TM_9-6115-659-13 P_(5kW-Jan_2010).pdf

TECHNICAL MANUAL

OPERATOR AND FIELD MAINTENANCE MANUAL INCLUDING REPAIR PARTS

AND SPECIAL TOOLS LIST

FOR

POWER UNIT, DIESEL ENGINE DRIVEN, 1 TON TRAILER

MOUNTED, 5 kW, 50/60 Hz

PU-797

(NSN: 6115-01-332-0741) (EIC: N/A)

POWER UNIT, DIESEL ENGINE DRIVEN, LIGHT TACTICAL

TRAILER MOUNTED, 5 kW, 50/60 Hz

PU-797A

(NSN: 6115-01-413-3820) (EIC: N/A)

POWER PLANT, DIESEL ENGINE DRIVEN, 1 TON TRAILER

MOUNTED, 5 kW, 50/60 Hz

AN/MJQ-35

(NSN: 6115-01-313-4216) (EIC: N/A)

POWER PLANT, DIESEL ENGINE DRIVEN, LIGHT TACTICAL

TRAILER MOUNTED, 5 kW, 50/60 Hz

AN/MJQ-35A

(NSN: 6115-01-414-9697) (EIC: N/A)

POWER PLANT, DIESEL ENGINE DRIVEN, 1 1/2 TON

TRAILER MOUNTED, 5 kW, 50/60 Hz, AN/MJQ-36

(NSN: 6115-01-313-4215) (EIC: N/A)

*TM 9-6115-659-13&P

*SUPERSEDURE NOTICE - This manual supersedes TM 9-6115-659-13&P dated 1 June 2007.

DISTRIBUTION STATEMENT A - Approved for public release; distribution is unlimited.

HEADQUARTERS, DEPARTMENT OF THE ARMY

30 JANUARY 2010

GENERAL HAZARDOUS MATERIALS WARNINGS DESCRIPTION

Hazardous materials are not to be used by the operator in the operation and maintenance of the Power Plant/Power Unit.

Engine exhaust fumes contain deadly poisonous gases.

Severe exposure can cause death or permanent brain damage.

Exhaust gases are most dangerous in places with poor airflow. The best defense against exhaust gas poisoning is very good airflow.

To protect yourself and others, always obey the following rules:

• Do not run engine indoors unless you have very good airflow.

• Do not idle engine for a long time unless there is very good airflow.

• Be alert at all times. Check for smell of exhaust fumes.

• Reminder: The best defense against exhaust gas poisoning is very good airflow.

• Exhaust gas poisoning causes dizziness, headache, loss of muscle control, sleepiness, coma, and death. If anyone shows signs of exhaust gas poisoning, get all personnel clear of the Power Plant/Power Unit. Make sure they have lots of fresh air. Keep them warm calm, and inactive. Get medical help. If anyone stops breathing give artificial respiration.

This warning summary contains general safety warnings and hazardous material warnings that must be understood arid applied during operation and maintenance of the generator set. Failure to observe these precautions could result in serious injury or death to personnel.

Also included are explanations of safety and hazardous materials icons used within the Technical Manual (TM).

For First Aid Information, Refer To Field Manual (FM) 4-25.11. See Work Package (WP) 0109, References.

Prior to starting any WP procedure, the warnings included in the WP must be reviewed and understood.

Also review the Materials/Parts listed in the INITIAL SETUP of the WP for hazardous materials used during maintenance of the equipment. Then, refer to the detailed warnings for hazardous materials listed separately in this WARNING SUMMARY.

This manual describes physical and chemical processes that may require the use of chemicals, solvents, paints, or other commercially available material. Users of the manual should obtain the Material Safety Data Sheets (MSDS) (Occupational Safety and Health Act (OSHA) Form 20 or equivalent) from the manufacturers or suppliers of materials to be used. Users must be completely familiar with manufacturer/supplier information and adhere to their procedures, recommendations, warnings, and cautions for safe use handling, storage. and disposal of these materials.

TM 9-6115-659-13&P

WARNING SUMMARY

a

FIRST AID

For First Aid information, refer to FM 4-25.11.

5 SAFETY STEPS TO FOLLOW IF SOMEONE IS THE VICTIM OF ELECTRICAL

SHOCK:

DO NOT TRY TO PULL OR GRAB THE INDIVIDUAL.

IF POSSIBLE, TURN OFF THE ELECTRICAL POWER.

IF YOU CANNOT TURN OFF THE ELECTRICAL POWER, PULL, PUSH OR LIFT THE

PERSON TO SAFETY USING A DRY WOODEN POLE OR A DRY ROPE OR SOME

OTHER INSULATING MATERIAL.

SEND FOR HELP AS SOON AS POSSIBLE.

AFTER THE INJURED PERSON IS FREE OF CONTACT WITH THE SOURCE OF

ELECTRICAL SHOCK, MOVE THE PERSON A SHORT DISTANCE AWAY AND IMME-

DIATELY START ARTIFICIAL RESUSCITATION.

