TM_9-6115-769-10_(7.5kW).pdf

TM 9-6115-769-10

TECHNICAL MANUAL

OPERATOR'S MANUAL

FOR

GENERATOR SET, DIESEL ENGINE 7.5 KW

PU-835/T (60 HZ)

NSN 6115-01-611-8093 (EIC N/A)

DISTRIBUTION STATEMENT C - Distribution authorized to U.S. Government agencies and their contractors for administrative or operational use as determined on 8 August 2012. Other requests for this document shall be referred to Commander, U.S. Army Communications-Electronics Command, 6001 Combat Drive, ATTN: AMSEL-LCL-ECM, Aberdeen Proving Ground, MD 21005-1846.

WARNING - This document contains technical data whose export is restricted by the Arms Export Control Act (Title 22, U.S.C., Sec 2751, et seq.) or the Export Administration Act of 1979 (Title 50, U.S.C., App. 2401 et seq.), as amended.

Violations of these export laws are subject to severe criminal penalties. Disseminate in accordance with provisions of DOD Directive 5230.25.

DESTRUCTION NOTICE - Destroy by any method that will prevent disclosure of contents or reconstruction of the document.

HEADQUARTERS, DEPARTMENT OF THE ARMY

15 JULY 2013

WARNING SUMMARY

a

FIRST AID

For First Aid information, refer to Field Manual (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, 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. Immediately start artificial respiration if necessary.

WARNING SUMMARY - Continued b

The Warning Summary summarizes critical safety and hazardous material warnings that must be understood and applied during operation and maintenance of the Generator Set, Diesel Engine 7.5 kW, PU-835/T (60 Hz).

These warnings are important.

Study and understand all warnings.

These warnings can save your life and the lives of personnel with whom you work.

Some general warnings found in the Warning Summary will not be repeated within the Technical Manual

(TM).

Specific warnings will be listed above the task or paragraph to which they apply.

Operation and maintenance of the Generator Set, Diesel Engine 7.5 kW, PU-835/T (60 Hz) contains many possibilities for injury or death to personnel. Be sure to be familiar with general first aid procedures as references in FM 4-25.11, First Aid.

WARNING ICONS

The following icons are used in conjunction with warnings so that you do not miss important information. They are not meant to be a substitute for reading the warnings, but they provide graphic description of the danger.

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

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

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

HIGH PRESSURE - Human hand being penetrated by high pressure shows system pressures present a danger to life or limb.

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

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

c

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

SHARP OBJECT - Human hand being punctured shows equipment presents a danger to life or limb.

WARNING DESCRIPTIONS

WARNING

Electrical

High voltage is produced when this generator set is in operation. Verify Control switch is in the OFF position and negative battery cable is disconnected, and unit is completely shut down and free of any power source before attempting any troubleshooting or maintenance on unit. Failure to comply may cause injury or death to personnel.

Metal jewelry can conduct electricity. Remove metal jewelry when working on the electrical system or components. Failure to comply can cause injury or death to personnel by electrocution.

High voltage is produced when the generator set is in operation. 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. Failure to comply may cause injury or death to personnel.

DC voltages are present at the generator set electrical components even after the generator set is shut down.

Avoid shorting any positive with ground/negative. Do not ground yourself in standing water. Failure to comply may cause injury or death to personnel and damage to equipment.

High voltage is produced when the generator set is in operation. Never attempt to connect or disconnect load cables while the generator set is running. Failure to comply can cause injury or death to personnel.

Short circuits in electrical appliances and tools can cause fire and electrical shock leading to severe personal injury or death. Read and follow the appliance manufacturer’s instructions and warnings regarding use, maintenance and proper grounding.

d

Heat

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

Cold

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

Jewelry/Clothing

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.

Operating

Starting the engine when the unit is partially disassembled is dangerous. Run the engine in this condition only as long as required to test operation. Keep away from unprotected moving engine parts during operation. Failure to comply may cause injury or death to personnel.

e

Sharp Object

The heat shield may contain sharp edges. Handle with care. Failure to comply may cause injury or death to personnel.

The cooling fan has sharp blades. Use caution and wear gloves when removing or installing the fan. Failure to comply may cause injury or death to personnel.

HAZARDOUS MATERIALS ICONS

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

EXPLOSION—Rapidly expanding symbol shows that the material may explode if subjected to high temperatures, source 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.

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

f

HAZARDOUS MATERIALS WARNING DESCRIPTIONS

There is a potential risk that soldiers and other users may be exposed to chemical substances and diesel engine exhaust during the operation, maintenance, and repair of the Generator Set, Diesel Engine 7.5 kW, PU-835/T (60 Hz).

Potential sources of chemical substances include fuels, oils, lubricants, paints, cleaners/solvents, engine coolant fluids, cold start fluid, fire extinguishing agents, battery acid/chemicals, and miscellaneous chemicals used during the setup/operation/maintenance and sustainment throughout the life-cycle of the Generator Set, Diesel Engine

7.5 kW, PU-835/T (60 Hz).

