bar
DESCRIPTION AND USABLE ON CODES - TM-9-6115-662-13P_240
Figure F- 15. Contactor
DESCRIPTION AND USABLE ON CODES - TM-9-6115-662-13P_242
Figure F-16. Power Lead
DESCRIPTION AND USABLE ON CODES - TM-9-6115-662-13P_244
DESCRIPTION AND USABLE ON CODES - TM-9-6115-662-13P_245
Figure F-17. Power Switch Wiring Harness, W18
DESCRIPTION AND USABLE ON CODES - TM-9-6115-662-13P_248
Figure F-18. Switch Box Support
DESCRIPTION AND USABLE ON CODES - TM-9-6115-662-13P_250
Figure F-19. Accessories
Figure F-20. Oil Drain, Fire Extinguisher and Ground Cable
DESCRIPTION AND USABLE ON CODES - TM-9-6115-662-13P_253
Figure F-21. Fuel Assembly Drain
DESCRIPTION AND USABLE ON CODES - TM-9-6115-662-13P_255
Figure F-22. Trailer Assembly
DESCRIPTION AND USABLE ON CODES - TM-9-6115-662-13P_257
Figure F-23. Rear Steps
DESCRIPTION AND USABLE ON CODES - TM-9-6115-662-13P_259
Figure F-24. Accessory Box
DESCRIPTION AND USABLE ON CODES - TM-9-6115-662-13P_261
Figure F-25. Fenders
DESCRIPTION AND USABLE ON CODES - TM-9-6115-662-13P_263
Figure F-26. Brake Assembly
DESCRIPTION AND USABLE ON CODES - TM-9-6115-662-13P_265
Figure F-27. Front Sfeps
DESCRIPTION AND USABLE ON CODES - TM-9-6115-662-13P_267
Figure F-28. Front Platform
DESCRIPTION AND USABLE ON CODES - TM-9-6115-662-13P_269
Figure F-29. Ground Stud
DESCRIPTION AND USABLE ON CODES - TM-9-6115-662-13P_271
Figure F-30. Trailer Chassis
DESCRIPTION AND USABLE ON CODES - TM-9-6115-662-13P_273
DESCRIPTION AND USABLE ON CODES - TM-9-6115-662-13P_274
SECTION IV CROSS-REFERENCE INDEXES - TM-9-6115-662-13P_277
NATIONAL STOCK NUMBER INDEX - TM-9-6115-662-13P_278
PART NUMBER INDEX - TM-9-6115-662-13P_279
PART NUMBER - TM-9-6115-662-13P_280
PART NUMBER - TM-9-6115-662-13P_281
PART NUMBER - TM-9-6115-662-13P_282
PART NUMBER - TM-9-6115-662-13P_283
PART NUMBER - TM-9-6115-662-13P_284
PART NUMBER - TM-9-6115-662-13P_285
FIGURE AND ITEM NUMBER INDEX - TM-9-6115-662-13P_286
FIGURE AND ITEM NUMBER INDEX - TM-9-6115-662-13P_287
FIGURE AND ITEM NUMBER INDEX - TM-9-6115-662-13P_288
FIGURE AND ITEM NUMBER INDEX - TM-9-6115-662-13P_289
FIGURE AND ITEM NUMBER INDEX - TM-9-6115-662-13P_290
FIGURE AND ITEM NUMBER INDEX - TM-9-6115-662-13P_291
FIGURE AND ITEM NUMBER INDEX - TM-9-6115-662-13P_292
APPENDIX G ILLUSTRATED LIST OF MANUFACTURED ITEMS
Figure G-1. B Unit Cable Assembly W19 (Sheet 1 of 2).
Figure G-1. B Unit Cable Assembly W19 (Sheet 2).
Figure G-2. Control Wiring Harness W7 (Sheet 1 of 2).
Figure G-2. Control Wiring Harness W7 (Sheet 2).
Figure G-3. Switch Box Power Wiring Harness W17 and W18 (Sheet 1 of 2.).
Figure G-3. Switch Box Power Wing Harness W17 and W18 (Sheet 2).
Figure G-4. Input/Output Connector Wiring Harness W9 and W10 (Sheet 1 of 2).
Figure G-4. Input/Output Connector Wiring Harness W9 and W10 (Sheet 2).
Figure G-5. Electrical Leads W11 -W16.
Figure G-6. Power leads W1-W5 (Shed 1 of 2).
Figure G-6. Power Leads W1 -W5 (Sheet 2).
Figure G-7. Control Panel Harness Assembly W20 (Sheet 1 of 2).
Figure G-7. Control Panel Harness Assembly W20 (Sheet 2).
Figure G-8. Fuel Drain Assembly.
APPENDIX H TORQUE LIMITS
GLOSSARY - TM-9-6115-662-13P_311
Section Il. DEFINITION OF UNUSUAL TERMS
FO-2. POWER PLANT SCHEMATIC - TM-9-6115-662-13P_330

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