TM 9-6115-659-13&P

WARNING SUMMARY - Continued b

WARNING ICONS

EAR PROTECTION - Headphones over ears shows that noise level will harm ears.

ELECTRICAL - Electrical wire to arm with electricity symbol running through human body shows that shock hazard is present.

ELECTRICAL - Electrical wire to hand with electricity symbol running through hand shows that shock hazard is present.

HEAVY OBJECT - Human figure stooping over heavy object shows physical injury potential from improper lifting technique.

HOT AREA - Hand over object radiating heat shows that part is hot and can burn.

MOVING PARTS - Human figure with an arm caught between gears shows that the moving parts of the equipment present a danger to life or limb.

MOVING PARTS - Hand with fingers caught between gears shows that the moving parts of the equipment present a danger to life or limb.

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c

WARNING DESCRIPTIONS

WARNING

Operation and maintenance of the Power Plant/Power Unit contains many possibilities for injury or death to personnel. Be sure to be familiar with general first aid procedures as referenced in FM 425.11, First Aid (WP 0109, References). Failure to comply may cause injury or death to personnel.

WARNING

Metal jewelry can conduct electricity and become entangled in generator set components.

Remove all jewelry and do not wear loose clothing when working on equipment. Failure to comply may cause injury or death to personnel.

WARNING

High voltage is produced when generator set is in operation. Do not connect to a load that is not protected with appropriate safety devices. Do not connect from output terminal board to output terminal board unless directed by higher command. Never attempt to start the generator set unless it is properly grounded. Do not ground yourself in standing water. Never attempt to connect or disconnect load cables while the generator set is running. Do not contact output cables when operating this generator set. Make sure that the connection between generator set and load is completely deenergized (safety device opens circuit) prior to disconnecting load cables or performing maintenance on the output terminal board. Failure to comply may cause injury or death to personnel.

WARNING

Shut down generator sets before performing internal inspection of switch box. Failure to comply with this warning can cause injury or death to personnel.

WARNING

Shut down generator sets before performing inspection of load cables. Failure to comply may cause injury or death to personnel by electrocution.

WARNING

Shut down generator sets before performing inspection of wiring. Failure to comply with this warning can cause injury or death to personnel.

WARNING

Ensure nuts on ground terminals are properly secured creating a good ground. Failure to comply with this warning can cause injury or death to personnel.

WARNING

High voltage is produced when this generator set is in operation. Do not contact output cables when operating this generator set. Failure to comply may cause injury or death to personnel.

WARNING

Dangerous voltage exists on live circuits. Always observe precautions and never work alone.

Failure to comply with this warning can cause injury or death to personnel.

TM 9-6115-659-13&P

d

Generator set operator is permitted to make connections to out terminal board only. Connections to load distribution points or to equipment beyond the output terminal board shall only be made by properly trained and authorized personnel. Failure to comply may cause injury or death to personnel.

WARNING

Shut down generator sets before removing indicator lamp. Failure to comply with this warning can cause injury or death to personnel.

WARNING

Fuel is combustible and toxic to eyes. skin, and respiratory tract. Skin and eye protection are required when working in contact with fuel. Avoid repeated or prolonged contact. Provide adequate ventilation. Operators are to wash exposed skin and change soaked clothing promptly if exposed to fuel. Failure to comply may cause injury or death to personnel.

WARNING

Fuels used in the generator set are combustible. Do not smoke or use open fire when performing maintenance. Fire and possible explosion may result. Failure to comply may cause injury or death to personnel and damage to equipment.

WARNING

Fuels used in the generator set are combustible. Ensure fuel source grounding strap is connected to unit fuel fill grounding stud. When filling the fuel tank maintain metal-to-metal contact between filler nozzle and fuel tank opening to eliminate Electrostatic Discharge (ESD).

Failure to comply may cause injury or death to personnel.

WARNING

Hot engine surfaces from engine and generator circuitry are possible sources of ignition. When refueling during unit operation with Diesel Fuel (DF)-1. DF-2, Jet Propulsion Fuel (JP) 5, or JP8, avoid fuel splash and fuel spill. Do not smoke or use open flame when performing refueling.

Remember Preventive Maintenance Checks and Services (PMCS) are still required. Flames and possible explosion may result. Failure to comply may cause injury or death to personnel.

WARNING

Cooling system operates at high temperature and pressure. Contact with high-pressure steam and/or liquids can cause burns and scalding. Shut down generator set and allow system to cool before performing checks, services, and maintenance. Wear gloves, additional protective clothing, and goggles as required. Contact with high-pressure steam and/or liquids can cause burns and scalding. Failure to comply may cause injury or death to personnel.

WARNING

In extremely cold weather, skin can stick to metal. Avoid contacting metal items with bare skin in extremely cold weather. Failure to comply may cause injury or death to personnel.