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. Failure to comply with all procedures, recommendations, warnings, and cautions for safe use, handling, storage, and disposal of these materials may result in serious injury or death to personnel.

Exhaust

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.

Exhaust discharge contains deadly gases, including carbon monoxide. Exhaust gases are most dangerous in places with poor ventilation. 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.

Exhaust gases are most dangerous in places with poor ventilation. The best defense against exhaust gas poisoning is very good ventilation. To protect yourself and others, always obey the following rules:

Do not run the engine indoors unless you have very good ventilation.

Do not idle the engine for a long time unless there is very good ventilation.

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

g

Failure to comply may cause injury or death to personnel.

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 generator. Make sure they have lots of fresh air. Keep them warm, calm, and inactive. Get medical help. If anyone stops breathing, give artificial respiration. Failure to comply may cause injury or death to personnel.

Eye

Flying debris or material may enter the eyes or strike the face. Wear appropriate eye/face protection while performing maintenance tasks. Failure to comply may cause injury or death to personnel.

Eye protection is required when working with compressed air. Do not use compressed air to clean skin. Do not aim at personnel. Compressed air can propel particles at high velocity and injure eyes. Failure to comply may cause injury or death to personnel.

Compressed air is dangerous and could cause serious bodily harm, if protective means or methods are not observed to prevent a chip or particle (of whatever size) from being blown into the eyes or to prevent unbroken skin of the operator or other personnel. Compressed air shall not be used for cleaning purposes except where reduced to less than 30 pounds per square inch gauge (psig). Use it only with effective chip-guarding and personnel protective equipment such as safety glasses or full face shield. Do not apply compressed air to your skin or direct an air at personnel. Never use compressed air to clean dirt from your clothes. Failure to observe this warning could result in severe personal injury or damage to the equipment.

Fuel

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

Fuel is combustible and toxic to the 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 skin and change clothing promptly if in contact with fuel. Failure to comply may cause injury or death to personnel.

h

Fuels used in the generator set are combustible. When filling the fuel tank, maintain metal-to-metal contact between filler nozzle and fuel tank opening to the ESD. Fire and possible explosion may occur. Failure to comply may cause injury or death to personnel.

Do not operate the generator set if any fuel leaks are present. Fuel is combustible. Always perform PMCS before operation. Failure to comply may cause injury or death to personnel.

High Temperature/Pressure

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

Engine coolant is toxic to eyes and poisonous if ingested. Eye protection is required when working with engine coolant. Avoid repeated or prolonged contact. Failure to comply may cause injury or death to personnel.

Hot coolant can burn. If the radiator cap is hot to the touch, it is too hot to open. Allow the coolant to cool before opening the radiator cap. 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

Noise

Hearing protection is required during maintenance or repair with the engine running. Failure to comply can cause hearing loss.

LIST OF EFFECTIVE PAGES / WORK PACKAGES

NOTE: Zero in the "Change No." column indicates an original page or work package.

Original 15 July 2013 Date of issue for the original manual is:

TOTAL NUMBER OF PAGES FOR FRONT AND REAR MATTER IS 32 AND TOTAL

NUMBER OF WORK PACKAGES IS 21, CONSISTING OF THE FOLLOWING:

Page / WP No. Change No.

Page / WP No. Change No.

Front Cover 0 Blank 0 Warning Summary (8 pgs) 0 Blank 0 i - vi 0 Chp 1 Title Page 0 Index 0 WP 0001 (4 pgs) 0 WP 0002 (6 pgs) 0 WP 0003 (4 pgs) 0 Chp 2 Title Page 0 Index 0 WP 0004 (2 pgs) 0 WP 0005 (8 pgs) 0 WP 0006 (4 pgs) 0 WP 0007 (2 pgs) 0 Chp 3 Title Page 0 Index 0 WP 0008 (4 pgs) 0 WP 0009 (12 pgs) 0 Chp 4 Title Page 0 Index 0 WP 0010 (2 pgs) 0 WP 0011 (6 pgs) 0 WP 0012 (2 pgs) 0 WP 0013 (2 pgs) 0 WP 0014 (4 pgs) 0 WP 0015 (2 pgs) 0 WP 0016 (2 pgs) 0 WP 0017 (4 pgs) 0 WP 0018 (4 pgs) 0 Chp 5 Title Page 0 Index 0 WP 0019 (2 pgs) 0 WP 0020 (2 pgs) 0 WP 0021 (2 pgs) 0

INDEX-1 - INDEX-2 0

Inside back cover 0

Back cover 0

A/B blank

HEADQUARTERS

DEPARTMENT OF THE ARMY

WASHINGTON, D.C. 15 JULY 2013

TECHNICAL MANUAL

OPERATOR'S MANUAL

GENERATOR SET, DIESEL ENGINE 7.5 KW

PU-835/T (60 HZ)

NSN 6115-01-611-8093 (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:

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 Communications-Electronics Command, 6001 Combat Drive, ATTN: AMSEL-LCL-ECM, Aberdeen Proving Ground, MD 21005-1846. You may also send in your recommended changes via electronic mail or by fax. Our fax number is 443-861-5521, DSN 848-5521. Our e-mail address is: usarmy.APG.cecom.mbx.amsel-lc-leo-pubs-chg@mail.mil. Our online web address for entering and submitting DA Form 2028s is: http://edm.apg.army.mil/pubs/2028.html.

