TM-9-6115-666-13-P AN/MJQ-1612 60kW 50/60 Hz Power Plant Diesel Engine Driven 5 Ton Trailer Mounted Manual

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TM-9-6115-666-13-P

TECHNICAL MANUAL
5 Safety Steps to Follow if Someone is the Victim of Electrical Shock
WARNING
WARNING (cont)
WARNING (cont)
WARNING (cont)
TABLE OF CONTENTS
TABLE OF CONTENTS-continued
TABLE OF CONTENTS-continued
TABLE OF CONTENTS-continued
LIST OF ILLUSTRATIONS
LIST OF TABLES
HOW TO USE THIS MANUAL
CHAPTER 1 INTRODUCTION
Section II. TROUBLESHOOTING
APPENDICES
Section II. REPAIR PARTS LIST
APPENDIX H. ILLUSTRATED LIST OF MANUFACTURED ITEMS
How to do the Task
How to do the Task (cont)
Chapter 1. INTRODUCTION
SECTION I. GENERAL INFORMATION
Figure 1-2. Curbside Front Three Quarter View
PREPARATION FOR STORAGE AND SHIPMENT.
NOMENCLATURE CROSS-REFERENCE LIST.
SECTION II. EQUIPMENT DESCRIPTION
Table 1-2. Description of Major Components, Power Plant AN/MJQ-1612 andAN/MJQ-1632.
DIFFERENCES BETWEEN MODELS.
SECTION III. PRINCIPLES OF OPERATION
Chapter 2. OPERATING INSTRUCTIONS
SECTION I. DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS
Figure 2-1. Switch Box Controls and Indicators for AN/MJQ-1612 andAN/MJQ-1632 (sheet 2 of 3).
Figure 2-1. Switch Box Controls and indicators or AN/MJQ-1612 andAN/MJQ-1632 (sheet 3 of 3).
Table 2-1. Description of Switch Box Controls and Indicators for AN/MJQ-1612 and AN/MJQ-1632.
SECTION II. OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
Leakage Definitions
Operation of Power Plant with Minor Leaks.
Figure 2-2. Operators PMCS Routing Diagram (sheet 1 of 2).
Figure 2-2. Operators PMCS Routing Diagram (sheet 2 of 2).
Table 2-2. Operator Preventive Maintenance Checks and Services for AN/MJQ-1612 and AN/MJQ-1632
Table 2-2. Operator Preventive Maintenance Checks and Services for AN/MJQ-1612 and AN/MJQ-1632 (cont)
Table 2-2. Operator Preventive Maintenance Checks and Services for AN/MJQ-1612 and AN/MJQ-1632 (cont)
Table 2-2. Operator Preventive Maintenance Checks and Services for AN/MJQ-1612 and AN/MJQ-1632 (cont)
Table 2-2. Operator Preventive Maintenance Checks and Services for AN/MJQ-1612 and AN/MJQ-1632 (cont)
Table 2-2. Operator Preventive Maintenance Checks and Services for AN/MJQ-1612 and AN/MJQ-1632 (cont)
Table 2-2. Operator Preventive Maintenance Checks and Services for AN/MJQ-1612 and AN/MJQ-1632 (cont)
Table 2-2. Operator Preventive Maintenance Checks and Services for AN/MJQ-1612 and AN/MJQ-1632 (cont)
Table 2-2. Operator Preventive Maintenance Checks and Services for AN/MJQ-1612 and AN/MJQ-1632 (cont)
Table 2-2. Operator Preventive Maintenance Checks and Services for AN/MJQ-1612 and AN/MJQ-1632 (cont)
Table 2-2. Operator Preventive Maintenance Checks and Services for AN/MJQ-1612 and AN/MJQ-1632 (cont)
Table 2-2. Operator Preventive Maintenance Checks and Services for AN/MJQ-1612 and AN/MJQ-1632 (cont)
Table 2-2. Operator Preventive Maintenance Checks and Services for AN/MJQ-1612 and AN/MJQ-1632 (cont)
Table 2-2. Operator Preventive Maintenance Checks and Services for AN/MJQ-1612 and AN/MJQ-1632 (cont)
Table 2-2. Operator Preventive Maintenance Checks and Services for AN/MJQ-1612 and AN/MJQ-1632 (cont)
Table 2-2. Operator Preventive Maintenance Checks and Services for AN/MJQ-1612 and AN/MJQ-1632 (cont)
SECTION III. OPERATION UNDER USUAL CONDITIONS
Grounding of Power Plant.