WARNING

Operating generator set with unit doors open or panels removed exposes personnel to a high noise level. Close unit doors and replace panels or wear hearing protection while operating or working near a running generator set. Failure to comply may cause injury.

TM 9-6115-659-13&P

e

Exhaust discharge contains deadly gases, including carbon monoxide. Do not operate generator set in an enclosed area unless exhaust discharge is properly vented. Failure to comply may cause injury or death to personnel.

WARNING

Hot exhaust gases can ignite combustible materials. Allow room for safe discharge of hot gases.

Failure to comply may cause injury or death to personnel.

WARNING

Top housing panels can get very hot. Allow panels to cool down before performing maintenance.

Wear gloves and additional protective clothing as required. Failure to comply may cause injury or death to personnel.

WARNING

When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut down generator set and allow generator to cool before checks, services, and maintenance. Wear gloves and additional protective clothing as required. Failure to comply may cause injury or death to personnel.

WARNING

Batteries give off combustible gas. Do not smoke or use open flame when performing maintenance. Failure to comply may cause injury or death to personnel and damage to equipment.

WARNING

Battery acid can cause burns to unprotected skin. Wear safety goggles and chemical gloves and avoid acid splash while working on the batteries. Failure to comply may cause injury or death to personnel.

WARNING

Do not disconnect trailer from towing vehicle before hand brakes are set and front landing leg and rear support leg are lowered. Failure to comply with this warning can cause personal injury or death from trailer tipping or rolling, and equipment damage.

WARNING

If trailer is not coupled to towing vehicle, ensure that wheels are securely chocked. Failure to comply with this warning can cause trailer to roll, resulting in severe personal injury and damage to equipment.

WARNING

Before performing any maintenance that requires climbing on or under trailer, make sure that trailer handbrakes are set, trailer front landing leg/support leg is lowered, and leveling-support jack is lowered. Failure to comply with this warning can cause personal injury or death to personnel from trailer suddenly rolling or tipping.

WARNING

Steel strapping used in packaging of the power plant/power unit has sharp edges. Wear gloves and use care when cutting and handling steel strapping. Failure to comply with this warning can cause personal injury.

TM 9-6115-659-13&P

f

Use the aid of an assistant when removing the fender, splash guard, and switch box as an assembly. Failure to comply with this warning can cause severe personal injury.

WARNING

When lifting generator set, use lifting equipment with minimum lifting capacity of 1,750 pounds (793.8 kg). Do not stand or put arms, legs, or any part of the body under hoisted load. Do not permit generator set to swing. Failure to comply with this warning can result in personal injury or death and damage to equipment.

WARNING

Impact disk must be tightened to end of threads on rod. Also, lock washer and nut must be tightened firmly against impact disk. Failure to comply with this warning can result in severe personal injury and/or damage to the equipment.

WARNING

Before removing trailer leveling-support jack, support rear of trailer with jack stand(s). Failure to comply with this warning can cause severe personal injury or death.

WARNING

Do not attempt to seat a lockring when tire is inflated. Improperly seated lockring could fly off.

Failure to comply can cause severe personal injury to personnel.

WARNING

Solvent used to clean parts is potentially dangerous to personnel and property. Clean parts in a well-ventilated area. Avoid inhalation of solvent fumes. Wear goggles and rubber gloves to protect eyes and skin. Wash exposed skin thoroughly. Do not smoke or use near open flame or excessive heat. Failure to comply with this warning can cause severe personal injury and/or damage to equipment.

WARNING

When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut down generator set and allow generator to cool before checks, services, and maintenance. Wear gloves and additional protective clothing as required. Failure to comply may cause injury or death to personnel.

WARNING

When operating, muffler has hot metal surfaces that will burn flesh on contact. Shut down generator set and allow (specific component) to cool before performing maintenance. Wear gloves and additional protective clothing as required. Failure to comply may cause injury or death to personnel

HAZARDOUS MATERIALS WARNINGS

BIOLOGICAL - Abstract symbol bug shows that a material may contain bacteria or viruses that present a danger to life or health.

CHEMICAL - Drops of liquid on hand shows that the material will cause burns or irritation to human skin or tissue.

CRYOGENIC - Hand in block of ice shows that the material is extremely cold and can injure human skin or tissue.

TM 9-6115-659-13&P

g

EXPLOSION - Rapidly expanding symbol shows that the material may explode if subjected to high temperatures, sources of ignition or high pressure.

EYE PROTECTION - Person with goggles shows that the material will injure the eyes.

FIRE - Flame shows that a material may ignite and cause burns.

POISON - Skull and crossbones shows that a material is poisonous or is a danger to life.

RADIATION - Three circular wedges shows that the material emits radioactive energy and can injure human tissue.

VAPOR - Human figure in a cloud shows that material vapors present a danger to life or health.