A reply will be furnished to you.

DISTRIBUTION STATEMENT C - Distribution authorized to U.S. Government agencies and their contractors for administrative or operational use as determined on 8 August 2012. Other requests for this document shall be referred to Commander, U.S. Army Communications-Electronics Command, 6001 Combat Drive, ATTN: AMSEL- LCL-ECM, Aberdeen Proving Ground, MD 21005-1846.

WARNING - This document contains technical data whose export is restricted by the Arms Export Control Act (Title 22, U.S.C., Sec 2751, et seq.) or the Export Administration Act of 1979 (Title 50, U.S.C., App. 2401 et seq.), as amended. Violations of these export laws are subject to severe criminal penalties. Disseminate in accordance with provisions of DOD Directive 5230.25.

DESTRUCTION NOTICE - Destroy by any method that will prevent disclosure of contents or reconstruction of the document.

i/ii blank

Table of Contents iii

Page No.

WP Sequence No.

How to Use This Manual ......................................................................................................................................... v

Chapter 1 - General Information, Equipment Description and Theory of Operation General Information............................................................................................................................... WP 0001 Equipment Description and Data...........................................................................................................WP 0002

Figure 1. Generator Set, PU-835/T............................................................................................. WP 0002-1 Figure 2. Air Filter and Access Door........................................................................................... WP 0002-2 Figure 3. Generator Set with Housing Removed.........................................................................WP 0002-4 Table 1. Equipment Data.............................................................................................................WP 0002-4

Theory of Operation.............................................................................................................................. WP 0003 Figure 1. Generator Set Operation..............................................................................................WP 0003-1

Chapter 2 - Operator Instructions Description and Use of Operator Controls and Indicators.................................................................... WP 0004

Figure 1. Operator's Console.......................................................................................................WP 0004-1 Table 1. Operator's Console........................................................................................................WP 0004-1

Operation Under Usual Conditions........................................................................................................WP 0005 Figure 1. Ground Connection...................................................................................................... WP 0005-2 Table 1. Typical Appliance Loads............................................................................................... WP 0005-3 Table 2. Power vs. Altitude..........................................................................................................WP 0005-3 Figure 2. Operator Console......................................................................................................... WP 0005-5

Operation Under Unusual Conditions....................................................................................................WP 0006 Figure 1. Ambient Temperature...................................................................................................WP 0006-1

Emergency.............................................................................................................................................WP 0007 Figure 1. Operator Console......................................................................................................... WP 0007-1

Chapter 3 - Operator Troubleshooting Procedures Crew Troubleshooting Introduction........................................................................................................WP 0008

Table 1. Fault Codes................................................................................................................... WP 0008-2 Table 2. Symptom / Malfunction Index........................................................................................ WP 0008-3

Crew Troubleshooting Procedures........................................................................................................ WP 0009

Chapter 4 - Operator Maintenance Instructions Crew PMCS Introduction.......................................................................................................................WP 0010 Crew PMCS...........................................................................................................................................WP 0011

Table 1. Crew Preventive Maintenance Checks and Services....................................................WP 0011-3 Door Assembly - Remove, Inspect, Install............................................................................................ WP 0012

Figure 1. Engine Compartment Access Door..............................................................................WP 0012-1 Engine System - Inspect....................................................................................................................... WP 0013

Figure 1. Generator oil fill and Dipstick....................................................................................... WP 0013-2 Cooling System - Inspect, Service........................................................................................................ WP 0014

Figure 1. Cooling System............................................................................................................ WP 0014-1 Figure 2. Coolant Fill................................................................................................................... WP 0014-2 Table 1. Coolant Mixtures............................................................................................................WP 0014-3

Fuel System - Inspect........................................................................................................................... WP 0015

Table of Contents - Continued iv

Page No.

WP Sequence No.

Figure 1. Fuel System................................................................................................................. WP 0015-2

Air Cleaner Assembly - Inspect, Service...............................................................................................WP 0016 Figure 1. Air Cleaner Assembly...................................................................................................WP 0016-1

Air Filter Assembly - Inspect, Service................................................................................................... WP 0017 Figure 1. Air Filter Assembly....................................................................................................... WP 0017-1 Figure 2. Air Filter Element..........................................................................................................WP 0017-2

Lubrication Instructions..........................................................................................................................WP 0018 Figure 1. Generator oil fill and Dipstick....................................................................................... WP 0018-2

Chapter 5 - Supporting Information References.............................................................................................................................................WP 0019 Components of End Item (COEI) and Basic Issue Items (BII) Lists......................................................WP 0020

Table 1. Components of End Item List........................................................................................WP 0020-2 Table 2. Basic Issue Items List................................................................................................... WP 0020-2

Expendable and Durable Items List...................................................................................................... WP 0021 Table 1. Expendable and Durable Items.....................................................................................WP 0021-1

Index

How to Use This Manual v

HOW TO USE THIS MANUAL

This Operator Technical Manual includes operator maintenance, supporting information, and instructions for the Generator Set, Diesel Engine 7.5 kW, PU-835/T (60 Hz). It is important to become familiar with this manual and with the overall functions of the Generator Set before attempting any maintenance tasks.