Grounding of Power Plant. (cont)
Figure 2-5. Typical Ground Rod Installation.
Connecting Load Cables.
Auxiliary Fuel Source
Figure 2-7. Auxiliary Fuel Connection.
INITIAL ADJUSTMENTS, CHECKS, AND SELF TEST.
Operating a Single Generator Set.
Figure 2-8. Power Plant Operation
Operating Generator Sets in Parallel
Operating Generator Sets in Parallel (cont)
Removal from Parallel Operation.
Figure 2-9. Load Transfer Operation.
Load Transfer Procedures (Sets connected for parallel operation).
Figure 2-10. AN/MJQ-1612 Identification/Transportation Data Plate.
Figure 2-12. Power Plant Instruction Plate.
Figure 2-13. Disconnecting Load Cables.
PREPARATION FOR MOVEMENT.
Figure 2-14. Ground Rod Removal
Disconnecting Ground Cable and Ground Rod
Figure 2-15. Ground Rod, Grounding, and Slide Hammer Disassembly.
SECTION IV. OPERATION UNDER UNUSUAL CONDITIONS
Chapter 3. OPERATOR MAINTENANCE
SECTION I OPERATOR LUBRICATION
SECTION II. TROUBLESHOOTING
SECTION III. MAINTENANCE PROCEDURES
Figure 3-1. Indicator Lamps DS1 or DS2 Fails to Light With Generator Set Running .
Figure 3-2. Output Indicator Lamp(s) (DS3 thru DS6)Fails to Light When Circuit Breaker(s) (CB1 thru CB4) is placed in the ON position .
Figure 3-3. Switch Box has no power output.
Figure 3-4. Power Plant Fails to Parallel.
INDICATOR LAMP AND/OR LENS REPLACEMENT.
Chapter 4. UNIT MAINTENANCE
SECTION I. REPAIR PARTS; SPECIAL TOOLS; TEST, MEASUREMENT, AND DIAGNOSTIC EQUIPMENT (TMDE); AND SUPPORT EQUIPMENT
SECTION II. SERVICE UPON RECEIPT
INSTALLATION INSTRUCTIONS.
SECTION III. UNIT LUBRICATION
SECTION IV. UNIT PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
Figure 4-1. Unit PMCS Routing Diagram.
Table 4-1. Unit Preventive Maintenance Checks and Services for AN/MJQ-1612 and AN/MJQ-1632
SECTION V. TROUBLESHOOTING
Figure 4-2. Indicator Lamps, DS1 or DS2 are good but do not light.
Figure 4-3. Output Indicator Lamp (DS3 thru DS6) Fails to light when Circuit Breaker is placed in the ON position.
Figure 4-4. Switch Box has no power output.
Figure 4-5. Power Plant fails to parallel.
SECTION VI. MAINTENANCE PROCEDURES
Figure 4-6. Switch Box Replacement
SWITCH BOX ASSEMBLY MAINTENANCE
SWITCH BOX COVER AND LATCH MAINTENANCE
Figure 4-7. Switch Box Latch Replacement
SWITCH BOX STRAP ASSEMBLY MAINTENANCE.
INSTALLATION
SWITCH BOX CIRCUIT BREAKER/SWITCH MAINTENANCE.
Figure 4-9. Circuit Breaker/Switch Replacement
INSTALLATION
SWITCH BOX ELECTRICAL LEAD MAINTENANCE.
INSTALLATION
INDICATOR LIGHT MAINTENANCE.
Figure 4-10. Indicator Light Replacement.
FUEL SYSTEM MAINTENANCE.
REPAIR
Figure 4-11. Fuel System Components.
Figure 4-12. Fuel System Bracket Components.
CABLE STORAGE BOX MAINTENANCE.
Figure 4-13. Cable Storage Box Replacement.
FIRE EXTINGUISHER BRACKET MAINTENANCE (TYPICAL).
Figure 4-14. Fire Extinguisher Bracket Maintenance (Typical).
ACCESSORY BOX MAINTENANCE
INSTALLATION
ACCESSORY BOX CLAMPING CATCH MAINTENANCE
LADDER ASSEMBLY MAINTENANCE
SECTION VII. ADMINISTRATIVE STORAGE.