TM 9-6115-659-13&P

h

Front Cover 0 Blank 0 Warning summary (8 pgs) 0 i - xxii Chp 1 title page 0 Index 0 WP 0001 (10 pgs) 0 WP 0002 (6 pgs) 0 WP 0003 (2 pgs) 0 Chp 2 title page 0 Index 0 WP 0004 (4 pgs) 0 WP 0005 (28 pgs) 0 WP 0006 (2 pgs) 0 Chp 3 title page 0 Index 0 WP 0007 (2 pgs) 0 WP 0008 (6 pgs) 0 Chp 4 title page 0 Index 0 WP 0009 (8 pgs) 0 WP 0010 (20 pgs) 0 WP 0011 (2 pgs) 0 WP 0012 (2 pgs) 0 Chp 5 title page 0 Index 0 WP 0013 (2 pgs) 0 WP 0014 (10 pgs) 0 Chp 6 title page 0 Index 0 WP 0015 (10 pgs) 0 WP 0016 (4 pgs) 0 WP 0017 (2 pgs) 0 WP 0018 (2 pgs) 0 WP 0019 (2 pgs) 0 WP 0020 (8 pgs) 0 WP 0021 (4 pgs) 0 WP 0022 (4 pgs) 0 WP 0023 (4 pgs) 0 WP 0024 (4 pgs) 0

WP 0025 (4 pgs) 0 WP 0026 (4 pgs) 0 WP 0027 (2 pgs) 0 WP 0028 (2 pgs) 0 WP 0029 (4 pgs) 0 WP 0030 (2 pgs) 0 WP 0031 (2 pgs) 0 WP 0032 (4 pgs) 0 WP 0033 (4 pgs) 0 WP 0034 (2 pgs) 0 WP 0035 (4 pgs) 0 WP 0036 (4 pgs) 0 WP 0037 (4 pgs) 0 WP 0038 (2 pgs) 0 WP 0039 (4 pgs) 0 WP 0040 (10 pgs) 0 WP 0041 (4 pgs) 0 WP 0042 (8 pgs) 0 WP 0043 (4 pgs) 0 WP 0044 (4 pgs) 0 WP 0045 (4 pgs) 0 WP 0046 (4 pgs) 0 WP 0047 (4 pgs) 0 WP 0048 (4 pgs) 0 WP 0049 (2 pgs) 0 WP 0050 (2 pgs) 0 WP 0051 (4 pgs) 0 WP 0052 (2 pgs) 0 WP 0053 (2 pgs) 0 WP 0054 (2 pgs) 0 WP 0055 (2 pgs) 0 WP 0056 (6 pgs) 0 WP 0057 (2 pgs) 0 WP 0058 (2 pgs) 0 WP 0059 (2 pgs) 0 WP 0060 (2 pgs) 0 WP 0061 (2 pgs) 0 WP 0062 (4 pgs) 0 WP 0063 (6 pgs) 0 WP 0064 (6 pgs) 0

TM 9-6115-659-13&P

LIST OF EFFECTIVE PAGES / WORK PACKAGES

NOTE: This manual supersedes TM 9-6115-659-13&P dated 1 June 2007. Zero in the "Change No." column indicates an original page or work package.

Date of issue for the original manual is:

Original 30 JANUARY 2010

TOTAL NUMBER OF PAGES FOR FRONT AND REAR MATTER IS 56 AND TOTAL NUMBER OF WORK

PACKAGES IS 115, CONSISTING OF THE FOLLOWING:

Page / WP No. Change No. Page / WP No. Change No.

A

WP 0065 (2 pgs) 0 WP 0066 (4 pgs) 0 WP 0067 (2 pgs) 0 WP 0068 (2 pgs) 0 WP 0069 (2 pgs) 0 Chp 7 title page 0 Index 0 WP 0070 (6 pgs) 0 WP 0071 (4 pgs) 0 WP 0072 (4 pgs) 0 WP 0073 (4 pgs) 0 WP 0074 (4 pgs) 0 WP 0075 (4 pgs) 0 WP 0076 (4 pgs) 0 WP 0077 (4 pgs) 0 WP 0078 (4 pgs) 0 WP 0079 (4 pgs) 0 WP 0080 (4 pgs) 0 WP 0081 (4 pgs) 0 WP 0082 (4 pgs) 0 WP 0083 (4 pgs) 0 WP 0084 (4 pgs) 0 WP 0085 (4 pgs) 0 WP 0086 (4 pgs) 0 WP 0087 (4 pgs) 0 WP 0088 (4 pgs) 0 WP 0089 (4 pgs) 0 WP 0090 (4 pgs) 0 WP 0091 (4 pgs) 0 WP 0092 (4 pgs) 0 WP 0093 (4 pgs) 0 WP 0094 (4 pgs) 0 WP 0095 (4 pgs) 0 WP 0096 (4 pgs) 0 WP 0097 (4 pgs) 0 WP 0098 (4 pgs) 0 WP 0099 (4 pgs) 0 WP 0100 (4 pgs) 0 WP 0101 (4 pgs) 0 WP 0102 (4 pgs) 0 WP 0103 (4 pgs) 0 WP 0104 (4 pgs) 0 WP 0105 (2 pgs) 0 WP 0106 (2 pgs) 0 WP 0107 (4 pgs) 0 WP 0108 (6 pgs) 0 Chp 8 title page 0 Index 0 WP 0109 (4 pgs) 0