This Operator Technical Manual is part of a family of manuals that includes a Field Maintenance Manual with Repair Parts and Special Tools List (RPSTL) (TM 9-6115-769-23&P), a Lubrication Order (9-6115-769-13) and a National Maintenance Work Requirement (NMWR) maintenance manual (NMWR 9-6115-769).

Front Matter

This section provides a Warning Summary, a List of Effective Pages and Work Packages, a Table of Contents, and this "How to Use This Manual" section.

Chapter 1. General Information, Equipment Description and Theory of Operation

General Information (WP 0001) provides general information about this manual and the related forms and records. Instructions are provided for making equipment improvement and recommendation materiel to prevent enemy use. A nomenclature cross-reference list is provided as well as a list of abbreviations and acronyms.

Equipment Description and Data (WP 0002) describes the characteristics, capabilities, and features of the Generator Set, Diesel Engine 7.5 kW, PU-835/T (60 Hz) and provides information on location and description of major components.

Theory of Operation (WP 0003) provides an overview of the operation of the generator set.

Chapter 2. Operator Instruction

Description and Use of Operator Controls and Indicators (WP 0004) provide a description of the controls and indicators used to operate the generator set.

Operation Under Usual Conditions (WP 0005) provides instruction on how to Assemble and prepare the Generator Set, Diesel Engine 7.5 kW, PU-835/T (60 Hz) for operation. This WP also provided Operating Procedures and Preparation for movement.

Operation Under Unusual Conditions (WP 0006) provides instruction on how to operate or sustain the generator set during Unusual Environment/Weather.

Emergency (WP 0007) provides instruction on how to shut down the Generator Set, Diesel Engine 7.5 kW, PU-835/T (60 Hz) in case of an Emergency.

Chapter 3. Operator Troubleshooting Procedures

The Generator Set, Diesel Engine 7.5 kW, PU-835/T (60 Hz) generator set provides some electronic troubleshooting through the control panel display. If a malfunction occurs or is about to occur to a component monitored by the control, a fault or warning code is displayed on the display panel on the control box. This fault and warning information, along with manual troubleshooting guidelines, provide a comprehensive level of information to identify problems that may occur with the generator set and minimize downtime for repair.

Operator Troubleshooting Introduction (WP 0008) provides the operator with a Malfunction/ Symptom Index that list fault codes and possible faults that may occur during operation of the generator set.

Operator Troubleshooting Procedures (WP 0009) provides the operator with corrective action used to troubleshoot the possible Symptoms and Malfunction that may occur during operation of the generator set.

How to Use This Manual - Continued vi

Chapter 4. Operator Maintenance Instructions

Every generator set requires some periodic scheduled maintenance. The theory of the scheduled maintenance or Preventative Maintenance Check and Services (PMCS) is outlined in Operator PMCS Introduction (WP 0010). A detailed table to guide through the scheduled maintenance tasks is provided in Operator PMCS (WP 0011). This chapter also contains detailed instructions for inspection and service of the Engine System, Cooling System, Fuel System, Air Cleaner Assembly and Air Filter Assembly.

Chapter 5. Supporting Information

References (WP 0019) provides information about all related reference material used to sustain the Generator Set, Diesel Engine 7.5 kW, PU-835/T (60 Hz). This chapter also provides a Components of End Item (COEI) and Basic Issue Items (BII) List, Additional Authorized List (AAL), and Expendable and Durable Items List.

Rear Matter

The Department of the Army (DA) Form 2028, Recommended Changes to Publications and Blank Forms, is the document to be submitted to correct errors found in the manual or to make recommended changes that will improve the manual.

FEATURES OF THIS MANUAL

• A table of contents is provided for all work packages included in the eight chapters of this manual.

• Warnings, cautions, notes, subject headings, and other important information are highlighted in bold print.

• Statements and words of particular importance are printed in capital letters and bolded to create emphasis.

• Instructions are located together with figures to illustrate the specific maintenance tasks.

FOLLOW THESE GUIDELINES TO USE THIS MANUAL

• Read through this manual and become familiar with its contents before proceeding to specific maintenance tasks.

• A warning summary is provided at the beginning of this manual and should be read before performing any maintenance tasks.

CHAPTER 1

GENERAL INFORMATION, EQUIPMENT

DESCRIPTION AND THEORY OF OPERATION

GENERATOR SET, DIESEL

ENGINE 7.5 KW PU-835/T (60 HZ)

CHAPTER 1

GENERAL INFORMATION, EQUIPMENT DESCRIPTION AND THEORY OF OPERATION

WORK PACKAGE INDEX

Title WP Sequence No.