Chapter 5. DIRECT SUPPORT MAINTENANCE
SECTION I. REPAIR PARTS; SPECIAL TOOLS; TEST, MEASUREMENT, AND DIAGNOSTIC EQUIPMENT (TMDE); AND SUPPORT EQUIPMENT
SECTION II. TROUBLESHOOTING
Figure 5-1. No Voltage Output from switch box
Figure 5-2. Power Plant fails to parallel
SECTION III. MAINTENANCE PROCEDURES
Figure 5-3. Generator Replacement
REPLACE GENERATOR SET
REPLACE GENERATOR SET (Continued).
BUS BAR MAINTENANCE
Figure 5-4. Bus Bar Maintenance.
ELECTRICAL LEADS MAINTENANCE
Table 5-1. Electrical Leads.
WIRING HARNESS MAINTENANCE
Figure 5-5. Wiring Harness Maintenance.
Table 5-2. Wire Harness W6
TEST
CABLE ASSEMBLY MAINTENANCE.
Figure 5-6. Cable Assembly Maintenance.
Table 5-6. Cable Assembly W1
OUTPUT CABLE MAINTENANCE.
TRAILER MAINTENANCE.
Figure 5-7. Ground Stud Replacement.
Figure 5-8. Ladder Bracket Replacement.
Appendix A. REFERENCES
FEDERAL SPECIFICATIONS
TECHNICAL MANUALS
Appendix B. MAINTENANCE ALLOCATION CHART
EXPLANATION OF COLUMNS IN THE MAC, SECTION II.
EXPLANATION OF COLUMNS IN TOOL AND TEST EQUIPMENT REQUIREMENTS, SECTION III.
SECTION II. MAINTENANCE ALLOCATION CHART FOR AN/MJQ-1612 AND AN/MJQ-1632 POWER PLANTS
SECTION II. MAINTENANCE ALLOCATION CHART FOR AN/MJQ-1612 AND AN/MJQ-1632 POWER PLANTS (cont)
SECTION III. TOOL AND TEST EQUIPMENT REQUIREMENTS FOR AN/MJQ-1612 AND AN/MJQ-1632 POWER PLANTS
SECTION IV. REMARKS
Appendix C. UNIT AND DIRECT SUPPORT MAINTENANCE REPAIR PARTS AND SPECIAL TOOLS LIST
Source Code
Maintenance Code
Recoverability Code
EXPLANATION OF COLUMNS (SECTION IV)
SPECIAL INFORMATION
When National Stock Number or Part Number is Known.
Figure 1. Generator Set Installation.
Repair Parts List
Figure 2. Switch Box Mounting
Repair Parts List
Figure 3. Switch Box Assembly
Repair Parts List
Figure 4. Switch Box Identification Plates
Repair Parts List
Figure 5. Latch Assembly
Repair Parts List
Figure 6. Covers
Repair Parts List
Figure 7. Circuit Breaker/Switch
Repair Parts List
Figure 8. Ground Stud
Repair Parts List
Figure 9. Panel Cover
Repair Parts List
Figure 10. Electrical Leads, A1W10 thru A1W29 and Ground Cable (Sheet 1 of 3)
Figure 10. Electrical Leads, A1W10 thru A1W29 (Sheet 2 of 3)
Figure 10. Electrical Leads, A1W10 thru A1W29 (Sheet 3 of 3)
Repair Parts List
Repair Parts List (cont)
Repair Parts List (cont)
Repair Parts List (cont)
Figure 11. Electrical Leads, A1W30 thru A1W41 (Sheet 1 of 2)
Figure 11. Electrical Leads, A1W30 thru A1W41 (Sheet 2 of 2)
Repair Parts List
Repair Parts List (cont)
Figure 12. Wiring Harness, A1W6 Through A1W9 (Sheet 1 of 2)
Figure 12. Wiring Harness, A1W6 Through A1W9 (Sheet 2 of 2)
Repair Parts List
Figure 13. Light Indicator
Repair Parts List
Figure 14. Cable Assembly, W1 and W2
Repair Parts List
Figure 15. Bus Bar Assembly
Repair Parts List
Figure 16. Fire Extinguisher Bracket
Repair Parts List
Figure 17. Output Cable Assembly
Repair Parts List
Figure 18. Fuel System
Repair Parts List
Figure 19. Fuel System Brackets
Repair Parts List
Figure 20. Cable Storage Box
Repair Parts List
Figure 21. Identification Plates and Ground Stud
Repair Parts List