WP 0110 (4 pgs) 0 WP 0111 (4 pgs) 0 WP 0112 (8 pgs) 0 WP 0113 (2 pgs) 0 WP 0114 (2 pgs) 0 WP 0115 (2 pgs) 0

INDEX-1 - INDEX-6 0

Foldouts (6 pgs) 0 Inside back cover 0 Back cover 0

TM 9-6115-659-13&P

LIST OF EFFECTIVE PAGES / WORK PACKAGES - CONTINUED

Page / WP No. Change No. Page / WP No. Change No.

B

TECHNICAL MANUAL

OPERATOR AND FIELD MAINTENANCE MANUAL INCLUDING REPAIR PARTS AND SPECIAL TOOLS LIST

FOR

POWER UNIT, DIESEL ENGINE DRIVEN, 1 TON TRAILER MOUNTED,

5 kW, 50/60 Hz, PU-797

(NSN: 6115-01-332-0741) (EIC:N/A)

POWER UNIT, DIESEL ENGINE DRIVEN, LIGHT TACTICAL TRAILER MOUNTED,

5 kW, 50/60 Hz, PU-797A

(NSN: 6115-01-413-3820) (EIC:N/A)

POWER PLANT, DIESEL ENGINE DRIVEN, 1 TON TRAILER MOUNTED,

5 kW, 50/60 Hz, AN/MJQ-35

(NSN: 6115-01-313-4216) (EIC:N/A)

POWER PLANT, DIESEL ENGINE DRIVEN, LIGHT TACTICAL TRAILER MOUNTED,

5 kW, 50/60 Hz, AN/MJQ-35A

(NSN: 6115-01-414-9697) (EIC:N/A)

POWER PLANT, DIESEL ENGINE DRIVEN, 1 1/2 TON TRAILER MOUNTED,

5 kW, 50/60 Hz, AN/MJQ-36

(NSN: 6115-01-313-4215) (EIC:N/A)

REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS

You can help improve this manual. If you find any mistakes or if you know of a way to improve the procedures, please let us know. Reports, as applicable by the requiring Service, should be submitted as follows:

(A) Army - Mail your letter or DA Form 2028 (Recommended Changes to Publications and Blank Forms) located in the back of this manual, directly to: Commander, U.S. Army CECOM Life Cycle Management Command (LCMC) and Fort Monmouth, ATTN: AMSEL-LCL-ECM, Fort Monmouth, NJ 07703-5006. You may also send in your recommended changes via electronic mail or by fax. Our fax number is 732-532-1556, DSN 992-1556. Our e-mail address is MONM-AMSELLEOPUBSCHG@conus.army.mil. Our online web address for entering and submitting DA Form 2028s is http://edm.monmouth.army.mil/pubs/2028.html.

A reply will be furnished to you.

*TM 9-6115-659-13&P

HEADQUARTERS,

DEPARTMENTS OF THE ARMY

WASHINGTON, D.C., 30 JANUARY 2010

*SUPERSEDURE NOTICE - This manual supersedes TM 9-6115-659-13&P dated 1 June 2007.

DISTRIBUTION STATEMENT A - Approved for public release; distribution is unlimited.

i

TABLE OF CONTENTS

Page No.

WP Sequence No.

How to Use This Manual Chapter 1 - General Information, Equipment Description and Theory of Operation

General Information .............................................................................................................................. WP 0001 Scope .................................................................................................................................................0001-1 Figure 1. Features of AN/MJQ-35 ......................................................................................................0001-2 Figure 2. Features of AN/MJQ-36 ......................................................................................................0001-3 Figure 3. Features of AN/MJQ-35A....................................................................................................0001-4 Figure 4. Features of PU-797A...........................................................................................................0001-5 Figure 5. Features of PU-797 .............................................................................................................0001-6 Maintenance Forms, Records, and Reports.......................................................................................0001-6 Reporting Equipment Improvement Recommendation (EIR) .............................................................0001-6 Corrosion Prevention and Control (CPC) ...........................................................................................0001-6 Destruction of Army Materiel to Prevent Enemy Use .........................................................................0001-7 Preparation for Storage or Shipment..................................................................................................0001-7 Nomenclature Cross-Reference List ..................................................................................................0001-7 List of Abbreviations/Acronyms ..........................................................................................................0001-7 Supporting Information for Repair Parts, Special Tools, TMDE and Support Equipment ..................0001-9 Repair Parts........................................................................................................................................0001-9