GENERAL INFORMATION.......................................................................................................................... WP 0001 EQUIPMENT DESCRIPTION AND DATA.................................................................................................. WP 0002 THEORY OF OPERATION......................................................................................................................... WP 0003

TM 9-6115-769-10 0001

0001-1

OPERATOR MAINTENANCE

GENERAL INFORMATION

SCOPE

This Operator Maintenance Manual provides operator instruction for the safe operation of the Generator Set, Diesel Engine 7.5 kW, PU-835/T (60 Hz). This manual also provides maintenance and troubleshooting procedures to be used by the operator. This generator is designed to provide years of trouble free service if operated, and maintained in accordance with this manual.

Model Number and Equipment Names: Generator Set, Diesel Engine 7.5 kW, PU-835/T (60 Hz).

MAINTENANCE FORMS, RECORDS, AND REPORTS

Department of the Army forms and procedures used for equipment maintenance will be those prescribed by (as applicable) DA PAM 750-8, The Army Maintenance Management System (TAMMS) Users Manual; DA PAM 738-751, Functional Users Manual for the Army Maintenance Management Systems - Aviation (TAMMS-A); or AR 700-138, Army Logistics Readiness and Sustainability.

REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR)

If your equipment needs improvement, let us know. Send us an EIR. You, the user, are the only one who can tell us what you don't like about your equipment. Let us know why you don't like the design or performance. If you have Internet access, the easiest and fastest way to report problems or suggestions is to follow the instructions and links below:

If you have a user's account you can submit the PQDR for ALL CECOM (B16) Warranty, EIR and PQDRs (including those B16 Aviation related) through the Navy's Web Product Quality Deficiency Reporting (PQDR) site, https://www.pdrep.csd.disa.mil/pdrep_files/report_tools/pqdr.htm. If you do not, either go to EZ PDR, https:// pdrep.csd.disa.mil/pdrep/ezdr.doc, and input your PQDR there or establish a new account. New accounts can be established at https://www.pdrep.csd.disa.mil/pdrep_files/accessforms/useraccess.htm and selecting the "User Access Request" link on the left side of the Web page.

CECOM (B16) aviation PQDRs will not go to AMCOMs Joint Deficiency Reporting System (JDRS). If AMCOM should get a CECOM aviation PQDR, they will re-direct it to the CECOM PQDR Team. Use the PQDR for Warranties, EIRs, and PQDRs. There is a block on the PQDR that you can click if it is a Warranty. The originator can still put in the description that they want this investigated as an EIR and then enter what the issue is.

You may also submit your SF 368 (Product Quality Deficiency Report) via email (usarmy.apg.cecom.mbx.lrc-leo-b16-pqdr-support-team@mail.mil), facsimile (443-861-6356) or regular mail (call 443-861-6310 or 443-861-6311 or 443-861-6312 for the current mailing address).

We will send you a reply.

CORROSION PREVENTION AND CONTROL (CPC)

Corrosion Prevention and Control (CPC) of Army materiel is a continuing concern. It is important that any corrosion problems with this item be reported so that the problem can be corrected and improvements can be made to prevent the problem in future items.

Corrosion specifically occurs with metals. It is an electrochemical process that causes the degradation of metals. It is commonly caused by exposure to moisture, acids, bases, or salts. An example is the rusting of iron.

Corrosion damage in metals can be seen, depending on the metal, as tarnishing, pitting, fogging, surface residue, and/or cracking.

Plastics, composites, and rubbers can also degrade. Degradation is caused by thermal (heat), oxidation (oxygen), solvation (solvents), or photolytic (light, typically UV) processes. The most common exposures are excessive heat or light. Damage from these processes will appear as cracking, softening, swelling, and/or breaking.

CORROSION PREVENTION AND CONTROL (CPC) - Cont

0001-2

SF Form 368, Product Quality Deficiency Report should be submitted to the address specified in DA PAM 750-8, The Army Maintenance Management System (TAMMS) Users Manual.

OZONE DEPLETING SUBSTANCES (ODS)

The use of Class 1 Ozone-Depleting Substances (ODS) for new acquisitions has been curtailed by Section 326 of the National Defense Authorization Act of Fiscal Year 1993 (Public Law 102, 484) and related Army policy.

DESTRUCTION OF ARMY MATERIEL TO PREVENT ENEMY USE

Destruction of Army electronics materiel to prevent enemy use shall be in accordance with TM 750-244-2.

PREPARATION FOR STORAGE OR SHIPMENT

Administrative storage of equipment issued to and used by Army activities will have Preventive Maintenance Checks and Services (PMCS) performed before storing. When removing the equipment from administrative storage, the PMCS checks should be performed to assure operational readiness.