Figure 22. Fire Extinguisher and Bracket
Repair Parts List
Figure 23. Ladder Assembly
Repair Parts List
Figure 24. Container Adapter
Repair Parts List
Figure 25. Ground Rod
Repair Parts List
Figure 26. Oil Drain
Repair Parts List
Figure 27. Accessory Box
Repair Parts List
Figure 28. Trailer
Repair Parts List
Repair Parts List (cont)
NATIONAL STOCK NUMBER INDEX
NATIONAL STOCK NUMBER INDEX (cont)
NATIONAL STOCK NUMBER INDEX (cont)
PART NUMBER INDEX
PART NUMBER INDEX (cont)
PART NUMBER INDEX (cont)
PART NUMBER INDEX (cont)
PART NUMBER INDEX (cont)
PART NUMBER INDEX (cont)
PART NUMBER INDEX (cont)
PART NUMBER INDEX (cont)
PART NUMBER INDEX (cont)
FIGURE AND ITEM NUMBER INDEX
FIGURE AND ITEM NUMBER INDEX (cont)
FIGURE AND ITEM NUMBER INDEX (cont)
FIGURE AND ITEM NUMBER INDEX (cont)
FIGURE AND ITEM NUMBER INDEX (cont)
FIGURE AND ITEM NUMBER INDEX (cont)
FIGURE AND ITEM NUMBER INDEX (cont)
FIGURE AND ITEM NUMBER INDEX (cont)
FIGURE AND ITEM NUMBER INDEX (cont)
Appendix D. COMPONENTS OF END ITEM (COEI) AND BASIC ISSUE ITEMS (BII) LIST
SECTION III. BASIC ISSUE ITEMS
Appendix E. ADDITIONAL AUTHORIZATION LIST
SECTION II. ADDITIONAL AUTHORIZED ITEMS LIST
Appendix F. EXPENDABLE AND DURABLE ITEMS LIST
Section II. EXPENDABLE AND DURABLE ITEMS LIST
Appendix G. OPERATOR LUBRICATION INSTRUCTIONS
Appendix H. ILLUSTRATED LIST OF MANUFACTURED ITEMS
Figure H-1. Cover, Switch Box (Sheet 1 of 2).
Figure H-1. Cover, Switch Box (Sheet 2 of 2).
Figure H-2. Cover, Input Control (Sheet 1 of 2).
Figure H-2. Cover, Input Control (Sheet 2 of 2).
Figure H-3. Cover, Output Control (Sheet 1of 2).
Figure H-3. Cover, Output Control (Skeet 2 of 2).
Figure H-4. Wiring Harness Output Connector A1W6 thru A1W9 (Sheet 1 of 2).
Figure H-4. Wiring Harness Output Connector A1W6 thru A1W9 (Sheet 2 of 2).
Figure H-5. Wire Leads A1W10 thru A1W41 (Sheet 1 of 7).
Figure H-5. Wire Leads A1W10 thru A1W41 (Sheet 2 of 7).
Figure H-5. Wire Leads A1W10 thru A1W41 (Sheet 3 of 7).
Figure H-5. Wire Leads A1W10 thru A1W41 (Sheet 4 of 7).
Figure H-5. Wire Leads A1W10 thru A1W41 (Sheet 5 of 7).
Figure H-5. Wire Leads A1W10 thru A1W41 (Sheet 6 of 7).
Figure H-5. Wire Leads A1W10 thru A1W41 (Sheet 7 of 7).
Figure H-6. Cable Assembly W1 and W2 (Sheet 1 of 2).
Figure H-6. Cable Assembly W1 and W2 (Sheet 2 of 2).
Figure H-7. Cable, Assembly 100 AMP/PHASE 13230E4565 AND 13230E4589 (She t 1 of 2).
Figure H-7. Cable Assembly 100 AMP/PHASE 13230E4565 AND 13230E4589 (Sheet 2 of 2).
Figure H-8. Boarding Ladder.
H-9. Fuel Line Maintenance MS52103B050420R and MS52103B050600R (Sheet 1 of 2).
H-9. Fuel Line Maintenan ce MS52103B050420R and MS52103B050600R (Sheet 2 of 2).
Appendix I. TORQUE LIMITS
Appendix J. MANDATORY REPLACEMENT PARTS
SECTION II. PARTS LIST
GLOSSARY
INDEX
INDEX (cont)
INDEX (cont)
INDEX (cont)
FO-1. 60Hz Power Plant Schematic.
FO-2. 60Hz Power Plant Schematic.
FO-3. 400 Hz Power Plant Schematic.
FO-4. 400 Hz Power Plant Schematic.
The Metric System and Equivalents
TM-9-6115-666-13-P
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Distribution
Recommended Changes to Equipment Technical Publications