Equipment Description and Data .......................................................................................................... WP 0002 Equipment Characteristics, Capabilities, and Features......................................................................0002-1 Equipment Description .......................................................................................................................0002-1 Capabilities and Features...................................................................................................................0002-1 Location and Description of Major Components.................................................................................0002-2 Figure 1. Location of Major Components, AN/MJQ-35 and AN/MJQ-35A .........................................0002-2 Table 1. Description of Major Components, AN/MJQ-35 AND AN/MJQ-35A.....................................0002-3 Figure 2. Location of Major Components, AN/MJQ-36.......................................................................0002-3 Table 2. Description of Major Components, AN/MJQ-36. ..................................................................0002-3 Figure 3. Location of Major Components, PU-797 and PU-797A.......................................................0002-4 Table 3. Description of Major Components, PU-797 and PU-797A. ..................................................0002-4 Differences Between Models..............................................................................................................0002-5 Table 4. Differences Between Models................................................................................................0002-5 Differences Between Switch Boxes....................................................................................................0002-5 Equipment Data..................................................................................................................................0002-5 Table 5. Tabulated Data for Power Plants/Power Units. ....................................................................0002-6 Table 6. Towed Speeds for Power Plants/Power Units......................................................................0002-6

Theory of Operation .............................................................................................................................. WP 0003 Functional Description ........................................................................................................................0003-1 Power Plant Functional Description....................................................................................................0003-1 Power Unit Functional Description .....................................................................................................0003-1 Related Technical Manuals ................................................................................................................0003-1

Chapter 2 - Operator Instructions

Description and Use of Operator Controls and Indicators .................................................................... WP 0004 Figure 1. Switch Box Controls and Indicators (NEW).........................................................................0004-2

TM 9-6115-659-13&P

ii

TABLE OF CONTENTS - Continued

WP Sequence No.

Figure 2. Switch Box Controls and Indicators (OLD)..........................................................................0004-3 Table 1. Switch Box Controls and Indicators......................................................................................0004-4

Operation Under Usual Conditions ....................................................................................................... WP 0005 Assembly and Preparation for Use.....................................................................................................0005-1 Unpacking the Power Plants/Power Units ..........................................................................................0005-1 Installation Instructions .......................................................................................................................0005-1 Figure 1. Rear Leveling-Support Jack ................................................................................................0005-2 External Fuel Line Connection ...........................................................................................................0005-2 Figure 2. Auxiliary Fuel (Typical) ........................................................................................................0005-3 Figure 3. Ground Rod and Slide Hammer ..........................................................................................0005-5 Connecting Load ................................................................................................................................0005-6 Connection to Switch Box Load Terminals.........................................................................................0005-7 Figure 4. Power Plant and Power Unit Ground Connections .............................................................0005-8 Figure 5. Typical Ground Rod Installations ........................................................................................0005-9 Figure 6. Switch Box Load Cable Connections (NEW) ......................................................................0005-10 Figure 7. Switch Box Load Cable Connections (OLD) .......................................................................0005-11 Table 1. Load Terminal Voltage. ........................................................................................................0005-11 Positioning of Fire Extinguishers ........................................................................................................0005-12 Initial Adjustments, Checks, and Self Test .........................................................................................0005-12 Operating Procedures ........................................................................................................................0005-12 Generator Set Operating Procedures.................................................................................................0005-13 Trailer Operating Procedures .............................................................................................................0005-13 Power Plant Switch Box Operating Procedures .................................................................................0005-13 Operating a Single Generator Set. .....................................................................................................0005-13 Figure 8. Power Plant Operation (OLD and NEW) .............................................................................0005-14 Stopping Power Plant Set...................................................................................................................0005-16 Decals and Instructions Plates ...........................................................................................................0005-16 Figure 9. AN/MJQ-35 Identification/Transportation Data Plate ..........................................................0005-16 Figure 10. AN/MJQ-36 Identification/Transportation Data Plate ........................................................0005-17 Figure 11. PU-797 Identification/Transportation Data Plate ...............................................................0005-17 Figure 12. AN/MJQ-35A Shipping Data/Identification Plate ...............................................................0005-18 Figure 13. PU-797A Shipping Data/Identification Plate......................................................................0005-19 Figure 14. AN/MJQ-35A and PU-797A Trailer Chassis Identification Plate .......................................0005-19 Figure 15. Power Plant Instruction Plate ............................................................................................0005-20 Figure 16. Power Plants AN/MJQ-35, AN/MJQ35A, and AN/MJQ-36 Identification Plate .................0005-21 Figure 17. AN/MJQ-35 Item Unique Identification (IUID) Plate ..........................................................0005-21 Figure 18. AN/MJQ-35A and PU-797A Item Unique Identification (IUID) Plates ...............................0005-21 Figure 19. AN/MJQ-36 Item Unique Identification (IUID) Plate ..........................................................0005-22 Figure 20. PU-797 Item Unique Identification (IUID) Plate.................................................................0005-22 Figure 21. Switch Box Item Unique Identification (IUID) Plate ...........................................................0005-23 Preparation for Movement ..................................................................................................................0005-24 Disconnect Load Cables.....................................................................................................................0005-24 Retrieve Ground Cable and Rod ........................................................................................................0005-25 Figure 22. Remove Ground Rod ........................................................................................................0005-26 iii

WP Sequence No.