LIST OF ABBREVIATIONS / ACRONYMS

ABBREVIATION /ACRONYM DEFINITION

AC Alternating Current

AMC Army Materiel Command

AMCOM Aviation And Missile Command amp Ampere

APG Aberdeen Proving Ground

AR Army Regulation

ASB Aviation Support Battalion

C Celsius

CAGEC Commercial And Government Entity Code cc Cubic Centimeter

CCA Cold Cranking Amps

CECOM Communications And Electronics Command

CPC Corrosion Prevention Control

CTA Common Table Of Allowances

DA FORM Department Of The Army Form

DA PAM Department Of The Army Pamphlet

DC Direct Current

DD FORM Department Of Defense Form

DF Diesel Fuel

DoD Department Of Defense

LIST OF ABBREVIATIONS / ACRONYMS - Cont

0001-3

ABBREVIATION /ACRONYM DEFINITION

DR Drum

EA Each

EIC End Item Code

EIR Equipment Improvement Recommendation

F Fahrenheit

FM Field Manual ft Feet

GL or gal Gallon gph Gallon Per Hour

Hz Hertz

IDN Initial Distribution Number

in. Inches

JDRS Joint Deficiency Reporting System

JP Jet Propulsion kg Kilogram(S)

KW Kilo Watt l Liter lb Pound

LO Lubrication Order

LRU Line-Replaceable Unit

MIL-PRF Military Performance Specification mm Millimeter

MSDS Material Safety Data Sheets

MTOE Modified Table Of Organization And Equipment

NMWR National Maintenance Work Requirements

NSN National Stock Number

OAASA Office Of The Administrative Assistant To The Secretary Of The Army

ODS Ozone Depleting Substances

OSHA Occupational Safety And Health Act

PAM Pamphlet

PDR Product Data Reporting

PMA Permanent Magnet Alternator

PMCS Preventive Maintenance Checks And Services

LIST OF ABBREVIATIONS / ACRONYMS - Cont

0001-4

ABBREVIATION /ACRONYM DEFINITION

PQDR Product Quality Deficiency Report psig Pounds Per Square Inch Gauge

QT or qt Quart

QTY Quantity

RPM Revolutions Per Minute

RPSTL Repair Parts And Special Tools List

SCISM Supply Catalogs/Supply Manuals

SF Special Form

TAMMS The Army Maintenance Management System

TASMG Theater Aviation Sustainment Maintenance Group

TM Technical Manual

TOE Table Of Organization And Equipment

UV Ultra-Violet

VAC Volt Alternating Current

W Watts

WP Work Package

END OF WORK PACKAGE

TM 9-6115-769-10 0002

0002-1

EQUIPMENT DESCRIPTION AND DATA

EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES

The Generator Set, Diesel Engine 7.5 kW, PU-835/T (60 Hz) is a fully enclosed, self-contained, portable unit.

This generator set consists of seven major assemblies/systems: engine assembly, generator assembly, electrical system, cooling system, fuel system, housing and frame assembly, and intake and exhaust systems.

This AC generator set is built for continuous running at sites when main power is not available or as stand-by in cases of interruption of the mains power provider. This generator set operates at 60 Hz, 120 VAC. It is equipped with the controls, instruments, and accessories necessary for operation as a single unit. This generator set is driven by a 3-cylinder, liquid-cooled, indirect injection, 4-cycle diesel engine.

LOCATION AND DESCRIPTION OF MAJOR COMPONENTS

Figure 1. Generator Set, PU-835/T.

Housing Group

A steel housing consisting of five individual body panels encloses the Generator Set, PU-835/T and protects it from the environment. The housing (Figure 1, Item 2) provides acoustical protection, entry access to generator set assemblies, control of air flow over internal surfaces, and mounting for generator set components. The steel housing is durable enough so that no damage should occur within normal usage.

The housing consists of a door assembly (Figure 2, Item 3) that allows for easy interior access to the engine compartment for routine operations, scheduled service, and preventive maintenance.

Air Cleaner Assembly

The air cleaner assembly (Figure 1, Item 6) is mounted on a bracket on the bottom of the engine compartment and is accessible through the bottom access panel. The filter element is cleanable and replaceable. See WP 0016.

AIR INTAKE SYSTEM - Cont

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Air Filter Assembly

If used, the air filter assembly (Figure 2, Item 2) is mounted on top of the generator set. The air filter assembly (Figure 2, Item 2) contains an integrated, centrifugal pre-cleaner that removes most dust particles prior to entering the air cleaner element. These larger contaminants are easily ejected from the air cleaner assembly through a squeeze-type, exhaust boot-type fitting. This extends filter life and reduces maintenance costs and downtime. The air filter assembly (Figure 2, Item 2) is fitted with an indicator (Figure 2, Item 1) to show when the filter capacity is exceeded. The filter element is cleanable and replaceable (WP 0017).

Intake Air Resonator

The intake air resonator (Figure 3, Item 7) is mounted on the engine and assists with providing air to the engine at the engine intake manifold.

Figure 2. Air Filter and Access Door.

Air Exhaust System

The exhaust system is mounted inside the generator housing and is accessible through the air outlet opening under the generator (Figure 1, Item 5). It includes a spark arrestor muffler (Figure 3, Item 4) with a cleanout plug for maximum generator engine performance.

Radiator

An aluminum radiator (Figure 3, Item 3) acts as a heat exchanger for the coolant. The 4.2 quart radiator is located at the rear of the generator under the top cover. The radiator (Figure 3, Item 3) is filled at the coolant recovery tank (Figure 3, Item 1).