Retrieve Fire Extinguisher(s) ..............................................................................................................0005-26 Disconnect External Fuel Source .......................................................................................................0005-26 Figure 23. Disconnect Auxiliary Fuel (Typical) ...................................................................................0005-27

Operation Under Unusual Conditions ................................................................................................... WP 0006 Generator Sets ...................................................................................................................................0006-1 Trailer .................................................................................................................................................0006-1 Winterization Kit..................................................................................................................................0006-1

Chapter 3 - Operator Troubleshooting Procedures

Operator Troubleshooting Index ........................................................................................................... WP 0007 General Information............................................................................................................................0007-1

Operator Troubleshooting Procedures.................................................................................................. WP 0008 Troubleshooting..................................................................................................................................0008-1 Figure 1. ON Indicator Lamp Fails to Light with Generator Set Running ...........................................0008-2 Figure 2. ON-LINE Indicator Lamp Fails to Light When ON/OFF Switch is Placed in ON Position...............................................................................................................................................0008-3 Figure 3. SYNCHRONIZING Indicator Lamps Fail to Light when TRANSFER Switch is Operated.............................................................................................................................................0008-4 Figure 4. With All Indicator Lamps Working Properly, Load Will Not Transfer ...................................0008-5 Figure 5. SYNCHRONIZING Indicator Lamps Fail to Operate in Unison when Transfer Switch is Operated.............................................................................................................................................0008-6

Chapter 4 - Operator Maintenance Instructions

Operator Preventive Maintenance Checks and Services (PMCS) Introduction.................................... WP 0009 Table 1. Leakage Definitions. .............................................................................................................0009-3 Figure 1. Power Plant AN/MJQ-35 Operator PMCS Routing Diagram...............................................0009-4 Figure 2. Power Plant AN/MJQ-36 Operator PMCS Routing Diagram...............................................0009-5 Figure 3. Power Plant AN/MJQ-35A Operator PMCS Routing Diagram ............................................0009-6 Figure 4. PU-797A Power Unit Operator PMCS Routing Diagram.....................................................0009-7 Figure 5. PU-797 Power Unit Operator PMCS Routing Diagram.......................................................0009-8

Operator Preventive Maintenance Checks and Services (PMCS)........................................................ WP 0010 Table 1. Operator Preventive Maintenance Checks and Services. ....................................................0010-1

Operator Lubrication ............................................................................................................................. WP 0011 Lubrication ..........................................................................................................................................0011-1

Operator Maintenance: Repair or Replacement ................................................................................... WP 0012 Replacement of On, On-line, and Synchronizing Lamps:...................................................................0012-1

Chapter 5 - Field Troubleshooting Procedures

Field Troubleshooting Index.................................................................................................................. WP 0013

Field Troubleshooting ........................................................................................................................... WP 0014 Figure 1. ON Indicator Lamp Serviceable but Fails to Light with Generator Set Running..................0014-2 Figure 2. ON-LINE Indicator Lamp Serviceable but Fails to Light when ON/OFF Switch is Placed in ON Position.........................................................................................................................0014-3 Figure 3. SYNCHRONIZING Indicator Lamps Fail to Light when Transfer Switch is Operated.........0014-4 Figure 4. No Power to Load with ON-LINE Indicator Lamp On ..........................................................0014-5 iv

WP Sequence No.

Figure 5. All Indicator Lamps Working Properly but Load will not Transfer........................................0014-5 Figure 6. ON Indicator Lamp Assembly Tests Good, But ON Indicator Lamp Fails to Light with Generator Set Running.......................................................................................................................0014-6 Figure 7. 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 ...................................0014-7 Figure 8. SYNCHRONIZING Indicator Lamp Assembly and Transfer Switch Serviceable, but SYNCHRONIZING Indicator Lamps Fails to Light when TRANSFER Switch is Closed and then Released ............................................................................................................................................0014-8 Figure 9. All Indicator Lamps Working Properly, but Load Will Not Transfer .....................................0014-9

Chapter 6 - Field Maintenance Instructions

Service Upon Receipt ........................................................................................................................... WP 0015 Unpacking...........................................................................................................................................0015-1 Checking Unpacked Equipment .........................................................................................................0015-1 Processing Unpacked Equipment ......................................................................................................0015-2 Installation ..........................................................................................................................................0015-2 Tools, Test Equipment, and Materials Required for Installation .........................................................0015-2 Assembly of Equipment......................................................................................................................0015-3 Preliminary Checks and Adjustment of Equipment ............................................................................0015-5 Figure 1. Installation of Power Cables on AN/MJQ-35 .......................................................................0015-6 Figure 2. Installation of Power Cables on AN/MJQ-36 .......................................................................0015-7 Figure 3. Installation of Power Cables on AN/MJQ-35A.....................................................................0015-8 Figure 4. PU-797 and PU-797A Ground Wire Installation ..................................................................0015-9