Coolant Recovery Tank

The coolant recovery tank (Figure 3, Item 1) is accessible from the operator console (Figure 2, Item 5). The coolant recovery tank (Figure 3, Item 1) is clearly visible for the inspection of the coolant level.

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Blower

A centrifugal blower (Figure 3, Item 8) is mounted to the end of the generator rotor to move air for cooling the generator set and radiator. The blower pulls air from an opening in the bottom of the generator set frame to pressurize the engine compartment. Air flows through the radiator from the top side into the muffler compartment and then out the bottom. Air circulates through the radiator, reducing coolant temperature. The generator blower is visible through the access compartment located on the bottom of the unit behind the air intake grill (Figure 1, Item 7).

V-Belt

The V-belt (Figure 3, Item 5) is mounted to the coolant pump pulley and is driven by the crankshaft pulley to circulate coolant throughout the engine.

Fuel System

The Generator Set, PU-835/T is designed to utilize diesel fuel or an acceptable substitute (Grade Number (No) 1-d and Grade No 2-d fuels per A-A-52557), and includes design adaptations to accommodate the usage of Jet Propulsion (JP)-8. The Generator Set, PU-835/T requires fuel from an external source for operations. The fuel fill quick connections (Figure 1, Item 3) are located on the right side of the generator set and allows refueling during operation.

Electrical System

The Generator Set, PU-835/T requires 120 VAC from an external source for operations. The positive and negative battery connections (Figure 1, Item 4) are located on the right side of the generator set.

Operator Console Panel

The operator console (Figure 2, Item 5) is located on the left front of the generator. The operator console (Figure 2, Item 5) contains a control switch and a status light that allows the operator and maintainer to operate, monitor and diagnose the generator set.

Controller-Inverter

The controller-inverter (Figure 3, Item 9) is an integrated microprocessor-based engine and generator control. It provides all of the control, monitoring, and diagnostics functioning required to operate the generator set.

Engine Assembly - Engine

The Generator Set, PU-835/T uses a Kubota D772-B Engine (Figure 3, Item 6). The vertical, liquid-cooled, four-cycle indirect injection, three-cylinder, diesel engine (Figure 3, Item 6) consists of the cylinder head and valve cover, crankcase assembly, pistons, main bearing case, and lubrication system. It is mounted to the frame assembly toward the front panel of the generator set.

Generator Assembly - Alternator

The Generator Set, PU-835/T uses a brushless, bearingless, permanent magnet alternator (PMA). The alternator (Figure 3, Item 2) is located in the engine compartment and is directly attached to the engine.

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Figure 3. Generator Set with Housing Removed.

Framing Group

The housing (Figure 1, Item 2) sits on a steel frame assembly (Figure 1, Item 1). The engine and AC generator are directly mounted to the frame assembly. Data plates (Figure 2, Item 4) are located on the mounting base directly below the door assembly.

EQUIPMENT DATA

Table 1. Equipment Data.

SPECIFICATIONS

GENERATOR SET CONTROLLER: Integrated Microprocessor Based Engine and Generator Controller

GENERATOR: Brushless, Exciterless, Bearingless, Permanent Magnet Alternator

AC OUTPUT RATINGS

Power (@1.0 power factor) 7500W

Voltage 120V

Frequency 60 Hz

Number of Phases 1

Current 62.5 ampere

Line Circuit Breaker(s) 2-pole, 30 or 35 amp

ENGINE: 3-Cylinder In-Line, Water-Cooled, Indirect-Injection, 4-Stroke Cycle Diesel

Bore 2.64 in. (67 mm)

Stroke 2.68 in. (68 mm)

Displacement 44 in. (719 cc)

EQUIPMENT DATA - Cont Table 1. Equipment Data. - Continued

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SPECIFICATIONS

Compression Ratio 23: 1

Oil Capacity (with filter)* 3 quart (2.8 L)

Cooling System Capacity** 4.2 quart (3.9 L)

Intake and Exhaust Valve Lash (Cold) 0.0065 in. (0.165 mm)

OPERATING SPEED RANGE 1600 to 3200 RPM

FUEL CONSUMPTION:

No-load .13 gph (.49 L/H)

Half-load (4000 W) .49 gph (1.85 L/H)

Full-load .96 gph (3.63 L/H)

DC SYSTEM:

Nominal Battery Voltage 12V

Minimum Battery Capacity 450 CCA*** down to 0 °F (-17 °C)

650 CCA*** down to -20 °F (-29 °C)

Maximum Regulated-Voltage Battery Charging Current (Optional)

10 ampere

Fuse F1 (control circuit) 10 ampere mini-bayonet

Fuse F2 (starter solenoid circuit) 10 ampere mini-bayonet

Fuse F3 (glow plug circuit) 25 ampere

WEIGHT AND SIZE

Weight (wet)

Length X Width X Height

420 lb (191 kg)

36.3 x 23.6 x 22.3 in. (922 x 599 x 566 mm)

* See oil filling instructions.