Field Preventive Maintenance Checks and Services (PMCS) Introduction .......................................... WP 0016 Introduction to Field PMCS Table.......................................................................................................0016-1 Figure 1. Field PMCS Routing Diagram (Sheet 1 of 2). .....................................................................0016-2 Figure 1. Field PMCS Routing Diagram (Sheet 2 of 2). .....................................................................0016-3

Field Preventive Maintenance Checks and Services (PMCS) .............................................................. WP 0017 Table 1. Field Preventive Maintenance Checks and Services. ..........................................................0017-1

Field Lubrication.................................................................................................................................... WP 0018 Power Plant/power Unit Lubrication ...................................................................................................0018-1 Figure 1. Rear Leveling-Support Jack Lubrication Points ..................................................................0018-2

Field Maintenance................................................................................................................................. WP 0019 Maintenance of Generator Sets..........................................................................................................0019-1 Maintenance of Trailers ......................................................................................................................0019-1

Power Cable: Test, Removal, Installation, Replace.............................................................................. WP 0020 Test and Inspection ............................................................................................................................0020-1 Figure 1. Power Cable Connections to Switch Box Contactors..........................................................0020-2 Removal .............................................................................................................................................0020-2 Figure 2. Disconnect Power Cable from Generator Set .....................................................................0020-3 Figure 3. Disconnect Power Cable From Switch Box (NEW) Terminals ............................................0020-4 Figure 4. Disconnect Power Cable From Switch Box (OLD) Terminal ...............................................0020-5 Installation ..........................................................................................................................................0020-6 Replacement ......................................................................................................................................0020-7 v

WP Sequence No.

Switch Box (Old): Inspect, Replace, Removal, Installation ................................................................... WP 0021 Test and Inspection ............................................................................................................................0021-1 Replacement ......................................................................................................................................0021-2 Removal .............................................................................................................................................0021-2 Installation ..........................................................................................................................................0021-2 Figure 1. Switch Box Repair (OLD) ....................................................................................................0021-3

Switch Box (New): Inspect, Replace, Removal, Installation ................................................................. WP 0022 Test and Inspection ............................................................................................................................0022-1 Replacement ......................................................................................................................................0022-2 Removal .............................................................................................................................................0022-2 Installation ..........................................................................................................................................0022-2 Figure 1. Switch Box Repair (NEW) ...................................................................................................0022-3

Indicator Light Assembly: Test, Removal, Disassembly, Assembly, Installation, Replace ................... WP 0023 Test and Inspection ............................................................................................................................0023-1 Figure 1. Indicator Light Assembly. ....................................................................................................0023-2 Table 1. Indicator Light Assembly Test Points. ..................................................................................0023-2 Removal .............................................................................................................................................0023-3 Disassembly .......................................................................................................................................0023-3 Assembly ............................................................................................................................................0023-3 Installation ..........................................................................................................................................0023-3 Replacement ......................................................................................................................................0023-3

Synchronizing Light: Test, Removal, Installation, Replace ................................................................... WP 0024 Figure 1. Synchronizing Light .............................................................................................................0024-1 Test and Inspection ............................................................................................................................0024-2 Removal .............................................................................................................................................0024-2 Installation ..........................................................................................................................................0024-3 Replacement ......................................................................................................................................0024-3

Toggle Switch: Test, Removal, Installation, Replace............................................................................ WP 0025 Test and Inspection ............................................................................................................................0025-1 Table 1. Switch Continuity Test. .........................................................................................................0025-1 Removal .............................................................................................................................................0025-2 Installation ..........................................................................................................................................0025-2 Figure 1. Toggle Switch......................................................................................................................0025-2 Replacement ......................................................................................................................................0025-3

Switch Box Load Terminal: Inspect, Removal, Repair, Installation, Replace ....................................... WP 0026 Test and Inspection ............................................................................................................................0026-1 Removal .............................................................................................................................................0026-2 Repair .................................................................................................................................................0026-2 Installation ..........................................................................................................................................0026-2 Replacement ......................................................................................................................................0026-2 Figure 1. Switch Box Load Terminal Maintenance (Sheet 1 of 2). .....................................................0026-3 Figure 1. Switch Box Load Terminal Maintenance (Sheet 2 of 2). .....................................................0026-4 vi

WP Sequence No.

Load Terminal Cover (Old): Inspect, Removal, Installation, Replace ................................................... WP 0027 Test and Inspection ............................................................................................................................0027-1 Removal .............................................................................................................................................0027-1 Installation ..........................................................................................................................................0027-1 Replacement ......................................................................................................................................0027-2 Figure 1. Load Terminal Cover (OLD) ................................................................................................0027-2

Load Terminal Cover (New): Inspect, Removal, Installation, Replace.................................................. WP 0028 Test and Inspection ................