** Includes coolant recovery tank.

*** Cold Cranking Amps@ 0° F (-17° C).

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THEORY OF OPERATION

PRINCIPLE OF OPERATION

Scope

The Generator Set, Diesel Engine 7.5 kW, PU-835/T (60 Hz) was specifically designed for the best possible performance, focusing on areas such as reliability, maintainability, weight, dimensions, and fuel consumption. The Generator Set, PU-835/T is designed for deployment in the battlefield to provide continuous power generation necessary for today's fielded electronic devices and various electrical equipment demands. The generator set is developed to be fixed or mobile mounted giving the flexibility of movement. The generator set is designed to accommodate the paralleling of generator sets as well additional and back-up power generation.

Operation

The Generator Set, PU - 835/T is powered by a Kubota vertical, liquid-cooled, four-cycle indirect injection, three-cylinder, diesel engine that is mounted to the frame assembly toward the front panel of the generator set. The fuel and electrical system is supplied through an external source. Air intake is received through the air filter, cleaner, and intake resonator to improve generator performance. During operation, the engine produces mechanical energy and interconnects with the AC generator permanent magnet alternator (PMA) via a rotating shaft. The AC generator receives mechanical energy from the engine and converts it to electrical energy. The electricity produced by the PMA is transmitted to the controller-inverter. The controller-inverter is an integrated microprocessor-based engine and generator control. It provides all the control, monitoring and diagnostics functions that are required to operate the generator set and transfers the information to the operators console for operator interface. The inverter converts 3-phase AC output of the PMA into 1-phase AC output at the voltage and frequency the generator is configured for. The controller maintains normal AC voltage output during steady state operation.

Figure 1. Generator Set Operation.

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Housing System

The housing system provides protection from the elements, structural integrity, transportability, noise suppression, and the cooling system for the generator set. The generator set cooling system is described separately below.

The generator set housing is insulated to provide "tactical quiet" noise suppression which makes detection of the generator set by its audio signature more difficult under battle conditions. Air baffles allow for airflow to cool the generator set with as little impact as possible to the generator set's noise output.

Air Intake and Exhaust Systems

The engine air intake and exhaust systems consists of an air filter assembly, air cleaner assembly, intake air resonator intake manifold, exhaust manifold, and muffler. The air filter assembly includes a dust collector, filter element, and restriction indicator. Air is drawn into the air filter assembly and passes through the filter element.

Airborne dirt is removed and trapped in the dust collector and filter element. Some dust can be removed from the dust collector by pinching the rubber boot. The restriction indicator indicates when the filter should be serviced.

Filtered air is drawn out of the filter through air intake tubes forced into the engine.

Engine exhaust gases are expelled into the exhaust manifold and are channeled into the muffler that deadens the sound of the exhaust gases. Gases pass from the muffler through the muffler outlet and are vented upward through the exhaust pipes in the front roof assembly.

Combustion gases, which enter the crankcase, are filtered through the crankcase breather filter to remove oil droplets and are then recycled through the intake manifold.

Cooling System

The engine cooling system consists of a radiator, centrifugal blower, hoses, thermostat, water pump, oil cooler, cooling fan, and cooling jackets (part of the engine).

The water pump forces coolant through passages (cooling jackets) in the engine block and cylinder head where the coolant absorbs heat from the engine. When the engine reaches normal operating temperature, the thermostat opens and the heated coolant flows through the upper radiator hose assembly into the radiator. The cooling fan circulates air through the radiator where the coolant temperature is reduced.

The operator console, in conjunction with the fault system, provides automatic shutdown in the event that the coolant temperature gets too high.

Fuel System

The Generator Set, PU-835/T requires fuel from an external source for operations.

The fuel system consists of fuel lines, fittings, fuel filter, fuel pump, injection pump, governor spring, and injectors.

The injection pump output is controlled by the speed control plate. With the engine cranking or running, fuel is drawn from the external fuel source by the fuel pump. After reaching the fuel pump, fuel then passes through a fuel filter where water and small impurities are removed. The fuel is then routed to the injection pump. With the governor system engaged, the fuel is metered, pressurized and pushed through the injection pipes to the injection nozzles by the injection pump. Fuel is sprayed by the injectors into the diesel engine combustion chambers where it is mixed with air and ignited. Fuel that is not used by the injectors is returned to the fuel tank by an excess fuel return line. The fuel supply is shut off whenever the control switch is set to the 'OFF' position.

Electrical System

The Generator Set, PU-835/T requires 120 VAC from an external source for operations.

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The electrical system consists of an operator console, controller inverter, engine harness, battery harness, and AC harness. The battery power that is supplied from an external source to the starter during the start cycle energizes the starter, which engages the rotor, causing the engine to turn over. When the engine start is complete, the starter is de-energized and disengages from the rotor.

Engine Lubrication System

The engine lubrication system consists of an oil pan, dipstick, pump, oil pressure sender, and filter. The oil pan is a reservoir for engine lubricating oil. The dipstick indicates the oil level in the pan. The pump draws oil from the oil pan through a screen and oil filter that removes large impurities. From the filter, oil is distributed to the engine and then returns to the oil pan.